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CNC Basics

MTS TeachWare Students Book

MTS Mathematisch Technische Software-Entwicklung GmbH Kaiserin-Augusta-Allee 101 D-10553 Berlin


Phone: +49 / 30 / 349 960 - 0 Fax: +49 / 30 / 349 960 -25 World Wide Web: http://www.mts-cnc.com email: mts@mts-cnc.com
CNC-Basics

MTS TeachWare Students Book

MTS Mathematisch Technische Software-Entwicklung GmbH

Kaiserin-Augusta-Allee 101 D-10553 Berlin

Phone: +49 / 30 / 349 960 - 0

Fax: +49 / 30 / 349 960 - 25

eMail: mts@mts-cnc.com

World Wide Web: http://www.mts-cnc.com

Created by BK & BM, 2005.


All rights reserved, including photomechanical reproduction and storage on electric media
Contents

Introduction into CNC Technology .................................................................................. 9


1.1 History and Development of CNC Technology ................................................................................9
From conventional machine tool to Computer Integrated Manufacturing (CIM) ..............................9
1.2 Conventional vs. CNC Machine Tool .............................................................................................11
Machine Structure ..........................................................................................................................11
Function ..........................................................................................................................................11
Productivity .....................................................................................................................................12
1.3 Characteristics of modern CNC machine tools ..............................................................................13
Controllable feed and rotation axis.................................................................................................13
Path measuring systems ................................................................................................................15
Main drive and work spindle...........................................................................................................17
Work part clamping devices ...........................................................................................................17
Tool change facilities ......................................................................................................................18
Security precautions on CNC machine tools..................................................................................19
Control test CNC Basics.........................................................................................................................21

Basic Geometry for CNC Machining .............................................................................. 23


2.1 Coordinate systems on CNC machine tools ..................................................................................23
Types of coordinate systems..........................................................................................................23
Cartesian coordinate system..........................................................................................................23
CNC-Exercise ...........................................................................................................................................28
Feed and Turning Axes on CNC Machines....................................................................................31

CNC-Demo........................................................................................................................ 34
CNC milling ...............................................................................................................................................34
CNC turning ..............................................................................................................................................35
2.2 NC Mathematics .............................................................................................................................36
Basics of coordinate point calculations ..........................................................................................36
Calculation of NC coordinates........................................................................................................39
2.3 Zero and reference points on CNC machine tools .........................................................................41
Types of zero and reference points................................................................................................41
Setting the work part zero point W on a CNC lathe .......................................................................44
Setting the work part zero point W on a CNC milling machine ......................................................45
CNC exercise............................................................................................................................................47
2.4 Numeric Controls on CNC Machine Tools .....................................................................................53
Control chain and control loop........................................................................................................53
CNC Control ...................................................................................................................................53
Types of CNC controls ...................................................................................................................56
DNC operation................................................................................................................................60
2.5 Tool Compensations for CNC Machining.......................................................................................62
Inhalt

Using tool compensation values.................................................................................................... 62


Tool length compensation for milling and turning.......................................................................... 62
Tool radius compensations............................................................................................................ 63
Tool measuring and adjusting with an adjusting device ................................................................ 69
Tool measuring and setup using the CNC machine...................................................................... 71
2.6 Path Measuring Systems............................................................................................................... 75
Infeeds, position control and position adjustment of the NC axis.................................................. 75
Path measuring.............................................................................................................................. 75
CNC exercise ........................................................................................................................................... 77

Control test Basic Geometry .......................................................................................83

3 Technological Basics for CNC Machining...............................................................85


3.1 CNC tool systems for turning and milling ...................................................................................... 85
Tool carriers ................................................................................................................................... 85
Tool holder ..................................................................................................................................... 85
Tungsten carbide indexable inserts............................................................................................... 86
3.2 Structure and use of lathe tools for CNC machining ..................................................................... 87
Types of lathe tools and the corresponding ISO designation........................................................ 87
Cutting materials ............................................................................................................................ 88
Cutting edge geometry .................................................................................................................. 90
Abrasion and cutting edge ............................................................................................................. 91
Cutting value .................................................................................................................................. 92
Examples: Calculating technological values for CNC machining.................................................. 94
3.3 Structure and application of milling tools for CNC machining ....................................................... 95
Milling and milling operations......................................................................................................... 95
Types of milling tools ..................................................................................................................... 97
Cutting edge materials................................................................................................................... 99
Cutting geometry ......................................................................................................................... 100
Cutting values .............................................................................................................................. 102
Calculation examples of technological values for CNC machining ............................................. 104
3.4 Calculation of technological data for CNC machining ................................................................. 107
Calculation examples of technological data for CNC turning ...................................................... 107
Calculation examples of technological data for CNC milling ....................................................... 115
3.5 CNC clamping systems ............................................................................................................... 119
Types of clamping systems ......................................................................................................... 119
Types and characteristics of clamping devices for turning.......................................................... 123
Types and characteristics of clamping devices for milling .......................................................... 132

Control test Technological Basics............................................................................137

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Contents

4 Introduction into NC programming........................................................................ 139


4.1 Work organization and flow of manual NC programming ............................................................139
Comparison of work preparation of conventional and CNC machining .......................................139
Organizing the steps of NC programming....................................................................................140
Programming procedure for manual NC programming at programming seat..............................143
Quality assurance during CNC production...................................................................................145
4.2 NC programming basics...............................................................................................................146
NC programming standards (ISO)................................................................................................146
Structure of an NC program .........................................................................................................146
Structure of a program block ........................................................................................................147
Structure of a program word.........................................................................................................147
Comparison of programming codes/keys of various CNC controls .............................................149
4.3 Introduction to manual NC programming .....................................................................................156
Procedure for manual NC programming ......................................................................................156
Manual NC programming Turning ................................................................................................159
Manual NC programming Milling ..................................................................................................180

2. Control test Introduction into NC programming ............................................... 195

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Instroduction into CNC technology

2. Introduction into CNC Technology


1.1 History and Development of CNC Technology
From conventional machine tool to Computer Integrated Manufacturing (CIM)

The idea of numerical control (NC) of machine tools emerged in 1949/50 at the MIT (Massachusetts Institute
of Technology, Cambridge, USA) as a result of a US Air Force order to manufacture important airplane parts
from full material rather than by riveting and welding material together.

The templates and patterns needed for form cutting were however very complicated and could only be
manufactured with a considerable time and cost increase when using conventional technology. Since how-
ever the contours of the large parts could easily be represented as mathematical functions it was decided to
develop a control to control a milling machine on this basis.

NC Numerical control
CIM
CNC Numerical control with inte-
CAD / CAM grated computer
CAD FFS Flexible manufacturing sys-
tem
FFS CAD Computer aided draw-
CNC ing/design

NC CAM Computer aided manufactur-


ing
CIM Computer integrated manu-
facturing with planning, de-
1950 1960 1970 1980 1990 sign and manufacturing

Figure 1
Development into CIM technology

The technical realization of this idea required a control which interprets binary and digital entries for travel
paths and switching operations in such a way that they could be understood and processed by the milling
machine. Herewith the basic principle was formulated for the application of numerical controls. The rapid
development of electronic data processing then enabled the practical realization.

First a corresponding NC control was developed for a vertical milling machine. The machining path and
switching information necessary for manufacturing was given on punch card. The idea was to control the
infeed axis of the milling machine so that separately working motors control the axis movements of the tool
carrier. The sequence of the travel path and switching information in form of code letters and numbers was
called a NC program.

This first NC machine tool already showed all the characteristics of the NC machines to be developed later
on:

Entry unit with numerical starting value for the travel path and switch information on a punch card.
Computer control to process the travel path and switch information.
Separate power supply for each infeed axis and spindle to control the movements of the tool and tool
carrier.
Measuring and control systems returning feedback to the controlling computer regarding the tool posi-
tions.

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Instroduction into CNC technology

In the mid 50s almost all machine tool manufacturers began developing and manufacturing numerically con-
trolled milling machines which were soon followed by NC lathes. The rapid development of new microele-
tronic components, such us micro processors and micro computers, enhanced the development of NC con-
trols to CNC (computerized numerical control) controls in the mid 70s.

With the increased contribution of high-performance microprocessors it was possible to extend the opera-
tions of the computer controlled machine tools. The current microcomputers and CNC controls as well as the
PLC (programmable logic controller) of the machine tools have improved NC programming efficiency. Con-
tour precision and machining speed of the tools as well as cutting power have continuously improved. Mod-
ern CNC controls additionally offer a multitude of further characteristics. This has made it possible, for in-
stance, to program complex tool geometries without using mathematical calculations.

The continuous further development of CNC machine tools takes place in a reciprocal innovation exchange
between the manufacturers of microelectronic components, CNC controls, tools and machine tools. Users
also facilitate this increasingly rapid development by continuously demanding new and improved solutions.
CNC machining centers, flexible production systems (FFS) and fully automated manufacturing (CIM) mark
significant stages of this development which started in the 50s.

The following list shows some of the current user requirements:

interfaces with high performance for more rapid transfer of constantly increasing data
complete machining centers with high precision, e.g. CNC lathes with 7-32 NC axis, several spindles and
live milling tools for turning
high speed machining for turning, milling and boring with maximum dynamic travel path accuracy
development of servo motors whose scanning rate for defining the manufacturing dimensions becomes
smaller and smaller (presently the scanning speed is already less than 1ms)
minimizing the programming effort for the individual manufacturing tasks
simple, high-performance NC programming systems with dynamic-interactive simulation of the machining
processes
graphic control error diagnosis of the CNC machine tool or of the complete machining system

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Introduction into CNC Technology

1.2 Conventional vs. CNC Machine Tool


Machine Structure
The CNC machine tools are basically built in the same way as conventional machine tools. The difference
lies in the fact that the machine components relevant for turning and milling processes are controlled by
computers.

The movement directions of the components of a CNC controlled machine tool are specified by a coordinate
system, which refers to the work part to be machined and shows axes located parallel to the main linear
movement. The movements necessary for machining the individual machine tool assemblies (table, turret
and others) are calculated, controlled and tested by a computer. For this purpose each machining direction
has a separate measuring system to calculate the corresponding positions of the machine tool assemblies
and to return this information to the control.
Function
In the following overview conventional, NC and CNC machine tools are compared in their basic functionality:

Conventional NC Machine Tools CNC Machine Tools


Machine Tools

Entry: Entry: Entry:


The qualified worker manually The NC program is transmitted to NC programs can be entered into
adjusts the machine tool according the NC control using a punch card. the CNC control either using a
to the drawing, clamps the raw part keyboard, disks or data interface
as well as the tools and aligns (serial, Bus). Several NC programs
them. are stored in an internal storage,
whereby modern controls also use
hard disks.
Manual control: NC control: CNC control:
The qualified worker manually sets The NC control processes the path The micro computer integrated in
the machining values (number of and feed information of the NC the CNC control and the corre-
rotations, infeed) and controls the program and passes the corre- sponding software take over all
machining using hand wheels. sponding control signals to the control functions of the CNC ma-
components of the NC machine. chine. Hereby internal storage are
used for programs and sub-
programs, machine data, tool and
compensation values and fixed
and free cycles. Frequently, error
monitoring software is integrated in
the CNC control.
Dimension control: NC machine: CNC machine:
The qualified worker manually The NC machine ensures the di- The CNC machine ensures the
measures and verifies the dimen- mensional stability of the work part dimensional stability of the work
sions of the work part and, if nec- already during the machining part already during the machining
essary, must repeat the machining process with the continuous feed- process with the continuous feed-
process. back from the measuring system back from the measuring system
and the servo motors. and the servo motor, which is con-
trolled by the number of rotations.
Integrated measuring sensors
make it possible to control the
dimensions during the machining.
In parallel to active machining it is
possible to continue work on the
CNC control, e.g. to test and opti-
mize new NC programs.

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Instroduction into CNC technology

Productivity
Advantages of the CNC machine tool
1. The higher machining speed of the CNC machine tool as well as decreased basic, auxiliary, preparation
and finishing times on the machine increases productivity. The following factors are especially influential:
programming directly on the machine tool with manual entries
shared responsibility in a department responsible for work preparation for programming, materials and
tools and due entry of the data at the CNC work seat
storing recurrent machining processes of a tool specific program in form of subprograms
optimizing NC programs on the control
description of the work part shapes to be machined with simple geometry entries
automatic infeed of the tool until the required dimension has been reached
automatic initiation of all functions of the machine and direct intervention when identifying errors or
disturbances
automatic monitoring of the production through the CNC control (automatic measuring and testing)
universal application of tools in tool clamping systems
possibility to preset the tools outside of the machine tool without influencing machine run-time

2. Constant quality of the work part and less scrap.


3. Increased dimension precision of the work part through high basic precision of the machine tool
(1/1000 mm)
4. Short run-through-times through product organization and combination of split machining processes
5. Improved machine utilization and rentability
6. Improved production flexibility through machining systems and correspondingly rational production of
small lots or single work parts with high complexity
Due to the advantages mentioned above the CNC machine tools are prevalent in cutting production. The
wide application field (see figure 2) is a typical characteristic of the CNC machine tools.

larger lot sizes

increased complexity and


production precision
3
CNC machine tools

conventional machine tools

4 2

Figure 2
Application field of CNC machine tools

Requirements for using CNC machine tools

To operate and program CNC machine tools the machine operator needs a higher qualification. Experience
from conventional machining can not necessarily be transferred.

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Introduction into CNC Technology

1.3 Characteristics of modern CNC machine tools


Controllable feed and rotation axis
Work part machining on CNC machine tools requires controllable and adjustable infeed axes which are run
by the servo motors independent of each other. The hand wheels typical of conventional machine tools are
consequently redundant on a modern machine tool.

CNC lathes (see figure 3) have at least 2 controllable or adjustable feed axes marked as X and Z.

Figure 3
Controllable NC axes on an automatic lathe

CNC- milling machines (see figure 4) on the other hand have at least 3 controllable or adjustable feed axes
marked as X, Y, Z.

Figure 4
Controllable NC axes on a milling machine

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In addition to the linear movements along the X, Y and Z axes it is possible to control rotation around each
axis.

These controllable rotation axes are marked with A, B and C (see figure 5).

+Y

+B

+A

+X
+C

+Z

Figure 5
Feed and rotation axes
in Cartesian coordinate system

Often further controllable feed axes are needed. These are then marked as U, V, W. Additionally there are
the adjustable rotation axes around which the machining table, head stock and tool holder can rotate inde-
pendent of the feed axes. They are marked as A, B and C.

The required tool and work part carriers are moved by feed drives. The feed drives meet the highest re-
quirements due to high machining and iteration precision. The individual axis movements must be carried
out with maximum feed speed and minimum positioning time. To meet these requirements a modern feed
drive (see figure 6) consists of the following components:

motor, mechanical gears against overload as well as electronic control


ball screw drive for power transfer free from play
sensor as path measuring system, mostly located at the free end of the axis
power amplifier with analog or digital interfaces for CNC control

For exact positioning the feed drives are connected with the measuring facilities. Each controllable axis of a
CNC machine needs a path measuring system with automatic interpretation of the measuring signal. The
most frequently used resolution for length measuring is 0.001 mm, however for the X axis of the lathe (di-
ameter dimension) 0.0005 and for the precision grinding machine up to 0.0001 are customary.

2 feed drive
1 3
work table
measuring system
ball screw
4
5 ball screw nut

Figure 6
Feed drive for carrier with ball screw drive

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Introduction into CNC Technology

The embodiment of the measure is usually a ball circulating screw. If the spindle is set in motion by the mo-
tor, then the spherical thread nut, which works almost free of play, moves in longitudinal direction and
pushes the corresponding tool or work part carrier along the carrier track (see figure 7). The almost friction-
free transfer of power from the spindle to the carrier is achieved through a system of balls. To guarantee the
minimum of thread play the two halves of the ball thread nut are clamped against each other to achieve high
and reproducible accuracy of production. Eventual pitch errors of the spherical contour spindle can be auto-
matically rectified by the CNC control through the spindle pitch error compensation. Further mechanical pos-
sibilities are for instance the rack/pinion and spindle/nut. If less accuracy is sufficient hydraulic drives are
used as well.

2
ball screw nut
1 3 Clamping ring
balls
Drive spindle

3
4

Figure 7
ball screw drive with play-free double nut

The manufacturing tolerances resulting from the manufacturing process of the ball screw drive can be recti-
fied by modern CNC controls using the spindle pitch error adjustment. For this purpose the tolerances are
measured by laser measuring systems and stored in the CNC control.

Path measuring systems

Depending on the applied measuring device or scale direct and indirect position measuring are differentiated
as well as absolute and incremental position measuring. The most accurate measuring values are achieved
with direct measuring scales.

In direct position measuring (see figure 8) the measuring scale is given in the carrier or on the machine
table so that inaccuracies on spindle and drive connection have no influence on the value measured.

The measuring values are specified by an optical pick-up on a scanning pattern of the measuring scale. The
pick-up converts these values into electrical signals and transfers them to the control.

pick-up
X glass ruler with scale

Y
1
2

Figure 8
Direct position measuring

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Instroduction into CNC technology

In indirect position measuring (see figure 9) the travel path is specified using the rotation of the ball circu-
lating screw, which is equipped with a pulse disk as a measuring scale. A signal generator registers the rota-
tions of the pulse disk and transfers them to the control. The control then calculates the exact carrier move-
ments or its present positions based on the rotation pulses.

1
carrier
2
pulse disk as a measuring scale
spindle

X 3 signal generator

Figure 9
Indirect position measuring

In absolute position measuring (see figure 10) a coded measuring scale immediately shows the position
of the carrier with reference to one fixed orientation point on the machine. This point is the machine zero
point, which is specified by the machine manufacturer. This method presupposes that the reading-in area of
the measuring scale is as large as the machining area and that the coding of the measuring scale is binary.
This is to enable the control to allocate a numerical value to each read-in position.

012345678
1 2
binary-coded measuring scale
current tool carrier position

Figure 10
Absolute position measuring

In incremental position measuring (see figure 11) a measuring scale with a simple grating consisting of
light and dark fields is used. For a feed movement passing the sensor the sensor counts the number of light
and dark fields and calculates the current carrier position based on the difference from the last carrier posi-
tion.

1 2 3 4
ruled grating
previous carrier position
current carrier position
carrier on reference point

Figure 11
Incremental position measuring

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Introduction into CNC Technology

The control has once to be given one absolute position, which it then uses as a reference point when calcu-
lating the current carrier position using incremental position measuring. Therefore, it is necessary to go to
this absolute point once the control is started. This absolute point is called the reference point on the ma-
chine. Each axes movement, even when traveled manually using the hand wheel or buttons, needs to be
registered by the control.

Since the control loses the control/information on mechanical movements when switched off the reference
point has to be returned to each time the control is switched on.

Main drive and work spindle

The main drive of a CNC machine needs to transmit the necessary power output for machining the current
work part. This power output is transmitted from the main drive to the drive of the corresponding work spin-
dle. The friction loads of the mechanical parts of the machine are also to be considered. They ultimately
determine the efficiency of the CNC machine. It is necessary to have a drive with high stability, i.e. the mo-
ment of rotation has to be so that the current machining position remains unchanged even if the machining
loads are high. In addition to this, the drive has to possess sufficient dynamics to master speed changes
rapidly and without overshooting.

The work spindle and the eventually available counter spindle were previously driven by a direct-current
motor. To keep the cutting speed constant a stepless regulation of the rotation speed of these motors within
a wide range, for instance to turn various diameters, is required. A disadvantage of the direct-current motor
is the abrasion of the carbon brushes, which need to be regularly checked and changed if necessary.

Thanks to the progressive development of microelectronic components three-phase motors are now mostly
used. Their disadvantage, the complicated control of the number of rotations, has become irrelevant due to
the price development in electronic controls.

There are two types of three-phase motors: asynchronous and synchronous motors. They have consider-
able advantages compared with direct-current motors. With identical dimensions higher rotation moments
are achieved. Furthermore, up to three times higher number of rotation and much better power output is
possible. These motors work without carbon brushes, without collectors or collecting rings and are corre-
spondingly maintenance free.

The spindle head of the work spindle is standardized to guarantee the maximum possible exchange of
clamping devices. In CNC machines, the work spindle as well as many other parts are more solidly built than
in conventional machine tools because of the considerably higher acceleration rate (10 to 40m/s) and higher
machining performance.

Work part clamping devices

Work part clamping devices hold the work part in the correct and exact position on the work spindle for turn-
ing or on the work table for milling. The work part must be clamped so that it is absolutely free from play,
positioned correctly and exactly, and fully resistant to dynamic stresses. A multitude of work part clamping
devices are available.

In milling, loading and withdrawal of work parts will automatically be done by charging robots in the future
(see MTS robot simulator ROBIN). For turning, mostly controllable jaw chucks of different types are used.
These chucks are designed to allow pneumatically or hydraulically controlled automatic charging and ap-
proach of the chucks. The clamping powers are adjustable. Depending on weight, material, length/diameter
relation, clamping depth and other machining conditions the clamping powers have to be adjusted higher or
lower.

Chuck jaws for high number of rotations have a centrifugal force compensation so that the clamping power is
not reduced by the contrary centrifugal force. This centrifugal force is realized for instance by compensation
weights, which are connected with the clamping jaws by a lever. The centrifugal force of the compensation
weight exerts then an opposite force to the centrifugal force of the chuck jaws. The clamping power is kept
constant with this compensation. For machining between centers mostly drivers, face drivers and controlla-
ble live turrets are used. For clamping small parts controllable collet systems are commonly used.

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Instroduction into CNC technology

In CNC milling the main function of the work part clamping devices is the correct positioning of the work
parts. The work part clamping should allow a work part change which is as quick, easy to approach, cor-
rectly and exactly positioned, reproducible as possible. For simple machining controllable, hydraulic chuck
jaws are sufficient. For milling on all sides the complete machining should be possible with as few re-
clamping as possible. For complicated milling parts milling fixtures, also with integrated automatic rotation,
are being manufactured or built out of available modular systems to allow, as far as possible, complete ma-
chining without re-clamping. Work part pallets, which are loaded with the next work part by the operator out-
side the work room and then automatically taken into the right machining position, are increasingly being
used.

Tool change facilities

CNC tool machines are equipped with controllable


automatic tool change facilities. Depending on the
type and application area these tool change facilities
can simultaneously take various quantities of tools
and set the tool called by the NC program into work-
ing position. The most common types are:

the tool turret


the tool magazine.

The tool turret (see figure 12) is mostly used for


lathes and the tool magazine for milling machines.

If a new tool is called by the NC program the turret


rotates as long as the required tool achieves working
position. Presently such a tool change only takes
fractions of seconds.

Figure 12
Example of a turret

Depending on the type and size, the turrets of the CNC machines have 8 to 16 tool places. In large milling
centers up to 3 turrets can be used simultaneously. If more than 48 tools are used tool magazines of differ-
ent types are used in such machining centers allowing a charge of up to 100 and even more tools. There are
longitudinal magazines, ring magazines, plate magazines and chain magazines (see figure 13) as well as
cassette magazines.

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Introduction into CNC Technology

Figure 13
Example of a chain magazine

1 milling tools
2
tool gripper (tool changer)

work spindle

tool magazine

Figure 14
Automatic tool change facility

In the tool magazine the tool change takes place using a gripping system also called tool changer (see figure
14). The change takes place with a double arm gripping device after a new tool has been called in the NC
program as follows:

Positioning the desired tool in magazine into tool changing position


Taking the work spindle into changing position
Revolving the tool gripping device to the old tool in the spindle and to the new tool in the magazine
Taking the tools into the spindle and magazine and revolving the tool gripping device
Placing the tools into the spindle sleeve or magazine
Returning the tool gripping device into home position

The tool change procedure takes between 6 to 15 seconds, whereby the quickest tool changers are able to
make the tool change in merely one second.

Security precautions on CNC machine tools

The target of work security is to eliminate accidents and damages to persons, machines and facilities at work
site.

Basically the same work security precautions apply to working on CNC machines as to conventional ma-
chine tools. They can be classified in three categories:
Danger elimination
Defects on machines and on all devices necessary for work need to be registered at once.
Emergency exits have to be kept free.
No sharp objects should be carried in clothing.
Watches and rings are to be taken off.
Screening and marking risky areas:
The security precautions and corresponding notifications are not allowed to be removed or inacti-
vated.
Moving and intersecting parts must be screened.
Eliminating danger exposure
Protective clothing must be worn to protect from possible sparks and flashes.

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Instroduction into CNC technology

Protective glasses or protective shields must be worn to protect the eyes.


Damaged electrical cables are not allowed to be used.
When setting up and operating CNC machines the following is to be taken into consideration:
In general, setting-up is allowed only on a machine which has been switched off. The only exceptions
being the operations which required the machine power to be switched on, such as re-setting the work
part with tools.
The operator should not go to the rotation or work area of the machine since within this area the ma-
chine can automatically rotate the turrethead or feed the tool carrier.
The specific security precautions of the machine manufacturer have to be followed.

The following security precautions are to be followed as well:


Blocking system against loose parts or parts which have not been allocated correctly, against auto-
generated movement of not fixed elements and against starting an automatic machining procedure
before setting-up work has been completed.
Blocking system of the work part clamping device when charging the CNC machine manually.
Keeping the security distance between the parts of the neighbouring CNC machines coming closest to
the machine in a system where CNC machines are connected with each other and
protection against chips and coolant splashes.
Sucking off the machine room air.

Workshop

Clarification of machine parts of CNC machines in the workshop.

The parts of machine tools should be shown and explained on the available machine tools. Similarities and
differences between conventional machine tools and CNC machine tools are to be emphasized.

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Instroduction into CNC technology

Control test CNC Basics

1. Discuss relevant differences between CNC machine tools and conventional machine tools.

1. Name characteristic features of numerically controlled machine tools!

1. What are the advantages of CNC machine tools compared with conventional machine tools?

1. Why is it necessary to have adjustable feed axes on CNC machines?

1. Which components make up a modern feed drive?

1. How many feed axes at minimum should be available on a CNC lathe?

1. What are the feed axes called?

1. How many feed axes at minimum should be available on a CNC milling machine?

1. What are the feed axes called?

1. Give some examples of controllable rotation axes on CNC machines!

1. Which operations can be achieved by controllable rotation axes on CNC lathes?

1. Which operations can be achieved by controllable rotation axes on CNC milling machines?

1. Discuss the significance and function of a ball screw!

1. Discuss the difference between direct and indirect position measuring?

1. Discuss the difference between absolute and incremental position measuring?

1. What are the advantages of main drive motors with controllable number of rotations?

1. Which automatic tool installations are available on CNC machine tools?

1. Which types of tool magazines are available on CNC milling machines?

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Basic Geometry for CNC Machining

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Basic Geometry for CNC Machining

3. Basic Geometry for CNC Machining


2.1 Coordinate systems on CNC machine tools

Types of coordinate systems


Coordinate systems enable the exact description of all points on a work plane or room. Basically there are
two types of coordinate systems:
Cartesian coordinate system and
polar coordinate system.

Cartesian coordinate system


A Cartesian coordinate system, also called rectangular coordinate system includes for the exact description
of the points
two coordinate axes (two-dimensional Cartesian coordinate system) or also
three coordinate axes (three-dimensional Cartesian coordinate system),
located vertically to each other.

In the two-dimensional Cartesian coordinate system, e.g. in the X, Y coordinate system, each point on the
plane is explicitly defined (see figure 15). The distance from the Y axis is called the X coordinate and the
distance from the X axis is called Y axis. These coordinates can either have a positive or a negative sign.

Y
Example:

P2
P1 P1

P2
X= 80

X= -80
Y= 40

Y= 70

P3 X= -50 Y= -40

X P4 X= 40 Y= -70

P3
P4

Figure 15
Cartesian coordinate system with 2 axis (X;Y)

If a work part drawing is placed in this coordinate system all important work points can be determined. De-
pending on where the zero point of the work part is placed, it is possible to exactly define the points either
with positive or also with negative coordinates.

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Basic Geometry for CNC Machining

The three-dimensional Cartesian coordinate system is necessary for the description and location specifica-
tion of three-dimensional work parts, e.g. milling parts. To describe a point in space three coordinates are
required. These are called X, Y or Z according to the corresponding axis (see figure 16).

Such three-dimensional coordinate systems with positive and negative areas of the coordinate axis enable
the exact description of all points, for instance in the operating space of a milling machine, regardless of
where the zero point of the work part is positioned.

Z Y Example:

P1 X= 30 Y= 20 Z= 0
P1
P2 X= 30 Y= 0 Z= -10

P2

Figure 16
Cartesian coordinate system with 3 axes (X,Y,Z)

The specifications of the three axes as well as the three coordinates is done as a so-called clockwise-
rotating system and follows the right-hand-rule (see figure 17). The fingers of the right hand always show to
the positive direction of each axis.

This system is also called the clockwise-rotating coordinate system.

+Y

+X

+Z
Figure 17
Right-hand-rule

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Basic Geometry for CNC Machining

Polar coordinate system


In the Cartesian coordinate system a point is described, for instance, by its X and Y coordinates. For rotation
symmetrical contours, such as circular boring patterns, calculating the needed coordinates requires exten-
sive computing.

