1.

INTRODUCTION

1.1 COMPUTER-AIDED MANUFACTURING

Computer-aided manufacturing (CAM) is the use of computer-based software

tools that assist engineers and machinists in manufacturing or prototyping product
components. Its primary purpose is to create a faster production process and components
with more precise dimensions and material consistency, which in some cases, uses only
the required amount of raw material (thus minimizing waste), while simultaneously
reducing energy consumption. CAM is a programming tool that makes it possible to
manufacture physical models using computer-aided design (CAD) programs. CAM
creates real life versions of components designed within a software package

CNC Technology
Numerical Control (NC) is a software-based machine tool control technique
developed at Massachusetts Institute of Technology (MIT) in early 1960s. It has now
evolved into a mature technology known as Computer Numerical Control (CNC).
Although major applications of CNC even today continue to be in machining, it finds
applications in other processes such as sheet metal working, non-traditional machining
and inspection. Robots and Rapid Prototyping machines are also CNC controlled. In
fact, any process that can be visualized as a sequence of motions and switching
functions can be controlled by CNC. These motions and switching functions are input in
the form of alphanumeric instructions. CNC is the basis of flexible automation which
helps industries cut down time-to-market and enables launch of even low volume
products. Unlimited muscle power, unmanned operation, independent axes coordinated
through software, simplified generic tooling even for the most complex jobs and
accurate construction are some of the salient features of CNC.

CNC Machining
Automats and Special Purpose Machines (SPMs) require special cams/ templates
and clutch settings for each part. Manufacture of these cams/ templates is costly and
slow. Furthermore, changing over from one part to the other on these machines also
consumes considerable time. The high cost and long time of these hard automated
machines to produce parts can be justified only in mass production. With the advent of

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 1

 fast, rigid and accurate CNC machines and sophisticated CAM packages, generation of
NC programs and change over from one product to the other are easy and fast as it does
not require any mechanical change. These in conjunction with advanced cutting tools
have made High Speed Cutting (HSC) of hard materials a reality. Therefore, CNC
machining has become a standard means to produce dies and molds; tool makers today
require EDM only for producing inaccessible regions, sharp corners, tiny features and
desired surface quality. Intricate aerospace parts are realized through 5 axis CNC
machining. Internet technology in a global village enables designing in one place, NC
programming and verification in another place and actual machining in yet another
place.

Advantages of CNC

Flexibility
Accuracy
Speed
Complicated shapes can be produced
Simplified fixturing and generic cutting tools
Low lead time for production
Storage of machining skill in CNC programs
Less skilled operators will do
Less fatigue to the operators

Limitations of CNC
Initial cost is high
Maintenance of CNC machines requires a high order of skill and trained
personnel
Higher initial maintenance cost and support cost

1.2 BASIC ELEMENTS OF COMPUTER NUMERICAL CONTROL

A CNC system consists of three basic components (shown in Fig.1):

1 . Part program
2 . Machine Control Unit (MCU)

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 2

3 . Machine tool (lathe, drill press, milling machine etc)

Fig. 1: A CNC System

Part program: The part program is a detailed set of commands to be followed by the
machine tool. Each command specifies a position in the cartesian coordinate system
(x,y,z) or motion (workpiece travel or cutting tool travel), machining parameters and
on/off function. Part programmers should be well versed with machine tools, machining
processes, effects of process variables and limitations of CNC controls. The part
program is written manually or by using computer assisted language such as APT
(Automated Programming Tool).

