Cnc lab manual

B.L.D.E.A’S S S M POLYTECHNIC, VIJAYAPUR CNC LAB MANUAL
Compiled By S.D.PATIL Mechanical Department
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IINNTTRROODDUUCCTTIIOONN
Numerical control NC machine is a form of programmable automation in which
the processing equipment is control by means of numbers, letters and other
symbols are coded in an appropriate format.
1.2 Co-ordinate system
Using an NC drill press as an example, the drill spindle is in a fixed horizontal
position, and the table is more relative to the spindle. However to make things
easier for the part programme is adopted that the work piece is stationary while
the tool is moved related to it. accordingly the NC co-ordinate is defined with
respect to the machine tool table.
Two axis, X & Y, are defined in the plane of the table, as shown in figure 2. The
Z axis is perpendicular the plane and movement in the Z direction is controlled
by the vertical motion of the spindle. The positive & negative direction of
motion of tool relative to the table along these axes are shown in fig2.
NC drill process are classified as either two – axis of three – axis machines
depending on whether or not they have the capability to control the Z axis.
A NC milling machine & similar machine tool (boring mill, for e. g) use an axis
system similar to that of the drill press. However, in addition to the three linear
axes, these machines may possess the capacity to control one or more rotation
axis. Three rotational axes are defined in NC: a, b, &c axes. These axes use to
specify angles about the X, Y & z axes, respectively. To distinguish positive
&negative angular motions, the “right – hand – rule” can be used. Using the
right hand with the thumb pointing in the positive linear axes direction (X, Y or
Z), the figures of the hand are curled to point in the positive rotational direction.
This is illustrated in figure 2.

FIG 2: MACHINE TOOL COORDINATE SYSTEM FOR NC
FIG 3: X & Z AXEA FOR TURNING
For turning operations, two axes are normally all that are require to command
the movement of the tool relative to the rotating work piece. The Z – axis is the
axis of rotation of the work part, and x –axis defines the radial location of the
cutting tool. This arrangement is illustrated in fig 3.

1.3 Dimensioning system
There are two types of dimensioning systems used in CNC programming-
1. Absolute Dimensioning system
2. Incremental dimensioning system
 Absolute Dimensioning system
It is most commonly used method of dimensioning for drawing of part
production on CNC Machines in this system all dimension are taken from
a single point called a Datum Point or Origin which is denoted by the
preparatory functions G90.
x-axis
y
a
x
i
s
22,66
datum(0,0)
49,63
85,97
hole1
hole2 hole3
44,94
70,34
58,23
This method has advantage that if a hole 2 in the above figure is put in
wrong location hole 3 would be not affected this reason helps for using of
absolute system than Incremental dimensioning system.

 Incremental dimensioning system.
Incremental Dimensioning the measurement is taken from hole to
take this method is different form absolute dimensioning system this system
gives advantages for machining a complicated pocket or recess and is denoted
by the Preparatory Function G91
x-axis
y
a
x
i
s
datum(0,0)
22,66 26,96 36,34 14,03
25,4
12,11
44,94
Note:-Proper care should be taken when using Incremental Dimensioning
because hole will be Increases positional.

1.5 Preparatory functions (G-codes)
SSLL.. NNOO GG--CCOODDEE DDEESSCCRRIIPPTTIIOONN
1 G00 Rapid Traverse
2 G01 Linear Traverse
3 G02 Circular Interpolation (Clock Wise)
4 G03 Circular Interpolation( Counter Clock Wise)
5 G04 Dwell
6 G20 Inch Data Input
7 G21 Metric Data Input
8 G28 Reference Point Return
9 G70 Finishing Cycle
10 G71 Stock Removal In Turning
11
G72 Stock Removal in Facing
12
G73 Pattern Repeating

13 G74 Peck Drilling in Z-Axis
14 G75 Grooving in X-Axis
15 G76 Thread Cutting Cycle
16 G90 Inner or Outer Diameter Cutting
17 G98 Feed Per Minute
19 G99 Feed Per Revolution
20 G94/98 Feed Per Minute
21 G95/99 Feed Per Revolution

