Experiment 1: Introduction to CNC Machines

Need to learn CNC programming?

• Role of programming in mechanical industry.

• Importance in new product development

Conventional ways of machining or manufacturing

• Lathe, Drill, shapers, planer, mill machines etc. (Manual machines)

• Limitations of conventional machine or need of CNC machines.

Need of CNC machines (Advantages of CNC machines)

• High productivity
• High accuracy and repeatability
• Offer more flexibility in machining, variety of complex shape, profile can be easily generated
• Single operator can handle more than one machine at a time that leads to reduced manpower
• Program once fed to the machine can be edited easily and can be checked or verified using
display screen available on the machine panel
• Double beds available in some of the machine offer reduced changeover time and make
setting for next consecutive job.
• Easy & accurate setting of input parameters and ease of addition ensure require surface finish
(accuracy) & increase tool life.
• Many programs can stored at a time in a CNC machine so large variety of components can be
produced any time without any extra time for programming
• Variety of operations (drillings, turnings, taping, boring etc.) can be done on a single
machine using same program so it reduces requirement of variety of machines & spare for it
• Once machine is programmed accurately it do not required much skilled operator.
• Due to higher accuracy and reliability, it has lesser maintenance, repair or inspection cost for
finished parts.
Disadvantages of CNC machine

• Very high initial cost

• Programming & maintenance of a machine requires highly skilled manpower which is
expensive too.
• Maintenance & repair is complicated & time consuming activity leads to more down time of
a machine
• Due to high initial & maintenance cost machine downtime is not affordable
• Requires multiple extra accessories like voltage stabilizer, hydraulic unit and transformer etc.
• Not affordable for lesser or low volume of production
• Higher tooling cost
• Leads to unemployment

NC and CNC machine

• In early 60 after world war second there is need to increase the efficiency & productivity of a
machine & to reduce manual interruption in machining
• To achieve mass production, SPM and copying machines were made which gradually
enhance the production efficiency in earlier phase.

NC machines

• John C. Parson from US invented the first NC machine in the year 1947. Then MIT launch
and execute NC milling demo in year 1952 in an exhibition & ask for suggestions from
people.
• Accordingly they made some improvement in it & made available first NC machine for sale
in US market in year 1955.

Working of NC machine

• NC machine tools may be defined as a method of automation in which various functions of

machine tool (movement of tool, speed, feed, coolant etc.) are controlled by letters, numbers
and symbols.
• As per sequence of operation one need to create a program consists of commands or
instructions in a sequence in different blocks.
• All these instructions are fed to machine block wise sequentially.
• It is initial phase only the tool rather tool motions are controlled using NC. But in later stage
along with tool path machine inputs (speed, feed, coolant etc.) are also controlled &
monitored using program.
• In these machines paper tape or magnetic tape one used to prepare a program. So to execute
the same i.e. operational program one required to rewind it and run it again.
• Repetitive use of tape cause breaking or malfunction of it or even a small change in program
require to prepare a separate tape which is very time consuming, costly and lead to fatigue to
operator.
• Due to all this one hardly able to match requirement to prepare tapes, time & accuracy in
machining which intern pose a challenge to make it feasible and reliable.

CNC Machines

• With the availability of microprocessors in mid-70 the controller technology has made a
tremendous progress.
• CNC are characterized by the availability of a dedicated computer and enhanced memory in
the control
• Using this, computer interface was provided to NC machine along with use of servo motor,
ball lead screw & slide ways. So most of all limitations of NC machine were overcome & it
can work more efficiently.
• With computer interface it becomes quite easy to feed programs, edit it & to complete the job
in lesser time period.
• As all machine movements are controlled using computer interface it is known CNC
machine.
• On CNC machine all programs are prepared and stored on memory of a computer and can be
used anytime whenever required.
DNC (Direct Numerical Control) System

CNC M/C 2
CNC M/C 1

Main Computer

CNC M/C 4 CNC M/C 3

• Some of the industries where more than one CNC machine is used for production.
• So programming on every individual machine will require certain time period for which
machine remains idle & reduce productivity.
• To avoid this all CNCs are connected with a central computer with large storage capacity
using LAN and operated from that computer.
• Now a day wireless DNC units are also available which can send programs to individual
CNC machines within range of 100 m but it requires devices like wireless nodes, access point
which make it expensive.

