History of CNC

• Motor Controlled Apparatus for

Positioning Machine Tool
• Patent No. 2,820,187
• NC and CNC Machines
• History: US Air Force commissioned MIT
to develop the first "numerically controlled"
machine in 1949. It was demonstrated in
1952.
 Con’t
• 1947 John Parsons began • In 1952 the first NC
experimenting the idea of Using
three-axis curvature data. machine was built at
• June 1947 John obtained a Cincinnati Hydrotel .
research grant from athe AIR
force for $200,000.
• In 1955 AIA
• John became a subcontractor organized the first sub
for MIT • Air Force awarded $
MIT demonstrated the the First NC
35 million for the
in 1951. manufacture 100 NC.
 What is Numerical Control?
• ( EIA) Electronic Industries Association
– A System in Which actions are controlled by
the direct insertion of Numerical data at some
points
• The coded instruction are converted into
two types of Instructions:
– Pulses of Output signals
– ON/OFF Control Signals
 NC Controller Technology
• Vacuum tubes 1952
• Relays 1955
• Semiconductors 1960
• IC 1965
• DNC 1968
• CNC 1970
 Types of NC
• NC
• DNC ( Direct Numerical Controlled
Machines)
• DNC ( Distributed Numerically Controlled
• CNC ( Computerized Numerically Control
Machines)
CNC Hardware and Software
CNC
 Direct Numerical Control
• Introduced in the 1966
– To get ride of the
Punched Tape
Distributed Numerically Control
• Introduced after 1980
– Network
– Advanced
Communication
– Integrated to other
– Production Planning
Activities
 Elements of CNC
Machine
Structure
Lead Screw

Machine Drive System

Control
Unit
CNC Ball Screw
 The motion control
• Depending on the application, motion
control can refer to:
– simple on-off control or
– a sequencing of events,
– controlling the speed of a motor,
– moving objects from one point to another
– precisely constraining the speed,
acceleration, and position of a system
throughout a move
Controlled actuation

Perception
(sensing)

Controlled
Intelligence Environment
(control)

Action
(actuation)
 Drive system:
general arrangement
• General arrangement of a drive system is
presented below:
Motor
Speed Reference
Control Power
Circuits Circuits
Tacho

Speed Feedback
Open Control System
Closed System
Machine Controller
Control Interface
 Control System
On/off Switch •Power and Control Switch

Cycle Start •Starts program execution or MDI command

Emergency Stop •Stops all machine activities

Optional Stop •Temporarily stops the Program

Dry Run •Enables Program Testing at fast federates

Federate Override •Overrides the programmed spindle speed

Speed Override Override spindle speed

Manual Toggle between MDI and manual mode

Auto Allows automatic operations

JOG To jog the axes during set up

Rapid To control the rapid movement of the machine

Coolant switch
 Input Devices to the Machines

• Input devices:
– Punched Cards
– Tape
– MDI
– Diskette
– Magnetic Tape
 NC Codes
• Bit 0 or 1
• Character ( a collection of 8 bit) across a row
• Address ( the letter used before each word to define the meaning.
– A Angular Dimension in X axis
– G Preparatory Function
– M Miscellaneous function
– X Primary motion in X axis
• Word A collection of Character ( Address followed by number)
– N10 or G01 …..etc
• Block A collection of Words
• N10 G01 X 10.0 ( three word Block)
• N05 Go1 X10.01 Y 30.5 Z 5.8 ( five word Block)
• Program A collection of Blocks
 WORD ADDRESS FORMAT

