CIM & Automation Lab Manual

B M S INSTITUTE OF TECHNOLOGY
YELAHANKA, BANGALORE – 64
DEPARTMENT OF MECHANICAL ENGINEERING

VII SEMESTER

CIM & AUTOMATION LABORATORY

MANUAL
10MEL78

Department of Mechanical Engineering 1 BMSIT&M, Bangalore

 CIM & Automation Lab Manual

Department of Mechanical Engineering, BMSIT, Bangalore 560 064

Vision
To become one of the best mechanical engineering departments in the country and aim to
achieve global and societal recognition.

Mission

To impart quality education in Mechanical Engineering and allied areas by providing
state-of-the-art infrastructure and dedicated faculty.
To provide conducive environment for both students and faculty to pursue higher
education and research to work ethically for the benefit of society.

Programme Educational Objectives (PEO)

Graduates of the program will:
PEO-1: Be successful professionals in the field of Mechanical Engineering and allied
areas
In a global scenario there is a need of professionals enriched with knowledge and skill in the
field of mechanical engineering. The primary objective of our programme is to produce
mechanical engineering graduates who can excel in both manufacturing and service sectors.
PEO-2: Exhibit skills to work effectively and ethically in multiple domains of
engineering as part of a team
In the present context most of the disciplines are integrated because of technological
advancement. The graduates are expected to work as a team member in multiple domains of
engineering to succeed in their profession.

PEO-3: Excel in higher studies, research and adapt in a world of constantly developing
technology
Present technology has a high degree of automation which requires qualified and innovative
professionals for technological developments. Graduates are required to upgrade their
knowledge by continuous learning to meet the challenges of changing technology.
Programme Outcomes (PO)

POs Our graduates will be able to:

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 CIM & Automation Lab Manual

PO-1 Apply knowledge of mathematics and science in solving mechanical

engineering problems.
PO-2 Identify, formulate and solve mechanical engineering problems.
PO-3 Design and conduct experiments to get solutions for mechanical engineering
problems.
PO-4 Analyze data and interpret the experimental data for complex mechanical
engineering problems.
PO-5 Use the techniques, skills and modern engineering tools necessary for
engineering practice.
PO-6 Understand the impact of engineering solutions in environmental and
societal circumstances.
PO-7 Understand the legal and cultural aspects relevant to mechanical engineers.
PO-8 Understand professional and ethical responsibilities for engineering practice.
PO-9 Work independently and also to work in a team.
PO-10 Communicate effectively with superiors and subordinates.
PO-11 Apply the management and engineering principles to work effectively and to
reduce cost.
PO-12 Change according to latest technical developments.

Corse Outcomes of CIM & Automation Lab

1. Ability to understand and learn the available simulation software.

2. Illustrate the procedure to write a CNC program to produce the components.
3. Select the tools for various types of operations.
4. Estimate to determine the cutting speed, feed and depth of cut required for various
operations for various tool and work material combinations.
5. Demonstrate the principles of programming and to operate a robot for pick & place
operations.

Department of Mechanical Engineering 3 BMSIT&M, Bangalore

 CIM & Automation Lab Manual

CIM & AUTOMATION LAB

Subject Code : 10MEL78 IA Marks : 25

No. of Practical Hrs./ Week : 03 Exam Hours : 03
Total No. of Practical Hrs. : 42 Exam Marks : 50

PART - A

CNC part programming using CAM packages. Simulation of Turning, Drilling, Milling
operations. 3 typical simulations to be carried out using simulation packages like Master-
CAM, or any equivalent software.

PART - B

(Only for Demo/Viva voce)

1. FMS (Flexible Manufacturing System): Programming of Automatic storage and Retrieval
system (ASRS) and linear shuttle conveyor Interfacing CNC lathe, milling with loading
unloading arm and ASRS to be carried out on simple components.
2. Robot programming: Using Teach Pendent & Offline programming to perform pick and
place, stacking of objects, 2 programs.

PART - C

(Only for Demo/Viva voce)

Pneumatics and Hydraulics, Electro-Pneumatics: 3 typical experiments on Basics of these
topics to be conducted.

