NC I CNC

INTRODUCTION TO
CNC AND CAM TECHNOLOGY

Introduction to CNC and CAM
1. Machine tools
2. Introduction to CNC and CAM
3. NC axes on machine tools
4. Machine and CNC coorporation
5. The structure of NC programs
6. Example of NC program for thread milling
7. Cutting conditions
8. Milling strategies – entrance strategies
9. Milling strategies – examples of technological strategies
10. Milling strategies – examples of geometrical strategies
11. Some thoughts on 5-axis milling strategies
COPYRIGHT (C) 2015, Seco Tools AB. All rights reserved. No part of this publication may be reproduced in any material form (including photocopying or
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of the copyright owner.
Copyright © Seco Tools AB 2

MACHINE TOOLS
Lathe
Workpiece Tool Control

clamping clamping system
Cover
Frame
Tailstock
Tool movement Frame

mechanism

Milling machine
Spindle
Motor
Milling cutter
Control system
Coolant supply
Machine table
Chip conveyor
Manual control
Frame

Conventional versus NC machine tool
Conventional machine
The movements of the tool are controlled by
an operator. Complex workpieces are
difficult to produce.
CNC machine
The movements of the tool are controlled by
computer, programmed by an operator.
Complex workpieces are easy to produce.

Numerically controlled machines
The same technological capabilities as conventional machines

in terms of machining, but differ in control of machine functions.
Elements of NC system
 Part program
 Machine control unit (MCU)
 The machine tool
Capabilities of machine control unit (MCU) of an NC machine

 Positioning the tool
 Turning the spindle ON/OFF
 Setting cutting speeds/feed rates
 Turning coolant ON/OFF
 Direction and feed rate of slide motion, spindle rotation
 …

Numerically controlled lathe
Cover Chuck Turret Window

Step motor Feed motors
Main spindle Frame
Clamping unit NC monitor
Main motor NC command
Tail stock
Chip conveyor
Lathe bed
Chip conveyor
Tool slides

Numerically controlled milling machine
Main spindle Main motor
Tool slides
Table slides
Cover
Tool storage and
automatic changer
Machine
table
NC command

INTRODUCTION TO CNC
AND CAM
Numerical Control (NC):

 "A system in which actions are controlled by the direct insertion of
numerical data. The system must automatically interpret at least some
portion of this data.
Computerized numerical control (CNC):
 “A numerical control system wherein a dedicated, stored program
computer is used to perform some or all of the basic NC functions
according to control programs stored in the memory of the computer.”
Direct numerical control (DNC):
 “A system connecting a set of numerically controlled machines to a
common memory for part program or machine program storage with
provisions for on-demand distribution of data to the individual machine
memories.”

NC and CNC machining provides several advantages

over conventional or manual machining. With NC and
CNC machining, parts can be reproduced with
improved accuracy. NC and CNC technology
automates the machining process, therefore requiring
fewer machine operators and avoiding operator error.
This automation, combined with the improved

repeatability, yield improved quality control over
the machining process. Furthermore, when linked to
computer aided design software, NC and CNC
technology provide the foundation for agile
manufacturing.

In general, we should consider using a CNC

system when the production situation has:
 Similar workpieces in terms of raw material
 Workpieces produced in various sizes and with
complex geometries, and in small to medium
batch sizes
 Sequence of similar machining steps required to
complete the operation on each workpiece
 Design changes are frequent

Important milestones in the development

of NC.
 1954 first industrial produced NC-machine
 1958 first symbolic programming language
developed
 1965 first automatic tool change
 1969 DNC first installation
 1972 first CNC machine with built-in
microprocessor
 1984 First CNC machine with graphically
supported programming help
 1994 closing of the process chain between
CAD, CAM, CNC
 2000 internet interfaces enable global data
sharing and intelligent fault diagnosis

There are 2 different ways to create a

part on a CNC machine.
 The first is the use of Computer Aided
Manufacturing software (CAM) to interface
Computer Aided Design (CAD) technology with
CNC machine tools. This technology transforms
CAD representations of a workpiece into a
tangible product.
 The second method is called manual part
programming where the user writes the code
by hand and directly enters this code into the
CNC machine via a keypad on the machine
itself.

Computer Aided Manufacturing (CAM)

 Reduces the manual calculations
 To prove the program by path simulation,
identify errors
 Set of events can be programmed with fewer
commands, leading to shorter programs
 English-like structure of the programming systems
makes it easier for programmers to learn
 Program preparation is simplified by use of
English-like commands that are easy to
understand and program. It reduces the
likelihood of errors in the program.
PS. CAM terminology is

very supplier dependant.

CAM
 Links CAD to CNC
PS. CAM terminology is
very supplier dependant.

