VISVESVARAYA TECHNOLOGICAL UNIVERSITY

JNANA SANGAMA, BELAGAVI-590018, KARNATAKA

An Internship Report
On
“CNC MILLING PROGRAMMING AND OPERATION”
Submitted in partial fulfillment of the requirements for
Bachelor of Engineering in Mechanical Engineering
In the academic year 2019-20

Submitted by

AKSHAY R

USN: 1RN16ME019

Under the guidance of

Mr. Vasudev Upadhya

Assistant Professor

Department of Mechanical Engineering

RNS INSTITUTE OF TECHNOLOGY

(AICTE Approved, VTU Affiliated & NAAC ‘A’ Grade Accredited)
UG Programs - CSE, ECE, ISE, EIE and EEE have been Accredited by NBA for the
Academic years 2018-19, 2019-20 and 2020-2021
Dr. Vishnuvardhan Road, Rajarajeshwari Nagar, Channasandra, Bengaluru-560098

2019-2020
 CERTIFICATE

This is to certify that the internship work titled ‘CNC MILLING

PROGRAMMING AND OPERATION’ has been successfully completed
by AKSHAY R (1RN16ME019), a bonafied student of RNS Institute of
Technology in partial fulfillment of the requirements of Bachelor of
Mechanical Engineering of Visvesvaraya Technological University,
Belagavi during academic year 2019-2020. It is certified that all
corrections/suggestions have been incorporated in the report deposited in the
departmental library. The internship report has been approved as it satisfies
the academic requirements in respect of said course.

Dr. T Sreenivasan

(Signature of HOD)
 DECLARATION

I, AKSHAY R (1RN16ME019), student of VII semester B.E,

Mechanical Engineering, RNS Institute of Technology, Bengaluru, hereby
declare that the internship titled ‘CNC MILLING PROGRAMMING
AND OPERATION’ has been carried out by me and submitted in partial
fulfillment of the requirement for the VII semester degree of Bachelor of
Engineering in Mechanical Engineering of Visvesvaraya Technological
University, Belagavi, during academic year 2019-20.

AKSHAY R
 ACKNOWLEDGEMENT

The satisfaction and euphoria that accompany the successful completion of

any task would be incomplete without the mention of the people who made
it possible, whose constant guidance and encouragement crowned the efforts
with success. I would like to thank the Management of RNS Institute of
Technology for providing such an opportunity to complete the internship
work. I would like to express our thanks to the Director
Dr. H N Shivashankar and the Principal Dr. M K Venkatesha for their
encouragement that motivated us to successfully complete the internship.
It gives me immense pleasure to thank Dr. T Sreenivasan, Professor and
Head of Department, Mechanical Engineering for his constant support and
encouragement. I wish to express my deepest sense of gratitude to the
trainers of ‘GOVERNMENT TOOLS AND TRAINING CENTER’ for
their constant support and guidance throughout the internship period. Last,
but not the least, we would like to hereby acknowledge and thank our
parents who have been a source of inspiration and also instrumental in the
successful completion of internship.

AKSHAY R
(1RN16ME019)
 CONTENTS

1. CHAPTER 1 – INTRODUCTION .............................................................................. 1

Evolution of CNC machines .......................................................................... 1

Numeric control machine .............................................................................. 1
CNC machine ................................................................................................ 2

2. CHAPTER 2 - TECHNICAL CHARACTERISTICS AND APPLICATION ....... 8

3. CHAPTER 3 - CNC PROGRAMMING ................................................................... 10

4. CHAPTER 4 – G AND M CODES ............................................................................ 11

G codes for Milling m/c ................................................................................ 11

M codes for Milling m/c ............................................................................... 12

G codes for Turning m/c...............................................................................13

M codes for Turning m/c ............................................................................. 14

5. CHAPTER 5 – DIMENSIONING ............................................................................. 15

6. CHAPTER 6 – PROGRAMMING TYPES .............................................................. 17

7. CHAPTER 7 – CNC PROGRAMS ........................................................................... 18

8. CHAPTER 8 – SUMMARY AND CONCLUSIONS ............................................... 26

9. CHAPTER 9 – REFRENCES .................................................................................... 27

CNC Milling Programming and Operation

CHAPTER 1

INTRODUCTION

CONVENTIONAL MACHINES:

In a conventional m/c parameters like feed, depth of cut and speed are manually
controlled by the operator. The accuracy of the job depends mainly on the skill of the
worker. These machines have the following disadvantages.

