Académique Documents
Professionnel Documents
Culture Documents
Time lag between operation ------------------ Low. Ratio of cutting time to non
cutting time ---Low. Variety of Components to be produced ---- More. Design
changes------------------------------------ Frequent. Non uniform cutting conditions
-------------- Required. Cost of special tooling involved--------------- High. Skill
required by the operator ---------------- High. Set-up time /Inspection
time----------------- Low. Number of dimensions to be maintained-- Many
Precision involved in the components------ High.
8. 8. MACHINE TYPES 1. Group 1: -M/C Tools with rotating tool i.e. Milling M/C,
Drilling M/C, Boring M/C , Tapping M/C 2. Group 2: -M/C Tool with Rotating
work piece i.e. Lathe. 3. Group 3: -Non Rotating work Piece and non rotating
tool i.e. Shaper, Planer, EDM, Wire cut. 4. Group: -Other than above Z
Categories i.e. NC Drafting.
9. 9. Classification of Controllers 1. Point to Point type (P-Type) A. )Only
Positioning. B.) No Control over Feed speed. C.) Semi Automatic Drilling M/C
Spot Welding M/C etc. 2. Position Control (2PL) 3. 2L/3L Controllers. 4.
Continuous Control (C-Type Controllers) A.) 2CLa.) 2 Axis Controllers. b.)
Simultaneous Control of two Axis + Feed control of one Axis. c.) Can make 2D Fig. Like Circle, Arc Ellipse. B.) 3C a.) 3 Axis Simultaneous b.) Can do
interpolation in 3 Dimensions C.) Can Produce Sphere D.) Most Suitable for
Production Operations
10. 10. Motion and coordinate system for NC machine Z-axis: Always aligned with
the spindle that imparts cutting power. This spindle might rotate the workpiece as in a lathe, it might rotate a tool as in a milling machine. It is
perpendicular to work-holding surface if there is no such spindle. Positive
motion in z axis tends to increase the separation between the work-piece and
the tool X axis: Positioning the moving element, parallel to the work-holding
surface, horizontal (if possible). On machines with rotating work-pieces, it is
radial and parallel to the cross-slide On machines with rotating tools, 1.If the
Z-axis is horizontal, the positive x motion is to the right when looking from
the spindle to the work-piece. 2. If the z axis in vertical, the positive x axis is
to the right when looking from the spindle to the column On machines with
non-rotating workpieces and non-rotating tools, the x axis is parallel to and
directed toward the principal cutting direction Y-axis: be in such a direction as
to complete a right-handed Cartesian coordinate system
11. 11. What , if you have Multi spindle M/C Select principle spindle as Primary
Z axis and other slides/quills are termed as secondary tertiary motion axis.
Axis Rotator Axis A,B,C Principal: Second: Tertiary: X,Y,Z U,V,W P,Q,R Fanuc
used: - U,V,W to designates Incremental Movement in X,Y,Z direction.
X,Y,Z is used to designates Absolutes Motion.
12. 12. Axes convention
13. 13. Axes convention The tool can be moved to any position in a 3 dimensional
cartesian co-ordinate system. The Z axis is along the spindle axis. The X and
Y axes are perpendicular to Z. VMC (Vertical Machining Center)
26. 26. Fixed zero V/S Floting zero Fixed zero: -Origin is always located at some
position on M/C table (usually at south west corner/Lower left-hand) of the
tables & all tool location are defined W.R.T. this zero Floting Zero: Very
common with CNC M/C used now a days. Operator gas lobeity to set zero
point at any convenient position on M/C table The Coordinate system is
knows as work coordinate system (WCS)
27. 27. Part Programme The coded instructions or commands listed in a logical
sequence to have a machine tool perform a specific tasks or a series of tasks
in order to produce a finished product in the minimum amount of time.
Programming Format % N G X,Y,Z U,V,W P,Q,R I,J,K A,B,C R F S T/D M EOB
Programme Number. Sequence Number (Block Identification Number).
Preparatory functions (G00 to G99). This prepares the M/C for next operation.