APT (Automatically programmed tools)

 APT processor checks for errors in defined geometry and in required tool
motions  generates CL file (cutter location file)
 Post processor converts CL data into final NC codes.
• Convert the CL data into machine tool coordinates.
• Check for speed, feed, movement limitations.
• Develop motion command codes.
• Process machine specific functions.
• Select acceleration, deceleration, etc.

NC AXES ON MACHINE TOOLS
NC axes on machine tools
DIN 66217 states

 Z-axis: aligned with the spindle that imparts cutting power. This spindle
might rotate the workpiece as in a lathe, it might rotate a tool as in a
milling machine. Positive motion in z axis tends to increase the
separation between the workpiece and the tool.
 X axis: positioning of the moving element, parallel to the workholding
surface, horizontal (if possible).
• On machines with rotating workpieces, it is radial and parallel to the
cross-slide
• On machines with rotating tools
• If the Z-axis is horizontal, the positive x axis is to the right when looking
from the spindle to the workpiece.
• If the z axis in vertical, the positive x axis is to the right when looking from
 Y-axis: be in such a direction as to complete a right-handed Cartesian

the spindle to the column.
coordinate system.

Lathe

Lathe

Lathe
Reference or zero points - lathe

 Machine reference point M
 Axis reference point R
 Workpiece reference point W
 Tool reference point T

Milling machine

Milling machine
Different configurations or concepts are possible.

Milling machine
Reference or zero points – milling machine

 Machine reference point M
 Axis reference point R
 Workpiece reference point W
 Tool reference point T

Milling machine
Number of axes on a milling

machine
 2 axes
 2.5 axes
 3 axes
 5 axes

Milling machine
Reference or zero points – tool reference point

X length (radius)
Tool
reference
point
Z length

Milling machine
 Point-to-point programming
 Line programming
 Curve programming

Motion control system
 Point to point system

 Continuous path system
Workpiece

 Point to point system

 Continuous path system

 A point-to-point system moves the tool from one position to another and
disregards the path along the way. Each axis of motion is controlled
independently so that the path steps from the start position to the next
position as shown in the picture. The path is not unique as some point-to-
point systems first satisfy the X command and then the Y, while others
reverse the order. Because the traverse path is not controlled, point to
point systems are primarily used in applications for positioning, e.g. drilling.
 Continuous path system is a more versatile type of control system. The

controller can simultaneously coordinate the motion and control the
tangential feed rate of more than one axis. The path of the cutter is
continuously controlled to generate the desired geometry of the workpiece.
In this system the controller generates a path between points by
interpolating intermediate coordinates.

Continuous path system

NURBS interpolation
Linear interpolation uses straight line
segments to approximate the path of a
curve. NURBS interpolation uses curved
line segments instead. In this way, NURBS
interpolation reduces the number of
program blocks needed for precision
milling of a complex form.

MACHINE AND CNC
COORPERATION
Machine and CNC coorporation
Production time with various CAM packages

 CAM simulation and machine simulation. Reality?
600
Finsihing
Semi finishing
500 Roughing
400
300
200
100

Correct Vc and fz , also in reality?

 Radial cutting depth/cutter diameter (ae/D).
 Effective diameter.
Cutting speed Cutting diameter

Chip thickness Number of teeth
Correct RPM
Chip thickness? Table feed

RPM and hm – programmed Vf – real Vf
real Vf < programmed Vf

hm smaller
programmed Vf = real Vf shorter tool life
tool life OK

Machine accuracy
 Deviations in perpendicularity of the machine spindle.
 Deviations in straightness.
 Thermal influences.
 Deviations due to weight and cutting forces.
 Peaks due to collision/friction of protective covers.
 Elastic deformation.
 Incorrect parameter settings.

Speed and accuracy Y

 What is important?
 Which are the demands?
1 2
3
X
Profile of workpiece Milling path
50 12000
49.999
10000
49.998
49.997
8000
49.996
49.995 6000
49.994
4000
49.993
49.992
2000
49.991
49.99 0
100 1000 2500 5000 10000 0.5 0.2 0.1 0.05 0.02 0.01 0.005 0.001 0.0005 0.0001

Accurate movements?

Stability
1. Normal stable vibration. There is no
variation in the chip thickness, the vibration
does not automatically strengthen and will
not increase.
2. Chatter. Variation in chip thickness,

large increase in cutting forces.
The vibration automatically strengthens
and
increases.

Machine accuracy - dynamic

Stability lobes (according to Tlusty/Tobias)
Stability (cutting depth)
RPM

CAM/CNC and machine control

 Cutting technology present or influenceable?
 Selection of milling strategy influenceable?
 Number of lifts or air movements?

THE STRUCTURE OF
NC PROGRAMS
The structure of NC programs
An NC program is a series of instructions

that control the operation mode of
a machine tool.
The structure of the NC program corresponds
to the rules defined in DIN 66025.
PS. Not all codes are fully standardized.

Some are CNC supplier dependant.

