CAM Lab - Manual

P.A COLLEGE OF ENGINEERING AND TECHNOLOGY

POLLACHI - 6420 002

LAB MANUAL CUM

RECORD NOTE BOOK

080120040 - COMPUTER AIDED MANUFACTURING LABORATORY

VI - SEMESTER, BE - MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

P.A. COLLEGE OF ENGINEERING AND TECHNOLOGY, POLLACHI - 6420 002

(Affiliated to Anna University - Coimbatore)

P.A COLLEGE OF ENGINEERING AND TECHNOLOGY

POLLACHI, COIMBATORE - 642 002.

BONAFIDE CERTIFICATE

Registration No.

Certified that this is the bonafide record of work done by

Mr.………………………………………………..……… of …………. - semester

B.E. Mechanical Engineering Branch / Batch during the academic year

…………………………. in the Computer Aided Manufacturing laboratory.

Head of the Department Staff In-Charge

Submitted for the University practical examination held

on…………………… at P.A College of Engineering and Technology,

Pollachi.

Internal Examiner External Examiner Date:………………… Date:…………………

LABARATORY CLASSES - INSTRUCTIONS TO STUDENTS

1. Students must attend the lab classes with ID cards and in the prescribed uniform.

2. Boys-shirts tucked in and wearing closed leather shoes. Girls’ students with cut

shoes, overcoat, and plait incite the coat. Girls’ students should not wear loose

garments.

3. Students must check if the components, instruments and machinery are in working

condition before setting up the experiment.

4. Power supply to the experimental set up/ equipment/ machine must be switched on

only after the faculty checks and gives approval for doing the experiment. Students

must start to the experiment. Students must start doing the experiments only after

getting permissions from the faculty.

5. Any damage to any of the equipment/instrument/machine caused due to

carelessness, the cost will be fully recovered from the individual (or) group of

students.

6. Students may contact the lab in charge immediately for any unexpected incidents

and emergency.

7. The apparatus used for the experiments must be cleaned and returned to the

technicians, safely without any damage.

8. Make sure, while leaving the lab after the stipulated time, that all the power

connections are switched off.

9. EVALUATIONS:

All students should go through the lab manual for the experiment to be carried

out for that day and come fully prepared to complete the experiment within

the prescribed periods. Student should complete the lab record work within

the prescribed periods.

Students must be fully aware of the core competencies to be gained by doing

experiment/exercise/programs.

Students should complete the lab record work within the prescribed periods.

The following aspects will be assessed during every exercise, in every lab

class and marks will be awarded accordingly:

Preparedness, conducting experiment, observation, calculation, results,

record presentation, basic understanding and answering for viva

questions.

In case of repetition/redo, 25% of marks to be reduced for the respective

component.

NOTE 1

Preparation means coming to the lab classes with neatly drawn circuit diagram

/experimental setup /written programs /flowchart, tabular columns, formula, model

graphs etc in the observation notebook and must know the step by step procedure

to conduct the experiment.

Conducting experiment means making connection, preparing the experimental

setup without any mistakes at the time of reporting to the faculty.

Observation means taking correct readings in the proper order and tabulating the

readings in the tabular columns.

Calculation means calculating the required parameters using the approximate

formula and readings.

Result means correct value of the required parameters and getting the correct

shape of the characteristics at the time of reporting of the faculty.

Viva voice means answering all the questions given in the manual pertaining to the

experiments.

Full marks will be awarded if the students performs well in each case of the

above component

NOTE 2

Incompletion or repeat of experiments means not getting the correct value of the

required parameters and not getting the correct shape of the characteristics of the

first attempt. In such cases, it will be marked as “IC” in the red ink in the status

column of the mark allocation table given at the end of every experiment. The

students are expected to repeat the incomplete the experiment before coming to

the next lab. Otherwise the marks for IC component will be reduced to zero.

NOTE 3

Absenteeism due to genuine reasons will be considered for doing the missed

experiments.

In case of power failure, extra classes will be arranged for doing those experiments

only and assessment of all other components preparedness; viva voice etc. will be

completed in the regular class itself.

NOTE 4

The end semester practical internal assessment marks will be based on the average

of all the experiments.

INDEX

Ex.

No Date Name of the Experiment Mark

Page

No Staff Signature

1

2

3

4

5

6

7

8

9

10

Completed date:

Average Mark: Staff - in - charge

INDEX

Ex.

No Date Name of the Experiment Mark

Page

No Staff Signature

11

12

13

14

15

16

17

18

19

20

Completed date:

Average Mark: Staff - in - charge

STUDY EXERCISE ON CNC MACHINES

EX. NO: 1

DATE:

Aim:

To conduct a brief study into various aspects of CNC machines

1. The evolution of CNC:

Shortly after world war – II, USAF faced with the complex machining of aircraft

components and inspection fixtures to close accuracies on a repetitive basis. During this

time Mr. John Parson was working on a project for developing equipment that would

machine flat templates for inspecting contours of helicopter blades. He succeeded in it and

the proposal for manufacturing such a machine was submitted to USAF in 1948 by Parson

Corporation of Traverse City, Michigan, and resulted in a development contract in 1948.

Parson found that the card reader was too slow and approached MIT to develop a tape

reader and power drive for the proposed machine. The collaboration between Parson and

MIT went into troubles later. USAF then awarded a prime contract to MIT in 1951. The servo

machines laboratory of MIT successfully demonstrated a three motion- milling machine.

The following three successive years witnessed hardware refinements and

development of mathematical functions for tape preparation in 1955. USAF awarded $35

millions for manufacturing approximately 100 CNC machines of various types. Giddings and

Lewis, General Electric and Bendix are the companies who took interest in adopting NC

technology in its early years. The subsequent developments in CNC technology are primarily

attributed to refinements in computer hardware & part programming languages.

2. Difficulties faced by early NC machines

2.1 NC Controller

In a conventional NC system, the control is hardwired and therefore any

modifications of addition in facility call for many changes in the controller, which may or may

not be possible due to limitations of basic configuration.

2.2 Punched Tape

Paper tape is especially fragile and its susceptibility to war and tear makes it to be an

unreliable NC component for repeated use on the shop floor. More durable materials like

miler, Aluminum foil are used to overcome this difficulty. However these materials are also

relatively expensive. Besides this, the tape heeds to be loaded each time and some errors in

reading. If any change in instruction is needed, modification or editing of the tape is also not

possible.

2.3 Tape Reader

It is the least reliable hardware component of the system. NC System breakdowns

are mainly caused by tape readers.

2.4 Management information

The conventional NC System cannot provide timely information on operational

performance to management. Such information might include piece counts, machine

breakdowns and tool changes.

2.5 Non-optimal Speeds and Feeds

The conventional NC does not have facilities to optimize the speeds and feeds during

the machining process. Consequently, the part programmer must plan the cutting conditions

conservatively and this reduces productivity.

3. Canned Cycle

A Canned cycle is a combination of machine movements that perform machining

operations like drilling, milling, boring and tapping. For example, the drilling cycle consists of

the following movements of the tool.

Fast approach to work piece.

Drill at feed rate

Rapid return to initial position.

These movements can be combined to form a cycle and give a code. When this code is

invoked, the machine performs all these operations. The use of canned cycle reduces

programming effort. This also saves the length of the program, thus saving the space

required to store the program.

4. General Machining Features available in a typical CAM Software

Complete integration with other software’s ensuring no discrepancy between

design and machined part.

Choice of cutter simulation, cutter path, cutter tools itself or machined work piece.

Machining output to ISO Standard CL data.

Single or double precision CL data.

Repetitive tasks by command files

Cutting tool database adaptable to company standards.

ATC Support.

Estimation of machining times and tool path length (to establish tool wear).

Manual editing of cutter path at any time.

Efficient machining algorithms for optimum cutter path generation times.

5. Candidature of NC for the industry

When the following conditions are met, NC machines become a candidate for the

production industry.

When

Quantity of parts per setup is small

Parts are complex

Repeated lots occur.

