COMPUTER AIDED MANUFACTURING

LABORATORY MANUAL

M.Tech. (CAD/CAM)

Semester II

Name : _________________________________________________________________

Roll No : _________________________________________________________________

Year : _________________________________________________________________

DEPARTMENT OF MECHANICAL ENGINEERING

S. V. NATIONAL INSTITUTE OF TECHNOLOGY

SURAT – 395007

(GUJARAT) INDIA
 DEPARTMENT OF MECHANICAL ENGINEERING

S. V. NATIONAL INSTITUTE OF TECHNOLOGY

SURAT, GUJARAT – 395007

INDIA

CERTIFICATE

This is to certify that Mr./Ms. _________________________________________

of M.Tech. (CAD/CAM) semester II, Admission No. ________________________

has satisfactory completed the laboratory term work in the subject of

_______________________________________ during the year _____________.

Faculty Member Head of Department

 INDEX
Sr.
Title Date Signature
No.

Demonstration of CNC Milling machine with user interface and

1 calculating the Co-ordinates of given geometry in absolute and
increment mode for cutter path.
Introduction of G codes and M codes and write the CNC part
programming for a given geometry using Linear, Circular
2
interpolation. (Using FANUC Controller)

Write the CNC part programming for a given geometry using

3 Mirror and Subroutine. (Using FANUC Controller)

Write the CNC programming for a given geometry using Polar

4
Co -ordinate for drilling cycles.
Write the CNC part programming for a given geometry using
5 Tool Radius Compensation and Repeat loop for Peck Drilling
Cycle. (Using FANUC Controller)

Introduction and programming of all canned cycle of Milling

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machine. (Using FANUC controller)

Demonstration and study of CNC Lathe machine with sample

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programming.

Write CNC programming for given geometry (Lathe) using

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stock removal cycles (Using FANUC controller)

Demonstration of FMS setup.

9 (AS / RS, AGV, CNC Lathe, CNC Milling, Robot & CMM
setup)
Demonstration of Advance manufacturing Machines like AJM
10 (Abrasive Jet Machine), EDM (Electro Discharge Machine), µ
Machine (Micro Machine), VMS (Vision Measuring System).
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Practical No: 01
AIM: Demonstration of CNC Milling machine with user interface and calculating
the Co-ordinates of given geometry in absolute and increment mode for
cutter path.

Coordinate System for a CNC Mill:

Machining of a workpiece by an NC program requires a coordinate system

to be applied to the machine tool. As all machine tools have more than
one slide, it is important that each slide is identified individually. There are
three planes in which movement can take place.

 Longitudinal

 Vertical

 transverse

Each plane is assigned a letter and is referred to as an axis, i.e.

 Axis X

 Axis Y

 Axis Z

The three axis are identified by upper case X, Y and Z and the direction of
movement along each axis is specified as either PLUS (+) or Minus (-).
The Z axis is always parallel to the main spindle of the machine. The X
axis is at right angles to both Z and X axis. Fig. 1 shows Coordinate
System for Milling Work.

Fig. 1 Coordinate System for Milling Work

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Zero points and Reference Points

On CNC machines, tool traverses are controlled by coordinating systems.

Their accurate position within the machine tool is established by ‘Zero
Points’.

Machine Zero Point (M):

This is specified by the manufacturer of the machine. This is the zero point
for the coordinate systems and reference points in the machine.

The machine zero point can be the center of the table or a point along the
edge of the traverse range as shown in Fig. 2. The position of the machine
zero point generally varies from manufacturer to manufacturer. The
precise position of the machine zero point as well as the axis direction
must therefore be taken from the operating instruction provided for each
individual machine.

Fig. 2 Example of the Position of Machine Zero Points

Reference Point (R):

This point serves for calibrating and for controlling the measuring system
of the slides and tool traverses. The position of the reference point as
shown in Fig. 3 is accurately predetermined in every traverse axis by the
trip dogs and limit switches. Therefore, the reference point coordinates
always have the same, precisely known numerical value in relation to the
machine zero point.

