CNC Programing

&
CNC Machining

1
 Index

S.No Contents Page No.

1 Introduction 3
2 History of CNC 4
3 Introduction to CAD 5
4 Introduction to CAM 6
5 What is CNC & Types of CNC 7
6 CNC Milling Machine 8
7 Types of Milling Machine 9
8 Co-Ordinate system used in CNC Programming 16
9 Specification of CNC Milling 17
10 Introduction of Operating Panel 18
11 Introduction of G-Codes 19
12 Introduction of M-Codes 21
13 Programming 22
14 How to Write a Program 24
15 Milling Tools & Its Operations 25
16 Linear Interpolation 27
17 Circular Interpolation 30
18 Canned Cycle 33
19 Materials 35
20 Properties of Materials 38
21 Safety Precautions 39
22 Cutter Radius Compensation 41
23 Measuring Instruments 45
24 Blue Print Reading 51

2
 Introduction to CNC

CNC Stands for Computer Numerical Control .CNC always refers to how a machine operates
that is, its basic methods of controlling movements .Put on another way, a CNC machines
uses G-Code from computer to move motors and other positioning system in order to guide a
spindle over raw material.

A CNC machines uses mathematics and coordinates system to understand and process
information about what to move, to where, and how fast. Most CNC machines are able to
move in three controlled directions at once (called 3 axes). These directions are called axes
and given by name X, Y, Z axis (based on Cartesian coordinates System).

CNC Process Flow Charts

Design CAD CAM Controlling Machining

3
 History of CNC
The first commercial NC machines were built in the 1950's, and ran from punched tape.
While the concept immediately proved it could save costs, it was so different that it was very
slow to catch on with manufacturers. In order to promote more rapid adoption, the US Army
bought 120 NC machines and loaned them to various manufacturers so they could become
more familiar with the idea. By the end of the 50's, NC was starting to catch on, though there
were still a number of issues. For example, g-code, the nearly universal language of CNC we
have today, did not exist. Each manufacturer was pushing its own language for defining part
programs (the programs the machine tools would execute to create a part).

1959 CNC Machine: Milwaukee-Matic-II was first machine with a tool changer...

A number of key developments brought CNC rapidly along during the 1960's:

- Standard G-Code Language for Part Programs: The origin of g-code dates back to MIT,
around 1958, where it was a language used in the MIT Servomechanisms Laboratory. The
Electronic Industry Alliance standardized g-code in the early 1960's.

- CAD came into its own and started rapidly replacing paper drawings and draftsmen during
the 60's. By 1970, CAD was a decent sized industry with players like Intergraph and
Computer vision, both of whom I consulted for back in my college days.

4
 Introduction to CAD

It is stand for Computer aided design and it is used to translate the design into computer.

There are two types of CAD

2D 2 Dimensional X, Y Axis

3D 3 Dimensional X, Y, Z Axis

CAD Software
(2D, 3D)

These are famous software which are using worldwide.

PRO E WILD FIRE

DELCAM
SOLID WORKS
INVENTOR
RHINO CAD
AUTO CAD

5
 Introduction to CAM

(2D, 3D, 4th axis, 5th Axis)

It is Stand for computer aided manufacturing and it is used to converting CAD files
into machines Languages and these are used for CNC Programming, to generate G-Codes.
Feed, Speed, and G-
Codes Files.

CAM Software
There are numbers of these Industry in all over the
world Are famous software which are using worldwide.

MASTER CAM
DELL CAM
EDGE CAM
ART CAM
PRO-E WILD FIRE
CATIA

6
 What is CNC
Computer Numeric Control

A machine which Can Perform different operation with the Help of Computer.

Types of CNC
There are different types of CNC which are used in different industry according to nature of
work in all over the world.

CNC Milling
CNC Turning/Lathe
CNC wood Router
CNC Laser Cutting
CNC Water jet
CNC wire cut
CNC EDM

7
 CNC Milling machine:

A machine which can perform different operations for example Milling, Drilling, Pocketing,
Slotting, Facingetc. with the help of computer.
In this Machine Workpiece is clamped on Table which move in X & Y-axis direction while
tool is clamped in Spindle which rotate with any speed

CNC Machining Centre:

A CNC machine that can perform multiple operations with the variety of tools clamped in the
Automatic Tool Changer (A.T.C).