Repeated design changes occur

Minimum lead time is must

Scrapping would be costly

Floor space is at a premium

6. Designation of coordinate systems in NC Machines

In an NC System, each axis of motion is equipped with a separate driving source

such as DC motor, stepper motor etc. The three main axes of motion are referred to as X, Y

and Z-axes. The Z-axes is perpendicular to both X and Y-axes in order to create a right hand

co-ordinate system. This is detailed as follows

6.1 Z - Axis

(i) On a work piece-rotating machine, such as a lathe, the Z-axis is parallel to the

spindle, and the positive motions the tool away from the work piece.

(ii) On a tool-rotating machine, such as a milling or boring machine, Z-axis is

parallel to the tool axis, and the positive motion moves the tool away from the

work piece.

(iii) On other machines such as press, a planning machine, Z-axis is

perpendicular to the tool set and the work piece.

6.2 X - Axis

(i) On a lathe, X – axis is the direction of tool movement and the positive motion

moves the tool away from the work piece.

(ii) On a horizontal milling machine, the X-axis is parallel to the table.

(iii) On a vertical milling machine, the positive X-axis points to the right when the

programmer is facing the machine.

6.3 Y - Axis

This is the axis left in a standard Cartesian Co-ordinate system.

6.4 Rotational axis

A, B and C axis represent rotating about X, Y and Z respectively.

7. General format of a manual CNC Program

The CNC program block generally contains the following format

N-G-X-Y-Z-A-B-C-F-S-T-M

Where,

N – Sequence number of instructions

G- Preparatory function

X, Y, Z, A, B, C Co -ordinate and angular data

F- Feed

S- Spindle speed

T-Tool code

M- Miscellaneous function.

8. Control systems used in CNC Machines

Though there are many control systems in the market, the following are widely used:

(i) Allen Bradley

(ii) Anilam

(iii) Bosch

(iv) Fanuc OM, OT, 18T, 3M, 3TF..

(v) GE 550,1050..

(vi) Heidenhain

(vii) Mazak

(viii) Philips

(ix) Hinumeric

(x) Elpro

9. Execution of part program written in CAPP Language

There are two major classes of part programming languages (Smith and Earns,

1977)

9.1. Machine oriented languages

They create tool paths by doing all the necessary calculations in one computer

processing stage by computing directly the special Co-ordinate data format and the coding

for speed and feed requirements.

9.2. General purpose languages

The computer processing can be broken down to into two stages, viz., a processing

stage and post processing stage. The processing stage creates an intermediate set of data

points called CL data. The following figure illustrates a generalized flow chart for most NC

processors to show the execution of the program written in a language like APT. The

elements in the flow chart are explained of follows

9.3. NC Processor

It is computer application program that accepts as input user oriented language

statements that describe the NC operations to be performed. The translation section

translator symbolic inputs contained in the section performs geometric and trigonometric

calculations required to generate the part surface. The path of the centerline of the cutter is

also calculated here. This section generates the cutter location data.(CL data)

9.4. Post processor

It is also a program that converts the CL data into program blocks, which are used to

machine the component. This is machine tool dependent.

9.5. CL Data

It is the intermediate data points, which represents the co-ordinates of various

machinable features in the work piece. It is a neutral file and acceptable to any post

processor.

10. The requirements of a spindle drive and feed drive

(a) The requirements of a spindle drive motor are

(b) High rotational accuracy

(c) Wide constant power band

(d) Excellent running smoothness

(e) Compactness

(f) Fast dynamic response

(g) High over load capacity

(h) Infinitely variable speed within the range

11. Spindle drives commonly used in CNC machine tools

(a) Squirrel cage induction motors

(b) DC shunt motors

(c) Permanent magnet AC induction motors

(d) Hydraulic drives

(e) Pneumatic drives.

12. Requirements of Feed drives

(a) Constant torque to overcome friction and working forces

(b) Infinitely variable driving speed

(c) Smallest possible positioning increments (typical:1-2 m)

(d) Quick response characteristics (High peak torque)

(e) Integral mounting feedback devices

(f) Low armature inertia

(g) High torque-to-weight ratio

(h) Total enclosed non-ventilated design (TENV)

12.1 Feed drives commonly used in CNC machines

Permanent magnet DC Servo motor

Synchronous three phase AC servo motor with permanent magnet rotor

Linear motor.

13. Important constituent parts of a CNC machine tool

(a) Machine structure

(b) Guide ways

(c) Feed drives

(d) Spindle & spindle bearings

(e) Measuring and feedback systems

(f) Controls, software and operator interface

(g) Tool monitoring

14. CNC machining centers vis-à-vis CNC machines

Initially the CNC technology was applied on basic metal cutting machines like lathes,

milling machines etc. To increase the flexibility of the machines in handling a variety of

components and to finish them in a single set-up on the same machine, a CNC machining

center for machining prismatic components combining operations like milling, drilling, boring

and tapping. These machining centers are very powerful, heavy-duty production machines

with the capability to change tools using ATC, A which can select any tool automatically, by

the computer program from the tool magazine. A typical tool magazine can contain more

tools of the order to 32 and above.

While vertical and horizontal machining centers could be respectively utilized for

machining only on one face and four faces of the component in a set-up, complete

machining of all five faces of cubical component in a single set up was possible with a

feature to change the spindle configuration automatically from vertical to horizontal and vice

versa, as the case may be, within the programmed cycle. These machines are called

universal machinating centers (UMC). Further, the concept of multi operations was also

entered for machining cylindrical components, which led to the developments of turning

centers.

Result:

Thus the overview and basic function of CNC machine were studied.

STUDY OF CNC CODES (M and G CODES

EX. NO: 2

DATE:

Aim:

To study the preparatory and miscellaneous function of CNC codes.

Miscellaneous Function (M - Code):

M00 Unconditional stop

M01 Conditional stop

M02 End of program

M03 Spindle clockwise

M04 Spindle counterclockwise

M05 Spindle stop

M06 Tool change (see Note below)

M19 Spindle orientation

M20 Start oscillation (configured by G35)

M21 End oscillation

M30 End of program

M40 Automatic spindle gear range selection

M41 Spindle gear transmission step 1






M70 Spline definition, beginning and end curve 0

M71 Spline definition, beginning tangential, end curve 0

M72 Spline definition, beginning curve 0, end tangential

M73 Spline definition, beginning and end tangential

M80 Delete rest of distance using probe function, from axis measuring input

M81 Drive On application block

M101-M108 Turn off fast output byte bit 1 (to 8)

M109 Turn off all (8) bits in the fast output byte

M111-M118 Turn on fast output byte bit 1 (to 8)

M121-M128 Pulsate (on/off) fast output byte bit 1 (to 8)

M140 Distance regulation “on” (configured by G265)

M141 Distance regulation “off”

M150 Delete rest of distance using probe function, for a probe input

M151-M158 Digital input byte 1 bit 1 (to bit 8) is the active probe input

M159 PLC cannot define the bit mask for the probe inputs

M160 PLC can define the bit mask for the probe inputs (up to 16)

M161-M168 Digital input byte 2 bit 1 (to bit 8) is the active probe input

M170 Continue the block processing look ahead of the part program (cancel the M171)

M171 Stop the block processing look ahead of the probe input part program segment

M200 Activate the handwheel operation in the automatic mode

M201-M208 Select the axis (by number from 1 to 8) for the handwheel operation

M209 Activate the handwheel operation in the automatic mode, with PLC control

M210 Deactivate the handwheel input while in the automatic mode

M211 Deactivate this handwheel feature and also remove the handwheel offset (if any)

M213 Spindle 2 clockwise

M214 Spindle 2 counterclockwise

M215 Spindle 2 stop

M280 Switchable spindle/rotary axis, rotary axis on, first combination

M281 Switchable spindle/rotary axis, rotary axis on, second combination

M290 Switchable spindle/rotary axis, spindle enabled, first combination

M291 Switchable spindle/rotary axis, spindle enabled, second combination

Geometric codes (G - Code):

G00 Rapid traverse

G01 Linear interpolation with feedrate

G02 Circular interpolation (clockwise)

G03 Circular interpolation (counter clockwise)

G2/G3 Helical interpolation

G04 Dwell time in milliseconds

G05 Spline definition

G06 Spline interpolation

G07 Tangential circular interpolation / Helix interpolation / Polygon interpolation

G08 Ramping function at block transition / Look ahead "off"

