1

CNC PROGRAMMING & MACHINING.

CONTEXT.

1.0 NC/CNC/DNC system 2.0 CNC Systems 3.0 CNC part programming (Fanuc & Siemens) 4.0 Speed and Feed 5.0 Cutting Tools 6.0 Inserts and Tool Holders 7.0 Clamping devices 8.0 3D programming and CAM 9.0 High speed machining

1. NC/CNC/DNC SYSTEMS
NC TECHNOLOGY 1.1 INTRODUCTION

1.1.1 HISTORY OF NC TECHNOLOGY We all know and heard the word automation. These machine works with primitive mechanical control system. The operating systems controlled by mechanical devices had their own advantages. As the industrial growth immersed the research and development of each company all over the world there engrossed with new ideas to bring out better machines which can deliver quality product in less time and with very little human effort. Scientists in Massachusetts institute of technology in the year 1948 started working on U.S. Air force concept projects to develop a computer packed controlling system for machine tools. The first ever numerically controlled (NC) machine, a hydraulic vertical spindle machine was built by Cincinnati Company in the year 1948. Then onwards a rapid technological advancement in the area of NC technology began. In the year 1960, the NC machines built by Germans were displayed at the Hanover international trade fair. In the year 1965 the first batch of NC machines with automatic tool changer had appeared in the world market. In the year 1969, NC machines with pallet changing system was marketed. In the year 1972 the first batch of CNC incorporated system came in the world market. In the year 1978 onwards the fast growth of CNC techniques was noticed. The features like graphic assisted path movements, interactive program inputs, scaling factors, mirror imaging etc. were incorporated in the machine memory system and side by side the computer integrated manufacturing developed and introduced. 1.1.2 NC TECHNOLOGY

Numerical control can be defined as an operation of machine tools by means of specifically coded instructions to the machine control system. The instructions are combinations of alphabet, digits and selected symbols. All instructions are written in a logical order and in a predetermined form. The collection of all instructions necessary to machine a part is called an NC program, CNC program or a part program. Such a program can be stored for future use and are used repeatedly to achieve identical machining results at any time. The modern NC system uses internal micro processor. (i.e. a computer) this computer contains memory registers storing a variety of instructions that are capable of manipulating logical functions. That means the part programmer or the machine operator can change the program on the control itself. (At the machine). This flexibility is the greatest advantage of CNC system and probably the key element that contributed to such a wide use of technology in modern manufacturing. The CNC program and logical functions are stored on special computer chips as software instructions.

3 When describing a particular subject that related to the numerically controlled technologies, it is customary to use either the term NC or CNC, NC can also mean CNC but CNC can never refer to the term NC the old technology. 1.1.3 APPLICATIONS OF CNC MACHINES CNC can be applied to all types of machines ranging from simple sawing machine to complex contour grinding machines. Major application areas as follows: 1. Metal cutting machines: CNC milling, CNC turning, CNC drilling/jig boring, gear cutting CNC grinding etc. 2. Metal forming machines: Press tools, Injection/ Blow Moldings / Die casting machines tube bending etc. 3. Non Conventional machining processes such as, EDM Die- sinking and EDM wire cut machines, Plasma Arc cutting machines. Electron beam machining, Laser beam machining, Ion beam machining, Ultrasonic Machining, etc. 4. Welding machines: TIG, MIG, Submerged Arc welding, etc. 5. Inspection and quality control systems: CMM, LMM 6. Assembly, Testing and Des-patch equipment and 7. Tool and work handling systems. Today the CNC concepts are applied to every aspect of manufacturing and its area of applications is widening day-by-day. The well known statement saying CNC machines are ideal for small and medium batch production is no-longer valid and now-a-days CNC is finding increasing applications in transfer lines, special purpose machines and even in single purpose machines producing one-off components. The rapid evolution of CNC technology transformed the complete manufacturing technology and leads to modern concepts of CIM- Computer integrated Manufacturing and Engineering. 1.1.4 ADVANTAGES AND DISADVANTAGES OF CNC MACHINE ADVANTAGES: i).REDUCED NON PRODUCTIVE TIME: It accomplishes this by means of fewer set ups, less time in setting up, reduce work piece handling time, automatic tool changes on some machines etc. ii).CONSISTENT CUTTING TIME (Cutting time): CNC machining is under the control of a computer. The main benefit of a consistent cutting time is for repetitive jobs where the production scheduling and work allocation to individual machine tools can be done very accurately. iii).GREAT MANUFACTURING FLEXIBILITY: Can easy to modify engineering changes, alterations of production schedule etc.

4 iv).IMPROVED QUALITY CONTROL: CNC produces part greater accuracy, reduced scrap and inspection frequencies. v).REDUCED INVENTORY: Due to fewer setups and more operation using same tool, the amount of inventory carried by the company is reduced. vi).REDUCE FLOOR SPACE REQUIREMENTS: Since one CNC machine can often accomplish the production of several conventional machines, reduce floor space . DISADVANTAGES: i).HIGHER INVESTMENT COST: The capital investment cost is high ,because of advanced design. ii).HIGHER MAINTENANCE COST: Because CNC is a more complex technology the maintenance problems become more acute. Maintenance cost for CNC machines will generally be higher than conventional machine tools. ii). SKILLED PERSONNEL: For effective utilization of cnc machine requires skilled programmer,setter,and maintenance personnel.

2. CNC SYSTEM
The advantages derived from CNC machines are due to their salient constructional features listed below. 2.1 MACHINE STRUCTURE High rigidity High stiffness to weight ratio Thermal stability Good damping characteristics 2.1.1SLIDE WAYS Antifriction bearing elements like re-circulating ball packs, re-circulating ball bushings. Hydrostatic or Aerostatic slide ways. Plastic or non-metallic liners like PTFE (Poly Tetra Fluro Ethylene), Turcite B, etc.

2.1.2 SPINDLE DRIVE Wide spindle speed range to meet cutting parameters DC motors with silicon controlled rectifier drive or AC motors with variable frequency. Spindle orientation for Automatic Tool change and fine boring applications. 2.1.3FEED DRIVE Slides are actuated by precision re-circulating ball screw mechanism driven by servo motors. DC motors with silicon controlled rectifier drive or AC motors with variable frequency. 2.1.3 FEED-BACK SYSTEMS The accuracy of positioning in any CNC machine achieved by measuring the position or displacement of the slide and comparing it with the commanded position as per the part program. The servo system then actuates the slide such that the error, which is the difference between actual position and commanded position, is brought to zero. That is why CNC is called Error driven systems. The position measuring devices could be direct or indirect depending upon whether the device is fitted directly in the slides or at the end of the ball screw. Some of the measuring devices are linear inductosyns, Optical scales with gratings, rotary encoders, rotary inductosyns, brush less synchro resolvers, etc. 2.1.4 AUTOMATIC TOOL CHANGER (ATC)

Automatic Tool Changer (ATC) is an important element of machining centers responsible for increase in productivity by reduction of idle time during tool change. Present day CNC machines are equipped with ATC units capable of performing tool changes within 3 to 7 seconds. In act ATC unit, the tool magazine can be drum type with capacity up to 40 tools or chain type with capacity up to 132 tools. The tool change arm can be of single gripper type or of double gripper type. The tool selection can be of Sequential type (applicable for less no, of tools and consuming more time) or of Random type (applicable for more no. of tools and consuming less time). The latter type is more commonly used. 2.1.5 AUTOMATIC PALLET CHANGER (APC)

Similar to ATC the Automatic pallet changer (APC) aids in increase of productivity by reducing the job setup time considerably. The function of the pallet changer is to

6 interchange the pallet on the machine that one pallet has the finished component and the other pallet with newly loaded component. The pallet when transferred from the Pallet changer on the machine gets located and clamped with heavy clamping force either hydraulically or mechanically. APC could be of dual pallet type or multiple pallet pool type. 2.1.6 SOME OF THE OTHER SALIENT FEATURES Thermal stabilization of headstock, feed drive elements and machine structural elements by re-circulating refrigerated oil. Axial calibration for all fixed mechanical elements. Lost motion compensation for backlash, axial and torsional deflections. Usage of Touch trigger probes for post process metrology purpose, tool condition monitoring. Tool measurement and setting of tool offsets and thermal error compensation. Centralized lubrication of slides, etc, controlled by timer or soft ware. Coolant systems of either flood type or mist type. Chip conveyors for collection and disposal of chips. Auto diagnostic facilities to aid for maintenance and service personnel. 2.2 SLIDE ACTUATION IN CNC MACHINES: In a conventional machine hand wheels actuate slides. Occasionally when automatic feed is needed the slides are power driven from the machine spindle.

PULSES AMPLIFIER MCU (Machine control unit) MOTOR

LEAD SCREW

SLIDE

BASIC ELEMENTS OF SLIDE MECHANISM IN CNC

7 But in a CNC machine the story is quite different. Here the hand wheels are replaced by motors and each slide has its won independent motor. The motor speed can be infinitely varied to get the desired feed rate. A schematic diagram of the slide actuation mechanism of a CNC machine is shown. This diagram is rather an oversimplified one and is given only to understand the fundamental principle of slide actuation. The following description will help understand its working. MCU reads the program as soon as it receives the start signal from the operator. It processes the instruction and sends out low-level electrical pulses. (voltage) An amplifier magnifies these low voltage pulses high enough to drive the motor. The motor rotates and drives the lead screw and this in turn causes the slide to move.

The number of pulses sent by the MCU would depend on the following facts. M/c. resolution Feed rate Distance to be traveled 2.3 MACHINE RESOLUTION: Every single pulse sent out by the MCU causes the slide to move a specific distance and machine resolution is the distance moved by the slide for a single pulse. Thus a resolution of 0.001 would mean that the slide would move 0.001mm for every pulse. In other words for a travel of 1mm the MCU will send out 1000 pulses.

2.3.1 PULSE FREQUENCY: The number of pulses sent out by the MCU every second is called pulse frequency and the input voltage to motor depends directly on this factor. The pulse frequency is not a constant value. It depends on the required feed rate and the machine resolution. Pulse frequency = Feed rate in mm/min / M/c resolution x 60. pulse / second. As the resolution is constant for a given machine the pulse frequency may be taken as directly proportional to the feed rate. It may thus be concluded that as the MCU read the instruction it sends out pulses at frequencies corresponding to the desired feed rates. Since the input voltage to the motor is proportional to the pulse frequency, the motor speed is automatically adjusted to achieve the desired feed rate. Example1. Determine the pulse frequency for a feed rate of 30mm/min if the M/c resolution is 0,001 mm. Solution: Pulse frequency = Feed rate in mm/min ----------------------------M/c resolution x 60 = 30 / 0.001 x 60

8 = 500 pulses/sec. Example2. Determine the number of pulses in the above example for a travel of 40mm. Solution: No. of pulses = Distance to travel ------------------------Resolution = 40 / 0.001 = 40,000 pulses. 2.4 FEED BACK CONTROL SYSTEM Based on feed back control NC system is classified as follows: 2.4.1 OPEN LOOP SYSTEM: In an open loop control system hsa no provisions for detecting or comparing the cutting tool movement with the commanded value.These systems are not used where extremely accurate positioning is required.

O NLO P S S E PE O YTM
M C IN A H E C NR L O T O U IT N
M C IN S E A H E LID D PLA E E T IS CMN

D IV R E M T R OO

2.4.2 CLOSED LOOP CONTROL: In closed loop control system has provisions for detecting or comparing the cutting tool movement with the commanded value. A closed loop control has a device called encoder and this can continuously ascertain the distance actually travelled by the tool and then monitor the same by feedback signals to the control. The control takes corrective action in case any error is detected .

C NR L OTO C MUE O P TR
P O RM R GA IN U PT C M A AO O P RT R C M A DV L E O MN AU

C OE L O SSE L SD O P YTM
D IV M T R R E OO S ID L E T AE E E R VR S MAU E E T E S R MN

E C DR NOE

A T A VL E C U L AU

F E B C S NL E D A K IG A S

2.5 MOTION CONTROL SYSTEM Based on the motion control system the NC machine is classified as follows: NC MOTION CONTROL SYSTEM: There are three basic type of motion control systems. 1. Point to point 2. Straight cut 3. Contouring 2.5.1 Point to point: Machines with point-to-point control provide only one feed axis while the other two axes can perform only rapid motion. E.g.: Drilling

POINT TO POINT CONTROL 2.5.2 Straight cut: This system provides feed motion in two axes (but not simultaneously) and hence their capability is limited to performing operation either along X-axis and Y-axis.

STRAIGHT CUT CONTROL

2.5.3 Contouring: This can provide feed control in three axes. They are also capable of providing simultaneous feed in 2 or 3 axes. Milling machine with contouring control can mill contours made up of straight lines and arc/circular elements. Depending on the number

10 of axes that can be simultaneously fed, contouring controls are further classified as 2D control, 21/2D control and 3D control.

