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CNC Machining
Manufacturing Processes I
14.7 Schematic illustration of the major components of a numerical control machine tool.
FIGURE 14.8 Schematic illustration of the components of (a) an open-loop, and (b) a closed-loop control system for a numerical control machine. DAC means digital-to-analog converter.
FIGURE 14.9 Direct measurement of the linear displacement of a machine-tool worktable. (b) and (c) Indirect measurement methods.
Path of Cutters in NC
FIGURE 14.10 Movement of tools in numerical control machining. (a) Point-to-point system: The drill bit drills a hole at position 1, is then retracted and moved to position 2, and so on. (b) Continuous path by a milling cutter. Note that the cutter path is compensated for by the cutter radius. This path can also compensate for cutter wear.
Types of Interpolation
FIGURE 14.11 Types of interpolation in numerical control: (a) linear; (b) continuous path approximated by incremental straight lines; and (c) circular.
FIGURE 14.12 (a) Schematic illustration of drilling, boring, and milling operations with various cutter paths. (b) Machining a sculptured surface on a five-axis numerical control machine. Source: The Ingersoll Milling Machine Co.
Overview
A part is machined by running a program. The program defines a sequence of NC machining operations. Machining operations are interpreted by the machine with commands.
Types of Commands
Preparatory Functions (G codes) Coordinate words Feed Functions (F functions) Auxiliary Control Functions
Preparatory Functions
(G Codes)
Consist of the address G, plus a number Are divided into 3 groups : - Position commands - Modal commands - Canned cycle commands
Example : G01
Linear Translation
Prompt a mode or format Are effective until the Mode is altered with another Command
Example : G90,G91
Absolute/Incremental Positioning
Example : G81 =
Coordinate Words
Specifies an axis movement Consists of the address of the axis and
the value indicating the direction of the motion and the distance.
Example : X2 Y5 Z.5
Feed Functions
Feed Functions prompt the machine
Example : F10
= Move at 10 I.P.M.
Auxiliary Functions
3
Types : - Spindle Speed S Function - Tool Function T Function - Miscellaneous Function M Command
S Function
Prompts Spindle Speed
T Function
Example : T6
Tool 6
M Function
Initiates various machine tool functions and establishes various control conditions. Example: M8 = Turns coolant on
Cutter Compensation
Used in profile milling operations Offsets tool to compensate for diameter of tool G41 = Cutter Compensation Left G42 = Cutter Compensation Right
Cutter Compensation
Cutter Compensation
Programming
Putting it all together
A block contains various commands to form a machine operation. Each block is on a separate line of code.
Block Example
G0 X4 Y5 Z.1 S3000 M3
G0 X4 Y5 Z.1 S3000 M3 = = GO TO: X4 Y5 Z.1 SPINDLE ON, 3000 RPM
Code Example 1
T1M6 'D DRILL S3800. M3 M8 G0G90 X.3822 Y.3917 Z.1 G81 Z.25 F7.5 X.3822 X.6572 Y.3389 ( Tool Call ) ( Spindle on ) ( Coolant on ) ( Rapid to position ) ( Rapid to part surface ) ( Drill cycle ) ( 2nd Drill location ) ( 3rd Drill location )
Code Example 2
T2M6 '1/2 MILL S1900. M3 M8 G0G90 X.5 Y1.005 Z.1 G1 Z-.26 F3.8 X2.2541 Y1.0521 X2.8096 Y.9455 G2 X2.9405 Y1.0283 R.5867 G1 Y1.1954 G0 Z.1 ( Tool Call ) ( Spindle on ) ( Coolant on ) ( Rapid to position ) ( Rapid to part surface ) ( Plunge into part ) ( Go to 1st point ) ( Go to 2nd point ) ( Make arc to 3rd point ) ( Go to 4th point ) ( Rapid to part surface )
Code example 3
M5 M9 M22 (Spindle off) (Coolant off) (Go to home)
Programming
Programming
