ME 5402 Metal Cutting and

Machine Tools

BY

Dr. V.S. SENTHIL KUMAR

Professor
Department of Mechanical
Engineering
College of Engineering Gundy
campus
Anna University, Chennai – 600 025.

May 11, 2025 1

 Unit V: Syllabus Overview
CNC Machine Tools and Part Programming 9(L)
Numerical control (NC) machine tools
CNC: types, constructional details, special features
Design considerations of CNC machines for
improving machining accuracy
structural members – slide ways –linear bearings –
ball screws – spindle drives and feed drives
Part programming fundamentals – manual
programming – computer assisted part programming

May 11, 2025 Slide 2

 NUMERICALLY CONTROLLED
MACHINE TOOLS

INTRODUCTION
For consistency in quality, especially in
the manufacture of complex components,
human intervention has to be eliminated.
Special purpose or automatic machine
tools are highly specialized and have
high rates of production.

May 11, 2025 Slide 3

 NUMERICALLY CONTROLLED
MACHINE TOOLS

INTRODUCTION
Initial costs are high.
Suitable and economical for mass
production only; Inflexible

May 11, 2025 Slide 4

 INTRODUCTION
 Thus, when the main requirement is:
quantity, consistency in quality and
delivery schedule, mass production or
automation.
 Numerically controlled machine tools are
highly flexible and are economical for
producing a single or a large number of
parts.
May 11, 2025 Slide 5
 INTRODUCTION
 Numerical control, NC, can be defined
simply as control by numbers.
 Electronics Industries Association
defines NUMERICAL CONTROL as "a
system in which actions are controlled
by the direct insertion of numerical data
at some point.
May 11, 2025 Slide 6
 INTRODUCTION
 In numerically controlled machine tools, the input
information, for controlling the machine tool
motion is provided by means of punched paper
tapes, plastic tapes (Mylar), floppy disk, hard disk
or magnetic tapes in a coded language.
 Thus, with numerical control, the operation and
motions of a machine tool are controlled
electronically.
 NC machine tools are thus automated production
machines.
May 11, 2025 Slide 7
 INTRODUCTION
 The key difference in this system is that of
"reprogrammability".
 In NC, a changeover to a new product does
not require extensive physical changes in the
machine set up.
 Only a change in the control program itself is
required.

May 11, 2025 Slide 8

 INTRODUCTION
 Thus, the flexibility of general purpose
machine tools can be combined with the
precision and accuracy of special-purpose
machine tools.
 This opened up the development of the
concept of Computer Numerical Control
(CNC), and other functions such as
automatic tool change or part manipulation.
May 11, 2025 Slide 9
 INTRODUCTION
 All this led to highly, Sophisticated,
multipurpose machining centers;
complete with a range of support
functions such as tool change, head
change, transport and manipulation and
so on-all under computer control.

May 11, 2025 Slide 10

 INTRODUCTION
 The next development was the idea of
Direct (or distributed) Numerical Control
(DNC), in which more than one machine
tool (along with associated functions) could
be grouped into a manufacturing cell under
the overall control of a larger, supervisory
computer.

May 11, 2025 Slide 11

 INTRODUCTION
 The early numerically controlled machine
tools were milling and profiling machines that
provided faster and less expensive means
for producing aircraft parts.
 Now, NC, has been applied to other machine
tools, such as lathes, drilling and boring
machines, welding and flame cutting
machines, punching machines and
inspection devices.
May 11, 2025 Slide 12
 Advantages
The major advantages of NC over conventional
methods of machine control are as follows:

Higher precision: NC machine tool are

capable of machining at very close tolerances, in
some operations as small as 0.005 mm;

Machining of complex three-dimensional

shapes

May 11, 2025 Slide 13

 Advantages
Cont.
 Better quality: NC systems are capable of
maintaining constant working conditions for all
parts in a batch thus ensuring less spread of
quality characteristics;
 Higher productivity: NC machine tools
reduce drastically the non machining time.
 Adjusting the machine tool for a different
product is as easy as changing the computer
program and tool turret with the new set of
cutting tools required for the particular part.
May 11, 2025 Slide 14
 Advantages
Cont.
 Multi-operational machining: some NC
machine tools, for example machine
centers, are capable of accomplishing a
very high number of machining operations
thus reducing significantly the number of
machine tools in the workshops.

May 11, 2025 Slide 15

 Advantages
Cont.
 Low operator qualification: the role of
the operation of a NC machine is simply to
upload the workpiece and to download the
finished part.
 In some cases, industrial robots are
employed for material handling, thus
eliminating the human operator.

May 11, 2025 Slide 16

 Disadvantages
 The major disadvantage of NC machines are
their costs.
 Therefore, the machines must have sufficient
use to justify the investment.
 Programming of NC machines has been
greatly simplified and machine availability
above 95% is common.