After initiating the control system, the reference point must always be
approached from all axis to calibrate the traverse measuring system. If
current slide and tool position data should be lost in the control system
as, for example, through an electrical failure, the machine must again be
positioned to the reference point to re-establish the proper positioning
values.

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Fig. 3 Position of Reference Point on a Milling Machine

Workpiece Zero Point (W):

The point determines the workpiece coordinate system in relation to the

machine zero point. The workpiece zero point is chosen by the
programmer and input into the CNC System when setting up the machine.
The position of the workpiece zero point can be freely chosen by the
programmer within the workpiece envelope of the machine. It is,
however, advisable to place the workpiece zero point in such a manner
that the dimensions in the workpiece drawing can be conveniently
converted into coordinate values and orientation when clamping/chucking,
setting up and checking, the traverse measuring system can be affected
easily.

For milled parts, it is generally advisable to use an extreme corner point

as the “Workpiece Zero Point” as shown in Fig. 4. Occasionally, the
workpiece zero point is also called the ‘Program zero point’.

Fig. 4 Example for the Position of Workpiece Zero Point for a Milling Part

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Tool Reference Points:

When machining a workpiece, it is essential to able to control the tool

point or the tool cutting edges in precise relationship to the workpiece
along the machining path. Since tool have different shapes and
dimensions, precise tool dimensions have to be established beforehand
and input into the control system. The tool dimensions are related to a
fixed tool setting point during pre-setting.

The tool setting point E is located at a certain point on the tool holder as
shown in Fig. 5. This setting point permits measuring of tool away from
the CNC machine. The data thus measured such as tool length, tool point
offset or tool radius are input into the tool data storage (memory) of the
control system. The mate of the tool setting point is the socket point N on
the tool carrier. When the tool or tool holder is inserted into the tool
carrier (e.g., turret), the setting point and the tool socket point coincide.

When programming a workpiece contour, it is always the traverse of the

tool cutting edge that is of significance. The tool carrier, e.g., the main
spindle on a milling machine, must then move in a way that the tool
cutting edge follows precisely in the desired contour.

Fig. 5 Tool Reference Points

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Cutter Path Co-ordinate Calculations:

Absolute Increment

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Practical No: 02
AIM: Introduction of G codes and M codes and write the CNC part programming
for a given geometry using Linear, Circular interpolation. (Using FANUC
Controller)

G-codes:
G00 Positioning G45 Tool compensation increase
G01 Linear interpolation G46 Tool compensation decrease
G02 Circular interpolation CW G49 Tool length compensation cancel
G03 Circular interpolation CCW G73 Peck drilling cycle
G04 Dwell, Exact Stop G74 Counter tapping cycle
G05 High-speed continuous cutting G76 Fine boring cycle
G07 SINE interpolation G80 Canned cycle cancel
G09 Exact stop check G81 Drilling cycle
G10 Offset value setting / work zero G82 Drilling cycle/counter boring
offset setting G83 Peck drilling cycle
G17 XY plane selection G84 Tapping cycle
G18 ZX plane selection G85 Boring cycle with feed retraction
G19 YZ plane selection G86 Boring cycle with rapid retraction
G20 Inch data input G87 Back boring cycle
G21 Metric data input G88 Boring cycle
G22 Stored stroke limit on G89 Boring cycle
G23 Stored stroke limit off G90 Absolute programming
G27 Zero return check G91 Incremental programming
G28 Automatic Zero Return G92 Programming of absolute zero
G31 Skip cutting point
G33 Thread cutting G94 Feed per minute
G40 Cutter compensation cancel G95 Feed per revolution
G41 Cutter compensation left side G98 Return to initial point level in
G42 Cutter compensation right side canned cycle
G43 Tool length compensation (+) G99 Return to R point level in canned
G44 Tool length compensation (-) cycle

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M -codes:
(These are just EIA standard M-codes and every machine builder can make his own codes.)