Components of CNC:
1. Bed
2. Spindle.
3. Column
4. Saddle.
5. Lead Screw.
6. Main Control Unit (M.C.U).
7.Motors.
X-axis
Y-axis
Z-axis
8. Hydraulic Unit.
9. Pneumatic Unit.
10. Drives
X-axis
Y-axis
Z-axis

8
 Types of Milling Machine
According to Structure:

Bed Milling Knee Milling

According to the Position of Tool and Job:

Horizontal Milling Vertical Milling

9
According to Work:

Copy Milling

Universal Milling

10
Co-ordinate Systems use in CNC programming

A numerical system used to describe the location of an object in three-dimensional space. A

coordinate system expresses the distance from any point to the fixed intersection of three
linear axes: X, Y, and Z.

Types of Co-ordinate system

Cartesian Co-ordinate System
Polar Co-ordinate system

Cartesian coordinate system

The numerical system that describes the location of an object by numerically expressing its
distance from a fixed position along three linear axes.

11
Types of Cartesian Co-ordinate System
Absolute Co-ordinate System
Incremental/ Relative Co-ordinate System

12
Absolute Co-ordinate System:

A series of numerical positions that are calculated from a fixed point of origin.

All dimensions relate to the same origin, the dimension reference point.

Incremental Co-ordinate System:

A series of numerical positions that use the previous position as the point of
origin.

Origin point is not fix, Each point is zero point for its next point

13
 Examples of Absolute & Incremental Co-ordinates

Example # 1

Absolute Incremental
G0 X10.0 Y10.0 ; G0 X10.0 Y10.0 ;
G01 X110.0 Y10.0 ; G01 X100.0 Y0.0 ;
G01 X110.0 Y60.0 ; G01 X0.0 Y50.0 ;

Example # 2

Absolute Incremental
G0 X20.0 Y20.0 ; G0 X20.0 Y20.0 ;
G01 X50.0 Y50.0 ; G01 X30.0 Y30.0 ;
G01 X150.0 Y50.0 ; G01 X100.0 Y0.0 ;

14
 Polar Co-ordinate System

In mathematics, the polar coordinate system is a two

dimensional system in which each point on a plane is determined by
a distance from a fixed point and an angle from a fixed direction.

Types of Co-ordinate System In CNC

i. Machine Co-ordinate system

A fixed coordinate system with the machine zero point as its origin. The
machine coordinate system covers the entire range of movement in the
work area and is the basis for the other coordinate systems. It is define
By Manufacturer of the machine

ii. Workpice Co-ordinate System

A temporary coordinate system with the workpiece zero point as its
origin. The workpiece coordinate system simplifies programming and is
defined by a part programmer.

15
 Definitions
Zero point

The point at which the three axes of a coordinate system meet. The reference zero point is
also called the origin and is located at X=0, Y=0, Z=0.
Machine zero
The position located at the farthest possible distance in a positive direction along the X-, Y-,
and Z-axes. This position is permanently set for each particular CNC machine.

Program zero
The position that acts as the origin for the part program of a particular workpiece. This
position is unique to each workpiece design, and it is selected by the part programmer.

Workpiece zero point

The origin of both the workpiece coordinate system and the part program for a particular
workpiece. Workpiece zero, commonly called program zero, is unique to each workpiece
design and is selected by a part programmer.

Home position
The origin of the machine coordinate system located above the lathe spindle and to the far
upper right-hand corner of the lathe work area. The unchangeable home position is also
known as the machine zero point.

X- axis

The linear axis representing motions and positions that travel the longest distance parallel to
the worktable.

Y-axis

The linear axis representing motions and positions that travel the shortest distance parallel
to the worktable.
Z-axis
The linear axis that represents motions and positions perpendicular to the worktable. The Z-
axis is always parallel to the spindle.

16
 Specification of CNC Milling

Control:
Fanuc

Hurco

Meldas

Siemens

Make:
Mitsubishi
Leadwel
Doosan

Made:
Year of Made (1960-2018)

Bed Size:
Bed Size in X & Y.

Travel In X, Y & Z

Other:
Spindle Orientation

Machine Type

Number of Axis

Spindle Speed

Automatic Tool Changer (Number of Tools)

CAD / CAM Software

Feed Rate

17
Introduction to Operating Pannel

18
 Introduction to G-Codes:

G Codes are instructions what are given to machine for cutting /removal of
material, machine setup etc.

A word that finds the type of operation performed on the machine for e.g.
cutting, drilling, tapping etc.