May 11, 2025 Slide 17

 TYPES OF THE CNC SYSTEM
 ACCORDING TO THE TYPE OF MOTION CONTROL
SYSTEMS
 Point-to-point / positioning system.
 Contouring (or) continuous-path.
 Straight cut.
 ACCORDING TO THE STRUCTURE OF CONTROL
SYSTEMS.
 Analog system
 Digital system.

May 11, 2025 Slide 18

 TYPES OF THE CNC SYSTEM
 ACCORDING TO THE PROGRAMMING
MODE
 Incremental programming mode
 Absolute programming mode
 ACCORDING TO THE TYPE OF CONTROL
LOOPS.
 Open loop system
 Closed loop system

May 11, 2025 Slide 19

 WORKING OF NC MACHINE TOOL

May 11, 2025 Slide 20

Controlled axes

 NC system can be classified on the number of

directions of motion they are capable to
control simultaneously on a machine tool.
 Each free body has six degree of freedom,
three positive or negative translations along x,
y, and z-axis, and three rotations clockwise or
counter clockwise about these axes.
May 11, 2025 Slide 21
Controlled axes
(a) Identification
of controlled axes
for a lathe

(b) vertical spindle

milling machine
(c)horizontal
spindle milling
machine
May 11, 2025 Slide 22
Controlled axes
 Commercial NC system are capable of
controlling simultaneously two, two and half,
three, four and five degrees of freedom, or
axes.
 The NC systems which control three linear
translations (3-axis systems), or three linear
translations and one rotation of the worktable
(4-axis systems) are the most common.
May 11, 2025 Slide 23
Controlled axes

 Although the directions of axes for a

particular machine tool are generally
agreed as shown in the figure, the
coordinate system origin is individual for
each part to be machined and has to be
decided in the very beginning of the
process of CNC part programming.
May 11, 2025 Slide 24
Point-to-point vs continuous systems
 The two major types of NC systems are
 Point-to-point (PTP) system
 Contouring system

Point-to-point (PTP) system

 PTP is a NC system, which controls only the
position of the components.
 In this system, the path of the component motion
relative to the workpiece is not controlled.
May 11, 2025 Slide 25
Point-to-point (PTP) system
 The travelling between different positions is
performed at the traverse speed allowable for
the machine tool and following the shortest
way.
 In a Point-to-point system, the path of the
cutting tool and its feed while traveling from
one point to the next one are without any
significance.
May 11, 2025 Slide 26
Point-to-point (PTP) system
 Therefore, this system would require only
position-loops for controlling the final position
of the tool when reaching the place to be
drilled.
 The data for desired position is given by co-
ordinate values and the resolution depends
on the system.

May 11, 2025 Slide 27

Point-to-point (PTP) system
 The simplest example of a point-to-point NC
system is a drilling machine.
 In a drilling machine the work piece is moved
along the axis of motion until the centre of the
hole to be drilled is exactly beneath the drill.

May 11, 2025 Slide 28

Point-to-point vs Contour systems

point-to-point Systems Continuous systems

(Contour)

May 11, 2025 Slide 29

Contouring NC systems
 These are capable of controlling not only the
positions but also the component motion, i.e.,
the travelling velocity and the programmed
path between the desired positions:
 Contouring is the most flexible, complex and
the most expensive type of machine tool
control method.

May 11, 2025 Slide 30

Contouring NC systems
 This has the feature of capacity for
simultaneous control of more than one axis
movement of the machine tool.
 The path of the cutter is continuously
controlled to generate the desired geometry
of the work piece.
 For this valid reason, this system is also
called continuous-path CNC system.
May 11, 2025 Slide 31
Contouring NC systems
 The process of maxing curved path on the
work piece surface is performed in a CNC
contouring system the direction of the feed
rate must continuously be changed so as to
follow the path.

May 11, 2025 Slide 32

STRAIGHT CUT NC SYSTEMS
 This system is called a straight-cut system
since the cutting tool can move only along
straight lines which are parallel to the main
axis of motion of the machine tool.
 The simplest example in a shaping machine
 Cutting of the work piece is done while the
cutting tool is moving, but the latter can move
along the X, Y or Z axis.
May 11, 2025 Slide 33
STRAIGHT CUT NC SYSTEMS
 In this system, velocity control loops, for feed
control of the axis of motion, are used but
they are relatively simple as they only have to
establish the finished surface quality and not
the dimensions of the part an interpolator is
not required for the straight-cut system as no
simultaneous operation of the axis is
necessary.
May 11, 2025 Slide 34
Straight Cut CNC

May 11, 2025 35

INTERPOLATION
 The method by which contouring systems
move from one programmed point to another
is called interpolation.