Types of CNC machines

• Generally on any CNC machine tool is moved along basic three axes i.e. X, Y & Z.
• Besides these three U, V & W are the virtual axes used parallel to X, Y, Z respectively.
• Along with parallel axis system A & B axes are used where A is rotational axis about X and
B is rotational axis about Y.
• Depending upon various tool movement & method of material removal CNC machines are
classified as
➢ CNC lathe
➢ VTC (Vertical Turning Centre)
➢ VMC ( Vertical Machining Centre)
➢ HMC (Horizontal Machining Center) etc.
CNC machine parts
(Show actual CNC machine & various parts)
• Servo motors
• Ball lead screws
• High speed spindle
• Linear motion guide ways
• Turret head
• Tool magazine
• Automatic tool changer
• Pallet changer
• Chip conveyor
• Hydraulic system
• Lubrication system
• Computerized panel
• Coolant system
• Voltage stabilizer

Machine Coordinate system

• Before doing any kind of programming on a CNC machine one need consider coordinate
system.
• Firstly to define tool path one need to take work zero position and with respect to this work
zero i.e. reference position all other coordinates are defined.
• First zero position of the tool is defined and using coordinate system as per requirement of
the shape all other path or tool travel is defined.

2nd (- +) 1st (+ +)

3rd (- -) 4th (+ -)
• To determine coordinates on CNC machine two types of system are generally used.
Absolute Coordinate system
• For CNC machine generally this system is used. In this system once reference point/work
zero position is defined with respect to this point position of tool is defined.
• Here along with position of tool direction of tool travel is also important.

5 Pt. 3
Pt. X Y

1 35 5
25 20 Pt. 2
2 20 8
Pt. 1
8
3 05 25
5

35

Incremental Coordinate system:

• In this system once work zero position is defined with respect to that coordinate of first point
is defined.
• For every next point previous point is considered as original point and with respect to that
coordinates of that point are defined.

Pt. 2 Pt. X Y

12 1 5 3
7 8
20 2 7 20

Pt. 3
Pt. 1 3 12 -8

5
 Experiment 2: Introduction to part programming

Part programming fundamentals

• CNC part program is a detailed List of instructions that need to be executed by the Machine
Control Unit (MCU) to achieve the final component shape.
• The machining sequence needed to manufacture given part is broken down into small
elements and are in a specific format understood by the MCU.
• The programming language needs to be studied to develop meaningful part programs.
• The total steps involved in the development of a part program and its proving is shown in fig
below.
• The following are some of the steps that are detailed
➢ Process planning
➢ Axes selection
➢ Tool selection
➢ Cutting process parameters planning
➢ Job and tool set up planning
➢ Machining- path planning
➢ Part program writing
➢ Part program simulation

Process planning:

Process plan is a detailed plan of the steps involved in manufacturing is given part. The
following are the contents of a process plan.

• Machine tool used

• Fixture required
• Sequence of operations
• For each operation
➢ Cutting tools required
➢ Process parameter

A programmer is supposed to carry out a careful study of the part drawing to prepare the process
plan. The choice of machine tool used depends upon the operations required, accuracy
requirement, machine tool capacity – availability etc. A careful choice of various options at this
stage helps in deciding the final cost of manufacture of the part.

Axes selection:

All the CNC machine tools rely on the axes system for describing the axes motion. To
correctly describe the motion, it is therefore necessary to establish the axes system to be followed
with the particular parameter

Tool selection:

Cutting process parameters planning

Job and Tool Set-up planning:

This basically is aimed at setting the job on machine tool and adjusting the cutting tool to the
correct position. This is important since the accuracy of the geometry generated by the CNC
machine tool is dependent on the initial position carefully defined.

Machining-Path planning:

This is a very important aspect of programming wherein the knowledge of machining

operations plays a vital role. A careful planning of the path ensures that requires manufacturing
specifications are achieved at the lowest cost.

Part Program Writing:

This aspect deals with the actual writing of the part programs undertaking the format & syntax
restrictions into account.

Part Program simulation

This is another aspect, which the programmer should very carefully do before the part program is
released to the shop. Once the program is made it should be verified before it can be loaded on
the machine tool controller for the manufacture of the component. It is obvious that a faulty
program can cause damage to the tool, w/p and machining tool itself. Sometimes, these accidents
can prove grave for the operator and others around. One of the preliminary ways of avoiding
such possibilities is to carry out a visual check of the program manuscript and of the displayed
program on VDU (visual display).

