CNC Programming& Operation

❖ Introduction to CNC Machine Generation.

❖ Why CNC?
❖ Advantages & Disadvantages of CNC
❖ Types of CNC Machines.
❖ DNC.
❖ Co-ordinate systems.
❖ Machine Part Detail & Explanation.
❖ Cutting Parameters.
❖ Tooling.
❖ Terms in Programming
❖ Part programming
 CNC MILLING
1.Basic programming concept(Fanuc control).
2.Compensations in CNC machine.
3.Circular interpolation G02/G03.
4.Sub programming/Sub routines.
5.Without sub program multiple passes.
6.Mirror images.
7.Programming on various profiles…All Practical
Demonstration
 Canned cycle

1.Rectangular pocket.
2.Circular pocket.
3.Drilling.
4.Reaming.
5.Tapping …All Practical Demonstration
 EVOLUTION OF CNC MACHINES

CONVENTIONAL MACHINES: In a conventional m/c

parameters like feed, depth of cut and speed are manually
controlled by the operator. The accuracy of the job depends
mainly on the skill of the worker. These machines have the
following disadvantages.
1. More time consumption.
2. Less accuracy.
3. Less production.
4. Requires skilled labour.
5. More wastage of material.
NUMERICAL CONTROL MACHINE: Numerical control means
directing, guiding or retaining power over something by the use of numbers.
Numerical control can defined as a form of programmable automation on which the
process is controlled by numbers, letters and symbols. A numerically controlled m/c
tool is basically a conventional m/c tool where the operator is replaced by punched
tape containing various machining instructions. The numbers, letters and symbols
gathered together and logically organized to direct a m/c tool for a specific job are
called an NC program. An NC m/c tool with a mini computer as the controller unit is
called as CNC machine tool. The year which followed world war-II increased the needs
of aerospace industries that created demands on the capabilities of m/c tools. Using
techniques which had advanced rapidly during the war, machine tool designers &
electronic engineers together built machine tools to produce profiles & shapes that
were nearly impossible by conventional machine tools. US Air force combined with
Parsons corp. to produce first NC machine in the year 1947. The term numerical
control was coined by Massachusetts institute of technology, USA. By mid 1960s,
Russia, Japan, West-Germany, England etc was, leading manufacturers of NC
machines.
CNC MACHINES: In earlier days the conventional machines were used in
industries where the operator used to control the various machining
parameters such as feed, speed, depth of cut etc. in the year 1947, the united
states Air force introduced NC machine for manufacturing Air craft components.
But these machines were commercially available in the year 1955. In the year
1971, there was a rapid development in the field of electronics like integrated
circuits and micro controllers were developed. These devices were used to
control the NC machines. A simple computer was interfaced to the NC system
which stored the data, instructions and programs which were required to run
the CNC machines. In a CNC machine all the numerical functions are controlled
by the computer. The computer also gives the display of various parameters of
the machine like spindle speed, feed rate, depth of cut etc. It consists of
electronic instrumentation to measure the output.
ADVANTAGES OF CNC MACHINES:
1.It eliminates human errors.
2.Requires semi-skilled labour.
3.Higher flexibility.
4.High accuracy.
5.Wastage is minimum.
6.Suitable for batch production.
7.Less space is required.
8.Reduces inspection cost.
9.More operational safety.
10.Quality of product is high.
DISADVANTAGES:
1.Initial cost is high.
2.It require skilled programmer.
3.It is not suitable for small scale production.
4.Maintenance cost is more.
APPLICATIONS:
1.Numbers of operations per component are many.
2.Complexity of the operation.
3.Size of batches is medium.
4.Repetition of batches is large.
5.Layout cost of the component is high.
6.Variety of components to be produced is more.
7.Design changes are frequent.
8.Number of dimension in a component is more.
9.Precision required in a component.
10.Uniform cutting conditions.
MAJOR DIFFERENCES BETWEEN CONVENTIONAL, NC AND CNC
MACHINES:
TOPIC CONVENTIONAL M/C NC CNC
Communication Hand wheel/Push Punched CD,
button tapes Floppy,DNC
Repeatability Not possible Possible Possible

