DEPARTMENT OF MANUFACTURING AND

MATERIALS

WORKSHOP TECHNOLOGY
MME 1103

CNC MACHINING
MANUFACTURING AND MATERIALS DEPARTMENT MME1103
Workshop Technology Manual
CNC Machining

Apparatus:

Tools : Turning tools Machine: CNC Turning Center

Milling tools CNC Machine Center

Introduction:
The abbreviation CNC stands for computer numerical control, and refers
specifically to a computer "controller" that reads G-code instructions and drives the
machine tool, a powered mechanical device typically used to fabricate metal components
by the selective removal of metal. CNC does numerically directed interpolation of a
cutting tool in the work envelope of a machine. The operating parameters of the CNC can
be altered via software load program.

NC was developed in the late 1940s and early 1950s by John T. Parsons in
collaboration with the MIT Servomechanisms Laboratory. CNC was preceded by NC
(Numerically Controlled) machines, which were hard wired and their operating
parameters could not be changed. The first CNC systems used NC style hardware, and
the computer was used for the tool compensation calculations and sometimes for editing.

Punched tape continued to be used as a medium for transferring G-codes into the
controller for many decades after 1950, until it was eventually superseded by RS232
cables, floppy disks, and finally standard computer network cables. The files containing
the G-codes to be interpreted by the controller are usually saved under the .NC extension.
Most shops have their own saving format that matches their ISO certification
requirements.

The introduction of CNC machines radically changed the manufacturing industry.

Curves are as easy to cut as straight lines, complex 3-D structures are relatively easy to
produce, and the number of machining steps that required human action have been
dramatically reduced.

With the increased automation of manufacturing processes with CNC machining,

considerable improvements in consistency and quality have been achieved. CNC
automation reduced the frequency of errors and provided CNC operators with time to
perform additional tasks. CNC automation also allows for more flexibility in the way
parts are held in the manufacturing process and the time required to change the machine
to produce different components.

In a production environment, a series of CNC machines may be combined into

one station, commonly called a "cell", to progressively machine a part requiring several
operations. CNC machines today are controlled directly from files created by CAM
software packages, so that a part or assembly can go directly from design to
manufacturing without the need of producing a drafted paper drawing of the
manufactured component. In a sense, the CNC machines represent a special segment of

1
MANUFACTURING AND MATERIALS DEPARTMENT MME1103
Workshop Technology Manual
CNC Machining

industrial robot systems, as they are programmable to perform many kinds of machining
operations (within their designed physical limits, like other robotic systems). CNC
machines can run over night and over weekends without operator intervention. Error
detection features have been developed, giving CNC machines the ability to call the
operator's mobile phone if it detects that a tool has broken. While the machine is awaiting
replacement on the tool, it would run other parts it is already loaded with up to that tool
and wait for the operator. The ever changing intelligence of CNC controllers has
dramatically increased job shop cell production. Some machines might even make 1000
parts on a weekend with no operator, checking each part with lasers and sensors.

Figure 1: CNC Turning Center

2
MANUFACTURING AND MATERIALS DEPARTMENT MME1103
Workshop Technology Manual
CNC Machining

Figure 2: CNC Milling Machine

Example of NC part programming (2D contouring)

Figure 3: Sample Part

3
MANUFACTURING AND MATERIALS DEPARTMENT MME1103
Workshop Technology Manual
CNC Machining

We assume that the machining is a contouring operation along the outer boundary of a
simple part, whose nominal geometry is as shown on Fig.3.

The tool size is 0.25 inch, and the feed rate of 6 inch per minute is used.

The cutting speed is required to be 300 rpm. To simplify the program, we ignore the Z-
axis motions, and that the home position of the tool is at the correct height, centered on
the point located in the machine tool coordinates as (2, 2).

In order to specify the geometry of the motion, we need to compute the location of 5
points from p1 to p5 (later, we shall see that additional points will be needed).

The cutting will proceed along the contour: p0 Æ p1 Æ p2 Æ p3 Æ p4 Æ p5 Æ p1.

// Block 1: start program, use absolute coordinates, spindle speed in rpm, feed in
inch/min, select tool no 1001, turn coolant ON, use up milling (CCW in this case)

N010 G70 G90 G94 G97 M04[EOB]

NOTE: we could use M14 instead of M04 and M08 that we shall use in the next block.

// Block 2: cutting on XY plane, set feed, spindle speed,

N020 G17 F6.0 S300 T1001 M08 [EOB]

// Block 3: move to first point in a straight line (linear interpolation). We now need to
compute the coordinates of p1, as shown in figure below:

Figure 4 : Calculating p1 coordinate

4
MANUFACTURING AND MATERIALS DEPARTMENT MME1103
Workshop Technology Manual
CNC Machining

N030 G01 X3.875 Y3.698 [EOB]

// Block 4: move to p2 in straight line. coordinates of point p2: x = same as p1; y = 4 + 5

+ 0.125.

