MECH414 / MECH6611 – Computer Numerically Controlled Machining

CONCORDIA UNIVERSITY
GINA CODY SCHOOL OF ENGINEERING AND COMPUTER SCIENCE

MECH-414/MECH-6611 XX: Computer Numerically Controlled Machining

Copyright © 2021 by Jones & Bartlett Learning, LLC an Ascend Learning Company. www.jblearning.com
Lecture 8

CNC Mill Programming

Lecture XX: MON 5:45 pm – 8:15 pm (FG B040 SGW)

Instructor: Sam Eskandarian, Ph.D. PEng (Ontario)

Lecture 8
 MECH414 / MECH6611 – Computer Numerically Controlled Machining 2

References
! Instructor’s lecture notes will be posted in MOODLE.

Reference Books for this lecture presentation:

Copyright © 2021 by Jones & Bartlett Learning, LLC an Ascend Learning Company. www.jblearning.com
!

o Rick Calverley, CNC Manufacturing Technology, The

Goodheart-Willcox Company, 2021, ISBN 978-1-63563-883-7.

o Michael Fitzpatrick, Machining and CNC Technology, 4th

Edition McGraw Hill, 2019, SBN 978-1-260-04785-1.

o Bob Dixon, Machining Fundamentals, The Goodheart-Willcox

Company, 11th Edition, 2019, ISBN 978-1-64925-979-0.

o Mascle, C. et Wygowski, W., Fabrication avancée et méthodes

industrielles, Presses internationales Polytechnique.

Lecture 8
 MECH414 / MECH6611 – Computer Numerically Controlled Machining 3

Contact info & Recalls

§ Office: EV3.238
Office Hours: WED 11:00AM - 12:00PM (Individual ZOOM meetings by email reservation when needed)
Email: [email protected]

Copyright © 2021 by Jones & Bartlett Learning, LLC an Ascend Learning Company. www.jblearning.com
§ Recalls:
- Important communications will be posted in MOODLE (“Announcement Section”). You can
communicate by emails (You should write MECH414 or MECH6611 in the subject line). No emails
will be answered in weekends.
o Tutorials (POD): Monday Mar 20 @ 5.45 PM in FG-B040.
o Assignment #2 and submission link are added to MOODLE – Section: Assignment.
This assignment has a weight of 10%. Due date SUN Mar 26 @ 23:59.
o Lab #1: Scheduled for the week of Mar 27 (morning). Detailed info and booking link will be added
soon in MOODLE.
o Final Exam:

Lecture 8
 Copyright © 2021 by Jones & Bartlett Learning, LLC an Ascend Learning Company. www.jblearning.com
5

Lecture 8
MECH414 / MECH6611 – Computer Numerically Controlled Machining

Course plan (2/3)

 Copyright © 2021 by Jones & Bartlett Learning, LLC an Ascend Learning Company. www.jblearning.com
6

Lecture 8
MECH414 / MECH6611 – Computer Numerically Controlled Machining

Course plan (3/3)

CNC
Manufacturing
Technology
 CNC Mill Programming
(Chapter 9)

Ref.: Rick Calverley, CNC Manufacturing Technology,

Copyright © 2021 by JonesThe Goodheart-Willcox
& Bartlett Company,
Learning, LLC an Ascend Learning 2021, ISBN 978-1-63563-883-7.
Company. www.jblearning.com.
 9 CNC Mill
Programming

This chapter covers codes specifically for FANUC-and Haas-controlled machines.

Ref.: Rick Calverley, CNC Manufacturing Technology, The Goodheart-Willcox Company, 2021, ISBN 978-1-63563-883-7.
 Chapter 6

Programming Concepts and

Job Planning
Ch 9 Objectives
• Describe the process of program planning.
• Explain how workholding affects programming.

