CNC MILL TRAINER

POWER MILL
MODEL SS-PM-200

ACTIVITY MANUAL
FOR
MACHINE OPERATION
SOFTWARE CONTROLS
MAINTENANCE

1
 CONTENTS

INTRODUCTION 3

TECHNICAL SPECIFICATION 6

CONTROL PANEL INDICATIONS 9

SYSTEM CONFIGURATION 11

CNC CONTROL SOFTWARE 14

PART PROGRAMMING CODES 26

MAINTENANCE 41

2
 INTRODUCTION

AIM OF LEARNING CNC TRAINER OPERATIONS

 TO GET FAMILIAR WITH BASIC OPERATIONS OF CNC

MACHINES.

 TO KNOW THE THEOROTICAL & PRACTICAL CONCEPTS OF

CNC MACHINE.

 TO LEARN BASIC CONCEPT OF CNC PART PROGRAMMING.

 THE MOST IMPORTANT IS TO INCREASE THE CONFIDANCE

OF THE USER.

 TO UNDERSTAND THE BASIC WORKING PRINCIPLE OF CNC

SYSTEM, ELECTRONIC, SOFTWARE, MECHANICAL SYSTEM.

3
 SAFETY PRECAUTIONS

1. Never attempt to machine a workpiece without first checking the

operation of the trainer. Before starting a trainer, ensure that the trial run
is ok by operating the trainer with neither a tool nor workpiece mounted.

2. Operating the trainer with incorrect data may result in damage

to the workpiece &trainer or injury to the user.

3. Before attempting to perform programming, read this manual

carefully to operate the trainer safely.

4. Coordinate setting is very important factor while operating the

CNC trainer. Incorrect coordinates may damage the tool, the
machine, or user.

5. When performing positioning, the tool path must be carefully

confirmed before performing programming.

6. Before giving numerical i/p command determine the current

position of the tool & workpiece & ensure the axis, direction &
command have been specified correctly & the entered values are
valid.

7. Do Lubrication once in a week.

8. It is very dangerous to touch any rotating part of the machine,

NEVER attempt to remove swart whilst the machine is in
Motion.

9. After setting tools, perform trial cut using manual operation.

10. Remember to use tool offsets to avoid machining errors.

4
11. Never clean the machine or its attachments when the
machine is running.

12. When an emergency stop is required press the EMERGENCY

STOP red keys switch on the front of the machine, this will cut
power to the spindle and the axis drives.

13. Earthing is one of the most important thing for proper

working of machine & controller. Check periodically the voltage
between Neutral & Earth of the incoming single phase 230 V AC
supply. The voltage should not be more than 2 to 3 Volts. If it is
more than this please get it done.

SAFETY FUNCTION

 Key operated isolator switch.

 Emergency Stop.

 Totally Covered machine guard.

 Axes Limit Switches.

 Graphics Facility for proving programs prior to machining.

5
 CNC Machining Curriculum

CNC Machine Application & Part Programming Training

This curriculum holds different lessons layouts for CNC Lathe

machine. This will give you an idea about CNC Machine
Applications, machining & programming concepts using CNC
Simulation & Control Software. Using CNC machines the training
is divided into – CNC Basic, Exercises & Job Trails. Students will
use the machine to get use of co-ordinate system, learn the
industrial CNC controller programming codes to create the CNC
Program. The teach- ware will help with diagram, program
example to assist the student to complete the task using the
programming codes. Skill acquired is directly transferable to
today’s industrial machines & software.

General Topics:
1. CNC Programming codes & co-ordinate system.
2. Safety operations
3. Machine operations.
4. Lathe Introduction & usage.
5. Tooling for different operations & their off-sets.

6
How is the CNC Training system physical flow in teaching CNC?

Student CNC Teach ware about

With Zero CNC Basics, Simulation
Knowledge Programming &
in CNC Machining

CNC Machining

7
 CNC Lathe Introduction & Training

The following lesson outline indicates the primary

tasks individuals will be able to perform upon completion of each
lesson. The information that is required is to be learned.
The training system is designed to accommodate the
various Lathe operations & the programming codes used by
Fanuc-0T model. The instructional technique employed will
enable individuals to setup & operate the many configurations of
Lathes & CNC controls with little difficulty.

Lesson 1
Primary Components & Controls
After completing this lesson, the student would able to:
1. Explain how the CNC control directs the movements of the
Lathe.
2. Locate & name the basic component of a lathe equipped
with different control.
3. Jog the tool in each axis & define the co-ordinates based on
sign.
4. Use the various menus of the CNC software
5. Identify &explain the basic CNC operations.
6. Turn on Spindle in Clockwise & Counter- Clockwise
directions for simple linear cutting.

8
 Lesson 2
Reading Machine Information
After completing this lesson, the student would able to:
1. Display machine status on machine.
2. Read machine movement co-ordinates, feedrate, spindle,
cutting speed & G code information.
3. Use machine Jog for various tool speeds.
4. Rotate the Turret for various tool clamping.
5. Select the Auto mode for program execution.
6. Use the editor for writing the CNC Program.

Lesson 3
Setting the Lathe operation for Job Trials
After completing this lesson, the student would able to:
1. Define & explain the machine zero point for tool.
2. Consider the depth of cut & total material removal for the
job.
3. Select the proper tool for various operations like Turning
Drilling, Threading, Parting etc.
4. Calculate the tool offsets for all the required tools.

Lesson 4
Make the Program for required Job
After completing this lesson, the student would able to:
1. Understand the programming format for Fanuc controller.
2. Understand the procedure for writing the program.
3. Locate & explain the purpose of G,M,S,F,T & other block
codes.
4. Verify the program in Simulation mode before the execution
on the machine.
5. Learn the various canned cycles like G70, G71, G72, G73,
G74, and G92.
6. Able to modify or correct the program if system gives some
error for the program.
7. Verify the job trail in single block mode.

