Student's

Lab
Handbook

CNC Programing for Milling

CADEM TM
 CNC Milling Lab Handbook
For students

What the student learns

The exercises can be used to impart training on these:

1. Writing CNC programs manually and checking them through seeNC Mill.
2. Generating CNC programs automatically through CAPSmill.
3. Process planning.
4. Tool selection.
5. Cutting parameters selection.
6. Cycle time calculation.
7. Spindle power calculation and its significance.
8. Shop documents like Tools list.

The exercises are in the order of increasing difficulty.

Abbreviations
OD : Outer diameter
DOC : Depth of cut
Vc : Cutting speed

CNC Milling Lab handbook – for Students Page 1 of 14

 Exercises
Exercise plans
Difficulty level 1
1. Exercise-1. Program manually, check in seeNC Mill. Use suggested process sequence, tools and cutting
parameters.
2. Exercise-3. Program manually, check in seeNC Mill. Use suggested process sequence, tools and cutting
parameters.
3. Exercise-3. Program through CAPSmill. Use suggested process sequence, tools.
4. Exercise-4. Program through CAPSmill. Use suggested process sequence, tools.

Difficulty level 2
1. Exercise-2. Program manually, check in seeNC Mill. Use suggested process sequence, tools and cutting
parameters.
2. Exercise-4. Program manually, check in seeNC Mill. Decide process sequence, tools and cutting parameters.
3. Exercise-4. Program through CAPSmill. Decide process sequence, tools.
4. Exercise-5. Program through CAPSmill. Decide process sequence, tools.

Difficulty level 3
1. Exercise-3. Program manually. Use suggested process sequence, tools and cutting parameters.
2. Exercise-4. Program manually. Decide process sequence, tools and cutting parameters.
3. Exercise-4. Program through CAPSmill. Decide process sequence, tools.
4. Exercise-5. Program through CAPSmill. Decide process sequence, tools. Determine the cycle time. Reduce the
cycle time by 10 % by increasing the depth of cut in milling.
5. Exercise-6. Program through CAPSmill. Decide process sequence, tools. Reduce the spindle power in milling
by 15 % by reducing the cutting speed.

Note : The drawing and the process plan are on different pages in each exercise to enable you to photocopy and
hand out just the drawing pages to the students if necessary.

CNC Milling Lab handbook – for Students Page 2 of 14

 Sample-1

Drawing

CNC Milling Lab handbook – for Students Page 3 of 14

Process plan

No. Operation Tool name Tool Geometry Vc DOC Feed

1 Drilling Dia. 6mm HSS twist drill 15 2 70

Skills learnt
1. Drilling using basic motions.
2. Drilling using canned cycles.

NC program

Without canned cycle With canned cycle

CNC Milling Lab handbook – for Students Page 4 of 14

 Sample-2

Drawing

CNC Milling Lab handbook – for Students Page 5 of 14

Process plan

No. Operation Tool name Tool Geometry Vc DOC Feed

1 Face milling 40mm dia. 160 2 300

2 Pocket milling 8mm endmill-carbide 120 2 200

Skills learnt
1. Pocket milling with basic motions – no canned cycles and subprograms.

NC program

Without canned cycle With canned cycle

No canned cycle

CNC Milling Lab handbook – for Students Page 6 of 14

 Sample-3

Drawing

CNC Milling Lab handbook – for Students Page 7 of 14

Process plan

No. Operation Tool name Tool Geometry Vc DOC Feed

1 Side milling 5mm endmill-carbide 120 2 200

Skills learnt
1. Programming arcs.
2. Programming contour milling with Cutter radius compensation (CRC) commands.
3. Programming a compensated path – without CRC commands.

NC program

Without CRC With CRC

CNC Milling Lab handbook – for Students Page 8 of 14

 Sample-4

Drawing

CNC Milling Lab handbook – for Students Page 9 of 14

Process plan

No. Operation Tool name Tool Geometry Vc DOC Feed

1 Side milling 8 mm endmill-carbide 120 2 200

Skills learnt
1. Pocket milling using subprograms and subprogram repetition with CRC.

NC program

With Sub program repetition

CNC Milling Lab handbook – for Students Page 10 of 14

 Sample-5

Drawing

Blank Size = 60 X 60X30

CNC Milling Lab handbook – for Students Page 11 of 14

Process plan

No. Operation Tool name Tool Geometry Vc DOC Feed

1 Pocket milling 10mm end mill-carbide 120 2 200

2 Drilling 9mm Insert drill 200 300

3 Tapping M10 x 1.5mm HSS tap 10 Pitch

4 Chamfer milling 16dia x 45deg 120 2 250

Carbide insert
5

Skills learnt
1. Pocket milling using basic motion commands.
2. Tapping cycle.
3. Chamfer milling with CRC.

NC program

With canned cycle

CNC Milling Lab handbook – for Students Page 12 of 14

 Sample-6

Drawing

DOC = 2
Blank size= 75X75X20
All dimensions are in mm.

CNC Milling Lab handbook – for Students Page 13 of 14

 Process plan

No. Operation Tool name Tool Geometry Vc DOC Feed

1 Side milling 8 mm end mill-carbide 120 2 200

Skills learnt
1. Using mirror command.

NC program

With Sub program repetition

CNC Milling Lab handbook – for Students Page 14 of 14

About Cadem

Cadem is a 20 year old company, India's leading provider of productivity solutions for the manufacturing industry. Its
range of industrial products for CAD/CAM and DNC are enabling shop floors to improve the productivity of their CNC
machines. Many of India's best known CNC shop floors use the products. Cadem's products are exported to 30 countries,
in 4 languages. Premier CNC machine tool companies endorse and recommend Cadem's software to their customers.

Cadem's CNC educational products are the first-choice for Engineering Institutes in India. The products form the mainstay
of CAD/CAM labs in most of India's best known institutes, and in in-house tech centers and training centers of industries.
The Productivity Institute of the IMTMA (Indian Machine Tool Manufacturers' Association) uses Cadem software and
know-how for training engineers from industry around the country.

Cadem has won the coveted CMTI-PMT Trust award for Best Design Innovation Award 3 times and was named as one of
the TOP 100 Innovators in 2007 by NASSCOM.

Developed in India with pride, used worldwide.

About the author

G.V. Dasarathi has a BE in Mechanical

Engineering from NIT, Surat and an
M.Tech. in Production Technology
from IIT, Kharagpur. He has been
involved with CNC machining for the
past 25 years.He started his career in
Bharat Earth Movers Ltd., KGF, where
he was in charge of the CNC cell
machining. His next stint was in the
Government Tool Room and Training
Centre, Bangalore and he was in
charge of the CAD/CAM programming
cell and CNC machining cell.
CADEM TM

Later in 1990, he founded Cadem effiCNC

Technologies Pvt.Ltd. At CADEM he is
responsible for the design and Cadem Technologies Pvt Ltd
264/75, 36th cross, 8th Block Jayanagar
architecture of the award winning Bangalore – 560 070, INDIA
CNC software products for CAD/CAM, Phone: +91 80 2663 4767 Fax: +91 80 2244 2732
DNC and CNC education. Website: www.cadem.com Email: [email protected]