Scheme of Examinations

Two questions from Part A – 40 Marks (10 Write up +30)

Viva Voce – 10 Marks
Total – 50 Marks

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CIM AND AUTOMATION LAB

Do’ s

1. Leave the footwear outside the lab in the designated place.

2. Enter login details in the register.
3. Work only on the allotted system throughout the semester.
4. Wait patiently at your designated place for instructions.
5. Bring the Lab manual, Observation book and Lab record regularly.
6. Record should be completely written with previous experiments updated.
7. Maintain strict discipline inside the lab.
8. Keep your lab clean and free of disorder.

Don’ts

1. Bring Pen drives / Mobile / CDs inside the lab. In case they are found, they will be
confiscated.
2. Change any setting on the computer.
3. Leave the lab without the permission of the staff concerned / instructor.
4. Turn on your monitor and start working until instructions have been given.
5. Start the machine without knowing its operation.

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CNC PROGRAMMING

CNC programming is a detailed list of instructions that need to be executed by the

machine control unit to achieve the final component shape. CNC programming can be done
by two different ways.

1. Manual Part programming

2. Computer Assisted Part Programming

MANUAL PART PROGRAMMING: MPP involves writing a programmes with a set of

alphabets & numbers. The commonly used part programming formats are
1. Fixed sequential format
2. Tab sequential format
3. Word address format
Word address format is the commonly used.

NC BLOCK: NC block is a collection of NC words. An NC word is a collection of address

letters & a sequence number. It gives information about the movement of the tool in X,Y & Z
co ordinates, the tool to be used, spindle speed, feed etc.
A generalized NC block is given below:

N_ G_ X_ Y_ Z_ R_ F_ S_ T_ M_
N is the Sequence number. Each block or line starts with a sequence number which
identifies the block. It gives an identifying number for each block of information. It is
generally good practice to increment each block number by 5 or 10 to allow additional blocks
to be inserted if future changes are required.
G is the Preparatory functions which are used to set the control for the various
machine movements such as linear movement, circular movement. Preparatory functions
preapares the controller to carry the instructions that are to follow after the G letter.
X,Y & Z are used to specify the co ordinates along X,Y & Z axes. R is the arc radius
to be used in circular interpolations. F is the Feed Rate in mm/min or mm/rev. S is the spindle

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speed in RPM. T is the tool function which specifies the type of the tool & its offset number
in automatic tool changer.
M is the Miscellaneous function used to perform auxillary functions which do not
relate to the dimensional movements of the machine tool or the cutting tool.

SEE NC TURN
See NC turn is special purpose CNC part programme verification software used for
the turning center programmes. Turning centers typically use only X and Z axis as shown in
the fig below. The X-axis denotes the axis perpendicular to the spindle and controls the
diameter of the part. The Z-axis denotes the movement of the tool parallel to the spindle axis
and controls the length of the part.

Spindle
Workpiece
Chuck

Axes convention :

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 CIM & Automation Lab Manual

The main screen of the See NC turn consists of three screens namely

1. Programme editor screen : Wherein the programmer enters the part programmes.
2. Syntax error message screen : Where in the errors in the part programme are
displayed.
3. Tool path simulation screen : Where in the specified path of the tool can be
observed.
PROCEDURE

1. Double click on the See NC turn icon

2. Start a new file.Enter the part programme in the programme editor screen.
3. Define the shape of the blank.
4. Select the machine
5. Check the programme for any syntax errors and correct the errors.
6. Assigning a tool for the different operation.
7. Tool path simulation

PREPARATORY CODES: ( G Codes)

G-code Function
G00 Positioning rapid traverse
G01 Linear interpolation (feed)
G02 Circular interpolation CW
G03 Circular interpolation CCW
G04 Dwell
G20 Inch unit
G21 Metric unit
G28 Automatic zero return
G32 / G33 Thread cutting (single motion)
G40 Tool nose radius compensation cancel
G41 Tool nose radius compensation left
G42 Tool nose radius compensation right
G70 Finishing cycle
G71 Stock removal in turning
G72 Stock removal in facing
G73 Pattern repeating
G74 Peck drilling on Z axis / Face grooving
G75 Grooving cycle
G76 Multiple threading cycle
G94 / G98 Feed per minute
G95 / G99 Feed per revolution

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 CIM & Automation Lab Manual

G00 POSITIONING IN RAPID

N_ G00 X_ Z_

The G00 command is a rapid tool move. A rapid tool move is used to move the tool linearly
from position to position without cutting any material. When the tool being positioned at a
point preparatory to a cutting motion, to save time it is moved along a straight line at Rapid
traverse, at a fixed traverse rate which is pre-programmed into the machine's control system.
Typical rapid traverse rates are 10 to 25 m /min., but can be as high as 80 m/min.

