Manual Part Programming

• Principles of an NC Program
• Part Program is a set of instruction which
instruct the machine tool about the
processing step to be performed for the
manufacture of a part.
• Types of control Information.
1)Information on desired work-tool relationship:
This is also called dimensional information. This
includes input such as position (a series of
coordinates for all the axes X,Y,Z, direction of
movement (positive /negative) and amount of
movement (magnitude).
• Information on rate of change of work-tool
relationship:
This information is also referred as non-
dimensional information which includes
cutting parameters such as speed and feed.
• Information on auxiliary or miscellanies
functions:
• This is also called management information
which is also non-dimensional information. In
eludes information such as mode of operation,
selection of units (metric/inch), work-tool
loading unloading, use of coolant on/off, tool
selection, spindle rotation CW/CCW etc
 Word Address Format (WAF)
• Word address format is the method generally
used today for the numerical control
• The machine control unit (MCU) recognize a
word by its address rather than by its position
in a particular sequence, therefore words
need not be programmed in a particular order,
• X indicates x coordinate,S indicatets spindle
Speed etc.
• The various advantages of this format are
a. The sequence is not necessary since all
information is labelled by an alphabet.
b. Repetition is not necessary; controller takes the
information from the previous blocks.
c. Eliminates the chances of any error and also
shorten the program length to a large extent.
d. Thus it saves a lot of valuable time in preparing,
editing and debugging the program.
 Types of part programming
• Manual Part programming.
• Computer Assisted part programming.
 Word Address 1
N – Sequence or line number
A tag that identifies the beginning of a block of code. It
is used by operators to locate specific lines of a
program when entering data or verifying the program
operation.

G – Preparatory function
G words specify the mode in which the milling
machine is to move along its programmed axes.
Reserved Code Words Worksheet
N – Sequence or line number
G – Preparatory function

Dimension Words:
X–
Y–
Z–
 Word Address 2
Dimension Words
X – Distance or position in X direction
Y – Distance or position in Y direction
Z – Distance or position in Z direction

M – Miscellaneous functions
M words specify CNC machine functions not related to
dimensions or axial movements.
 Word Address 3
F – Feed rate (inches per minute or millimeters per
minute)
Rate at which cutting tool moves along an axis.

S – Spindle speed (rpm – revolutions per minute)

Controls spindle rotation speed.

T – Tool number
Specifies tool to be selected.
 Word Address 4
I – Circular cutting reference for x axis

J – Circular cutting reference for y axis

K – Circular cutting reference for z axis

 G Word
G words or codes tell the machine to perform
certain functions. Most G words are modal
which means they remain in effect until
replaced by another modal G code.
Functions of a Few Common G-Codes
 Common G Codes
G00 – Rapid positioning mode
Tool is moved along the shortest route to
programmed X,Y,Z position. Usually NOT used for
cutting.
G01 – Linear Interpolation mode
Tool is moved along a straight-line path at
programmed rate of speed.
G02 – Circular motion clockwise (cw)
G03 – Circular motion counter clockwise (ccw)
 Common G Codes, con.,

G17 – XY plane
G18 – XZ plane
G19 – YZ plane
G20 – Inch Mode
G21 – Metric Mode
G28 – Return to axis machine Zero (Home)
 G Codes: G90, G91
G90 – Absolute Coordinate Reference
References the next position from an absolute zero
point which is set once for the entire program.
G91 – Incremental Coordinate Reference
References the next position from the previous
position.
G 95 Per Revolution Feed rate
G 94 Feed Rate mm/min
G 93 RPM Range
 G Codes: Canned Cycles
G80 – Cancel canned cycle
G81 – Drilling cycle
G83 – Peck drilling cycle
G84 – Tapping cycle
G85 – Boring cycle

NOTE: A canned cycle stays in effect until cancelled by

a G80.
 Canned Cycles: G81
G81 – Drilling Cycle
Feed to depth, rapid return

Example of program code:

N35 G81 X.500Y.500Z-1.000 R.100 F1.50
N36 X1.000Y1.500
N37 X1.500Y2.000
N38 G80
 Canned Cycles: G83, G84
G83 – Peck Drilling Cycle
Feed to an intermediate depth, rapid out, rapid back
to just above previous depth, feed to next depth,
rapid out, repeat until reaching full depth.