Primary motion Dimension in the X,Y,Z direction respectively. Secondary
motion Dimension in the X,Y,Z direction respectively. Tertiary motion
Dimension in the X,Y,Z direction respectively. Distance to the are center or
thread leads parallel to X,Y,Z respectively. Angular Dimension around in the
X,Y,Z direction respectively. Parameters. Feedrate. Spindle Speed/Cutting
Speed. Tool number. Miscellaneous function (Machine Codes) End of Block.
28. 28. PART PROGRAMMING FOR CNC The transfer of an engineering blueprint of
a product to a part program can be performed manually using a calculator or
with the assistance of a computer language. A part programmer must have
an extensive knowledge of the machining processes and the capabilities of
the machine tools . In this section, we describe how the part programmers
execute manually the part programs. First, the machining parameters are
determined . Second, the optimal sequence of operations is evaluated . Third,
the tool path is calculated . Fourth, a program is written. Each line of the
program, referred to as a block, contains the required data for transfer from
one point to the next. A typical line for a program is given below. N100 G91 X
-5.0 Y7 .0 F100 S200 T01 M03 (EOB)
29. 29. DEFINITIONS WITHIN THE FORMAT 1. CHARACTER : A single alphanumeric
character value or the "+" and "-" sign. 2. WORD : A series of characters
defining a single function such as a, "X" displacement, an "F" feedrate, or G
and M codes. A letter is the first character of a word for each of the different
commands. There may be a distance and direction defined for a word in a
program. The distance and direction in a word is made up of a value, with a
plus (+) or minus (-) sign. A plus (+) value is recognized if no sign is given in
a word. 3. BLOCK : Series of words defining a single instruction. An instruction
may consist of a single linear motion, a circular motion or canned cycle, plus
additional information such as a feedrate or miscellaneous command (Mcodes). 4. POSITIVE SIGNS : If the value following an address letter command
such as A, B, C, I, J, K, R, U, V, W, X, Y, Z, is positive, the plus sign need not be
programmed in. If it has a minus value it must be programmed in with a
minus (-) sign. 5. LEADING ZERO'S : If the digits proceeding a number are
zero, they need not be programmed in. The control will automatically enter in
the leading zero's. EXAMPLE: G0 for G00 and M1 for M01, Trailing zeros must
be programmed: M30 not M3, G70 not G7.
30. 30. 6. MODAL COMMANDS : Codes that are active for more than the line in
which they are issued are called MODAL commands. Rapid traverse, feedrate
moves, and canned cycles are all examples of modal commands. A NONMODAL command which once called, are effective only in the calling block,
and are then immediately forgotten by the control. 7. PREPARATORY
FUNCTIONS : "G" codes use the information contained on the line to make the
machine tool do specific operations, such as : 1.) Move the tool at rapid
traverse. 2.) Move the tool at a feedrate along a straight line. 3.) Move the
tool along an arc at a feedrate in a clockwise direction. 4.) Move the tool
along an arc at a feedrate in a counterclockwise direction. 5.) Move the tool
through a series of repetitive operations controlled by "fixed cycles" such as,
spot drilling, drilling, boring, and tapping. 8. MISCELLANEOUS FUNCTIONS :
"M" codes are effective or cause an action to occur at the end of the block,
and only one M code is allowed in each block of a program. 9. SEQUENCE
NUMBERS : N1 thru N99999 in a program are only used to locate and identify
a line or block and its relative position within a CNC program. A program can
be with or without SEQUENCE NUMBERS. The only function of SEQUENCE
NUMBERS is to locate a certain block or line within a CNC program.
