CNC Machining Simulation Lab

Tutorial

Work Integrated Learning Program

WISE Simulation Lab
Birla Institute of Technology & Science, Pilani
 Errors to IGNORE During the tutorial

While creating new

project software will
ask you to save the NC
file, if you say YES then
After cycle start you may get
the above error
this error dialogue box, ignore
message may appear. this error, click CLOSE and
Ignore this error continue. If the error continues,
message just Click OK Ignore the floating decimals in
While switch ON the controller above error
and continue to your origin while editing in the
may appear, just ignore this error and
next steps. program. Just enter the
proceed with next steps. reference value as whole
numbers without any decimal
You may get these ignorable error messages during any tutorial. points
Collision and Over Travel error because of your wrong inputs

 “Collision Occur” is a common error message you will get because of your wrong input parameters. This
indicates that your input parameters are leading the spindle in wrong path instead of proper material
removal and collision occurs between the tool, work piece clamping fixture or the table

 Reasons for Collision and Over Travel

 Wrong work part origin reference value in NC program and
 Wrong tool dimensions

 Remedy
 Enter correct reference value as mentioned in the TUTORIAL Manual
 Enter correct tool nomenclatures as mentioned in the TUTORIAL Manual
Problems

Sl. No. Operation Workpiece size Tool used Controller

Vertical Milling
1. □ 100 x 100 x 20 Flat end mill ∅16 H 100 Siemens - Sinumeric
(Linear Interpolation)
Vertical Milling
2. □ 80 x 80 x 20 Flat end mill ∅24 H 100 Siemens – Sinumeric
(Profiling)
Vertical Milling
3. □ 80 x 80 x 20 Flat end mill ∅16 H 100 Fanuc 21i-MB5
(Profiling)
Flat end mill ∅ 20 H 100
Vertical Milling Central Drill -∅3 H 100
4. □ 100 x 100 x 20 Fanuc 21i-MB5
(Profiling) Drill ∅8.5 H95
Tap D10 H100
Horizontal Milling
5. □ 205 x 155 x 100 Ball End Mill D8 H100 Siemens – Sinumeric
(Profiling)
Problem 2: Vertical Machining-Profiling

Lab Perquisites: Basics of NC code in connection with vertical machining is required. Knowledge about flat

end mill tool and their corresponding nomenclatures is mandatory before entering to this example.

Workpiece size: Rectangular piece (80 x 80 x 20 mm)

Tool required: V-CNC Pro

Mounting details: Length : 50mm & Height : 35 mm

Goal: To do the basic facing and profiling on the above workpiece in Siemens – Sinumeric machining center.

At the end of this example students will understand how to do the machining operation in Siemens 840 D

controller and further a student shall interpret the NC code.

Problem 2: Vertical Machining - Profiling

Given work part diagram

Problem 2: Vertical Machining - Profiling

Desired work part diagram

Problem 2: Vertical Machining - Profiling

Experiment Outline
Part I : Set up the workpiece and machine Part II : Set up the controller and cycle start
 Open V-CNC Pro Mill Software  Simulation environment settings
 Save Project  Set collision check
 Open wizard floating menu  Power on the controller
 Select machine  Spindle Zero Return
 Select controller  Cutter Compensation
 Open NC File  Edit H number in Program
 Create work part  Start the machining process
 Load work part
 Edit Magazine & Tool
 Set origin of the work part
Problem 2: Vertical Machining - Profiling

Experiment Outline (Contd.,)

Part III – Verification
 Verification of Machined component window open
 Verification of Machined component - Tool path
 Verification of Machined component - Gouge check
 Verification of Machined component - View sections
 Verification of Machined component - Work part drawing preparation
 Verification of Machined component - Save Work part diagram
 Save and close the project
Problem 2: Vertical Machining - Profiling
Shortcuts to represent various mouse shortcuts in the tutorial for convenience.

LMB: Left Mouse Button Single click RMB: Right Mouse Button click once

DLMB: Left Mouse Button Double click

 Problem 2: Vertical Machining - Profiling

Experiment Outline
Part I : Set up the workpiece and machine
Step 1: Open V-CNC Pro Mill Software
 Once log in to the citrix server, click
VCNCProStart.
 VCNCProStart window will appear
 Click Machining Center in the
window and wait for some time, then
you can see VCNC Promill software
window open in your system.

