UNIPARTS

Achieving Your Goals

Path to Structured Learning &

 CNC
COMPUTER
NUMERICAL
CONTROL

By:
Sudhir Nair
 10.00 am Pre-Assessment

10.15 am Session on CNC

11.00 am Tea-Break

11.15 am Session Resumes

Schedule 1.30 pm Lunch Break

of the Day 2.15 pm Session Resumes

3.15 pm Tea-Break

3.45 pm Session Resumes

5.00 pm Post-Assessment

5.30 pm Q & A - End of Session

CNC 3
 •Rule 01
Mute when not speaking;
Phone Off
•Rule 02
Video ON
•Rule 03
Participate
Ground
Rules

CNC 4
 • A link has been sent to you
• Please take the pre-
assessment and submit
• Your attendance will be
marked only if you submit
both, pre-assessment and
post-assessment
Pre-Assessment

CNC 5
 • Your Name
• Your Organization
• Your CNC experience

Introductions

CNC 6
 AG END A
 What is CNC Milling machine?
 CNC Milling machine parts and their
functions
 How to ON the machine
 How to do size controlling in CNC Milling
 How to do component setting in CNC
Milling
 CNC Milling opertion
 Program structure
 G & M Codes
 Chamfering .
 Usage of M99P4
 Canned Cycles
 G81,G82,G83,G84,G85,G86,G87,G76G73,G
74
 CNC Milling Maintenance check sheet
 Tool nose radius compensation
CNC  Alarms in CNC Milling . 7
 Work sheets
 Face Milling
 Side Milling
 Slot Milling
 Face milling with subprogram
 Side Milling with subprogram
 Slot Milling with subprogram
 Chamfer milling- Angle
 Chamfer milling –Coordinates.
 Radius milling CW & CCW.
 Slot milling or side milling with G41, G42.
 Drilling, Reaming, Boring
 Hole chamfering

CNC 8
 WHAT IS A CNC MILLING
MACHINE

CNC 9
 Some Basics!

What is CNC vertical milling machine ?

• A CNC vertical milling machine is a machine that uses a

computer-controlled cutting tool to remove material
from a workpiece in a vertical orientation:
• In Milling control is manual . In CNC control is by
computer.
• CNC full form is Computer numerical Control.

CNC 1
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 Benefits of CNC

• Increases PROFITS
• Increase Quality
• Increase Productivity
• Fa s t o p e r a t i o n s - M i n m a n u a l w o r k w a s t a g e .

CNC 1
1
 VMC PARTS

CNC 1
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 MAIN PARTS OF VMC MACHINE

1. CONTROL 8. VMC TOOL MAGAZINE

PANEL 9. AXIS OF VMC MACHINE
10. FIXTURE
2. PLC PANEL
11.CHIP GUARD DOOR
3. INDICATOR 12.HYDRAULIC OIL TANK
13.LUBRICATION OIL TANK
4. SPINDLE
14.COOLANT TANK
5. SERVO ERICAN BULLET
MOTOR

6. BALL SCREW

7. VMC TOOLS
 CNC Machine Parts
CNC Machine

Spindle Bed side Coolant CNC Power Pack Electrical

Side tank System Side Cabin
Screen 3 phase step
Servo motor X & Through Power pack Tank
Spindle Soft Keys down
y coolant motor Oil
Spindle Motor Alpha numerical transformer
Encoder X & y Coolant Motor Motor
Spindle keys Relays
Axis. Coolant tank Pump
Encoder. Manual selection MCB
Ball Screw X & y Coolant filter Coupler
Timer belt. keys X & Z combo
axis. Round Shank Lubrication Solenoid manifold
V Belts. JOG Selection drive.
Bed t-slot system Solenoid valve
Ball screw zaxis Feed control Drive battery
Bed Chuck & Tailstock
Servo motor z Spindle control
Cable from
axis Program edit key
electrical cabin
Emergency
Oil cooling fan
MPG Handle
Pressure display
Cycle start
system
Turret Indexing
Tap return

1
4
 SPINDLE Side
Sl no Machine part Function Remarks

1 Servo Stabilizer Voltage Control Outside machine

Spindle Side

1 Chuck For holding Base Jaws 3 jaw,4 jaw

Base jaws For holding Jaws Fixed on chuck
Jaws For holding component Can fix on base jaws by T nut &
bolt
T nut + Bolts For fixing jaws on base jaws On Chuck
Greasing unit
Chuck grease For proper lubrication of base jaws of chuck. OKS grease
Collet chuck For holding collet
Collet For holding component Customized collets

2 Drawbar For connecting chuck with cylinder For clamp de clamp

3 Spindle Cylinder For drawbar to fro movement For clamp de clamp

4 Spindle Servo motor Provides power to chuck by belt

5 Spindle Encoder For giving feed back to CNC system

6 Timer belt Connect Spindle with encoder

1
5
 TURRET Side
Sl no Machine part Function Remarks
Turret Side
1 Turret For holding & indexing tool
2 Servo Motors X & Z
3 Encoder X & Z
4 Ball Screws X & Z
5 Turret coolant
arrangement
6 Tools Square shank
7 Tools Round Shank
8 Turret pocket For clamping tools
9 Tool Packaging For holding tool In turret pocket
10 Boring bar block For holding boring bar sleeve
11 Boring bar sleeve For holding boring bar On turret

