CNC Programming

& Application
Federal TVET Institute
Manufacturing Technology Department
Addis Abeba
Ethiopia
Mr. Gezae Mebrahtu
Masters in Mechanical Manufacturing and Automation
 1. What is machining?
• Machining is basically removal of material, most
often metal, from the work-piece, using one or more
cutting tools to achieve the desired dimensions.
• There are different machining processes, such as,
turning, milling, boring etc.
• For all metal-cutting processes, the cutting speed,
feed, and depth of cut are important parameters.
 2. Why CNC?
• Modern precision manufacturing demands
extreme dimensional accuracy and surface finish.
Such performance is very difficult to achieve
manually, if not impossible, even with expert
operators. In cases where it is possible, it takes
much higher time due to the need for frequent
dimensional measurement to prevent overcutting.
 2. Why CNC?
• It is thus obvious that automated motion control
would replace manual “hand-wheel” control in
modern manufacturing. Development of
computer numerically controlled (CNC) machines
has also made possible the automation of the
machining processes with flexibility to handle
production of small to medium batch of parts.
 3. What is NC?
• Numerical control (NC) refer to control of a machine
or a process using codes consisting of characters and
numerals.
• The word CNC came into existence in 7th when
microprocessors and microcomputers replaced
integrated circuit IC based controls used for NC
machine.
 3. What is NC?
• The concept of NC was proposed in the
late 1940s by john Parsons who
recommended a method of automatic
machine control that would guide a
milling cutter to produce a curvilinear
motion in order to produce a curvilinear
motion in order to generate smooth
profiles on the work pieces.
4. Components of traditional NC systems
 5. Advantages of NC systems over manual methods of
production
• Better control of the tool motion under
optimum cutting conditions.
• Improved part quality and repeatability
• Reduced tooling costs, tool wear, and job
setup time.
• Reduced scrap
• Better production planning and
placement of machining operations in the
hand of engineering.
 6. Computer Numerical Control (CNC)
• Computer numerical control CNC is the numerical control
system in which a dedicated computer is built into the control
to perform basic and advanced NC functions.
• CNC controls are also referred to as soft wired NC systems
because most of their control functions are implemented by
the control software programs.
• CNC is a computer assisted process to control general
purpose machines from instructions generated by a processor
and stored in a memory system.
7. Components of modern CNC systems
 8. Advantages of CNC systems
• CNC machines can be used continuously and only need to
be switched off for occasional maintenance.
• These machines require less skilled people to operate
unlike manual lathes/milling machines etc.
• CNC machines can be updated by improving the software
used to drive the machines.
• Training for the use of CNC machines can be done through
the use of “virtual software”.
 8. Advantages of CNC systems
• The manufacturing process can be simulated virtually and no need
to make a prototype or a model. This saves time and money.
• Once programmed, these machines can be left and do not require
any human intervention, except for work loading and unloading.
• These machines can manufacture several components to the
required accuracy without any fatigue as in the case of manually
operated machines.
• Saving in time that could be achieved with the CNC machines are
quite significant.
 9. Disadvantages of CNC systems
• CNC machines are generally more expensive than manually
operated machines.
• The CNC machine operator only needs basic training and
skills, enough to supervise several machines.
• Increase in electrical maintenance, high initial investment and
high per hour operating costs than the traditional systems.
• Fewer workers are required to operate CNC machines.
Investment in CNC machines can lead to unemployment.
 10. Direct Numerical Control (DNC)
• In a Direct Numerical Control system (DNC), a mainframe computer
is used to coordinate the simultaneous operations of a number NC
machines.
• The main tasks performed by the computer are to program and edit
part programs as well as download part programs to NC machines.
• Machine tool controllers have limited memory and a part program
may contain few thousands of blocks. So the program is stored in a
separate computer and sent directly to the machine, one block at a
time.
 11. Distributed Numerical Control (DNC)
• Distributed NC is known by the same acronym as Direct Numerical Control
(DNC).
• After the introduction of CNC, the machine tools have had the capability of
storing large amount of information. Therefore, there have been no need to
have drip feed information system, like, Direct Numerical Control. Instead,
Distributed Numerical Control is introduced. In such a system, a host
computer communicate with many CNC machine tool via networks and
download or upload programs.
• With Distributed Numerical Control systems, it is possible to monitor the
activities in individual CNC machine tools on host computer. Therefore,
better shop floor control can be achived.
 12. Application of CNC machine tools
• CNC was initially applied to metal
working machinery: Mills, Drills,
Boring machines, Punch presses
etc and now expanded to robotics,
grinders, welding machinery,
EDM’s, flame cutters and also for
inspection equipment etc.
12. Application of CNC machine tools
• The machines controlled by CNC can be classified into the
following categories:
– CNC mills and machining centers,
– CNC lathes and turning centers,
– CNC electrical discharge machining (EDM)
– CNC grinding machines
– CNC cutting machines (laser, plasma, electron, press, bending
machine, or press brake)
– CNC welding machines
12. Application of CNC machine tools