31. 31. Programming Key Letters O - Program number
(Used for program identification) N - Sequence number (Used for line
identification) G - Preparatory function X - X axis designation Y - Y axis
designation Z - Z axis designation R - Radius designation F Feed rate
designation S - Spindle speed designation H - Tool length offset designation D
- Tool radius offset designation T - Tool Designation M - Miscellaneous function
32. 32. List of G-codes G-code Function G00 Positioning rapid traverse G01 Linear
interpolation (feed) G02 Circular interpolation CW G03 Circular interpolation
CCW G04 Dwell G20 Inch unit G21 Metric unit G28 Automatic zero return G40
Tool nose radius compensation cancel G41 Tool nose radius compensation left
G42 Tool nose radius compensation right G43 Tool length compensation G54
Work co-ordinate system 1 selection G55 Work co-ordinate system 2 selection
G56 Work co-ordinate system 3 selection G57 Work co-ordinate system 4
selection G58 Work co-ordinate system 5 selection G59 Work co-ordinate
system 6 selection
33. 33. G80 G81 G82 G83 G84 G85 G86 G87 G90 G91 G94 G95 G98 G99 Canned
cycle cancel Drilling cycle Drilling cycle with dwell Peck drilling cycle / deep
drill Tapping cycle Boring / Reaming cycle Boring cycle Back boring cycle
Absolute command Incremental command Feed per minute Feed per
revolution Return to initial point in canned cycle Return to R point in canned
cycle
34. 34. List of M codes M codes vary from machine to machine depending on the
functions available on it. They are decided by the manufacturer of the
machine. The M codes listed below are the common ones. M-codes M00 M01
M02 M03 M04 M05 M06 M07 M08 M09 M30 M98 M99 Function Optional
program stop automatic Optional program stop request Program end Spindle
ON clock wise (CW) Spindle ON counter clock wise (CCW) Spindle stop Tool
change Mist coolant ON (coolant 1 ON) Flood coolant ON (coolant 2 ON)
Coolant OFF End of program, Reset to start Sub program call Sub program
end
35. 35. History of CNC The word address format Each line of program == 1 block
Each block is composed of several instructions, or (words) Sequence and
format of words: N3 G2 sequence no X+1.4 Y+1.4 Z+1.4 I1.4 J1.4 K1.4
destination coordinates dist to center of circle preparatory function F3.2 S4
T4 M2 tool feed rate spindle speed miscellaneous function
36. 36. ABSOLUTE PRESET G92 USED TO SHOW CURRENT TOOL POSTION W.R.T.
ZERO AT THE TIME OF STARTING M/C. ONCE THE CUTTER POSITION IS
DEFINED USING G92 M/C WILL DRAW ITS CO-ORDINET SYSTEM ONCE G92 IS
DEFINED THEN THERE IS NO NEED TO DEFINE G90 IT IS MODEL FORMAT G92
X__ Y__ Z__ ZERO OF JOB) (CURRENT TOOL POSITION W.R.T
37. 37. REFERENCE POINT AND RETURN G28 Return To Reference Point, set
optional intermediate point The G28 code is used to return to the machine
zero position on all axes. If an X, Y, Z, or A axis is on the same block and
specifies a location, only those axes will move and return to the machines
zero reference point and the movement to the machines zero reference
point will be through that specified location. Format: -G91 G28 X0 Y0 Z0;
38. 38. Setting work co-ordinate system (G54 - G59) G54 Work co-ordinate
system 1 selection G55 Work co-ordinate system 2 selection G56 Work coordinate system 3 selection G57 Work co-ordinate system 4 selection G58
Work co-ordinate system 5 selection G59 Work co-ordinate system 6 selection
G54 X_ Y_ Z_
39. 39. G00 Rapid traverse When the tool being positioned at a point preparatory
to a cutting motion, to save time it is moved along a straight line at Rapid
traverse, at a fixed traverse rate which is pre-programmed into the machine's
control system. Typical rapid traverse rates are 10 to 25 m /min., but can be
as high as 80 m/min. Format N_ G00 X__ Y__Z__
40. 40. G01 Linear interpolation (feed traverse) The tool moves along a straight
line in one or two axis simultaneously at a programmed linear speed, the
feed rate. Format N__ G01 X__ Y__Z__ F__
41. 41. G02/03 Circular interpolation
42. 42. Format N__ G02/03 X__ Y__Z__ I__ J__K__ F__ using the arc center OR N__
G02/03 X__ Y__Z__ R__ F__ using the arc radius G02 moves along a CW arc
G03 moves along a CCW arc Arc center The arc center is specified by
addresses I, J and K. I, J and K are the X, Y and Z co-ordinates of the arc
center with reference to the arc start point. I = X coord. of center - X coord. of
M98 M99: -An M99 ends a sub-program and returns back to the next line in
the main program after the M98 sub-program call.