Copyright © 2021 by Jones & Bartlett Learning, LLC an Ascend Learning Company. www.jblearning.com
• Define the three parts of a CNC mill program.
• Explain the use of G codes.
• Describe when to use an M code.
• Specify when a pocketing toolpath would be used.
• Explain the contour toolpath.
• Describe the benefits of canned cycles.
• Explain the use of cutter compensation.
• Use a G02 and G03 arc command.
• Program angle moves.
• Describe at least two different tool entry techniques.
• Enter tool offsets on the appropriate offset page.
Ref.: Rick Calverley, CNC Manufacturing Technology, The Goodheart-Willcox Company, 2021, ISBN 978-1-63563-883-7. 11
Outline (1/2)
9.1 Introduction to CNC Mill Programming
9.2 Program Planning (Print Review, Part Workholding, Tool
Selection)
9.3 Program Format (Opening Statement, Program Body, Closing
Statement)
9.4 Address Codes (G Codes, M Codes)
9.5 Contouring (Tool Start Position, Cutter Compensation)

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Outline (2/2)
9.6 Radius and Angle Milling (G02 and G03 Radial Movements, I, J, and K
Method, Programming Angles)
9.7 Pocketing (Cutter Entry, Roughing Method)
9.8 Canned Cycles (G83 Cycle - Full Retract Peck Drilling, G73 Cycle -
Chip Break Peck Drilling, G81 Cycle - Spot Drilling, G82 Cycle -
Counterbore Cycle, G84 Cycle - Tapping Cycle, G85 Cycle - Fine
Boring Cycle, G86 Cycle - Spindle Stop Boring Cycle)
9.9 Tool Setting (Length Offsets, Diameter Offsets)
9.10 Work Coordinate Offsets (Finding WCS on Material, Setting WCS on
Control)
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9.1 Introduction - Program Annotation
• Critical information that may be included:
• Location of work offset
• Style, length, and diameter of cutting tools
• Insert specifications
• Workholding information
• Warnings of past mistakes
• Customer part number, material information
• Individual processes within program
• Program information
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Figure 6.2 A typical setup sheet. The setup sheet is a quick way to communicate
the essential information about a CNC machining job.
 Planning a CNC Machining Job

• Steps to planning and executing a CNC

machining job:
1. Study the workpiece drawing
2. Plan the operations and setups
3. Determine which tools are available
4. Write the part program
5. Test and revise the program
 Workholding and Locating
Principles
• The 3-2-1 locating principle:
– Locates a workpiece by making contact on
three surfaces simultaneously

Figure 6.5 The 3-2-1 locating principle starts with the concept that a sphere will contact
another solid surface at only one point. Three points contacting (tangent to) the surface
will create a flat plane. In this illustration, three ball bearings are resting in the face of a
workpiece creating a plane.
 Figure 6.8 The 3-2-1 principle in practice. The
primary datum of the workpiece (translucent) is
Figure 6.7 The 3-2-1 locating principle. The located against the solid jaw of a machining vise
bottom is located on 3 points, the back on 2 (sliding jaw removed for clarity). The secondary
points, and the left side on only 1 point. datum rests on a parallel bar that will allow it
some degree of rotation. Finally, the tertiary
datum is formed by the bar stop that is mounted
to the vise.
Figure 6.9 Uneven surfaces will have to be machined before the surface can be
used for locating.
9.2 Program Planning
• Writing a CNC program is as simple as telling a story one tool at a time.
Your most important tool is the creativity and planning you bring to the
project before making even one keystroke toward writing a program.
• Critical step for success
• Important considerations – workholding, fixturing
• Consider machines and tooling available
• Assemble team:
• Customer representative, engineering staff, setup specialist, operator
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9.2.1 Print Review
• First step — interpret design intent
• Examine tolerances
• Position from which tolerances established
• Establish work coordinate system
(WCS) origin

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9.2.1 Print Review
• The block size is dimensioned as 6′′ by 3′′, with a total tolerance of .020′′.
• A reader can determine from the print that this block could be manufactured from 3′′-wide stock
and that the 6′′ length cannot be left as saw cut, but the block is also not intended for a close fit
into another assembly.