CONTOURING CONTROL
2.5.3.1 2D control: Machines with 2D control can have simultaneous feed only in two or three axes. They can mill only contours with constant depth that too in just one plane. (X,Y)

2-D CONTOURING CONTROL

2.5.3.2 21/2D control: Machines with 21/2D control can have simultaneous feed of any of the two axes X-Y, X-Z, Y-Z and hence they can mill contours (of constant depth) in any one of the three planes.

2-1 DCONTOURING CONTROL

2.5.3.3 3D control: Machines with 3D control can have simultaneous feed in 3 axes. These controls can performs contours of increasing or decreasing depth, such as is required in helical milling.

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3-D CONTOURING CONTROL

2.6 Co Ordination of slide movement (INTERPOLATION) Interpolation is the technique by which a cnc machine axes (minimum two) simultaneously moves to facilitate machining in angular or circular paths, in mathematical sense it means to manipulate the axes in between two given values.

PULSES FOR PROGRAMMED FEED RATE

PULSES FOR Y-AXIS INTERPOLATOR PULSES FOR X-AXIS

MCU (Machine control unit) PRINCIPLE OF INTER POLATION

The system execute the given axes co-ordinates in order to decide the correct pulse rate/feed rate for individual axis. To do this the system divides the tool path into short straight line segments as shown below.

1 2 3 4 5
Y4 X 4 Y3 X 3 Y2 X 2 Y1 X 1

1 4 3 2
Y1 X 1 Y2 X 2

Y3 3 Y4 X X 4

X1,X2,X3 AND X4 ARE EQUAL Y1,Y2,Y3 AND Y4 ARE EQUAL

X1,X2,X3 AND X4 ARE NOT EQUAL Y1,Y2,Y3 AND Y4 ARE NOT EQUAL

2.7 AXIS DRIVE Servomotors control the entire axis in a CNC machine. The movement along the different axis is required either to move the cutting tool or the work material to the desired positions.

12 In order to accomplish accurate control of position and velocity, stepper motors are used for axis drive. The principle of working of a stepper motor is that on receiving a signal i.e. pulse, from the control unit, the motor spindle will rotate through a specified angle called step. The step size depends on the design of the motor and lies between 1.8 degree and 7.5 degree, which means that one rotation of the spindle can be divided into 200 parts. If a single pulse is received from the control system the motor spindle will rotate by one step. The control unit generates pulses corresponding to the programmed value of movement required for the tool or work. The rate of movement of tool or work is controlled by the speed at which the pulses are received by the stepper motor. The rate at which pulses are sent to the stepper motor is accurately governed by the control system. Hence there is no need of providing positional or velocity feedback system. The use of stepper motor considerably simplifies the system, as the feed back devices are not used. The cost of the machine tool is also less. However stepper motors are suitable only for light duty machines due to low power output. 2.7.1 BALL LEAD SCREW

Recirculating balls Ball return tube

Nut Ground thread screw

Reciprocating ball screw and nut 2.7.2 METALLIC & NON-METALLIC GUIDE WAYS In the conventional machine tools, there is direct metal-to-metal contact between the slide way and the moving slides. Since the slide movements are very slow and machine utilization is also low, this arrangement is adequate for conventional machine tools. However, the demand on slide ways is much more in CNC machines because of rapid movements and higher machine utilization. The conventional type of arrangement with

13 metal-to-metal contact does not meet the requirement of numerically controlled machine tools. The design of slide way in CNC machine tools should: (a) (b) (c) (d) Reduce friction Reduce wear Satisfy the requirements of the movement of the slides Improve smoothness of the drive.

To meet these requirements in CNC machine tool slide ways, the techniques used include hydrostatic slide ways, linear bearing with balls, rollers or needles and surface coating.

2.8 THE ADVANTAGES OF USING BALL SCREW AND NUT ASSEMBLY : i).HIGH EFFICIENCY: As compared to conventional lead screw the efficiency of ball screw and nut assembly is very high (over 90%). The power requirement for the ball screw arrangement is also less due to reduced friction. ii). REVERSIBILITY: The ball screw and nut assembly is reversible which makes it possible to back drive the unit i.e. by applying axial force to either nut or screw, the unconstrained member can be made to rotate. iii). WEAR AND LIFE: The re-circulating rollers reduce wear to a minimum and the ball screw, therefore, has longer life without loss of accuracy. iv).NO STICK SLIP: Stick slip is the phenomenon, which occurs when small movements between two lubricated elements. The lubricating medium tries to cause the mating elements to stick to each other to resist motion and results in a jerky motion as the mating elements try to stick and then slip during their relative movement. Since the sliding metal-to-metal contact is substituted by rolling contact, the stick-up phenomenon is eliminated in the ball screw and nut assembly. 2.9 DIFFERENT FEED BACK DEVICES There are three types of feedback devices being used in CNC machines. They are, a) Velocity feedback devices. b) Position feedback devices. c) Linear position measuring transducers.

14 2.9.1 VELOCITY FEEDBACK DEVICES A device called Tachogenerator normally provides velocity feedback. It generates voltage output, which is proportional to its speed. The tachogenerator is normally built in the servomotor case and is directly fitted on the servomotor shaft. The output voltage from the tachogenerator is used as feedback to monitor the motor speed. Rotary encoders are also used to provide feedback for velocity control. 2.9.2 POSITION FEEDBACK DEVICES The ideal method of measuring the displacement or position of the cutting tool is to continuously measure the position of the cutting tool edge relative to the datum point The positional feedback is provided by measuring the slide movements with measuring devices. The position measuring devices used are either rotary or linear measuring transducers. 2.9.3 LINEAR POSITION MEASURING TRANSDUCERS Linear position measuring transducer also operates on the photoelectric principle. The linear measuring system measures the displacement of the machines lies from a fixed datum. A linear measuring system consists of a precision linear scale engraved with close spaced alternate transparent and opaque parallel lines as one unit and a photocell and light source as the second unit. One of the units is fixed on the stationary element of the machine tool and the other unit is fixed to the moving worktable. A pulse is generated by the photocell as it is exposed to light source through the transparent areas of the linear scale. From the known number of the engraved lines per unit length on the linear scale and by counting the pulses, the displacement of the worktable can be established. The linear system may have either a glass scale in which light passes through the transparent area or a stainless steel scale in which the light is reflected from the transparent areas. 2.9.4 ROTARY OR ANGULAR POSITION MEASURING TRANSDUCERS Angular position measuring transducers operates by measuring the angular speed of a rotating element, normally of a lead screw, from the known value of lead screw, movement of worktable or machine slide is calculated by control system. Most commonly used angular position measuring transducers operate on the photoelectric principle. The transducer consists of a disc fitted on the axis of lead screw. The disc made up of uniform alternate transparent and opaque areas. A light source is fitted on one side of the disc and photocell on the other side. When the disc rotates with rotation of the lead screw, the photocell and light source. The photocell gives output voltage based on the intensity of light falling on it and the output from photocell resembles a sine-wave, which is converted into square shaped pulses to make it useful for control purposes. the rotary speed of the lead screw is calculated from the known number of lines engraved on the rotating disc. The displacement of the slide is then calculated from the lead of the lead screw. The direction of the rotation of lead screw is sensed by putting a second photocell in the circuit. Position measurement by angular position measuring transducer is indirect as the output of the transducer has to be converted into table displacement.

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2.10 TRANSDUCERS / ENCODERS

Transducers are used in CNC machines to trace the movement of members for feed back information. Transducer converts into electrical signals which in turn are recognized by the comparator for controlling the movement. Movement of liver and rotary movements can use optical or electrical transducers.

Two photocells sense direction of movement by phase difference figure.

Photocell 2

Photocell 1

Angular position measuring transducer

Light source

phot ocell

Leadscrew

Radial grating disc

Linear positioning measuring transducer

16

W table ork

Linear grating

Light source (fix ed) Photocell

Photocell Mounting

2.11 AUTOMATIC TOOL CHANGER (ATC): An automatic tool changer (ATC) is an important part of a machining center. An ATC picks up a tool from the magazine and keeps it ready for swapping with the tool in the spindle, which is presently cutting. The time for tool change varies between 3 to 7 seconds. The ATC plays a significant role in reducing idle time during tool change operations. There are a number of different designs for automatic tool changers.

2.12 AUTOMATIC PALLET CHANGER (APC): For machine with Automatic pallet changer (APC) the table is replaced by pallets. The function of the pallet changer is to interchange the pallet on the machine, in which one pallet has the finished component, and the other pallet with newly loaded component.

17 2.13 AUTOMATIC SCRAP REMOVAL MECHANISM: CNC machines are designed to work at optimum cutting conditions with the improved cutting tools on a continuous operation basis. Since the cutting time is much more in CNC machines, the volume of scrap generated is also more. Unless the scrap is quickly and efficiently removed from the cutting zone, it can affect the cutting process. In addition some auxiliary function like automatic component loading or automatic tool change may also be affected by accumulation of scrap. To avoid these problems an efficient scrap control system should be provided with CNC machine tools with some mechanism to remove the scrap from the cutter and cutting zone and for the disposal of scrap from the machine tool area itself. 2.14 SINUMERIK [810 D / 840 D/ 840Di] OPERATION The control systems 810D/840D/840Di are based on an open control concept which allows the machine manufacturers (and partially also you as the user) to configure the control system according to individual requirements. Thats why it is possible that there will be differences in the manual as regards the sequences of action. 2.14.1OVERVIEW OF THE CONTROL SYSTEM Structure and handling of the control system components Keyboard and display OP 010C operator panel for nt with TFT color screen, soft key bars and mechanical CNC full keypad with 65 keys These components are used mainly for the programming and processing of data. Machine Control Panel with override potentiometers

This control panel influences the machine movements directly. To a certain degree, it can also be configured by the machine manufacturer according to the customers requirements. SI.No FEATURE 1.0 Turning on 1.1 1.1.1 1.1.2 1.1.3 Area Switchover Menu selected Parameter Program DESCRIPTION After turning on, the control system is in the machine operating area. The main menu is displayed in the active machine operating area. By using menu selected on the slim line operator panel <Area switchover>key you can unhide the main menu with six operating areas of the control system. Change with the soft key to the parameter operating area. The parameter are extended to manage your tools and the label zero offsets In this operating area you can write & simulate NC programs

18 1.1.4 1.1.5 1.1.6 1.2 2.1 2.1.1 Services Diagnosis Startup Turning off Keyboard and screen layout(slim line operator panel) Key H1-H8 In this operating area you can manage files and receive them in and out via the serial interface or a floppy disk Alarm & service information are displayed & documented here This operating area is intended for system engineers in order to adapt NC data to the machine. Trip the main switch to disconnect the system from the mains

2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.1.7 2.1.8 2.1.9

Key V1-V8 Menu Select etc (>) Machine (M) Recall (^) Page up & Page down End Selection or toggle key

2.1.10 Delete 2.1.11 Backspace 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 Mechanical control panel Emergency stop Cycle start Cycle stop Reset Single block

By using horizontal soft keys (numbered for m the left to right) you can change between operating areas, with one operating are, you get into further menu areas and functions which can be called via vertical soft keys. By using the vertical soft keys (numbered for m top to the bottom) you activate functions or branch to further sub functions which are called via vertical soft key bar. By using the area switchover key the main menu with the operating system is displayed. By using the etc key, you extend the horizontal soft key bar. By using Machine key you can directly go to the operating area (Machine) The Recall key closes the window on top and lets you return to the higher level These keys are used to move the scrollbar of a window allowing you to scroll through long part programs By pressing this key, you can move the cursor to the end of the line By pressing these keys on the numeric key groups with NUM LOCK By pressing this key you can delete the selected character of the value of the input field. You can delete the character to the left of the cursor with this key Emergency stop, stops all drives as fast as possible This key is intended mainly to start the execution of program By pressing this key you stop the execution of the current program. Then you can continue the execution. By pressing this key, you can interrupt the program execution of the current program, messages are cleared and the control system is reset to the initial state. This key allows you to execute a program block by block. If the single block function is effective either of the entries SBL1, SBL2 or SBL3 is displayed in the channel. The program execution stops automatically after each block and can be contained with cycle start. Pressing single block again lets you to return to the following block.