CNC programming codes

• Before start with actual program, various codes are enlisted
• ISO standards for coding
A- Angular dimension around X axis
B- Angular dimension around Y axis
C- Angular dimension around Z axis
F- Feed function
G- Preparatory function
M- Miscellaneous function
N- Sequence number
S- Spindle speed function
T- Tool function
X- Primary X motion dimension
Y- Primary Y motion dimension
Z- Primary Z motion dimension

Preparatory function (G code)

G00 – Point to point, rapid traverse
G01 – Line interpolation
G02 – Circular interpolation, clockwise (WC)
G03 – Circular interpolation, anticlockwise
G04 – Dwell
G05 – Hold/delay
G08 – Acceleration of feed rate
G09 – Deceleration of feed rate
G10 – Linear interpolation of long distance (more than 10 inch)
G11 – Linear interpolation of short distance (up to 10 inch)
G17 – XY plane designation
G18 – ZX plane designation
G19 – YZ plane designation
G33 – Thread cutting constant lead
G40 – Cutter compensation, cancels to zero
G43 - Cutter compensation, positive
G44 - Cutter compensation, negative
G62 – Rapid traverse positioning
G63 – Tapping cycle
G71 – Dimension in metric units
G80 – Canned cycle cancelled
G96 – Spindle feed rate for constant feed
G97 – Spindle speed in rpm

Miscellaneous function
M00- Program stop, spindle and coolant off
M02- End of program (Interchangeable with M30)
M03- Spindle on CW
M04-Spindle on CCW
M05-Spindle stop
M06-Tool change
M07-Coolant Supply No1 on
M08-Cooland supply No2 on
M09-Coolant off
M10-Clamp
M11-Unclamp
M13-Spindle on CW+ coolant on
M14-Spindle on CCW+ coolant on
M15-Rapid traverse in + direction
M16-Rapid traverse in – direction
M19-Spindle stop at specified angular position
M30-program stop at end tape + tape rewind
M31-Interlock by pass
M32-35-Constant cutting velocity
M68-Clamp part
M69-Unclamp part.

Program configuration (format)

• Program is very important element while working on CNC machine. Various English letters
and number are used to prepare a program
• A number along with preceding letter formulate a word in CNC program
• Only one letter is used at a time to formulate a word e.g. X-54.5, G-01, R-5 etc.
• All such words are put in sequence according to operation to be performed on job formulate a
instruction such a line of instruction is known as block
• Set of instructions are known as program which is prepared as per required operations.
Number of block together formulate a program. Programs are basically two types, main
program and sub program
• Subprograms are called in main program as per requirement. A main program may have a
number of sub programs. A subprogram may be called within another subprogram.

Main Program
Sub Program
Program Number
Program Number;
Block1;
Block1;
Block2;
Block3; Block2;
………. ………..
………..
Subprogram call
…….......
Block n; Block n;
Program end;
Return to main Program;

General programming functions

Program number
• Each of the program that is stored in the controller memory requires an identification, which
is used while running and editing of the program directly from the directory
• This identification is specified in terms of program number that starts with letter O
e.g. – O3492, O0008, O1239 etc.
• The program number must be on the first line of the program & it consists of 4 digits

Block number
• As already stated blocks are the lines consist of many words that specify the tool motion one
at a time
• Blocks are required to be numbered according to their sequence of operation
• Accordingly they can be given a number in ascending order
• Generally same gap is place while block numbering to facilitate any addition in the blocks in
later stage

End of block (EOB)

• As block numbers are provided at the start of any block, similarly end of block function is
used to show closing/ending of any block
• In control system ; or * signs are used to show end of block command
• EOB used at the end of any block automatically facilitate course to move on to the next block

Tool function
• Tools are selected in a program through the T word. The T word selects the turret station that
is to be indexed to the cutting operation and activates the tool offset register number (i.e. tool
offset information led earlier)

Explain tool offset operation

• Tool function specified as Tmmnn , here first two digits specify the turret station and the last
two digits(nn) specify the location of the tool offset

Speed function
• The spindle speed can be specified in two way, either direct rpm or in constant surface speed
in m/min
 • The constant surface speed option would be useful in turning, because the cutting speed is
directed by the diameter of the rotating workspace
• Hence to maintain a constant cutting force and uniform surface finish it is necessary to vary
the spindle rpm in direct proportion to the change in work diameter at the cutting tool edge
• This is achieved by constant surface speed option which can be involved by using the G96
• The following example gives use of S word
N090 G50 max. Spindle rpm is 4000
N100 G96 spindle speed is set 200m/min
N080 G97 spindle speed is set 2500 rpm
Feed specification
• Similar to the speed, feed rate can be specified in two forms in the normal mm/min as well as
mm/rev
• These two formats can be obtained by using the following G codes
G98 feed in mm/min
G99 feed in mm/rev
Preparatory function
• All G codes are preparatory functions which gives tool motion or tool path
• Many times X, Y or Z co-ordinates are specified in front of G codes to quantify tool
motion
• Each G code demonstrate different tool motion that is useful for different operations to
perform
e.g. – G00, G01, G90 etc.
Miscellaneous functions
• The M codes are miscellaneous function which convey action to the machine i.e all
machine movements accept tool motion are all controlled by M codes
• e.g. – M01, M30 etc.
 Experiment 3: Turning and facing operation