9
 Lesson 5
Machining Process Analysis

After completing this lesson, the student would able to:

1. Understand &Identify information such as:
a. Single tool change &machining time.
b. Overall machining time.
c. Material removal rate & volume.
d. Overall report for the particular exercises.
2. Determine the problems from point of production such as
machining time too long, too much waste material &
programmed too long tools travel path & etc.
3. Re-simulate & analyze the correct & require machining
conditions.
4. Print the program & its 2D simulation output for further
study.
Lesson 6
Integrate CAD & CAM into CNC Machining
After completing this lesson, the student would able to:
1. Understand the definition of CAD (Computer Aided Design)
2. Able to create simple drawing by standard geometry
technique
a. Line
b. Circle
c. Dimensioning
d. Absolute / Incremental co-ordinate system.
3. Understand the definition of CAM (Computer Aided
Manufacturing)
4. Study & follow the CNC commands for various operations
such as:
a. Longitudinal roughing cycle
b. Cross roughing cycle
c. Multiple Pass cycle.
d. Auto-Finishing cycle.
e. Threading.
5. Understand CAM system information
a. Tool changed.
b. Constant cutting speed.
c. RPM / Feed / Coolant
d. Finishing allowances
e. Machining data, total depth, single cut depth, return
tool travel, dwell time etc.
10
 How is The CNC System Flow?

Job Automati CNC

Drawing c Help
Study

LATHE
Initial Setup
1. Machine Setup M
Single
Block Machining
SIMULATION
2. Material / Work
piece
3. Tool Selection
4. Tool Offsets

Teach Tool3-D
In View
Trace

Save Data in CNC

Software

11
 TECHNICAL
SPECIFICATION

STANDARD EQUIPMENT & ACCESSORIES

12
  SS-PM-200 CNC MILL TRAINER.

 6 STATION AUTOMATIC TOOL CHANGER

 ONE SHOT AUTOMATIC LUBRICATION SYSTEM

 1.5 HP SPINDLE MOTOR

 3 KVA SERVO STABILISER

 PERSONAL COMPUTER

 ALLEN KEYS & SPANNER SET

 ONE SET OF DIFFERENT TOOL HOLDER

CNC MILL SOFTWARE: CNC PROGRAMMING, SIMULATION &

MACHINE CONTROL SOFTWARE.

13
 CNC MILL TRAINER SPECIFICATIONS

MODEL NO. : SS-PM-200

Mechanical Specifications
TABLE
Size 500 mm x 175 mm
Three T slots 10 mm slot width

TRAVEL
Longitudinal (X axis) Travel 200 mm
Cross (Y axis) Travel 160 mm
Vertical (Z axis) Travel 175 mm

SPINDLE
Spindle Nose ISO 30
Speed 50 to 3000 rpm.
Spindle to table 225mm
Spindle to column 170mm

Resolution: 0.005 mm

Position accuracy: 0.020mm

Controller Details
Control system PC Based
X and Y axis Stepper motor 20 Kg-Cm
Z axis Stepper motor 28 Kg-Cm
Spindle Motor 1.5 HP, PMDC motor.
Emergency stop facility By Hardware and Software

NOTE :

Power Supply Single phase 230 V AC, 12 Amp.

Operating Temperature 0 to 50°C
Humidity Below 80%

14
CONTROL PANEL
INDICATIONS

15
 FRONT PANEL INDICATIONS & SWITCHES

INDICATIONS:

- Mains ON (Red `ON’ lamp)

When the key switch is turned ON, this lamp will glow.

- Spindle ON (Green lamp)

It will glow when the spindle is turned ON to move in
turned forward direction through program or in JOG
mode.

- Manual Clamp (Yellow Push Button)

This button is used to Clamp or release the tool. This
button is activated only in Jog mode.

- Emergency Stop (Red lamp)

This lamp will glow when somebody presses the
Emergency stop switch on front panel. It indicates that
there is no power supply to the machine motors & other
circuit. If you run the program you will get ‘Power
Failure ‘ message.

SWITCHES

1) Mains ON switch:
This switch is used to turn on the main supply. Now the computer is
to be started.

2) CNC ON Switch:
This switch will start the supply to the stepper motor, Spindle motor
& other electronic circuits. But remember to switch ON this only after
the PC is started.

3) Emergency Stop Switch (Red colour):

This is a Press-To-Lock switch. These will cut-off the machines
supply but the computer will not be off.

16
 SYSTEM
CONFIGURATION

17
 SYSTEM CONFIGURATION

SQUARE SYSTEMS make CNC Mill is the Computer Numerically Controlled

Mill Trainer. This Machine Tool system has following configurations.

 Machine is as per Mechanical Specifications specified in Manual.

 Machine Controller consists of,

Pentium IV (866 MHz) with preinstalled Windows-XP along with CNC
Mill Software.
128 MB RAM
40 GB HDD
SVGA Color Monitor
Keyboard & Mouse
I/O interface card. (Inside PC)

 Electronic Stabilizer
Capacity - 3KVA
Regulation 1%
Voltage 230V
Current - 14 Amp.
Freq.- 50 Hz.

 D.C Spindle Drive

Capacity – 1.5HP
Voltage 180 V D.C.
Current - 9 Amps.

 DC Spindle Motor
Capacity – 1.5 HP
Voltage 180 V D.C.
Current - 9 Amp.
RPM-3000

 Lubrication motor
Voltage 230V
Current - 1 Amp.
Operating Pressure: 6 -15 Kg/Cm2
 X,Y & Z Axes Stepper motor
Capacity – 20 KG-CM for X, Y Axis & 28 KG-CM for Z Axis.
Operating Voltage 36 V DC
O/P Current - 4 Amp.
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 Power Supply
Input 230 V, 5 Amps.
Output 24V, 2 Amp.
5V, 2 Amp, 15/0/-15V 500 mA

 SPECIFICATIONS OF I/O CARD: (PCI 1751)

I/O Controller - 8255-2
Slot for connection – PCI slot on the motherboard pf the PC.
I/O Lines – 32 output & 16 inputs.

