CAD/CAM LABORATORY

MEL58

RAMMING FUNDAMENTA
NC PROCEDURE
The following arethe basicstepsin NC procedure
o processplanning
o part programming
o Part program entry
o Proving the part program
o Production
A) PROCESSPLANNING
The part programmerwill often carryoutthe task of processplanning.Processplanning
is the procedureof deciding what operationsare to be done on the component,in wtrat ordef
and with what tooling and work holding facilities. Both the proceis planning and part
programmingaspectsof manufactureoccur after the detail drawingsof a componenthave been
prepared.The following procedure may be used as a guide to assist the programmer,by
describing
rDlng eac
eachSsteprequired
ul
in preoarinsthe method
m
methodo
of nrocfirction
tlon

PROCESSPLANNING
o

Receivethe part drawing . from part drawing information,check suitabilityof part

to be machinedagainstthe machinecapacity.
o Determine a method of driving the component(chuck type, chuck sir., typ. or
jaw) and the method of qachining.
a
Determinethe tooling requiredto suit the methodof machiningand utilize as
much as possiblethe tools which are permanentlyin the turret set upon the
machine.

o Determinetheorderof machiningandthetoolingstations.
. D;t"
operator
Determinecutting speedsbasedon
- Componentmaterial,methodof driving, rigidity of component
- Tooling selectedfor roughingand finishing
o Determne the depths of cr,4and feeds for roughing operations
o Determinesurfacefinish requirements,the cutternoseradiusmost suiteclfor
finishing operationsand determinefeed rates.
r Allocatestool o&g!!3s required
. Cqmpleteplanningsheet
o

ART PROGRA

NG

o After completingthe planningsheet,draw the componentshowingthe cutter

s (a simple sketchis sufficient for simple com
Selecta componentdatum and carryoutthe necessarycalculationsat slopesand

Pre p a re to o l i n g l a yo u tsheeishowingtoolstobeusediir theffi

the stationnumberfor eachtool.
rts to be used.
lltlte the part programaccordingto the sequenceof operations.

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C) PART PROGRAM ENTRY OR TAPE PREPARATION

The part program is prepared/ punchedon a 25 mm wide paper tape with 8 tracks and
is fed to MCU in order to produce a componentof interest on machine tool. Other forms of
input media include, punchedcards,magnetictape, 35 mm motion picture film. The input to
the NC systemcan be in two ways : l)lv{anualdatainput 2)Direct Numerical control.
1) Direct Data Inpu(MDI) : Complete part programsare enteredinto CNC control unit via'
the consolekeyboard.It is suitedonly for relativelysimplejobs. The most common application
for MDI is the editing of part programsalreadyresidentin controllersmemory.
One variation of MDI is a concept called "Conversational Programming". CNC
machinesare programmedvia a questionand answertechniquewhereby a residentsoftware
program asks the operator a series of questions.In responseto the operatorsinput, and by
rammed data file, the
control can
accessinqa
- Selectnumericalvaluesfor usewithin machiningcalculations
- Performcalculationsto optimizemachiningconditions
- Identiff standardtools and coordinates
- Calculatecutter pathsand coordinates
- Generatethe oart Drosramto machinethe comoonent
A typical dialogue from the machinewould be as follows for the operatorto identify such
things as :
- Material to be cut
- Surfaceroughnesstolerance
- Machined shaperequired
- Size of the raw materialblank
- Machining allowances,cut directions
- Tools and tool detail etc.
The operatormay then examine and prove the program via computer graphics simulation on the
consoleVDU. After this, the program is storedor punchedon tape. Although there is some
sacrifice in machine utilization, actual programming time is minimal and much tedious
productionengineeringwork is eliminated.
2) Direct Numerical Control : The processof transferringpart programs into memcry of a
CNC machinetool from a host computeris calledDirect Numerical Control or DNC
D) PROVING PART PROGRAMS
It is safe practiceto check the programmedpath for any interferencebetweenthe tool
and the work before using the part program for production.The proving part programis done
by:
o Visual inspection
. Singlestepexecution

Dryrun

. Graphicalsimulation.
Visual Inspection : It representsthe method of checking visually the program presentin the
memory of the CNC machine.In this, actualprogramis run and the programmedmovementsin
all axesare to be checkedalong with ensuringthe tool offset and cutter compensationfeatrrre.
This methodrepresentsthe leastform of verificationand should not be relied up on entirely.