LIST OF G-CODES
1. Motion Codes:
G0 = Rapid
G1 = Linear interpolation
G2 = Circular interpolation (CW)
G3 = Circular interpolation(CCW)
2. Plane Selection Codes:
G17 = XY - Axis
G18 = YZ - Axis
G19 = ZX - Axis
3. Distance mode Codes:
G90 = Absolute Co-ordinate System
G91 = Incremental Co-ordinate system
4. Spindle Speed Mode:
G93 =
G94 =
5. Units Selection Codes:
G20/G70 = Inches
G21/G71 = Metric
6. Cutter Dia Compensation Codes:
G40 = Compensation Cancel.
G41 = Compensation Left
G42 = Compensation Right
7. Tool Length Compensation Codes:
G43 = Tool Length Compensation
G49 = Tool Length Compensation Cancel

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8. Canned Cycle Codes:
G80 = Drilling Cycle Cancellation
G81 = Drilling Cycle
G82 = Deep Hole Drilling
G83 = Peck Drilling
G84 = Tapping Cycle
G85 ~ G89 = Boring Cycle

9. Return Mode in Canned Cycle:

G98 = Return to Home Position
G99 = Return to Retract Position
10. Co-ordinate System Selection:
G53 = Machine Co-ordinate system Selection
G54 ~ G59 = Work piece Co-ordinate system selection
G92 = Part Zero selection.

20
 Introduction to M-Codes:

A word used to signal an action from miscellaneous group of commands.

M-Codes are used for spindle turnings, coolant on/off, Program end, work piece
clamping/unclamping etc.

LIST OF M-CODES

M00 = Program Stop

M01 = Program Optional Stop

M02 = Program End

M03 = Spindle Rotation Clock Wise

M04 = Spindle Rotation Counter Clock wise

M05 = Spindle Stop

M06 = Tool Change

M08 = Coolant On

M09 = Coolant Off

M10 = Clamp On

M11 = Clamp Off

M30 = End of Program Reset to Start

M98 = Call Sub-Program

M99 = Return to Main Program

21
 Programming:
Introduction:

What is program?
A series of numerical instructions used by a CNC machine to
perform necessary sequence of operations to machine a work piece.

Programmer:
The person responsible for the creation of part program.

Program Zero:
The position that acts as an origin for the part program of specific work
piece. This position is unique for each work piece design and it is selected
by the programmer.

S-Codes:
A word that finds the spindle speed during cutting operation.
Spindle speed is s
Spindle speed = S
Unit = Rpm (revolution/min)
F-Codes:
A word that finds the feed during cutting operation. It is also known as

Feed Rate = F
Unit = mm/min
T-Codes:
A word that finds which specific cutting tool will be selected during the
tool change.

G-Codes:
A word that finds the type of an operation performed on the machine.

M-Codes:
A word used to signal an action from miscellaneous group of commands.

N-Codes:
It is a sequence number or title of program block.

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 Program Structure:
A CNC Program is made up of one or more blocks.

Block:
Each block contains one or more words.

Word:
A word is generally an address register for a value.
For e.g. BLOCK: N10 G01 X10.0 Y10.0 F100.0 M08 ;
WORDS: (N52), (G01), (X10.0), (Y10.0), (M08)
Address:
Address is a command o letter followed by a number given to the machine.
For e.g N, G, X, Y, F, M, R, S

Different Codes used in Programming.

O = Program Number.

H = Value of Tool Length Compensation.

D = Cutter Dia Compensation.

E.O.B = End of Block.

X-axis = Longest axis perpendicular to the spindle.

Y-axis = Perpendicular to X & Z-axis.

Z-axis = Along the line of spindle or Parallel to the line of

spindle.
I, J, K, & R codes
These codes are used for circular interpolation.

I = Distance of Arc start point to the centre of the arc along X-

axis.
J = Distance of Arc start point to the centre of the arc along Y-
axis.
K = Distance of Arc start point to the centre of the arc along Z-
axis.

R = A value used for radius of arc in circular interpolation.

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 How to Write a Program?

