MAKERERE UNIVERSITY

COLLEGE OF ENGINEERING, DESIGN, ART AND

TECHNOLOGY

SCHOOL OF ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

BACHALOR OF SCIENCE IN MECHANICAL

ENGINEERING

COMPUTER AIDED ENGINEERING LABORATORY

ASSIGNMENT REPORT, 2023

Instructor: Mr. Matovu Alexander

Group members
Name Student Number Registration Number Signature

KAKINDA MARVIN
AYEBALE GODFREY 2000700777 20/U/0777
Contents
TABLE OF FIGURES..................................................................................................................................iii
CHAPTER 1: INTRODUCTION..................................................................................................................1
1.1 History of CNC....................................................................................................................................1
1.2 Advantages of NC machining..............................................................................................................2
1.3 Disadvantages of NC machining.........................................................................................................2
1.4 Classification of CNC machines..........................................................................................................3
1.5 Fundamentals of Part Programming....................................................................................................5
1.6 CAD/CAM Approach to Part Programming........................................................................................7
CHAPTER 2: PROCESS PLAN FOR A CONNECTING ROD................................................................10
2.1 Introduction........................................................................................................................................10
2.2 Part Design.........................................................................................................................................10
2.3 Material selection...............................................................................................................................11
2.4 Operations to carry out on the part....................................................................................................13
PART A...................................................................................................................................................13
2.4.1 Roughing..............................................................................................................................13
2.4.2 Facing...................................................................................................................................13
2.4.3 Pocketing.............................................................................................................................14
2.4.4 Spot drilling.........................................................................................................................14
2.4.5 Drilling.................................................................................................................................15
2.4.6 Sweeping operation..............................................................................................................15
2.4.7 Profile Contouring...............................................................................................................16
PART B....................................................................................................................................................17
2.5 Machining conditions for some of the operations..............................................................................19
2.5 NC Part Program..........................................................................................................................22
TABLE OF FIGURES
Figure 1: Physical connecting rod................................................................................................................10
Figure 2: Padded body.................................................................................................................................11
Figure 3: Stock.............................................................................................................................................12
Figure 4: Roughing operation......................................................................................................................12
Figure 5: Face milling operation..................................................................................................................13
Figure 6: Pocketing operation......................................................................................................................13
Figure 7: Spot drilling operation..................................................................................................................14
Figure 8: Drilling operation.........................................................................................................................14
Figure 9: Sweeping operation......................................................................................................................15
Figure 10: Profile contouring.......................................................................................................................15
CHAPTER 1: INTRODUCTION
Numerical control (NC) is a system that uses prerecorded information prepared from numerical
data to control a machine tool or the machining process. NC describes the control of machine
movements and various other functions by instructions expressed as a series of numbers and
initiated via electronic control system.
Computer numerical control (CNC) is the term used when the control system includes a
computer.
Manufacturing areas of NC, CNC, and DNC include flame cutting, riveting, punching, piercing,
tube bending, and inspection. NC and CNC are particularly suitable for the manufacture of a
small number of components needing a wide range of work, such as those with complex profiles
or a large number of holes. They are also suitable for batch work. In NC machining, the part
programmer analyzes the drawing, decides the sequence of operations, and prepares the
manuscript in a language that the NC system can understand.
The NC system consists of data input devices, a machine control unit (MCU), servo drive for
each axis of motion, a machine tool operative unit, and feedback devices. The program written
and stored on the tape is read by the tape reader, which is a part of the MCU. The MCU
translates the program and converts the instructions into the appropriate machine tool
movements. The movement of the operative unit is sensed and fed back to the MCU. The actual