Complex & Precision jobs Not possible Possible Possible

Cost(Basic+Maintenance) Low Medium High

CONVENTION MACHINE NC MACHINE
 CNC PROGRAMMING:
What is CNC programming?
It is a set of instructions given to the machine to perform a given task.
CNC Programming can be done in two ways.
1. EIA/ISO Format (Fanuc/ISO Control)
EIA: Electronics industries association O-series.
ISO: International standard organization.
In this method programming can be done by use of G and M codes.
G codes are called preparatory functional codes and M codes are called miscellaneous/
Machine function/ on-off functions.

2. Dialogue based programming (Heidenhain / Mazatrol control)

In this method the programming can be done by use of symbols like line, circle, square,
ellipse, pentagon, spline, multi-line etc.
 Following are the G and M codes used in CNC Programming.
G codes for Milling m/c
• G00-Rapid traverse
• G15-Moves in the same direction as
• G01-Linear traverse the last arc to be performed
• G02-Circular interpolation in CW • G16-Tangential arc polar
• G03-Circular interpolation in CCW
• G17-Selection of XY plane
• G04-Dwell
• G18-Selection of XZ plane
• G05-Moves in the same direction
as the last arc to be performed • G19-Selection of YZ plane

• G06-Tangential arc • G28-Mirror image

• G07-Single arc • G30-Blank form(Bottom corner of

billet)
• G11-linear polar
• G12-Circular polar CW • G31- Blank form(Top corner of billet)

• G13-Circular polar moves CCW • G40-Tool radius compensation cancel

• G54,G55,G56…….:Work
offset/work datum • G41-Tool radius compensation left side

• G74-Slot milling • G42-Toolradius compensation right side

• G75-Rectangular pocket(CW) • G43-Tool length offset

• G76- Rectangular pocket (CCW) • G90-Absolute dimensioning

• G77-Circular pocket (CW) • G91-Incremental dimensioning

• G78-Circular pocket (CCW) • G98-Start to initial point/Label

• G79-Cycle call • G99-Tool definition

• G80-Cancellation of CANNED
cycle

• G81/G82-Spot drilling/Boring

• G83-Peck drilling
 M codes for Milling m/c
M00-Program stop M20-ATC Arm in

M01-Optional stop M21-ATC Arm out

M02-Program end M22-ATC Arm down

M03-Spindle in CW M23-ATC Arm up

M04-Spindle in CCW M24-ATC Arm clamping activate

M05-Spindle stop M25-Atc Arm clamping release

M06-Tool change M30-Program end

M08-Coolant pump ON M32-ATC CW rotation

M09-Coolant pump OFF M33-ATC CCW rotation

M10-Work clamp open M38-Door open

M11-Work clamp close M39-Door close

M13-Spindle forward + coolant ON M98-Sub program call

M14- Spindle forward + coolant OFF M99-Subprogram repetition(Incremental depth)

M19-Spindle orientation
G codes for Turning m/c M codes for Turning m/c
G00-Rapid traverse M00-Program stop