In the polar coordinate system a point is specified by its distance (radius r) to the point of origin and its angle
() to a specified axis. The angle () refers to the X axis in the X,Y coordinate system. The angle is positive,
if it is measured counterclockwise starting from the positive X axis (see figure 18). In the opposite direction it
is negative (see figure 19).

Y
Y

r X
P


P
X r

Figure 18 Figure 19
Polar coordinate system (positive angle ) Polar coordinate system (negative angle )

Rotation angle of axis

Each of the 3 main axes X, Y and Z also have a rotation axis revolving around the corresponding angle.
These rotation angles of the axes are indicated with A, B, C, whereby A rotates on the X, B on Y and C on Z
axis (see figure 20).

The rotation direction is positive if the rotation is clockwise when seen from the coordinate zero point in the
positive coordinate direction (corresponds to the rotation of a screw with a right-hand thread or the rotation
direction of a corkscrew).

The specification of the angles A, B and C of the polar coordinates can be derived from figure 20. If the point
which is to be approached is located on the X/Y plane of the coordinate system, then the polar coordinate
angle corresponds to the rotation angle on the Z axis, i.e. C. On the Y/Z plane the polar coordinate angle
corresponds to the rotation angle on X axis, i.e. A. In the X/Z plane it corresponds to the rotation angle Y, i.e.
B.

Figure 20

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Basic Geometry for CNC Machining

Axis angle of rotation with rotation direction


Coordinate system definition with reference to machine or work part
Machine coordinate system
The machine coordinate system of the CNC machine tool is defined by the manufacturer and cannot be
changed. The point of origin for this machine coordinate system, also called machine zero point M, cannot
be shifted in its location (see figure 21).

Work part coordinate system


The work part coordinate system is defined by the programmer and can be changed. The location of the
point of origin for the work part coordinate system, also called work part zero point W, can be specified as
desired (see figure 22).

Y Z
M Y
X
W X

M Machine zero point W Work part zero point


Figure 21 Figure 22
Machine coordinate system Work part coordinate system

CNC milling machine


The design of the CNC machine specifies the definition of the respective coordinate system. Correspond-
ingly, the Z axis is specified as the working spindle (tool carrier) in CNC milling machines (see figure 23),
whereby the positive Z direction runs from the work part upwards to the tool.

26 MTS TeachWare CNC-Grundlagen Students Book


Basic Geometry for CNC Machining

The X axis and the Y axis are usually parallel to


the clamping plane of the work part.

When standing in front of the machine the positive


X direction runs to the right and the Y axis away
from the viewer.

The zero point of the coordinate system is rec-


ommended to be placed on the outer edge of the
work part.

Figure 23
Milling part in three-dimensional Cartesian coordinate
system

For an easier calculation of the points needed for programming it is advisable to use the outer edges of the
upper (see figure 24) or the lower area (see figure 25).

Z
Y

Figure 24 Figure 25
Work part zero point in the upper left outer edge Work part zero point in the lower left outer edge

CNC lathes
In the CNC lathes the working spindle (tool carrier) is specified as Z axis. This means the Z axis is identical
to the rotation axis (see figure 26 and 27). The direction of the Z axis is specified so that the tool withdraws
from the work part when moving to the positive axis direction.

The X axis is located in a right angle to the Z axis. However, the direction of the X axis always depends on if
the tool is located in front of (see figure 26) or behind (see figure 27) the rotation center.

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Basic Geometry for CNC Machining

+X

W +Z +Z
W

+X

Figure 26 Figure 27
Milling work part in Cartesian coordinate system Milling work part in Cartesian coordinate system
with 2-axis tool in front of the rotation center with 2-axis tool behind the rotation center

CNC-Exercise

Working with different coordinate systems

Y
Enter the coordinates of the points in the table.
a

b
X Y

a
X
b
d
c
c
d

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Basic Geometry for CNC Machining

Y
Enter the following points in the diagram.

X Y

a 10 20
X
b -80 -30

c 40 -70

d -30 50

Z
Enter the Cartesian coordinates of the points a to d in the
Y table.

a X Y Z
c
a

X c

d
b d

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Basic Geometry for CNC Machining

Enter the Cartesian coordinates of the points a to h in the table.

X Y

g f a

b
h e
c

a d d

e
b c
f

In a drawing milling work parts are specified by their diameter. Therefore, the diameter is also included for
programming.

Enter the Cartesian coordinates of the points a to g in the table. Determine the corresponding diameter val-
ues of the X coordinates!

X Z

g f a

b
e d
c

c b d

e
a
f

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Basic Geometry for CNC Machining

Feed and Turning Axes on CNC Machines

Location and Designation of the NC axes

CNC milling machines differ in their design with respect to the layout of the working spindles and the location
of the NC axes (see figure 28 and 29). The Z axis is identical with the rotation axis of the working spindle.
The positive Z direction is specified to run from the work part to the tool. Since a three-dimensional Cartesian
coordinate system is used, the other two coordinate axes can be determined by the right-hand-rule.

+Z
+Y
-Z
-Y

-X

-X +X

+X

+Z -Y

+Y
-Z

Figure 28 Figure 29
Axis on the vertical milling machine Axis on the horizontal milling machine

In a CNC lathe the working spindle is defined as the Z axis (see figure 30). The positive Z direction runs from
the work part to the tool. The X axis is vertical to the Z axis. The positive direction of the X axis runs here to
the rear (tool behind the rotation center). One rotation axis - the C axis - is available when the working spin-
dle is approached..

C +X

+Z

Figure 30
Axes on the lathe

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Basic Geometry for CNC Machining

Directions of motion on CNC machine tools


During machining relative motions between the work part and tool have to take place on the available axes.
The axes of CNC machine tools are specified by their design (see chapter Location and marking of the NC
axis). They refer to the work part, whereby a three-dimensional Cartesian coordinate system is used. It is
always assumed that only the tool moves, even though tool carrier of the vertical milling machine shown
below moves along the X and Z axes (see figure 31).

+Y

+Z
+X

Figure 31
Directions of motion on a milling machine

To be able to program regardless of machine, the following definition is introduced.


During programming it is always assumed that the tool moves. The coordinate
system always refers to the work part.
Using this definition the work part coordinates can always be applied to generate the NC program.

NC compatible dimensioning
Two different types of dimensioning are used in NC programming:
absolute dimensioning and
incremental dimensioning (incremental values).
Absolute dimensioning always refers to the work part zero point, i.e. reference dimensions are used
(see figure 32). In contrast, incremental dimensioning uses incremental values which are always measured
from the current point to the next point (see figure 33).
When turning, the X values for absolute dimensioning are diameter values, whereas for incremental dimen-
sioning they refer to radius values.

+X +X

-Z

-Z

Figure 32 Figure 33
Example for absolute dimensioning Example for incremental dimensioning

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Basic Geometry for CNC Machining

Absolute dimensioning is recommended for programming, because of the following advantages compared
with incremental dimensioning:

measuring tolerances do not cumulate,


changes of individual values do not necessarily influence the subsequent dimensions,
one incorrect value does not lead to subsequent errors,
absolute coordinates indicate the current traverse path distance from the tool, so that single program
steps can be traced back more easily.

NC compatible drawings should therefore avoid incremental values and use coordinate values referring to
one reference point.
Despite these advantages it is not always possible to avoid incremental dimensioning in programming. It is,
for example, an advantage when several identical contour parts, such as recesses, are consecutively ma-
chined.

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Basic Geometry for CNC Machining

4. CNC-Demo
Controllable NC axes on the CNC simulator
Similar to a real CNC machine tool, the CNC simulator also permits manual travel along the NC axes. Sub-
sequently, the necessary steps on a CNC simulator are described.

When entering data, only the indicated keys are to be pressed (for example, F5 corresponds to the function
key F5)

CNC milling
Description Entry

1. Call CNC milling in the main menu. F2 (Milling)


2. Select setup mode. F3 (Setup mode) (NUM keyboard ON)
3. Go to X, Y or Z axis and check the travel path. Press the corresponding key on the numerical
keyboard.
Travel directions available:
+Z +Y
6 ( + X - direction )
7 8 9 4
Pos 1 Bild ( - X - direction )
-X +X 9
4 5 6 Bild ( + Y - direction )
1 ( - Y - direction )
Ende
1 2 3 8
-Y Ende Bild ( + Z - direction )
-Z
0 , 2 ( - Z - direction )
Einfg Entf

The travel path can be checked using the displayed


axis coordinates.

4. Quit the setup menu F8 (Quit)

CNC-Exercise: With the CNC simulator each student practices moving along the NC axes.

34 MTS TeachWare CNC-Grundlagen Students Book


Basic Geometry for CNC Machining

CNC turning
Description Entry

1. Call CNC turning in the main menu. F1 (Turning)


2. Select setup mode. F3 (setup mode) (NUM keyboard ON)
3. Go to the X or Z axis and check the travel Press the corresponding key on the numerical
path. keyboard.
Travel directions available:
+X

7 8 6 ( + Z - direction )
Pos 1
4 ( - Z - direction )
-Z 4 5 6 +Z
8 ( + X - direction )

2 3 2 ( - X - direction )
Bild
-X
0 ,
Einfg Entf

The travel path can be checked using the displayed


axis coordinates.

4. Quit the setup menu. F8 (Quit)

CNC-Exercise: With the CNC simulator each student practices moving along the NC axes.

Workshop
Using the CNC machines available the students move along the controllable NC axes. Hereby the corre-
sponding operation instructions of the machine have to be followed.

Exercise: With the CNC simulator each student practices moving along the NC machine tool.

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Basic Geometry for CNC Machining

2.2 NC Mathematics
Basics of coordinate point calculations
When programming a CNC program the corresponding points of the contour to be machined have to be
entered. In most cases it is possible to directly take these point from the drawing, providing the drawing di-
mensions are NC compatible. In some cases it is however necessary to calculate coordinate points.

Characteristic values of a triangle


To calculate the missing coordinates the relations within a triangle are very helpful. There are various possi-
bilities to describe a triangle. Some of the following characteristic values, such as corner points, angles or
sides are used (see figure 34).

Corner points
C A, B and C mark the three corner points of a
triangle.

Angles
, and are the corresponding angles in
the corners of the triangle.
b a Sides
a, b and c mark the sides of the triangle op-
posite to the corners A, B and C.

The component parts of the triangle are al-


ways marked counterclockwise.
A c B
Figure 34
Characteristic values of a triangle

Angles of the triangle


The angles of the triangle specify the type of the triangle. Depending on the sizes of the triangle angles the
triangle is either an acute-angled, obtuse or right-angled triangle (see figure 35 - 37)

C
C C


a
b a b a
b


A c B A c B A c B
Figure 35 Figure 36 Figure 37
Acute-angled triangle Obtuse triangle right-angled triangle
All angles are smaller than 90. One angle is larger than 90. One angle is 90.

For a triangle the relation applies: the sum of the triangle angles , and is always 180.

+ + = 180o
With this formula it is possible to calculate one unknown angle if the other two angles are known.

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Basic Geometry for CNC Machining

Right-angled triangle
The right-angled triangle (see figure 38) has a special significance in analytical geometry, since the sides of
such a triangle stand in a certain mathematical relation to each other. The sides of a right-angled triangle
have specific names:
The longest side is located opposite the right angle and is called hypotenuse.
The two sides of the triangle forming the right angle are each called cathetus
or together the legs of the right-angled triangle.
The side which is located opposite the angle is called counter cathetus.
The side located adjacent to the angle is called adjacent cathetus.

In a right-angled triangle the right angle (see figure 38) is described by a quarter circle and a point within the
angle.

counter cathetus

3 adjacent cathetus

1 hypotenuse

right angle
2

Figure 38
Right-angled triangle

The following applies for a right-angled triangle:

In a right-angled triangle it is possible to calculate the length of an unknown side if the other two side lengths
are known. For this, the Pythagorean theorem (see figure 39) is used.

The Greek Pythagoras (approx. 580 - 496 BC) was


the first to verify the following mathematical relation
which was called after him
the Pythagorean theorem

b The sum of the squares of the legs


of a right triangle is equal to the
a square of the length of the hypote-
nuse.
b a
c or expressed as an equation:

a2 + b2 = c 2
With the corresponding transformation the sides of
the triangle can be calculated as follows:
c
a = c 2 b2
b = c 2 a2
Figure 39
The Pythagorean theorem c = a2 + b2

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Basic Geometry for CNC Machining

Trigonometric functions
The trigonometric functions describe the relation between the angle and the sides of the right angle. With
these trigonometric functions it is possible to calculate unknown side lengths if one angle and the length of
one side is known. The choice of the trigonometric function between sine function (see figure 40), cosine
function (see figure 41) or the tangent function (see figure 42) depends on which side and angle are known.

counter cathetus

hypotenuse
2

1
counter cathetus
sin =
hypotenuse

Figure 40
Sine function

adjacent cathetus

hypotenuse
2

adjacent cathetus
cos =
hypotenuse

Figure 41
Cosine function

counter cathetus

adjacent cathetus
1

counter cathetus
tan =
2
adjacent cathetus

Figure 42
Tangent function

When calculating the unknown side the corresponding equations need to be transformed according to the
following example:
known values: the angle and the length of the adjacent cathetus
unknown value: the length of the counter cathetus

equation: counter cathetus (see figure 42), resulting in:


tan =
adjacent cathetus

counter cathetus = adjacent cathetus tan

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Basic Geometry for CNC Machining

Calculation of NC coordinates
Work part drawings are not always dimensioned NC-compatible. In addition to incremental values, angle
values are also frequently given in drawings. Consequently, when programming manually the programmer
has to calculate unknown Cartesian coordinates using the points to be programmed.

In the following drawing the coordinates of the points b, c and f need to be calculated. The other points are
known.

Y X Y

f a 15 15
e
25 b ? 15
g
c ? 35
c d
d 85 35
25

a b e 85 85

X f ? 85

g 15 65

Calculation of the point b:

known : x from center point = 65 mm


unknown : x from point b = ?

b 25
solution : x = 65 mm - dx
dx = radius of the arc
dx dx = 25 mm
? x = 65 mm - 25 mm

x = 40 mm

Calculation of the point c:

c known : x from center point = 65 mm


radius of the arc r = 25 mm
dy = 35 mm - 15 mm = 20 mm
dy

25
unknown : x from point c = ?

dx solution : x = 65 mm + dx
equation: dx = r 2 dy 2
dx = ( 25mm ) ( 20mm )
2 2

? dx = 225mm 2
dx = 15mm
x = 65 mm + 15 mm
x = 80 mm

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Basic Geometry for CNC Machining

? known : x from the beginning of the incline = 15 mm


angle of the incline = 25
dy = 85 mm - 65 mm = 20 mm
unknown : x from point f = ?
dx
solution : x = 15 mm + dx

f equation: counter cathetus = adjacent cathesis * tan


dy

dx = 20 mm * tan 25
25 dx = 20 mm * 0.4663
dx = 9.326 mm
x = 15 mm + 9.326 mm
x = 24.326 mm

CNC exercise
Enter the Cartesian coordinates from the center points of the drillings a to h in the table. Give all values
rounded to three decimal points.

Y
X Y

c b a

b
d a
c
100

d
60

h e
e
50

f
f g
X g
50
h
100

Calculate the unknown coordinates in the following examples.

90 85
80 70
50
35

30
85
80
?

unknown : Y coordinate unknown: Y coordinate

40 MTS TeachWare CNC-Grundlagen Students Book


Control test Basic Geometry

2.3 Zero and reference points on CNC machine tools


Types of zero and reference points

M machine zero point

W work part zero point

R reference point

E tool reference point

B tool setup point

A tool shank point

N tool change point

Machine zero point M

R Each numerically controlled machine tool works with


E
N
a machine coordinate system. The machine zero
point is the origin of the machine-referenced coordi-
nate system. It is specified by the machine manufac-
M W
turer and its position cannot be changed. In general,
the machine zero point M is located in the center of
the work spindle nose for CNC lathes and above the
left corner edge of the work part carrier for CNC ver-
tical milling machines.
Figure 43
Location of the zero and reference points for turning

Reference point R

A machine tool with an incremental travel path meas-


uring system needs a calibration point which also
serves for controlling the tool and work part
movements. This calibration point is called the refer-
R ence point R. Its location is set exactly by a limit
M A N switch on each travel axis. The coordinates of the
reference point, with reference to the machine zero
W
point, always have the same value. This value has a
set adjustment in the CNC control. After switching the
machine on the reference point has to be ap-
proached from all axes to calibrate the incremental
travel path measuring system.

Figure 44
Location of the zero and reference point for milling

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Basic Geometry for CNC Machining

Work part zero point W


+X
The work part zero point W is the origin of the work
part-based coordinate system. Its location is speci-
fied by the programmer according to practical criteria.
The ideal location of the work part zero point allows
M +Z the dimensions to be directly taken from the drawing.
W In case of turning the work part zero point is gener-
ally in the center of the left or right side of the com-
pleted part, depending on which side the dimension-
ing was started from.

The work part zero point can be shifted in the NC


program, e.g. when a turned part is to be completely
machined between centers on two sides. In this case
it is advisable to alternately shift the work part zero
M W +Z point to the right or left side of the machined part.

+X

Figure 45
Work part zero point of the turned part

For milling, the outer corner point is usually chosen


Z as the work part zero point, depending on which cor-
Y ner point is selected as the reference point when
dimensioning the work part.

Figure 46
Work part zero point of a milled part.

Tool reference point E

A further important point in the machine work space is the tool reference point E. The tool reference point E
of a CNC lathe is a fixed point on its tool carrier. On a CNC milling machine the tool reference point E is lo-
cated on the tool spindle.

The CNC control refers first to the tool reference point for all target point coordinates. When programming
the target coordinates either the tool tip of the turning tool or the center of the milling tool is referred to. To be
able to control exactly the tool tip in turning or the tools in milling along the desired machining travel path
they have to be measured precisely. It is possible to measure the tools either outside the machine with a
preset device or directly on the machine using special optics. When using an optic, the measured values are

42 MTS TeachWare CNC-Grundlagen Students Book


Control test Basic Geometry

directly entered into the machine storage. If however the preset device is used the measured values need to
be entered manually for each tool into the corresponding compensation value storage of the control.
Two additional points are needed to preset the tool outside the CNC machine. These are the tool setup point
B and the tool shank point A.

Location of the tool setup point B


on a turning tool

B B tool setup point


L length = distance of the cutter tip to the tool setup
point in X
Q overhang = distance of the cutter tip to the tool
Q

setup point in Z
R cutter radius
R
L

Figure 47
Tool setup point of a turning tool

Location of the tool setup point at B


of a milling tool

B tool setup point


L length = distance of the cutter tip to the tool setup
B point in Z
R radius of the milling tool
L

Figure 48
Tool setup point of a milling tool

Location of the toolholding point A


on a turret

A toolholding point

Figure 49
Toolholding point of a turret

If the tool system (tool post with tool) is placed into the tool carrier (i.e. a turret), then the tool setup point B
and the toolholding point A fall together and make up the tool reference point E.

Tool change point N


The tool change point N is the point in the CNC machine work space on which the tools can be changed
without collision. In most CNC controls the tool change point can be configured.

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Basic Geometry for CNC Machining

Setting the work part zero point W on a CNC lathe


Setting the work part zero point W coordinates the work part zero point with the drawing zero point. The
drawing dimensions can then be used directly for programming.

Setting the work part zero point is done with refer-


ence to the machine zero point M of the CNC ma-
chine.

The machine zero point of a lathe is generally located


on the rotation axis of the main spindle on the plane
M W surface of the spindle flange on which the jaw chuck
is flanged (see figure 50).

Using the operation functions described below the


distance between the machine zero point M and the
work part zero point W is specified. This value zw,
also called the zero point shift, is then entered into
the CNC control.
zw

Figure 50
Setting the work part zero point on a CNC lathe

Procedure
Starting situation: All machining tools have been measured and are available on the turret head.
The clamping device is prepared and the work part has been correctly clamped.

1. Switch on the spindle (counterclockwise rotation).


1. Change the tool to set the work part zero point, i.e. rotate the turret head to the corresponding position,
for instance T02.
Note: The rotation area of the turret has to be checked first to avoid collision during rotation.
3. Touch the front plane area of the work part:
carefully move with the tool using the hand wheel
or using the corresponding arrow keys of the keyboard of the CNC control
until the cutting edge reaches a marking on the work part.
3. Enter the desired plane area allowance (e.g. 0.5 mm) on the CNC control.
Actuate with the zero key.
(The dimensions are used to face the front surface in z=0)

3. The CNC control then stores the value of the zero point shift zw.
The work part zero point W is clearly specified since the X coordinate zero is located on the rotation axis.
3. Because of eventual allowance the front side needs to be faced. This needs to be considered when pro-
gramming the NC program.

44 MTS TeachWare CNC-Grundlagen Students Book


Control test Basic Geometry

Setting the work part zero point W on a CNC milling machine


Similar to a lathe the work part zero point corresponds with the drawing zero point when the work part zero
point W is set on a CNC milling machine. This allows the drawing data to be directly used for programming.

The work part zero point is set with reference to the


machine zero point M. In most cases the machine
zero point of a CNC vertical milling machine is lo-
cated above the left corner edge of the machine table
(see figure 51).

With the operations described below the distance is


R specified between the machine zero point M and the
M A N
work part zero point W in the three coordinates X, Y
and Z. These values are then entered into the CNC
control.
W
Procedure

Starting situation:
The work part is adjusted and firmly clamped in the
machine table. All tools are gauged to each other.
The corresponding compensation values were en-
tered into the CNC control. The zero setting tool is
clamped and the spindle rotation is switched on.

1. Resetting Z direction
Figure 51
Setting the work part zero point on a CNC milling
machine
Y
Z The machine table with the clamped work part is
moved below the work spindle (in X and Y) in which
the reset tool is clamped.
Now the tool is recessed in Z direction to the work
W
part surface (X, Y plane), with the spindle switched
on (see figure 52), until a small marking is made on
the work part (touching the work part) surface.
After this the Z axis is reset and the Z value of the
X work part zero point W is transferred and stored into
the CNC control using the IST key.

2. Resetting in X direction
Figure 52
Resetting in Z
The tool is raised again and taken into the new reset-
Y ting position for the X axis. With the spindle switched
Z
on it is moved along the side surface of the work part
(Y, Z plane) in the X direction (see figure 53) until a
small marking is made on the work part surface
W (touching the work part).
When touching the work part in X axis the radius of
the applied tool has to be considered when confirm-
ing the value with the IST key, since the center point
coordinates of the tool are always used in NC pro-
X
gramming.
If the milling tool of the adjacent figure has, for in-
stance, a radius of 15 mm, then the value X=-15 is
entered into the NC control and confirmed with IST.
Figure 53 .
Resetting in X

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Basic Geometry for CNC Machining

3. Resetting in Y direction
Y
Z
The last step is to take the tool to resetting position
for the Y axis. With the spindle switched on, the tool
is taken into Y direction (see figure 54), to the side
W
surface of the work part (X, E Plane) until a small
marking is done on the work part surface (touching
the work part).
When touching the work part in X axis the radius of
X the applied tool has to be considered when confirm-
ing the value with the IST key, since the center point
coordinates of the tool are always used in NC pro-
gramming.
If the tool of the adjacent figure has, for instance, a
Figure 54 radius of 15 mm then the value Y=-15 is entered into
Resetting in Y the CNC control and confirmed with IST.

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CNC exercise
Setting the work part zero point W in the CNC simulator Turning
By setting the work part zero point W the relation between the machine based and work part based coordi-
nate system is created. The work part zero point corresponds to the drawing zero point. Consequently, the
drawing dimensions can be used in programming. Using the operation steps described below the distance
between the machine zero point M and the work part zero point W can be specified. This Z value is also
called the zero shift zw.
Starting situation:

All machining tools are dimensioned and available


on the turret head.
M W The work part is clamped in chuck jaws.
The work part zero point is located on the front
plane surface, whereby an allowance of 1mm has
to be considered.

zw

Description Entry

1. Call CNC turning in the main menu. F1 (Turning)


2. Select setup mode. F3 (Setup mode)
3. Switch on the spindle in counterclockwise Type M04 using the keyboard and
rotation.
confirm.
4. Change the tool for the definition of the work Type T0404 using the keyboard and confirm.
part zero point.

5. Move the lathe tool in rapid speed so that it is Using the numeric keyboard press the corre-
located in front of the front plane surface with sponding arrow key simultaneously with the
a distance of approx. 5mm to the front plane shift key:
surface.
+ 4 for rapid speed in -Z direction
+X
+ 2 for rapid speed in -X direction

+Z

Travel direction options:


+X

7 8 6
Pos 1 ( + Z - direction )
-Z 4 5 6 +Z 4 ( - Z - direction )
8 ( + X - direction )
2 3
Bild 2 ( - X - direction )
-X
0 ,
Einfg Entf

MTS TeachWare CNC-Grundlagen Students Book 47


Basic Geometry for CNC Machining

6. Switch the increment from 1mm to 0,1mm or F3 (Technology)


0,01 mm for further machining. .
F5 (Increment)

F2 (Increment 0.1)

7 Move the lathe tool in negative Z-direction Press the arrow key on the numeric keyboard.
until it touches the plane surface of the work
4
part . Then press
ESC
and
F8 (Quit).
8. Set the work part zero point in Z. F4 (Tool datum)

F4 (Set datum)

F1 (Set Z coord.)
Type z+1using the keyboard and confirm
F8 with (allowance of 1mm).
The Z value can be checked for the current zero
point using the displayed coordinates.

9. Take the tool off in +Z direction and in Using the numeric keyboard press the arrow
+X direction . key together with the shift key:

+ 6 for rapid speed in +Z direction

+ 8 for rapid speed in +X direction


10. Quit the setup mode F8 (Quit)

F8 (Quit)

F8 (Quit)

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Setting the work part zero point W in the CNC simulator milling
In milling, setting the work part zero point W coordinates the work part zero point with the drawing zero point.

Please note that only the tool moves in the MTS simulator!

Using the operation steps described below the distance between the machine zero point M and the work
part zero point W in the three coordinates X, Y and Z is defined.

Starting situation:
Z Y
All machining tools are dimensioned and avail-
able in the magazine.
The work part is adjusted and clamped on the
machine table in the simulator.
W The location of the work part zero point should
X be the left top corner of the work part.

Description Entry

1. Call CNC milling in the main menu. F2 (Milling)


2. Select the setup mode. F3 (Setup mode)
3. Switch on the spindle in clockwise rotation. Type M03 using the keyboard and
confirm.
4. Change the tool to define the work part zero Type T0202 using the keyboard and
point.
confirm.
5. Setting the zero point in Z direction Using the numeric keyboard press the corre-
Move the tool in rapid speed to a position sponding arrow key together with the shift
approx. 5mm above the work part surface. key:
Y Ex.: + 2 for rapid speed in -Z direction.
Z

W
X

Further travel direction options:


+Z +Y
6
( + X direction )
7 8 9 4
Pos 1 Bild ( - X direction )
-X +X 9
4 5 6 Bild ( + Y direction )
1
Ende ( - Y direction )
1 2 3 8
-Y Ende Bild ( + Z direction )
-Z
2
0 , ( - Z direction )
Einfg Entf

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Basic Geometry for CNC Machining

6. Switch the increment from 1mm to 0,1mm or F3 (Technology)


0,01mm for further machining.
F5 (Increment)

F2 (Increment 0.1)

7 Move the tool in negative Z direction until it Press the arrow key on the numeric keyboard
touches the surface of the work part.
2
Then press
ESC
and
F8 (Quit).
8. Set the work part zero point in Z. F4 (Tool/ Datum)

F4 (Set Datum)

F3 (set Z coord.)
Type in the data on the keyboard 0 and
F8 confirm it.
Check Z by setting the zero point and using the dis-
played coordinate values.

9. Setting the zero point in X direction Using the numeric keyboard press the arrow
Withdraw the tool in +Z direction.
key together with the shift key:

+ 8 for rapid speed in +Z direction


10. Move the tool in rapid speed to the new zero Press the corresponding arrow key on the
setting position approx. 5mm off the side sur- numeric keyboard
face.
together with the shift key:
1 1) in -X direction

Y + 4 for rapid speed in -X direction


Z 2 2) in -Z direction

+ 2 for rapid speed in -Z direction


W
X

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11. Move the tool in positive X direction until it Press the arrow key on the numeric keyboard.
touches the left side of the work part. 6
Then press
ESC
and
F8 (return).

12. Set the work part zero point in X. F4 (tool, zero point)
Please note the tool radius!
F4 (set datum)
So, enter for the X coordinate the negative
value of the radius of the applied tool, for in- F1 (set X coordinate)
stance -10.
Type -10 using the keyboard and confirm.
F8
Check the X by setting the zero point using the dis-
played coordinate values.

13. Setting the zero point in Y direction Using the numeric keyboard press the arrow
Take off the tool in -X direction and then in +Z key together with the shift key:
direction.
+ 4 for rapid speed in -X direction then

+ 8 for rapid speed in +Z direction.


