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Abstract
Basic controls and operations of CNC machine are discussed in this lab repoert. In
the CNC milling lab, we studied and learned how to control different control types of
CNC milling machine, its codes, its operations and the precautions to be considered
while operating it. The main purpose of the lab was to familiarize ourselves with the 3-
axis CNC milling machine. Moreover, we had to learn different commands upon which
the 3-axis CNC milling machine operates.
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Contents
1 Introduction ..................................................................................................... 1
1.1 Basic Programming Methods in CNC: .................................................... 2
1.2 Conversational CNC programming: ........................................................ 2
1.3 Advantages of CNC machine tools: ......................................................... 3
1.4 CNC Manufacturing Process .................................................................. 3
1.4.1 G-codes: ............................................................................................ 3
1.4.2 M-codes: ........................................................................................... 4
1.5 ABSOLUTE AND INCREMENTAL CO-ORDINATES. ...................... 4
1.5.1 Absolute Co-ordinates: ..................................................................... 4
1.5.2 Relative co-ordinates: ....................................................................... 5
1.6 Orientation of the axes in vertical CNC milling tool: .............................. 5
............................................................................................................................ 6
2 Task performed in Lab .................................................................................... 7
3 Results: .......................................................................................................... 10
4 Discussion ..................................................................................................... 11
5 Conclusion..................................................................................................... 12
6 References ..................................................................................................... 13
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List Of Figures
Figure 1: Coordinate axes ....................................................................................... 5
Figure 2: CNC manufaturing process ..................................................................... 6
Figure 3: Dimensions of Workpiece ....................................................................... 9
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List of Tables
Table 1…………………………………………………………..4
Table 2…………………………………………………………..4
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1 Introduction
In the process of milling, we use a milling cutter to remove material from the
surface of a workpiece. Milling cutter is a rotary cutting tool, often with multiple cutting
points.
Unlike drilling, where the tool is advanced along its rotation axis, the cutter in
milling is usually moved perpendicular to its axis so that cutting occurs on the
circumference of the cutter. As the milling cutter enters the workpiece, the cutting edges
of the tool repeatedly cut into and exit from the material, shaving off chips from the
workpiece with each pass. The cutting action is shear deformation; material is pushed
off the workpiece in tiny clumps that hang together to a greater or lesser extent
(depending on the material) to form chips. This makes metal cutting somewhat different
(in its mechanics) from slicing softer materials with a blade.
The milling process removes material by performing many separate, small cuts.
This is accomplished by using a cutter with many teeth, spinning the cutter at high
speed, or advancing the material through the cutter slowly; most often it is some
combination of these three approaches. The speeds and feeds used are varied to suit a
combination of variables.
Feed rate: The speed at which the piece advances through the cutter; it is most often
measured in length of material per full revolution of the cutter.
There are two major classes of milling process:
 Face milling, the cutting action occurs primarily at the end corners of
the milling cutter. Face milling is used to cut flat surfaces (faces) into
the workpiece, or to cut flat-bottomed cavities.
 Peripheral milling, the cutting action occurs primarily along the
circumference of the cutter, so that the cross section of the milled surface
ends up receiving the shape of the cutter. In this case the blades of the
cutter can be seen as scooping out material from the work piece.
Peripheral milling is well suited to the cutting of deep slots, threads, and
gear teeth.
CNC (Computerized Numerical Control) is the general term used for a system
which controls the functions of a machine tool using coded instructions processed by a
computer. It refers to any machine tool (i.e. mill, lathe, drill press, etc.) which uses a
computer to electronically control the motion of one or more axes on the machine [2].
The development of NC machine tools started from a task supported by the
US Air Force in the early 1950’s, involving MIT and several machine-tool
manufacturing companies. The need was recognized for machines to be able to
manufacture complex jet aircraft parts.
As computer technology evolved, computers replaced the more inflexible
controllers found on the NC machines; hence the dawn of the CNC era.
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1.1 Basic Programming Methods in CNC:

There are two ways to program modern CNC machine tools.
1. Conversational Programming.
This is the simpler of the two methods. In effect, this is a macro programming
language used to instruct the machine to perform pre-programmed cycles (i.e.
facing, drilling holes in arrays, etc.).
When writing a conversational program, you simply enter the appropriate
parameters associated with each machining cycle.
2. CAM Programming.
This is the more powerful of the two methods. Using this method, one can
import part model into a CAM (computer aided manufacturing) or CAD
(computer aided designing) program and define the parameters associated with
each and every machined feature on the part. These parameters include tool
diameter and length, depth of cut, tool path geometry, etc.