G09 No ramping function at block transition / Look ahead "on"

G10 Stop dynamic block preprocessing

G11 Stop interpolation during block preprocessing

G12 Circular interpolation (cw) with radius

G13 Circular interpolation (ccw) with radius

G14 Polar coordinate programming, absolute

G15 Polar coordinate programming, relative

G16 Definition of the pole point of the polar coordinate system

G17 Selection of the X, Y plane

G18 Selection of the Z, X plane

G19 Selection of the Y, Z plane

G20 Selection of a freely definable plane

G21 Parallel axes "on"

G22 Parallel axes "off"

G24 Safe zone programming; lower limit values

G25 Safe zone programming; upper limit values

G26 Safe zone programming "off"

G27 Safe zone programming "on"

G33 Thread cutting with constant pitch

G34 Thread cutting with dynamic pitch

G35 Oscillation configuration

G38 Mirror imaging "on"

G39 Mirror imaging "off"

G40 Path compensations "off"

G41 Path compensation left of the work piece contour

G42 Path compensation right of the work piece contour

G43 Path compensation left of the work piece contour with altered approach

G44 Path compensation right of the work piece contour with altered approach

G50 Scaling

G51 Part rotation; programming in degrees

G52 Part rotation; programming in radians

G53 Zero offset off

G54 Zero offset #1

G55 Zero offset #2

G56 Zero offset #3

G57 Zero offset #4

G58 Zero offset #5

G59 Zero offset #6

G63 Feed / spindle override not active

G66 Feed / spindle override active

G70 Inch format active

G71 Metric format active

G72 Interpolation with precision stop "off"

G73 Interpolation with precision stop "on"

G74 Move to home position

G75 Curvature function activation

G76 Curvature acceleration limit

G78 Normalcy function "on" (rotational axis orientation)

G79 Normalcy function "off"

G80 - G89 for milling applications:

G80 Canned cycle "off"

G81 Drilling to final depth canned cycle

G82 Spot facing with dwell time canned cycle

G83 Deep hole drilling canned cycle

G84 Tapping or Thread cutting with balanced chuck canned cycle

G85 Reaming canned cycle

G86 Boring canned cycle

G87 Reaming with measuring stop canned cycle

G88 Boring with spindle stop canned cycle

G89 Boring with intermediate stop canned cycle

G81 - G88 for cylindrical grinding applications:

G81 Reciprocation without plunge

G82 Incremental face grinding

G83 Incremental plunge grinding

G84 Multi-pass face grinding

G85 Multi-pass diameter grinding

G86 Shoulder grinding

G87 Shoulder grinding with face plunge

G88 Shoulder grinding with diameter plunge

G90 Absolute programming

G91 Incremental programming

G92 Position preset

G93 Constant tool circumference velocity "on" (grinding wheel)

G94 Feed in mm / min (or inch / min)

G95 Feed per revolution (mm / rev or inch / rev)

G96 Constant cutting speed "on"

G97 Constant cutting speed "off"

G98 Positioning axis signal to PLC

G99 Axis offset

G100 Polar transformation "off"

G101 Polar transformation "on"

G102 Cylinder barrel transformation "on"; cartesian coordinate system

G103 Cylinder barrel transformation "on," with real-time-radius compensation (RRC)

G104 Cylinder barrel transformation with center line migration (CLM) and RRC

G105 Polar transformation "on" with polar axis selections

G106 Cylinder barrel transformation "on" polar-/cylinder-coordinates

G107 Cylinder barrel transformation "on" polar-/cylinder-coordinates with RRC

G108 Cylinder barrel transformation polar-/cylinder-coordinates with CLM and RRC

G109 Axis transformation programming of the tool depth

G110 Power control axis selection/channel 1

G111 Power control pre-selection V1, F1, T1/channel 1 (Voltage, Frequency, Time)

G112 Power control pre-selection V2, F2, T2/channel 1


G114 Power control pre-selection T4/channel 1


G116 Power control pre-selection T6/pulsing output

G117 Power control pre-selection T7/pulsing output

G120 Axis transformation; orientation changing of the linear interpolation rotary axis

G121 Axis transformation; orientation change in a plane

G125 Electronic gear box; plain teeth

G126 Electronic gear box; helical gearing, axial

G127 Electronic gear box; helical gearing, tangential

G128 Electronic gear box; helical gearing, diagonal

G130 Axis transformation; programming of the type of the orientation change



G133 Zero lag thread cutting "on"

G134 Zero lag thread cutting "off"

G140 Axis transformation; orientation designation work piece fixed coordinates

G141 Axis transformation; orientation designation active coordinates

G160 ART activation

G161 ART learning function for velocity factors "on"

G162 ART learning function deactivation

G163 ART learning function for acceleration factors

G164 ART learning function for acceleration changing

G165 Command filter "on"

G166 Command filter "off"

G170 Digital measuring signals; block transfer with hard stop

G171 Digital measuring signals; block transfer without hard stop

G172 Digital measuring signals; block transfer with smooth stop

G175 SERCOS-identification number "write"

G176 SERCOS-identification number "read"

G180 Axis transformation "off"

G181 Axis transformation "on" with not rotated coordinate system

G182 Axis transformation "on" with rotated / displaced coordinate system

G183 Axis transformation; definition of the coordinate system

G184 Axis transformation; programming tool dimensions

G186 Look ahead; corner acceleration; circle tolerance

G188 Activation of the positioning axes

G190 Diameter programming deactivation

G191 Diameter programming "on" and display of the contact point

G192 Diameter programming; only display contact point diameter

G193 Diameter programming; only display contact point actual axes center point

G200 Corner smoothing "off"

G201 Corner smoothing "on" with defined radius

G202 Corner smoothing "on" with defined corner tolerance

G203 Corner smoothing with defined radius up to maximum tolerance

G210 Power control axis selection/Channel 2

G211 Power control pre-selection V1, F1, T1/Channel 2



G214 Power control pre-selection T4/Channel 2

G215 Power control pre-selection T5/Channel 2

G216 Power control pre-selection T6/pulsing output/Channel 2


G220 Angled wheel transformation "off"

G221 Angled wheel transformation "on"

G222 Angled wheel transformation "on" but angled wheel moves before others

G223 Angled wheel transformation "on" but angled wheel moves after others

G265 Distance regulation – axis selection

G270 Turning finishing cycle

G271 Stock removal in turning

G272 Stock removal in facing

G274 Peck finishing cycle

G275 Outer diameter / internal diameter turning cycle

G276 Multiple pass threading cycle

G310 Power control axes selection /channel 3








Result:

Thus the Miscellaneous and Geometric function of CNC machine were studied.

STUDY EXERCISE ON SPECIFICATIONS AND PROGRAMMING CODES

EX. NO: 3

DATE:

Aim

To study the specifications and various codes used in programming a CNC machine

tool (FANUC controller).

XL TURN CNC LATHE SPECIFICATIONS

1. Swing over Bed - 150mm

2. Swing over Cross slide - 50mm

3. Z axis travel - 170mm

4. X axis travel - 80mm

5. Spindle - 1 HP

6. Speed - Max 3000 RPM

(For pneumatic chuck)

7. Feed - 0-1000mm/min

8. Spindle nose taper bore - MT3/20mm

9. Tail stock sleeve taper/travel - MT2/30mm

10. Z axis ball screw - Dia 16x5mm lead

11. Z axis ball screw - 12x2.5mm lead

12. Coolant tank capacity - 4Lrs.

13. Overall size - 700x500mm

14. Weight - 110Kg.

XLMILL CNC (STARMILL) SPECIFICATIONS

1. Table clamping size - 425x130mm

2. Traverses X axis - 180mm

3. Traverses Y axis - 120mm

4. Traverses Z axis - 115mm

5. Spindle Taper ISO 30 Speed - 0- 3000 RPM

3.1 NC Program Build – UP

In a NC program, the machining steps (operations) for producing a part on the

machine tool are laid down in a form that the control system can understand. A program

comprises of several blocks. A block is a collection of NC words. A NC word is a collection of

address letter and a sequence of numbers. Table. 1. Shows the address letters according to

DIN 66025

Table. 1. Address Characters as Per DIN 66025

Character Meaning

A Rotation about X-axis

B Rotation about Y-axis

C Rotation about Z-axis

D&E Rotation about additional axes

F Feed

G Preparatory function, identifying the action to be executed

H Unassigned

I Interpolation parameter / Thread pitch parallel to X-axis

J Thread pitch parallel to Y-axis

K Thread pitch parallel to Z-axis

L Unassigned

M Auxiliary function

N Block number

O Not number

P,Q,R Thread movement parallel to X, Y, Z axes respectively.