G01 LINEAR INTERPOLATION

N_ G01 X_ Z_ F_

The G01 command is mainly used for the linear removal of material from a workpiece. Any
combination of the X or Z axes can be used. The machine tool wiill follow a linear trajectory
from the current position to the target position. The tool moves along a straight line in one or
two axis simultaneously at a programmed linear speed, the feed rate.

G02 CIRCULAR INTERPOLATION (CLOCKWISE):

N_ G02 X_ Z_ R_ F_ (R specifies the radius)

Circular Interpolation is defined by the G02 command. It executes all circular or radial cuts
in a clockwise motion. The G02 command requires an endpoint for the move, the radius, and
a feedrate.

Department of Mechanical Engineering 9 BMSIT&M, Bangalore

 CIM & Automation Lab Manual

G03 CIRCULAR INTERPOLATION (COUNTER-CLOCKWISE)

N_ G03 X_ Z_ R_ F_ (R specifies the radius)

The G03 command executes all radial cuts in a counterclockwise motion. It requires an
endpoint for the move, then the radius, the distance from the startpoint to the centerpoint, and
a feedrate.

G04 DWELL
N_ G04 P_

The G04 command is a nonmodal dwell command that halts all axis movement for a
specified time while the spindle continues revolving at the specified rpm. A dwell is
sometimes used to allow for the clearance of chips .

Department of Mechanical Engineering 10 BMSIT&M, Bangalore

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G20 INCH UNITS

N_ G20

The G20 command defaults the system to inch units. When a program is being run and the
G20 command is encountered, all coordinates are stated as inch units. This command is
usually found at the beginning of a program. However, it can be used to switch between inch
and metric units while the middle of a program.

G21 METRIC OR SI UNITS

N_ G21

The G21 command defaults the system to metric units. When a program is being run and the
G21 command is encountered, all coordinates are stated as millimeter units. This command is
usually found at the beginning of a program. However, it can be used to switch between
metric and inch units in the middle of a program.

G28 AUTOMATIC RETURN TO REFERENCE POINT

N_ G28 X_ Z_

The G28 command is commonly used prior to an automatic tool change. It allows the
existing tool to be positioned to the predefined reference point automatically via an
intermediate position. This ensures that when the tool turret is engaged, it is properly aligned
and clears the workpiece.

G33 THREAD CUTTING MOTION

Thread cutting is done by moving the tool along the thread repeatedly at different depths tiil
the final thread profile is formed. Each cut must start at the same angular position on the part.
The spindle has an encoder, which generates a pulse at exactly the same angular position in
every revolution. When a threading motion is programmed, the linear motion of the tool
starts when this pulse is detected. This ensures that every cut starts at the same angular
position. Thread cutting must be done at constant spindle speed.

Block format
N__ G33 X__ Z__ F__

X, Z are the end point of the thread and F is the pitch of the thread.

The controller calculates feed rate through the following relationship

Feed rate = Pitch x Spindle speed
Each threading cut involves 4 motions: 1 threading motion and 3 rapid traverse motions.
Since a thread normally requires multiple cuts, G32 results in a long program and is not
normally used. The G76 canned cycle is normally used for threading.

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G40 TOOL NOSE RADIUS (TNR) COMPENSATION CANCEL

N_ G40

The G40 command cancels any cutter compensation that was applied to the tool during a
program. It also acts as a safeguard to cancel any cutter compensation applied to a previous
program or G-codes.

G41 TOOL NOSE RADIUS (TNR) COMPENSATION LEFT

N_ G41

The G41 command applies cutter compensation to the left hand side of the programmed tool
path. This amount is equal to the current tool's nose radius value, which is stored in the Tool
Offset Register table of the controller. This register number is referenced by the last two
digits in the tool change command. For example, a tool change command with T0202 will
reference the tool nose radius value in register #2.

G42 TOOL NOSE RADIUS COMPENSATION RIGHT

N_ G42

The G42 command applies cutter compensation to the right hand side of the programmed
tool path. This amount is equal to the current tool's nose radius value, which is stored in the
Tool Offset Register table of the controller.

CANNED CYCLES:
A canned cycle simplifies a program by using a few blocks containing G-codes functions to
specify the machining operations usually specified in several blocks.

