CNC Machining Simulation Lab

Tutorial

Work Integrated Learning Program

WISE Simulation Lab
Birla Institute of Technology & Science, Pilani
 Errors to IGNORE During the tutorial

While creating new

project software will
ask you to save the NC
file, if you say YES then
After cycle start you may get
the above error
this error dialogue box, ignore
message may appear. this error, click CLOSE and
Ignore this error continue. If the error continues,
message just Click OK Ignore the floating decimals in
While switch ON the controller above error
and continue to your origin while editing in the
may appear, just ignore this error and
next steps. program. Just enter the
proceed with next steps. reference value as whole
numbers without any decimal
You may get these ignorable error messages during any tutorial. points
Collision and Over Travel error because of your wrong inputs

 “Collision Occur” is a common error message you will get because of your wrong input parameters. This
indicates that your input parameters are leading the spindle in wrong path instead of proper material
removal and collision occurs between the tool, work piece clamping fixture or the table

 Reasons for Collision and Over Travel

 Wrong work part origin reference value in NC program and
 Wrong tool dimensions

 Remedy
 Enter correct reference value as mentioned in the TUTORIAL Manual
 Enter correct tool nomenclatures as mentioned in the TUTORIAL Manual
Problems

Sl. No. Operation Workpiece size Tool used Controller

Horizontal Milling
1. □ 100 x 100 x 20 Flat end mill ∅16 H 100 Fanuc 0iMD
(Linear Interpolation)
Horizontal Milling
2. □ 80 x 80 x 20 Flat end mill ∅16 H 100 Fanuc 0iMD
(Profiling)

Flat end mill ∅20 H 75

Flat end mill ∅12 H 100
Horizontal Milling
3. □ 100 x 100 x 20 Flat end mill ∅12 H 85 Fanuc 18i-MB5
(Profiling) Drill ∅10 H100
Central Drill - ∅04 H 100

Flat end mill ∅ 22 H 100

Horizontal Milling Central Drill -∅3 H 100
4. □ 150 x 100 x 100 Fanuc 18i-MB5
(Step milling) Drill ∅8.5 H95
Tap D10 H100
Horizontal Milling
5. □ 205 x 155 x 100 Ball end mill ∅20 H 100 Mitsubishi
(Curvature profiling)
Problem 4: Horizontal Machining-Profiling

Lab Perquisites: Basics of NC code in connection with Horizontal machining is required. Knowledge about

flat end mill, center drill and tap tool along with their corresponding nomenclatures is mandatory before

entering to this example.

Workpiece size: Rectangular piece (150 x 100 x 100 mm)

Tool required: V-CNC Pro

Mounting details: Length : 140mm & length : 30 mm

Goal: To do the step milling on the above workpiece in Fanuc 18i-MB5 machining center.

At the end of this example students will understand how to do the machining operation in Fanuc 18iMB5

machining center and further we shall interpret the NC code.

Problem 4: Horizontal Machining - Profiling

Given work part diagram

Problem 4: Horizontal Machining - Profiling

Desired work part diagram

Problem 4: Horizontal Machining - Profiling

Experiment Outline
Part I : Set up the workpiece and machine Part II : Set up the controller and cycle start
 Open V-CNC Pro Mill Software  Simulation environment settings
 Save Project  Set collision check
 Open wizard floating menu  Power on the controller
 Select machine  Spindle Zero Return
 Select controller  Cutter Compensation
 Open NC File  Edit H number in Program
 Create work part  Start the machining process
 Load work part
 Edit Magazine & Tool
 Offset Mill Fixture
 Set origin of the work part
Problem 4: Horizontal Machining - Profiling

Experiment Outline (Contd.,)

Part III – Verification
 Verification of Machined component window open
 Verification of Machined component: Tool path
 Verification of Machined component: Gouge check
 Verification of Machined component: View sections
 Verification of Machined component: Work part drawing preparation
 Verification of Machined component : Save Work part diagram
 Save and close the project
Problem 4: Horizontal Machining - Profiling
Shortcuts to represent various mouse shortcuts in the tutorial for convenience.