50. 50. Tool length compensation (G43) Different tools of different lengths are
used in machining any part. The lengths of the tools are not considered in the
part program. They are entered in the machines memory, and are
considered automatically for each motion in the program depending on the
tool that is being used. The tool lengths in the Z direction are called the Tool
length offsets. Codes Function G43 Make the value of the cutters offset add
to the value of Z coordinates of the program G44 Make the value of the
cutters offset subtract the value of Z coordinates of the Program G49 Cancel
the offset of the length of the cutter Format: G43 Z_ H_ G44 Z_ H_ G49
Z_
51. 51. Canned cycles Canned or fixed cycles are programming aids that simplify
programming. Canned cycles combine many programming operations and
are designed to shorten the program length, minimize mathematical
calculations, and use minimal tool motions. Examples : drilling, peck drilling,
tapping, boring, back spot facing. G81 Drilling cycle G82 Drilling cycle with
dwell (Counter bore cycle) G83 Peck drilling cycle / deep drill G84 Right hand
tapping cycle G85 Boring / Reaming cycle G86 Boring cycle G87 Back boring
cycle G74 Left hand tapping cycle G76 Fine boring cycle G98/G99 plane of
return point When the tool gets to the bottom of the hole, it can return back
to the plane of R point and the initialized plane initialized by G98/G99.
Generally speaking, G99 is used in the first drilling plane while G98 is used in
the last drilling, even though we use G99 to drill, the plane of the initialized
position would keep the same.
52. 52. G81 X_Y_Z_R_F_K_ X_ Y_: Data of hole site Z_: Depth of the bottom of
hole(absolute coordinate R_: Starting point or raising point per
timeabsolute coordinate F_: Feeding rate of cutting K_: Number of
replication (if necessary)
53. 53. G82 X_Y_Z_R_P_F_K_ X_ Y_: Data of hole site Z_: Depth of the bottom of
hole(absolute coordinate R_: Starting point or raising point per time
(absolute coordinate P_: Pause time (unitms) F_: Feeding rate of cutting
K_: Number of replication (if necessary)
54. 54. G83 X_Y_Z_R_Q_F_K_ Z_: Depth of the bottom of hole(absolute
coordinate R_: Starting point or raising point per time (absolute
coordinate Q_: Offset of hole bottom F_: Feeding rate of cutting K_: Number
of replication (if necessary)
55. 55. G84 X_Y_Z_R_P_F_K_operation manual FANUC milling programming X_
Y_: Data of hole site Z_: Depth of the bottom of hole(absolute coordinate
R_: Starting point or raising point per timeabsolute coordinate P_: Pause
time (unitms) F_: Feeding rate of cutting K_: Number of replication (if
necessary)
64. 64. CIRCULAR POCKET MILLING There are two G codes, G12 and G13 that will
provide for pocket milling of a circular shape. They're different only in which
direction of rotation is used. G12 and G13 are non-modal. G12 Circular Pocket
Milling Clockwise X Position in X axis to center of circular pocket Y Position in
Y axis to center of circular pocket Z Z depth of cut, or it's the increment depth
of cuts when used with G91 I Radius Of First Circle (Or it's the finish radius if K
is not used) K Radius Of Finished Circle (If specified) Q Radius cut increment
step-over of the spiral out (Q is used with K only) L Loop count for repeating
incremental depth of cuts (L is used with G91) D* Cutter Comp. Offset
Number (Enter cutter size in offset display register) F Feed Rate in inches
(mm) per minute This G12 code implies the use of G42 cutter compensation
right G13 Circular Pocket Milling Counterclockwise This G13 code implies the
use of G41 cutter compensation left and will be machining in a
counterclockwise direction, but is otherwise the same as G12. G13 is usually
preffered instead of G12, since G13 will be climb cutting when used with a
standard right handed tool.