Program Number O0001 ;

Initial Line G0 G80 G21 G17 G49 G40 ;
Spindle on (CW) S2000 M03 ;
G0 X0.0 Y0.0 ;
Workpiece Zero in G92 X0.0 Y0.0 ;
G0 Z0.0 ;
Workpiece Zero in G92 Z0.0 ;
Safe Height of Tool G0 Z30.0 ;
Cut Position X50.0 Y50.0 ;
Depth of Cut & Plunge Feed G01 Z-1.0 F100.0 ;
Co-ordinates Values X350.0 Y50.0 F1000 ;
Co-ordinates Values X350.0 Y250.0 ;
Co-ordinates Values X50.0 Y250.0 ;
Co-ordinates Values X50.0 Y50.0 ;
Safe Height of Tool G0 Z30.0 ;
Spindle Stop M05 ;
Program End & Reset to Start M30 ;

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 Milling Tools & Operations

Milling Operations:
Facing
Pocketing
Slotting
Grooving
End milling
Profile milling
Surface milling
Drilling
Boring
Reaming
Tapping
Counter sinking
Counter boring
Chamfering

Facing Pocketing Slotting End Milling

Surface Milling Drilling Boring Reaming

Tapping Countersinking CounterBoring Chemfering

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 Milling Tools

Facing Tool End Mill

Bull Nose End Mill Ball Nose End Mill

Drill Bit & Center Drill Boring Tool

Reamer Threading Tool

Counter bore Countersink Chamfering Tool

26
 Examples of Linear Interpolation.

G0 & G01

Example # 1

G0 X10.0 Y10.0 ;
G01 X110.0 Y0.0 ;

Example # 2

G0 X20.0 Y20.0 ;
G01 X50.0 Y50.0 ;
X150.0 Y50.0 ;

27
 Complete Program of Linear Interpolation.

Example # 1

O00001;
G0 G80 G21 G17 G49 G40 ;
S2000 M03 ;
G0 X0.0 Y0.0 ; (Touching Value)
G92 X0.0 Y0.0 ;
G0 Z0.0 ; (Touching Value)
G92 Z0.0 ;
G0 Z30.0 ;
X50.0 Y50.0 ;
G01 Z-1.0 F100.0 ;
X350.0 Y50.0 F1000 ;
X350.0 Y250.0 ;
X50.0 Y250.0 ;
X50.0 Y50.0 ;
G0 Z30.0 ;
M05 ;
M30 ;

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 Complete Program of Linear Interpolation.

Example # 2

O0002;
G0 G80 G21 G17 G49 G40 ;
S2000 M03 ;
G0 X0.0 Y0.0 ; (Touching Value)
G92 X0.0 Y0.0 ;
G0 Z0.0 ; (Touching Value)
G92 Z0.0 ;
G0 Z30.0 ;
X50.0 Y50.0 ;
G01 Z-1.0 F100.0 ;
X300.0 Y50.0 F1000 ;
X350.0 Y100.0 ;
X350.0 Y250.0 ;
X100.0 Y250.0 ;
X50.0 Y200.0 ;
X50.0 Y50.0 ;
G0 Z30.0 ;
M05 ;
M30 ;

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 Circular Interpolation

G02 & G03

These codes are used for circular interpolation.

I = Distance of Arc start point to the centre of the arc along X-

axis.

J = Distance of Arc start point to the centre of the arc along Y-

axis.

K = Distance of Arc start point to the centre of the arc along Z-

axis.
R = A value used for radius of arc in circular interpolation.

Examples of Circular Interpolation.

Example # 1

G0 X40.0 Y0.0 ;
G03 X0.0 Y40.0 I-40.0 J0.0 ;

G03 X0.0 Y40.0 R40.0 ;

Example # 2
G0 X0.0 Y40.0 ;
G03 X-40.0 Y0.0 I0.0 J-40.0 ;
G03 X-40.0 Y0.0 R40.0 ;

Example # 3

G0 X-10.0 Y35.0 ;
G03 X-40.0 Y0.0 I10.0 J-35.0

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 Complete Program of Circular Interpolation
Example # 1

G0 G80 G21 G17 G49 G40 ;

S2000 M03 ;
G0 X0.0 Y0.0 ; (Touching Value)
G92 X0.0 Y0.0 ;
G0 Z0.0 ; (Touching Value)
G92 Z0.0 ;
G0 Z30.0 ;
X15.0 Y15.0 ;
G01 Z-1.0 F100.0 ;
X145.0 Y15.0 F1000.0 ;
G03 X195.0 Y93.0 I-49.0 J87.0 ;
G01 X195.0 Y135.0 ;
X51.0 Y135.0 ;
G03 X15.0 Y85.0 I38.0 J-64.0 ;
G01 X15.0 Y15.0 ;
G0 Z30.0 ;
M05 ;
M30 ;

31
 Subprogram
A program separate from the main program that executes a series of operations
that occurs multiple times during the machining cycle. Subprograms shorten
and simplify manual programming.