The structure of the NC program corresponds to the

rules defined in DIN 66025.
Line number
Preparatory function
End point coordinates
Technological information
Machine function

 Preparatory function: necessary

operation conditions
 Axis motion commands: control the
amount of relative motion
 Feed and speed commands:
control the cutting conditions
 Identification commands: to identify
specific entities in the program,
such as cutting tools used
 Miscellaneous commands: controls
various aspects of the machine’s
operation such as turning the spindle
on and off and changing tools

 What is G-Code?
• G-Code programming is a very robust and simple language. G-codes are what
CNC machines run on. A CNC control program process the G-code line by line
and send this information to the machine. The machine then takes this
information and makes precise movements.
 Where does G-Code come from?
• It comes from the CAM program. When the design is processed in the CAM
program, various machining parameters and inputs are matched with the CNC
machine the workpiece will be run on and then post-processed. The CAM
program then spits out very precise G-codes for the machine and the workpiece.
 Post Processors
• A post processor is a specific way the CAM program will process the design.
There are standard ones and custom ones. If a standard one doesn’t work for,
most good CAM software gives the option to customize the post processor to fit
specific needs.

 G0 or G00 – Rapid traverse. The most rapid movement the CNC machine
can make to the next position. If moving in multiple axes, each axis will
move as fast as they can independently of one another.
 G1 or G01 – Linear interpolation. A straight move with a speed defined by
an “F” (F=Feed) If moving in multiple axis, the machine will move in each
axis until it reaches its defined position.
 G2 or G02 – Circular interpolation Clockwise. A circular movement in 2-axis
in a clockwise motion. Will create an arc to a specified radius defined by an
R or I/J/K combination.
 G2 or G03 - Circular interpolation Counter Clockwise. A circular movement
in 2-axis in a counter-clockwise motion. Will create an arc to a specified
radius defined by an R or I/J/K combination.
 G4 or G04 – Dwell. Machine will dwell once reached position to a user
defined time, noted by a “P”.
 G5 or G05 – Spline definition/interpolation.

G0 – linear interpolation with max feed
can make to the next position. If moving in multiple axes, each axis will
 Be careful with how the machine reacts to this.

G0 – linear interpolation

Y
90 G0 - Linear interpolation with
80 the maximum feed available
70 1 on the machine.
60
50 G1 - Linear interpolation with
40 programmed feed.
30
20
10 2 X
10 20 30 40 50 60 70 80 90

G0 – linear interpolation
can make to the next position. If moving in multiple axis, each axis will

G2/G3 – circular interpolation

R or I/J/K combination.
 G2 or G03 - Circular interpolation
Y
Counter Clockwise. A circular
movement in 2-axis in a counter- 90
clockwise motion. Will create an arc 80
70 1
to a specified radius defined by an
R or I/J/K combination. 60 I
G2 – Circular interpolation in clockwise 50
direction. 40 J
G3 – Circular interpolation in counter 30
20 2
clockwise direction.
I, K, J – Point coordinates for centre of 10 X
interpolation 10 20 30 40 50 60 70 80 90


R or I/J/K combination. Y
 G2 or G03 - Circular interpolation Counter
Clockwise. A circular movement in B
2-axis in a counter-clockwise motion.
G3 G2
Will create an arc to a specified radius
defined by an R or I/J/K combination.
G2
G3
G3 G2
B

 G2 or G02 – Circular interpolation

Clockwise.
 G2 or G03 - Circular interpolation
Counter Clockwise.
Copyright © Seco Tools AB

G5 – spline interpolation (example)
Example tangential entrance strategy
P0
R N60
N50 G5 G41 P1
The G5 does not remains stored and only works in the

scheduled sentence.

The structue of NC programs
 G11 - feed correction

 G17 - XY plane selection
 G18 - ZX plane selection
 G19 - YZ plane selection
 G40 - Corrections tool path Cancel
 G41 - Corrections tool path Left
 G42 - Corrections tool path Right
 G43 - Tool Length Compensation +
 G44 - Tool Length Compensation -

Feed correction
rf + rp
FK = Fp
rp FK
rf Fp
rp
rK
With G11 active, feed is corrected during circular movement,

the programmed feed is maintained at the periphery of the tool.

Corrections tool path
G41 – Correction of tool path to

the left side of the workpiece surface.
P0
R N60
N50 G41 P1
G42 – Correction of tool path

right side of the workpiece surface.

Corrections tool path
 G40 - Corrections tool path Cancel

 G41 - Corrections tool path Left
 G42 - Corrections tool path Right

Radius compensation
 Without radius compensation the

machined shape would be wrong.
 Radius compensation creates Offset
curve.