movement is compared with the input command and the servomotor operates until the error
signal is zero.
1.1 History of CNC
The history and development of NC dates back to 1952, when the first NC conventional milling
machine was demonstrated at the Massachusetts Institute of Technology (MIT). In 1957, aircraft
manufacturers installed a milling machine—the beginning of NC technology—that was used for
machining complex profiles for the aircraft and aerospace industries. Drilling machines, jig
borers, lathes, and other NC machine tools were soon developed with less tooling, more
operations performed in the same setup, and involvement of the operator in controlling the
machine was avoided. NC machining centers and turning centers then appeared and gave the
machine designers and builders a chance to improve NC-machined products in terms of accuracy
and surface quality. The development in electronics industry played a key role in the growth and
acceptance of NC machine tools. Since the 1960s, smaller electronic components such as
transistors, resistors, and diodes have increased the reliability and reduced the size and cost of
machine tools. The development of integrated circuits in 1965 led to a further reduction of the
size and cost of the control units and provided the basis for the use of minicomputers in CNC and
direct numerical control (DNC) machining.
Earlier systems of NC machines consisted of a specially built control unit permanently
connected to the machine tool. They are relatively inflexible, as they are special-purpose
machine tools. Developments in the area of miniaturization and integration of circuits has led to
the introduction of new, small, and powerful computers that are used to control the machine tools
(CNC) instead of a conventional controller. The advantages of CNC are related to the control
system, which allows a great deal of flexibility unobtainable with NC. DNC involves controlling
more than one machine using the same computer and data transmission lines. The major
advantage of CNC and DNC over NC is that punched tapes are not used directly to control the
machine tool. Instead, all information flows from a computer that interfaces with each MCU
1.2 Advantages of NC machining
 Greater flexibility. With NC, a wide variety of operations can be performed, changeovers
from one run to another through tape or program changes can be made rapidly, and
design changes to parts can be made rapidly through minor changes to the part program.
 Elimination of templates, models, jigs, and fixtures. The NC control tape takes over the
job of locating the cutting tools, which eliminates the design, manufacture, and the use of
templates, jigs, and fixtures.
 Easier setups. By using more simple work holding and locating devices, the operator does
not have to set table limit stops or dogs, or depend on the feed screw dials when setting
up for machining.
 Reduced machining time. Machining with NC allows the use of a wider range of speeds
and feeds than conventional machine tools. Optimum selection of feed rates and cutting
speeds is ensured. The NC equipment can also move from one cutting operation to the
next faster than the operator, which significantly reduces the total machining time.
 Greater accuracy and uniformity. During NC machining, no human errors are possible
and machining of the same part is performed in the same way through the stored tape or
program, which improves the uniformity and interchangeability of the machined parts.
Therefore, inspection time is greatly reduced, and is necessary for the first piece only, in
addition to random checks for critical dimensions. Hence, scrape and rework are greatly
reduced or completely eliminated by using NC.
 Greater safety. The operator is not as closely involved with the actual machining
operations as with conventional machine tools. As the tape is checked out before actual
production runs, there is less chance of machine damage that may cause human injuries.
 Conversion to the metric system. An NC system can be converted to accept either inch or
metric inputs.
1.3 Disadvantages of NC machining
 NC follows programmed instructions that can lead to machine destruction if not properly
prepared.
 NC cannot add any extra machining capability to the machine tool, as no more power
from the original drive motor and no more table travel than originally built into the
machine tool can be added.
 NC machines cost five to ten times more than conventional machines of the same
working capacity. The machine, therefore, cannot remain idle and needs special
maintenance.
 The skills required to operate an NC are usually high, because of the sophisticated
technology involved, which requires part programmers, tool setters, punch operators, and
 maintenance staff who are more educated and well-trained than conventional machine
operators.
 Special training for personnel in software and hardware is very important for successful
adoption and growth of the NC technology.
 NC requires high investments in terms of wages of highly skilled personnel and
expensive spare parts.
1.4 Classification of CNC machines
There are many types of CNC machines, which can be classified into the following categories
based on different classifications.
a) Classification by functions
 CNC milling machines: used to create shapes, slots, holes, notches, grooves,
pockets, and specialty faces, and perform the machining process of
manufacturing CNC milling parts, the rotary cutting tools on the mill to remove
material from the stationary work piece.
 CNC lathes: used to manufacture cylindrical objects, and perform the process of
producing CNC turning parts, a cutting tool will shape the work piece while the
material block is turning rapidly on a spindle.
 CNC drilling machines: used to drill hole in the work piece, the tool can locate
the position for drilling quickly and accurately, sophisticated drilling machines
can also perform reaming, counter boring, and tapping holes.
 CNC plasma cutters: a machine carries a plasma torch, which is for cutting
metals, involves cutting through electrically conductive materials by an
accelerated jet of hot plasma.
 CNC grinders: a machine uses a rotary wheel to graze the material by grinding or
grating it into the desired shape, it’s easier to program than milling machines and
lathes.
b) Classification by motion type
 Point to point systems: the material and tool are placed at certain fixed relative
positions at which they retaining until the cutter finishes the process and retracts,
this type equipment including drilling, boring and tapping machines.
 Contouring systems: the machine tool cuts the material following a contour of a
part, so it works in a continuous path, this type equipment including lathes, mills
and routing machines.