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SYSTEM CONTROL
SOFTWARE

20
 SYSTEM CONTROL SOFTWARE

Square Systems has built its own CNC controller for CNC Mill .All the
software and hardware for CNC Mill is indigenously developed and tested
according to industry norms. Software for controlling the CNC machine is
written in dot net & ‘VB’ languages. Software is WINDOWS based as real
time control of hardware is developed in Windows based system. The
master controller in this system is the PC itself. Software is user friendly
and allows the user to use Pointing device for selection of menus and
parameters. It is developed as a full GUI package.

In CNC Mill Machine, the computer controls each operation. There is a

communication link between actual machine and the computer. A
computer sends command to the Machine controller as well as it receives
the status of machine and its operations at the same time.

To control the machine operations, software makes the use of I/O

channels supplied with computer using I/O card. Input and output
commands from computer are routed through the I/O card to the
controller and then to actual machine. Software reads the status of
machine in real time.

Software is fully menu driven for ease in learning. The Display and
functions are arranged in the same way as regular CNC machine console.
The functions and facilities that are included in the software are as follows,
After loading the software it performs the self-diagnostics as well as the
machine diagnostics. If there is any kind of malfunctioning it will display
the Error Alarms and will guide the user.

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Features of Windows based CNC-Mill software
1) Powerful Graphic user interface.

2) All the programming codes are compatible to the

Fanuc–0M model.

3) 2-D simulation

4) Program editing facility.

5) Program execution in Auto, Single Block mode.

6) Program Pause, Resume & Stop facility.

7) Programmable Delay.

8) Print option with 2-D simulation & program.

9) Various canned cycles.

10) Tool Offsets for 6 tools.

11) Dry Run facility.

12) On line information about File name, Spindle

speed, Tool No., Feed etc.

13) On line programming help facility.

14) Programmable Hardware addresses.

15) Comments in the program can be added by ‘ (‘

bracket.

16) Manual Data Input facility.

17) Automatic Job diameter & length setting by

“#BILLET” command.

22
About CNC Mill Software installation
This is windows based simulation software for the CNC Mill machine,
developed by SQUARE SYSTEMS. The system requirement for this is
Windows XP.
The software is already installed on the PC supplied with the machine. In
this folder you will find CNC Milling file, which is an .exe file. Double click
on this file.
About CNC Mill software:
To run the software the EXE file is CNC Milling. It will take you to
the main screen of the software as shown below.

23
You will see various menus here.
The menus at the top:
The main menus of this software are File, Program and Settings
FILE MENU
When file menu is selected the following screen is displayed.

Here you can see various menus, which are very similar to the normal
menus seen in MS-Office or other software’s. With New you can create a
blank file, which is seen in the editor window. Now you can start writing
the CNC program. You can save the program by giving a name & the
location. The already saved program in the memory can be seen by Open
menu. The loaded file can be saved by another name with Save As menu.
The printing option is somewhat different from the regular pattern. Here
first the program should be executed then print command is given. So in
printout you will see the final 2D shape of the job & the program below
that.

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 FILE\OPEN MENU

PROGRAM\OPEN\EDIT MENU
The Edit menu is used mainly to modify the program. It has the various
menus such as Undo, Cut, Copy and Paste. It is activated only after a
program is loaded.

25
 PROGRAM MENU
The Program menu has different options, which can be seen in the
following picture:

By Run (Hotkey F5) the program simulation can be seen. The software is
in simulation mode by default whenever the software is started. In Auto
execution all the program lines are executed one by one till the Program
End command.

In Run Selected the selected lines are executed

The other menus such as Pause, Resume, and Stop are used during
program execution. With Pause the program is stopped & can be started
from the same point again by Resume. But with Stop menu the program is
stopped. If you start the program then it will start from the first block.

26
 SETTINGS MENU
The Settings menu is seen like this:

1. Billet Menu: This menu is used to define the work piece size. This is
used mainly for simulation purpose. According to the program the
maximum X, Y & Z values has to be entered so that the simulation is
seen properly.
2. View Menu: By this menu the user can select the required plane. The
various menus are Top View ( XY Plane), Side view ( XZ Plane),
Another side view ( YZ Plane) & the isometric view.
Jog MENU
But before machining the initial Job & Tool setting has to be carried out.
For that Machine Configuration menu has to be selected which is seen like
this:

This is the JOG mode.

27
 The X, Y & Z co-ordinates seen are Editable. The current co-
ordinates are nothing but the current tool position. This position can be
changed here
The tool change can take place by selecting the tool no.s from 1 to 6
from Tool no. Window.
The spindle motor can be started by selecting Spindle Direction.
Similarly Lubrication motors can be started to check their
functionality. The lubrication motor is automatically started after one hour
whenever the software is started. The motor ON timing can be set in the
Time window.

Axis direction Buttons

-Y
+Z
+X -X

+Y -Z

By these keys the user can move the axis independently so as to define
the center or the starting point of the job.
According to pulses the stepper motors moves with the feedrate, which
can be set from the Jog feed rate window. When the tool is near to the
job, the pulses have to be reduced so that the motor’s movement is
reduced.
The MDI (Manual Data Input) menu is used to execute a single line
command. This is normally used to check the functionality of axes or
spindle.

28
 Program Mode
By default the software is in Simulate mode. So whenever a program is
executed only simulation is seen. The Execute & Simulation mode is used
when actually Job has to be carried out on the machine. In this mode on
line simulation is also seen. So the general practice is that the user should
write a program or load a program then first see the simulation. If the
required output is OK then the user should go for machining.

Cycle Mode

The simulation or the execution can be carried out in Auto or Single block
mode with this menu. In Auto mode all the lines are executed one by one
till the program end. But in Single block mode only a single line is
executed. The software will wait for user interference. By pressing Enter
key next line will be executed. The user can switch the control from Single
line to Auto mode.
TOOLS INFO MENU
In this you can edit the various tool’s information. The information of the
tool dia. & length of the tools which are going to be used can be entered
here so as to use multiple tools in a program. The tool offsets are
calculated by the software with the help of this menu.