19 i) FEED HOLD: When Feed hold button is pressed during a rapid motion, it will immediately stop the motion. This action applies to all the axes active at that time. Operations like threading or tapping cannot be stopped by this way. ii).EMERGENCY STOP: Every machine has a button marked as emergency stop or Estop. When this button is pressed all the motions will stop immediately. This top switch is mandatory safety feature on all the CNC Machines. iii).MANUAL DATA INPUT: [MDI] A CNC Machine is not always operated by means of a program. During a part setup, the CNC operator has to do a number of operations that require physical movements of the machine slides, rotation of a spindle, tool change etc. There are no mechanical devices on a CNC machine. The handle (Manual pulse Generator) is an electronic, not a mechanical unit. In order to operate a CNC machine without conventional devices the control system offers a feature known as Manual Data Input. The Manual Data Input enables the input of a program data into the system one program instruction at a time. To access the MDI mode, the MDI key on the operation panel must be selected. That opens the screen display majority of the programming codes are allowed in the MDI mode. iv).RAPID FEED RATE OVERRIDE This switch allows temporary rapid motion settings which modifies the rapid motion of the machine tool. This switch can be set to one of the four settings. Three of them are marked as the percentage of the maximum rate, typically as 100%, 50% and 25%. By switching to one of them, the rapid motion rate changes. The fourth position of the switch often has no percentage assigned and is identified as an F1 which can be customized for the user needs. In this setting, the rapid motion rate is even slower than 25%. v).SPINDLE SPEED OVERRIDE It modifies the programmed spindle r/min. If the programmed spindle sped is too high or too low, it may be changed temporarily by this switch. Overriding the programmed spindle speed on the CNC machine should have only one purpose to establish the spindle speed rotation for the best cutting conditions. Vi).FEED RATE OVERRIDE The most commonly used override switch is one that changes programmed feed rates. The new Feed rate calculation based on the overridden federate setting is Fn = Fp x p x 0.01

20 vii).DRY RUN OPERATION This is a special kind of override. It only has a direct effect on the federate and allows much higher federate that is used for actual machining. Its purpose is to test the integrity of the program before the CNC operator cuts the first part. Dry Run can be used in combination with several other features of the operation panel. viii).Machine Lock When this function is enabled, the motion of all axes is locked. This gives a chance to test the program with virtually no chance of a collision. When this lock is enabled, only the axis motion is locked but all other functions are executed normally.

CNC MACHINES CONTROL SYSTEM

Feature ON \ OFF Switch Cycle start Emergency stop Feed hold Single block Optional stop Block skip Dry run Spindle override Feed override Chuck clamp Table clamp Coolant switch Gear selection Spindle rotation Spindle orientation Tool change Reference position Handle Tailstock switch Indexing table switch Description Power and control switch for the main power and the control unit. Starts program execution or MDI command Stops all machine activity and turns off power to the control unit Temporarily stops motion of all axes Allows program run one block at a time Temporarily stops the program execution (M01 required in program) Ignores blocks preceded with a forward slash (/) in the program Enables program testing at fast federates (without a mounted part) Overrides the programmed spindle speed, usually within 50-120% range Overrides the programmed federate, usually within 0-200% range Shows current status of the chuck clamping (outside / inside clamping) Shows current status of table clamping Coolant control ON / OFF / AUTO Shows current status of working gear range selection Indicates spindle rotation direction (clockwise or counter clockwise) Manual orientation of the spindle Switch allowing a manual tool change Switches and lights relating to setup of the machine from reference position Manual pulse generator (MPG), used for axis select and handle increment switches Tailstock and/or quill switch to manually position the tailstock Manually indexes machine table during setup

21 MDI mode AUTO mode MEMORY mode TAPE mode EDIT mode MANUAL mode JOG mode RAPID mode Memory access Error lights Manual data input mode Allows automatic operations Allows program execution from the memory of the CNC unit. Allows program execution from an external device, such as a desktop computer or a punched tape Allows changes to be made to a program stored in the CNC memory Allows manual operations during setup Selects the jog mode for setup Selects the rapid mode for setup Key (switch) to allow program editing Red light indicating an error

2.15 AXES DESIGNATION 2.15.1 Typical configuration of a two axis slant bed CNC lathe rear type

HEADSTOCK CHUCK J AW S TOOL X + TAILSTOCK Z+ CENTRE X QUILL

Z-

Schematic representation of a vertical CNC lathe

Z +

X -

X +

Z -

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AXES OF CNC MACHINES:

Z

+Y +Z +Y +X

+Z

+X

VERTICAL MILLING MACHINE

HORRIZONTAL MILLING MACHINE

3.0 CNC PART PROGRAMMING

3.1 CO-ORDINATE SYSTEMS 3.1.1 DEFINING A POINT IN A PLANE The point of intersection of two axes is called zero point.. CNC machine has two methods of specifying the zero point. 1. Fixed zero: The origin is always located at the same position on the machine table. 2. Floating zero: The reference point for current dimensions is from previous position. It is called floating zero. The zero point should be located based on part programming convenience.

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3.1.2 LINEAR AND ROTARY ZERO OFFSET i).LINEAR ZERO OFFSET: There are work pieces in which the dimensions are distributed from several points. In such cases the co-ordinate system can be relocated in the course of machining operation. This procedure is called zero offset.
35

22

50

20

20 100

LINEAR ZERO OFFSET

ii).ROTARY ZERO OFFSET: In case of dimensions given in an angular way the co-ordinate system may be rotated about the zero point.
40

40

20

R20

20 30

100

ROTARY ZERO OFFSET

Linear and rotary zero offset save you lot of co-ordinate calculations and avoid mistakes during calculations. The transformation of co-ordinate is carried out by the control system. 3.2 CO-ORDINATE SYSTEM 3.2.1 CARTESIAN CO-ORDINATE SYSTEM (Rectangular): The method of defining a point in space by specifying its distance in x, y and z axes from a reference point is called Cartesian co-ordinate system.

70

70

30

24
CARTESIAN COORDINATES

Y1 Y

P1

0 0 X
DISTANCE J

3.2.2 POLAR CO-ORDINATE SYSTEM: The method of defining a point in space by specifying its distance from a pole and the angle between the line from the pole to the point and the main axis of the co-ordinate system.

X1

P0

P1 P0
E GL AN

0 I 0

POLAR COORDINATES

. 3.3 METHOD USED FOR SPECIFYING THE TOOL MOVEMENT: Absolute positioning & incremental positioning: Absolute positioning means that the tool locations are always defined in relation to the zero point. But in incremental positioning the next tool location must be defined with reference to the previous tool location.

Absolute & Incremental Positioning

P2

P1

P3

25 POINTS IN ABSOLUTE METHOD Poin t P1 P2 P3 X Y POINTS IN INCREMENTAL METHOD Poin t P1 P2 P3 X Y

Generally the program is created with the absolute command. In incremental command, if a co-ordinate value is mistaken, next values become improper. The incremental command is applied for pitch machining of constant interval. 3.4 FUNDAMENTALS OF PROGRAMMING The control system can move a tool along any straight line or circular path. For this, control system should know, The target position. (To define the point using Cartesian co-ordinate X, Y and Z) Cutter path (straight line/circular path/rapid traverse rate) Feed rate Spindle speed etc.

X20 Y20 X50 Y50 X30 Y70

X20 Y20 X30 Y30 X20 Y-20

i).PROGRAM: A set of machine codes (G, M, axis X, Y, Z) in sequence forms the program. This program command the machine to move correct target position.

ii).SUB PROGRAM: Sub program or subroutine program means, a separate program will nesting with the main program to minimize main program length, while working with more different operation. iii).MACRO PROGRAM: Macro programs are master template programs created to perform a particular task and these programs are used to repeat the operation on many jobs. The macro program can be called from other main programs. PROGRAM BLOCKS N10 G01 X50 Y100 Z30 F100 S1000

Block number

Type of Movement

Target co-ordinate

Feed rate

Spindle speed

3.5 TERMS IN PROGRAMMING:

26 i).PROGRAM NUMBER: a) b) c) d) e) The program number functions as addressing symbol for accessing a program. The program number is expressed by four digits numerals after the alphabet O. Numerals from 0001 to 9999 can be used. E.g. O4090. The program number can be input with numbers of smaller than 4 digits. The same number cannot be used twice.

ii).SEQUENCE NUMBER: a) The sequence number is used to - Search - Callout the position is being executed. - The position you want to edit in the program easily. b) Sequence number is expressed by numerals of 5 digits or less after the alphabet N. c) Numerals from 1 to 99999 can be used. E.g. N1 or N01 or N001. d) Generally sequence numbers are inserted into important places of the program. (Beginning of each block). If a program is over memory capacity, eliminate the sequence number to save memory capacity. iii).PART PROGRAM: Part program is used to process the machining and movement of machine to achive required shape. iv).ADDRESS: The address is expressed by the alphabets. E.g. G00 X100 Y100

ADDRESS v).DATA: Numerals (including the sign and decimal point) succeeding to the address are called data. E.g. G00 X100 Y100

DATA vi).WORD: Word is minimum unit for specifying the functions. It consists of the numerical values (data) including the address and sign. E.g. G00 X100 Y100

27

WORD vii).BLOCK: Block consists of words. Block is the minimum unit necessary to operate a machine. On the program each one line corresponds to one block. E.g. 3.5 NC WORDS The different words used in the CNC are G00 X100 Y100 Block

1) G-Code (Preparatory code): This word is used to prepare the NC controller for instructions that are to follow. For eg: G02 is used to prepare the NC controller unit for circular interpolation along an arc in the clockwise direction. There are two types of G codes modal codes and non model codes. Modal codes remain active until cancelled by a contradictory code. Eg: G01, G02, G03 etc. Non modal codes are active only in the block in which they are programmed.

X, Y & Z codes (Coordinates): These give the coordinate positions of the tool. In a two-axes system, only two of the words would be used. In a four or five axes machine, additional words would specify the angular position. (A, B & C) 2. F-Code (Feed rate): This specifies the feed in a machining operation. Units are inches/minutes or mm/minute. 3. S-Code (spindle speed): This specifies the spindle speed, the rate at which the spindle rotates. 4. T-Code (Tool selection): This word would be needed only for machines with a tool turret or automatic tool changer. The T-word specifies which tool is to be used in the operation. E.g. T05 might be the designation of tool location 5 on an turret/ magazine. 5. M-Code (Miscellaneous function):

28 The M-code is used to specify certain miscellaneous or auxiliary functions, which may be available on the machine tool. E.g. M03 to start the spindle rotation.

3.6 G CODES FOR TURNING & MILLING

COD E G00 G01 G02 G03 G04 G09 G10 G11 G15 G16 G17 G18 G19 G20 G21 G28 G40 G41 G42 G43 G44 G49 G50 G51 G52 G53 G54 G55 G56 G57 G58 G59 G60 G61 G62 G63 G65 TURNING Rapid Positioning Linear Interpolation Circular interpolation clockwise Circular interpolation counterclockwise Dwell (as a separate block) Exact stop check one block only Programmable data input (data setting) Data setting mode cancel English units of input Metric units of input Machine zero return (reference point1) Tool nose radius offset cancel Tool nose radius offset left Tool nose radius compensation right Tool position register/Maximum r /min preset Local coordinate system setting Machine coordinate system setting Work coordinate offset 1 Work coordinate offset 2 Work coordinate offset 3 Work coordinate offset 4 Work coordinate offset 5 Work coordinate offset 6 Exact stop mode Automatic corner override mode Custom macro call MILLING Rapid positioning Linear Interpolation Circular interpolation clockwise Circular interpolation counter clockwise Dwell (as a separate block) Exact stop check one block only Programmable data input (data setting) Data setting mode cancel Polar coordinate command cancel Polar coordinate command XY plane designation XZ plane designation YZ plane designation English units of input Metric units of input Machine zero return (reference point1) Cutter radius compensation cancel Cutter radius compensation left Cutter radius compensation right Tool length compensation positive Tool length compensation negative Tool length offset cancel Scaling function cancel Scaling function Local coordinate system setting Machine coordinate system setting Work coordinate offset 1 Work coordinate offset 2 Work coordinate offset 3 Work coordinate offset 4 Work coordinate offset 5 Work coordinate offset 6 Single direction positioning Exact stop mode Automatic corner override mode Ting mode Custom macro call

29 G66 G67 G68 G69 G70 G71 G72 G73 G74 G75 G76 G80 G81 G82 G83 G84 G85 G86 G87 G90 G90 G91 G92 G94 G94 G95 G96 G97 G98 G99 Custom macro modal call Custom macro modal call cancel Mirror image for double turrets Mirror image for double turrets cancel Profile fishing cycle Profile roughing cycle Z axis direction Profile roughing cycle X axis direction Pattern repetition cycle Drilling cycle Grooving cycle Threading cycle Cutting cycle A [Group type A] Absolute command [Group type B] Incremental command [Group type B] Thread cutting cycle [Group type A] Cutting cycle B [Group type A] Constant surface speed control Constant surface speed control cancel Feed rate per minute Feed rate per revolution [Group type A] Custom macro modal call Custom macro modal call cancel Mirror image for double turrets Mirror image for double turrets cancel High speed peck drilling cycle(deep hole) Left hand threading cycle Fine boring cycle Fixed cycle cancel Drilling or spot drilling cycle Dwell or counter boring cycle Peck-drilling cycle (deep hole drilling cycle) Right hand threading cycle Boring cycle Boring cycle Back boring cycle Absolute dimensioning mode Incremental dimensioning mode Tool position register Feed rate per minute [Group type B] Feed rate per revolution [Group type B] Return to initial level in fixed cycle Return to R level in a fixed cycle.