M00 Program Stop M18 Unassigned

M01 Optional (Planned) Stop M19 Oriented Spindle Stop
M02 End of Program M20-29 Permanently Unassigned
M03 Spindle CW M30 End of Tape
M04 Spindle CCW M31 Interlock Bypass
M05 Spindle OFF M32-35 Unassigned
M06 Tool Change M36-39 Permanently Unassigned
M07 Coolant No. 2 ON M40-45 Gear Changes if Used,
M08 Coolant No. 1 ON Otherwise Unassigned
M09 Coolant OFF M46-47 Unassigned
M10 Clamp M48 Cancel
M11 Unclamp M49 Bypass Override
M12 Unassigned M50-89 Unassigned
M13 Spindle CW & Coolant ON M70 Mirror in X
M14 Spindle CCW & Coolant ON M71 Mirror in Y
M15 Motion + M98 Subprogramme Call
M16 Motion - M99 Subprogramme calcel
M17 Unassigned

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Parameters
Block Code X Y Z Comment

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Parameters
Block Code X Y Z Comment

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Practical No: 03
AIM: Write the CNC part programming for a given geometry using Mirror and
Subroutine. (Using FANUC Controller)

M-codes for Mirror:

XL Mill (FANUC Controller) Denford CNC Machine

M70 Mirror in X On G10 Mirror in X On
M71 Mirror in Y On G11 Mirror in X Off
M80 Mirror in X Off G12 Mirror in Y On
M81 Mirror in Y Off G13 Mirror in Y Off

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Parameters
Block Code X Y Z Comment

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Parameters
Block Code X Y Z Comment

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M-codes for Sub Program:

XL Mill (FANUC Controller) Denford CNC Machine

M98 Sub Program Call G65 L1 Subroutine Call
M99 Sub Program End and Return G28 L1 Subroutine Start
G05 Subroutine End

 A subprogram is a fixed sequence of operations which can be programmed by the

user and called from within a program or another subprogram.
 It is just like a canned cycle because subprogram is used for repetitive operations
and for programming of frequently repeated patterns.
 In subprogram the tool movements are user defined and fixed for a specific
application.
 It has its own program number and contains all the usual features of standalone
program.
 It can be loaded in memory of controller and can be called, viewed, edited and
deleted by the programmer as and when required.
 It can’t be run independent of standalone program.

Parameters
Block Code X Y Z Comment

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Parameters
Block Code X Y Z Comment

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Practical No: 04
AIM: Write the CNC programming for a given geometry using Polar Co -ordinate
for drilling cycles. (Using FANUC Controller)

G-codes for Polar coordinate:

G16 Polar coordinate system set/on

G17 Polar coordinate system cancel

 Most machining center programmer use trigonometry to calculate the

cartesian coordinates for the each hole on pitch circle diameter.

 They forced to use cartesian coordinate system because many CNC

controllers do not support polar coordinate system.

Parameters
Block Code X Y Z Comment

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Parameters
Block Code X Y Z Comment

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Practical No: 05
AIM: Write the CNC part programming for a given geometry using Tool Radius
Compensation and Repeat loop for Peck Drilling Cycle. (Using FANUC
Controller)

G-codes for Tool Radius Compensation:

XL Mill (FANUC Controller)

G40 Cancel Cutter Radius Compensation
G41 Left Hand Cutter Radius Compensation
G42 Right Hand Cutter Radius Compensation

Parameters
Block Code X Y Z Comment

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Parameters
Block Code X Y Z Comment

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Parameters
Block Code X Y Z Comment

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Parameters
Block Code X Y Z Comment

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G-codes for Loop:

Denford CNC Machine

G73 Repeat Loop

G06 End of Loop

G-codes for Peck Drilling Cycle:

XL Mill (FANUC Controller)

G73 High Speed Peck Drilling Cycle G83 Deep Hole Peck Drilling Cycle

 When machining, the drill is positioned at the co-ordinate point of the first hole,
for the X and Y axes and at the initial level, for the Z axis.