• N... G.. X.. Y.. Z.. I.. J.. K.. F.. H.. S.. T.. M
 Con’t
Characters

6 F . -
Word
F 275.0 G01

Block
N 5 G 0 1 Y – 6 Y – 6. 4 8 F 2 7 5 . 0
Mathematics for NC
Cont’t
 What is Numerical Control?
• ( EIA) Electronic Industries Association
– A System in Which actions are controlled by
the direct insertion of Numerical data at some
points
• The coded instruction are converted into
two types of Instructions:
– Pulses of Output signals
– ON/OFF Control Signals
 NC Controller Technology
• Vacuum tubes 1952
• Relays 1955
• Semiconductors 1960
• IC 1965
• DNC 1968
• CNC 1970
 Types of NC
• NC
• DNC ( Direct Numerical Controlled
Machines)
• DNC ( Distributed Numerically Controlled
• CNC ( Computerized Numerically Control
Machines)
CNC
 Direct Numerical Control
• Introduced in the 1966
– To get ride of the
Punched Tape
Distributed Numerically Control
• Introduced after 1980
– Network
– Advanced
Communication
– Integrated to other
– Production Planning
Activities
Elements of CNC
Mathematics for NC
Cont’t
 To Machine a part
• 1- Prepare a plan
• 2- Prepare tool(s)
• 3- Set-up
• 4- Loading and executing program
 Plan ?
• Where is My Origin ?
• What is the shape of My raw
Material ( Blank)
• Who to Fix My Blank ? 1"
• What are the main
Operations?
• What are the needed tools ?
• How to Sequence the
operations
 Tooling

Which tool(s) to use ?

 Set up
Which elements I should
use to build my fixtures?
 Loading and Executing the
Program
• Communicate with your Machine
• Load your Tools in the Tool Magazine
(Turret)
• Fix your Part
• Set the Fixtures offset(s)
• Set the Tool(s) offsets
• USE CNC or DNC modes
 Communications with the VMC

• Command Mode
• MDI ( manual data mode )
• Manual bottom is used to toggle between
them.
Manual
 Command Mode
• Command Mode is to set up the machine
• To run a program.
 MDI mode
• MDI stands for Manual Data Input
– Single Blocks of G and M codes can be typed
• May be used to set fixture and toll offsets
CNC Programming Syntax
 Parts for a CNC Program
• Program Startup
• Tool Safety Block
• Tool Load Blocks
• Tool Motion Blocks
• Tool Cancel Blocks
• End of Tape Blocks
 Program Start up
• % O 1000
• (**** programmer is Mr. Ali…***)
• (* it is used to cut Aluminum*)
• (* for steel Please reduce the override knobs
to 50 %*)
 Tool Safety Block
• The tool safety block is used to
• issue commands to cancel for any machine
modes that could have been left active.

• N20 G00 G70 G90 G28 G40 G49

 Tool Load Block
• Simply to load tool from the tool carasol

• M6T07
 Tool Motion Blocks
• Rapid Movement (G00)
• Interpolation (G02,G03)
• Fixed Cycles
• Subroutines
 Tool Cancel Blocks
• Tool cancel blocks turns off the tool length
compensation and returns to the tool change
position
 End tape
• End of program code
• M02 or M30
Grouping of Codes
 Interpolation
• Linear Interpolation
• Circular Interpolation
• Helical Interpolation
• NURBS Interpolation
 Linear Interpolation
• The Term Linear means that the controller
is capable of generating thousands of
intermediate steps between the tart point
and the end point of the cut.

• G01 X9.0 Y 10 F 20.0

Circular Interpolation
• G73
• G74
• G76
• G80
• G
Fixed (Canned Cycle)
 Cycles
• G73 High speed peck drilling • G86 Boring Cycle
• G74- Left hand tapping
• G87 Back Boring
• G76 Precision Boring
• G80 Cancellation of the fixed Cycle
cycles • G88 Boring Cycle
• G81 Drilling Cycle
•
• G89 Boring Cycle
G82
• G83 peck drilling cycle
• G84 Right hand tapping cycle
• G85 Boring Cycle
 Syntax

• N..G..G..X..Y..R..Z..P..Q..I..J..F..L..(k..)
• N = Block Number • Z= Z-axis end
• G first G Position= Z depth
• G second G • P Dwell Time
• X = hole position in X • Q depth of peck
• Y hole position in Y • I shift in X
• R=Z axis start • J shift in Y
position = R level • F feeedrate
• L or K repetitions
 Why?
• Machining Holes is the most Common type
done on CNCN mills and Machining
Centers.
• It is Called Point to Point drilling
• Drilling is characterized by repetitive type
of programming.
 Point-to-Point Machinig
• Step1
– Rapid motion to the hole location (X, and Y)
• Step2
– Rapid Motion in along Z to the cut start
• Step3
– Feedrate to the Specified Depth
• Step4
– Return to the Clear
Hole Pattern
X 2.047 X 3.87 X5.9