G84 – Tapping Cycle

This cycle creates internal threads in an existing hole.

NOTE: One cannot over-ride the feed rate.

 Canned Cycles: G85, G86
G85 - Boring Cycle
Feed to depth, feed back out.

G86 – Boring Cycle

Feed to depth, rapid out.
 M Word

M words tell the machine to perform certain

machine related functions, such as: turn
spindle on/off, coolant on/off, or stop/end
program.
Functions of a Few Common M-Codes

• M or miscellaneous codes are used to either turn ON or OFF

different functions which control certain machine tool operations
 Common M words
M00 – Programmed pause
Automatically stops machine until operator pushes a button to
resume program.

M01 – Optional stop

A stop acted upon by the machine when operator has signaled
this command by pushing a button.

M02 – End of program

Stops program when all lines of code are completed. Must be last
command in program.
 Common M words
M03 – Turn spindle on
In clockwise direction
M04 – Turn spindle on
In counter clockwise direction
M05 – Stop spindle
Usually used prior to tool change or at end of program.

M06 – Tool change

Stops program and calls for a tool change, either automatically
or manually.
 Common M words
M08 – Turns Accessory 1 on./Coolant on
M09 – Turns Accessory 1 off./Coolant Off.
M10 – Turns Accessory 2 on.
M11 – Turns Accessory 2 off.
M30 – End of program & rewind.
Similar to M02 but M30 will also “rewind” the program.
Must be last statement in program. If used, DO NOT use
M02.
M41- Medium Speed Range
 Zero Points
Part Zero (W)
– Used for absolute programming mode.
– Usually a position on the part that all absolute
coordinates are referenced to.
– Changes with different parts and programs.

Machine Zero or Machine Home Position(M)

– Fixed for each machine from the manufacturer.
– Not changeable.
 Cutter Path Generation
Cutter path is generated by moving the tool
from point to point. The points are previously
defined from the part drawing dimensions.
Each line of code will show the destination point
of where the tool will go to.
 Programming types
• 1)Diameter based programming
Value of diameter is specified in the column for
X axis 1mm programmed movement=0.5 mm
actual movement of toll in radial direction
• 2) Radius based programming
• Value of Radius is specified in the column for
X axis 1mm programmed movement= 1mm
actual movement of toll in radial direction
 Interpolation
Method of determining intermediate points
along a cutting path.

Two methods:
• Linear interpolation – cut a path along a specified
angle at a specified feed rate.
• Circular interpolation – cut a path along an arc or
circle at a specified feed rate.
Write a manual part programming for the above
component.Assume the speed and feed as 400r.p.m and 0.35
mm/rev resp.Assume 1 mm material is to be removed radially from
external diameter
• V = πDN/1000 m/min.
• where D is diameter of tool in mm, N- RPM of
spindle (tool), v- Cutting speed in m/min.
• Assume V=30 / min,
• Feed is given by,
• Fr = ft.T.N
• Where, fr = feed in mm/ min, ft = feed in mm/tooth,
T = number of teeth, N =RPM of cutter.
 Canned Cycle
• Canned Cycles for Lathe, Milling and Drilling:
• Canned cycles are also called as fixed cycles. They are
predefined sequence of movements stored in memory of
machine control unit. These sequences are usually repetitive
until cancelled. In actual practice, there are various
situations in which we find that the series of motions are
repeated. For example while drilling a hole following
sequence of operations are involved.
• a. The tool has to position a little above the work-piece in
rapid position
• b. Move to the required depth with a given feed rate.
• c. After drilling retract the tool rapidly at the top of the hole.
• Thus for drilling a hole we require three NC blocks
to perform above three steps , this overhead can
be reduced by using canned cycle by using only
single NC block. Therefore if we are intended to
drill 10 holes, then instead of 30 NC blocks (3 x 10),
we need only 10 NC blocks using canned cycles,
which save lot of time, as well as programming
efforts. Canned cycles are initiated by the using
various G codes which are listed below.
• G80: Cancel Canned Cycles- N_ G80 ( Modal)
• This command cancels all previous canned cycles
and are modal. Canned cycles includes tapping,
boring, drilling, spot facing. When creating
programming canned cycles, it is good idea to
include a G80 command in the program setup at
the beginning as well as after the canned cycle is
completed, lamps, coolant hose etc.
• 2. G81 Drilling Cycle
• This command calls a drill cycle at specified locations. This
cycle provides a feed in, rapid out sequence suitable for
drilling a series of holes of the same diameter and depth.

