NATIONAL INSTITUTE OF TECHNOLOGY, TIRUCHIRAPPALLI

Department of Production Engineering

MANUAL PART PROGRAMMING &

PREPARATORY/MISCELLANEOUS FUNCTIONS

PRESENTED BY : Abir Chakraborty (Roll No - 214124001)

Adheena P A(Roll No - 214124002)
FACULTY: Dr. Jerald
BATCH : (Manufacturing Technology) SUBJECT: Product Automation & CNC Technology
INTRODUCTION

CNC machining refers to a manufacturing process where

a computer numerically controlled (CNC) machine

precisely cuts and shapes raw materials into finished

parts using pre-programmed instructions, known as "part

programs," which dictate the tool movements and

operations required to achieve the desired

geometry; essentially, it allows for highly accurate and

repeatable production with minimal human intervention.

TYPES OF CNC PROGRAMMING
1. Manual Part Programming
2. Computer-Assisted Part Programming
🔹 Definition: The programmer writes the CNC code (G-code
🔹 Definition: The programmer uses specialized software (like
and M-code) manually, specifying every movement and
APT, CAD/CAM) to generate the CNC program automatically
machining parameter.
based on part geometry.
🔹 Features:
🔹 Features:
 Requires knowledge of G-codes, M-codes, tool paths, and  Reduces human effort by automating toolpath calculations.
machining operations.
 Generates optimized programs for complex shapes.
 Used for simple parts with basic geometric shapes.
 Requires training in CAM software.
 Time-consuming and prone to human errors.
🔹 Example Software:
🔹 Example Code:
 APT (Automatically Programmed Tool) – An early high-
N10 G90 G00 X0 Y0 Z5 (Rapid move to start position)
level language for CNC.
N20 G01 X50 Y50 F100 (Linear interpolation at feed rate 100)  CAD/CAM Software – Mastercam, Fusion 360, SolidCAM,
N30 M30 (End of program) etc.
🔹 Applications: 🔹 Applications:
 Simple 2D machining operations like drilling and basic Complex 3D contour machining, aerospace, and automotive
milling. industries
 Small production runs or prototyping.
TYPES OF CNC PROGRAMMING
3. Conversational Part Programming (Shop-Floor 4. Automated Part Programming (CAM-Based Programming)
Programming) 🔹 Definition: Uses CAM (Computer-Aided Manufacturing) software to
🔹 Definition: The CNC machine has built-in software that generate CNC programs automatically from CAD models.
allows operators to enter machining parameters interactively, 🔹 Features:
without needing detailed G-code knowledge.
 Fully automated and suitable for complex shapes.
🔹 Features:
 Includes toolpath optimization, collision detection, and simulation.
 User-friendly, menu-driven programming.
 Requires CAD/CAM software and expertise.
 Reduces programming time for simple to moderately
complex parts. 🔹 Example Software:
  Mastercam, Fusion 360, SolidCAM, NX CAM, CATIA, etc.
Found in CNC machines with conversational controls (like
FANUC Manual Guide, Mazatrol, Siemens ShopMill). 🔹 Applications:
🔹 Applications:  High-precision industries like aerospace, medical, and automotive.
 Small job shops where operators handle programming  Complex 3D surface machining, mold making, and multi-axis
directly. machining.
 Quick one-off parts and small batch production.
COMPARISON OF CNC PART PROGRAMMING METHODS
WHAT IS MANNUAL PART PROGRAMMING?
Manual part programming involves writing CNC machine instructions (G-code and M-code) manually, without the use of CAM software. It requires a
thorough understanding of machine functions, tool movements, and coordinate systems.

1. Basics of CNC Manual Programming

CNC programs are written using:
✅ G-codes (Preparatory codes) – Control tool movement and machining operations.
✅ M-codes (Miscellaneous codes) – Control auxiliary functions like spindle start/stop and coolant.
✅ Coordinates (X, Y, Z) – Define tool positions.
✅ Feed (F) and Speed (S) values – Control cutting speed and feed rate.
STRUCTURE OF A PART PROGRAM
Character
 A character is the smallest unit of the CNC program. The combination of digit, letter and symbol is referred to as
alphanumerical characters.
 It may be:
a digit (0 to 9)
a letter (A to Z)
a symbol (+, –, %, ( ) etc.).