LMB: Left Mouse Button Single click RMB: Right Mouse Button click once

DLMB: Left Mouse Button Double click

 Problem 4: Horizontal Machining - Profiling

Experiment Outline
Part I : Set up the workpiece and machine
Step 1: Open V-CNC Pro Mill Software
 Once log in to the citrix server, click
VCNCProStart.
 VCNCProStart window will appear
 Click Machining Center in the
window and wait for some time, then
you can see VCNC Promill software
window open in your system.

V-CNC Pro Mill Software Interface

Part 1: Set up the workpiece and machine

 Problem 4: Horizontal Machining - Profiling
Step 2: Reset the toolbar
 View (LMB)
Toolbars (LMB)
Init Toolbar (LMB)

Note: There may not be any changes in the screen after this step, proceed to next step.
Part 1: Set up the workpiece and machine
 Problem 4: Horizontal Machining - Profiling
Step 3: Save project
 File (LMB)
Project save(LMB)
 Save as project file window will pop up
LMB the drop down menu (Save in:)
Personal Directory (P:) (LMB)
Create new folder inside the
personal directory and name it as your
BITS ID (for example 201518… )
 DLMB the created folder
 Type File name”Tutorial4”
 Save (LMB)

Part 1: Set up the workpiece and machine

Problem 4: Horizontal Machining - Profiling
Step 4: Open wizard floating menu
 Settings (LMB)
Wizard (LMB)
 Now you can see the floating window
included the steps, Set User
Information, Select Machine and so on.

Part 1: Set up the workpiece and machine

Problem 4: Horizontal Machining - Profiling
Step 5: Select Machine
 Select Machine (LMB) (in wizard)
 Now Select Machine window will Tool Magazine
pop up.
2_Horizontal M-C (LMB) Tool Head
Apply (LMB)
Tool Assembly

Work part and

Fixture
Table
Rotate, Move and other icons

Part 1: Set up the workpiece and machine

Problem 4: Horizontal Machining - Profiling
Step 6: Select Controller
 Select Controller (LMB) (in wizard)
 Now Select Controller window will
pop up.
Commercial controllers (LMB)
Among the list of controllers
select Fanuc 0iMD (M/C) (LMB)
Apply (LMB)
 Fanuc 18iMB5 controller interface
window will pop up now.
 Maximize the controller interface
to have a better view. (Refer next
page for the maximized controller
interface)

Part 1: Set up the workpiece and machine

 Problem 4: Horizontal Machining - Profiling
Power
ON
MDI Mode
Remote Single
Block
Display Edit Mode
Auto Mode Machine
Lock

Zero
Cycle Start Cycle Stop return
Feed
Override
Reset
Spindle
Position Override

Emergenc
Set Offset y Stop

Fanuc 18i-MB5 Controller Interface Part 1: Set up the workpiece and machine
 Problem 4: Horizontal Machining - Profiling
Step 7: Open NC File (Numerical Code)
 Before starting this step, Minimize (find in
right top) the controller down
 Open NC File (LMB) (in wizard)
 Now Open window will appear
 In the Look in drop down menu select
Tutorial Share (T:) Scroll down and find V-
CNC Pro Tutorial Folder. DLMB the folder. You
can find NC Files folders (DLMB), find
“Tutorial 4” folder. DLMB the same folder.
 Tutorial4 notepad file (LMB)
 Open (LMB)

Part 1: Set up the workpiece and machine

 Problem 4: Horizontal Machining - Profiling
Step 8: Create Work Part
 Create Work Part (LMB) (in wizard)
 Create work-part window will appear
Type 150 in W(width) box
Type 100 in D(depth) and H(height) box
 Let the material be unchanged
 Reload (LMB)
 Wait for a moment, work part will be reloaded
in the fixture.
 Now the work part will be loaded in the fixture.