14. Take the tool in rapid speed to the new reset- Using the numeric keyboard press the corre-
ting position approx. 5mm off the front side. sponding arrow key together with the shift
key:
1 Y 1) in +X direction
Z + 6 for rapid speed in +X direction
2 2) in -Y direction
3 1 for rapid speed in -Y direction
W + Ende

X 3) in -Z direction

+ 2 for rapid speed in -Z

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15. Take the tool in positive Y direction until it Press the arrow key on the numeric keyboard.
touches the front of the work part.
9
Bild Then press
ESC
and
F8 (Quit).
16. Set the work part zero point in Y. F4 (Tool/Datum)
Please, note the tool radius!
F4 (set Datum)
So, enter for the Y coordinate the negative
value of the radius, for instance -10. F2 (set Y coord.)
Type -10 using the keyboard and confirm
F8 key.
Check the Y by setting the zero point using the dis-
played coordinate values.

17. Withdraw the tool in -Y and then in +Z direc- use the numeric keyboard and press the ar-
tion. row key together with the shift key:
1 for rapid speed in -Y direction, then
+ En de

+ 8 for rapid speed in +Z


18. F8 (Quit)
19. Quit the setup mode menu. F8 (Quit)

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2.4 Numeric Controls on CNC Machine Tools


Control chain and control loop
The current controls of the numeric-controlled machine tools are CNC controls. For the control it is
characteristic to have an open movement path (see figure 55). The control gives the set value to the
machine tool without controlling it directly. This is called a control chain.

1 2 input value (set value)

output value (actual value)


4
disturbance value

control path
3

Figure 55
Function principle of a control chain

Since such a control chain generates an incorrect output value it is connected with the control. The control is
a sequence of operations which constantly recalculates and adjusts the actual value to reach the required
value.This closed sequence of operations is called a control loop (see figure 56)..

1 2 entry value (set value)

4 output value (actual value)

disturbance value
6

3 control path

measuring equipment
5
output value (actual value)

Figure 56
Function principle of a control loop

In a CNC machine tool the principle of a control loop is applied as a position control for the axis.

CNC Control

Structure and function

The CNC control is designed to decode a NC program and to process it as geometrical and technological
information. Using CNC control it is possible to control or check the corresponding components of the CNC
machine tool so that the desired work part is formed. The functions of the CNC control can be classified as
data entry, data processing or data output (see figure 57).

Data entry and data processing


The data entry is done using the control panel consisting of a keyboard and monitor. Here the NC programs
can be generated and managed, data can be entered or program simulations can be called . The NC pro-
grams can also be read in or stored using external data carriers, such as data cassettes. It is also possible

MTS TeachWare CNC-Grundlagen Students Book 53


Basic Geometry for CNC Machining

to have an external data transmission to a computer (DNC operation) via serial interfaces or network input
ports. It is then possible to generate (MTS system) and manage NC programs on this computer.

CNC control
1 technological
Y
processing
geometrical
2 4 X processing

adjustment con-
trol
5
3
X,Y,Z axis control
6 Z

actual position
value
data entry data processing data output

Figure 57
Structure of a CNC control

The data needed by the CNC machine tool to operate and machine the work part is generated out of the NC
data by the data processing of the CNC control.

The technological data is used e.g. for tool selection, for adjusting the spindle rotation speed, for selecting
the spindle direction of rotation or for switching the coolant on and off. They are transmitted through the ad-
justment control to the corresponding component of the CNC machine tool.

The geometrical information of a NC program is translated from the CNC control into set values for the dif-
ferent axial drives under consideration of the infeed values. The travel movements which are so created are
continuously controlled by the position control loop of the feed axis.

Travel movement using interpolation

In technical applications by far all contour lines can be classified in straight lines and circular elements. This
is the reason why the majority of the CNC controls manufactured today are equipped only with straight line
and circular interpolation. In our CNC controls interpolations of parabolas and cubic parabolas, helical inter-
polations and spline interpolations are also available.

If a tool goes from the starting point to a target point which is not parallel to the axis it is a question of a
straight line interpolation. To achieve a straight tool path the relevant axes have to be correspondingly ad-
justed to each other. The relation of the axis feeds defines then the direction of the straight lines
(see figure 58 and 59).

Y Y
1
1 2
1
2 1
X X
aimed travel movement aimed travel movement
Figure 58 Figure 59
Relation of axial feeds Relation of axial feeds

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The best way to demonstrate the principle of tool feed along curves, lines and arcs on a plane is to use a
plotter with a step motor. A step motor is controlled by current pulses. A positive or negative current pulse
rotates the wave of the step motor with a jerk in a certain angle to the right or to the left. As a result, each of
the two plotter axes can reach only a certain axial value. Therefore the plotter can only go to the points of a
tight grid on its drawing area. Just like on a monitor screen an incline is drawn through the axis-parallel
movement of the plotter (see figure 60).

1 aimed plotter movement

movement in the X axis

movement in the Y axis


2 3
Figure 60
Travel path of a plotter pen

The same principle is used for the interpolator of a CNC control. It calculates the intermediate values needed
for interpolation and transmits them as set values to the position control circles.

In straight line interpolation two or three axes move simultaneously (see figure 61), whereby their travel
movements are adjusted to each other in a certain relation.

If the tool moves in a circular path from the starting point it is a question of a circular interpolation
(see figure 62). The tool moves here either in clockwise or in counterclockwise direction. To achieve a circu-
lar tool path the travel movements of both axes, also depending on the path already traveled, have to be
adjusted to each other. The axis movement corresponds to a sine or cosine curve. The overlay of the two
axis makes out the arc.

X
X

Z
X
X

Travel path of a plotter pen Travel path of a plotter pen

Figure 61 Figure 62
Straight line interpolation Circular interpolation

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Basic Geometry for CNC Machining

Types of CNC controls


The axis of the CNC machine tool receive their travel signals (commands) from the CNC control. These sig-
nals are coded and are based on the entered NC program. They are evaluated by the control and transmit-
ted to the feed motor. The travel paths of the tools are exactly set. Depending on the type of the travel paths
the following control type classification is used:
point control
line control
path control: - 2D path control
- 2 D path control
- 3D path control
Point control

It is the simplest control type. In case of a point con-


trol a target point is approached in rapid speed and a
machining operation is carried out at the target point
(see figure 63). In the same way several target points
can be approached one after an other.

The point control can be applied to work parts for


which machining is made only at certain points, e.g.
for machining surfaces by boring, reaming, recess-
ing, threading, spot welding, punching.

Figure 63
Point control
Line control

With the line control only tool travel paths which are
parallel to axes and which have programmed infeed
values can be controlled (see figure 64).

The generated work part contours can only be paral-


lel to axis.

The line control can be applied in cases where ma-


chining is supposed to take place only on planes
parallel to the guideways of the machine, e.g. for
simple plane and straight turning, plane parallel mill-
ing or breakthrough milling where machining takes
Figure 64 place in one direction at a time.
Line control

Path control

In path control it is possible to control any travel


paths (straight, inclines, circular, splines) of the tool
applied on planes or in space.

It is possible to achieve any contour line


(see figure 65) through the controlled interaction of
two or more infeed motors.

To be able to carry out the movements simultane-


ously on all machine axes all intermediate values
located on the mathematically specified curve be-
tween the starting and end point need to be first cal-
Figure 65 culated by the CNC control.
Path control on a CNC machine

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Basic Geometry for CNC Machining

Path controls are further classified depending on the number of axes which can be simultaneously con-
trolled:
2 D path control

With the older 2 D path control it is possible to simul-


taneously control two axes. So it is possible to carry
out straight and circular tool movements on one
plane (see figure 65).

If, for example, a 3 axes CNC milling machine has a


2 D path control it means that it is possible to mill
contours in two axes. The third axes has to be en-
Figure 66 tered separately.
2D path control
2 D path control

The 2 D path control makes it possible to carry out tool movements on several planes by switching the
interpolation in each case on one of the three main planes. All three axes are controllable in 2 D path con-
trol, however in every plane only two axes simultaneously. The third axes is the so-called infeed axis.
Depending on the selected machining plane different
axis can be controlled simultaneously so that it is
possible to travel in the following directions:

- X/Y plane (see figure 67),


- X/Z plane (see figure 68),
- Y/Z plane (see figure 69).

Figure 67
2D path control (X/Y plane)

Figure 68 Figure 69
2D path control (X/Z plane) 2D path control (Y/Z plane
3 D path control

In 3 D path controls three axes are interpolated si-


multaneously. Herewith it is possible to realize three-
dimensional tool movements.

It enables complicated contours, e.g. in tool construc-


tion, especially in molded construction, to be ma-
chined in one clamping.

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Basic Geometry for CNC Machining

DNC operation

Characteristics of DNC operation

DNC is the abbreviation of direct numerical control. It is the name of an operation mode in which several NC
and CNC machines as well as further devices are connected with each other. These devices can be for in-
stance tool presetting machines, measuring machines, programming seats and a central material and tool
management (see figure 70).

NC-Program-
CAD ming PPS ...

Local area
Network (LAN)

Tool presetting machines

Master
computer
Measuring machines

...
NC
archive
Figure 70
Structure of a DNC system

The connection between the components of a DNC system is realized by a data bus. This direct data trans-
mission makes the conventional data carriers such as punch cards, magnetic stripes, discs as well as the
corresponding recording and read-in instruments unnecessary.

The significant characteristic of the DNC operation is the management and timely disposition of the informa-
tion. To be able to calculate and distribute this information to the right position, interfaces are needed.
Through the interfaces all the integrated parts of the DNC net are connected with the master computer. The
master computer is able to calculate machine and production data, switch operation modes, address, read-in
and record the correct storage location as well as automatically transmit them to the machine upstream com-
puters.

Data input and data processing in DNC operation

Through the structure of a DNC system (see figure 70) it is possible to enter data into different devices.
These devices can be located far away from each other.

Small NC programs can be written directly on the CNC machine tool. For writing extensive or complicated
NC programs it is better to use an external programming work station.

A DNC system generally includes the following basic functions.

storage and management of NC programs


correct distribution of NC programs to the machines
re-transmission of the corrected and optimized NC programs from the machine to the master data
storage medium

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For this purpose there is a central management of the NC programs in the DNC system. The generated and
optimized NC programs are transmitted to the corresponding computers through data links. In case the CNC
machine tool is not equipped with a special DNC port a DNC terminal controls the organization of the data
transmission between the CNC control and master computer.

Depending on the model of a DNC system the following additional functions can be available:
central tool management and tool compensation data
interface for tool presetting devices
work part management
set time value and definition of working sequences
control of the material flow
central storage of the current data bases
central cooperation data and machine data acquisition (BDE, MDE) with graphical evaluation
NC programming with postprocessor conversion
graphical simulation with representation of the tool, clamping device and work part contour

Advantages of the DNC operation system


A DNC operation system has the following advantages compared with a solution with non-integrated CNC
machine tools:
improved workshop organization
immediate availability of programs and additional information
minimal standstill times of the CNC machine through the continuous provision of NC programs,
tools and material
reduced data entry errors
operating data and machine data acquisition (BDE, MDE) enable the user to control and record at
any time the production data (machine operating times, out-of-service-times, down times, etc.),
maintenance information and information on reasons for out-of-service-times

Workshop
The different CNC control types are demonstrated on the CNC machine tools available.

If no CNC machine tools are available for point or line control these CNC control types can be simulated with
the help of the corresponding work parts.

Example:
point control
milling machine: go to boreholes
line control
milling machine: travel parallel to axis
lathe: travel parallel to axis
2D path control
milling machine: travel linear on two axis
milling machine: travel in a circle
lathe: machine a cone or rounding
2 D path control
milling machine: travel on various planes
milling machine: travel in a circle on various planes
3 D path control
milling machine: travel linear on two axis

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Basic Geometry for CNC Machining

milling machine: travel on a circle in space

2.5 Tool Compensations for CNC Machining


Using tool compensation values

Using the tool compensation values it is easy to program a work part without consideration of the actually
applicable tool lengths or tool radii. The available work part drawing data can be directly used for program-
ming. The tool data, lengths as well as radii of the milling machines or indexable inserts are automatically
considered by the CNC control.

Tool length compensation for milling and turning

A tool length compensationregarding the reference point enables the adjustment between the set and actual
tool length, as in case of tool finishing. This tool length value has to be available for the control. For this it is
necessary to measure the length L, i.e. the distance between the tool setup point B and the cutting tip, and
to enter it into the control (see chapter on tool measuring page 69 ff.).

In case of milling tools the length is defined in Z direction (see figure 71).

B tool setup point


L length = distance of the cutting tip to the tool
setup point in Z
R radius of the milling tool
B
L

Figure 71
Tool compensation values on a cutting tool

In case of lathe tools the length L is defined in Z direction (see figure 72).

B tool setup point


L length = distance of the cutting tip to the tool
set-in point in Z
B
Q overhang = distance of the cutting tip to the
tool setup point in X
R cutting radius
Q

R
L

Figure 72
Tool compensation values on a lathe tool

In the CNC control these tool compensation values are stored in the compensation value storage, whereby
in most CNC controls it is possible to describe up to 99 tools. These values have to be activated during ma-

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chining. This is done by calling the data within the NC program, e.g. with the address H or by specific places
in the T word.
Tool radius compensations

The CNC controls have an integrated cutter radius compensation for milling machines and tool tip compen-
sation for lathes. Using these aids it is possible to directly program the finished contour of the work part.

Cutter radius compensation (milling)

To enable the tool to generate the programmed contour with high precision the tool center point has to travel
on a path running parallel to the programmed path. This tool center point path is called equidisant
(see figure 73).

1 Milling center point paths (equidisant)

work part contour

Figure 73
Milling center point paths (equidisants)

One equidisant is the tool center point path running in constant distance to the programmed path (contour) of
the work part. In discontinuous path transitions, i.e. in the inner and outer corners (see figure 74 and 75),
the transitions become equidisants, for instance, through insertion of arcs, in accordance with the control-
specific rules.

1 2 1

programmed path programmed path

tool travel path tool travel path


Figure 74 Figure 75
Inner corner in milling Outer corner in milling
In case of inner corners an arc corresponding to the In case of outer corner the tool makes a compen-
radius of the milling machine is created. sating arc.

The CNC control calculates the contour-parallel milling center point path necessary for machining. The cal-
culations are based on the radius value of the current milling tool, which is stored in the tool compensation

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Basic Geometry for CNC Machining

value storage. The radius is not given in the NC program as such, the corresponding compensation switch is
instead called.

Due to the fact that machining can be done in two ways the NC control has to be informed if machining is to
take place on the left or right of the programmed contour (see figure 76).

1 2
left of the contour

right of the contour

3 programmed contours

Figure 76
Machining directions in milling radius correction

The following figures demonstrate the selection of the milling radius compensation which depends on the
position of the tool with reference to the contour to be machined
outside machining (see figure 77) and in
inside machining (see figure 78).

2 1

1 2

3 3

left of the contour left of the contour


right of the contour right of the contour
programmed contour programmed contour

Figure 77 Figure 78
Milling radius compensation in outside machining Milling radius compensation in inside machining

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If subsequent travel movements without milling radius compensation are to be done, for instance in borings,
these have to be entered to the CNC control with the corresponding command.
Tool nose compensation (turning)
In milling, milling radius compensation is used and in turning, tool nose correction, due to the fact that the
control calculates the travel paths based on a theoretical tool nose of the lathe tool. This theoretical tool nose
moves along the programmed path.

Since the actual tool dimensions, i.e. tool nose radius of the lathe tool, are not considered errors are un-
avoidable. Consequently, as a rule, roundings remain in inside corners or the contours (see figure 79). In
tool movements which are not parallel to X or Z axis considerable dimension and form deviations are the
result (see figure 80). These errors can be avoided by using tool nose correction, also called tool nose
compensation, in the CNC control.

3
3

4 3
5
5
3
2 1
2 1

Figure 79 Figure 80
Unavoidable error in turning: Error in turning: cone is not true-to-size
contour inside corner remains according to the programmed contour
programmed contour programmed contour
theoretical cutting point theoretical cutting point
theoretical tool tip theoretical tool tip
actual tool tip actual tool tip
contour corner remains unmachined incorrect deviation from the programmed
because of the cutter radius contour

The location of the actually traveled tool paths (equidisant see figure 81) is automatically calculated by the
cutter radius compensation in modern CNC controls.The following three facts have to be considered:
1. The radius of the tool tip has to be available in the compensation value storage of the CNC control.
1. The location of the tool tip (cutter compensation value vector) has to be available for the CNC control.
1. The machining direction of the tool with reference to the contour has to be correspondingly
programmed in NC programming.

programmed contour path


the center point path (equidisant) calcu-
2
lated by the CNC control on which the
tool travels during machining
1

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Basic Geometry for CNC Machining

Figure 81
Equidisant in turning

To enable the control to correctly calculate the actual cutting point the so-called cutting tip is described for
each tool by the cutter compensation vector (SRK vector). Hereby the SRK vector gives the position of the
cutter tip in I and K (X and Y direction) with reference to the cutter center point (see figure 82). The SRK
vector is defined in advance for each tool in the tool management of the MTS CNC simulator.

4
theoretical cutting edge
R theoretical cutting tip
3 theoretical cutting tip
I
1 cutting radius compensation value vector
R cutting radius
2

Figure 82
Cutting radius compensation value vector

Different cutting radius compensation value vectors have to be entered into the control depending on the fact
in which machining quadrant the applied tools are located (see figure 83). When entering the compensation
values I and K the signs of the resulting value have to be considered.

8 For the cutting radius R the value of the current


tool has to be entered.
4 3

1. quadrant: K=R I=R

2. quadrant: K = -R I=R

3. quadrant: K = -R I = -R
5 7
4. quadrant: K=R I = -R

5. quadrant: K=R I=0

6. quadrant: K=0 I=R

7. quadrant: K = -R I=0
1 2
6 8. quadrant: K=0 I = -R

Figure 83
Values for the cutting radius compensation value vector
which depend on the current machining quadrant of the
tool.

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The following example demonstrates how to define the compensation values I and K (see figure 84).

cutting edge in machining quadrant 3


cutting edge radius R = 0,8 mm

The values I and K are as follows:


K = -0,8
R
I = -0,8
I

Figure 84
Example: Cutting edge radius compensation value

When calling the cutting edge radius compensation in the program the location of the turning tool in travel
direction has to be entered into the CNC control by using the corresponding command:
turning tool is located left of the contour in travel direction or
turning tool is located right of the contour in travel direction
The following figures demonstrate the programming of the cutting radius compensation in dependence upon
the location of the tool with reference to the contour to be machined in case of
outside machining (see figure 85 and figure 86) and in case of
inside machining (see figure 87 and figure 88).

1 1

2 2

Figure 85 Figure 86
Cutting radius compensation in case of outside ma- Cutting radius compensation in case of outside ma-
chining chining
left of the contour right of the contour

machining direction of the tool machining direction of the tool


left of the contour right of the contour

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Basic Geometry for CNC Machining

programmed contour programmed contour

2 2

1 1

Figure 87 Figure 88
Cutting radius correction, inside machining, Cutting radius correction, inside machining,
left of the contour. right of the contour

machining direction of the tool machining direction of the tool


left of the contour right of the contour
programmed contour programmed contour

Just like programming a milling work part it is possible to directly program the contour to be machined using
the work part drawings data without data conversion. In turning as well, the selected cutting edge radius
compensation has to be switched off with the corresponding command.

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Control test Basic Geometry

Tool measuring and adjusting with an adjusting device

To guarantee efficient CNC machine capacity utilization the tool measurement (tool set-up) generally takes
place outside the CNC machine. For this a universal tool measuring and setup device is used. The term
universal refers here to the fact that turning and milling tools are measured with different tool holders to
define the corresponding setup values. Modern tool measuring and adjusting devices convey the calculated
data directly to the CNC control or to an other data carrier or a printer via DNC for an output.

Structure and function of a tool setup device

A tool setup device is used to define the compensation values of turning or milling tools. It is not possible to
correctly program a work part contour without the tool compensation values (see chapter on the milling ra-
dius compensation p.63 ff. or the tool nose compensation p. 65 ff).

Figure 89
Universal tool measuring and setup device

A tool setup device consists in general of four main components:


the base plate,
the compound slide rest,
the tool holder
the tool shank

In addition to this, an electronic measuring device for measuring the tool compensation values and a storage
medium for storing data, e.g. the milling radius R and length L, are available.

Tool measuring and setup


The following describes how to measure a turning tool using a tool setup device.

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The target is to precisely define the length L and the overhang Q (see figure 90) of the turning tool to be
able to give the CNC control the corresponding compensation values in X and Z.

B tool set-up point


B L length = distance of the cutting edge tip
to the tool set-up point in Z
Q overhang = distance of the cutting edge tip to the
tool setup point in X
Q

R
L

Figure 90
Measuring a turning tool
Clamp the turning tool to be measured in the tool shank corresponding to the current turret.
Switch on and adjust the tool measuring and setup device.
Measure the lathe tool.
Using the control desk of the tool setup device the compound slide rest is moved with the lathe tool to
be measured in X and Z (see figure 91).

Figure 91
Display crosslines of a tool setup device
with exact positioning of the tip of the turning tool

The aim of the infeed is to adjust the tool cutting edge exactly on the display crosslines of the measur-
ing device.
Now the length L and the overhang Q of the lathe tool on the tool setup device display can be read-in.
These values correspond to the compensation values of the clamped lathe tool in X and Z.
Store the measured compensation values
The compensation values are now either manually listed for a later entry into the CNC machine, or
they are directly carried into the CNC machine through a data link between the tool set-up device and
the CNC control in DNC mode.
Declamp the turning tool
The turning tool can now be declamped from the tool set-up device to allow a further tool to be meas-
ured.

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Tool measuring and setup using the CNC machine

Direct tool measuring on the CNC lathe


Measuring the tools directly on the CNC machine tool is only customary for CNC lathes.

For direct tool measuring the work part is clamped together with the tool in any position (for instance machin-
ing a cylinder). The work part is then measured with reference to the machine zero point M. The measured
values are entered in the tool compensation register of the CNC control.

After that, the second tool is clamped, the tool slide is taken into the same position as it was for the first tool
and the machined work part contour is worked out again. The control then calculates the compensation val-
ues for the second tool based on the new actual position of the tool slide.

Direct tool measuring is time-consuming, requires however no additional investments.

Defining the deviation between target and actual value with various aids

Tool measuring using so-called zero tools on the CNC milling machine

A commonly applied method for tool measuring on CNC milling machine uses a zero tool to define the differ-
ent lengths of the milling tools. The radius compensations of all tools have been defined and entered into the
CNC control in advance.

Procedure:

With the first tool, also called zero tool, an area on the clamped work part is machined. For this tool the
measured Z value is set zero.

The next tool is clamped and then moved as far as to touch the work part surface. The current Z position can
now be entered into the compensation register including its sign. Herewith the compensation values of the
tool length become the deviation values of the zero tool length.

This procedure will be repeated for all further tools.

Tool measuring on the display of a CNC lathe

In the machining room of some CNC machines there is an optical system installed on a fixed point, whose
position is known to the machine. The coordinates have been stored in the CNC control as parameters.

The tools to be measured are clamped in any position and are taken one after the other to the center of the
crosslines of the optical system using an electronic hand wheel (see figure 92). The control then calculates
without further data entry the value overhang Q as well as the length L and stores these values in the tool
compensation value register.

Figure 92

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Inside optical measuring

Advantages and disadvantages of direct tool measuring on CNC machine

Advantages Disadvantages

increased flexibility machine stand-still during measuring


improved design of machine work places high precision cannot be achieved
reduced investment since
- tool setup devices
- complicated tool holder systems
are not needed

CNC exercise

Working with tool compensation values in the MTS simulation

The MTS software, just like a real CNC machine tool, allows the user to allocate one or several compensa-
tion switches to each tool. With these switches the tool compensation values of the tool are called.

Exercise:
The following work part is to be machined, including rough turning and final turning, using a left corner turn-
ing tool and the set compensation switches. The corner turning tool
T05 LEFT CORNER TOOL CL-SDJCL-2020/L/1204 ISO30
is applied with the setting value for overhang Q and the length L to be entered in the compensation value
register D25.

It is assumed:
Setting-up the MTS simulator according to the following set-up data:

PART
CYLINDER D060.000 L082.000
MATERIAL C 45 W-Nr: 1.0503
DENSITY 007.90
MAIN SPINDLE WITH WORKPART
CHUCK KITAGAWA B-208
STEP JAW KITAGAWA-1
CHUCKING DEPTH E32.000
RIGHT SIDE OF THE PART: Z+209.500
TOOLS
T05 LEFT CORNER TOOL CL-SDJCL-2020/R/1204 ISO30

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Procedure:

Description Entry

1. Call CNC turning in the main menu. F1 (Turning)


2. Select setup mode. F3 (Setup mode)
3. Select menu for the compensation value reg- F4 (Tool data)
ister.
F2 (Turret display)

4. Setting the additional compensation register Enter on the keyboard 25 using


No. 25. F1 (change values) confirm.
Cutting point: Z: +43.0
X: +60.5
Cutting radius: R: 0.4
Size: G: 0.0
Recessing angle: E: 32.178
Compensation: K: -0.4
I: -0.4
The quadrant Q3 is automatically set by MTS when
the arrow key or the tabulator key has been
actuated subsequent to the entry of the values! Only
then it is possible to accept/confirm the data.

5. Enter the data for the compensation register Use the keyboard to enter the data by press-
No. 25. ing

or

by selecting the data one by one.

6. Quit the compensation register menu. F8 (Quit)

F8 (Quit)

F8 (Quit)

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Now the NC program BOLZEN can be simulated either in single step or in automatic run.

Drawing NC program: BOLZEN

N010 G90
N015 G54 X+000.000 Z+207.500
N020 F000.300 T0101 M04
N025 G96 S0180
N030 G92 S3000
N035 G00 X+062.000 Z+000.000
N040 G01 X-001.000 M08
N045 Z+002.000
N050 G00 X+120.000 Z+040.000 M09
N055 F000.300 T0525 M04
N060 G00 X+050.000 Z+002.000
N065 G01 Z-044.800 M08
N070 X+061.000
N075 G00 Z+002.000
N080 X+040.000
N085 G01 Z-044.800
N090 X+051.000
N095 G00 Z+002.000
N100 X+030.000
N105 G01 Z-014.800
N110 X+042.000
N115 G00 Z+002.000
N120 T0505 M04 F000.160
N125 G00 X+030.000
N130 G01 Z-015.000
N135 X+040.000
N140 Z-045.000
N145 X+062.000
N150 G00 X+120.000 Z+040.000 M05 M09
N155 M30

Workshop

Working with tool setup devices


The students should individually define the compensation values of the tool on a real tool setup machine.

The necessary operation steps can be found in the operating manual of the applied tool setup machine.

Optical measuring of tools on the CNC machine


Direct dimension measuring using the CNC machine

The students should individually measure turning and milling tools on the CNC machine tools in workshop.

The details of this procedure are given in the chapter Tool measuring and setup using the CNC machine.
The operation steps on the CNC machine are given in the respective operation.

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Control test Basic Geometry

2.6 Path Measuring Systems


Infeeds, position control and position adjustment of the NC axis
The CNC control invocates the travel movements of the tool or tool carriage using the NC program com-
mands. Hereby the programmed coordinates have to be approached on the axis on a preset path (position)
using the preset speed (infeed) in highest precision.

The exact spatial position of the controllable and moving machine parts has to be constantly fed back to the
CNC control. This is done by the position sensor whose data is fed into the position control loop
(see figure 93).

On the CNC machine tool the position of the tool carriage is constantly measured. Based on the change of
time along the path, the current path position (actual value) as well as the path speed is calculated and com-
pared with the programmed path (set value).

For instance the machining forces as well as friction and play in guidance influence the feedback loop. They
are called disturbance variables and are to be compensated by the control (CNC control).

Approximately every millisecond the control delivers a new position set value to the position feedback loop,
which the control aims for. Considering the high clock rate the control receives a new set value even before
the previous set value has been achieved. This phenomenon of the position feedback loop is based on
physical facts (i.e. too high infeed) and creates the so-called lag error.

input variable (set position


1 2 value)

4 5 output variable (actual position


value)

7 disturbance variables
3 3
motor

ball screw
6

measuring equipment
Figure 93
Position feedback loop output value (actual position
value)

Path measuring
To define the current position of the tool carriage (actual value of the position feedback loop) there is a path
measuring system available for each travel axis of the CNC machine tool. Depending on the travel path dif-
ferent path measuring methods are applied.

Absolute and incremental path measuring


For absolute path measuring (see figure 94) each pitch of the binary coded measuring scale indicates the
exact numerical value. This value corresponds to an exact position of the tool slide opposite to the machine
zero point M. This means that the current tool slide position can be directly conveyed to the CNC control at
any time. The fact that the read-in area of the measuring scale has to be as large as the machining area is a
disadvantage. In connection with the binary coding this results in large, technically complicated measuring
scales.

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For incremental path measuring (see figure 95) counting pulses result from the constant change of light and
dark fields of the ruled grating during the travel movement. These pulses are constantly added or subtracted
by the CNC control. The current tool slide position is the difference of the new position to the last position.
Therefore, after the CNC control has been switched on, the tool slide has to go once to an absolute point,
the reference point, to enable the CNC control to calculate the absolute coordinates.