N10 T1 M6 S1000 N20 M3 N30 M8 N40 G90 G70 Absolute, Inch Rapid transverse, Cutter compensation left Linear interpolation, Feed rate N50 G0 G41 X-.5 Y-.5 Z.1 N60 G1 Z-.255 F10. N70 X0. Y-.5 N80 Y2. N90 X4. N100 Y.5 N110 G2 X3.5 Y0. I3.5 J.5 N120 X-.25 N130 G0 Z.1 N140 G40 X-1. Y1. N150 M5 N160 M9 N170 M22 Rapid transverse above part Cutter compensation off Spindle off Coolant off Go to clear point Circular interpolation clockwise Tool selection, Tool change, Spindle speed Spindle on clockwise Coolant on flood
Programming
N10 T1 M6 S1000 N20 M3 N30 M8 N40 G90 G70 Absolute, Inch Rapid transverse, Cutter compensation left Linear interpolation, Feed rate N50 G0 G41 X-.5 Y-.5 Z.1 N60 G1 Z-.255 F10. N70 X0. Y-.5 N80 Y2. N90 X4. N100 Y.5 N110 G2 X3.5 Y0. I3.5 J.5 N120 X-.25 N130 G0 Z.1 N140 G40 X-1. Y1. N150 M5 N160 M9 N170 M22 Rapid transverse above part Cutter compensation off Spindle off Coolant off Go to clear point Circular interpolation clockwise Tool selection, Tool change, Spindle speed Spindle on clockwise Coolant on flood
Programming
N10 T1 M6 S1000 N20 M3 N30 M8 N40 G90 G70 Absolute, Inch N50 G0 G41 X-.5 Y-.5 Z.1 N60 G1 Z-.255 F10. N70 X0. Y-.5 N80 Y2. N90 X4. N100 Y.5 N110 G2 X3.5 Y0. I3.5 J.5 N120 X-.25 N130 G0 Z.1 N140 G40 X-1. Y1. N150 M5 N160 M9 N170 M22 Rapid transverse above part Cutter compensation off Spindle off Coolant off Go to clear point Circular interpolation clockwise Rapid transverse, Cutter compensation left Linear interpolation, Feed rate Tool selection, Tool change, Spindle speed Spindle on clockwise Coolant on flood
Programming
N10 T1 M6 S1000 N20 M3 N30 M8 N40 G90 G70 Absolute, Inch N50 G0 G41 X-.5 Y-.5 Z.1 N60 G1 Z-.255 F10. N70 X0. Y-.5 N80 Y2. N90 X4. N100 Y.5 N110 G2 X3.5 Y0. I3.5 J.5 N120 X-.25 N130 G0 Z.1 N140 G40 X-1. Y1. N150 M5 N160 M9 N170 M22 Rapid transverse above part Cutter compensation off Spindle off Coolant off Go to clear point Circular interpolation clockwise Rapid transverse, Cutter compensation left Linear interpolation, Feed rate Tool selection, Tool change, Spindle speed Spindle on clockwise Coolant on flood
Programming
N10 T1 M6 S1000 N20 M3 N30 M8 N40 G90 G70 Absolute, Inch N50 G0 G41 X-.5 Y-.5 Z.1 N60 G1 Z-.255 F10. N70 X0. Y-.5 N80 Y2. N90 X4. N100 Y.5 N110 G2 X3.5 Y0. I3.5 J.5 N120 X-.25 N130 G0 Z.1 N140 G40 X-1. Y1. N150 M5 N160 M9 N170 M22 Rapid transverse above part Cutter compensation off Spindle off Coolant off Go to clear point Circular interpolation clockwise Rapid transverse, Cutter compensation left Linear interpolation, Feed rate Tool selection, Tool change, Spindle speed Spindle on clockwise Coolant on flood
Programming
N10 T1 M6 S1000 N20 M3 N30 M8 N40 G90 G70 Absolute, Inch N50 G0 G41 X-.5 Y-.5 Z.1 N60 G1 Z-.255 F10. N70 X0. Y-.5 N80 Y2. N90 X4. N100 Y.5 N110 G2 X3.5 Y0. I3.5 J.5 N120 X-.25 N130 G0 Z.1 N140 G40 X-1. Y1. N150 M5 N160 M9 N170 M22 Rapid transverse above part Cutter compensation off Spindle off Coolant off Go to clear point Circular interpolation clockwise Rapid transverse, Cutter compensation left Linear interpolation, Feed rate Tool selection, Tool change, Spindle speed Spindle on clockwise Coolant on flood
Programming
N10 T1 M6 S1000 N20 M3 N30 M8 N40 G90 G70 Absolute, Inch N50 G0 G41 X-.5 Y-.5 Z.1 N60 G1 Z-.255 F10. N70 X0. Y-.5 N80 Y2. N90 X4. N100 Y.5 N110 G2 X3.5 Y0. I3.5 J.5 N120 X-.25 N130 G0 Z.1 N140 G40 X-1. Y1. N150 M5 N160 M9 N170 M22 Rapid transverse above part Cutter compensation off Spindle off Coolant off Go to clear point Circular interpolation clockwise Rapid transverse, Cutter compensation left Linear interpolation, Feed rate Tool selection, Tool change, Spindle speed Spindle on clockwise Coolant on flood
Programming