Part 1: Set up the workpiece and machine

 Problem 4: Horizontal Machining - Profiling
Step 9: Load Work Part
 Load Work Part (LMB) (in wizard)
 Load work-part window will appear
Type 140 in Mounting Length box
Type 30 in Mounting length box
 Load (LMB)
 Create Work Part (LMB)
 Reload (LMB)
 Wait for a moment, work part will be reloaded
in the fixture.
 Now the work part will be loaded with the
specified mounting length and length in the
fixture.
Part 1: Set up the workpiece and machine
 Problem 4: Horizontal Machining - Profiling
Step 10: Edit Magazine & Tool (T01-FEM∅20 H 75)
 Edit Magazine & Tool (LMB) (in wizard)
 Magazine window will appear
Flat end mill (LMB)
Modify Tool (LMB) below window will appear
 Edit the Tool Dia. 10 into 22.
 (DLMB the tool dia and length text box and edit
the value, then press ENTER)

 Add tool to Tool

No. 1.
 Click Next Tool>>
and keep the tool
no 2 active. (To
add the next tool)

Part 1: Set up the workpiece and machine

 Problem 4: Horizontal Machining - Profiling
Step 10: Edit Magazine & Tool
(T02-Central Drill ∅03 H100)
Central drill (LMB)
Enter the following parameters
Tool Dia 20
Tool Length 90
Blade Length 30
L 15
a 120
d 3
 Add tool to Tool
No. 2.
 Click Next Tool>>
and keep the tool
no 3 active. (To
add the next tool)

Part 1: Set up the workpiece and machine

 Problem 4: Horizontal Machining - Profiling
Step 10: Edit Magazine & Tool (T03-Drill ∅10 H100)
Drill (LMB)
Modify Tool (LMB) below window will appear
 Enter the following values Tool Dia-8.5, Tool
length 85 and Blade length 60.
 (DLMB the tool dia and length text box and edit
the value, then press ENTER)

 Add tool to Tool

No. 3.
 Click Next Tool>>
and keep the tool
no 4 active. (To
add the next tool)

Part 1: Set up the workpiece and machine

 Problem 4: Horizontal Machining - Profiling
Step 10: Edit Magazine & Tool (T04-TAP∅10 H100)
Tap(LMB)
Modify Tool (LMB) below window will appear
 Enter the following values

Tool Dia 10 Blade Length 10

Tool Length 100 Shank Dia 6

 Add tool to Tool

No. 4.
 OK (LMB)

Enter Blade length and Shank dia first to avoid grid error.
Part 1: Set up the workpiece and machine
 Problem 4: Horizontal Machining - Profiling
Step 10: Edit Magazine & Tool (Contd.,)
 Now Tool library manager window will disappear
and magazine window will appear.
 OK (LMB).
 Now do you want to save pop up window will
appear press Yes.

Part 1: Set up the workpiece and machine

 Problem 4: Horizontal Machining - Profiling
Step 10: Edit Magazine & Tool (Contd.,)
 LMB the drop down menu (Save in:)
Personal Directory (LMB)
Your folder DLMB
 Type File name”Tutorial4-Tool”
 Save (LMB)
 Tool library has been saved
confirmation window will appear
click ok.

Part 1: Set up the workpiece and machine

 Problem 4: Horizontal Machining - Profiling
Step 11: Hide Machine
 Machine (LMB)
Part Colour (LMB)
 Part View Control window will appear
 Click Hide Machine

Part 1: Set up the workpiece and machine

 Problem 4: Horizontal Machining - Profiling
Step 12: Set origin work part
 Set origin work part (LMB) (in wizard)
 Work-Part origin setting (auto) window will appear
 Click the corner of the rectangle as shown
 In Work-Part drop down box click Hexahedron
 In NC Code drop down box select G92
 Shown X, Y and Z values are the origin point of the
component. NC code is generation for the same
origin.
X = 308.32
Y = 463.09
Z = 329.755

Ignore the minus sign.

Part 1: Set up the workpiece and machine

 Problem 4: Horizontal Machining - Profiling
Part II : Set up the controller and cycle start
Step 1: Simulation Environment settings
 Settings (LMB)
Environment setting (LMB)
 Environment Setting window will appear
Reduce the simulation speed to 70% (drag the
horizontal bar towards left)
 Simulation On is selected.
 Select High speed mode not use
 Give Tool Tolerance of 0.06
Select Coolant Effect ON
 Select the Show tool path option
 Click OK.

Part II: Set up the controller and cycle start

 Problem 4: Horizontal Machining - Profiling
Step 2: Set collision check
 Settings (LMB)
Set collision check (LMB)
 Collision Setting window will appear
Select Stop
Apply (LMB)

When there is a collision occurs between tool,

table, or any other components machining
operation will be stopped.

