Federal Technical & Vocational Education & Training Agency

CENTER OF EXCELLENCE FOR ENGINEERING

Technology Accumulation & Transfer – Industry Extension & Services
Addis Ababa, Ethiopia

TRAINING OF TRAINERS 2015

ELECTRICAL/ ELECTRONICS

BASIC PROGRAMMING
MANUAL FOR CNC LATHE
AND MILLING MACHINES
ALAIN VINCENT M. COMENDADOR

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 TABLE OF CONTENTS

Page
Introduction 4

Machine Using CNC 4

Cartesian Coordinate System 7

The Role of Operator 9

CNC Machinist Responsibilities and Duties 10
Programmer Responsibilities and Duties 11
Lathe Machine 13
- Safety 15
- Machine and Control Panel 17
- CRT and MDI ( Manual Data Input) 19
- Manual Operating Procedure 20
- G Codes and M Codes 21
- MDI and control Keyboard 26
- Program and Sequence Number Search Procedure 29
- Loading and Editing of Existing Program 29
- Program Checking 30
- Tool Offset 30
- Automatic Operating Procedure 31
- Machine shutdown Procedure 32
Milling Machine 34
- Safety 36
- Machine and Control Panel 38
- CRT and MDI ( Manual Data Input) 40
- Manual Operating Procedure 41
- G Codes and M Codes 42
- MDI and control Keyboard 45
- Program and Sequence Number Search Procedure 48
- Loading and Editing of Existing Program 49
- Program Checking 49
- Tool Offset 50
- Automatic Operating Procedure 51
- Machine shutdown Procedure 52
Examples
Exercises

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Technical and Vocational Education and Training (TVET) in Ethiopia seeks to create
competent and self-reliant citizens to contribute to the economic and social
development of the country, thus improving the livelihoods of all Ethiopians and
sustainably reducing poverty.

One of the conceptual strategies of TVET is to give Training of Teachers in order to

enhance their practical skills to impart to their students.

This manual is developed as a guide for the basic operations of CNC Lathe and Milling
Machines in which they are responsible for following the safety procedures as outlined.

At the end of the training the trainees should be able to:

1. Familiarize and identify the controls and switches in the control panel and CRT
display of the CNC.
2. Properly operate the controls and switches in manual and MDI (manual data
input) modes.
3. Familiarize with the G codes and M codes and its functions.
4. Load, edit and check programs.
5. Observe proper safety standards and proper energizing and shutdown procedure
of the machine.
6. Produce a work piece.

Trainees should have the following minimum requirements to be able to actively

participate in this Training:

1. Should be at least level B graduate.

2. Deeper understanding on mathematical analysis.
3. Must have experience in conventional lathe and milling machines.
4. Must be conversant in English.

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INTRODUCTION

The term numerical control is a widely accepted and commonly used term in the
machine tool industry. Numerical control (NC) enables an operator to communicate with
machine tools through a series of numbers and symbols. NC which quickly became
Computer Numerical Control (CNC) has brought tremendous changes to the
metalworking industry. New machine tools in CNC have enabled industry to consistently
produce parts to accuracies undreamed of only a few years ago. The same part can be
reproduced to the same degree of accuracy any number of times if the CNC program
has been properly prepared and the computer properly programmed. The operating
commands which control the machine tool are executed automatically with amazing
speed accuracy, efficiency, and repeatability. The ever-increasing use of CNC in
industry has created a need for personnel who are knowledgeable about and capable of
preparing the programs which guide the machine tools to produce parts to the required
shape and accuracy. With this in mind, the authors have prepared this manual to take
the mystery out of CNC – to put it into a logical sequence and express it in simple
language that everyone can understand. The preparation of a program is explained in a
logical step-by-step procedure, with practical examples to guide the student.

MACHINE USING CNC

Early machine tools were designed so that the operator was standing in front of the
machine while operating the controls. This design is no longer necessary, since in CNC
the operator no longer controls the machine tool movements. On conventional machine
tools, only about 20 percent of the time was spent removing material. With the addition
of electronic controls, actual time spent removing metal has increased to 80 percent and
even higher. It has also reduced the amount of time required to bring the cutting tool
into each machining position.

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MACHINE TYPES

Lathe

The engine lathe, one of the most productive machine tools, has always been an
efficient means of producing round parts. (Fig. 1)

Most lathes are programmed on two axes.

• The X axis controls the cross motion of the cutting tool. Negative X (X-) moves
the tool towards the spindle centerline; positive X moves the tool away from the
spindle centerline.
• The Z axis controls the carriage travel toward or away from the headstock.

Fig. 1. The main axes of a lathe or turning center. (Emco Maier Corp)

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Milling Machine

The milling machine has always been one of the most versatile machine tools
used in industry (Fig. 2). Operations such as milling, contouring, gear cutting, drilling,
boring, and reaming are only a few of the many operations which can be performed on
a milling machine.

The milling machine can be programmed on three axes:

• The X axis controls the table movement left or right.

• The Y axis controls the table movement toward or away from the column.
• The Z axis controls the vertical (up or down) movement of the knee or spindle.

Fig. 2 The main axes of a vertical machining center. (Denford Inc.)

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Cartesian Coordinate System

Almost everything that can be produced on a conventional machine tool can be

produced on a Computer numerical control machine tool, with its many advantages. The
machine tool movements used in producing a product are of two basic types: point-to-
point (straight-line movements) and continuous path (contouring movements).