LINEAR INTERPOLATION:
 Linear interpolation, programmed points
connected by straight lines, is used for
straight line moves, whether the length
between the Z points is short or long.
May 11, 2025 Slide 36
LINEAR INTERPOLATION
 In the early days of NC, it was used to
produce curves that had to be broken into a
very large number of short, straight-line
programmed points to produce the required
shape.
 Most modem CNC controls have circular

interpolation that can produce contour and

curved shapes with very few programmed
steps.
May 11, 2025 Slide 37
LINEAR INTERPOLATION

May 11, 2025 Slide 38

LINEAR INTERPOLATION
 Most CNC machine tools can also mill straight
lines along either the X or Y axis figure.
 In positioning, the tool is moving from one

position to the next at a rapid traverse rate,

which could be hundreds of inches per
minute.
 A milling cut must be programmed at a feed

rate to suit the material being cut and the type

and diameter of the cutter.
May 11, 2025 Slide 39
CIRCULAR INTERPOLATION
 The programming of circles and arcs has
been greatly simplified by the development
of circular interpolation.
 Arcs up to 90° degree may be generated and

these may be joined together to form half,

three-quarter or full circle as desired circular
interpolation is limited to one plane at a time.

May 11, 2025 Slide 40

CIRCULAR INTERPOLATION

May 11, 2025 Slide 41

CIRCULAR INTERPOLATION
 Circle requires the start and end point of the
used to come close to producing a curve arc,
the center location, the radius, and the on
surfaces that are not true arcs.
 Many other curves and free-form shapes can

be closely approximated with a series of arcs,

using circular interpolation

May 11, 2025 Slide 42

PARABOLIC INTERPOLATION
 Parabolic interpolations are used to provide
approximations of free-form curves using
higher-order equations.
 They require considerable computational
power and are not as common as linear and
circular interpolation.

May 11, 2025 Slide 43

PARABOLIC INTERPOLATION

May 11, 2025 Slide 44

ANALOG AND DIGITAL CONTROL
 In analog control system the quantities may
be varied continuously, while in digital
systems the quantities are varied discreetly
 Such as the presence or absence of a
quantity.
 The shortest cycle of presence - absence is
the resolution of the digital system and
displays its accuracy.
May 11, 2025 Slide 45
ANALOG AND DIGITAL CONTROL
 In digital system of machine tools, every cycle of
in formations provide a voltage- pulse format.
 The each pulse are represents a basic length unit.
 These pulses are also determines the system

resolution. Therefore, the digital system is of a

finite accuracy.
 While analogue information can accept any value.

Both digital and analog controls are used in CN

systems.

May 11, 2025 Slide 46

INCREMENTAL/ABSOLUTE SYSTEM

Incremental system:
 An incremental system is one in which the
reference point to the next instruction is the
end point of the preceding operation.
 Each dimensional data is applied to the
system as a distance increment, measured
from the preceding point at which the axis
of motion was present.
May 11, 2025 Slide 47
INCREMENTAL SYSTEM
 Incremental dimensions are distance
between adjacent points.
 These distances are converted into
incremental co-ordinates by accepting the
last dimension point as the co-ordinate
origin for the new point.

May 11, 2025 Slide 48

INCREMENTAL SYSTEM

May 11, 2025 Slide 49

ABSOLUTE SYSTEM
 An absolute system is one in which the all
the points are taken from a common
reference point.
 Each dimensional data is applied to the
system as a new distance , measured from
the reference point.

May 11, 2025 Slide 50

ABSOLUTE SYSTEM

May 11, 2025 Slide 51

 MAIN PARTS of NC Machines

1. The machine control unit (MCU), also

known as NC console or Director.
2. The drive units, or actuators.
3. The position feedback package.
4. Magnetic box.
5. Manual control.

May 11, 2025 Slide 52

 Functional elements of MCU
The hardware also includes the associated
circuits. The functional elements involved in
MCU are :
1. Data Input.
2. Data Processing.
3. Data Output.
•MCU basically consists of two elements:
Data Processing Unit (DPU) and the Control
Loops Units (CLU).
May 11, 2025 Slide 53
 Functional elements of MCU
•DPU processes the data (in coded form)
read from the tape or any other source and
passes the information regarding the various
controls to CLU.
•NC is used to provide the following controls:
-All cutting speeds - Complete path and
feed rates of a cutter in relation to the
workpiece or fixture - All auxiliary functions
such as turning cutting fluids off and on.
May 11, 2025 Slide 54
 Feedback System