• In the hole position, the tolerances are a little closer.

Those tolerances reference the top-left corner of the
part. It is a good idea to establish the work coordinate
system (WCS) origin—the point where both X and Y
values are zero—at the same corner on the top-left
edge. In the Cartesian coordinate system, this would
be in quadrant 4, or the X+, Y− quadrant.

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9.2.2 Part Workholding
• Workholding:
• Vise
• Specialty fixtures
• specialized devices
like magnetic or
vacuum chucks

• Objectives:
• Maximize machining work per fixture
• Minimize setups
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9.2.3 Tool Selection
• Objectives:
• Reduce tool changes and cycle time
• Minimize number of tools used
• Evaluate using same tools for multiple features
For example, if cutting a .625′′-wide slot and a .750′′-wide slot on one part, a 1/2′′ end mill can
accomplish both without using a second tool.

• Best practice – spot drilling

It is also best practice to spot drill every hole before drilling.

• If any specialized tooling is required, it is best to identify this in the

planning phase so that it can be accounted for while programming.

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9.3 Programming with G & M Codes
• G & M codes:
• Simple instructions programmer writes to make
the machine behave in a certain way
• Just a few can get the work done
• Others are enhancements
• Two types of codes:
• First type: controls machine functions and settings
• Second type: modifies and performs machining
functions
• A block is a single-line code of an NC part program

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9.3 Program Format
• Opening statement
• Body
• Closing statement

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9.3.1 Opening Statement
• Program number – correlate with part number (best practice) - Letter O
• Default block – cancels commands from previous program
• Zero return – returns spindle to Z-axis home position

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9.3.2 Program Body
• Defines tools and movements
• Program for each tool:
• Opening statement
• Body
• Closing statement
• Consistent programming is important

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9.3.2 Program Body

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9.3.2 Program Body

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9.3.2 Program Body

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9.3.3 Closing Statement
• Prepares machine for next part
• Defines optimum position:
• Part removal
• Loading new material

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 9.4 Address Codes
• Single-letter characters – begin each word
• Designate commands or machine functions
• G and M most frequently used

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9.4.1 G Codes
• Preparatory command
• Place CNC control in specific mode
• Can be used for canned cycles
G codes can be used to command canned cycles, or
abbreviated multi-movement cycles, such as G83,
which commands a drilling cycle but does not produce
any machine movement.

• Machine-specific G codes offered

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9.4.1 G Codes (Cont’d)
• Preparatory command
• Place CNC control in specific mode
• Can be used for canned cycles
G codes can be used to command canned cycles, or
abbreviated multi-movement cycles, such as G83,
which commands a drilling cycle but does not produce
any machine movement.

• Machine-specific G codes offered

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9.4.1 G Codes

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9.4.2 M Codes
• Machine function
• Codes act as switch
• Open M codes – for optional equipment
• Only one M code per program line
• Machine-specific M codes offered

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Table 6.2 G & M-Code Functional Groups
 Words, Addresses, and Numbers
• A block is a line of code constructed from
words
– Each word is made up of letters and numbers:
• X is an address (letter)
• 1.5 is a number
• X1.5 is a word
• G is an address (letter)
• 01 is a number
• G01 is a word
• Block: G01 X1.5
 Modal and Nonmodal Codes
• Nonmodal codes:
– Used just once and then discarded
• Modal commands:
– Remain in active memory until superseded
– MCU treats most commands as modal commands
 Programming Grammar
• In the following code, Y3.0 does not have
to be repeated:
N01 G01 X1.5 Y3.0
N02 X6.0
– No spaces between letters and numbers
• Group codes into functional patterns that
place the addresses in a logical order
according to the intended function
 More on the Safe Line
• Safety resets:
– In this code:
N10 G20 G40 G49 G54 G80 G90 G98
• G40: cancels automatic tool radius compensation
• G49: cancels previous length compensation values
• G80: cancels canned drilling cycles and parameter
• G98: forces tool back to higher position
 More on the Safe Line (cont’d.)
• Setup parameters:
– G20: tells control all coordinates and feeds
are to be interpreted in inches
– G90: absolute positioning
– G91: incremental positioning
– G54: meant to represent primary coordinate
system which setup person has selected
Figure 6.1 A simple toolpath
to machine a square shape.
Planning the Toolpath
• Plot out center locations
of tools as they make
their way around the
workpiece

