Introduction To Computer Aided Manufacturing

INTRODUCTION TO COMPUTER AIDED MANUFACTURING
INTRODUCTION TO COMPUTER
AIDED MANUFACTURING
1. WHAT IS COMPUTER AIDED MANUFACTURING?
Most machines need control systems to operate. There are many kinds of control systems, for
example, manual control, automatic control, computer control or remote control. For the
convenience of mass production, machines need to repeat precise, speedy and automatic actions
continuously. These machines may use mechanical, pneumatic and electrical systems to control.
However, some fixed procedures, changing procedures or tools may need a lot of time to restore
the whole system (Fig. 1).
Fig. 1 Industrial mass production facility
Fig. 2 CNC machine
by Mr. TCHASSI MICHEL 1

As technology advances, electronic and computer technologies have been applied to a lot of
production machines to reduce the production time and increase both the quality and efficiency.
So, modern factories usually use numerical control machines, simply called NC machines. And
an NC machine that comes along with a computer is called a computer control numerical
machine, simply CNC machine (Fig. 2). A CNC machine uses digital information to control the
movements of tools and parts, for example, the spinning speed, the cutting speed, the moving
direction of tools etc. So, we can change quickly the production procedures simply by modifying
the information or program in the computer.
Fig. 3 (a) Computer aided design
(b) Computer aided manufacturing

The production method that requires a computer to control the machines is called a computer
aided manufacturing, simply called CAM. CAM is closely related to the computer-aided design
(CAD) because the output information about the products from the CAD can assist the
composing of production program. Tests and productions can start immediately. This simplifies
the procedures from the designing to manufacturing of the product (Fig. 3).
(a) THE MERITS OF COMPUTER NUMERICAL CONTROLLED

(CNC) MACHINE
There are many advantages of a CNC machine:
(i) The computer can design the best tool path, spinning and cutting speeds of tools
according to the information of the product. This can help decrease the cost and time.
(ii) CNC machines usually have automatic changing tools function.
(iii) CNC machines can control precisely the tools movement in any axis, so it can cut
some complicated workpiece efficiently.
(iv) With the use of various input devices and the memories of computer, a CNC
machine can download and modify program efficiently, so the production procedures
can be made quickly.
(v) In operating the CNC machine, manual adjustment is not needed. Therefore, the
CNC machine can run at a high speed, and it requires less skillful workers to reduce
the labour cost.
(vi) CNC machine uses various designs to produce feedback, and so it can keep its
high
reliability and quality, this can help decrease the number of disqualified product and
the
cost of inspection.
(b) THE RESTRICTIONS OF CNC MACHINE
But, there are some restrictions of CNC machine:
(i) The cost of the machine is so high that some small factories may not be able to
afford.
(ii) Operators need to be trained to compose computer control program.

(iii) The control system is complicated and sophisticated; therefore, the maintenance
cost is high.
2. THE INDUSTRIAL APPLICATIONS OF CNC MACHINE
a) THE DESIGN OF CNC MACHINE
CNC machine needs new designs to suit the needs of automation. Firstly, CNC
machine needs a precise path measuring system, so that the computer can detect
the position of tools and workpieces automatically (Fig. 4a). There are many
designs of path measuring system, for example, using the photoelectric detecting
device to input the electronic signals into the computer directly.
Fig. 4 (a) Path measuring system
(a) Photoelectric detecting device
b) SUPPORTING MACHINERY COMPONENTS
CNC machine needs relatively more supporting machinery components. For

example, a tools clamp, an automatic tools changing system, a tools holding
device and a transfer system, etc, are needed to make the changing of tools
easier. Some machines use a turntable to store the tools allowing the automatic
system to change tools easier. Others use robotic arm to change the tools or
workpiece automatically (Fig. 5).
Fig. 5 (a) CNC machine uses automatic system to change tools
(b) Machine uses robotic arm to install workpiece
c) COORDINATE SYSTEM
CNC machine needs a coordinate system to control the tools. For example,
internationally used ISO R841 standardized format is a common standard. Tools
are needed to cut three dimensional workpieces. That means that the tools will
move in a three-dimensional space. Therefore the coordinate system should have
three perpendicular axes. The axes used are called x-axis, y-axis and z-axis
respectively. Their respective position can be shown by making the thumb, index

finger and middle finger of the right hand perpendicular to each other as shown
Fig. 6a, called the right-hand rule.
Fig. 6 (a) Right-hand rule
(b) Main axis and rotational axis coordinate system
The rotational axis can be set by the main axes, A, B and C representing the rotational
axes that rotate about X, Y and Z axes respectively. Most of the rotational axes take
clockwise as positive value and anti-clockwise as negative value, as shown in Fig. 6b.
Furthermore, U, V and W are usually used to represent the minor axes that are parallel
to the main axes X, Y and Z; P, Q and R are usually used to represent axes that are far
away but parallel to the main axes X, Y and Z, for example, the axes on the workpiece.

d) INTRODUCTION TO VARIOUS KINDS OF CNC MACHINES
There are various kinds of CNC machines, for examples, CNC drilling machine,
CNC lathe, CNC milling machine, etc.
 CNC DRILLING MACHINE
A CNC drilling machine uses holding device to hold the drill, and then control
the rotational speed of the drill, the depth (Z-axis) of the drilling into the
workpiece and its width. The workpiece is usually clamped on the table that can
move on the surface (X and Y-axis). Because drills have different length,
therefore some CNC drilling machines use a program to compensate for the
depth of the drilling (Fig.7). Some CNC machines have an automatic drill change
system.
Fig. 7 Compensate the depth of drilling
 CNC LATHE
Most CNC lathes need to control the X and Z-axis (Fig. 8a), but some of them
need to increase the control of w-axis (Fig. 8b). Besides controlling the linear
path, CNC lathe can also control the rotational speed of the rotational axis,
cutting speed and tools exchange, etc.