The Cartesian, or rectangular, coordinate system was devised by the French

mathematician and philosopher Rene‟ Descartes. With this system, any specific point
can be described in mathematical terms from any other point along three perpendicular
axes. This concept fits machine tools perfectly since their construction is generally
based on three axes of motion (X, Y, Z) plus an axis of rotation. On a plain vertical
milling machine, the X axis is the horizontal movement (right or left) of the table, the Y
axis is the table cross movement (toward or away from the column), and the Z axis is
the vertical movement of the knee or the spindle. CNC systems rely heavily on the use
of rectangular coordinates because the programmer can locate every point on a job
precisely. When points are located on a workpiece, two straight intersectinglines, one
vertical and one horizontal, are used. These lines must be at right angles to each other,
and the point where they cross is called the origin, or zero point. (Fig.3)

Fig.3. Intersecting lines from right angles

and establish the zero point (Allen-
Bradley)

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 The three-dimensional coordinate planes are shown in Fig. 4. The X and Y planes
(axes) are horizontal and represent horizontal machine
table motions. The Z plane or axis represents the
vertical tool motion. The plus (+) and minus (-) signs
indicate the direction from the zero point (origin) along
the axis of movement. The four quadrants formed when
the XY axes cross are numbered in a counterclockwise
direction (Fig. 3). All positions located in quadrant 1
would be positive (X+) and positive (Y+). In the second
quadrant, all positions would be negative X (X-) and
positive (Y+). In the third quadrant, all locations would
be negative X (X-) and negative (Y-). In the fourth
Fig. 4 The three-
quadrant, all locations would be positive X (X+) and dimensional coordinate
negative Y (Y-). planes (axes) used in CNC.
(The Superior Electric
Company)

In Fig. 5, point A would be 2 units to the right of

the Y axis and 2 units above the X axis. Assume
that each unit equals 1.000. The location of point
A would be X + 2.000 and Y + 2.000. For point B,
the location would be X + 1.000 and Y - 2.000. In
CNC programming it is not necessary to indicate
plus (+) values since these are assumed.
However, the minus (-) values must be indicated.
For example, the locations of both A and B would
be indicated as follows:

Fig. 5 The quadrants formed when

the X and Y axes cross are used to A X2.000 Y2.000
accurately locate points from the XY B X1.000 Y-2.000
zero, or origin, point (Allen-Bradley)

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THE ROLE OF THE OPERATOR

 Analyze and interpret all blueprints and manuals for various CNC operations and
supervise all setups for same.

 Maintain knowledge on all G-code commands and perform minor modification on

machines if required and ensure compliance to all specifications for all finished
pieces.

 Identify and replace all dull cutting tools and install and secure all tools for
attachment with help of various hand tools and measuring instruments.

 Analyze and measure all controls for machine factors such as speed and coolant
flow and assist to edit all computerized machine control media and identify all
malfunctions in machines and ensure timely repair of same.

 Identify all sounds of machines during operation and adjust same to resolve all
issues and assist others to adjust speed in case of automatic programming
machines and perform all work according to machining sequences.

 Perform all work on machines with help of hoist and cranes if required and
modify all cutting programs for various operations.

 Analyze and insert all control instructions on machines with assistance to start
operations and operate all measuring tools and equipments with help of veneers
and gauges.

 Perform visual inspection on all machines and recommend required adjustments

to same and participate in all Quality Manual Standards programs.

 Ensure compliance to all safety procedures and prepare reports for all unsafe
conditions in processes and ensure optimal use of all materials and equipments.

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  Monitor inventory of stock and manage communication with all CNC operators
and ensure neat and clean work area at all times and free of all unwanted
materials.

CNC MACHINIST RESPONSIBILITIES AND DUTIES

 Install all machines and administer all operating controls.

 Perform editing on all programs and ensure compliance to all client requirements
and interpret all drawings and specifications to set up all equipments.

 Analyze all engineering drawings and specifications and perform work according
to geometric dimensions and generate all CNC codes with help of all software.

 Administer and perform all editing on all CNC programs and identify all errors
and determine all tools and fixtures for all parts.

 Perform and mark all dimensions for various machines and develop plans for all
preventative maintenance procedures for all equipments.

 Adjust machines as per requirement and ensure quality in all production

processes and manage all communication with engineers and supervisors and
resolve issues for quality.

 Provide an effective interface with manufacturing engineering team and design

all specifications for products and perform troubleshoot to resolve all quality
issues.

 Inspect all parts for measuring instruments and ensure compliance to all
specifications and maintain safe procedures and regulations.

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  Perform preventative maintenance on all equipments and ensure adherence to
manufacturer instruction and perform troubleshoot on all processes.

CNC PROGRAMMERS RESPONSIBILITIES AND DUTIES

 Ensure optimal utilization of all spreadsheets and bill of materials and analyze all
sketches and drawings.

 Establish all reference points and provide assistance to machine paths and
calculate all angular and linear dimensions and design sequence for all machine
parts and prepare geometric layout with help of various software.

 Install and operate all machines and design all instruction sheets and develop all
machine instructions with help of all symbolic languages and ensure accuracy of
all instructions.

 Identify all instruction errors and assist to resolve same and operate various
machines to ensure appropriate trial run and design new programs for all
production machines to ensure quality.

 Analyze and select all cutting tools and speed for CNC programs.

 Evaluate all designs to ensure reduction in manufacturer cost and time and utilize
all raw materials for various applications and oversee all process validation
functions.

 Monitor all CNC programs and ensure accuracy of all instructions through
comparison with original blueprints and design program network to increase
efficiency of all programs.

 Prepare and verify all technical documents for CNC programs.

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  Provide all required tooling information and reduce cycle time for all programs
and manage communication with all engineers and plant personnel.

 Design all new processes to reduce time for all CNC programs and resolve all
issues in same and provide training to all operators to develop new CNC
programs and equipments.

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 LATHE
MACHINE

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INTRODUCTION

In order to operate and program a CNC controlled machine, a basic understanding of

machining practices and a working knowledge of math is necessary. It is also important
to become familiar with the control console and the placement of the keys, switches,
displays, etc., that are pertinent to the operation of the machine.

This manual can be used as both an operators‟ manual and a programmer‟s manual. It
is intended to give a basic understanding of CNC programming and its applications. It is
not intended as an in-depth study of all ranges of machine use, but as an overview of
common and potential situations facing CNC programmers.

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S A FE T Y O PE RA T I NG P RO C E D U R E S

DO NOT use this machine unless the technician has

instructed
you in its safe use and operation and has given permission.

Safety glasses must be worn at Long and loose hair must be

all times in work areas. contained.

CSA footwear must be worn at Close fitting/protective clothing

all times in work areas. must be worn.