Controller Unit: The second major component of the CNC system is the Machine
controller unit(MCU). The MCU has to read and decode the part program, to provide the
decoded instructions to the control loops of the machine axes of motion and to control
the machine tool operation.
The MCU consists of two main units:
Data processing unit(DPU)
Control logic unit (CLU)

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 3

 Data processing unit (DPU): It decodes the information received from the program,
process it and provide data to the CLU. Such data contains the new required position of
each axis, its direction of motion and velocity and auxiliary control signals to relays.
Control logic unit (CLU): It provides the signal announcing that the previous segment is
completed and that the DPU can read at a new block of the part program. The CLU
operates the drives attached to the machine leadscrews and receives feedback signals on
the actual position and velocity of each one of the axes. Each lead screw is equipped
with a separate driving device and a separate feedback device, but the latter exists only
in closed-loop system.
In CNC systems, the DPU functions are always performed by the control program
contained in the CNC computer. The major part of the CLU, however, is always
implemented in hardware, even in most sophisticated CNC systems.

Machine Tool or Controlled Process:

The machine tool is the part of the CNC system which performs useful work. In
the most common example of an CNC system, one designed to perform machining
operations, the machine tool consists of the worktable and spindle as well as the motors
and controls necessary to drive them. It also includes the cutting tools, work fixtures and
other auxiliary equipment needed in the machining operation.

1.3 COORDINATE SYSTEMS AND MACHINE MOTIONS

To program a sequence of tool motions, we need a coordinate system and must
remember that programs are written as if the tool moves around the workpiece (even
though in most cases it is the workpiece that moves around the tool). All vertical CNC
milling machines use the same right hand coordinate system shown in Fig. 2. The z-axis
is always along the axis of spindle rotation, with the positive direction away from the
workpiece. The primary or longest travel direction of the table determines the x-axis and
the third or y-axis can be determined by the right hand rule.
This means that for the CNC milling the axes are:
X axis (table motion, +X to the right)
Y axis (saddle motion, +Y away from you)
Z axis (quill motion, +Z is up away from the workpiece table)

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 4

 Fig. 2: Right hand coordinates for vertical milling machines.

For the CNC lathe this means that the axes are (Fig.3):
X axis (motion perpendicular to the spindle, +X towards the operator)
Z axis (along the axis of the spindle, +Z away from the quill)
(Note that there are only two axis on a lathe so there is no Y)

Fig.3: CNC lathe coordinate system.

1.4 MANUAL PART PROGRAMMING

The preliminary steps in part programming always involves planning and

specifying the sequence of steps to be performed by the CNC machine. The geometry,
either in the form of an engineering drawing or a CAD model, is the starting point. Then
the cutting speeds and feed rates need to be determined, based on surface finish, forces,
or past experience. Next, the programmer specifies the path that the tool follows, taking
into account the fact that some features like, for example, a tapped hole require drilling
and tapping operations be programmed. This programming can be done either manually
or through computer assistance. In the computer assisted mode, the part programmer
specifies the geometry of the part through an interactive program and can define
material to be removed. The computer then automatically generates the program

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 5

 instructions for the CNC machine. In the manual method the programmer writes all the
lines of code from a detailed drawing. In manual part programming, the programmer
prepares the CNC code using the G and M Codes. Manual part programming can be
used for both point-to-point and contouring jobs. G codes control movement of the
machine, tool and coordinate setup, canned cycles. Canned cycles are built in routines
for automating common tasks, like drilling a hole. M or miscellaneous codes control the
spindle, coolant, tool changer, and other non-machining tasks.

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 6

 Introduction to G-codes
G-Codes or preparatory functions are functions in the Numerical control programming
language. The G-codes are the codes that position the tool and do the actual work, as
opposed to M-codes, that manages the machine, T for tool-related codes. S and F are
tool-Speed and tool-Feed. The programming language of Numerical Control (NC) is
sometimes informally called G-code. But in actuality, G-codes are only a part of the NC-
programming language that controls NC and CNC machine tools.