3.7

M-CODES FOR TURNING AND MILLING

MCODE

TURNING

MILLING

M00 M01 M02 M03 M04 M05 M06 M07 M08 M09

Compulsory program stop Optional program stop End of program (usually with reset no rewind) Spindle rotation normal Spindle rotation reverse Spindle stop Coolant mist ON Coolant ON (coolant pump motor ON) Coolant OFF (coolant pump motor OFF)

Compulsory program stop Optional program stop End of program (usually with reset no rewind) Spindle rotation normal Spindle rotation reverse Spindle stop Automatic tool change (ATC) Coolant mist ON Coolant ON ( coolant pump motor ON) Coolant OFF (coolant pump motor OFF)

30 M10 M11 M12 M13 M19 M21 M22 M30 M98 M99 Chuck open Chuck close Tailstock quill IN Tailstock quill OUT Spindle orientation (optional) Tailstock forward Tailstock backward Program end (always with reset and rewind) Subprogram call Subprogram end Spindle orientation Program end (always with reset and rewind) Sub program call Subprogram end

3. List of codes
A B C F G H I J K M N O P Q R S T X Y Z Specifies rotating angle of the NC rotary table Specifies rotating angle of the NC rotary table Specifies indexing angle of the coolant nozzle Specifies feed rate of the tool Specifies machining method and movement of axis on each block of the program Specifies tool length offset number Specifies component of circular command corresponding to the dimension of X axis Specifies component of circular command corresponding to the dimension of Y axis Specifies component of circular command corresponding to the dimension of Z axis Controls ON/OFF functions of the machine Specifies sequence number Specifies program number Specifies time command in the Dwell function / Program number in subprogram call Specifies depth of cut as per pass at hole machining canned cycle Specifies radius of circular command point R in the hole machining canned cycle Specified spindle speed Specifies tool number Specifies position in the direction of X axis Specifies position in the direction of Y axis Specifies position in the direction of Z axis

3.3.5 G Codes CO-ORDINATE SYSTEMS

i). ABSOLUTE G90

31 The destination of movement is specified with the coordinate value with reference to origin.
Y+

Y+
60

10
10

10

60

X +

10

X +

G90 X60.0 Y10.0;

G90X10.0Y60.0;

ii). INCREMENTAL G91 The movement is specified by the incremental value to the destination referring the current position.

Y+

Y+ 10

60

10

10

60

X +
10 Y+ X +

G91 X50.0; ABSOLUTE (G90) & INCREMENTAL (G91)

60

G91 Y 50.0;
B

G90 and G91 are abbreviated as ABS & INC respectively 20 A

20 60

X+

32 From point A to point B ABS G90 X60.0 Y60.0 ; INC G91 X40.0 Y40.0 ; From point B to point A ABS G90 X20.0 Y20.0 ; INC G91 X-40.0 Y-40.0 ABS is better when each hole position is indicated from a reference point, programming is made easy by setting as the origin.

INC is better when the pitch between the position of each hole is indicated. when position with the same pitch is repeated.

Y+ 60 50 40 30 20 10 X + 10 20 30 40 50 60

33 Example 1 (G90 &G91) O0001 (ABS) ; G90 G54 (X20.0) Y60.0 ; X60.0 Y10.0 ; (X60.0)Y60.0 ; O0002 (INC) ; G91 G54 (X0) Y50.0 ; X40.0 Y-50.0 ; (X0)Y50.0 ;
Y+

Example 2 (G90 &G91) O0001 (ABS) ; G90 G54 X-60.0 (Y20.0) ; X-20.0 Y60.0 ; X-60.0 (Y60.0) ; O0002 (INC) ; G91 G54 X-40.0 (Y0) ; X40.0 Y40.0 ; X-40.0 (Y0) ;
X6 0 5 0 4 0 3 0 20 1 0

60 50 40 30

20
10

ABS & INC Command for Z Axis movement When the cutter is started 100mm above the top of the work piece and driven 10mm in Z direction.

100mm.

Z100.0 G00
100.0 Z-98.0

10mm

2mm
work piece
G01

Z2.0 Z0

2mm
10.0
Work piece

Z-12.0

Z-10.0

G90 G54 G00 Z2.0; G01 Z-10.0 F100; G00 Z100.0;

G91 G54 G00 Z-98.0; G01 Z-12.0 F100 G00 Z110.0;

3.4 Circular Interpolation G02, G03 Commands G02, G03 are used to cut circles or arcs. G02 is

34 Specified for CW circle motion. G03 for CCW circle motion. CW Clockwise ( Right hand ) CCW Counterclockwise ( Left hand )

THE CIRCLE CENTRE COORDINATE I AND J G17 Vertical Machining Centre

M A In the plane G17 I and J

CENTRE POINT CCW START POINT

J I

+Y
START POINT

CENTRE POINT

CCW

+X
I is a coordinate parallel to the X axis J is a coordinate parallel to the Yaxis

A=start point E=end point M=centre

I-

K-

I-

USED IN TURNING

USED IN MILLING

J-

35

G02

G03

QUADRANT I
I0 J I- J I- J 0 I- J -

QUADRANT II
I+J 0 I+ J I0 J I+J -

QUADRANT III
I0 J + I+ J I+ J 0 I+ J +

QUADRANT IV
I- J 0 I- J + I0 J + I- J +

G03

G01

G01 G02 G01

G00

K-

G03

G02

Dimension I & J

I+
R

36 Command I & J specify the distance from the start point of circle arc A to the center. I, J & K must be specified incrementally even under ABS mode, adding plus or minus for the direction of I, J & K. I : Incremental distance between start point to centre point in X - axis J : Incremental distance between start point to centre point in Y- axis K : Incremental distance between start point to centre point in Z - axis
Y
Y

`
Start

G02

40

B(End of circular arc) G03 A(Start of circular arc)

X 10 20 40
J+ IJI+

20

Center

End

10

ABS G90 G30 X20.0 Y40.0 I-30.0 J-10.0 F100 ; INC G91 G03 X-20.0 Y20.0 I-30.0 J-10.0 F100 ; Specifying radius of circle/arc R The radius of circle arc can be directly specified by R instead of specifying the center of circle arc by I, J & K. When the center angle of arc is 180 or more, the radius R must be specified with negative (-) sign.
Y
Y
70

A(Start of arc)
70

0 R5

Start

0 R5

180 OR MORE

20

20

20

ABS G90 G02 X70.0 Y20.0 R50.0 F100 ; INC G91 G02 X50.0 Y-50.0 R50.0 F100 ;

70

R-50.0 F100 ; R-50.0 F100 ;

A complete circle With I, J & K, a complete circle can be programmed by using one block.
Y+
A

J+
R .0 40

X+ IJ-

I+

20

70

of arc)

End

37

From A point ABS G90 G02 J-40.0 F100 ; INC G91 G02 J-40.0 F100 ;

From B point ABS G90 G02 I-40.0 F100 ; INC G91 G02 I-40.0 F100 ;

3.4 Machine Zero point & Work Piece Zero point

+X
Z REF POINT

-X

TURRET DISC ZERO OFFSET (Z)

+Z
X REF.POINT
TOOL

-Z
GEOMETRY RADIUS V ALUE

PART LENGTH SPINDLE M ACHINE ZERO POINT OV SIZE ER

TOOL ZERO POINT

L2

(POINT COMM ANDED BY CNC)

+X +Z

-Z

W ORK PIECE ZERO POINT BLANK LENGTH

TAIL STOCK L1 = XTOOL OFFSET L2 =Z TOOL

3.5 WORK ZERO IN MILLING LENGTH CHUCK AND JAW -X

X-MOTION

MACHINE ZERO XY AXES

MACHINE TABLE TOP AREA

Y-MOTION TOP VIEW

W1

W2

38

Work Coordinate System G54~G59

What is work coordinate system The work coordinate system is a coordinate system to be set specifically for a work piece which is fixed on the table. The machining programs are created on the basis of this work coordinate system. Setting Procedure for X,Y

X-303.444 Machine Origin G91 G28 X Y0 0 Y-170.123 G54

G59

3.6

Setting Procedure for Z

CUTTER LENGTH COMPENSATION: In order to know how far the machine slide has to be down feed the control system must know the length of the tool used. If retrieves the tool length required for a machinery operation from the tool life. G43 Tool length compensation + G44 Tool length compensation G49 Cancellation will not takeaway the production time. PRESETTING TOOL LENGTHS: Each tool is assigned a specific identification number (H) along with a list of measured tool lengths. The CNC operators must set the tools in their correct location in the tool magazine and register each tool length in the offset register using the proper offset number. Any tool can be recalled by a command in the CNC program whenever a specific tool is required.

39
G U AG E L IN E

G 54

H 01

H 02

H 03

Z0 P AR T

TOUCH OFF METHOD (FROM ZO GIVING THE VALUE) Each tool is assigned as H number also called the tool length offset number which usually corresponds to the tool number. The set up procedure is to measure the distance the tool travels from the machine zero position (Hm) to the program zero position (ZO). This distance always negative in entered into the corresponding H offset numbers under the tool length offset means of the central system. The Z value for any work offset (G54, G59 and the common offset) is normally set to ZO.

GUAGE LINE

H01

H03

H02

Z0 PART

40 MASTER TOOL METHOD: The master tool method using the largest tool can greatly reduce the amount of time spent in setting tool lengths. The master tool length compensation method is very efficient by following the proper procedure.

1) Install the master tool in the m/c spindle. 2) Zero the Z-axis and check that the read cut screen show .000 3) Measure the length of the master tool from the tool tip to ZO using launch method. Register it to G54 G59 work offsets under Z setting (-ve) 4) The touching level of (cutting edge) the cutter is made zero in Z-axis and the other tool lengths are measured with reference to the material tool. 5) The values are centered the H offset number in the tool length offset screen. (The values are always negative for any tool shorter than the master tool)
GUAGE LINE T01

H01

H03

G54

H02 =0.0 Z0

PART

3.7 PLANE SELECTION It is necessary to select a plane on which the circle interpolation, tool radius compensation, coordinate rotation or drilling carried out. A plane is signified with a horizontal axis first and then a vertical axis, e.g the left figure is called XY plane. This plane is viewed from the positive side of the Z axis

Y
ca tio Pl an e Si gn ifi n

41

G 17(XY PLANE)

42 The X Y Plane is the plane which is viewed from the positive side of Z axis toward the work piece top surface.

G18(XZ Plane) The ZX Plane is the plane which is viewed from the positive side of Y axis toward the work piece Y+direction.

G19 (YZ Plane) The YZ Plane is the plane which is viewed from the positive side of X axis toward the work piece x+direction.

43

3.8 CUTTER RADIUS COMPENSATION

Cutter compensation is a method of shifting the tool path so that the actual finished cut is moved to either the left or right of the programmed path. Normally cutter compensation is programmed to shift by exactly the radius of the tool. So that the finished cut matches the programmed path. The offset display is used to enter the amount of tool to be shifted. The offset is entered either the diameter or radius and wear values can be given for both. The effective value is the sum of wear value and the geometry.

Programming Format G41, G42 & G40

P n s le io la e e ct n G7 1 G8 1 G9 1 C n lin a ce g

T o co p n aio o l me s t n X _ _Y G0 G2 0 4 Z _ _X G1 G1 0 4 Y _ _Z G0 0 G1 0 X _ _Y Z _ _X Y _ _Z

Of e n m e fs t u b r D ; _

G0 4

The radius compensation commands used on the CNC lathe are the same preparatory Gcodes that are used for programming CNC mills, G41 compensation of the tool-nose radius to the left of the contouring direction.

44 G42 - compensation of the tool-nose radius to the right of the contouring direction. G40 - cancels of the tool-nose radius compensation.