VSM - Value Stream Mapping 1

6
 TAILSTOCK Side
Sl no Machine part Function Remarks
Turret Side
1 Tailstock To hold the quill
2 Machine base

3 Tailstock Quill Holding the part by locating

on the center
4 Coolant Motor For coolant flow
5 Coolant filter To ensure no jam in line
6 Coolant tank For coolant storage
7 Lubrication system To prevent slide wearout.
8
9
10
11

CNC 1
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 CNC System
Sl no Machine part Function Remarks
Computer
1 Display Screen
2 Soft Keys

3 Alpha numerical keys

4 Manual selection keys

5 JOG Selection

6 Feed control

7 Spindle control

8 Program edit key

9 Emergency

10 MPG Handle

11 Cycle start

12 Turret Indexing

13 ID/OD Select key

VSM - Value Stream Mapping 1

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 POWER PACK Side

Sl no Machine part Function Remarks

Power pack
1 Power pack To store oil Used for clamp & de clamp
2 Motor To work pump During clamp & de clamp
3 Pump To pump oil
4 Motor pump coupler To join motor & pump Plastic component
Solenoid Manifold
5 Solenoid valve-Chuck For chuck clamp unclamp
6 Solenoid valve- For tailstock forward &
Tailstock reverse movement
7 Oil Cooling fan To cool hydraulic oil
8 Pressure gauge To display chuck clamp
pressure.

VSM - Value Stream Mapping 1

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 CNC Electrical Cabin
Sl no Machine part Function Remarks
Others
1 3 Phase stepdown
motor
2 Relay
3 MCB
4 Servo Drive
5 Servo battery
6
7
8
9
10
11

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 VMC Tooling Accessories
Sl no Machine part Function Remarks
1 3jaw chuck Round job holding
2 T-nut To tighten the holding
device
3 M16Stud To tighten the holding
device
4 Claimp To tighten the holding
device
5 M16 nut & step block To tighten the holding
device
6 Needle file For burr removal
7 Wrench er 32 Tool to tighten Er 32 tool holder
8 Nylon Hammer For Hammering
9 Test bar 150*40 Check spindle Run out Of spindle
10 Pull stud After damage change pull
stud
11 Chip collection magnet For chip collection
12 Tool tight stand To tighten the tool Changing tool holder
13 Iron rod for chip removal For pulling chips From coolant tray. 2
1
 CNC Milling Tool parts
Sl no Machine part Function Remarks
1 Tool Holder Holding tool end mill
2 Boring Head Use boring operation
3 T-NUT/stud/nut For Clamping fixture/chuck
4 Stud For locking boring bar in sleeve
5 Cutter For holding insert
6 Wrench for Er collect Tight & open tool
7 Claimp For Clamping fixture/chuck

8 Dial stand For Check run out tool In middle of tool holder
9 Allen keys For tightening insert clamps
10 Star Screws For tightening small inserts
11 File For removing burr
12 Pipe For tightening
13 3 JAW chuck For holding component
2
2
 CNC Measuring instruments
Sl no Machine part Function Remarks
1 Vernier For length checking
2 Micrometer For dia checking
3 Dial Gauge For component inspection
4 V block For runout checking
5 Height gauge For inspection of component
6 Magnetic block For holding puppy dial Chuck run out , center setting
7 Micron(Puppy) dial For machine inspection
8 10 micron dial For component inspection During product development
9 Level indicator For machine levelling During machine installation
10 Profile projector For chamfer , radius checking
11 Surface finish tester For surface finish checking
12
13

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 VMC MACHINE COMPUTER PANEL
CRT DESCRIPTION
DISPLAY NEUMERICAL
SCREEN & ALPHABET
KEYS
SOFT KEYS POSITION
PROGRAM
JOG
DELETE
AUTO
MDI
RESET
EDIT
SPINDLE
M/C RPM KEY
LOCK

CYCLE
START FEED KEY
CYCLE
STOP PROGRAM
REFERANCE EDIT ON/OFF
RETURN KEY

JOG HANDLE SPEED TURRET TAP RETURN SPINDLE CCW

HANDLE INDEX ROTATION 2
1X,10X,100X 4
 RESET COOLANT ON
REFRENCE CHIP CONVERYOR FORWARD
PROGRAM CHIP CONVERYOR REVERSE
SINGLE SPINDLE START
EDIT ON/OFF
BLOCK
KEY EMERGENCY JOG
LUBRICATION ON SPINDLE STOP