Word
 A program word is a combination of meaningful characters creating a single instruction which will be decoded by the
control system.
 It indicate axes position, preparatory commands, speed command, feed command, miscellaneous functions etc.
 Each word normally begins with a capital letter followed by a number representing a program code or actual value.

Block
 A block is a line of the program and is used as a multiple instruction. It contains all the data required for transferring
the cutting tool from one point to the next one.
 A block begins with a line number (optional in some systems) and ends with an end of block (EOB) symbol like “ ; ”.
A small segment of a CNC program is given below:

N40 G90 G00 G54 X20.5 Y40.0 S2000 M03;

N50 G43 Z3.0 H02;
N60 G01 Z–40.0 F400.0;
N60 G00 Z3.0;

A program consists of several lines.

For example, N40, G90, G00, G54, X20.5, Y40.0, S2000, M03; is a block.
A block is composed of a number of words. For eg. Z–40.0.
In Z-40.0, Z, 4, 0—are all characters.

Block Format
 The block format specify the way in which the programming instructions are coded. Currently in wide use is the word address format
in this format each word starts with a letter.
 In manual program preparation, the programmer has to determine the machining parameters and the optimal sequence of operations to
be performed.
 Based on this sequence, the tool path is determined and a program is written. The arrangement of the information within a block is
referred to as block format.
A typical block form is:
G01 X43.56 Z –39.52 F0.2 M08;
 The letter and the number which follows it as a whole
is referred to as a ‘word’. The first letter of the word is
the ‘word address’.

 The machine control unit (MCU) uses this address

letter to identify the meaning of the word following
this letter.

 In this type of format, the words need not be arranged

in any specific order within the block since the letter
identifies the corresponding word. The address
characters used as;
MANNUAL PART PROGRAMMING - ADVANTAGES
1. Better Control Over the Program
🔹 The programmer has full control over tool paths, machining sequences, and cutting conditions.
🔹 Ideal for fine-tuning machining parameters to optimize cycle time and tool life.
2. Useful for Simple Parts
🔹 For basic shapes like rectangles, holes, and straight cuts, manual programming is faster and more efficient than using CAM software.
🔹 Eliminates the need for complex software tools.
3. No Need for Expensive Software
🔹 Reduces costs by eliminating the need for CAM software and powerful computers.
🔹 Can be done with just a basic text editor and CNC machine controller.
4. Faster for Minor Edits and Modifications
🔹 If an existing CNC program needs small adjustments, such as feed rate or tool changes, manual programming is quicker than regenerating a CAM
program.
5. Helps in Learning CNC Fundamentals
🔹 Enhances the understanding of machine operations, tool paths, and machining principles.
🔹 Essential for troubleshooting and debugging CNC programs.
6. Suitable for One-Off or Small-Batch Production
🔹 Ideal for low-volume manufacturing, prototypes, and repair jobs where full automation is unnecessary
 Mannual Part Programming - Disadvantages
1. Time-Consuming for Complex Parts
🔹 Writing long and detailed programs manually is inefficient for complex 3D shapes or multi-axis machining.
🔹 CAM software is much faster for such tasks.
2. High Chance of Human Error
🔹 A small mistake in the code (e.g., missing a decimal point in a coordinate) can lead to costly machining errors or even machine crashes.
🔹 Requires careful checking and simulation before execution.
3. Requires Skilled Programmers
🔹 CNC programming knowledge, math skills, and machining expertise are essential.
🔹 Training is required, making it difficult for beginners to create complex programs.
4. No Automatic Toolpath Optimization
🔹 CAM software automatically calculates the most efficient tool paths, reducing cycle time.
🔹 Manually programmed tool paths might be less optimized, leading to longer machining times.
5. Difficult to Modify for Different Parts
🔹 If a part design changes slightly, the entire manual program may need editing, which can be time-consuming.
🔹 CAM software can easily regenerate a new program with modified dimensions.
6. Limited to Basic Geometries
🔹 Manual programming is not practical for complex 3D contours, sculpted surfaces, or multi-axis machining.
🔹 CAM software is necessary for intricate designs
PREPARATORY FUNCTIONS (G CODES) OF MANNUAL PART PROGRAMMING
PREPARATORY FUNCTIONS (G CODES) OF MANNUAL PART PROGRAMMING
PREPARATORY FUNCTIONS (G CODES) OF MANNUAL PART PROGRAMMING
PREPARATORY FUNCTIONS (G CODES) OF MANNUAL PART PROGRAMMING
STEPS INVOLVED IN DEVELOPMENT OF PART PROGRAM