Commonly used G-codes for FANUC CNC MACHINES

1. G00 Positioning (Rapid Traverse)

2. G01 Linear Interpolation (Feed)
3. G02 Circular Interpolation (CW)
4. G03 - Circular Interpolation (CW)
5. G04 - Dwell
6. G28 reference point return
7. G40 tool nose radius compensation cancel
8. G41 tool nose radius compensation left
9. G42 tool nose radius compensation right
10. G70 - finishing cycle
11. G71 - stock removal in turning
12. G72 stock removal in facing
13. G73 pattern repeating
14. G74 - peck drilling
15. G76 thread cutting cycle
16. G81 - drilling cycle
17. G84 tapping cycle
18. G86 - boring cycle
19. G90 - absolute dimension program
20. G91 - incremental dimensions
21. G98 - feed per minute
22. G99 - feed per revolution

Miscellaneous Functions (M codes):

M codes are instructions describing functions like calling the tool, spindle
rotation, coolant on etc. The following M-codes which are commonly used for FANUC
machines

1. M00 - program stop

2. M02 - optional stop
3. M03 - spindle Forward (CW)
4. M04 - spindle Reverse (CCW)
DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 7
 5. M05 - spindle stop
6. M06 - tool change
7. M08 - coolant on
8. M09 - coolant off
9. M10 - chuck open
10. M11 - chuck close
11. M30 - program reset and rewind
12. M98 subprogram call
13. M99 - subprogram exit

1.5 PROGRAM BUILD UP FOR FANUC CNC LATHE

CNC program can be divided into 3 parts: Start up, Body and end of the program

Start up of CNC Program

O1000
[BILLET X20 Z60
G21/G20 G98/G99 G40
G28 U0 W0
M06 T0101
M03/M04 S1000
G00 X21 Z1

Explanation
O1000 While writing a program on FANUC controller first line has to be
started with letter O followed by four digit number specifies the
program name.
[BILLET X20 Z60 This directive is used only for simulation purpose. It defines the
work piece dimensions as 60 mm length and 20 mm diameter
G21/G20 G98/G99 G21- this code specifies that program is done in metric units
G40 Or
G20 this code specifies that program is done in imperial units
G98 gives the unit of feed in mm/minute
Or
G99 gives the unit of feed in mm/revolution
G40- compensation cancel
G28 U0 W0 Makes the tool to go home position. U & W are secondary
movements about x and z axis
M06 Tool change
DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 8
 T0101 The first two digits specify the tool position in the turret and last
two digits denotes the tool offset number
M03/M04 S1000 M03- makes the spindle rotate in clockwise direction
M04- makes the spindle to rotate in counter clockwise direction
S1000- spindle rotates at 1000 rpm
G00 X21 Z1 G00 gives rapid position of the tool to a point X21 Z1 which is
just above the billet. This point is called as the tool entry point.

Body of the Program: This part contains number of instructions which are required for
performing various operations.
End of Program
G28 U0 W0
M05
M02/M30
Explanation
G28 U0 W0 Makes the tool to go home position. U & W are secondary
movements about X and Z axis.
M05 Stop the spindle rotation
M02/M30 M02 Program end
M30 Program stop and rewind

Viva-Voce Questions
1. What are the difference between CAD and CAM?
2. Mention the major components of the CNC machine?
3. What is the expansion of FANUC?
4. What type of co-ordinate system used for CNC Lathe?
5. Explain about co-ordinate system for milling.
6. What is meant by G-Code?
7. What is the purpose of M-code?
8. Distinguish between absolute and incremental system?
9. What is the difference between workpiece zero point and machine zero point?
10. Distinguish between manual part programming and computer assisted part
programming.

2. CNC TURNING

2.1 LATHE JOB-1: SIMPLE FACING OPERATION

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 9

 Aim: To write a CNC manual part program for the job shown in Fig. 2.1 and simulate
the program using FANUC software.