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Single Step Execution : Before auto-runningthe part program it should be executedin a

step
mode i.e block by block. During this execution,spindle speedand feed rate override facilities
are to be used so that axes movementcan be easily monitored.This operationmay be canied
out with or without mounting the componenton the machine.
Dry run : A dry run consists of running the part program in auto-mode. During this,
the
componentis not installedon the machinetable and the cutting is done in air. The purpose
of
this run is to verifu the programmedpath of the tool under continuousoperationand to check
whether adequateclearanceexist between the clamping arrangementand other projections
within the set up. Feedrate override facilities are used to slow down the speedof execution
of
the program.
Graphical simulation : A graphicalsimulationpackageemulatesthe machinetool and,
using
computergraphics,plots out the machinemovementson a VDU screen.Machine ,''ou.*.ni
often takes the form a cutting tool shape moving around the screen according to
the
programmedmovements. When the tool shape passesover a shaded representation
of the
component,it erasesthat part of the component.The resulting shape,lest after the execution
representsthe shapeof the finished component.Any gross deviations from the intended
tool
path can be observedand any potentialinterferences
can be highlighted.

PART PROGRAMMINGGBOMETRY
A. COORDINATE SYSTBM FOR A CNC LATHE.
Machining of a workpieceby an NC programrequiresa coordinatesystemto be appliedto
the machinetool- As all machinetools havemore than one slide, it is importantthat each
slide
is identifiedindividually. Thereare two planesin which movementscan takeplace
. Longitudinal.
o Transverse.
Eachplane is assigneda letter and is referredto as an axis.
o Axis X
. Axis Z
The two axis are identified by upper caseX,Zand the direction of movementalong each
axis
(+) or (-). The Z axis is alwaysparallelto the main spindleof the machine.The X axis
is
alwaysparallelto the work holding surface,and alwiys at right anglesto the Z axis. The
coordinatesystemfor tuming operationsis shown in figure below :

DEPARTMENTOF'MECHANICAL ENGINBERING,K.S.I.T, BANGALORE-62

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MEL58

CAD/CAM LABORATORY

+
I
Fio 1, COBRDINATE
S Y S T E MF O R T U R N I N GO P E R A T I O N S

B. ZERO POINTS AND REFERENCE POINTS

All CNC machine tool traversesare controlled by coordinating systems.Their accurate
positionwithin the machinetool is establishedby "ZERO POINTS".
MACHINE ZERO POINT (M) : is specifiedby the manufacturerof the machine.This is the
zero point for the coordinate systemsand referencepoints in the machine. On turning lathes,
the machine zero point is generally at the center of the spindle nose face. The main spindle axis
(center line) representsthe Z axis, the face determinesthe X axis. The directions of the positive
X and Z axespoint toward the working areaas shown in figure below:

NE ZERtr PIINT
WI R K P ] I C f Z E R D P N I N T
RfFfRfNCE PIINT

WORKPIECE ZERO POINT (W) : This point determinesthe workpiececoordinatesystem

in relation to the machine zero point. The workpiece zerc pint is chosenby the programmerand
input into the CNC systemwhen setting up the machine.The position of the workpiece zero
point can be freely chosenby the programmerwithin the workpieceenvelopeof the machine.It

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is however advisable to place the workpiece zero point in such a manner that the dimensions
in
the workpiece drawing can be conveniently coni'erted into coordinate values and
orientation
when clamping 1 chucking, setting up and checking, the traverse measuring system
can be
effectedeasily.
For turned parts, the workpiece zero point should be placed along the spindle
axis
(centerline), in line with the right iand or left hand enclface of the finished
contouras shown
'
in figure. Occasionallythe workpiecezero point is also calledthe "programzero point.',
REFERNCE POINT ( R) : This point servesfor calibratingand for controllingthe
measuring
systemof the slides and tool traverses.The position of theieference point as ,ho*.,
in figur!
below is accuratelypredeterminedin every traverseaxis by the trip dogs and limit
switches.
Therefore,the referencepoint coordinatesalways have the same preciselyknown
numerical
,
value in relation to the machinezero point. After initiating the control .yrt.-,
the reference
point must always be approachedfrom all axes to calibratethe traverse
measuringsystem.If
currentslide and tool position datashouldbe lost in the control systemas for."urr1pt.,
through
an electricalfailure, the machinemust againbe positionedto the referencepoint
to re-establish
the properpositioningvalues.
C. NC- RELATED DIMENSIONING
Dimensional information in a workpiece drawing can be statedin two ways :
P1
P2
P3
F4
P5
F6
P7
PE
P9