1 2 1 2 3 4
012345678

binary coded measuring scale ruled grating


current tool slide position last tool slide position
current tool slide position
tool slide on the reference point
Figure 94 Figure 95
absolute path measuring incremental path measuring

In general, only incremental path measuring is applied in CNC machine tools due to the fact that the refer-
ence point can be gone to at any time.

In case of welding line robots, however, collisions can occur with the work parts when going to the reference
point. Therefore, absolute path measuring is required here.

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CNC exercise

Moving to the reference point

CNC turning

Procedure:

Description Entry

1. Call CNC turning in the main menu. F1 (turning)


2. Select setup mode. F3 (setup mode)
3. Select go to reference point. F2 (reference point)
Message: enter default value for the travel
axis.
4. Select the order of the travel axis. X (first the X then the Z axis) or
Z (first the Z and then the X axis) confirm

The system goes to the reference point automati-


cally on both axes.
The position can be read-in using the displayed axis
coordinates.

5. Quit the setup mode. F8 (Quit)

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Moving to the reference point

CNC milling

Procedure:

Description Entry

1. Call CNC milling in the main menu. F2 (milling)


2. Select the setup mode. F3 (setup mode)
3. Select go to reference point. F2 (reference point)
Message: Enter default value for the travel
path.
4. Select the order of the travel axis. X (1. the X , 2. the Y then the Z axis) or

Y (1. the Y , 2. the X then the Z axis) or


Z (1. the Z , 2. the X then the Y axis).

The system goes to the reference point automati-


cally on both axes.
The position can be read-in using the displayed axis
coordinates.

5. Quit the setup mode menu. F8 (Quit)

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Control test Basic Geometry

Touching the turning tool on the plane surface

Procedure:

Description Entry

1. Call CNC turning in the main menu. F1 (turning)


2. Select setup mode. F3 (setup mode)
3. Switch on the spindle in counterclockwise Use the keyboard to enter M04 and
rotation.
confirm.
4. Change the tool to define the work part zero Use the keyboard to enter T0404 and con-
point. firm.

5. Move the lathe tool in rapid speed so that it is Use the numeric keyboard to press the arrow
located in front of the front plane surface with key together with the shift key:
a distance of approx. 5mm to the front plane
surface. + 4 for rapid speed in -Z direction

+X + 2 for rapid speed in -X direction

+Z

Further travel direction options:


+X

7 8 6
Pos 1 ( + Z direction )
-Z 4 5 6 +Z 4 ( - Z direction )
8 ( + X direction )
2 3
Bild 2 ( - X direction )
-X
0 ,
Einfg Entf

6. Switch the increment from 1mm to 0,1mm or F3 (technology)


0,01 mm for further machining.
F5 (increment)

F2 (increment 0.1)

7 Move the lathe tool in negative Z direction Now first press the arrow key on the numeric
until it touches the plane surface of the work keyboard.
4
part.
ESC

and then
F8
press (Quit).

8. Quit the setup mode. F8 (Quit)

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Basic Geometry for CNC Machining

Touching the milling tool on the upper side

Procedure:

Description Entry

1. Call CNC milling in the main menu. F2 (milling)


2. Select the setup mode. F3 (setup mode)
3. Switch on the spindle in clockwise rotation. Enter M03 using the keyboard and
confirm.
4. Change the tool to define the work part zero Enter T0202 using the keyboard and
point.
confirm.
5. Move the tool in rapid speed to a position Use the numeric keyboard to press the arrow
approx. 5mm off the work part surface. key together with the shift key:
Y Ex.: + 2 for rapid speed in - Z direction.
Z

W
X

Further travel direction options:


+Z +Y
6
( + X direction )
7 8 9 4
Pos 1 Bild ( - X direction )
-X +X 9
4 5 6 Bild ( + Y direction )
1
Ende ( - Y direction )
1 2 3 8
-Y Ende Bild ( + Z direction )
-Z
2
0 , ( - Z direction )
Einfg Entf

6. Switch the increment from 1mm to 0,1mm or F3 (technology)


0,01mm for further machining.
F5 (increment)

F2 (increment 0.1)

7 Move the tool in negative Z direction until it Now press the arrow key on the numeric key-
touches the surface of the work part. board,
2
then press
ESC

and
F8
(Quit).

8. Quit the setup mode. F8 (Quit)

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Control test Basic Geometry

Touching the milling tool on the lateral side

Procedure:

Description Entry

1. Call CNC milling in the main menu. F2 (milling)


2. Select the setup mode. F3 (setup mode)
3. Switch on the spindle in clockwise rotation. Enter M03 using the keyboard and
confirm.
4. Change the tool to define the work part zero Enter T0202 using the keyboard and
point.
confirm.
5. Take the tool in rapid speed to the new reset- Press the corresponding arrow key on the
ting position approx. 5mm off the side surface. numeric keyboard
1 together with the shift key:
1) in -X direction
Y
Z 2 + 4 for rapid speed in - X direction
2) in -Z direction

+ 2 for rapid speed in -Z direction


W
X

Further travel direction options:


+Z +Y
6
( + X direction )
7 8 9 4
Pos 1 Bild ( - X direction )
-X +X 9
4 5 6 Bild ( + Y direction )
1
Ende ( - Y direction )
1 2 3 8
-Y Ende Bild ( + Z direction )
-Z
2
0 , ( - Z direction )
Einfg Entf

6. Switch the increment from 1mm to 0,1mm or F3 (technology)


0,01mm for further machining.
F5 (increment)

F2 (increment 0.1)

7. Move the tool in positive X direction until it Now press the arrow key on the numeric key-
touches the left side of the work part. 6 board,

ESC then press

and
F8
(return) key.

8. Quit the Setup mode. F8 (Quit)

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Basic Geometry for CNC Machining

Touching the milling tool on the front side

Procedure:

Description Entry

1. Call CNC milling in the main menu. F2 (milling)


2. Select the setup mode. F3 (Setup mode)
3. Switch on the spindle in clockwise rotation. Type M03 using the keyboard and
confirm.
4. Change the tool to define the work part zero Type T0202 using the keyboard and
point.
confirm.
5. Take the tool in rapid speed to the new reset- Use the numeric keyboard to press the arrow
ting position approx. 5mm off the front side. key together with the shift key:

1 Y 1) in +X direction

Z + 6 for rapid speed in +X direction

2 2) in -Y direction
1 for rapid speed in -Y direction
3 + En de

W 3) in -Z direction
X + 2 for rapid speed in -Z

Further travel direction options:


+Z +Y
6
( + X direction )
7 8 9 4
Pos 1 Bild ( - X direction )
-X +X 9
4 5 6 Bild ( + Y direction )
1
Ende ( - Y direction )
1 2 3 8
-Y Ende Bild ( + Z direction )
-Z
2
0 , ( - Z direction )
Einfg Entf

6. Switch the increment from 1mm to 0,1mm or F3 (Technology)


0,01mm for further machining.
F5 (Increment)

F2 (Increment 0.1)

7. Take the tool in positive Y direction until it Press the arrow key on the numeric keyboard.
touches the front of the work part.
9
Bild Then press
ESC
and
F8 (Quit) key.
8. Quit the Setup mode. F8 (Quit)

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5. Control test Basic Geometry

1. Indicate the possible travel movements for turning in a coordinate system.

1. Indicate the possible travel movements for milling in a coordinate system.

1. For which applications is it reasonable to use the polar coordinate system in milling?

1. Give two examples of control types on CNC milling machines.

1. Which types of 2 D path controls can be differentiated on CNC milling machines?

1. How can the different possibilities of 2 D path control be explained?

1. Explain the zero and reference point on numerically controlled machine tools.

1. Where should the work part zero point, which is set by the user, be positioned?

1. What are the advantages of absolute programming?

1. Why is incremental programming sometimes unavoidable?

1. Incrementally dimension the sketched milling work part with absolute dimensions:

12. What is the main difference between the principle of a control chain and a feedback loop?

12. Discuss the control as an operation.

12. Why is it necessary to have milling radius compensation in milling?

12. Which values are considered by the tool compensation in milling?

12. Why is it necessary to have cutting radius compensation in turning?

12. Which values are considered by the tool compensation in turning?

12. What is the significance of the working quadrants of the turning tool edge?

12. List the different types of tool dimensioning.

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Technological Basics for CNC Machining

6. 3 Technological Basics for CNC Machining


3.1 CNC tool systems for turning and milling
CNC machine tools use special NC tools. These tools meet the following criteria:
better milling performance with high stand still times
short changing and setup times to enable economical production of small production lots
standardized and rationalized tools
improved tool management and flexible production
The NC tools are either a single tool or they are put together of the cutter edge holder and tool holder. To
enable a quick tool change and to secure good exchangeability of the NC tools the tool carriers are stan-
dardized.

Tool carriers
Special forms have been stablished for tool carriers. They differ from each other in their machining method.
For turning tools a straight shank with toothing (see figure 96) is mostly used and for cutting tools a steep-
angle taper (see figure 97). Both tool shanks can be used with automatic and/or quick manual tool change.

Figure 96 Figure 97
Straight shank with toothing Steep-angle taper

Tool holder
Many lathe and milling tools are a combination of several components. Indexable inserts are used which are
attached, for example with clamping devices (see figure 98).

1
Clamping finger
2
indexable insert
3
pin
4
Insert
5
indexable insert carrier

Figure 98
Example of a clamping system

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The main components of a modern lathe tool are the clamping holder or indexable insert holder, the index-
able insert and the clamping device. The indexable inserts are placed in the holder which has two supporting
edges and an insert. The insert serves to convey larger cutting forces and to protect the holder from damage
in case of an eventual breach in the indexable insert.

Since the indexable inserts are exposed to the cutting forces of the lathe and to the centrifugal forces of the
milling machine, there is the danger of loosening supports or slipping tools. Clamping and screw clamping
fixtures are therefore used to accurately fix and position the indexable inserts.

The clamping fixtures and the indexable inserts are standardized to a large extent.

Tungsten carbide indexable inserts


In CNC technology indexable inserts are increasingly being used since they achieve very high stand-still
times and are easy to change. Indexable inserts have several cutting edges. This allows the insert to be
rotated or turned when one edge of the insert becomes dull.

Indexable inserts are made either of tungsten carbide or cutting ceramics (see chapter cutting materials
pp. 88 ff.).They are sintered. This production method, in which metal powder is first pressed and then heat
treated, enables economical indexable inserts to be manufactured in various designs (see figure 99).

S B E T P H R
Figure 99
Forms of indexable inserts

Indexable inserts are classified according to their basic form, angles, cutting edges, tolerance class as well
as their clamping system and main dimensions. Based on a norm sheet ISO 1832 / DIN-4987 the following
example (see figure 100) shows the norm title of an indexable insert.

indexable insert ISO 1832 - ECMT 09 T3 08 FR - P10


Designation Example
Norm main number DIN 4987
1) basic form E = orthorhombic 75
2) normal-clearance angle C = 7
3) tolerance class M
4) face and clamping characteris- T = counterborehole
tics 60on face
5) insert size side length: 9,52 mm
6) insert thickness s = 3,97mm
7) cutting edge radius r = 0,8mm
8) cutting edge characteristics F = sharp edged
9) cutting direction R = right
10) cutting edge material tungsten carbide P10
Figure 100
Description of an indexable insert

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3.2 Structure and use of lathe tools for CNC machining


Types of lathe tools and the corresponding ISO designation

The lathe tools, also called cutting tools, can be classified according to the following criteria:
according to the cutting material:
cutting tool edges out of high-speed steel,
cutting tool edges out of tungsten carbide,
cutting tool edges out of ceramics or
cutting tool edges out of diamond;
according to the location of the application area:
cutting tool for outer machining or
cutting tool for inner machining;
according to their form:
straight cutting tool,
offset cutting tool,
cranked cutting tool,
sharp cutting tool or
wide cutting tool;
according to the location of the major cutting edge
left cutting tool,
right cutting tool or
neutral cutting tool;
according to the application purpose e.g.:
recessing tool,
corner cutting tool or
tapping tool.

Details of the cutting tools are described in the corresponding norms (ISO 243, 504 or 514).

A selection of commonly used cutting tools is listed in the below table 101 according to their application area.
These cutting tools are stored with all their dimensions in the tool management of the MTS turning simulator.
They can be called from there for simulaton on the MTS turning simulator.

cutting tool thread cutting tool recessing tool boring tool


corner cutting tool outer tapping tool (right outer recessing tool
(right cutting) cutting)
outer corner cutting tool (left outer tapping tool (left cut-
cutting) ting)
copying lathe tool
outer cutting tool (round
cutting edge)
inner cutting tool (pre- inner tapping tool (preaxial) inner recessing tool
inner axial) (preaxial)
inner cutting tool inner tapping tool (postaxial) inner recessing tool
(postaxial) (postaxial)
axial recessing tool centering drill
axial twist drill
indexable insert
reamer
Figure 101
Classification of cutting tools

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Cutting materials
Hard metals are primarily used as the cutting material for lathe tools. For certain types of cutting high-speed
steels (HSS steels) are used. Their cutting surface is usually coated. In special cases ceramic materials
(cutting ceramics) are used as indexable inserts and in some cases industrial diamonds as well.

High-speed steels
High-speed steel is a high-alloyed tool steel (HSS = high-speed steel). It is highly durable and can therefore
easily take impact loads. The cutting speed is considerable lower compared with hard metals and cutting
ceramics.

It is used for tools whose form, for instance boring and reaming tools, do not allow the use of indexable in-
serts or machining of thermoplastic plastics and light alloys. HSS tools are frequently coated with a hard coat
of titanium nitrid TiN. This extremely hard, golden colored coating increases the abrasion resistance and
allows higher cutting speeds.

Hard metals
Hard metals are materials which are cintered as indexable inserts using hardening materials and a binding
agent. In most cases the hardening materials are tungsten, titanium or tantalum carbide. Cobalt is used as a
binding agent.

Hard metals are considerably harder than HSS steels. They are extremely abrasion-resistent and allow very
high working temperatures. They do, however, tolerate far less temperature fluctuation and impact exposure
than the HSS steels.

Hard metals can be classified according to the main cutting groups and cutting application groups.

Main cutting Cutting application groups


groups
Abbreviation Materials Applications
superfinish turning, high abrasion resistance
P01 high surface quality high cutting speed

precision machining,
P10 high cutting speed
P P20 steel
blue P30 cast steel medium cutting speed
P40 malleable cast iron short
shipping
P50 rough cutting high hardness
interrupted cutting high infeeds
precision machining high abrasion resistance
M10 steel high cutting speed high cutting speed

M M20 hard steel medium cutting speed


yellow M30 cast iron
M40 non-iron metals rough cutting high hardness
interrupted cutting high infeeds
high abrasion resistance
K01 hard cast iron precision machining high cutting speed
K K10 cast iron
red K20 malleable cast iron short
shipping
K30 plastics
K40 wood rough cutting high hardness
interrupted cutting high infeeds
Figure 102
Application areas of hard metals

The abrasion resistance of hard metals can be increased with a corresponding coating. As coating materials
titanium nitrid, titanium carbide and aluminium oxide are applied in several layers in vacuum in a tempera-
ture of 1000C

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Cutting ceramics
Ceramic materials which are even harder than hard metals are used as cutting ceramics. Cutting ceramics
allow a working temperature up to 1200C. They are very brittle and sensitive to fluctuating cutting forces.
Cutting ceramics are manufactured as indexable inserts and are clamped in the tool holder just like hard
metals.

Cutting ceramics are applied for cutting with constant cutting conditions, without coolant application. The
cutting speed is higher than that of hard metals. They are ideal for cutting iron materials since they do not
create built-up edges. They, however, cannot be used for aluminium alloys.

The applicable cutting ceramics can be classified in the three following groups:
oxide ceramics
mixed ceramics
nitrid ceramics
Cutting ceramics alloys of pure Al2O3 are called oxide ceramics. They have no metallic binding agent. They
are especially ideal for cutting iron alloys since they are highly abrasion resistant to them.

In case of mixed ceramics hard materials are added to the Al2O3 such as titanium carbide. Mixed ceramics
are used for finishing gray-cast iron or steel as well as for cutting hardened iron materials.

Nitrid ceramics are based on silicium nitrid Si3N4. This non-oxide cutting material is extremely brittle and
sensitive to temperature fluctuations. High abrasion in cutting steel is a disadvantage. The nitrid ceramics is
applied for machining gray cast iron.

Diamond
Diamands are harder than all other materials. They are extremely sensitive to impact, however create no
built-up edges during machining.

They are used for cutting non-iron materials and their alloys as well as for composite materials (GRP), hard
metal, gas and ceramics.

Diamands cannot be applied for machining steel. Here they have very high abrasion since the carbon atoms
of diamonds are given off to the iron (diffusion abrasion).

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Cutting edge geometry


Each machining process requires its cutting edge geometry. Only this can guarantee ideal production times,
long cutting-edge life and high surface quality. The angles of the tool cutting edge play a decisive role here
(vgl. Abbildung 103).

0 clearance angle

0 0 0 wedge angle

0 0 angle of rake

r angle of point

s angle of inclination

r s r adjustment angle

Figure 103
Cutting geometries in turning

Clearance angle : The clearance angle reduces friction and heating up of the tool edge and the work
part.

Wedge angle : The size of the wedge angle depends on the hardness and toughness of the work
part. The smaller the wedge angle the lighter the cutting, however, the larger the edge
abrasion and the shorter the cutting edge life.

Angle of rake : The angle of rake has an influence on chip building and cutting forces. The larger the
angle of rake the smaller the cutting force, however, cutting edge breach and abrasion
are increased because of total decarburization. Solid, medium hard materials require
an angle of rake of approx. 10. Hard and brittle materials require a small or even a
negative angle of rake.

Adjustment angle : In the first place the entering angle has an influence on infeed force, on the forces
against the work part clamping and work part as well as on the cutting width and
thickness. In case of solid clamping situation an entering angle of 30 to 60 is se-
lected. Only for thin shafts or right angled offsets 90 is selected for the adjustment
angle.

Inclination angle : For finishing a positive, for roughing a negative inclination angle is frequently selected.
When negative angles of rake are used the cutting edge tip is exposed to less stress.
When positive inclination angle is used the chip flow is directed away from the work
part.

Angle of point : The larger the angle of point the better the stability of the tool edge and the better the
heat removal.

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Abrasion and cutting edge


During cutting the tools are subject to wear, also called abrasion. This is due to the cutting friction, the diffu-
sion in high temperatures as well as to the chip flow.

Due to the high temperature of the tool cutting edge small work part particles can be welded on to the tool
face. A built-up edge can be created (see figure 105).

Figure 104 Figure 105


New lathe tool Built-up edge

During the cutting process material particles continuously break off from the lathe tool. Correspondingly, the
geometry of the tool cutting edge changes with the time. Depending on the choice of the tool cutting edge
angle the abrasion can take different forms (see figure 106 to 109).

Figure 106 Figure 107


Open cutting edge wear Chip surface wear

Figure 108 Figure 109


Crater wear Edge rounding

Due to tool wear the surface quality of the machining as well as the dimensional stability of the work part are
reduced. As soon as the required surface quality or dimensional stability are not maintained any more the
cutting-edge life of the tool has been reached.

Cutting-edge life is the time during which the cutting edge is in operation and the following requirements are
met:
Generation of required surface quality
Dimensional stability within the required tolerances
When cutting-edge life has been reached it is necessary to change the tool or to resharpen it. When using
indexable inserts the insert can be turned or changed. Prior to using the tool again tool dimensioning has to
be done.

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Cutting value
Turning is a cutting operation with a circular cutting movement and an infeed which can be in any relation to
the cutting direction. In most cases the cutting movement is made by the rotation of the work part and the
infeed of the tool (see figure 110). The
cutting speed vc and the
infeed speed vf
overlap and result in a continuous cutting process.

Cutting speed vc
Cutting speed is the movement between the tool and the work part causing only a single chip removal during
one rotation without infeed. The symbol for cutting speed is vc and is indicated in m/min.

In general the speed indicates the traversed path s within a certain period of time t. It is calculated as fol-
lows:
s
v= in path/time
t
The traversed path s for a work part rotation can be generated in turning using the work part diameter d on
the cutting edge tip and the constant :

s = *d in m

The starting point for the calculation of the cutting speed is now a time unit t = 1 min. The result is herewith
cutting speed vc :

*d
vc = in m/min
t
The number or work part rotations in one minute is indicated as a number of rotations n (in rotations per
minute):

1
t= in min
n
As a result the following formula is achieved for the calculation of the cutting speed vc:

vc = * d * n in m/min

vc
n n number of rotations in U/min

vf infeed speed in mm/

vf vc cutting speed in m/min

vc =*d*n

Figure 110
Cutting values in turning

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Infeed speed vf
Together with the cutting movement Infeed allows a continuous chip removal during several rotations. The
infeed speed vf is indicated in mm/min.

Often the infeed f is given in mm per rotation as well. The infeed f is the path the lathe tool makes in the in-
feed fixture during one spindle rotation. The following relation exists between these two forms:

vf = n *f in mm / min

For each cutting process a certain infeed is required. Together with the spindle number of rotations n it de-
fines the machining time for each travel path. Its value has a decisive influence on an ideal cutting force and
on the sufrace quality of the machined surface.

Chip size
The chip diameter A describes the material diameter, which is cut in one cut (see figure 111). Its size largely
defines the cutting force created.

Without considering the cutting edge radius, the chip diameter A is the product of the cutting depth a and
infeed f. It is given in mm2. The cutting depth a, i.e. the depth of the tool cutting, is the value to be fed in step
by step.

A = a *f in mm2
Using the entering angle it is possible to calculate the width b and the thickness h of the chip.

h = f *sin in mm

a
b= in mm
sin

f
f
b

h
a cutting depth adjustment angle
f infeed per rotation b chipping width
h chipping thickness
Figure 111
Chipping sizes

The following cutting values have to be selected always considering the specific appliction, and the lathe is
to be correspondigly set up.
cutting speed vc
infeed f
cutting depth a
This requires extensive experience. As a support standard value tables are therefore available indicating the
cutting values regarding the material to be cut and the cutting edge material.

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Examples: Calculating technological values for CNC machining

Cutting speed vc

vc = * d * n in m/min

1. Example:

What is the cutting speed in plain turning if the cutting is done with a 60 mm diameter and num-
ber of rotations of 1500 1/mm.

datum: d = 60 mm
n = 1500 1/min

unknown: vc in m/min

valid : vc = * d * n

vc = * 0,06 m 1500 1 min

solution: m
vc = 283
min

2. Example:

How many number of rotations are required if the smallest diameter to be machined on the same work
part with this cutting speed is 12mm?

datum: vc = 283 m/min


d = 12 mm

unknown: n in 1/min

valid : vc = *d * n , or

vc
n=
*d
283m
n=
* min* 0,012m

n = 7511 1 min
solution:

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3.3 Structure and application of milling tools for CNC machining


Milling and milling operations
Milling is a cutting operation with a geometrically specified cutting edge in which the tool makes the rotating
main movement, and the feed as well as the infeed movement are generally made by the work part
(see figure 112).

rotation of the milling tool

work part feed

Figure 112
Milling

Milling operations are classified according to the position of the milling axis towards the work part, i.e. be-
tween face milling and peripheral milling.

In case of face milling the milling axis is located vertically to the machining area (see figure 113). The work
part surface is machined by the main cutting edges. Also, the work part surface is further finished with auxil-
iary cutting edges.

In case of peripheral milling the milling axis is located parallel to the machining axis (see figure 114). The
milling tool machines the work part surface with the main cutting edges (the peripheral cutting edges). Fur-
thermore, a difference is made between synchronous and conventional milling.

Figure 113 Figure 114


Face milling Plain-milling

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Additionally, synchronous and conventional milling (see figure 115 and 116) are differentiated.

In case of conventional milling the rotation direction of the milling tool is opposite to the feed direction of
the work part (see figure 115).

The milling tool chamfer edge starts with chip thickness zero. The milling tool cutting edge slides in front of
the chip chamfer edge until the required minimum chip thickness has been achieved for chip building.

The friction created by sliding results in high abrasion of the tool flanks and in hardening of the work part
surface. This leads to a shorter cutting edge life of the tool compared with synchronous milling.

Conventional milling is recommended to be used for machining work parts with hard surfaces (cast material)
since the hard surface is cut through from inside.

For synchronous milling the rotation direction of the milling tool and the feed movement of the work part
are parallel (see figure 116).

The tooth of the milling cutter immediately penetrates into the work part. Since the milling tool cutting edge is
exposed to impact forces the feed drive needs to be playfree. Several cutters should always be in operation.

The surface quality is flatter and duller when synchronous milling is used. Compared with conventional mill-
ing higher feed movements and cutting speeds within the same cutting edge life can be achieved.

1
1

Work part feed Work part feed


Figure 115 Figure 116
Conventional milling Synchronous milling

The tool cutting edge is subject to constant cutting interruptions in all milling operations. Due to the cutting
path comma-form chips are cut with a changing chip thickness (see figure 117).

cutting chip

Figure 117
Milling plan

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Types of milling tools


Milling tools can be classified according to the following criteria:
according to the type of the material to be cut in
tool type N (for normal steel),
tool type H (for soft, long-chipping materials),
tool type W (for hard, short-chipping materials),
according to the cutting material in
cutter with cutting edge of high-speed steel tool,
cutter with cutting edge of hardmetal,
cutter with cutting edge of ceramics or
cutter with cutting edge of diamond;
according to the type of the tool carrier
shell mill or;
end mill;
according to the milling form, for instance in
T slot cutter;
face milling cutter;
side mill or
form cutter;
according to the form of the milling tool tooth in
pointed teeth cutter or
back-off teeth cutter
Details of milling tools are given in the manufacturers catalogues and in the corresponding norm sheets.

A selection of common milling tools are shown below, classified according to their application field:

end mill
standard types plain milling cutter
face milling cutter
counterbore drill screw tap
drills indexable insert drill reamer
stepped drill
radius form cutter angle cutter (form A) concave cutter
special forms T slot mill angle cutter (form B) side mill
Figure 118
Classification of milling tools

The above milling tools including all their data are included in the MTS CNC milling simulator and can be
called by the user. These tools can be modified or extended to meet the users demand.

End mill / Slot drill T-slot cutter Shell end mill

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Face end cutter Radius cutter Angular cutter (type A)

Angular cutter (type B) Tap drill Drill

Step drill Reversible tip drill Reamer

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Countersink Concave cutter Side milling cutter

Cutting edge materials


In milling, the cutting edges are not in operation all the time. The milling cut is a discontinuous cut with a
changing cutting diameter. Therefore, the cutting edge is exposed to high impact forces. The cutting edge
material has to be tough and heat resistant.

Today, mostly indexable inserts made of hardmetal are used as milling tools. Only in case of small milling
machines soldered hardmetal cutting edges made of high-speed steel or coated high-speed steel tools are
used.

High-speed steel
High-speed steel is a high-alloyed tool steel. Due to its high toughness it is able to withstand impact forces.
The cutting speed is considerably lower compared with hardmetals or cutting ceramics.

It is used for drills, small milling tools and tools with a complicated form (profile cutter). Cutting tools made of
high-speed steel are used for cutting less tough materials, for profile cutting and for cutting with low cutting
speed.

Hardmetals
Hardmetals are materials which are sintered in form of indexable inserts by using hardening materials and
a binding agent. By increasing the binding agent proportion in hardmetal production it is possible to increase
the hardness of the material as required. The abrasion resistance of hardmetals can be increased by a tita-
nium nitrid, titanium carbide or aluminium oxide coat.

Hardmetal cutting plates are soldered on the milling tool or screwed on it in form of indexable inserts.

Cutting ceramics
Cutting ceramics are rarely used for milling because of their brittleness and sensitivity to fluctuating cutting
forces. However, because of the high hardness aluminium oxide is used for machining hardcast materials
and hardened steel as well as silicon nitrid for grey cast. Both of these materials are used for cutting without
coolant application.

Like hardmetal, cutting ceramics are manufactured to be used in form of indexable inserts.

Diamond
Cutting plates made of polycrystalline diamonds are used to cut non-iron metals and plastics. The extraordi-
nary hardness of the diamonds enables double as high cutting speeds with ten times longer cutting edge
lifes are achieved as compared with hardmetals.

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Diamonds cannot be used for cutting steel. Here they are exposed to high abrasion since the carbon atoms
of the diamond are given off to iron atoms (diffusion abrasion).

Cutting geometry

Unlike lathe tools milling tools have several cutting edges (see figure 119). Typical of milling is the discon-
tinuous cut as each cutting edge works only for a time.

d: diameter of the milling tool

z: number of teeth

fz: feed per tooth

ae: entering point

fz
d

s S: entering angle
ae

0 0:
0
clearance angle

0: wedge angle

0 0: angle of rake

S: angle of twist of the edges


ap

ap: cutting width

s
Figure 119
Cutting geometry milling

Clearance angle : The clearance angle is to reduce the friction and consequently the heating of the cut-
ting edge and of the work part.

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Wedge angle : The size of the wedge angle depends on the hardness of the work part. The smaller
the wedge angle the lighter the cutting, however the greater the cutting abrasion and
the shorter the cutting edge life.