c) Classification by number of axes

2-axis CNC machines: a machine gives access to only two axes, like the lathe machines,
the tool moves in 2 directions, like X and Z.
 2.5-axis CNC machines: is also a 3-axis system but the movement is not in three-
dimensional, the X and Y-axis moved to the position first and then the third axis
starts to work, such as the drilling and tapping machines.
  3-axis CNC machines: three axes (X, Y and Z) move simultaneously in three-
dimensional, it’s the most widely used and versatile machine that can achieve
high accuracy and precision, can be used for automatic/interactive operation,
milling slots, drilling holes, and cutting sharp edges.
 4-axis CNC machines: the 3-axis machine with one more rotation on A-axis or B-
axis, the common example is a vertical machine or horizontal machine. In the
case of 4-axis machining, milling is performed on the additional axis, while the
operation on the X, Y and Z is the same as the 3-axis system, and the rotation on
the A or B axis is around the X-axis.
 5-axis CNC machines: the 3-axis machine with extra rotation along two
directions (Y and Z) on A-axis and B-axis, the rotations are respectively given by
the bed and spindle movement (pivot point). 5-axis machines are advanced CNC
machines and its multidimensional rotation and tool movement allows the
creation of precise and intricate parts due to the improved access to undercuts and
deep pockets, unmatched finish and speed, often used for high-level applications,
like aerospace parts, artificial bones, titanium pieces, oil and gas machine parts,
military products and more.
d) Classification by control loop
 Open-loop CNC machine: refers to a system where the communication between
the controller system and the motor is one way. The process for an open-loop
system is simple, CNC software creates the information with necessary step and
direction signals based on the user’s purpose, the computer relays this
information to the controller which then energizes the motor, and no feedback.
Open-loop CNC machines use stepper motors.
 Closed-loop CNC machine: has a feedback system to monitor the output of the
motors, also able to correct errors in position, velocity, and acceleration. The
feedback can be returned to the CNC controller or computer. The system with
feedback fed into the signal generator or computer usually exists in high-end
machines.
e) Classification by technology used
 Plasma cutter: These machines use a plasma torch to penetrate wood or sheet
metal. Laser: CNC laser cutters operate quite like CNC plasma cutters, but
instead, a laser is used to cut the wood or metal. Lasers can also be used to cut
plastic.
 Water jet cutters: These use pressurized water to cut part through the material
 Electro-discharge machining: These machines use electrical discharges between
tools to cut through materials.
 3D Printer: 3D printers use CNC technology and operate using similar
technology as CNC lasers, but utilize an extruder to slowly deposit plastic in a
consistent motion until the desired product is complete.
 Pick and Place: Pick and Place CNC Machines consist of several nozzles that
pick up electrical components for electronic equipment and place them in the
 desired location. These are very commonly used in the construction of cell
phones, computers, tablets, etc.
1.5 Fundamentals of Part Programming
The following are the basic steps in NC procedure
 Process Planning
 Part Programming
 Part Program entry
 Proving the part program
 Production
A) Process Planning
The part programmer will often carryout the task of process planning. Process planning is the
procedure of deciding what operations are to be done on the component, in what order, and with
what tooling and work holding facilities. Both the process planning and part programming
aspects of manufacture occur after the detail drawings of a component have been prepared. The
following procedure may be used as a guide to assist the programmer, by describing each step
required in preparing the method of production.
 Process Planning
 Receive the part drawing from part drawing information, check suitability of part to
be machined against the machine capacity.
 Determine a method of driving the component (chuck type, chuck size, type of jaw)
and the method of machining.
 Determine the tooling required to suit the method of machining and utilize as much as
possible the tools which are permanently in the turret set upon the machine.
 Determine the order of machining and the tooling stations.
 Determine planned stops for checking dimensional sizes where required by operator
Determine cutting speeds based on;
o Component material, method of driving, rigidity of component
o Tooling selected for roughing and finishing
 Determine the depths of cut and feeds for roughing operations
 Determine surface finish requirements, the cutter nose radius most suited for finishing
operations and determine feed rates.
 Allocates tool offsets as required
 Complete planning sheet
B) Part Programming
 After completing the planning sheet, draw the component showing the cutter paths (a
simple sketch is sufficient for simple components)
 Select a component datum and carryout the necessary calculations at slopes and arcs.
 Prepare tooling layout sheet showing tools to be used in the program and indicate the
station number for each tool.
  Indicate the ordering code for each tool and grade and type of inserts to be used.
 Write the part program according to the sequence of operations.
C) Part Program Entry or Tape Preparation
The part program is prepared / punched on a 25 mm wide paper tape with 8 tracks and is fed
to MCU in order to produce a component of interest on machine tool. Other forms of input
media include, punched cards, magnetic tape, 35 mm motion picture film. The input to the
NC system can be in two ways:
1. Manual data input
2. Direct Numerical control.
1) Direct Data Input (MDI): Complete part programs are entered into CNC control unit via
the console keyboard. It is suited only for relatively simple jobs. The most common
application for MDI is the editing of part programs already resident in controllers’
memory. One variation of MDI is a concept called “Conversational Programming”. CNC
machines are programmed via a question and answer technique whereby a resident
software program asks the operator a series of questions. In response to the operators
input, and by accessing a pre-programmed data file, the computer control can
 Select numerical values for use within machining calculations
 Perform calculations to optimize machining conditions
 Identify standard tools and coordinates
 Calculate cutter paths and coordinates
 Generate the part program to machine the component
A typical dialogue from the machine would be as follows for the operator to identify
such things as:
 Material to be cut
 Surface roughness tolerance
 Machined shape required
 Size of the raw material blank
 Machining allowances, cut directions
 Tools and tool detail etc.