G70 FINISHING CYCLE

N_ G70 P_ Q_

The G70 command is used immediately after a roughing cycle, such as a G71 Rough
Turning, or G72 Rough Facing cycle command. The remaining material is machined as
specified by the P and Q block number values, which point to the start and finish blocks of
the desired part profile contour.

Department of Mechanical Engineering 12 BMSIT&M, Bangalore

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G71 ROUGH TURNING CYCLE

Format
G71 U (d) R (e)
G71 P (n) Q(n) U(u) W(w) F(f)

N (n) _ _ _ _
_______
_______
N (n)_ _ _ _

d = Depth of cut
e = Retract amount
n = Number of the first block of the shape
n = Number of the last last block of the shape
u = Finishing allowance in X
w =Finishing allowance in Z
f = Feed rate

The G71 command automatically generates roughing passes to turn a workpiece to a

specified profile leaving an allowance for finishing. It reads a program segment specified by
the P and Q letter addresses and determines the number of passes, the depth of cut for each
pass, and the number of repeat passes for the cycle.

G72 ROUGH FACING CYCLE

Format
G71 W(d) R (e)
G71 P (n) Q(n) U(u) W(w) F(f)

N (n) _ _ _ _
_______
_______
N (n) _ _ _ _

d = Depth of cut
e = Retract amount
n = Number of the first block of the shape
n = Number of the last last block of the shape
u = Finishing allowance in X
w =Finishing allowance in Z
f = Feed rate

The G72 command automatically faces off a part to a predefined profile, with preset offsets
and feedrates leaving an allowance for finishing. It reads a program segment specified by the
P and Q letter addresses and determines the number of passes, the depth of cut for each pass,
and the number of repeat passes for the cycle.

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G74 Peck Drilling Cycle

N_ G74 X0 Z_ K_ F_

The G74 command involves individual peck moves in each drilling operation. When this
command is invoked, the tool positions itself as in a standard G81 drill cycle. The K value
specifies the peck depth.

G75 GROOVING CYCLE

N_ G75 R(e)
N_ G75 X_ Z_ P_ Q_ F_

The G75 command invokes an outside diamter groove cycle. This cycle involves plunges
into the workpiece from the outside of the workpiece parallel to the X axis. The X value is
the final diameter. The Z value represents the final Z position. The R value specifies the
retract after every plunge. The P and Q values specify the incremental movements in the X
and Z axes, respectively.

G76 THREADING CYCLE

N_ G76 X_ Z_ D_ K_ A_ F_

The G76 command automatically performs all cutting operations required to achieve a
thread. The G76 cycle code is used for the CNC lathe single point threading applications.
This code allows the CNC programmer to enter the data required for a specified thread size
& the controller will determine the number of thread passes & automatically position the
tool. The G76 code reduces the number of programming blocks required for a threading
operation.

Format:
G76 P Q R
G76 X Z P Q F
Ex: G76 P031560 Q150 R0.015

P 03 indicates Number of passes for finishing operations.

15 indicate a Pull out angle (150 to 220) .
60 indicate Thread Angle.
Q150 is the depth of cut for each pass in microns.
R 0.015 is the finishing allowance.

G76 X9.854 Z-20 P1073 Q300 F1.75

X 9.854 is the Minor Diameter in mm for M12 X 1.75mm pitch.

Z-20 is the length of the thread
P1073 is the height of the thread in microns.
Q300 is the Depth of cut for first pass in microns.
F1.75 is the pitch of the thread.

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G90 ABSOLUTE POSITIONING

N_ G90

The G90 command defaults the system to accept all coordinates as absolute coordinates.
These coordinates are measured from a fixed origin (X0, Y0, Z0) and expressed in terms of
X, Y, and Z distances.

G91 INCREMENTAL POSITIONING

N_ G91

The G91 command defaults the system to accept all coordinates as incremental, or relative,
coordinates. This command is found at the beginning of some programs to default the system
to incremental coordinates. It is possible to switch between incremental and absolute
coordinates at any time within a program (see the G90 command).

G98 LINEAR FEEDRATE PER TIME

N_ G98

The G98 command sets the linear feedrate to units (inch or millimeter) per time (minutes).
The setting depends on which type of unit is currently active.

G99 FEEDRATE PER REVOLUTION

N_ G99

The G99 command sets the feedrate to units (inch or millimeter) per revolution. The setting
depends on which type of unit is currently active.