Fig. 8 (a) Two axes center lathe
(b) Three axes center lathe
 CNC MILLING MACHINE
CNC milling machine can be divided into two kinds, upright and horizontal, they
usually have continuous path controlling function, and they can control motion
that involved 3, 4, 5 or more axes (Fig. 9). More than that, most CNC milling
machines make use of the computer’s calculation function to find the linear or
curve path between two points automatically. That is why they can do cutting of
very complicated shapes.

 CNC SPOT WELDER
Welding is a process that uses two electrodes to generate electric current to weld
metals. CNC spot welder is commonly used in automobile industry where
several welders are used to form a welding production line.
 CNC LASER CUTTING MACHINE
Laser cutting machines (Fig. 16) use high energy and focused laser to cut
metallic workpiece precisely. CNC laser cutting can use computer program to
control the 2-dimensional movement of a workpiece precisely, and so it can cut
things into complicated shapes
Fig. 16 Laser cutting machine

Fig. 17 Workpiece cut by using laser cutting
 OTHER CNC MACHINES
There are many other functions of CNC machine, for examples, CNC grinding
machine, CNC pipe deformer, CNC hydraulic cutting machine, etc. And because
computer technology is becoming more and more powerful, it is for sure that
more and more CNC machines will be available, for example, many factories
start to use robotic arms to do many processes.

3. THE OPERATION OF CNC MACHINE
a) BASIC OPERATION THEORY
Fig. 19 Simplified operation procedures of CNC machine
Firstly, the engineering drawing according to the design of the workpiece is

prepared. CAD software can be used in this procedure. Then based on the
information in the engineering drawing, the computer numerical controlled
machinery program (CNC machinery program) will be composed. The CNC
machinery
program includes all the geometrical and technical information. The geometrical
information decides the target position of the tools movement, cutting direction
and movement priority, etc. Technical information includes the choice of tools,
the rotational speed of the main axis, the rotating direction, cutting speed, etc.
The CNC machinery program will input the geometrical and technical
information into the digital controllers, while the input devices include paper
tape, magnetic tape, external keyboard, etc. After the digital controller has
processed all the information, the moving path of the tools and the suitable

procedures will be available. Lastly, the digital controller will control the whole
machine and its tools to process the materials into a required workpiece. The
composition of machinery program of the CNC machine usually follows the
internationally
recognized ISO R358 standardized format. But the USA or some other nearby
countries may use a similar US format EIA RS244
b) PROGRAMMING
There are many methods to compose a program by using ISO codes. The most
common one is the ISO standardized word and address format. It divides the whole
program into a number of blocks, and alphabets are used to represent different words
within the blocks. The lengths of the block and word depend on the needs of the
design.
Fig. 21 CNC machinery program
Fig. 21 shows the structure of a CNC machinery program. The program is composed
by blocks. Each block uses different steps to control the order of the work. Each block
contains geometrical processing steps, and some of them may contain mechanical
functions. The blocks will be given numbers in order and they are separated by an end
code of $ sign. Each block is composed by one or more word. Every word is
composed of one identify alphabet and a group of numbers that are responsible for the
motion and exchange functions of the machine. A block can include different
commands, as shown on Table 1. For example, alphabet F represents the feeding rate,
so F200 means the feeding rate is 200 mm/min. The identifying alphabet in the front
of every word is called the address.

The words within blocks are usually composed of addresses and numerical values. An
address is represented by an alphabet (for example: G) with corresponding numerical
values behind it. So every address should appear only once in each block.
Furthermore, care should be taken for the decimal place of the numerical value, like
whether the 0 is in front or behind, and the numerical number unit, etc. The following
are some examples of words ： N20 means sequence no. 20; G00 means the tools
moving rapidly to the appointed position (with given co-ordinates); F60 means the
tools moving with feeding rate of 60 mm per minute; M06 means change of tool, etc.
Words can be classified into codes that represent different function in more detail, for
example, G and M codes. Table 2 and 3 shows some common G and M codes that are
used in CNC machines. Several words form a block. Table 4 lists some blocks in a

program as an example. Several blocks will form a complete CNC machinery

program.
4. APPLICATION SOFTWARE OF CNC MACHINES

A CNC machinery program is composed of simple alphabets and numerical values. It
is hard to understand and will take a long time to calculate and compose. Thus it is
easy to make mistake when programming.
To decrease the workload of programmers, researchers have developed some
computer aided programming software, for example: COMPAC, SPLIT, COMPACT
II, MASTERCAM, etc.
The programmer only needs to make a draft of the working steps and data according to
the engineering drawing, and then uses the application software to input the
procedures. The application software will then analyze the data automatically to
produce the CNC machinery program. Application software have a number of
advantages:
 Usually some easy symbolic language is used to represent geometric and technical
data.
 Can reduce the time required to describe the workpiece and processing procedures.
 Minimize the works like data entry, calculation, etc, so it can reduce the mistakes of
the CNC machinery program.
 Application software can usually be applied to different machines, so programmer

can ignore the different coding of different machines.

 Some application software can even have a simulation program, so as to help the
programmer to check the mistakes and to modify the program. This can reduce the
time and money wasted when something goes wrong.
5. SAFETY MEASURES OF USING CNC MACHINES

For safety reason, we should pay special attention on the followings when using CNC
machines:
1. Choose a suitable controller to make sure that the computer and the controller match
each other.
2. Choose a suitable computer program to control the system.
3. Simulation of cutting should be undergone in the computer control program before

use, making sure that there is no mistake and avoiding damages.
4. Use CNC machinery program required by the manufacturer of the CNC machine.
5. Choose a suitable safety device for the CNC machine, as Fig. 24 shown, for
example:
 A see-through protecting device
 Revolution fluctuation sensing device
 Over-sliding safety restriction
 Feedback from closed-loop encoder
 Electronic locking protection device
Find where the emergency stop button is before operating the CNC machine.
 Make sure the operation of CNC machine is totally stopped before entering the
working area of the CNC machine.
 Use a clean towel to clean the grease on table and board, and use suitable tools
to remove the waste.
 No tools or materials should be put on the top of the machine.
 Avoid hitting the control part of the CNC machine.
 Make sure there are safety arrangements before operating the CNC machine.
 Do not touch any moving parts of the machine.
 Do not leave the machine unattended while the machine is operating.