Rings and jewellery must not be Gloves must not be worn when
worn. using this machine.

PRE-OPERATIONAL SAFETY CHECKS

1. Check workspaces and walkways to ensure no slip/trip hazards are present.
2. Locate and ensure you are familiar with the operation of the ON/OFF starter and E-
Stop (if fitted).
3. Ensure all guards are in place.
4. Check that the job is clamped tight in the chuck.
5. Remove all tools from the bed and slides of the machine.
6. Ensure correct speed for machining process is selected.
7. Remove the chuck key before starting the lathe.

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8. Do not try to lift chucks or face plates that are too heavy for you.
9. Faulty equipment must not be used. Immediately report suspect machinery.

OPERATIONAL SAFETY CHECKS

1. Never leave the lathe running unattended.
2. Before making adjustments or measurements switch off and bring the machine to a
complete standstill.
3. Do not attempt to slow/stop the chuck or revolving work by hand.
4. Avoid letting swarf build up on the tool or job. Stop the machine and remove it.
5. Always remove the chuck key from the chuck.
6. Do not store tools and parts on top of the machine.

HOUSEKEEPING
1. Switch off the machine and reset all guards to a fully closed position.
2. Leave the machine in a safe, clean and tidy state.

POTENTIAL HAZARDS
 Flying objects - chuck key left in chuck

 Cutting tool injury when cleaning, filing or polishing

 Rotating machine parts - entanglement

 Metal splinters/swarf

 Eye injuries

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THE MACHINE AND CONTROL PANEL

CONTROL/INDICATOR FUNCTION

 On- coolant pump runs regardless of program.

 Auto- coolant pump controlled by program.
COOLANT MAIN or
 Supply to coolant nozzles only when MAIN COOLANT
TURRET
selected.
On/Off auto switches
 Supply to nozzles and turret when TURRET
COOLANT selected
TAILSTOCK
Tailstock in UP or DOWN position.
UP/DOWN switch
QUILL
Quill extend and retract.
IN/OUT switch
COLLET
Opens and closes the collet
OPEN/CLOSE
 Operative only in manual JOG mode.
RAPID
 Tool will move along the axis in the selected direction
Pushbutton with integral
in a rapid traverse rate, while this button is pressed.
lamp
 Feedrate is not affected.
 Operates pulse generator enabling fine positional
adjustment.
 Generates 100 pulses per revolution.
 Amount of movement per pulse can be switched to
FEED two levels by means of the AXIS SELECT x1 and x10
HANDWHEEL/HANDLE switch as follows:-
o and 0.01 mm for metric input.
o and 0.001 inch for inch input.
 HAND/STEP mode must be selected before FEED
HANDWHEEL is operative.

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  Provides manual control of spindle stopping, lamp
SPINDLE STOP
lights when the spindle has stopped.
Pushbutton with integral
 Interlock enables sliding door to be opened when
lamp
button has been pressed.
EMERGENCY STOP  All machine functions stop immediately when button is
palmbutton pressed. Remains in until reset by pulling button out.
 Operative in JOG and HAND MODES. Select the
required AXIS for manual control.
AXIS SELCT  Operative in HAND mode and used in conjuction with
„X‟, „Z‟ switch FEED HANDWHEEL.
 x1= 0.001 mm (0.0001 in) movement per degree of
„x1‟, x‟10‟ switch FEED HANDWHEEL.
 X10= multiples the amount of movement per degree
by 10.
JOG selection Joystick control for selecting a +ve or –ve feed axis direction.
TURRET SELECTION Manual control of turret indexing. Depress button after
pushbutton making a Turret Selection
TURRET SELECT Eight-position rotary selector enables manual pre-selection of
selector a turret station.
 Four-position rotary selector. Graduated in % enables
RAPID TRAVERSE
operator to override the programmed rapid traverse
OVERRIDE (%)
federate.
selector
 Fo setting is the basic federate by the manufacturers.
 Graduated in 10% increments from 0 (stop) to 150%.
JOG AND FEEDRATE
This is a combination switch enabling the JOG
OVERRIDE (%)
federate to be set or the programmed federate to be
selector
overridden.
MACHINE ON  Lamp lights when main supply isolator, on electrical
Pushbutton with integral equipment cabinet, is switched ON. Pressing the
lamp button will energize machine control circuits providing:

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 1. All access doors are closed
2. Emergency stop button has been reset.
3. An axis end of travel limit switch is not operated.

CRT (Cathode Ray Tube) AND MDI ( Manual Data Input) PANEL

The CRT and MDI panel consist of a video display unit and control keyboard.
The machine‟s functional state and other Information is displayed on the CRT. The MDI
pushbutton and keys enables commands to be fed into the controller by the operator.
Each key is labelled showing the related inputs available. Figure below shows the
arrangement of the CRT and MDI panel.

CRT STATUS DISPLAY

During machine operation the operational state and condition of the control system is
indicated along the bottom of the screen, as follows:

STATUS DISPLAY INDICATION

NOT READY Control on system is not ready for operation.
Alarm condition exists. Press ALARM key to display of
ALARM
alarm information
Power level in battery is low. Battery used to prevent
BAT
loss of data stored in memory when power is off.
Command data read into buffer register has not been
BUF
executed.
JOG JOG mode selected.
HNDL HAND/STEP mode selected
AUTO AUTO mode selected
MDI MDI mode selected
EDIT mode selected. Status displayed at center of
EDIT
bottom line.

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 Editing in progress. Status displaying at right-hand side
EDIT
of bottom line.
SEARCH Sequence number or word search in progress.
OUTPUT Program being output by use of input/output interface
INPUT Program being input by use of input/output interface.
Program being compared with memory content using
COMPARE
input/output interface.
Label skip condition for input and collation of program by
LSK
I/O interface.
ZRN That a reference point return has been operated.

SWITCHING ON THE MACHINE

ACTION CHECK
Switch the MAINS
Machine ON button is lit.
ISOLATOR
Press MACHINE ON Hydraulic pumps start. Control system energized.
BUTTON and hold until Machine area lamp is lit (providing lamp switch has
position information is been selected on). Position information displayed on
displayed CRT

MANUAL OPEARTING PROCEDURES

The following manual operating procedures are possible by the application of

manual controls on the machine control panel.