Y 3.4

Y 1.89
Example
 With canned cycle
• G20
• G17G40G80
• G90G54G00X5.9Y1.89S900M03
• G43z1.0h01m08
• G99G82R0.1Z-0.6813P200F5
• X3.87Y3.4
• X2.047
• G80G28X2.047Y3.4Z1.0
Canned Cycle
 Con’t
• R level Selection

stands for reference or

Rapid to start Point
 G98 , G 99
• G 98
– Will cause the cutting tool to retract to the
initial position = z address
• G 99
– Will cause the cutting tool to retract to the R
level Position
Z depth Calculation

0.1
2.25
0.225

incremental
 G81 drilling Cycle
• G98G81X..Y..R..Z..F..
 G82 Spot Drilling
• G99G82 X…Y…R…Z…P…F…
G73 Deep Hole Drilling
 G83 Peck Drilling
• G98G83X..Y..R..Z..Q..F..
 G73 Peck Drilling HS
• G98G73X..Y..R..Z..Q..F..
 G84 Tapping Cycle
• G89G84X..Y..R..Z..F..
 Fixed Cycle Cancellation
• G80
 Fixed Cycle Repetitions
• L and K address

• G81X17.Y20.R0.15Z-2.4 L1
• X22L1
• X27. L1
• G80
• L0 means do not execute
Machining Holes
Circular Interpolation

G02, G03
 Why ?
Desired
• If we do not have to machine the circle:
h a
• Go 01 ax ay az
• G01 bx by bz g b Programmed
• path
G01 cx cy cz
• G01 dx dy bz c
f
• G01 fx fy fz
• G01 gx gy gz e d
• G01 hx hy hz
 Circular Interpolation

• G02 CW

• G03 CCW
Con’t
 G02 Format
• IJK ( Arc Radius )

• Arc Programming ( ARC Center )

Plane Selection
Plane Selection
Con’t
 IJK method
• G17G02 Xxx.xxx Yyy.yyy Iii.iii Jjj.jjj fff.fff

Arc Direction
Con’t
Con’t
Arc Method
 Arc Method
• G17 G03 Xxx.xxx Yyy.yyy Rrrr.rrr Fff.fff
Example
IJK Method
Arc Method
Cutter Compensation Lecture7
 G41 G42 G40
• G40 Cutter Comp Cancelled

• G41 Cutter Comp to the Left

• G42 Cutter Comp to the Right

G41
G42
 Syntax
• N60 G41 X 5.00 D14
 Exercise
• Do the following exercise using traditional
and cutter comp method, Tool Radius 0.75

18º 2.25

1.125 R0.625

2.25
Point No. X Y
1 0 0
2 0 1.125
3 2.25 1.8561
4 2.25 .625
5 1.625 0
6
Point No X Y
1 -0.375 -0.375
2 -0.375 1.3975
3 2.625 2.3722
4 2.625 0.625
5 2.62 -0.375
6
 Program with Cutter Comp

• G17G20G40G80
• G90E1g00 x –0.625 y –0.625 S1000 M03
• G43 Z1.0 H01
• G01 Z –0.55 F 25.0 M08
• G41 X0 D14 F30
• Y 1.125
• X2.25Y1.8561
• Y0.625
• G02X1.625Y0 R0.625
• G01X-0.625
• G00 G40 Y-0.625
• Z1.0 M09
• G28 X-0.625 Y-0.625
• M30
Towards a better Understanding
of CAM Programming
 Objective

• When Should I use Manual Programming?

• Understanding the Building Blocks of CAM Programming

• Understanding Limitations of CAM Programming

• Improving Efficiency of CAM Programmer

 What is CAM Programming?
• Cam Programming is a new terminology
derived from industry meaning how to
generate an error free and safe tool path.
• It also means generating a CNC Program to
be send to a CNC machine.
Process Basic Mechanics
Machine

Vertical Milling Center

 Tooling

Which tool(s) to use ?

 Set up
Which elements I should
use to build my fixtures?
Machining Process

tool
Turning
Raw Material
Finished Piece
Finished Piece Stock
Milling
Understanding The Process
How The Tool Path Generation Process Works?
Tool Selection
Operation Steps

b) Finishing
Tool Path Generation in Commercial CAD/CAM
SurfaceSystems
Linearization

Mathematical Errors
Due to linearization
 How the Linearization
(digitization) works?