3.1 Elements on the Panel Processing Unit (PPU) front

1. Vertical and horizontal softkeys (calls specific menu functions)

2. Return key (returns to the next higher-level menu)

Menu extension key (opens the next lower-level menu or navigate between
3.
the menus of the same level)

4. Alphabetic and numeric keys (used to write codes/program)

5. Control keys (used to edit a program)

6. Alarm cancellation key

On-board wizard key (provides step-by-step guides on basic commissioning

7.
and operation procedures)

8. Help key (calls help information)

9. Cursor keys (used to move the cursor within a program)

 Operating area keys (used to choose a screen like to shown active program,
10.
active tool coordinates or open program directory etc.)

11. USB interface (used to connect pendrive and transfer or copy programs)

12. Status LEDs (shows active functions with green light)

3.2 Elements on the Machine control panel (MCP) Front

1. Emergency stop button

2. Handwheel key (controls the axis movement with external handwheels)

3. Tool number display (displays the current tool number)

4. Operating mode keys

5. Program control keys

User-defined keys (used to activate lamp, coolant, tool-magazine rotation,

6.
chip convener or lock/unlock door)

7. Axis traversing keys (Used to facilitate the (X, Y, Z) axes movement)

8. Spindle override switch (enables to controls the spindle speed manually)

9. Spindle state keys (used to rotate the spindle CW or CCW)

 10. Feedrate override switch (enables the axis movement at specified feedrate)

11. Keys for program start, stop, and reset

3.3 Different operating modes

Jog Mode: It enables to control the axes movement using Axis traversing keys

Handwheel mode: It enables to control the axes movement using handwheel

Auto mode: It is used to execute the program

Single block mode: It enables to run the program in a single block i.e. program is executed step
by step by pressing single block

3.4 CNC Lathe offset setting

(Describe offset setting steps)

3.5 CNC Program

(Part Drawing)

Given: (Speed 1000 rpm, Feed 120 mm/min, and Depth of cut 1 mm (in each step))

N02 G75 X0 Z0; (Tool moves to home position)

N04 G71 G94 G90; (Metric unit, Feed in mm/min, Absolute coordinate system)

N06 M06 T1D1 M08; (Tool change, Tool No. 1, offset No. 1, Coolant ON)

N08 M03 S1000; (clockwise spindle on, speed 1000 rpm)

N10 G00 X27 Z3; (rapidly moves to safe position i.e. [27, 3])

N12 G00 X 27 Z-1; (rapidly moves to Z= [-1] with same X [27])

N14 G01 X-1 F120; (Linear interpolation till X= [-1] with feed 120 m/min)

N16 G00 X27 Z3; (Tool rapidly moves back to safe position)
N18 G00 Z-2; (Tool rapidly moves till Z = [-2])

N20 G01 X-1; (Linear interpolation till X= [-1])

N22 G00 X27 Z3; (Return back to safe position)

N24 G00 X24; (Tool rapidly moves to X= [24])

N26 G01 Z-40; (Linear interpolation till Z= [-40])

N28 G00 X27 Z3; (Tool rapidly moves back to safe position)

N30 G00 X23; (Tool rapidly moves to X= [23])

N32 G01 Z-40; (Linear interpolation till Z= [-40])

N34 G00 X27 Z3; (Return back to safe position)

N24 M09 M05; (Coolant and spindle stop)

N26 G75 X0 Z0; (home position)

N28 M30; (Program stop)

 Experiment 4: Step and taper turning operation

N10 G75 X0 Z0;

N20 G71 G94;

N30 M06 D1T1;

N40 M03 S1500;

N50 G00 X30 Z5;

N60 CYCLE95(“C1”, 0.2, 0.2, 0.2, 0.2, 150, 80, 120, 9, 0, 0, 5);

N70 G00 X30 Z5;

N80 M05 M30;

Sub-Program ‘C1’

NC:/MPF/C1

N10 X0 Z-0.5;

N20 G01 X10;

N30 G03 X13 Z-3 CR3;

N40 G01 X13 Z-16;

N50 G01 X16 Z-18;

N60 G01 X16 Z-29;

N70 G01 X19;

N80 G01 X23 Z-46;

N90 G01 X24;

N100 G01 Z-52;

N110 G01 X25;

M17; (End of subroutine)

Cycle Description:

NPP : Program name

MID : Infeed depth (without sign)- this specifies the depth of cut

FALZ : Finishing allowance along Z and X axis respectively.

FALX :

FAL : Finishing allowance for contour

FF1 :

FF2 : Feedrate for roughing, plunging, and finishing respectively.