 G54-G59 - Coordinate definition  G82 - Drilling Cycle

and transfer. User defined, XYZ  G83 - Pecking Cycle
 G60 - exact stop/start movement  G84 - Tapping Cycle
 G64 - continues movement  G85 - Boring Cycle
 G68 - Coordinate Rotation  G86 - Boring Cycle
 G69 - Coordinate Rotation Cancel  G87 - Back Boring Cycle
 G70 - Measuring system inch  G90 - Absolute Command
 G71 - Measuring system mm  G91 - Incremental Command
 G73 - Peck Drilling Cycle  G92 – Position reset
 G76 - Boring Cycle  G94 - Feed per minute
 G80 - Cancel Canned Cycle  G95 - Feed per revolution
 G81 - Drilling Cycle

Intermediate movements
Y
90
N30
With function G60 is active, only when
80 3 4 exact position of the sentence is
70 N40 achieved, the following sentence
60 N20 5 movement starts.
50 N50 6
40 With function G64 is active, the machine
30 2 does not stop at the end of the sentence
20 1 N10 movement, but is continuously moving
10 X to the next position.
10 20 30 40 50 60 70 80 90

 The G70 and G71 commands set the measuring system for
inch or metric conditions.
 G70 and G71 commands remain stored.

Absolute coordinates
Y
90 G90
80 3 4 1 X = 20 Y = 20
70
2 X = 30 Y = 30
60 5
3 X = 30 Y = 80
50 6
40 4 X = 60 Y = 80
30 2 5 X = 60 Y = 60
20 1 6 X = 70 Y = 50
10 X
10 20 30 40 50 60 70 80 90
Copyright © Seco Tools AB 66 66

Type of scaling
Incremental coordinates
Y
90 G91
80 3 4 1 X = 20 Y = 20
70
2 X = 10 Y = 10
60 5
3 X = 0 Y = 50
50 6
40 4 X = 30 Y = 0
30 2 5 X = 0 Y = –20
20 1 6 X = 10 Y = –10
10 X
10 20 30 40 50 60 70 80 90
Copyright © Seco Tools AB 67 67

 M-Codes are other codes throughout an CNC Program. M-Codes are

usually very specific to the machine. For example, “M03” might stand for
“Torch Off” on a CNC Plasma Cutter. It also might stand for “Spindle Turn
Clockwise” on a CNC milling machine.

 M0 - program stop  M30 - program end, pallet shuttle,

 M1 - optional program stop and reset
 M2 - program end  M48 - enable speed and feed
 M3 - turn spindle clockwise overrides
 M4 - turn spindle counterclockwise  M49 - disable speed and feed
 M5 - stop spindle turning overrides
 M6 - tool change  M60 Part exchange (pallets)
 M7 - mist coolant on  M68 Workpiece clamping
 M8 - flood coolant on  M69 Workpiece unclamping
 M9 - mist and flood coolant off  M99 End of subroutine
 M26 - enable automatic b-axis
clamping
 M27 - disable automatic b-axis
clamping

EXAMPLE OF NC PROGRAM
FOR THREAD MILLING
Example of NC program for thread milling
X Z

N360 G0 G54 X-64 Y0 Z5 S4081 M3 M8 M21
 G0 = Linear movement with rapid feed

 G54 = Assume the coordinates in relation to the zero reference
 X-64 = X-axis linear movement
 Y0 = Keep the Y axis at the current position
 Z5 = Linear movement of the Z axis
 S4081 = Set the rotation of the spindle to 4081 rpm
 M3 = Turns the spindle clockwise
 M8 = Connect the external supply of fluid
 M21 = Connect the internal supply of high pressure fluid

Understanding the sequence of movement
N360 G0 G54 X-64 Y0 Z5 S4081 M3 M8 M21
5
Y
X Z

N370 G0 Z-17.5
 G0 = Linear movement with with rapid feed

 Z-17.5 = Z axis linear movement into the hole

N370 G0 G60 Z-17.5

17.5
Y
X Z

N380 G1 G5 G11 G64 X-66.05 Y0 F55
 G1 = linear movement
 G5 = Enables tangential entry strategy
 G11 = Correction of the feed for circular movement
 G64 = Enables continuous movement
 X-66.05 = Linear movement in X
 Y0 =Keeps the Y axis at the current position
 F55 = Set feed to 55 mm/min

N380 G1 G5 G11 G64 X-66.05 Y0 F55
66.05
X Z

N390 G3 X-66.05 Y0 Z-19 I0 J0 F110
 G3 = Circular interpolation with counterclockwise motion

 X-66.05 = Circular shift to the position in X
 Y0 = Keeps the Y axis at the current position
 Z-19 = Combined with circular interpolation generates a helical
movement with a pitch of 1.5 mm
 I0 = Coordinate of the center of the circular interpolation for the axis X
 J0 = Coordinate of the center of the circular interpolation for the axis Y
 F110 = Adjust the feed to 110 mm/min