MMIISSCCEELLLLAANNEEOOUUSS FFUUNNCCTTIIOONN (( MM CCOODDEESS ))
M codes are instructions describing miscellaneous functions like calling the
tool, spindle rotation, coolant on etc.
SL. NO M-CODES DESCRIPTION
1
M01 Optional Stop
2 M02 Program Reset
3 M03 Spindle On Clock Wise
4 M04 Spindle On Counter Clock Wise
5 M05 Spindle Stop
6 M06 Auto Tool Change
7 M08 Coolant On
8 M09 Coolant Off
9 M10 Chuck Open
10 M11 Chuck Close
11 M30 Program End and Reset

A part program consists of number of block in which each as information about
the sequence number type of machining counter or any other preparatory
function, dimensions the coordinates spindle, rpm, feed rate, spindle direction,
tool change, sub program call, sub program end etc.
Eg:- Block: N050 G01 X25 Z-10 F60 S2000
The letter and number which follows it are referring as a „word‟. Eg: X25 F60
etc. are words. The first letter of the word is called as „word addresses. This
type of format is called „word addresses format‟ in which word addresses are
denoted as follows.
N: Sequence number
T: Tool number word
F: Feed function word
S: Spindle speed function
X, Y, Z: Dimensional words
G: Preparatory function word
1.7 Control system & their standards [ISO & EIA]
The primary function of the CNC system is control of the machine tool. This
involves conversion of the part program instructions into machine tool motions
through the computer interface and servo system.

1.8 Programming methodology.
PROGRAM
Program is the series of instruction statements containing the contents of works
written in conformity with the rule according to the processing schedule.
A program is necessary when operating the CNC machine tool. It is specified by
input an alphabet and numerals succeeding to it.
Suppose if we have to machining a component as shown, starting from a point
„a‟ passing through points „b‟, „c‟, „d‟, „e‟, „f‟ and ending at point „a‟, the
program is as follows:
PPRROOGGRRAAMM DDEESSCCRRIIPPTTIIOONN
04567 Program Number
N1 (Finishing); Sequence no. and corresponding operation
G92/G50 S3000; Limiting maximum spindle speed
G00 T0404; Selecting turret station no.4
G96 S200 M03; Rotating spindle clockwise at 200 mm/rev
G00 X70. Z1. ; Rapid approaching up to point „b‟
G01 Z-20. F0.2 ; Cutting up to point „c‟ at feed 0.2mm/rev
X90. ; Cutting up to point„d‟
Z-75. ; Cutting up to point „e‟
X150. Cutting up to point „f‟
G00 X200. Z120. ; Rapid returning to point „a‟
M01; Optional stop
M30; Advising end of program.

1.9 Work pieces, job zero, tool zero, and reference zero tool
magazines
Job Zero or Program Zero or Part Origin:-
The part origin is the zero point from which all the part program
dimensions were created.
Tool zero or Tool change position or Machining Origin
The tool change position is a safe location that the machine return to
when indexing to a new tool.
Reference zero or Machine Zero
The reference zero point is the point at which all the axes are zeroed
out this point is generally set by the manufacture

MILLING OPERATIONS
G –CODES FOR MILLING OPERATION
SL. NO G- CODES FUNCTION
1 G00 Rapid Traverse
2 G01 Linear Traverse
3 G02 Circular Interpolation (CW)
4 G03 Circular Interpolation (CCW)
5 G04 Dwell
6 G20 Inch Unit
7 G21 Metric Unit
8 G28 Automatic Zero Return
9
G80 Canned Cycle Cancel
10
G81 Drilling Cycle
11
G83 Peck Drilling Cycle/ Deep Drill

12
G86
Boring Cycle
13 G90 Absolute Command
14 G91 Incremental Command
15 G94 Feed/Min
16 G95 Feed/Rev
17 G98 Return To Initial Point In Canned Cycle
18 G99 Return R Point In Canned Cycle
M –CODES FOR MILLING OPERATION
SL.NO M-CODES FUNCTION
1 M00 Optional Program Stop Automatic
2 M01 Optional Program Stop Request
3 M02 Program End
4
M03 Spindle On Clock Wise(CW)
5 M04 Spindle On Counter Clock Wise(CCW)

6 M05 Spindle Stop
7 M06 Tool Change
9 M08 Coolant On
10 M09 Coolant Off
12 M30 End Of Program, Reset To Start
13 M98 Sub Program Call
14
M99
Sub Program End/Return
15
M70 X-Mirror On
16
M71 Y-Mirror On
17
M80 X-Mirror OFF
18
M81 Y-Mirror OFF

