Dsce Bangalore - 78 Manual Department of Mechanical Engineering Cim & Automation Lab: 10MEL78

MANUAL
DSCE Department of Mechanical

CIM & AUTOMATION LAB:
Bangalore – 78 Engineering
10MEL78
CONTENTS
Page No.
1. Introduction to CNC Turning, programs on turning 2
2. Introduction to CNC Milling, programs on Milling 32
3. CapsTurn and CapsMill 46
4. Simulation of Hydraulic and pneumatic circuits using LMS Image

Lab (AMESim) Software. 48
5. Exercise Problems 50
6. Definitions of FMS and ASRS 52
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1. INTRODUCTION TO CNC TURNING, PROGRAMS ON TURNING
NC TECHNOLOGY
1.1 Numerical Control (NC):
It is the acronym for ‘Numerical Control’. Numerical Control refers to the use of coded
numerical information in the automatic control of equipment. NC can be defined as a kind of
programmable automation in which the process is controlled by numbers, letters & symbols. The
numbers letters & symbols are arranged as a ‘program of instructions’ for a particular job. Such a
program is called a part program.
NC can be applied to various operations in engineering, like drafting, machining, assembly,
inspection, etc. The main area of NC application is metal machining operations.
1.2 Basic Components of an NC System:
An NC system consists of three basic components.
1. Program of instructions
2. Machine control unit
3. Machine tool
PROGRAM OF MACHINE
MACHINE TOOL
INSTRUCTIONS CONTROL UNIT
Above Figure shows the block diagram of an NC machine. The program of instructions sends
commands to the Machine Control Unit, which in turn controls the machine tool.
1.3 NC Coordinate systems:
The relative movement of the machine tool spindle & worktable is due to the individual slides
being operated by instructions from the part program.
Normally, three slides are required in a NC machine tool.
 Longitudinal
 Vertical
 Transverse
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The position and direction of movement of each slide is given by the right hand coordinate
system. Here we have three axes X, Y & Z mutually perpendicular to each other.
Position of axes: Usually the Z axis is located (positioned) along the machine tool spindle. The
X axis is positioned parallel to the machine worktable and perpendicular to the Z axis. The Y
axis is perpendicular to both Z & X axis.
Direction of axes: If the movement of the slide is such that the tool moves away from the work
piece, the direction of that slide axis is positive (+ ve). Similarly, if the movement of the slide is
such that the tool moves nearer to or into the work piece, the direction of that slide axis is
negative ( - ve).
Zero points & Reference points:
The accurate position of the machine tool slides with the machine tool is established by the ‘Zero
Point’. The Zero Points may be (a) Machine Zero Point & (b) Work Zero Point.
Machine Zero Point is specified by the manufacturer of the machine. This is the zero point for
the coordinate systems and other reference points in the machine.
Workpiece Zero Point determines the workpiece coordinate system in relation to the machine
zero point. This point is chosen by the programmer, and input into the CNC system when setting
up the machine. The position of this point can be freely chosen by the programmer within the
workpiece envelope of the machine. Its position is chosen such that the dimensions in the
workpiece drawing can be conveniently converted into coordinate values and also to effectively
take care about the clamping/chucking, setting up, etc.
Reference Point or Home Position serves for calibrating and controlling the measuring systems
of the slides and tool traverses. The position of the reference point is accurately predetermined in
every traverse axis by the trip dogs and the limit switches. Therefore the reference point
coordinates always have the same precisely known numerical values in relation to the machine
zero point. After initiating the control system, the reference point must always be approached
from all axes to calibrate the traverse measuring system.
Dimension System: Dimensional information in the work piece drawing can be stated in 2
methods – Absolute Dimensioning & Incremental Dimensioning.
In Absolute dimensioning, the coordinate data are taken with respect to a fixed reference point on
the workpiece drawing (usually the workpiece zero).
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In Incremental Dimensioning, the coordinate data are taken with respect to the previous
coordinate value. i.e., every coordinate programmed will be the origin for the next coordinate to
be programmed.
1.4 NC & CNC: During the early period of NC technology, most of the control activities in the
controller were performed by electronic hardware devices like diode valves. The electronics
consisted of many mechanical devices which frequently posed problems of non-contact. The
machine tools and processes then controlled by such controllers were called as NC Machines.
With the improvement of technology and with the evolution of ‘integrated circuits’ mechanical
problems with electronic devices were solved. Also with the very fast development of
computers, almost all the control activities, performed by the hardware of the controller unit,
could then be tackled by software (programs). The machine tools and processes presently being
controlled by powerful computers is termed as CNC Machines. CNC is the acronym for
‘Computer Numerical Control’.
1.5 CNC Part Program:
It consists of a set of properly arranged sequence of instructions which when executed
initiates the controller to send various signals to different machine tool drives in accordance with
the program sequence so as to perform the desired work/job.
The CNC program (also called as the CNC part program) is made up of number of ‘lines of
instructions’. Each ‘line of instruction’ is called a Block. Each Block in turn consists of a few
‘alpha-numeric words’ called as ‘CNC Words’
Figure here shows a sample part program depicting the ‘Blocks’ and ‘CNC Words’.
Also, it may be noted that each CNC word starts
with a Word Address (upper-case alphabet) followed
by a numeric data.
Such a CNC program format is called ‘Word
Address Format’.
CNC Words: The different types of CNC words

used in CNC programming are as follows.
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a) Sequence Number (N-word): It is used to identify a block.