N390 G3 X-66.05 Y0 Z-19 I0 J0 F110
19
Y
66.05
X Z

N400 G1 G5 G11 X-64 Y0 F165
 G1 = linear interpolation
 G5 = Enables tangential entry strategy
 G11 = Active correction of the feed circular motion
 X-64 X = linear movement to the center of the hole
 Y0 = Y Maintain the current position
 F165 = Adjust the feed to 165 mm/min

N400 G1 G5 G11 X-64 Y0 F165
X Z

N410 G0 G60 Z5
 G0 = Linear movement with with rapid feed

 G60 = Enables the need to stop at end
 Z5 = Z axis linear movement out the hole

N410 G0 G60 Z5
5
Y
X Z

CUTTING CONDITIONS
Introduction
vc = Cutting speed (m/min) ap = Depth of cut (mm)
D = Diameter (mm)
n = rpm
n ×π × D
vc = = [m / min]
1000
f = feed (mm/rev)
Introduction
Dc = Cutter diameter (mm) Feed speed / feed per

Zn = Number of teeth revolution:
v f = n × Zc × f z = [mm / min]
Zc = Effective number of teeth
Vc = Cutting speed (m/min)
f = Zc × f z = [mm / rev]
N = rpm
Ap = Axial depth of cut (mm)
Ae = Radial depth of cut (mm)
Fz = Feed per tooth (mm/tooth) n = rpm:
v × 1000
n= c = [rpm]
F = Feed per revolution (mm/rev)
Vf = Feed speed (mm/min) π × Dc
n × π × Dc
vc = = [m / min]
1000

Cutting conditions
Feed
Feed is the movement of the centre point.

Cutting conditions
Feed
Feed is the movement of the centre point.

Cutting conditions
Radical depth of cut
ae
Correct definition of radial cutting depth.

Cutting conditions

Cutting conditions

ae

Cutting conditions
ae ae
In linear milling, the material In circular milling, the material over-

over-stock is the radial cutting stock is not the radial cutting depth.
depth. The feed must be adjusted to avoid
risk of vibration and damage to the
cutting edge.

Cutting conditions

Internal External

Cutting conditions
“Material overstock” “Material overstock”

ae ae
D1
D D D1
D0 D0
ae > “Material overstock” ae > “Material overstock”
ae = D02 – D12 ae = D02 – D12

4 (D0 – D) 4 (D1 – D)
MILLING STRATEGIES –
ENTRANCE STRATEGIES
Entrance conditions
Entrance strategy
Tangential feed direction is Radial feed direction is not

recommended because it results recommended because the varying
in an even cutting force. There radial cutting depths result in varying
will be no tool breakage and cutting forces. This can result in tool
surface damage (start/stop). breakage and surface damage.

Entrance conditions
Entrance strategy – straight entry

fz
Before the cutter is fully

engaged there are thick chips
on exit, resulting in edge
failure, poor tool life and
vibration (exit failure).

Entrance conditions
Entrance strategy – curved entry fz

Rolling into cut keeps chip thin on exit, reducing
vibrations and giving better tool life.

Entrance conditions
Entrance strategy – ramp entry

Ramping into cut keeps chip thin on exit and engagement
angle low - reducing vibrations and allowing higher
productivity.

Entrance conditions
Entrance strategy – external corners

 Keep cutter constantly engaged to prevent re-entering the workpiece.
 Turn the cutter around radii.

Entrance conditions
Entrance strategy – external corners

 Program radii to prevent excessive arc of engagement causing vibration.
 Reduce feed in radii if not using radius compensation.

EXAMPLES OF
TECHNOLOGICAL STRATEGIES
Basic milling methods
Face milling Slot milling
Square shoulder milling Copy milling

Rampling or copy milling Helical interpolation milling
Trochoidal milling Peel milling

Plunge milling Z level milling

Milling strategy
Geometrical strategy:
 linear and non-linear
 complex (circular, helical,
trochoidal, …)
 radial and axial
 …
Technological strategy:
 hard cutting
 high speed cutting
 high feed cutting
 high RPM cutting
 high performance cutting
 …

Technological milling strategies
Hard milling, high speed milling, high feed milling,

high RPM milling, high performance milling, …
 Productivity = metal removal rate
 Metal removal rate
Cutting
speed
• Depths of cut
• Feed
• Cutting speed
Metal removal rate
Feed
Depth of cut

Technological milling strategy
High performance milling

(high ap)
 Large axial cutting depth.
 Large radial cutting depth.
 Medium feed.
 Medium cutting speed.
 Ideal for stable operations

High feed milling (high fz)

 Small axial cutting depth.
 Large radial cutting depth.
 High feed.
 Medium / high cutting speed.
 Ideal for large tool overhangs.

High feed milling (high fz)

High cutting speed milling

(high vc)
 Small radial cutting depth.
 Small chip thickness.
 High cutting speed.
 Sharp cutting edges.
 Hard cutting material.