MISELLANEOUS CODES: (M codes)

M codes vary from machine to machine depending on the functions available on it and the
manufacturer of the machine decides them. The M codes listed below are the common ones.

M-codes Function
M00 Optional program stop automatic
M01 Optional program stop request
M02 Program end
M03 Spindle ON clock wise (CW)
M04 Spindle ON counter clock wise (CCW)
M05 Spindle stop
M06 Tool change
M07 Mist coolant ON (coolant 1 ON)
M08 Flood coolant ON (coolant 2 ON)
M09 Coolant OFF
M30 End of program, Reset to start
M98 Sub program call
M99 Sub program end

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 CIM & Automation Lab Manual

. PROBLEM 1:

RAWMATERIAL SIZE: DIA75mm

LENGTH103mm

70

40
50 50

O1001
BILLET DIA 75 LENGTH 103 START Z 3

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 CIM & Automation Lab Manual

N01 G21 G99 N23 G00 Z5

N02 G28 U0 W0 N24 G01 X41
N03 M06 T0101 N25 G01 Z-49 F0.2
N04 M03 S1000 M08 N26 G01 X42 F2
N05 G00 X76 Z2 N27 G00 Z5
N06 G01 X-1 F0.2 N28 M09 M05
N07 G00 Z5 F2 N29 G28 U0 W0
N08 G00 X73 N30 T0202 M06
N09 G01 X73 Z-100 F0.2 N31 M03 S500 M08
N10 G01 X74 F2 N32 G00 X71 Z0
N11 GOO Z5 N33 G01 X-1
N12 G01 X71 F2 N34 G01 Z2
N13 G01 X71 Z-100 F0.2 N35 G00 X40
N14 G01 X72 F2 N36 G01 Z-50 F0.05
N15 G00 Z5 N37 G01 X70 F0.05
N16 G01 X61 N38 G01 Z-100 F0.05
N17 G01 Z-49 F0.2 N39 G01 X72 F2
N18 G01 X62 F2 N40 G00 Z0
N19 G00 Z5 N41 G28 U0 W0
N20 G01 X51 N42 M09 M05
N21 G01 Z-49 F0.2 N43 M30
N22 G01 X52 F2
PROBLEM 2:

2
DRILLING: DIA5mm
10
R 5
R
20
40
50

10

10
40 15 20 20

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O 02
BILLET DIA 55 LENGTH 120 START Z 3

N01 G21 G99 N35 G00 Z3

N02 G28 U0 W0 N36 G01 X31 F2
N03 M06 T0101 N37 G01 X31 Z-25 F0.2
N04 M03 S1000 M08 N38 G01 X32 F2
N05 G00 X55 Z1 N39 G00 Z3
N06 G01 X-1 F0.2 N40 G01 X21 F2
N07 G01 Z3 F2 N41 G01 X21 Z-25 F0.2
N08 G00 X53 N42 G01 X22 F2
N09 G01 X53 Z-110 F0.2 N43 G00 Z3
N10 G01 X54 F2 N44 M09 M05
N11 G00 Z3 N45 G28 U0 W0
N12 G01 X51 F2 N46 T0202 M06
N13 G01 X51 Z-110 F0.2 N47 M03 S500 M08
N14 G01 X52 F2 N48 G00 X20 Z0
N15 G00 Z3 N49 G01 X0 F0.05
N16 G01 X47 F2 N50 G01 X10 Z0 F0.05
N17 G01 X47 Z-65 F0.2 N51 G03 X20 Z-5 R5 F0.025
N18 G01 X48 F2 N52 G01 X20 Z-25 F0.05
N19 G00 Z3 N53 G02 X40 Z-35 R10 F0.025
N20 G01 X44 F2 N54 G01 X40 Z-55 F0.05
N21 G01 X44 Z-60 F0.2 N55 G01 X50 Z-70 F0.05
N22 G01 X45 F2 N56 G01 X50 Z-110 F0.05
N23 G00 Z3 N57 G01 X51 F2
N24 G01 X41 F2 N58 G00 X51 Z0
N25 G01 X41 Z-55 F0.2 N59 M09 M05
N26 G01 X42 F2 N60 G28 U0 W0
N27 G00 Z3 N61 M06 T0303
N28 G01 X37 F2 N62 M03 S300 M08
N29 G01 X37 Z-32 F0.2 N63 G00 X0 Z1
N30 G01 X38 F2 N64 G01 Z-10 F0.01
N31 G00 Z3 N65 G01 Z30 F0.2
N32 G01 X34 F2 N66 M09 M05
N33 G01 X34 Z-29 F0.2 N67 G28 U0 W0
N34 G01 X35 F2 N68 M30

