Co:-Develop part program for CNC Turning, Milling and verify on

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 A part program is a series of coded instructions
required to produce a part. It controls the
movement of the machine tool and the on/off
control of auxiliary functions such as spindle
rotation and coolant. The coded instructions are
composed of letters, numbers and symbols and are
arranged in a format of functional blocks as in the
following example
N10 G01 X5.0 Y2.5 F15.0
| | | | |
| | | | Feed rate (15 in/min)
| | | Y-coordinate (2.5")
| | X-coordinate (5.0")
| Linear interpolation mode
Sequence number
 The program input device is the mechanism
for part programs to be entered into the CNC
control. The most commonly used program
input devices are keyboards, punched tape
reader, diskette drivers, throgh RS 232 serial
ports and networks.
 The machine control unit (MCU) is the heart of a
CNC system. It is used to perform the following
functions:

 Read coded instructions

 Decode coded instructions
 Implement interpolations (linear, circular, and
helical) to generate axis motion commands
 Feed axis motion commands to the amplifier
circuits for driving the axis mechanisms
 Receive the feedback signals of position and speed
for each drive axis
 Implement auxiliary control functions such as
coolant or spindle on/off, and tool change
 Offline programming linked to CAD
programs.
 Conversational programming by the operator.
 MDI ~ Manual Data Input.
 Manual Control using jog buttons or
`electronic handwheel'.
 Word-Address Coding using standard G-
codes and M-codes.
Commands are input into the controller in
units called blocks or statements.

Block Format:
1. Fixed sequential format
2. Tab sequential format
3. Word address format
 Assume that a drilling operation is to be
programmed as:

1. The tool is positioned at (25.4,12.5,0) by a

rapid movement.
2. The tool is then advanced -10 mm in the z
direction at a feed rate of 500 mm/min., with the
flood coolant on.
3.The is then retracted back 10 mm at the rapid
feed rate, and the coolant is turned off.
2. Tab sequential format
0050 TAB 00 TAB +0025400 TAB +0012500 TAB +0000000 TAB
0060 TAB 01 TAB TAB TAB -0010000 TAB 0500 TAB 08
0070 TAB 00 TAB TAB TAB -0000000 TAB 0000 TAB 09

3. Word address format

N50 G00 X25400 Y125 Z0 F0
N60 G01 Z-10000 F500 M08
N70 G00 Z0 M09
1. Preparatory Information: units, incremental or absolute
positioning
2. Coordinates: X,Y,Z, RX,RY,RZ
3. Machining Parameters: Feed rate and spindle speed
4. Coolant Control: On/Off, Flood, Mist
5. Tool Control: Tool and tool parameters
6. Cycle Functions: Type of action required
7. Miscellaneous Control: Spindle on/off, direction of
rotation, stops for part movement
This information is conveyed to the machine through a
set
of instructions arranged in a desired sequence – Program.
 N135 G01 X1.0 Y1.0 Z0.125 F5
 Restrictions on CNC blocks
 Each may contain only one tool move
 Each may contain any number of non-tool move G-
codes
 Each may contain only one feedrate
 Each may contain only one specified tool or spindle
speed
 The block numbers should be sequential
 Both the program start flag and the program number
must be independent of all other commands (on
separate lines)
 The data within a block should follow the sequence
shown in the above sample block
Example CNC Program
 N5 G90 G20 Each instruction to the machine
 N10 M06 T3 consists of a letter followed by a
 N15 M03 S1250 number.
 N20 G00 X1 Y1
 N25 Z0.1
 N30 G01 Z-0.125 F5 Each letter is associated with a
 N35 X3 Y2 F10 specific type of action or piece of
 N40 G00 Z1 information needed by the machine.
 N45 X0 Y0
 N50 M05 Letters used in Codes
 N55 M30
N,G,X,Y,Z,A,B,C,I,J,K,F,S,T,R,M
 G00 Rapid traverse
 G01 Linear interpolation  G40 Cutter compensation –
 G02 Circular interpolation, cancel
CW  G41 Cutter compensation –
 G03 Circular interpolation, left
CCW  G42 Cutter compensation-
 G04 Dwell right
 G08 Acceleration  G70 Inch format
 G09 Deceleration  G71 Metric format
 G17 X-Y Plane  G74 Full-circle programming
 G18 Z-X Plane off
 G19 Y-Z Plane  G75 Full-circle programming
 G20 Inch Units (G70) on
 G21 Metric Units (G71)  G80 Fixed-cycle cancel
 G81-G89 Fixed cycles
 G90 Absolute dimensions
 G91 Incremental dimensions
 M00 Program stop
 M01 Optional program stop
 M02 Program end
 M03 Spindle on clockwise
 M04 Spindle on counterclockwise
 M05 Spindle stop
 M06 Tool change
 M08 Coolant on
 M09 Coolant off
 M10 Clamps on
 M11 Clamps off
 M30 Program stop, reset to start
 Gives an identifying number for each block of
information.