COORDINATE SYSTEMS AND POINTS

PROGRAMMING ORIGIN OR PROGRAMM REFERENCE ZERO
Obviously it would be difficult to write a CNC program in relation to Machine Coordinates.
The home position is
far away from the table, so values in the CNC program would be large and have no easily
recognized relation to
the part model. To make programming and setting up the CNC easier, a programming
origin is established for each CNC program. . The PRZ is the master reference point on which the
program and the setup are based.
Selecting the PRZ location relative to the part’s geometric
features is among the first critical decisions for planning. The WCS is a point selected by the
CNC programmer on the part, its selection requires careful consideration.
The WCS location must be able to be found by mechanical means such as an edge finder,
coaxial indicator
or part probe.
It must be repeatable: parts must be placed in exactly the same position every time.
It should take into account how the part will be rotated and moved as different sides
of the part are
machined.

Local Reference Points

When writing a program it’s possible to switch from the PRZ to a temporary local reference
zero (LRZ) point that lies at a known distance from the PRZ.
Once the features are machined that relate to it, the LRZ is
canceled to again refer to the PRZ. Local references are used
for a couple reasons.
A feature, or group of features, refers to a reference
other than the PRZ (Fig. 17-28). Many calculations
would be required to write absolute value coordinates
for each cutout referring back to the PRZ for each coordinate

The math required to write coordinates for

this instrument panel’s features could be simplified by using a
temporary local reference for each cutout pattern.
But setting a local reference point, at the

center, then referring to it for that group saves math and
programming time when writing the program without
CAM. Using a CAM system, this step wouldn’t be
needed—it can make all the calculations, one of the
many advantages to computer-assisted programming.
An LRZ can also be used to repeat the entire program

or a part of a program in another location within the
work envelope. The repeat could be on one part as the
instrument cutouts, or we could be machining two of
the same parts in two vises. The second part would
use a local reference, at a given distance from the first

We also use an LRZ on very large parts such as wing

spars, for example, where the master PRZ might be
hundreds of feet away. A temporary point can be
established that’s far more convenient for setup work.
Geometry Points
Geometry points are those you intend to use for position or

motion—a location to be machined. They are the end of a
cut.
Identifying Geometry Points A geometry point occurs at
the junction between any two entities . An entity
is a familiar term for those with CAD training. They are individual straight lines or arcs. Each has a start
and end point
coordinate. Where any two entities join, become tangent, intersect, or cross, there is also a unique
geometry point common to both.
Programming Systems
Two types of programming modes, the incremental system and

the absolute system, are used for CNC. Both systems have
applications in CNC programming, and no system is either right or
wrong all the time. Most controls on machine tools today are
capable of handling either incremental or absolute programming.

ABSOLUTE MODE (G90)

It is a modal function initialized at the starting of the program. All the points are always given
from the programming origin OP. that is In absolute dimensioning
and programming, each point or location on the workpiece is given
as a certain distance from the zero or reference point.
Program to move the machine to these

4 hole locations when using G90 (Abs.)
X 1.0000 Y 1.0000
X 9.0000 Y 1.0000
X 9.0000 Y 9.0000
X 1.0000 Y 9.0000
Incremental mode (G91)

These refer to a coordinate set where each entry represents

the identified point’s distance from the previous point. These
points can be envisioned as jumps from the present location
to the next. Using incremental values often saves math and
time during setups and editing of programs.
Program to move the machine to the same

4 hole locations using G91 (Incr.)
X 1.0000 Y 1.0000
X 8.0000
Y 8.0000
X -8.0000



A programme is the transposition of the machining process in to language understood by the

machine . this language is alphanumeric. Programs are arranged into sets of command lines
(shortened to commands), or command blocks. Whatever you call them, a command is a complete
instruction containing words and/or coordinates for one action. (If the action includes axis movement, it’s
sometimes called a motion
statement. The command might be as short as G00 X1.0, which has one word and one coordinate,
causing a rapid positioning to X1.0. Or the command may contain several words, numbers, and
coordinates longer than one entire screen line.).
REMARKS ON WORDS
A word is the composition of several characters . example X-50 is a word of 4 characters.
A word is formed by the lettering address, the sign and the module
 THE LETTERING ADDRESS
A lettering address may define an axis or a function
 AXIS
 A FUNCTION
A true CNC machining center will allow you to control just about all of its functions in a program. There should
be very little or no operator intervention during a CNC machining cycle.
A program function is any letter of the program beyong thes which define dimensions . they are
necessary for good operation of the numerical control machine. The principal functions are those
starting by the following address: G,F,S,T,M and N
According to their mode of action ,we distinguish three types of functions
The preparrtory functions.

The miscellaneous functions.

The particular functions.
Which will be dicuss the upcoming chapters
Program Structure
A program consists of a number of program blocks which follow a
certain structure, syntax and format rules. Each block consists of a
number of commands. See the figure below:
Command Format
A command consists of address characters (command word) and digital
numbers with characters (e.g. dimension word) or without characters (e.g.
preparatory function character command: G-code). Example: G01 X100
Z-90
Different commands in the program block may have different meaning in
different environments.
Program Block Format

A program block specifies the commands executed by a numerical
control device.
The block format specifies the syntax of the functional words of each
program block. See the figure below:
General Program Structure

A program must include the start symbol and end symbol.
A program is executed based on the input order of the blocks, rather than
the order of block numbers. However, when you write a program, it is
recommended to write block numbers in the ascending order.
Start symbol
The symbol "%" (or "O") must be followed by a number (e.g. % 3256).
The program start symbol should be in a separate line, starting at the first
line and first character of the program.
Program end
M02: End the program
M30: End the program and return to the program head

Single-line command
During G-code programs writing, please be noted that some commands
must be in a separate line. Examples: M30, M02, M99, M6T, CTOS,
STOC, G16, G15, G05.1, G04
N gives an identifying number for each block of information.

It is generally good practice to increment each block number by 5 or 10 to allow additional
blocks to be inserted if future changes are required.