JOG FEED

Select mode switch and select the required federate on the JOG and FEEDRATE
OVERRIDE (%) selector. Then select the axis direction by means of the JOG joystick.

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 If Rapid Traverse is required, when the JOG FEED also press the RAPID button
on the control panel.

HAND FEED

Set MODE SELECT switch to HAND/STEP. Set AXIS SELECT switches to the
„X‟ or „Z‟ axis and x1 or x10 movement, as required. Rotate the FEED HANDWHEEL,
clockwise +ve direction or counter-clockwise for –ve direction. DO NOT rotate the
handwheel too rapidly.

MANUAL REFERENCE POINT RETURN

The tool can be returned to the reference (start) point from a point in the
machining area:

Set MODE SELECT switch to JOG. Press REF POINT RETURN

BUTTON and hold pressed whilst operating the JOG joystick in the required axis
direction. (one axis at a time)

G CODES AND M CODES

The most common codes used when programming CNC machines tools are G-
codes (preparatory functions), and M codes (miscellaneous functions). Other codes
such as F, S, D, and T are used for machine functions such as feed, speed, cutter
diameter offset, tool number, etc. G-codes are sometimes called cycle codes because
they refer to some action occurring on the X, Y, and/or Z axis of a machine tool.

G CODES

G00 (modal) Rapid positioning

G01 (modal) Linear interpolation

G02 (modal) Circular interpolation, clockwise (CCW)

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G03 (modal) Circular interpolation, Counterclockwise (CCW)

G04 (non-modal) Dwell mode

G20 (modal) Inch Selection

G21 (modal) Metric Selection

G28 (non-modal) Automatic Reference Point Return

G32 (modal) Thread cutting

G40 (modal) Tool nose radius compensation cancel

G41 (modal) Tool nose radius compensation left

G42 (modal) Tool nose compensation radius right

G50 (non-modal) Co-ordinate System Setting

G70 to G76 (non-modal)

The following multiple repetitive cycle are available:

G70 finishing cycle

G71 rough turning cycle

G72 rough facing cycle

G73 pattern repeating

G74 peck drilling in Z axis

G75 grooving in X axis

G76 thread cutting cycle

G90, G92, G94 (modal)

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G90 Cutting Cycle A (straight or taper turning)

G92 Thread cutting cycle (straight or taper threading)

G94 Cutting Cycle B (straight or taper facing)

G96, G97 By implementing the G96 code the spindle speed is controlled so that the
surface speed remains constant at any tool position. If G97 is programmed the spindle
speed is directly commanded by a 4-digit S command word.

G97 is set when power is turned ON.

G98,G99 ( modal) The cutting federate can be set in feed per minute ( G98) or in feed
per revolution (G99) which is synchronized with spindle revolution.

The actual federate occurring on the machine may be modified by the operator
using the Jog and Feedrate override Control. This control is calibrated in 10%
increments from 0% (STOP) to 150%.

M CODES

These represent miscellaneous functions which are commanded by an M

address followed by a 2-digit numeric value. Signals transmitted by the codes are used
for the On/Off control of a machine function, or end of program and program stop
functions. Only one M code can be commanded in one block. When two or more M
codes are commanded, only the last one is effective.

The following M codes are avalaible:

M00 Program Stop, Spindle and Coolant Off

M02 Program End, Spindle and Coolant Off

M03 Spindle counterclockwise (CCW)

M04 Spindle clockwise (CW)

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M05 Spindle Stop

M06 Turrent Coolant “Off”

M07 Main Coolant “Off”

M08 Main Coolant “On”

M09 Turret Coolant and Main Coolant “On”

M10 Collet “open”

M11 Collet “close”

M28 Tailstock “Down”

M29 Tailstock “Up”

M30 End of Tape

M31 Tailstock Quill Extend

M32 Tailstock Quill Retract

M33 workcatcher Out

M34 workcatcher In

M36 Tool Change counterclockwise (CCW)

M37 Tool change clockwise (CW)

M40 Tool drive counterclockwise (CCW)

M41 Tool drive clockwise (CW)

M42 Tool drive off

M61 to M64 Spindle index position from 0 degrees to 360 degrees

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M98 Sub-program Call

M99 End of Sub-program

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MDI (Manual Data Input) CONTROL KEYBOARD

The following information briefly explains the function of each key when pressed.
For further details refer to Fanuc system operators manual.

The following keys, when pressed, enable the display of specific functional
information data. As several pages of data may be available for a specific function
adjustment pages can be selected by means of a PAGE keys.

KEY FUNCTION
Displays the current position of the tool, the actual
POS (position)
difference moved and the distance to end of travel.
Enables the following:
PRGRM Edit and display of the program in the memory.
(program) Input and display of the MDI data.
Display of command values.
OFSET
Enables setting and display of tool offset values.
(offset)
PARAM
Enables the settings and display of parameter.
(parameter)
When an alarm occurs the word ALARM key displays
ALARM the alarm message. This could be an overheat, system,
overtravel, servo or program errors (P/S) alarm.
When pressed various data is displayed enabling the
DGNOS operator to check details and conditions of NC
(diagnostics) input/output signals, parameter values, alarms, servo
system, etc.
Moves a page of information
PAGE select
Data, as selected on the CRT select keys, in the
(arrow keys)
direction of the arrowed key pressed.
INPUT Keyed data, displayed on the CRT screen, is set into

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 the program by pressing the input key.
START For program loading and unloading only.
A cursor symbol- appears on the CRT screen as each
page of information is selected.
CURSOR select Press ↓ key- cursor moves forward (right)
(Arrowed Keys) Press↑ Key- cursor moves backwards (left)
Hold key pressed and cursor movement is continuous,
across and down or up.
Executes a reset condition. Generally used to release
RESET
an alarm status. Also resets a current NC status.
These alpha-numeric keys enables the input of data
into the computer memory in the MDI and EDIT modes.
DATA INPUT KEYS
Each key is multi-functional and is used as a numeric
or address key.
PROGRAM Edit keys
These keys are used when program editing and are
only operative when in the EDIT mode and the PRGM
key has been pressed.
ALTER Enables an existing word in the program to be altered
(change)

INSRT Enables an additional word to be inserted in the

program.

