CIM Lab.pdf

Mechanical Engineering Department CIM & Automation Lab (10ME78)
LIST OF PROGRAMS
TURNING OPERATION
1) Write a manual part program for Simple Facing Operation
2) Write a manual part program for Simple Turning Operation
3) Write a manual part program for Linear and Circular Contour Operation
4) Write a manual part program for Box Facing Operation
5) Write a manual part program for Taper Facing Operation
6) Write a manual part program for Multiple Facing Operation
7) Write a manual part program for Step Turning Operation
8) Write a manual part program for Taper Turning Operation
9) Write a manual part program for Multiple Turning Operation
10) Write a manual part program for External Grooving Operation
11) Write a manual part program for External Threading operation
12) Write a manual part program for Peck drilling operation
13) Write a manual part program for Step Boring operation
14) Write a manual part program for Boring operation
15) Write a manual part program for turning and parting off operation through subprograms
MILLING OPERATION
16) Write a manual part program for Contouring operation
17) Write a manual part program for contouring operation with left cutter diameter compensation
18) Write a manual part program for contouring operation with right cutter diameter compensation
19) Write a manual part program for contouring operation through subprogram
20) Write a manual part program for Mirroring operation
21) Write a manual part program for Drilling operation
PESIT Page 1

PART PROGRAMMING FUNDAMENTALS
NC PROCEDURE
The following are the basic steps in NC procedure
 Process Planning
 Part Programming
 Part Program entry
 Proving the part program
 Production
A) PROCESS PLANNING
The part programmer will often carryout the task of process planning. Process planning is the procedure of
deciding what operations are to be done on the component, in what order, and with what tooling and work
holding facilities. Both the process planning and part programming aspects of manufacture occur after the
detail drawings of a component have been prepared. The following procedure may be used as a guide to
assist the programmer, by describing each step required in preparing the method of production.
PROCESS PLANNING
 Receive the part drawing . from part drawing information, check suitability of part to be
machined against the machine capacity.
 Determine a method of driving the component (chuck type, chuck size, type of jaw) and
the method of machining.
 Determine the tooling required to suit the method of machining and utilize as much as
possible the tools which are permanently in the turret set upon the machine.
 Determine the order of machining and the tooling stations.
 Determine planned stops for checking dimensional sizes where required by operator
 Determine cutting speeds based on
- Component material, method of driving, rigidity of component
- Tooling selected for roughing and finishing
 Determine the depths of cut and feeds for roughing operations
 Determine surface finish requirements, the cutter nose radius most suited for finishing
operations and determine feed rates.
 Allocates tool offsets as required
 Complete planning sheet
B) PART PROGRAMMING
 After completing the planning sheet, draw the component showing the cutter paths (a
simple sketch is sufficient for simple components)
 Select a component datum and carryout the necessary calculations at slopes and arcs.
 Prepare tooling layout sheet showing tools to be used in the program and indicate the
station number for each tool.
 Indicate the ordering code for each tool and grade and type of inserts to be used.
 Write the part program according to the sequence of operations.
C) PART PROGRAM ENTRY OR TAPE PREPARATION
The part program is prepared / punched on a 25 mm wide paper tape with 8 tracks and is fed to MCU in
order to produce a component of interest on machine tool. Other forms of input media include, punched
cards, magnetic tape, 35 mm motion picture film. The input to the NC system can be in two ways :
1. Manual data input
2. Direct Numerical control.
PESIT Page 2

1) Direct Data Input(MDI) : Complete part programs are entered into CNC control unit via the console
keyboard. It is suited only for relatively simple jobs. The most common application for MDI is the editing
of part programs already resident in controllers memory.
One variation of MDI is a concept called “Conversational Programming”. CNC machines are programmed
via a question and answer technique whereby a resident software program asks the operator a series of
questions. In response to the operators input, and by accessing a pre-programmed data file, the computer
control can
- Select numerical values for use within machining
calculations
- Perform calculations to optimize machining conditions
- Identify standard tools and coordinates
- Calculate cutter paths and coordinates
- Generate the part program to machine the component
A typical dialogue from the machine would be as follows for the operator to identify such things as :
- Material to be cut
- Surface roughness
tolerance
- Machined shape required
- Size of the raw material
blank
- Machining allowances,
cut directions
- Tools and tool detail etc.
The operator may then examine and prove the program via computer graphics simulation on the console
VDU. After this, the program is stored or punched on tape. Although there is some sacrifice in machine
utilization, actual programming time is minimal and much tedious production engineering work is
eliminated.
2) Direct Numerical Control : The process of transferring part programs into memory of a CNC machine
tool from a host computer is called Direct Numerical Control or DNC
D) PROVING PART PROGRAMS
It is safe practice to check the programmed path for any interference between the tool and the work
before using the part program for production. The proving part program is done by :
- Visual
inspection
- Single step
execution
- Dry run
- Graphical
simulation.
Visual Inspection : It represents the method of checking visually the program present in the memory of
the CNC machine. In this, actual program is run and the programmed movements in all axes are to be
checked along with ensuring the tool offset and cutter compensation feature. This method represents the
least form of verification and should not be relied up on entirely.
Single Step Execution : Before auto-running the part program it should be executed in a step mode i.e
block by block. During this execution, spindle speed and feed rate override facilities are to be used so that
axes movement can be easily monitored. This operation may be carried out with or without mounting the
component on the machine.
PESIT Page 3

Dry run : A dry run consists of running the part program in auto-mode. During this, the component is not
installed on the machine table and the cutting is done in air. The purpose of this run is to verify the
programmed path of the tool under continuous operation and to check whether adequate clearance exist
between the clamping arrangement and other projections within the set up. Feed rate override facilities are
used to slow down the speed of execution of the program.
Graphical simulation : A graphical simulation package emulates the machine tool and, using computer
graphics, plots out the machine movements on a VDU screen. Machine movement often takes the form a
cutting tool shape moving around the screen according to the programmed movements. When the tool
shape passes over a shaded representation of the component, it erases that part of the component. The
resulting shape, lest after the execution represents the shape of the finished component. Any gross
deviations from the intended tool path can be observed and any potential interferences can be highlighted.
PART PROGRAMMING GEOMETRY
A. COORDINATE SYSTEM FOR A CNC LATHE.
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 two planes in which movements can take place
 Longitudinal.
 Transverse.
Each plane is assigned a letter and is referred to as an axis,
 Axis X
 Axis Z
The two axis are identified by upper case X,Z and the direction of movement along each axis (+) or (-).
The Z axis is always parallel to the main spindle of the machine. The X axis is always parallel to the work
holding surface, and always at right angles to the Z axis. The coordinate system for turning operations is
shown in figure below
PESIT Page 4

B. ZERO POINTS AND REFERENCE POINTS
All CNC machine tool traverses are controlled by coordinating systems. Their accurate position within the
machine tool is established by “ZERO POINTS”.
MACHINE ZERO POINT (M) : is specified by the manufacturer of the machine. This is the zero point
for the coordinate systems and reference points in the machine. On turning lathes, the machine zero point
is generally at the center of the spindle nose face. The main spindle axis (center line) represents the Z axis,
the face determines the X axis. The directions of the positive X and Z axes point toward the working area
as shown in figure below:
WORKPIECE ZERO POINT (W) : This point determines the workpiece coordinate system in relation
to the machine zero point. The workpiece zero pint 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 effected easily.
For turned parts, the workpiece zero point should be placed along the spindle axis (center line), in line with
the right hand or left hand end face of the finished contour as shown in figure. Occasionally the workpiece
zero point is also called the “program zero point.”
REFERNCE 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 figure below 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 axes 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.
PESIT Page 5

C. NC- RELATED DIMENSIONING
Dimensional information in a workpiece drawing can be stated in two ways :
1.Absolute Dimension System: Data in absolute dimension system always refer to a fixed reference point
in the drawing as shown in figure A above. This point has the function of a coordinate zero point as in
figure B. The dimension lines run parallel to the coordinate axes and always start at the reference point.
Absolute dimensions are also called as “Reference dimensions”.
2. Incremental Dimension System: When using incremental dimension system, every measurement refers
to a previously dimensioned position as shown in figure A below. Incremental dimensions are distance
between adjacent points. These distances are converted into incremental coordinates by accepting the last
dimension point as the coordinate origin for the new point. This may be compared to a small coordinate
system, i.e. shifted consequently from point to point as shown in figurer B. Incremental dimensions are
also frequently called “Relative dimensions” or “Chain dimensions”.
NC PROGRAM BUILD UP
In an NC program the machining steps (Operations) for producing a part on the machine tool are laid down
in a form that the control system can understand. A program is composed of several blocks. A block is a
collection of NC words. An NC word is a collection of address letter and a sequence of numbers. Table
shows the address letters
Address Characters
Character Meaning
A Rotation about, X-axis
B Rotation about, Y-axis
C Rotation about, Z-axis
PESIT Page 6

D & E Rotation about additional axis
F Feed
G Preparatory function, identifying the action to be executed
I Interpolation parameter / Thread pitch parallel to X-axis.
J Thread pitch parallel to Y-axis
K Thread pitch parallel to Y-axis
M Auxiliary function
N Block Number
P,Q,R Thread movement parallel to X,Y,Z axis respectively. P & Q are also
used as parameters in cycles.
S Spindle speed
T Tool
U,V,W Second movement parallel to X,Y,Z axis respectively
X Movement in X-axis
Y Movement in Y-axis
Z Movement in Z-axis
All the NC words may not be used on every CNC machine. Using these words as an example, the
composition of a block is assembled as follows:
N G X Z F S T M ;
PART PROGRAM FORMATS
The order in which these words appear in a block of instructions is called the format. Basically there are
two types of format:
 Fixed Block Format
-Fixed sequential format
-Tab sequential format
 Word Address Format
1. FIXED BLOCK FORMAT :
a)Fixed Sequential Format : Every instruction contains all the words in the same sequence irrespective of
the words being the same as in the previous blocks. Hence the identifying address letter need not be
provided. For example, if some coordinate values remain constant from one block to next block these
values have to be specified in the next block also. The data must be input in a specified sequence and
characters within each word must be of the same length.
Example : N010 G00 X10 Z0 F60 S800 EOB
N020 G01 X20 Z0 F60 S800 EOB
b)Tab Sequential Format : The words in each instruction / block are always provided in the same
sequence but each word is preceded by the TAB character. If instructions remain unchanged in succeeding
blocks, the instructions need not be repeated but TAB character must be punched. Here also, the
identifying letter address need not be employed.
Example : N010 G00 X10 TAB Z0 TAB F60 TAB S800 EOB
N020 G01 X20 EOB
2. WORD ADDRESS FORMAT: Each word is preceded and identified by its letter address. This format
enables instructions which remain unchanged from the preceding block, to be omitted from succeeding
blocks. This system speeds programming, and tape lengths are considerably reduced. This is the format
PESIT Page 7