b) Preparatory function word (G-code): This command prepares the machine controller to
follow a given instruction. E.g. G00 stands for Rapid Movement (point-to-point position)
c) Coordinate Data(X, Y & Z words): These words specify the coordinate position of the
cutting tool. E.g. X15, Y-40, Z-2
Coordinate Data may also contain the I, J & K words which specify the coordinate values
of the arc. I, J & K values are also called as the ‘interpolation parameters’.
d) Arc Radius (R-word): Instead of programming the interpolation parameters (arc-center-
coordinates) I, J & K, the arc radius can be programmed using the R-word.
e) Feed Rate (F-word): These words specify the feed rate of the tool in a machining
operation. It is usually expressed in mm/min. E.g. F30
f) Cutting Speed (S-word): These words specify the cutting speed of the tool/spindle
rotation in RPM. E.g. S1200
g) Tool Selection (T-word): This command is used to access a required tool from a tool
turret or an automatic tool changer. This command is usually used in CNC machines with
Automatic Tool Changing facility. E.g. T10 may specify that a 10 mm drill must be
selected from position number 10 of a tool magazine (holder).
h) Miscellaneous Functions (M-code): These are used to specify certain miscellaneous or
auxiliary functions (coolant on, coolant off, spindle on CW/CCW, spindle stop, etc)
available on the given machine.
NC LATHE
Chuck
X Face
Dia
Z
(0,0)
Z– Z+
Length
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1.6 Dimensional Notations used in CNC lathe are:

1. Absolute Dimensioning – X & Z are used.
2. Incremental Dimensioning – U & W are used.
P6 P5
P4 P3
 30
 25 P2 P1
 20
25 30 25
ABSOLUTE INCREMENTAL
Point
X Z U W
P1 20 0 20 0
P2 20 -25 0 -25
P3 25 -25 5 0
P4 25 -55 0 -30
P5 30 -55 5 0
P6 30 -80 0 -25
Note: Incremental program is easy to program but tedious to change values in between. Error
committed in any block is carried over to the consecutive blocks. Whereas, absolute
programming is a bit inconvenient as all coordinates are measured from a fixed point. Error
committed in any block will affect only that block. Consecutive blocks are not affected.
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1.7 Zero points & Reference points on a CNC lathe:

R
Max X
X
M W
Z
(0,0)
Max Z
M: Machine Zero Point W : Workpiece(Program) Zero Point
R: Reference point OR Home Position

Above figure shows the location and the relationship between Zero Points & Reference Point on
a CNC lathe.
1.8 Commonly used G-codes on the XLTURN machine:
G00 Positioning(Rapid Feed)
G01 Linear Interpolation(Cutting Feed)
G02 Circular Interpolation CW
G03 Circular Interpolation CCW
G04 Dwell
G17 XY Plane
G18 ZX Plane
G19 YZ Plane
G20 Inch Mode Input
G21 Metric Mode Input
G28 Return To Reference Point(Homing)
G70 Finishing Cycle
G71 Profile Turning Cycle
G72 Profile Facing Cycle
G74 Drilling Cycle
G75 Grooving Cycle
G76 Threading cycle
G90 Turning Cycle
G92 Treading Cycle
G94 Facing Cycle
G98 Feed per Minute
G99 Feed per Revolution
1.9 Commonly used M-codes on the XLTURN machine:

M00 Program Stop 7
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M01 Optional Stop

M02 Program Reset
M03 Spindle Forward
M04 Spindle Reverse
M05 Spindle Stop
M06 Auto Tool Change
M08 Coolant ON
M09 Coolant OFF
M13 Spindle Forward and Coolant ON
M14 Spindle Reverse and Coolant ON
M98 Sub Program Call
M99 Sub Program Exit
M30 Program Reset and Rewind
G00 Rapid traverse

When the tool being positioned at a point preparatory to a cutting motion, to save time it is
moved along a straight line at Rapid traverse, at a fixed traverse rate which is pre-programmed
into the machine's control system. Typical rapid traverse rates are 10 to 25 m /min., but can be as
high as 80 m/min.
Format
N_ G00 X_ Z_
G01 Linear interpolation (feed traverse)

The tool moves along a straight line in one or two axis simultaneously at a programmed linear
speed, the feed rate.
Format
N__ G01 X__ Z__ F__
G02/03 Circular interpolation
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Format
N__ G02/03 X__ Z__ I__ K__ F__ using the arc center
OR
N__ G02/03 X__ Z__ R__ F__ using the arc radius
G02 moves along a CW arc
G03 moves along a CCW arc
Arc center
The arc center is specified by addresses I and K. I and K are the X and Z co-ordinates of the arc
center with reference to the arc start point.
I =(X coord. of center - X coord. of start point)/2

K = Z coord. of center - Z coord. of start point
I and K must be written with their signs.
Arc radius
The radius is
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Specified with address R.

G02 X__ Z__ R__ F__
N__ G03 X__ Z__ R__ F__
If the radius is used, only arcs of less than 180 deg. can be programmed in a block. An arc with
included angle greater than 180 deg. must be specified in two blocks.
1.10 Canned cycles
A canned cycle simplifies a program by using a few blocks containing G-codes functions to
specify the machining operations usually specified in several blocks
I. Turning Cycle - G71
Format
G71 U (d) R (e)
G71 P(n) Q(n) U(u) W(w) F(f)
N (n) _ _ _ _
_______
_______
N (n) _ _ _ _
d = Depth of cut
e = Retract amount
n = Number of the first block of the shape
n = Number of the last block of the shape
u = Finishing allowance in X
w =Finishing allowance in Z
f = Feed rate
II. Step Facing Cycle (G94 Cycle):
It is a ‘Box type’ cutting cycle.
SYNTAX:
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G94 X… (U….) Z….. (W…..) F…..