Fig 2.1: Lathe Job 1

Requirement:
i) Pentium IV System
ii) FANUC programming software

Part program:
[BILLET X25 Z60
G21 G40 G98 Note:
G28- Go to reference point
N005 G28 U0 W0; M06- Tool change
N010 M06 T01; M03-Spindle rotation clock wise
G01-Linear interpolation
N015 M03 S1200;
G03-Circular interpolation (CCW)
N020 G00 X25 Z1; M05-Spindle stop
N025 G01 Z-0.5 F40; M02-Program end

N030 X0;
N035 X25;
N040 Z-1;
DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 10
 N045 X0;
N050 X25;
N055 Z-1.5;
N060 X0;
N065 X25;
N070 Z-2;
N075 G28 U0 W0;
N080 M05;
N085 M02;

Result: Thus the part program was written for the given job and simulation is
performed.

2.2 LATHE JOB-2: SIMPLE TURNING

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 11
 Aim: To write a CNC manual part program for the job shown in Fig. 2.2 and simulate
the program using FANUC software.

Fig. 2.2: Lathe Job-2

Requirement:
i) Pentium IV System
ii) FANUC programming software

Part program:
[BILLET X25 Z70
G21 G40 G99
N005 G28 U0 W0;
N010 M06 T01;
N015 M03 S1000;
N020 G00 X25 Z1;
N025 X23 ;
N030 G01 Z-20 F40;
N035 X25;
N040 G00 Z1;
N045 X21;
N050 G01 Z-20;
N055 X25;
N060 G00 Z1;
N065 X19;

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 12

 N070 G01 Z-20;
N075 X25;
N080 G00 Z1;
N085 X17;
N090 G01 Z-20;
N095 X25;
N100 G00 Z1;
N105 X15;
N110 G01 Z-20;
N115 X25;
N120 G00 Z1;
N125 X14;
N130 G01 Z-20;
N135 X25;
N140 G28 U0 W0;
N145 M05 ;
N150 M02;

Result: Thus the part program was written for the given job and simulation is
performed.

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 13

 2.3 LATHE JOB-3: STEP TURNING USING MULTIPLE TURNING CYCLE

Aim: To write a CNC manual part program for the job shown in Fig. 2.3 and simulate
the program using FANUC software.

Fig. 2.3: Lathe Job-3

Requirement:
i) Pentium IV System
ii) FANUC programming software

Part program: Multiple turned cycle[Canned cycle for turning]

G71 U(*u1) R (*r)
[BILLET X20 Z60 G71 P(*p) Q(*q) U(*U2) W(*W2) F(*f) s(*s) T(*t)
Where
G21 G40 G99 *u1 = depth of cut per pass
*r = Relief amount
N005 G28 U0 W0; *p =Block number at start point
N010 M06 T01; *q =Block number at end point
*u2 =Finishing allowance in the X-axis
N015 M03 S1000; *w2 = Finishing allowance in the Z-axis
*f = feed rate
N020 G00 X25 Z1; *s =speed
N025 G01 Z0; *t =tool number

N030 G71 U0.5 R1;

N035 G71 P40 Q60 U0.01 W0.01 F20;
N040 G01 X10;

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 14

 N045 Z-15;
N050 X15;
N055 Z-30
N060 X 20
N065 G28 U0 W0;
N070 M06 T02;
N075 M03 S1500;
N080 X20 Z1;
N085 G70 P10 Q60;
N090 G28 U0 W0;
N095 M05 ;
N100 M02;

Result: Thus the part program was written for the given job and simulation is
performed.

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 15

 2.4 LATHE JOB-4: LINEAR AND CIRCULAR INTERPOLATION

Aim: To write a CNC manual part program for the job shown in Fig. 2.4 and simulate
the program using FANUC software.