EOB EOB key used in EDIT and MDI modes. Each

command on block of information keyed into the
memory must end with the EOB key.

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Examples:

To rapidly positions the cutting tool when it is above the workpiece from one point to
another on a job us G00 code. During the rapid traverse movement, either the X or Z
axis can be moved individually or both axes can be moved at the same time.

G00 →Input X ____ → Input Z ____ → Input Start/ Cycle Start

For automatic reference point return

G28 → Input X 0.0 → Input Z 0.0 → Input Start/ Cycle Start

For changing Tool

M36 or M37 → Input T0300 → Input Start/Cycle Start

Note: 03 – Tool Number

00 – Tool compensation

To turn On the spindle

S______ → M03 or M04 → Input Start/Cycle Start

To Turn Off the Spindle

MO5 Start/ Cycle Start

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PROGRAM AND SEQUENCE NUMBER SEARCH PROCEDURE

Program and sequence numbers are displayed at the top right of the CRT screen. The
search facility enables the operator to quickly locate a program or sequence number for
editing purposes.

PROGRAM SEARCH NUMBER

1. Set MODE SELECT switch to EDIT or AUTO.

2. Press the PRGRM key. Key-in address O or : and the program number to be
searched.
3. Press CURSOR key.

SEQUENCE NUMBER SEARCH

This facility enables a sequence number (e.g. N112) search anywhere in the program.
Normally used when it is required to start or restart the program at the block of the
particular sequence number.

1. Set MODE SELECT switch to AUTO

2. Press PRGRM key
3. By the means of data input keys select the program number in which the
sequence number to be searched belongs.
4. Key-in N and the sequence number to be searched for
5. Press the CURSOR ↓ key.

LOADING AND EDITING OF EXISTING PROGRAM

1. Set PROGRAM PROTECT switch to OFF

2. Set MODE SELECT switch to EDIT.
3. Press PRGRM key
4. Key-in the address O and program number and press INSRT key.
5. Press EOB key.
6. Key-in the required program block. After each word press INSRT key.

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 7. After each block of information, press the EOB key.
8. Continue as in actions 6 and 7 until complete program is loaded.
9. Set the PROGRAM PROTECT switch to ON.

EDITING THE PROGRAM

Programs loaded into the memory can be edited by switching the EDIT mode and using
the following three methods:

Alter The changing of a word or words already keyed into the memory.

Insert To enter or add words which has been omitted.

Delete To delete or erase an unwanted word or block of words.

Note: PROGRAM PROTECT switch to OFF in order to edit a program and switch to ON
after editing.

PROGRAM CHECKING

Having entered and edited the program it is recommended that prior to actual
machining operations a Dry Run is executed in order to check the program.

DRY RUN

this method of checking the program is useful for observing the slide and
turret movements. Spindle rotation and coolant flow is inhibited.

1. Set MODE SELECT switch to AUTO.

2. Switch DRY RUN switch to ON.
3. Set or select the required program by carrying out a Program number search.
4. Press CYCLE START button.

TOOL OFFSETS

The use of tool offsets enable the operator to compensate the changes in the tool
shape, tool mounting position and for tool wear. An offset which compensate for tool

TRAINING OF TEACHERS 2016 Page 30

wear is made by moving the tool. To compensate for the changes in the tool shape or
position a tool geometry offset is made which shifts the co-ordinate system without
moving the tool.

1. Set MODE SELECT switch to EDIT.

2. Press OFFSET key and press PAGE keys as necessary, to bring up the required
offset number line.
3. Press the required address key and input the offset value (with decimal point) by
means of data input keys.
4. Press the INPUT key.

AUTOMATIC OPERATING PROCEDURES

This machine can be operated according to the program in the automatic mode.

STARTING IN THE AUTO MODE

To start a machining program registered in the memory, proceed as follows:

1. Set or select the required program by carrying out a program number search.
2. Set MODE SELECT switch to AUTO.
3. Press CYCLE START button.

FEED HOLD OPERATION

Feed movement on both axes can be temporarily stopped during an Auto Cycle
or MDI operation, and can be resumed by pressing CYCLE START button. It is
also possible to operate in a manual mode before resuming the axis feed.

1. Press FEED HOLD button.

2. Restart cycle after feed hold condition.
3. Press CYCLE START button.

SINGLE BLOCK OPERATION

1. Set SINGLE BLOCK switch to make a temporary stop.

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 2. Press CYCLE START.
Note: Repeat action 2 to run each program block.
3. On the completion of single block operation set SINGLE BLOCK to OFF.

MANUAL OPEARTION WHEN IN AUTO

1. Press FEED HOLD button or set SINGLE BLOCK switch to ON to make a

temporary stop.
2. Press POS key on MDI keyboard.
3. Complete the required manual operation and return tool to the recorded position
noted in action 2.
4. Reset MODE SELECT switch to the position prior to manual operation and set
SINGLE BLOCK switch is OFF.
5. Press CYCLE START button.

MDI (Manual Data Input) WHEN IN AUTO

This procedure enables instructions by manual data input to be keyed-in when the
machine is being operated in the automatic mode.

1. Switch SINGLE BLOCK switch to ON.

2. Switch MODE SELECT switch to MDI position.
3. Key-in the required data by means of the MDI keyboard.
4. Reset MODE SELECT switch to AUTO, select SINGLE BLOCK to OFF and
press CYCLE START button.

MACHINING SHUTDOWN PROCEDURE

NORMAL

To shutdown the machine from normal production at the end of a shift proceed
as follows:

1. Allow machining cycle to finish. (program completed)

2. Set MODE SELECT switch to JOG.

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 3. Press and hold REF POINT RETURN button and at the same time operate
the JOG joystick to bring the turret to the X-Z axes reference point.
4. Switch OFF the MAIN ISOLATOR.
EMERGENCY
To stop the machine in an emergency, press the EMERGENCY STOP
pushbutton on the control panel. All machine functions stop immediately.
Before resetting the machine rectify the reason for the emergency stop.
Pull out the EMERGENCY STOP button to reset it and return turret to X-Z
axes reference point as detail for normal shutdown.