High cutting speed milling (high vc)
ALU HSM
STEEL HSM
HARD STEEL HSM
CAST IRON HSM
TiAl6V HSM
Vc : 120 200 500 1000 2000 m/min

High cutting speed milling (high vc)

 Some advantages  Some disadvantages
• Shorter electro erosion time • More expensive
• Quicker finishing of 3D shapes • More complex programming
• Harder workpiece materials • Qualified personnel
• Machining quality/Ra • Learning time
• Less deformation • Planning / profitability
• Higher productivity • Workload on the machine
• Lower temperature • Safety

Small arc of engagement strategy
Slot milling Side milling

Small arc of engagement strategy
Temperature
Critical temperature
Temperature
Contact time

Hard milling (high vc in hard material)

Cutting speed
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Radial depth op cut

High cutting speed milling (high vc in high material)

 Small chip thickness. Hardness ae
 Sharp cutting edges.

35 – 45 HRc 0.07D
Hard cutting material.
46 – 55 HRc 0.05D
56 – 62 HRc 0.01D
63 – 70 HRc 0.005D

Peel milling
 Large axial cutting depth.
 Geometry of cutter important.
 Eliminates semi finishing.

Trochoidal milling
 Combination technology and
geometry.
 Based on “small arc of
engagement”.
 The axial cutting depth and
cutting speed can be increased.

Trochoidal milling
 The roughing cycle with the classic
methods.
 Trochoidal milling only when there
is risk of cutter jamming (big radial
depth of cut).
 Avoid milling with the full cutter,
so that higher feed can be used.

Raceline milling
 The tool path is smoothed to
minimise sudden changes in feed
direction, this allows higher feeds
and gives longer tool life (less
breakage).

Plunge milling
 Method for larger overhang and weaker machines.
 Medium cutting speed.
 Good method for difficult materials such as Inconel.
 Roughing method which increases productivity.

Milling strategy
Thin walls
External roughing Helical milling Internal roughing
Plunge milling Finishing (Z level)

Milling strategy
Thin walls

Milling strategy
Thin buttoms
Steep walls

Copy milling

Ball nose cutter
Copy milling  two basic methods, peel milling

strategy and Z level milling strategy.

Ball nose cutter
D = Milling cutter diameter

ap = Axial cutting depth
Dw = Effective diameter

Ball nose cutter
Copying up (1) or down (2), copying angle  effective diameter

Ball nose cutter
Take the correct cutting depth into account.

Ball nose cutter
Correct RPM
Ø cutter
Ø effective
• 13
1
Ball nose cutter
Shank inclination
n : 12000 t/min
Vf : 2500 mm/min
ae = ap : 0.3 mm Coated micrograin
Tool life : 100
• 13
2
Ball nose cutter
Shank inclination
n : 12000 t/min
Vf : 2500 mm/min
ae = ap : 0.3 mm
PCBN insert
Tool life : 50
• 13
3
Ball nose cutter
Shank inclination
n : 12000 t/min
Vf : 2500 mm/min
ae = ap : 0.3 mm
CBN insert
Tool life : 450
• 13
4
Cutter with round inserts
• 13
5
Price of Price of
tool inserts Performance Programming
Ball nose
Round
insert
• 13
6
• 13
7
Ball nose cutter Round inserts cutter
Plunge milling
Method peel milling Method Z level milling
• 13
8
Milling in corners (pencil milling)

 Milling against a wall increases the angular engagement and the
axial depth of cut and creates risk of vibration.
 Reducing the radius of the tool, reducing the feed or material
overstock helps but reduces productivity.

EXAMPLES OF
GEOMETRICAL STRATEGIES
Zig-zag or one-way milling
 Zig-Zag – cuts are made in both directions to remove material. Suitable

for cutter and material conditions that do not require maintaining
cutting conventions.
 One-Way – unidirectional cuts ensure that the milling method is always
up or down milling.

2D roughing
 A series of Z-Plan programs to rough. Smaller tools machine only

in areas where preceding larger tools could not machine.
 Z-Plan machining strategy combines clearing with corner cutting
techniques depending on the left over stock condition.
 Zig-Zag, Spiral Outside-In, Spiral Inside-Out clearing options.

Corner cutting technique
 Milling in a corner increases the angular engagement and the axial

depth of cut and creates risk of vibration.
 Reducing the radius of the tool, reducing the feed or material overstock
helps but reduces productivity.

2D profiling


3D roughing


3D roughing with clearing

 High speed machining possible to smooth interior corners.
 Machining by level or by pocket.
 Plunge, or helical or contour ramping.

3D roughing without clearing
 Different Z-level program styles to address different part geometry and

machining conditions.
 High speed machining possible with circular entrance and exit.
 Machine multiple regions by pocket or by level.
 Lifts retract the tool only as high as necessary.