PREPARRTORY FUNCTIONS
They may sometime be refer as G-codes or cycle codes . they prepare the
machine for what is coming up in the current command and possibly in the up
coming command . in many cases, they set mode meaning once a G-code is
instated , it will remain in effect untill the mode changes is change or cancel
Modal
There are two kinds of G-codes based on their validity:
- Non-Modal G-code: valid only when the G-code is specified,

invalid when not specified.
- Modal G-code: saved in the CNC system when it is executed once,

and valid until other codes of the same group is executed
Below is the list of some few mostly used G-codes



AUXILIARY FUNCTION OR MISCELLANEOUS FUNCTION (M)

Codes that begin with M are called miscellaneous words. They control machine auxiliary
options like coolant and spindle direction. Only one M-‐code can appear in each block of
code.
The table below lists the most common M codes and their meaning.
Auxiliary function commands consist of the address character "M" and digital numbers. It is used to
control the motion of the programs, various auxiliary switch of the machine, the start and stop of
the spindle, end of the program, etc.
Generally, one program block has only one valid M command. In this system, up to four M
commands can be specified in one block (M commands in the same group cannot be specified in the
same line).
The M commands (M00, M01, M02, M30, and M99) must be in a separate line. In other words, the
program line which contains any of the M commands mentioned above can contain only one M
command, and cannot have other commands such as G commands or T commands. The relationship
between the M commands and their functions depends on the specific settings of the machine
manufacturer.
Modal
The M functions include non-modal and modal functions:
- Non-modal M function (valid only in the current block)
- Modal M function (continuously valid)
Modal Group
Modal M commands are grouped according to different functions. Once the defined modal M
command has been executed, it remains valid until it is canceled by other modal M commands in
the same group.
The Modal M function group contains a default function which is the initial function when the
system is powered on.
Pre- and Post- M functions
The M function can also be divided into pre-M function and post-M function:
- Pre-M function
Executed before the axis motion specified by the program block.
- Post-M function
Executed after the axis motion specified by the program block.

M02 End program

M02 is created in the last program block of the main program.
When the CNC system executes the M02 command, all the spindle, feed,
and coolant functions are stopped and the machining is ended.
After the program is ended by M02, you need to recall the program or

press the Restart key under the auto machining sub menu, and press the
Start button on the control panel if you want to re-execute the program.
M02 indicates the non-modal post-M function.
Spindle Control M03, M04, M05

The M03 command starts and rotates the spindle in a clockwise direction
(from the positive direction toward the negative direction of the Z axis)
at the speed specified in the program.
The M04 command starts and rotates the spindle in a counter clockwise
direction at the speed specified in the program.
The M05 command stops the spindle rotation.
The M03 and M04 are modal pre-M functions. M05 is a modal post-M
function, which is the default function.
M03, M04, M05 can be canceled by each other.
M06 Tool Change

M06 is used to call a tool that will be installed on the spindle from the
machining center. The tool will be automatically installed on the spindle
When executing this command. Example: M06 T01 can be used to install
the 01 tool on the spindle.
M06 indicates a non-modal post-M function.
For the machines with armless type ATC, the tool change process is as
follows (e.g. to change the tool 15 on the spindle to tool 01, execute M06
T01.):
1. Move the spindle quickly to the fixed tool change position which
has been defined by the commissioning personnel.
2. Directionally rotate the spindle.
3. Rotate the tool magazine to the position (the position of the tool 15
in Group 0).

4. The cylinder drives the tool magazine, and chucks the tool on the
spindle.
5. The cylinder releases the tool on the spindle, and blows to clean the
spindle.
6. The spindle moves upward, and moves away completely from the
tool.
7. The tool magazine rotates to the tool position of tool 01(the tool
number of Group 0 in the tool magazine changes to 01).
8. The spindle moves downward, and catches the tool.
9. The cylinder on the spindle clamps the tool.
10. The tool magazine returns to the original position.
11. Release the orientation of the spindle.

Coolant Control M08 , M09
M08 is used to enable the coolant control.
M09 is used to disable the coolant control.
M08 is a modal , M09 is a modal .
PATUCULAR FUNCTION
S Commands
The S command is used to control the spindle rotation speed. The
number that follows S indicates the spindle speed in revolution per
minute (r/min).
The S command is a modal command, and the S function is valid only
when the spindle speed is adjustable.
T Commands

T commands are used for tool selection. The value that follows T
indicates the selected tool number. The relationship between T
commands and the tool is defined by the machine manufacturer.
Milling System
machining center to input a code signal or a strobe signal into the
machine, thereby controlling the rotation of the tool magazine to the
selected tool, and then wait until the completion of the tool change with
the M06 command. For armless type ATC, the M06 and T commands
must be written in the same block. During tool change, the tool number
(e.g. 15) of Group 0 must be the position of the tool clamped on the
spindle in the tool magazine. When you change the tool to another, you
need to firstly return the tool to the corresponding tool position in the
tool magazine (that is No. 15). Then there should be no tool in the
position of No.15, otherwise a collision may occur. The tools in the tool
magazine are automatically managed by the system, and cannot be
modified. After the machine starts, tool position(e.g. No. 15) facing to
the spindle must be the same as tool number of Group 0 in the tool
magazine, and there should be no tool in the corresponding tool position
(e.g. No. 15).
Therefore, when installing tools to the tool magazine, it is recommended
to firstly install the tool on the spindle, then in the MDI mode, run the M
and T commands (e.g. M06 T01) to install the tool through the spindle.
They ensure good functioning of the machine. We have:

F-code: used to specify the feed rate
S-code: used to specify the spindle speed
T-code: used to specify the tool identification number associated with the tool to be used in
subsequent operations.
REMARK the above functions can be modal(remain active beyond the block in
which they were programmed)or not modal (active only in the block in which
they were programmed).
 THE SIGN
It gives the direction of the tool displacement
 THE MODULE
It is the numerical character. Example: (M3 3 is the module) ; (S53 53 is the module); (T40 40 is the
module)