Angle of rake : The angle of rake influences cutting chip formation and cutting forces. The larger the
angle of rake of the chip the smaller the cutting force, however the risk to breach as
well as abrasion of the cutting edge are increased due to erosion.

Entering angle S: The entering angle indicates the machining path of the tool with reference to the cir-
cumference. It depend on the size of the entering point.

Inclination angle : The size of the inclination angle influences the process of chamfering and cutting-out.
Since the inclined cutting edges are consecutively engaged the milling tool runs with
increased quietness.

The configuration of the adjustment angle (see figure 120) is very important in milling. The adjustment angle
is the angle between the main cutting edge and the surface to be cut.

: adjustment angle

Figure 120
Adjustment angle of milling tools

If the adjustment angle is 90, the highest radial forces are exposed. This angle value is therefore only rec-
ommended for right-angled contours. For most milling works an adjustment angle of 75 or 60 is ideal. For
long cutting materials the adjustment angle of = 45 is ideal.

If hardmetal indexable inserts are mostly used, then two cutting angles are available. They can be measured
using the reference lines:
radial cutting angle (reference line through the centerof the milling tool)
axial cutting angle (reference line parallel to milling axis)
In case of plain milling with a plain milling cutter the following combinations are mostly used (see figure 121):
double positive geometry
double negative geometry
positive-negative geometry

2 2 2

+ - +

1 + - -
1 1
double positive geometry double negative geometry positive-negative geometry

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radial cutting angle axial cutting angle


Figure 121
Cutting geometries on plain milling cutter
In case of double positive geometry only light driving power is required due to small cutting forces. It is there-
fore possible to machine thin-walled work parts as well. The spiral-form chips drop off from the tool easily. In
case of materials which tend to form built-up edge, for instance aluminium, this geometry is recommended.
Double negative geometry is used for machining hard steels and grey cast as well as for roughing. The high
cutting forces created hereby require strong driving power and high stability of the machine. Due to the ge-
ometry the chips curl on the tool. In case of long-chipping materials this can lead to a chip jam.
Positive-negative geometry makes large feeds and big cutting depths possible since the negative radial an-
gle of rake contributes to high breaking strength of the indexable insert. Here the chipping is ideal since the
chips flow off from the tool. Tools with a positive-negative geometry are therefore applied for various situa-
tions.

Cutting values
Milling is a cutting operation with a rotating tool, whereby the cutting edges are not in operation all the time.
The cutting movement is caused by the rotation of the tool. Feed direction and cutting direction do not de-
pend on each other. It is realized either by the tool or by the work part or by both of them (see figure 122).
The
cutting speed vc and the
feed speed vf
overlap each other and results in a continuous cutting operation.

Cutting speed vc
The cutting movement is the movement between the tool and the work part, generating only one non-
recurrent chip cut during one rotation without a feed movement. Cutting speed corresponds to circumferen-
tial speed of the milling tool on the current cutting edge. It is expressed as vc and m/min. Under considera-
tion of the number of rotations of the spindle n the following formula is received

vc = * d * n in m/min

The cutting speed of a cutting tool depends on the number of the rotations. The direction constantly changes
however during cutting operation (see figure 122

vc vc
n number of rotation

vc vf feed speed

n vc cutting speed
d

vf d diameter of the cutting tool


vc
vc
Figure 122
Cutting values for milling

Feed speed vf

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The feed movement together with the cutting movement enable a constant chip removal during several rota-
tions. In milling, the feed can be indicated in three ways:
feed speed vf in mm / min
feed per tooth fz in mm
feed per milling rotation f in mm
The calculation of the feed speed vf is based on the feed fz , i.e. the feed path per milling tooth. Under con-
sideration ot the number of rotations n and the number or teeth z the formula is as follows:

v f = fz * n * z in mm / min

The feed speed can be expressed with the following formula as well with reference to the feed per milling
rotation.

vf = f *n in mm / min

Consequently, the following equivalence is valid:

v f = f * n = fz * n * z in mm / min

Cutting width
Unlike in turning, a nonuniform chip is cut in milling (see figure 123). The average cutting thickness hm is
used as reference.

actual chip
fz
fz: feed per tooth

h m: average cutting thickness


1

hm
Figure 123
Cutting thickness

In plain milling, the cutting width ap is the penetration width of the tool into the work part. The working en-
gagement ae is measured on an imagined plane of the working plane. The cutting and feed direction are
located on the working plane (see figure 124).

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1
1

ap
ae

ae

ap working plane

ap: cutting plane ap: cutting depth


ae: entering point ae: entering point
Figure 124
Operating variables in milling
In face milling, ap is the cutting depth measured vertically to the working plane. The working engagement ap
is identical with the width of the milled surface.

The following cutting values must be selected case by case depending on the application and then entered
into the milling machine:
number of rotations n
feed f
working engagement ae
cutting depth or cutting width ap
This requires extensive experience. As a support standard value tables are therefore available containing
cutting values regarding the material to be cut and to the cutting edge material.
Calculation examples of technological values for CNC machining

Cutting speed vc

vc = * d * n in m/min

Feed speed vf

v f = f * n = fz * n * z in mm / min

1. Example:

Calculate the cutting speed for milling if the milling tool diameter d = 50 mm and the
number of rotations n = 520 1/min.

known: d = 50 mm
n = 520 1/min

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unknown: vc in m/min

it applies : vc = *d * n

vc = * 0,05 m 520 1 min

solution: m
vc 82
min

2. Example:

Calculate the number of rotations n of an end mill with a diameter of = 12 mm and cutting
speed of vc = 120m/min.

known: d = 12 mm
vc = 120 m/min

unknown: n in 1/min

it applies : vc = *d * n , or

vc
n=
*d
120m
n=
* min* 0,012m

n = 3183 1 min
solution:

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3. Example:
In plain milling with a face milling cutter a cutting speed of vc = 180 m/min has been scheduled
and the number of rotations should not exceed 400 1/min. What is the maximum diameter d of
the face milling cutter so that these values are not exceeded?

known: n = 400 1/min


vc = 180 m/min

unknown: d in mm

it applies : vc = *d * n , or

vc
d=
*n
180000mm * min
d=
* min* 400
Solution: d = 143mm

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3.4 Calculation of technological data for CNC machining


Calculation examples of technological data for CNC turning
1. Example:

On a CNC-lathe the sketched bolt is to be roughed as


well as finished in four cuts with cutting depths of 6; 6; 5
and 5 mm and a finishing allowance of 0,5 mm.

The cutting speed for roughing is vcv = 280 m/min and

70

45

25
for finishing vcf = 400 m/min.

Calculate the number of rotations for each cut.

20

50

60

Calculating the number of rotations for roughing (Cut 1-4) and for finishing (Cut 5-6)

datum: vcv = 280 m/min


vcf = 400 m/min

unknown: n in 1/min

valid : vc
n=
*d

1. Cut 2. Cut
= 58mm vcv = 280 m/min = 46mm vcv = 280 m/min
280m 280m
n1 = n2 =
* min* 0,058m * min* 0,046m
n1 = 1537 1 min n2 = 1938 1min

3. Cut 4. Cut
= 36mm vcv = 280 m/min = 26mm vcv = 280 m/min
280m 280m
n3 = n4 =
* min* 0,036m * min* 0,026m
n 3 = 2476 1 min n4 = 3428 1min

5. Cut 6. Cut
= 25 mm vcf = 400 m/min = 45 mm vcf = 400 m/min
400m 400m
n5 = n6 =
* min* 0,025m * min* 0,045m
n5 = 5393 1 min n6 = 2830 1min

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2. Example:

On a CNC-lathe the sketched bolt is to be roughed in


four cuts with cutting depths of 6; 6; 5 and 5 mm, a feed
of fv = 0,2 mm and a finishing allowance of 0,5 mm.

Because of the various specified roughness heights the


45 will be finished with a feed of ff1 = 0.07 mm and all

70

45

25
other surfaces with a feed of ff2 = 0.12 mm.

The lengths of the approach and retreat movements will


each be programmed with 2 mm.
20
The machining time for roughing thuv and for finishing thuf
as well as well as the entire machining time thu are to be 50
calculated.
60

Calculating the machining time for roughing thuv and for finishing thuf

The machining time for turning is calculated with the following formula:

L *i
th = in min
n *f
The variables are:
L Feed Path
i Number of Cuts
n Number of Rotations
f Feed per Rotation
The feed path L is calculated from the path in which the cutting edge is operating (length l = feed mo-
tion in Z and X !) and possible approach / withdrawal paths (length la or lu) that are traveled in the feed.

The following feed paths result for each cut with consideration to 2mm for the approach / withdrawal
paths:

1. Cut L = l + la + lu = 50mm + 6mm + 2mm + 2mm = 60mm


1. Cut L = l + la + lu = 50mm + 12mm + 2mm + 2mm = 66mm
1. Cut L = l + la + lu = 20mm + 5mm + 2mm + 2mm = 29mm
1. Cut L = l + la + lu = 20mm + 10mm + 2mm + 2mm = 34mm
1. Cut L = l + la + lu = 20mm + 1mm + 2mm + 2mm = 25mm
1. Cut L = l + la + lu = 30mm + 12mm + 2mm + 2mm = 46mm

datum: L = Feed Path


i =1

unknown: th in min

valid : L *i
th =
n *f

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Calculating the machining time for preturning thuv

1. Cut 2. Cut
L = 60mm fv= 0.2 mm n= 1537 1/min L = 66mm fv= 0.2 mm n= 1938 1/min
L *i L *i
th = th =
n *f n *f
60mm * 1 min 66mm * 1 min
th = th =
1537 * 0,2mm 1938 * 0,2mm
t h = 0,195 min t h = 0,172 min
3. Cut 4. Cut
L = 29mm fv= 0.2 mm n= 2476 1/min L = 34mm fv= 0.2 mm n= 3428 1/min
L *i L *i
th = th =
n *f n *f
29mm * 1 min 34mm * 1 min
th = th =
2476 * 0,2mm 3428 * 0,2mm
t h = 0,059 min t h = 0,050 min
t huv = 0,195 min+ 0,172 min+ 0,059 min+ 0,050 min
t huv = 0,476 min

Calculating the machining time thuf f for finishing

5. Cut 6. Cut
L = 25mm fv= 0.12 mm n= 5393 1/min L = 46mm fv= 0.07 mm n= 2830 1/min
L *i L *i
th = th =
n *f n *f
25mm *1 min 46mm * 1 min
th = th =
5393 * 0,12mm 2830 * 0,07mm
t h = 0,039 min t h = 0,232 min
t huf = 0,039 min+ 0,232 min
t huf = 0,271 min

Calculating the entire machining time thug

t hug = t huv + t huf


t hug = 0,476 min+ 0,271 min
t hug = 0,747 min

MTS TeachWare CNC-Grundlagen Students Book 109


Basic Geometry for CNC Machining

3. Example:

On a CNC-lathe the sketched bolt is to be preturned in


four cuts with cutting depths of 6; 6; 5 and 5 mm and
with a feed of fv = 0,2 mm.

Because of the various specified roughness heights the


25 will be finish turned with a feed of ff1 = 0.07 mm

70

45

25
and all other surfaces with a feed of ff2 = 0.12 mm.

The cutting speed for preturning is vcv =280 m/min and


for finishing vcf =400 m/min.
20
The cutting edge curve for the preturning tool is rv = 0.8
mm and for the finishing tool rf = 0.4 mm. 50

The attained roughness height are to be calculated. 60

Calculating the attained roughness heights Rt

The roughness height reached by turning is calculated with the following formula:

f2
Rt = in mm
8* r
The variables are:
f Feed per Rotation
r Cutting Edge Radius

datum: f = 0.07 mm datum: f = 0.12 mm


r = 0.4 mm r = 0.8 mm

unknown: Rt in mm unknown: Rt in mm

1. Calculating the roughness height Rt1.6 for 2. Calculating the roughness height Rt 6.3 for
the surface 45 the other surfaces

f 2 mm2 f2 mm2
Rt1.6 = = mm Rt 6.3 =
8r 1 mm = mm
8 r 1 mm
0. 07 2
0.12 2
Rt1.6 = Rt 6.3 =
8 0. 4 8 0.8
0. 0049 0. 0144
Rt1.6 = Rt 6.3 =
3. 2 8 0. 8
0. 0144
Rt 6.3 = mm
6. 4
Rt1.6 = 0,00153 mm Rt 6.3 = 0,00225 mm

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Technological Basics for CNC Machining

Calculating the cutting forces and the motor power

For operating a CNC-machine it is important that the skilled worker understands the relevant mechanisms of
the cutting force as well as the machining performance and the drive motor's rated power and actual output..

The multitude of variables influencing the cutting forces do not allow precise calculation with a formula.
Some of these factors can only be determined in tests. This has shown, for example, that every material to
be machined has a specific cutting force value which varies according to e.g consistency (hard or soft) or
machining duration (short or long). Moreover, the tool, its cutting material and its characteristics should be
considered. Also important are the programmed operation values, such as feed, number of rotations, cutting
speed, chip thickness, chip diameter, machining mechanisms as well as the cutting edge geometry, whereby
the angle of rake and the adjustment angle are especially relevant. The cutting edge wear also plays a role.

Example:
From a 60 mm shaft the sketched peg out of Ck 45 is to be preturned and then finish turned in one
cut.

Hard-metal corner cutting tools with indexable inserts are available (0=90, r=90).
The feeds are f v = 0. 2 mm and f f = 0.1mm ,
cutting speeds are vcv=200m/min and vcf=300m/min.
Allowance after preturning is 0.5 mm.
The output of the main drive motor is =0,8.

To be calculated:
1. the cutting force Fcv,
1. the cutting performance Pcv and
1. the required power output from the drive Pab .

Datum: turning length l = 50 mm


cutting depth ap = 4.5 mm
feed f v = 0.20 mm
cutting speed vcv=200m/min

adjustment angle r=90


output =0,8

MTS TeachWare CNC-Grundlagen Students Book 111


Basic Geometry for CNC Machining

1. The cutting force FC

The cutting force FC is calculated with the formula:

cutting force = chip diameter * specific cutting force f


Fc = b h k c = a p f v k c , (with r=90)

if r is smaller than 90, then b is calculated with


ap
b= ,
sin r

a
h aus h = f sin r und
k N
kc = cm11c ,
h mm2
where kcl-1 is the kc-value based on the test conditions and mc
is a chip thickness index; kcl-1 and mc can be taken from the
following table.

2
Materials Specific Cutting Force kc in N/mm by thickness of cut h in mm

However, the formula mentioned above is not sufficient for calculating the cutting force. Various compensa-
tion factors must first be taken into account. After these compensation factors are considered, the applicable
formula is as follows:

Fc = a p f v k c K o K v K sch K ver [N ]
The compensation factors in the formula are:

K0 is the angle of rake variation factor. It is calculated from


o ok
K o = 1 , whereby 0 is the given angle of rake and ok is the angle of rake used for de-
66. 7
termining the kc-Werte.

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Technological Basics for CNC Machining

Kv is the cutting speed variation factor. The tabular values are only for the area between vc=90...125 m/min.
It is taken from the following Kv-vc-Diagram.

Kv- vc - diagram:
The identificated Kv - values are valid for:
Kv

v c in m/min
Example:

Ksch is the cutting edge variation factor for hard-metal to cutting ceramic, whereby hard-metal is 1 and cutting
ceramic is set between 0.9....0.95.

Kver is the cutting edge abrasion factor. It has to be estimated since the kc-values from the table only apply to
working sharp tools. For this reason a Kver-value of 1.3...1.5 is used.

Solution:
The compensation value Ksch conform with the table provisions and can be set with 1. aP and f v are given.
All other values must be determined:

kc11 N o ok
kc = K o = 1
h mc mm2 66.7
2220 10 6
kc = K o == 1
0.20.14 66.7
N K o = 0,94
kc = 2781
mm2
Selected as the compensation values:
Kver=1,3 and taken from the diagram
Kv=0,96. For the desired cutting force this yields:

Fc = a p f k c K 0 Kv Ksch Kver
Fcv = 4.5mm 0. 2 mm 2781 N / mm 2 0. 96 0. 94 1 1. 3
Fcv = 2936 N

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Basic Geometry for CNC Machining

2. The cutting performanc PC

The cutting performance PC is calculated with the equation

m 1 min Nm
Pc = Fc v c N = , using the values from the examples yields
min 60s 60s
m
Pcv = 2936 N 200
min
Nm
Pcv = 9786, 7 , da 1Nm/s = 1W (Watt) ist, sind 9786,7 Nm/s = 9,787 KW
s
Pcv = 9. 787 KW

3. The power output of the drive motor Pab

With known cutting performacne the power output of the drive motor Pab is calculated with the formula:

Pcv KW
Pab = = KW
1
9.787
Pab =
0.8
Pab = 12.23KW

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Technological Basics for CNC Machining

Calculation examples of technological data for CNC milling


Calculating the infeed speed vf

For milling the infeed speed vf is usually calculated in mm per min. However, the feed per tooth fz is just as
important, since the skilled worker foremostly knows what feed a cutting edge can endure. This feed must be
distinguished from a feed attained in a milling cutter rotation.
infeed speed vf vf in mm / min
feed per tooth fz in mm
feed per rotation f in mm

The following formulae are available for calculation:

v f = fz * n * z in mm / min

vf = f *n in mm / min

v f = f * n = fz * n * z in mm / min

1. Example:

A plate made from C15 is to be milled in one cut using an end-face mill with indexable inserts.
The step is 10 mm high. The cutting speed vc is 160 m/min and the feed per cutter edge fz is
0,18 mm. The end-face mill with = 63 mm has four cutting edges.
How high is the infeed speed vf?

datum: vc = 160 m/min


d = 63 mm
fz = 0,18 mm
z =4
unknown: vf in mm/min

valid : v f = fz * n * z ,

vc = * d * n or

vc
n= , it follows:
*d
v
v f = c * fz * z
*d
160000mm
vf = * 0,18mm * 4
* min* 63mm
solution: v f = 582mm / min

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Basic Geometry for CNC Machining

2. Example:

Calculating thein feed speed vf

On a CNC-vertical milling cutter the slot of the sketched work part is to be milled in one cut with a two-edged
slot boring cutter of 12mm , n = 1800 1/min number of rotations and a feed f z of 0.12 mm. How high is the
infeed speed?

datum: 1
n = 1800
min
f z = 0.12 mm
z=2
unknown: vf in mm/min

valid : v f = fz * n * z ,

1
v f = 0,12mm * 1800 *2
min
solution: v f = 432mm / min

3. Example

Calculating the number of rotations n

How high must the number of rotations be when the slot is machined with a boring feed of 0.1 mm per edge
and a longitudinal feed of 0.15 mm and with an infeed speed of 200 mm/min ?

f b = 0.10mm 1
datum: datum: n = 1800
min
f z = 0.15mm
mm f z = 0.12 mm
v f = 200
min z=2
unknown: 1 unknown: 1
nb in nl in
min min
valid : v mm valid : vf mm
nb = f nl =
fb z min mm fzl z min mm
200 1
200 nf =
nb = . 2 min
015
0.1 2 1
nf = 667
1 min
nb = 1000
min

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Technological Basics for CNC Machining

Calculating the cutting force and motor power

For calculating the cutting force, the same compensation factors are used for milling as in for turning..

ap cutting depth
ae entering point
b chip width
Fcz cutting force per edge (mean)
s entering angle
hm middle chip thickness
fz feed per edge
s
z number of cutter edges
ze number of edges in operation
D diameter of milling cutter
angle of twist of edges
adjustment angle of edges
kc specific cutting force
kc1-1 specific cutting force related to chip diame-
ter b hm =1 mm
mc chip thickness index

These are either taken from a book of specifications or, as in the case of the angle of rake variation factor,
o ok
calculated with the formula K o = 1 . For milling, the cutting force is:
66. 7
Fc = Fcz ze N 1 = N . In this formula
z s
ze = and
360
Fcz = b hm k c . Herewith are
ae
b= mm and
cos
360ae
hm = f z sin mm .
d s
=90- for milling cutters with angle of twist.

Taking into account the compensation factors, the cutting force can be calculated with the formula:

N
Fc = ze b h m kc K o K v K ver mm mm 2
= N and with ze , b , hm yields the formula
mm
z s ae 360a p
Fc = f z sin k c K o Kv Kver
360 cos s d

MTS TeachWare CNC-Grundlagen Students Book 117


3.4 Calculation of technological data for CNC machining

Example:

As shown in the figure, a guide recess should be milled with a 4-edged end-face mill =40 mm into a guide
plate made of C35.
data : miller diameter d = 40mm
milled width ae = 40mm
milled depth ap = 6mm
feed f z = 0.12 mm
angle of rake 0 = 10
angle of twist = 30
adjustment angle = 90
material C35
machine output M = 0.82
cutting speed vc=140mm/min

Calculating the cutting force Fc

z s a e 360a p mm mm N
Fc = f z sin k c K o K v K ver 1 mm 1 = N
360 cos s d 1 mm mm 2

4 1 40 3606
Fc = 0.12 sin 90k c K o Kv Kver ;
360 cos 30 1 40
the kc-value can not be taken directly from the table. It is calculated as follows:
k c11
kc = ,
h mc
kc11 with 1860 can be taken from the table as well as mc with 0.2. The hm-value is calculated as follows:
360a p
hm = f z sin
s d
Consequently,
360 6
hm = = 3. 87 mm and
44. 4 40
1860 N
kc = 0.2
= 1420 .
3. 87 mm 2
ok 10 6
K o = 1 o = 1 = 0. 94
66. 7 66. 7
Kv with 0.97 is taken from the diagram. 1.3 is selected for the edge abrasion compensation value Kver. All
values for the cutting force are therefore established and can be calculated:
4 40 6 0.12 1
Fc = 1420 0. 94 0. 97 1. 3
0. 866 40
Fc = 1782 N

Calculating the cutting performance Pc


The following formula is used for calculating the cutting performance Pc:
Pc = Fc *v c
m
Pc = 1782N *140
min
Nm
Pc = 1782 *140
60s
Pc = 415W

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Technological Basics for CNC Machining

Calculating the required motor output Pab

The following formula is used for calculating the motor output Pab:

Pc
Pab =
M c
0,45KW
Pab =
0,82
Pab = 055KW

Calculating the machining time

In one cut the sketched base sheet made from ST50 (see fig. 1) is to be milled in 12 mm gradations with a
three-edged end mill of 32 mm and 16 mm cutting edge lengths. How long is the machining time of the
CNC-machine when milled with a feed of 0.12 mm per cutter edge and cutting speed of 120 mm/min? The
lenghth of the approach and retreat movements are 22 mm.

data: material: ST50


miller diameter d =32 mm
feed per edge f z = 0.12 mm
m
cutting speed v c = 120
min
approach and retreat movements =
22mm
cutting depth ap = 12mm
work part length Ll = 90mm
work part depth Lb = 50mm

The following formula is used for calculating the machining time tnu:

Lges i mm 1 mm min
t nu = = = = min
f vc mm mm

min
(2L + 2L
l b + 2 A )
t nu = ;; with
f vc
vc . 3 140
012 mm
f v= fz z = f vc = = f v = 501 yields:
c d 0.032 c min
2 110 + 2 70 + 2 22
t nu =
501
t nu = 0.81 min

3.5 CNC clamping systems

Types of clamping systems


A clamping system attaches the work part to the machine tool. It must fulfill two essential functions:

MTS TeachWare CNC-Grundlagen Students Book 119


3.5 CNC clamping systems

1. It must clearly determine the position of the work part.


1. It must detain all forces from the work part.
The clamping elements constrain the work part and the required force for this is called clamping power.

In order to keep the costs for the clamping system as well as for production low, further requirements are
made on the clamping system:
simple and quick handling
versatile usage
easy exchangeability of the clamping elements
high accuracy with repeated clamping

Clamping power generation

Manual clamping is usually used on conventional machine tools. This requires a high energy exertion by the
worker. Special clamping systems for individual clamping equipment has been developed to reduce auxiliary
times and ease clamping for the worker. Various methods are used for generating clamping power:
mechanical clamping power generators
hydraulic clamping power generators
pneumatic clamping power generators
electric clamping systems

Mechanical clamping power generators are usually in the form of wedge lever-type or bellcrank lever-type
power chucks. These types of force chucks are usually used for turning machines.

1
4

chuck chuck
drawbar drawbar
wedge lever bellcrank lever
jaws jaws
Figure 125 figure 126
wedge lever-type power chuck (mechanical) Bellcrank lever-type power chuck (mechanical)

Hydraulic clamping fixtures generate the movement and power needed for clamping with hydraulically
powered pistons. These are usually manually controlled by the operator with valves. The clamping power
can be accurately controlled and is monitored on a display. Although hydraulic systems require high techni-
cal effort, they are quite reliable.

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Technological Basics for CNC Machining

Figure 127
Hydraulic actuating cylinders with through-hole Rhm SZ

Pneumatic clamping fixtures are operated with air pressure and function similiarly to hydraulic clamps.
Compressors are used for generating air pressure (compression).

Figure 128
Air actuating cylinders with through hole Rhm LHS

MTS TeachWare CNC-Grundlagen Students Book 121


3.5 CNC clamping systems

Electric clamps which rotate are used for force chucks with geared scroll systems. They enable a quick
adjustment to various work part diameters.

An electromagnetic clutch in the clamp blocks the spindle during the clamping and declamping process, so
that the full clamp torque is transmitted to the chuck.

Furthermore, there are electric clamps with stroke movements for operating clamping devices and force
chucks.

: thread nut
: thread spindle
: tie bar
: clutch
: epicyclic gears
: motor

Figure 129
Electric clamp with stroke movement

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Technological Basics for CNC Machining

Types and characteristics of clamping devices for turning

The different clamping devices for turning will be introduced in this section. In general, the following clamping
variations can be distinguished:
clamping in chucks
clamping with collets
clamping between centers
clamping on mandrels
clamping on faceplates
clamping with turning fixtures
clamping using steady rests

Clamping in chucks
Chucks are differentiated according to the number of jaws, i.e. two-, three- and four-jaw chucks. Self-
centering three-jaw chucks are most commonly used. They guarantee a quick, secure and centered mount-
ing of round blanks. With a four-jaw chuck, four-, eight- or twelve sided blanks as well as round blanks can
be clamped.

Figure 130 Figure 131


Self-centering three-jaw chuck Rhm ZG-ZS Self-centering four-jaw chuck Rhm ZG-ZS

The jaws are usually hardened and have increments. The jaws can be adjusted so that they can clamp parts
with various diameters. By exchanging jaws the turned parts can be either clamped from the inside or out-
side.

Clamping power transmission is usually based on the principal of geared scrolls or key bars.

MTS TeachWare CNC-Grundlagen Students Book 123


3.5 CNC clamping systems

Clamping power with a geared scroll

Chucks with geared scrolls are for lower clamping power. Only low force can be transmitted since the area
between the geared scroll and the jaw is so small.

Figure 132 Figure 133


Geared scroll chuck Rhm EG-ES Jaw operating mechanism

The disadvantage of chucks with geared scrolls is that changing requires the chucks to be fully dismounted.

: reversible top jaw


: adjusting screw
spindle
: base jaw
: pinion
: scroll
: pinion holder screw
: operating screw
: adjusting key

Figure 134
Geared scroll chuck Rhm EG-ES

Operation:
The rotation of the pinion (4) causes the scroll (5) to turn. The base jaw (3) consequently moves towards the
turning axis and clamps the work part.

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Technological Basics for CNC Machining

Clamping power with a key bar

The key bar chuck enables a quick change of jaws and generates higher clamping power than chucks with
geared scrolls.

Components:
22 cover 33 indicator pin 51 body
23 drive ring 34 bearing 56 key bar with inner thread
24GB base jaw 35 thrust ring 57 press pin
24EB one-piece jaw 36 pressure spring 58 locking slide
25 reversible top jaw 37 pressure spring 76 chip guard
27 operating screw 38 taper key 90 key with toggle
28 slide 39-42 socket head cap screw
29 jaw retaining pin 44 straight pin
Figure 135
Chuck with thrust ring and key bars Rhm Duro

Operation
The tangentially arranged operating screw (27) engages the internal thread of the actuating key bar (56) to
move a slide (28) which in turn moves the drive ring (23). Two further slides in the drive ring (23) transmit the
force to the other key bars. The key bars are provided witch helical teeth which engages the teeth of the
base jaws (24GB) so that the work part is gripped accurately and concentrically.

MTS TeachWare CNC-Grundlagen Students Book 125


3.5 CNC clamping systems

Clamping with collets

Collets enable cylindrical work parts to be quickly and accurately clamped. The collet clamps the work part
from the outside. Collets are usually only applicable for one work part diameter or a component group since
it only has a minimal, radial range of adjustment.

: work part
: clamping bocy
: spindle
: clamping tube

Figure 136
Collet

Clamping between centers

Clamping between centers is applied for longer parts. The work parts must be cut to length and centered on
both sides.

Figure 137
Clamping between centers

The following possibilities for clamping between centers can be distinguished based on the maching specifi-
cations:
face drivers with revolving or fixed centers
driver with a vise chuck with clamping ring revolving or fixed centers

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Technological Basics for CNC Machining

Face drivers are generally contained by the main spindle. They are used when the entire surface is to be
machined. The work part is clamped between the face driver and the tailstock. A disadvantage is that only
low torques are transmitted.