1.2 Conversational CNC programming:

The following cycles are typical of the machining operations available when
programming a 3-axis CNC milling machine.
 Position. Used to move the XYZ coordinates at rapid feedrate.
 Drill_one. Used to position the tool at a specific XYZ coordinate position in
order to automatically drill a hole. The automatic drill cycles allow for simple
drilling, peck drilling, spot-facing and bore cycles.
 Drill_pattern. Used to define polar or rectangular hole arrays for automatic
drilling.
 Line. Used to cut straight lines along an axis or a diagonal at the desired
feedrate.
 Arc. Used to cut a circle or partial circle that is part of a series of cuts that
usually includes lines as well.
 Face. Used to define a rectangular zig-zag pattern used to clean off a part
surface.
 Pocket. Used to clear the material out of a rectangle, circle or polygon.
 Frame. Used to cut the inside or outside outline of a rectangle, circle or
polygon.
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 Tool. Used to enter tool parameters, machine function parameters and

program pause/stop codes.
 Scale/mirror. Used to scale and/or mirror other part features.
 Rotate. Used to repeat other part features around a specific center of rotation.

1.3 Advantages of CNC machine tools:

I. CNC machine tools use software programs to provide the instructions
necessary to control the axis motions, spindle speeds, tool changes and so
on.
II. CNC machine tools allow multiple axes of motion simultaneously, resulting in
2D and 3D contouring ability.
III. CNC technology also increases productivity and quality control by allowing
multiple parts to be produced using the same program and tooling.

1.4 CNC Manufacturing Process

The figure (2.1) shows the main stages involved in producing a component on a
CNC system.
1) A part program is written, using G and M codes. This describes the sequence of
operations that the machine must perform in order to manufacture the component. This
program can be produced off-line, ie, away from the machine, either manually or with
the aid of a CAD/ CAM system.
2) The part program is loaded into the machines computer, called the controller. At
this stage, the program can still be edited or simulated using the machine controller
keypad/input device.
3) The machine controller processes the part program and sends signals to the
machine components directing the machine through the required sequence of operations
necessary to manufacture the component.
Codes in CNC milling tool:
There are two types of machine codes used to interact with CNC machine tools as
discussed below:
1.4.1 G-codes:
Preparatory functions, called G codes, are used to determine the geometry of tool
movements and operating state of the machine controller; functions such as linear
cutting movements, drilling operations and specifying the units of measurement [3].
They are normally programmed at the start of a block.
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A G code is defined using the G address letter and a two digit number as follows,
G ØØ
Address. Two digit number.
Common G commands are as follow.
CODE FUNCTION
G00 Rapid transverse
G01 Linear interpolation
G02 Circular interpolation (clockwise)
G03 Circular interpolation (Anti-
clockwise)
G81 Drilling
G90 Absolute Positioning
Table 1

1.4.2 M-codes:
Miscellaneous functions, called M codes, are used by the CNC to command on/off
signals to the machine functions. ie, MØ3 - spindle forward (CW), MØ5 – spindle stop,
etc.....
An M code is defined using the M address letter and a two digit number as follows,
M ØØ
Address. Two digit number.

Common M commands are as follow.

CODE FUNCTION
M00 Program stop
M01 Optional Program stop
M02 Program End
M03 Spindle on (Clockwise)
M04 Spindle on (Anti-clockwise)
M06 Tool change
M08 Coolant on
Table 2

1.5 ABSOLUTE AND INCREMENTAL CO-ORDINATES.

1.5.1 Absolute Co-ordinates:
The addresses X, Y and Z within a program, when G90 (Absolute co-ordinates) is
active, relate to a coordinate position from the workpiece datum (the zero position).
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1.5.2 Relative co-ordinates:

The addresses X, Y and Z within a program, when G91 (Incremental co-ordinates)
is active, relate to the individual axis movements required to reach the new position,
from the last position reached by the tool.

1.6 Orientation of the axes in vertical CNC milling tool:

In a 3-axis CNC milling machine, the x, y and z co-ordinates are defined as
follow.
X-axis: Positive towards right.
Y-axis: Positive in the direction away from the worker (operator).
Z-axis: Positive in upward direction.
The orientation of the axes is shown in the fig 2.2.