1. More time consumption.

2. Less accuracy.
3. Less production.
4. Requires skilled labor.
5. More wastage of material.

EVOLUTION OF CNC MACHINES

NUMERICAL CONTROL MACHINE:

Numerical control means directing, guiding or retaining power over something by the
use of numbers. Numerical control can defined as a form of programmable automation on
which the process is controlled by numbers, letters and symbols. A numerically controlled
m/c tool is basically a conventional m/c tool where the operator is replaced by punched tape
containing various machining instructions. The numbers, letters and symbols gathered
together and logically organized to direct a m/c tool for a specific job are called an NC
program. An NC m/c tool with a mini computer as the controller unit is called as CNC
machine tool. The year which followed world war-II increased the needs of aerospace
industries that created demands on the capabilities of m/c tools. Using techniques which had
advanced rapidly during the war, machine tool designers & electronic engineers together built
machine tools to produce profiles & shapes that were nearly impossible by conventional
machine tools. US Air force combined with Parsons corp. to produce first NC machine in the
year 1947. The term numerical control was coined by Massachusetts institute of technology,
USA. By mid 1960s, Russia, Japan, West-Germany, England etc was, leading manufacturers
of NC machines.

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CNC MACHINES:

In earlier days the conventional machines were used in industries where the operator
used to control the various machining parameters such as feed, speed, depth of cut etc. in the
year 1947, the united states Air force introduced NC machine for manufacturing Air craft
components. But these machines were commercially available in the year 1955. In the year
1971, there was a rapid development in the field of electronics like integrated circuits and
micro controllers were developed. These devices were used to control the NC machines. A
simple computer was interfaced to the NC system which stored the data, instructions and
programs which were required to run the CNC machines. In a CNC machine all the
numerical functions are controlled by the computer. The computer also gives the display of
various parameters of the machine like spindle speed, feed rate, depth of cut etc. It consists of
electronic instrumentation to measure the output.

MAJOR DIFFERENCES BETWEEN CONVENTIONAL MACHINES, NC AND CNC

MAJOR DIFFERENCES BETWEEN CONVENTIONAL, NC AND CNC

MACHINES:
TOPIC CONVENTIONAL M/C NC CNC
Communication Hand wheel/Push Punched CD,
button tapes Floppy, DNC
Repeatability Not possible Possible Possible

Complex & Precision jobs Not possible Possible Possible

Cost(Basic+Maintenance) Low Medium High

Table 1

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CNC Milling Programming and Operation

Figure 1

CONVENTION MACHINE

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CNC Milling Programming and Operation

Figure 2

NC MACHINE

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CNC Milling Programming and Operation

FANUC CNC MACHINE

Figure 3

FANUC develops cutting edge CNC and motion control systems for a wide range of
applications from basic high-volume, high-repetition commodity production to unique,
highly complex, parts that require the highest precision and advanced machining techniques

With industry leading reliability (up to 52-year Mean-Time-Between-Failure rates) and

lifetime parts and maintenance support, FANUC controls provide the lowest total cost of
ownership, low operating costs, high performance and a high resale value.

FANUC CNC systems, drives, motors, I/O and connectivity combine to provide the best
machine performance for applications ranging from the most simple and straightforward to
the most complex.

This is the machine we used at the GT&TC to execute most of our programs which were
written and those programs were even used to machine on job using different tools and
different centralization processes.

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CNC Milling Programming and Operation

SIEMENS CNC MACHINE

Figure 4

SINUMERIK combines automation, technology competence and digitalization to form a

unique range of solutions, thus increasing the productivity. SINUMERIK CNC systems are
the optimum solution for individual parts or mass production, for simple or complex
workpieces.

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CNC Milling Programming and Operation

Figure 5

SINUMERIK PANEL USED IN CNC

This compact and user friendly entry-level solution is used for turning and milling
applications. Features such as a simple operation, easy commissioning and maintenance- and
also an optimum cost position – represent the perfect basis for equipping entry-level CNC
machines.

It is clear that the most of the CNC machines are using these two controllers. If you buy a
new control, they both have comparable capabilities.Market share percentage is about 30%
for each one.

Siemens gives the builder all of the options but FANUC charges for options.Siemens is
more flexible from a machine tool builder perspective.Siemens has long descriptions of
parameters and help files.

FANUC is a bit more expensive when compared with other controllers.FANUC is much
more prevalent in the US market.

Siemens controls are more powerful, faster, and easier to use. Siemens is complicated and
over designed. Siemens can control more axes up to 93.It’s typically easier to troubleshoot
problems on FANUC.

Everything is an option on FANUC, where it's standard on most other controls. FANUC is
more reliable from a hardware perspective.