M98 = Call Sub-Program

M99 = Return to Main Program

Main Program # Oooo3 Sub Program # Oooo4

G0 G80 G21 G17 G49 G40 ; G91 G01 Z-1.0 F200
S2000 M03 ; G90 G01

G0 X0.0 Y0.0

G0 Z30.0 ;
M98 P5ooo4

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 CANNED CYCLE:
Drilling Cycle
Canned cycles are used for various drilling, boring, ramming, and tapping
functions using specified G-codes in variables of program lines.
Codes used for canned cycle are:
G80 = Canned Cycle Cancellation
G81 = For Spot Drilling Cycle
G82 = Counter Boring Cycle
G83 = Deep hole Drilling
G84 = Tapping Cycle
G85 ~ G89 = Boring Cycle
G98 = Return to Initial point
G99 = Return to Retract Point

Explanation:
G98 & G99 can be used for all canned cycles to return to the initial
point
Or retract point.

I = Start point of Drill

R = Rapid Point Specified in Program
Z = Depth of Drill

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 Example of a Drilling Program:

G0 G80 G21 G17 G49 G40 ;

S2000 M03 ;
G0 X0.0 Y0.0 ; (Touching Value)
G92 X0.0 Y0.0 ;
G0 Z0.0 ; (Touching Value)
G92 Z0.0 ;
G0 Z30.0 ;
X44.5 Y0.0 ;
G83 X44.5 Y0.0 Z-10.0 R5.0 Q2.0 F100.0 ;
X-13.66 Y31.47 ;
X-31.50 Y13.0 ;
X-31.50 Y-13.0 ;
X-13.66 Y-31.47 ;
X13.66 Y-31.47 ;
X31.50 Y-13.0 ;
X31.50 Y13.0 ;
X13.66 Y31.47 ;
G0 Z0.0 ;
M05 ;
M30 ;

34
 Materials

Type of Materials

I. Ferries
These are metals which contain iron. They may have small amounts of other metals or
other elements added, to give the required properties.
All ferrous metals are magnetic and give little resistance to corrosion
II. Non Ferries
These are metals which do not contain any iron. They are not magnetic and are usually
more resistant to corrosion than ferrous metals.

Ferries Non Ferries

Steel Aluminum & Alloys
Cast Iron Copper & Alloys
Carbon Steel Zink & Alloys
Alloy Steel Brass
Hard Steel Lead
Tool Steel Tin
Stainless Steel Gilding metal

Pure Metals

A pure metal only consists of a single element. This means that it only has one type of atom
in it.
The common pure metals are aluminum, copper, iron, lead, zinc, tin, silver and gold.

Alloys

An alloy is a mixture of two or more metals. When a material is needed which requires
certain properties and this does not exist in a pure metal we combine metals.

Pure white aluminum is very soft and ductile. Other elements can be added to create an
aluminum alloy. This can produce a metal which is stronger than Mild Steel has improved
hardness and is resistant to corrosion while still remaining light in weight.

35
 Ferrous Metals Chart
Name Composition Properties Uses

Tough, high tensile strength, ductile.

0.15 to0.30% Because of low carbon content it can girders, Plates, nuts and
Mild Steel
carbon not be hardened and tempered. It bolts, general purpose.
must be case hardened.

medium
carbon,
Can be hardened and tempered. Can
High Speed tungsten,
be brittle. Retains hardness at high Cutting tools for lathes.
Steel chromium
temperatures.
and
vanadium.

18%
chromium, Kitchen draining boards.
Stainless Steel Corrosion resistant
and 8% nickel Pipes, cutlery, aircraft.
added.

Low carbon
High Tensile steel,,
Very strong and very tough. Gears, shafts, engine parts.
Steel nickel,and
chromium.

0.70% to Chisels, hammers, drills,

High Carbon The hardest of the carbon steels. Less
1.40% files, lathe tools, tapsand
Steel ductile, tough and malleable.
carbon. dies.

0.30 % to
Medium Stronger and harder than mild steels. Metal ropes, wire, garden
0.70%
Carbon Steels Less ductile, tough and malleable. tools, springs.
carbon.

Heavy crushing machinery.