FF3 :

VARI : Type of operation (by pressing ‘select’, different operations available can be selected)

DT : Dwell time (this specifies the time (in sec.) tool will pause after a particular cut)

DAT : Path for roughing interrupt (here after each ‘x’ mm cutting/tool travel tool will pause to
ensure chip breakage)

_VRT : Retract path from contour – Tool will retract with ‘x’ mm distance after every cut and
again start engaging for next cut
 Experiment 5: Step turning, drilling, boring and grooving operations

Turning cycle (95)

N10 G75 X0 Z0;

N20 G71 G94;

N30 M06 D1T1;

N40 M03 S1500;

N50 G00 X25 Z5;

N60 CYCLE95(“STP”, 0.15, 0, 0, 0, 180, 80, 120, 9, 0, 0, 0);

N70 G00 X25 Z5;

N80 M05 M30;

NC:/MPF/STP

N10 G01 X0 Z0;

N20 G01 X20;

N30 G01 Z-50;

N40 G01 X25 Z-54;

M17; (End of subroutine)

Drilling cycle (83)

N100 T4D1;

N110 G95 G17; (feed in mm/rev and plane selection)

N120 M03 S1000;

N130 G00 X0 Z10;

N140 CYCLE83(5, 0, 2, -20, 20, 2, 2, 0, 0, 0, 1, 1, 3, 2, 5, 0, 0);

N150 G00 X0 Z10;

N160 M05;

N170 M30;

Cycle Description:

RTP : Retract and reference plane respectively

RFP :

SDIS : Safety distance without sign

DP : Final drilling depth (absolute)

DPR : Final drilling depth relative to reference plane

FDEP : Drilling depth 1 (absolute) (initially a small (e.g. 2 mm) depth will be drilled to avoid
shock on a tool and then remaining drill is completed)

FDER : Drilling depth 1 relative to reference plane

DAM : Degression amount without sign (this is the amount/distance with which tool will
proceed in each step to complete the full depth i.e. once first drilling step is completed based on
‘FDEP’ remaining depth is drilled stepwise considering specified ‘DAM’ value)

DBT : Dwell time at each drilling depth

DTS : Dwell time at starting point

FRF : Feedrate factor for first drilling depth (this specifies the reduction factor to applied
feedrate so as to complete first drill ‘FDEP’ smoothly)

VARI : Defines the type of operation (here ‘0’ indicate the operation in which tool retract with
specifies distance in ‘VRT’ while for operation type ‘1’ tool retracts to reference position after
each drill step ensuring chip breakage)

AXN : Defines axis of drill (like AXN=1 is drill along Z axis i.e. XY plane; AXN=2 is drill
along Y axis i.e. ZX plane and AXN=3 is drill along X axis i.e. YZ plane)

MDEP : Defines minimum drilling depth (If the calculated drilling stroke (based on degression
factor) become shorter than the minimum drilling depth i.e. ‘MDEP’ the remaining depth is
machined in strikes equalling the length of minimum drilling depth)
VRT : Retraction distance for chip breaking (specifies for ‘VARI’ i.e. operation type 0)

DTD : Dwell time at final drilling depth

DIS1 : Programmable limit distance (this specifies max. lead distance at tool reinsertion i.e. an
amount with which a tool can proceed max. in depth with respect to earlier drill depth)

Grooving CYCLE (93)

N200 G71 G94;

N210 M06 T3D1;

N220 M03 S600;

N230 G00 X22 Z5;

N240 CYCLE93(21, -40, 3, 1.5, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0.1, 2, 1, 5, 0)

N250 G00 X22 Z5;

N260 M05;

Cycle Description:

SPD : Starting point along facing axis (X position)

SPL : Starting point along longitudinal axis (Z position)

WIDG : Groove width without sign.

DIAG : Groove depth (this is from one side so if ‘DIAG’ is 1.5 the dia. will reduce by 3 mm)

STA1 : Starting angle (this is the angle w. r. to 1st axis/ horizontal plane- can be seen on machine
screen for more clarity)

ANG1 : Flank angle 1 and 2- this defines the angle of inside walls w. r. to vertical plane

ANG2 : (shown in figure)

RCO1 :

RCO2 : Chamfer (neg.)/ radius (positive) at position O1, O2 (outside recess wall) and

RCI1 : I1, I2 (inside recess wall) as shown in figure

RCI2 :
FAL1 : Finishing allowance of groove base and flank (walls) respectively

FAL2 :

IDEP : Infeed depth (depth of cut)

DTB : Dwell time at the bottom of groove

VARI : Type of operation

_VRT : Variable retraction path for grooving (this is given if the groove is done in steps)

Boring CYCLE (95)

(For both turning and boring cycle 95 is used, in latter case the operation type ‘11’ is selected
instead of operation ‘9’)