 Prepare the process plan.

 Identify the machine tool.

 Select the drive axes.

 Choose tools.

 Determine machining parameters such as feed rate , depth of cut, spindle speed.

 Make job and tool set- up plans.

 Decide the tool path.

 Write the part program.

 Test the program.

 Document the program

NOMENCLATURE OF THE CNC

Co-ordinate System

 Fixing of the co-ordinate system is the first requirement in part programming.

 The relative positive directions of the axes in all cases can be fixed by using the
right hand convention.
Six representations of the co-ordinate systems are shown in this figure.

Machine Types
It is convenient through not necessary, in the context of the standard, to classify
the CNC machines in the following four groups:
Group I: Machine tools with rotating tools are classified as group I (i.e., Spindle providing
the cutting power)
Machine having vertical spindle are classified as I(a) and that having horizontal spindle are
categorised as II(b).

Group II: All Machine tools with rotating workpieces (i.e., spindle generating surface of
revolution) like lathes, grinding machines are classified as group II machines.

Group III: Machine tools with non-rotating workpieces and non-rotating tools (i.e., no
spindles) like shaper, planer are classified as group III machines.

Group IV: Machines other than machine tools, like CNC drawing machine are classified
as belonging to group IV.
GROUP IV
REFERENCE POINTS FOR MANUAL PROGRAMMING
(i) The Machine Datum - M:
The machine datum is the origin to the co-ordinate system.
For lathes, it is on the mounting flange of the main spindle and the tuning axis.
Cannot be changed by the user - fixed by the manufacturer and programmed
into the computer memory.
The point generally has the co-ordinates X = 0, Z = 0.
Machine Zero of a vertical machining centre
(iii) Workpiece Zero-Point - W:
The workpiece reference point is commonly known as program zero or workpiece zero. In
principle, the workpiece zero can be selected anywhere. Three factors influencing the
choice of workpiece zero are:
● Accuracy of machining
● Convenience of setup and operation
● Safety
In the case of prismatic components machined in a vertical machining centre, the centre
point of the top surface can be taken as the workpiece reference point.
(iv) Tool Post Reference Point–T:
In milling and related operation the reference point of the tool is usually the
intersection of the tool center line and the lowest positioned cutting tip.
In turning and boring, the most common tool reference point is an imaginary point
on the tool insert.
For tools like drills, the reference point is the extreme tip of the tool, as measured
along the Z-axis.
ZERO-SUPPRESSION
• All CNC machines are equipped with decimal point input.
• In order to simplify program input the leading zeros can be omitted. e.g., 12.145 instead of 0012.145.
• Trailing zeros after decimal point also need not be entered. e.g., 12 instead of 12.000, 10.4 instead of
10.400.