The operator may then examine and prove the program via computer graphics simulation on the
console VDU. After this, the program is stored or punched on tape. Although there is some
sacrifice in machine utilization, actual programming time is minimal and much tedious
production engineering work is eliminated.
2) Direct Numerical Control: The process of transferring part programs into memory of a
CNC machine tool from a host computer is called Direct Numerical Control or DNC
D) Proving Part Programs It is safe practice to check the programmed path for any interference
between the tool and the work before using the part program for production. The proving part
program is done by:
  Visual inspection
 Single step execution
 Dry run
 Graphical simulation.
Visual Inspection: It represents the method of checking visually the program present in the
memory of the CNC machine. In this, actual program is run and the programmed movements in
all axes are to be checked along with ensuring the tool offset and cutter compensation feature.
This method represents the least form of verification and should not be relied up on.
Single Step Execution: Before auto-running the part program it should be executed in a step
mode i.e block by block. During this execution, spindle speed and feed rate override facilities are
to be used so that axes movement can be easily monitored. This operation may be carried out
with or without mounting the component on the machine.
Dry run: A dry run consists of running the part program in auto-mode. During this, the
component is not installed on the machine table and the cutting is done in air. The purpose of this
run is to verify the programmed path of the tool under continuous operation and to check
whether adequate clearance exist between the clamping arrangement and other projections within
the set up. Feed rate override facilities are used to slow down the speed of execution of the
program.
Graphical simulation: A graphical simulation package emulates the machine tool and, using
computer graphics, plots out the machine movements on a VDU screen. Machine movement
often takes the form a cutting tool shape moving around the screen according to the programmed
movements. When the tool shape passes over a shaded representation of the component, it erases
that part of the component. The resulting shape, lest after the execution represents the shape of
the finished component. Any gross deviations from the intended tool path can be observed and
any potential interferences can be highlighted.
1.6 CAD/CAM Approach to Part Programming
Computer Aided Design (CAD)
CAD is a technology that involves a computer in the design process. It enables the engineer to
develop, change, and interact with the graphical model of a part. Computers are strong in the
areas of graphics, calculations, analysis, modeling, and testing. During CAD stages, the engineer
draws the part on the screen. This information can be used to create a program to machine the
part. The designer must work closely with the manufacturing experts to establish some standards
for the design.
CAD allows different layers to be created. This technology allows other software to take the part
geometry from each layer and assign different tools to machine it. The computer allows design to
be viewed and tested before manufacturing. CAD systems stress-test parts to meet the strength
requirements of the application. Graphics capabilities allow three-dimensional (3D) viewing of
parts from any angle. CAD systems can also export the CAD part fi le in-Drawing Exchange File
(DXF) format. Using CAD systems, the following advantages can be secured:
  Increase the productivity of the designers
 Create better designs
 Reduce redundant effort
 Allow easy and rapid modification of prints
 Enable integration of engineering and manufacturing
Computer-Aided Manufacturing (CAM)
CAM utilizes computers in the manufacturing stage. Such a modern technique has the following
features:
 Allows the programmer to develop a model that represents the part and the machining
operations.
 The programmer can interact with the model graphically to make the necessary
adjustments and modifications before the CNC code is generated.
 CAM software reads the DXF that contains the part geometry and the levels or layers that
the geometry exists on.
 CAM software utilizes a job plan to assign the correct tool path to each layer.
 The job plan knows the work material that will be used so that it can calculate speeds and
feeds for each tool.
The integrated CAD/CAM approach prepares the part program directly from the CAD part
geometry, either by using NC programming commands called in the CAD/CAM system or by
passing the CAD geometry into a dedicated CAM program. Using CAD/CAM systems, the CAD
drawings can therefore be changed to CNC programs. The CAD/CAM approach has the
following advantages:
 No need to encode the part geometry and the tool motion
 Allows the use of interactive graphics for program editing and verification
 Displays the programmed motions of the cutter with respect to the WP, which allows
visual verification of the program
 Allows interactive editing of the tool path with the addition of the tool moves and
standard cycles
 Incorporates the most sophisticated algorithms for part programming generation
The programming steps for CAD/CAM approach are as follows:
The aspects of the part geometry that are important for machining purposes are identified (and
perhaps isolated on a separate level or layer); geometry may be edited or additional geometry
added to define boundaries for the tool motion.
1. Tool geometry is defined; for instance, by selecting tools from a library.
2. The desired sequence of machining operations is identified and tool paths are defined
interactively for the main machining operations.
3. The tool motion is displayed and may be edited to refi ne the tool motion, or other details
may be added for particular machining cycles or operations.
4. A CLDATA fi le is produced from the edited tool paths.
5. The CLDATA fi le is post processed to MCD, which is then transmitted to the machine
CHAPTER 2: PROCESS PLAN FOR A CONNECTING ROD
2.1 Introduction
Each group member was tasked to come up with a product idea for which CNC machining could
be applied. This product was supposed to be something that is useful in society. The ideas
generated were;
 A connecting rod
 A Spanner
After considering design limitations and manufacturability constraints, a connecting rod was
chosen by the group members as the product to manufacture. The task at hand was to design the
part and prepare a process plan for the manufacture of a connecting rod on a CNC machine. This
task was to be done using CATIA.
2.2 Part Design
A connecting rod, also called a 'con rod', is the part of a piston engine which connects the piston
to the crankshaft. Together with the crank, the connecting rod converts the reciprocating motion
of the piston into the rotation of the crankshaft.