Figure 6.16 A finished workpiece to be

machined from a larger block of raw stock.
Figure 6.17 The setup and toolpath for the workpiece in Figure 6.16. The toolpath has been offset by .250 to create
the correct feature size.
Table 6.3 The Tool Coordinates for the Workpiece Shown in Figure 6.16 and Figure 6.17
9.5 Contouring
• Typically performed with end mill.
• Contouring is a commonly used
toolpath, typically performed with
an end mill.
• Cut follows joined path or single
piece of geometry

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9.5 Contouring

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 9.5.1 Tool Start Position
• Start off of the part In the program, notice that the starting point of this
tool is G90 G54 X−.5 Y0.
• Position may be dictated by fixture
• In a contour toolpath, it is important to
start the end mill off the part → take the
tool down to the initial Z depth → then
move into the part whenever possible.
• Driving the tool straight down the edge
of a contour will create a mark or defect.

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 Selecting the Work Zero
• Work zeros are selected for convenience
and repeatability

Figure 6.12 The work zero can be set at one of many locations. Each location
will offer some advantage.
9.5.2 Cutter Compensation
• A contour toolpath program directs the center of the spindle, or tool,
through the Cartesian coordinate points of the part.
• Compensation needed for diameter of tool
• Manual adjustment
• Using G codes
• G40 turns tool cutter compensation off.
• G41 moves tool cutter compensation left.
• G42 moves tool cutter compensation right.

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9.5.2 Cutter Compensation

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 9.5.2 Cutter Compensation
• The toolpath in our example needs to move to the left-hand side of the plan geometry, to
compensate for climb cutting with end mills in a contour.
• There are two ways to make this adjustment.
• The first way requires recalculating all movements and positions. Since this program uses a
1/2′′ end mill, this potential solution requires moving the radius of the tool, or .250′′, to the left
of all the geometry.
• The second solution is using G code commands.
Turn on cutter compensation left (G41) in the first move
into the part, and then cancel cutter compensation (G40)
on the exit move off the part.

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9.5.2 Cutter Compensation
• Review the adjusted program and new results:

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 9.5.2 Cutter Compensation
• With cutter compensation, the programmer simply needs to enter the coordinates for the
geometry of the part.
• The simple addition of G41 on the initial entry move and G40 on the exit move has moved
the toolpath outside the part.
• There are two keys to make this work:
• First, for the control to correctly offset the tool, the initial entry move has to be larger than
the tool radius. A good practice is to make the first positioning move the same distance as
the tool diameter. This program started at X−.5 and moved into X0.
• Second, designate the offset used (D1 in the given example) and enter the tool diameter
in the tool offset page, Figure 9-11.
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9.5.2 Cutter Compensation

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9.5.3 Diameter Offsetting
• In a machine shop environment, it is sometimes necessary to use a
tool with a different diameter than originally specified in the program
(program is written for a 1/2′′ end mill, but 5/8′′ end mill is available),
• you would have to start a new program to accommodate the
difference in size. With the control calculating G41 or G42 positions,
it is a simple matter to go back to the tool offset page and change
the diameter geometry offset to .625′′.