N040 G01 X3.875 Y9.125 [EOB]

// Block 5: move to p3. coordinates calculated as shown in figure below:

Figure 5 : Calculating p3 coordinate

N050 G01 X5.635 Y9.125 [EOB]

// blocks 6, 7, 8: now we need to cut along a circular arc.

Most NC controllers cannot cut along a full circle directly -- they need to be programmed
once FOR EACH QUADRANT of the arc. In our case, the circular path of the tool goes
through tree quadrants, so we need to find two additional points, p31, and p32.

Programming for circular interpolation (moving the tool along a circular arc):

Circular arcs are machined only in main planes. The plane is selected by the preparatory
functions (G17, G18, G19).

The direction of the tool along the arc must be specified

(G02, G03, G20 G21, G30, G31).

5
MANUFACTURING AND MATERIALS DEPARTMENT MME1103
Workshop Technology Manual
CNC Machining

Four dimension words are needed per block. Two dimension words specify the distance
to the end of the arc from current position. Two circular dimension words specify the
distance to the arc center. Usually, I, J, K specify the distances parallel to the X, Y, Z
axes, respectively.

The I, J, K values are absolute values (unless there is ambiguity).

The following figure shows the computations of the next three blocks of motion:

Figure 6 : Circular movement from p3 to p4

The corresponding blocks are:

*NOTE: EOB stands for End Of Block

N060 G03 X5.625 Y9.0 I0.866 J0.125 [EOB]

N070 G03 X6.5 Y8.125 I0.875 J0.0 [EOB]

N080 G03 X7.375 Y9.0 I0.0 J0.875 [EOB]

// block 9: the next move is to point p4 (coordinates computed similar to p3).

N090 G03 X7.366 Y9.125 I0.875 J0.00[EOB]

6
MANUFACTURING AND MATERIALS DEPARTMENT MME1103
Workshop Technology Manual
CNC Machining

// blocks 10, 11, 12: all linear interpolation. Computations for the point p5 are as follows:

p4: y = 9.125; x = 9 + 0.125 tan 67.5 = 9.302

N100 G01 X9.302 [EOB]

NOTE: here we did not specify the Y coordinate, so it will be kept constant !

N110 G01 X3.875 Y3.698 [EOB]

N120 G01 X2.0 Y2.0 M30 [EOB]

CNC TURNING

Table 1: Basic codes/ Basic Keys

G- Function M-code Function
code
G00 Positioning (Rapid Traverse) M00 Program STOP
G01 Linear Interpolation (Cutting M01 Program STOP optional
Feed)
G02 Circular Interpolation/Helical M03 Spindle START CW
Interpolation CW
G03 Circular Interpolation/Helical M04 Spindle START CCW
Interpolation CCW
G17 XY plane selection M05 Spindle STOP
G18 ZX plane selection M08 Coolant ON
G19 YZ plane selection M09 Coolant OF
G20 Input in inch M30 END of program
G21 Input in mm M41 Spindle gear range 1-LOW
(45-1500RPM)
G28 Auto Return to reference point M42 Spindle gear range 1-
HIGH(135-4500RPM)
G54- Working coordinate system (1-6 Other
59 selection) codes
G70 Finishing cycle N Block Number
G71 Stock Removal in turning F Feed (mm/min or inch/min)
G72 Stock Removal in Facing T Tool
G73 Pattern repeating ; End of block [EOB]
G74 End face peck drilling U Incremental coordinate for x-
axis
G92 Maximum Spindle speed W Incremental coordinate for z-
axis
G96 Constant Surface speed control

7
MANUFACTURING AND MATERIALS DEPARTMENT MME1103
Workshop Technology Manual
CNC Machining

ABBREVIATION KEY SYMBOL DESCRIPTION

Axis Home Selection :
HOME Both axes move to home
(ZERO RETURN) position

JOG feed selection:

JOG Mode is step feed

MANUAL PULSE
MPG GENERATOR:
To use Handwheel

AUTO Mode Selection:

AUTO Mode is automatic
operation

SINGLE BLOCK program

SINGLE execution for test
BLOCK operation.

EDIT Mode Selection:

EDIT for editing program

MANUAL PULSE
MPG x1 GENERATOR:
electronics handwheel, low
feed rate
MANUAL PULSE
MPG x10 GENERATOR:
electronics handwheel,
medium feed rate
MANUAL PULSE
MPG x100 GENERATOR:
electronics handwheel,
high feed rate
Automatic operation is
CYCLE START started

Automatic operation is
CYCLE STOP stopped

8
MANUFACTURING AND MATERIALS DEPARTMENT MME1103
Workshop Technology Manual
CNC Machining

COOLANT ON:
CLNT ON Manual selection of
coolant ON

COOLANT OFF:
Manual selection of
CLNT OFF coolant OFF

POSITION:
POS Shows all coordinates

TOOL OFFSET
OFFSET SETTING SETTING:
Write mode selection,
manually input tool offset
data
PROGRAM:
PROG To open existing program,
load new program, edit
program
To cancel input data
CANCEL *same as ‘backspace’ key
in computer keyboard