Part II: Set up the controller and cycle start

 Problem 4: Horizontal Machining - Profiling
Step 3: Power ON the controller
 Maximize the controller window
 Power ON (LMB)
ignore any error messages in the display
 EDIT (LMB) (Green LED should glow)
 RESET (LMB)
 Click PROG icon.
 Check the G92 reference value in the
program.
 Check the 4 th block
N4 G92 G90 X308.32 Y463.09 Z329.755;

Part II: Set up the controller and cycle start

 Problem 4: Horizontal Machining - Profiling
Step 4: Spindle Zero return
 Click Zero return and cycle start will also do
the above process.
 POS button will show the position of the
spindle.
 Use rotate and pan option to get the shown
work part view. (Side View)
 Click POS to check the spindle position.

Spindle Zero
Position

Part II: Set up the controller and cycle start

 Problem 4: Horizontal Machining - Profiling
Step 5:Tool length and cutter
radius compensation
 Set offset button (LMB)

 Offset window will appear in the

desktop
 Enter compensation values as
shown in Figure (which will be
called in the NC code as D and
H numbers)
 Click EDIT

Part II: Set up the controller and cycle start

 Problem 4: Horizontal Machining - Profiling
Program call function used in NC code Sub Program
Refer the below blocks O1501 //Program No.
 N34 M98 P1501; T02 -Center Drill G90 Y50.;
 N39 M98 P1501; T03 - Drill G99 Y15. R2.;
 N44 M98 P1501; T04 - Tap G99 X75. R2.;
G99 Y85. R2.;
G99 X25. R3.;
Y15.;
M99;
M06 Tool Change to tool no 3 (T03)
Center drill operation NC code:
N36 T03 M06; M98 Sub program call (This program will repeat N38 block 6 times in the
N37 G00 G43 Z10. H12 S700 M03; following positions Y50, Y15, Y75, Y85, X25, Y15)
N38 G99 G81 X125. Y85. Z-23. R-7. F60 M08; G90 Absolute command
N39 M98 P1501;
G99 Return to R point in canned cycle
N40 G00 G80 G49 Z200. M09;
R Return to R (reference point) Here R2 stands for 2 mm above the surface.
M99 End of the sub program

Part II: Set up the controller and cycle start

 Problem 4: Horizontal Machining - Profiling
Step 6: Start the machining process
 Auto (LMB) Green led should glow
 Rotate the FEED OVERRIDE to 40% (108
mm/min)
 Press the cycle start
 Once the machining starts, press SINGLE
BLOCK (green LED should glow)
 Now, press cycle start to execute each and
every block.
 Once the simulation is completed, take the
spindle to its original position.

Part II: Set up the controller and cycle start

 Problem 4: Horizontal Machining - Profiling
Part III – Verification
Step 1: Verification of Machined
component window open
 Inspection (LMB)
Verification
 Separate verification module page
will open as shown.
In Move Work-Part dialogue box
enter 0,0,0 in X, Y and Z then click
Move.

Part III: Verification

 Problem 4: Horizontal Machining - Profiling
Step 2: Verification of … Tool path without machining ___ Tool path during machining
Machined component :
Tool Path
 View(LMB)
Tool Path (LMB)
 Tool path attribute
icon (LMB)
 Color drop down
menu and select black
colour,
 OK (LMB)

Note: Cutter compensation will be added during interpolation Part III: Verification
 Problem 4: Horizontal Machining - Profiling
Step 3: Verification of Machined
component : Gouge Check
Gouge check (LMB)
Open Model File(o) LMB
In the Look in drop down menu select
Tutorial Share (T:) Scroll down and find V-
CNC Pro Tutorial Folder. DLMB the folder.
You can find STL Files folders (DLMB), find
“Tutorial 4” folder. DLMB the same folder.
Tutorial4 STL file (LMB) Open (LMB)
Machined component is overlapped with
the final component to check the undercut
and overcut.
Green color portion indicates that there is
no under cut in the model.
Blue and Red colored areas are the under
cut and over cut respectively.
Gouge check usually decides whether the
machine settings, NC code and offset is in
par with the desired workpart geometry.
Finish gouge check (LMB) Use rotate and pan option to manipulate the component Part III: Verification
 Problem 4: Horizontal Machining - Profiling
Step 4: Verification of Machined
component : View Section
 Measure (LMB)
View section
Select the points as shown in the
Fig.
OK (LMB)
 View Section window will appear
 In the view Section window, click
next to cross check the
coordinates. (This will help us to
Point
cross verify geometry of the
selected
complex curvature geometry)
 Close the View Section window
 Take different cross section and
check the coordinates of the
component.