• Curved surface are

approximated by
straight lines
• Red indicate minus
tolerance, green
indicate plus tolerance
Machine Controlled Axis
Programming
Embodiment Plan Translate Execute

Manual
Programming/
Blueprint/ Machine
CAD file
or G Code
CAM Part
Programming
 Example Manual Programming
• Write the Plane (Define
operation Steps)
• For each operation define
tool and write the
Coordinate Sheet
• For each Sheet write the
Corresponding Gcode file
• Send these File(s) to the
machine
• Perform set-up and
machine the part
CAD Drawing
 Plan

Operation 12
Operation
   
 
RAISE  FACE CIRCULAR MILLING
CIRCULAR MILLING
RAISE FACE Operation 3
Center Milling 
 
CENTER
  HOLE
CIRCULAR MILLING  
CONTOUR CIRCULAR MILLING
   
10 HOLES SPOT DRILLING
DEEP PECK
DRILLING
GRAPHICAL CORDIANTE SHEET
 Text COORDINATE SHEET 1

7000
:
PROGRAMME
R: PAOLA GUTIERREZ

PART ID: FLANGE

POINTS COORDINATES REMARK

X Y Z R (I,J)
 

1 3.000 -0.750 0.250  

2 3.000 -0.750 -0.125  

3 3.000 0.000 -0.125  

4 3.000 0.000 -0.125

TOOL SHEET
 The Gcode (CNC Program)
%
O7001
G17 G20 G40 G80 G90 G94
M06 T14 (CONTOUR - 1/2" FLAT END MILL D14)
G0 G90 E1 X3.0 Y-.25 M3 S1000
G43 H14 Z.5 M08 (.25 ABOVE PIECE)
N10 G01 Z-.25 F20.0 (CUT OF DEPTH:.25)
N20 G01 G41 X0.0 Y0.0 D14
N25 G01 Y3.0
N30 G02 X0.0 Y3 I6.0 J0.0
N40 G01 Z-.5
N50 G02 X0.0 Y3.0 I6.0 J0.0
N60 G01 Z-.75
N70 G02 X0.0 Y3.0 I6.0 J0.0
N80 G01 Z-1.0
N90 G40
N100 G0 Z.5 M09
G28 X0.0 Y0.0
M30
%
 How would you machine this
mould?
• Divide The problem into
Pieces
• Divide each piece as a
roughing, semi finish and
a finishing operation
• For each operation choose
the appropriates cutting
tool, cutting condition,
entry and exit escapes, and
a cutting Strategy
Con’t
CAM Programming Building
Blocks
Tool Containment
Machining Angle
About Cutting Method
Surface Flow Line
Tool Entry and Exit
Maximum Step Over
Tool Path for Roughing
How to Over Come Surfaces Gaps
 3-D operation
• 3-D operation is probably the main reason
why CAM Systems are needed in industry
• Example of 3-D operation
– 3-D contouring
– Offsetting
– Flow line cutting
– Parallel Cutting
 2-D Operation
• Since 2-D operation Contributes to 75 % of the
Machining Work, Special attention has to be given
to 2-D operation
• Example of 2-D:
– 2-D Contouring
– Drilling, tapping, Counter-boring, etc.
– Pocketing
– Semi Finishing (Pencil and special cleaning operation)
 2.5 Cutting Operation
• Special attention has been done in the
recent years to develop this technique
• Why?
– To take advantage of 2-D operation to perform
3-D operation
– To improve Utilization of CAM system
– To Free the CAM Programmer from doing time
consuming tasks
 3-D operation
• Intended to Machine parts like Moulds and
dies
• It is used basically to support machining of
free form surfaces
• Usually done in tow steps 2.5D followed by
3-D
 5-Axis Machining
• It is like 3-D except the Tool Axis is
aligned with the Part Surface Normal.
• Benefits
– Less Machining Time
– Better Surface Finish
• Drawback
– Difficult to Program and Model
 1-D, and 2-D Machining

Contouring
Drilling
Internal Pocketing
Example of 2.5 D Operation
 3-D operation

Surface Model Tool Path

 Finishing Path
After Roughing path
Scallop Removal from walls Leftover Clean Up
Final Part
 5-Axis Machining

3- Axis 5-Axis
 Summery and Conclusion
• This presentation is intended to provide an
overview of CAM programming
• The first step to improve CAM System Utilization
is to improved users understanding of CAM
Modeling
• CAM system is a must in 2-5 D operation till 5-
axis machining
• In 1-D and 2-D it depends on the user knowledge
and skills