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 MAIN SCREEN DETAILS

The above image shows the simulation of a program. The left

window on the upper side shows the 2D shape of the job. This shows the
online simulation of the job according to the program.
The left bottom window is the status window. It shows the
information about the X, Y, Z values of the tool position plus the current
tool no., Feed rate etc. These values are updated during the program
execution.
The Feed rate window is used during the machining. This is useful to
change the Feed during the cutting operations.
The Right side window is the Program window. This will show the
current loaded program. When the program is executed the current
executing line is highlighted & the program is scrolled.

30
 PART
PROGRAMMING CODES

31
 G-CODE

SR. CODE FUNCTION

1. G00 POINT TO POINT POSITIONING

2. G01 LINEAR INTERPOLATION.

3. G02 CIRCULAR INTERPOLATION Arc CW.

4. G03 CIRCULAR INTERPOLATION Arc CCW.

5. G04 DWELL IN SECONDS.

6. G12 CIRCULAR POCKETING CLOCKWISE

7. G13 CIRCULAR POCKETING ANTICLOCKWISE

8. G15 P.C.D. DRILLING CANCEL

9. G16 P.C.D. DRILLING CYCLE

10. G17 X-Y PLANE SELECTION FOR ARC MOVEMENT.

1

11. G18 Z-X PLANE SELECTION FOR ARC MOVEMENT.

1

12. G19 Y-Z PLANE SELECTION FOR ARC MOVEMENT.

1

13. G51 SCALING FACTOR

1

14. G52 CANCEL G51

1

15. G70 INCH PROGRAMMING

1

16. G71 METRIC PROGRAMMING

1

17. G81 FIXED CYCLE NO.1 DRILL, SPOT DRILL

32
1

18. G82 FIXED CYCLE NO.2 DRILL, COUNTERBORE

1

19. G83 FIXED CYCLE NO.3 DRILL, DEEP HOLE

1

20. G90 ABSOLUTE DIMENSION INPUT

2

21. G91 INCREMENTAL DIMENSION INPUT

2

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 M-CODE
1. M00 PROGRAM STOP.

2. M01 OPTIONAL PROGRAM STOP

3. M02 PROGRAM END

4. M03 SPINDLE MOTOR ON & NORMAL CLOCKWISE

5. M04 SPINDLE MOTOR ON & REVERSE

ANTICLOCKWISE
6. M05 SPINDLE MOTOR OFF.

7. M06 AUTOMATIC TOOL CHANGE

8. M21 MIRROR IMAGE ALONG X AXIS

9. M22 MIRROR IMAGE ALONG Y AXIS

10. M23 MIRROR IMAGE CANCEL

3

11. M30 PROGRAM END & REWIND.

3

12. M98 SUBPROGRAM CALL WITH PROGRAM NO. P

3

13. M99 SUBPROGRAM END

3

34
 CNC Programming Basics

A CNC program comprises a series of commands with which the CNC

Machine tool is instructed to manufacture a certain profile.
For each machining process on a CNC machine, the CNC program
has a command with relevant information. This command consists of
letters, numbers & characters.

CNC Programming Standards (ISO)

The ISO- Norm 6983 is for standardizing the CNC programming of

machines. This is however limited to standardizing certain commands as
well the general structure of a CNC program. CNC manufacturers have
considerable liberty for incorporating their own CNC commands in their
control. Sequentially the general structure of a CNC program according to
ISO 6983 is illustrated.

Structure of a CNC Program

The first line of the CNC program contains the program name
(ex. G02-dia 25). This name can contain alphanumerical or numerical
characters.
A CNC program consists of a sequence of blocks. They contain the
relevant geometric & technical information that the CNC control requires
for each machining step.
The program end is commanded with M30 or M02.
The comments are also allowed within the program for identifying an
operation. These however must be set in brackets.

35
 Structure of a Program Block

Every CNC block consists of a block number as well as specific control

character, which inform the CNC Control about the necessary action to be
performed.

Structure of a Program Word

A word consists of a address letters & a number with a
plus or minus sign. The definition & sequence are designated
in the programming instructions of the CNC control system.
Depending upon the address letter, the number either has a
code or a value.

36
 Block number N :
The block number is the first word in a block.
The block number has no influence on the execution of the
individual blocks since they are invoked following the order in
which they were entered into the control.
G – Function :
Together with the words for the co-
ordinates. This word essentially determines the geometrical
part of the CNC program. It consists of the address letter G
& a 2 digit code.
Co-ordinates X & Z :
The co-ordinates X, Z defines the target
points that are needed to travel.
Interpolation parameters I & K :
The interpolation parameters I, K are used to
define the center of a circle for circular movements.
Feed F :
The speed at which the tool is to be moved is
programmed with the function F. This value in entered in
mm/min.
Spindle Speed S :
The function S is for entering the spindle
speed. It can be directly programmed in rotations per
minute.

37
 G and M
PROGRAMMING CODES
In Detail

38
 G & M CODES IN DETAIL

Part Programming codes that are available with this machine are
according to the latest ISO standards and adopted by the Industrial CNC
controller manufacturers worldwide. Following G, M, F, and T, S
commands are included in this controller.
G - CODES

G00 - RAPID TRAVERSE ( Rapid Positioning )

This motion type is used to command motion at the machine's fastest

possible rate. It is used to minimize non-productive time during the
machining cycle. Common uses for rapid motion include positioning the
tool to and from cutting positions, moving to clear clamps and other
obstructions, and in general, any non-cutting motion during the program.
The command almost all CNC machines use to initiate rapid motion is G00.
Within the G00 command, the end point for the motion is given .

The G00 command moves the tool to the position in the work piece
coordinate system with an absolute or incremental format at a rapid
traverse rate.

In the Absolute format command, Coordinate value of the end point is

programmed. In Incremental format command, the distance the tool is to
be moved is programmed.
In this case last command for respective axis will be considered. i.e. X
command will be ignored and U command will be executed. No Feedrate
(F Word) is required to be programmed as it is taken from internally set
values.