Remelted pig Hard, brittle, strong, cheap, self-
Car cylinder blocks, vices,
iron with lubricating.
machine tool parts, brake
Cast Iron small
drums, machine handle and
amounts of Whitecast iron, grey cast iron, gear wheels, plumbing
scrap steel. malleable cast iron. fitments.

36
 Non-Ferrous Metals Chart
Name Composition Properties Uses
Greyish-White, soft, malleable,
Aircraft, boats, window
conductive to heat and
frames, saucepans,
electricity, It is corrosion
Aluminium Pure Metal packaging and
resistant. It can be welded but
insulation, pistons and
this is difficult. Needs special
cranks.
processes.

Aluminium
Aluminium +4% Ductile, Malleable, Work Aircraft and vehicle
alloys-
Copper+1%Manganese Hardens. parts.
Duraluminium)

Electrical wire, cables

Red, tough, ductile, High
and conductors, water
electrical conductor, corrosion
and central heating
Copper Pure metal resistant, Can work hard or
pipes and cylinders.
cold. Needs frequent
Printed circuit boards,
annealing.
roofs.
Very corrosive, yellow in
colour, tarnishes very easily. Castings, ornaments,
Brass 65% copper +35%zinc.
Harder than copper. Good valves,forgings.
electrical conductor.
The heaviest common metal.
Protection against X-
Soft, malleable, bright and
Ray machines. Paints,
Lead Pure metal shiny when new but quickly
roof coverings,
oxidizes to a dull grey.
flashings.
Resistant to corrosion.
Makes brass. Coating
A layer of oxide protects it for steel galvanized
Zinc Pure metal from corrosion, bluish-white, corrugated iron roofing,
easily worked. tanks, buckets, rust-
proof paints

White and soft, corrosion Tinplate, making

Tin Pure metal
resistant. bronze.

Corrosion resistant, golden Beaten metalwork,

Gilding metal 85% copper+15% zinc.
colour, enamels well. jewellery.

37
 Properties of Materials
Hardness The resistance a materials has to cutting and surface indentations.

This describes the amount of energy a material can absorb without

Toughness breaking. This is the opposite to brittleness. We measure a material's
ability to absorb shock.

The maximum force a material can withstand in tension(pulling)

Tensile Strength compression(squashing) , torque(twisting) and shearing(sideways
pressure).

The amount of hammering, pressing and shaping a material can take

Malleability
without breaking.

Ductility The length that a material can be stretched without breaking.

The length that a material can be stretched and return to its original
Elasticity
length when released.

Heat and Electrical

The measure of how well a material can conduct heat or electricity.
Conductivity

The denseness of materials. A dense material will be heavy in relation

Heaviness
to its size.

The measure of how a material withstands a heavy load without

Strength
breaking.

38
 Safety Precautions
1. Worker Safety
2. Machine Safety
3. Tool Safety
4. Job Safety

Worker Safety:
Clothes should not be loosed.
Ties Loose Sleeves are prohibited.
Remove the jewelry while working.
Be aware of what is going around you.
Concentrate on what you are doing.
Do not run in the workshop.
Keep the floor free of oil and Greece.
Do not attempt to measure the part that is moving.
Never Handel the chips by your hand or finger.
Light should be sufficient.
Machine door should be closed while running.

Machine Safety: (Before Starting Machine)

Do not step or operate any machinery without an Instructor.
Before starting the machine you should know about it.
You should know that which part is stationary, moving, fixed and sharp.
Double check that your workpiece is securely held.
Remove keys wrenches and other tools from the machine table.
Check the pressure of compressor

Do not leave the machine without an attendant.

Machine Safety: (After Starting Machine)
First of all send the machine to its home position.
Check the part zero before program running (Cycle start).
Check the tool for a safe height.
Select a proper tool for a proper job.
Operator should be careful about the right program for right job.
Do not run the machine on rush speed or feed.
Operator should be concentrate on machine sound and cutter sound.
program running.

39
Tool Safety
Sharp edges or points of tools to be carried or stored, should be Protected.
Files must never be used without a handle.
Wooden handles should be renewed if they show signs of splitting.
Screwdriver blades should be kept in good condition. The correct type and size of
screwdriver should be used for the job.
Both hands should be kept behind the blade when applying pressure.
Screwdrivers should not be used as levers or chisels.
Hammerheads must be kept tightly wedged in place.
Punches or chisels that have mushroomed heads must not be used.
They must be reground.
The correct size spanner to fit the nut or bolt head should always be used.