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CNC Milling Programming and Operation

CHAPTER 2

TECHNICAL CHARACTERISTICS AND APPLICATION

The main technical characteristics of the machining centers are as follows:

1. The milling cutters can be differentiated by their type of teeth, cutting

direction or shape.
2. The spindle axis may be horizontal (the z-axis is horizontal), vertical
(z-axis is vertical) or universal.
3. The milling machine can have 3 axes, 4 axes (three linear axes plus one
rotary table) or 5 axes (three linear axes plus 2 rotary axes).
4. The production speed (this also depends on the material and the machined
part).

Figure 6

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ADVANTAGES:
1. It eliminates human errors.
2. Requires semi-skilled labor.
3. Higher flexibility.
4. High accuracy.
5. Wastage is minimum.
6. Suitable for batch production.
7. Less space is required.
8. Reduces inspection cost.
9. More operational safety.
10. Quality of product is high.

DISADVANTAGES:
1. Initial cost is high.
2. It require skilled programmer.
3. It is not suitable for small scale production.
4. Maintenance cost is more.

APPLICATIONS:
1. Numbers of operations per component are many.
2. Complexity of the operation.
3. Size of batches is medium.
4. Repetition of batches is large.
5. Layout cost of the component is high.
6. Variety of components to be produced is more.
7. Design changes are frequent.
8. Number of dimension in a component is more.
9. Precision required in a component.
10. Uniform cutting conditions.

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CHAPTER 3

CNC PROGRAMMING

What is CNC programming?

It is a set of instructions given to the machine to perform a given task.

CNC Programming can be done in two ways:

1. EIA/ISO Format (Fanuc/ISO

Control) EIA: Electronics industries
association O-series.

ISO: International standard organization.

In this method programming can be done by use of G and M codes.

G codes are called preparatory functional codes and M codes are called miscellaneous/
Machine function/ on-off functions.

2. Dialogue based programming (Heidenhain / Mazatrol control)

In this method the programming can be done by use of symbols like line, circle, square,
ellipse, pentagon, spline, multi-line etc.

Figure 7

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CHAPTER 4

G AND M CODES

Following are the G and M codes used in CNC Programming:

G codes for Milling m/c

• G00-Rapid traverse
• G01-Linear traverse
• G02-Circular interpolation in CW
• G03-Circular interpolation in CCW
• G04-Dwell
• G05-Moves in the same direction as the last arc to be performed
• G06-Tangential arc
• G07-Single arc
• G11-linear polar
• G12-Circular polar CW
• G13-Circular polar moves CCW
• G15-Moves in the same direction as the last arc to be performed
• G16-Tangential arc polar
• G17-Selection of XY plane
• G18-Selection of XZ plane
• G19-Selection of YZ plane
• G28-Mirror image
• G30-Blank form(Bottom corner of billet)
• G31- Blank form(Top corner of billet)
• G40-Tool radius compensation cancel
• G41-Tool radius compensation left side
• G42-Toolradius compensation right side
• G43-Tool length offset
• G90-Absolute dimensioning
• G91-Incremental dimensioning
• G98-Start to initial point/Label
• G99-Tool definition
• G54,G55,G56…….:Work offset/work datum
• G74-Slot milling
• G75-Rectangular pocket(CW)

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• G76- Rectangular pocket (CCW)

• G77-Circular pocket (CW)
• G78-Circular pocket (CCW)
• G79-Cycle call
• G80-Cancellation of CANNED cycle
• G81/G82-Spot drilling/Boring
• G83-Peck drilling

M codes for Milling m/c

• M00-Program stop
• M01-Optional stop
• M02-Program end
• M03-Spindle in CW
• M04-Spindle in CCW
• M05-Spindle stop
• M06-Tool change
• M08-Coolant pump ON
• M09-Coolant pump OFF
• M10-Work clamp open
• M11-Work clamp close
• M13-Spindle forward + coolant ON
• M14- Spindle forward + coolant OFF
• M19-Spindle orientation
• M20-ATC Arm in
• M21-ATC Arm out
• M22-ATC Arm down
• M23-ATC Arm up
• M24-ATC Arm clamping activate
• M25-Atc Arm clamping release
• M30-Program end
• M32-ATC CW rotation
• M33-ATC CCW rotation
• M38-Door open
• M39-Door close
• M98-Sub program call
• M99-Subprogram repetition(Incremental depth)

