Department of Mechanical and Aerospace Engineering

NC MANUAL PROGRAMMING – MID SEMESTER TEST

TRC4902 (Mechatronics and Manufacturing)

Student’s Name
Surname Given Name
Student’s ID Number
Practical day/time

Instructions:

• This is a take-home written Mid-Semester test.

• The test is available on Moodle from 4:00 pm (MYT), Week 9 Tuesday, 19th September 2023.
• The test is due to be submitted by 6:00 pm (MYT), Week 9 Tuesday, 19th September 2023.
• Type out the answers in a Word / Google / Document and submit a single .pdf file to the designated
submission box on Moodle
• GM codes are available in the last 2 pages of this document.

For office use only:

Marks Awarded Suggestions:
Program 1 / 20
Program 2 / 30
Program 3 / 30
Question 3 / 20
Total Marks: /100

TRC4902 NC Programming Test (2023) Page 1

Question 1
Write two concise NC programs to machine the 14 mm thick cast part shown in
Figure 1. A finishing cut of the entire thickness of the part profile is required to
be done on a CNC milling machine.

The machine home position is located at (-50.0, 10.0, 40.0) from the coordinate
system shown in Figure 2. Z is equal to 0 on the top surface of the unmachined
part.

Program 1 – Face milling of the entire top surface of the part to decrease the
thickness of the part to 12 mm using a maximum depth of cut of 2 mm. (20 Marks)

Program 2 – Finish machining the full depth of the outer profile of the part
using a maximum depth of cut of 2 mm in a counter-clockwise (tool path)
fashion. (30 Marks)

Table 1: The tools, feed rates and spindle speeds for different operations.

Tool Type Tool Tool Diameter Feed Rate Spindle Speed

No. (mm) (mm/min) (RPM)
Face Mill T02 8 40 1100
End Mill T03 10 40 900

(20 + 30 = 50 Marks)

TRC4902 NC Programming Test (2023) Page 2

 Figure 1: The Cast Part

(0, 0, 0)

Figure 2: Detailed Drawing of the Part (All Dimensions are in mm)

TRC4902 NC Programming Test (2023) Page 3

Suggested Solutions:
Program 1:
O0010;
N010 M06 T02 (% Ø8 mm Face Mill)
N020 G17 G21 G90 G92 X -50 Y10 Z40 M03 S1100
N030 G00 X-6 Y2 Z5
N040 G01 G94 Z-2 F40 M08
N050 G91 M98 P0011 L6
N060 G90 Z5 M09
N070 G00 X -50 Y10 Z40 M05
N080 M30
Subprogram
O0011;
N010 G01 X132
N020 Y6
N030 X -132
N040 Y6
N050 M99

TRC4902 NC Programming Test (2023) Page 4

Program 2:
O0020;
N010 M06 T03 (% Ø10 mm End Mill)
N020 G17 G40 G21 G90 G92 X -50 Y10 Z40 M03 S900
N030 G00 X-5 Y-5 Z5
N040 G10 P02 R5
N050 G94 G01 G42 X10 Y0 Z -1 D02 F40 M08
N060 G91 M98 P0021 L7
N070 G90 G01 Z5 M09
N080 G40 G00 X -50 Y10 Z40 M05
N090 M30
Subprogram
O0021;
N010 G01 Z -2
N020 X70
N030 G02 X20 Y0 R10
N040 G01 X10
N050 G03 X10 Y10 R10
N060 G01 Y20
N070 X -10 Y10
N080 G03 X -19.8 Y19.8 R14
N090 G01 X -11 Y10.4
N100 X -23 Y -11
N110 G02 X -32.1 Y -16.2 R18
N120 G01 X -24 Y -13
N130 Y-20
N140 G03 X10 Y-10 R10
N150 M99

TRC4902 NC Programming Test (2023) Page 5

Question 2
Write a concise NC program to drill all the holes in the 10 mm thick part shown
in Figure 3, using polar coordinates.

The machine home position is located at (350.0, 300.0, 40.0) from the coordinate
system shown in Figure 4. Z is equal to 0 on the top surface of the unmachined
part.

Program 3 – Through drilling of all the holes using the appropriate tools from
Table 2. (30 Marks)

Table 2: The tools, feed rates and spindle speeds for different operations.