Where,
X is the diameter to which the movement is being made OR U is the incremental distance from
the current tool position to the required final diameter.
Z is the Z axis coordinate to which the movement is being made OR W is the incremental
distance from the current tool position to the required Z axis position.
F is the feed rate.
TP-1. Write a program to perform the step facing of the component as shown in the figure:
O1001
2.5 2.5
([BILLET X30 Z70)
G21 G98
 30
G28 U0 W0 R Tool Entry
point
M06 T0101
M03 S1200  20
G00 X31 Z0 F R
G94 X10 Z-0.5 F30

 10
Z-1
Z-1.5 F
Z-2
Z-2.5
X20 Z-3
Z-3.5
Z-4
Z-4.5
Z-5
G28 U0 W0
M05
M30
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III. Step Turning Operation using the Box Turning Cycle (G90):
The Step Turning Operation can be performed by using the “Box Turning Cycle – G90 Cycle” as
below. Tool Entry
R
SYNTAX:
F RPoint
G90 X…..Z……F…….
Where,
F
X is the diameter to which movement is being made
Z is the Z axis coordinate to which the movement is being made
F is the feed rate being used
TP-2 Using the G90 Cycle; write a part program to step turn a work piece as shown below:
O1003
G21 G98
G28 U0 W0
M06 T0101
M03 S1200
G00 X30 Z1 Tool Entry point
G90 X30 Z-55 F30
X29
 30
X28
 25
X27
 20
X26
30 25
X25
G00 X25 Z1
G90 X25 Z-25 F30
X24
X23
X22
X21
X20
G28 U0 W0
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M05
M30
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IV. Taper Turning Cycle (G90 Cycle):

The above taper turning operation can be performed by the standard “G90 Taper Turning
Cycle”. Its syntax is:
G90 X….Z….R…..F…..
Where,
X is the diameter to which the movement is being made.
Z is the Z axis coordinate to which the movement is being made.
R is the difference in incremental of the cut start radius value and the cut finish radius value.
TP-3 Write a part program to perform the taper turning operation using the “G90 Taper Turning
Cycle (R –ve)” for the work part shown in figure.
O1004
G21 G98
G28 U0 W0  30
M06 T0101
 25
M03 S1200
10
G90 X30 Z-10 R0 F50 [(30-30)/2 = 0]

X30 R-0.5 [(29-30)/2 = -0.5]
X30 R-1 [(28-30)/2 = -1]
X30 R-1.5 [(27-30)/2 = -1.5]
X30 R-2 [(26-30)/2 = -2]
X30 R-2.5 [(25-30)/2 = -2.5]
G28 U0 W0
M05
M30
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TP-4. Write a part program to perform the taper turning operation using the “G90 Taper Turning
Cycle (R +ve)” for the work part shown in figure.
O1005  30
G21 G98
G28 U0 W0  25
M06 T0101
M03 S1200 10
Tool
Entry Tool
G90 X30 Z-10 R0 F50 [(30-30)/2 = 0] Point Entry
X29 R0.5 [(30-29)/2 = 0.5] X2
Point
X28 R1 [(30-28)/2 = 1] 9
X2
X27 R1.5 [(30-27)/2 = 1.5] 8
X26 R2 [(30-26)/2 = 2] X2
7
X25 R2.5 [(30-25)/2 = 2.5]
X2
6
G28 U0 W0 X2
5
M05
M30
V. Multiple Turning Cycle (G71 Cycle):
The Multiple Turning Cycle is used when the major direction of cut is along the Z axis. This
cycle causes the profile to be roughed out by turning. Two G71 blocks are needed to specify all
the values.
Syntax: G71 U……R……

U is the depth of cut.
G71 P…..Q……U…..W…..F……
R is the relief or retract amount
P is the block number of the start of the final profile
Q is the block number of the end of the final profile.
U is the finishing allowance for the X axis

W is the finishing allowance for the Z axis
VI. Finishing Cycle (G70 Cycle):
F is the feed rate
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On completion of any roughing operation, the material left as finishing allowance is removed
using the ‘Finishing Cycle’. The same tool path used in the roughing operation is used in the
G70 cycle. The G70 Cycle causes a range of specified blocks to be executed, then control passes
on to the block after the G70 Cycle.
Syntax: G70 P….Q….F…..

Where, P is the block number of the start of the final profile
Q is the block number of the end of the final profile.
TP-5 Write a part program for Multiple Turning operation for the component shown in the
figure.
P10
P9
O1006
G21 G98  30  28  24
P8
P7 R8
G28 U0 W0
M06 T0101 P6 P5
 22
M03 S1200 R8
 17 P4
 14 P3 P2
G71 U0.5 R1 P1
G71 P1 Q10 U0.5 W0.5 F50 9

7
5 7 5 5 7 13 2
N1 G01 X7
N2 X9 Z-2
N3 Z-15
POINT X Z
N4 G02 X14 Z-22 R8 P1 7 0
N5 G01 X17 Z-27 P2 9 -2
P3 9 -15
N6 Z-32
P4 14 -22
P5 17 -27
N7 G03 X22 Z-39 R8 P6 17 -32
P7 22 -39
N8 G01 X24
P8 24 -39
N9 X28 Z-44 P9 28 -44
N10 X30 P10 30 -44
G70 P1 Q10 F50
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G28 U0 W0
M05
M30
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figure. Use a finishing tool for the finishing cycle.
O1007
[BILLET X30 Z70
G21 G98  30
G28 U0 W0 R 10
M06 T0101 (Select roughing tool)
M03 S1200  20
G00 X30 Z1 (Select Entry Point)
G71 U0.5 R1
G71 P10 Q20 U0.5 W0.5 F50  10 8
10 10 13 2
N10 G01 X8
X10 Z-2
Z-15
G03 X20 Z-25 R10
N20 G01 X30 Z-35
G28 U0 W0
M06 T0303 Select Finishing Tool
M03 S1450
G00 X30 Z1
G70 P10 Q20 F40
G28 U0 W0
M05
M30
Note: Whenever a tool change is to be made, current tool must be sent to ‘Home Position’ by
using the G28 command, so as to ensure that turret indexing will not interfere with workpiece or
machine tool parts (work table).
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figure. Note that it is the same component as shown above except that there is an extra taper
before the circular interpolation.
It should be noted that the G71 cycle works only for continuously increasing (for external
operation) or decreasing (for internal operations) dimensions only. Hence the shaded portion in
the figure must be removed separately (by using the G90 R +ve cycle) after using the G71 cycle.
O1008
G21 G98
G28 U0 W0
M06 T0101
M03 S1200
G71 U0.5 R1
G71 P10 Q20 U0.5 W0.5 F50
N10 G01 X8
X10 Z-2
Z-15
G03 X20 Z-25 R10
N20 G01 X30 Z-35
G00 X10 Z-2
G90 X10 Z-15 R0 F30
X9 R0.5
X8 R1
G90 Cycle to machine the taper.
X7 R1.5
X6 R2
X5 R2.5
G28 U0 W0
M05
M30
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1.12 Subprogram:
A CNC program is divided into a main program & a subprogram. Normally the CNC operates
according to the main program but when a command calling a subprogram is encountered in the
main program, control is passed to the subprogram. When a command indicating a return to the
main program is encountered in the subprogram, control is returned to the main program. The
first block of the main program & sub program must contain a program number starting with
letter ‘O’.
Use of subprogram: When a program contains certain fixed sequences or frequently repeated
patterns, these sequences or patterns can be entered into the memory as a subprogram to simplify
programming. If a subprogram can call another subprogram, it is regarded as a one loop sub
program call.
Syntax: M98 P0000000 Command used in main program
Subprogram No.
No. of repetitions
Subprogram call
Command used in Subprogram
M99
Main Program Subprogram Subprogram