Flg

A. Absotute

Dlnenslons

o
eo
o
50
o
30

-2n

-70

Incremento.(

FIE

E.

lncr^emental

IJlrnenslons

dlnenslons

Incrementat

Coordlnates

l.Absolute Dimension System: Data in absolutedimension system always refer

to a fixed
referencepoint in the drawing as shown in figure A above. This point has the function
of a
coordinatezero point as in figure B. The dimensionlines run parallel to the coordinate
axesand
always start at the reference point. Absolute dimensions are also called as ,.Reference
dimensions".
2. Incremental Dimension System: When using incrementaldimension system,
every
measurementrefers to a previously dimensioned position as shown in figure
A below.

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Incremental dimensions are distance between adjacent points. These distances are converted
into incrementalcoordinatesby acceptingthe last dimensionpoint as the coordinateorigin for
the new point. This may be comparedto a small coordinatesystem,i.e. shifted consequently
frorn point to point as shown in figurer B. Incrementaldimensionsare also frequently called
"Relativedimensions"or "Chain dimensions".

NC PROGRAM BUILD UP
In an NC program the machining steps(Operations)for producing a part on the machine
tool are laid down in a form that the control systemcan understand.A program is composedof
severalblocks. A block is a collection of NC words. An NC word is a collection of address
letterand a s e
oIf num
numbers.Table
e showsthe addressletter S :
AddressCharacters
Character Meaning
Rotationabout.X-axrs
A
B
Rotationabout,Y-axrs
Rotation about, Z-axrs
C
D&E
Rotationaboutadditionalaxis
Feed
F
Preparatoryfunction,identifuinethe action to be executed
G
Interpolationparameter/ Threadpitch parallel to X-axis.
I
Threadpitch parallelto Y-axis
J
Threadpitch parallelto Y-axis
K
Auxiliarv function
M
N
Block Number
P,Q,R Threadmovementparallelto X,Y,Z axis respectively.P & Q
are also usedas parametersin cycles.
Spindlespeed
S
T
Tool
U.V.W Secondmovementparallelto X,Y,Z axis respectively
X
Movementin X-axis
Y
Movementin Y-axis
Z
Movementin Z-axis
All the NC words may not be used on every CNC machine.Using these words as an
example,the com
tion of a block is assembled
as follows:

PART PROGRAMFORMATS
The order in which thesewords appearin a block of instructionsis called the format.
Basicallythereare two typesof format:
. Fixed Block Format
-Fixed sequentialformat
-Tab sequentialformat
. Word Address Format

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I. FIXED BLOCK FORMAT :

a)Fixed Sequential Format : Every instructioncontainsall the words in the same sequence
irrespectiveof the words being the same as in the previous blocks. Hence the identifuing
addressletter need not be provided. For example,if some coordinatevalues remain constant
from one block to next block thesevalueshaveto be specifiedin the next block also. The data
must be input in a specifiedsequenceand characterswithin each word must be of the same
'
length.

Example:

N0l0 G00X10 Z0 F605800EOB

N020cOl x20 20F60s800EoB

b)Tab Sequential Format : The words in eachinstruction/ block are always provided in the
same sequencebut each word is precededby the TAB character.If instructions remain
unchangedin succeedingblocks, the instructionsneednot be repeatedbut TAB charactermust
be punched.Here also,the identifuingletteraddressneednot be em

Example:

N010c00 XlO TAB Z0 TAB F60TAB 5800EOB

N020cOl x20 EoB

2. WORD ADDRESS FORMAT: Each word is precededand identified by its letter address.
This format enablesinstructions which remain unchangedfrom the precedingblock, to be
omitted from succeedingblocks. This system speedsprogramming, and tape lengths are
considerablyreduced.This is the format adoptedby most CNC machinecontrol units. Detailed
format classification is provided by the control systemmanufacturer.