adopted by most CNC machine control units. Detailed format classification is provided by the control
system manufacturer.
Example : N010 G00 X10 Z0 F60 S800 EOB
N020 G01 X20 EOB
FANUC TURNING PROGRAMMING
MISCELLANEOUS FUNCTION (M Codes)
M Codes are instructions describing machine functions such as calling the tool, spindle rotation, coolant
on, door close/open etc.
M CODES
M00 Program Stop
M02 Optional Stop
M03 Spindle Forward (CW)
M04 Spindle Reverse (CCW)
M05 Spindle Stop
M06 Tool Change
M08 Coolant On
M09 Coolant Off
M10 Vice Open
M11 Vice Close
M13 Spindle Forward, Coolant On
M14 Spindle Reverse, Coolant On
M30 Program End
M38 Door Open
M39 Door Close
M98 Subprogram Call
M99 Subprogram Exit
M00 PROGRAM STOP : By inserting M00 in a program, the cutting cycle is stopped after the block
containing M00 code. This facility is useful if an inspection check is necessary during an operation. The
cycle is then continued by a cycle start.
M01 OPTIONAL STOP : Cycle operation is stopped after a block containing M01 is executed. This code
is only effective when the optional stop switch on the machine control panel has been pressed.
M02 PROGRAM END : This code is inserted at the end of the program, when encountered the cycle will
end. To produce another, the system must be reset.
M03 SPINDLE FORWARD : Starts the spindle spinning forward, clockwise or negative direction at the
last specified spindle rate.
M04 SPINDLE REVERSE : Starts the spindle spinning reverse, counter clockwise or positive direction
at the last specified spindle rate.
M05 STOP SPINDLE : Stops the spindle without changing the spindle speed.
M06 TOOL CHANGE : The M06 in conjunction with “T” word is used to call up the required tool on an
automatic indexing turret machine, and to activate its tool offsets. The left most digit of the “T” ignoring
zeros, Selects the new tool. Tool changes are normally performed with the tool post at a safe position away
from the workpiece, so the code G28 REFERENCE POINT RETURN would be used in the block prior to
M06.
M08 COOLANT ON : Turns the coolant on.
M09 COOLANT OFF : Turns the coolant off.
PESIT Page 8

M10 CHUCK OPEN : Opens pneumatic or similar automatic chuck to allow for bar feed.
M11 CHUCK CLOSE : Closes the chuck.
M13 SPINDLE FORWARD, COOLANT ON : Sets spindle rotation forward and sets the coolant on,
both are performed by single code.
M14 SPINDLE REVERSE, COOLANT ON : Sets the spindle rotation in reverse direction and sets the
coolant on.
M30 PROGRAM END : Stops the spindle, turns the coolant off, terminates and resets the CNC program.
M38 DOOR OPEN : Opens the door, waiting until the door is open.
M39 DOOR CLOSE : Closes the door, waiting until the door is closed.
PREPARATORY FUNCTION (G-Codes).
G CODES
G00
G01
G02
G03
Positioning (Rapid Tranverse)
Linear Interpolation (Feed)
Circular Interpolation (CW)
Circular Interpolation (CCW)
G04 Dwell
G20
G21
Inch Data Input
Metric Data Input
G28 Reference point return
G40
G41
G42
Tool nose radius compensation cancel
Tool nose radius compensation left
Tool nose radius compensation right
G50 Work coordinate change/ Max. Spindle speed setting
G70
G71
Finishing cycle
Multiple Turning Cycle in turning
G72
G73
G74
G75
G76
Stock removal in facing
Pattern repeating
Peck drilling in Z axis
Grooving in X axis
Thread cutting cycle
G90
G94
Cutting cycle A (Turning)
Cutting cycle B (Facing)
G96
G97
Constant surface speed control
Constant surface speed control cancel
G98
G99
Feed per minute
Feed per revolution
G00 FAST TRAVERSE
Description Illustration
PESIT Page 9

A rapid traverse instruction traverses the tool to
the target point at the maximum traverse rate. The
tool normally takes the shortest path from the
starting point to the destination point. The rapid
traverse is used for movements where no tool is in
engagement.
G01 LINEAR MOTION
G01 traverses the tool along a linear path to the
given target point with the feed rate input as a
supplementary function. The feed rate determines
the speed with which the workpiece is machined.
The choice of feed rate depends on the tool, the
material being machined, the required surface finish
and the drive rating and rigidity of the machine tool.
When giving the instructions G01, the coordinates
of the destination point can be expressed using
either absolute or incremental dimensions.
Example : G01 X30 Z10 F100 S1000
Target point Feed Speed
G04 DWELL
A G04 causes the program to wait for a specified amount of time. The
time can be specified in seconds with the “X” or “U” prefixes or in
milliseconds with the “P” prefix. A G04 code can be inserted between
the two statements to make a sharp corner.
G04 X1.5
G04 U1.5
G04 P1500
G20 INCH DATA INPUT : A G20 causes position to be as being in imperial units. All the input values
are in inches. This can only be at the start of the main program.
G21 METRIC DATA INPUT : A G21 causes positions to be interpreted as being in metric units. All the
input values are in mm. This can only be at the start of the main program.
G28 REFERENCE POINT RETURN
A G28 causes a fast traverse to the specified position and then to the
machine datum.
G28 X35 Z5
G28 U0 W0
PESIT Page 10

G40, G41, G42 TOOL NOSE RADIUS COMPENSATION
Description
On Modern CNC machines, special calculation functions or cutter radius compensation codes are
provided to allow a user to utilize part profile coordinates obtainable from the part drawing to
program a contouring motion. These are the G41 and G42 codes for tool radius compensation on
the left and right hand sides of a profile. A left or right compensation is based on the fact that the
tool is on left or right hand side when one goes along the part profile in the direction specified by
the contouring motion statements in the program. A G40 code is provided to cancel the cutter
radius compensation.
G50 COORDINATE SETTING
Description
G50 enables tool nose radius compensation to the left of the programmed path. G50 has 2 uses.
Coordinate setting block has “X”,”Z”,”U”, or “W” upon it. A maximum spindle speed block does
not have all these.
G96 CONSTANT SURFACE SPEED
Description
The cutting speed during turning is the peripheral speed of the work. The peripheral speed is a
rotating work represents the peripheral path in a given unit time as shown in figure. The
peripheral speed or cutting speed is thus the fully stretched chip length produced in one time. The
cutting speeds vary in direct relation to the diameters, even if the number of revolutions per
minute is the same in all cases.
The correct selection of the cutting speed for turning is very important,
Cutting speed too low : Time loss and low surface finish. With increasing cutting speed
the surface speed is improved.
Cutting speed too high : High tool wear.
G97 NORMAL SPINDLE SPEED
Description
G97 cancels constant surface speed. The spindle speed will not change until the next “S” value is
reached.
G98 FEED PER MINUTE :
This command coupled with the F word is used
to specify feed rate per minute. This can be in
either mm/min or inch/min. this is the default.
PESIT Page 11

G99 FEED PER REVOLUTION
This command coupled with the F word is used to
specify a feed rate per revolution. This can be in mm/rev
or inch/rev. the feed rates available in the machine
simulation are 0.01-200 mm/min. Recommended feed
rates are published by tool and cutter manufacturers,
along with recommended cutting speeds. If the feed rate
is expressed as mm/rev, a simple calculation can be used
to convert to mm/min.
FEED, mm/min=FEED(mm/rev) X spindle speed(r.p.m)
PROGRAM BUILD-UP FOR CNC LATHE (FANUC)
CNC program can be divided into 3 parts, Start-up, Body and End of the program.
START-UP OF CNC PROGRAM
O1000
[BILLET X20 Z60
G21/G20 G98/G99 G40
G50 S1800
G28 U0 W0
M06 T0101
M03/M04 S1000
G00 X21 Z1
EXPLANATION
O1000 While writing a program on FANUC controller first line has to be started with
letter ‘O’ followed by four digit number which specifies the program name.
[BILLET X20 Z60 This directive is used only for simulation purpose. It defines the work piece
dimensions as 60 mm long and 20 mm in diameter.
G21/G20 G98/G99 G40 G21 – code specifies that program is done in metric units.
G20 - code specifies that program is done in imperial units
G98 – gives the unit of feed in mm/minute.
G99 - gives the unit of feed in mm/revolution.
G40 – Compensation cancel.
G50 S1800 Clamps the spindle speed at 1800 rpm.
G28 U0 W0 Makes the tool to go to home position. U & W are Secondary movements about
X and Z axis.
M06
T0101
Tool change
The first two digits specify the tool position in the turret and last two digits
denotes the tool offset number.
M03/M04 S1000 M03- makes the spindle rotate in clockwise direction.
M04 – makes the spindle rotate in counter-clockwise direction.
S1000-Spindle rotates at 1000 rpm.
G00 X21 Z1 G00 gives rapid position of the tool to a point X21 Z1 which is just above the
billet. This point is called as the tool entry point.
BODY OF THE PROGRAM: This is dealt operation wise in the succeeding pages.
END OF THE PROGRAM:
G28 U0 W0
M05
M02/30
PESIT Page 12

EXPLANATION
G28 U0 W0 Makes the tool to go to home position. U & W are secondary
movements about X and Z axis.
M05 Stops the spindle rotation
M02/30 M02 – Optional stop
M30 – Program stop and rewind.
METAL CUTTING PARAMETERS FOR STARTURN LATHE
BILLET MATERIAL : Aluminum
OPERATIONS SPEED,
rpm
FEED
mm/min
DEPTH OF CUT,
mm
TURNING 1000-1500 45-55 0.5-1.0
GROOVING 600-800 15-25 0.25-0.5
THREADING 300-350 0.03-0.04
SIMPLE FACING
Write a manual part program for Simple Facing Operation for the component shown in figure
below.
DWG. NO. 1
PLANNING AND OPERATIONS SHEET
BILLET SIZE : 22 x 60 MATERIAL : Aluminum
PROGRAM NO : 1001 DWG NO : 1
SL.NO Operation Tool
Holder
Tool Tip Tool
Station
No
Tool
Offset
No
Spindle
Speed,
rpm
Feed,
mm/min
1 Simple
Facing
SDJCR
1212H11
DCMT
11T304
1 1 1200 45
TOOL OFFSET SHEET
Tool offset No. Compensations, mm Toolnose
Radius, mm
Standard Tool
Number
X Z R
1 0.4 3
PESIT Page 13