Figure 138
Face driver Rhm 681

The revolving tailstock center is inserted into the tail spindle of the tailstock. Since the center can revolve on
its own, higher cutting speeds during turning operation are possible.

Figure 139
Revolving tailstock center Rhm 601

MTS TeachWare CNC-Grundlagen Students Book 127


3.5 CNC clamping systems

The application area of dead centers is very limited. They only enable minor cutting depths because they
warm up and wear too quickly.

Figure 140
Dead center Rhm 667

Figure 141
Dead center with half point Rhm 670

A vise chuck with clamping ring centers the work part and additionally radially clamps it with a clamping bolt.
Consequently, larger torques can be transmitted and a higher machining performance is reached.

: driving disk

: sleeve with clamping bolt

: work part

Figure 142
vise chuck with clamping ring

128 MTS TeachWare CNC-Grundlagen Students Book


Technological Basics for CNC Machining

Clamping on mandrels
Work parts that have a bore hole, which can be very small, are clamped from the inside with clamping man-
drels. Two types can be distinguished: fixed mandrels and expanding mandrels.

Fixed mandrels are minimally conical (cone 1:2000) and are clamped between centers. They are only used
for finish turning since only low cutting depths are possible. The rotary accuracy of the centers must be
checked before being used.

Expanding mandrels are inserted into the inner cone of the main spindle. Clamping is established by the
slotted clamping part of the mandrel according to the rotary accuracy as well as by an even grip on the work
part. Clamping is enabled by pressing in the taper plug.

Figure 143
Cartridge mandrels Rhm

: clamping ring

: clamping sleeve

Figure 144
Cartridge mandrel Rhm MZB

Expanding mandrels are clamped between centers and only have a minor clamping area. They operate by
expanding a thin-walled, non-slotted sleeve made from a plastic for elastic deformation.

MTS TeachWare CNC-Grundlagen Students Book 129


3.5 CNC clamping systems

Clamping on face plates

Face plates enable irregularly formed parts to be clamped. The four or more clamping pistons can individu-
ally be adjusted as well as be turned. The clamping areas are constructed so that outer and inner clamping
is possible. Attaching fixtures and compensating weights is possible with the available clamping slots.

Figure 145
Hydraulically operated 6-jaw pull-down finger chuck Rhm

Clamping with turning fixtures


The perforated disk with threaded borings offers a variety of clamping possibilities. However this clamping
method requires a careful gyrating mass compensation, because the spindle run will otherwise be imbal-
anced. This consequently leads to imprecise machining results and in the worst case, damage to the ma-
chine tool..

: work part

: clamping body

: clamping bridge

: gyrating mass compensation

Figure 146
Turning fixture

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Technological Basics for CNC Machining

Clamping with steady rests

Steady rests are used for clamping long, slim work parts in order to withstand work part bending caused by
cutting force and own weight.

Figure 147
Self-centering steady rests Rhm SLZ

The work part is clamped between centers and additionally supported by steady rests.

Figure 148
Fixed steady rest

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3.5 CNC clamping systems

Types and characteristics of clamping devices for milling


Various possibilities for clamping work parts on milling cutters are introduced in this section. The following
clamping variations can be distinguished.
Jaw Chucking
Magnetic Chucking
Modular Chucking

Jaw Chucking

1. The vise can be turned in steps of 90 on


the machine table.

2. Its position can be changed.

3. The chucked part can be moved along


the x- and z-axes.

Magnetic Chucking

1. The position of the part on the machine


table can be freely defined.

Modular Chucking

1. The position of the part on the machine


table can be changed.

2. The chuck elements can be defined as


modules. The chuck position is specified
by the user.

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Technological Basics for CNC Machining

The milling cutter machine table with its T-slots is the basis for work part clamping. Depending on how the
work part is to be clamped, the following clamping devices can be distinguished:
mechanical clamping devices
hydraulic clamping devices
pneumatic clamping devices
electric clamping devices

Mechanical clamping devices


Mechanical clamping devices usually consist of various individual components, e.g. clamping iron, clamping
board and clamping bolts with T-nuts.

: work part

: clamping iron

: clamping board
1 2 3
: machine table

4
Figure 149
Clamping iron and clamping bard

For bedding with heavy work parts, alignment and support elements are used.

: support element

1 : work part

2 3 4 : clamping iron

: clamping board

: machine table

Figure 150
Clamping iron, clamping board and support element

MTS TeachWare CNC-Grundlagen Students Book 133


3.5 CNC clamping systems

Shallow clamps are used for flat work parts whose surfaces need to be kept free for machining.

: work part

: shallow clamp

Figure 151
shallow clamp

A dividing apparatus with circular table enables work parts to be quickly and symmetrically machined from
both sides. It is also possible to flange a chuck to a dividing apparatus which then can be used for accurately
dividing and machining round work parts.

Figure 152
Dividing apparatus with circular table

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Technological Basics for CNC Machining

Machine vises

Machine vises are easy to use and reliable. They are used for clamping smaller work parts. Alignment is
achieved with a measuring gauge.

Figure 153
Machine vise Rhm UZ

The clamping force transmission of machine vises is illustrated in the following figure.

Figure 154
Power transmission

Universal machine vises can be horizontally as well as vertically turned. Furthermore, there are also vises
that pneumatically generate clamping power.

Figure 155
Precision sine vise Rhm PS-SV

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3.5 CNC clamping systems

Pneumatic and hydraulic clamping devices

High precision NC vises, that are operated by pneumatic and hydraulic clamping cylinders, are used for
CNC-machine tools. Pneumatically operated high precision NC vises allow short opening and closing times.
However, the low operating pressure impedes high clamping power. On the other hand, depending on the
pressure adjustment, hydraulic clamping elements can exert high clamping power.

Figure 156
High precision NC vice Rhm RBA
The construction of a high precision NC vises is illustrated in the following figure.

1 fixed clamping jaw 2 movable clamping jaw 3 hydraulic unit


4 movable jaw 5 spindle 6 spindle nut
7 basic body 8 pneumatic spring
Figure 157
High precision NC vice Rhm RBA

Magnetic clamping devices

Work parts made of iron can be clamped with electromagnetic devices. The work part is drawn to the clamp-
ing plate after a current is switched on. It can be easily removed after the current is switched off.

Figure 158
Electromagnetic clamping plate

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Control test Technological Basics

7. Control test Technological Basics

1. What does a tool system on a CNC-lathe consist of?

1. Why are hard-metal indexable inserts primarily used for tools for CNC-machine tools?

1. Roughly describe the application areas of hard-metals.

1. Explain the significance of the clearance angle for machining tools.

1. What are the advantages of a larger angle of rake for the machining process?

1. What are the disadvantages of a larger angle of rake for the machining process?

1. When are negative are negative angles of rake necessary?

1. What is the significance of the adjustment angle for the machining process?

1. Exercise: Calculating the number of rotations


A shaft with a diameter of d=80mm is to be roughed with vc=120m/min.
How high is the number of rotations n?

1. Exercise: Calculating the cutting speed


A disk with a diameter of d=250mm rotates with n=100 /min. How high is the cutting speed vc during
turning at the circumference?

1. Name the functions of a clamping system.

1. Name the different types of chucks.

1. What parts are clamped on a faceplate?

1. When are steady rests used?

1. Name the different types of clamping power generators.

1. Name the clamping possibilities on a milling cutter.

1. What advantages do fixtures have?

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3.5 CNC clamping systems

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Introduction into NC programming

8. 4 Introduction into NC programming

4.1 Work organization and flow of manual NC programming

Comparison of work preparation of conventional and CNC machining

CNC-manufacturing has advantages over manufacturing with conventional machine tools, e.g. shorter pro-
duction times and a higher manufacturing capacity. In order to effectively use these advantages, the work
preparation must be accordingly adapted.

The objective of manufacturing is to keep the machining time on the machine tool as high as possible. How-
ever, to achieve this extensive planning must be done.

On conventional machine tools, the skilled worker can only produce or plan. However, on a CNC-machine
tool, the worker can concentrate on planning in parallel to the autonomous execution of the NC-program.
This consequently leads to much higher machining times on the CNC-machine tool.

Using conventional machine tools for production, the workshop drawing, a work plan and work order are
available to the worker. Furthermore, the worker must thoroughly plan the work steps and select the tools.
Since tool measuring is not possible on conventional machine tools, following each operation the tools must
be marked (touched) and then be measured. These steps are redundant when using a CNC-machine tool.
However, this does require the tools to be precedingly measured.

Many prepatory tasks can be transferred to the machine for CNC-work preparation. The objective is to allo-
cate all documents, tools and clamping devices as well as the blanks so that setting-up and production can
immediately begin. The tasks of work preparation can be divided into the following categories:
creating the required documents,
tool measuring,
managing tools and clamping devices, and
allocating all documents and accessories.
The documents required for CNC-manufacturing are much more defined compared with those for manufac-
turing on conventional machine tools. Creating these documents takes more time, however they are then
immediately accessible for repeated orders.

In addition to the NC-program, a set-up form is created for setting-up the CNC-machine tool. All information
on the used tools and the tool parts clamping situation is documented in this form.

Tool measuring enables the autonomous operation of the CNC-machine tool and easy application of tools on
various machines.

Tool and clamping device management is more extensive in CNC-work preparation, since they are generally
more varied than those for conventional machine tools and accordingly their description is more detailed.
The data is stored in tool and clamping device indices.

A complete allocation of all documents, preset tools and accessories enables the quick set-up of the CNC-
machine tool. The objective is to avoid machining delays and therefore, increase machining time

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4.1 Work organization and flow of manual NC programming

Organizing the steps of NC programming


NC-programs can be generated in different departments. Accordingly, the following forms of NC-
programming can be differentiated:
programming as part of production organization and
programming in the workshop.
The organizational classification of both these forms is illustrated in the following figure.

figure 159
Organizational classification of NC-programming

Programming as part of production organization


All planning measures for realizing a manufacturing order are carried out in the department for production
planning and precede manufacturing. Programming in this department is termed external programming since
the department is outside the workshop area.

The NC-programs are written by staffmembers who are specifically trained in NC-programming. They usually
work at a programming terminal and create the programs on a computer. Programs are not only generated
here but managed as well. The connection to the CNC-machine tool is over a DNC-system.

It is practical to generate programs in production planning when


extensive NC-programs or
NC-programs for complicated work parts are to be created, when
many NC-programs need to be managed or
when there are many CNC-machine tools.
Disadvantageous is that
the NC-programs must be optimized on the CNC-machine tools and
there is little contact with the workshop.

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Introduction into NC programming

Programming in the workshop

Generating NC-programs in the workshop is known as machine-based programming. The NC-programs can
either be directly created on a machine or at a programming terminal near the machines.

The NC-programs written in the workshop and in production planning are directly controlled and optimized
on the CNC-machine tool by the operator during set-up.

It is practical to generate programs in production planning when:


the experience of the workshop staff is to be considered,
short NC-programs or
NC-programs for simple tool parts are to be created,
there are only few CNC-machine tools, or
available NC-programs are to be quickly accessed.
Disadvantageous is that
the workshop personnel needs to specially trained and
lengthy programming time can possibly result in machining standstill.

Differences between the programming types

For manual programming, the programmer formulates the NC-program so that it can be directly understood
by the CNC-control. Every step that a CNC-machine tool is to execute must be individually programmed.

Extensive geometric calculations must be made with respect to the CNC-control efficiency and the geometric
complexity of the work part. Possible errors or collisions with e.g. clamping devices can not be automatically
detected. Simulations, which illustrate the tool movements, are integrated into most CNC-controls for testing
the NC-program.

For computer-aided (automatic) programming, the programmer is supported by a programming system. This
system takes over routine work that is susceptible to error when programming manually, such as calculating
coordinates and cutting data.

The fundamental difference to manual programming is that not the tool path is defined step-by-step, but
rather how the tool part is meant to look after machining. The geometric and technological data is herewith
strictly separated.

For automatic programming the sequence of operations for generating a NC-program is as follows:
1. First the work part must be geometrically defined. A representation of the finished part as
well as the blank is necessary.
1. Subsequently, the individual machining operations are specified. The programming system
assists the programmer in selecting the appropriate tool and automatically calculates the
necessary cutting data.
1. Finally a NC-program for a specific CNC-machine tool with a specific CNC-control is gen-
erated and can then be transferred to the machine.

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4.1 Work organization and flow of manual NC programming

CNC-programming can be done with different procedures and at different places. An overview of these pos-
sibilities is given in the following figure.

figure 160
Overview of NC-programming procedures and systems

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Introduction into NC programming

Programming procedure for manual NC programming at programming seat


Manufacturing on CNC-machine tools requires thorough planning and production preparation. All operations
that are executed by a skilled worker on a customary turning or milling machine must be well thought-out
and defined by the programmer in advance.

In manual NC-programming, the programmer formulates the machining task in an NC-program without as-
sistance from a programming system. The subsequent steps are herewith followed:
1. definition of machining steps
1. definition of necessary tools
1. calculation of technological data
1. calculation of geometric data
1. generating NC programs for individual machining processes
1. control of NC programs

The partial tasks to be executed are illustrated in fig. 3 and are subsequently explained.

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4.1 Work organization and flow of manual NC programming

figure 161
NC Programming Phases

Definition of machining steps


Specifying the machining sequence structures the NC-program to be generated. The programmer defines
the individual operations based on the production drawing. Furthermore, the necessary clampings and the
applicable clamping devices are registered in a clamping plan. Similarly, the individual machining steps are
registered in an operation sheet.

Definition of necessary tools


The programmer specifies the tools needed for each machining step. The tools are selected from a tool in-
dex.

Calculation of technological data


The cutting data with respect to the material and the used tool must be specified for each machining step.

Calculation of geometric data


The coordinates needed for programming traverse are taken from the production drawing or are specified by
calculating known coordinates.

Generating NC programs for individual machining processes


With respect to the previously determined geometric and technological data, the programming steps are
registered on a programming sheet.

Control of NC programs
The travel movements are simulated on a CNC-machine tool in order to detect and control programming
errors.

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Introduction into NC programming

Quality assurance during CNC production


The quality of parts manufactured on conventional machine tools is especially dependent upon the machine
operators training and constancy. In contrast, identical work parts of consistent quality can be repeatedly
manufactured on CNC-machines over a long period of time.

The following factors can affect the quality of the manufactured work part:
the created NC-program,
tool abrasion (cutting-edge life of the tool edge),
the work part material (characteristics and form),
the CNC-machine (precision and non-oscillating installation),
environmental factors (temperature effects) and
the operators behavior (error recognition with respect to quality).

Possibilities for regulating quality


How can the factors influencing quality be minimized?
Test, optimize and carefully run the program for the first work part as well as make necessary correc-
tions with respect to accurate dimensioning.
Tool wear can be monitored on a CNC-machine. This monitoring function is done by the CNC-control,
e.g. when the maximum machining duration for the tool has been reached, the tool is automatically
replaced by an identical one. Another possibility for determining abrasion is with a modern CNC-
machine equipped with a cutting force gauge. Herewith a tool is automatically changed as soon as the
cutting force increases beyond a set limit.
Deviations in dimension can be detected with integrated measuring systems. For internal tool measur-
ing, e.g. a probe is incorporated in a collision-free position in the turret of a CNC-lathe (see fig. 4). In
the cyclical sequence of part manufacturing, a measuring process is included and automatically im-
plemented. This process is executed by a CNC-measuring program accessed by the CNC-control.

1
probe

tool

turret
3

Figure 162
Internal tool measuring
Calibrated measurement and test techniques for precise measuring and verification.
Operator training.
Air-conditioning the workshop rooms.
Observing quality when purchasing and installing a machine.

Workshop

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4.2 NC programming basics

The different programming procedures, the NC-program management as well as the clamp and tool indices
should be demonstrated.

4.2 NC programming basics

A NC-program comprises a series of commands with which the CNC-machine tool is instructed to manufac-
ture a certain tool.

For each machining process on a CNC-machine tool, the NC-program has a command with relevant infor-
mation. These commands are alphanumerically coded, i.e. they consist of letters, numbers and characters.

NC programming standards (ISO)

The ISO-Norm 6983 strives for standardizing the NC-programming of machines in the production area. This
is however limited to standardizing certain commands as well the general structure of a NC-program. CNC-
control manufacturers have considerable liberty for incorporating their own NC-commands in their controls.
Subsequently, the general structure of an NC-program according to ISO 6983 is illustrated.

Structure of an NC program

Structure of an NC program:
A complete NC-program consists of the following elements:

% TP0147 NC-program beginning,

N10 G54 X80 Y100... a series of NC-blocks

... with the information for machining and

N75 G01 Z-10 F0.3 S1800 T03 M08

...

N435 M30 a command for ending the program.


figure 163
Structure of an NC-program

The program beginning consists of a character or a command (ex. %) which informs the CNC-control that
a NC-program will follow. Additionally, the first line of the NC-program also contains the program name (ex.
TP0147). Furthermore, both characteristics are also important for the NC-program manager as well as for
calling the NC-programs in the CNC-control.

NC-program names can contain alphanumerical or numerical characters. For most CNC-controls 2-6 digit
character sequences are used for identification.

An NC-program consists of a chronological sequence of blocks. They contain the relevant geometric and
technical information that the CNC-control requires for each machining step.

The program end is commanded with M30 or M02.

Everything that stands before the character % for commenting the program is ignored by the control. This
enables any explanations on the program or tool to be attached preceding the actual program. Comments
are also allowed within a program, e.g. for identifying particular blocks. These, however, must be set in
brackets.

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Structure of a program block

Every NC-block consists of a block number, a number of words as well as a specific control character which
informs the CNC-control that the NC-block has ended. This control character is called LF for line feed. It is
automatically generated in NC-programming when the enter-key of the CNC-control or the enter-key on the
PC-keyboard is pressed.

N75 G01 Z-10.75 F0.3 S1800 T03 M08 LF

Number of Word Word Word Word Word Word invisible block


the NC-block ending charac-
ter
figure 164
Structure of a program block

Structure of a program word

A word consists of address letters and a number with a plus/minus sign. The definition and sequence are
designated in the programming instructions of the CNC-control systems. Depending on the address letter,
the number either pertains to a code or a value.

Example Address Number Definition

N75 N 75 For the address N, 75 is the number of the NC-block.

G01 G 01 For the address G, 01 is a code. The NC-command G01 is "Moving


the tool along a straight line at infeed speed".

Z-10.75 Z -10.75 For the address Z, -10.75 is a value. Corresponding to the NC-
command G01 of the preceding NC-block example, this means that
the tool is to be moved to the position Z=-10.75 in the current tool co-
ordinate system.
figure 165
Structure of a program word

The form of numerical entry depends on the CNC-control: Z-35.5 is equivalent to e.g. the same target coor-
dinates as Z-035.500. For most CNC-controls the positive sign "+" can be excluded in the NC-program.

Generally, three groups of words in an NC-block can be differentiated:

G-Functions Coordinates Additional and Switching Func-


tions

G00 X F

G01 Y S

G02 Z T

G54 M
figure 166
Groups of program words

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4.2 NC programming basics

The sequence of the words in an NC-block is designated as follows:

Address Definition

1. N block number

2. G G-functions

3. X, Y, Z coordinates

4. I, J, K interpolation parameter

5. F feed

6. S speed

7. T tool position

8. M additional functions
figure 167
Sequence of program words

Words that are not needed by a block can be excluded.

Block number N
The block number is the first word in a block and designates it. It can only be conferred once. The block
number has no influence on the execution of the individual blocks since they are invoked following the order
in which they were entered into the control.

G-function
Together with the words for the coordinates, this word essentially determines the geometric part of the NC-
program. It consists of the address letter G and a two-digit code.

Coordinates X, Y, Z
The coordinates X, Y, Z define the target points that are needed for travel.

Interpolation parameters I, J, K
The interpolation parameters I, J, K are e.g. used to define the center of a circle for circular movements.
They are usually entered incrementally.

Feed F
The speed at which the tool is to be moved is programmed with the function F. The infeed speed is usually
entered in mm/min. For turning, the unit mm/U pertaining to spindle rotation can also be used.

Spindle speed S
The function S is for entering the spindle speed. It can be directly programmed in rotations per minute.

Tool position T
The address T together with a numerical code designates a specific tool. The definition of this address dif-
fers according to the control and can have the following functions:
Saving the tool dimensions in the tool offset table
Loading the tool from the tool magazine.

Additional functions M
The additional functions, also known as auxiliary functions, primarily contain technical data that is not pro-
grammed in the words with address letters F, S, T. These functions are entered with the address letter M
and a two-digit code.

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Comparison of programming codes/keys of various CNC controls


The basic commands are standardized in ISO 6983. CNC-control manufacturers add their own extensions or
commands to these basic ones.

Subsequently, a comparison of commands in different controls is given

Description MTS OKUMA FANUC 16M


rapid traverse G00 G00 G00
linear interpolation in slow feed motion G01 G01 G01
circular interpolation clockwise G02 G02 G02
circular interpolation counter-clockwise G03 G03 G03
Dwell Time G04 G04 G04
cancel Cutter or tool nose compensation G40 G40 G40
Cutter or tool nose compensation: left G41 G41 G41
Cutter or tool nose compensation: right G42 G42 G42
Maximum spindle speed designation G50
Select work cordinate system one G54
Activate absolute dimensioning G90 G90 G90
Activate incremental dimensioning G91 G91 G91
feedrate in mm per min G94 G94 G94
feedrate in mm per revolution G95 G95 G95
Constant Speed Cutting ON G96
Constant Speed Cutting OFF G97
X-coordinate of the target point X X X
Y-coordinate of the target point Y Y
Z-coordinate of the target point Z Z Z
Distance between starting position and circle center in X I I I
Distance between starting position and circle center in Y J J
Distance between starting position and circle center in Z K K K
spindle speed S S S
Feedrate F F F
Tool Changing T T T
activate the spindle in clockwise rotation M3 M3 M3
activate the spindle in counter-clockwise rotation M4 M4 M4
deactivate the spindle M5 M5 M5
Mounting the tool M6
Activate coolant M8 M8 M8
deactivate coolant M9 M9 M9
Program hold M00 M00 M00
program end and backspacing M30 M30 M30

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4.2 NC programming basics

Select the higher spindle speed Range M42


ignoring spindle rotation M code answer M63

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CNC Exercise
In the following NC-program, the contour of a pre-turned part is finished. For each command give the corre-
sponding definition.

Block Commands Description


No.
O 0300 0300 program name
N05 T040404 select the tool from the turret position 4
M3
M42
M63
G96
S140
N10 G50
S3000 spindle speed (revolution per minute)
N15 G0
X20
Z2
M8
N20 G1
X20
Z0
G42
N25 G3
X28
Z-4
I0
K-4
N30 G1
Z-28
N35 G2
X34
Z-31
I3
K0
N40 G1
X38
Z-33
N45 G1
Z-53
N50 G1
X44

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4.2 NC programming basics

Block Commands Description


No.
N55 G3
X50
Z-56
I0
K-3
N60 G1
Z-64
N65 G2
X62
Z-70
I6
K0
N70 G1
X66
N75 G1
X71
Z-72
N80 G1
X76
N85 G40
N90 G0
X500
Z500
M5
M9
N95 M30

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CNC Exercise
In the following NC-program, the contour of a work part is milled. For each command, give the corresponding
definition.

Block Commands Description


No.
FX100 program name
N05 G54
N10 G90
G49 cancel tool length compensation
G80 cancel canned cycle
G40
G17 select the X-Y-plane
G21 metric input
N20 G91
G28 reference point return
Z0.
M9
N25 G91
G28 reference point return
X0.
Y0.
N30 T01 select the tool number 1 from the magazine
M06
N35 G90
S1600
M03
N40 G0
G43 tool length compensation
Z20.
H17 offset number for the tool length
N45 X-20.
Y-20.
N50 Z-6.
M08
N55 G1
G41
X10.
D1 offset number for the cutter radius
F250. feedrate (in mm per min)
N60 G1
Y82.

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4.2 NC programming basics

Block Commands Description


No.
N65 G2
X18.
Y90.
R8. radius of the circle
N70 G1
X82.
N75 G2
X90.
Y82.
R8.
N80 G1
Y18.
N85 G2
X82.
Y10.
R8.
N90 G1
X18.
N95 G2
X10.
Y18.
R8.
N100 G3
X-10.
Y38.
R20.
N105 G0
G40.
X-20.
Y-20.
N110 G0
Z40.
M5

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Block Commands Description


No.
N115 G91 activate incremental dimensioning
G28 reference point return
Z0.
M9
N120 G90
G80 cancel canned cycle
G49 cancel tool length compensation
G40
N125 M30

Workshop

On the CNC-machine tools, available NC-programs are to be loaded and be executed step-by-step.

Special attention should be paid to the respective control panels with the manufacturer-specific pictograms.

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4.3 Introduction to manual NC programming

4.3 Introduction to manual NC programming


Procedure for manual NC programming
The procedure for manual programming can be divided into four steps:
1. analysis of workshop drawings
1. definition of work plans
1. choice of clamping devices and necessary tools (set-up sheet)
1. generating the NC program (program sheet)
Various documents must be analyzed and plans for production execution must be created. (see fig. 168).

study study
work order workshop drawing

tools programmer clamping


devices

work plan set-up form

program sheet

figure 168
Procedure for manual programming

Analysis of workshop drawings


The workshop drawing (see fig. 169) contains the geometric and technical information for the finished part.
The dimensions, the surface specifications as well as information on the machining procedure to be used
(e.g. cutting, threading, hardening) are taken from the drawing. Information on the work to be executed as
well as on the number of work parts and the deadlines is specified in the work order.

figure 169 figure 170


Workshop drawing turning Workshop drawing milling

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Definition of work plans


The workshop drawing and the work order determine the machining operation sequence.

Basic type No..: 4711 Standard work plan No.: 007 Date 13.03.91

Sketch for basic type: Gear wheel Maximum ratings: Work piece material:
90 <= Da < 150 Round bar
35 <= Di < 80 Dr = 1.05 x Da
10 <= NB < 20 Lr = L + 5
2 <= Z < 20 Material: C45

Da: = External diameter Z: = Counter value Dr: = Work piece diameter


Di: = Internal diameter NB: = Slot width Lr: = Work piece length

N. Machining description Production Machining alternatives Machine Cost tr [min] Calculation formula for time per piece te
aids group center [min/piece]
Decision criteria

01 saw LR mm long and 55/1 1101 3 te = 0,5 x Dr


deburr

02 turning and main drilling sketch 120 <= Da < 240 and 66/1 1212 12 te = 1,5 x (Dr - Da) + 0,1 x Lr
30 <= L < 80

03 sketching axial drillings available 1300 0 te = 0,5 x number of drillings

04 auxiliary drillings axial drillings available and


drilling- <= 10 mm 71/1 1217 2 te = 0,5 x number of drillings
axial drillings available and
drilling- > 10 mm 72/2 1217 2 te = 0,05 x number of drillings x
drilling depth

figure 171
Work order

This sequence is then registered in a work plan. The clamping situation must already be considered at this
time. Clamping must be sketched for complicated situations or reclamping.

figure 172
Work plan

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4.3 Introduction to manual NC programming

Choice of clamping devices and necessary tools


In this phase, all data needed for executing the individual machining operations, i.e. for high-quality produc-
tion, is entered into the work plan (see fig. 14). After selecting the required clamping elements, the neces-
sary tools are chosen and the pertinent cutting data for each operation is calculated.

figure 173
Set-up form
All data that is needed for setting up the CNC-machine tool is listed in the set-up form (see fig. 15). Espe-
cially the information on the program number and drawing number as well as the work part name identifies
all documents required for the order. For repeated orders, information on the position of the work part en-
ables an easier set-up of the clamping situation.
Generating the NC program
The programmer creates the NC-program based on the workshop drawing and work plan, and enters the
individual program blocks into a program sheet (see fig. 16). This program sheet supplements the docu-
ments at hand. For a repeated order, the machine can then immediately be set-up.