Figure 1: Physical connecting rod

The part design was developed in CATIA with the help of sketch tools and body features using
the following steps;
Step 1: Sketch
A sketch of the part geometry was made using sketch tools like lines, corner and the dimensions
were put using smart dimension to fully define the sketch.
Step 2: Pad
The pad was achieved by use of the pad tool to obtain a solid model of the connecting rod

Figure 2: Padded body

2.3 Material selection

When deciding on the material to use, we had various options which included wood, hard plastic,
Steel and Aluminum. We chose steel because of the following reasons:

 Strength and Durability

 Connecting rods experience immense forces during engine operation.
 Engines generate a lot of heat, and connecting rods need to withstand these high
temperatures without losing their strength or shape. Steel has a high melting point
and excellent thermal stability, making it ideal for this demanding environment.
 Fatigue Resistance
 Connecting rods are constantly subjected to cyclic stresses as the engine
runs. Steel has excellent fatigue resistance, meaning it can withstand these
repeated stresses without breaking. This is crucial for long engine life.
Our design was separated into two different sections called the rod and the cap

Figure 3: Rod Stock

Figure 4: Cap stock

2.4 Operations to carry out on the part
Various operations were carried out on the stock material in order to achieve the desired
connecting rod shape. The following processes show the steps we carried to make the connecting
rod:
PART A
This section gives details about the operations carried out on the rod part of the connecting rod.
The operations were carried out on one half of the stock, this was later turned and the operations
repeated on the other half of the stock.
2.4.1 Roughing
Roughing is the initial stage of material removal from a workpiece. We used this process to
quickly and efficiently remove the bulk of the material to bring the raw block or cast closer to its
final shape.