Linear and Circular Tool Paths

Tool paths are the movements that we program once we have loaded our tool, turned our spindle
on,
and have approached the part. It is the motion that we generate with a particular tool to generate
the
shapes and sizes we need to complete our parts.
Rapid Position Commands

G00 Rapid Motion Positioning
X Optional X-axis motion command

Y Optional Y-axis motion command
Z Optional Z-axis motion command
This G code is for rapid traverse of the axes of our machine. The human mind thinks point to point,
and as
in the example below, we will move from X-3.0 Y-1.0 to X2.25 Y1.25 and we want to think the
machine
will move strait or “as the crow flies”. The code G00, means “MOVE AS FAST AS POSSIBLE”, which
means
move all axis at full speed. Since all of the axis will move at the same speed, the machine will make a
45
degree move till it achieves the position in one axis (Y in the example below) and finish the other till
the
point is achieved.
G01 LINEAR INTERPOLATION

The linear interpolation command causes the tool to move along a straight-line path, in a cutting mode, at a
programmed feedrate. The feedrate word is also modal, so it stays in effect until it is changed. A feedrate of
F3.5 equals 3.5 inches per minute (IPM), or millimeters per minute

The G01 command is used primarily to machine straight surfaces on your workpiece, such as facing, milling a
straight surface, and milling angular surfaces. G01 can command moves on a single axis, or simultaneous
moves of all axes.
The G01 end point location depends on the programming mode in use. If in the absolute mode (G90), the end
point is taken from program. If programming in the incremental mode (G91), the
end point is measured from the tool’s current position prior to the motion command.
Example 1
Example 2

Circular Interpolation (G02 and G03) Commands

G02 CW Circular Interpolation Motion
F Feed rate in inches (mm) per minute
I Optional distance along X-axis to center of circle
J Optional distance along Y-axis to center of circle
K Optional distance along Z-axis to center of circle
R Optional radius of circle
X Optional X-axis motion command
Y Optional Y-axis motion command
Z Optional Z-axis motion command
A Optional A-axis motion command
Circular interpolation commands are used to move a tool along a circular arc to the commanded end
position.
Five pieces of information are required for executing a circular interpolation command:

1) Plane selection
2) Arc start position coordinates
3) Rotation direction
4) Arc end position coordinates
5) Arc center coordinates or arc radius.
1 – Plane Selection – The machine is capable of cutting an arc on different axes, basically
meaning which
two ball screws need to turn to achieve the desired arc. If we want a arc cut parallel to the top
of the
table of the machine (using the X & Y ball screws), we use a code called G17 (X&Y Plane
Selection) to do
so. NOTE* G17 is a machine default, and is the most common setting. If we need to cut a arc
along the
left to right of the machine, down towards the table of the machine (using the X & Z ball screws)
then we
use the code G18. If we are going to cut an arc town towards the table along the front to rear of
the
machine (using the Y & Z) then we use G19.
2 – Arc Start Position – This is as simple as the position of the last move prior to the arc.
3 - Arc Direction – This is why we define G02 or G03, Clockwise vs. Counter – Clockwise from
the start
point. This is defined as the way the tool is looking at the arc, not necessarily the way you are
looking at it
on the machine.
4 – Arc End Co-Ordinates – This is where we want the arc to end. We define the end point of
the arc in
either G90 or G91, and we can use up to 3 axis to do so.
5 – Center of Arc Location – I, J, and K method or R method
I,J,K are used to define the distance from our known Start Point of our arc to the center of the
arc. I = the
incremental distance in X, J = the incremental distance in Y, and in the case of G18 and G19, K =
the
incremental distance in Z. All of these values tell the machine our arc “hinges” on a point so far
from the
arc start point.
R method enables the machine to find the location on it’s own. In our arc command line we
define the
end point, then tell the machine to maintain a certain radius between the points. The R method
will work
on arcs from 0 – 359.9999 degrees. If it is a full circle, we use I,J,K

Either system is valid. The R method arrived after machines were smart enough to calculate an
arc.
G02 Circular Interpolation Clockwise Command
The circular interpolation contouring control uses the axis information contained in a block to
move the
tool in a CLOCKWISE arc of a circle up to 360 degrees.
The velocity at which the tool is moved is controlled by the feedrate (F) command.
All circles are defined and machined by programming three pieces of information to the control:
1) START POINT of the arc
2) END POINT of the arc
3) ARC CENTER distance from the start point
The START POINT is defined prior to the G02 line, usually by a G01 linear positioning move.
The END POINT is defined by the “X” and “Y” coordinates within the G02 line when in the
G17 – XY PLANE.
The ARC CENTER is defined in the G02 line by the “I” and “J” values, when in the G17-XY
PLANE, or by a “R” value. Note the above will cut a .500 radius on the part.
To cut a complete circle of 360 degrees, program I, J, or K to define the center of the
circle. You
do not need to specify X, Y, or Z as an ending point. The following line will cut a
complete circle:
G02 I-2.5 (this command will interpolate a 360 degrees, 5.0 diameter circle)
G02 CW Circular Interpolation Using “I”, and “J” for the X & Y Axis
The “I”, “J”, and “K” values are INCREMENTAL distances from where the tool starts cutting the
arc (START
POINT) to the ARC CENTER.
When I, J or K are used to specify the center of the arc, R is not used. Only the I, J or K specific to
the
selected plane (IJ for G17, IK for G18, JK for G19) are allowed. If only one of the I, J K is specified,
the
others are assumed to be zero. The I, J or K is the distance from the starting point to the center

of the
circle. Using I, J, or K is the only way to cut a complete 360 degree arc; in this case, the starting
point is
the same as the ending point and no X, Y, or Z is needed. To cut a complete circle of 360 degrees
(360⁰),
you do not need to specify an ending point X, Y, or Z; just program I, J or K to define the center
of the
circle.
NOTE: This example of G02 circular moves is not using cutter compensation, and so the circular
moves
that are shown here are defined from the center of the cutter around the arc. For 90 degree
corners or
fillets the “I” and “J” values can be defined like you see below.
G02 Circular Interpolation Clockwise Command Using “R”

The letter address “R” can be substituted for the letter addresses “I”, “J”, and/or “K” for various
corners
or fillets, which is more easily defined.
Just as “I”, “J”, and “K” are used to locate the ARC CENTER in relation to the START POINT, “R”
does the
same function with less input.
When R is used to specify the center of the circle, a complete 360 degree arc is not possible.