 It is generally good practice to increment

each block number by 5 or 10 to allow
additional blocks to be inserted if future
changes are required.
 X, Y, and Z codes are used to specify the
coordinate axis.
 Number following the code defines the
coordinate at the end of the move relative to
an incremental or absolute reference point.
 I, J, and K codes are used to specify the
coordinate axis when defining the center of a
circle.

 Number following the code defines the

respective coordinate for the center of the
circle.
 F-code: used to specify the feed rate

 S-code: used to specify the spindle speed

 T-code: used to specify the tool identification

number associated with the tool to be used in
subsequent operations.
 Format: N_ G01 X_ Y_ Z_ F_

 Linear Interpolation results in a straight line

feed move.

 Unless tool compensation is used, the

coordinates are associated with the centerline
of the tool.
 . As an example, for the motion that occurs in
x-y plane with the same maximum speed for
the x- and y-axis, initial motion is at an
angle of 45o to the axes until motion in one
of

 the axes is completed and then the balance

of the motion occurs in the other axis. This is
called point-to-point motion.
2 5

B C
2 0

1 5

1 0 P o s i t i o n i n g m o t i o n f r o m A t o C

N 1 0 G 0 0 X 3 0 0 0 0 Y 2 0 0 0 0 F 0
A
5

5 1 0 1 5 2 0 2 5 3 0
G01 Linear Interpolation

Z
 G02 is also a preparatory function to specify
that the tool should be moved to a specified
location along a circular path in a clockwise
direction. In order to specify the path to the
MCU, the end point of the arc and the
location of the center of the arc should be
specified. Within the block in which the G02
code is programmed, the center of the arc is
given by specifying its location relative to the
start of the arc.
 The G02 command
requires an endpoint
and a radius in order
to cut the arc.
 I,J, and K are relative to
the start point.

N_ G02 X2 Y1 I0 J-1
F10
or
N_ G02 X2 Y1 R1
 C i r c u l a r i n t e r p o l a t i o n f r o m A t o B

a b o u t a c i r c l e c e n t e r e d a t C

N 1 0 G 0 2 X 2 0 0 0 0 Y 1 0 0 0 0

2 5 I 5 0 0 0 J 1 5 0 0 0 F 2 5 0 0

I = 5 A C
2 0

1 5
J = 1 5

1 0 B

C
5

5 1 0 1 5 2 0 2 5 3 0
 Canned Cycles
The sequence of some machining operations is may be
the same for any part and for any machine. For example,
drilling a hole involves the following steps:

Position the tool above the point where the hole will be
drilled

Set the correct spindle speed

Feed the tool into the workpiece at a controlled feed rate

to a predetermined depth

Retract the tool at a rapid rate to just above the point

where the hole started
 Some Commonly Used Canned Cycle
Code Function Down feed At bottom Retracti
on
G81 Drilling Continuous No action Rapid
feed
G82 Spot face, Continuous Dwell Rapid
counterbore feed
G83 Deep hole drilling Peck No action Rapid
G84 Tapping Continuous Reverse Feed
feed spindle rate
G85 Through boring(in Continuous No action Feed
& out) feed rate
G86 Through boring(in Continuous Stop Rapid
only) feed spindle
 Part 1- Program Petup
 N5 G90 G21 (Absolute units, metric)

 N10 M06 T2 (Stop for tool change, use

tool # 2)
 N15 M03 S1200 (Turn the spindle on CW
to 1200 rpm)
 Part 2- Chip Removal
 N20 G00 X1 Y1 (Rapid to X1,Y1 from origin
point)
 N25 Z0.125 (Rapid down to Z0.125)
 N30 G01 Z-0.125 F100 (Feed down to Z-0.125
at 100 mm/min)
 N35 G01 X2 Y2 (Feed diagonally to X2,Y2)
 N40 G00 Z1 (Rapid up to Z1)
 N45 X0 Y0 (Rapid to X0,Y0)
 Part 3- System Shutdown
 N50 M05 (Turn the spindle off)

 N55 M00 (Program stop)

 First pass : conventional
mill to a depth of 0.125
around edge profile. Tool 1
is a ½ inch dia. end mill.

%
:1002
N5 G90 G20
N10 M06 T1
N15 M03 S1200
N20 G00 X0.125 Y0.125
N30 Z0.125
N35 G01 Z-0.125 F5
N40 X3.875
N45 Y4.125
N50 X0.125
N55 Y0.125
 Second pass:
conventional mill to
a depth of 0.25
around edge
profile.

N35 Z-0.250
N40 X3.875
N45 Y4.125
N50 X0.125
N55 Y0.125
N60 Z0.125
 Third pass:
conventional mill to
a depth of 0.125
around pocket
profile.

N65 G00 X1.25

Y1.0
N70 G01 Z-0.125
F5
N75 X1.75
N80 Y2.5
N85 X1.25
N90 Y1.0
 Fourth pass: climb
mill to a depth of
0.125 across
remaining material.

N100 Y2.125
N105 X2.625
N110 Z0.125
N115 G00 X-5 Y-5
Z5
N120 M05
N125 M30
 Advanced features:

 Execution of the part of the program in

a rotated or mirrored position.
 Ability to scale the program and
produce larger or smaller programs.
 Three dimensional circular interpolation
which produces a helical shape.
 Parabolic and cubic interpolation.
 Computer Aided Part Programming:

 NC program preparation may be tedious

and difficult if the part to be machined has
a complex geometry. The main difficulty is
to find out the cutter locations during the
machining. Computers may be used to
assist the programmers in preparing the
NC codes.
 Advantages of applying computer-aided
part programming include the following:

 1. It reduces the manual calculations

involves in determining the geometric
characteristics of the part.
 It provides the cutter path simulation.
 It provides tool collision checking.
 It shortens the program preparation time.
 It makes the program preparation easier.
 The Aerospace Industries Association
sponsored the work that led to the first
part programming language, developed in
MIT in 1955.
 This was called: Automatically
Programmed Tools (APT).
 APT is an English like simple programming
language which basically produce the
Cutter Location (CL) data.
 Using the cutter location data, the
program can generate the actual NC codes
by using a postprocessor .
 CAD/CAM Based Part Programming:

 The output of any CAD package include

the geometric data of the part to be
machined. Therefore, many CAD/CAM
package can produce cutter location (CL)
data to be used for NC code generation.
 There is still to be a process planning
module for a workable NC code
generation.
 Some of the CAD/CAM packages that have
the NC code generation capabilities are
Computervision, CATIA, CADAM,
ProEngineer, MechanicalDesktop (Auto
Desk).
Program structure
Every program consists of:
1. Program Start
The program start is the program number. The program number begins
with character/letter O.
2. Program Contents
NC blocks
3. Program End
M30 for a main program
M17 for a sub-program