O0001 O2222 O3333
…….. …….. ……..
…….. …….. ……..
M980012222 M980013333 ……..
…….. …….. ……..
…….. …….. ……..
…….. …….. ……..
M30 M99 M99
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Note: If the Number of repetition is omitted, the called subprogram is executed only once.
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TP-8. Write a part program to machine the component shown in the figure making use of a sub
program.
10 5 5 5 5 5 5
O1009
[BILLET X22 Z70  22  20
G21 G98
G28 U0 W0
M06 T0101  15
M03 S1200
G90 X22 Z-40 F50

X21 O2000
X20 G90 X20 W-5 R0 F30
X20 R-0.5
G00 X20 Z0 X20 R-1
M98 P0032000 X20 R-1.5
X20 R-2
G00 X20 Z-30 X20 R-2.5
G90 X20 Z-40 F50 G00 X20 W-5
G90 X20 W-5 R0 F30
X19 X19 R0.5
X18 X18 R1
X17 R1.5
X17 X16 R2
X16 X15 R2.5
G00 X20 W-5
X15 M99
G28 U0 W0
M05
M30
Note: (1) While writing the subprogram, incremental dimensioning is normally used.
Dimensions which remain constant in every pass can be programmed as absolute dimensions.
(2) Main program and sub-programs are written in separate files
Subprogram Nesting: When one subprogram calls for another subprogram, subprogram nesting
is said to be done.
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TP-9 Write a part program for the component shown in figure making use of the ‘Subprogram
Nesting’.
O1010
[BILLET X22 Z70
G21 G98
G28 U0 W0
M06 T0101
M03 S1200

G90 X22 Z-60 F50
X21
X20
G00 X20 Z0 5 5 5 5 5 5 5 5 5 5 5
5
M98 P0012020
M98 P0012020  22  20
M98 P0012020
G28 U0 W0
M05  15
M30
O2030
O2020
G90 X20 W-5 F50
G90 X20 W-5 R0 F30
X20 R-0.5 X19
X20 R-1 X18

X20 R-1.5
X17
X20 R-2
X16
X20 R-2.5
G00 X20 W-10 X15
G90 X20 W-5 R0 F30 G00 X20 W-5

X19 R0.5 M99
X18 R1
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X17 R1.5
X16 R2
X15 R2.5
G00 X20 W-5
M98 P0012030
M99
VII. External Grooving (G81 Cycle):
Syntax: G81 X….Z…..F…..

Where,
X is the diameter up to which the grooving must be done.
Z is the Z-axis coordinate where the grooving must be done.
F is the feed rate.
TP-10 Write a part program for performing the external grooving operation for the component
shown in figure. 5
R7
 22 4
O1011
 15  18
[BILLET X22 Z70
 12
G21 G98  10  10
8 10 7 5 13 2
G28 U0 W0
M06 T0101
M03 S1200
G71 U0.5 R1
G71 P10 Q20 U0.5 W0.5 F40
N10 G01 X10
X12 Z-2
X12 Z-20 3 mm
G02 X18 Z-27

G01 X18 Z-37
N20 X22 Z-45 Note: The required grooves are 4 mm wide whereas
the width of the tool tip is only 3mm. Hence, 24
the sequence of G81 cycles are used twice,
during the second set, tool is made to move by
1 mm so that the final groove width will be 4
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G28 U0 W0
M06 T0303 Call grooving tool
M03 S800
G00 X12 Z-15
G81 X11.5 Z-15 F30
X11
X10.5
X10
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G00 X13 Z-15 G00 X19

G81 X11.5 Z-14 F30 Z-36
X11 G81 X18.5 Z-36 F30
X10.5 X18
X10 X17.5
G00 X19 X17
Z-37 X16.5
G81 X18.5 Z-37 F30 X16
X18 X15.5
X17.5 X15
X17 G00 X19
X16.5 G28 U0 W0
X16 M05
X15.5 M30
X15
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MANUFACTURING: 06MEL77
VIII. External Threading: The threading operation can be performed by using the ‘Box
Threading Cycle-G92 Cycle’.
Syntax: G92 X…..Z…..F…..

Where, X is the diameter up to which the thread must be cut.
Z is the Z axis coordinate up to which the thread must be cut.
F is the pitch.
ISO Metric Thread Parameters:
For Metric Thread, (60o tool

angle), given the major diameter and pitch, the thread height can be given by:
h = (pitch) × 0.61343
Then the Core (Minor) Diameter can be given as:
Core Diameter = (Major diameter) – 2(h)
Commonly used thread parameters for ISO metric thread:
Major Diameter Pitch Major Diameter Pitch
(mm) (mm) (mm) (mm)
M 2.5 0.45 M 12 1.75
M3 0.5 M 16 2
M4 0.7 M 20 2.5
M5 0.8 M 24 3
M6 1 M 30 3.5
M8 1.25 M 33 3.5
M 10 1.5 M 36 4
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TP-11 Write a part program to perform the threading operation on the component as shown
in the figure.
O1012 M10 × 1.5
[BILLET X22 Z70  22 4
2
G21 G98
G28 U0 W0
 10 8
M06 T0101 7
M03 S1200 10 25
G71 U0.5 R1
G71 P10 Q20 U0.5 W0.5 F50
N10 G01 X8 Calculation of Core dia:
X10 Z-2
Z-25
Thread height = h = (pitch) × 0.61343
N20 X22 Z-35
G28 U0 W0 = 1.5 × 0.61343
M06 T0303 Call grooving tool = 0.920 mm
M03 S800
M98P0022040
O2040
G28 U0 W0
M06 T0505 Call threading tool
G81 X10 W0 F30
M03 S800 X9.5