When
defining an arc less than 360 degrees using the R command, the X, Y, or Z needs to specify an
endpoint
different than the starting point. And R defines the distance from the starting point to the center
of the
circle. With a positive R, the control will generate a radius of 180 degrees or less; to generate a
radius of
over 180 degrees, you need to specify an R command with a negative value.
NOTE: This example of G02 circular moves is not using cutter compensation, and so the circular
moves
that are shown here are defined from the center of the cutter around arc. For 90 degree corners
or fillets
the “R” values can be defined like you see below:
G03 Circular Interpolation Counterclockwise Command

G03 Works exactly the same as G02, all that changes is the direction of the arc (clockwise vs.
counterclockwise)
Interpolation Exercise
Cutter will be a .500 diameter end mill. Start contour from the lower left corner of part and mill
around
outside of part .375 deep. To position around the part, mill around outside of part with tool by

defining
the very center of the cutter.
O0010 (Enter in this program as #10)

G00 G17 G40 G49 G80 G90 G98
G00 G53 Z0
T1 M06 (.500 diameter 4 flute. End Mill)
G90 G54 G00 X______ Y______ S1000 M03
G43 H01 Z.1 M08
G01 Z______ F50.
X______ F10. (feed onto left side of part programming from center of tool)
Y______ (feed up to start point of upper left radius and continue on around to the end)
G0__ X______ Y______ I______ J______ or R______
G0__ X______
G0__ X______ Y______ I______ J______ or R______
G0__ Y______
X______
G0__ X______ Y______ I______ J______ or R______
G0__ Y______
X______
G00 Z1. M09
G00 G53 Z0 M05
G00 G53 Y0
M30
Coordinate System
Select Coordinate Planes (G17, G18, G19)
The coordinate plane selection command G17/G18/G19 is used to select
machining planes during circular interpolation, cutter radius
compensation (M), rotation transformation (M), etc.
Description
G code Plane
G17 XY plane
G18 ZX plane
G19 YZ plane
Attention
G17, G18, and G19 are modal functions, which can be canceled by each
other.
The motion command has nothing to do with the plane selection. For
example, the Z axis moves even the command G17 G01 Z10 is executed.
G70 and G71 INCH AND METRIC UNITS

G70 specifies inch mode. G71 specifies metric mode. Inch mode is initialized.
If you intend to work in the metric mode, all related dimensions must be input in metric. Everything in the
program, from program zero point measurements to tool length and radius offsets to feedrates must be in
millimeters! For this reason, most programmers shy away from using the metric mode for one or two
applications. Unless a great percentage of your drawings are produced with metric dimensions, it is hardly
worth changing over to the metric mode.
If your company intends to use both modes for the various parts you produce, we strongly recommend that
you
include a G70 or G71 at the beginning of all programs to avoid the possibility of being in the wrong mode
when
the program is activated. You will have real problems if you try to run a metric program in the inch mode!
Example commands:
N050 G70 (Selects inch move)
N055 G71 (Selects metric mode)
Cutter Compensation (G41, G42)

As you can see with the above examples, programming our contours can require a certain
amount of
thinking and math to work with our tool diameters. The math isn’t hard, as long as we have
sharp corners
and even sized end mills and even sized parts. When we start running re-grind tooling, have
special angels
or arcs, or any other no-typical variables on our part, programming becomes more difficult.
As time progressed, the machine computer controls became sophisticated enough to self-
compensate for
our tool diameters. We could tell the machine we had a .500 roughing tool and finish with
another tool
that was .375 and still the same program. We just had to tell the machine our tool was of a
different size.
We do this by using a feature called Cutter Compensation, or Cutter Comp. for short. With cutter
comp
we program the contour of our part, tell the machine what side of the profile to keep the tool
on, and the
tool diameter.
Advantages of Cutter Compensation
1) The mathematical computations for determining a tool path are greatly simplified.
2) The part, and not the tool center, is programmed. Therefore, the same program can be used
for a variety of different cutter diameters.
3) The same program path can be used for roughing, as well as finishing cuts, by using different
cutter offsets.
4) Inside, as well as outside, cuts can be performed.
Some Restrictions with Cutter Compensation
1) A cutter compensation command (G41 or G42) must be on the same block with an X and/or
Y linear move when ramping on to the part using cutter compensation.
2) You can only use cutter compensation in the G17 XY plane.
3) Cancel of cutter compensation command (G40) must be on the same block with an X and/or
Y linear move when ramping off the part using cutter compensation.
When activating cutter compensation, use this type of procedure
1) Position our tool at a X & Y location that is off of our part with enough room to allow us to
move from un-compensated to fully compensated, at least ½ our tool diameter.
2) Bring the “Z” axis down without cutter compensation in effect.
3) From our position in (1) above, program a X & Y location that would put us exactly on the
profile that we are trying to cut. Then include a G41 (LH) or a G42 (RH) compensation
command to tell the machine what side of the profile to keep the tool on. Also include the
D number of your tool. This move has to as large or larger than the amount of offset (radius)
that we are compensating for.
When canceling cutter compensation, care must be taken to:
1) Select a clearance point in “X” and/or “Y” axis off the part.
2) DO NOT cancel cutter compensation on any line that is still cutting the part.
3) Cancel of cutter compensation may be a one or two axis move.
4) Cancel of cutter compensation (G40) may need values entered for both “X” and “Y” axis.
This may need to be done to ensure that both axes will position to the location you want or
remain fixed and not move during the cancel (G40) process. This is a programming
technique that may be a programmer’s preference.
5) Linear move equal to or greater than the amount being compensated for (radius of the tool).
The cutter compensation commands are:
1) Cutter Comp Off (G40)
2) Cutter Comp Left (G41)
3) Cutter Comp Right (G42).
G40 Cutter Compensation Cancel
G40 will cancel the G41 or G42 cutter compensation commands. The tool will change from a
compensated position to an uncompensated position. Programming D00 will also cancel cutter
compensation.
G41 Cutter Compensation Left
G41 will select cutter compensation left; that is, the tool is moved to the left of the programmed
path to
compensate for the radius of the tool. A Dnn must also be programmed to select the correct
tool size
from the Tool Offset Register (D01 = Diameter Offset #1, D2 = #2, etc..)
G42 Cutter Compensation Right