Figure 5: Roughing operation for rod

2.4.2 Facing
Face milling is a CNC machining process that uses a milling cutter to create flat surfaces parallel
to the spindle axis. The milling cutter is rotated and fed across the workpiece, removing material
with each pass. We used this process to create a flat surface on the workpiece in order to prepare
the surface for other machining operations.
Figure 6: Face milling operation for rod

2.4.3 Pocketing
Pocketing is a crucial operation for creating recessed areas, cavities, and pockets within a
workpiece. Imagine carving out a bowl from a block of wood – that's essentially what pocketing
does but with the precision and control of a CNC machine.

We used this operation to removes material within a closed boundary and to create cavities of
various shapes and depths.

Figure 7: Pocketing operation for rod

2.4.4 Spot drilling

Spot drilling is a machining process that involves creating a small, shallow indentation or pilot
hole on a workpiece to guide the starting point for a larger drill bit. It is commonly used to
ensure accurate and precise drilling, especially when drilling into hard or delicate materials.
Figure 8: Spot drilling operation for rod

2.4.5 Drilling
CNC drilling is a machining process that utilizes a rotating cutting g tool, or drill bit, to create
precise round holes in a stationary workpiece. The drill bit is fed into the workpiece along the
spindle axis, removing material with each pass. This operation was used to create the hole at the
back of the rod.

Figure 9: Drilling operation for rod

2.4.6 Sweeping operation

Sweeping operation in CNC machining, also known as sweep milling or ruled surface milling, is
a powerful technique for creating complex 3D geometries by progressively moving a 2D profile
along a defined path.
The purpose of sweeping to create the fillets on the edges of the rod.
Figure 10: Sweeping operation for rod

2.4.7 Profile Contouring

Profile contouring, also known as profile milling or contouring, is a CNC machining process that
involves moving the cutting tool along a defined path or contour to create a specific shape or
profile on a workpiece. We used this process to obtain the outside profile of the connecting rod.
An end mill tool was used to mill the stock and achieve the desired shape.

Figure 11: Profile contouring for rod

PART B
This section gives details about operations carried out on the cap of the connecting rod. The
operations were carried out on one half of the cap stock, which was later turned and the
operations repeated on the second half.
2.4.8 Facing
We used this process to create a flat surface on the workpiece in order to prepare the surface for
other machining operations

Figure 12: Facing operation on cap

2.4.9 Profile contouring

This process was used to come up with the outside profile of the cap of the connecting rod

Figure 13: Profile contouring operation on cap

2.4.10 Sweeping

Figure 14: Sweeping operation on cap

2.5 Machining conditions for some of the operations

Machining Roughing Profile Spot drilling Drilling
Condition Contouring
Tool path Back and forth Helix n/a n/a
style
Finishing No finish pass No finish path n/a n/a
mode
Direction of Climb Climb n/a n/a
cut
Machining 0.1mm 0.1mm n/a n/a
tolerance
Fixture 0.1mm 0.1m n/a n/a
accuracy
Type of Circular Circular n/a n/a
contour
Compensati 1 1 n/a n/a
on
Radial Step over ratio Tool diameter ratio n/a n/a
mode
Distance 20mm 5mm n/a n/a
between
path
Percentage 50 n/a n/a
of tool
diameter
Axial mode Maximum Maximum depth of n/a n/a
depth of cut cut
Maximum 0.5mm 0.5mm n/a n/a
depth of cut