Tool Type Tool Tool Diameter Feed Rate Spindle Speed

No. (mm) (mm/min) (RPM)
Drill T04 5 40 970
Drill T05 10 40 970
Drill T06 20 50 1000
Drill T07 30 50 1000

Figure 3: The Part to be Drilled

TRC4902 NC Programming Test (2023) Page 6

 Figure 4: Dimension of the Part (All Dimensions are in mm)

30 Marks
Suggested Solutions:
Program 3:
O0003;
N010 M06 T04 (% Ø5 mm Drill)
N020 G17 G21 G90 G92 X350 Y300 Z40 M03 S970
N030 G16
N040 G93 I95 J75
N050 G00 X25 Y0 Z5
N060 G94 G91 G99 G81 Y30 Z -12 R -4 F40 L12 M08
N070 G80 G90 Z25 M09
N080 X67.5 Y0 M05

TRC4902 NC Programming Test (2023) Page 7

N090 M06 T05 (% Ø10 mm Drill)
N095 Z5 M03 S970
N100 G94 G91 G99 G81 X0 Y36 Z -12 R -4 F40 L10 M08
N115 G80 G90 Z25 M09
N120 X50 Y15 M05
N130 M06 T06 (% Ø20 mm Drill)
N135 Z5 M03 S1000
N140 G94 G91 G99 G81 Y30 Z -12 R -4 F50 L12 M08
N141 G80 G90 Z25 M09
N145 M05
N150 M06 T07 (% Ø30 mm Drill)
N155 Z5 M03 S1000
N160 G99 G81 X0 Y0 Z -11 R1 F50 M08
N170 G80 M09
N180 G15 Z40
N190 X350 Y300 M05
N200 M30

TRC4902 NC Programming Test (2023) Page 8

Question 3
(a) What difficulties may be faced when moving from a process layout
to a cell layout? (5 marks)

(b) How can concurrent engineering be used to achieve continuous

improvement? (5 marks)

(c) How can cellular manufacturing reduce the economical lot size of a
product? Would this approach be suitable to manufacture cars?
(5 marks)

(d) Choose two of Dr Demings 14 points (Lecture 6) and explain how

they can be used to improve quality. (5 marks)

• Grades for management questions are based on the students’ responses.

• Full marks require detailed answers containing definitions and sufficient discussion
of the question.
• See moodle feedback for further details.
• Typically the number of points expected is either equal to or one lesser than the
mark for the question (eg: 5 marks means 4-5 valid points in the answer)

End of Test 20 Marks

TRC4902 NC Programming Test (2023) Page 9

 G&M Codes
G codes Group No. Function

G00 Rapid transverse

G01 Linear interpolation

01
G02 Circular interpolation motion (clockwise)

G03 Circular interpolation motion (counter clockwise)

G04 Dwell
00
G10 Setting offset values

G17* X-Y plane selection

G18 02 Z-X plane selection

G19 Y-Z plane selection

G20 Inch input

06
G21 Metric input

G28 00 Return to reference point

G40* Cancelling cutter compensation

G41 07 Cutter radius compensation left

G42 Cutter radius compensation right

G80* Cancelling cycle motion defined by G80s code

G81 Spot drilling cycle

09
G83 Peck drilling cycle

G85 Boring cycle

G90 Programming in absolute coordinates

03
G91* Programming in incremental coordinates

G92 00 Setting origin of machine coordinate system

G94 Per minute feed

05
G95 Per revolution feed

G98 Return to initial point in cycle motion

10
G99 Return to R point in cycle motion

G15 Polar coordinate system cancel (Off or inactive)

TRC4902 NC Programming Test (2023) Page 10

 G16 Polar coordinate system (On or active)

G93 Polar origin selection

M Code Functions
M00 Program stop (usually used in the middle of program
Optional stop (This function is effective only when
M01
optional stop button on control panel is depressed.
M02 End of program
Spindle start clockwise (milling machine)
M03
Spindle start forward (lathe)
Spindle start counter-clockwise (milling machine)
M04
Spindle start reverse (lathe)
M05 Spindle stop
M06 Tool change
M08 Coolant on
M09 Coolant off
M30 End of program and memory (or tape) rewind
M41 Lower range of spindle speed
M42 Higher range of spindle speed
M98 Call a subprogram
M99 Return to main program

TRC4902 NC Programming Test (2023) Page 11