To enter data
INPUT

To insert every single code

INSERT into the program

To delete code, data, block,

DELETE program

To change program
ALTER number, input data

To terminate the current

RESET operation

9
MANUFACTURING AND MATERIALS DEPARTMENT MME1103
Workshop Technology Manual
CNC Machining

MDI MANUAL DATA INPUT

Example for CNC Turning Program

O1234; Program name

N10 G28 U0 W0; Go to Reference point (Machine Zero position)
N20 G92 S1200 M41 M03; Max. spindle speed, 1200 RPM, Low gear, Spindle
CW
Constant surface speed, 400 RPM, Tool no. 4 with
N30 G96 S400 T0404;
tool offset no. 4
Rapid positioning(without cutting) to position
N40 G00 X2.6 Z0 M08;
X=2.6, Z=0 in mm, coolant ON
Facing process tool will move to position X=0.74
N50 G01 X0.74 F0.5;
with feed 0.5mm/min
Rapid positioning(without cutting) to position X=3,
N60 G00 X3. Z5. M09;
Z5 in mm, coolant OFF
N70 G28 U0 W0; Go to Reference point (Machine Zero position)
N80 M30; End of program

10
MANUFACTURING AND MATERIALS DEPARTMENT MME1103
Workshop Technology Manual
CNC Machining

CNC MILLING

Table 2: Basic Codes/ Basic Keys

G-code Function M-code Function
G00 Positioning (Rapid Traverse) M00 Program STOP
Linear Interpolation (Cutting
G01 M01 Program STOP optional
Feed)
Circular Interpolation/Helical
G02 M03 Spindle START CW
Interpolation CW
Circular Interpolation/Helical
G03 M04 Spindle START CCW
Interpolation CCW
G17 XY plane selection M05 Spindle STOP
G18 ZX plane selection M06 Tool Change
G19 YZ plane selection M08 Coolant ON
G30 Return to reference point Z0 M09 Coolant OF
Cutter Diameter compensation
G40 M30 END of program
OFF
Cutter Diameter compensation
G41
LEFT
Cutter Diameter compensation Other
G42
RIGHT codes
Tool length compensation +ve
G43 N Sequence Number
direction
Tool length compensation -ve Feed (mm/min or
G44 F
direction inch/min)
Tool length compensation
G49 T Tool number
CANCEL
Working coordinate system (1-6
G54-59 ; End of block
selection)
G70 or Incremental coordinate
Input in inch U
G20 for x-axis
G71 or Incremental coordinate
Input in mm V
G21 for y-axis
Incremental coordinate
G90 Absolute Dimension Input W
for z-axis
G91 Incremental Dimension Input R Radius
Axis Interpolation
G92 Position Set I,J,K
Parameter
Fixture Offset Selector
G96 Constant Surface speed control H
(Tool length)

11
MANUFACTURING AND MATERIALS DEPARTMENT MME1103
Workshop Technology Manual
CNC Machining

ABBREVIATION SYMBOL DESCRIPTION

POS POSITION:
Shows all coordinates
PROG PROGRAM:
To open existing program,
load new program, edit
program
OFFSET SETTING TOOL OFFSET SETTING:
Write mode selection,
manually input tool offset
data
CAN To cancel input data
*same as ‘backspace’ key in
computer keyboard
INPUT To enter data
ALTER To change program number,
input data
INSERT To insert every single code
into the program
DELETE To delete code, data, block,
program
RESET To terminate the current
operation
MDI MANUAL DATA INPUT

*NOTE: CNC milling and turning machine have the same basic keys. Refer to Table 1.

Example for CNC Milling Program

O1234; Name of program

N10 G21 G40 G49; Metric programming, tool compensation cancel
N20 G91 G30 Z0; Incremental programming, Return to zero position
for z
N30 T02 M06; Change tool no. 2
N40 M03 S1000; Spindle rotates clockwise 1000RPM
N50 G43 H5 Z2.; Tool length compensation +ve direction up to 2 mm
Working coordinate G55, Absolute programming,
N60 G55 G90 G00 X0 Y0;
Tool at X=0 Y=0 position
N70 G01 Z-5. F10; Cutting in Z-direction until it reaches z = –5mm
with feed 10mm/min
N80 G01 X0 Y50. F100; Cutting to Y-direction to Y=50 with 100mm/min
N90 Y100.; Cutting to Y-direction Y=100
N100 X100.; Cutting to X-direction X=100
N110 X0; Cutting to X-direction X=0
N120 G30 Z0 Return to zero position for z

12
MANUFACTURING AND MATERIALS DEPARTMENT MME1103
Workshop Technology Manual
CNC Machining

N130 M30; End of program

Question
CNC Turning Center

1. List the steps of operating the machine starting with;

i. ON/OFF the machine
ii. Reference set-up
iii. Tool offset set-up
2. Write a program on turning and facing process.
3. Give 3 advantages of using CNC turning machine compare to conventional machine.

CNC Machine Center

1. List the steps of operating the machine starting with;

iv. ON/OFF the machine
v. Reference set-up
vi. Tool offset set-up
2. Write a program on facing process.
3. Give 3 advantages of using CNC milling machine compare to conventional machine.

13