Fig. 2.4: Lathe Job-4

Requirement:
i) Pentium IV System
ii) FANUC programming software

Part program:

[BILLET X40 Z60

G21 G40 G98
N005 G28 U0 W0;
N010 M06 T01;
N015 M03 S1000;

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 16

 N020 G00 X40 Z1;
N025 G71 U0.5 R1;
N030 G71 P40 Q80 U0.1 W0.1 F35;
N035 G01 X5;
N040 Z0;
N045 X10 Z-10;
N050 Z-15;
N055 G02 X 25 Z-25 R10;
N060 G01 Z-30;
N065 G03 X35 Z-37 R10;
N070 G01 Z-42;
N075 X40 Z-47;
N080 G01 Z-52
N085 G28 U0 W0;
N090 M06 T02;
N095 M03 S1500;
N100 X20 Z1;
N105 G70 P10 Q60;
N110 G28 U0 W0;
N115 M05 ;
N120 M02;

Result: Thus the part program was written for the given job and simulation is
performed.

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 17

 2.5 LATHE JOB-5: INTERNAL OPERATION

Aim: To write a CNC manual part program for the job shown in Fig. 2.5 and simulate
the program using FANUC software.

Fig. 2.5: Lathe Job-5

Requirement:
i) Pentium IV System
ii) FANUC programming software

Part program:
[BILLET X50 Z100 G74-PECK DRILLING OPERATION
G74 R (*r1)
G21 G40 G98 G74 Z(W) Q(*q) R(*r2) F(*f)
N005 G28 U0 W0; Where
*r1 = relief amount
Z =total depth (absolute)
DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING,
W =total GUNTUR-19 18
depth (incremental)
*q =depth of cut
*r2 =relief amount of tool at the
bottom of work piece for drilling
this value is zero
*f =feed rate
 N010 M06 T01;
N015 M03 S1000;
N020 G00 X0 Z0;
N025 G74 R1;
N030 G74 X0 Z-79 P0 Q500 R0 F25;
N035 G28 U0 W0;
N040 M06 T02;
N045 M03 S1200
N050 G00 X12 Z1
N055 G71 U0.5 R1;
N060 G71 P65 Q100 U0.1 W0.1 F40;
N065 G01 X50;
N070 G02 X40 Z-8 R8;
N075 G01 Z-20;
N080 G03 X30 Z-25 R5;
N085 G01 X22 Z-45;
N090 G01 X20;
N095 Z-70;
N100 X12 Z-79;
N105 G28 U0 W0;
N110 M05 ;
N115 M02;

Result: Thus the part program was written for the given job and simulation is
performed.

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 19

 2.6 LATHE JOB-6: THREAD CUTTING

Aim:To write a CNC manual part program for the job shown in Fig. 2.6 and simulate
the program using FANUC software.

20

Fig. 2.6: Lathe Job-6

Requirement:
i) Pentium IV System
ii) FANUC programming software

Part program:

[BILLET X20 Z60

G21 G40 G98
N005 G28 U0 W0;

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 20

 N010 M06 T01;
N015 M03 S1000;
N020 G00 X20 Z1;
N025 G71 U0.5 R1;
N030 G71 P35 Q75 U0.1 W0.1 F35;
N035 G01 X11;
N040 X12 Z-1;
N045 Z-20;
N050 G02 X16 Z-30 R25;
N055 G01 Z-40;
N060 G03 X20 Z-50 R25;
N065 G01 Z-60;
N070 G28 U0 W0;
G76- Multiple threading cycle
N075 M06 T02; G76 P(m) (r) (a) Q(*q1) R(*r1)
G76 X(*x) Z(*z) P(*p2) Q (*q2) F(*f)
N080 M03 S1200; Where m =repetitive count finishing (1 to 99)
r =chamfering amount (0.01 to 9.9 l)
N085 X21 Z1; a =angle of tool tip
N090 P35 Q75; *q1 =min. Cutting depth
*r1 =finishing allowance
N095 G28 U0 W0; *x =finished depth of thread
*z =end position of thread
N100 M06 T03; *p2 =height of thread
N105 G00 X12 Z2; *q2 =depth of first cut
*f =lead or pitch of the thread
N110 G76 P031160 Q50 R0.1;
N115 X9.853 Z-18 P1073 Q250 R1.25;
N120 G28 U0 W0;
N125 M06 T04
N130 M03 S800
N135 G00 X12 Z-20
N140 G81 X11.5 F30
N145 X11
N150 X10.5
N155 X10
N160 X9.5
N165 G28 U0 W0;
N170 M05;

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 21

 N175 M02;

Result: Thus the part program was written for the given job and simulation is
performed.