Program Sheet

Programming
N G X Z I K F M T

figure 174
Program Sheet

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Manual NC programming Turning

CNC exercise

Instructed generation of NC-programs for CNC-turning operations

Task:
An NC-program is to be generated for manufacturing the following part.

figure 175

Follow the subsequent steps for generating the NC-program:

1. definition of the work plan


1. choice of clamping devices and necessary tools
1. generating the NC program
1. simulating the NC program

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4.3 Introduction to manual NC programming

Definition of the work plan

Work plan for machining the first side:

Machining Sequence Tool Turret Posi- Cutting Outline


tion Values
1 check blank
1
dimensions
2 clamp work part
1.side
3 define work part zero
point 3
2

4 Face Turning Left Corner Tool T04 G96


4
CL-SCLCL-2020/R/1208 F0.15
S140

5 Centering Center Drill T09 G97


CD-03.15/050/R/HSS F0.16
5
S1800

6 Drilling Twist Drill 14mm T07 G97


DR-18.00/130/R/HSS F0.22
6
S1000

7 Outside contour Left Corner Tool T04 G96


roughing 7
CL-SCLCL-2020/R/1208 F0.1
S140

8 Outside contour finish- Left Corner Tool T02 G96


ing 8
CL-SVJCL-2020/R/1604 F0.1
S280

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Work plan for machining the second side:

Machining Sequence Tool Turret Posi- Cutting Outline


tion Values
1 check work part
1
2 clamp work part 2
2.side 3
3 define work part zero
point

4 Face Turning with Left Corner Tool T04 G96


offset 0.2mm
CL-SCLCL-2020/R/1208 F0.28
4
S140

5 Outside contour Left Corner Tool T04 G96


roughing 5
CL-SCLCL-2020/R/1208 F0.28
S140

6 Predrilling Reversible Tip Drill T12 G97


22mm
F0.2
DI-22.00/051/R/HMT 6
S850

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4.3 Introduction to manual NC programming

Machining Sequence Tool Turret Posi- Cutting Outline


tion Values
7 Inside contour rough- Inside Turning Tool T05 G96
ing with offset Post
F0.2
BI-SDQCL-1616/R1104 7
S120

8 Inside contour finish- Inside Turning Tool T10 G96


ing Post
F0.1
BI-SVQJCL-2020/R/1604 8
S220

9 Outside contour finish- Left Corner Tool T02 G96


ing 9
CL-SVJCL-2020/R/1604 F0.1
S280

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Setting-up the CNC machine (set-up sheet)

After start, the MTS-simulator is automatically set-up with blank, clamping and turret allocation. If the follow-
ing set-up data does not conform with the current set-up data, then it must be changed in the set-up opera-
tion.

figure 176 figure 177


Setup Dialog Interactivmod

Set-up sheet for machining the first side:


CONFIGURATION
MACHINE MTS01 TM-016_-R1_-060x0646x0920
CONTROL MTS TM01
PART
CYLINDER D075.000 L100.000
MATERIAL AlMg 1::Aluminium
DENSITY 002.70
MAIN SPINDLE WITH WORKPART
CHUCK "Chuck Turning\Jaw chuck\KFD-HS 160"
STEP JAW "Jaw\Step jaw\HM-160_200-02.001"
TYPE OF CHUCK EXTERNAL CHUCK OUTSIDE STEP JAW
CHUCKING DEPTH E18.000
TAILSTOCK
TAILSTOCK POSITION Z+1095.000
CURRENT TOOL
T01
TOOLS
T02 "DIN69880 V 30\ Left corner tool\CL-SVACL-2020 L 1604 ISO30"
T04 "DIN69880 V 30\ Left corner tool\CL-SCLCL-2020 L 1208 ISO30"
T05 "DIN69880 V 30\ Inside turning tool postaxial\BI-SDQCL-1212 L 0704 ISO30"
T07 "DIN69880 V 30\ Twist drill\DR-14.00 108 R HSS ISO30"
T09 "DIN69880 V 30\ Center drill\CD-04.00 056 R HSS ISO30"
T12 "DIN69880 V 30\ Reversible tip drill\DI-22.00 051 R HMT ISO30"
T14 "DIN69880 V 30\ Inside turning tool postaxial\BI-SDQCL-1212 L 0704 ISO30"
TOOL COMPENSATION
D02 T02 Q3 R0.4 X+70.0 Z+45.0 G0.0 E52.393 I-0.4 K-0.4 A+2.372 L16.178 N01
D04 T04 Q3 R0.8 X+70.0 Z+45.0 G0.0 E05.005 I-0.8 K-0.8 A+4.375 L11.855 N01
D05 T05 Q2 R0.4 X-8.364 Z+160.0 G0.0 E18.027 I+0.4 K-0.4 A+16.744 L7.029 N01
D07 T07 Q7 R0.0 X+0.0 Z+180.0 G14.0 E59.0 I+0.0 K+0.0 A+0.0 L0.0 N01
D09 T09 Q7 R0. 0 X+0. 0 Z+70.0 G04.0 E0.0 I+0.0 K+0.0 A+0.0 L0.0 N01
D12 T12 Q7 R0.0 X+0.0 Z+180.0 G22.0 E0.0 I+0.0 K+0.0 A+0.0 L0.0 N01
D14 T14 Q2 R0.4 X-8.364 Z+160.0 G0.0 E18.027 I+0.4 K-0.4 A+16.744 L7.029 N01

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4.3 Introduction to manual NC programming

Set-up sheet for machining the second side:


For machining the second side, the work part is reclamped, i.e. no blank is clamped!

The work part is clamped after the first side is machined. The current form is defined in part GEOMETRY.

File Selection Window

figure 178 figure 179


Diagram of the menu sequence for the Work part File information for loading a preproduced work
Manager. part.

CONFIGURATION
MACHINE MTS01 TM-016_-R1_-060x0646x0920
CONTROL MTS TM01

PART
GEOMETRY X+071.331 Z+0165.500
G01 X+075.000 Z+0165.500
G01 X+075.000 Z+0191.000
G01 X+014.000 Z+0191.000
G01 X+014.000 Z+0093.000
G01 X+020.000 Z+0093.000
G02 X+028.000 Z+0097.000 I+000.000 K+004.000
G01 X+028.000 Z+0121.000
G03 X+034.000 Z+0124.000 I+003.000 K+000.000
G01 X+034.000 Z+0145.600
G03 X+034.800 Z+0146.000 I+000.400 K+000.000
G01 X+044.000 Z+0146.000
G02 X+050.000 Z+0149.000 I+000.000 K+003.000
G01 X+050.000 Z+0157.000
G03 X+062.000 Z+0163.000 I+006.000 K+000.000
G01 X+066.000 Z+0163.000
G01 X+070.766 Z+0165.383
G03 X+071.331 Z+0165.500 I+000.283 K-000.283
M30
MAIN SPINDLE WITH CHUCK "Chuck Turning\Jaw chuck\KFD-HS 160"
WORKPART
STEP JAW "Jaw\Step jaw\HM-160_200-02.001"
CHUCKING DEPTH E53.000
Right side of the part: Z+0191.000
CHUCK "Chuck Turning\Jaw chuck\KFD-HS 160"

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Introduction into NC programming

NC programming

NC program for the first side

Block Commands Description


No.
%200 Program name

4) Plandrehen
N010 G54 Z+226.000 G54 set absolute zero
Z+226.000 Z- coodinate of the current workpart zero
N015 G96 S0140 T0404 M03 G96 Constant speed cutting ON
S140 Spindle speed
T0404 Selection of the tool from turret position 4
M3 activate the spindle in clockwise rotation
N020 G92 S3000 G92 Speed limit
S3000 Spindle speed
N025 G00 X+078.000 Z+000.200 G00 Rapid traverse
X+078.000 X- Coordinate of the target point
Z+000.200 Z- Coordinate of the target point
N030 G01 X-001.000 F000.150 M08 G01 Linear interpolation in slow speed motion
X-001.000 X- Coordinate of the target point
F000.150 feedrate in mm per revolution
M8 activate coolant
N035 G00 Z+002.000 G00 Rapid traverse
Z+002.000Z- Coordinate of the target point
N040 X+200.000 Y+200.000 M5 M9 X200.000 X- Coordinate of the target point
Z200.000 Z- Coordinate of the target point
M5 deactivate spindle
M9 deactivate coolant

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4.3 Introduction to manual NC programming

Block Commands Description


No.
5) Centering
5) Zentrieren
N045 G97 S1800 T0909 M03 G97 Constant Speed Cutting OFF
S1800 Spindle speed
T0909 Selection of the tool from turret position 9
M3 activate the spindle in clockwise rotation
N050 G00 Z+002.000 G00 Rapid traverse
Z2 Z- Coordinate of the target point
N055 X+000.000 X+000.000 X- Coordinate of the target point
N060 G01 Z-005.800 F000.160 M08 G01 Linear interpolation of slow feed motion
Z-005.800 Z- Coordinate of the target point
F000.160 feedrate in mm per revolution
M08 activate coolant
N065 G00 Z+002.000 G00 Rapid traverse
Z002.000 Z- Coordinate of the target point
N070 X+200.000 Z+200.000 M5 M9 X200.000 X- Coordinate of the target point
Z200.000 Z- Coordinate of the target point
M5 deactivate spindle
M9 deactivate coolant

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Block Commands Description


No.
6) Drilling
N075 F000.220 T0707 M03 F000.220 feedrate in mm per revolution
T0707 Selection of the tool from turret position 7
M3 activate the spindle in clockwise rotation
N080 G97 S1000 G97 Constant Speed Cutting OFF
S1000 Spindle speed
N085 G00 Z+002.000 G00 Rapid traverse
Z+002.000Z-Coordinate of the targer point
N090 X+000.000 M08 X000.000 X- Coordinate of the target point
M08 activate coolant
N095 G84 Z-105.000 A+001.000 G84 Drilling cycle
B+001.000 D+005.000
Z-105.000 Z-coordinae of the target point
K+025.000
A+001.000 Dwell time after retraction
B+001.000 Dwell time when target point is reached
for chip breaking
D+005.000 Digression (reduction of drilling depth)
K+025.000 first depth of cut
N100 G00 X+200.000 G00 Rapid traverse
X200.000 X- Coordinate of the target point
N105 Z+070.000 M5 M9 Z070 Z- Coordinate of the target point
M5 deactivate spindle
M9 deactivate coolant

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4.3 Introduction to manual NC programming

Block Commands Description


No.
7) Outside contour roughing
N110 G96 S0140 T0404 M03 G96 Constant speed cutting ON
S0140 Spindle speed
T0404 Selection of the tool from turret position 4
M3 activate the spindle in clockwise rotation
N115 G92 S3000 G92 Maximum spindle speed
S3000 Spindle speed
N120 G00 X+075.000 Z+002.000 G00 Rapid traverse
X+075.000 X- Coordinate of the target point
Z+002.000 Z- Coordinate of the target point
N125 G57 X+000.600 Z+000.200 G57 finishing allowance activation
X+000.600 finishing allowance activation in X-Richtung (durch-
messerbezogen)
Z+000.200 finishing allowance activation in Z-Richtung
N130 G81 X+018.000 Z+002.000 G81 straight roughing cycle
I+004.000
X+018.000 X- Coordinate of contour start point
Z+002.000 Z- Coordinate of contour start point
I+004.000 Infeed
N135 G42 G42 tool nose compensation: right of the contour
N140 G01 X+018.000 Z+000.000 G01 Linear interpolation of slow feed motion
X+018.000 X- Coordinate of the target point
Z+000.000 Z- Coordinate of the target point
N145 X+020.000 X+018.000 X- Coordinate of the target point
N150 G03 X+028.000 Z-004.000 G03 circular interpolation counter-clockwise
I+000.000 K-004.000
X+028.000 X- Coordinate of the target point
Z-004.000 Z- Coordinate of the target point
I+000.000 Distance between starting position and circle center in
X
K-004.000 Distance between starting position and circle center in
Z
N155 G01 Z-028.000 G01 Linear interpolation of slow feed motion
Z-028.000 Z- Coordinate of the target point
N160 G01 X+018.000 Z+000.000 G01 Linear interpolation of slow feed motion
X+018.000 X- Coordinate of the target point
Z+000.000 Z- Coordinate of the target point

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N165 G02 X+034.000 Z-031.000 G02 Circular interpolation counter-clockwise


I+003.000 K+000.000
X+034.000 X- Coordinate of the target point
Z-031.000 Z- Coordinate of the target point
I+003.000 Distance between starting position and circle center in
X
K-000.000 Distance between starting position and circle center in
Z

Block Commands Description


No.
N170 G01 Z-053.000 G01 Linear interpolation of slow feed motion
Z-053.000 Z- Coordinate of the target point
N175 G01 X+044.000 G01 Linear interpolation of slow feed motion
X+044.000 X- Coordinate of the target point
N180 G03 X+050.000 Z-056.000 G03 Circular interpolation counter-clockwise
I+000.000 K-003.000
X+050.000 X- Coordinate of the target point
Z-056.000 Z- Coordinate of the target point
I+000.000 Distance between starting position and circle center in
X
K-003.000 Distance between starting position and circle center in
Z
N185 G01 Z-064.000 G01 Linear interpolation of slow feed motion
Z-064.000 Z-Coordinate of the target point
N190 G02 X+062.000 Z-070.000 G02 Circular interpolation counter-clockwise
I+006.000 K+000.000
X+062.000 X-Coordinate of the target point
Z-070.000 Z-Coordinate of the target point
I+006.000 Distance between starting position and circle center in
X
K-000.000 Distance between starting position and circle center in
Z
N195 G01 X+066.000 G01 Linear interpolation of slow feed motion
X+066.000 X- Coordinate of the target point
N200 G01 X+071.000 Z-072.500 G01 Linear interpolation of slow feed motion
X+071.000 X- Coordinate of the target point
Z-072.500 Z- Coordinate of the target point
N205 G01 X+076.000 G01 Linear interpolation of slow feed motion
X+076.000 X-Coordinate of the target point
N210 G40 G40 cancel tool nose compensation
N215 G80 G80 End of contour definition for straight roughing cycle

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4.3 Introduction to manual NC programming

N220 G00 X+200.000 Z+200.000 M5 G0 Rapid traverse


M9
X200.000 X-Coordinate of the target point
Z200.000 Z-Coordinate of the target point
M5 deactivate spindle
M9 deactivate coolant

8) Outside contour finishing


N225 G96 F000.100 S0280 T0202 G96 Constant speed cutting ON
M03
F000.100 feedrate in mm per revolution
S0280 Spindle speed
T0202 Selection of the tool from turret position 2
M03 activate the spindle in clockwise rotation
N230 G92 S4000 G92 Speed limit
S4000 Spindle speed
N235 G00 X+010.000 Z+002.000 G00 Rapid traverse
X+010.000 X- Coordinate of the target point
Z+002.000 Z- Coordinate of the target point
N240 G42 G42 tool nose compensation: right of the contour
N245 G01 X+013.000 Z+000.000 G01 Linear interpolation of slow feed motion
X+013.000 X- Coordinate of the target point
Z+000.000 Z- Coordinate of the target point
N250 G23 O135 Q210 G23 Programmteilwiderholung
O135 Start block number
Q210 End block number

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N255 G00 X+200.000 Z+200.000 M5 G00 Rapid traverse


M0
X200.000 X-Coordinate of the target point
Z200.000 Z-Coordinate of the target point
M5 deactivate spindle
M9 deactivate coolant
N260 M30 M30 End of program

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4.3 Introduction to manual NC programming

NC program for the second side

Block Commands Description


No.
%201 Program name

4) Face Turning
N005 G54 Z+188.000 G54 set absolute zero
Z+188.000 Z-Coordinate of the current workpart zero
N010 G96 S0140 T0404 M03 G96 Constant Speed Cutting ON
S140 Cutting Speed
T0404 Selection of the tool from turret position 4
M3 activate the spindle in clockwise rotation
M42 Select the higher spindle speed range
N015 G92 S3000 G92 Spindle speed limitation
S3000 Maximum spindle speed
N020 G00 X+078.000 Z+001.5 0 G00 Rapid traverse
X+078.000 X-Coordinate of the target point
Z+001.500 Z-Coordinae of the target point
N025 G01 X-001.000 F000.280 M08 G01 linear interpolation in slow feed motion
X-001.000 X-Coordinate of the target point
F000.280 feedrate in mm per revolution
M8 activate coolant

N030 G00 Z+002.000 G00 Rapid traverse


Z+002.000 Z-Coordinate of the target point

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Block Commands Description


No.
5) Outside contour roughing
N035 G00 X+078.000 G00 Rapid traverse
X+078.000 X-Coordinate of the target point
N040 G00 Z+000.200 G00 Rapid traverse
Z+000.2000 Z-Coordinate of the target point
N045 G01 X+012.000 G01 Linear interpolation of slow feed motion
X+012.000 X-Coordinate of the target point
N050 G88 X+070.400 Z+000.200 G88 Cycle radius
R+004.000
X+070.400 X-Coordinate of the target point
Z+000.200 Z-Coordinate of the target point
R+004.000 Rounding radius
N055 G01 Z-025.000 G01 Linear interpolation of slow feed motion
Z-025.000 Z-Coordinate of the target point

N060 G00 X+200.000 Z+200.000 M5 G00 Rapid traverse


M9
X200.000 X-Coordinate of the target point
Z200.000 Z-Coordinate of the target point
M5 deactivate spindle
M9 deactivate coolant

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4.3 Introduction to manual NC programming

Block Commands Description


No.
6) Predrilling
N065 G97 S0850 T1212 M03 G97 Constant Speed Cutting OFF
S0850 Spindle speed
T1212 Selection of the tool from turret positiion 12
M3 activate the spindle in clockwise rotation
N070 G92 S1500 G92 Speed limit
S1500 Spindle speed
N075 G00 Z+002.000 G00 Rapid traverse
Z+002.000 Z-Coordinate of the target point
M8 activate coolant
N080 X+000.000 F000.200 M08 X+000.000 X-Coordinate of the target point
F000.200 feedrate in mm per revolution
M08 activate coolant
N085 G84 Z-034.800 A+001.000 G84 Drilling cycle
B+001.000 D+004.000
Z-034.800 Z Coordinate of the target point
K+020.000
A+001.000 Dwell time after retraction
B+001.000 Dwell time when target point is reached for
chip breaking
D+004.000 Digression (reduction of drilling depth)
K+020.000 first depth of cut
N090 G00 X+200.000 G00 Rapid traverse
X200.000 X-Coordinate of the target point

N095 Z+070.000 M5 M9 Z70 Z-Coordinate of the target point


M5 deactivate spindle
M9 deactivate coolant

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Block Commands Description


No.
7) Inside contour roughing
N100 G96 F000.200 S0120 T0505 G96 Constant speed cutting ON
M04 F000.200 feedrate in mm per revolution
S0120 Spindle speed
T0505 Selection of the tool form turret positin 5
M4 activate the spindle counter clockwise
N105 G92 S3000 G92 Speed limit
S3000 Spindle speed
N110 G00 X+021.000 Z+002.000 G00 Rapid traverse
X+021.000 X-Coordinate of the target point
Z+002.000 Z-Coordinate of the target point
N115 G57 X-000.600 Z+000.200 G57 finishing allowance activation
X+000.600 Finshingin X allowance
Z+000.200 Finishing in Z allowance
N120 G81 X+040.000 Z+002.000 G81 straight roughing cycle
I+002.500 X+040.000 X-Coordinate of contour start point
Z+002.000 Z-Coordinate of contour start point
I+002.500 Infeed
N125 G41 G41 Tool nose compensation: left of the contour
N130 G01 X+038.000 Z+000.000 G01 Linear interpolation of slow feed motion
M08 X+038.000 X-Coordinate of the target point
Z+000.000 Z-Coordinate of the target point
M8 activate coolant
N135 X+034.000 Z-002.000 X+034.000 X-Coordinate of the target point
Z-002.000 Z-Coordinate of the target point
N140 G88 X+034.000 Z-015.000 G88 Cycle radius
R+002.000 X+034.000 X-Coordinate of the target point
Z-015.000 Z-Coordinate of the target point
R+002.000 Rounding radius
N145 G01 X+026.000 G1 Linear interpolation of slow feed motion
X+026.000 X-Coordinate of the target point
N150 Z-035.000 Z-035.000 Z-Coordinate of the target point
N155 X+013.000 X+013.000 X-Coordinate of the target point
N160 G40 G40 cancel tool nose compensation
N165 G80 G80 End of contour definition
N170 G00 X+200.000 G00 Rapid traverse
X200.000 X-Coordinate of the target point
N175 Z+070.000 M5 M9 Z+070.000 Z-Coordinate of the target point
M5 deactivate spindle
M9 deactivate coolant

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4.3 Introduction to manual NC programming

Block Commands Description


No.
8) Inside contour finishing
N180 G96 F000.100 S0220 T1010 G96 Constant speed cutting ON
M04
F000.1000 feedrate in mm per revolution
S0220 Spindle speed
T1010 Selection of the tool from turret position 10
M4 activate the spindle counter-clockwise
N185 G92 S4000 G92 Speed limit
S4000 Spindle speed
N190 G00 X+040.000 Z+002.000 G00 Rapid traverse
X+040.000 X-Coordinate of the target point
Z+002.000 Z-Coordinate of the target point
N195 G23 O125 Q160 G23 program part repetition
O125 Start block number
Q160 End block number

N200 G00 Z+002.000 G00 Rapid traverse


X+002.000 Z-Coordinate of the target point
N205 X+200.000 X+200.000 X-Coordinate of the target point
N210 Z+070.000 M5 M9 Z+070.000 Z-Coordinate of the target point
M5 deactivate spindle
M9 deactivate coolant

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Block Commands Description


No.
9) Outside contour finishing
N215 G96 F000.100 S0280 T0202 G96 Constant speed cutting ON
M03
F000.100 feedrate in mm per revolution
S0280 Spindle speed
T0202 Selection of the tool from turret position 2
M3 activate the spindle in clockwise rotation
N220 G92 S4000 G92 Speed limit
S4000 Spindle speed
N225 G00 X+034.000 Z+001.000 G00 Rapid traverse
X+034.000 X-Coordinate of the target point
Z+001.000 Z-Coordinate of the target point
N230 G42 G42 tool nose compensation: right of the contour
N235 G01 Z+000.000 M8 G01 Linear interpolation of slow feed motion
Z+000.000 Z-Coordinate of the target point
M8 activate coolant
N240 G88 X+070.000 Z+000.000 G88 Cycle radius
R+004.000
X+070.000 X-Coordinate of the target point
Z+000.000 Z-Coordinate of the target point
R+004.000 Rounding radius
N245 G01 Z-026.000 G01 Linear interpolation of slow feed motion
Z-026.000 Z-Coordinate of the target point
N250 X+072.000 X+072.000 X-Coordinate of the target point
N255 G40 G40 cancel tool nose compensation
N260 X+200.000 Z+200.000 M5 M9 X+200.000 X-Coordinate of the target point
Z+200.000Z-Coordinate of the target point
M5 deactivate spindle
M9 deactivate coolant
N240 M30 M30 End of program

MTS TeachWare CNC-Grundlagen Students Book 177


4.3 Introduction to manual NC programming

Simulation of the NC program and Quality control by measuring work results

In automatic mode, the generated NC-programs are simulated in real-time and with respect to possible colli-
sions.

figure 180 figure 181


Automatic Mode menu diagram. Automatic Mode menu.

To start an NC program in Automatic Mode, two procedural steps are required:

1. As a first step after starting Automatic Mode, the main menu is loaded, allowing you to enter the
name of the NC program (par example: %200) to be simulated.
Accept program: Use F1 or to confirm the program name appearing in the information line. If
the program is available, it is subsequently loaded into program memory; if not, an appropriate er-
ror message is displayed.
1. Continue by selecting the desired simulation mode for program execution
Automatic: Select F1 to execute the program specified in the dialogue line under continuous auto-
matic control.
Single NC block: Use F2 to activate single block operation.

figure 182 figure 183


Menu during continuous automatic run. CNC Turning, 3D Display, Optional section.

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Introduction into NC programming

Quality control by measuring work results

A work part can be measured after machining (automatic mode) or during machining after every operation
(single block) and can be compared with the values in the drawing.

Procedure:

Description Entry

1. Call CNC turning in the main menu. F1 (turning)


2. Select menu automatic mode. F2 (automatic mode)
3. Call a present NC program, Using the keyboard type in%200 and
par example %200. confirm.
4. Select the simulation type automatic mode. F1 (Automatic mode)
On the screen the simulation of the ma-
chining starts.

5. Select menu measurement. F6 (Dimension 3D)


6. Select menu point dimension. F6 (Point dimension)
7. Select the point for measurement. F1 (next point) or

F2 (previous point)
For the selected point the data are shown
on the screen

8. Quit the menu measurement. F8 (Abort)

F8 (Quit)

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4.3 Introduction to manual NC programming

Manual NC programming Milling

CNC Exercise

Instructed generation of NC-programs for CNC-milling

Task:
An NC-program is to be generated for manufacturing the following part:

figure 184

Follow the subsequent steps for generating the NC-program:

1. definition of the work plan


1. choice of clamping devices and necessary tools
1. generating the NC program
1. simulating the NC program

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Introduction into NC programming

Work plan

Machining Sequence Tool Magazine Cutting Outline


Position Values
1 check blank Y
dimensions
2 clamp work part
3 define work part zero 1
point 2

3
X

4 Contour left side SLOT MILLING TOOL T01 F250


mill 8mm deep S1600 4

5 Contour right side SLOT MILLING TOOL T01 F250


mill 8mm deep S1600 5

6 Contour octagon SLOT MILLING TOOL T01 F250


mill 4mm deep S1600

7 Contour with arcs SLOT MILLING TOOL T01 F250


mill 6mm deep S1600
7

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4.3 Introduction to manual NC programming

8 Contour Circle SLOT MILLING TOOL T01 F250


r=25mm
S1600
mill 2mm deep
8

9 Circular Pocket SLOT MILLING TOOL T02 F50


r=15mm
S1800
mill 4mm deep
9

10 4 x Centering CORE DRILL T03 F80


S2000 10

11 Drill 4 x core hole DRILL T04 F50


11
M6 S1500

12 4 x tapping TAP T05 F150


12
M6 S150

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Setting-up the CNC machine (set-up sheet)

After start, the MTS-simulator is automatically set-up with blank, clamping and turret allocation. If the follow-
ing set-up data does not conform with the current set-up data, then it must be changed in the set-up opera-
tion

figure 185 figure 186


SetupDialog Set-up Mode; Work part and clamping fixture defini-
tion" menu.