May 11, 2025 Slide 55

 OPEN LOOP CONTROL SYSTEMS
 The term open-loop control system
means that since the loop is open there
is no feed back and the action of the
controller has no reference to the result
it produces.
 When a command signal is given to the
drive system by means of the program
Instructions through the computer.
May 11, 2025 Slide 56
 OPEN LOOP CONTROL SYSTEMS
 Then the slide of the machine tool
moves with respect to the program, this
does not care whether the moving
member arrived at the desired position.
 This is an open loop CNC system where
there is no check on the actual position
arrived with reference to the position
desired.
May 11, 2025 Slide 57
 CLOSED LOOP CONTROL SYSTEM
 In this system, measures the actual
position and velocity of the axis and
compares them with the desired
reference.
 The difference between the actual and
the desired values is the “error” The
actual value is measured by means of
feed back system of the machine tool
control.
May 11, 2025 Slide 58
 CLOSED LOOP CONTROL SYSTEM
The most extreme care must be taken
during the design of closed-loop systems.
By increasing the amount of feed back
signals which are produced from the feed
back devices (like limit switches and
touch sensor etc.) this loop is made more
sensitive.
That is known as increasing the open-
loop gain.
May 11, 2025 Slide 59
 CLOSED LOOP CONTROL SYSTEM
 By excessively increasing the open-loop
gain the closed loop system may
become unstable, which should be
avoided.
 If actual value > desired value, then it
indicates the “negative feed-back” one.
 Error = Desired Value - Actual Value

May 11, 2025 Slide 60

 Types
Machine controls are divided into three groups
 Traditional numerical control (NC)
 Computer numerical control (CNC)
 Distributed numerical control (DNC)

May 11, 2025 Slide 61

 New conceptions:
 Computer Numerical Control (CNC)
 Direct Numerical Control (DNC)
 Computer Aided Design (CAD)
 Computer Aided Manufacturing (CAM)
 Adaptive Control (AC), and Integrated
Manufacturing System.

May 11, 2025 Slide 62

 COMPUTER NUMERICAL CONTROL (CNC)

CNC system basically consists of the following:

 Central processing unit (CPU)
 Servo-control unit
 Operator control unit
 Machine control unit
 Other peripheral devices
 Programmable logic unit
 Computer Numerical Control (CNC)
May 11, 2025 Slide 63
 COMPUTER NUMERICAL CONTROL (CNC)

 CNC is a bare minimum of electronic

hardware is used and the functions of MCU
of the conventional NC system are partly or
wholly taken over by a dedicated micro-
computer of the machine tool.

May 11, 2025 Slide 64

 COMPUTER NUMERICAL CONTROL (CNC)

 The control program (called Executive

programme) is stored which performs all
the basic NC functions. Thus, in this
system, the machine control data comes
directly from a micro-minicomputer, instead
of from a continuously read tape (as in
conventional NC system).

May 11, 2025 Slide 65

General Configuration of CNC system

May 11, 2025 66

Schematic Diagram of a CNC Machine Tool

May 11, 2025 67

Hybrid CNC

May 11, 2025 68

Straight CNC

May 11, 2025 69

 COMPUTER NUMERICAL CONTROL (CNC)

 By changing or modifying the executive

programme (through paper tape), the
system can be used for another machine
tool. Thus, this system is flexible or soft
wired system.

May 11, 2025 Slide 70

 ADVANTAGES OF CNC SYSTEMS
OVER CONVENTIONAL NC SYSTEMS:
2. More versatility: Editing and debugging
programs, reprogramming and plotting and
printing part shapes are simpler.
3. Program to manufacture a component can
be easily called. This saves time and -
eliminates errors due to tape reading.
4. Greater accuracy.
5. Ease of operation.

May 11, 2025 Slide 71

 ADVANTAGES OF CNC SYSTEMS
OVER CONVENTIONAL NC SYSTEMS:
6. The micro-processors used in place of
hard-wired NC circuits are very reliable and
have self diagnostic features. This makes
trouble shooting extremely easy.
7. The dedicated computers need less
memory storage- and even small
computers possess large memory.

May 11, 2025 Slide 72

 DIRECT NUMERICAL CONTROL (DNC)

 In DNC system, several NC machines

can be controlled by a large central
computer.
 Direct link may be established between
the programming computer and the
large central control computer.

May 11, 2025 Slide 73

 DIRECT NUMERICAL CONTROL (DNC)
 This system is very expensive and
highly skilled software knowledge is
needed and can usually be justified
only in large corporations or if the
system is expanded to include
process management and control
(CAM and CAD).