• It consists following sequence of operations-as shown in Fig.

• 1. Rapid move from z current position to Z initial plane.
• 2. Tool rapids from Z initial plane to Z- retract plane.
• 3. Tool feeds in workpiece to Z depth at a specified depth.
• 4. Tool returns to Z retract plane at specified feed rate.
• 5. Tool rapids back to initial plane, where it is ready to go on
next hole.
• Canned Cycle lathe is nothing but stock
removing cycle .
Tooling Compensation
• G 17 X Y Plane
• G 40 Cutter diameter compensation cancel
• G41 Cutter diameter compensation LEFT
• G42 Cutter diameter compensation RIGHT
• G 43 + Ve Tool length compensation
• G 44 –ve Tool length compensation
• G49 cancel Tool length compensation
• G 80 Cancel Canned cycle.
• G 90 Absolute Programming mode
• G 91 Position tool to reference point
• G 92 Reset Origin point
Part Programming for Milling
 APT Programming Example
Cylindrical Part

F 25
Raw Material

70

F 22.5
F 17.5
Finished Part

20

30
APT Programming Example (Cylindrical Part)
O0013
N0005 G53
N0010 T0303
N0020 G57 G00 X26.00 Z0.0 S500 M04
N0030 G01 X-0.20 F100
N0040 G00 Z2.0
N0050 X50.0 Z50.0
N0060 T0404
N0070 G57 G00 X22.50 Z2.0 S500
N0080 G01 Z-30.0 F100
N0090 G00 X23.0 Z2.0 S500
N0100 G84 X17.5 Z-20.0 D0=200 D2=200 D3=650
N0110 G00 Z2.0
N0120 X50.0 Z50.0
N0130 M30
 APT Program Interpretation
O0013
Program identification number
 APT Program Interpretation
O0013
N0005 G53
To cancel any previous working zero point
 APT Program Interpretation
O0013
N0005 G53
N0010 T0303

N0010 Sequence number

T0303 Select tool number 303
 APT Program Interpretation
O0013
N0005 G53
N0010 T0404
N0020 G57 G00 X26.0 Z0.0 S500 M04
G57 To set the working zero point as saved
G00 Rapid movement (no cutting)
X26.0 X location (as a diameter; 13 form zero)
Z0.0 Z location
S500 Spindle speed is 500 rpm
M04 Rotate spindle counterclockwise

x
+ve

z
(0,0) +ve
 APT Program Interpretation

O0013
N0005 G53
N0010 T0404
N0020 G57 G00 X26.00 Z0.0 S500 M04
N0030 G01 X-0.20 F100

G01 Linear interpolation (cutting)

X-0.20 Move only in x direction until you pass
the center by 0.1 mm (facing)
F100 Set feed rate to 100 mm/min.
 APT Program Interpretation
O0013
N0005 G53
N0010 T0404
N0020 G57 G00 X26.00 Z0.0 S500 M04
N0030 G01 X-0.20 F100
N0040 G00 Z2.0

G00 Move rapidly away from work piece (no cutting)

Z2.0 the movement is 2 mm away from the face.
 APT Program Interpretation
O0013
N0005 G53
N0010 T0404
N0020 G57 G00 X26.00 Z0.0 S500 M04
N0030 G01 X-0.20 F100
N0040 G00 Z2.0
N0050 X50.0 Z50.0

Go to a safe location away from the

workpiece [x = 50 (25 from zero), z = 50] to
change the tool.
 APT Program Interpretation
O0013
N0005 G53
N0010 T0404
N0020 G57 G00 X26.00 Z0.0 S500 M04
N0030 G01 X-0.20 F100
N0040 G00 Z2.0
N0050 X50.0 Z50.0
N0060 T0404