Part III: Verification

 Problem 4: Horizontal Machining - Profiling
Step 4: Verification of Machined
component : View Section
 Measure (LMB)
View section
Select the points as shown in the
Fig.
OK (LMB)
 View Section window will appear
 In the view Section window, click
next to cross check the
coordinates. (This will help us to
Point
cross verify geometry of the
selected
complex curvature geometry)
 Close the View Section window
 Take different cross section and
check the coordinates of the
component.

Part III: Verification

 Problem 4: Horizontal Machining - Profiling
Step 4: Verification of Machined
component : View Section
 Measure (LMB)
View section
Select the points as shown in the
Fig.
OK (LMB)
 View Section window will appear
 In the view Section window, click
next to cross check the
coordinates. (This will help us to
Point
cross verify geometry of the
selected
complex curvature geometry)
 Close the View Section window
 Take different cross section and
check the coordinates of the
component.

Part III: Verification

 Problem 4: Horizontal Machining - Profiling
Step 4: Verification of Machined
component : View Section
 Measure (LMB)
View section
Select the points as shown in the
Fig.
OK (LMB)
 View Section window will appear
 In the view Section window, click
next to cross check the
coordinates. (This will help us to
Point
cross verify geometry of the
selected
complex curvature geometry)
 Close the View Section window
 Take different cross section and
check the coordinates of the
component.

Part III: Verification

 Problem 4: Horizontal Machining - Profiling
Step 4: Verification of Machined
component : View Section
Dimension
 Measure (LMB)
View section
Select the points as shown in the
Fig.
OK (LMB)
 View Section window will appear.
Tick the Dimension check box.
 Check the dimension of the
section. (Click the consecutive
vertex points shown in Figure to
check the dimension.
 First and last vertex point in the
shown cut section is selected and
the figure indicates the respective
dimension.
 Similarly check the dimensions of
various cut sections. Part III: Verification
 Problem 4: Horizontal Machining - Profiling
Step 4: Verification of Machined
component : View Section
Dimension

 While checking the dimension, you

may end up with the shown error.
 This error message indicates that
the dimension can check only in
the horizontal or Horizontal cut
section. That is the selection points
should be a straight line (either
Horizontal or horizontal).
 Click ok and redo the cut section
with different point (selected
points should be approximately
straight)

Part III: Verification

 Problem 4: Horizontal Machining - Profiling
Step 5: Verification of
Machined component : Work
Part diagram
 Measure (LMB)
Work Part Diagram (LMB)
 Separate CbDrawer window
will appear.
 Click at the corner as shown in
the Fig and press OK.

 Continue in the next page…

Part III: Verification

 Problem 4: Horizontal Machining - Profiling
Step 6: Verification of Machined
component : Work Part diagram
 Give the dimensions as shown.
 Use Horizontal direction,
Horizontal Direction dimension
icon and add dimension to the
component.

Zoom in Pan

Zoom Out Zoom All

Part III: Verification

 Problem 4: Horizontal Machining - Profiling
Step 6: Verification of Machined
component : Save Work part
diagram
 Save image icon (LMB)
 In the Save in drop down menu click
Personal Directory (P:)
 DLMB – Folder created in the first
step.
 Give File name in the text box
 Save (LMB)
Step 7: Save and close the project
 Work part Diagram window (Close)
 Verification window (close)
 File (LMB) in VCNC PRO Mill
Software page
 Project Save (LMB)
 File (LMB)
 Exit (LMB)
 Save the program alert (Click save)
Part III: Verification
Contact us if you have any queries

Work Integrated Learning Program

WISE Simulation Lab
Birla Institute of Technology & Science, Pilani

Email : wise@wilp.bits-pilani.ac.in
Text @ Hangout : wise@wilp.bits-pilani.ac.in