By pocket or by plan
 Machine by pocket – completes machining each cavity area before

proceeding to the next area to machine.
 Machine by level – each Z-Level is completed before descending to the
next level to machine. Useful for thin-wall part conditions.

Plunge roughing
 Center cutting or edge-cutting styles.

 Maximum plunge depth to machine in layers.
 Step-back retracts to avoid dragging tool during retract motions.
 Z-Level cleanup program removes cusps left over from plunge roughing.

Flow line machining
 Drive a primary curve only or primary and secondary curve where cuts
are trimmed at the intersection of the secondary curve.
 Walk the cutter into or away from the flow curve.
 High speed machining possible for transition smoothing and precision
finishing.
 One-way or zig-zag machining.
Radial machining
 One-way and zig-zag cutting options.

 High speed machining possible for transition smoothing and precision
finishing.

Contour machining
 Offset on-surface machining following the shape of a bounding curve.

 Inside-out or outside-in cutting style.
 Fixed step-over or on-surface step-over.
 Directional control to enforce climb or conventional cutting..

Pencil machining
 Detection bi-tangency condition of workpiece surface to tool geometry

produces candidate paths for selection to include in the program.

Rib machining
 Machining strategy to cut grooves. In many cases, rib machining can be

faster than using conventional EDM methods.

Spiral machining
 Perfect for cutting circular features, this cutter path produces a

continuous spiral from one specified diameter to another.
 Machine outside-in or inside-out.
 Clockwise or counter-clockwise direction to enforce climb or
conventional milling.

Scribe machining
 Engrave text or lines at a specified depth.

 Step-down option controls the amount of stock removed for each pass.
 One-way or zig-zag cutting style.
 Cut by level or by curve.

SOME THOUGHTS ON 5-AXIS
MILLING STRATEGIES
5-axis machining strategies
3-axis machining machining using linear X, Y and Z axes

Z
Y
5-axis machining machining using linear X, Y and Z

axes and rotary 2 axes
Z
A
X

Z Z
C
A B
x y x
y
3-axis machining 5-axis machining

Applications
 Structural elements
• Engines

• Turbine blades
Mould and die industry
 Automotive industry
 Marine industry
 Medical industry

Benefits of 5-axis machines

 Flexibility: one machine for
• 3-axis machining (HSM)
• Positional 5-axis
• Continuous 5-axis
• 5-axis drilling
 Machine technology On a 5-axis machine, dedicated '5-axis machine

improvements devices' should be used. They are designed to
• Faster axis & spindles allow operators to use the full potential of a 5-
• More accurate & rigid axis machine.
• Smaller
• Cheaper

5-axis machine configurations
Z
A
C
X
Y

A
Y
X Z

B
Z
X Y

Types of 5-axis machining
Multi-axis indexing with fixed tool angle (drilling)

 Moving and tipping of the workplane allows workpieces to be
machined from different directions without reclamping. The direction
of machining corresponds to the orientation of the tool. Program part
repetition can be used in moved and tilted workplanes, reducing
programming time.
Positional milling with fixed option 3+2

 For 3D machining with a tool that is tilted relative to the machining
direction, milling areas can be programmed easily, defined without
overlaps and gaps, and checked for collisions. This strategy ensures
that all areas including details are completely calculated.

Automatic indexing
 Automated 3+2 milling offers an alternative if the machine does not
fulfil the dynamic requirements for 5-axis simultaneous milling. Large
areas that require various tool angles are programmed and milled in a
single operation. Automatic indexing scans for fixed tool inclinations
for the corresponding tool paths. If there are possible holder
collisions, the respective path segment can be subdivided into smaller
segments with the corresponding tool positions.

5-axis simultaneous machining

 This set of 5-axis machining cycles is the alternative to positional 3+2
milling for machining on or near steep walls. To avoid collisions, a tool
tilt to the Z-axis is defined. The continuous movement of the tool
around the Z-axis is calculated either fully automatically or as a result
of defined guide curves. Optimising tool tilt angles improve cutting
conditions when milling surfaces.


 Positional 3-axis machining with 5-axis
indexing. Normal linear 3-axis
machining after indexing the inclined
plane by using rotary axis.
 Simultaneous 5-axis machining with

rotary 2 axes while machining with
linear 3 axes.

