INSTITUTE OF ENGINEERING, MECHANICAL ENGINEERING

INTRODUCTION TO PRAC4

BAS KEMPERMAN
CURRICULUM
• First lesson
Is a theory lesson. 1.5 clock hours R26

• Second lesson
Is a kind of practical lesson. R26
In the practical room we look at the CNC milling machine. How does this work ?

• Third lesson
Is an excursion.
We visit a production company: Doeko at Weurt

Hand in report on Friday 2 June via HAND-IN, see education online for the assignment description
 INTRODUCTION TO CNC TECHNOLOGY

CNC stands for: Computer Numeric Control

This means that with the aid of a computer, a
machine can be numerically controlled.

“The degree of success depends largely on the uniformity of

programming, setup and tool selection.”
 TYPES OF CONTROL SYSTEMS

• Heidenhain
• Okuma
• Fanuc

And many variants for all kinds of

machining stations such as
lathes, milling machines,
drilling machines, cutting tables, etc.

Source:http://www.helmancnc.com/cnc-program-block/
13-1-2020

Here we will discuss a Fanuc control system for a milling machine

 BASIC TERMS

A CNC machine is controlled by a computer program that issues

commands to execute certain assignments.
This is done by entering certain codes.
Some basic terms and rules regarding these basic codes can be
found below.

- Modal/non-modal codes
- Default codes:
 MODAL/NON-MODAL CODES

What are modal/non-modal codes?

• A code is modal if it remains active in a program after a command until it is cancelled by another
code.

For instance, starting an engine

• Non-modal codes effect only the lines on which they occur.

 DEFAULT CODES

What are default codes?

• There are codes that are always active once the machine is started up and are only changed if
another code is programmed.

• E.g. G21 metric programming (active with power on) and G20 inch programming. (only active if
specified in program)

• In case of a RESET or POWER OFF, the first one becomes active again.
This also applies to zero points. After a reset, the machine often returns to G54,
which is the first zero point.
 GROUPS OF CODES

Groups:
Codes are also divided into groups.
This means that codes from the same group cannot be programmed on the same line.

E.g.: G01 / G02

G01 = linear motion

G02 = circular motion
(Different typs of movements)
Source:http://www.manufacturinget.org/2011/12/cnc-g-code-g02-and-g03
13-1-2020
Codes from different groups can be programmed on the same line at the same time.
/

E.g.: G17 G90 G40 G01

Typed of groups:
• G codes
• M codes
• T codes
• S codes
• F codes
 GROUPS OF CODES

G code:
• Codes that can be used to specify linear/circular motion.
• But also functions such as radius compensation, choice of coordinate system, drilling cycles, zero
points, etc.

M code:
• Code that turns a machine function on/off.
• Acts like a switch: stays on until it is turned off.
• E.g. M3 = spindle clockwise, M5 = spindle stop, M9 = cooling off, M8 = cooling on.
• Tool change often cancels some of these functions.

T code:
• Code related to a tool.
• E.g. T1 M6 = tool number 1, perform tool change.
 GROUPS OF CODES

S code:
• Code representing the rotational speed.
• E.g. S1000 M3 = 1000 rpm, direction of rotation clockwise.

F code:
• Code to specify the feed rate.
• E.g. G1 X100 F250 = Linear motion X+ axis with a feed rate of 250mm/min.
• This code is not cancelled by a G00 (rapid mode) but remains active until
another feed rate is programmed.
 IMPORTANT G CODES

• If a code is modal, or remains coordinately the same on the next line, it may be omitted.

• G90 = Absolute programming. (modal)

• Coordinates are given as motions in relation to the selected workpiece zero point, regardless of
where the tool is at that point.

For instance:
• G90 X10 Y10  motion to X10 Y10 (hole 1)
• X30 Y20  motion to X30Y20 (hole 2)
 IMPORTANT G CODES

G91
Incremental programming. (modal)
Coordinates are given as motions in relation to the current position.

(From point to point)

For instance:
G91 IX10 IY10  motion to X10 Y10 (hole 4.)
IX20 IY10  motion to X30 Y20 (hole 5)
 WORKPIECE ZERO POINT

Because a drawing consists of a number of numerical values, length, width, hole

diameter, etc., these data are also offered to the machine as numerical values.
However, this requires a workpiece zero point to be determined first.

• A workpiece zero point is usually determined by the dimensioning

of the workpiece in the drawing.

Workpiece Zero
Point

• A CNC drawing therefore contains a dimensioning based on one point (G90)on

the drawing. And this is often used to determine the setup. Source: BMT Machine Tools
BV
13-1-2020
/
 MACHINE ZERO POINT

The machine zero point is determined by three reference switches that must be activated when the
machine is started. In the X-axis, Y-axis and Z-axis

As soon as these are passed, the machine knows where each point is located in the coordinate
system, allowing the machine to be used.

Workpiece Zero Point

Machine
Zero Point

• WS Source: Fanuc Instruction booklet cncinstructieburo.nl

13-1-2020
 COORDINATE SYSTEM

Coordinates are entered according to the right-handed Cartesian coordinate system.