G42 will select cutter compensation right; that is, the tool is moved to the right of the
programmed path
to compensate for the size of the tool. A Dnn must also be programmed to select the correct
tool size
from the Tool Offset Register (D01 = Diameter Offset #1, D2 = #2, etc..)
Format
G17 (or G18/G19) G41 (or G42) G00 (or G01) IP_ D_;
Establish Tool Compensation
G17/G18/G19: Define the compensation plane, XY, YZ, ZX plane
respectively
G41/G42: Tool radius compensation is valid. G41: left compensation.
G42: Right compensation.
D: Define the tool radius compensation number.
Cancel Tool Radius Compensation

G40 IP_;
G40: Cancel tool radius compensation (G40, G41, G42 are modal codes,
which can be canceled by each other.)
IP_: The command value of axis movement

DRILLING CYCLE
This command allows the programmer to specify that a hole be drilled to depth in one command. The G81
command makes an excellent command for center drilling and reaming.
Programming words involved with G81:

N - Sequence number
X - X position of hole center
Y - Y position of hole center
Z - Z position at hole bottom (absolute value)
R - Rapid Plane (Z position of tool before the hole is drilled)
F - Feedrate in inches per minute
Here is how the hole will be machined when under the influence of this cycle:
1) Rapid move to X and Y position in the canned cycle command.
2) The tool will rapid in Z to the R-plane (if not already there).
3) The tool will feed into the hole until the hole depth (Z value) is reached.
4) The tool will rapid out of the hole to the initial plane (unless G99 is specified).

EXAMPLE
Conduct drilling of the holes as shown in the figure below:

%3343
N10 G92 X0 Y0 Z80
N15 M03 S600
N20 G98 G81 G91 X20 Y15 G90 R20 Z-3 L2 F200
N30 G00 X0 Y0 Z80
N40 M30
Drilling Cycle with Pause (G82)

Description
This instruction is mainly used for processing sink holes, blind holes, to
improve the hole depth precision. Except for the pause at the hole bottom,
other operations are similar as that of G81. The figure below shows the
operation of G82:
Format

G82 X_ Y_ Z_ R_ P_ F_ L_;
Paramete
Description
r
The absolute position of the hole for absolute
programming (G90), or the distance from the current
XY tool position to the hole for incremental
programming
(G91).
The absolute position of the hole bottom along Z
axis
for absolute programming (G90), or the distance
Z
from
the hole bottom to the point R for incremental
programming (G91).
The absolute position of the point R for absolute
programming (G90), or the distance from the point
R R
to the initial plane for incremental programming
(G91).
The duration that the tool remains at the hole
P bottom.
Unit: millisecond
F Cutting feed speed.
The repeat count (Generally used for multi-hole
L machining to simplify programming. It is optional
when L=1.)
Operation procedure
1. The tool moves rapidly to the point B over the hole center.
2. Move rapidly to the point R, close to the workpiece.
3. Conduct drilling downward at the speed of F, to the point Z at the
hole bottom.
4. Delay P milliseconds with the rotation of the spindle.
5. Move upward rapidly to the point R
Attention
1. The drilling axis must be the Z axis.
2. If the movement amount of Z is zero, the command is not executed.
3. The G82 command data is saved as modal data.
4. Before using the command of G82, use the corresponding M
command to rotate the spindle.
G83 PECK DRILLING CYCLE (DEEP HOLE)

This command allows the programmer to specify a peck drilled hole to depth in one command. This peck cycle
is best used for deep hole machining. As a hole is machined, the chips tend to collect in the flutes of the drill.
G83 pecks the tool the value of Q per pass, then rapids the tool out of the hole to clear the chips.

Here is how the hole will be machined when under the influence of this cycle:
1) Rapid move to X and Y position.
2) The tool will rapid in Z to the R-plane (if not already there).
3) The tool will peck into the hole the amount specified by the “Q” word.
4) The tool will rapid out of the hole to the R-plane (to clear chips).
5) The tool will rapid back into the hole to the peck break distance (see Machine Setup Parameter)
above the previous peck depth.
6) The tool will feed to the incremented peck amount.
7) Steps 3 through 5 will be repeated until the hole depth (commanded by Z) is reached.
8) The tool will rapid out of the hole to the initial plane
Format
G83 X_ Y_ Z_ R_ Q_ K_ F_ L_ P_;
Paramete
Description
r
XY programming (G90), or the distance from the current tool
position to the hole for incremental programming (G91).
The absolute position of the hole bottom for absolute
Z programming (G90), or the distance from the hole bottom
to the point R for incremental programming (G91).
R The absolute position of the point R for absolute

programming (G90), or the distance from the point R to

the initial plane for incremental programming (G91).
The each downward drilling depth (incremental value,
Q
negative).
The distance away from the upper surface of drilled hole
K
(incremental value, positive). K cannot be greater than Q.
The repeat count (Generally used for multi-hole machining
L
to simplify programming. It is optional when L=1.)
The duration that the tool remains at the hole bottom. Unit:
P
millisecond
Tapping Cycle (G84)