OPTIONAL STOP
FEED START

FEED STOP

BLOCK
SKIP
REMOTE

MACHINE ON

MAGINE JOG
MODE
TOOL CLAIMP
ARM JOG MODE DRY RUN OR DECLAIMP
JOG MODE
ALPHA NEUMERICAL
KEYS

OPEERATIONA
KEYS
 MODES IN CNC MACHINE
MODES USAGE
1 AUTO mode For cycle the program and making component in mass
production.
2 EDIT mode For program input , change corrections etc.
3 MDI mode For basic machine operations by command. (M03,04,10,11)
For parameter change.
4 REFERANCE RETURN For taking turret to home position
5 JOG mode For basic machine operations manually.(Turret index , coolant
ON/OFF, Spindle rotation CW & CCW)
6 HANDLE mode (MPG- For movement of turret in “X” ‘’ Y’’& “Z” directions
manual Pulse generator) X1,X10,X100 – 1,10,100 micron movement.
7 SINGLE BLOCK mode To run the program line by line-used during program prove
out.
8 OPTIONAL STOP mode To stop the program for inspection after running each tool
9 BLOCK SKIP If we put “/” in front of each line and on this button that line
will get skip during running of the program.
10 TURRET INDEX To call the required tool during offset taking , insert change.

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 4 MOST FREQUENTLY USED
OPERATING KEYS

MODES USAGE
1 POSITION Shows the position , part count and run time.
2 PROGRAM For program related work
3 MDI mode For executing manual operations by codes
4 SYSTEM For opening system page
5 MESSAGE For showing alarm
6 CUSTOM GRAPH To show the graph
7 RESET To reset the program in edit mode

2
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 How to On the CNC Machine
ACTIVITY REMARKS
1 On Main.
2 On CNC servo
3 On Hydraulic
4 On CNC
5 Select Handle
6 Select X 100 manual speed button.
7 Move turret in X-Y & Z- direction.
8 Reference the turret.
9 Select Jog mode Optional
10 Press Turret Index button. Optional
11 Press Edit button
12 Press Program button
13 Press Reset button
14 Press Auto button
15 Press Cycle start button. 2
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 HOW TO CONTROL SIZE IN VMC

Shifting control uses work offset

Size control changing tool radius uses tool offset (Program use G41/G42)
Without uses G41/G42 program changing the program coordinate size control
Depth control uses Z offset

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 WORK OFFSET

Job face centre coordinates from home position.

X ZERO : Tool touch to edge and zero to relative value & touch to
2nd edge value half to machine zero position
Y Zero : same as x

Work origin

X zero value

Y Zero value
3
1
 TOOL Z OFFSET

Tool touch to workpiece face and whiche value machine position

put the value z offset give no the programe H

Tool
Work origin

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 TOOL WAER AND TEAR .
When do cutting, tool will have wear & tear.
To compensate that we will do corrections in Z tool offset and
change the tool radius or Programe changinge
If do tool radius + (0.05
+input) ID &outer diameter
will Decrease
If do tool radius – (-0.05
+input) ID&outer diameter
will increase

When depth size not ok when give the tool offset z offset depth less
the .05 the offset give -.05.depth the more .05 the offset give +.05

3
3
 WEAR OFFSET for “Z”

When do cutting tool will have wear & tear.

To compensate that we will do corrections in Z offset.
Z+

Z- If do Z – (-0.05 +input)
Tool will move inside.

If do Z – (-0.05 +input)
chamfer will increase

3
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 WORK OFFSET

When all tools need to move inside or outside ,or z axis use work
offset

Z- Z+

VSM - Value Stream Mapping 3

5
CNC JOB SETUP
PROCEDURE

3
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 Step 1 –Prepare the jaws for holding
the parts
1) Decide where to clamp the component – Fixture /chuck .
2) Select program
3) Check the fixture
4) Tight the fixture (holding device)
5) Dial the holding device(fixure/jig/chuck etc.)
6) Do Alignment of jaws (Equal distance from center-Check with TNMG or CCMT tool)
7) Set clamp pressure
8) Select OD/ID button.
9) Touch tool on ID or OD where dummy to hold.
10) Make relative position U 0.0 by pressing relative , origin.
11) Touch tool on dummy butting face.
12) Make relative position W 0.0 by pressing relative , origin.
13) Cut the jaws & make space for holding Dummy or ring.
14) Select OD/ID button.
15) Holding dummy or ring by clamping
16) Cut on jaws and make space for holding the component.
17) Take out dummy/ring.
18) Clamp part (Part must be sliding fit)
19) Rotate the part in MDI mode and check part is rotating smoothly.
20) If not repeat step 9 to 19 again till parts rotate smoothly.

3
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 Step 2 – Taking “Z” & “X” offset.

TAKING “Z” OFFSET TAKING “X” OFFSET

1) Touch tool on the face of 1) Measure OD (or ID).

component 2) Touch tool on OD(or ID) of
2) Select geometry. the component.
3) Write Z 0.0 3) Write the dia (Eg :20.0)
4) Press Measure button. 4) Press measure button.
5) Z Offset taken. 5) X offset taken.

Reference the turret after taking offset.

Repeat above procedure for all other tools.

3
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 Step 3 – Prove out the program.

1) ON Auto mode
2) ON single block
3) Run program.
4) Check part dimensions
5) Do proper corrections in wear or geometry.
6) Run again.
7) Part will come ok.