G00 X15 Z2 X9
G92 X10 Z-23 F1.5
X8.5
X9.75
X9.50 X8
X9.25 X7.5
X9.00 X7
X8.75
G00 X11
X8.50
W1
X8.25
X8.159 M99
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G28 U0 W0
M05
M30
Exercise Programs:
EXTRA CLASS
Internal Operation: The motion commands G00, G01, G02 & G03 as well as some of the
cycles G90 (Linear & Taper), G71, G81, etc. can be performed as internal operations also.
Pilot Hole Drilling (G74 Cycle): The Pilot hole required to perform any other internal
operations can be performed by using the G74 Cycle.
Syntax: G74 R……

G74 X…..Z…..Q…..F……
Where, R is the relief or retract amount
X is the diametral position of the hole
Z is length of the hole
Q is the peck increment (in microns, where, 1 mm = 1000 microns)
F is the feed rate
TP-12 Write a part program to perform the ‘Pilot Hole Drilling’ on the component as shown
8
in the figure.
 30
O1013
[BILLET X30 Z70
G21 G98
8
G28 U0 W0
M06 T0505 Call 8 mm center drill
M03 S1200 8
CENTER
G74 R1
DRILL
G74 X0 Z-8 Q500 F50
8
G28 U0 W0
M05
M30 29
MANUAL
COMPUTER INTEGRATED
TP-13 Write a part program to perform the internal step turning operation (internal boring)
on the component as shown in the figure.
O1014
 30
[BILLET X30 Z70
 28
G21 G98  22
G28 U0 W0  16

M03 S1200  12

16 20 20 20
G74 R1
G74 X0 Z-8 Q500 F50
G28 U0 W0
M03 S800
G00 X0 Z2
10
G74 R1
G74 X0 Z-75 Q500 F30 10 mm boring bar
G28 U0 W0
M06 T0101 Call 10 mm boring bar
M03 S1200
G00 X12 Z2
G90 X12 Z-6 F50
X13
X14
X15
X16
X17 Z-40
X18
X19
X20
X21 30
MANUAL
COMPUTER INTEGRATED
X22
X23 Z-20
X24
X25
X26
X27
X28
G28 U0 W0
M05
M30
TP-14 Write a part program to perform the internal contouring operation on the component
as shown in the figure.
R5
 30
R6  28
 22
 17
 12
 13
20 15 10 8 10 7 5
O1015
[BILLET X30 Z70
G21 G98
G28 U0 W0
M03 S1200
G74 R1
G74 X0 Z-8 Q500 F50
G28 U0 W0
M03 S800 31
MANUAL
COMPUTER INTEGRATED
G00 X0 Z2
G74 R1
10
G74 X0 Z-75 Q500 F30
G28 U0 W0 10 mm boring bar
M06 T0101 Call 10 mm boring bar

M03 S1200
G00 X12 Z2
G71 U0.5 R1
G71 P10 Q20 U0.2 W0 F50
N10 G01 X30
X28 Z-5
G02 X22 W-7 R5
X17
W-10
G03 X13 W-8 R6
G01 W-10
N20 G01 X12 W-15
G70 P10 Q20 F50
G28 U0 W0
M05
M30
32
MANUAL
COMPUTER INTEGRATED
2. INTRODUCTION TO CNC MILLING, PROGRAMS ON MILLING

CNC MLL
In CNC Mill we have 3 axes – X axis (along length), Y axis (along breadth) & Z axis (along
thickness). The position of the Z axis is along the spindle axis and it is +ve in a direction
away from the workpiece. The position of the X & Y axis is parallel to and on the worktable.
X axis is along the length and Y axis is along the breadth of the table. X and Y axes are +ve
in directions moving away from the workpiece.
2.1 Automatic Tool Changer (ATC): It is a facility or device provided on the CNC Mill for
automatically indexing the tool magazine and making the required tool change as indicated in
the CNC program.
2.2 Automatic Pallet Changer (APC): It is a time saving facility provided on the CNC Mill
for automatically loading and unloading the pallets. Pallets are portable work holding
devices. While a loaded pallet is being used, a machined-component may be unloaded from
the pallet and a to-be-machined workpiece may be loaded on to the pallet.
2.3 Dimensional Notations used in CNC Mill are:

X Coordinate value along the length of the table
Y Coordinate value along the breadth of the table
Z Coordinate value along the vertical to the table
33
MANUAL
COMPUTER INTEGRATED
2.4 Programming Method - Absolute & Incremental Programming:

Absolute programming is specified by the G code G90 and incremental programming by
G91. In absolute programming, coordinate values are measured from the program zero point.
In incremental programming, the coordinate values are measured from the previous
programmed point
6 4
P 0 P 0
3
0
2 3
P P5
4
4
0
P7 P
3
0
6
P P8
2 8
1
0 0
ABSOLUTE (G90) INCREMENTAL
(G91)
Point X Y X Y
P1 0 0 0 0
P2 0 100 0 100
P3 60 100 60 0
P4 60 70 0 -30
P5 100 70 40 0
P6 100 30 0 -40
P7 20 30 -80 0
P8 20 0 0 -30
P1 0 0 -20 0
Note: Incremental program is easy to program but tedious to change values in between. Error
committed in any block is carried over to the consecutive blocks. Whereas, absolute
programming is a bit inconvenient as all coordinates are measured from a fixed point. Error
committed in any block will affect only that block. Consecutive blocks are not affected.
2.5 Commonly used G-codes on the FANUC Controller CNC Mill
Rapid Traverse (Tool moves at a predetermined rapid speed