CNC program for Simple Facing
Material to be removed by facing : 2mm
O1001 --------- Program Number 1001
[BILLET X22 Z60 --------- Defining Billet size dia : 22 length 60 mm
G21 G98 --------- Initial settings
G28 U0 W0 --------- Going to home position
M06 T0303 ---------- Selecting Tool No. 3 with offset No. 3
M03 S1200 ---------- Setting spindle speed at 1200 rpm
G00 X22 Z1 ---------- Tool moving to tool entry point X22 Z1 at
rapid traverse.
G01 Z-0.5 F45 ---------- Giving depth of cut of 0.5 mm at a feed rate of
45 mm/min.
G01 X0 ---------- Moving the tool to spindle center line
G01 Z1 --------- Retract back the tool
G00 X22 --------- Moving the tool to X22
G01 Z-1 F45 --------- Giving the second depth of cut.
G01 X0
G01 Z1
G00 X22
G01 Z-1.5
G01 X0
G01 Z1
G00 X22
G01 Z-2
G01 X0
G01 Z1
G00 X22 --------- Retract back the tool
G28 U0 W0 -------- Going to home position
M05 -------- Stop the spindle
M30 -------- Program stop and rewind
Note: Tool used External turning MTJNL 2020 K16 R0.8
OR
Tool used Face groove 20*20, 6 W, 28 depth, RH
PESIT Page 14

SIMPLE TURNING
Write a manual part program for Simple Turning Operation for the component shown in figure
below.
DWG. NO. 2
Holder
Tool Tip Tool
Station
No
Tool
Offset
No
Spindle
Speed,
rpm
Feed,
mm/min
1 Simple
Turning
SDJCR
1212H11
DCMT
11T304
1 1 1200 45
TOOL OFFSET SHEET
Radius, mm
Standard Tool
Number
X Z R
1 0.4 3
(CNC program for Simple Turning
(Reducing the diameter from 22 mm to 14 mm
M06 T0303 ---------- Selecting Tool No. 3 with offset No 3
G01 X21 F45 rapid traverse.
G01 Z-30 F45
G00 X22 ---------- Simple Turning operation
G00 Z1
G01 X21
G01 Z-30 F45
G00 X22
G00 Z1
G01 X20
G01 Z-30 F45
G00 X22
G00 Z1
G01 X19
G01 Z-30 F45
G00 X22
G00 Z1
G01 X18
PESIT Page 15

G01 Z-30 F45
G00 X22
G00 Z1
G01 X17
G01 Z-30 F45
G00 X22
G00 Z1
G01 X16
G01 Z-30 F45
G00 X22
G00 Z1
G01 X15
G01 Z-30 F45
G00 X22
G00 Z1
G01 X14
G01 Z-30 F45
G00 X22
G00 Z1
M30 -------- Program stop and rewind.
CIRCULAR INTERPOLATION – G02/G03
Data to be given Command Meaning
1 Rotation Direction G02 Clockwise direction (CW)
G03 Counter clockwise direction
(CCW)
2 End point position Absolute
command
X,Z End point position in the work
coordinate system
Incremental
command
U,W Distance from start point to end
point.
3 Distance from start
point to center
I,K Distance with direction from start
point to arc center.
Radius of arc R Radius of arc.
The end point of an arc is specified by address X,Z or U, W and is expressed as an absolute or
incremental value. For the incremental value, the coordinate of the endpoint which is viewed from the start
point of the arc is specified. The arc center is specified by addresses I and K for the X and Z axis. The
numerical value following I,J is always specified as an incremental value. I and K must be signed
according to the direction. The radius is specified with address R, if the circular path is greater than 1800
,
then R should be negative. For a lathe, because of the characteristics of the turning operation, the circular
motion can only be less than 1800
.
Clockwise and counter clockwise directions of rotations are distinguished on the basis of the rule
that when one looks from the positive direction of the axis perpendicular to the plane on which the circular
motion is performed, the motion is in clockwise and counter clockwise directions respectively. The
clockwise or counter clockwise direction varies in right or left hand coordinate systems as shown in figures
below :
PESIT Page 16

CONTOURING
Write a manual part program for Linear and Circular Contour Operation for the component shown
in figure below.
DWG. NO. 3
Holder
Tool Tip Tool
Station
No
Tool
Offset
No
Spindle
Speed,
rpm
Feed,
mm/min
1
Linear
Interpolation
SDJCR
1212H11
DCMT
11T304
1 1 1200 45
2 Contouring
SDJCR
1212H11
DCMT
11T304
1 1 1200 25
TOOL OFFSET SHEET
Radius, mm
Standard Tool
Number
X Z R
1 0.4 3
PESIT Page 17

(CNC program for Linear and circular interpolation
M06 T0303 ---------- Selecting Tool No. 3 with offset No. 3
rapid traverse.
G00 X5
G01 Z0 F30
G01 X10 Z-10 F45
G01 X10 Z-15
G02 X20 Z-25 R10 F25 ---------- Clockwise Interpolation – G02
G01 Z-30 F45
G03 X25 Z-37 R10 F25 ---------- Counter Clockwise Interpolation – G03
G01 Z-42 F45
X30 Z-47
Z-52
G94 – FACING CYCLE
A G94 is a “Box Type” cutting cycle. This cycle
is used for stock removal either parallel or at an
angle to workpiece face. It is the equivalent of
rapid to Z position, feed to X position, feed to
start Z position, and rapid to start X position. If
the “R” value is specified tapering will be
performed. The sign of “R” depends on
direction of the taper. The initial rapid move will
be to the Z position plus “r” value. As canned
cycles are modal, to repeat the cycle for
removing further material only the value in the
axis to be moved needs to be changed.
a)G94 X(U) Z(W) F
b) G94 X(U) Z(W) R- F
c) G94 X(U) Z(W) R+ F
Where X = diameter to which the movement is
being made.
U= The incremental distance from the current tool
position to the required final diameter.
Z= The Z axis coordinate to which the movement is
being made.
W = The incremental distance from the current tool
position to the required position.
R= The difference in incremental of the cut start
radius value and the cut finish radius value.
PESIT Page 18

BOX FACING
Write a manual part program for Box Facing Operation for the component shown in figure below.
DWG. NO. 4
Holder
Tool Tip Tool
Station
No
Tool
Offset
No
Spindle
Speed,
rpm
Feed,
mm/min
1 Box
Facing
SDJCR
1212H11
DCMT
11T304
1 1 1200 45
TOOL OFFSET SHEET
Radius, mm
Standard Tool
Number
X Z R
1 0.4 3
(CNC program for Facing cycle
G00 X22 Z1 ---------- Tool moving to tool entry point X22 Z1
G94 X10 Z-0.5 F35 ----------- G94 Box Facing cycle
Z-1 G94 code Syntax : G94 X Z F
Z-1.5
Z-2
Z-2.5
Z-3
Z-3.5
Z-4
Z-4.5
Z-5
G00 X22 Z-5
G94 X14 Z-5.5 F35 ----------- G94 Box Facing cycle
Z-6
Z-6.5
Z-7
Z-7.5
PESIT Page 19

Z-8
Z-8.5
Z-9
Z-9.5
Z-10
TAPER FACING
Write a manual part program for Taper Facing Operation for the component shown in figure below.
DWG. NO. 5
Holder
Tool Tip Tool
Station
No
Tool
Offset
No
Spindle
Speed,
rpm
Feed,
mm/min
1 Plain
Turning
SDJCR
1212H11
DCMT
11T304
1 1 1200 35
2 Taper
Facing
SDJCR
1212H11
DCMT
11T304
3 3 1000 30
TOOL OFFSET SHEET
Radius, mm
Standard Tool
Number
X Z R
1 0.4 3
3 0.2 3
CNC program for Taper Facing cycle
G94 X10 Z-0.5 F35 ----------- G94 For Facing cycle
PESIT Page 20

Z-1 G94 code Syntax : G94 X Z F
Z-1.5
Z-2
Z-2.5
Z-3
Z-3.5
Z-4
Z-4.5
Z-5
Z-5.5
Z-6
Z-6.5
Z-7
Z-7.5
Z-8
Z-8.5
Z-9
Z-9.5
Z-10
M06 T0101 -------- using Left Hand Tool
M03 S1000
G00 X22 Z-10
G90 X22 Z-25 R0 F30 ------- Taper Facing Cycle – G94
X22 R-0.5
X22 R-1
X22 R-1.5
X22 R-2
X22 R-2.5
X22 R-3
X22 R-3.5
X22 R-4
X22 R-4.5
X22 R-5
X22 R-5.5
X22 R-6
G28 U0 W0 --------- Going to Home position.
Note: Tool used External turning MTJNL 2020, K16 , R0.8
G72 MULTIPLE FACING
This multiple facing cycle is
used when the major direction
of cut is along the “X” axis.
This cycle causes the profile to
be roughed out by facing.
Control passes on to after the
last block of the profile. Two
G72 blocks are needed to
specify all the values.
G72 W R
G72 P Q U W F S T
Where W – Depth of cut in Z axis
R – Escape of relief amount
P- The line number in the program marking the start of the finished
form required.
Q - The line number in the program marking the end of the finished
form required.
U – The amount and direction of the finishing allowance left in the X
axis
PESIT Page 21

W – The amount and direction of the finishing allowance left in the Z
axis
F – Feed rate
S – Speed
T - Tool number
The values of F,S and T contained in the data blocks for the profiles
are ignored when G72 line is read.
MULTIPLE FACING
Write a manual part program for Multiple Facing Operation for the component shown in figure
below.
DWG. NO. 6
Holder
Tool Tip Tool
Station
No
Tool
Offset
No
Spindle
Speed,
rpm
Feed,
mm/min
1 Multiple
rough
facing
SDJCR
1212H11
DCMT
11T304
1 1 1200 45
2 Finishing SDJCR
1212H11
DCMT
11T302
2 2 1450 25
TOOL OFFSET SHEET
Radius, mm
Standard Tool
Number
X Z R
1 0.4 3
2 0.2 3
(CNC program for Multiple Facing cycle
[BILLET X30 Z60 --------- Defining Billet size dia : 30 mm length 60 mm
(MULTIPLE FACING CYCLE – G72
PESIT Page 22