3
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Setup Display

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G & M Codes

4
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 Basic G Codes
G00 Air cut movement . Tool moves in air
G01 Material Cut movement in Feed. Facing , Boring , OD Turning &
chamfering.
G02 Circular interpolation Clockwise
G03 Circular interpolation Counter Clock wise
G04 Dwell time –Used mainly in drilling.
G10 Zero offset shift G10 X…Y….Z….
G11 Zero offset cancel
G17 XY PALNE (Z=Spindle)
G18 ZX Plane(Y=Spindle)
G19 YZ Plane (X=Spindle)
G20 Inch mode
G21 Mm mode

G28 Return to reference point

4
2
G29 Return from reference point
G30 Return to 2nd or 3rd reference

G40 Tool nose radius compensation cancel

G41
Tool nose radius compensation left
G42
Tool nose radius compensation right
G43 Tool length compensation + direction

G44 Tool length compensation – direction

G49 Tool length compensation cancel

G45
G46
G54,55,56,57, Work offset- Define new origin.
58,59
G73 High speed Peck drilling cycle
G74 Left-spiral cutting circle(left hand tapping)

G81 Drilling cycle, spot boring cycle

G82 Drilling cycle or counter boring cycle

G83 Peck drilling cycle
G84 Tapping cycle
G85 Boring cycle
G86 Boring cycle
G87 Back boring cycle
G88 Boring cycle
G89 Boring cycle
G76 Fine boring cycle
G90
Absolute command
G91 increment command
G92 Cancel G96. G97 S850;Part starts rotating in steady RPM.
G94 Air cut movement . Tool moves in air

G95 Material Cut movement in Feed. Facing , Boring , OD Turning &

chamfering.

G96 Circular interpolation Clockwise

G97 Circular interpolation Counter Clock wise

G98 Return to initial point in canned cycle

G99 Return to R point in canned cycle

 Basic M Codes

M01 Optional stop on (Used to stop after each tool running)

M03 Clockwise rotation (Can be CCW in some machines)
M04 Counter clockwise rotation (Can be CW in some machines)
M05 Spindle Stop
M08 Coolant ON
M09 Coolant off
M19 Spindle orientation stop.
M20 Spindle orientation stop cancel

M99 Sub program call Eg: M99 P4-Program directly jumps to N4.

4
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 COMPONENT MANAUFACTURING
SEQUENCE
Decide how Decide how to
Study Drawing
many setup hold the
or component
needed component

Choose Drill or Decide on

End mill Tools selection which machine
to manufacture

Make Fixture
Decide how to
arrangements selection
check the part
for checking

Mass
Prove out the Program
production as
program development
per Control plan 4
7
 How to calculate COSTING in
CNC
Cycle time =
Machining time + Tool indexing time +15 % acceleration deceleration.

Length
Machining time = mins
Feed X RPM

Tool index time = 3 sec for each tool

Acceleration &
= 15% of Machining time
Deceleration time

4
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 PER MIN COSTING OF CNC

PER MIN COST FOR ALUMINIUM = 3.50 Rs per min.

Note : Cost will be 4 Rs if need super finish.

PER MIN COST FOR Brass = 3.50 Rs per min.

PER MIN COST FOR MS(Mild Steel) = 4 Rs per min

Note : Insert cost will be more, Inspection cost will be
more.

Per min cost for SS(Stainless Steel) = 4 Rs per min.

Note : Insert cost will be more, Machine maintenance cost
will be more.
4
9
 HOW TO READ A DRAWING
DRAWING

DIMENSIONS SYMBOLS

Normal GD & T

In bracket ( 55)
Reference dimension

In square box 55
Basic Dimensions

5
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14 GD & T SYMBOLS

5
1
 Program Structure

Header
Body
Footer.
5
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 PROGRAM HEADER
O0001 Program No
N1; Sequence no for 1st Tool

G28Z0.0; Machine Home Position

M06T1; Tool no1,Offset no 1
G0G90G54X0.0Y0.0 Machine position
M03S1000 Spindle speed
M08; Coolant ON
G0G43H1Z100.0 Z Height compensation

This header remains same for all programs.

VSM - Value Stream Mapping 5
3
 How to calculate SPINDLE
SPEED.
VC =
VC = Cutting Speed.
D =Tool Diameter in mm
N = RPM

VC = 90-160
Feed = 0.2-0.3
Tool Diameter = 10 mm
150 = 3.14 x 10 x N 1000
N = 4777
( This one we need to put in M03 S 4500 ; )

5
4
 From were we can get Cutting Speed
& Feed

Vc normally given below drill or End mill box.

Measure tool diameter use which tool
We can calculate the RPM and put it there in S……

5
5
 PROGRAM BODY

G00 X (Dia+5mm) Z 5mm ; (1st line – Positioning infront of

component)
…………………………………
…………………………………
………………………………....
G00 X (Dia+5mm) Z 5mm ; (Last line –Positioning away
from component)

This will vary for different programs.

5
6
 PROGRAM FOOTER

M09; Coolent off

M05; Spindle off
G28U0.0W0.0; Turret goes to home position
M01; Optional Stop

This footer remains same for all programs.