V-CNC Pro Mill Software Interface

Part 1: Set up the workpiece and machine

 Problem 2: Vertical Machining - Profiling
Step 2: Reset the toolbar
 View (LMB)
Toolbars (LMB)
Init Toolbar (LMB)

Note: There may not be any changes in the screen after this step, proceed to next step.
Part 1: Set up the workpiece and machine
 Problem 2: Vertical Machining - Profiling
Step 3: Save project
 File (LMB)
Project save(LMB)
 Save as project file window will pop up
LMB the drop down menu (Save in:)
Personal Directory (P:) (LMB)
Create new folder inside the
personal directory and name it as your
BITS ID (for example 201518… )
 DLMB the created folder
 Type File name”Tutorial2”
 Save (LMB)

Part 1: Set up the workpiece and machine

Problem 2: Vertical Machining - Profiling
Step 4: Open wizard floating menu
 Settings (LMB)
Wizard (LMB)
 Now you can see the floating window
included the steps, Set User
Information, Select Machine and so on.

Part 1: Set up the workpiece and machine

Problem 2: Vertical Machining - Profiling
Step 5: Select Machine
 Select Machine (LMB) (in wizard)
 Now Select Machine window will Tool Magazine
pop up.
1_Vertical M-C (LMB) Tool Head
Apply (LMB)
Tool Assembly

Work part and

Fixture
Table
Rotate, Move and other icons

Directions in vertical
machining center

Part 1: Set up the workpiece and machine

Problem 2: Vertical Machining - Profiling
Step 6: Select Controller
 Select Controller (LMB) (in wizard)
 Now Select Controller window will
pop up.
 Commercial controllers (LMB)
 Among the list of controllers
select Siemens 840D (M/C) (LMB)
 Apply (LMB)
 Controller interface window will
pop up now.
 Maximize the controller interface
to have a better view. (Refer next
page for the maximized controller
interface)

Part 1: Set up the workpiece and machine

Problem 2: Vertical Machining - Profiling

Part 1: Set up the workpiece and machine

Problem 2: Vertical Machining - Profiling

CRT Screen

Part 1: Set up the workpiece and machine

Problem 2: Vertical Machining - Profiling

Control Panel

Part 1: Set up the workpiece and machine

Problem 2: Vertical Machining - Profiling

Control Panel

Part 1: Set up the workpiece and machine

Problem 2: Vertical Machining - Profiling

Control Panel

Part 1: Set up the workpiece and machine

Problem 2: Vertical Machining - Profiling

Key Pad

Part 1: Set up the workpiece and machine

Problem 2: Vertical Machining - Profiling

Soft Key Screen

Part 1: Set up the workpiece and machine

Problem 2: Vertical Machining - Profiling

Part 1: Set up the workpiece and machine

Problem 2: Vertical Machining - Profiling

Part 1: Set up the workpiece and machine

 Problem 2: Vertical Machining - Profiling
Step 7: Create Work Part
 Create Work Part (LMB) (in wizard)
 Create work-part window will appear
Type 80 in W(width) and D(depth) box
Type 20 in H(height) box
 Let the material be unchanged
 Reload (LMB)
 Wait for a moment, work part will be reloaded
in the fixture.
 Now the work part will be loaded in the fixture.

Part 1: Set up the workpiece and machine

 Problem 2: Vertical Machining - Profiling
Step 8: Load Work Part
 Load Work Part (LMB) (in wizard)
 Load work-part window will appear
Type 50 in Mounting Length box
Type 35 in Mounting Height box
 Load (LMB)
 Create Work Part (LMB)
 Reload (LMB)
 Wait for a moment, work part will be reloaded
in the fixture.
 Now the work part will be loaded with the
specified mounting height and length in the
fixture.
Part 1: Set up the workpiece and machine
 Problem 2: Vertical Machining - Profiling
Step 9: Edit Magazine & Tool
 Edit Magazine & Tool (LMB) (in wizard)
 Magazine window will appear
Flat end mill (LMB)
Modify Tool (LMB) below window will appear
 Edit the Tool Dia. 10 into 24.
 DLMB the tool dia text box and delete value 10
& type 24, then press ENTER)
 OK (LMB)

Part 1: Set up the workpiece and machine

 Problem 2: Vertical Machining - Profiling
Step 9: Edit Magazine & Tool (Contd.,)
 Now Tool library manager window will disappear
and magazine window will appear.
 Next Tool>> (LMB 11 time) to move to tool room Spindle
no. 12. Tool no
 Now click Add tool in magazine window
 OK (LMB).
 Now do you want to save pop up window will
appear press Yes.

Part 1: Set up the workpiece and machine

 Problem 2: Vertical Machining - Profiling
Step 9: Edit Magazine & Tool (Contd.,)
 LMB the drop down menu (Save in:)
Desktop (LMB)
Your folder (201518… in desktop)
DLMB
 Type File name”Tutorial2-Tool”
 Save (LMB)
 Tool library has been saved
confirmation window will appear
click ok.