CONFIGURATION
MACHINE MTS VMC-024_ISO30_-0500-0400x0450
CONTROL FANUC SERIE 16M
BLANK DIMENSIONS
X+100.000 Y+100.000 Z+025.000
VISE "Chuck Milling\Vise\RS 110"
CHUCKING DEPTH E+010.000
SHIFT V+000.000
ORIENTATION A0
PART POSITION X+150.000 Y+150.000
left corner of the part: X+150.000 Y+150.000 Z+105.000
CURRENT TOOL
T01
TOOLS
T01 "ISO SK 30\ Slot Milling tool\MS-20.0 038K HSS ISO 1641"
T02 "ISO SK 30\ Slot Milling tool\MS-20.0 038K HSS ISO 1641"
T03 "ISO SK 30\ Core drill\DC-08.0 090 HSS ISO 3294"
T04 "ISO SK 30\ Drill\DR-05.00 052 HSS ISO 235
T05 "ISO SK 30\ Tap\TA-M06.0 1.00 HSS ISO 2857"
TOOL COMPENSATION
D01 T01 R010.000 Z+119.000 N01
D02 T02 R010.000 Z+119.000 N01
D03 T03 R000.000 Z+065.000 N01
D04 T04 R002.500 Z+097.900 N01
D05 T01 R010.000 Z+119.000 N01

WORKPART ZEROPOINTS
G54 X150.000 Y+150.000 Z+105.000

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4.3 Introduction to manual NC programming

NC programming

Block Commands Description


No.
O 200 O Program number O and program name
N005 G90 G80 G40 G49 G17 G21 G90 Absolute Dimensioning
G80 Canned cycle cancel
G40 Tool radius compensation cancel
G49 Tool length compensation cancel
G17 XY plane
G21 Metric input
N010 G91 G28 Z0 G91 Incremental dimensioning
G28 Reference point return
Z0 Z-Coordinate of the Intermediate Point
N015 G91 G28 X0 Y0 G91 Incremental dimensioning
G28 Reference point return
X0 X-Coordinate of the Intermediate Point
Y0 Y-Coordinate of the Intermediate Point
N020 G54 G54 Work coordinate system 1 selection

4) Contour left side mill 8mm deep


N025 T01 M06 T01 Select the tool 1
M06 Mounting the tool 1
N030 G90 G00 X-20 Y-20 G90 Absolute dimensioning
G00 rapid traverse
X-20 X-Coordinate of the target point
Y-20 Y-Coordinate of the target point
N035 G43 Z20 H17 G43 Tool length compensation +
Z20 Z-Coordinate of the target point
H17 Select the compensation offset 1
N040 S1600 M03 S1600 spindle speed
M03 activate the spindle in clockwise rotation
N045 Z-8 M08 Z-8 Z-Coordinate of the target point
M08 activate coolant
N050 G41 G1 X5 D1 F250 G41 Tool radius compensation left
G1 linear interpolation in slow feed motion
X5 X-Coordinate of the target point
D1 Select the compensation offset 1
F250 feedrate in mm/min
N055 Y110 Y110 Y-Coordinate of the target point

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Introduction into NC programming

Block Commands Description


No.
5) Contour right side mill 8mm deep
N060 G0 X95 G0 rapid traverse
X95 X-Coordinate of the target point
N065 G1 Y-10 G1 linear interpolation in slow feed motion
Y-10 Y-Coordinate of the target point
N070 G40 G0 X-20 Y-20 G40 Tool radius compensation cancel
G0 rapid traverse
X-20 X-Coordinate of the target point
Y-20 Y-Coordinate of the target point

6) Octagon mill 4mm deep


N075 Z-4 Z-4 Z-Coordinate of the target point
N080 G41 G0 X15 D1 G41 Tool radius compensation left
G0 rapid traverse
X15 X-Coordinate of the target point
D1 Select the compensation offset 1
N085 G1 Y65 G1 linear interpolation in slow feed motion
Y65 Y-Coordinate of the target point
N090 X35 Y85 X35 X-Coordinate of the target point
Y85 Y-Coordinate of the target point

N095 X65 X65 X-Coordinate of the target point


N100 X85 Y65 X85 X-Coordinate of the target point
Y65 Y-Coordinate of the target point
N105 Y35 Y35 Y-Coordinate of the target point

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4.3 Introduction to manual NC programming

Block Commands Description


No.
N110 X65 Y15 X65 X-Coordinate of the target point
Y15 Y-Coordinate of the target point
N115 X35 X35 X-Coordinate of the target point
N120 X5 Y45 X5 X-Coordinate of the target point
Y45 Y-Coordinate of the target point
N125 G40 G0 X-20 Y-20 G40 Tool radius compensation cancel
G0 rapid traverse
X-20 X-Coordinate of the target point
Y-20 Y-Coordinate of the target point

7) Contour with arcs mill 6mm deep


N130 Z-6 Z-6 Z-Coordinate of the target point
N135 G41 G1 X10 D1 G41 Tool radius compensation left
G1 linear interpolation in slow feed motion
X10 X-Coordinate of the target point
D1 Select the compensation offset 1
N140 G1 Y82 G1 linear interpolation in slow feed motion
Y82 Y-Coordinate of the target point
N145 G2 X18 Y90 R8 G2 circular interpolation clockwise
X18 X-Coordinate of the target point
Y90 Y-Coordinate of the target point
R8 radius r=8 of the circular arc
N150 G1 X82 G1 linear interpolation in slow feed motion
X82 X-Coordinate of the target point
N155 G2 X90 Y82 R8 G2 circular interpolation clockwise
X90 X-Coordinate of the target point
Y82 Y-Coordinate of the target point
R8 radius r=8 of the circular arc
N160 G1 Y18 G1 linear interpolation in slow feed motion
Y18 Y-Coordinate of the target point
N165 G2 X82 Y10 R8 G2 circular interpolation clockwise
X82 X-Coordinate of the target point
Y10 Y-Coordinate of the target point
R8 radius r=8 of the circular arc
N170 G1 X18 G1 linear interpolation in slow feed motion
X18 X-Coordinate of the target point

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Introduction into NC programming

Block Commands Description


No.
N175 G2 X10 Y18 R8 G2 circular interpolation clockwise
X10 X-Coordinate of the target point
Y18 Y-Coordinate of the target point
R8 radius r=8 of the circular arc
N180 G3 X-10 Y38 R20 G2 circular interpolation counter-clockwise
X-10 X-Coordinate of the target point
Y38 Y-Coordinate of the target point
R8 radius r=8 of the circular arc
N185 G40 G0 X-20 Y-20 G40 Tool radius compensation cancel
G0 rapid traverse
X-20 X-Coordinate of the target point
Y-20 Y-Coordinate of the target point

8) Contour circle r=25mm mill 2mm deep


N190 Z-2 Z-2 Z-Coordinate of the target point
N195 G41 X25 D1 G41 Tool radius compensation left
X25 X-Coordinate of the target point
D1 Select the compensation offset 1
N200 G1 Y50 G1 linear interpolation in slow feed motion
Y50 Y-Coordinate of the target point
N205 G2 X25 Y50 I25 G2 circular interpolation clockwise
X25 X-Coordinate of the target point
Y50 Y-Coordinate of the target point
I25 X-Coordinate of the center of circular arc
N210 G40 G1 Y65 G40 Tool radius compensation cancel
G1 linear interpolation in slow feed motion
Y65 Y-Coordinate of the target point
N215 Z5 Z5 Z-Coordinate of the target point
N220 G91 G28 Z0 M5 G91 Incremental dimensioning
G28 Reference point return
Z0 Z-Coordinate of the Intermediate Point
M5 deactivate spindle
N225 G91 G28 X0 Y0 M9 G91 Incremental dimensioning
G28 Reference point return
X0 X-Coordinate of the Intermediate Point
Y0 Y-Coordinate of the Intermediate Point
M9 deactivate coolant

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4.3 Introduction to manual NC programming

Block Commands Description


No.
9) Circular pocket r=15mm mill 4mm deep
N230 T02 M06 T02 Select the tool 2
M06 Mounting the tool 2
N235 G90 G0 X50 Y50 G90 Absolute dimensioning
G00 rapid traverse
X50 X-Cordinate of the target point
Y50 Y-Coordinate of the target point
N240 G43 Z20 H18 G43 Tool length compensation +
Z20 Z-Coordinate of the target point
H18 Select the compensation offset 2
N245 S1800 M3 S1800 spindle speed
M03 activate the spindle in clockwise rotation
N250 Z2 M8 Z2 Z-Coordinate of the target point
M8 activate coolant
N255 G1 Z-4 F50 G1 linear interpolation in slow feed motion
Z-4 Z-Coordinate of the target point
F50 feedrate in mm/min
N260 G42 G1 X38 Y53 D2 G42 Tool radius compensation right
G1 linear interpolation in slow feed motion
X38 X-Coordinate of the target point
Y53 Y-Coordinate of the target point
(Starting point of the quarter-round starting move r=12)
D2 Select the compensation offset 2

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Introduction into NC programming

Block Commands Description


No.
N265 G2 X50 Y65 R12 F200 G2 circular interpolation clockwise
X10 X-Coordinate of the target point
Y18 Y-Coordinate of the target point
(Target point of the quarter-round remove r=12)
R12 radius r=12 of the circular arc
F200 feedrate in mm/min
N270 G2 J-15 G2 circular interpolation clockwise
(full circle milling r=15)
J-15 Y-Coordinate of the center of circular arc
N275 G2 X62 Y62 R12 G2 circular interpolation clockwise
X62 X-Coordinate of the target point
Y62 Y-Coordinate of the target point
(Target point of the quarter-round remove r=12)
R12 radius r=12 of the circular arc
N280 G40 G1 X50 Y50 G40 Tool compensation cancel
G1 linear interpolation in slow feed motion
X50 X-Coordinate of the target point
Y50 Y-Coordinate of the target point
N285 G0 Z50 M9 G0 rapid traverse
Z50 Z-Coordinate of the target point
M9 deactivate coolant
N290 G91 G28 Z0 M5 G91 Incremental dimensioning
G28 Reference point return
Z0 Z-Coordinate of the Intermediate Point
M5 deactivate spindle
N295 G91 G28 X0 Y0 G91 Incremental dimensioning
G28 Reference point return
X0 X-Coordinate of the Intermediate Point
Y0 Y-Coordinate of the Intermediate Point

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4.3 Introduction to manual NC programming

Block Commands Description


No.
10) 4x centering
N300 T03 M06 T03 Select the tool 3
M06 Mounting the tool 3
N305 G90 G90 Absolute dimensioning
N310 G43 Z20 H19 G43 Tool length compensation +
Z20 Z-Coordinate of the target point
H19 Select the compensation offset 3
N315 S2200 M03 S2200 spindle speed
M03 activate the spindle in clockwise rotation
N320 G0 Z1 G0 rapid traverse
Z1 Z-Coordinate of the target point
N325 G98 G81 Z-5 R-3 F80 L0 G98 Return to the initial point
G81 Drilling cycle, spot boring
R-3 Z-Coordinate of the safety plane
Z-5 Coordinate at the bottom of the hole
F80 feedrate in mm/min
L0 The Drilling cycle is only stored!
N330 M98 P1910 M98 P Subprogram call
1910 Subprogram number

190 MTS TeachWare CNC-Grundlagen Students Book


Introduction into NC programming

Block Commands Description


No.
11) 4x Core hole drilling
N335 T04 M06 T04 Select the tool 4
M06 Mounting the tool 4
N340 G90 G0 X0 Y0 G90 Absolute dimensioning
G0 rapid traverse
X0 X-Coordinate of the target point
Y0 Y-Coordinate of the target point
N345 G43 Z20 H20 G43 Tool length compensation +
Z20 Z-Coordinate of the target point
H20 Select the compensation offset 4
N350 S1500 M03 S1500 spindle speed
M03 activate the spindle in clockwise rotation
N355 G0 Z1 G0 rapid traverse
Z1 Z-Coordinate of the target point
N360 G98 G83 Z-10 Q6 R-3 F50 L0 G98 Return to the initial point
G83 Peck drilling cycle
Z-10 Coordinate at the bottom of the hole
Q6 Digression
R-3 Z-Coordinate of the safety plane
F50 feedrate in mm/min
L0 The Peck drilling cycle is only stored!
N365 M98 P1910 M98 P Subprogram call
1910 Subprogram number

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4.3 Introduction to manual NC programming

Block Commands Description


No.
12) 4x Tapping
N370 T05 M06 T05 Select the tool 5
M06 Mounting the tool 5
N375 G90 G0 X0 Y0 G90 Absolute dimensioning
G0 rapid traverse
X0 X-Coordinate of the target point
Y0 Y-Coordinate of the target point
N380 G43 Z20 H21 G43 Tool length compensation +
Z20 Z-Coordinate of the target point
H21 Select the compensation offset 5
N385 S150 M3 S150 spindle speed
M03 activate the spindle in clockwise rotation
N390 G00 Z1 G00 rapid traverse
Z1 Z-Coordinate of the target point
N395 G98 G84 Z-8 R-3 F150 L0 G98 Return to the initial point
G84 Tapping cycle
Z-8 Coordinate at the bottom of the hole
R-3 Z-Coordinate of the safety plane
F150 feedrate in mm/min
L0 The Tapping cycle is only stored!!
N400 M98 P1910 M98 P Subprogram call
1910 Subprogram number

N405 G90 G49 G80 G40 M30 M30 program end and backspacing

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Introduction into NC programming

NC subprogram

Block Commands Description


No.
O 1910 O Program name
N10 G90 X18 Y18 M8 First drilling position:
G90 Absolute dimensioning
X18 X-Coordinate of the drilling position
Y18 Y-Coordinate of the drilling position
M8 activate coolant
N15 Y82 Second drilling position:
Y82 Y-Coordinate of the drilling position
N20 X82 Third drilling position:
X82 X-Coordinate of the drilling position
N25 G98 Y18 Fourth drilling position:
G98 Return to the initial point
Y18 Y-Coordinate of the drilling position
N30 G00 G90 G80 Z50. M9 G00 Rapid Traverse
G90 Absolute dimensioning
G80 Canned cycle cancel
Z50 Z-Coordinate
M9 deactivate coolant
N35 G91 G28 Z0 M5 G91 Incremental dimensioning
G28 Reference point return
Z0 Z-Coordinate of the Intermediate Point
M5 deactivate spindle
N40 G91 G28 X0 Y0 G91 Incremental dimensioning
G28 Reference point return
X0 X-Coordinate of the Intermediate Point
Y0 Y-Coordinate of the Intermediate Point
N45 M99 M99 subprogram end

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4.3 Introduction to manual NC programming

Simulation of the NC program

In automatic mode, the generated NC-programs are simulated in real-time and with respect to possible colli-
sions.

figure 187 figure 188


Automatic Mode menu Diagram. Automatic Mode menu.

To start an NC program in Automatic Mode, two procedural steps are required:

1. As a first step after starting Automatic Mode, the main menu is loaded, allowing you to enter the
name of the NC program (par example: 1909) to be simulated.
Accept program: Use F1 or to confirm the program name appearing in the information Line. If
the program is available, it is subsequently loaded into program memory; if not, an appropriate er-
ror message is displayed.
1. Continue by selecting the desired simulation mode for program execution
Automatic: Select F1 to execute the program specified in the dialogue line under continuous
automatic control.
Single NC block: Use F2 to activate single block operation.

figure 189 figure 190


Menu during continuous automatic run. CNC Milling, 3D Display, Optional section.

Workshop

The students are to manufacture the programmed part on the CNC-milling machine.

194 MTS TeachWare CNC-Grundlagen Students Book


9. Control test Introduction into NC programming

1. List the steps for manual programming.

2. What is the difference between a work plan and a programming sheet?

3. Explain the meaning of "switching information".

4. Name and explain five commands for a CNC-machine.

5. Explain the structure of an NC-program.

6. Explain the structure of a program block.

7. Explain the structure of a program word.

8. Explain the address letters F, S, T, M, X, Y, Z.

9. Explain the following program words for


a) absolute programming (G90)
b) incremental programming (G91)!
X 53, Z 184.005

10. What do the address letters I, J, K express?

11. Define the following functions with the corresponding program words
(G-command or M-command)
clockwise circular interpolation
activate coolant
activate spindle in clockwise rotation

12. For which cases are constant cutting speeds required? Explain why.

13. With which G-function is constant cutting speed programmed?

14. Read and explain the following program block.


Illustrate the sequence of motions.
G01 G95 X100 Z-5 F0.25 S600 T0101

15. Read and explain the following program block.


Illustrate the sequence of motions.
G02 G96 X30 Z-30 I30 K-15 F0.2 S180
16.
Read and explain the following program section!

N5 G90 G96 T0101 S100 M3 M8


N10 G0 X133 Z2
N20 G1 Z-395 F0.3
N30 G0 X135 Z2
N40 X123
N50 G1 Z-269.8
N60 G2 X133 Z-274.8 I133 K-269.8 O70
N70 G0 Z2

MTS TeachWare CNC-Grundlagen Students Book 195


4.3 Introduction to manual NC programming

Solution of the CNC exercise on page 151


In the following NC-program, the contour of a pre-turned part is finished. For each command give the corre-
sponding definition.
Block Commands Description
No.
O 0300 0300 program name
N05 T040404 select the tool from the turret position 4
M3 activate the spindle in clockwise rotation
M42 select the higher spindle speed range
M63 ignoring spindle rotation M code answer
G96 Constant speed cutting ON
S140 spindle speed
N10 G50 maximum spindle speed designation of
S3000 revolution per minute
N15 G0 rapid traverse
X20 X-Coordinate of the target point
Z2 Z-Coordinate of the target point
M8 activate coolant
N20 G1 linear interpolation in slow feed motion
X20 X-Coordinate of the Target Point
Z0 Z-Coordinate of the Target Point
G42 tool nose compensation: right
N25 G3 circular interpolation counter-clockwise
X28 X-Coordinate of the target point
Z-4 Z-Coordinate of the target point
I0 Distance between starting position and circle center in X
K-4 Distance between starting position and circle center in Z
N30 G1 linear interpolation in slow feed motion
Z-28 Z-Coordinate of the target point
N35 G2 circular interpolation clockwise
X34 X-Coordinate of the target point
Z-31 Z-Coordinate of the target point
I3 Distance between starting position and circle center in X
K0 Distance between starting position and circle center in Z
N40 G1 linear interpolation in slow feed motion
X38 X-Coordinate of the target point
Z-33 Z-Coordinate of the target point
N45 G1 linear interpolation in slow feed motion
Z-53 Z-Coordinate of the target point

196 MTS TeachWare CNC-Grundlagen Students Book


Solution of the CNC exercise on page 162

Block Commands Description


No.
N50 G1 linear interpolation in slow feed motion
X44 X-Coordinate of the target point
N55 G3 circular interpolation counter-clockwise
X50 X-Coordinate of the target point
Z-56 Z-Coordinate of the target point
I0 distance between starting position and circle center in X
K-3 distance between starting position and circle center in Z
N60 G1 linear interpolation in slow feed motion
Z-64 Z-Coordinate of the target point
N65 G2 circular interpolation clockwise
X62 X-Coordinate of the target point
Z-70 Z-Coordinate of the target point
I6 distance between starting position and circle center in X
K0 distance between starting position and circle center in Z
N70 G1 linear interpolation in slow feed motion
X66 X-Coordinate of the target point
N75 G1 linear interpolation in slow feed motion
X71 X-Coordinate of the target point
Z-72 Z-Coordinate of the target point
N80 G1 linear interpolation in slow feed motion
X76 X-Coordinate of the target point
N85 G40 cancel tool nose compensation
N90 G0 rapid traverse
X500 X-Coordinate of the target point
Z500 Z-Coordinate of the target point
M5 deactivate the spindle
M9 deactivate coolant
N95 M30 program end and backspacing

MTS TeachWare CNC-Grundlagen Students Book 197


4.3 Introduction to manual NC programming

198 MTS TeachWare CNC-Grundlagen Students Book


Solution for the CNC exercise on page 164

Solution for the CNC exercise on page 153


In the following NC-program, the contour of a work part is milled. For each command, give the corresponding
definition.
Block Commands Description
No.
FX100 program name
N05 G54 select work cordinate system one
N10 G90 activate absolute dimensioning
G49 cancel tool length compensation
G80 cancel canned cycle
G40 cancel tool radius compensation
G17 select the X-Y-plane
G21 metric input
N20 G91 activate incremental dimensioning
G28 reference point return
Z0. Z-Coordinate of the target point
M9 deactivate coolant
N25 G91 activate incremental dimensioning
G28 reference point return
X0. X-Coordinate of the target point
Y0. Y-Coordinate of the target point
N30 T01 select the tool number 1 from the magazine
M06 mounting the tool
N35 G90 activate absolute dimensioning
S1600 spindle speed
M03 activate the spindle in clockwise rotation
N40 G0 rapid traverse
G43 tool length compensation
Z20. Z-Coordinate of the target point
H17 offset number for the tool length
N45 X-20. Z-Coordinate of the target point
Y-20. Z-Coordinate of the target point
N50 Z-6. Z-Coordinate of the target poin
M08 activate coolant
N55 G1 linear interpolation in slow feed motion
G41 cutter compensation: left
X10. X-Coordinate of the target point
D1 offset number for the cutter radius
F250. feedrate in mm per min

MTS TeachWare CNC-Grundlagen Students Book 199


4.3 Introduction to manual NC programming

Block Commands Description


No.
N60 G1 linear interpolation in slow feed motion
Y82. Y-Coordinate of the target point
N65 G2 circular interpolation clockwise
X18. X-Coordinate of the target point
Y90. Y-Coordinate of the target point
R8. radius of the circle
N70 G1 linear interpolation in slow feed motion
X82. X-Coordinate of the target point
N75 G2 circular interpolation clockwise
X90. X-Coordinate of the target point
Y82. Y-Coordinate of the target point
R8. radius of the circle
N80 G1 linear interpolation in slow feed motion
Y18. Y-Coordinate of the target point
N85 G2 circular interpolation clockwise
X82. X-Coordinate of the target point
Y10. Y-Coordinate of the target point
R8. radius of the circle
N90 G1 linear interpolation in slow feed motion
X18. X-Coordinate of the target point
N95 G2 circular interpolation clockwise
X10. X-Coordinate of the target point
Y18. Y-Coordinate of the target point
R8. radius of the circle
N100 G3 circular interpolation counter-clockwise
X-10. X-Coordinate of the target point
Y38. Y-Coordinate of the target point
R20. radius of the circle
N105 G0 rapid traverse
G40. cancel cutter compensation
X-20. X-Coordinate of the target point
Y-20. Y-Coordinate of the target point
N110 G0 rapid traverse
Z40. Z-Coordinate of the target point
M5 deactivate spindle

200 MTS TeachWare CNC-Grundlagen Students Book


Solution for the CNC exercise on page 164

Block Commands Description


No.
N115 G91 activate incremental dimensioning
G28 reference point return
Z0. Z-Coordinate of the target point
M9 deactivate coolant
N120 G90 activate absolute dimensioning
G80 cancel canned cycle
G49 cancel tool length compensation
G40 cancel tool radius compensation
N125 M30 program end and backspacing

MTS TeachWare CNC-Grundlagen Students Book 201


4.3 Introduction to manual NC programming

Answers for the control test CNC Basics:

1. - The CNC machine tool is not operated manually but programmed.


It then automatically processes the entered NC program.
- The CNC machine has adjustable axle drives.
- The CNC machine has a path measuring system for each travel axis.
2. - All information necessary for machining the work part is entered as commands.
-The computer, integrated in the CNC control, controls all functions and adjusts all travel move-
ments.
3. - CNC machine tools work with higher machining speeds.
- CNC machine tools work with constant quality.
- CNC machine tools work with higher precision.
- CNC machine tools lead to shorter transit times.
4. - The feed axes must be controllable to enable the tool to be moved into the exact position desired.
5. - motor
- mechanical clutch to avoid overload as well as electronic control
- ball thread drive for play-free power transmission
- sensor as a travel path measuring system
- power amplifier with analog or digital interfaces to the CNC control
6. - two axes minimum
7. - the X axis (face rotating axis)
- the Z axis (longitudinal axis)
8. - three axes minimum
9. - the X axis
- the Y axis
- the Z axis
10. - The controllable spindle axis C on the CNC lathe.
- The rotation axis C of a rotary table on a CNC milling machine.
11. - Driven tools enable milling and boring on a CNC lathe.-
12. - The rotary table enables turning on a CNC milling machine.
- The work part can be machined from various sides.
13. - It enables playfree movement of the feed axes
- Both halves of the ball thread nut are clamped to each other. The power is transmitted between the
spindle and the nut without friction by the balls.
14. - In case of direct position measuring the position is measured directly on the slide.
- In case of indirect position measuring the position is defined based on the rotation of the spindle.
15. - In case of absolute position measuring the position can be directly defined on the measuring scale.
- In case of indirect position measuring only movements are added together. Therefore the position
must be constantly re-calculated.
16. - To keep the cutting speed constant.
- To control the start and the halt.
17. - Tool turret
- Tool magazine with tool change device
18. - chain magazine
- line magazine
- ring magazine
- plate magazine
- cassette magazine

202 MTS TeachWare CNC-Grundlagen Students Book


Answers for the control test Basic Geometry

Answers for the control test Basic Geometry:

1. - Turning :

C +X

+Z

2. - Milling :

3. - If points are dimensioned using an angle and a distance, example: drilling hole circle.
4. - Point control
- Line control
- Path control
5. - 2 D path control on the X/Y plane
- 2 D path control on the X/Z plane
- 2 D path control on the Y/Z plane
6. - In case of a 2 D path control all three axes can be traveled to one by one, only two at one time
however. Therefore, the plane on which the travel movement is to take place has to be selected first.
7. - The machine zero point M is the origin of the machine coordinate system.
- The work part zero point W is the origin of the work part referenced coordinate system. It is set so
as to enable the drawing dimensions to be taken directly from it.
- The reference point R is required for machines with incremental path measuring system to indicate
the control first an absolute position.
- The tool reference point E is used to measure the applied tools.
8. - The work part zero point W should be positioned so that the drawing dimensions can be directly
taken over for programming.
- In turning, in the rotation axis and in most cases on the front face of the work part.
- In milling, in most cases on the left lower corner point of the work part surface.
9. - Dimension tolerances do not cumulate.
- Single incorrect dimensions do not lead to subsequent errors.
- In turning work parts the diameter values can be directly entered as X value.

MTS TeachWare CNC-Grundlagen Students Book 203


4.3 Introduction to manual NC programming

10. - When incrementally dimensioning points.


- When identical contours or boring patterns as well as recesses are to be machined repeatedly.
11.

15
20
30
20
15

15 20 30 20 15
12. - A control chain is open - a feedback loop is closed!
- In case of a control chain machines are affected without controlling the consequences. Resulting
from internal or external influences deviations from the desired set values are possible.
- In case of a feedback loop these deviations are corrected by measuring the actual values and ad-
justing them to the set values by the feedback loop.
13. - Example: Position feedback loop:
When the tool moves, the desired position is transferred to the position feedback loop as a set
value.The path measuring system measures the actual position and returns the value to the feed-
back control. If these values are not identical, also as a result of internal and external influences
(disturbance entities), the corresponding movement is initiated until the desired position (set value)
has been reached.
14. - As milling tools with various diameters are eventually used. If only the milling machine center point
path were considered deviations would appear on the work part.
15. - The length of the milling tool L.
- The radius of the milling tool R.
16. - In travel movements, which do not run parallel to the X and Z axis, dimension deviations are cre-
ated.
17. - The length of the turning tool L.
- The measurement of Q.
- The tool tip radius R.
18. - To enable the control to calculate the tool tip radius in the correct direction.
19. - Measuring with a tool setup device.
- Measuring with zero tools.
- Direct measuring when machining a work part.
- Optical measuring on a CNC machine tool.

204 MTS TeachWare CNC-Grundlagen Students Book


Answers for the control test Technological Basics

Answers for the control test Technological Basics:

1. - Tool carriers

- Tool holders

- Indexable inserts

2. - higher cutting speeds and higher cutting-edge life compared with high-speed steels

- quick and simple exchange of indexable inserts

3. - P (blue) fr long shipping material

- M (yellow) for materials which are difficult to be machined

- K (rot) for short shipping materials

4. - The clearance angle influences friction on the work part and consequently, the heating-up of the
cutting edge.

5. - A larger angle of rake improves the machining flow.

- A larger angle of rake reduces the cutting forces.

6. - A larger angle of rake increases the cutting edge breach.

- A larger angle of rake increases the decarburization.

7. - Negative angles of rake are necessary for machining hard and brittle material.

8. - The adjustment angle influences the feed power, the forces against the work part, the cutting width
and the cutting depth.

9. vc = *d * n , or

vc
n=
*d
120m
n=
* min* 0,08m

n = 477 1 min

10. vc = * d * n

vc = * 0,25 m 100 1 min

m
vc = 78
min

MTS TeachWare CNC-Grundlagen Students Book 205


4.3 Introduction to manual NC programming

11. - It must clearly determine the position of the work part.


- It must detain all forces from the work part.

12. - keybar chucks

- jaw chucks with scrolls

possibly two-jaw chucks

three-jaw chucks

four-jaw chucks

13. - large work parts

- irregularly formed work parts

14. - For clamping long, slim work parts

15. - mechanical power generation

- pneumatic power generation

- hydraulic power generation

- electric power generation

16. - clamping with clamping elements

- machine vises

- fixtures

17. - quick work part exchange

- accurate clamping of work part

206 MTS TeachWare CNC-Grundlagen Students Book


Instroduction into CNC technology

Answers for the control test Introduction into NC programming:

1. The programmer must determine all necessary information required for the NC-program. The steps
are:

1. defining machining steps


2. defining necessary tools
3. calculating technological data
4. calculating geometric data
5. generating the NC-program
6. controlling the NC-program

2. The work plan contains all machining operations, clamping devices and technological data that was
calculated in the production drawing.

3. Switching information relates to commands that switch machining functions on or off. Example:
spindle rotation
coolant
tool change

4. see Comparison of programming codes/keys of various CNC-controls

5. An NC-program consists of a beginning (Ex. %), an end (Ex. M30) and a chronological sequence of
NC-blocks.

6. An NC-block consists of a block number and series of words.

7. A program word consists of an address letter and a number with +/-sign.

8. F feed
S speed
T tool position in tool storage or turret
M additional or switching information
X target coordinates in X-direction
Y target coordinates in Y-direction
Z target coordinates in Z-direction

9. a) Travel to a diameter of 53mm and to target coordinate Z 184.005.


b) Travel incrementally from the present tool position 53mm in +X-direction and 184.005 in +Z-
direction.

10. The address letters I, J, K are interpolation parameters. For example, when programming circular
movements they incrementally define the coordinates of the circle center with respect to the starting
point of the circular movement.

11. clockwise circular interpolation: G02


activate coolant: M8
activate spindle in clockwise rotation: M3

12. A constant cutting speed is used for face and form turning. A constant surface quality is obtained
since the number of rotations adapts to the changing diameters.

13. With the command G96 and starting speed S


Ex.: G96 S2000

14. G01 G95 X100 Z-5 F0.25 S600 T0101


Travel tool Nr. 1 considering the tool compensation value in storage Nr. 1 in a linear movement with
a feed of 0,25mm per rotation towards target coordinates X100 (diameter) and Z-5.

MTS TeachWare CNC-Grundlagen Students Book 207


4.3 Introduction to manual NC programming

15. G02 G96 X30 Z-30 I15 K-15 F0.2 S180


Travel clockwise in a circular movement with constant cutting speed and a feed of 0,2mm per rota-
tion towards the target coordinates X30 and Z-30. The circle center is incrementally located 15mm in
+X-direction and 15mm in +Z-direction from the starting point.

16. N5 G90 G96 T0101 S100 M3 M8


Absolute programming call, constant cutting speed with starting speed of 100 rotations per minute,
the tool Nr. 1 with the compensation value in storage Nr. 1. Activate the spindle in clockwise rotation
and coolant.
N10 G0 X133 Z2
The tool moves in rapid traverse to the coordinates X133 and Z2.
N20 G1 Z-395 F0.3
The tool travels with a feed of 0,3mm per rotation to the target point X133 and Z-395.
N30 G0 X135 Z2
The tool moves in rapid traverse to the coordinates X135 and Z2.
N40 X123
The tool moves in rapid traverse to the coordinates X123 and Z2.
N50 G1 Z-269.8
The tool travels with a feed of 0,3mm per rotation to the target point X123 and Z-269.8.
N60 G2 X133 Z-274.8 I5 K0
The tool travels clockwise with a feed of 0,3mm per rotation in a circular movement to the target
point X133 and Z-274.8. The circle center is incrementally located 5mm in +X-direction from the
starting point.
N70 G0 Z2
The tool moves in rapid traverse to the target point X133 and Z2.

208 MTS TeachWare CNC-Grundlagen Students Book

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