FANUC TURNING PROGRAMMING

MISCELLANEOUS FUNCTION (M Codes)
M Codesare instructionsdescribingmachinefunctionssuch as calling the tool, spindle
rotation,coolanton, door cl<lse/open
etc.

M CODES
M00
M02
M03
M04

ProgramStop
OptionalStop
SpindleForward(CW)

M0s

SpindleStop
Tool Chanee
CoolantOn
CoolantOff
Vice Open
Vice Close
SpindleForward,CoolantOn
SpindleReverse,CoolantOn
ProgramEnd
Door Open

M06

l\{08
M09
Ml0
Ml1

M1 3

ltrl4
N{30
M38
M39
M98
M99

(CCW)
SpindleReverse

DoorClose
Subprogram
Cali
Subprogram
Exit

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M00 PROGRAM STOP : By inserting M00 in a program,the cutting cycle is stoppedafter

the block containingM00 code.This faciliW is useful if an inspectioncheck is necessaryduring
an operation.The cycle is then continued by a cycle start.
M01 OPTIONAL STOP : Cycle operation is stopped after a block containing MOl is
executed.This code is only effective rvhen the optional stop switch on the machine control
panelhasbeenpressed.
M02 PROGRAM BND : This code is insertedat the end of the program, when encountered
the cycle will end.To produceanother,the systemmust be reset.
M03 SPINDLE FORWARD : Starts the spindle spinning forward, clockwise or negative
directionat the last specifiedspindlerate.
M04 SPINDLE REVERSE : Startsthe spindlespinningreverse,counterclockwiseor positive
directionat the last specifiedspindlerate.
M05 STOP SPINDLE : Stopsthe spindlewithout changingthe spindlespeed.
M06 TOOL CHANGE : The M06 in conjunctionwith "T" word is usedto call up the required
tool on an automatic indexing turret machine,and to activate its tool offsets. The left most digit
of the "T" ignoring zeros,Selectsthe new tool. Tool changesare normally performedwith the
tool post at a safe position away from the workpiece,so the code G28 REFERENCE POINT
RETURN would be usedin the block prior to M06.

M08 COOLANT ON : Turns the coolanton.

M09 COOLANT OFF : Turns the coolantoff.
MlO CHUCK OPEN : Openspneumaticor similar automaticchuck to allow for bar feed.
Mll CHUCK CLOSE : Closesthe chuck.
Ml3 SPINDLE FORWARD, COOLANT ON : Sets spindle rotation forward and sets the
coolanton, both areperformedby singlecode.
M14 SPINDLE RBVERSE, COOLANT ON : Setsthe spindle rotation in reversedirection
and setsthe coolanton.
M30 PROGRAM END : Stops the spindle, turns the coolant off, terminatesand resetsthe
CNC program.
M38 DOOR OPEN : Opensthe door, waiting until the door is open.
M39 DOOR CLOSE : Ciosesthe door, waiting until the door is closed.

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PREPARATORYFUNCTION (G-Codes).
G CODES
G00

G0r
G02
G03
G04

G20
G2l
G28
G40
G4l
G42

Gs0
G70
G7l
G72
G73
G74

G7s
G76
G90
G94
G96
G97
G98
G99

Positioning(Rapid Tranverse)
Linear Interpolation(Feed)
Circular Interpolation(CW)
Circular Interpolation(CCW)
Dwell
lnch Data Input
Metric Data Iqput
Referencepoint return
Tool noseradiuscompensationcancel
Tool noseradiuscompensationleft
Tool noseradiuscompensationright
Work coordinatechange/.Max.Spindlespeedsettins
Finishingcycle
Multiple Turning Cycle in turning
Stock removalin facing
Patternrepeating
Peckdrilling rn Z axis
Grooving in X axis
Ihreqd cutting cycle
Cutting cycle A (Turning)
Cutting gycleB (Facing)
Constantsurfacespeedcontrol
Constantsurfacespeedcontrol cancel
Feedper minute
Igg4l.r revolution

GOOFAST TRAVERSE

Illustration
A rapid traverse instruction traversesthe
tool to the target point at the maximum
traverserate. The tool normally takes the
shortestpath from the starting point to the
destinationpoint. The rapid traverseis used
for movements where no tool is in
engagement.