CNC Prg. Basics 45

Program Numbers

O6999
.
.
.
O0256
O0255
.
.
.
O0000

CNC Prg. Basics 46

• N is the address
• Block numbers from N0000 to
• N9999
• A block consists of number and words
• Words are contents of a block
• Block numbers are selected in the jumps of
ten for the purpose of insertion

CNC Prg. Basics 47

• A block consists of one or more blocks
• A Word consists of a character (address)
and a number.
• Every address has a certain meaning, on
which the corresponding number depends

CNC Prg. Basics 48

• The maximum block length must not exceeded four lines. If max. length exceeded
alarm 650 occurs.
• Every block starts with a block number.
• After the block numbers follows the G command.
• Words consists of coordinates X(U), Z(W).
• For G02, G03 program interpolation parameter I and K are placed after X(U),
Z(W).
• The F word (feed, thread pitch).
• The S word (cutting speed).
• The T word (tool address).
• The M word (additional functions).

CNC Prg. Basics 49

Example:

 P0 N… …
P0  P1 N… G01 X40. Z25. F…
P1  P2 N… G01 X60. Z-40. F…
P2  N… …

Absolute coordinate
system

CNC Prg. Basics 50

 Example:

 P0 N… …
P0  P1 N… G01 U5. W-25. F…
P1  P2 N… G01 X10. Z-15. F…
P2  N… …

Incremental coordinate
system

CNC Prg. Basics 51

 Example:

 P0 N… …
P0  P1 N… G01 U5. W-25. F…
P1  P2 N… G01 X60. Z-15. F…
P2  N… …

Mixed coordinate
system

CNC Prg. Basics 52

• The majority of G and M commands and other words are self-holding,
remain active until overwritten or deactivated/deselected.
• Aimed to simplify and to reduce programming tasks.

Example: G41 can be deactivated by issuing G40 command.

CNC Prg. Basics 53

Take-over of G00 commands in block N0110
In block N0120 G00 is deactivated by G01. G01 is active.

N0100 G00 X50. Z+10.

Example 1: N0110 X36. Z+2.
N0120 G01 X40. Z-10. F…

N0050 M03 M03 activated at N0050 and effective

N0060 … from N0050 through N120. M03
… deactivated at N0120 by M04 command
Example 2:
N0120 M04

CNC Prg. Basics 54

M = Machine zero point.
(unchangeable ref. Point determined
by machine manufacturer)
N = Tool mounting reference point
W = Work piece zero point. (can be
freely determined by the programmer
and can be moved within program

CNC Prg. Basics 55

CNC Prg. Basics 56
CNC Prg. Basics 57
G00: Rapid traverse
G01: Linear interpolation
G02: Circular interpolation clockwise
G03: Circular interpolation counter clockwise
G70: Measuring in Inch (USA)
G71: Measuring in mm (Other countries)

M03: Spindle ON clockwise

M04: Spindle ON counter clockwise
M20: Tailstock back
M21: Tailstock forward

CNC Prg. Basics 58

 Absolute dimensions of the target point
Tool position X69 Z5
coordinates:
N030 G90
N040 G00 X48 Z-26
An absolute X coordinate related to
the diameter.

Incremental dimensions of the target point

coordinates:
N030 G91
N040 G00 X-10,5 Z-31

CNC Prg. Basics 59

 G90:
G01 X… Z…
N030 G00 X39 Z2
N040 G01 X39 Z0
N050 G90
N060 G01 X48 Z-37
G91:
N030 G00 X39 Z2
N040 G01 X39 Z0
N050 G91
N060 G01 X4.5 Z-37

P0: tool position

CNC Prg. Basics 60

 G90
G01 X+140 Z-90
Target point abs.

G91
G01 X+40 Z-60
Target point incr.

PO: Start Point

P1: Target Point

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