N10 G75 X0 Z0;

N20 G71 G94;

N30 M06 D1T6;

N40 M03 S1000;

N50 G00 X12 Z5;

N60 CYCLE95(“MM1”, 0.1, 0.1, 0.1, 0.1, 60, 60, 60, 11, 0, 0, 0);

N70 G00 X12 Z5;

N10 G75 X0 Z0;

N80 M05 M30;

NC:/MPF/MM1

N10 G01 X14 Z0;

N20 G01 Z-15;

N30 G01 X12;

N40 G01 Z10;

M17; (End of subroutine)

Treading CYCLE (99)

N5 G71 G90 G94;

N10 M06 T5D1;

N20 M03 S500;

N30 G00 X22 Z5;

N40 CYCLE99(0, 20, -30, 20, 1, 1, 0.8, 0.1, 30, 0, 20, 3, 1, 300103, 1, 0, 0, 0, 0, 0, 0, 0, 0, 1, 0,
0, 0, 0)

N50 G01 X22 Z5;

N60 M05 M30;

Cycle Description:

SPL : Thread starting point along longitudinal axis

DM1 : Diameter of thread at starting point

FPL : Thread end point along longitudinal axis

DM2 : Diameter of thread at end point

APP : Run-in path without sign

ROP : Run-out path without sign

TDEP : Thread depth without sign

FAL : Finishing allowance

IANG : Infeed angle without sign

NSP : Starting point offset first thread

NRC : Number of roughing cuts and NID : Number of noncuts

PIT : Thread pitch value

VARI : Type of operation

_VRT : Variable retraction path for thread

PSYS : No modifications of the internal parameters

 Experiment 6: Engraving Letters using VMC (“NIT-AP”)

N20 G71G94 G90

N40 M06 T4D2

N50 G0 G54X0Y0

N60 M03 S2000

N70 G0Z50

N80 G0X5Y10

N90 G0Z5

N100 G01Z-0.1F200

N110 G01X5Y35

N120 G01X20Y10

N130 G01X20Y35

N140 G0Z5

N150 G01X25Y10

N160 G01Z-0.1

N170 G01X25Y35

N180 G0Z5

N190 G01X37.5Y10

N200 G01Z-0.1
N210 G01X37.5Y35

N220 G01X30

N230 G01X45

N240 G0Z5

N250 G01X50Y22.5

N260 G01Z-0.1

N270 G01X55

N280 G0Z5

N290 G01X60Y10

N300 G01Z-0.1

N305 G01X67.5Y35

N307 G01X75Y10

N308 G0Z5

N309 G01X72Y20

N310G01 Z-0.1

N320 G01X63Y20

N330 G0Z5

N340 G01X80Y10

N350 G01Z-0.1

N360 G01X80Y35

N370 G01X90

N380 G02X90Y22CR=8

N390 G01X80Y22

N400 G0Z50

N410 M05 M30

 Experiment 7: Rectangular and circular pocket milling operations

Various machining cycles

• Drilling cycles

CYCLE81: Drilling, centering

CYCLE82: Drilling, counterboring

CYCLE83: Deep-hole drilling

CYCLE84: Rigid tapping

CYCLE840: Tapping with compensating chuck

CYCLE85: Reaming 1

CYCLE86: Boring

CYCLE87: Drilling with stop 1

CYCLE88: Drilling with stop 2

CYCLE89: Reaming 2

• Drilling pattern cycles

HOLES1: Row of holes

HOLES2: Circle of holes

CYCLE802: Arbitrary positions

• Milling cycles

CYCLE71: Face milling

CYCLE72: Contour milling

CYCLE76: Milling the rectangular spigot

CYCLE77: Circular spigot milling

LONGHOLE: Elongated hole

SLOT1: Groove milling pattern on a circle

SLOT2: Circumferential groove milling pattern

POCKET3: Rectangular pocket milling (with any milling tool)

POCKET4: Circular pocket milling (with any milling tool)

CYCLE90: Thread milling

CYCLE832: High speed settings

;DIA 40 MM CIRCULAR POCKET and Depth 5 mm

N10 M06T6D1

N20 G90 G0 G54X0Y0

N30 M03 S1000

N40 G0 Z50

N50 POCKET4(5, 0, 0.5, -5, 20, 30, 30, 0.3, 0, 0, 250, 100, 2, 1, 3, 5, 0.2, 0, )

N60 G0Z50

N70 G0Z100

;SQUARE 40×40 MM POCKET and Depth 5 mm

N80 G0Z50

N90 POCKET3(5, 0, 0.3, -5, 40, 40, 0, 70, 70, 0, 0.2, 0, 0, 300, 100, 2, 1, 5, 10, 10, 0.2, 0, 2)