The G73 command is then read into the machine controller and the cycle begins.

The drill will rapid traverse to the R point level and begin to feed in, until a cut-in
distance of Q is attained.

At this point, the drill will retract a small distance (set within the machine
controller).

A cut-in distance of Q at the same feedrate will begin again, followed by a similar
retraction.

These movements will continue until the total Z depth has been reached.

The drill will rapid traverse out to the Initial level, if a G98 code is programmed
within the cycle, or to the R point level, if a G99 code is programmed within the
cycle.

At this point the next block is read into the machine controller.

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If this block contains an X, Y or X and Y coordinate the drill will position itself at
that point and the high speed peck drilling cycle will begin again.

Parameters
Block Code X Y Z Comment

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Parameters
Block Code X Y Z Comment

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Exercise:
Write a manual part program for Pocketing operation for the given component

Parameters
Block Code X Y Z Comment

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Parameters
Block Code X Y Z Comment

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Practical No: 06
AIM: Introduction and programming of all canned cycle of Milling machine.
(Using FANUC controller)

 A canned cycle simplifies the program using a single block with a G code to
specify the machining operations usually specified in several blocks.

 Generally, a canned cycle consist of a sequence of six operations as shown below

Operation Description
1 Positioning of axes X and Y (including another axis)
2 Rapid traverse up to point R
3 Hole machining
4 Operation at the bottom of a hole
5 Retraction to point R
6 rapid traverse up to the initial point

 There are three command modes for canned cycles, as follows:

1) Data Format (G90 and G91).

2) Return Point Level (G98 and G99).

3) Cycle Mode (G73 to G89).

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DATA FORMAT COMMAND MODES.

The data format used in canned cycles is specified by the codes G90 and G91, as
shown below:

G90 - Absolute Data Format

G91 - Incremental Data Format

RETURN POINT LEVEL COMMAND MODES.

The return point position of the tool (i.e. to the Initial Level, or the R Level) is
specified by the codes G98 and G99.

The Initial level refers to the absolute value of the Z axis, at the time of change
from the positioning mode top the canned cycle mode.

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G98 - Initial Point Level Return G99 - R Point Level Return

 The format for machining data in a canned cycle is written as follows:

(G90) (G98)
or or G.... X.... Y.... Z.... R.... P.... Q.... K.... F....
(G91) (G99)

where,

G.... is defined as the canned cycle.

X.... Y.... is defined as the hole position, in absolute or incremental value.

Z.... is defined as the distance from the R point to the bottom of the hole in
incremental mode, or the position of the hole bottom in absolute mode.

R.... is defined as the distance from the initial level to the R point level in
incremental mode, or the position of the Z datum in relation to the R point
level in absolute mode.

P.... is defined as the dwell time to be performed at the bottom of the hole (i.e.
G04 code).

Q.... is defined as the cut-in distance value or shift value (Note - this is always
specified as an incremental value).

K.... is defined as the number of repeats, for a series of holes. When not
specified, K=1.

F.... is defined as the feedrate for machining.

 Note:

1) The addresses P and Q are omitted within some canned cycles.

2) Once the drilling data has been specified and read into the machine
controller, it is retained until it is either changed, or the canned cycle
cancelled.

All the required data must be specified when the canned cycle is started and
only the data to be changed has to be specified during the cycle.