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G codes for Turning m/c

• G00-Rapid traverse
• G01-Linear traverse
• G02-Circular movement CW
• G03-Circular movement CCW
• G04-Dwell for programed duration
• G05-Delay/Hold(Until resumed by operator)
• G10-Offset value setting by program
• G20-Inch data input
• G21-Metric data input
• G22-Stored stroke check on
• G23- Stored stroke check off
• G27-Reference point return check
• G28-Reference point return
• G29-Return from reference point
• G30-Return to 2nd Reference point
• G31-Skip function
• G32-Thread cutting
• G34-Variable lead thread cutting
• G36-Automatic tool compensation--X
• G37-Automatic tool compensation--Z
• G40-Tool nose radius compensation cancel
• G41-Tool nose radius left
• G42-Tool nose radius right
• G50-Work co-ordinate/Max.spindle speed setting
• G65-Macro program call
• G66-Macro modal call
• G67-Macro modal call cancel
• G70-Finishing cycle in turning
• G71-Stock removal in turning(Multiple turning cycle)
• G72-Stock removal in facing
• G73-Pattern repeating
• G74-Peck drilling cycle
• G75-Grooving in X axis
• G76-Thread cutting cycle(Multiple thread cutting)
• G81-Drilling cycle
• G90-Absolute dimensioning
• G91-Incremental dimensioning
• G92-Thread cutting cycle
• G94-Facing cycle
• G96-Constant cutting speed
• G97-Constnt surface speed control cancel(variable surface)
• G98-Feed per minute
• G99-Feed per revolution

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M codes for Turning m/c

• M00-Program stop
• M01-Optional stop
• M02-Program end
• M03-Spindle in CW
• M04-Spindle in CCW
• M05-Spindle stop
• M06-Auto tool change
• M07-Coolant ‘’B’’ ON
• M08-Coolant ‘’A’’ ON
• M09-Coolant OFF
• M10-Çhuck open
• M11-Chuck close
• M13-Spindle forward + coolant ON
• M14- Spindle reverse + coolant OFF
• M16-Special tool call(Tool call ignores turret)
• M19-Spindle orientation
• M20-Spindle index A
• M21-Spindle index 2A
• M22-Spindle index 3A
• M23-Spindle index 4A
• M25-Quill extend
• M26-Quill retract
• M29-Select DNC mode
• M30-End of program and rewind
• M31-Increment part counter
• M37-Door open to stop
• M38-Door open
• M39-Door close
• M62-Output 1 on
• M63-Output 2 on
• M64-Output 1 off
• M65-Output 2 off
• M98-Sub program call
• M99-Subprogram repetition(Incremental depth)

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CHAPTER 5

DIMENSIONING

There are two types of dimensioning:

• Absolute dimensioning (G90)

• Incremental dimensioning (G91)

1. Absolute dimensioning:

In absolute dimensioning all the dimensions/points are measured from common reference
point or zero point. This zero point is called datum point.

Figure 8

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CNC Milling Programming and Operation

2. Incremental dimensioning:

In incremental dimensioning all the points are measured from current tool position.
These dimensions are measured from the previous measuring point.

Figure 9

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CNC Milling Programming and Operation

CHAPTER 6

PROGRAMMING TYPES
Two type of programming:

1. Offline programming

2. Online programming

In offline programming initial information:-

➢ Analyzing of part Drawing

➢ Part number, material, size means maximum length, width, height and diameter.
➢ Input condition like casting/forge/bar
➢ Process details like Drilling, Machining, inspection, Heat treatment.
➢ Allowances / Tolerance, Control
dimension Machine :-

➢ Milling, lathe, Grinding etc.

➢ Specification of machine eg:-stroke length, Spindle axis

In Part Programming

CNC programming include:-

➢ Alphabets[A-Z]
➢ Number[0-9]
➢ Symbols [/ ;()]
G-codes: - Generating profile creating those called G-codes. (Preparatory function)

M-codes: - Miscellaneous function vary from machine to machine depending on the

function available on it and manufacturing of the machine decides them.

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CHAPTER 7
CNC PROGRAMS
CNC Part Programs to mill the components as per drawing:

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CHAPTER 8

SUMMARY AND CONCLUSION

The main objective of the Internship was to learn and gain knowledge regarding the
CNC Milling Programming and Operation at Govt. Tool-Room and Training Centre.
We have gained significant amount of experience in operating the CNC Machines and
coding for the given drawings for a span of 4 weeks.

We were given access to the FANUC CNC Machine as well as the SIEMENS CNC Milling
Machine in the institutes respective work areas set up for training. This access to operation
of machines openly in such environment has immensely helped us gain confidence in
operating real time CNC machines and their operations.

We even received training regarding handling of the machine by various methods and its
centralization and dimensioning the way it is to be done as per standards. Maximum
execution of programs were done using the FANUC CNC machine which is internationally
recognized. We were exposed to all of its features from verifying the program via the panel in
the machine and executing them to obtain the drawing and later conducting the milling
operation on the given workpiece. This Internship has immensely helped us gain confidence
in the environment and knowledge regarding the industrial CNC machines.

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CHAPTER 9
REFERENCES

1. Standard charts and tabled from M/s GT & TC.

2. www.google.com

3. www.wikipedia.com

4. www.prototechasia.com

5. www.fanucamerica.com

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