T0404 Select tool number 404

 APT Program Interpretation
O0013
N0005 G53
N0010 T0404
N0020 G57 G00 X26.00 Z0.0 S500 M04
N0030 G01 X-0.20 F100
N0040 G00 Z2.0
N0050 X50.0 Z50.0
N0060 T0404
N0070 G57 G00 X22.50 Z2.0 S500
G57 PS0
G00 Rapid movement (no cutting)
X22.50 X location (as a diameter; 11.25 form zero)
Z2.0 Z location
S500 Spindle speed is 500 rpm
 APT Program Interpretation
O0013
N0005 G53
N0010 T0404
N0020 G57 G00 X26.00 Z0.0 S500 M04
N0030 G01 X-0.20 F100
N0040 G00 Z2.0
N0050 X50.0 Z50.0
N0060 T0404
N0070 G57 G00 X25.00 Z2.0 S500 M04
N0080 G01 Z-30.0 F100
G01 Linear interpolation (cutting)
Z-30 Move only in z direction (external turning)
F100 Set feed rate to 100 mm/min.
 APT Program Interpretation
O0013
N0005 G53
N0010 T0404
N0020 G57 G00 X26.00 Z0.0 S500 M04
N0030 G01 X-0.20 F100
N0040 G00 Z2.0
N0050 X50.0 Z50.0
N0060 T0404
N0070 G57 G00 X25.00 Z2.0 S500 M04
N0080 G01 X22.5 Z-70.0 F100
N0090 G00 X23.0 Z2.0 S500

G00 Move rapidly away from work piece (no cutting) to

location x= 23.0 (11.50 from zero) and z = 2.0.
O0013 APT Program Interpretation
N0005 G53
N0010 T0404
N0020 G57 G00 X26.00 Z0.0 S500 M04
N0030 G01 X-0.20 F100
N0040 G00 Z2.0
N0050 X50.0 Z50.0
N0060 T0404
N0070 G57 G00 X25.00 Z2.0 S500 M04
N0080 G01 X22.5 Z-70.0 F100
N0090 G00 X26.0 Z2.0 S500
N0100 G84 X17.5 Z-20.0 D0=200 D2=200 D3=650
G84 Turning cycle for machining the step
X17.5 final diameter
Z-20 length of step is 20 mm
D0=200 Finish allowance in X direction (0.2 mm) D2=200 Finish allowance in Z
direction (0.2 mm)
D3=650 Depth of cut in each pass (0.65 mm)
 APT Program Interpretation
O0013
N0005 G53
N0010 T0404
N0020 G57 G00 X26.00 Z0.0 S500 M04
N0030 G01 X-0.20 F100
N0040 G00 Z2.0
N0050 X50.0 Z50.0
N0060 T0404
N0070 G57 G00 X25.00 Z2.0 S500 M04
N0080 G01 X22.5 Z-70.0 F100
N0090 G00 X26.0 Z2.0 S500
N0100 G84 X17.5 Z-20.0 D0=200 D2=200 D3=650
N0110 G00 Z2.0

G00 Move rapidly away from workpiece (no cutting)

Z2.0 the movement is 2 mm away from the face.
 APT Program Interpretation
O0013
N0005 G53
N0010 T0404
N0020 G57 G00 X26.00 Z0.0 S500 M04
N0030 G01 X-0.20 F100
N0040 G00 Z2.0
N0050 X50.0 Z50.0
N0060 T0404
N0070 G57 G00 X25.00 Z2.0 S500 M04
N0080 G01 X22.5 Z-70.0 F100
N0090 G00 X26.0 Z2.0 S500
N0100 G84 X17.5 Z-20.0 D0=200 D2=200 D3=650
N0110 G00 Z2.0
N0120 X50.0 Z50.0

X50.0 Z50.0 Move to the tool changing location

Example 1: NC Block
 .125 GRID
Top View NC Block SPACES

Origin (0,0)
Download Worksheet

Click here to open Practice Exercises

 Worksheet Problem 1 .125 GRID
SPACES

D( , ) I( , ) J( , )
B( , ) K( , )

L( , )

E( , )
A( , )

F( , )

C( , )
H( , ) G( , )
Origin (0,0)
Pause Lesson
 Example 1: Program NC
N01 G90 G80 T00
N02 G00 X0 Y3.000 Z1.000
N03 M03 S1000