P&Q are also used as parameters in cycles

S Spindle speed

T Tool

U,V,W Second movement parallel to X,Y,Z axes respectively

X Movement in X-axis

Y Movement in Y-axis

Z Movement in Z-axis

3.2. G and M codes for Milling Operations:

Miscellaneous Functions (M codes):

M00 Program Stop

M01 Optional Stop

M02 Program End

M03 Spindle Forward

M04 Spindle Reverse

M05 Spindle Stop

M06 Tool Change

M08 Coolant On

M09 Coolant Off

M10 Vice Open

M11 Vice Close

M13 Coolant, Spindle Fwd

M14 Coolant, Spindle Rev

M30 Program End and Rewind

M62 Output 1On

M63 Output 2On

M64 Output 1Off

M65 Output 2Off

M66 Output 2Off

M67 Wait Input 1 Off

M70 X Mirror On

M71 Y Mirror On



M80 X Mirror Off

M81 Y Mirror Off

M98 Subprogram Call

M99 Subprogram Exit

Preparatory Functions (G Codes)

G Code Group Function

G00

01

Positioning (Rapid traverse)

G01 Linear interpolation (Cutting feed)

G02 Circular interpolation CW

G03 Circular interpolation CCW

G04 00 Dwell, Exact stop

G17

02

XY Plane selection

G18 ZX Plane selection

G19 YZ Plane selection

G20

06

Input in inch

G21 Input in mm

G28 00 Return to reference point

G40 Cutter compensation cancel

G41 07 Cutter compensation Left

G42 Cutter compensation Right

G43

08

Tool Length compensation + direction

G44 Tool Length compensation - direction

G49 Tool Length compensation cancel

G73

09

Peck drilling cycle

G74 Counter tapping cycle

G76 Fine boring

G80 Canned cycle cancel

G81 Drilling cycle, spot boring

G82 Drilling cycle, counter boring

G83 Peck drilling cycle

G84 Tapping cycle

G85 Boring cycle

G86 Boring cycle

G87 Back boring cycle

G88 Boring cycle

G89 Boring cycle

G90 03 Absolute command

G91 Incremental command

G92 00 Programming of absolute zero point

G94 05 Feed per minute

G95 Feed per rotation

G98 10 Return to initial point in canned cycle

G99 Return to R point in canned cycle

3.3. G and M codes for Turning Operations:

Miscellaneous Functions (M codes):

M00 Program Stop

M02 Optional Stop

M03 Spindle Forward (CW)

M04 Spindle Reverse (CCW)

M05 Spindle Stop

M06 Tool Change

M08 Coolant On

M09 Coolant Off

M10 Vice Open

M11 Vice Close

M62 Output 1On

M64 Output 1Off

M65 Output 2Off

M66 Output 2Off




M98 Subprogram Call

M99 Subprogram Exit

Preparatory Functions (G Codes)

G Code Group Function

G00

1

Positioning (Rapid traverse)

G01 Linear interpolation (Cutting feed)

G02 Circular interpolation CW

G03 Circular interpolation CCW

G04 0 Dwell, Exact stop

G20

6

Input in inch

G21 Input in mm

G28 9 Return to reference point

G32 1 Thread cutting

G40

7

Tool nose radius compensation cancel

G41 Tool nose radius compensation Left

G42 Tool nose radius compensation Right

G49 Tool Length compensation cancel

G50 0 Work co-or. change / spindle speed setting

G70 4 Finishing cycle

G71 Stock removal in turning

G72 Stock removal in facing

G73

Pattern repeating

G74 Peck drilling in Z axis

G75 Grooving in X axis

G76 Thread cutting cycle

G90 1 Cutting cycle A

G92 Thread cutting cycle

G94 Cutting cycle B

G96 2 Constant surface speed control

G97 Constant surface speed control cancel

G98 11 Feed per minute

G99 Feed per revolution

MILLING OPERATIONS:

1. CIRCULAR POCKETING:

Definitions for the terms used in the G170 and G171 circular pocket canned cycle as follows:

N0080 G170 R0 P0 Q3 X0 Y0 Z-6 I0.5 J0.1 K-24 ;

N0090 G171 P75 S2000 R75 F250 B2500 J200 Z5;

For G170 block,

R defines the position of the tool to start cycle ie. 0 (surface of job).

P defines when P is zero(0) the cycle is a roughing cycle and P is one (1) the cycle is

finishing cycle

Q defines the peck increment, 2 pecks each of 3mm.

X defines the pocket centre in X axis (0).

Y defines the pocket centre in Y axis (0).

Z defines the pocket base (-6mm) from job surface.

I defines the side finish allowance (leaves a finishing allowance of 0.5).

J defines the base finish allowance (leaves a finishing allowance of 0.1).

K defines the radius of pocket (-24) negative value - cut in CCW direction).

For G171 block,

P defines the cutter width percentage.

S defines the roughing spindle speed (S2000).

R defines the roughing Feed in Z (75).

F defines the roughing feed X,Y (250).

B defines the finishing spindle speed (2500).

J defines the finishing feed (200).

Z defines for to lift tool for safety purpose.

2. RECTANGULAR POCKETING:

Definitions for the terms used in the G172 and G173 rectangular pocket canned cycle as

follows:

N0080 G172 I50 J50 K0 P0 Q3 R0 X25 Y25 Z-6 ;

N0090 G173 I0.5 K0.1 P75 T1 S1000 R75 F250 B1500 J200 Z5 ;

For G172 block,

I define the pocket X length (50).

J defines the pocket Y length (50)

K defines the radius of corner roundness (not applicable to Denford software).

P defines that 0 = roughing cycle and 1 for finishing cycle.

Q defines the pocket Z increment (peck increments in above cycle 2-3mm pecks).

R defines the Absolute Z 'R' point.

X defines the pocket corner X (Absolute position relative to the X datum position).

Y defines the pocket corner Y (Absolute position relative to the Y datum position).

Z defines the absolute Z base of pocket (-6, ie, a depth of 6mm).

For G173 block,

I defines the pocket side finish (0.5 finishing allowance) on the finishing pass.

K defines the pocket base finish (0.1 finishing allowance) on the finishing pass.

P defines the cut width percentage (75% of tool dia.).

T defines the pocket tool (tool 1).

S defines the spindle speed for roughing (1000rpm).

R defines the roughing feed for Z (75).

F defines the roughing feed X and Y (250).

B defines the finishing spindle speed (1500 rpm).

J defines the finishing feed (200).

Z defines the safety Z (5mm above 'R' point).

When values are stated for the I and K elements, the program will perform a finishing pass

after completion of the final roughing cut.

3. PECK DRILLING CYCLE:

A G83 (Deep hole Peck drilling) command is written in the following format:

G99 G83 X.... Y.... Z.... Q.... R.... F....

G98 G80

Sequence of moves:

1) Rapid position to X, Y and Z (the initial level).

2) Rapid traverse to R point level.

3) Feed rate in the value of Q.

4) Rapid traverse out to R point. Rapid traverse back to within 1mm of depth of Q cut.

Operation moves 2 and 4 are repeated until Z depth is reached.

5) Rapid traverse to Initial level (G98) or R point level (G99).

1 - Positioning of the X and Y axes.

2 - Rapid traverse in the Z axis to the "R" point.

3 - Hole machining procedure.

4 - Operation at bottom of hole.

5 - Retraction to R point.

6 - Rapid traverse in the Z axis to the Init ial level.

G.... is defined as the canned cycle.

X.... Y.... is defined as the hole position, in absolute or incremental value.

Z.... is defined as the distance from the R point to the bottom of the hole in incremental

mode, or the position of the hole bottom in absolute mode.

R.... is defined as the distance from the initial level to the R point level in incremental

mode, or the position of the Z datum in relation to the R point level in absolute mode.