3.5.1 Tool Nose

The tool nose on turning tools is the corner of the cutting tool or insert where the cutting edges blend together. This is the point that is programmed, and is called the command point or the imaginary point. It is referred to as the imaginary point because in reality the cutting-tool insert does not have a sharp point, there is usually a radius on the insert to provide strength and longer life during the cutting operation. Cutting tools for turning have a small radius usually:

to Z0 to X0
.015in. (0.4 mm .030in. (0.8mm) .047in. (1.2mm)
R Reference point a

Reference point R

to Z0
b

to X0

45 These codes allow the MCU to accurately produce arcs and tapers on the work piece by automatically accounting for the size of the radius on the tool nose. Without tool-nose radius compensation, the work piece profiles cut by the tool nose would be subject to undercutting and over cutting.
PROGRAMMED CONTOUR

PROGRAMMED CONTOUR

TOOL PATH

TOOL PATH

INSUFFICIENT CUTTING

TOOL NOSE

Compensation not used

Compensation used

TOOL NOSE

Arbitrary tool tip numbers for tool nose radius compensation. The dot is the point of reference. The tool tip orientation number and the value or size of the tool radius must be entered in the machine control system.

46

Memory aid : G41 = left

Workpiece edge

Direction of movement=direction of vision

G40 cancels G41,G42

G41 G41

G42 G42
X X

Cutter radius compensation, changes a milling cutters programmed centerline path to compensate cutter radius. Advantages allows the use of cutters that have been sharpened to a smaller diameter.

47 permits the use of a larger or smaller tool already in the machines storage area. allows the tool to be backed away when roughing cuts are required due to excessive material. permits compensation for unexpected tool or part deflection if the deflection is constant throughout the programmed path. Sample of Program for G41, G42& G40.
O 1000 ( 20 ENDMILL ) ; T32 M06; G01 G41 X0 Y-50.0 D32 F100 ; X100.0; Y50.0; X-100.0; Y-50.0 X0; G40 X0 Y0; M30;

200

100

Effect of cutter radius compensation

r
R

Should not be less than 45

Angle should be

1 1
I

3 r

23
I

4I

r>R
I

r>2,3

48

3.6 TURNING CYCLES (FANUC)

G70 Finishing Cycle Format: G70 P__ Q__ F__; P Starting block number. Q Ending block number. F Feed. G71 Rough turning cycle Format: G71 U__ R__; G71 P__ Q__ U__ W__ F__;

U Depth of cut per pass in x axis. (radial value). R Tool relief. P Starting block number. Q Ending block number. U Finishing allowance in x axis. (Diametric value) W Finishing allowance in z axis. F Feed. EXAMPLE: 1 G71 ROUGH TURNING CYCLE (Profile roughing in z axis)

28

40

20
O0010; N10 G28 U0 W0; N20 T0101 G96S200;

15

10

20

49 N30 G50 S1500 M03; N40 G00 X50.0 Z0.0 M08; N50 G01 X0.0 F0.12; N60 G00 X45.0 Z2.0; N70 G71 U1.0 R1.0; N80 G71 P90 Q160 U1.0 W1.0 F0.25; N90 G01 16.0; N100 Z0.0; N110 X20.0 Z-2.0; N120 Z-10.0; N130 X28.0; N140 Z-25.0; N150 X40.0 Z-31.0; N160 Z-51.0; N165 X46.0 N170 G00 X48.0 Z2.0; N180 G70 P90 Q160 F0.10; N190 G00 X48.0 Z2.0 M09; N200 G28 U0 W0 M05; N210 M30; G72 ROUGH TURNING CYCLE (Profile roughing in x axis) Format: G72 W__ R__; G72 P__ Q__ U__ W__ F__; (Finishing cycle) (Profile roughing in z axis)

W Depth of cut per pass in z axis. R Tool relief. EXAMPLE: 2 G72 ROUGH TURNING CYCLE (Profile roughing in x axis)

50

25 50

17

10 10 40

16

O0011; N10 G28 U0 W0; N20 T0101 G96S250; N30 G50 S1500 M03; N40 G00 X55.0 Z0.0 M08; N50 G01 X0.0 F0.12; N60 G00 X55.0 Z2.0; N70 G72 W1.0 R1.0; N80 G72 P90 Q190 U1.0 W1.0 F0.25; N90 G01 Z-40.0; N110 X50.0; N120 Z-35.0; N130 G02 X40.0 Z-30.0 R5.0; N140 G01 X25.0; N150 Z-20.0; N160 X17.0 Z-16.0; N170 Z-1.0; N180 X15.0 Z0.0; N190 X0.0; N200 G00 55.0 Z2.0; N210 G70 P90 Q190 F0.10; N220 G00 X100.0 Z50.0 M09; N230 G28 U0 W0 M05; N240 M30; (Profile roughing in x axis)

51 G73 PATTERN REPETITION CYCLE Format: G73 U__ W__ R__; G73 P__ Q__ U__ W__ F__; U Maximum raw material in X-Axis W - Maximum raw material in Z-Axis U Finishing allowance in X-Axis W Finishing allowance in Z-Axis R Number of passes. F - Feed EXAMPLE: 3 G73 PATTERN REPETITION CYCLE
R6 35 50 25 R2.5

20

25

20

O0012; N10 G28 U0 W0; N20 M06 T0101; N30 M03 S1500; N40 G00 X55.0 Z0.0 M08; N50 G01 X0.0 F0.12; N60 G00 X55.0 Z2.0; N70 G73 U1.0 W1.0 R5.0; N80 G73 P90 Q170 U5.0 W5.0 F0.25; N90 G00 X20.0; N100 G01 Z0.0; N110 G03 X25.0 Z-2.5 R2.5; N120 G01 Z-20.0; N130 X35.0 Z-25.0; N140 Z-44.0; N150 G02 X47.0 Z-50.0 R6.0; N160 G01 X50.0; (Pattern repetition cycle)

52 N170 Z-70.0 N175 G00 X55.0 Z3.0; N180 G70 P90 Q170 F0.10; N190 G00 X55.0 Z2.0 M09; N200 G28 U0 W0 M05; N210 M30;

G74 PECK DRILLING CYCLE Format: G74 R__; G74 Z__ Q__ F__; R Tool relief. Z Total depth. Q Depth of cut per pass (in microns). F Feed. EXAMPLE: 4 G74 PECK DRILLING CYCLE Tools: 1. Centre drill 2. 10 mm drill (G74) O0013; N5 G28 U0 W0; N10 T0101; (c.d) N15 S1000 M03; N20 G00 X0.0 Z2.0 T0101 M08; N25 G01 Z-3.0 F0.10; N30 G00 Z2.0 M09; N35 G28 U0 W0 M05; N40 M01; N45 G28 U0 W0; N50 T0202; (10 mm drill) N55 S500 M03; N60 G00 X0.0 Z2.0 M08; N65 G74 R500.0; N70 G74 Z-60.0 Q10000 F0.10; N75 G00 Z10.0 M09; (Peck Drilling cycle)

53 N80 G28 U0 W0 M05; N85 M30; G75 GROOVING CYCLE Format: G75 R__; G75 X__ Z__ P__ Q__ F__;
TOOL

R Tool relief. X Groove diameter. Z Groove length from zero point. P Depth of cut in X axis (in microns). Q Depth of cut in Z axis (shifted value). F Feed. EXAMPLE: 5 G75 GROOVING CYCLE

70

60

30
O0014; N5 G28 U0 W0; N10 T0505 G96 S120; (4mm insert) N15 G50 S1500 M03; N20 G00 X72.0 Z0.0 M08; N25 Z-29.0; N30 G75 R200;

20

25

N35 G75 X60.0 Z-45.0 P500 Q3000 F0.12; N40 G00 X80.0; N45 Z10.0 M09; N50 G28 U0 W0 M05; N55 M30;

(Grooving cycle)

54 THREAD CUTTING
P H d Z D

D Major dia. d Minor dia. H Height of thread. P Pitch. Z Thread length. M 30 X 1.5 Pitch Major diameter Metric thread Formula to calculate diameter d = D 2h h = 0.649 x P (to find the height of the thread) G76 THREAD CUTTING CYCLE Format: G76 P__ Q__ R__; G76 X__ Z__ P__ Q__ F__; P Thread angle Chamfer angle No. of finishing passes Q Minimum depth of cut in microns (Radial value) R Finishing depth of cut in microns X Thread diameter Minor dia Z Thread length P Height of thread in microns Q Depth of cut/pass in microns (Radial value) F Feed (Pitch value)

55 EXAMPLE: 6 G76 THREAD CUTTING CYCLE External threading

5 80

50

Using formula, h = 0.649 x P h = 0.649 x 2.5 = 1.6225 d = D 2h = 40 (2 x 1.6224) d = 40 3.245 = 36.755 Minimum No. of passes N = 4 x P = 4 x 2.5 = 10 passes. O0017; N5 G28 U0 W0; N10 T0606; N15 G97 S500 M03; N20 G00 X42.0 Z4.5 M08; N25 G76 P030060 Q150 R25; N30 G76 X36.755 Z-52.0 P1623 Q500 F2.5; N35 G00 X50.0; N40 Z20.0 M09; N45 G28 U0 W0 M05; N50 M30;

56

3.7 CANNED CYCLES (milling)

Tool

Rapid traverse Cutting feed

Movement 1 Initial point Z+ Movement 6 Movement 5

Movement 2 Movement 3

Movement 4

Point Z Workpiece

Z-

Movement 1 : Positioning to hole machining start position Movement 2 : Moving of X,Y and Z axis. Movement 3 : Moving to point R at rapid traverse Hole machining is carried out. Movement 4 : Movement at hole bottom Specify dwell command if necessary Movement 5 : Return to point R To return at either rapid traverse or cutting feed varies according to G code for the hole machining canned cycle. Movement 6 : Return to initial point at rapid traverse The tool returns to the start point (Initial point) of the movement at rapid traverse.

57

initial level

R level

R level

G98

G99

3.7.1 DRILLING CYCLES

G81 DRILLING OR SPOT DRILLING CYCLE G82 SPOT DRILLING OR COUNTER BORING CYCLE G83 PECK DRILLING CYCLE G73 HIGH SPEED PECK DRILLING CYCLE Format: G98 or G99 G81 X__ Y__ Z__ R__ F__; (Spotting /Drilling)

G98 or G99 G82 X__ Y__ Z__ R__ P__ F__; (Spotting /Counter Boring) G98 or G99 G83 X__ Y__ Z__ R__ Q__ F__; (Peck Drilling) G98 or G99 G73 X__ Y__ Z__ R__ Q__ F__; (High Speed Peck Drilling) X,Y Positioning points. Z Total depth. R feed starting level. F cutting feed. P dwell time Q pecking depth

EXAMPLE: (G81, G82, G83,G73)

58

8holes14mm drill,depth20mm equallyspaced on a PCD 100mm

150

Tools 1. C.d (centre drill) 2. 14mm drill Points 1. X50.0 Y0.0 2. X35.35 Y35.35 3. X0.0 Y50.0 4. X-35.35 Y35.35 5. X-50.0 Y0.0 6. X-35.35 Y-35.35 7. X0.0 Y50.0 8. X35.35 Y-35.35 O0006; N5 G00 G91 G28 Z0.0; N10 G28 X0.0 Y0.0; N15 M06 T1; (c.d) N20 G00 G90 G54 X50.0 Y0.0 S2000 M03; N25 G43 H1 Z100.0; N30 G00 Z50.0 M08; N35 G98 G81 X50.0 Y0.0 Z-3.0 R5.0 F100.0; N35 G98 G82 X50.0 Y0.0 Z-3.0 R5.0 P500 F100.0; N40 X35.35 Y35.35; ( Spotting /Drilling) ( Spotting /Counter Boring)

59 N45 X0.0 Y50.0; N50 X-35.0 Y35.35; N55 X-50.0 Y0.0; N60 X-35.35 Y-35.35; N65 X0.0 Y-50.0; N70 X35.35 Y-35.35; N75 G00 G80 Z100.0 M09; N80 G00 G91 G28 Z0.0 M05; N85 G28 X0.0 Y0.0; N90 M01; N95 M06 T2; (14mm drill) N100 G00 G90 G54 X50.0 Y0.0 S2000 M03; N105 G43 H2 Z100.0; N110 G00 Z50.0 M08; N115 G98 G83 X50.0 Y0.0 Z-20.0 R5.0 Q3.0 F100.0; (Peck Drilling) ( Tool Retract to Initial Level R) N115 G98 G73 X50.0 Y0.0 Z-20.0 R5.0 Q3.0 F100.0; ( High Speed Peck Drilling) ( Tool Retract set by machine builder) N120 X35.35 Y35.35; N125 X0.0 Y50.0; N130 X-35.0 Y35.35; N135 X-50.0 Y0.0; N140 X-35.35 Y-35.35; N145 X0.0 Y-50.0; N150 X35.35 Y-35.35; N155 G00 G80 Z100.0 M09; N160 G00 G91 G28 Z0.0 M05; N165 G28 X0.0 Y0.0; N170 M30; (Canned cycle cancel)

60

3.8 TAPPING CYCLES

G84 RIGHT HAND TAPPING CYCLE Format: G98 or G99 G84 X__ Y__ Z__ R__ P__ F__; X,Y Positioning points. Z Total depth. R Relief. P Dwell time in milliseconds. F Feed. (Pitch value) Note: G84 cycle is used for right hand tapping. In this the tool moves inside in clockwise direction (M03) in feed. At the bottom dwell time is performed, during that time spindle speed, feed stops and spindle automatically reverses its direction (M04). Return movement is also in feed. Spindle speed should be given less (200 500).