May 11, 2025 Slide 74

General Configuration of DNC System

May 11, 2025 75

DNC with Satellite minicomputers

May 11, 2025 76

 DIRECT NUMERICAL CONTROL (DNC)
 The NC units used in the conventional
DNC system may be:
1. Of the conventional hard-wired type,
with the tape reader being replaced by a
direct communicating link to the Central
Computer, or
2. Specialized units which like CNC
system, use a micro/minicomputer as
the MCU.
May 11, 2025 Slide 77
 DIRECT NUMERICAL CONTROL (DNC)
 DNC system has the main drawback
that if the Central mainframe computer
goes down, all the machine tools
become inoperative.
 This drawback has been overcome by a

more recent definition of DNC as

"Distributed Numerical Control" in place
of "Direct Numerical Control" still
abbreviated as DNC.
May 11, 2025 Slide 78
 DIRECT NUMERICAL CONTROL (DNC)
 In this system, a Central large computer
is still used as in conventional DNC.
 But, the individual NC machines are not

directly controlled by this central

computer.
 Each NC machine has its own dedicated

on-board micro-computer just like a

CNC system.

May 11, 2025 Slide 79

 DIRECT NUMERICAL CONTROL (DNC)
 All these individual micro-computers
are linked to the central large
computer, which serves as the
Central control system.
 In that if the central computer goes

down, the NC machines will not

become inoperative.

May 11, 2025 Slide 80

 DIRECT NUMERICAL CONTROL (DNC)
 Moreover, this system provides a larger
memory and computational capabilities
and increased flexibility.
 DNC, system appeared in the market

earlier-than CNC system but with the

development of dedicated mini-
computers, the benefits of DNC system
can be realized in CNC system.
May 11, 2025 Slide 81
 DIRECT NUMERICAL CONTROL (DNC)
 Moreover, with the availability of small
computers with large memory, micro-
processors and program editing
capabilities, CNC machines are widely
used at present.
 Also, the availability of low cost-
programmable logic controllers (PLCs)
has helped in the successful
implementation of CNC systems.
May 11, 2025 Slide 82
MACHINING CENTRE
A machining centre or work centre consists
of a single, but sometimes two machine
tools with the specific feature of an
automatic tool changer and capable of
performing a number of operations.
(drilling, tapping, milling, boring and turning
etc.) on a work piece.
May 11, 2025 Slide 83
MACHINING CENTRE

May 11, 2025 Slide 84

MACHINING CENTRE
 Most machines are numerically controlled,
but other types of controls will work as
well.
 The major advantage is that the job needs
clamping on the work holding surface only
once the machine then performs a variety
of machining operations on all the job's
faces except the base.
May 11, 2025 Slide 85
MACHINING CENTRE
 Work handling time is thus decreased
because there is no movement of the work
piece from one machine to another.
 Some machines are equipped with two
work-tables that can be moved into or out
of the machine.

May 11, 2025 Slide 86

MACHINING CENTRE
 While the work is going on one works
table, the next component can be set up
on the other work-table.
 When the job is complete on the first work-
table, it is moved out of the way and the
second work-table is moved into position.
 For storing the preset tools, various
magazine systems are used.
May 11, 2025 Slide 87
MACHINING CENTRE
 These preset tools are removed from their slots
by a hand-arm mechanism.
 When a particular machining operation is
completed, the tool is removed from the spindle
and returned to its storage slot, then another tool
is picked up and mounted in the tool spindle.
 A machining centre is mainly used for batch
production of main components of a product.

May 11, 2025 Slide 88

MACHINING CENTRE
 The main components of a product are
usually small (about 10%) but are expensive
(they represent about 50% of the product
value) because they have, considerable
material value and usually require a large
amount of machining.
 For such components, the machining centre
is generally most economical.
May 11, 2025 Slide 89
MACHINING CENTRE
 Machining centers have high metal removal
rate capabilities.
 The high degree of accuracy and multi-
operation in the same set up, make the
machining centers highly versatile and
increase productivity.
 Some models are made with manual tool
change-facility.
May 11, 2025 Slide 90
CONSTRUCTIONAL FEATURES

Various mounting arrangements of Linear Motion Guides

May 11, 2025 91
CONSTRUCTIONAL FEATURES

Antifriction guide ways used in CNC Machine Tools

May 11, 2025 92
CONSTRUCTIONAL FEATURES

Ball Bush used for Linear Movement in

CNC Machine Tools

May 11, 2025 93

BALL SCREWS
 Low co-efficient of friction: It is of the order of
0.004 as compared to 0.1 to 0.5 which is typical
of sliding friction power screws.
 Wear is therefore less and there is very little

need for frequent adjustment.

 In a ball screw, the load between the threads of

the screw and the nut is not transmitted by

direct method contact but through intermediate
rolling members (spherical balls).
May 11, 2025 94
BALL SCREWS
 The ball rotates between the helical grooves
of the screw and nut in a manner akin to their
function in ball bearings.
 An essential feature of almost all ball screws
is the provision of recirculation of balls.

