PRACTICAL 1 (CAM)

AIM: To install SES-LATHE software into a Computer System

EQUIPMENT REQUIRED:
 PC computer
 SES-LATHE software

THEORY
The TPS-3920 is a computerized turning machine system for sliver processing of metal (aluminum), plastic and hard wood
products. The system enables us to manufacture products from these materials. The system includes a spindle motor operated by
a DC motor. The processed material is tightened into the spindle bore. The turning tool is installed on a table, which moves on
two axes (X and Z). The processed material is a round rod that rotates and the turning tool movement on X direction cuts it on
its perimeter. The turning tool movement on Z direction is along the rod. The movement of each axis is done by a DC motor,
which includes a magnetic encoder with hall effect sensors. The encoder outputs pulses according to the motor's rotation.

The system is located inside a metal structure with a transparent door in the front. The door operates a magnetic switch when it
is closed. The system includes a computerized control unit. The control unit operates the motors, receives the pulses from the
encoders and operates the DC motor of the spindle. The system stops each time the front door is opened. A computerized system
for sliver processing is called CNC (Computerized Numeric Control). The system's controller receives data, which determine the
movement of the turning tool (location and speed) and moves it accordingly in a controlled manner.

A special language was created for CNC machines called G&M-Code. This language is a universal language and despite this,
each machine has its own unique commands. This book describes the TPS-3920 command set and the system's programming
method. The programming language enables us to create programming files, where each file is designated to manufacture a
certain product (or part). The files are saved in the computer's disk. In this way, we can manufacture a certain part in the same
level of accuracy and unity at each manufacturing, even if the first manufacturing was a long time ago.

The CNC system enables us to manufacture the exact amount of products we need. All it takes is to load the computer with the
appropriate file and run the program. This process turned the manufacturing significantly flexible. Flexibility means an easy
transfer from one product to another. These machines are called FMS (Flexible Manufacturing Systems). The TPS-3920 system
is accompanied with the SES-LATHE software. This software enables us to create and edit a G&M-Code file and run it.

Running the file can be done in two ways – by simulation or by operating the machine. In the simulation method, the software
draws the turning tool movement on the screen. In the machine operation method, the computer sends a movement commands to
the system's control unit and the control unit executes the processing.

G&M-Code Language
The G-Code language is a very simple programming language and this is the secret of its popularity. The programming file is a
text file written by a text editor (a simple word processing).

PROCEDURE (Installing the SES-LATHE software)

1) The PC was turned ON.
2) Using "My Computer" functions, the SES-LATHE sub-directory was copied from the diskette to the hard disk.
3) A short-cut to the software SES-LATHE.exe, which is in the SES-LATHE sub-directory was created.
4) The short-cut was moved to the desktop window.
5) To run the SES-LATHE software, the application icon was double click on.

CONCLUSION
In conclusion, the SES Lathe software was successfully installed on the laptop for turning operation.

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Experiment 2 – NC Turning Processing
AIM: To write the first turning program according to a drawing and run the program on simulation

Equipment required:
 PC computer
 SES-LATHE software

Discussion:
In turning we have several processing types: Turning, Grooving and Threading. The processed material (a rod of metal, plastic
or wood) is installed in the spindle bore and rotates fast. When the turning tool goes on Z dimension, it removes slivers from the
perimeter of the rod (like peeling). The turning tool speed on Z direction should not be faster than the spindle rotation. When the
Z movement is faster than the spindle rotation we get a thread. When the turning tool goes on X direction only into the rod, it
creates a groove along its perimeter. The turning drawing shows only half of the part projection. This is enough because of the
complete symmetry. The drawing includes a symmetry axis.

In the experiments that follow we will process the part shown in the following figure.

The symbol indicates the project home position. It is also the origin of the axes. The X, Z absolute values relate to this
point. The numbers on the right show the distance from the home project on X axis. The processing process is done by turning
one millimeter at a time as described in the figure 1-1. With a special turning tool and on grooving process we cut off the
required processed material from its base. The rod is cut when the groove depth is equal to the rod's radius.

We define the starting point outside the main material. We turn an extra part in front of the required processing area. This part is
called 'Face' or 'Forehead'. Usually, we use a rod with a diameter greater than required and we turn it to the required diameter, in
order to ensure straight and symmetrical rod. In this experiment we will turn a 20 mm rod into 18 mm rod above the cut off
position. This also processes area No. 1.