Job Safety
Keep your finish at proper place.
It should be not strike with hard material.
Avoide the finish job from scratches.
Carefully deburn the finish job.
Be carefully about atmospheric condition for Micronics accuracy.

40
 Cutter radius compensation
Cutter radius compensation allows a program to be written without considering the
size of the cutter being used.
Three G codes are used to control compensation G40, G41 and G42. They are group
modal.
G40 cutter compensation off, centre line programming.
G41 cutter compensation to the left of the programmed path.
G42 cutter compensation to the right of the programmed path.
The axes that the compensation works in are dependent on the currently active plane.
The radius used for compensation is stored in the Tool Table and the correct tool must
be active when the compensation is applied.

When compensation is active the machine calculates a tool path continuously parallel
to the programmed path.

On external corners the control will add auxiliary movements to fill the gaps left in the
parallel path. There is usually an option of whether these moves will be arcs or
intersections of the path segments. This feature is normally controlled with G codes.
On internal corners there will be profile errors where the round cutter can not get into
the sharp points.

41
It is usually possible to determine where the feedrate will apply, either at the point of
contact with the programmed profile or the tool centre. This feature is normally
controlled with G codes.

Programming moves smaller than the cutter radius usually results in either profile
errors or machine errors.
Applying compensation should be done before getting to the profile as in the example
below.

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A) start and finish point

B) Cutter compensation on to the right hand side

C) Radius approach move

D) Profile

E) Radius away from the profile

F) Cutter compensation off move

A generic CNC program to machine this cut out in plastic on a router.

Note that all dimensions are in mm and the feedrate is in mm/min.

I would strongly suggest that a cycle is programmed to set the machine to a 'normal'
condition and that cycle is the first thing done in any program. As cycles vary from
control to control no further details will be put here.

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N100 (MACHINE CUT OUT) [Program identity]
N110 (MACHINE NORMAL CYCLE GOES HERE) [Cycle to clear all switchable
conditions]
N120 T1 M6 M3 S25000 [Activate tool 1, tool change and spindle start]
N130 G54 G0 X-60 Y150 [Activate zero shift 1, rapid move to start position]
N140 Z10 [Rapid down to clearance height]
N150 G42 G1 Y180 Z-2 F3000 M8 [Activate compensation to the right at feedrate
and turn on coolant]
N160 G2 X-30 Y150 R-30 [Arc move to meet profile]
N170 G1 Y60 [Machine profile]

N180 G2 X-50 Y40 R-20

N190 G1 X-110
N200 G2 X-130 Y60 R-20
N210 G1 Y220
N220 G2 X-110 Y240 R-20

N230 G1 X-50

N240 G2 X-30 Y220 R-20

N250 G1 Y150 [Finish machining profile]
N260 G2 X-60 Y120 R-30 [Arc move away from profile]

N270 G40 G1 Y150 Z10 [Cancel cutter compensation and move out of the material]
N280 G53 G0 Z0 T0 M9 [Cancel zero shift and tool, turn coolant off and retract Z
axis to machine zero]
N290 X0 Y0 [Move away from workpiece]
N300 M30 [End of program]

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 Measuring Instruments
Vernier caliper:

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How to read the Vernier caliper:
1), Read the centimeter mark on the fixed scale to the left of the 0-mark on the vernier scale.
(10mm on the fixed caliper)

2). Find the millimeter mark on the fixed scale that is just to the left of the 0-mark on the
vernier scale. (6mm on the fixed caliper)

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3). Look along the ten marks on the vernier scale and the millimeter marks on the
adjacent fixed scale, until you find the two that most nearly line up. (0.25mm on the

vernier scale)

4). To get the correct reading, simply add this found digit to your previous reading.
(10mm + 6mm + 0.25mm= 16.25 mm)

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Micrometer Screw-Gauge:

To take a reading of Micrometer:

First look at the main scale. This has a linear scale

reading on it.The long lines are every millimetre
the shorter ones denote half a millimetre in
between.

On the diagram this reading is 2.5 mm

Now look at the rotating scale. That denotes 46

divisions - each division is 0.01mm so we have 0.46mm from this scale.

The diameter of the wire is the sum of these readings: 2.5 + 0.46 = 2.96 mm

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Height gauge:

Depth gauge:

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Dial Indicator

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 Blueprint Reading

Types of Lines
Angel of Projection
Symbols use in Drawing

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Types Of Line

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53
Angel of Projection

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Symbols use in Drawing

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