May 11, 2025 95

BALL SCREWS
 By preloading the assembly, clearance and
consequent backlash can be eliminated and
the axial stiffness of the ball screw can be
increased.
 The axial stiffness of an ordinary power screw
and accuracy of ball screws also high.

May 11, 2025 96

BALL SCREWS
 Friction force is virtually independent of the
travel velocity and the friction at rest is very
small consequently.
 The stick slip phenomenon is absent ensuring
uniformity of motion.

May 11, 2025 97

BALL SCREWS
 High transmission efficiency (2-9 times) which
is particularly marked at low values of helix
angle of screw (2° - 5° ) that are typical for
power screws.
 This high efficiency allows larger thrust loads
to be carried with less torque.

May 11, 2025 98

Preloading of a Recirculating Ball Screw
A high preload makes it possible to obtain
better positioning accuracy and higher
system stiffness.
 It will require a higher torque to drive the
screw, If the preload is too high.
 The increase of the driving torque will
exceed that of system stiffness, resulting in
a decrease of life.
May 11, 2025 99
Preloading of a Recirculating Ball Screw
 Too high of preload may result in less
positioning accuracy.
 It depends on the characteristic of the
servo loop.
 The low preload gives low drag torque but
also low system stiffness and reduced
positioning accuracy.
May 11, 2025 100
Electronics control

May 11, 2025 101

Electric drives on a CNC lathe

May 11, 2025 102

Spindle Drives
Function:
 Centering the work piece.
 Clamping the work piece or cutting tool as
the case may be such that the work piece
or Cutting tool is reliably held in position
during the machining operation.
 Imparting rotary motion
May 11, 2025 103
Speed power requirement of spindle drive

May 11, 2025 104

PROGRAMMING FOR NC MACHINES
 The information punched on the paper tape
includes:

1. The co-ordinate values of the entire tool path.

2. The co-ordinate values are prefixed with

certain codes indicating the type of movement
of the tool (point-to-point, straight-line,
contour) one co-ordinate to the next.
May 11, 2025 Slide 105
PROGRAMMING FOR NC MACHINES

3. The co-ordinate values are also suffixed with

certain codes indicating the various machine
functions, such as, start/stop, spindle coolant
etc. The-co-ordinate values are also
supplemented with other functions such as
feed rates; spindle speeds, etc..

May 11, 2025 Slide 106

PROGRAMMING FOR NC MACHINES
 Programming to obtain the punched paper
tape can either be done manually or with the
help of a computer.
 Simple point-to-point programs can be easily
developed manually, but more complex ones;
as well as almost all contouring programs are
developed with the help of computers.

May 11, 2025 Slide 107

PROGRAMMING FOR NC MACHINES
 Before making the part programme, the
programmer first studies the part drawing and
decides upon: the proper sequence of
operations, the cutting tools, the path of the
cutter/tool, speeds and feeds at various points
and the other related information, such as
starting and stopping of the machine etc.

May 11, 2025 Slide 108

Manual Programming

May 11, 2025 Slide 109

Manual Programming
 The firsts step is to establish the zero
reference axes on the part drawing and
determine the co-ordinate dimensions for
each operation.
 The set up instruments to establish the
workpiece properly on the machine table
with respect to the tool are established.
May 11, 2025 Slide 110
Manual Programming
 Then, all the data and the instructions are
entered in a 'program sheet' in a particular
format acceptable to the machine tool-control
unit combination.
 This sheet includes the following information:

the co-ordinate dimensions-for each

operation, the spindle traverse that
determines the depth of cut, the spindle
speed and feed, tool change.
May 11, 2025 Slide 111
Manual Programming
 After preparing the 'programme sheet', the
programmer uses it to prepare the
punched paper tape on a typewriter-like
tape punching machine.

May 11, 2025 Slide 112

Computer Programming
 To develop the program with the help of a
computer, specialized programming
'languages, such as-APT (Automatically
Programmed Tool) have been developed to
facilitate the production of punched paper
tapes with relatively little knowledge of
computers.
May 11, 2025 Slide 113
Computer Programming

The various steps in computer programming are:

1. Writing the part programme manuscript'
using the simplified programming
language.
2. Copying the part programme manuscript
onto a deck of punched cards with the help
of a keypunch operator.

May 11, 2025 Slide 114

Computer Programming

This is known as the 'part programme'. On

each card, a specific machine-tool
instruction is punched.
3. The part programme along with 'computer
programme' and 'post-processor
programme' are then fed to a general-
purpose computer.
May 11, 2025 Slide 115
Computer Programming
 The 'computer programme' is a previously
prepared deck of punched' cards, or tape,
that contain instructions for the computer
for executing the part-programme
instructions, and also those from 'post-
processor programme.