PROBLEM 3:

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10
R

R
25
40
35

10

5
5 5 5 7 5 10 5 10
52

O 03
BILLET DIA 42 LENGTH 60 START Z 0

N01 G21 G98 N14 G03 X35 Z-37 R10 F25

N02 G28 U0 W0 N15 G01 Z-42
N03 M06 T0101 N16 X40 Z-47
N04 M03 S1200 N17 G01 Z-52
N05 G00 X42 Z1 N18 G28 U0 W0
N06 G71 U0.5 R1 N19 M06 T0202
N07 G71 P08 Q17 U0.1 W0.1 F35 N20 M03 S1500
N08 G01 X5 Z0 N21 G00 X10 Z1
N10 X10 Z-10 N22 G70 P08 Q17 F25
N11 Z-15 N23 G28 U0 W0
N12 G02 X25 Z-25 R10 F25 N24 M05 M09
N13 G01 Z-30 F30 N25 M30

PROBLEM 4:

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 CIM & Automation Lab Manual

4 BILLET OF DIA55mmLENGTH113mm 10
DRIILINGDIA5mm R

5
R
40

20
50

10
40 15 20 20

110

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O 04
BILLET DIA 55 LENGTH 113

N05 G21 G99 N85 G28 U0 W0

N10 G28 U0 W0 N90 M09 M05
N15 M06 T0101 N95 M06 T0202
N20 M03 S1000 M08 N100 M03 S500 M08
N25 G00 X55 Z1 N105 G70 P40 Q70 F0.05
N30 G71 U0.5 R0.5 N110 G28 U0 W0
N35 G71 P40 Q70 U0.1 W0.1 F0.2 N115 M09 M05
N40 G01 X10 Z0 N120 M06 T0303
N45 G03 X20 Z-5 R5 F0.15 N125 M03 S500 M08
N50 G01 X20 Z-25 F0.2 N130 G00 X0 Z1
N55 G02 X40 Z-35 R10 F0.15 N135 G01 Z-10 F0.01
N60 G01 X40 Z-55 F0.2 N140 G01 Z30 F0.2
N65 G01 X50 Z-70 N145 M09 M05
N70 G01 X50 Z-110 N150 G28 U0 W0
N75 G00 X55 N155 M30
N80 M09 M05

PROBLEM 5:
6

5
R

5
R
20
32

10

25 5 10 10 15
70

BILLET : DIA32mm
LENGTH70mm

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O 05
BILLET X32 Z70

N05 G21 G98 N60 G01 X20 Z-40

N10 G28 U0 W0 N65 G02 X30 Z-45 R5
N15 M06 T0101 N70 M05 M09
N20 M03 S1500 N75 G28 U0 W0
N25 G00 X33 Z1 N80 M06 T0202
N30 G71 U0.5 R1 N85 M03 S1000
N35 G71 P40 Q65 U0.1 W0.1 F40 N90 G70 P40 Q65 S2000 F25
N40 G01 X0 Z0 N95 G28 U0 W0
N45 G03 X10 Z-5 R6 N100 M05
N50 G01 X10 Z-20 N105 M30
N55 G01 X20 Z-30

PROBLEM 6:

BILLET : DIA32mm
LENGTH60mm
24
32

12
6
8
1

10 10 6 4 30

N05 G21 G98 N50 G01 X24 Z-40

N10 G28 U0 W0 N55 G01 X16 Z-34
N15 M06 T0101 N60 G01 X12 Z-34
N20 M03 S1500 N65 G01 X12 Z0
N25 G00 X33 Z1 N70 G70 P10 Q20 S2000 F20
N30 G72 W0.5 R1 N75 M06 T0202
N35 G72 P40 Q65 U0.1 W0.1 F40 N80 G00 X12 Z-32
N40 G01 X32 Z-50 N85 G75 R1
N45 G01 X24 Z-50 N90 G75 X8 Z-34 P100 Q200 F15

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N95 G28 U0 W0 N105 M30

N100 M05

PROBLEM 7:

BILLET 42 DIA 100 LENGTH START Z 2

N01 G21 G98 N09 G01 X12 Z-46

N02 G28 U0 W0 N10 G01 X20 Z-51
N03 M06 T0101 N11 G01 X20 Z-61
N04 M03 S1500 M08 N12 G03 X36 Z-69 R8 F35
N05 G00 X42 Z1 N13 G01 X36 Z-79 F40
N06 G71 U0.5 R1 N14 G01 X40 Z-84
N07 G71 P08 Q15 U0.1 W0.1 F40 N15 G01 X40 Z-94
N08 G01 X12 Z0 N16 M05 M09
N17 G28 U0 W0 N35 M05 M09
N18 M06 T0202 N36 G28 U0 W0
N19 M03 S2000 M08 M06 T0505
N20 G70 P08 Q15 F20 M03 S350 M08
N21 M05 M09 G00 X12 Z-32
N22 G28 U0 W0 G75 R1
N30 M06 T0404 G75 X8 Z-36 P100 Q1000 F15
N31 M03 S300 M08 M05 M09
N32 G00 X12 Z5 G28 U0 W0
N33 G76 P031560 Q50 R0.015 N37 M30
N34 G76 X9.854 Z-30 P1073 Q100
F1.75

Department of Mechanical Engineering 23 BMSIT&M, Bangalore

 CIM & Automation Lab Manual

PROBLEM 8:

M20 X 1.5

20
40
36

16

18
10 5 20 46 30 2

82

BILLET DIA 42 L 85

N05 G21 G98 N110 G75 R1

N10 G28 U0 W0 N115 G75 X16 Z-38 P100 Q1000 F15
N15 M06 T0101 N116 M05 M09
N20 M03 S1500 M08 N117 G28 U0 W0
N25 G00 X42 Z1 N118 M06 T0303
N30 G71 U0.5 R1 N119 M03 S500 M08
N35 G71 P40 Q60 U0.1 W0.1 F40 N120 G00 X40 Z-69
N40 G01 X18 Z0 N125 G75 R1
N45 G01 X20 Z-2 N130 G75 X36 Z-77 P100 Q1000 F15
N50 G01 X20 Z-42 N135 M05 M09
N55 G01 X40 Z-62 N140 G28 U0 W0
N60 G01 Z-82 N145 M06 T0404
N65 M05 M09 N150 M03 S500 M08
N70 G28 U0 W0 N155 G00 X20 Z-2
N75 M06 T0202 N160 G76 P031560 Q50 R0.015
N80 M03 S2000 M08 N165 G76 X18.161 Z-32 P919.5 Q100
N85 G70 P40 Q60 F20 F1.5
N90 G28 U0 W0 N170 M05 M09
N95 M06 T0303 N175 G28 U0 W0
N100 M03 S500 M08 N180 M30
N105 G00 X20 Z-34

Department of Mechanical Engineering 24 BMSIT&M, Bangalore

 CIM & Automation Lab Manual

PROBLEM 9:

BILLET : DIA22mm
LENGTH80mm

R15

R15
M12 X 1.25
20

16

8
10 10 10 10 4 30
BILLET DIA 22 L 75

Department of Mechanical Engineering 25 BMSIT&M, Bangalore

N01 G21 G98 N26 M05 M09
N02 G28 U0 N27 G28 U0 W0
W0 N28 M06 T0606
N03 M06 N29 M03 S400
T0101 M08
N04 M03 N30 G00 X12 Z1
S1500 M08 N31 G76
N05 G00 X22 P031560 Q50
Z1 R0.015
N06 G71 U0.5 N32 G76
R1 X10.4675 Z-30
N07 G71 P10 P766.25 Q100
Q20 U0.1 W0.1 N33 F1.25
F35 N34 M05 M09
N08 N10 G01 N35 G28 U0 W0
X12 Z0 N36 G28 U0 W0
N09 G01 Z-34 N37 M30
N10 G02 X16
Z-44 R15
N11 G01 Z-54
N12 G03 X20
Z-64 R15
N13 N20 G01
Z-74
N14 M05 M09
N15 G28 U0
W0
N16 M06
T0202
N17 M03
S2000 M08
N18 G70 P10
Q20 F20
N19 M05 M09
N20 G28 U0
W0
N21 M06
T0505
N22 M03 S400
M08
N23 G00 X12
Z-32
N24 G75 R1
N25 G75 X8 Z-
34 P100 Q1000
F20
SEE NC MILL

See NC mill is special purpose CNC part programme verification software used
for the machining center programmes. Milling machines uses all the three axes as shown
in the figure below. In the vertical miling machine, the Z-axis denotes the movement
parallel to the spindle axis ie, the up and down movement of the spindle. The X-axis
moves to the operators left and right. The Y axis moves towards and away from the
operator.