PROCEDURE:
Step 1: The mouse was used to click over the SES-LATHE icon on your desktop to display the introductory window on
the screen.

Step 2: The FILE function and the NEW sub-function was select to display the Editor Window for more functions such as
EDIT, VIEW, and RUN.

Step 3: Type the following G&M-Code turning program for range 1:

M S2000 ;start spindle motor at 2000

4 RPM
G0 X-9 ; range 1 move to 9mm from the rod
center
G1 Z-66 F200 ;move to point 2
G1 X-10 Z-70 ;move to point 1
G0 Z0 ;return
M ;stop spindle motor
5

Step 4: The program was compared with the drawing.

Step 5: The function FILE and the SAVE AS sub-function was selected to display a dialog window requesting the file
name.
Step 6: PART1 was typed as the file name and then OK was clicked. The program is saved under the name PART1.TAP.
Step 7: The OPTIONS function selected again and then the SIMULATION sub-function. (In simulation mode, the
software simulates the machine behavior on the screen, without processing the material. This option enables us to
check our program before turning the material.)
Step 8: The function RUN was selected and then RUN sub-function. (A graph window appears.
Step 9: If the graph is not correct according to the program, correct the program and run it again.
Step 10: Add to the program the instruction for range No. 2.

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 M4 S2000 ;start spindle motor at 2000 RPM
G0 X-9 ; range 1 move to 9mm from the rod center
G1 Z-66 F200 ;move to point 2
G1 X-10 Z-70 ;move to point 1
G0 Z0 ;return
G0 X-8 ; range 2 move to 8mm from the rod center
G1 Z-38 ;move to point 4
G1 X-9 Z-50 ;move to point 3
G0 X-10 ;move out
G0 Z0 ;return
M ;stop spindle motor
5

Step 11: Compare the program with the drawing. Check each instruction.
Step 12: Select the FILE function and the SAVE sub-function or click [Ctrl+S] for saving the program.
Step 13: Select the function RUN and the RUN sub-function. A graph window appears. The program is executed step
by step graphically on the window. Observe the drawing.
Step 14: If the graph is not correct according to the program, correct the program and run it again.

PRECAUTION:
Don’t cut more than 1mm each time. Cutting more than 1mm can brake the tool or jam the machine.

Figure 1-1
CONCLUSION
The G & M-Code was used to write the NC programming language according to the drawing profile. After the programme was
simulated and ran, the program was executed step by step graphically on the window.

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Experiment 3 – NC Turning Operation (Arches)
Objectives:
 Understanding arch programming.
 Understanding arch processing.

Equipment required:
 PC computer
 SES-LATHE software

Discussion:
An arch is part of a circle. To define an arch we define the center of its circle and the starting point on the circle's perimeter (see
the description of G2 and G3 instructions).
15
13 14
12
1 3
2 4 5 6
0
-1 -2
10 11 -3
8 9 -4
5 6 7 -5 -6
4 -7
2 3 -8
-9
Z
1

-70 -66 -50 -38 -36 -26 -16 -6 -2

Figure 1-2
Face (Forehead)
Area No.3 includes an arch and its center is at points X=-8 and Z=-36. Check that. Because the radius of the arch is 2mm only,
we will process the arch in two stages.

Procedure:
Step 1: Click with the mouse over the SES-LATHE icon on your desktop.
Step 2: Select the FILE function and the OPEN sub-function.
A dialog window is opened requesting the file name.

Step 3: Select the PART1.TAP file.

Step 4: Add to the program the instruction for range No. 3.

M4 S2000 ;start spindle motor at 2000 RPM

G0 X-9 ; range 1 move to 9mm from the rod center
G1 Z-66 F200 ;move to point 2
G1 X-10 Z-70 ;move to point 1
G0 Z0 ;return
G0 X-8 ; range 2 move to 8mm from the rod center
G1 Z-38 ;move to point 4
G1 X-9 Z-50 ;move to point 3
G0 X-10 ;move out
G0 Z0 ;return
G0 X-7 ;range 3 move to 7mm from the rod center
G1 Z-36 ;move to point 5
G3 R2 I-8 K-36 C150 E180 ;move to point 4
G0 X-9 ;move out
G0 Z0 ;return
G1 X-6 ;move to 6mm from the rod center
G1 Z-36 ;move to point 6
G3 R2 I-8 K-36 C90 E150 ;move to point 5
G0 X-8 ;move out
G0 Z0 ;return
M5 ;stop spindle motor

Step 5: Compare the program with the drawing. Check each instruction.
Step 6: Select the FILE function and the SAVE sub-function or click [Ctrl+S] for saving the program.