EXERCISES
TURNING PROGRAMS
PROGRAM -01 SIMPLE TURNING
25
15
[BILLET X25 Z30
G21 G98
G28 U0 W0
M06 T01
M03 S1500
G00 X25 Z2
G90 X25 Z-15
G28 U0 W0
M05
M30

PROGRAM -02 STEP TURNING
25
15
15
[BILLET X25 Z30
G21 G98
G28 U0 W0
M06 T01
M03 S1500
G00 X25 Z2
G90 X25 Z-15
G90 X24 Z-15
G90 X23 Z-15
G90 X22 Z-15
G90 X21 Z-15
G90 X20 Z-15
G28 U0 W0
M05
M30

1515
20
15
25
[BILLET X25 Z30
G21 G98 G90 X19 Z-15
G28 U0 W0 G90 X17 Z-15
M06 T01 G90 X16 Z-15
M03 S1500 G90 X15 Z-15
G00 X25 Z2 M05
G90 X25 Z-30 M30
G90 X24 Z-30
G90 X23 Z-30
G90 X22 Z-30
G90 X21 Z-30
G90 X20 Z-30
G00 X20 Z2
G90 X20 Z-15

151515
10
20
30[BILLET X40 Z70
G90 X16 Z-15
G21 G98 G90 X20 Z-30
G28 U0 W0 G00 X20 Z2
M06 T01 G90 X18 Z-15
M03 S1500 G90 X22 Z-30
G00 X40 Z2 G90 X14 Z-15
G90 X38 Z-45 F60 G90 X10 Z-15
G90 X36 Z-45 M05
G90 X35 Z-45 M30
G90 X32 Z-45
G90 X30 Z-45
G00 X30 Z2
G90 X28 Z-30 F60
G90 X26 Z-30
G90 X24 Z-30

PROGRAM-05 TAPER TURNING
15
O25
[BILLET X30 Z60
G21 G98 G28 U0 W0
G28 U0 W0 M05
M06 T01 M30
M03 S1200
G00 X25 Z2
G90 X25 Z-15 R0.5 F60
G90 X25 Z-15 R-1
G90 X25 Z-15 R-1.5
G90 X25 Z-15 R-2
G90 X25 Z-15 R-2.5
G90 X25 Z-15 R-3
G90 X25 Z-15 R-3.5
G90 X25 Z-15 R-4
G90 X25 Z-15 R-4.5
G90 X25 Z-15 R-5

PROGRAM-06 STEP & TAPER TURNING
1515
O=18
O=25
[BILLET X30 Z60
G21 G98 G90 X25 Z-30 R-1.5
G28 U0 W0 G90 X25 Z-30 R-2
M06 T01 G90 X25 Z-30 R-2.5
M03 S1500 G90 X25 Z-30 R-3
G00 X25 Z2 G90 X25 Z-30 R-3.5
G90 X25 Z-15 F60 G00 U0 W0
G90 X24 Z-15 M05
G90 X23 Z-15 M30
G90 X22 Z-15
G90 X20 Z-15
G90 X18 Z-15
G00 X25 Z-15
G90 X25 Z-30 R-0.5 F60
G90 X25 Z-30 R-1

PROGRAM-07 MULTIPLE TURNING
510
O20
O25
O30
5105
[BILLET X32 Z70
G21 G98
G28 U0 W0
M06 T01
M03 S1500
G00 X20 Z2
G90 X20 Z-5 R-1 F60
G90 X20 Z-5 R-2
G90 X20 Z-5 R-3
G90 X20 Z-5 R-4
G90 X20 Z-5 R-5
G00 X25 Z2
G90 X24 Z-15
G90 X23 Z-15

G90 X22 Z-15
G90 X21 Z-15
G90 X20 Z-15
G00 X25 Z2
G90 X25 Z-20 R-0.5 F60
G90 X25 Z-20 R-1
G90 X25 Z-20 R-2.5
G00 X30 Z2
G90 X28 Z-30
G90 X26 Z-30
G90 X25 Z-30
G00 X30 Z2
G90 X30 Z-35 R-0.5 F60
G90 X30 Z-35 R-1
G90 X30 Z-35 R-1.5
G90 X30 Z-35 R-2
G90 X30 Z-35 R-2.5
G28 U0 W0
M05
M30

