CNC Part Programming

PRPC17-Computer Numerical Control (CNC) Systems

Part program and its elements- methods of programming – manual part programming,
formats. codes and cycles –computer-assisted part programming - custom macro – APT and its
variations - FMS
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 Computer Numerical Control (CNC)

In CNC (Computer Numerical Control), the instructions are stored as a program in a micro-
computer attached to the machine.

CNC Lathe Machine

CNC APPLICATIONS
• Machining
Turning ~ Lathes, Turning Centre
Milling ~ Machining Centres
• Forming
➢ 2D
Plasma and Laser Cutting
Blanking and punching
➢ 3D
Rapid Prototyping CNC Vertical Machining Centre 2
 INTRODUCTION
Programming languages
First systems developed and use a programming language similar to
FORTRAN or BASIC
Automatically Programmed Tools (APT) and its many variants
COMPACT II

CAD/CAM systems Dedicated CAM systems

Major CAD systems have integrated manufacturing In these systems a dedicated CAM system helps in
systems for better interfacing and translation developing the CNC part programs
Examples are: May be linked to a major CAD system such as
Pro engineer – Pro Manufacture AutoCAD, Solidworks, CADKEY,….
Unigraphics Examples
I-DEAS – Solids machining Mastercam
CATIA Virtual Gibbs
Intergraph Smartcam
Edgecam
Alphacam

CNC manufacturers

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 CNC Controller

The software which controls the program in different interface languages is known as the
controller.

FANUC

SINUMERIK

HEIDENHAIN

MAZATROL

MAZAK

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 AXIS NOMENCLATURE

RIGHT HAND RULE

Vertical Machine Horizontal Machine

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CNC-Introduction-Axis nomenclature

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CNC-Introduction-Axis nomenclature

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CNC-Introduction-Multi-axis nomenclature

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 AXIS NOMENCLATURE

Turning machine Three-axes milling machine

The axes are named

according to DIN 66217. B+

Axis and motion nomenclature for numerically

controlled machines (German National Standard)

A+
C+

Six-axis milling machine

VIDO VIDEO
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 AXIS NOMENCLATURE

Reference systems

M - Machine Zero or home: This is set by the manufacturer as the origin of the coordinate
system of the machine.

W -Part zero or point of origin of the part: This is the origin point that is set for
programming the measurements of the part. It can be freely selected by the programmer.

R-Machine Reference point. This is a point on the machine established by the

manufacturer around which the synchronization of the system is done. The control positions
the axis on this point.

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 AXIS NOMENCLATURE
Reference systems

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CNC MACHINE SETUP AND OPERATION

Check coolant and air supply levels,

ensure work area is clean, …

Fill the tool carousel.

Define Tool Length & Radius Offsets

Once he workholding device is properly

installed and aligned, set part X,Y&Z zero
datum.

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 CNC-REFERENCE SYSTEMS
Machine Reference (R) setting T1 T2 T3 T4

R R R R
TOOL LENGTH
COMPENSATION OFF

G44 L1 L2 L3 L4
OFFSET TABLE

TOOL TOOL RADIUS LENGTH

OFFSE
T
T1 D1 55.234
T2 D1 72.345
T3 D1 61.098
T4 D1 66.683
… … ... …

TOOL LENGTH
COMPENSATION ON

G43

R R R R
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 CNC-REFERENCE SYSTEMS
Machine Reference (R) setting

Tool on the workpiece

T1 T2 T3 T4

R R R R

W
L1 < 0
W L3 < 0 L4 = 0
L2 > 0

Low accuracy.
Time consuming method.
Only tool length (L) values are measured.
Tool is rotating and thus, part or referencing block gets marked.
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CNC_Reference systems_Machine reference setting_Tool on the workpiece

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 CNC-REFERENCE SYSTEMS
Machine Reference (R) setting

BASED ON A REF. TOOL

Using a tool length setter gauge R R

L1=0 L2<0

BASED ON MACHINE DATUM

R
R

VIDEO L1
L2
z1
z2
Good accuracy.
Time consuming method. 50 50
M
Only tool length (L) values are measured.
L1= z1-50 L2= z2-50
Part or referencing block does not get marked. TOOL LENGTH MEASUREMENT
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 CNC-REFERENCE SYSTEMS
Part zero (W) setting

Prior to defining part zero, procedure should be:

1. Study how the drawing is dimensioned.
2. Decide on the workholding device type and part zero (W) definition.
Machine operator defines part zero (W) position anywhere.
Most common positions:
o Left lower side of the part (all data position values are positive).
o Part symmetry axis.
o CLAMP CASE Centering pins side.
Stationary chuck
o VISE CASE Stationary chuck & vise stop side.
Movable chuck
Clamps Centering pins

Vise stop

Clamps (with or without centering pins) Vise (with or without vise stop)
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 CNC-REFERENCE SYSTEMS
Part zero (W) setting