(Depth of cut for each pass W=0.5 mm
(Relief amount R = 0.5 mm
(P & Q – Beginning & end of cycles sequence Nos.
(Allowances on X and Z axis = 0.1 mm respectively.
(Feed rate F=35 mm/min.
G72 W0.5 R0.5
G72 P10 Q20 U0.1 W0.1 F35
N10 G01 Z-52
X30
Z-47
X25 Z-42
Z-37
G02 X20 Z-30 R10 F25
G01 Z-25
G03 X10 Z-15 R10
G01 Z-10 F35
N20 X5 Z0
G20 U0 W0
M06 T0202 -------- Using Left Hand Finishing tool
M03 S1450
G00 X31 Z1
G70 P10 Q20 F25 --------- Finishing Cycle
G28 U0 W0 --------- Going to Home position.
Note: Tool 1:Tool used External turning MTJNL 2020 K16 R0.8
Tool 2: Tool used External turning MTJNL 2020 K16 R0.8
G90 SINGLE TURNING CYCLE
This cycle can be used to produce either a parallel or tapered tool path. This cycle performs four distinct
moves with one line of information and it is equivalent of
 Rapid to X position
 Feed to Z position
 Feed to start X position
 Rapid to start Z position
With the above command the cycle will execute
removing material to the required diameter and
length. To repeat this cycle to reduce the diameter
but maintain the same length, only the value to be
changed need to be programmed.
G90 X(U) Z(W) F
Where X – Diameter to which the movement
is being made.
U- The incremental distance from the current
tool position to the required final diameter
Z- The Z axis coordinate to which the
movement is being made.
W- The incremental distance from the current
tool position to the required Z axis position
F- Feed
PESIT Page 23

STEP TURNING
Write a manual part program for Step Turning Operation with G90 cycle for the component shown
in figure below.
DWG. NO. 7
Holder
Tool Tip Tool
Station
No
Tool
Offset
No
Spindle
Speed,
rpm
Feed,
mm/min
1 Step
Turning
SDJCR
1212H11
DCMT
11T304
1 1 1200 30
TOOL OFFSET SHEET
Radius, mm
Standard Tool
Number
X Z R
1 0.4 3
(CNC program for Step Turning
G90 X22 Z-30 F30 ----------- G90 Step Turning cycle
X21 G90 code Syntax : G90 X Z F
X20
X19
X18
X17
X16
X15
X14
G00 X14 Z1
G90 X13 Z-15 F30
X12
X11
X10
PESIT Page 24

G90 TAPER TURNING
If an “R” value is specified in the command
format of G90 cycle, tapering will be performed.
The sign of “R” will depend on the direction of
the taper. The initial rapid move will be to the X
position plus the “R” value.
G90 X(U) Z(W) R F
Where X – Diameter to which the movement is
being made.
U- The incremental distance from the current tool
position to the required final diameter
Z- The Z axis coordinate to which the movement is
being made.
W- The incremental distance from the current tool
position to the required Z axis position
R- The difference in incremental of the cut start
radius value and the cut finish radius value.
F- Feed
TAPER TURNING
Write a manual part program for Taper Turning Operation for the component shown in figure
below.
DWG. NO. 8
PESIT Page 25

Holder
Tool Tip Tool
Station
No
Tool
Offset
No
Spindle
Speed,
rpm
Feed,
mm/min
1 Taper
Turning
SDJCR
1212H11
DCMT
11T304
1 1 1200 35
TOOL OFFSET SHEET
Radius, mm
Standard Tool
Number
X Z R
1 0.4 3
(CNC program for Taper Turning
G90 X22 Z-54 F35 ----------- G90 Step Turning cycle
X21 G90 code Syntax : G90 X Z F
X20
X19
X18
X17 Z-6
X16
X15
X14
X13
X12
X11
X10
X9
G00 X18 Z-6
G90 X18 Z-21 R0 F30 -------- Taper Turning – G90 R-
X18 R-0.5 R=(D1-DF)/2
X18 R-1 18 =(9-18)/2
X18 R-1.5 DF 9 D1 =-9/2 = -4.5
X18 R-2
X18 R-2.5
X18 R-3
X18 R-3.5
X18 R-4
X18 R-4.5
G01 X18 Z-33
G90 X18 Z-48 R0 F50 -------- Taper Turning – G90 R+
X17 R0.5 R=(D1-DF)/2
X16 R1 =(18-9)/2
X15 R1.5 9 DF 18 D1 =9/2 = 4.5
X14 R2
X13 R2.5
PESIT Page 26

X12 R3
X11 R3.5
X10 R4
X9 R4.5
G00 X18 Z-48
G90 X18 Z-54 F30 -------- Taper Turning – G90
X17
X16
X15
X14
X13
X12
X11
X10
X9
Note: Tool used External turning PDJNL 2020 K11 R0.4
G71 MULTIPLE TURNING
This multiple turning cycle is used when the major
direction of cut is along the ‘Z’ axis. This cycle causes
the profile to be roughed out by turning. Control
passes on to after the last block of the profile. Two
G71 blocks are needed to specify all the values.
G71 U(*u1) R
G71 P Q U(*u2) W F S T
Where u1 – Depth of cut (Radius
Designation).
R- Relief amount, F – Feed rate, S - Speed
P- Line or block number of the start of the
final profile.
Q- Line or block number of the end point of
the final profile, T – Tool number.
U2 – Finishing allowance in the X axis.
W- Finishing allowance in the Z axis.
G70 FINISHING CYCLE
On completion of roughing out operation using cycles
G71, G72 or G76, the material left as a finishing
allowances is removed using the finishing cycle G70.
the tool path program used as the finishing cycle are
the same programming lines that the roughing cycle is
based on. A G70 cycle causes a range of blocks to be
executed, then control passes to the block after the
G70.
N40 G71 U(*u1) R
N50 G71 P60 Q120 U(*u2) W F S
…………….
…………….
…………….
N130 G70 P60 Q120
The ‘P’ and ‘Q’ values specifies the ‘N’ block
numbers at the start and end of the profile.
PESIT Page 27

MULTIPLE TURNING
Write a manual part program for Multiple Turning Operation for the component shown in figure
below.
DWG. NO. 9
Holder
Tool Tip Tool
Station No
Tool
Offset No
Spindle
Speed,
rpm
Feed,
mm/min
1 Multiple
Rough
turning
SDJCR
1212H11
DCMT
11T304
1 1 1200 35
2 Finishing SDJCR
1212H11
DCMT
11T302
2 2 1450 25
TOOL OFFSET SHEET
Radius, mm
Standard Tool
Number
X Z R
1 0.4 3
2 0.2 3
(CNC program for Multiple Turning
(G71 MULTIPLE TURNING
(Depth of cut for each pass U=0.5 mm
(Relief amount R= 1.0 mm
(P and Q : Beginning and end of cycle sequence Nos.
(Allowances on X(U) and Z(W) axis=0.1 mm respectively.
(Feedrate= 35 mm/min.
G71 U0.5 R1
G71 P10 Q20 U0.1 W0.1 F35
PESIT Page 28

N10 G01 Z0
G01 X5
G01 X10 Z-10
G01 Z-15
G02 X20 Z-25 R10
G01 Z-30
G03 X25 Z-37 R10
G01 Z-42
X30 Z-47
N20 Z-52
G28 U0 W0
M06 T0202 ---------- Using RH Finishing tool.
M03 S1450
G00 X32 Z1
G70 P10 Q20 F25
G75 EXTERNAL GROOVING CYCLE
This cycle is designed for Outer/ Inner
diameter drilling. The drill entering the
workpiece by a predetermined amount then
backing off by another set amount to
provide breaking and allowing swarf to
clear the drill flutes. The cycle is
commanded by two distinct lines of data.
G75 R
G75 X(u) Z(w) P Q F
Where R – Return amount
X – Total depth along X axis(absolute)
U – Total depth along X axis(Incremental)
Z – Total width along Z axis(absolute)
W – Total width along Z axis (Incremental)
P – Peck increment in X axis in microns.
Q – Stepping distance in Z axis in microns.
F- Feed rate in mm.
EXTERNAL GROOVING
Write a manual part program for External Grooving Operation for the component shown in figure
below.
DWG. NO. 10
PESIT Page 29

Holder
Tool Tip Tool
Station
No
Tool
Offset No
Spindle
Speed,
rpm
Feed,
mm/min
1
Multiple
Rough
turning
SDJCR
1212H11
DCMT
11T304
1 1 1200 45
2 Finishing
SDJCR
1212H11
DCMT
11T302
2 2 1450 25
3 Grooving HSS
3 mm
width
5 5 750 15
TOOL OFFSET SHEET
Radius, mm
Standard Tool
Number
X Z R
1 0.4 3
2 0.2 3
5
G21 G40 G98 --------- Initial settings
G71 U0.5 R1 ---------- MULTIPLE TURNING
G71 P10 Q20 U0.1 W0.1 F45
N10 G01 X8
G01 Z0
X10 Z-1
Z-22
X18 Z-29
N20 Z-38
G28 U0 W0
M06 T0202 ----------- CALLING FINISHING TOOL
M03 S1450
G00 X22 Z1
G70 P10 Q20 F25 ------------ Calling Finishing cycle.
G28 U0 W0 ------------ GROOVING OPERATION USING G81
M06 T0505 ------------ Calling 3 mm GROOVING TOOL
M03 S750
G00 X12 Z-22
G81 X10 F20
X9.75
X9.5
X9.25
X9
X8.75
X8.5
X8.25
X8
PESIT Page 30

G00 X19 Z-34
G75 R1 ----------- GROOVING USING G75 CYCLE
G75 X16 W-2 P100 Q1500 F15 Z
X
(Relief amount, R=1.0 mm.
(Depth of Groove, X= 2mm. 16
(P- Peck increment along X axis 0.1 mm = 100 Microns.
(Q – Stepping distance along Z axis 1.5 mm = 1500 Microns.
M30 -------- Program stop and rewind
G76 MULTIPLE THREADING CYCLE
This is a “Box type” cycle that is repeated a given
number of times. After the first pass subsequent
passes cut with one edge of the threading tool only
to reduce the load at the tool tip. This cycle
requires two distinct blocks of data. When the
cutting depth of one cycle becomes smaller than
the limit, the actual amount of cut is clamped at
the minimum cut depth.
G76 P(m)(r)(a) Q(q1)(r1)
G76 X(x) Z(z) P(p2) Q(q2) F
Where m – Repetitive count in finishing (1 to 99)
r – Chamfering amount(0.01 to 9.91)
a – Angle of tool tip(800
,600
,550
,300
,290
& 00
)
q1 – Minimum cutting depth.
R1 – Finishing allowance.
x – Finished depth of thread
z – End position of thread
p2 – Height of the thread as a radius value x 1000,
as the controller accepts this value in microns. Eg.
1.02 mm becomes P1020
q2 – Depth of first cut as a radius value X 1000,
value in microns, F- Lead or pitch of thread.
EXTERNAL MULTIPLE THREADING
Write a manual part program for External Threading operation for the component shown in figure
below.
DWG. NO. 11
Holder
Tool Tip Tool
Station
No
Tool
Offset
No
Spindle
Speed,
rpm
Feed,
mm/min
1 Multiple
Rough
SDJCR
1212H11
DCMT
11T304
1 1 1200 35
PESIT Page 31

turning
2 Finishing SDJCR
1212H11
DCMT
11T302
2 2 1450 25
3 Grooving HSS 3 mm
width
5 5 750 25
4 Threading HSS 7 7 500 25
TOOL OFFSET SHEET
Radius, mm
Standard Tool
Number
X Z R
1 0.4 3
2 0.2 3
5 5
7 8
rapid traverse.
G71 U0.5 R1 ---------- MULTIPLE TURNING
G71 P10 Q20 U0.1 W0.1 F35
N10 G01 X10
G01 Z0
X12 Z-1
Z-20
G02 X16 Z-30 R25
G01 Z-40
G03 X22 Z-50 R25
N20 G01 Z-55
G28 U0 W0
M06 T0202 ----------- CALLING RH FINISHING TOOL
M03 S1450
G00 X22 Z1
G70 P10 Q20 F25 ------------ FINISHING OPERATION
G28 U0 W0
M06 T0505 ---------- CALLING 2mm Width Grooving tool
M03 S650
G00 X13 Z-20
G81 X12 Z-20 F25 ---------- GROOVING OPERATION G75
X11.75
X11.5
X11.25
X11
X10.75
X10.5
X10.25
X10
X9.75
X9
G28 U0 W0
M06 T0707 ----------- CALLING THREADING TOOL
G00 X17 Z23
PESIT Page 32