Q.... is defined as the cut-in distance value or shift value (Note - this is always specified as

an incremental value).

F.... is defined as the feed rate for machining.

G80- Drilling cycle cancelled.

4. BORING OPERATION:

G86 (Boring Operation) command is written in the following format:

G86 G99 X.... Y.... Z.... R.... K… F....

G98 G80

Sequence of moves:

1) Rapid position to X, Y and Z (the initial level).

2) Rapid traverse to R point level.

3) Feed motion up to the Z level, the bottom of the hole.

4) Rapid traverse up to the R point level Initial level (G99) and up to the Initial tool

Level (G98)

1 - Positioning of the X and Y axes.

2 - Rapid traverse in the Z axis to the "R" point.

3 - Hole machining procedure.

4 - Operation at bottom of hole.

5 - Retraction to R point.

6 - Rapid traverse in the Z axis to the Initial level.

G.... is defined as the canned cycle.

X.... Y.... is defined as the hole position, in absolute or incremental value.

Z.... is defined as the distance from the R point to the bottom of the hole in incremental

mode, or the position of the hole bottom in absolute mode.

R.... is defined as the distance from the initial level to the R point level in incremental

mode, or the position of the Z datum in relation to the R point level in absolute mode.

K.. is the number of repetitions (defaults to 1).

F.... is defined as the feed rate for machining.

G80… cycle cancelled.

TURNING OPERATIONS:

1. MULTIPLE TURNING (Canned Cycle)

G71 MULTIPLE TURNING

G71 U(*ul) R (*r)

G71 P(*p) Q (*q) U(*u2) W (*w2) F(*f) S(*s) T(*t)

Where,

*u1 = depth of cut (radius designation)

*r = relief amount

*p = line or block number of the start of the final profile

*q = line or block number of the end of the final profile

*u2 = finishing allowance in the X axis

*w2 = finishing allowance in the Z axis

*f = feed rate

*s = speed

*t = tool number

G70 FINSHING CYCLE

G70 P(p) Q(q) F(f)

2. GROOVING CYCLE

G75 GROOVING CYCLE

G75 R1

G75 X16 W-3 P100 Q1500 R1 F15

Relief amount, R= 1.0mm

Depth of groove, X =2mm

Width of groove, W=6.0mm

P-peck increment along, X axis 0.1mm

Q- Stepping distance along Z axis 1.5 mm

3. MULTIPLE THREADING CYCLE

G76 MULTIPLE THREADING CYCLE

G76 P031560 Q250 R0.15

G76 X9.853 Z-19 P1073 Q300 F1.75

(03 =Number of passes for finishing operation

(15 =Chamfer amount in microns

(60 =Angle of the thread in deg.

(Q =Minimum cutting depth=0.25 mm

(R =Finishing allowance =0.15mm

(X = Core diameter =9.853 mm for M12 thread

(Z =Length of thread =19 mm

(P Height of thread =1.073 mm

(Q =Depth of cut for first pass =0.3 mm

(F =Pitch of the thread =1.75 mm

THREAD PARAMETERS

Nominal diameter, mm

Pitch mm F Core diameter, X

Bolt Nut Height of

thread ,mm

M2.5 0.45 1.948 2.013 0.276

M3 0.5 2.387 2.459 0.307

M4 0.7 3.141 3.242 0.429

M5 0.8 4.019 4.134 0.491

M6 1 4.773 4.918 0.613

M8 1.25 6.466 6.647 0.767

M10 1.5 8.160 8.376 0.920

M12 1.75 9.853 10.106 1.074

M16 2 13.546 13.835 1.227

M20 2.5 16.933 17.294 1.534

M24 3 20.320 20.752 1.840

M30 3.5 25.706 26.211 2.147

M33 3.5 28.706 29.211 2.147

M36 4 31.093 31.67 2.454

M8 X1 1 6.773 6.918 0.613

M10 X1.25 1.25 8.466 8.647 0.767

M12 X1.25 1.25 10.466 10.767 0.767

M16 X1.5 1.5 14.16 14.376 0.920

M20 X1.5 1.5 18.16 18.376 0.920

M24 X2 2 21.546 21.835 1.227

M30 X2 2 27.546 27.835 1.227

M36 X3 3 32.32 32.752 1.840

Result:

Thus the study exercise on specifications and programming codes of CNC machine

were studied.

DENFORD MACHINE TOOL - FANUC (Lathe and milling)

EX. NO: 4

DATE:

This is Fanuc programming system.

It was created at Denford machine tools .The current version number can be seen at the top

of the screen.

CNC lathe (FLSTEP) - Denford Fanuc Turning V1.42

CNC Milling (FANUCMD) - Denford Fanuc milling V1.96

In the main window screen press F1....the following menu will appear,

Edit and simulate:

You are now editing a CNC program. A variety of instructions can be keyed in on each line.

At any time you can start a simulation of machining of your program via the F9 menu. Whilst

typing, characters will appear at the cursor position. The cursor is flashing or steady blob.

Some "hot keys" are shown at the bottom.

Main window.

Edit keys

Hot keys

CNC instructions

Example

G codes

M codes

Directives

Tutorials

Comments

Screen display

Edit Keys

Whilst editing a CNC program you can use these keys

Cursor keys - Move cursor in the appropriate direction

DEL - Deletes one character at the cursor

Back arrow - Deletes one character to the left of the cursor

INS - Toggles between insert and overwrite

HOME - Move to start of the line

END - Move to end of the line

PGUP - Moves up a page

PGDN - Moves down a page

Ctrl PGUP - Moves to first line

Ctrl PGDN - Moves to last line

Ctrl Y - Deletes all of current line

Ctrl N - Inserts a new blank line

Ctrl R - Restores line after edit

(This is only possible if you do not move off the line)

These keys are used for block marking:

If marking in “anchor” mode:

F7 - Sets start of marked area

F8 - Sets end of marked area

If marking in “drag” mode:

F7 - Starts marking: use the arrow keys to mark out of the drag area

F8 - Stops marking and then if pressed again cancels marked area

These keys relate to block edits:

Alt D - Deletes marked area

Alt M - Moves marked area to current cursor position

Alt C - Copies marked area to current cursor position

Remember these quick “hot” keys:

F2 - Quick saves current program if it has been given a name

F3 - Quick load of different program

Hot Keys

There are a number of special “hot” keys that can be pressed virtually anytime.

This is a list of them:

F1 - Get help

CtrlF1 - Get G/M code help

F2 - Quick save CNC program

F3 - Quick load CNC program

F5 - Get information

F9 - Check/run CNC programs

F10 - Get main menu

In addition to the function keys there are the following key combinations:

Alt-E - Returns to the edit

Alt-E - Quits the Fanuc system

CNC Instructions

There are a number of different types of CNC program instructions. Select one of them from

the menu to get more information. Note that G and M codes can be prefixed with an N block

number.

Example

G codes

M codes

Directives

Tutorials

Comments

Example

EXAMPLE PROGRAM

[BILLET X30 Z60 - define material size

O1234 - program number

G21 G28 U0 W0 - metric, travels to machine datum

G99 G97 S2000 - mm/rev, sp speed set at 2000rpm

M06 T0101 - change tool to No 1

M03 G00 X30 Z2 - spindle on, rapid positioning

G71 U2 R0.5 - roughing cycle, this code is a

G71 P1 Q2 U1 W0.2 F0.15 - two line instruction

N1 G01 X12 F0.1 - Between N1 and N2 the finished

Z-20 - Profile is defined. The depth

G03 X20 Z-24 R4 - of cut is 2mm, U and W defines

G01 Z-30 - the amount of stock left on

N2 X30 - end of profile

G70 P1 Q2 - finishing cycle

G28 U0 W0 - returns to machine datum

M30 - end of program

The above example turns a shaft down to 26mm diameter using tool 1g and a spindle

speed of 2000 rpm.

G codes

G codes are instructions describing machine tool movement.

A G code quite often requires other information, for example a feed rate or axes co-

ordinates. The Fanuc machine has a large selection of G codes, and help can be obtained

for them all.

Press Page-down for a list of G codes.

The G codes of listed in Appendix A.

M codes

M codes are instructions describing auxiliary machine functions.