N10 T1 M6 S1000 N20 M3 N30 M8 N40 G90 G70 Absolute, Inch N50 G0 G41 X-.5 Y-.5 Z.1 N60 G1 Z-.255 F10. N70 X0. Y-.5 N80 Y2. N90 X4. N100 Y.5 N110 G2 X3.5 Y0. I3.5 J.5 N120 X-.25 N130 G0 Z.1 N140 G40 X-1. Y1. N150 M5 N160 M9 N170 M22 Rapid transverse above part Cutter compensation off Spindle off Coolant off Go to clear point Circular interpolation clockwise Rapid transverse, Cutter compensation left Linear interpolation, Feed rate Tool selection, Tool change, Spindle speed Spindle on clockwise Coolant on flood
Programming
N10 T1 M6 S1000 N20 M3 N30 M8 N40 G90 G70 Absolute, Inch N50 G0 G41 X-.5 Y-.5 Z.1 N60 G1 Z-.255 F10. N70 X0. Y-.5 N80 Y2. N90 X4. N100 Y.5 N110 G2 X3.5 Y0. I3.5 J.5 N120 X-.25 N130 G0 Z.1 N140 G40 X-1. Y1. N150 M5 N160 M9 N170 M22 Rapid transverse above part Cutter compensation off Spindle off Coolant off Go to clear point Circular interpolation clockwise Rapid transverse, Cutter compensation left Linear interpolation, Feed rate Tool selection, Tool change, Spindle speed Spindle on clockwise Coolant on flood
Programming
N10 T1 M6 S1000 N20 M3 N30 M8 N40 G90 G70 Absolute, Inch Rapid transverse, Cutter compensation left Linear interpolation, Feed rate N50 G0 G41 X-.5 Y-.5 Z.1 N60 G1 Z-.255 F10. N70 X0. Y-.5 N80 Y2. N90 X4. N100 Y.5 N110 G2 X3.5 Y0. I3.5 J.5 N120 X-.25 N130 G0 Z.1 N140 G40 X-1. Y1. N150 M5 N160 M9 N170 M22 Rapid transverse above part Cutter compensation off Spindle off Coolant off Go to clear point Circular interpolation clockwise Tool selection, Tool change, Spindle speed Spindle on clockwise Coolant on flood
Programming
N10 T1 M6 S1000 N20 M3 N30 M8 N40 G90 G70 Absolute, Inch N50 G0 G41 X-.5 Y-.5 Z.1 N60 G1 Z-.255 F10. N70 X0. Y-.5 N80 Y2. N90 X4. N100 Y.5 N110 G2 X3.5 Y0. I3.5 J.5 N120 X-.25 N130 G0 Z.1 N140 G40 X-1. Y1. N150 M5 N160 M9 N170 M22 Rapid transverse above part Cutter compensation off Spindle off Coolant off Go to clear point Circular interpolation clockwise Rapid transverse, Cutter compensation left Linear interpolation, Feed rate Tool selection, Tool change, Spindle speed Spindle on clockwise Coolant on flood
Programming
N10 T1 M6 S1000 N20 M3 N30 M8 N40 G90 G70 N50 G0 G41 X-.5 Y-.5 Z.1 N60 G1 Z-.255 F10. N70 X0. Y-.5 N80 Y2. N90 X4. N100 Y.5 N110 G2 X3.5 Y0. I3.5 J.5 N120 X-.25 N130 G0 Z.1 N140 G40 X-1. Y1. N150 M5 N160 M9 N170 M22 Rapid transverse above part Cutter compensation off Spindle off Coolant off Go to clear point Circular interpolation clockwise Tool selection, Tool change, Spindle speed Spindle on clockwise Coolant on flood Absolute, Inch Rapid transverse, Cutter compensation left Linear interpolation, Feed rate
Poi n t p 1; see Fi g u r e ( b ) f or i l l ustr at i on s. x = 4 - 0.125 = 3.875 y = 4 - 0.125 t an 67.5 = 3.698 Poi n t P2 x = 3.875 y = 4 + 5 + 0.125 = 9.125 Poi n t p 3; see Fi g u r e ( c) f or i l l ustr ati on s. y = 9 + 0.125 = 9.125 ( - x + 6.5) 2 + 0.1252 = ( 1 - 0. 125) 2 6.5 - x = 0.866 x = 5.634 Poi n t P4 y = 9.125 x = 6.5 + 0.866 = 7.366 Poi n t P5; see Fi g u r e ( d) f or i l l ustr ati on s. y = 9.125 x = 9 + .125 tan 67.5 = 9.302 H av i n g th e coor di n ates of th ose p oi n ts, w e ar e ab l e to w r i te a par t pr og r am to m ach i n e th e par t. N 10 N 20 N 30 N 40 N 50 N 60 N 70 N 80 F6.0 S400 M 03 G01 X3.875 Y 3.698 G01 X3.875 Y 9.125 G01 X5.634 Y 9.125 G03 X7.366 Y 9.125 16.5 J9 G01 X9.302 G01 X3.875 Y 3.698 G01 X2.0 Y 2.0 M 30
Machine Operation
Tool Change
Spindle on..Coolant on
Profile Milling
Drilling Cycle
Finished Part
Write a manual part program for the part shown below, in mm unit. Assume a uniform depth of 10 throughout. 1. With cutter compensation. 2.Without cutter compensation Cutter Diameter T1 Diameter (d1) = 2.5 ( end mill) T2 Diameter (d2) = 5 (drill) T3 Diameter (d3) = 8 (drill) Solution : Cutter position at (-2., -2., 2.), Set left bottom corner as (0., 0., 0.), Z down is negative direction.