G76 P031560 Q20 R0.15 ---------- MULTIPLE THREADING CYCLE.
G76 X9.853 Z-19 P1073 Q30 F1.75
(03 – Number of passes for finishing operation
(15 - Chamfer amount or pull out angle (60 – Angle of the thread, deg
(Q – Minimum cutting depth = 250 microns ( .25 mm)
(R - Finishing allowances = 0.15 mm (X – Core diameter = 9.853 mm for M12
(Z – Length of thread=19 mm (P - Height of thread = 1073 microns (1.073 mm)
(Q – Depth of cut for first pass = 300 microns (0.3 mm)
(F – Pitch of the thread = 1.75 mm
INTERNAL OPERATIONS
G74 END FACE PECK DRILLING
This cycle is designed for deep hole drilling,
the drill entering the workpiece by a
predetermined amount then backing off by
another set amount to provide breaking and
allowing swarf to clear the drill flutes. The
cycle is commanded by two distinct lines of
data
G74 R(r1)
G74 Z(W) Q(q) R(r2) F
Where r1 – Return amount
Z – Total depth(absolute)
W – Total depth (Incremental)
q – Depth of cut (incremental, unsigned)
F- Feed rate
PECK DRILLING
Write a manual part program for Peck drilling operation for the component shown in figure below.
DWG. NO. 12
Holder
Tool Tip Tool
Station
No
Tool
Offset
No
Spindle
Speed,
rpm
Feed,
mm/min
1 Center
Drill
6 mm - 6 6 1200 20
2 Drilling 12 mm - 8 8 800 20
TOOL OFFSET SHEET
Radius, mm
Standard Tool
Number
X Z R
6 - 6
PESIT Page 33

8 - 8
(CNC program for Drilling operation – G74 CYCLE
M06 T0101 ---------- Using 6 mm center drill with tool no 6.
G74 R1 ---------- PECK DRILLING CYCLE
G74 X0 Z-5 Q500 F20
(R = Relief amount = 1.0 mm
(X, Z = Position of the bottom of the hole 0, -5
(Q = Depth of cut for each pass – 500 microns (0.5 mm)
G28 U0 W0
M06 T0202 ----------- Using 12 mm drill.
M03 S800
G00 X0 Z2
G74 R1
G74 X0 Z-35 Q500 F20
Note: Tool used Tool 1. Centre drill 12mm
Tool 2. Twist drill 12mm
STEP BORING
Write a manual part program for Step Boring operation for the component shown in figure below.
DWG. NO. 13
SL.NO Operation Tool Holder Tool
Tip
Tool
Station
No
Tool
Offset
No
Spindle
Speed,
rpm
Feed,
mm/min
1 Center
Drill
6 mm - 6 6 1200 20
2 Drilling 12 mm Drill - 8 8 800 15
3 Boring 10 mm
Boring bar
- 2 2 1200 20
PESIT Page 34

TOOL OFFSET SHEET
Radius, mm
Standard Tool
Number
X Z R
2 2 2
6 6 6
8 8 8
(CNC program for Internal operation, Face Drilling, Step boring cycle
rapid traverse.
G74 R1
G74 X0 Z-5 Q500 R0 F20
(X, Z = Position of the bottom of hole (0,-5)
(R = Relief amount for the tool at the bottom of the hole = 0.0 mm
G28 U0 W0
M06 T0202 ----------- Using 12 mm drill.
M03 S800
G00 X12 Z1
G74 R1
G74 X0 Z-35 Q500 R0 F15
G28 U0 W0
M06 T0303 --------- CALLING 10 MM DIA BORING TOOL
M03 S1200
G00 X12 Z1
G90 X12 Z-30 F20 ---------- INTERNAL BORING USING G90
X13
X14
X15
X16 Z-20
X17
X18
X19
X20
Note: Tool used Tool 1. Centre drill dia 5mm
Tool 2. Twist drill dia 12mm
Tool 3. Bore S10M-SCLCL 06 R0.5
Bore tool will be in internal turn
PESIT Page 35

BORING
Write a manual part program for Boring operation for the component shown in figure below.
DWG. NO. 14
Holder
Tool Tip Tool
Station
No
Tool
Offset
No
Spindle
Speed,
rpm
Feed,
mm/min
1 Drilling 12 mm
Drill
- 8 8 700 15
2 Boring 10 mm - 1 1 800 20
TOOL OFFSET SHEET
Radius, mm
Standard Tool
Number
X Z R
8 0.4 8
1 0 9
(CNC program for Internal operation, Boring cycle
rapid traverse.
G74 R1
G74 X0 Z-5 Q500 F15
(X, Z = Position of the bottom of hole (0,-5)
G28 U0 W0
M06 T0202 ----------- Using 12 mm drill.
M03 S700
G00 X12 Z1
G74 R1
G74 X0 Z-35 Q500 R0 F15
G28 U0 W0
PESIT Page 36

M06 T0303 --------- CALLING 10 MM DIA BORING TOOL
M03 S800
G00 X12 Z1
G71 U0.2 R0.5 --------- BORING OPERATION
G71 P10 Q20 U0.1 W0.1 F20
N10 G01 X30
G02 X25 Z-8 R8 F15
G01 Z-16 F20
G03 X20 Z-21 R8 F15
G01 X16 Z-31 F20
N20 G01 X12
G70 P10 Q20 F50 -------- CALLING FINISHING CYCLE.
NOTE: Tool used Tool 1. Centre drill dia 5mm
Tool 2. Twist drill dia 12mm
Tool 3. Bore S10M-SCLCL 06 R0.5
Bore will be in internal turn
SUBPROGRAM CALL / EXIT – M98 / M99
Main Program SubProgram
A Program is divided into a main program and
subprogram. Normally the CNC operates
according to the main program but when a
command calling a subprogram is encountered in
the main program control is passed to the
subprogram. When a command indicating to
return to the main program is encountered in the
subprogram, control is returned to the main
program. The first block of program / subroutine
must contain a program number “O”.
When a program contains certain fixed sequences
or frequently repeated patterns these sequences or
patterns may be entered into memory as a
subprogram to simplify programming. A
subprogram can call another subprogram. When
the main program call a subprogram, it is regarded
as a one-loop subprogram call.
Main program
O0001;
-------;
-------;
M98 P1000;
--------;
--------;
M30;
Subprogram Subprogram
O1000; O2000;
--------; ---------;
--------; ---------;
M98 P2000; ---------;
---------; ---------;
---------; ---------;
M99; M99;
1st
Loop 2nd
Loop
Nesting Nesting
PESIT Page 37

PARTING OFF
Write a manual part program for turning and parting off operation through subprograms for the
component shown in figure below.
DWG. NO. 15
Holder
Tool Tip Tool
Station
No
Tool
Offset
No
Spindle
Speed,
rpm
Feed,
mm/min
1 Turning SDJCR
1212H11
DCMT
11T304
1 1 1000 45
2 Grooving HSS 2 mm 5 5 750 25
TOOL OFFSET SHEET
Radius, mm
Standard Tool
Number
X Z R
1 0.4 3
5 - 8
(CNC program for parting off using subprograms
G21
--------- Initial settings
M06 T0101 ---------- Using RH Roughing tool
PESIT Page 38

rapid traverse.
M98 P0101000 --------- Calling subprogram for turning[01000] 10 times
G00 X22 Z-15
M98 P0061000 ---------- Calling subprogram for turning[01000] 6 times
(PARTING OFF OPERATION
G28 U0 W0
M06 T0505 ---------- Calling grooving tool with 2 mm width.
M03 S750
G00 X23 Z-32
M98 P0421021 --------- Calling subprogram ‘1021’ 42 times.
G00 X22
O1000 -------- SUBPROGRAM FOR TURNING
G90 U-1 W-15 F45
G01 U-1
M99
O1021 -------- SUBPROGRAM FOR PARTING
G01 U-0.5 F50
M99
NOTE:Tool used External turn
MTJNL 202016 R 0.8
PESIT Page 39

COMPUTERISED NUMERICAL CONTROL MILLING
PART PROGRAMMING FUNDAMENTALS
1. PART PROGRAMMING GEOMETRY
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, ie.,
 Axis X
 Axis Y
 Axis Z
The three axes are identified by upper case X, Y and z and the direction of movement along each axis is
specified as either ‘+’ or ‘-‘. The Z axis is always parallel to the main spindle of the machine. The X axis is
always parallel to the work holding surface, and always at right angles to the z axis. The Y axis is at right
angles to both z and X axis. Figure shows the coordinate system for milling.
B. ZERO POINTS AND REFERENCE POINTS
MACHINE ZERO POINT (M): This is specified by the manufacturer of the machine. This is the xzero
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 figure the position of the
machine zero point generally varies from manufacture. The precise position of the machine zero point as
well as the axis direction must therefore be taken from the operating instructions provided for each
individual machine.
PESIT Page 40