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9.5.3 Diameter Offsetting
• Another benefit to using diameter offsetting is the ability to make small,
incremental changes.
• This part is defined as a 6.000′′ × 3.000′′ rectangular part. But what if this
piece comes out to 6.010′′ × 3.010′′? The machinist can make a small
change to the .500′′ tool diameter offset to make the part either bigger or
smaller (.490′′ diameter or smaller to move the path closer into the part
and cut the part smaller).
• Remember, the machine is cutting lines on both sides of the rectangle, so
moving in the tool will affect both sides.

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9.6 Radius and Angle Milling
• Method for created arcs
• G02 and G03 codes
• I, J, and K method (used in older controls or to create circles).

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9.6.1 G02 and G03 Radial Movements
• The G02 and G03 codes are the simplest methods to program arcs.
• Arc – circular shape less than 360°
• Modal commands: G0, G01, G02, G03 (they stay on until they are turned
off).
• If you turn on a G0, you will continue in rapid movements until an alternate
movement is commanded, or until the modal command is turned off.
• G02 moves tool clockwise (true in both lathe and mill programming)
• G03 moves tool counterclockwise (true in both lathe and mill programming)

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9.6.1 Arc Less Than 180°
• This method can be
used for all arcs
less than 180°.

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 9.6.1 Arc Greater Than 180°
• By default, the • For an arc that is more
control will do a less
than 180° arc. So than 180° but less than
how can the 360°, things become
programmer create more complicated. As
a path for a 270°
arc? Simply make shown, there are two
the R value in the mathematical possibilities
program a negative
(−) number. for this arc.

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9.6.1 G02 and G03 Codes – Full Circle
• Create two 180° arcs (tools starts at the center)

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9.6.1 G02 and G03 Codes – Full Circle
• It is even acceptable to ramp down while cutting the arc by adding Z− moves onto the G03 lines,
Figure 9-15. In this case, the cutter ends up at Z−.25, so the move to Point 1 will cover half of the
Z-depth distance (−.125), and the second G03 move will go to Z−.25. This creates the following
toolpath:.

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9.6.2 I, J, and K Method
• Used with:
• Older machine controllers
• Creation of circles
• Output from CAM systems
• Known as alternate axis
addresses
• Incremental position of the tool
from arc start to arc center

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9.6.3 Programming Angles
• Requires moving along two axes simultaneously
• Can be any two axes
• Trigonometry may be required:
Example: There appears to be
no coordinate for Point 2 in the
X axis, Figure 9-17A.
This omission requires the
right triangle calculations.
There is a triangle highlighted in
Figure 9-17B with enough
measurements for the programmer
to calculate Point 2.

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9.7 Pocketing
• Pocket milling – machining inside
closed area
• Pocket can include islands or
internal components
• Walls or bottom can be flat or
tapered

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9.7.1 Cutter Entry – Pilot Holes
• Pilot hole drilled in center of pocket
• Allows for less tool pressure upon entry
• Requires programming extra tool
• Caution near bottom of pocket

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9.7.1 Cutter Entry – Helical Entry
• Helical interpolation around center of area
• Produces smooth transition into pocket
• Feed rates:
• Reduced upon entry
• Turned up once depth
is achieved

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9.7.1 Cutter Entry – Ramp Angle Entry
• Tool positioned above part
• Moved in X,Z line or Y,Z line
• 3° angle of entry
• Requires additional lines of code
• Feed rate:
• Increased on ramp
• Reduced for pocket roughing
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9.7.2 Roughing Method
• Once entry has been considered, the tool must now be programmed to
• remove the material from the pocket.
• Straight-line moves in X or Y axis
• Step-over and travel back (moving the tool over an amount in the
opposite axis and then travelling back)
• Good starting number for the step-over amount – radius of end mill
• Leave small amount for finish pass
• Tool radius must be smaller than part radii
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9.7.2 Roughing Method (Example)