G01-Linear traverse M01-Optional stop

G02-Circular movement CW M02-Program end

G03-Circular movement CCW M03-Spindle in CW

G04-Dwell for programed duration M04-Spindle in CCW

G05-Delay/Hold(Until resumed by operator) M05-Spindle stop

G10-Offset value setting by program M06-Auto tool change

G20-Inch data input M07-Coolant ‘’B’’ ON

G21-Metric data input M08-Coolant ‘’A’’ ON

G22-Stored stroke check on M09-Coolant OFF

G23- Stored stroke check off M10-Çhuck open

G27-Reference point return check M11-Chuck close

G28-Reference point return M13-Spindle forward + coolant ON

G29-Return from reference point M14- Spindle reverse + coolant OFF

G30-Return to 2nd Reference point M16-Special tool call(Tool call ignores turret)
G31-Skip function M19-Spindle orientation
G32-Thread cutting M20-Spindle index A
G34-Variable lead thread cutting M21-Spindle index 2A
G36-Automatic tool compensation--X M22-Spindle index 3A
G37-Automatic tool compensation--Z M23-Spindle index 4A
G40-Tool nose radius compensation cancel M25-Quill extend
G41-Tool nose radius left M26-Quill retract
G42-Tool nose radius right M29-Select DNC mode
G50-Work co-ordinate/Max.spindle speed setting M30-End of program and rewind
G65-Macro program call M31-Increment part counter
G66-Macro modal call M37-Door open to stop
G67-Macro modal call cancel M38-Door open
G70-Finishing cycle in turning M39-Door close
G71-Stock removal in turning(Multiple turning M62-Output 1 on
cycle)
G72-Stock removal in facing M63-Output 2 on
G73-Pattern repeating M64-Output 1 off
G74-Peck drilling cycle M65-Output 2 off
G75-Grooving in X axis M98-Sub program call
G76-Thread cutting cycle(Multiple thread cutting) M99-Subprogram repetition(Incremental
G81-Drilling cycle depth)

G90-Absolute dimensioning

G91-Incremental dimensioning

G92-Thread cutting cycle

G94-Facing cycle

G96-Constant cutting speed

G97-Constnt surface speed control cancel(variable

surface)

G98-Feed per minute

G99-Feed per revolution
 DIMENSIONING:
Two types of dimensioning
•Absolute dimensioning (G90)
•Incremental dimensioning (G91)

1. Absolute dimensioning:
In absolute dimensioning all the dimensions/points are measured from
common reference point or zero point. This zero point is called datum point.
 2. Incremental dimensioning :
In incremental dimensioning all the points are measured from current tool
position. These dimensions are measured from the previous measuring point.
 CNC programming
Two type of programming
1.Offline programming
2.Online programming

In offline programming
Initial information:-
➢ Analyzing of part Drawing
➢ Part number, material, size means maximum length, width, height,
and diameter.
➢ Input condition like casting/forge/bar
➢ Process details like Drilling, Machining, inspection, Heat treatment.
➢ Allowances / Tolerance, Control dimension
Machine :-
➢ Milling, lathe, Grinding etc.
➢ Specification of machine eg:-stroke length, Spindle axis
 Part Programming
CNC programming include:-
➢ Alphabets[A-Z]
➢ Number[0-9]
➢ Symbols[/;()]
G-codes:-(Preparatory function)
Generating profile creating those called G-codes
M-codes:-Miscellaneous function
Vary from machine to machine depending on the
function available on it and manufacturing of the
machine decides them
 Program Structure
❖ Start
❖ Tool change
❖ Spindle Rotation
❖ Axis Moment
❖ Metal cutting
❖ Program End
Terms in programming
1.Program Number:-The program number functions as addressing
symbol for accessing a program. The program number is expressed by
putting the numericals of four digits after the alphabet “O”, numericals
from 0001 to 9999 can be used.
• Example: O2244;
• The program number can be input with numericals of smaller than
four digits.
• Example: O10; = O0010;
• If the number to be input already in the memory that program can not
be input, input with the other number.
 Terms in programming
2. SEQUENCE NUMBER(N)
The sequence number is used to
• search
• Callout the position is being executed.
• The position you want to edit in the program easily.

Sequence number is expressed by the numerals of 5 digits or less after

alphabet “N” numerals from 1 to 99999 can be used.