REFERENCE POINT (R): this point serves for calibrating and for controlling the measuring system of
the slides as tool traverses. The position of the reference point 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 axes to calibrate the traverse measuring
system. If current slide and tool position data should be lost in the control systems, for example, through an
electrical failure, the machine must again be positioned to the reference point to re-establish the proper
positioning values.
WORKPIECE ZERO POINT(W) : This 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 workpicese envelope of the machine. It is however, advisable to place the
workpiece zero pijnt in such a manner that the dimensions in the workpice drawing can be conveniently
converted into coordinate values and orientation when clamping/ chucking, setting up and checking the
traverse measuring system can be effected easily. For milled parts, it is generally advisable to use an
extreme corner point as the “workpiece zero point”. Occasionally, the workpiece zero point is called the
“program zero point”
CNC MILL PROGRAMMING
CNC PROGRAM BUILD-UP
Table1 shows the address letters according DIN 66025
Address Characters
Character Meaning
A Rotation about, X-axis
B Rotation about, Y-axis
C Rotation about, Z-axis
D&E Rotation about, Additional-axis
F Feed
G Preparatory function, identifying the action to be executed
H Unassigned
I Interpolation parameter/ thread pitch parallel to x-axis
J Thread pitch parallel to y-axis
K Thread pitch parallel to Z-axis
L Unassigned
M Auxillary function
N Block Number
O Not used
P,Q,R Thread movement parallel to X,Y & Z axes respectively
P&Q are also used as parameters in cycles
S Spindle speed
T Tool
U,V,W Second movement parallel to X,Y,Z axes respectively
X Movement I X-axis
Y Movement in Y-axis
Z Movement in Z-axis
All the NC words may not be used on every CNC machine. Using these words, as an example the
composition of a block is assembled as follows:
PESIT Page 41

N G X Z F S T M ;
PART PROGRAM FORMATS
The order in which these words appear in a block of instructions is called the format. Basically there are
two types of format:
 Fixed Block Format
-Fixed sequential format
-Tab sequential format
 Word Address Format
1. FIXED BLOCK FORMAT:
a)Fixed Sequential Format : Every instruction contains all the words in the same sequence irrespective of
the words being the same as in the previous blocks. Hence the identifying address letter need not be
provided. For example, if some coordinate values(i.e., x, y and z coordinates) remain constant from one
block to next block these values have to be specified in the next block also. The data must be input in a
specified sequence and characters within each word must be of the same length.
Example : N010 G00 X10 Y5 Z0 F60 S1200 EOB
N020 G01 X10 Y5 Z-0.5 F60 S800 EOB
b)Tab Sequential Format : The words in each instruction / block are always provided in the same
sequence but each word is preceded by the TAB character. If instructions remain unchanged in succeeding
blocks, the instructions need not be repeated but TAB character must be punched. Here also, the
identifying letter address need not be employed.
Example : N010 G00 X10 TAB Y5 TAB Z0 TAB F60 TAB S800 EOB
N020 G01 X20 TAB Z-0.5 EOB
2. WORD ADDRESS FORMAT: Each word is preceded and identified by its letter address. This format
enables instructions which remain unchanged from the preceding block, to be omitted from succeeding
blocks. This system speeds programming, and tape lengths are considerably reduced. This is the format
adopted by most CNC machine control units. Detailed format classification is provided by the control
system manufacturer.
Example : N010 G00 X10 Y5 Z0 F60 S800 EOB
N020 G01 X20 Z-0.5 EOB
MISCELLANEOUS AND PREPARATORY FUNCTIONS
M Codes are instructions describing machine functions such as calling the tool, spindle rotation,
coolant on, door close/open etc.
M CODES
M00 Program stop
M01 Optional stop
M02 Program end
M03 Spindle forward
M04 Spindle reverse
M05 Spindle stop
M06 Tool change
M08 Coolant on
M09 Coolant off
M10 Vice open
M11 Vice close
M13 Coolant, spindle fwd
PESIT Page 42

M14 Coolant, spindle rev
M30 Program stop and rewind
M70 X mirror On
M71 Y mirror On
M80 X mirror off
M81 Y mirror off
M98 Subprogram call
M99 Subprogram exit
M00 PROGRAM STOP : By inserting M00 in a program, the cutting cycle is stopped after the block
containing M00 code. This facility is useful if an inspection check is necessary during an operation. The
cycle is then continued by a cycle start.
M02 END OF PROGRAM : M02 halts program execution. The spindle is turned off and the tool moves
to the most positive position on the z-axis.
M03 START SPINDLE : M03 instruction starts forward spindle motion. It requires a speed within the
range 100 to 3000rpm.
Example: M03 S2200
M04 REVERSE SPINDLE : M04 instruction starts reverse spindle motion. It requires a speed within the
range 100 to 3000 rpm.
Example: M04 S2200.
M05 STOP SPINDLE : M05 instruction stops spindle rotation. It is good programming practice to issue
an M05 before a tool change, and at the end of program. However this will be done automatically should
you omit this instruction.
M06 CHANGE TOOL : M06 instruction causes the FANUC to change to a different tool.
Example: M06 t01
M08 COOLANT ON : M08 turns the coolant on
M09 COOLANT OFF : M09 turns the coolant off
M10/11 WORK CLAMP OPEN/CLOSE : M10 opens the work clamp
M11 closes the work clamp
M13 COOLANT, SPINDLE FORWARD : M13 turns the coolant on and starts reverse spindle motion.
Example: M13 S1000
M14 COOLANT, SPINDLE REVERSE : M14 turns the coolant on and starts reverse spindle motion.
Example: M14 S1000
M30 PROGRAM STOPAND REWIND : Stops the spindle. Turns the coolant off. Terminates and resets
the CNC program.
M38/39 DOOR OPEN/CLOSE : M38 opens the door, M39 closes the door
M70 X MIRROR ON : M70 sets x axis mirroring about the current x axis position
M71 Y MIRROR ON : M71 sets Y-axis mirroring about the current Y axis position
M80 X MIRROR OFF : M80 disables X axis mirroring
M80 Y MIRROR OFF : M80 disables X-axis mirroring
PESIT Page 43

SUBPROGRAM CALL / EXIT- M98 / M99
Main program Subprogram
A Program is divided into main program
and subprogram. Normally the CNC
operates according to the main program
but when a command calling a
subprogram is encountered in the main
program control is passed to the
subprogram. When a command indicting
to return to the main program is
encountered in the subprogram is
encountered in the subprogram, control
is returned to the main program. The first
block of program/subroutine must
contain a program number “o”
When a program contains certain fixed sequences or
frequently repeated patterns, these sequences or patterns
may be entered into memory as a subprogram to simplify
programming. A subprogram can call a subprogram it is
regarded as a one-loop subprogram call.
FORMAT:
O0001;
………;
………;
M98 POOOOOOO
Subprogarm Number
Number of repetitions
Subprogram call
……….
……….
M99
Subprogram exit
Main Program Subprogram Subprogram
Ist Loop Nesting 2nd
Loop nesting
PESIT Page 44
O0001;
……..;
……..;
M98 P1000;
……..;
……..;
M30
O1000;
……..;
……..;
M98 P2000;
……..;
……..;
M99
O2000;
……..;
……..;
M98 P3000;
……..;
……..;
M99

PREPARATORY FUNCTIONS (G CODES)
G CODES
G00
G01
G02
G03
Positioning (Rapid Tranverse)
Linear Interpolation (Feed)
Circular Interpolation (CW)
Circular Interpolation (CCW)
G04 Dwell
G20
G21
Inch Data Input
Metric Data Input
G28 Reference point return
G40
G41
G42
Tool nose radius compensation cancel
Tool nose radius compensation left
Tool nose radius compensation right
G43 Tool length compensation + direction
G44 Tool length compensation - direction
G73
G74
G76
G80
G81
G82
G83
G84
G85
G86
G87
G88
G89
Peck drilling cycle
Counter tapping cycle
Fine Boring
Canned cycle cancel
Drilling cycle, spot boring
Drilling cycle, counter boring
Peck drilling cycle
Tapping cycle
Boring cycle
Boring cycle
Back boring cycle
Boring cycle
Boring cycle
G90
G91
Absolute command
Incremental command
G92 Programming of Absolute zero point.
G94
G95
Feed per minute
Feed per revolution
G98
G99
Return to initial point in canned cycle
Return to R point in canned cycle.
PESIT Page 45

G00 FAST TRAVERSE
A G00 moves the tool to a certain position in the
work coordinate system with an absolute command
or to a position specified distance from the current
position with an incremental command at a rapid
traverse rate.
Example: G00 X20 Y30 Z1
Here the tool is moved to
X20mm,
Y30mm, and
Z1mm
G01 LINEAR MOTION
This command actuates the linear interpolation mode. The
values of X,Y and z define the distance of tool travel which will
be conducted in absolute or incremental mode, according to the
current status of G90/G91. The feed rate is set to a cutting feed
speed commanded by F code and is modal data. The feed rate
commanded by the F code is measured along the tool path.
G01 X(*x) Y(*y) Z(*z) F(*f)
Example: G21
G01 X20 Y30 Z-1
CIRCULAR INTERPOLATION (G02/G03)
Sl no. Data to be given command Meaning
1 Plane selection G17 Specification of arc on XY
plane
G18 Specification of arc on ZX
plane
G19 Specification of arc on YZ
plane
2 Direction of rotation G02 Clockwise direction
G03 Counter clock wise direction
3 End point
position
G90 Mode
G91 Mode
Two of the X,Y and Z axis End point position in the Work
Coordinate System
Twoz of the X,Y and Z axes
4 Dist. From start point to
center
Two of the I,J and K axes Distance from start point to
end point
Arc radius R Arc radius
5 Feed rate F Velocity along arc
The view is from the positive direction of the z axis(Y axis or X axis) to the negative direction on XY
plane (ZX plane or YZ plane) in the right hand cartesian coordinate system. The following sketch shows
the CW and CCW directions in different planes
G04 DWELL
A G04 causes the program to wait for specified amount of time. The time can
be specified in seconds with the “X’ prefixes or in milliseconds with the “I”
prefix. One of the uses of this code is to get a sharp corner on the profile of
the workpiece in cutting feed. It is also used at the end of drilling cycle.
During cutter motion, a deceleration at the end of the motion specified by
G04 X1.5
G04 P1500
PESIT Page 46

one statement and an acceleration at the start of the motion specifies by the
next statement are usually applied automatically by the controller.
G20 IMPERIAL UNITS : A G20 causes position to be as being in imperial units. All the input values are
in inches. This can only be at the start of the main program.
G21 METRIC UNITS : A G21 causes positions to be interpreted as being in metric units. All the input
values are in mm. This can only be at the start of the main program.
G28 GO TO REFERENCE POINT
This command specifies automatic return to the reference point for the
specified axes. The co-ordinates defined in this command is an
intermediate co-ordinate and is commanded by absolute or incremental
value. The G28 block is used to position the tool at the intermediate
point of all specified axes at the rapid traverse speed, and then move to
the reference point at the rapid traverse rate. In general this command
is used for automatic tool changing. For safety reasons the cutter
radius compensation, and tool length compensation should be
cancelled before executing this command
G91 G28 X0 Y0Z0
makes the cutting tool to
move to datum point
directly.
G91 G28 X0 Y0 Z20
makes the cutting tool to
go to datum point via the
intermediate point Z20.
G40, G41, G42 TOOL NOSE RADIUS COMPENSATION
Description
On Modern CNC machines, special calculation functions or cutter radius compensation codes are
provided to allow a user to utilize part profile coordinates obtainable from the part drawing to
program a contouring motion. These are the G41 and G42 codes for tool radius compensation on the
left and right hand sides of a profile. A left or right compensation is based on the fact that the tool is
on left or right hand side when one goes along the part profile in the direction specified by the
contouring motion statements in the program. A G40 code is provided to cancel the cutter radius
compensation.
G92 SET DATUM
G92 sets the datum relative to the current
positions
Example: G00 X30 Y40
G90 X10 Y10
Makes the position that was X30 Y40 to become
X10 Y10
G94 PER MINUTE FEED
PESIT Page 47