FEED WORD (F)

• Feed in turning is the advance of the tool into the workpiece for every revolution of the workpiece.
• In machining centers (for drilling, milling, boring, etc.) feed rate is used.
• Feed rate is the product of feed and the rpm of the tool.
• While feed is expressed as mm/rev, feed rate is expressed as mm/min.
• Examples:
F0.25 Feed 0.25 mm/rev
F500 Feed rate 500 mm/min
SPINDLE SPEED WORD, S or V
The spindle speed can be specified in rpm, whereas, the cutting speed is given in m/min. The speed
word allows for both cases.
The spindle speed word is directly programmed in revolutions per minute. For example a speed of 450
rpm is programmed directly as: G97 S450
The spindle speed can be specified as: G96 V250.
The spindle speed can also be directly programmed in a block as:
N04 G01 X70.0 Z–50.5 S450 F0.3 ;
It may be necessary to specify the clockwise and counterclockwise rotation of the spindle. M03 is
used to specify clockwise rotation and M04 counterclockwise rotation.
TOOL WORD, T
T function is used to denote the tool.
In general tools are referred as:
T01, T02, T03, etc.
MISCELLANEOUS FUNCTION (M)
The address M in a CNC program block denotes a miscellaneous function.
M-functions control the program flow or activates some functions of the machine.
It does not relate to dimensional movement of the machine, such as spindle
command, or coolant on/off and other functions.
There are two types of M-functions:
(i) Machine related functions
These control typically:
Spindle rotation, CW or CCW, stop Gear change Automatic tool change Automatic
pallet change Coolant on or off Tailstock quill movement.
(ii) Program related functions
M-functions are also used to control the execution of program flow.
Examples are:
Program stop, Program end, Program end with rewind of program, Optional stop etc.
INTERPOLATION FUNCTIONS

Instructions which represent movement of the tool in a specified path which may be along a
straight line or along a part of a circle or a specified curve.
Three common interpolation functions are:
(i) Linear interpolation
Move the machine slides in a straight line either in the rapid traverse or feed mode. Linear
interpolation can be along a single axis or along two or more axes simultaneously.
(ii) Circular interpolation
The programming of the slides of a machine to result in a path which is part of an arc of a
circle is called circular interpolation.
(iii) Helical interpolation
Helical interpolation is an operation where a circular interpolation uses three axes
simultaneously.
It is a simultaneous two axes circular motion in the working plane with a linear motion along
the remaining axis.
A typical example of application of helical interpolation is thread milling.
COMMON MISTAKES AND TROUBLESHOOTING IN CNC
PROGRAMMING
A. Syntax Errors (Incorrect Code Format)
•Problem: Incorrect or missing G/M codes, typos in coordinates, or improper program structure.
•Example:
•Incorrect: G01X100Y50F200 (missing spaces)
•Correct: G01 X100 Y50 F200
•Solution:
•Follow the proper format and syntax.
•Use spaces or proper delimiters between codes.
•Refer to the CNC machine's programming manual.

B. Coordinate and Dimensional Errors

•Problem: Wrong tool positioning due to incorrect coordinates, leading to part defects.
•Example:
•Entering X50 Y50 instead of X5 Y5, causing the tool to cut in the wrong area.
•Solution:
•Double-check dimensions before running the program.
•Use dry run mode to verify tool movement.

C. Incorrect Tool Selection or Compensation

•Problem: Using the wrong tool number or failing to apply tool compensation (e.g., G41/G42 for cutter compensation).
•Example:
•Forgetting G41 (left cutter compensation) in contour milling may result in oversized parts.
•Solution:
•Ensure the correct tool number is assigned (T01, T02, etc.).
•Use appropriate tool length and diameter compensation (G43 H01 for tool length).
D. Feed and Speed Errors
•Problem: Improper feed rate (F) or spindle speed (S), causing poor surface finish or tool damage.
•Example:
•Too fast: F2000 on a delicate material → tool breakage.
•Too slow: F20 on a hard material → inefficient machining.
•Solution:
•Follow recommended cutting speed (S) and feed rate (F) based on material type.
•Use trial runs and adjust speeds accordingly.

E. Missing or Incorrect G/M Codes

•Problem: Missing essential preparatory (G) or miscellaneous (M) codes.
•Example:
•Forgetting M06 for tool change → Machine may not switch tools.
•Omitting M30 → Program may not stop correctly.
•Solution:
•Always include start and end commands in the program.
•Review all necessary G and M codes before execution.
Thank you