Example : O1001
Generally sequence numbers are inserted in to important
Sequence Number places of the program
Example :
N01 G00 X50 Y50
•Beginning of each tool
Sequence Number •If the program memory is over the memory capacity :
N02 G1 Z-50 F20 Eliminate the sequence numbers to save memory capacity.
 Terms in programming
3. Part Program
• Part program is used to specify the machining process for a single tool.
• That is a program for each process ( First process, Second process etc.) required.
• Number of a part program corresponding to the required number of tools is
included.
Example : O1001;
N01 G00 X50 Y50 ;
Part program
M01;

N02
G54 G00 X60 Y60 ;
Part program
M01;
M30;
 Terms in programming
4. Address
The address is expressed by the alphabet.
Example :
G00 X100 Y100

Address
5. Data
Numerals (Including the sign and the decimal point). Succeeding to the address is
called data.
G00 X100 Y100

Data
 Terms in programming
6. Word
• Word is minimum unit for specifying the functions.
• It consists of the numerical values (data) including the address and sign.
Example :
G00 X100 Y100

Word
7. Block
▪ Block Consists of words.
▪ Block is minimum unit necessary to operate a In machine.
▪ program each line corresponds to one block.

G00 X100 Y100

Block
Drawing to Machined part steps
 Cutting Speed for Milling, Drilling, Turning,
Boring.
Work Tool Brazed
Coated Carbide
Inserts
material HSS Carbide Rough Medium Fine