• CNC vertical machining center

12. Application of CNC machine tools

CNC Turning machining center

12. Application of CNC machine tools

• CNC laser cutting machine

12. Application of CNC machine tools

• CNC EDM machine

12. Application of CNC machine tools

CNC Hydraulic plate punching and marking machine

12. Application of CNC machine tools

CNC Four-point Welding Machine

 13. Classification of CNC Machines
1. Classification based on the motion type.
2. Classification based on the control loops.
3. Classification based on the number of axes.
4. Classification based on the power supply.
 14. Classification based on the motion type
• Point to point systems.
1. It is used in some CNC machines such as drilling, boring and tapping
machines…etc.
2. The control equipment for use with them are known as point to
point control equipment.
3. Feed rates need not to be programmed.
4. In these machine tools, each axis is driven separately.
14. Classification based on the motion type

Interpolation used for continuous path movement.

 15. Classification based on the control loops
• Open loop systems
– Programmed instructions are fed into the controller
through an input device.
– These instructions are then converted to electrical
pulses (signals) by the controller and sent to the
servo amplifier to energize the servo motors.
– The primary drawback of the open loop system is
that there is no feedback system to check whether
the program position and velocity has been
achieved.
 15. Classification based on the control loops

• Open loop systems

– The open loop system is generally used in point to
point systems where the accuracy requirements are
not critical.
– Very few continuous path systems utilize open loop
control.
 15. Classification based on the control loops

• Closed loop system

– The closed loop system has a feedback
subsystem to monitor the actual
output and correct any discrepancy
from the programmed input.
– These systems use position and
velocity feed back.
– The feedback system could be either
analog or digital.
 15. Classification based on the control loops
• Closed loop systems
– The analog systems measure the variation of physical variables such as
position and velocity in terms of voltage levels.
– Digital systems monitor output variations by means of electrical pulses.
– Closed loop systems are very powerful and accurate because they are
capable of monitoring operating conditions through feedback
subsystems and automatically compensating for any variations in real-
time.
 16. Classification based on the number of axes
• 2&3 axes CNC Machines
– CNC lathes will be coming under 2 axes machines. There will be
two axes along which motion takes place.
– The saddle will be moving longitudinally on the bed (Z-axis) and
the cross slide moves transversely on the saddle (along X-axis).
– In 3-axes machines, there will be one more axis, perpendicular
to the above two axes.
– By the simultaneous control of all the 3-axes, complex surfaces
can be machined.
16. Classification based on the number of axes
16. Classification based on the number of axes
16. Classification based on the number of axes
 17. Classification based on the power supply
• Mechanical power unit refers to a
device which transforms some
form of energy to mechanical
power which may be used for
driving slides, saddles or gantries
forming a part of machine tool.
• The input power may be of
electrical, hydraulic or pneumatic.
 nk you! ! !
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 Part Programming
• A part program is a set of instructions often
referred to as blocks, each of which refers to a
segment of the machining operation performed
by the machine tool. Each block may contain
several code words in sequence. These provide:
1. Coordinate values (X, Y, Z, etc.) to specify the desired
motion of a tool relative to a work piece

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Gezae Mebrahtu (Mechanical Engineer)
 Part Programming
2. Machining parameters such as, feed rate,
spindle speed, tool number, tool offset
compensation parameters etc
3. Codes for initiating machine tool functions like
starting and stopping of the spindle, on/off
control of coolant flow and optional stop.

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 Part Programming
4. Program execution control codes, such as block
skip or end of block codes, block number etc.
5. Statements for configuring the subsystems on
the machine tool such as programming the
axes, configuring the data acquisition system
etc.