15310583
O20
O23
O28
O32
[BILLET X32 Z70
G21 G98 N7 G01 X28 Z-41
G28 U0 W0 N8 G02 X32 Z-44 R3
M06 T01 G70 P1 Q8
M03 S1500 G28 U0 W0
G00 X32 Z2 M05
G71 U0.5 R1 M30
G71 P1 Q8 U0.1 W0.1 F60
N1 G01 X18 Z0
N2 G01 X20 Z-2
N3 G01 X20 Z-15
N4 G03 X23 Z-18 R3
N5 G01 X23 Z-28
N6 G01 X28 Z-33

1058310583
2X45°
O=20
O=23
O=28
O=30
O=32
R3
R
3
[BILLET X32 Z70
G21 G98 N6 G02 X28 Z-26 R3
G28 U0 W0 N7 G01 X28 Z-36
M06 T01 N8 G03 X30 Z-41 R3
M03 S1500 N9 G01 X30 Z-49
G00 X32 Z2 N10 G01 X32 Z-52
G71 U0.5 R1 G70 P1 Q10
G71 P1 Q10 U0. 1 W0.1 F60 G28 U0 W0
N1 G01 X18 Z0 M05
N2 G01 X20 Z-2 M30
N3 G01 X20 Z-10
N4 G01 X23 Z-15
N5 G01 X23 Z-23

1058310583
2X45°
R
3
R
3
O=20O=23
O=28
O=30
O=32
[BILLET X30 Z70
G21 G98 N5 G01 X20 Z-23
G28 U0 W0 N6 G02 X25 Z-27 R4
M06 T01 N7 G01 X25 Z-37
M03 S1500 N8 G03 X30 Z-41 R3
G00 X32 Z2 G70 P1 Q8
G71 U0.5 R1 G28 U0 W0
G71 P1 Q8 U0.1 W0.1 F60 M05
N1 G01 X8 Z0 M30
N2 G01 X10 Z-2
N3 G01 X10 Z-10
N4 G03 X20 Z-13 R3

153104
R3
R3 O=18
O=21
O =25
[BILLET X30 Z70
G21 G98 N3 G01 X18 Z-15
G28 U0 W0 N4 G02 X21 Z-18 R3
M06 T01 N5 G01 X21 Z-28
M03 S1500 N6 G03 X25 Z-32 R4
G00 X25 Z2 G70 P1 Q6
G71 U0.5 R1 G28 U0 W0
G71 P1 Q6 U0.1 W0.1 F60 M05
N1 G01 X16 Z0 M30
N2 G01 X18 Z-2

20
16
12
15 10
1015
[BILLET X50 Z70
G21 G99 G40 G02 X44 Z-58 R8
G29 U0 W0 G01 X44 Z-68
M06 T04 G01 X50 Z-68
M03 S2500 G70 P80 Q160 F0.06
G00 X52 Z2 M05
G71 U1.0 R1.0 G28 U0 W0
G71 P80 Q160 U0.5 W0.5 F0.05 M30
G01 X8
G01 X8 Z-10
G01 X12 Z-18
G01 X12 Z-28
G03 X28 Z-36 R8
G01 X28 Z-50

PROGRAM-13 GROOVING
105
O32 O29
3
[BILLET X30 Z70
G21 G98
G28 U0 W0
M06 T03
M03 S600
G00 X33 Z-10
G75 R0.5
G75 X29 Z-15 P250 Q100 F35
G28 U0 W0
M05
M30

PROGRAM-14 EXTERNAL THREAD CUTTING
15
M18x1.5pitch
[BILLET X30 Z70
G21 G98
G28 U0 W0
M06 T05
M03 S600
G00 X18 Z2
G76 P030060 Q500 R0.02
G76 X16.161 Z-15 P919 F1.5
G28 U0 W0
M05
M30

PROGRAM-15 INTERNAL THREAD CUTTING
15
M15x1Pitch
[BILLET X30 Z70
G21 G98
G28 U0 W0
M06 T06
M03 S600
G00 X14 Z2
G76 P030060 Q500 R0.02
G76 X16.22 Z-15 P919 Q500 F1.5
G28 U0 W0
M05
M30

MILLING PROGRAMS
Program-01
15 15 40 15 15
1515401515
15X45°
R
15
[BILLET X100 Y100 Z10
[EDGEMOVE X0 Y0 Z0
G21 G94
G91 G28 U0. W0. Z0.
M05 S2000
M06 T01
G90 G00 X15. Y30. Z5

G01 Z-2. F50
G01 X15. Y30.
G01 X30. Y15.
G01 X70. Y15.
G01 X85. Y30.
G01 X85. Y70.
G03 X70. Y85. R15
G01 X30. Y85.
G01 X15. Y70.
G01 X15. Y30.
G90 G00 Z5.
G91 G28 X0. Y0. Z0.
M05
M30

Program-02
10 10 60 10 10
1010601010
R
10
10X45°
R
10
R
10
[EDGEMOVE X0 Y0 Z0
G21 G94
G91 G28 U0. W0. Z0.
M06 T01
M05 S2000
G90 G00 X10.Y20.Z5.
G01 Z-2.F50.