Format : G00 X __ Y__ Z __

NOTE: The rapid traverse rate in the G00 command is set

internally for each axis drive. In the Positioning mode actuated by
G00, the tool is accelerated to a predetermined speed at the start
of block and it is then decelerated at the end of the block.
As this is a trainer machine double axis movement in G00 is not
possible. If both X & Z values are given in G00 code, first X-axis
movement will take place & then Z.

39
Example :
If present tool position is X = 0,Z = 0 & the required tool position is Z =
-30, the program code is as follows,
G00 X30
G00 Z-30

Thus tool will move from X=0 mm to X = 30 mm and then it will have Z-
axis movement from Z=0 to Z=-30 mm with rapid travel. There is no
machining action in G00 cycle. It is purely rapid positioning cycle.

There is no machining action in G00 cycle. It is

purely rapid positioning cycle for Tool. Here double
axis movement is not possible. This code is not used
for any cutting operation.

40
 G01 - LINEAR INTERPOLATION

A G01 word is commonly used to specify straight-line motion. This is the

most common code used for almost all the cutting operations. In this code
single axis (individual) as well as double axis movement is possible. Double
axis movement is used for taper turning operation.

The G01 command moves the tool to the position in the work piece
coordinate system with an absolute or incremental format at a
programmed feed rate in the straight line.

In the Absolute format command, Coordinate value of the end point is

programmed. In Incremental format command the distance the tool is to
be moved is programmed.

The tool moves from the current position at the specified feed rate (F) to
the final position .The tool path is a direct straight line joining current
position to final position. This code is useful for OD/ID/face turning, also
for taper turning.

Format: G01 X__Y__Z__ F__

Here F is feed rate (tool movement speed) given in mm/min. As this code
is used for cutting operation the value of F is very less that has to be
decided according to the material of job.

41
 G02 - CIRCULAR INTERPOLATION (CLOCKWISE)

The G02 command is utilized to move the tool in the circular arc profile.
With G02 the movement will be in the Clockwise direction. The movement
taken will be at the programmed feed rate
. Arcs can be specified by either by radius or Arc Center.

Format: G02 X__Y__ Z__ I__ J__K__ F__

G02 X__Y__ Z__ R__ F__

Here in first syntax,

I = Distance between start point & center point of arc along X-axis.
J= Distance between start point & center point of arc along Y-axis.
K= Distance between start point & center point of arc along Z-axis.

& In second syntax

R = Radius of the arc.

Example:
To machine the radius of 10mm in XY plane, starting from center point i.e.
X=0, Y=0 up to the depth of 1mm.Following program code is used.

Example: G02 X0 Y20 R15 F80

Here The Tool is Moved to X 30mm, Y 20mm.

The Arc has a Radius of 15mm."I" and "J" specify the arc center relative
To the arc start. If the value is 0, then it needn't be specified.

Example: G02 X30 I15

42
 G03 - CIRCULAR INTERPOLATION (ANTI-CLOCKWISE)

The G03 command is used to move the tool in the anti circular arc profile.
The movement taken will be at the programmed feed rate.

Format: G03 X__ Y__Z__ I__ J__K__ F__

G03 X__Y__ Z__ R__ F__

Here,
I = Distance between start point & center point of arc along X-axis.
J= Distance between start point & center point of arc along Y-axis.
K= Distance between start point & center point of arc along Z-axis.

& In second syntax

R = Radius of the arc.

Example:
To machine the radius of 12mm on diameter =24mm, starting from X=0,
Z=0 up to the length of 12mm.Following program code is used.,

G04 - PROGRAMMED DWELL

G04 Command will delay the execution of next block by given time.

Format: G04 X__

X specifies dwell in seconds.

This code is used mainly after the spindle ON command, as the

spindle will require some time to reach to the specified speed,
before that the cutting operation should not start.

43
 G12 – CIRCULAR POCKETING CLOCKWISE

Format: G12 I__ F__

Here,
I= RADIUS of pocketing

G13 – CIRCULAR POCKETING ANTICLOCKWISE

Format: G13 I__ F__

Here,
I= RADIUS of pocketing

G15 – P.C.D. DRILLING CANCEL

G16 – P.C.D. DRILLING CYCLE

Format: G16
G81 X__Y__ Z__ R__ F__
G15
Here,
G81=Drilling cycle
X =RADIUS of required PCD
Y=ANGLE spacing between drills

44
G17-X-Y PLANE SELECTION FOR ARC MOVEMENT

Format: G17
G03 X__Y__ Z__ R__ F__

G18-X-Z PLANE SELECTION FOR ARC MOVEMENT

Format: : G18
G03 X__Y__ Z__ R__ F__

G19-Y-Z PLANE SELECTION FOR ARC MOVEMENT

Format: G19
G03 X__Y__ Z__ R__ F__

45
G51-SCALING FACTOR

Format: G51 I__ J__ P__

G03 X__Y__ Z__ R__ F__
Here,
I =X CO ORDINATE OF SCALING CENTER
J =Y CO ORDINATE OF SCALING CENTER
P =SCALING FACTOR

G52-CANCEL G51

G70-INCH PROGRAMMING
G71-METRIC PROGRAMMING

G81-FIXED CYCLE NO.1 DRILL,SPOT DRILL

Format: G81 X__ Y__Z__R__ F__

Here,
X=Drilling X coordinate
Y= Drilling Y coordinate
Z= Drilling Z coordinate
R=RETRACT from job surface

46
G82-FIXED CYCLE NO.2 DRILL,COUNTER BORE

Format: : G82 X__ Y__Z__R__P__ F__

Here,
X=Drilling X coordinate
Y= Drilling Y coordinate
Z= Drilling Z coordinate
R=RETRACT from job surface
P=Delay in seconds when final depth is achieved
for fine boring

G83-FIXED CYCLE NO.3 DRILL,DEEP HOLE

Format: : G81 X__ Y__Z__R__ Q__ F__

X=Drilling X coordinate
Y= Drilling Y coordinate
Z= Drilling Z coordinate
R=RETRACT from job surface
Q=PECK DEPTH