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GOl LINEAR MOTION

Description
G01 traversesthe tool along a linear path to
the given target point rvith the feed rate
input as a supplementary function. The
feed rate determines the speed with which
the workpiece is machined.The choice of
feed rate dependson the tool, the material
being machined, the required surface finish
and the drive rating and rigidity of the
machinetool.
When giving the instructionsG0l, the
coordinatesof the destinationpoint can be
expressed using either absolute or
incrementaldimensions.

Illustration

Example: GOl X30 Zl0 F100 51000

TargetpointFee4 Speed
GO4DWELL
Description
A G04 causes the program to wait for a specified
amount of time. The time can be specified in seconds G04
with the "X" or "IJ" prefixes or in milliseconds with the G04
"P" prefix. A G04 code can be insertedbetweenthe two G04
statementsto make a sharpcorner.

Illustration

x1.5
ul.5
Pls00

G20 INCH DATA INPUT : A G20 causespositionto be as beingin imperialunits.All the

inputvaluesare in inches.This canonly beat the startof the main program.
G21 METRIC DATA INPUT : A G21 causespositionsto be interpreted
as beingin metric
units.All theinputvaluesarein mm.Thiscanonly beat the startof themainprogram.
G28REFERENCEPOINT RETURN
Description

Illustration
A G28 causes a fast traverse to the specified G28X35 Z5
positionand then to the machinedatum.
G28U0 W0

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MEL58

G4t,C42 TOOL NOSERADIUS COMPENSATION

Descrintion
onModernCNCmachines,specialcalculationfu"ctionso.cutG@
codesareprovidedto allow a userto utilizepartprofilecoorCinates
obtainable
fiom the

part drawing to programa contouringmotion. Theseare the G41 and G42 codesfor
tool
radius compensationon the left and right hand sides of a profile. A left or
right
compensationis basedon the fact that the tool is on left or right hand side when one goes
along the part profile in the directionspecifiedby the contouringmotion statementsin
the
am. A G40 code is provided to cancelthe cutter radius com

GsOCOORDINATE SETTING
G50 enablestool noseradiusco*pensat
uses.coordinate setting block has "x","2","u",
block doesnot haveall these.

or "w" upon it. A maximum spindle

G96CONSTANT SURFACESPEED
n

The cutting speedduring turning is the t;

speedis a rotatingwork represents
the peripheralpathin a givenunit time as shownin

figure' The peripheral speed or cutting speed is thus the fully stretchedchip length
producedin one time. The cutting speedsvary in direct relation to the diameters,
even if
the numberof revolutionsper minute is the samein all cases.
The correctselectionof the cutting speedfor turning is very important,
Cutting speedtoo low : Time loss and low surfacefinish. With increasingcutting speed
the surfacespeedis improved.
Cutting speedtoo hiqh : Hish tool wear.

NORMAL SPINDLE SPEED

G97 cancelsconstant surfacespeed.The spind
value is reached.

G98FEED PER MINUTE :

Description

Illustration

This commandcoupled with the F word is

used to speci$, feed rate per minute. This
can be in eithermm/min or inch/min.this is
the default.

F=nisplncement o{ong the Z qxis

per minute

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CAD/CAM LABORATORY
G99FEED PER REVOLUTION
Descrintion
This command coupled with the F word is used
to speciff a feed rate per revolution. This can
be in mrn/rev or inch/rev. the feed rates
available in the machine simulation are 0.01200 mm/min. Recommended feed rates are
published by tool and cutter manufacturers,
along with recommendedcutting speeds.If the
feed rate is expressedas mm/rev, a simple
calculationcan be usedto convertto mm/min.
FEED, mm/min:FEED(mm/rev) X spindle
speed(r.p.m)