May 11, 2025 Slide 116

Computer Programming
 The computer translates the 'part programme
into numbers and computing instructions and
performs the calculations.
 The output of the computer, which is
translated with the aid of 'post processor
programme into a form acceptable to the
particular machine tool, may be in the form of
a magnetic tape or a punched paper tape.
May 11, 2025 Slide 117
Computer Programming
 If the output is in the form of a magnetic
tape, it is converted into punched tape with
the help of conversion equipment.
 The punched tape is now ready to be fed
into machine tool control, The complete
scheme' of computer programming is
shown in Fig.
May 11, 2025 Slide 118
Computer Programming

May 11, 2025 Slide 119

Computer Programming
 APT, the first programming language used
for NC machine tools, was developed in
1950.
 It used English type statements. After that,
many subsets of APT and new languages
have been developed.

May 11, 2025 Slide 120

Computer Programming
 In APT-II, the complete job of part program
preparation from' the part drawing was
undertaken by the computer.
 Then came the APT Long Range Program
(ALRP). In 1965, ALRP was changed to
Computer-Aided Manufacturing-I (CAM-I).

May 11, 2025 Slide 121

Computer Programming

The subsets of APT and its expanded forms

and other new languages are given below:
ADAPT {Adaptation of APT for smaller
components}
UNIAPT Handles full power of APT on a
smaller computer.
 It differs from APT only in its internal design
of processor.
May 11, 2025 Slide 122
Computer Programming
 NELAPT: Developed by National
Engineering Laboratory in U.K.
 This language contains advanced features
not available in APT.
 EXAPT (Extended APT) was developed in
Germany.
 It 'is both geometrically and technologically
oriented. Its various versions are available.
May 11, 2025 Slide 123
Computer Programming

(i) EXAPT 1: for positioning machine tools,

eg: drilling machines,
(ii) EXAPT 2 : for turning centres.
(iii) EXAPT 3 : for milling operations.
 AUTOSPOT (Automatic, System for
Positioning Tools): was developed by
IBM in 1962 for three axes, point-to-point
motion control.
May 11, 2025 Slide 124
Computer Programming
 COMPACT: -This language was developed
for simultaneous servicing of multiple users
from a remote computer over telephone
lines.
 COMPACT - II: This is the latest version of
COMPACT. This is available to the
users ,on a time sharing basis.
May 11, 2025 Slide 125
Computer Programming
 SPLIT (Sunstrand Processing Language
Internally Translated): This language can
handle upto 5-axis positioning and
possesses contouring capability.

May 11, 2025 Slide 126

 List of CNC Codes and its functions

May 11, 2025 Slide 127

 ADDRESS CHARACTERS
 The address characters are the meaning
and the function of the alphabet (only
upper case) which are used in the CNC
part programming.
 Some of the meaningful alphabets are
listed in the table.

May 11, 2025 Slide 128

 ADDRESS CHARACTERS

May 11, 2025 Slide 129

 ADDRESS CHARACTERS

May 11, 2025 Slide 130

 ADDRESS CHARACTERS
LIST OF G-CODES FOR TURNING PROGRAMS
 The G-codes are also called as preparatory
functions which are used to control the
 movement of the machine tool. FANUC

lathe control various types of G-codes are

used.
 They are given below in the table.

May 11, 2025 Slide 131

 ADDRESS CHARACTERS

May 11, 2025 Slide 132

 ADDRESS CHARACTERS

May 11, 2025 Slide 133

 ADDRESS CHARACTERS

May 11, 2025 Slide 134

 ADDRESS CHARACTERS

May 11, 2025 Slide 135

 ADDRESS CHARACTERS
LIST OF M-.CODES USED IN THE CNC
TURNING PROGRAMS
 The address M in a CNC program identifies
a miscellaneous function,
 Sometimes called as machine functions.
 Not all miscellaneous functions are related
to the operation, of a CNC Lathe - quite few
are related to the processing the program
itself
 The mainly used M-codes are given below
in the table.
May 11, 2025 Slide 136
 ADDRESS CHARACTERS