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CANNED CYCLES

Drilling Operation at the Retraction

G Code Application
(-Z direction) bottom of a hole (+Z direction)

G73 Intermittent - Rapid traverse High speed

feed peck drilling
cycle

G74 Feed Dwell--> spindle Feed Left Hand

CW tapping cycle
G76 Feed Oriented spindle Rapid Traverse Fine boring
stop cycle

G80 - - - Canned cycle

Cancel

G81 Feed - Rapid Traverse Drilling Cycle,

spot drilling
cycle

G82 Feed Dwell Rapid Traverse Drilling Cycle,

Counter Boring
cycle

G83 Intermitted - Rapid Traverse Deep Hole

Feed Peek drilling
cycle

G84 Feed Dwell--> Feed Tapping Cycle

Spindle CCW
G85 Feed - Feed Boring cycle
G86 Feed Spindle stop Rapid traverse Boring Cycle
G87 Feed Spindle CW Rapid Traverse Back boring
cycle
G88 Feed Dwell--> spindle Manual Boring cycle
stop

G89 Feed Dwell Feed Boring Cycle

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Parameters
Block Code X Y Z Comment

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Parameters
Block Code X Y Z Comment

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Practical No: 07
AIM: Demonstration and study of CNC Lathe machine with sample
programming.

 The engine lathe, one of the most productive machine tools, has always been an
efficient means of producing round parts.

 Most lathes are programmed on two axes.

 The X axis controls the cross motion of the cutting tool.

 Negative X (X-) moves the tool towards the spindle centerline; positive X moves
the tool away from the spindle centerline.

 The Z axis controls the carriage travel toward or away from the headstock.

Programming Hints

Indicates the X Z 0 (zero) location which is the starting point for

programming.

Indicates the tool-change position.

 For a program to run on a machine, it must contain the following codes:

M03 To start the spindle/cutter revolving.

Sxxx The spindle speed code to set the r/min.

The feedrate code to move the cutting tool or workpiece to the desired
Fxx
position.

 The X Z coordinates of the small diameter, the large diameter, and a feedrate
must be programmed.

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 Z moves the cutting tool longitudinally away from the end of the workpiece.

 Z- moves the cutting tool along the length of the workpiece towards the chuck
(headstock).

 X moves the cutting tool away from the work diameter.

 X- moves the cutting tool into the work diameter.

 The G28 code is used to set the programmed offset of the reference point.

 Codes are modal and do not have to be repeated in every sequence line.

 All dimensions are entered as decimals.

CNC Turning Center G Codes

G Code Application

G00 RAPID POSITIONING MOTION

G01 LINEAR INTERPOLATION MOTION

G01 CHAMFERING AND CORNER ROUNDING

G02 CW CIRCULAR INTERPOLATION MOTION

G03 CCW CIRCULAR INTERPOLATION MOTION

G04 DWELL (P) (P=seconds”.”milliseconds)

G05 FINE SPINDLE CONTROL MOTION (X,Z,U,W,R,F) (LIVE TOOLING)

G09 EXACT STOP, NON-MODAL

G10 PROGRAMMABLE OFFSET SETTING (X,Z,U,W,L,P,Q,R)

G14 MAIN-SPINDLE SHIFT TO SUB-SPINDLE

G15 MAIN-SPINDLE SHIFT TO SUB-SPINDLE CANCEL

G17 CIRCULAR MOTION XY PLANE SELECTION

G18 CIRCULAR MOTION ZX PLANE SELECTION

G19 CIRCULAR MOTION YZ PLANE SELECTION

G20 VERIFY INCH COORDINATE POSITIONING

G21 VERIFY METRIC COORDINATE POSITIONING

G28 MACHINE ZERO RETURN THRU REF. POINT

G29 MOVE TO LOCATION THROUGH G29 REF. POINT

G31 FEED UNTIL SKIP FUNCTION

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CNC Turning Center G Codes

G Code Application

G32 THREAD CUTTING PATH, MODAL

G40 TOOL NOSE COMPENSATION CANCEL G41/G42

G41 TOOL NOSE COMPENSATION, LEFT

G42 TOOL NOSE COMPENSATION, RIGHT

G50 SPINDLE SPEED MAXIMUM RPM LIMIT (S)