4
Step 7: Select the function RUN and the RUN sub-function. A graph window appears. The program is executed step
by step graphically on the window.
Observe the drawing.
Step 8: If the graph is not correct according to the program, correct the program and run it again.
Step 9: Add to the program the instruction for ranges No. 4, 5 and 6.

M4 S2000 ;start spindle motor at 2000 RPM

G0 X-9 ; range 1 move to 9mm from the rod center
G1 Z-66 F200 ;move to point 2
G1 X-10 Z-70 ;move to point 1
G0 Z0 ;return
G0 X-8 ; range 2 move to 8mm from the rod center
G1 Z-38 ;move to point 4
G1 X-9 Z-50 ;move to point 3
G0 X-10 ;move out
G0 Z0 ;return
G0 X-7 ;range 3 move to 7mm from the rod center
G1 Z-36 ;move to point 5
G3 R2 I-8 K-36 C150 E180 ;move to point 4
G0 X-8 ;move out
G0 Z0 ;return
G1 X-6 ;move to 6mm from the rod center
G1 Z-36 ;move to point 6
G3 R2 I-8 K-36 C90 E150 ;move to point 5
G0 X-8 ;move out
G0 Z0 ;return
G0 X-5 ;range 4 move to 5mm from the rod center
G1 Z-26 ;move to point 8
G1 X-7 ;move out
G0 Z0 ;return
G0 X-4 ;range 5 move to 4mm from the rod center
G1 Z-16 ;move to point 10
G1 X-7 ;move out
G0 Z0 ;return
G0 X-3 ;range 6 move to 3mm from the rod center
G1 Z-2 ;turning the forehead
G2 R4 I0 K-6 C-48.6 E-90 ;move to point 11
G0 X-4 ;move out
G0 Z0 ;return
G1 X-2
G1 Z-2
G2 R4 I0 K-6 C-30 E-48.6 ;move to point 12
G0 X-4
G0 Z0 ;return
G1 X-1 ;move to point 13
G1 Z-2
G2 R4 I0 K-6 C-14 E-30
G0 X-4
G0 Z0 ;return
G1 X0 ;move to point 14
G1 Z-2 ;move out
G2 R4 I0 K-6 C0 E-14.5
G0 X-4
G0 Z0 ;return
M5 ;stop spindle motor

Step 10: Select the FILE function and the SAVE sub-function or click [Ctrl+S] for saving the program.
Step 11: Select the function RUN and the RUN sub-function.
A graph window appears. The program is executed step by step graphically on the window. Observe the drawing.
Step 12: If the graph is not correct according to the program, correct the program and run it again.

CONCLUSION
After simulation and running of the written program, the monitor executed the program according to the drawn part profile.

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Experiment 4 – Turning the Rod
AIM: To know how to setup the system, locate the turning tool and process the rod.

Equipment required:
 PC computer
 SES-LATHE software
 TPS-3920
 Turning tool
 80 x 20mm plastic rod

Discussion:
In the previous experiments we have built a program that turns a 20mm rod to the following figure.
15
13 14
12
1 3
2 4 5 6
0
-1 -2
10 11 -3
8 9 -4
5 6 7 -5 -6
4 -7
2 3 -8
-9
Z
1

-70 -66 -50 -38 -36 -26 -16 -6 -2

Face (Forehead)
Figure 1-10

In this experiment we shall install the rod in the turning machine spindle, setup the turning tool and process the rod.

Procedure:
Step 1: The power cable was connected to the TPS-3920 power inlet.
Step 2: The D-connector was connected to the serial communication outlet of the PC (COM1 or COM2) and the earphone
plug to the earphone inlet. The serial communication cable (CBL-1) is a 3 wire cable with a D-connector on one
side and an earphone plug on the other side.
Step 3: The power supply of the TPS-3920 was connected to the Mains.
Step 4: Emergency Pushbutton on the front panel was then turned ON by turning it to the right.
Step 5: The power supply Main switch was turned ON.
Step 6: The mouse was used to click on the SES-LATHE icon on the desktop.
Step 7: Select the FILE function and the OPEN sub-function. A dialog window is opened requesting the file name.
Step 8: Select the PART1.LAT file.
The following program will appear.