An M code quite often requires other information, for example a spindle speed or tool

number. The machine has a selection of M codes, and help can be obtained for them all.

PAGE gives part two.

You may select an item with the arrow keys and get help with it by pressing EOB.

The M codes of listed in Appendix B

Directives

Billet Definition

This directive allows the billet in the simulation window to be given a size.

The billet definition should be placed at the start of a program, after the measure has

optionally been set.

Example: G21

Sets the measure to metric.

[BILLET X30.0 Z50.0

Defines the billet as 50mm long with a diameter of 30mm (if diameter programming is

active).

Clear Directive

This clears the tutorial messages window.

Example: [CLEAR

Step Directive

This directive switches over to single step execution on-screen and when linked to the fanuc

machine.

Example: [STEP

Single Step Off Directive

This directive switches off single step execution on-screen and when linked to the fanuc

machine.

Example: [NOSTEP

Enable Simulation

This directive allows the operations to be simulated.

Example: [SHOW

Disable Simulation

This directive stops the operations being simulated.

Example: [NOSHOW

Subprogram Directive

This directive allows a program with a non numeric name to be called as a subprogram.

Example: [SUBPROGRAM 2 FRED

M98 P2

Tutorials

Interactive lessons can be developed through the tutorials facility. Messages and Questions

can be embedded within the CNC program.

! - Displays message without stopping.

? - Displays message but stops for key press.

TUTORIAL MESSAGE:

Tutorial message instructions begin with the “!” exclamation mark which is followed by some

text.

When the CNC program is executed your text will appear in the “tutorial” window at the

bottom of the screen.

Example: Using tool 2 ….

Tutorial pause instructions begin with the “?” question mark which is followed by

some text. When the CNC program is executed your text will appear in the “tutorial”

window at the bottom f the screen. You will then be prompted to press RETURN to

continue.

Example: Check the position

Comments

Comments begin with the “(“open bracket character. They can be used to annotate a

program, and are ignored when it is executed.

Example: (Entering circular cycle)

Screen Display

The top line of the screen gives the following information (left to right):

Title and version of the software.

Global units of measure (metric/imperial)

Current CNC program name.

The bottom line lists a set of key which can currently be used. It also shows the shift key

states.

Press F2…..

Load CNC Program

Key is the name of a CNC program you wish to load.

To get a list of available programs blank out the prompt box and then press RETURN.A

menu of the programs will then appear and you can select one with the arrow keys.

Press RETURN to confirm your choice of program.

If the program currently in memory has not been saved, then you will be asked if you want to

save it before loading the new program. Answer yes or no, or press ESC to stop loading all

together.

Save CNC Program

If the program in memory has no name or you have selected “save as” on the CNC files

menu, you will be asked to give a name for it. Key this in, or ask for a list names.

New CNC Program

You have selected the “new program” option before saving the one currently in memory.

You must now decide whether or not you want to save the old program before beginning a

new one.

Simulation

Check syntax

Run program

Dry run

Set tooling

Set view

3D view

Post process

Check Syntax:

Checks through the whole program for errors in the way it is written.

Run program:

Starts on-screen simulation.

Dry run:

Runs the program without an on-screen display. This provides fast over travel checking.

Set datum:

Allows a zero point to be set before on-screen simulation.

Set tooling:

Allows a tool shape to be allocated to a tool number.

Set view:

Use this facility to indicate the view you require for the on-screen simulation.

3D screen:

Produce a 3D view of the billet.

To set 3D view

PGUP swaps between front and rear views.

PGDN redraws the image.

The arrow keys select the slice to start displaying from.

The SPACE BAR changes the distance the arrow keys move.

Press ESC to leave the 3D view.

Post process:

Produces a program for a different machine.

Press F10…

Main menu

Edit only

Edit and simulate

Simulate only

Machine link

CNC files

Print

Remove link

Settings

Utilities

Quit

Edit only:

Changes to display of just the editor only (no simulation).

Edit and simulate:

Changes to simultaneous display of both the editor and the simulation.

Simulate only:

Changes to display of just the simulation only (no editor).

Machine link:

Programs can be received from or transmitted to the Fanuc controller. It is advisable to

simulate program operation before transmitting to the controller.

CNC files:

Gives access to a sub-menu of disc operations you can load and save, change directory and

delete files.

Load:

Loads CNC programs. Also allows another program to be merged with the

current one.

New:

Destroys the current program and so allows a new one to be keyed in.

Save:

Saves the CNC program in the same file that it was loaded from.

Save as:

Saves the CNC program after prompting you to key in a new name for it.

Change dir:

Allows you to change to a different default directory on disc.

Print:

Prints your CNC program on paper in various formats.

Remote link:

Links to additional external devices, such as tape punch machines ,for CNC program

transfer.

Settings:

Allows you to customize this software.

Utilities:

Lets you run other software packages that are installed on your computer.

Quit:

Leaves the Fanuc programming system and returns you to DOS.

Result:

Thus the study exercise on denford machine tool - fanuc (lathe and milling) of CNC

machine were studied.

SIMPLE FACING

EX. NO: 5

DATE:

AIM:

To simulate and face the work piece to the required dimension using CNC lathe

PROCEDURE:

1. Switch ON the machine control first and ON the computer.

2. Press F10 key and click the CNC files.

3. Click new, then type the program and save it.

4. Check the program for syntax.

5. Go to machine control and press HOME KEY.

6. Press the X and Z axis key .

7. Set the tool offset for both X and Z direction.

8. Switch on the spindle.

9. Press F9 key and execute the CNC program.

PROGRAM:

[BILLET X20 Z60

G21 G40 G98

G28 U0 W0

M06 T01

M03 S1200

! SIMPLE FACING

G00 X21 Z1

G94 X0 Z-1 F1.5

Z-2

Z-3

Z-4

Z-5

G28 U0 W0

M05

M30

RESULT:

Thus the simulation and facing were done on work piece by the CNC lathe to the

required dimension.

STEP TURNING

EX. NO: 6

DATE:

AIM:

To simulate and turn the work piece to the required dimension using CNC lathe

PROCEDURE:










PROGRAM:

[BILLET X20 Z55

G21 G40 G98

G28 U0 W0

M06 T1

G97 M03 S1200

! SIMPLE TURNING

G00 X21 Z1

G00 X19

G01 Z-30

G01 X20

G00 Z1

G00 X18

G01 Z-30

G01 X20

G00 Z1

G00 X17

G01 Z-30

G01 X20

G00 Z1

G00 X16

G01 Z-30

G01 X20

G00 Z1

G00 X15

G01 Z-30

G01 X20

G00 Z1

G00 X14

G01 Z-30

G01 X20

G00 Z1

G28 U0 W0

M05

M30

RESULT:

Thus the simulation and turning were done on work piece by the CNC lathe to the

required dimension.

STRAIGHT TURNING AND TAPER TURNING

EX. NO: 7

DATE:

AIM:

To simulate and to make the taper turning on the work piece to the required

dimension using CNC lathe

PROCEDURE:










PROGRAM:

[BILLET X25 Z60

G21 G40 G98

G28 U0 W0

M06 T1

M03 S1200

!TURNING 4

G00 X26 Z1

G19 X23 Z-30 F1.5

X21

X20

!TAPER TURNING 5

G00 X26 Z-30

G90 X25 Z-35 R0 F1.5

X25 R-1.5

X25 R-2.5

!TURNING 2

G00 X21 Z1

G90 X18 Z-15 F1.5

X16

X14

X12

X10

!TAPERTURNING 3

G00 X21 Z-15

G90 X20 Z-20 R0 F1.5

X20 R-2.5

X20 R-5.0

!END ARC TURNING

G00 X26 Z01

G00 X0 Z1

Z0

G03 X10 Z-5 R5

G28 U0 W0

M05

M30

RESULT:

Thus the simulation and taper turning were done on work piece by the CNC lathe to

the required dimension.