5
7
 Knowledge about
DIMENSION
0.001 ( 1 Micron)
0.010 (10 Micron)
0.100 (100 Microns)
1.000 (1000 Microns)

In CNC work is majorly from 200 microns to 10 microns.

Size of our hair is 60 microns.

5
8
HOW TO READ A VERNIER

5
9
HOW TO READ A MICROMETER

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 PROGRAM STRUCTURE
O0001;
O0001;
N3;
Third
NI; First Tool G28 U0.0W0.0; Tool
G28 U0.0W0.0; T0303;
T0101; M08;
M08; G50S2000;
G50S2000; G96S120M03;
G96S120M03; GOO X(DIA+5)Z5.0;
GOO X(DIA+5)Z5.0; ……………………………….
………………………………. ………………………………
……………………………… GOO X(DIA+5)Z5.0;
GOO X(DIA+5)Z5.0; M09;
M09; G28U0.0W0.0;
N4; Fourth
G28U0.0W0.0;
N2;
Second G28 U0.0W0.0; Tool
G28 U0.0W0.0; Tool T0404;
T0202; M08;
M08; G50S2000;
G50S2000; G96S120M03;
G96S120M03; GOO X(DIA+5)Z5.0;
GOO X(DIA+5)Z5.0; ……………………………….
………………………………. ………………………………
……………………………… GOO X(DIA+5)Z5.0;
GOO X(DIA+5)Z5.0; M09;
M09; G28U0.0W0.0;
G28U0.0W0.0; M30;
%
6
1
 HOW TO USE M99

I want to call only the 4 tool.

th

Not want to run the entire

program.
What to do?

Use M99P4;
6
2
 M99 ADVANTAGE
O0001;
O0001;
M99 P4; Program will go directly to N4 N3; Third Tool
G28 U0.0W0.0;
NI;
T0303;
G28 U0.0W0.0;
M08;
T0101; First Tool G50S2000;
M08;
G96S120M03;
G50S2000;
GOO X(DIA+5)Z5.0;
G96S120M03;
……………………………….
GOO X(DIA+5)Z5.0;
………………………………
……………………………….
GOO X(DIA+5)Z5.0;
………………………………
M09;
GOO X(DIA+5)Z5.0;
G28U0.0W0.0;
M09;
G28U0.0W0.0;
N4; Fourth
N2; Second G28 U0.0W0.0;
T0404; Tool
G28 U0.0W0.0; Tool M08;
T0202;
G50S2000;
M08;
G96S120M03;
G50S2000;
GOO X(DIA+5)Z5.0;
G96S120M03;
……………………………….
GOO X(DIA+5)Z5.0;
………………………………
……………………………….
GOO X(DIA+5)Z5.0;
………………………………
M09;
GOO X(DIA+5)Z5.0;
G28U0.0W0.0;
M09;
M30;
G28U0.0W0.0;
%
6
3
 HOW TO MAKE A PROGRAM
RAW MATERIAL FINISH MATERIAL E
R2 D
C B
C1 A

20 10

12

24

6
4
 HOW TO MAKE A PROGRAM

Step 1 : Identify each point X & Z coordinates.

Point X Z
A 10.0 0
B 12.0 -1.0
C 12.0 -12.0
D 16.0 -12.0
E 20.0 -14.0

Step 2 : Identify tools to use.

Will use CNMG 0.8 for roughing & 04 for finishing.
Step 3 : Identify Sequence of program.
N1 : For rough facing
N2 : For rough OD turning.
N3 : For finish face & OD turning.
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5
 HOW TO MAKE A PROGRAM
Step 2 : Make program on paper
Rough facing Rough OD Turning Finish Turning
N2; N3; Point X Z
N1; G28U0.0 W0.0; G28U0.0 W0.0; A 10.0 0
G28 U0.0W0.0; T0202; T0303; B 12.0 -1.0
T0101; M08; M08; C 12.0 -12.0
G50 S1500; G50 S1500;
M08; D 16.0 -12.0
G96 S150 MO3; G96 S150 MO3;
G50S1600; G00 X21.0 Z5.0; G00 X21.0 Z5.0;
E 20.0 -14.0

G96 S150 MO3; G00 Z0.5; G00 Z0.0;

G00 X21.0 Z5.0; G71 U0.8 R0.5 G01 X-1.0 F0.1;
G94 X-1.0 Z4.0 F0.15; G71 P10 Q20 U0.3 W0.3 G00 X10.0 Z1.0;
Z3.6; N10 G01 X10.0 Z0.0 F1.0; G01 G42 X10.0 Z0.02 F1.0;
Z2.8; G01 X12.0 Z-1.0 F0.15; G01 X12.0 A135.0 F0.15;
Z1.6 Z-12.0; Z-12.0;
X 16.0; X16.0
Z0.8;
G03 X20.0 Z-14.0 R2.0; G03 X20.0 Z-14.0 R2.0;
Z0.4; N20 G01 X21.0; G01 U0.1 W-1.0 ;
G00 X21.0 Z5.0 M09; G00 X25.0 Z5.0; G40 G01 X25.0 Z5.0;
G28 U0.0W0.0; M09; M09;
M01; G28U0.0W0.0; G28U0.0W0.0;
G28U0.0W0.0; M01; M30;
% 6
6
 HOW TO MAKE A PROGRAM

Step 3 : Load program in machine with program no.