G90-ABSOLUTE DIMENSION INPUT

G91-INCREMENTAL DIMENSION INPUT

47
EXAMPLES----
1. N00 M03 S1000
N01 G00 X0.000 Y0.000 Z0.000
N02 G00 X20.000 Y20.000
N03 G01 Z-0.500 F50
N04 G02 X20.000 Y10.000 I0.000 J-5.000 F100
N05 G00 Z10.000
N06 M02

2. M03 S2500
G00 X40 Y75 Z2
G01 Z-1 F60
G03 Y35 R20
G01 Y23
G01 Y42
G01 Z2
G01 X37 Y42
G01 Z-1
G01 X44
G01 Z2
M30

3. #BILLET X100 Y100 Z30

#CENTER X0 Y0
M03
N01 G00 X20.000 Y20.000
N02 G01 Z0 F70
N03 G01 Z0
N04 G19
48
N05 G03 X20.000 Y40.000 I0.000 J10.000 F80
N06 M30
4. N01 G90 G00 X0 Y0 Z00 S2500 M03
N05 G01 Z-1 F50
N06 M98 P7001 L1
N08 G01 X20 Y20
N09 G01 Z-1
N10 G51 I20 J20 P0.2
N15 M98 P7001 L1
N20 G01 X30 Y30
N35 G51 I30 J30 P0.5
N38 G01 Z-1
N40 M98 P7001 L1
N50 G00 Z2
N125 M30
N130 O7001
N135 G91
N140 G01 X20 F10
N145 G01 Y20
N150 G01 X-20
N155 G01 Y-20
N160 G90
N165 G00 Z5
N170 M99

49
5. N3 G90 G00 X25 Y25
N4 M03 S1200

N5 G01 Z-1 F50

N6 G12 I4.5 F50
N8 G01 Z2
N9 G01 X25 F50
N10 G01 Z-1
N11 G12 I7 F50
N12 G01 Z2
N13 G01 X25
N14 G01 Z-1
N15 G12 I8 F50
N16 G01 X25
N18 G12 I10 F50
N19 G01 Z2
N20 G01 X25
N21 G01 Z-1
N22 G12 I12 F50.0
N26 M30

6. N00 G00 X0 Y0 Z0 M03

N02 G16
N03 G90 G81 X20 Y0 Z-5 R5 F100
N04 X20 Y45
N05 X20 Y90
N06 G15
N07 G01 Z5
N08 G00 X0 Y0 Z0
50
N09 G16
N10 G81 X25 Y0 Z-5 R5 F100
N11 X25 Y60
N12 X25 Y120
N13 X25 Y180
N14 X25 Y240
N15 X25 Y300
N16 G15
N17 G00 Z10
N18 G00 X00 Y00 Z50
N18 M30

7. #BILLET X200 Y100 Z30

#CENTER X-30 Y-10
N00 G00 X20.000 Y20.000 Z5.000
N01 G01 X10.000 Y10.000 Z5.000 F120
N02 G81 X25 Y25 Z-14 R2 F120
N03 G81 X50 Y25 Z-10 R2
N04 G81 X75 Y25 Z-10 R2
N04 G81 X100 Y25 Z-10 R2
N05 G81 X125 Y25 Z-10 R2
N06 M30

51
8. #BILLET X100 Y100 Z20
#CENTER X0 Y0
N00 G90 G00 X20.000 Y20.000 Z5.000
N01 G01 X10.000 Y10.000 Z5.000 F120
N02 G82 X25 Y25 Z-14 R2 P100 F120
N03 G82 Y50
N04 G82 Y75
N04 G82 X50
N05 G82 X75
N06 M30

9. BILLET X300 Y200 Z30

#CENTER X-70 Y-70
M03
G01 X10.000 Y10.000
G01 Z1 F100
G83 X25 Y25 R2 Z-10 Q5 F120
G01 X10 Y50
G83 X25 Y50 R2 Z-10 Q4 F120
M30

10. G00 X00 Y00 Z00

G00 Z2
M98 P27 L5 (First Subroutine call)
G00 X25 Y10 Z2
G90 X10 Y90 Z2
M98 P28 L5 (Second Subroutine Call)
G00 X00 Y00 Z50
M30
O27 (First Subroutine)
52
G91
G81 X15 Y15 Z-12 R2 F150
M99 (End of Subroutine)
O28 (Second Subroutine)
G91
G81 X15 Y00 Z-12 R2 F150
M99 (End of Subroutine)

11. #BILLET X100 Y100 Z20

#CENTER X10 Y10
G00 X0 Y0
M98 P123
M21
M98 P123
M22
M98 P123
M21
M98 P123
O123
G01 Z0
G00 X5 Y5
G01 Z-1
G01 Y20
G01 X20
G01 Y5
G01 X5
M99

53
 Miscellaneous Functions

M00-PROGRAM STOP.
M01-OPTIONAL PROGRAM STOP
M02-PROGRAM END
M03-SPINDLE MOTOR ON & NORMAL CLOCKWISE

Format: M03 S___

M04-SPINDLE MOTOR ON & REVERSE ANTICLOCKWISE

Format: M04 S___

M05-SPINDLE MOTOR OFF.

M06-AUTOMATIC TOOL CHANGE

Format M06 T___

T=Tool no.

M08-COOLANT PUMP MOTOR ON.

M09-COOLANT PUMP MOTOR OFF.

54
M21-MIRROR IMAGE ALONG X AXIS

Format: M21
M98 P---

M22-MIRROR IMAGE ALONG Y AXIS

Format: M21
M98 P---

M23-MIRROR IMAGE CANCEL

M30-PROGRAM END & REWIND.