PROFILE TURNING

EX. NO: 8

DATE:

AIM:

To simulate and to make the profile turning on the work piece to the required

dimension using CNC lathe

PROCEDURE:










PROGRAM:

[BILLET X40 Z52

G21 G40 G98

G28 U0 W0

M06 T0101

M03 S1200

!TURNING 6

G00 X41 Z1

G90 X39 Z-42 F1.5

X37

X35

!TAPER TURNING 7

G00 X41 Z-42

G90 X40 Z-47 R0 F1.5

X40 R-1.0

X40 R-2.0

X40 R-2.5

!TURNING 4

G00 X36 Z1

G90 X34 Z-30 F1.5

X32

X30

X28

X25

!ARC 5

G00 X36 Z-37

G02 X25 Z-30 R7 F1.5

!TURNING 2

G00 X26 Z1

G90 X23 Z-15 F1.5

X20

X17

X14

X12

X10

!ARC3

G00 X26 Z-25

G03 X10 Z-15 R10 F1.5

!TAPER TURNING 1

G00 X11 Z1

G90 X10 Z-10 R0 F1.5

X10 R-1.0

X10 R-1.5

X10 R-1.5

X10 R-2.5

G28 U0 W0

M05

M30

RESULT:

Thus the simulation and the profile turning were done on work piece by the CNC

lathe to the required dimension.

TURNING, CHAMFERING, GROOVING AND THREAD CUTTING

EX. NO: 9

DATE:

AIM:

To simulate and to make turning, chamfering, grooving and thread cutting on the

work piece to the required dimension using CNC lathe.

PROCEDURE:










PROGRAM:

[BILLET X20 Z63

G21 G40 G98

G28 U0 W0

M06 T1

M03 S1500

!TURNING 1

G00 X21 Z1

G90 X18 Z-43 F1.5

X17

X16

!TURNING 2

G90 X14 Z-23 F1.5

X12

!RADIUS 3

G00 X20 Z-43

G00 X16

G03 X20 Z-53 R20 F1.5

G00 X21 Z1

!RADIUS 4

G00 X12 Z-23

G02 X16 Z-33 R20 F1.5

G0 X21 Z1

!CHAMFERING 5

G00 X8 Z1

G01 X12 Z-2 F50

G28 U0 W0

!GROOVING 6

M06 T3

G0 X13 Z-23

G81 X11

X10

X8

G28 U0 W0

!THREAD CUTTING

M06 T5

G00 X12 Z-2

G92 X12 Z-20 F1.25

X11

X10.47

G28 U0 W0

M05

M30

RESULT:

Thus the simulation turning, chamfering, grooving and thread cutting were done on

work piece by the CNC lathe to the required dimension.

CIRCULAR INTERPOLATION

EX. NO: 10

DATE:

AIM:

To simulate and to make the profile on the work piece (circular interpolation) to the

required dimension using CNC milling machine.

PROCEDURE:










PROGRAM:

[BILLET X100 Y100 Z10

[TOOLDEF T1 D6

[EDGEMOVE X0 Y0

G21 G94

G91 G28 X0 Y0 Z0

G90 M06 T0101

M03 S1500

G00 X30 Y15 Z5

G01 X30 Y15 Z-1 F50

G03 X15 Y30 R15

G01 X15 Y75

G03 X30 Y90 R15

G01 X70 Y90

G02 X90 Y75 R15

G01 X90 Y30

G03 X75 Y15 R15

G01 X30 Y15

G0 X30 Y15 Z5

! CIRCULAR POCKETING

G90 X50 Y50 Z5

G170 R0.5 P0 Q1 X50 Y50 Z-3 I0 J0 K15

G171 P50 S1200 R50 F50 B1800 J60

G91 G28 X0 Y0 Z0

M05

M30

RESULT:

Thus the simulation and the profile (circular interpolation) were done on the work

piece by the CNC milling machine to the required dimension.

END MILLING

EX. NO: 11

DATE:

AIM:

To simulate and to make the profile on the work piece (end milling) to the required

dimension using CNC milling machine.

PROCEDURE:










PROGRAM:


[TOOLDEF T1 D6

[EDGEMOVE X0 Y0

G21 G94

G91 G28 X0 Y0 Z0

G90 M06 T0101

M03 S1500

G00 X20 Y10 Z5

G01 X20 Y10 Z-5

G01 X80 Y10

G01 X90 Y20

G01 X90 Y70

G02 X70 Y90 R20

G01 X20 Y90

G01 X20 Y60

G01 X10 Y60

G01 X10 Y20

G03 X20 Y10 R10

G00 Z5

G91 G28 X0 Y0 Z0

M05

M30

RESULT:

Thus the simulation and the profile (end milling) were done on the work piece by the

CNC milling machine to the required dimension.

PECK DRILLING

EX. NO: 12

DATE:

AIM:

To simulate and to make the profile on the work piece (peck drilling) to the required


PROCEDURE:










PROGRAM:


[TOOLDEF T1 D16

[EDGEMOVE X0 Y0

G21 G98

G91 G28 X0 Y0 Z0

G90 M06 T1

M03 S1500

G90 X0 Y0 Z1

! HOLE A

G00 X25 Y25 Z5

G83 X25 Y25 Z-18 R0 Q3 F1.5

G00 X25 Y25 Z5

! HOLE B

G00 X25 Y75 Z5

G83 X25 Y75 Z-18 R0 Q3 F1.5

G00 X25 Y75 Z5

! HOLE C

G00 X75 Y75 Z5

G83 X75 Y75 Z-18 R0 Q3 F1.5

G00 X75 Y75 Z5

! HOLE D

G00 X75 Y25 Z5

G83 X75 Y25 Z-18 R0 Q3 F1.5

G00 X75 Y25 Z5

G00 X0 Y0

G28 U0 W0

M05

M30

RESULT:

Thus the simulation and the profile (peck drilling) were done on the work piece by the


IRREGULAR MILLING

EX. NO: 13

DATE:

AIM:

To simulate and to make the profile on the work piece (irregular milling) to the

required dimension using CNC milling machine.

PROCEDURE:










PROGRAM:

[BILLET X80 Y80 Z10

[TOOLDEF T1 D6

[EDGE MOVE X0 Y0

G21 G94

G91 G28 X0 Y0 Z0

G90 M06 T0101

M03 S150

G00 X10 Y10 Z6

G01 Z-1 F50

G03 X70 Y10 R100

G03 X70 Y70 R100

G03 X10 Y70 R100

G03 X10 Y10 R100

G02 X70 Y10 R30

G02 X70 Y70 R30

G02 X10 Y70 R30

G02 X10 Y10 R30

G00 Z6

G91 G28 X0 Y0 Z0

M05

M30

RESULT:

Thus the simulation and the profile (irregular milling) were done on the work piece by

the CNC milling machine to the required dimension.

MIRRORING

EX. NO: 14

DATE:

AIM:

To simulate and to make the profile on the work piece (mirroring) to the required


PROCEDURE:










PROGRAM:


[TOOLDEF T1 D6

[EDGE MOVE X-50 Y-50

G21 G40

G94

G91 G28 Z0

G28 X0 Y0

M06 T01

M03 S2000

G90 G00 X0 Y0 Z5

M98 P1234

M70

M98 P1234

M80

M71

M98 P1234

M81

M70

M71

M98 P1234

G91 G28 X0 Y0 Z0

M05

M30

SUB PROGRAM:

[SAVED AS THE FILE NAME; 1234 SEPARATELY IN THE WORKING DIRECTORY]

G90

G00 X10 Y10 Z5

G01 Z-1.0 F50

G01 X10 Y40

G01 X20 Y40

G01 X20 Y20

G01 X40 Y20

G01 X40 Y10

G01 X10 Y10

G01 X0 Y0 Z5

M99

RESULT:

Thus the simulation and the profile (mirroring) were done on the work piece by the


MULTIPLE TURNING OPERATIONS USING EDGECAM

EX. NO: 15

DATE:

AIM:

To Generate the CNC part program for the component as shown in figure and

simulate the tool path using EDGECAM

MINIMUM SYSTEM CONFIGURATION:

Software : EDGECAM

Operating system : Windows 2000

Processor : Pentium IV

Speed : 1.3 GHz

Ram : 256MB

PROCEDURE:

1. Start Part Modeler. You will be working in the new 'Untitled Model' that automatically

opens.

2. Click Planar Construction menu ► Shapes ► Rectangle.

3. The cursor changes to, and in the bottom left of the screen a message appears

prompting you to 'Indicate First Corner of Rectangle '.