Step 4 : Prepare jaws for holding.

Step 5 : Take geometry offset.

Step 6 : Run program on component.

Step 7 : Check the part.

Step 8 : Do necessary corrections in Wear , Geometry.

Step 9 : Check again.

Step 10 : If all ok ,run mass production.

6
7
 CHAMFERING BY COORDINATES IN
CNC
MAKE CHAMFER OF 0.5 MM ON OD.
N1;
G28 U 0.0 W 0.0;
G50 S 2000;
G96 S 120 M03;
G00 X 25.0 Z5.0 ;
G01 X 19.0 Z 0.0 F1.0 ;
20 10 19 G01 X 20.0 Z -0.5 F0.1 ;
G01 Z -12.0 ;
G00 U 0.1 Z 1.0 ;
G00 X 25.0 Z 5.0 ;
M08 ;
M05 ;
G28 U 0.0 W0.0 ;
12
6
8
 CHAMFERING IN CNC

CHAMFERING

BY
BY ANGLE
COORDINATES

6
9
CHAMFERING ON INNER DIA

BY ANGLE

180⁰+45⁰ = 225⁰

7
0
 CHAMFERING BY COORDINATES IN
CNC
MAKE CHAMFER OF 0.5 MM ON ID.
N1;
G28 U 0.0 W 0.0;
G50 S 2000;
G96 S 120 M03;
G00 X 25.0 Z5.0 ;
G01 X 11.0 Z 0.0 F1.0 ;
20 10 11 G01 X 10.0 Z -0.5 F0.1 ;
G01 Z -12.0 ;
G00 U - 0.1 Z 1.0 ;
G00 X 25.0 Z 5.0 ;
M08 ;
M05 ;
G28 U 0.0 W0.0 ;
12
7
1
 CHAMFERING BY ANGLE IN CNC
MAKE CHAMFER OF 0.5 MM ON ID.
N1;
G28 U0.0 W0.0;
G50 S2000;
G96 S120 M03;
G00 X 25.0 Z5.0 ;
G01 X 11.0 Z 0.0 F1.0 ;
20 10 11 G01 X 10.0 A225.0 F0.1 ;
G01 Z -12.0 ;
G00 U - 0.1 Z 1.0 ;
G00 X 25.0 Z 5.0 ;
M08 ;
M05 ;
G28 U 0.0 W0.0 ;
12

Chamfering by angle is better than coordinates. 7

2
CHAMFERING ON OUTER DIA

BY ANGLE

90⁰ + 45⁰ = 135⁰

7
3
 CHAMFERING BY COORDINATES IN
CNC
MAKE CHAMFER OF 0.5 MM ON OD.
N1;
G28 U 0.0 W 0.0;
G50 S 2000;
G96 S 120 M03;
G00 X 25.0 Z5.0 ;
G01 X 19.0 Z 0.0 F1.0 ;
20 10 19 G01 X 20.0 Z -0.5 F0.1 ;
G01 Z -12.0 ;
G00 U 0.1 Z 1.0 ;
G00 X 25.0 Z 5.0 ;
M08 ;
M05 ;
G28 U 0.0 W0.0 ;
12
7
4
 CHAMFERING BY ANGLE IN CNC
MAKE CHAMFER OF 0.5 MM ON OD.
N1;
G28 U 0.0 W 0.0;
G50 S 2000;
G96 S 120 M03;
G00 X 25.0 Z5.0 ;
G01 X 19.0 Z 0.0 F1.0 ;
20 10 19 G01 X 20.0 A135.0 F0.1 ;
G01 Z -12.0 ;
G00 U 0.1 Z 1.0 ;
G00 X 25.0 Z 5.0 ;
M08 ;
M05 ;
G28 U 0.0 W0.0 ;
12
7
5
 RADIUS TURNING IN CNC
MAKE RADIUS OF 0.5 MM ON OD.
N1;
G28 U 0.0 W 0.0;
R 0.5 G50 S 2000;
0.5
G96 S 120 M03;
G00 X 25.0 Z5.0 ;
G01 X 19.0 Z 0.0 F1.0 ;
20 10 19 G01 X 20.0 Z-2.0 F0.1 ;
G01 Z -12.0 ;
G00 U 0.1 Z 1.0 ;
G00 X 25.0 Z 5.0 ;
0.5 M08 ;
M05 ;
G28 U 0.0 W0.0 ;
12
7
6
 QUALITY INSPECTION IN CNC

 FIRST 5 PARTS APPROVAL.

 CHECKING AT REGULAR INTREVELS

AS PER CONTROL PLAN.