G00 without making contact with the workpiece).
G01 Linear interpolation (Tool moves at a speed specified in the feed
34
MANUAL
COMPUTER INTEGRATED
word)
G20 Inches programming
G21 Metric programming
G28 Return to reference point OR home position
G02 Circular Interpolation CW
G03 Circular Interpolation CCW
G90 Absolute Programming
G91 Incremental Programming
G94 Feed programmed in mm/min
G95 Feed programmed in mm/rev
2.6 Commonly used M-codes on the FANUC Controller CNC Mill

M01 Optional stop
M02 Program end
M03 Spindle ON CW
M04 Spindle ON CCW
M05 Spindle OFF
M06 Tool change
M08 Coolant ON
M09 Coolant OFF
M30 Program stop & rewind
M70 X Mirror ON
M71 Y Mirror ON
M80 X Mirror OFF
M81 Y Mirror OFF
M98 Subprogram Call
M99 Subprogram end
2.7 Subprogram:
A CNC program is divided into a main program & a subprogram. Normally the CNC
operates according to the main program but when a command calling a subprogram is
encountered in the main program, control is passed to the subprogram. When a command
indicating a return to the main program is encountered in the subprogram, control is returned
to the main program. The first block of the main program & sub program must contain a
program number starting with letter ‘O’.
Use of subprogram: When a program contains certain fixed sequences or frequently
repeated patterns, these sequences or patterns can be entered into the memory as a
subprogram to simplify programming. If a subprogram can call another subprogram, it is
regarded as a one loop sub program call.
35
MANUAL
COMPUTER INTEGRATED
Syntax: M98 P0000000 Command used in main program
Subprogram No.
No. of repetitions
Subprogram call
M99 Command used in Subprogram
Main Program SubProgram SubProgram

O0001 O2222 O3333
…….. …….. ……..
…….. …….. ……..
M980012222 M980013333 ……..
…….. …….. ……..
…….. …….. ……..
…….. …….. ……..
M30 M99 M99
MP 1. Write a part program to perform the contour slotting operation on the component as
shown in the figure. The slot should have a width of 8 mm and a depth of 1 mm.
10 60
R 10
O0003 X Y
10
P1 20 10
([BILLET X100 Y100 Z10)
P4 P5 P2 10 20
10
([TOOLDEF T01 D8) P6 P3 10 80

P3
([EDGEMOVE X0 Y0) P4 20 90
P5 80 90
G21 G94
P6 90 80
60
80
0
G91 G28 Z0 P7 90 10
G28 X0 Y0 R 10 P1 20 10
P2
G90 36
P1 P7
20
20 70 10 Billet Size 100 x 100 x 10 mm

Cutter Dia: 8 mm
MANUAL
COMPUTER INTEGRATED
M06 T01
M03 S1200
G00 X20 Y10 Z5
G01 Z-1 F50 (P1)
G03 X10 Y20 R10 (P2)
G01 X10 Y80 (P3)
X20 Y90 (P4)
X80 Y90 (P5)
G02 X90 Y80 R10 (P6)
G01 X90 Y10 (P7)
X20 Y10 (P1)
G00 Z5
G91 G28 Z0
G28 X0 Y0
G90
M05
M30
37
MANUAL
COMPUTER INTEGRATED
MP 2. Write a part program to perform the contour slotting operation on the component as
shown in the figure for program MP 1. The slot should have a width of 8 mm and a depth of 5
mm. Use subprogram with a maximum depth of cut of 1 mm per pass.
O0004
G21 G94
G91 G28 Z0
O1155
G28 X0 Y0
G90 G91 G01 Z-1 F40 (P1)
M06 T01 G90

M03 S1200
G03 X10 Y20 R10 (P2)
G00 X20 Y10 Z5
G01 X10 Y80 (P3)
G01 Z0 F30
M98 P0051155 X20 Y90 (P4)
G01 Z5 X80 Y90 (P5)

G91 G28 Z0 G02 X90 Y80 R10 (P6)
G28 X0 Y0
G01 X90 Y10 (P7)
G90
M05 X20 Y10 (P1)
M30 M99
38
MANUAL
COMPUTER INTEGRATED
2.8 Slab Milling

MP 3. Write a part program to perform the square slab milling operation on a workpiece of
dimensions 100mm100mm10 mm. The slab’s dimension is 64mm64mm6mm and is
located at the centre of the workpiece. Use a cutter diameter of 10 mm. Take program zero at
the left bottom end of the workpiece.
O1122
10 mm
64 mm 6 mm
G21 G94
G91 G28 Z0
G28 X0 Y0
G90
M06 T01
100 mm
64 mm
M03 S1000
G00 X0 Y0 Z5
G01 Z0 F30
M98 P0063456
G01 Z5
G91 G28 Z0
G28 X0 Y0
100 mm
G90
M05 M30
O3456 X5 Y5
G91 G01 Z-1 F30 X10 Y10
G90 X90 Y10

X90 Y90
G01 X100 Y0
X10 Y90
X100 Y100
X10 Y10
X0 Y100
G42 G01 X18 Y18
X0 Y0
X82 Y18
X5 Y5 X82 Y82
X95 Y5 X18 Y82
X95 Y95 X18 Y18
X5 Y95 X50 Y18
39
MANUAL
COMPUTER INTEGRATED
X50 Y10 G01 X0 Y0