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 MILL
MACHINE

TRAINING OF TEACHERS 2016 Page 34

INTRODUCTION

In order to operate and program a CNC controlled machine, a basic understanding of

machining practices and a working knowledge of math is necessary. It is also important
to become familiar with the control console and the placement of the keys, switches,
displays, etc., that are pertinent to the operation of the machine.

This manual can be used as both an operators‟ manual and a programmer‟s manual. It
is intended to give a basic understanding of CNC programming and its applications. It is
not intended as an in-depth study of all ranges of machine use, but as an overview of
common and potential situations facing CNC programmers.

TRAINING OF TEACHERS 2016 Page 35

S A FE T Y O PE RA T I NG P RO C E D U R E S

Milling Machine

DO NOT use this machine unless a teacher has instructed

you in its safe use and operation and has given permission.

Safety glasses must be worn at Long and loose hair must be

all times in work areas. contained.

Sturdy footwear must be worn Close fitting/protective clothing

at all times in work areas. must be worn.

Rings and jewellery must not be Gloves must not be worn when
worn. using this machine.

PRE-OPERATIONAL SAFETY CHECKS

1. Ensure no slip/trip hazards are present in workspaces and walkways.
2. Locate and ensure you are familiar with the operation of the ON/OFF starter
and E-Stop (if fitted).
3. Do not leave equipment on top of the machine.
4. Check that machine guards are in position.
5. Ensure cutter is in good condition and securely mounted.
6. Check coolant delivery system to allow for sufficient flow of coolant.
7. Faulty equipment must not be used. Immediately report suspect machinery.

OPERATIONAL SAFETY CHECKS

1. Keep clear of moving machine parts.
2. Never leave the machine running unattended.
3. Follow correct clamping procedures- keep overhangs as small as possible and
check work piece is secure.
4. Set the correct speed to suit the cutter diameter, the depth of cut and the
material.

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5. Before making adjustments and measurements or before cleaning swarf
accumulations switch off and bring the machine to a complete standstill.

HOUSEKEEPING
1. Switch off the machine.
2. Remove milling cutters and store them safely.
3. Leave the machine and work area in a safe, clean and tidy state.

POTENTIAL HAZARDS
 Sharp cutters

 Moving components - hair/clothing entanglement

 Eye injury

 Skin irritation

 Metal splinters and burrs

 Flying debris

TRAINING OF TEACHERS 2016 Page 37

THE MACHINE AND CONTROL PANEL

CONTROL/INDICATOR FUNCTION

 On- coolant pump runs regardless of program.

 Auto- coolant pump controlled by program.
COOLANT MAIN
 Supply to coolant nozzles only when MAIN COOLANT
On/Off auto switches
selected.

Z LOCK Lock the Z axis and preventing it from moving

SWITCH OFF
Turning OFF the machine
pushbutton
TOOL
Opens and closes for changing tool
CLAMP/ UNCLAMP
 Operative only in manual JOG mode.
RAPID  Tool will move along the axis in the selected direction
SWITCH in a rapid traverse rate, while this button is pressed.
 Feedrate is not affected.
 Operates pulse generator enabling fine positional
adjustment.
 Generates 100 pulses per revolution.
 Amount of movement per pulse can be switched to
FEED two levels by means of the AXIS SELECT x1 and x10
HANDWHEEL/HANDLE switch as follows:-
o and 0.01 mm for metric input.
o and 0.001 inch for inch input.
 HAND/STEP mode must be selected before FEED
HANDWHEEL is operative.

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  Provides manual control of spindle stopping, lamp
SPINDLE START/STOP lights when the spindle has stopped.
Pushbutton  Interlock enables sliding door to be opened when
button has been pressed.
EMERGENCY STOP  All machine functions stop immediately when button is
Palmbutton pressed. Remains in until reset by pulling button out.
 Operative in JOG and HAND MODES. Select the
required AXIS for manual control.
AXIS SELCT  Operative in HAND mode and used in conjuction with
„X‟, „Y‟, „Z‟ switch FEED HANDWHEEL.
 x1= 0.001 mm (0.0001 in) movement per degree of
„x1‟, x‟10‟ switch FEED HANDWHEEL.
 X10= multiples the amount of movement per degree
by 10.
JOG selection Joystick control for selecting a +ve or –ve feed axis direction.
 Four-position rotary selector. Graduated in % enables
RAPID TRAVERSE
operator to override the programmed rapid traverse
OVERRIDE (%)
federate.
Selector
 Fo setting is the basic federate by the manufacturers.
 Graduated in 10% increments from 0 (stop) to 150%.
JOG AND FEEDRATE
This is a combination switch enabling the JOG
OVERRIDE (%)
federate to be set or the programmed federate to be
Selector
overridden.
 Lamp lights when main supply isolator, on electrical
equipment cabinet, is switched ON. Pressing the
MACHINE ON button will energize machine control circuits providing:
Pushbutton 4. All access doors are closed
5. Emergency stop button has been reset.
6. An axis end of travel limit switch is not operated.

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CRT (Cathode Ray Tube) AND MDI ( Manual Data Input) PANEL

The CRT and MDI panel consist of a video display unit and control keyboard.
The machine‟s functional state and other Information is displayed on the CRT. The MDI
pushbutton and keys enables commands to be fed into the controller by the operator.
Each key is labelled showing the related inputs available. Figure below shows the
arrangement of the CRT and MDI panel.