4. Move the cursor toward the marker at the centre of the graphics window until it

'snaps', as shown on the right. Then perform a left mouse click. Snapping means that

you don't have to exactly place the cursor. For example near a line end your click

may be automatically placed actually at the line end. The cursor changes to indicate

this and you will see in a later step that this is controlled by the Locate toolbar.

5. The marker shows the Construction Plane origin, which is where X, Y and Z = 0. You

are now following the prompt to 'Indicate 2nd corner of rectangle....'.

6. As you move the cursor this drags out the 2nd corner, and the Rectangle

Width/Height dialog dynamically indicates the current size.

7. With the help of part modeler option, create the whole profile as per requirement.

8. Save the part i.e., file> save… Now start the new session of EDGECAM, and follow

the given procedure, Right-click on any menu.

9. In the shortcut menu that appears click Profiles ► Turn Profile ► default. Config.

10. Operations > zx environment,

11. Solids> align body for Turning > select any surface > and set the CPL, Geometry >

stock/fixture > and set as per the requirement ,

12. Solids > feature finder > Turn > ok, Enter the Manufacturing mode by using ctrl+M,

13. On the Operations toolbar, click Straight Turn/Face Operation.

14. The status bar (at the bottom left of the window) prompts you to 'Digitise start point'

15. Click the point just clear of the right corner of the billet

16. On the Operations toolbar, click Turning Operation

17. Right-click to accept the default starts point on the profile.

18. Right-click to accept the default starts point of the cycle. For the outer billet, select

the white profile at the top.

19. The dialog for the Turning Operation is now displayed,

20. On the Main toolbar, (see location) click Simulate Machining.

21. On the Main toolbar, click Generate Code.

22. Enter a CNC Name of your choice and click OK.

MODEL:

RESULT:

Thus CNC part program for the component as shown in figure is generated as well

as simulated using EDGECAM

THREADING AND GROOVING OPERATIONS USING EDGECAM

EX. NO: 16

DATE:

AIM:




Software : EDGECAM



Speed : 1.3 GHz

Ram : 256MB

PROCEDURE:

1. Start Part Modeler. You will be working in the new 'Untitled Model' that

automatically opens. Click Planar Construction menu ► Shapes ► Rectangle.

2. The cursor changes to, and in the bottom left of the screen a message appears

prompting you to 'Indicate First Corner of Rectangle '.

3. Move the cursor toward the marker at the centre of the graphics window until it

'snaps', as shown on the right. Then perform a left mouse click. Snapping means

that you don't have to exactly place the cursor. For example near a line end your

click may be automatically placed actually at the line end. The cursor changes to

indicate this and you will see in a later step that this is controlled by the Locate

toolbar.

4. The marker shows the Construction Plane origin, which is where X, Y and Z = 0.

You are now following the prompt to 'Indicate 2nd corner of rectangle....’

5. As you move the cursor this drags out the 2nd corner, and the Rectangle

Width/Height dialog dynamically indicates the current size.

6. With the help of part modeler option, create the whole profile as per requirement,

Save the part i.e., file> save… Now start the new session of EDGECAM, and follow

the given procedure, Right-click on any menu.

7. In the shortcut menu that appears click Profiles ► Turn Profile ► default. Config.

8. Operations > zx environment,

9. Solids> align body for Turning > select any surface > and set the CPL, Geometry >

stock/fixture > and set as per the requirement ,

10. Solids > feature finder > Turn > ok,

11. Enter the Manufacturing mode by using ctrl+M,

12. On the Operations toolbar, click Straight Turn/Face Operation. The status bar (at

the bottom left of the window) prompts you to ' Digitise start point' click the

point just clear of the right corner of the billet

13. On the Operations toolbar, click Turning Operation Right-click to accept the

default start point on the profile. Right-click to accept the default starts point of the

cycle.

14. For the outer billet, select the white profile at the top.

15. The dialog for the Turning Operation is now displayed, On the Main toolbar; (see

location) click Simulate Machining.



MODEL:

RESULT:



PROFILE MILLING OPERATIONS USING EDGECAM

EX. NO: 17

DATE:

AIM:




Software : EDGECAM



Speed : 1.3 GHz

Ram : 256MB

PROCEDURE:

1. On the File menu, click Open.

2. In the Open dialog, navigate to, and open the Corresponding file,

3. In the top right corner of the Edge cam window, click Switch to Manufacture Mode,

In this part, the machining sequence has already been started. Edge cam may ask

you to confirm settings for the code generator. If so, click Cancel.

4. Right-click on any menu, click Profiles ► Mill Profile ► default. config.

5. On the Options menu, click Select Technology.

6. To select the Component Material, click Browse. (You leave the default setting for

Technology Adjustment unchanged.)

7. In the dialog that opens scroll down the list in the All tab, then click Steel - 150 HB to

select it, then click Select. > Click OK to close the Select Technology dialog > You

see a notification dialog about speeds and feeds - click OK in this dialog.

8. On the Operations toolbar click Face Mill Operation. > The status bar prompts you

to 'Select closed profiles to machine'. Click on the white part outline to select it, then

right-click to terminate the selection > the face mill operation dialog now now appear,

9. In the General tab set Mill Type to Climb, Angle to 0, %Stepover to 90, Lead

Length to 0, Lead Radius to 0 and Stock Offset to 0.5.

10. Click the Tooling tab and set Feedrate to 500, Plunge Feed to 200, Speed to 150,

and Diameter to 1.25. All other settings can be left blank.

11. Click the Depth tab and set Clearance to 0.25, Level to 0.04 and Depth to -0.04. All

other settings can be left blank. > Click OK. > The Face Mill operation is now

created.

12. On the Operations toolbar, click Roughing Operation. > The status bar prompts

you to 'Digitise Geometry to machine'. Rest the cursor on the cyan profile to highlight

it, then click. > Right-click to finish the geometry selection



MODEL:

RESULT:



PROFILE MILLING AND DRILLING OPERATIONS USING EDGECAM

EX. NO: 18

DATE:

AIM:




Software : EDGECAM



Speed : 1.3 GHz

Ram : 256MB

PROCEDURE:

1. On the File menu, click Open.

2. In the Open dialog, navigate to, and open the Corresponding file,

3. In the top right corner of the Edge cam window, click Switch to Manufacture Mode,

In this part, the machining sequence has already been started. Edge cam may ask

you to confirm settings for the code generator. If so, click Cancel.

4. Right-click on any menu, click Profiles ► Mill Profile ► default. Config.

5. On the Options menu, click Select Technology.

6. To select the Component Material, click Browse. (You leave the default setting for

Technology Adjustment unchanged.)

7. In the dialog that opens scroll down the list in the All tab, then click Steel - 150 HB to

select it, then click Select. > Click OK to close the Select Technology dialog > you

see a notification dialog about speeds and feeds - click OK in this dialog.

8. On the Operations toolbar click Face Mill Operation. > The status bar prompts you

to 'Select closed profiles to machine'. Click on the white part outline to select it, then

right-click to terminate the selection > the face mill operation dialog now now appear,

9. In the General tab set Mill Type to Climb, Angle to 0, %Stepover to 90, Lead

Length to 0, Lead Radius to 0 and Stock Offset to 0.5.

10. Click the Tooling tab and set Feedrate to 500, Plunge Feed to 200, Speed to 150,

and Diameter to 1.25. All other settings can be left blank.

11. Click the Depth tab and set Clearance to 0.25, Level to 0.04 and Depth to -0.04. All

other settings can be left blank. > Click OK. > The Face Mill operation is now

created.

12. On the Operations toolbar, click Roughing Operation. > The status bar prompts

you to 'Digitise Geometry to machine'. Rest the cursor on the cyan profile to highlight

it, then click. > Right-click to finish the geometry selection

13. On the Main toobar, click Generate Code.


MODEL:

RESULT:


as simulated using EDGECAM.

PREPARED AND PUBLISHED BY:

Mr.M.Mohan Prasad M.E., (MBA).

Assistant Professor,

Department of Mechanical Engineering,

P.A.College of Engineering and Technology,

Pollachi, Coimbatore - 642 002.

Email: [email protected]

CAM Lab - Manual

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