Viva-Voce Questions

1. What are the important lathe operations?

2. Mention few important G codes?
3. What is the difference between G00 and G01codes?
4. Write about some important M codes?
5. How to change the tool in CNC program?
6. How to change the tool speed in CNC lathe?
7. How to make taper turning in lathe ?
8. What is meant by canned cycle?
9. What is the code for multiple turning cycle?
10. How to cut the threads in CNC lathe?

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 22

 LAB ASSIGNMENT-I(CNC TURNING)
Write the part programs to completely machine the parts shown below from
rolled stock and simulate the program using FANUC lathe software. Clearly
show the set point and axes on sketch of the part.

Fig. 1

Fig. 2

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 23

 Fig. 3

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 24

 3. CNC MILLING
3.1 MILLING JOB 1: LINEAR AND CIRCULAR INTERPOLATION-I

Aim : To write a CNC manual part program for the job shown in Fig. 3.1 and simulate
the program using FANUC mill software.

Fig. 3.1: Milling Job-1

Requirement:
i) Pentium IV System
ii) FANUC programming software

Part program:

[BILLET X100 Y100 Z20

[TOOLDEF T01 D5
[EDGEMOVE X-50 Y-50
N005 G28 U0 W0;
N010 M06 T01;
N015 M03 S2000;
N020 G00 X-22.5, Y-37.5 Z2;
N025 G01 Z-5 F20;
N030 G03 X-37.5 Y-22.5 R15;

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 25

 N035 G01 X-37.5 Y22.5;
N040 G03 X-22.5 Y37.5 R15;
N045 G01 X22.5 Y37.5;
N050 G02 X37.5 Y22.5 R15;
N055 G01 X37.5 Y-22.5;
N060 G03 X22.5 Y-37.5 R15;
N065 G01 X-22.5 Y-37.5;
N070 G01 Z2;
N075 G01 X-15 Y0;
N080 G01 Z-5 F20;
N085 G02 X15 R15;
N090 G02 X-15 R15;
N095 G01 Z2;
N100 G28 U0 W0;
N105 M05;
N110 M02;

Result: Thus manual part program was written for the given job and simulation is
performed.

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 26

 3.2 MILLING JOB-2: LINEAR AND CIRCULAR INTERPOLATION-II

Aim : To write a CNC manual part program for the job shown in Fig.3.2 and simulate
the program using FANUC mill software.

Fig.3.2 Milling Job-2

Requirement:
i) Pentium IV System
ii) FANUC programming software

Part program:
[BILLET X120 Y60 Z20
[TOOLDEF T01 D5
[EDGEMOVE X-62.5 Y-30
N005 G28 U0 W0;
N010 M06 T01;
N015 M03 S2000;
N020 G00 X-22.5, Y-12.5 Z2;
N025 G01 x-5 F20;
N030 G03 X-35 Y0 R12.5;
N035 G02 X-22.5 Y12.5 R12.5;

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 27

 N040 G01 X22.5 Y12.5;
N045 G02 X35 Y0 R12.5;
N050 G02 X22.5 Y-12.5 R12.5;
N055 G01 X22.5 Y-12.5;
N060 G02 Z2;
N065 G28 U0 W0;
N070 M05;
N075 M02;

Result: Thus manual part program was written for the given job and simulation is
performed.

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 28

 3.3 MILLING JOB-3: RECTANGULAR POCKETING WITH CIRCULAR
LAND

Aim : To write a CNC manual part program for the job shown in Fig. 3.3 and simulate
the program using FANUC mill software.