With the per minute feed mode, tool feed rate per
minute is directly commanded by numerical value
after F. the “F” value specifies the feed rate in
millimeters, or inches per minute.
G95 PER REVOLUTION FEED
This command coupled with the F word is used to
specify a federate per revolution. The feed rate is
changed whenever the spindle changes. This can be
in mm/rev to inch/rev. The feedrates available in the
DENFORD FANUC simulation are 0.01-200
mm/min.
Recommended federates are published by tool and
cutter manufacturers, along with recommended
cutting speeds. If the feed rate is expressed as
mm/rev. a simple calculation can be used to convert
to mm/min.
Feed, mm/min = feed(mm/rev) x spindle speed(rpm)
F= the displacement along the z axis per
revolution of the workpiece
Example G(% S1200
G01 X10.0 f0.3
This sets the feed rate to 360(1200*0.3)
CANNED CYCLES(G73, G74, G76, G80-89)
A canned cycle simplifies the program using a single block with a G code to specify the machining
operations usually specified in several blocks. The following table give list of canned cycles.
Canned cycles
G code Drilling
(-z direction)
Operation at the
bottom of a hole
Retraction
(+z direction)
Application
G73 Intermittent
feed
- Rapid traverse High speed peck
Drilling cycle
G74 Feed Dwell spindle CW Feed Left hand tapping cycle
G76 Feed Oriented spindle
stop
Rapid traverse Fine boring cycle
G80 - - - cancel
G81 Feed - Rapid traverse Drilling cycle spot
drilling cycle
G82 Feed Dwell Rapid traverse Drilling cycle counter
drilling cycle
PESIT Page 48

G83 Intermittent
feed
- Rapid traverse Peck drilling cycle
G84 Feed Dwell spindle CCW Feed Tapping cycle
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 stop Manual Boring cycle
G89 Feed - Feed Boring cycle
Generally, a canned cycle consists of a sequence of six operations as shown below
Operation Description
1 Positioning of axes x and Y(including also 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
Positioning is performed on the XY plane and hole machining is performed on the Z axis. Positioning and
hole machining cannot be performed other than this plane and this axis combination. Canned cycle is
indifferent to the plane selection G command. These canned cycle operations, to be more strict, consists of
these three modes, each of which are specified in a particular modal G code. As shown below.
Data format G90 absolute
G91 Incremental
Return point level G98 Initial point level
G99 R point level
Drilling mode G73,G74,G76, G80, G81,………..G89
G91 INCREMENT MOVEMENT
All future movement will be absolute until overridden by a G91
instruction. This is the default setting.
Example: G90
G01 X30 Y0
The position becomes X30 Y0
G91 INCREMENT MOVEMENT
All future movement will be incremental until over-ridden by a
G90 instruction
Example: G90
G01 X15 Y0
G91
G01 X2 Y0
The position becomes X17 Y0
G73 FAST PECK DRILLING CYCLE
When drilling a deep hole, the drill should be retracted
occasionally to avoid congestion of chips between hole and the
drill. Since the Z-axis direction intermittent feed simplifies chip
disposal and permits a very small retraction value to be set in deep
hole drilling, efficient machining is performed. Retraction is
performed at the rapid traverse rate.
Example:
G73 X(*x) Y(*z) P(*p) Q(*q)
R(*r) F(*f)
Where
*x and *y = the next hole position
to drill at.
*z= the depth of the hole, which is
the absolute distance in G90 mode
PESIT Page 49

M06 T03
M03 S1500
G90 G00 X10 Y10 Z10
G99 G73 X10 Y10 z-20 P500 Q0.5
R2 F50
G80
and the incremental coordinate
from R point in the G91 mode.
*p= dwell time in sec.
*q= the depth of cut for each peck
drill always a positive incremental
value.
*r= the Z coordinates of the R
point (in G90 mode) or the
incremental Z coordinates from the
initial point to the R point(in G91
mode).
*f = feed, mm/min.
G74 LEFT HAND TAPPING CYCLE
The cycle consists of a single block command. At the bottom of
the hole, the spindle rotates clockwise and left handed tapping is
performed.
Note: During G74, the feed rate override is ignored and the cycle
does not stop until the end of the return operation. Even if a feed
hold is applied.
Example:
M06 T01
M04 S200
G90 G00 X0 Y20 z10
G99 G74 X20 Y20 z-10 R5 F50
G80
G74 X(*x) Y(*y) Z(*z) R9*r)
F(*f)
Where,
*x *y= the next position to drill at.
*r= The Z coordinates of the R
point in (g90 mode) or the
initial point to the R point in (G91
mode)
*f= feed in mm/min
G76 FINE BORING CYCLE
This cycle is commanded in single block. Since a spindle oriented
stop is performed at the bottom of the hole and the spindle retracts
after shifting in the direction opposite to the cutter-direction, high
precision and efficient boring is performed without scratching the
workpiece.
Example:
M06 T05
M03 S200
G90 G00 X0 Y20 Z10
G99 G76 X20 Y20 z-12 Q0.5 R-10 F50
G80
Note: the shift value is specified by Q. the Q value is always a
positive value. If a negative value is specified, the sign is ignored.
The Q value is modal in the canned cycle.
G76 X(*x) Y(*y) Z(*z) Q(*q)
R(*r) F(*f)
Where
*x,*y= the next position to drill at
*r= the z coordinate of the R
point(in G90 mode) or the
incremental z coordinates from
the initial point to the R point(in
G91 mode)
*f= feed in mm/min
G84 TAPPING CYCLE
PESIT Page 50

This cycle is commanded in single block. The spindle is reversed
at the bottom of the hole and the tapping cycle is performed.
Example:
M06 T01
M03 S200
G90 G00 X0 Y20 Z10
G99 G84 X20 Y20 Z-10 R5 F200
G80
G84 X(*x) Y(*y) Z(*z) R(*r) F(*f)
Where
*x,*y= the next position to drill at
and the incremental coordinate from
R point in the G91 mode.
*r= the z coordinate of the R
incremental z coordinates from the
mode)
*f= feed in mm/min
G87 BACK BORING CYCLE
This cycle is commanded in single block. After the tool is
positioned along the X and Y axes, the spindle stops at the
orientation position. The spindle is then shifted in the direction
opposite to the tool and is positioned at the bottom of the
hole(point R) at the rapid traverse arte. At this position, the tool
returns only for the shift value and the spindle rotates clockwise.
Machining is performed upto the point Z in the +z axis. At this
position, the spindle again stops at the orientation position and
shifts in the direction opposite to the tool and the tool is
withdrawn from the hole. After the tool returns to the initial point,
it returns only for the shift value. The spindle rotates clockwise
and the tool moves according to the command of the next block.
Example:
M06 T01
M03 S1500
G00 X20 Y10 Z20
G98 X20 Y10 Z20
G98 G87 X20 Y10 Z20 Q4 R-27 F50
G80
G87 X9*x) Y(*y) Z(*z) Q(*q)
R9*r) F(*f)
Where *x *y= the next position to
drill at.
*z= the depth of the hole which is
from R point in the G91 mode
*q=the depth of cut for each peck
drill always a positive incremental
value
*r= the Z coordinates of the R
mode)
G170-G171 CIRCULAR POCKETING
Using this cycle circular pocketing can be done. When the
tool has finished cutting, the tool retracts 1mm in Z axis.
Moves to the center of the circular pocket at rapid traverse,
retracts again in the Z axis, then moves away to the datum
point. It requires two blocks.
G170 R0 P0 Q3 X0 Y0 Z-6 I0 J0 K-24
G171 P75 S2000 R50 F150 B2500 J150
G170 r(*r1) P(*p1) Q(*q1) X(*x1)
Y(*y1) Z(*z1) I(*i1) J(*j1) K(*k1)
G171 P(*p2) S(*s2) R(*r2) F(*f2) B(*b2)
J(*j2)
Where
*r1= position of tool to start cycle ie., for
flat surface
*p1=0(roughing), = finishing
*q1= peck increment for each cut( always
a + value)
*x1, *y1, *z1: coordinates of center of
circular pocket
*i1: finishing allowance for side
PESIT Page 51

J1: finishing allowance for pocket base
*k1= radius of circular pocket(positive
value for CW arc)
*p2=cutter movement percentage for next
step (ex:50,75)
*s2= roughing spindle speed, rpm
*r2=Roughing feed in z direction for each
cut
*f2= roughing feed in XY directions
mm/min
*b2= finish spindle speed, rpm
*j2= finishing feed, mm/min
G172-G173 RECTANGULAR POCKETING
Illustration Example
G172 I(*i1) J(*j1) K(*k1) P(*p1) Q(*q1) R(*r1)
X(*x1) Y9*y1) Z(*z1)
G173 I(*i2) K(*k2) P(*p2) T9*t2) S(*s2) R(*r2)
F(*f2) B9*b2) J(*j2) Z(*z2)
Where
*I1= length of pocket in x direction
*j1=length of pocket in Y direction
*k1= corner radius(always zero)
*p1-0 Roughing=1(finishing)
*q1=depth of cut for each pass (1, 1.5,2)
*r1=Absolute depth from the surface( Z R point)
*x1= pocket cornerX
*y1=Pocket corner Y
*z1=absolute z base finish allowance
*p2= cutter width percentage(50,75 etc.,)
*t2= tool number
*s2= spindle speed rpm
*r2= roughing feed in Z, mm/min
*f2= roughing feed along XY mm/min
*b2= finishing spindle speed rpm.,
*j2= finishing feed mm/min
*z2=safety Z position.
G172 I-50 J-50 K0 P0 Q3 R0 X-25 Y-25 Z-6
G173 I0 K0 P75 T1 S2500 R75 F250 B2500 J200
Z5
PESIT Page 52