G74 LEFT HAND TAPPING CYCLE Format: G98 or G99 G74 X__ Y__ Z__ R__ P__ F__; X,Y Positioning points. Z Total depth. R Relief. P Dwell time in milliseconds. F Feed. (Pitch value) Note: G74 cycle is used for left hand tapping. In this the tool moves inside in counter clockwise direction (M04) in feed. At the bottom dwell time is performed, during that time spindle speed, feed stops and spindle automatically reverses its direction (M03). Return movement is also in feed. Spindle speed should be given less (200 500).

G84 RIGHT HAND TAPPING CYCLE

61 EXAMPLE:

100

25

20

80

Tools 1. C.d (centre drill) G81 2. 6.8mm drill G83 or G73 3. M8 tap G84 d = D Pitch value F = S x P where, F = Feed, S = Spindle speed, P = Pitch value d = 8 1.25 = 6.75 F = 200 x 1.25 = 250mm/min. d = 6.7 or 6.8mm. Points 1. X20.0 Y25.0 2. X60.0 Y25.0 3. X60.0 Y75.0 4. X20.0 Y75.0 O0009; N5 G00 G91 G28 Z0.0; N10 G28 X0.0 Y0.0; N15 M06 T1; (c.d) N20 G00 G90 G54 X20.0 Y25.0 S2000 M03; N25 G43 H1 Z100.0; N30 G00 Z5.0 M08; N35 G98 G81 Z-3.0 R5.0 F100.0; N40 X60.0 Y25.0; N45 X60.0 Y75.0;

62 N50 X20.0 Y75.0; N55 G00 G80 Z100.0 M09; N60 G00 G91 G28 Z0.0 M05; N65 G28 X0.0 Y0.0; N70 M01; N75 M06 T2; (6.8mm drill) N80 G00 G90 G54 X20.0 Y25.0 S2000 M03; N85 G43 H2 Z100.0; N90 G00 Z50.0 M08; N95 G98 G73 Z-30.0 R5.0 Q10.0 F100.0; N100 X60.0 Y25.0; N105 X60.0 Y75.0; N110 X20.0 Y75.0; N115 G00 G80 Z100.0 M09; N120 G00 G91 G28 Z0.0 M05; N125 G28 X0.0 Y0.0; N130 M01; N135 M06 T3; (M8 tap) N140 G00 G90 G54 X20.0 Y25.0 S200 M03; N145 G43 H3 Z100.0; N150 G00 Z50.0 M08; N155 G98 G84 Z-30.0 R5.0 P3000 F250.0; N160 X60.0 Y25.0; N165 X60.0 Y75.0; N170 X20.0 Y75.0; N175 G00 G80 Z100.0 M09; N180 G00 G91 G28 Z0.0 M05; N185 G28 X0.0 Y0.0; N190 M30; (Right hand tapping) (Spindle switched ON in cw)

63 G74 LEFT HAND TAPPING CYCLE EXAMPLE:

M8x1.25,depth 30mm(L.H)

100

25 20

80

(Above Lines Are Same As G84 Cycle Example) N135 M06 T3; (M8 tap) N140 G00 G90 G54 X20.0 Y25.0 S200 M04; N145 G43 H3 Z100.0; N150 G00 Z5.0 M08; N155 G98 G74 Z-30.0 R5.0 P3000 F250.0; N160 X60.0 Y25.0; N165 X60.0 Y75.0; N170 X20.0 Y75.0; N175 G00 G80 Z100.0 M09; N180 G00 G91 G28 Z0.0 M05; N185 G28 X0.0 Y0.0; N190 M30; (Left hand tapping) (Spindle switched ON in ccw)

64

3.9 BORING CYCLES

G85 REAMING OR BORING CYCLE (Rough) Format: G98 or G99 G85 X__ Y__ Z__ R__ F__; X,Y Positioning points. Z Total depth. R Relief. F Feed. Note: G85 cycle is used for reaming and rough boring operations. This cycle is same as G84 except dwell time.

G86 BORING CYCLE (Rough) Format: G98 or G99 G86 X__ Y__ Z__ R__ F__; X,Y Positioning points. Z Total depth. R Relief. F Feed. Note: G86 cycle is used for rough boring operation. This cycle is same as G81 except spindle orientation.

G76 BORING CYCLE (Fine) Format: G98 or G99 G76 X__ Y__ Z__ R__ Q__ F__; X,Y Positioning points. Z Total depth. R Relief. Q Shift amount in mm. (value should be very less between 0.1 0.5). F Feed.

65

SpindleCW Initial level Spindle CW Point R level PointR Point R

P OSS
q

P PointZ OSS
q

PointZ

G 76 (G 98)

G 76 (G 99)

BORING CYCLE EXAMPLE:

SQ.100 35H7

TOOLS 1. c.d (G81) 2. 15mm drill 3. 25mm drill (G83 orG73) 4. 35mm drill 5. 39mm rough boring (G85 or G86) 6. 40mm fine boring (G76) N135 M06 T5; (39mm rough boring tool) N140 G00 G90 G54 X50.0 Y50.0 S1200 M03; N145 G43 H5 Z100.0;

66 N150 G00 Z50.0 M08; N155 G98 G86 Z-35.0 R5.0 F100.0; N160 G00 G80 Z100.0 M09; N165 G00 G91 G28 Z0.0 M05; N170 G28 X0.0 Y0.0; N175 M01; N180 M06 T6; (40mm fine boring tool) N185 G00 G90 G54 X50.0 Y50.0 S1200 M03; N190 G43 H6 Z100.0; N195 G00 Z5.0 M08; N200 G98 G76 Z-35.0 R5.0 Q0.2 F100.0; N205 G00 G80 Z100.0 M09; N210 G00 G91 G28 Z0.0 M05; N215 G28 X0.0 Y0.0; N220 M30; (Fine boring) (Rough boring)

3.10 SUB PROGRAM

Sub programming or sub routing programming is a means by which we can make one program within the other. Subroutine allows the CNC program to define a series of commands which might be repeated several times in a program. Subroutine call is done by M98 and a P -------(number) which is the name of the subprogram. Another very important feature of subroutine is that M98 call block also include an L repeat count. If there is an L the subroutine call is repeated that number of times before the main program continues with the next block. To insert a subprogram in a main program, simply write the sub program member in the block where we want the subprogram to work.

O1
M98 P2 L

O2
J ump to subprogram
End of main program

M30

M99

Return tomain program

67

M98 Sub Program Call M99 Sub Program End M98 Sub Program Call Format: M98 P L Number of Repeats Sub program number PROFILE MACHINING (Using Sub Program) EXAMPLE: 4

30
0 R3

O0013; N5 G00 G91 G28 Z0.0; N10 G28 X0.0 Y0.0; N15 M06 T1; (12mm EM) N20 G00 G90 G54 X0.0 Y0.0 S1200 M03; N25 G43 H1 Z100.0; N30 G00 Z5.0 M08; N35 G01 G42 X10.0 Y10.0 D1; N40 G01 Z0.0 F80.0;

20 15

20

10

10

Sub program O0025; N1 G01 G91 Z-5.0 F80.0; N2 X60.0; N3 Y20.0; N4 G02 X-30.0 Y30.0 R30.0; N5 G01 X-30.0; N6 Y-50.0; N7 M99; (Subprogram end)

68 N45 M98 P0025 L3;(Sub program call) N50 G00 G40 X-20.0 Y-20.0; N55 G00 Z50.0 M09; N60 G00 G91 G28 Z0.0 M05; N65 G28 X0.0 Y0.0; N70 M30;

DRILLING OPERATION (Using Sub Program) EXAMPLE:

M10x1.5,depth 30mm

50 60 70 70

Operations 1. C.d (centre drill) G81 2. 8.5mm drill G83 or G73 3. M10 tap G84 d = D Pitch value F = S x P where, F = Feed, S = Spindle speed, P = Pitch value d = 10 1.5 = 8.5 F = 200 x 1.5 = 300mm/min. d = 8.5mm. Points 1. X60.0 Y50.0 2. X200.0 Y50.0 3. X200.0 Y190.0

70

70

69 4. X60.0 Y190.0 5. X130.0 Y130.0 O0014; N5 G00 G91 G28 Z0.0; N10 G28 X0.0 Y0.0; N15 M06 T1; (c.d) N20 G00 G90 G54 X60.0 Y50.0 S2000 M03; N25 G43 H1 Z100.0; N30 G00 Z50.0 M08; N35 G98 G81 Z-3.0 R5.0 F100.0; N40 M98 P0023; N45 G00 G80 Z100.0 M09; N50 G00 G91 G28 Z0.0 M05; N55 G28 X0.0 Y0.0; N60 M01; N65 M06 T2; (8.5mm drill) N70 G00 G90 G54 X60.0 Y50.0 S2000 M03; N75 G43 H2 Z100.0; N80 G00 Z50.0 M08; N85 G98 G83 or G73 Z-30.0 R5.0 Q10.0 F100.0; N90 M98 P0023; N95 G00 G80 Z100.0 M09; N100 G00 G91 G28 Z0.0 M05; N105 G28 X0.0 Y0.0; N110 M01; N115 M06 T3; (M10tap) N120 G00 G90 G54 X60.0 Y50.0 S200 M03; N125 G43 H3 Z100.0; N130 G00 Z50.0 M08; N135 G98 G84 Z-30.0 R5.0 P2000 F300.0; N140 M98 P0023; N145 G00 G80 Z100.0 M09; N150 G00 G91 G28 Z0.0 M05; N155 G28 X0.0 Y0.0; N160 M30;

70 Sub program O0023;(SUB PROGRAM) N5 X200.0 Y50.0; N10 X200.0 Y190.0; N15 X60.0 Y190.0; N20 X130.0 Y120.0; M99;

3.11 LOCAL CO ORDINATE SYSTEM

EXAMPLE:
4X16mm drill equally spaced on PCD 70mm,depth15mm

200 100 200 350

Operations 1. C.d (centre drill) G81 2. 16mm drill G83 or G73 Points 1. X35.0 Y0.0 2. X0.0 Y35.0 3. X-35.0 Y0.0 4. X0.0 Y-35.0

300

450

71 O0015; N5 G00 G91 G28 Z0.0; N10 G28 X0.0 Y0.0; N15 M06 T1; (c.d) N20 G00 G90 G54 X0.0 Y0.0 S2000 M03; N25 G43 H1 Z100.0; N30 G00 Z5.0 M08; N35 G52 X100.0 Y950.0; N40 M98 P0026; N45 G52 X300.0 Y500.0; N50 M98 P0026; N55 G52 X650.0 Y200.0; N60 M98 P0026; N65 G52 X0.0 Y0.0; N70 G00 G91 G28 Z0.0 M05; N75 G28 X0.0 Y0.0; N80 M01; N85 M06 T2; (16mm drill) N90 G00 G90 G54 X0.0 Y0.0 S2000 M03; N95 G43 H2 Z100.0; N100 G00 Z5.0 M08; N105 G52 X100.0 Y950.0; N110 M98 P0027; N115 G52 X300.0 Y500.0; N120 M98 P0027; N125 G52 X650.0 Y200.0; N130 M98 P0027; N135 G52 X0.0 Y0.0; N140 G00 G91 G28 Z0.0 M05; N145 G28 X0.0 Y0.0; N150 M30; 3.11.1 SUBROUTINE NESTING A subprogram may be called not only in a part program but also in a subprogram itself. One subprogram can be called in another subprogram and this may be called in yet another Sub program O0027; N5 G98 G81 X35.0 Y0.0 Z-15.0 R5.0 F100.0; N10 X0.0 Y35.0; N15 X-35.0 Y0.0; N20 X0.0 Y-35.0; N25 G00 G80 Z100.0; N30 M99; Sub program O0026; N5 G98 G81 X35.0 Y0.0 R5.0F100.0; N10 X0.0 Y35.0; N15 X-35.0 Y0.0; N20 X0.0 Y-35.0; N25 G00 G80 Z50.0; N30 M99;

72 subprogram and so on. This method of calling subprogram is in succession is called subroutine nesting. Sub programming up to 4 levels can be called in subroutine nesting.
Main program Sub program Sub program Sub program Sub program
O1(MAIN); O10(SUB); O20(SUB); O30(SUB); O40(SUB);