MEL58

Illustration

F=IJlspto.cer'1ent
o,[ong the Z oxls
per^ nevotr-ltlon of

the

workplec

PROGRAMBUILD.UP FOR CNC LATHE (FANUC)

CNC programcan be divided into 3 parts,Start-up,Body and End of the program.
START-UP OF CNC PROGRAM

or000
IBTLLETX20 260
G2r/G20G98/G99c40
G 5 0S1 8 0 0
G28U0 W0
M 0 6T0 1 0 1
M03/M0451000

G00x2r
zr
EXPLANATION

o1000

While writing a programon FANUC controller first line hasto be

started with letter 'O' followed by four digit number which
specifiesthe program name.
X20
260
This
directive is used only for simulation purpose.It definesthe
IBTLLET
work piecedimensionsas 60 mm long and 20 mm in diameter.
G2uG20G98/G99 G2l - code specifiesthat programis done in metric units.
G40
G20 - codespecifiesthat programis done in imperial units
G98 - gives the unit of feed in mm/minute.
G99 - gives the unit of feedin mm/revolution.
G40 - Compensationcancel.
G50S1800
Clampsthe spindlespeedat 1800rpm.
G28U0 W0
Makesthe tool to go to homeposition. U & W are Secondary
movementsaboutX and Z axis.
M06
Tool change
T0101
The first two digits specifythe tool position in the turret and last
two digits denotesthe tool offset number.
M03/fi40451000
M03- makesthe spindlerotatein clock'wisedirection.
M04 - makesthe spindlerotatein counter-clockwisedirection.
S1000-Spindle
rotatesat 1000rpm.
G00 gives rapid position of the tool to a point X2l Zl which is
G00x2r z1
iust abovethe billet. This point is cailed as the tool entrv ooint.

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BODY OF THE PROGRAM : Thisis dealroperation

wisein the succeedingpages.
END OF THE PROGRAM :
G28U0 w0
M05
M02t30
EXPLANA

G28 U0 W0

Makes the tool to go to ho

movementsaboutX and Z axis.
Stopr the spind
M02 - Optionu
M30 - Programstop and rewind.

M0s
M02/30

METAL
N
BILLET MATERIAL : Aluminum
OPERATIONS

FOR

ART

F'EED
mm/min

TURI\ING

0.25- 0.5

THREADING

SIMPLE FACING

Write a manual part program for SimpleFacing

Operafion for the componentshown in
figure below.

2 n r n rf o r

fACING
tl
tl

'l

fi?

tFtl
tl

DWG.NO.I

PLANNING
ANDOpnnnrtor,lssunnr

BILLET SIZE z22 x 60

PROGRAMNO : t00l
SL.NO 0peration

Simple
Faci

MATERIAL: Aluminum
DWGNO:1

SDJCR
t2t2llll

DEPARTMENT OF MECHANICAL ENGINEERING,

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MEL58
TOOL OFFSETSHEET

Tool offsetNo.

Compensations,mm

X
I

Toolnose
Radius. mm

Standard Tool
Number

R
0.4

(Drawing No .1
(CNC programfor Simple Facing
(Material to be removedby facing :2mm

ol00l
[BILLETX22 260
G2l G98
G28U0 W0
M06 T0303
M 0 3S1 2 0 0

G00x22zr
GOlz-0.5F4s
GOIXO
GOIZI

G00x22
G}l z-r F45

ProgramNumber 1001

DefiningBillet sizedia : 22length60 mm

Initial settings
Going to homeposition
SelectingTool No. 3 with offset No. 3
Settingspindlespeedat 1200rpm
Tool moving to tool entry point X22 Zl at
rapid traverse.
Giving depthof cut of 0.5 mm at a feed rateof
45 mm/min.
Moving the tool to spindle centerline
Retractback the tool
Moving the tool to X22
Giving the seconddepth of cut.

GOIXO
GOIZT

G00x22
G}rz-r.5
GOIXO
GOIZI

G00x22
G0rz-2
GOIXO
GOIZI
G00x22
G28U0 W0
M05
M30

Retractback the tool

Goingto homeposition
Stop the spindle
Proqramstop and rewind.

DEPARTMENTOF MECHANICAL ENGINEERING,K.S.I.T. BANGALORE-62