VISE Z VISE Z
Y Y
X
X

Y Y
Y Y
X Z
X Z

Symmetry

X-Y axis part symmetry Stationary chuck & Y axis part symmetry
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CNC_Reference systems_Part zero setting_Using the tool

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 CNC-REFERENCE SYSTEMS
Part zero (W) setting
Z
VISE CLAMP

Y
X
X
Z
X Z
X

Stationary chuck & left lower part Stationary chuck & Y axis part symmetry
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 CNC-REFERENCE SYSTEMS
Part zero (W) setting

1 Using the tool 2 Using a mechanical edge finder

VIDEO
Low accuracy. Low accuracy.
Tool is rotating and thus, part gets VIDEO
marked.
X Optical edge finder similar
Y DATUM SETTING X
DATUM SETTING
Z Y
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 CNC-REFERENCE SYSTEMS
Part zero (W) setting

3 Using a touch probe

High accuracy.

X
Y DATUM SETTING
VIDEO VIDEO Z
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 CNC-REFERENCE SYSTEMS
Part zero (W) setting

3 Using a touch probe

2 types:
1. Touch-trigger probes
2. Scanning probes (continuous measuring)
Touch probe stylus tips
PRO & CON:
Almost any machined geometry may be measured in-situ.
Reduced machine downtime.

Part unclamping for measuring is avoided.

It ca nnot consider possible machine axes errors.

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BASIC ISO PART PROGRAMMING

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 BASIC ISO PROGRAMMING

Block structure

N**** G** X****.*** Y****.*** Z****.*** A****.*** B****.*** C****.*** F****.** S****.**

Linear and angular

positioning data Feed function
Preparatory
functions
or G-codes

Speed function
Block identification
Identifies the block of information.

T** D** M** N** ; *****

Not ISO,
Block comment
= corresponds to
Number of block repetitions FAGOR 8055M
Miscellaneous or auxiliary functions
Tool offset number
Tool number 25
 BASIC ISO PROGRAMMING

Feed function (F) Speed function (S)

The feed function F is the speed at which the tool The speed function S is the speed at which the
center point moves. tool (in milling) or part (in turning) rotates.

The programmed F is effective working in linear The maximum S value is limited by the machine
(G01) or circular (G02, G03). parameters.

The maximum F value is limited by the machine

parameters.

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 BASIC ISO PROGRAMMING
Tool number (T)
The "T" code identifies the tool position in the tool magazine.

Tool offset number (D)

The tool offset contains the tool dimensions.
Each tool may have several offsets associated with it.

TOOL TOOL RADIUS LENGTH … TOOL TOOL RADIUS LENGTH …

OFFSE OFFSE
T T
T1 D1 8.002 55.234 … T2 D1 4.000 72.345 …
D2 7.502 55.234 … D2 11.990 60.036 … …
D3 8.002 55.026 … D3 7.500 33.110 …
… … … … … … … …

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 BASIC ISO PROGRAMMING

Auxiliary or Miscellaneous (M) functions

M functions DESCRIPTION
M00 Program STOP / Spindle STOP / Coolant OFF
M03 Spindle ON clockwise
M04 Spindle ON counterclockwise
M05 Spindle STOP
M06 Tool change
M08 Coolant ON
M09 Coolant OFF
M30 End of program

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 BASIC ISO PROGRAMMING

Preparatory functions or G-codes

M functions MODAL DESCRIPTION
G00 * Rapid traverse
G01 * Linear interpolation
G02 * Clockwise circular interpolation
G03 * Counterclockwise circular interpolation
G05 * Controlled corner rounding
G07 * Square corner
G36 * Automatic radius blend

G39 * Chamfer

G40 * Cancellation of tool radius compensation

G41 * Left-hand tool radius compensation
G42 * Right-hand tool radius compensation
G43 * Tool length compensation
G44 * Cancellation of tool length compensation
MODAL = Once programmed, it remains active until
G90 * Absolute programming
another incompatible G function is
G91 * Incremental programming programmed or until M30 / EMERGENCY
or RESET.
… … …

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 BASIC ISO PROGRAMMING

Preparatory functions or G-codes

Rapid traverse (G00) Linear interpolation (G01)

It is a positioning linear movement at maximum It is a working linear movement at the

F value defined in the machine parameters. programmed F value.

Not valid for cutting. It can be programmed as G01 or G1.

It can be programmed as G00, G0 or G.

G00 X Y G01 X Y

TP TP

(TP) (TP)

(SP) (SP)

… …
N80 G00 X500 Y300 N120 G01 X500 Y300 F400
… …
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 BASIC ISO PROGRAMMING
Preparatory functions or G-codes
Rapid traverse (G00) Linear interpolation (G01)

EXERCISE 1

= SP

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 BASIC ISO PROGRAMMING
Preparatory functions or G-codes
Clockwise circular interpolation (G02)

Counterclockwise circular interpolation (G03)

It is a working circular movement at the programmed F value.

It can be programmed as G02 or G2 / G03 or G3.