G40 M99
2.9 Circular Pocket Milling
MP 4.Write a part program to perform the Circular Pocket Milling operation on a workpiece
of dimensions 100mm100mm10 mm. The pocket’s dimension is R376mm depth and is
located at the centre of the workpiece. Use a cutter diameter of 10 mm. Take program zero at
the top face center of the workpiece.
O1123
G21 G94
G91 G28 Z0
G28 X0 Y0
G90
M06 T01
M03 S1000
G00 X0 Y0 Z5
G01 Z0 F30
M98 P0065973
G01 Z5
G91 G28 Z0
G28 X0 Y0
G90
M05
M30
O5973 G03 X-15 Y0 R15
G91 G01 Z-1 F30 X15 Y0 R15G01 X20 Y0
G90 G03 X-20 Y0 R20
G01 X5 Y0 X20 Y0 R20
G03 X-5 Y0 R5 G01 X25 Y0
X5 Y0 R5 G03 X-25 Y0 R25
G01 X10 Y0 X25 Y0 R25
G03 X-10 Y0 R10 G01 X30 Y0
X10 Y0 R10 G03 X-30 Y0 R30
G01 X15 Y0 X30 Y0 R30 40
MANUAL
COMPUTER INTEGRATED
G41 G01 X37 Y0 G01 X0 Y25

G03 X-37 Y0 R37 G40
X37 Y0 R37 G01 X0 Y0
X0 Y37 R37 M99
2.10 Square Pocket Milling
MP 5.Write a part program to perform the Square Pocket Milling operation on a workpiece
of dimensions 100mm100mm10 mm. The pocket’s dimension is 57mm57mm8mm and
is located at the centre of the workpiece. Use a cutter diameter of 10 mm. Take program zero
at the top face center of the workpiece.
O1124
8 mm
57 mm
G21 G94
10 mm
G91 G28 Z0
G28 X0 Y0
G90
100 mm
57 mm
M06 T01
M03 S1000
G00 X0 Y0 Z5
G01 Z0 F30
M98 P0087061
G01 Z5
100mm
G91 G28 Z0
G28 X0 Y0
G90
M05
M30
O7061 X5 Y0
G91 G01 Z-1 F30 X10 Y0
G90 X10 Y10
G01 X5 Y0 X-10 Y10
X5 Y5 X-10 Y-10
X-5 Y5 X10 Y-10
X-5 Y-5 X10 Y0
X5 Y-5 X15 Y0 41
MANUAL
COMPUTER INTEGRATED
X15 Y15 X-21.5 Y-21.5

X-15 Y15 X21.5 Y-21.5
X-15 Y-15 X21.5 Y10
X15 Y-15 X15 Y10
X15 Y0 G40
G41 G01 X21.5 Y0 G01 X0 Y0
X21.5 Y21.5 M99
X-21.5 Y21.5
2.11 Rectangular Pocket Milling
MP 6.Write a part program to perform the Rectangular Pocket Milling operation on a
workpiece of dimensions 100mm100mm10 mm. The pocket’s dimension is
73mm61mm5mm and is located at the centre of the workpiece. Use a cutter diameter of 10
mm. Length of the pocket is parallel to X axis. Take program zero at the top face center of
the workpiece.
O9128
G21 G94
G91 G28 Z0
5 mm
G28 X0 Y0 73 mm
G90 10 mm
M06 T01
M03 S1000
100 mm
61 mm
G00 X0 Y0 Z5
G01 Z0 F30
M98 P0058753
G01 Z5
G91 G28 Z0
Y/X = Breadth / Length =61/73 = 0.8356
G28 X0 Y0
G90  100 mm
Y = (0.8356) X
M05 X (mm) Y (mm)

M30 5 4.1781
10 8.3561
15 12.5342
O8753 20 16.7123
25 20.8904 42
30 25.0685
36.5 30.5
MANUAL
COMPUTER INTEGRATED
G91 G01 Z-1 F30

G90
G01 X5 Y0
X5 Y4.1781
X-5 Y4.1781
X-5 Y-4.1781
X5 Y-4.1781
X5 Y0
X10 Y0
X10 Y8.3561
X-10 Y8.3561
X-10 Y-8.3561
X10 Y-8.3561
X10 Y0
X15 Y0
X15 Y12.5342
X-15 Y12.5342
X-15 Y-12.5342
X15 Y-12.5342
X15 Y0
X20 Y0 X25 Y-20.8904 X-36.5 Y-30.5
X20 Y16.7123 X25 Y0 X36.5 Y-30.5
X-20 Y16.7123 X30 Y0 X36.5 Y10
X-20 Y-16.7123 X30 Y25.0685
X20 Y-16.7123 X-30 Y25.0685 X25 Y10
X20 Y0 X-30 Y-25.0685 G40
X30 Y-25.0685
X25 Y0 X30 Y0 G01 X0 Y0
X25 Y20.8904 G41 G01 X36.5 Y0 M99
X-25 Y20.8904 X36.5 Y30.5
X-25 Y-20.8904 X-36.5 Y30.5 43
MANUAL
COMPUTER INTEGRATED
44
MANUAL
COMPUTER INTEGRATED
2.12 Mirroring: If symmetrical contours (symmetry about X axis only, symmetry about Y
axis only OR simultaneous symmetry about both X & Y axes) are to be machined on a
component, the mirroring feature in CNC programming can be selected to ease the task of
programming. Here, part program (usually a sub-program) is written only for one of the
contours of the symmetric pair. Part program for the other part of the pair can be appended by
just selecting the ‘Mirror On’ feature.
M codes that are used for selecting the ‘Mirror On’ feature are:
M70 X Mirror ON means all future X coordinates programmed

are taken with –ve values.
M71 Y Mirror ON means all future Y coordinates programmed
are taken with –ve values.
M80 X Mirror OFF to cancle X Mirroring

M81 Y Mirror OFF to cancle Y Mirroring
Note: (1) Simultaneous mirroring of X & Y values is possible by programming both M70 &
M71.
(2) Mirroring changes the CW arc tool movement to CCW and vice-versa. In other
words, G02 becomes G03 and G03 becomes G02
45
MANUAL
COMPUTER INTEGRATED
MP 7.Write a part program to perform the mirroring operation on the component as shown in
the figure. Take cutter dia = 8 mm. Let the depth of the slot be 1 mm.
O7577 50 10 30 10
O0006
10
G00 X10 Y10
G21 G94
G91 G28 Z0 G01 Z-1 F50
30
G28 X0 Y0 X10 Y40
10
G90
X40 Y10
M06 T02
X10 Y10
50
M03 S1200
G00 X0 Y0 Z5 Z5
M98 P0017577 G00 X0 Y0