M4 S2000 ;start spindle motor at 2000 RPM

G0 X-9 ; range 1 move to 9mm from the rod center
G1 Z-66 F200 ;move to point 2
G1 X-10 Z-70 ;move to point 1
G0 Z0 ;return
G0 X-8 ; range 2 move to 8mm from the rod center
G1 Z-38 ;move to point 4
G1 X-9 Z-50 ;move to point 3
G0 X-10 ;move out
G0 Z0 ;return
G0 X-7 ;range 3 move to 7mm from the rod center
G1 Z-36 ;move to point 5
G3 R2 I-8 K-36 C150 E180 ;move to point 4
G0 X-8 ;move out
G0 Z0 ;return
G1 X-6 ;move to 6mm from the rod center

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 G1 Z-36 ;move to point 6
G3 R2 I-8 K-36 C90 E150 ;move to point 5
G0 X-8 ;move out
G0 Z0 ;return
G0 X-5 ;range 4 move to 5mm from the rod center
G1 Z-26 ;move to point 8
G1 X-7 ;move out
G0 Z0 ;return
G0 X-4 ;range 5 move to 4mm from the rod center
G1 Z-16 ;move to point 10
G1 X-7 ;move out
G0 Z0 ;return
G0 X-3 ;range 6 move to 3mm from the rod center
G1 Z-2 ;turning the forehead
G2 R4 I0 K-6 C-48.6 E-90 ;move to point 11
G0 X-4 ;move out
G0 Z0 ;return
G1 X-2
G1 Z-2
G2 R4 I0 K-6 C-30 E-48.6 ;move to point 12
G0 X-4
G0 Z0 ;return
G1 X-1 ;move to point 13
G1 Z-2
G2 R4 I0 K-6 C-14 E-30
G0 X-4
G0 Z0 ;return
G1 X0 ;move to point 14
G1 Z-2 ;move out
G2 R4 I0 K-6 C0 E-14.5
G0 X-4
G0 Z0 ;return
M5 ;stop spindle motor

Step 9: The program was compared with the drawing. Each instruction was checked and the turning tool path was marked
on the drawing.
Step 10: The OPTIONS function and the SIMULATION sub-function was selected in order to check the program by
simulation.
Step 11: Select the function RUN and the RUN sub-function. A graph window appeared. The program is executed step by
step graphically on the window. The drawing was observed.
Step 12: If the graph is not correct according to the program, correct the program and run it again.
Step 13: Select the OPTIONS function and the TURNING sub-function in order to operate the system.
Step 14: Select the function MONITOR and the sub-function CNC MONITOR.
The CNC monitor appears.

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 Make sure that all the check boxes of 'Home X', 'Home Y' and 'Home Z' are checked, and press the "GO TO
MACHINE HOME" button. The machine should move to the absolute home position.

Step 15: The material (80x20mm plastic rod) into the TPS-3920 spindle was installed and tighten it.
Step 16: Using the monitor buttons, bring the turning tool near the edge position of the rod as described in the following
figure.

Spindle Rod

Turning
Tool

Step 17: Turn ON the turning motor and approach the turning tool slowly until it touches the rod.
Step 18: Using the MONITOR buttons, move the turning tool 1mm to the right and 10mm to the center of the rod.
Step 19: Press the "DEFINE PFOJECT HOME" button.
Step 20: Select the RUN function and the RUN sub-function. The system should turn the material according to the
program.
Step 21: When the program ends, it stops the motor.
Step 22: Take out the processed rod and compare it with the drawing.

CONCLUSION

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EXPERIMENT 5 – SLOT PROCESSING
AIM:
To writing the first milling program according to a drawing, understand slot processing, run the program on simulation,
setup the material using the monitor and mill the material.

EQUIPMENT REQUIRED:
 PC computer
 SES-MILL software
 TPS-3910
 3mm milling cutter
 50x50x10 mm plastic material

DISCUSSION:
In milling we have several processing types: Slot, Profile, Pocket and Drill. In slot processing the milling machine creates a slot
according to the width of the milling cutter. In this experiment we will mill a slot according to the following drawing on a
50x50x10 mm material.