G01 X10.Y20.
G02 X20.Y10.R10.
G01 X80.Y10.
G03 X90.Y20.R10.
G01 X90.Y80.
G01 X80.Y90.
G01 X20.Y90.
G02 X10.Y80.R10.
G01 X10.Y20.
G90 G00 Z5.
G91 G28 X0. Y0. Z0.
M05
M30

Program-03
R
10
R10
R
10
10701010
10 70 10 10
[EDGEMOVE X0 Y0 Z0
G21 G94
G91 G28 X0. Y0. Z0.
M06 T01
M05 S2000

G90 G00 X10. Y10. Z5.
G01 Z-2. F50.
G01 X10. Y10.
G01 X80. Y10.
G02 X90. Y20. R10.
G01 X90. Y80.
G03 X80. Y90. R10.
G01 X20. Y90.
G02 X10. Y80. R10.
G01 X10. Y10.
G90 G00 Z5.
G91 G28 X0. Y0. Z0.
M05
M30

Program-04
50
302010X45°
40
20 X45°
10 10
10
10
10
[EDGEMOVE X0 Y0 Z0
G21 G94
G91 G28 U0. W0. Z0.
M06 T01
M05 S2000

G90 G00 X10. Y10.Z5.
G01 Z-2. F50.
G01 X10. Y10.
G01 X60. Y10.
G01 X60. Y50.
G01 X40. Y70.
G01 X20. Y70.
G01 X10. Y60.
G01 X20. Y60.
G01 X20. Y40.
G01 X10. Y40.
G01 X10. Y10.
G90 G00 Z5.
G91 G28 X0. Y0. Z0.
M05
M30

Program-05
R
10
60
R10
601010
1060
10 10
10X45° 10
[EDGEMOVE X0 Y0 Z0
G21 G94
G91 G28 X0. Y0. Z0.
M06 T01
M05 S2000

G90 G00 X10. Y20. Z5.
G01 Z-2. F50.
G01 X10. Y20.
G02 X20. Y10. R10.
G01 X80. Y10.
G03 X90. Y20. R10.
G01 X90. Y80.
G01 X80. Y80.
G01 X80. Y90.
G01 X20. Y90.
G01 X10. Y80.
G01 X10. Y20.
G90 G00 Z5.
G91 G28 X0. Y0. Z0.
M05
M30

Program-06
15 15 60 15 15
1515601515
15X45° 15X45°
15X45° 15X45°
[EDGEMOVE X0 Y0 Z0
G21 G94
G91 G28 X0. Y0. Z0.
M06 T01
M05 S2000

G90 G00 X15. Y30. Z5.
G01 Z-2. F50.
G01 X15. Y30.
G01 X30. Y15.
G01 X70. Y15.
G01 X85. Y30.
G01 X85. Y70.
G01 X70. Y85.
G01 X30. Y85.
G01 X15. Y70.
G01 X15. Y30.
G90 G00 Z5.
G91 G28 X0. Y0. Z0.
M05
M30

VVIIVVAA QQUUEESSTTIIOONNSS
1. What are G code and M code
2. How we write the format a program
3. How we fix a length of the tool for part program
4. What are the typical error found in NC program
5. How we verify the program procedure
6. Which G code is used for Tool nose radius
7. Which G code is used for Thread cutting
8. Which G code is used for Turning cycle
9. Which G code is used for Multiphase Turning cycle
10. Which G code is used for Axial drilling cycle
11. Which G code is used for Grooving cycle
12. What are the steps to be followed while programming
13. Which G code is used for Drilling and for different drills
14. Which are the basic tools used in part programming
15. Which are the different M codes used
16. Which are the G codes used for Boring cycle
17. When we use subprogram
18 Which are the G code used for Finishing cycle
19. What are P,Q,U,V,W,F used in program
20. Abbreviation of FANUC
21. Theoretical how do you find taper length.

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