M98 P10

M98 P20

M98 P30

M98 P40

M30

M99 First

M99 Second

M99 Third

M99 Fourth

It is recommended that the subprograms are programmed under G91 because subprogram under G90 causes the machining to be in the same position. But if command G52 is used, subprogram can be made with G90. G52 local co-ordinate system setting Example:

O00488 (Main) T01 M06 G90 G00 G54 X-2.5 Y0 S2000 F100. M03 G43 H01 Z10.0 M08 G00 X-2.5Y13.0 G01 Z5 F500 M98 P411 L4 G91 G28 X0 Z0 M09

73 M30 O00411 (sub) G0 G90 Z5.0 G0 G91 X21.0 G1G90 Z0.0F100 M98 P420 L3 M99 O00420 (sub nesting) G1 G91 Z-1.0 F50 G41 D01G01 X7.5 G01 Y22.0 G03 X-15.0 Y0 R7.5 G01 Y-22 G03 X15.0 Y0 R7.5 G1G40 X-7.5 M99

3.12 PROFILE MILLING

I).SLOT (OR) KEYWAY OPERATION

50

40

10

40

20

O0002; N5 G00 G91 G28 Z0.0; N10 G28 X0.0 Y0.0; N15 M06 T2; (10mm EM) N20 G00 G90 G54 X45.0 Y-20.0 S1200 M03;

74 N25 G43 H2 Z100.0; N30 G00 Z5.0 M08; N35 G01 Z-8.0 F80.0; N40 Y70.0; N45 G00 Z100.0 M09; N50 G00 G91 G28 Z0.0 M05; N55 G28 X0.0 Y0.0; N60 M30; II).PROFILE MILLING (Using cutter compensation)

20X45

R25 R20 40

150

R10

150

G40

G41

G42

G40 Cutter compensation cancel G41 Cutter compensation left G42 Cutter compensation right O0004; N5 G00 G91 G28 Z0.0; N10 G28 X0.0 Y0.0;

75 N15 M06 T1; (10mm EM) N20 G00 G90 G54 X-20.0 Y-20.0 S1200 M03; N25 G43 H1 Z100.0; N30 G00 Z5.0 M08; N35 G01 Z-10.0 F80.0; N37 G01 X-20 Y0; N40 G42 X140.0Y0.0 D1; N45 G03 X150.0 Y10.0 R10.0; N50 G01Y130.0; N55 G03 X130.0 Y150.0 R20.0; N60 G01X100.0; N65 G02 X75.0 Y125.0 R25.0; N70 G02 X50.0 Y150.0 R25.0; Instead of writing in two lines, we can write in one line using I, J method G02 X50.0 Y150.0 I-25.0 J0.0; N75 G01 X20.0; N80 X0.0 Y130.0; N85 Y-20.0; N87 G00 G40 X-20.0 Y20.0; N90 G00 Z100.0 M09; N95 G00 G91 G28 Z0.0 M05; N100 G28 X0.0 Y0.0; N105 M30; (Cutter radius compensation cancel) (Cutter radius compensation right)

76

4.0 FEED RATE F & SPINDLE SPEEDS S Function F and S code These are given according to the tools to be used and the material of the work piece to be cut.

F01 F10 F1000 S10 S1500 S4000

1mm/min 10 mm/min 1000 mm/min 10revolution per min (rpm) 1500 revolution per min 4000 revolution per min

CUTTING SPEED, RPM & FEED FORMULA Cutting Speed = 3.14 x D x RPM 1000 RPM = Cutting Speed x 1000 3.14 x D End Mill Feed = Speed x No of tooth x Feed per tooth Drill Feed = Speed x Feed per revolution Tap Feed = Speed x Pitch CUTTING SPEED (Vc) Vs RPM Vc dependant on material of work piece / tool & cutting conditions RPM dependant on diameter

77

Effective dia

Advance Per Tooth

of Cutter

Chip Thickness

Axial Depth of cut

Learning Activity_1 Calculation Speed & Feed Cutting speed (V)=250 m/min Cutter Diameter (d)= 10 mm

78

No of tooth (z) = 2 Feed per tooth (ft ) = 0.1

RPM: n = 250 x 1000 = 7960rpm 3.14 x 10 Feed : F = 7960 x 2 x 0.1 (n x z x f) F = 1592mm/min Learning Activity_2 Calculation Cutting Speed & Feed Per Tooth Rpm = 15000 rev/min Feed = 3000 mm/min No of tooth = 2 Cutter Diameter = 6 mm Cutting speed : V = 3.14 x 6 x 15000 = 283m/min. 1000 Feed per tooth : = 3000 =0.1mm/min. 2 x 15000

5.0 INSERT & TOOL HOLDERS

5.1 TOOL HOLDING DEVICES The tool holder system for machining centers shown in the figure is a modular tooling system. It consists of a basic tool holder, extension or reducer and tool adaptors. Tool adaptors are available for receiving various tools like milling cutters, drills reamers etc. Various methods of holding the tools are shown in figures.

79

5.2 TOOLS & TOOL MATERIAL USED IN CNC 5.2.1 TOOLS AND TOOL MATERIALS USED IN CNC MACHINE . The most important properties of the cutting tool material are: 1. The material must withstand excessive wear even though the relative hardness of the tool materials changes.

80 2. Ability to retain hardness under severe working condition. 3. Ability to withstand cutting forces. 4. The frictional coefficient must remain low for minimum wear and reasonable surface finish. 5. Cost and easiness of fabrication should have within reasonable limits.

5.2.2 TYPE OF TOOL MATERIAL CARBON STEELS It may only be used in manufacture of tools operating at low cutting speed (12mt/min). Disadvantages of carbon tool steel are they are comparatively low heat and wear resistance. HIGH-SPEED STEEL (HSS) HSS operate at cutting speeds 2 to 3 times higher than for carbon steels and retain their hardness up to 900c. Three general types of HSS are high tungsten, high molybdenum and high cobalt. Tungsten in HSS provides hot hardness and form stability. Molybdenum maintains keenness of the cutting edge. Cobalt makes the cutting tool more wear resistance. STELLITES Stellite is the trade name of a non-ferrous cast alloy composed of cobalt, chromium and tungsten. They are used for non-metal cutting application such as rubbers plastics etc. CARBIDES a) Solid Carbides b) Inserts. They are composed principally of carbon mixed with other elements. The basic ingredient of most carbide is tungsten carbide that is extremely hard, pure tungsten powder is mixed under high hear (1500c) with pure carbon in the ratio of 94% and 6% weight. The two types of carbides are the tungsten and titanium and both are more wear resistant.

81 Carbides are designed for machining tougher materials chiefly for various materials. COATED CARBIDES The coated carbide has substrate and coating layer. Substrate for toughness having hard materials and soft materials (cobalt + carbides) Coating layer of carbide (very hard) Better impact strength to resist fracture. MODERN COATING This layer of coating reduces friction between chip and tool and time duration is very limited. Modern coating (Multi Layer) Coating process Chemical vapour deposition. Physical vapour deposition. Plasma CVD coating. COATED CEMENTED CARBIDES The cemented carbides with a very thin coat of carbides. The layers of titanium carbides were only a few microns thick and increase the performance of carbide tools. COATED CARBIDES (GC) More than 75% of turning operations and more than 40% of milling operations are today performed with coated carbides. The main coating materials are Titanium carbide (Tic) Titanium nitride (Tin) Aluminum oxide ceramic (Al203) and Titanium carbon nitride (TiCN) 5.2.3 OTHER MATERIALS: CERMETS

82 Cermets-Ceramics and metal Characteristics of Cermets High hardness High hot hardness Resist oxidation Low friction Advantages of cermets High efficiency Long life Large batch Avoid build up edge Surface finish control Cermet has properties to use it for higher cutting speed and wear resistance. DIAMOND The diamond is the hardest known material and can be run at cutting speed about 50 times greater than that of HSS tool and 5 to 6 times of life than carbide. Diamond is incompressible readily conducts heat and has low coefficient of friction. Diamonds are suitable for cutting very hard material such as glass, plastics etc. By polycrystalline diamond the tool life is 30 times of carbide.

6.0 ISO DESIGNATION OF CUTTING TOOLS 6.1 INSERT

Inserts of several shapes are used for different application. In the below figure are rhomboidal shapes which are very popular. Shape C is particularly used for rough turning. Shape W is now preferred by many users. Shapes D and V are widely used for finish turning applications. Shape V is useful for contoured parts.

83

85

80

82

35

55

60

6.1.1 CLEARANCE ANGLE The second alphabet represents clearances angle which varies from 3 degrees to 11 degrees, the figure shows the designation of clearance angle.

15

30

20

25

11

C
6.1.2 TOLERANCES

84 The tolerances on the insert are important. The third alphabetical character denotes the tolerances.

d
d A C E G H M 0.025 0.025 0.025 0.025 0.0005 0.002

d
m 0.005 0.0125 0.025 0.025 0.0005 0.003 S 0.025 0.025 0.025 0.05 0.001 0.0005

6.1.3 LENGTH OF THE INSERT EDGE The length of the edge of the insert is the next number. Figure shows how the lengths are designated.

06-22

09-19

06-19

07-15

6.1.4 THICKNESS OF THE INSERT The next letter refers to the thickness of the insert. The thickness varies as shown in table.

DESIGNATION

THICKNESS (MM),S

85 02 03 T3 04 05 06 07 09 6.1.5 NOSE RADIUS Corner radius of the cutting edge is an important parameter. The corner radius influences the accuracy in contouring operations in turning. Therefore, tool nose radius compensation has to be called during profile turning operations. Corner radius should be input into the memory of the system to apply tool nose radius compensation. Tool nose usually varies between 0.4 mm to 2.4 mm in standard inserts 2.25 3 3.75 4.5 5.375 6.25 8.13 10

Tool Nose radius Code 04 08 12 16 24 mm

rE=0.4 rE=0.8 rE=1.2 rE=1.6 rE=2.4

6.1.6 CUTTING DIRECTION Inserts may be right hand turning inserts, left hand turning inserts or neutral inserts which may be used either way. This is shown in the figure

86

L N

In e ts a e s r hp
TNMG - 2 0 0 2 4 8
C- D m n 8 ia o d 0 D- D m n 5 ia o d 5 R- R u d on S- S u r q ae

cle r n a g a a ce n le
TNMG - 2 0 0 2 4 8

87
3
15

30

20

25

11

Tolerances
T N M G - 22 04 08
Class s G 0.13 M 0.13 U 0.13 E 0.025 ic 0.025 0.05 0.08 0.25

In rt T p se ye
T N MG - 2 0 0 2 4 8

88

7.0 CLAMPING SYSTEM

7.1 WORKHOLDING DEVICES It is important to ensure that a work piece setup is safe. The work piece must be securely fastened, and the setup must be rigid enough to with stand the forces that will be present during the machining operation. If the work piece of the holding device becomes loose during machining, damage can result to the tooling and / or the machine.

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The machine operator should be sure that all work holding devices are free from chips and burrs before use. The work holding devices, generally specified by the programmer, should be located in the proper position on the machine table. Failure to follow these instructions may result in operator injury, damage to the machine, or scrap work pieces. 7.1.1 Types of Work holding Devices The most important function of any Workholding device is to hold the part so that the surface to be machined is in the correct relationship to other surfaces as indicated on the part drawing. The part must be held securely enough that it can withstand the forces created during the machining operation without becoming loose or moving. Although Workholding devices differ due to the shape and size of the part, the most commonly used are: 7.1.1.1 The Swivel-base vise, fig.7.11.15A, which may be bolted to the machine table or a subplate. The swivel base enables the vise to be swiveled 360 in a horizontal plane.

3 2 1

4 5

1.Bevel pinion,2.Scroll disc,3.Bevel teeth on scroll disc,4.Chuck body,5.J aw.

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7.1.1.2 Angle plates, fig.7.11.15B, are L-shaped pieces of cast iron or steel accurately machined to a 90 angle. They are made in a variety of sizes and have holes or slots that provide a means for fastening the work piece.

ANGLE PLATE

7.1.1.3 V blocks, fig.7.11.15C are generally used in pairs to support cylindrical work. A U-shaped clamp may be used to fasten the work in a V block.

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1.T-bolt, 2.V-block, 3.Work, 4.Nut, 5.Clamp USE OF V-BLOCK

7.1.1.4 Step blocks, fig.7.11.16A, are used to provide support for strap clamps when work is being fastened to the table or Workholding devices.

Clamp or Straps, fig.7.11.16B are used to fasten work to the table, angle plate, or fixture. They are made in a variety of sizes and are usually supported at the end by a step block and bolted to the table by a T bolt. It is good practice to place the T-bolt in the clamp or strap as close to the work as possible. Sub plates are generally flat plates that may be fitted to the machine table to provide quick and accurate location of workpieces, Workholding devices, or fixtures. The fixturing holes in these sub

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plates are accurately located and, when set up on the machine table in relation to the machine datum, provide the programmer with known locating positions.