Part 1: Set up the workpiece and machine

 Problem 2: Vertical Machining - Profiling
Step 10: Set origin work part
 Set origin work part (LMB) (in wizard)
 Work-Part origin setting (auto) window will appear
 Click the corner of the rectangle as shown
 In Work-Part drop down box click Hexahedron
 Apply (LMB).
 Close (LMB)

Part 1: Set up the workpiece and machine

 Problem 2: Vertical Machining - Profiling
Part II : Set up the controller and cycle start
Step 1: Simulation Environment settings
 Settings (LMB)
Environment setting (LMB)
 Environment Setting window will appear
Reduce the simulation speed to 70% (drag the
horizontal bar towards left)
 Simulation On is selected.
 Select High speed mode not use
 Give Tool Tolerance of 0.06
Select Coolant Effect ON
 Select the Show tool path option
 Click OK.

Part II: Set up the controller and cycle start

 Problem 2: Vertical Machining - Profiling
Step 2: Set collision check
 Settings (LMB)
Set collision check (LMB)
 Collision Setting window will appear
Select Stop
Apply (LMB)

When there is a collision occurs between tool,

table, or any other components machining
operation will be stopped.

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Step 3: Type NC code in Controller
 Maximize the controller window
 Machine Area Key (LMB)
 Menu Selection Key (LMB)
 AUTO Softkey (LMB)
 Machine Area Key (LMB)
 Correct Program Softkey (LMB)
 Correct’n Block editor window will open as
shown in below figure.

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Step 3: Type NC code in Controller (contd.,)
 Type the below NC code in the block editor.
 Verify the program once and click Close editor
softkey

O0003 N10 X62.;

N1 G71 G40; N11 X72. Y62.;
N2 M6 T1; N12 Y8.;
N3 G54 G90 X0 Y0 Z100 G00; N13 X-5.;
N4 M8; N14 G0 G90 Z150. G49 M09;
N5G0 X-10. Y-10. Z100.; N15 G40 M05;
N6 G43 H01 Z5. S900 M03; N16 M30;
N7 G1 Z-6. F90;
N8 G41 X8. D01;
N9 Y72.;

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Step 4: Cutter compensation
 Maximize the controller window
 Machine Area Key (LMB)
 Menu Selection Key (LMB)
 Parameter Softkey (LMB)
 Parameter window will appear as
shown below

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Step 4: Cutter compensation (Contd.,)
 Enter 12 in Radius
 Make sure that the Tool number and
compensations number is set to “1”

 Use Tool + or – to adjust the tool

number and D + or – to adjust the
compensation number.

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Step 5: Reference axis offset
 Click Zero offset softkey
 Make sure that the G54 reference
offset is set in zero offset.
 Cross check the axis offset values
with the origin values (Part I step 14)
 Save softkey (LMB)
 Menu Selection Key (LMB)

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Step 6: Spindle Zero return
 JOG mode (LMB)
 Ref Pos (LMB)
 Cycle Start (LMB)
 Spindles Softkey (LMB) to check the spindle
position.

 Make sure that the spindle position reached

machine reference (0,0,0). Since the machine
reference return is not mentioned in the NC
code it is mandatory to move the spindle
position to the origin position to avoid
accidents during tool change.

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Step 6: Start the machining process
 Auto (LMB) Green led should glow
 Single block (LMB)
 Press the cycle start
 Now, press cycle start to execute each and
every block.
 Milling operation is done on the rectangular
work piece of 80 x 80 x 20 mm.
 Next, the dimension of the machined
component should be verified.

 If any error occur during cycle start, do the zero

return process once again, check the feed rate
(should be 100) and rerun the above step.
 Check the current block and the corresponding
position changes in the CRT screen.

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Start the machining process (Single block
positions)
 Click cycle start for executing each block.

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Start the machining process (Single block
positions)
 Click cycle start for executing each block.

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Start the machining process (Single block
positions)
 Click cycle start for executing each block.

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Start the machining process (Single block
positions)
 After 2nd block

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Start the machining process (Single block
positions)
 After 3rd block

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Start the machining process (Single block
positions)
 After 4th block

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Start the machining process (Single block
positions)
 After 5th block

Table moves from

-640 to -650 in X-Axis
-314 to -324 in Y-Axis and
Spindle moves from -334 to -235 in Z-Axis
Part II: Set up the controller and cycle start
 Problem 1: Vertical Machining-Linear Interpolation
Start the machining process (Single block
positions)
 After 6th block

Spindle moves from -235 to -330 in Z-Axis

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Start the machining process (Single block
positions)
 After 7th block

Spindle moves from -330 to -341 in Z-Axis

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Start the machining process (Single block
positions)
 After 8th block

Table moves from

-650 to -644 in X-Axis

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Start the machining process (Single block
positions)
 After 9th block

Table moves from

-324 to -230 in Y-Axis

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Start the machining process (Single block
positions)
 After 10th block

Table moves from

-644 to -573.029 in X-Axis

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Start the machining process (Single block
positions)
 After 11th block

Table moves from

-573.029 to -556.000 in X-Axis &
-230.000 to -247.029 in Y-Axis

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Start the machining process (Single block
positions)
 After 12th block