Figure 1-2
The symbol indicates the project home position. It is also the origin of the axes. The X,Y,Z absolute values relate to
this point. The circle at point 1 indicates the milling cutter diameter and the milling starting point. In milling drawing
we should have two projection drawings. The project home position should be indicated on both of them. We have to remember
that the milling cutter is round. Because of that, the corners of the slot processing will always be round according to the cutter
diameter. We also prefer not to start and end the program in a corner but in a center of a line.

Project home: The program values are related to the project home. After installing the matter on the table, we are moving the
cutter to the project home point and determine this as the project home by clicking on a certain button of the monitor program.

Clearance movement: Clearance movement is a movement to a point without milling at a certain level above the material. Z
movement is done first before moving according to X-Y.

PROCEDURE:
Step 1: Connect the power cable to the TPS-3910 power inlet.
Step 2: The serial communication cable (CBL-1) is a 3 wire cable with a D-connector on one side and an earphone plug on
the other side. Connect the D-connector to the serial communication outlet of the PC (COM1 or COM2) and the
earphone plug to the earphone inlet.
Step 3: Connect the power supply of the TPS-3910 to the Mains.
Step 4: TPS-3910 has an emergency pushbutton on the front panel. Turn it ON by turning it to the right. The pushbutton will
go out.

Step 5: Turn ON the power supply Main switch.

Step 6: Click with the mouse over the SES-MILL icon on your desktop. An introductory screen will appear on the screen.
9
Step 7: Select the FILE function and the NEW sub-function. An editor window appears and more functions are added to the
menu line. The added functions are EDIT, VIEW, and RUN.
Step 8: Type the following G&M-Code milling program:

M4 S2000 ;start spindle motor at 2000 RPM

G0 X15 Y25 Z3 ;move to point 1 at maximum feed (clearance = 3mm)
G1 Y30 Z-1 F100 ;move to point 2 feed=100 Z=-1mm
G1 X20 Y35 ;move to point 3
G1 X30 ;move to point 4
G1 X35 Y30 ;move to point 5
G1 Y20 ;move to point 6
G1 X30 Y15 ;move to point 7
G1 X20 ;move to point 8
G1 X15 Y20 ;move to point 9
G1 Y25 ;move to point 1 back
G0 X0 Y0 Z3 ;move to HOME position
M5 ;stop spindle motor

Step 9: Compare the program with the drawing. Check each instruction.
Step 10: Select the function FILE and the SAVE AS sub-function. A dialog window is opened requesting the file name.
Step 11: Type the name SLOT1 and click OK. The program is saved under the name SLOT1.TAP.
Step 12: Select the OPTIONS function again. Select the SIMULATION sub-function. In simulation mode, the software
simulates the machine behavior on the screen, without processing the material. This option enables us to check our
program before milling the material.
Step 13: Select the function RUN and the RUN sub-function. A graph window appears. The program is executed step by
step graphically on the window. Observe the drawing. The colors of the lines describe the Z-dimension of the
lines.
Step 14: If the graph is not correct according to the program, correct the program and run it again.
Step 15: Locate the material (50x50x10 mm plastic material) on the table of the TPS-3910 and tighten it with the handy
screws. Check that the material lies horizontally on the table.
Step 16: Select the OPTIONS function and the MACHINE sub-function in order to operate the system.
Step 17: Select the function MONITOR and the sub-function CNC MONITOR. The CNC monitor appears.

Make sure that all the check boxes of 'Home X', 'Home Y' and 'Home Z' are checked, and press the "GO TO
MACHINE HOME" button. The machine should move to the absolute home position.

Step 18: Move the cutter center to the relative project home with the STEPS (mm) and the MOVE buttons.
Step 19: Turn ON the milling motor by clicking over the "Start Spindle Motor" button.
Step 20: Lower the cutter slowly until the cutter almost touches the material surface.
Step 21: Press the "DEFINE PROJECT HOME" button.
Step 22: Select the RUN function and the RUN sub-function. The system should mill the material according to the program.

Precaution: Don’t cut more than 1mm each time. Cutting more than 1mm can brake the tool or jam the machine.

CONCLUSION

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