N100 G0Z50

N110 G0Z100

N120 M05

N130 M30

Milling - POCKET Description:

POCKET4 (_RTP, _RFP, _SDIS, _DP, _PRAD, _PA, _PO, _MID, _FAL, _FALD, _FFP1,
_FFD, _CDIR, _VARI, _MIDA, _AP1,_AD, _RAD1, _DP1)

POCKET3 (_RTP, _RFP, _SDIS, _DP, _LENG, _WID, _CRAD, _PA, _PO, _STA, _MID,
_FAL, _FALD, _FFP1, _FFD, _CDIR,_VARI, _MIDA, _AP1, _AP2, _AD, _RAD1, _DP1)
Circular Pocket (POCKET4):

_RTP: Retraction plane (absolute)

_RFP: Reference plane (absolute)

_SDIS: Safety clearance (to be added to the reference plane; enter without sign)

_DP: Pocket depth (absolute)

_PRAD: Pocket radius

_PA: Starting point (absolute), first axis of the plane

_PO: Starting point (absolute), second axis of the plane

_MID: Maximum infeed depth (enter without sign) (Depth of cut)

_FAL: Finishing allowance at the pocket edge (enter without sign)

_FALD: Finishing allowance at the base (enter without sign)

_FFP1: Feedrate for surface machining

_FFD: Feedrate for depth infeed

_CDIR: Milling direction: (enter without sign) 0: Down-cut milling (in the spindle
direction) (1: Conventional milling, 2: With G2 (independent of spindle direction), 3: With G3)

_VARI: Machining type (1: roughing, 2: finishing)

_MIDA: Maximum infeed width as a value in solid machining in the plane (Cutting width)

_AP1: Pocket radius blank dimension

_AD: Blank pocket depth dimension from reference plane

_RAD1: Radius of the helical path during insertion (relative to the tool center point path)

_DP1: Insertion depth per 360° revolution on insertion along helical path
 Experiment 8: Milling curved and angular slots as per drawing specifications

(Draw appropriate drawing showing all the points and dimensions based on following program)

;POWER SYMBOL

N10 G90 G71 G17 G94G54

N20 T6 D1

N30 M03 S1500

N40 G0 Z5

N50 G00 X0 Y0

N60 G00 G54 X0 Y0

N70 G00 X70 Y90

N80 G01 Z-0.3 F300

N90 G02 CR=38.5 X47 Y17.5

N100 G0Z5

N110 G0 X30 Y20.5

N120 Z2

N130 G01Z-0.3

N140 G02 CR=38 X42 Y89.5

N150 G0Z5

N160 G00 X50 Y97

N170 G01Z-0.3

N180 G01 X34 Y48

N190 G01 X50 Y48

N200 G01 X33 Y10

N210 G01 X71 Y60

N220 G01 X52 Y60

N230 G01 X65 Y97

N240 G01 X50 Y97

N250 G0Z5

N260 M05

N270 M30
 Experiment 9: Radial holes, pocket and slot milling operations

(Give/check the appropriate dimensions based on executed program)

(Make the appropriate/required changes in the drawing based on program)

Main Program

;CNC MILLING MODEL1

;8MM END MILL

;N10 G75Z0

N20 G40

N30 G71

N40 M06T5D1

N50 M03S1500

N60 G90G94

N80 G0G90G55X-20Y0

N90 Z50
N100 Z5

N130 CYCLE72("CNCMOD111", 3, 0.05, 0.2, -3.5, 0.25, 0, 0, 300, 70, 101, 42, 3, 0.01, 300, 1,
0.01)

N140 G0Z50

N150 M05

;RECTANGULAR POCKET

;6MM END MILL

N160 M06T3D1

N170 M03S1000

N180 G0G90G56X70Y15

N190 G0X72Y20

N200 G0Z50

N210 CYCLE72("CNCMOD112", 5, 0, 0.2, -3, 0.25, 0, 0, 200, 50, 101, 41, 3, 1, 200, 1, 0.5)

N220 G0Z50

N230 M05

;DIA30 POCKET

;8MM END MILL

N260 M06T5D1

N270 G0G90G55X48Y32.5

N260 M03S1000

N270 G0Z50

N280 POCKET4(5, 0, 0.2, -5, 15, 33, 32.5, 0.3, 0, 0, 250, 100, 3, 1, 5, 5, 0.2, 0, )

N290 G0Z50

N300 G0Z100

N310 M05
;DRILLINGPCD

;6MM DRILL

N340 M06T6D1

N350 M03S1100

N360 G71

N370 G17

N380 G94

N390 G0G90G57X52Y32.50

N410 G01X52Y32.5F200

N430 MCALL CYCLE83(5, 0, 0.5, -12.5, 12.5, -2, 2, 0, 0, 0, 1, 1, 3, 1, 2, 0, 0)