STRUCTURE OF A CNC PROGRAM
CNC program consists of three parts: program start-up, body and end of the program.
PROGRAM START-UP
O1000
[BILLET X100 Y100 Z10
[TOOLDEF T1 D5 T2 D10
[EDGEMOVE X-50 Y-50
G21/G20 G40 G49 G80
G94/G95
G50 S3500
G91 G28 Z0
G28 X0 Y0
M06 T1
M03/M04 S2000
EXPLANATION
O1000 While writing a program on fanuc controller first line has to be stared with letter
‘O’ followed by four digit number which specifies the program name.
[BILLET X20
Z60
This directive is used only for simulation purpose. It defines the workpiece as
60mm long and 20mm in diameter.
[TOOLDEF T1
D5 T2 D10
This directive sets the length and diameter of the tool for simulation
[EDGEMOVE This directive sets up the required offset from the program zero position to
lower left hand corner of the billet. This is used for simulation.
G21/G20 G40
G49 G80
G21-this code specifies that program is done in metric units
G20-this code specifies that program is done in imperial units
G40- compensation cancel
G49- length compensation cancel
G80- canned cycle
G50 S3500 Clamps the spindle speed at 3500 rpm
G94/G95 G91
G28 z0
G94- gives the unit of feed n mm/min
G95-gives the unit of feed in mm/rev
G28- go to home position along Z-axis
G28 X0 Y0 Go to home position laong X and Y axes
M06 T01 Tool change to tool No.1
M03/M04 S1000 M03- makes the spindle rotate in clockwise direction
PESIT Page 53

M04- makes the spindle rotate in counter-clockwise direction
S1000-setting the spindle speed at 1000rpm
G00 X0 Y0 Z5 G00- gives rapid position of the tool to appoint X0 Y0 Z5 which is just above
the billet. This point is called tool entry point.
BODY OF THE PROGRAM : This is dealt operation wise in the succeeding pages.
PROGRAM END
G91 G28 X0 Y0 Z0
M05
M30
EXPLANATION
G91 G28 X0 Y0 Z0 Makes the tool to go to home position
M05 Stops the spindle rotation
M02/M30 M02 Optional stop
M30 Program stop and rewind
PROGRAMMING EXAMPLES
LINEAR AND CIRCULAR INTERPOLATION
Write a manual part program for Contouring operation for the component shown in figure below :
DWG. NO. 1
BILLET SIZE: 100X100X10 MATERIAL: Aluminum
PROGRAM NO:1001 DWGNO :1
SL.NO Operation Tool type Tool dia.,
mm
Tool
station
No.
Tool
length
offset No
Spindle
speed
rpm
Feed
mm/min
1 Contouring Slot cutter 5 1 1 2000 30-50
(Drawing No .1
O1001
(G01-Linear interpolation
(G02-Circular interpolation
(G03-circular interpolation anti-clockwise
[BILLET X100 Y100 Z10 ---- it defines the billet dimensions
[EDGEMOVE X-50 Y-50 ---- this directive sets up the required offset from the
program zero position to the middle of the billet. This
PESIT Page 54

is used for simulation.
[TOOLDEF T1 D6 ----Defining tool
G21 G94 G21-this code specifies that program is done in metric units
G94 gives the unit of feed in mm/min
G91 G28 Z0 G28 go to home position along Z-axis in incremental mode
G28 X0 Y0 Go to home position along X and Y axis
M06 T1 Tool change to Tool No.1
M03 S2000 M03-makes the spindle rotate in clockwise direction
S2000-setting the spindle speed at 2000 rpm
G90 G00 X0 Y-37.5 Z5 G90-Absolute mode
G00 Gives rapid position of the tool to a point
X0 Y-37.5 Z5 which is just above the billet. This point is
called tool entry point
G01 Z-1 F50 Giving the depth of cut along Z axis at a federate of 50mm/min
G01 X-22.5 y-37.5
G03 X-37.5 Y-22.5 R15
G01 X-37.5 Y22.5 F50
G03 X-22.5 Y37.5 R15 F25
G01 X22.5 Y37.5
G02 X37.5 Y22.5 R15
G01 X37.5 Y-22.5
G03 X22.5 Y-35.5 R15
G01 X0 Y-37.5
G00 Z5
G00 X-15 Y0
G01 Z-1 F50
G02 X15 Y0 R15
G02 X-15 Y0 R15
G00 Z5
G91 G28 Z0 ----- makes the toll to go to home position
G28 X0 Y0
M05 ----- stops the spindle rotation
M30
NOTE: Tool used End mill finish –3 flute-6mm
CONTOURING WITH LEFT CUTTER DIAMETER COMPENSATION
Write a manual part program for contouring operation with left cutter diameter compensation for the
component shown in fig
PESIT Page 55

DWG. NO. 2
mm
Tool
station
No.
Tool
length
offset No
Spindle
speed
rpm
Feed
mm/min
1 Contouring Slot cutter 5 1 1 2000 35
(Drawing No .2
O1002
(G codes used G40, G41
(G-40 cutter diameter compensation cancel
(G41-Cutter diameter compensation left
[EDGEMOVE X0 Y0 ---- this directive sets up the required offset from the
G90 G41 G00 X35 Y40 Z5 G90-Absolute mode
G41 cutter diameter compensation left
G00 gives rapid position of the tool to a point X40 Y40,
Z5 which is just above the billet. This point is called tool
entry point
G01 X65 Y40
G03 X65 Y60 R10
PESIT Page 56

G01 X35 Y60
G03 X35 Y40 R10
G01 X65 Y40
G01 X65
G00 Z5
G40 ----- Cutter compensation cancel
G28 X0 Y0
M30 ----- Program stop and rewind
CONTOURING WITH LEFT CUTTER DIAMETER COMPENSATION
Write a manual part program for contouring operation with right cutter diameter compensation for the
component shown in fig
DWG. NO. 3
PESIT Page 57

mm
Tool
station
No.
Tool
length
offset No
Spindle
speed
rpm
Feed
mm/min
(Drawing No .3
O1003
(G codes used G40, G42
(G-40 cutter diameter compensation cancel
(G42-Cutter diameter compensation right
G90 G42 G00 X40 Y40 Z5 G90-Absolute mode
G42 cutter diameter compensation right
entry point
G01 X70 Y40
G03 X70 Y60 R10
G01 X40 Y60
G03 X40 Y40 R10
G00 Z5
G40 ------ Cutter compensation cancel
G28 X0 Y0
CONTOURING THROUGH SUBPROGRAM
Write a manual part program for contouring operation through subprogram for the component shown in
fig.
PESIT Page 58

DWG. NO. 4
mm
Tool
station
No.
Tool
length
offset No
Spindle
speed
rpm
Feed
mm/min
(Drawing No . 4
O1004
(PROGRAM FOR SUBPROGRAM
(MCODES USED M98, M99
(M98 SUB PROGRAM CALL
(M99 SUBPROGRAM EXIT
(TOTAL DEPTH OF CUT 5MM
(DEPTH OF CUT FOR EACH PASS:0.5mm
G90 G00 X10 Y10 Z5 G90-Absolute mode
entry point
G00 Z0
M98 P0014000 ----- Calling the subprogram 4000 five times
M98 P0014000
M98 P0014000
M98 P0014000
M98 P0014000
G00 Z5
PESIT Page 59

G28 X0 Y0
O4000 ----- Subprogram for increasing depth
G00 X0 Y0
G01 Z-1 F50
G01 X0 Y63
G01 X56 Y63
G01 X56 Y51
G03 X73 Y38 R13 F30
G01 X73 Y23
G02 X55 Y0 R 20 F30
G01 X0 Y0
G00 Z5
G00 X0 Y0
M30
M99
MIRRORING
Write a manual part program for Mirroring operation for the component shown in fig.
PESIT Page 60

DWG. NO. 5
mm
Tool
station
No.
Tool
length
offset No
Spindle
speed
rpm
Feed
mm/min
(Drawing No . 5
O1005
(PROGRAM FOR MIRRORING
(MCODES USED M70,M71,M80,M81
(M70 X-AXIS MIRROR ON
(M71 Y- AXIS MIRROR ON
(M80 X-AXIS MIRROR OFF
(M81 Y AXIS MIRROR OFF
entry point
G00 Z0
M98 P0015000 ----- Calling the subprogram 5000 one time
M70 ----- Mirroring about X axis
PESIT Page 61

M80 ----- Canceling of mirroring about X axis
M70 ----- Mirroring about X axis
M71 ----- Mirroring about Y axis
M80 ----- Canceling of mirroring about X axis
M81 ----- Canceling of mirroring about Y axis
M71 ----- Mirroring about Y axis
G00 Z5
G28 X0 Y0
O5000 ----- Subprogram
G00 X5 Y5 Z5 ----- Rapid traverse to 5,5,5
G01 Z-1 F50 ----- Feed rate at 35 mm/min.
X15 Y5
X15 Y15
X5 Y15
X5 Y5
G00 Z5
X10 Y10
G01 Z-1 F50
G00 Z5
X15 Y5
G01 Z-1 F50
G03 X25 Y15 R15 ----- CCW interpolation.
G01 X25 Y35
G02 X30 Y30 R5
G02 X35 Y25 R5
G01 X15 Y25
G03 X5 Y15 R15
G00 Z5
G00 X0 Y0
M99 ------ Exiting the subprogram O5000
DRILLING
Write a manual part program for Drilling operation for the component shown in fig.
PESIT Page 62

DWG. NO. 6
mm
Tool
station
No.
Tool
length
offset No
Spindle
speed
rpm
Feed
mm/min
1 Slotting Slot cutter 5 1 1 2000 35-50
2 Drilling Slot drill 5 2 2 1500 35
(Drawing No . 6
O1006
(PROGRAM FOR DRILLING
(GCODES USED G73,G83,G98,G99
(G73 – FAST PECK DRILLING CYCLE
(G83 – PECK DRILLING CYCLE
[TOOLDEF T1 D8 T2 D5 ----Defining tool
entry point
G83 G99 X0 Y20 Z-5 Q0.5 R0.5 F50 ------ Drilling cycle
PESIT Page 63

X17.32 Y10
Y-10
X0 Y-20
X-17.32 Y-10
Y10
G00 X-30 Y-30
G91 G99 G73 X10 Y0 Z-5 P100 Q0.5 R0.5 K5 F50 ------- Peck drilling cycle
G80
G91 G28 Z0 ------ Going to home position
G28 X0 Y0
M06 T2
M03 S1500
G90 G00 X-30 Y10 Z0
G01 Z-1
G01 X0 Y40
G01 X30 Y10
G00 Z5
G91 G28 Z0
G28 X0 Y0
NOTE: Tool 1.Tool used Twist drill bit-dia-5mm
Tool 2.Tool used is slot drill bit-dia-5mm
VIVA Questions
1. What is CAD?
2. What is CAM?
3. What is MRP?
PESIT Page 64

CIM Lab.pdf

Recomendados

Recomendados

Más contenido relacionado

La actualidad más candente

La actualidad más candente (20)

Similar a CIM Lab.pdf

Similar a CIM Lab.pdf (20)

Último

Último (20)

CIM Lab.pdf