M98-SUBPROGRAM CALL WITH PROGRAM NO. P

Format: M98
O__

Here,
O=Label of the program which is the subroutine to be called.
M99-SUBPROGRAM END

55
MAINTENANCE

56
 ELECTRICAL MAINTAINANCE & FAULT DIAGNOSIS :

FAULT CAUSE REMEDY

1) PANEL IS NOT 1) MAINS SUPPLY IS 1) MAIN SUPPLY IS
WORKING NOT GIVEN to PANAL GIVEN TO PANAL.
2) IN BUILT PANAL 2) M.C.B. IS ALWAYS
SHORT CIRCUIT ON.
PROTECTED M.C.BTO 3) EMERGENCY STOP
OFF IS REALSED.
3) EMERGENCY STOP 4) KEY SWITCH IS
IS PRESSED. ON.
4) KEY SWITCH OFF.
2) MACHINE IS NOT 1) SUPPLY IS NOT 1) PROPER SUPPLY IS
WORKING GIVEN TO PANAL. GIVEN TO PANAL.
2) CNC SWITCH IS 2) CNC SWITCH IS
OFF. ON.
3) IF NOT RECTIFIED
CONTACT SQUARE
SYSTEMS.
.
3) WE ARE IN CNC 1) POWER FAILURE. 1) POWER IS ON.
SOFTWARE BUT 2) EMERGENCY STOP 2) EMERGENCY STOP
PROG.IS NOT IS PRESSED. IS RELEASED.
EXECUTING 3) LIMIT SWITCHES 3) LIMIT SWATCHES
OPERATED. RELEASED.
4) COMMUNICATION 4) COMMUNICATION
CABLE IS NOT CABLE IS CONNECT
CONNECTED OR IT IS PROPER.
BROKEN. ..
5) LUBRICATION 1) PROPER 230VOLT 1) PROPER 230VOLT
57
MOTOR NOT SUPPLY NOT GIVEN. SPPLY TO GIVEN.
WORKING. 2) SIGNAL RELAY NOT 2) RELAY IS
WORKING. CHANGED.
3) IF NOT RECTIFIED
CONTACT SQUARE
SYSTEMS.
6) X MOTOR & Z 1) MAINS SUPPLY IS 1) MAIN SUPPLY IS
MOTOR DRIVE NOT NOT GIVEN TO GIVEN TO X MOTOR
WORKING. DRIVE. DRIVE, YMOTOR & Z
2) WIRE IS NOT MOTOR.
CONNECTED FROM 2) INTERFACING
INTERFACING CARD CABLE IS CONNECTED
TO DRIVE. PROPER.
3) MOTOR WIRES ARE 3) TO CHECK MOTOR
BROKEN END WIRES ARE
4) COMMUNICATION PROPER CONNECT
FAIL. 4) IF NOT RECTIFIED
CONTACT SQUARE
SYSTEMS.

ELECTRICAL PRECAUTIONS

* Ensure that the mains supply for the drive is single phase supply 230
VAC + / - 10 %, 50 Hz..

* Use of a C.V.T. (Constant Voltage Transformer) of rating 3 KVA 230 V

AC is recommended where wide line fluctuations are present.

* Ensure that proper earth connection is provided. The potential

between Earth And Neutral should be below 2V.

* Proper ventilation is necessary for the controller.

 Never connect or disconnect the motor from the drive when the
Panel is ON.

58
 DO & DO-NOT

Sr. Do
No.
1. Check the earthing once in a week. Earth to Natural Voltage
should be 3 Volts maximum.
2. Please clamp the Job with proper care.
3. Manually rotate the spindle & check the obstruction. If there is
obstruction do not start the machine.
4. Before starting the machine please remove the burr & dust
with clean Brush.
5. Release the Emergency stop of the machine.
6. Check oil level in tank once in a week.
7. Check the cutting edge of the tool before start.
8. Put the computer ON & Load the software program.
9. Before cutting the material please do dry run in air. If dry run
is OK then start the machine.
10. While stopping the machine please check that tool is away
from the job & tool removal is easily possible.

Sr. Do Not
No.
1. Do not start the machine on Load or in cutting position.
2. Do not start the machine without solid-state stabilizer.
3. Ambient temperature should not be above 320C.
4. Do not spray water or don’t clean the controller with wet cloth
for critical control part. Electronic IC will be defected in Humid
atmosphere.
5. Do not stop MACHINE on LOAD.
6. Do not start the machine when there is power fluctuation more
59
 than ± 10 %
7. Do not use the PC for any other purpose.
8. Do not leave the machine unattended.
9. Do not Tamper the CONTROLLER.
10. Do not change PC settings.

Maintenance Manual for CNC Mill

The CNC Mill machine is a very delicate machine. It is the combination of

Electronic, Electrical & Mechanical parts. A lot of attention is required to
keep the machine in working condition. Following are the points which has
to be checked.
General maintenance
1) Controller related:
The Electronic controller of the CNC machine works on
Single-phase supply (230 V AC 25 V). It contains various
parts such as Computer, Isolation cards, Stepper motor
drives, and Power supply. Stabilizer etc. The points given
below will take care of the controller.
1.Keep mains s/w off when machine is not in use.
2.Rout supply cable in a proper way so that it should not be bend,
twisted or damaged.
3.Check Earthing connected to the controller & the CNC machine.
Proper earthing is nothing but the potential difference between
neutral to earth of the mains supply. This difference should not be
more than 2 volts. If it is more than that the controller will
malfunction & can create dangerous shock If the earthing is not
proper please consult your Electrical department & get it done.
4.Always start PC first, go to the main menu of the CNC Mill software
& then start the CNC switch. This is a must.
5. Always check your program with simulation before actual
machining.
6.Check the level of humidity that should not be more than 70%.
7.There should not be any high current load (such as welding etc.)
on the same phase connected to the CNC machine. That can create
fluctuations in the supply.
8. Take care of the cables connected between the controller & the Mill machine.
Do not put any weight on it.
9. Do not try to change any wire or check anything inside the
controller unless & until you contact SQUARE SYSTEMS.

60
2) Mill related :
The Mill machine has various mechanical assemblies such as ball-
screw, Spindle etc. Please take care of these precision parts so that it should not
be damaged.