This works with three axes: the X-axis, the Y-axis and the Z-axis.
The following mnemonic aid helps quickly understand this coordinate system:

https://webshop.han.nl/
Stand in front of the machine.
Right arm straight out to the side.  X + axis
Left arm straight ahead.  Y + axis
Your head  Z + axis

Source: Image by Bas Kemperman

 COORDINATE SYSTEM

Axes can also be identified that rotate around an axis.

A-axis Rotates around the X-axis

B-axis Rotates around the Y-axis
C-axis Rotates around the Z-axis

Rotation in the + or - direction?

From the zero point, nose in the + direction of the axis and clockwise is +, counter-
clockwise is -.

G17 Programming in the XY plane and the Z-axis is the tool axis.
G18 Programming in the XZ plane and the Y-axis is the tool axis.
G19 Programming in the YZ plane and the X-axis is the tool axis.

In general, programming is done in G17 (2,5 D) and the further examples will
therefore also be in G17.
 TOOL GEOMETRY OFFSET

• In this offset register, the dimensions (geometry) of the tools are entered.

• The length offset is the measured value in the Z-axis, of the difference in millimetres from the spindle
nose (= fixed zero point) to the tip of the tool.
This is also often referred to as the projection length of the tool.

• The diameter offset represents the tool radius in the X/Y axis.

Source: Fanuc Instruction booklet cncinstructieburo.nl 13-1-2020

 TOOL GEOMETRY WEAR OFFSET

Here the wear or measurement differences of the tools are compensated in both length and radius.

Activating offsets

• The length/diameter offset is activated by the code G43:

G43 H1 (length compensation on)
• H1 stands for the length offset of T1 (Tool 1)
This also activates the wear offset since this is linked to the geometry offset.

• G41/G42 D1 (radius compensation left/right of contour on)

D1 stands for the radius compensation of T1
 EXAMPLE 1 FACE MILLING THE
WORKPIECE

We are going to face mill a block, which means that

2 mm is milled off the top. Notice that the workpiece
zero point is 2mm below the top surface of the
block.

The program is generated with the aid of a

CADCAM system

Source: BMT Machine Tools

BV
13-1-2020
 PROGRAMMING EXAMPLE 1

• Face milling
• O0001
• T10 M6; (FACE MILL CUTTER 40MM HM)
• N01 G54 G43 X-25 Y85 Z50 H10 D10 S1250 T10 M3 F5000 ;
• Z0 ;
• G01 X125 F500 ;
• G00 Z10 ;
• X-25 Y52 ;
• Z0 ;
• G01 X125 ;
• G00 Z10 ;
• X-25 Y19 ;
• Z0 ;
• G01 X125 ;
• M98 P1001 ;
• M30 ;
• O1001(SUB-PROGRAM CHANGE POSITION AND BENCH FORWARD)
• G90 G40 G80 G00 Z300 H0 D0 M09 ;
• G53 Y0 Z-10 ;
• M99 ;
 PROGRAM EXPLANATION
• Face milling = program name

• O0001 = program number (always starts with an O)

• T10 M6; (FACE MILL CUTTER 40MM HM) = Tool 10; - M6 is tool change

• N01 G54 G43 X-25 Y85 Z50 H10 D10 S1250 T10 M3 F5000 ;
N01 = line number G54 = activate zero point 1; G43 = enable tool length
compensation H; X-25 Y85 Z50 = Starting coordinates; H10 = call length
compensation from the wear offset for Tool No. 10; D10 = radius compensation of
Tool 10 on; S1250 = required rotational speed of Tool 10; M3 = spindle rotates
clockwise; F5000 = feed rate 5000mm/min

• Z0 ; = minimum safety height above workpiece is 0

• G01 X125 F500 ; = in linear motion to X125; F500 = feed rate 500mm/min
Source: BMT Machine Tools
BV
13-1-2020
/
 PROGRAM EXPLANATION CONTINUED

• G00 Z10 ; G00 = motion in rapid mode to height Z10

• X-25 Y52 ; motion to coordinates X-25 Y52
• Z0 ; move down to Z0 still in rapid mode because no other motion code has been specified yet (modal code)
• G01 X125 ; = in linear motion to X125; still with F500 = feed rate 500mm/min
• G00 Z10 ; G00 = motion in rapid mode to height Z10
• X-25 Y19 ; = motion to coordinates X-25 Y19
• Z0 ; move down to Z0
• G01 X125 ; = in linear motion X125
• M98 P1001 ; M98 = calls a sub-program P1001
• M30 ; = End of program

Program P1001 consists of:

• O1001(SUB-PROGRAM CHANGE POSITION AND BENCH FORWARD)
• G90 G40 G80 G00 Z300 H0 D0 M09 ;
G90 = Absolute positioning G40 = end of milling cutter compensation (G43) G80 = disable all motions.
G00 = rapid mode to height Z300. H0 D0 height compensation 0 and radius compensation 0. M09 = cooling
off.
• G53 Y0 Z-10 ; G53 = go to start position Y0 and Z-10
• M99 ; = close the sub-program
END OF PRESENTATION