STEEL 20 - 30 60 - 90 80 - 120 200 - 250 250 - 300 300 - 400

CAST
20 - 40 75 - 100 100 - 150 135 - 225 175 - 270 215 - 275
IRON

BRASS & 35 - 75 100 - 250 125 - 200 150 - 300 250 - 600 500 - 2500
Aluminum
 FANUC CONTROLL INTERFACING
FANUC:-Fujitsu Automatic Numerical Control-Oi Mate-TD
Power Switches ON:-Power to NC is turned on when the(POWER
ON) Switch pressed
Power Switches OFF:-Power to NC is turned off when
the(POWER FF) Switch pressed
❖ EMERGENCY STOP
Pressing the (EMERGENCY STOP) switch turn off the power supply
to the NC servo system and stops the machine. The EMERGENCY
STOP switch should be pressed During the following situations.
❑ If an Emergency state arises during operation
» OR
❑ To turn off the power supply at the end of an operation.
By turning the (EMERGENCY STOP) switch clockwise, the button is
released from the locked state.
 FANUC CONTROLL INTERFACING
❖ EDIT KEY SWITCH
This key switch is used to protect the stored program from being inadvertently
changed.
❑ PROGRAM EDIT ON
Program can be stored in the memory and a new program can be edited. This
key cannot be removed when the switch is set to this position.
❑ PROGRAM EDIT OFF
Program stored in the memory cannot be edited by the User. The key can be
removed when switch is set to this position.
❖ AUTOMATIC OPERATION SWITCHES
❑ CYCLE START
The switch is used to slot an automatic operation Auto or MDI mode. The
indicator above the switch is light during an automatic operation.
❑ CYCLE STOP (FEED HOLD)
This switch is used to temporarily stop the axis movement during an
automation operation. The indicator above the switch is light, while the axis
movement is stopped. Press (CYCLE START) to restart the interrupted
automatic operation.
 FANUC CONTROLL INTERFACING
❖ COOLANT SWITCHES
❑ COOLANT ON
When this switch is pressed, the coolant supplied through nozzle. Also when
the coolant ON M code is read in Auto mode the coolant is automatically
supplied.
❑ COOLANT OFF
When the COOLANT OFF switch is pressed the coolant being supplied is
stopped.
When M09 code is executed during an automatic operation coolant is stopped.
❖ SPINDLE SWITCHES
❑ CW
The spindle rotates in the clockwise direction (Viewing a work piece
from the direction of the spindle) when this switch is pressed.
❑ CCW
The spindle rotates in the counter clockwise direction (Viewing the work piece
from the direction of the spindle) when this switch is pressed.
❑ STOP
The spindle stops when the STOP switch is pressed.
 FANUC CONTROLL INTERFACING
SPINDLE LOAD METER
The spindle load meter indicates (as a percentage) the load applied
to the spindle motor.
❖ SPINDLE SPEED OVERRIDE %
The spindle speed is adjusted in the range of 50% to 120% of the
speed displayed in the program MDI (Manual Data Input) Screen.
Override setting is possible in increment of 10%.
❖ FEED OVERRIDE%
The feed(Linear Motion) is adjusted in the range of 0% to 150% of
the feed displayed in the program MDI (Manual Data Input) Screen.
Override setting is possible in increment of 10,%.
❖ RAPID OVERRIDE%
The Rapid feed(Air Motion) is adjusted in the range of 0% to 100% of
the feed displayed in the program MDI (Manual Data Input) Screen.
Override setting is possible in increment of 25,50,100,%.
 FANUC CONTROLL INTERFACING
❖ MODE SELECTION
This switch selects the machine operation mode. They are classified
into three groups
1) Program Edit:-
a. Edit Mode(EDT)
2) Automatic Operation:-
a. Single Auto Mode
b. Auto Cont. Mode
c. MDI Mode(Manual Data Input)
3) Manual Operation:-
a) Handle mode (MPG) MANUAL PULSE GENAREATOR
b) Jog mode (Jump over Geometry)
c) Zero Return mode (ZRN)
 FANUC CONTROLL INTERFACING
❖ EDIT
In EDIT mode following operations are possible:
➢ Inputting and storing the programs to the NC memory
➢Changing and deleting the program to the NC memory
➢Outputting a program stored in the NC memory using the
search functions ( Program number and search, sequence
number search)
❖ MDI
➢ A program created in the MDI mode will be cleared after it has been
executed, when the RESET key is pressed or when the power is turned
off.
➢ For this reason MDI mode is often used to rotate the spindle or to carry
out tool change operation.
➢ Setting parameter and other data.
 FANUC CONTROLL INTERFACING
❖ HANDLE
➢ Select the axis to be moved through the axis selector switch
➢ Turn the pulse handle in the direction (+ or -), the selected axis will
move
❖ MANUAL PULSE GENERATOR
➢ The manual pulse generator is used to move an axis in the handle mode.
➢ The axis movement amount per pulse is selected using the MPG scale
selection switch by placing it in either “X1” or “X10” or “X100”
❖ JOG
➢ An axis is moved while the axis direction switch is held down after selecting the
Axis to be moved through the Axis selector switch. The selected axis is moved
with the feed rate set by the Feed rate override switch.
 FANUC CONTROLL INTERFACING
❖ Single Auto
When the single block (SBK) mode is selected, the program is executed
block by block for every press of the (CYCLE START ) switch
❖ ZERO RETURN
With the selector switch in the Zero return position. The axes can be
returned to home position and the indicator for the Axes zero return
light will ON.
❖ OPTIONAL STOP
When the Optional stop (OSP) switch is in the ON position, Optional
stop function is called. The indicator above the switch will light when M01
command is executed and the machine operation is stopped. To continue
with the operation press the (CYCLE START) switch. Placing the switch
the OFF position cancels the optional stop function and the indicator goes
OFF.
 FANUC CONTROLL INTERFACING
❖ BLOCK DELETE
When the Block Delete ( BDT) switch is in the ON position, the indicator
above the switch is light will on and the block delete function is called and
the commands in the program is ignored with the slash code (/) . placing the
switch in the OFF position cancels the block delete function and the
indicator goes OFF
❖ DRY RUN
With DRY RUN function enabled, the cutting feed rate specified in the
program is ignored and all the axis feed commands are executed. At a feed
rate set by the override switch.
❖ MACHINE LOCK
When this function is ON, the axes movement commands are all locked
while the operation data displayed on the screen is updated according to
the execution on the program.