Simultaneous 5-Axis
 Both rotary and linear axes move
during cutting
 Rotary axes must support continuous
movement
 Tool axis can vary during a movement
 Generally, HSM is not possible because
rotary axes are slow

Simultaneous 5-Axis

Simultaneous 5-Axis

Simultaneous 5-Axis

Simultaneous 5-Axis

Positional 5-Axis (3+2 Axis)

 Rotary axes are used to position the
tool before cutting
 Rotary axes are locked during cutting
 Cutting operations use 3 linear axes
only – HSM is possible
 Majority of 5-axis users only use
positional 5-axis

Benefits - Positional 5-Axis

 Shorter cutters
 Faster cutting
 Longer tool life
 Improved accuracy
 Better surface finish
 Fewer set-ups
 Time savings
 Less setting errors
 Better machine utilisation
 Fairly simple programming
 HSM techniques can be used

Positional 5-Axis

Positional 5-Axis

Positional 5-Axis

Curved surface machining with face milling cutter
Ball nose cutter
→ Long machining time

3-axis machining 1) Small machining pitch
5-axis machining
→ Short tool life
Small 2) Tool center cutting
pitch Ball end
mill
Face milling cutter

1) Large machining pitch
→ Short machining time
2) Periphery cutting
Face milling cutter → Long tool life

Machining with short tools in deep pocket cutting
3-axis
machining
5-axis
machining
No long cutter and angled

attachment needed.

Reduced setup time and processes, and improved

machining accuracy
Multi-surface machining
3-axis with single chucking
machining
5-axis machining
Contour
machining
5-axis side cutting (Swarf Machining)

5-axis indexing
machining

Longer toollife ensured by eliminating the

machining at the center point of ball nose cutter
3-axis machining 5-axis machining
Toollife is short due to High cutting speed extends tool life

zero cutting speed at and improves machining efficiency.
the tool center point.

Undercut shaping possible
Simultaneous 5-axis
machining
Undercut shaped workpiece

5-axis technology
 5-axis strategies:
• Through a line
• Through a point
• Profiling
• Trimming
• Swarf
 Automatic calculation of optimum lead
and lag
 Collision checking on tool paths
 Visualization
 Support for full range of cutting tools

Through a point
 The tool is aligned so that the axis passes through a specified point
with the cutting end pointing away from the point

Through a point
 Keep tool short
 Better surface finish
 Longer tool life
 Shorter cycle time

Through a line
 The tool is aligned so
that the axis passes
through a specified line
with the cutting end
pointing towards the line.

Drive surface 5-axis

 Projection direction and tool
orientation determined by drive
surface
 Single drive surface but
multi-surface part
 Full gauge protection
 All cutter types

Swarf machining
 Tool path generation from surfaces
 From wireframe and using all tool
types including tapered tools

Swarf machining
 Improved results over surface swarf
 Where surfaces are not truly
developable
 Where internal surface structure is poor
 Where edge matching is not perfect

Through a curve
 Tool is controlled by a single curve
 Ensures full control over tool path
movement
 Eliminate potential machine tool
collisions
 Improve surface finish by having
more control over machine tool
kinematics

Collision avoidance

Simulation
 Tool paths in different colors gives
clearer understanding of machining
process
 Color changes for axis reversal and
possible dwell marks

Virtual visualization
 Takes into account cutter geometry and feeds and speeds to allow
approximate visualization of the part before machining has taken place.
Simulation Real part

 Machining the workpiece in one set up.

 Working with short overhang.
 Improvement of the surface finish by removing cutting action from the
centre of the tool (ball nose cutters).
 Reduction of machining time by using an end mill to realise the clearance
or the back clearance instead of copying with a ball nose cutter in 3 axis
(Swarf Machining).
 Programming of the end or centre of ball nose cutter to enable a perfect
repositioning on the surface of the shape when changing of tool.
 Allows the reduction of certain EDM operation
(Electrical Discharge Machining).

Roughing
 Work in 3 axis. Release an axis when a problem of accessibility occurs.
 Advantages: good dynamics and good machine stability.
Rest roughing
 Same strategy as the 3 axis with possibility of tool tilting.
Finishing
 Work in 4 axis with the 5th axis clamped according to an angle. Release the
5th axis to avoid collisions.
 Advantages: the tool is always in contact with the workpiece. Continuous
machining resulting in an excellent surface finish.

Do you have Questions?
Please send them to Patrick.de.vos@secotools.com

NC I CNC

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INTRODUCTION TO

CNC AND CAM TECHNOLOGY

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Workpiece Tool Control

Tool movement Frame

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The same technological capabilities as conventional machines

Capabilities of machine control unit (MCU) of an NC machine

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Cover Chuck Turret Window

Main spindle Frame

Clamping unit NC monitor

Main motor NC command

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Main spindle Main motor

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Numerical Control (NC):

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NC and CNC machining provides several advantages

This automation, combined with the improved

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In general, we should consider using a CNC

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Important milestones in the development

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There are 2 different ways to create a

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Computer Aided Manufacturing (CAM)

PS. CAM terminology is

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APT (Automatically programmed tools)

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DIN 66217 states

 Y-axis: be in such a direction as to complete a right-handed Cartesian

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Reference or zero points - lathe

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Different configurations or concepts are possible.

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Reference or zero points – milling machine

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Number of axes on a milling

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Reference or zero points – tool reference point

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 Point to point system

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 Point to point system

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 Continuous path system is a more versatile type of control system. The

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Continuous path system

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Production time with various CAM packages

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