Fig.3.3 Milling Job-3

Requirement:
i) Pentium IV System
ii) FANUC programming software

Part program:
[BILLET X90 Y90 Z30
[TOOLDEF T01 D20
[TOOLDEF T01 D5

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 29

 [EDGEMOVE X0 Y0
N005 G28 ;
N010 M06 T01;
N015 G42;
N020 M03 S1200;
N025 G00 X35 Y45 Z5;
N030 G01 Z-10;
N035 G03 X55 Y45 Z5;
N040 G03 X35;
N045 G01 X20;
N050 Y60;
N055 X20;
N060 Y10;
N065 X75;
N070 Y72;
N075 X10;
N080 Y80;
N085 X85;
N090 X90;
N095 G28 U0 W0;
N100 M06 T02;
N105 M03 S1200;
N110 G00 X10 Y15 Z5;
N115 G01 Z-20;
N120 X80;
N125 Y75;
N130 X10;
N135 Y15;
N140 G28 U0 W0;
N145 M06 T01;
N150 M03 S1200;
N155 G42;
N160 G00 X35 Y45 Z5;

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 30

 N165 G01 Z-20;
N170 G03 X55 Y45 R10;
N175 G03 X35;
N180 G01 Y32;
N185 Y60;
N190 G28;
N195 X30;
N200 Y32;
N205 X63;
N210 G28 U0 W0;
N215 M06 T02;
N220 M03 S1200;
N225 G00 X12 Y19 Z5;
N230 G01 Z-20;
N235 X78;
N240 Y72;
N245 X14;
N250 X20;
N255 G28;
N260 M05;
N265 M02;

Result: Thus manual part program was written for the given job and simulation is
performed.

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 31

 3.4 MILLING JOB- 4: CIRCULAR POCKETING WITH RECTANGULAR
LAND

Aim : To write a CNC manual part program for the job shown in Fig. 3.4 and simulate
the program using FANUC mill software.

Fig.3.4 Milling Job-4

Requirement:
i) Pentium IV System
ii) FANUC programming software

Part program:
DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 32
 [BILLET X90 Y90 Z30
[TOOLDEF T01 D20
[EDGEMOVE X0 Y0
N005 G28 U0 W0 ;
N010 M06 T01;
N015 M03 S2000;
N020 G42;
N025 G00 X37.5 Y35;
N030 G01 Z-10;
N035 G01 X52.5 Y35;
N040 Y55;
N045 X37.5 Y55;
N050 Y35;
N055 X30 Y20;
N060 X62.5 Y20;
N065 Y65;
N070 X30 Y65;
N075 X30 Y20;
N080 X20 Y10;
N085 X70 Y10;
N090 X70 Y70;
N095 X20 Y70;
N100 X20 Y10;
N105 X10 Y10;
N110 X75 Y10;
N115 X75 Y80;
N120 X125 Y80;
N125 X10 Y10;
N130 Z5;
N135 G28 U0 W0;
N140 M05;
N145 M02;

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 33

 Result: Thus manual part program was written for the given job and simulation is
performed.

3.5 MILLING JOB 5: CIRCULAR POCKETING

Aim : To write a CNC manual part program for the job shown in Fig. 3.5and simulate
the program using FANUC mill software.