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9.8 Canned Cycles
• Reduce repetitive machine code
• Make editing repetitive steps easy
• Single line of code defines multiple parameters
• Hole making is a common process in milling, and writing identical code
for multiple holes in a single part can be tedious and prone to program
errors.
• Allow a single line of code to define multiple parameters, and then all
subsequent holes can be positioned in the proper X and Y location to
repeat the process.
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9.8.1 G83 Cycle (Full Retract Peck Drilling)
• Peck drilling (G83)
• Hole depth ≥ 4X drill diameter
• Tool drives to partial depth
• Fully retracts to remove
chips/allow coolant
• Reenters to deeper depth

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9.8.1 G83 Cycle (Full Retract Peck Drilling)

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9.8.2 G73 Cycle (Chip Break Peck Drilling)
• Similar to G83
• Does not retract drill completely
• Used to break off chip

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9.8.3 G81 Cycle (Spot Drilling)
• Standard drilling cycle – does
not peck
• Travels to programmed Z depth
• Used for:
• Spot drilling
• Depth less than 4X diameter
• Solid carbide drills

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9.8.4 G82 Cycle (Counterbore Cycle)
• Creates counterbores in
predrilled hole
• Uses end mill or
counterboring tool
• Dwell while tool at
finished Z depth
• Creates flat-bottomed
hole or smooth finish
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9.8.4 G82 Cycle (Counterbore Cycle)
• Creates counterbores in
predrilled hole
• Uses end mill or
counterboring tool
• Dwell while tool at
finished Z depth
• Creates flat-bottomed
hole or smooth finish
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9.8.4 G82 Cycle (Counterbore Cycle)

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9.8.5 G84 Cycle (Tapping Cycle)
• Taps holes with single line of programming
• Cannot be hand programmed
• Calculate feed and speed to threads per inch (TPI)

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9.8.5 G84 Cycle (Tapping Cycle)

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9.8.6 G85 Cycle (Fine Boring Cycle)
• For boring or reaming holes
• Tool positioned over existing
hole
• Fed down to final Z depth
• Tool exits hole at feed rate
• Gives best surface finish

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9.8.7 G86 Cycle (Spindle Stop Boring Cycle)
• For boring or reaming holes
• Tool positioned over existing
hole
• Fed down to final Z depth
• Can create scratch in surface
finish
• Performed for rough or semi-
finish operations
• Faster than G85
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9.9 Tool Setting
• Tools must reach all programmed depths
• All tools placed in tool changer
• Programmed tool number
• Enter into controller:
• Tool length offsets
• Tool diameter offsets

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9.9.1 Length Offsets
• Distance from tool end to programmed Z0
• G43 – establishes tool length compensation
• Match height offset number to tool number
• One tool can have multiple offsets

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9.9.1 Determining Height for G43 Code
• To measure distance:
• Move tool to touch Z0 position
• Push Tool Offset Measure button
• Distance recorded – Tool Offset
Geometry page
• Repeat process for all tools
• Wear column – small final
adjustments
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Safety Note: Improper Length
Offsets
• Lead to severe machine crashes
• Tool engages material in full rapid movement

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9.9.2 Diameter Offsets
• G41 or G42 commands:
• Require tool diameter be defined
• Wear column – small final adjustments

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9.10 Work Coordinate Offsets
• Part position defined by work coordinate system
• G54–G59 designations
• Zero point entered
• Machine home – position at startup

Goodheart-Willcox Publisher

Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website.
9.10.1 Finding WCS on Material
• Various ways to locate
• Edge finder, indicator, hard post
• Offset entered – exact location of machine recorded

Goodheart-Willcox Publisher

Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website.
9.10.2 Setting WCS on Control
• Highlight X-axis box in G54–G59
row
• Press Part Zero Set button
• Repeat process for Y axis
• Z axis offset can be set if
necessary

Goodheart-Willcox Publisher

Copyright Goodheart-Willcox Co., Inc. May not be posted to a publicly accessible website.