7.2 FIXTURES CNC eliminates many of the expensive jigs and fixtures that were previously necessary to hold and locate a work piece on conventional machine tools. The repetitive position accuracy of an CNC machine tool also eliminates the need for guide bushings, which were previously required to locate the cutting tool. In CNC machine fixtures are used to accurately locate a part and hold it securely for machining operations. Fixture design should be kept simple so that the time required to the load and unload a part is kept as short as possible, since this is nonproductive time, the savings here will result in corresponding savings in the cost of producing a part. When designing a fixture to hold a part, it is important to consider the following points:

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Straight tail carrier Single pin catch plate

Bent tail carrier.

Double pin catch plate

Double slotted carrier

Double slotted catch plate Double tail carrier

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Plain mandrel

1.Flattened end

Step mandrel

Screwed mandrel

Cone mandrel

2 3 1 4

Collar mandrel

1.Fixed collar,2. Hollow workpieces,3. Movable collar,4. Nut.

1.Sleeve,2. Tapered pin

Expansion mandrel

1. Positive location The fixture must hold a work piece securely enough to prevent the work piece from linear movement in the X, Y, and Z axes, and rotational movement in either direction about each axis. 2. Repeatability Identical parts should always be held in exactly the same location for every part change.

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3. Ruggedness Fixtures must be designed to withstand the shock created during the machining and loading/unloading cycles. 4. Rigidity The work piece must be held securely to prevent any movement due to the forces created by the machining operation. 5. Design Modular fixtures using standard components are quicker to produce and less costly than custom fixtures. They can also be quickly modified to accommodate differently shaped parts, fig.7.11.18. 6. Low profile Parts of the fixture or the necessary clamping devices to hold the part should be designed to allow free movement for the cutting tool at any point in the machining cycle. 7. Part loading/unloading The fixture and its clamping devices should be designed so that they do not interfere with the rapid loading or unloading of a part. 8. Part distortion The fixture should be designed so that the part being machined is not distorted by gravity, machining forces, or clamping forces. Stress should never be put on a part by the clamping forces; otherwise the machined part will distort when the clamping forces are removed. MODULAR FIXTURES Modular fixtures provide many of the advantages of permanent fixtures but are flexible enough to accommodate various shapes of workpieces by changing certain components. A modular fixture can be built from a set of standard components to hold a certain part shape After the production run is complete, the fixture can be disassembled to allow the components to be reused. A manufacturer can thus make fixtures at any time to suit the part to be manufactured. Clamping Hints 1. Always place the bolt as close to the work as possible. 2. Place a piece of soft metal (packing) between the clamp and the work piece to prevent damage to the work piece and to spread the clamping force over a wider area. 3. Make sure the packing does not extend into the machining path of the cutting tool. 4. Use the table slots to prevent round work from moving. 5. Use two clamps whenever possible. 6. Parts that do not lie flat should be shimmed to prevent the work from rocking. Shimming will also prevent distortion when the work is clamped. 7. Tighten clamping bolts evenly to prevent work piece distortion.

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9.0 HIGH SPEED MACHINING (HSM)

High Speed Machining (HSM) of hardened die steels should not be feared but embraced. Many people feel that hard metal machining is a black art, but with a few basic principles it is not only profitable but also a straight forward machining process. There are several components of the process, which include: the effective utilization of the machine tool, cutting tools, tool holders, and programming. If these areas are addressed correctly, hard metal machining loses its mystery and mystique and becomes a predictable process where established formulae and guidelines can be used. In this article, the focus is on the cutting tool but other areas will be addressed as well. Choosing the Process There are three major machining methods: soft machining, hard machining, and EDM. The configuration and hardness of the die or mold material determine which method or combination of methods will work best. Soft machining machining the part prior to heat treatment should be considered when machining large parts of parts that require deep cuts. Semi finishing and finishing can then be done in the hardened state. If the part is not very large, or calls for shallow machining, the entire part can be milled in the hardened state. If the part geometry requires thin features and deep cuts, EDM may be the only option. Tool Selection Choosing the proper cutting tool is very important when machining hardened metal. There are three basic designs of cutters: ball end, corner radius (bull nose) or square end (Figure 1). The first choice in hard metal machining should be the ball end mill. The ball end mill should be used for roughing operations and most finishing operations. Its large radius dissipates the force and heat that is generated in cutting hard material at high speeds and feeds. The ball end mill allows the user to cut closer to the net three dimensional shape and allows for higher speeds and feeds. If a part requires large, flat areas on its floor, a corner radius tool should be used after the ball end tool has roughed out the part. The corner radius tool does not have as large of a radius as the ball, and therefore does not dissipate the heat and force as well as the ball end mill. The square corner radius tool has removed as much materials as possible from the part. The sharp corner of a square end tool acts as a focal point for all the heat and force and will have a tendency to chip. The only time a square end mill should be used is when a sharp corner is required at the transition of a floor and a wall. Tool rigidity is also an important factor to consider. In small diameter cutters, the shank of the tool should be much larger than the cutting diameter. This increases the stiffness of the cutter, which helps produce better finishes and affords longer tool life. It is important to choose the tool to fit the application as closely as possible. For example, Robb Jacks DM and MDM series end mills come with an 8^ per side draft angle. Yet, at the factory, it is very easy to modify this angle and it can be done very quickly. If the part has 3^ draft, the tool can be modified to 2 ^ draft. Generally, a tool should have 1/2^

97 less draft than the actual part. This ^ provides for angular clearance while keeping the tool as strong as possible (Figure 2). Additionally, the tool should not project from the holder any farther than is required. If straight walls are required, a neck can be utilized to strengthen the tool .Both methods allow the short-length-of-cut tool to cut deeper than its cutting length. Controlling Heat Generation Excessive heat changes the parts surface morphology, reducing cutting accuracy. However, one way of minimizing heat generation and retention is by controlling the radial step-over of the cutting tool. Radial step-over is the distance between centerlines of successive, parallel cuts (Figure 4). For roughing operations, the radial step-over should equal 25 to 40 percent of the cutters diameter. For finishing with a given cusp height on a flat surface, the radial step-over can be calculated with the following formula: Radial Step Over = 4 (Cusp Height X Tool Diameter) 4(Cusp Height^2) Example: 3/8 tool diameter with a 0.00024 tolerance. Radial Step over = 4(.00024 X .375) 4(.00024^2) = 0.019 Example: 3/8 tool diameter with a 0.019 radial step over.

Radial Step over: Radial step over determines how much heat is accumulated in the tool and the part by determining the length of time each flute spends in the cut and the amount of time it cools before entering the cut again (Figure 5). The graphical representation illustrates the effects of radial step over and heat generation. When the step over is too great, the flute builds up heat because there is insufficient time to cool the flute before it renters the part. By using smaller step overs, there is a continuous cooling action that controls heat generation. By regulating the heat generation with a continuous cooling action, higher rpms can be used without reaching the fatal temperature of the coating. Once the fatal temperature of the coating is reached, there is a rapid deterioration of the cutting edge; which increases force and temperature to the tool and part. When the proper process is implemented there should be no build up of heat in the part. Excessive heat leads to changes in the surface morphology and loss of cutting accuracy. By selecting the proper coating, higher temperatures can be reached without compromising the cutting tool. For example, the maximum working temperature for Titanium Carbonitride (TiCN) is 750 degree F (400 degree C) compared to Titanium Aluminium Nitride (TiAIN) with a maximum working temperature of 1470 degree F (800 degree C). Generally, TiAIN is the preferred coating for HSM of hardened die/mold materials because of its high heat resistance. The higher heat resistance of the TiAIN coating enables the use of faster RPMs without damaging the cutting tool. Heat Generating At The Cutting Edge

98 Proper speeds and feeds are essential in controlling heat build up. Large chip loads remove heat with the chip so it does not build up in the tool or part. If the chip load is too light, there is a rubbing or grinding type action which leads to heat build up. Therefore, it is very important for tool life to use the largest chip load possible without damaging the tool or part (Figure 6). For example, if the chip load per tooth should be 0.008 and the chip load used is 0.002, a part that should take 20 minutes to machine now takes 80 minutes. This means the tool spent four times as much time in the cut as required. The geometry of the tool also plays an important role in controlling heat. The geometry of the tool affects the way the chip is formed and evacuated from the cut. Incorrect geometry can result in premature tool failure and poor part finishes. This is why a tool should be designed specifically for hard metal machining. Flood coolant should not be used in most cases. The result of extensive testing by Robb Jack shows that using flood coolant in materials above 40 HRC reduces Robb Jack Recommended Chip Loads For Ball End Tools Chip Load Per Tooth Steels 30 40 HRc Steels 40 50 HRc Roughing Finishing Roughing Finishing Steels 50 60 HRc Roughing Finishing

DM-201-01 1/32 .0006 -.0008 .0005 -.0006 .0005 -.0006 .0004 -.0005 .0004 - .0005 .0003 -.0004 DM-201-02 1/16 .0013 -.0015 .0010 -.0013 .0010 -.0013 .0008 -.0010 .0008 -.0010 .0005 -.0008 DM-201-03 3/32 .0019 -.0023 .0015 -.0019 .0015 -.0019 .0011 -.0015 .0011 -.0015 .0008 -.0011 DM-201-04 1/8 .0025 -.0030 .0020 -.0025 .0020 -.0025 .0015 -.0020 .0015 -.0020 .0010 -.0015 DM-201-06 3/16 .0038 -.0045 .0030 -.0038 .0030 -.0038 .0023 -.0030 .0023 -.0030 .0015 -.0023 DM-201-08 1/4 .0050 -.0060 .0040 -.0050 .0040 -.0050 .0030 -.0040 .0030 -.0040 .0020 -.0030 DM-201-10 5/16 .0063 -.0075 .0050 -.0063 .0050 -.0063 .0038 -.0050 .0038 -.0050 .0025 -.0038 DM-201-12 3/8 .0075 -.0090 .0060 -.0075 .0060 -.0075 .0045 -.0060 .0045 -.0060 .0030 -.0045 DM-201-14 7/16 .0088 -.0105 .0070 -.0088 .0070 -.0088 .0053 -.0070 .0053 -.0070 .0035 -.0053 DM-201-16 1/2" .0100 -.0120 .0080 -.0100 .0080 -.0100 .0060 -.0080 .0060 -.0080 .0040 -.0060 (Speed and Feeds are only general starting points and may vary depending on specific application.)

Robb Jack Recommended RPM for Ball End Tools Roughing & Semi Finishing RPM Steels 30 40 HRc Steels 40 50 HRc Steels 50 60 HRc
DM-201-01 1/32 20,000 40,000 20,000 40,000 20,000 40,000 DM-201-02 1/16 20,000 40,000 20,000 40,000 20,000 16,000 DM-201-03 3/32 20,000 32,000 20,000 32,000 16,000 24,000 DM-201-04 1/8 15,000 24,000 18,000 24,000 12,000 18,000 DM-201-06 3/16 10,000 16,000 12,000 16,000 8,100 12,000 DM-201-08 1/4 7,600 12,000 9,100 12,000 6,100 9,100 DM-201-10 5/16 6,000 9,700 7,300 9,700 4,800 7,300 DM-201-12 3/8 5,000 8,100 6,100 8,100 4,000 6,100 DM-201-14 7/16 4,300 6,900 5,200 6,900 3,400 5,200 DM-201-16 1/2" 3,800 6,100 4,500 6,100 3,000 4,500 (Use maximum RPM if suggested RPM is higher than the machines capabilities.)

Finishing

99 RPM Steels 30 40 HRc Steels 40 50 HRc Steels 50 60 HRc

DM-201-01 1/32 20,000 40,000 20,000 40,000 20,000 40,000 DM-201-02 1/16 20,000 40,000 20,000 40,000 20,000 40,000 DM-201-03 3/32 20,000 40,000 20,000 40,000 20,000 40,000 DM-201-04 1/8 20,000 36,000 20,000 40,000 20,000 30,500 DM-201-06 3/16 20,000 24,000 20,000 32,000 16,000 20,300 DM-201-08 1/4 15,000 18,000 18,000 24,400 12,000 15,000 DM-201-10 5/16 12,000 14,000 14,600 19,000 9,700 12,000 DM-201-12 3/8 10,000 12,000 12,000 16,200 8,100 10,000 DM-201-14 7/16 8,700 10,400 10,000 13,900 6,900 8,700 DM-201-16 1/2" 7,600 9,100 9,100 12,200 6,100 7,600 (Use maximum RPM if suggested RPM is higher than the machines capabilities.) Figure 9