Fig.3.5 Milling Job-5

Requirement:
i) Pentium IV System
ii) FANUC programming software
CIRCULAR POCKETING CYCLE
Part program: G170 R(*r1) P(*p1) Q(*q1) X(*x1) Y(*y1) Z(*z1)I(*i1)
J(*j1) K(*k1)
[BILLET X90 Y90 Z20 G172 P(*p2) S(*s2) R(*r2) F(*f2) B(*b2) J(*j2)
Where
[TOOLDEF T01 D12 *r1=position of tool to start cycle i.e, for flat surface, *r=0
[EDGEMOVE X-45 Y-45 *p1=0 (roughing), 1(for finishing)
*q1=peck increment for each cut (always a positive value)
N005 G28 U0 W0; *x1,*y1,*z1= coordinate or centre of circular pocket
*i1=finishing allowance for side
N010 M06 T01; *j1= finishing allowance for pocket base
*k1=radius of circular pocket (positive value for clockwise arc)
N015 M03 S1200;
*p2=cutter movement % for next step (ex: 50,75)
*s2=roughing spindle speed, r.p.m
*r2=R.V.R.
DEPARTMENT OF MECHANICAL ENGINEERING, roughing in z direction
& J.C.COLLEGE for eachGUNTUR-19
OF ENGINEERING, cut 34
*f2= roughing feed in xy direction, for each cut,
mm/min
*b2=finish spindle speed, r.p.m
*j2=finishing speed, mm/min
 N020 G170 R0 P0 Q3
X0 Y0 Z-5;
N025 G171 P75 S1200
R75 F250;
N030 G28 U0 W0;
N035 M05;
N040 M02;
Result: Thus manual part program was written for the given job and simulation is
performed.
3.6 MILLING JOB 6: RECTANGULAR POCKETING

Aim : To write a CNC manual part program for the job shown in Fig. 3.6 and simulate
the program using FANUC mill software.

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 35

 Fig.3.6 Milling Job-6

Requirement:
i) Pentium IV System
ii) FANUC programming software

Part program:
RECTANGULAR POCKETING CYCLE
[BILLET X90 Y90 Z20 G172 I(*i1) J(*j1) K(*k1) P(*p1) Q(*q1) R(*r1) X(*x1)
Y(*y1) Z(*z1)
[TOOLDEF T01 D12 G173 I(*i2) K(*k2) P(*p2) S(*s2) R(*r2) F(*f2) B(*b2) J(*j2)
Z(*z2)
[EDGEMOVE X-45 Y-45 Where
N005 G28 U0 W0; *i1=length of pocket in X direction
*j1= length of pocket in Z direction
N010 M06 T01; *k1=corner radius zero always
*p1=0(roughing), 1(finishing)
N015 M03 S1200; *q1=depth of cut for each pass
*r1=absolute depth from surface (Z, R point)
N020 G172 I50 J50 K0
*x1=pocket corner X
P0 Q3 R0 X25 Y25 Z5; *y1= pocket corner Y
*z1=absolute Z base or pocket
N025 G01 Z2; *i2=pocket side finish allowance
*k2= pocket base finish allowance
N030 G28 U0 W0; *p2=cutter width % (50, 75 etc.,)
N035 M05; *s2=spindle speed in r.p.m
*r2=roughing feed in z, mm/min
N040 M02; *f2= roughing feed in x,y, mm/min
*b2=finishing spindle speed in r.p.m
*j2=finish speed in mm/min
*z2=safety z position

Result: Thus manual part program was written for the given job and simulation is
performed.

Viva-Voce Questions

1. What are the important milling operations?

2. Mention few important G codes for milling?

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 36

 3. What are the axes to be considered while writing program for CNC milling?
4. What is the file extension of CNC program?
5. What are the codes for coolants on or off?
6. What is the g code for circular pocketing?
7. How to change the depth of cut in milling operation?
8. What is the g code for rectangular pocketing?
9. What are the functional keys use in FANUC programming?
10. What is use of dry run option?

LAB ASSIGNMENT II (CNC MILLING)

Write the part program for machining of parts shown in Fig. 1 to 3 on a CNC
machining centre and simulate the program using FANUC mill software. Clearly
show the set points and axes on the sketch of the part. Show all the necessary
calculations.

Fig. 1

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 37

 Fig. 2

Fig. 3

DEPARTMENT OF MECHANICAL ENGINEERING, R.V.R. & J.C.COLLEGE OF ENGINEERING, GUNTUR-19 38