Description
on the same principle. In the G84 mode, the tool taps to the hole bottom
with the spindle rotation in the clockwise direction and then goes back
with the spindle rotation in the counter clockwise direction. See the
figure below:
Format
G84 X_ Y_ Z_ R_ Q_ P_ F_ L_H_J_;
Paramete
Description
r
XY tool position to the hole for incremental
programming
(G91).
Z The absolute position of the hole bottom for absolute

programming (G90), or the distance from the hole

bottom to the point R for incremental programming
(G91).
programming (G90), or the distance from the point R
R
to
The amount of each feed during segment tapping.
Q
Leave it blank in the H2 mode.
The duration that the tool remains at the hole
P bottom.
Unit: millisecond.
F Define thread lead.
machining, and therefore X or Y is incremental
L
value. It
is optional when L=1.)
J1: A axis tapping; J2: B axis tapping; J3 C: axis
J
tapping
Boring Cycle (G85)

The command is used to bore the holes which have low requirement for
precision. The operation specified by G85 is as shown below:
Format
G85 X_ Y_ Z_ R_ F_ L_;
Parameter Description
XY The absolute position of the hole for absolute
tool position to the hole for incremental programming

(G91). UW programming is not supported.

programming (G90), or the distance from the hole
Z
bottom to the point R for incremental programming
(G91).
R programming (G90), or the distance from the point R to
L machining to simplify programming. It is optional when
L=1.)
Operation procedure
1. The tool moves rapidly to the point B over the hole center.
2. Move rapidly to the point R, close to the workpiece.
3. Conduct boring downward at the
speed of F.
4. Move to the point Z at the hole bottom.
5. Exit upward rapidly to the point R (the spindle remains rotation).
6. Exit upward rapidly to the point B in the G98 mode.
REMARK
1. The boring axis must be the Z axis.
2. The point Z must be lower than the plane of point R; otherwise, an
alarm will be reported.
3. If the motion amount of Z, Q, and K are zero, the cycle is not
executed.
Boring Cycle (G89)

Description
This operation specified by the command G89 is almost the same as that
of G86. In the G89 mode, the spindle pauses at the hole bottom. Before
specifying G89, use auxiliary function the M command to rotate the
spindle. When the G89 command and M command are specified in the
same block, the system executes the M command while the first
positioning movement is performing , and then conducts the next boring.
If the repeat count L is specified, the system executes the M command
only for the first boring hole.
The operation specified by G89 is as shown below:

Format
G89 X_ Y_ Z_ R_ P_ F_ L;
Parameter Description
XY programming (G90), or the distance from the current tool
position to the hole for incremental programming (G91).
Z programming (G90), or the distance from the hole bottom
to the point R for incremental programming (G91).
R programming (G90), or the distance from the point R to
The duration that the tool remains at the hole bottom.
P
Unit: millisecond.
L machining, and therefore X or Y is an incremental
value.)
REMARK
1. The boring axis must be the Z axis.
2. The point Z must be lower than the plane of point R; otherwise, an
alarm will be reported.
4. G89 is similar as G86, but with a pause at the hole bottom.
5. If the movement amount of Z is zero, this command is not executed.

G52Z Transfert of the tool axis to the measuring origin
The concerned block is usually written after the

initialization block the G52z code is the right function
Example
N5 G0 G17 G40 G71 G90 M41
N10 G52z
N15 ……………………….
REMARK
G52z can also be used before tool changing or at the end of the
program.

Introduction To Computer Aided Manufacturing

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Introduction To Computer Aided Manufacturing

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INTRODUCTION TO COMPUTER AIDED MANUFACTURING

Fig. 1 Industrial mass production facility

Fig. 2 CNC machine

by Mr. TCHASSI MICHEL 1

Fig. 3 (a) Computer aided design

(b) Computer aided manufacturing

by Mr. TCHASSI MICHEL 2

(a) THE MERITS OF COMPUTER NUMERICAL CONTROLLED

There are many advantages of a CNC machine:

(ii) CNC machines usually have automatic changing tools function.

(b) THE RESTRICTIONS OF CNC MACHINE

But, there are some restrictions of CNC machine:

(ii) Operators need to be trained to compose computer control program.

by Mr. TCHASSI MICHEL 3

2. THE INDUSTRIAL APPLICATIONS OF CNC MACHINE

a) THE DESIGN OF CNC MACHINE

Fig. 4 (a) Path measuring system

(a) Photoelectric detecting device

b) SUPPORTING MACHINERY COMPONENTS

CNC machine needs relatively more supporting machinery components. For

Fig. 5 (a) CNC machine uses automatic system to change tools

(b) Machine uses robotic arm to install workpiece

by Mr. TCHASSI MICHEL 5

Fig. 6 (a) Right-hand rule

(b) Main axis and rotational axis coordinate system

by Mr. TCHASSI MICHEL 6

d) INTRODUCTION TO VARIOUS KINDS OF CNC MACHINES

 CNC DRILLING MACHINE

Fig. 7 Compensate the depth of drilling

by Mr. TCHASSI MICHEL 7

Fig. 8 (a) Two axes center lathe

(b) Three axes center lathe

 CNC MILLING MACHINE

by Mr. TCHASSI MICHEL 8

 CNC SPOT WELDER

 CNC LASER CUTTING MACHINE

Fig. 16 Laser cutting machine

Fig. 17 Workpiece cut by using laser cutting

 OTHER CNC MACHINES

by Mr. TCHASSI MICHEL 10

3. THE OPERATION OF CNC MACHINE

a) BASIC OPERATION THEORY

Fig. 19 Simplified operation procedures of CNC machine

Firstly, the engineering drawing according to the design of the workpiece is

by Mr. TCHASSI MICHEL 11

Fig. 21 CNC machinery program

by Mr. TCHASSI MICHEL 12

by Mr. TCHASSI MICHEL 13

program as an example. Several blocks will form a complete CNC machinery

4. APPLICATION SOFTWARE OF CNC MACHINES

 Application software can usually be applied to different machines, so programmer

by Mr. TCHASSI MICHEL 14

5. SAFETY MEASURES OF USING CNC MACHINES

2. Choose a suitable computer program to control the system.

3. Simulation of cutting should be undergone in the computer control program before

by Mr. TCHASSI MICHEL 16

COORDINATE SYSTEMS AND POINTS

by Mr. TCHASSI MICHEL 17

Local Reference Points

by Mr. TCHASSI MICHEL 18

The math required to write coordinates for

But setting a local reference point, at the