G02 X Y I J G03 X Y I J

TP Distance from the SP to TP Distance from the SP to

CARTESIAN COORDINATES

the Circle Center (CC). the Circle Center (CC).

WITH ARC CENTER

CC
TP TP
J J

CC
SP I I
SP

… …
N60 G02 X300 Y300 I200 J0 N60 G03 X300 Y300 I0 J200
… …
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 BASIC ISO PROGRAMMING

Preparatory functions or G-codes

Clockwise circular interpolation (G02)
Counterclockwise circular interpolation (G03)

A complete circle cannot be programmed.

G02 X Y R G03 X Y R

TP R + : Arc < 180º TP R + : Arc < 180º

CARTESIAN COORDINATES
WITH ARC RADIUS

TP

SP

TP
SP

… …
R+ N40 G02 X400 Y150 R150 R+ N40 G03 X400 Y300 R150
… …
… …
N40 G02 X400 Y150 R-150 N40 G03 X400 Y300 R-150
… …
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 BASIC ISO PROGRAMMING

Preparatory functions or G-codes

Clockwise circular interpolation (G02)
Counterclockwise circular interpolation (G03)

EXERCISE 2 EXERCISE 3

SP SP
w w

EXERCISE 4 EXERCISE 5

SP SP
w w
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 BASIC ISO PROGRAMMING
Preparatory functions or G-codes
Clockwise circular interpolation (G02)

Counterclockwise circular interpolation (G03)

EXERCISE 6

SP

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 BASIC ISO PROGRAMMING
Preparatory functions or G-codes
Absolute programming (G90)
Incremental programming (G91)

G90: The positioning data refers to the part zero (default).

G91: The positioning data corresponds to the distance to be travelled from the point where the
tool is situated.

= SP

Absolute programming (G90) Incremental programming (G91)

… …
N70 G01 G90 X70 Y15 F350 ; P2 N70 G01 G91 X50 Y0 F350; P2
N80 G01 X70 Y30 ; P3 N80 G01 X0 Y15 ; P3
N90 G01 X45 Y45 ; P4 N90 G01 X-25 Y15 ; P4
N100 G01 X20 Y45 ; P5 N100 G01 X-25 Y0 ; P5
N110 G01 X20 Y15 ; P6 N110 G01 X0 Y-30 ; P6
… …
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 BASIC ISO PROGRAMMING

Preparatory functions or G-codes

Absolute programming (G90)
Incremental programming (G91)

EXERCISE 7 EXERCISE 8

SP

SP

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 BASIC ISO PROGRAMMING

Preparatory functions or G-codes

Cancellation of tool radius compensation (G40)
Left-hand tool radius compensation (G41)
Right-hand tool radius compensation (G42)

The CNC automatically calculates the path the tool should follow based on the contour of the part
and the tool radius value stored in the tool offset table.

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 BASIC ISO PROGRAMMING

Preparatory functions or G-codes

Automatic radius blend (G36) Chamfer (G39)

G36 R G39 R
It rounds a corner with a determined radius, It chamfers corners between two straight lines,
without having to calculate the center nor the without having to calculate intersection points.
start and end points of the arc. Function G39 is not modal.
Function G36 is not modal.

… …
N60 G01 G36 R5 X250 Y450 F400 N60 G01 G39 R15 X350 Y600 F400
N70 G01 X400 Y0 N70 G01 X500 Y0
… …
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 BASIC ISO PROGRAMMING

Face milling For exercises consider:

70 ae = 50% of tool Ø

100

80
60
60
SP
40
Security
20
distance ~ 2 mm

20 40 60 80 100
N00 T1 D1 ; Ø28mm end-mill, assign tool 1 value D1
N10 M06 ; Tool change action
N20 G00 G43 X14 Y40 Z100 F400 S1500 M03
N30 G00 Z58
N40 G01 X116 Y40
N50 G00 X116 Y54
N60 G01 X14 Y54
N70 G00 X14 Y68
N80 G01 X116 Y68
N90 G00 X116 Y82
N100 G01 X14 Y82
N110 G00 X14 Y96
N120 G01 X116 Y96
N130 G00 Z100
N130 M30 ; End of program
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 BASIC ISO PROGRAMMING

Preparatory functions or G-codes

Cancellation of tool radius compensation (G40)
Left-hand tool radius compensation (G41)
Right-hand tool radius compensation (G42)

Tool entry & exit should always be perpendicular to the workpiece contour.
Tool entry & exit should be avoided to be from a workpiece edge may produce burr.

SP G41
…
22.5
30 N50 G01 G41 X77.5 Y70 F400
N60 G01 X100 Y70
70 • N70 G01
N80 G03
X100 Y60
X85 Y45 I0 J-15
60 N90 G02 X70 Y30 I-15 J0
N100 G01 X50 Y30
45 N110 G01 X20 Y20
N120 G01 X25 Y70
30 N130 G03 X55 Y70 I15 J0
N140 G01 X77.5 Y70
20
N150 G01 G40 X77.5 Y100
…

20 25 50 55 70 85 100
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