CRT STATUS DISPLAY

During machine operation the operational state and condition of the control system is
indicated along the bottom of the screen, as follows:

STATUS DISPLAY INDICATION

NOT READY Control on system is not ready for operation.
Alarm condition exists. Press ALARM key to display of
ALARM
alarm information
Power level in battery is low. Battery used to prevent
BAT
loss of data stored in memory when power is off.
Command data read into buffer register has not been
BUF
executed.
JOG JOG mode selected.
HNDL HAND/STEP mode selected
MEMORY AUTO mode selected
MDI MDI mode selected
EDIT mode selected. Status displayed at center of
EDIT
bottom line.
Editing in progress. Status displaying at right-hand side
EDIT
of bottom line.
SEARCH Sequence number or word search in progress.
OUTPUT Program being output by use of input/output interface

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 INPUT Program being input by use of input/output interface.
Program being compared with memory content using
COMPARE
input/output interface.
Label skip condition for input and collation of program by
LSK
I/O interface.
ZRN That a reference point return has been operated.

SWITCHING ON THE MACHINE

ACTION CHECK
Switch the MAINS
Machine ON button is lit.
ISOLATOR
Press MACHINE ON Hydraulic pumps start. Control system energized.
BUTTON and hold until Machine area lamp is lit (providing lamp switch has
position information is been selected on). Position information displayed on
displayed CRT

MANUAL OPEARTING PROCEDURES

The following manual operating procedures are possible by the application of

manual controls on the machine control panel.

JOG FEED

Select mode switch and select the required federate on the JOG and FEEDRATE
OVERRIDE (%) selector. Then select the axis direction by means of the button.

If Rapid Traverse is required, switch to RAPID on the control panel.

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HAND FEED

Set MODE SELECT switch to HAND/STEP. Set AXIS SELECT switches to the
„X‟ , „Y‟ or „Z‟ axis and x1 or x10 movement, as required. Rotate the FEED
HANDWHEEL, clockwise +ve direction or counter-clockwise for –ve direction. DO NOT
rotate the handwheel too rapidly.

MANUAL REFERENCE POINT RETURN

The tool can be returned to the reference (start) point from a point in the
machining area:

Set MODE SELECT REF POINT RETURN BUTTON and pressed

operating button in the required axis direction. (one axis at a time)

G CODES AND M CODES

The most common codes used when programming CNC machines tools are G-
codes (preparatory functions), and M codes (miscellaneous functions). Other codes
such as F, S, D, and T are used for machine functions such as feed, speed, cutter
diameter offset, tool number, etc. G-codes are sometimes called cycle codes because
they refer to some action occurring on the X, Y, and/or Z axis of a machine tool.

G CODES

G00 (modal) Rapid positioning

G01 (modal) Linear interpolation

G02 (modal) Circular interpolation, clockwise (CCW)

G03 (modal) Circular interpolation, Counterclockwise (CCW)

G04 (non-modal) Dwell mode

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G81 drilling

G96, G97 By implementing the G96 code the spindle speed is controlled so that the
surface speed remains constant at any tool position. If G97 is programmed the spindle
speed is directly commanded by a 4-digit S command word.

G97 is set when power is turned ON.

G98,G99 ( modal) The cutting federate can be set in feed per minute ( G98) or in feed
per revolution (G99) which is synchronized with spindle revolution.

The actual federate occurring on the machine may be modified by the operator
using the Jog and Feedrate override Control. This control is calibrated in 10%
increments from 0% (STOP) to 150%.

M CODES

These represent miscellaneous functions which are commanded by an M

address followed by a 2-digit numeric value. Signals transmitted by the codes are used
for the On/Off control of a machine function, or end of program and program stop
functions. Only one M code can be commanded in one block. When two or more M
codes are commanded, only the last one is effective.

The following M codes are avalaible:

M00 Program Stop, Spindle and Coolant Off

M02 Program End, Spindle and Coolant Off

M03 Spindle counterclockwise (CCW)

M04 Spindle clockwise (CW)

M05 Spindle Stop

M06 change tool

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M08 Main Coolant “On”

M09 Main Coolant “Off”

M30 End of Tape

M98 Sub-program Call

M99 End of Sub-program

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MDI (Manual Data Input) CONTROL KEYBOARD

The following information briefly explains the function of each key when pressed.
For further details refer to Fanuc system operators manual.

The following keys, when pressed, enable the display of specific functional
information data. As several pages of data may be available for a specific function
adjustment pages can be selected by means of a PAGE keys.

KEY FUNCTION
Displays the current position of the tool, the actual
POS (position)
difference moved and the distance to end of travel.
Enables the following:
PRGRM Edit and display of the program in the memory.
(program) Input and display of the MDI data.
Display of command values.
OFSET
Enables setting and display of tool offset values.
(offset)
PARAM
Enables the settings and display of parameter.
(parameter)
When an alarm occurs the word ALARM key displays
ALARM the alarm message. This could be an overheat, system,
overtravel, servo or program errors (P/S) alarm.
When pressed various data is displayed enabling the
DGNOS operator to check details and conditions of NC
(diagnostics) input/output signals, parameter values, alarms, servo
system, etc.
Moves a page of information
PAGE select
Data, as selected on the CRT select keys, in the
(arrow keys)
direction of the arrowed key pressed.
INPUT Keyed data, displayed on the CRT screen, is set into

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 the program by pressing the input key.
START For program loading and unloading only.
A cursor symbol- appears on the CRT screen as each
page of information is selected.
CURSOR select Press ↓ key- cursor moves forward (right)
(Arrowed Keys) Press↑ Key- cursor moves backwards (left)
Hold key pressed and cursor movement is continuous,
across and down or up.
Executes a reset condition. Generally used to release
RESET
an alarm status. Also resets a current NC status.
These alpha-numeric keys enables the input of data
into the computer memory in the MDI and EDIT modes.
DATA INPUT KEYS
Each key is multi-functional and is used as a numeric
or address key.
PROGRAM Edit keys
These keys are used when program editing and are
only operative when in the EDIT mode and the PRGM
key has been pressed.
ALTER Enables an existing word in the program to be altered
(change)

INSRT Enables an additional word to be inserted in the

program.

EOB EOB key used in EDIT and MDI modes. Each

command on block of information keyed into the
memory must end with the EOB key.

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Examples:

To rapidly positions the cutting tool when it is above the workpiece from one point to
another on a job us G00 code. During the rapid traverse movement, either the X or Z
axis can be moved individually or both axes can be moved at the same time.