1. Keep the machine clean. Remove the chips of the job.

2. Do not keep unnecessary things near the machine.

3. Use the machine for soft materials only (such as Aluminum, Brass,
Copper etc.).

4. Before machining always check that the job is clamped properly &
the tool is away from the job (i.e. the tool should be in positive
direction of Z axis.)

5. Please keep the depth of cut of 1 mm max.

6. Before machining check whether the tool is properly clamped.

7. Use proper feed & Speed values in the program. Keep the
federate at a low value to get a good finish.

8. Check Lubrication oil level once in a week

9. Always do the oiling first before actual working on the machine.

10. While actual machining if you find any problem use Emergency
stop button on the controller (Red colored) to avoid any accidents.

61
3) Electrical Maintenance

The CNC Machine requires 230vac 25 V at 50Hz input supply, which is
achieved through 15 AMP socket supplied by the Electrical board.

1) A 3 KVA stabilizer is provided with the machine for various

electronic parts. So even if the incoming supply is varied from 170 to
260 Volts it will provide a continues 230 V supply with 4%
regulation. But see that the supply for the machine is not varying
much.

2) As stated earlier it requires proper earthing .You have to measure

it once in a week. It should be located near machine & connected
to machine with continuous copper wire of 3 mm².

3) There should be gap around the controller for ventilation purpose

4) Before disconnecting any wire switch off controller & take off
power plug from mains input.

5) There are various MCBs provided inside the controller, their rating
& connection details are given below
a) 16 Amps. 2 Pole (1 no.): For total supply of the CNC
machine.
b) 4 Amps. 1 Pole (3 no.): For X, Z stepper motor drives &
Power supply.
c) 10 Amps. 1 Pole (1 no.): For D.C. drive & Spindle motor.
In case of any problem these MCBs can be tripped & provide
protection for the circuits.
.
6) Various fuses are provided for various Electronic circuits. Their
details are given below
a) Stepper motor drives: 2 Amp.
b) Power supply unit: 2 Amp. For mains
62
 2 Amps. For +5 V
2 Amps. For +24 V
500 mAmp for 15 V

7) For any Electrical fault wiring diagram is provided along with this
manual.

4) Conditional Checks:
Various checkpoints are given below for various problems

a) Stabilizer--- If it is tripped following problems will occur

1.Any motor will not work
2.Only PC will work
Check Points:
1. Check fuse
2. Press the trip button
3. Check input voltage, if that is below 170 V or above
260 V, the stabilizer will remain tripped.
4. If the problem persists contact SQUARE SYSTEMS.

b) Power supply ---The power supply contains +5 V, +24 V,

15V supply.
1. If 5Volts fails the lamps on the control cards will not
glow & no motor will work. Check the fuse ( 2 Amp.)
2. If 24 V fails spindle, turret, coolant & lubrication motor
will not work but X & Z axis motors will work. Check the
fuse (2 Amp.)
3. If 15 V fails the reference voltage to the DC Drive will
not be available so the spindle will not rotate. Check the
fuse
(500 mAmp.)
4. Check whether MCB is tripped.

c) DC drive -----This is located near the spindle motor below the

spindle assembly
If the spindle is not rotating
1. Check the MCB (10 Amp.) inside the controller that can be
tripped.
2. Check the fuse (10 Amp,) inside the DC drive.
3. Check for the loose connections at the drive.
63
 d) Stepper motor drive-----The stepper motor drives are for the X
& Z axis movements. If one of the drives is not working check the
following
1. Check the fuse on the drive (2 Amp.)
2. Check for loose connections on the drive.
3. Check for 5 Volts
4. Check the military connector on the controller side.

5) General problems:

a) Tube light------If the tube light provided on the Mill machine is

not working Check 1. The tube light switch is on (on the controller)
2. Check the starter on the machine
3. Check mains MCB 2pole 16amp inside the controller.

b)The Controller is not getting ON

Check1.Mains supply
2.Mains key lock switch on the front panel on the machine.
3.Main MCM (16amp 2pole) inside the controller.

c) Computer is not working

Check1.Input supply connecter
2.Mains cable connected to the computer at the back side.
3. The key lock switch

d) CNC is not getting ON

Check 1. The CNC switch on the front panel of the controller.
2. Emergency stop button is pressed. If it is pressed release it.
3. Stabilizer is tripped or not..

e) Lubrication or Coolant motor not working

Check1. Mains supply.
2. Military connector on the controller for loose connection.
3. Coolant or Lubrication relay in the controller.
64
5. LED signal from Isolation card.

65
66
67
68
69
70
71
72
73
74
75
ATC OPERATIONS

76
 The advantage of using CNC MILL machine is that you can do a job
having various operations such as Slotting, Facing, Drilling, Boring etc.
with the help of Automatic Tool Changer (ATC).
The Automatic Tool Changer (ATC) has been designed &
developed by SQUARE SYSTEMS to suite the requirements of CNC Mill
machine. It has the provision of 6tools.
The motor driving the mechanical assembly is of 230 Volts, 25
Watts & there are 2 Proximity sensors (for feedback signals), one for tool
no.1 signal & second sensor gives signal for each tool.
With the help of Software any tool can be indexed simply by
giving the tool no. (Between 1 to 6) such as T1, we can get its offset value
from the tool configuration table available in the Settings menu. After
executing the command the motor is made ON & then ATC disc is rotated
in Anti-clockwise direction till the required tool is reached.
The ATC can be operated in Program or in jog mode. The
description of jog mode menus for ATC is given in the System Control
Software chapter.
When multiple tools have to be used, the tools have to be fixed
on the ATC disc & then their tool offsets are to be calculated.
When a new tool is indexed, the length of new tool does not
come to the same point as with the previous tool. This physical difference
is nothing but the tool offset, which has to be calculated. The procedure is
very simple. Measure the length of cutting tool which is outside the tool
holder. The length of each cutter is the offset w.r.t. previous tool. All this
has to be done before the start of the job. While executing the program
this tool offsets are taken from the memory.

77