G51 RETURN TO MACHINE ZERO, CANCEL OFFSET

G52 WORK OFFSET COORDINATE POSITIONING

G52 GLOBAL WORK COORDINATE SYSTEM SHIFT

G53 MACHINE COORDINATE POSITIONING, NON-MODAL

G54 WORK OFFSET COORDINATE POSITIONING #1

G55 WORK OFFSET COORDINATE POSITIONING #2

G56 WORK OFFSET COORDINATE POSITIONING #3

G57 WORK OFFSET COORDINATE POSITIONING #4

G58 WORK OFFSET COORDINATE POSITIONING #5

G59 WORK OFFSET COORDINATE POSITIONING #6

G61 EXACT STOP, MODAL (X,Z)

G64 EXACT STOP G61 CANCEL (SETTING 56)

G65 MACRO SUB-ROUTINE CALL

G96 CONSTANT SURFACE SPEED, CSS ON (S)

G97 CONSTANT NON-VARYING SPINDLE SPEED, CSS OFF (S)

G98 FEED PER MINUTE (F)

G99 FEED PER REVOLUTION (F)

G10 MIRROR IMAGE CANCEL

G11 CARTESIAN TO POLAR TRANSFORMATION

G18 REVERSE TAPPING CANNED CYCLE

G19 SUB-SPINDLE / TAPPING CANNED CYCLE

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All Dimensions are in Inch

Parameters
Block Code X Z Comment

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Parameters
Block Code X Z Comment

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Exercise : 01

Write manual part program for the part shown in following figure. Assume that the
raw material is cylindrical bar of size Ø 52 mm × 125 mm.

Parameters
Block Code X Z Comment

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Parameters
Block Code X Z Comment

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Exercise : 02

Write manual part program using (1) radius of arc programming method and (2)
centre of arc programming method, for finishing cut only. Part is shown in following
figure. Assume that the part is already rough turned.

Parameters
Block Code X Z Comment

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Parameters
Block Code X Z Comment

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Practical No: 08
AIM: Write CNC programming for given geometry (Lathe) using stock removal
cycles (Using FANUC controller)

 Straight turning and taper turning are the basic operations perform on a tuning
center.

 Generally to perform both these operations, programmer has to write four block
by using G00 and G01 codes for single cut. These blocks are

1) G00 : Rapid positioning to start up position; at depth of cut

2) G01 : Material removal with specified feed

3) G01 : Retract the tool with already specified feed

4) G00 : Return to start up point

 A canned cycle or stock removal cycle combine all these blocks in a single NC
block. So, material is removed from the stock until the specified profile is
achieved.

 Hence, program length and time to write the program is reduce drastically. It
also reduces the programming error.

STOCK REMOVAL CYCLES

G Code Application

G71 O.D. / I.D. Stock Removal Cycle (Turning Cycle)

Roughing
G72 End Face Stock Removal Cycle (Facing Cycle)
Cycle

G73 Irregular Path Stock Removal Cycle (Profile repetition)

G70 Finishing Cycle

G74 Face Grooving or High Speed Peck Drill Cycle Finishing

Cycle
G75 O.D. / I.D. Peck Grooving Cycle

G76 Thread Cutting Cycle, Multiple Pass

G90 O.D. / I.D. Rectangular Turning Cycle

G92 Thread Cutting Cycle

G94 End Facing Cycle

G95 End Face Live Tooling Rigid Tap

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STOCK REMOVAL CYCLES

G Code Application

G77 Flatting Cycle

G80 Cancel Canned Cycle

G81 Drill Canned Cycle

G82 Spot Drill / Counter-bore Canned Cycle

G83 Peck Drilling Canned Cycle

G84 Tapping Canned Cycle

G85 Bore In, Bore Out Canned Cycle

G86 Bore In, Stop, Rapid Out Canned Cycle

G87 Bore In, Stop, Manual Retract Canned Cycle

G88 Bore In, Dwell, Manual Retract Canned Cycle

G89 Bore In, Dwell, Bore Out Canned Cycle

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Parameters
Block Code X Z Comment

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