Billet Size: 100 x 100 x 10 mm
M70 X Mirror ON
M99
M98 P0017577
M80 X Mirror OFF
M71 Y Mirror ON
M98 P0017577
M70 X Mirror ON
M98 P0017577
M80 X Mirror OFF
M81 Y Mirror ON
G91 G28 Z0
G28 X0 Y0
M05 M30
46
MANUAL
COMPUTER INTEGRATED
3. CAPSTURN AND CAPSMILL
3.1 CAPS Mill EXERCISE:

M10  1.5 pitch, 6 holes on 60
PCD, 60o pitch, 30 mm deep
Sequence
Operations
All dimensions in mm Tool
number
1 Facing 50 mm dia face mill
2 Contour pocketing 20 mm dia end mill
3 Rectangular pocketing 20 mm dia end mill
4 Drilling 9.8 mm dia twist drill
5 Counter Sinking 5-20 mm Counter sink 120o
6 Tapping M10  1.5 pitch
47
MANUAL
COMPUTER INTEGRATED
3.2 CAPSTurn EXERCISE:
All dimensions in mm
Sequence
Operations Tool
number
1 Plain Facing External facing tool
2 Contour turning External turning tool
3 Finish turning External finishing tool
4 Finish Facing External facing tool
5 Pilot hole drilling 8 mm dia center drill
6 Peck drilling 8.5 mm dia twist drill
48
MANUAL
COMPUTER INTEGRATED
4. SIMULATION OF HYDRAULIC AND PNEUMATIC CIRCUITS

USING LMS IMAGE LAB (AMESIM) SOFTWARE.
49
MANUAL
COMPUTER INTEGRATED
50
MANUAL
COMPUTER INTEGRATED
5. Exercise Problems
51
MANUAL
COMPUTER INTEGRATED
52
MANUAL
COMPUTER INTEGRATED
53
MANUAL
COMPUTER INTEGRATED
6. DEFINITIONS OF FMS AND ASRS

6.1 Flexible Manufacturing System (FMS)
An FMS can be defined as an integrated computer controlled configuration of NC machine

tools, other auxiliary production equipments, and a material handling system designed to
simultaneously manufacture low to medium volumes of a wide variety of high quality
products at low cost. An FMS is capable of processing a variety of different part styles
simultaneously at various workstations, the mix of part styles and quantities of production
can be adjusted in response to changing demand patterns. FMS is the most automated and
technologically sophisticated Group Technology cell. FMS is designed to produce parts (or
products) within a defined range of styles, sizes and processes. A typical FMS is shown in the
below illustration.
MC1- Machining center 1

MC2- Machining center 2
54
6.2 Automatic storage and Retrieval system
An automated storage and retrieval system (ASRS) can be defined as a storage system that
performs storage and retrieval operations with speed and accuracy under a defined degree of
automation. The performance of any manufacturing industry depends mostly on its material
handling and storage system. Generally, ASRS refers to a variety of computer-controlled
methods for automatically depositing and retrieving loads to and from defined storage
locations. Within an automated storage system environment, there are having several layouts
such as horizontal carousels, rotary carousels ,vertical carousels, vertical lift modules, and
fixed aisle storage and retrieval systems. A typical rotary carousels ASRS is show below.

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MANUAL

DSCE Department of Mechanical

2. Introduction to CNC Milling, programs on Milling 32

3. CapsTurn and CapsMill 46

4. Simulation of Hydraulic and pneumatic circuits using LMS Image

6. Definitions of FMS and ASRS 52

1. INTRODUCTION TO CNC TURNING, PROGRAMS ON TURNING

CNC Words: The different types of CNC words

a) Sequence Number (N-word): It is used to identify a block.

1.6 Dimensional Notations used in CNC lathe are:

1.7 Zero points & Reference points on a CNC lathe:

M: Machine Zero Point W : Workpiece(Program) Zero Point

R: Reference point OR Home Position

1.9 Commonly used M-codes on the XLTURN machine:

M01 Optional Stop

G00 Rapid traverse

G01 Linear interpolation (feed traverse)

G02/03 Circular interpolation

I =(X coord. of center - X coord. of start point)/2

Specified with address R.

G94 X… (U….) Z….. (W…..) F…..

G94 X10 Z-0.5 F30

IV. Taper Turning Cycle (G90 Cycle):

G90 X30 Z-10 R0 F50 [(30-30)/2 = 0]

Syntax: G71 U……R……

P is the block number of the start of the final profile

Q is the block number of the end of the final profile.

U is the finishing allowance for the X axis

Syntax: G70 P….Q….F…..

G71 P1 Q10 U0.5 W0.5 F50 9

Syntax: M98 P0000000 Command used in main program

Command used in Subprogram

Main Program Subprogram Subprogram

…….. …….. ……..

…….. …….. ……..

M980012222 M980013333 ……..

…….. …….. ……..

…….. …….. ……..

…….. …….. ……..

M30 M99 M99

G00 X22 Z1 Tool Entry point

G90 X22 Z-40 F50

G00 X22 Z1 Tool Entry point

X20 R-1 X18

G90 X20 W-5 R0 F30 G00 X20 W-5

VII. External Grooving (G81 Cycle):

Syntax: G81 X….Z…..F…..

G02 X18 Z-27

G00 X13 Z-15 G00 X19

Syntax: G92 X…..Z…..F…..

ISO Metric Thread Parameters:

For Metric Thread, (60o tool

M03 S800 X9.5

Syntax: G74 R……

M06 T0505 Call 8 mm center drill

G00 X0 Z1 Tool Entry point

M06 T0101 Call 10 mm boring bar

2. INTRODUCTION TO CNC MILLING, PROGRAMS ON MILLING

2.3 Dimensional Notations used in CNC Mill are:

2.4 Programming Method - Absolute & Incremental Programming:

2.5 Commonly used G-codes on the FANUC Controller CNC Mill

Rapid Traverse (Tool moves at a predetermined rapid speed