 RECORDING OF CHECKED
DIMENSIONS IN QUALITY CHECK
SHEETS.
7
7
 CANNED CYCLES IN CNC

G81 Stock removal in OD turning

G82 G94 Stock removal in facing.
G83 Stock removal in profile turning
G84
G85 Peck drilling Cycle
G86 Grooving cycle
G87
G88 Threading Cycle
G73
7
8
VMC DRILLING OR BORING CYCLE
N10T1 N10 T1
N20G90 G54G00 X30Y25 N20 G90 G54 G00 X30 Y25
N30 S100 M03
N30S100 M03 N40 G43 H01 Z5
N40G43 H01 Z5 N50 G84 Z-20 R2 P100 F1.25
N60 X80 Y50
N50G83 Z-20R2 F1.25 K2.0 Q5.0 N70 G80 G00 Z100 M09
N60X80Y50 N80 M30
N70G80 G00Z100 M09
N80M30
 G81-DRILLING CYCLE
G81 X... Y... Z... R... K... F...
N10 T1
Parameter Description N20 G90 G54 G00 X30 Y25
N30 S100 M03
X X Hole position in x-axis. N40 G43 H01 Z5
N50 G81 Z-20 R2 F1.25 K2.0
N60 X80 Y50
Y Y Hole position in x-axis. N70 G80 G00 Z100 M09
N80 M30
Z Depth, tool will travel with
Z feed to Z-depth starting from
R plane
R Position of the R plane
Number of cycle repetitions
K
(if required )
F Feed rate
Once G81 drilling cycle is defined, the canned cycle is repeated at every X-Y
position in sequential blocks. So G81 drilling cycle must be cancelled with G80.
G98 Tap will return to the initial level.G99 tap will return to R-plane
 G98 Tap will return to the initial
level.G99 tap will return to R-plane
 G82- COUNTOR DRILLING CYCLE
G82 X... Y... Z... R...P…. K... F...
Parameter Description N10 T1
N20 G90 G54 G00 X30 Y25
X X Hole position in x-axis. N30 S100 M03
N40 G43 H01 Z5
Y Y Hole position in x-axis. N50 G82 Z-20 R2 P1000 F1.25 K2.0
N60 X80 Y50
Z Depth, tool will travel with feed N70 G80 G00 Z100 M09
Z N80 M30
to Z-depth starting from R plane
R Position of the R plane

P Dwell at bottom of hole

P1000 1 SEC
Number of cycle repetitions (if
K
required
F Feed rate

G82 drilling cycle is also called G82 counter boring cycle.

G82 is a normal drilling cycle the only difference is that it dwell for specified
time at the bottom of the hole, normally used for accurate depth drilling.
 G71 STOCK REMOVAL ON OD

G71 UΔd Re ;
G71 Pns Qnf UΔu WΔw Ff ;

Δd = Depth of cut in “X”

e = Retraction amount
ns = Sequence no of 1st block
nf = Subsequent no of last block
of the program which specifies the finish path.
Δu = Finishing allowance in “X”.
Δw = Finishing allowance in “Z”
f = Feed.

8
3
 G71 STOCK REMOVAL ON OD

N1;
R 1.0 G28 U0.0W0.0;
T0101;
C 1.0 M08;
G50S1600;
G96 S150 MO3;
G00 X26.0 Z5.0;
Փ25 Փ16 G94 X-1.0 Z4.0 F0.15;
Rough
Z3.6;
49 Z2.8; Face
Z1.6 Turning
Z0.8; CNMG 0.8
Z0.4; INSERT
G00 X26.0 Z5.0 M09;
G28 U0.0W0.0;
M01;
G28U0.0W0.0;

8
4
 G71 STOCK REMOVAL ON OD
N2; N3;
G28U0.0 W0.0; G28U0.0 W0.0;
T0202; T0303;
M08;
M08;
G50 S1500;
G50 S1500; G96 S150 MO3;
G96 S150 MO3; G00 X26.0 Z5.0;
G00 X26.0 Z5.0; G00 X16.5 Z0.0;
Rough OD
G00 Z0.5; G01 X-1.0 F0.1; Finish
Turning
G71 U0.8 R0.5 G00 X14.0 Z1.0; Turning
G71 P10 Q20 U0.8 W0.8 CNMG 0.8 G01 G42 X14.0 Z0.02 F1.0; CNMG 0.4
N10 G00 X14.0 Z0.02; INSERT G01 X16.0 A135.0 F0.15;
INSERT
G01 X16.0 Z-1.0 F0.15; Z-49.0;
X23.0
Z-49.0;
G03 X25.0 Z-50.0 R1.0;
N20 X26.0; G01 U0.1 W-1.0 ;
G00 Z5.0; G40 G01 X26.0 Z5.0;
M09; M09;
G28U0.0W0.0; G28U0.0W0.0;
M01; M30;
% 8
5
 G76 THREADING CYCLE

m = No of finish passes.
G76 P mra Q Δdmin Rd ; r = Chamfering amount
a = Thread angle.
G76 Xu Zw Ri Pk QΔd Fl ; Δdmin = Subsequent depth of cut
d = Finishing allowance

u = Minor dia for External thread

Major dia for Internal thread
w = Last position of tool in “Z”.
50 20
i = Thread taper ( i minus means upward taper)
( i plus means downward taper) i =20-50/2 = -15

K = Thread Depth (0.6134 x pitch)

Δd = First depth of cut.