G00 →Input X ____ → Input Y ____ → Input Z ____ → Input Start/ Cycle Start

For automatic reference point return

G28 X 0.0 Y 0.0 Z 0.0 EOB Start/ Cycle Start

For changing Tool

M06 T03 EOB Start/Cycle Start

Note: 03 – Tool Number

00 – Tool compensation

To turn On the spindle

S______ M03 or M04 EOB Start/Cycle Start

To Turn Off the Spindle

MO5 EOB Start/ Cycle Start

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PROGRAM AND SEQUENCE NUMBER SEARCH PROCEDURE

Program and sequence numbers are displayed at the top right of the CRT screen. The
search facility enables the operator to quickly locate a program or sequence number for
editing purposes.

PROGRAM SEARCH NUMBER

4. Set MODE SELECT switch to EDIT or AUTO.

5. Press the PRGRM key. Key-in address O or : and the program number to be
searched.
6. Press CURSOR key.

SEQUENCE NUMBER SEARCH

This facility enables a sequence number (e.g. N112) search anywhere in the program.
Normally used when it is required to start or restart the program at the block of the
particular sequence number.

6. Set MODE SELECT switch to AUTO

7. Press PRGRM key
8. By the means of data input keys select the program number in which the
sequence number to be searched belongs.
9. Key-in N and the sequence number to be searched for
10. Press the CURSOR ↓ key.

LOADING AND EDITING OF EXISTING PROGRAM

10. Set PROGRAM PROTECT switch to OFF

11. Set MODE SELECT switch to EDIT.
12. Press PRGRM key
13. Key-in the address O and program number and press INSRT key.
14. Press EOB key.
15. Key-in the required program block. After each word press INSRT key.

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 16. After each block of information, press the EOB key.
17. Continue as in actions 6 and 7 until complete program is loaded.
18. Set the PROGRAM PROTECT switch to ON.

EDITING THE PROGRAM

Programs loaded into the memory can be edited by switching the EDIT mode and using
the following three methods:

Alter The changing of a word or words already keyed into the memory.

Insert To enter or add words which has been omitted.

Delete To delete or erase an unwanted word or block of words.

Note: PROGRAM PROTECT switch to OFF in order to edit a program and switch to ON
after editing.

PROGRAM CHECKING

Having entered and edited the program it is recommended that prior to actual
machining operations a Dry Run is executed in order to check the program.

DRY RUN

this method of checking the program is useful for observing the slide and
turret movements. Spindle rotation and coolant flow is inhibited.

5. Set MODE SELECT switch to MEMORY.

6. Switch DRY RUN switch to ON.
7. Set or select the required program by carrying out a Program number search.
8. Press CYCLE START button.

TOOL OFFSETS

The use of tool offsets enable the operator to compensate the changes in the tool
shape, tool mounting position and for tool wear. An offset which compensate for tool

TRAINING OF TEACHERS 2016 Page 49

wear is made by moving the tool. To compensate for the changes in the tool shape or
position a tool geometry offset is made which shifts the co-ordinate system without
moving the tool.

5. Set MODE SELECT switch to EDIT.

6. Press OFFSET key and press PAGE keys as necessary, to bring up the required
offset number line.
7. Press the required address key and input the offset value (with decimal point) by
means of data input keys.
8. Press the INPUT key.

AUTOMATIC OPERATING PROCEDURES

This machine can be operated according to the program in the automatic mode.

STARTING IN THE AUTO MODE

To start a machining program registered in the memory, proceed as follows:

4. Set or select the required program by carrying out a program number search.
5. Set MODE SELECT switch to MEMORY.
6. Press CYCLE START button.

FEED HOLD OPERATION

Feed movement on both axes can be temporarily stopped during an Auto Cycle
or MDI operation, and can be resumed by pressing CYCLE START button. It is
also possible to operate in a manual mode before resuming the axis feed.

4. Press FEED HOLD button.

5. Restart cycle after feed hold condition.
6. Press CYCLE START button.

SINGLE BLOCK OPERATION

4. Set SINGLE BLOCK switch to make a temporary stop.

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 5. Press CYCLE START.
Note: Repeat action 2 to run each program block.
6. On the completion of single block operation set SINGLE BLOCK to OFF.

MANUAL OPEARTION WHEN IN AUTO

6. Press FEED HOLD button or set SINGLE BLOCK switch to ON to make a

temporary stop.
7. Press POS key on MDI keyboard.
8. Complete the required manual operation and return tool to the recorded position
noted in action 2.
9. Reset MODE SELECT switch to the position prior to manual operation and set
SINGLE BLOCK switch is OFF.
10. Press CYCLE START button.

MDI (Manual Data Input) WHEN IN AUTO

This procedure enables instructions by manual data input to be keyed-in when the
machine is being operated in the automatic mode.

5. Switch SINGLE BLOCK switch to ON.

6. Switch MODE SELECT switch to MDI position.
7. Key-in the required data by means of the MDI keyboard.
8. Reset MODE SELECT switch to AUTO, select SINGLE BLOCK to OFF and
press CYCLE START button.

MACHINING SHUTDOWN PROCEDURE

NORMAL

To shutdown the machine from normal production at the end of a shift proceed
as follows:

5. Allow machining cycle to finish. (program completed)

6. Set MODE SELECT switch to JOG.

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 7. Press and hold REF POINT RETURN button and at the same time operate
the JOG joystick to bring the turret to the X-Z axes reference point.
8. Switch OFF the MAIN ISOLATOR.
EMERGENCY
To stop the machine in an emergency, press the EMERGENCY STOP
pushbutton on the control panel. All machine functions stop immediately.
Before resetting the machine rectify the reason for the emergency stop.
Pull out the EMERGENCY STOP button to reset it and return turret to X-Z
axes reference point as detail for normal shutdown.

Prepared by:

TRAINING OF TEACHERS 2016 Page 52

Alain Vincent M. Comendador
Electrical/ Electronics

Approved by:

MATHEWOS ASHENAFI
CEE Director, Industry Extension and Technology Transfer

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