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 Structure of a block in a part program

Block example End of

block

N_ G_ X_Y_ F_ S_ T_ M_ ;
Tool
Sequence Preparatory Feed Spindle function
number function function speed
Dimension Miscellaneous
function
word function

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 Part Programming

• A typical sequence of operations in a part

program would be,
1. Introductory functions such as units, coordinate definitions, coordinate
conventions, such as, absolute or relative etc.
2. Feeds, speeds, etc.
3. Coolants, doors, etc.
4. Cutting tool movements and tool changes
5. Shutdown

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 PROGRAM CONFIGURATION
• There are two program types, main program and
subprogram. Normally, the CNC operates according to the
main program.
• However, when a command calling a subprogram is
encountered in the main program, control is passed to the
subprogram.
• When a command specifying a return to the main program is
encountered in a subprogram, control is return to the main
program
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 Main Program :

• A program consists of the following components:

Tape start % TITLE ；
Program number
O 0001 ；
N1 ….
Sequence number
.
. Comment section
Program section （ COMMENT ）
. Program end
.
.
.
M30
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Gezae Mebrahtu (Mechanical Engineer)
 Subprogram
If a program contains a fixed sequence or frequently repeated
pattern, such a sequence or pattern can be stored as a
subprogram in memory to simplify the program.
A subprogram can be called from the main program.
A called subprogram can also call another subprogram.
Subprogram configuration O _ _ _ _;
Subprogram call .
M98 P 000 0000 ； .
.
Number of times the Subprogram M99;
subprogram is called number
repeatedly
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 AUXILIARY FUCTION

The following is main auxiliary code

• M00: Program stop
• M01: Optional stop
• M02: End of program
• M30: End of program ,different from M02 is M30
returning control to the start of the program.
• M03: Spindle rotates clockwise
• M04: Spindle rotates counterclockwise
• M05: Spindle stop
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 • M06: Change tool
• M08: Coolant Open
• M09: Coolant Close

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 PREPARATORY FUNCTION
（ G CODES ）

A number following address G determines the meaning

of the command for the concerned block.
G codes are divided into the following two types.
One-shot G code : The G code is effective only in the
block in which it is specified
Modal G code : The G code is effective until another G
code of the same group is specified.

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 COORDINATE VALUE
• Inch/Metric Conversion (G20,G21)
G20 : inch input
G21 : mm input
• Absolute and incremental programming (G90,G91)
There are two ways to command travels of the tool ; In the
absolute command , coordinate value of the end position is
programmed . In the incremental command ,move distance of the
position itself is programmed .
G90 : Absolute command
G91 : Incremental command

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 • Positioning (G00)
The G00 command moves a tool to the position
in the workpiece system specified with an
absolute or incremental command at a rapid
traverse rate .
G00 IP _ ;
• Liner interpolation (G01)
Tools can move along a line .
G01 IP _ F _ ;
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 • Circular interpolation (G02,G03)
The command below will move a tool along a circular arc.
Format:
Arc in the X p Y p plane
G02 I_J_ (K_)
G03 R_
Direction
G17 of the circular
X p_ interpolation:
Y p_ (Z p_) F_;
G02 : clockwise
G03 : counterclockwise

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 X p Y p Z p : Express the end point of an arc .
I , J , K : Distance from the start point to the center of arc.
(center coordinate minus the start point coordinate)
R : The radius of arc .
One arc is less than 180°, the R value is positive .
One arc is more than 180°, the R value is negative .
One arc is equal to 360°, use R will not move .
When an arc having a center angle approaching 180°is
specified , the calculated center coordinates may contain
an error. In such a case , specify the center of the arc with
I, J, and K .
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 • Example:

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 • Setting a Workpiece Coordinate System
The user can choose from G54~G56 to set
workpiece coordinate systems .
• Reference position return (G28)
The reference position is a fixed position on a
machine tool to which the tool can easily be moved
by the reference position return function.
For example , the reference position is used as a position at
which tools are automatically changed. Up to four reference
position can be specified by setting coordinate in the machine
coordinate system in parameters ( No.1240 to No.1243 ).

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 G28 IP_ ; Reference position
G30 P2 IP _ ; 2 nd reference position
G30 P3 IP _ ; 3 nd reference position
G30 P4 IP _ ; 4 nd reference position
IP _: Command specifying the intermediate position
• Return from reference (29)
G29 IP_ ;
IP _ : Command specifying the destination of return
from reference .
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 • Tool length offset (G43 G44 G49)
This function can be used by setting the difference
between the tool length assumed during
programming and the actual tool length of the tool
used into the offset memory . It is possible to
compensate the different without changing the
program .
G43 Z _ H _ ; Positive Offset
G44 Z_ H _ ; Negative Offset
G49 ; Tool length offset cancel
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 • Tool Compensation Start
G00 (or G01) G41(or G42) IP _ D _ ;
G41 : Cutter compensation left
G42 : Cutter compensation right
IP_ : Command for axis movement
D : Code for specifying as the cutter compensation
value
G40 : Cutter Compensation cancel

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 GOOD LUCK

Thank you !!!

04/02/2021 Gezae Mebrahtu (Mechanical Engineer)