8
l = Pitch (Feed) 6
 Points to take care during threading.

 For left hand and right hand inserts cutting edge

will be different. Even though both inserts will sit
on toolholders.
 Always use full form insert. Not range insert. It will
give burr.

 High and low rpm will impact thread quality .

(Normally 850 rpm)
 Play in leadscrews and bearing also impact thread
Go/No-go qualification.

8
7
 For Right hand thread on OD
Tool Right hand Left hand
Cutting edge position Reverse Straight
Rotation Counter clockwise Clockwise
Tool movement Towards spindle From inside out –
Away from the spindle

For Right hand thread on ID

Tool Right hand Left hand

Cutting edge position Reverse Straight
Rotation Counter clockwise Clockwise
Tool movement Towards spindle From inside out –
Away from the spindle

8
8
 M27 x 2 thread

On OD On ID

N4 N4
G28 U0.0W0.0; G28 U0.0W0.0;
T0404 M08; (Right hand reverse holding) T0404 M08; (Left hand straight holding)
G97 S850 M04 (Counter clock wise) G97 S850 M04 (Clock wise rotation)
G00 X29.0 Z5.0; G00 X24.0 Z5.0;
G00 Z1.0; G00 Z-14.0 ;
G76 P020060 Q100 R0.5; G76 P020060 Q100 R0.5;
G76 X24.6 Z-14.0 P1223 Q150 F2.0; G76 X24.6 Z-1.0 P1223 Q150 F2.0;
G00 X29.0 Z1.0; G00 X24.0 Z1.0;
M09; M09;
M05; M05;
M01; M01;
G28 U0.0 W0.0; G28 U0.0 W0.0;

8
9
 Tool Nose radius Compensation

Cutting point on Face

is this

This material left Cutting point on OD

behind is this

9
0
 Tool Nose radius Compensation

Cutting point on Face

is this

This material left

behind

Leading Tip – Cutting point on OD

Which is this
program
considers
9
1
 Tool Nose radius Compensation

Machine considers sharp edge . But actual cutting point is radius and
different points touch during cutting of OD & Face.

Cutting point on OD
is this

This material left

behind
Cutting point on Face
is this

This causes left behind some material, esp during radius making &
chamfering. To avoid this we use cutter compensation G41 & G42.
9
2
 Tool Nose radius Compensation

Compensated path

Programmed path
Cutting point on Face
is this

9
3
 TOOL TYPE - Tool Nose radius
Compensation

2 6 1

Tool type & radius value of 5

7 insert must enter in
geometry page.

3 4
8 9
4
 G 41 & 42 for OD Turning

Tool is in the Tool is in the

right left

Tool Tool

G42
Looking in the direction of
cut G41
9
5
 Tool Nose radius Compensation

Compensated path

Programmed path
Cutting point on Face
is this

9
6
 Tool Nose radius Compensation for
ID Turning
Looking in the
direction of cut Looking in the
direction of cut

Tool is in
the Right
Tool is in the
left

G41 G42
9
7
 MAINTENANCE CHECK SHEET OF
Item Condition
CNC
Frequency Control 1 2 3 4……….29 30 31

1S (Sort) No Unnecessary items Daily Red tag System

2S A place for everything & Daily Shadow board

everything is int’s place
3S(Shine) No Dust , Grease , Oil Daily Clean at shift
start & end
Chuck Clamp Pressure Depend on material & Daily Visual check
Component structure
Lubrication oil Not below min level Daily Visual check

Inserts Available and ok Daily Weekly inventory

Cutting Oil Concentration>3% Daily Refractometer

Electrical cabin Not above 30 degree. Daily Temperature

temperature display check
Chips Remove at shift end. Daily Shift supervision

Leakage of water, oil, air No leakage Daily Visual check

& electricity
Hydraulic oil Not below min level Weekly Visual check

Electric cabin Fans Rotate in right direction Weekly Visual check

Earthing No wire breakage Weekly Visual check

Documents Proper condition & updated Weekly Visual check

9
8
 COMMON ALARMS IN CNC

CNC Alarms

System Alarms Machine Alarms

(Fanuc/Siemens) (LMW/ACE)

0-999 Above 1000

0 -300
400-499
600-699
700-799
800-899
900-999

9
9
 Chuck not Clamp/De clamp problem

Problem Reason Countermeasure

Chuck Foot pedal wire loose Fix wires
Clamp Foot pedal sensor not ok Replace sensor
de-
clamp Computer panel button not Replace button
not working
happeni Draw bar connecting rod Weld the rod or
ng broken replace it with
new

1
0
 Chuck not Clamp/De clamp problem

Problem Reason Countermeasure

Lubrication oil Low Oil level lower than min level Fill oil in lubrication tank
Overtravel in X or Z Bring back to work range by using handle
wheel
APG 300 Low battery, Battery plug Needs replacement , Fix the plug,
loose-needs replacement
Turret not clamping
Low rpm Encoder faulty Replace Encoder-18000 Rs.

1
0
 ??
?
Questions

1
0
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1
0