May 11, 2025 Slide 137

 ADDRESS CHARACTERS

May 11, 2025 Slide 138

 ADDRESS CHARACTERS

May 11, 2025 Slide 139

Specification of programming axes

May 11, 2025 140

 SINGLE FACING CYCLE
[BILLET X20 Z70
G21 G98
G28 U0 W0
M06 T01
M03 S1500
G00 X21 Z1
G94 X0 Z-0.5 F50
Z-1
Z-1.5
Z-2
G28 U0 W0
M05
M30
May 11, 2025 Slide 141
 SINGLE TURNING CYCLE
[BILLET X25 Z70 X17
G21 G98 X15
G28 U0 W0 X13
M06 T01 X11
M03 S1500 X10
G00 X26 Z1 G28 U0 W0
G90 X25 Z-20 F40 M05 M30
X23
X21
X19
X17
May 11, 2025 Slide 142
 MULTIPLE FACING CYCLE
[BILLET X25 Z70 G02 X17 Z-13 R3
G21 G98 G03 X14 Y-10 R3
G28 U0 WO G01 X14 Z-5
M06 T01 N20 G01 X10 Z0
M03 S1500 G28 U0 W0
G00 X26 Z1 M05
G72 W0.5 R0.5 M30
G72 P10 Q20 U0.1 W0.1 F70
N10 G01 X25 Z-29
G01 X20 Z-24
G01 X20 Z-16
May 11, 2025 Slide 143
MULTIPLE TURNING CYCLE
G01 X15 Z-20
[BILLET X22 Z70
G01 X15 Z-28
G21 G98
N20 G01 X22 Z-28
G28 U0 WO
G70 P10 Q20 S1800 F80
M06 T01
G28 U0 W0
M03 S1500
M05
G00 X23 Z1
M30
G71 U0.5 R0.5
G71 P10 Q20 U0.5 W0.5 F70
N10 G01 X0 Z0
G03 X10 Z-5 R5
G01 X10 Z-15
May 11, 2025 Slide 144
Simulation Exercise for Milling
Simple Contouring Milling
[BILLET X100 Y100 Z10
[EDGEMOVE X0 Y0
[TOOLDEF T01 D5
G21 G94
G91 G28 Z0
G28 X0 Y0
M06 T01
M03 S1000
G90 G00 X35 Y25
G01 Z-1 F80
G01 X65
May 11, 2025 145
Simple Contouring Milling Cont.
G03 X75 Y35 R10
G01 X75 Y65
G02 X65 Y75 R10
G01 X35 Y75
G03 X25 Y65 R10
G01 X25 Y35
G02 X35 Y25 R10
G00 Z5
G91 G28 Z0
G28 X0 Y0
M05
M30
May 11, 2025 146
RECTANGULAR POCKETING
[BILLET X90 Y90 Z10
[EDGEMOVE X-45 Y-45
[TOOLDEF T01 D6
G21 G94
G91 G28 Z0
G28 X0 Y0
M06 T01
M03 S1000
G90 G00 X0 Y0 Z5
G172 P0 Q-1 R0 X-20 Y-15 Z-5 I40 J30 K0
May 11, 2025 147
RECTANGULAR POCKETING Cont.
[G173 P60 S1500 R40 F80 B2000 J30 I0.1 K0.1 T1 Z5
G172 P0 Q-1 R0 X-20 Y-15 Z-5 I40 J30 K0
G173 P60 S1500 R40 F80 B2000 J30 I0.1 K0.1 T1 Z5
G91 G28 Z0
G28 X0 Y0
M06
M30

May 11, 2025 148

CIRCULAR POCKETING
[BILLET X90 Y90 Z10
[EDGEMOVE X-45 Y-45
[TOOLDEF T01 D6
G21 G94
G91 G28 Z0
G28 X0 Y0
M06 T01
K = Radius of Pocket
M03 S1000
G90 G00 X0 Y0 Z5
G170 P0 Q-1 R0 X0 Y0 Z-5 I0.1 J0.1 K20
May 11, 2025 149
CIRCULAR POCKETING Cont.
G171 P60 S1500 R40 F80 B2000 J30
G170 P1 Q-1 R0 X0 Y0 Z-5 I0.1 J0.1 K20
G171 P60 S1500 R40 F80 B2000 J30
G91 G28 Z0
G28 X0 Y0
M06
M30
K = Radius of Pocket

May 11, 2025 150

Mirroring cycle ( With Sub Program)
[BILLET X90 Y90 Z10
[EDGEMOVE X-45 Y-45
[TOOLDEF T1 D6
G21 G94
G91 G28 Z0 X0 Y0
M06 T01
M03 S1500
G90 G00 X10 Y30 Z5
M98 P01234
M70
M98 P01234
May 11, 2025 151
Mirroring cycle Cont.
M80
M71
M98 P01234
M81
M70
M71
M98 P01234
M80
M81
G91 G28 X0 Y0 Z0

May 11, 2025 152

Mirroring cycle Cont.
M05
M30
Sub program
O1234
G90 G00 X10. Y30.
G90 G01 Z-1. F40.
G90 G01 X30. Y10.
G90 G01 X10. Y10.
G90 G01 X10. Y30.
G00 Z5.
M99
May 11, 2025 153
 End
of
UNIT – V

May 11, 2025 Slide 154