N440 HOLES2(33, 32.5, 19, 60, 60, 6)

N450 MCALL CYCLE83(5, 0, 0.5, -12.5, 12.5, -2, 2, 0, 0, 0, 1, 1, 3, 1, 2, 0, 0)

N455 M05

N460 M30

Subprogram ‘CNCMOD111’

N10 G01X8Y4

N20 X82Y4

N30 G03X86Y8CR=4

N40 G01X86Y57

N50 G03X82Y61CR=4

N60 G01X8Y61

N70 G03X4Y57CR=4

N80 G01X4Y8

N90 G03X8Y4CR=4
N100 M17

Subprogram ‘CNCMOD112’

N10 G01X78Y15

N20 X78Y50

N30 G03X68Y50CR=5

N40 G01X68Y15

N50 G03X78Y15CR=5

N60 M17

Contour milling - CYCLE72 Description:

CYCLE72 (_KNAME, _RTP, _RFP, _SDIS, _DP, _MID, _FAL, _FALD, _FFP1, _FFD,
_VARI, _RL, _AS1, _LP1, _FF3, _AS2, _LP2)

_KNAME: Name of contour subroutine

_RTP: Retraction plane (absolute)

_RFP: Reference plane (absolute)

_SDIS: Safety clearance (to be added to the reference plane; enter without sign)

_DP: Depth (absolute)

_MID: Maximum infeed depth (incremental; enter without sign)

_FAL: Finishing allowance at the edge contour (enter without sign)

_FALD: Finishing allowance at the base (incremental, enter without sign)

_FFP1: Feedrate for surface machining

_FFD: Feedrate for depth infeed (enter without sign)

_VARI: Machining type (enter without sign) (e.g., 1: roughing, 2: finishing)

_RL: Traveling around the contour either centrally, to the right or to the left (with G40,
G41 or G42; enter without sign)
_AS1: Specification of the approach direction/path: (enter without sign) (e.g., 1: Straight
tangential line, 2: Quadrant, 3: Semi-circle)

_LP1: Length of the approach travel (with straight-line) or radius of the approach arc
(with circle) (enter without sign)

_FF3: Retraction feedrate and feedrate for intermediate positions in the plane (in the
open)

_AS2: Specification of the retraction direction/path: (enter without sign) (e.g., 1: Straight
tangential line, 2: Quadrant, 3: Semi-circle)

_LP2: Length of the retraction travel (with straight-line) or radius of the retraction arc
(with circle) (enter without sign)

CYCLE83 Description:

CYCLE83 (RTP, RFP, SDIS, DP, DPR, FDEP, FDPR, DAM, DTB, DTS, FRF, VARI, AXN,
MDEP, VRT, DTD, DIS1)

RTP and RFP: Retract and reference plane respectively

SDIS : Safety distance without sign

DP : Final drilling depth (absolute)

DPR : Final drilling depth relative to reference plane

FDEP : Drilling depth 1 (absolute) (initially a small (e.g. 2 mm) depth will be drilled to
avoid shock on a tool and then remaining drill is completed)

FDER : Drilling depth 1 relative to reference plane

DAM : Degression amount without sign (this is the amount/distance with which tool will
proceed in each step to complete the full depth i.e. once first drilling step is
completed based on ‘FDEP’ remaining depth is drilled stepwise considering
specified ‘DAM’ value)

DBT : Dwell time at each drilling depth

DTS : Dwell time at starting point

FRF : Feedrate factor for first drilling depth (this specifies the reduction factor to
applied feedrate so as to complete first drill ‘FDEP’ smoothly)
VARI : Defines the type of operation (here ‘0’ indicate the operation in which tool retract
with specifies distance in ‘VRT’ while for operation type ‘1’ tool retracts to
reference position after each drill step ensuring chip breakage)

AXN : Defines axis of drill (like AXN=1 is drill along Z axis i.e. XY plane; AXN=2 is
drill along Y axis i.e. ZX plane and AXN=3 is drill along X axis i.e. YZ plane)

MDEP : Defines minimum drilling depth (If the calculated drilling stroke (based on
degression factor) become shorter than the minimum drilling depth i.e. ‘MDEP’
the remaining depth is machined in strikes equalling the length of minimum
drilling depth)

VRT : Retraction distance for chip breaking (specifies for ‘VARI’ i.e. operation type 0)

DTD : Dwell time at final drilling depth

DIS1 : Programmable limit distance (this specifies max. lead distance at tool reinsertion
i.e. an amount with which a tool can proceed max. in depth with respect to earlier
drill depth)