Number of 2 2 n/a n/a

levels
Tool name T1 Face Mill T2 End mill D10 T3 Spot Drill D 15 T5 Drill D 10
50
Tool 1 2 3 5
number
Approach 300mm_mn 300mm_mn 300mm_mn 300mm_mn
feed rate
Machining 1000mm_mn 1000mm_mn 1000mm_mn 1000mm_mn
feed rate
Retract feed 300mm_mn 300mm_mn 1000mm_mn 1000mm_mn
rate
Finishing 300mm_mn 300mm_mn
Transition Machining Machining Machining Machining
Transition 5000mm_mn 5000mm_mn 5000mm_mn 5000mm_mn
feed rate
Federate Linear Linear Linear Linear
unit
Spindle 70turn_mn 70turn_mn 70turn_mn 70turn_mn
speed
Spindle Angular Angular Angular Angular
output unit
Quality Finish Finish
Approach Build by user Build by user Build by user
mode
Approach n/a n/a
distance
Cornerized 3mm n/a n/a
distance
Clearance Safety plane Safety plane n/a n/a
Sequencing Radial first n/a n/a
Feed rate 80 n/a n/a
reduction in
corners
Maximum 45 deg n/a n/a
angle
Maximum 1mm n/a n/a
radius
Power n/a n/a From tool assembly From tool
 assembly
Approach n/a n/a 1mm 2mm
clearance
Depth mode n/a n/a None By tip (Dt)
Plunge n/a n/a None None
mode
Plunge n/a n/a 10mm_mn 10mm_mn
Tools
2.5 NC Part Program
After the machining operations were complete, a part program was generated. The following are
a summary of the part program for the different operations carried out.
;======================================================
;=== cPost Standard PP for SINUMERIK 840 D ===
;======================================================
N10 G0 G90 G40
N20 G17
N30 ;=============== TOOL CHANGE =================
N40 ; DESC : T1 End Mill D 10
N50 ;=============================================
N60 T1 M06
N70 D1
N80 G0 G90 G40 G17
N90 G94 F1000 S70 M3
N100 G64 SOFT
N110 G1 X0 Y110.763 Z-20 F300 G94
N120 Z1.5
N130 Y0 F1000
N140 X-22.776
N150 Y110.763
N160 X-45.552
N170 Y0
N180 X-68.328
N190 Y110.763
N200 X-91.104
N210 Y0
N220 X-113.88
N230 Y110.763
N240 X-136.656
N900 ;=============== TOOL CHANGE =================
N910 ; DESC : T2 End Mill D 10
N920 ;=============================================
N930 T2 M06
N940 D2
N950 G0 G90 G40 G17
N960 G94 F1000 S70 M3
N970 G64 SOFT
N980 G1 X-85.247 Y95.004 Z-20
N990 Z5
N1000 G2 X-97.629 Y50.269 I74.618 J-44.735 F1000
N1010 G2 X-82.975 Y1.946 I87 J0
N1020 G1 X-82.977 Y1.978
N1030 G2 X-30.629 Y-42.731 I52.348 J8.291
N1040 G1 X-24.606
N1050 X39.371 Y7.269
N1060 Y13.269
N1070 Y14.269
N1080 Y16.269
N1090 Y25.269
N1100 G2 X32.672 Y50.269 I-50 J0
N1110 G2 X39.371 Y75.269 I-43.301 J25
N1120 G1 Y84.269
N1130 Y86.269
N1140 Y87.269
N1150 Y93.269
N1160 Y95.269
N1170 G0 Z2.5
N1180 G0 X-76.486 Y92.064
N1190 G0 Z5
N1200 G2 X-88.629 Y50.269

N29820 ;=============== TOOL CHANGE =================

N29830 ; DESC : T3 Drill D 10
N29840 ;=============================================
N29850 T3 M06
N29860 D3
N29870 G0 G90 G40 G17
N29880 G94 F1000 S70 M3
N29890 G64 SOFT
N29900 G0 X-200.629 Y50.269 Z33
N29910 MCALL CYCLE81(33,32,0,,34.794)
N29920 X-200.629 Y50.269
N29930 MCALL
N29940 ;=============== TOOL CHANGE =================
N29950 ; DESC : T4 End Mill D 10
N29960 ;=============================================
N29970 T4 M06
N29980 D4
N29990 G0 G90 G40 G17
N30000 G94 F1000 S70 M3
N30010 G64 SOFT
N30020 G1 X-62.615 Y51.758 Z-20
N30030 Z22.5
N30040 X-68.576 Y50.262 F1000
N30050 X-62.615 Y48.78
N30060 X-62.608 Y51.728
N30070 X-52.855 Y58.388
N30080 G3 X-52.783 Y59.144 I-3.928 J0.756
N30090 G3 X-56.783 Y63.144 I-4 J0
N30100 G3 X-58.078 Y62.928 I0 J-4
N30110 G2 X-80.123 Y57.781 I-25.924 J61.247
N30120 G1 X-80.377 Y57.771
N30130 X-170.407 Y56.27
N30140 X-170.698 Y56.266
N30150 G3 X-175.417 Y53.884 I0.066 J-5.997
N30160 G1 X-175.629 Y50.269 Z23.481
N30170 X-175.499 Y46.812 Z22.613
N30180 X-174.966 Y46.124 Z22.5
N30190 X-174.379 Y45.586
N30200 X-172.856 Y44.699
N30210 X-170.698 Y44.272