Figure 1: Coordinate axes

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Figure 2: CNC manufaturing process

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2 Task performed in Lab

In the lab, we were given the geometry as shown in fig 3.1. We had to trace the
given shape on the Perspex sheet. The slots had to be of 3mm depth.
The complete code that we entered and operated on CNC milling machine line
by line is as follow.
S1500M3
G54G0X0Y0
G01Z-3F5
G01X40F30
G02R10X50Y-10F30
G01Y-50F30
G02R10X40Y-60F30
G01Y-10F30
G02R10X0Y0F30
G0X20Y-30
G01Z-16F5
M5
M30
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Figure 3: Dimensions of Workpiece

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3 Results:
We made our desired shape on the workpiece using CNC with great ease and in
less time. We only had to enter the code and wait for the machine to finish its job. The
shape was engraved with close tolerances of .001mm which was the least count of the
machine tool. A hole was also made at the center of the workpiece.
Different feed rates were used to operate the machine depending upon the nature
of the operation to be performed on the workpiece. The feed rates used for the task were
as feed rate of 30 for linear cut, 10 for circular arc and 5 for drilling the through hole.
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4 Discussion
Today, CNC system is highly automated using Computer Aided Design (CAD)
and Computer Aided Manufacturing (CAM) program. For this experiment CAM
program method is used. To operate the machine, the computer file is produced and
interpreted to extract the command needed. After that, the program is installed into
CNC machine for production. The coding was done because the NC machine cannot
read the design directly. The machine will run according to the coding that has been
inserting. The duration of the product based on the number of the coding inserting. For
about 1424 lines coding was inserted in the programming to make the product in this
experiment. About approximately 30 minutes for the CNC milling machine to complete
finish the product that has been design by CATIA software. CATIA is a software that
used to design products in computer files before installed into CNC machine. CATIA
also can eliminate the human error when design product. There are lots of advantages
of using CNC machine. One of the advantages is higher precision because machine tool
capable to machine at very close tolerance, as small as 0.005 mm. It is also can
machining the complex three-dimensional shapes. For example, variety of design such
as the steering car and rim of the car and motorcycle can be made using CNC machine.
The experiment results show that the three complex dimensional shapes are proven can
be produced. Besides, it has better quality because it can maintain constant working
condition for all parts. From the experiment product obtain, we can say that the surface
product is smooth. This is because there are two kind of process occur, roughing and
finishing.
Roughing is the process where the work piece is shaping for the first layer. In this
case, the surface of work piece is still rough. It is like sketching in the drawing. After
that, finishing process takes place. This is when the final product has been touching
up in order to make smoother surface. This experiment occurred when the cutter in
dry condition. There are no cooling agents to cool the work piece and tool. However,
the oil is added to the work piece as cooling fluid to make the milling process run
smoother without distraction of the work piece flash. The flashes stick to the oil that’s
why the machine is easy to drill the work piece. The work piece also has to be holding
tightly enough from moving during process occur to prevent any defection. There are
lots of products has been produce from CNC milling machine in industry. The product
requirement produces in varies industries such as electronic, instrumentation, medical,
microwave, optical and many more.
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5 Conclusion
Regarding to the experiment on using CNC machine to produce a steering wheel
using the prospect material, the product that was produced look a little rough on its
surface. Thus, due to the several factor on the beginning of the designing of the product.
The process of designing the steering start by using CATIA software design to design
the initial picture of the steering that need to be fabricate. Next, the analysis and the
visualization of the product that will be cut were done by the software. The cutting layer
of the product was set up to two types; rouging and finishing. To get the better surface
roughness there are two or three more setting that can be applied from the software but
it will consume a lot of time to produce a fine product with smooth surface finish. The
required time need to finish the product was 30 minutes. Before the design was
transferred to the machine it will be converted to a general coding of the CNC machine.
This process of converted the coding was run automatically by the CAM software. So,
that is one of the different between EDM wire cut and this CNC machine where EDM
wire cut machine, the coding was done manually by the user.
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6 References

[1] N. Seyferth, "Eagle Group," Eagle Group, 6 april 2018. [Online].

Available: https://blog.eaglegroupmanufacturers.com/introduction-to-cnc-
machining.

[2] D. Limited, "M and G programming for CNC Milling Machines".

[3] "Milling (machining)," [Online]. Available:

https://en.wikipedia.org/wiki/Milling_(machining).