Table moves from

-247.029 to -318.000 in Y-Axis

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Start the machining process (Single block
positions)
 After 13th block

Table moves from

-556.000 to -645.000 in X-Axis

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Start the machining process (Single block
positions)
 After 14th block

Spindle moves from

-341.000 to -185.000 X-Axis

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Start the machining process (Single block
positions)
 After 15th block

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Start the machining process (Single block
positions)
 After 16th block

Part II: Set up the controller and cycle start

 Problem 2: Vertical Machining - Profiling
Part III – Verification
Step 1: Verification of Machined
component window open
 Inspection (LMB)
Verification
 Separate verification module page
will open as shown.
In Move Work-Part dialogue box
enter 0,0,0 in X, Y and Z then click
Move.

Part III: Verification

 Problem 2: Vertical Machining - Profiling
Step 2: Verification of … Tool path without machining ___ Tool path during machining
Machined component -
Tool Path
 View(LMB)
Tool Path (LMB)
 Tool path attribute
icon (LMB)
 Color drop down
menu and select black
color,
 OK (LMB)

Note: Cutter compensation will be added during interpolation Part III: Verification
 Problem 2: Vertical Machining - Profiling
Step 3: Verification of Machined
component - Gouge Check
Gouge check (LMB)
Open Model File(o) LMB
In the Look in drop down menu select
Tutorial Share (T:), Scroll down and find V-
CNC Pro Tutorial Folder. DLMB the folder.
You can find Phase 2STL Files folder
(DLMB), find “Tutorial 2” folder. DLMB the
same folder.
Tutorial2 STL file (LMB) Open (LMB)
Machined component is overlapped with
the final component to check the undercut
and overcut.
Green color portion indicates that there is
no under cut in the model.
Blue and Red colored areas are the under
cut and over cut respectively.
Gouge check usually decides whether the
machine settings, NC code and offset is in
par with the desired workpart geometry.
Use rotate and pan option to manipulate the component Part III: Verification
 Problem 2: Vertical Machining - Profiling
Step 4: Verification of Machined
component - View Section
 Measure (LMB)
View section
Select the points as shown in the
Fig.
OK (LMB)
 View Section window will appear
 In the view Section window, click
next to cross check the
coordinates. (This will help us to
Point
cross verify geometry of the
selected
complex curvature geometry)
 Close the View Section window
 Take different cross section and
check the coordinates of the
component.

Part III: Verification

 Problem 2: Vertical Machining - Profiling
Step 4: Verification of Machined
component - View Section

 While checking the dimension, you

may end up with the shown error.
 This error message indicates that
the dimension can check only in
the horizontal or vertical cut
section. That is the selection points
should be a straight line (either
vertical or horizontal).
 Click ok and redo the cut section
with different point (selected
points should be approximately
straight)

Part III: Verification

 Problem 2: Vertical Machining - Profiling
Step 5: Verification of
Machined component - Work
Part diagram
 Measure (LMB)
 Work Part Diagram (LMB)
 Separate CbDrawer window
will appear.
 Click at the corner as shown in
the Fig and press OK.

 Continue in the next page…

Part III: Verification

 Problem 2: Vertical Machining - Profiling
Step 6: Verification of Machined
component - Work Part diagram
 Give the dimensions as shown.
 Horizontal direction icon (LMB)

 Use Zoom in, Zoom out, and Pan

to manipulate the diagram.
 Finally press Zoom all icon to have
the default diagram view

Zoom in Pan

Indicates the starting and end point of the dimension. Some of

Zoom Out Zoom All
the points cannot be selected for dimensioning. Hence these
points are traced from the tool interpolation.
Part III: Verification
 Problem 2: Vertical Machining - Profiling
Step 7: Verification of Machined
component - Work Part diagram
 Give the dimensions as shown.
 Vertical direction icon (LMB)

 Set Y and X section view to 40

  OK (LMB)
 Cancel (LMB)

 Press Radius icon and select the four

corner fillet circles as shown.
Part III: Verification
 Problem 2: Vertical Machining - Profiling
Step 8: Verification of Machined
component - Save Work part
diagram
 Save image icon (LMB)
 In the Save in drop down menu click
Personal Directory (P:)
 DLMB – Folder created in the first
step.
 Give File name in the text box
 Save (LMB)
Step 9: Save and close the project
 Workpart Diagram window (Close)
 Verification window (close)
 File (LMB) in VNC PRO Mill Software
page
 Project Save (LMB)
 File (LMB)
 Exit (LMB)
 Save the program alert (Click save)
Part III: Verification
Contact us if you have any queries

Work Integrated Learning Program

WISE Simulation Lab
Birla Institute of Technology & Science, Pilani

Email : wise@wilp.bits-pilani.ac.in
Text @ Hangout : wise@wilp.bits-pilani.ac.in