Axes convention

The tool can be moved to any position in a 3 dimensional cartesian co-ordinate system.
The Z axis is along the spindle axis. The X and Y axes are perpendicular to Z.

VMC (Vertical Machining Center)

LIST OF G-CODES

G-code Function
G00 Positioning rapid traverse
G01 Linear interpolation (feed)
G02 Circular interpolation CW
G03 Circular interpolation CCW
G04 Dwell
G20 Inch unit
G21 Metric unit
G28 Automatic zero return
G40 Tool nose radius compensation cancel
G41 Tool nose radius compensation left
G42 Tool nose radius compensation right
G43 Tool length compensation
G80 Canned cycle cancel
G81 Drilling cycle
G82 Drilling cycle with dwell
G83 Peck drilling cycle / deep drill
G84 Tapping cycle
G85 Boring / Reaming cycle
G86 Boring cycle
G90 Absolute command
G91 Incremental command
G94 Feed per minute
G95 Feed per revolution
G98 Return to initial point in canned cycle
G99 Return to R point in canned cycle

CUTTER RADIUS COMPENSATION (CRC)

G40 Tool nose radius compensation Cancel

G41 Tool nose radius compensation Left
G42 Tool nose radius compensation Right

G40 CUTTER COMPENSATION CANCEL

N_ G40

The G40 cancels any cutter compensation that was applied to the tool during a program
and acts as a safeguard to cancel any cutter compensation applied to a previous program
or G-codes.

G41 CUTTER COMPENSATION LEFT

N_ G41 X_ Y_ Z_ F_
The G41 compensates the cutter a specified distance to the left-hand side of the
programmed tool path. It is used to compensate for excessive tool wear or substitute a
tool to profile a part.

G42 CUTTER COMPENSATION RIGHT

N_ G42 X_ Y_ Z_ F_

The G42 compensates the cutter a specified distance to the right-hand side of the
programmed tool path. It is used to compensate for excessive tool wear or substitute a
tool to profile a part.

N__ G01 G41/42 X__ Y__ D__ F__

Necessity of using CRC

• Difficult to calculate cutter center co-ordinates

• If cutter center co-ordinates are used Same diameter of cutter is required to be used
Cutter wear can not compensated

G43 TOOL LENGTH COMPENSATION

N_ G43 H_

The G43 command compensates for tool length in a positive direction. Different tools of
different lengths are used in machining any part. The lengths of the tools are not
considered in the part program. They are entered in the machine’s memory, and are
considered automatically for each motion in the program depending on the tool that is
being used. The tool lengths in the Z direction are called the Tool length offsets.

CANNED CYCLES

Canned or fixed cycles are programming aids that simplify programming. Canned cycles
combine many programming operations and are designed to shorten the program length,
minimize mathematical calculations, and use minimal tool motions.

Examples : Drilling, peck drilling, tapping, boring, back spot facing.

G81 Drilling cycle

G82 Drilling cycle with dwell (Counter bore cycle)

G83 Peck drilling cycle / deep drill

G84 Tapping cycle

G85 Reaming cycle

G86 Boring cycle

G81 DRILLING CYCLE

The G81 invokes a drill cycle at specified locations.

G82 DRILLING CYCLE WITH DWELL OR COUNTER BORING CYCLE

N_ G82 X_ Y_ Z_ R_ P_ F_

The G82 cycle follows the same operating procedures as the G81 drilling cycle, with the
addition of a dwell.

G83 DEEP HOLE DRILLING CYCLE / PECKDRILL CYCLE

N_ G83 X_ Y_ Z_ R_ Q_ F_
The G83 involves individual peck moves in each drilling operation. When this command
is invoked, the tool positions itself as in a standard G81 drill cycle.
PROBLEM NO 1:

10

R
R

10
R
10

10
10
20

10
R
R
10
50

O01
BILLET 120 X 120 X 30 MM

N01 G21 G94 G90

N02 G28 X0 Y0 Z0
N03 T0101
N04 M03 S1500 M08
N05 G00 X0 Y0 Z5
N06 G01 X25 Y35 F35
N07 G01 Z-10 F40
N08 G01 Y55
N09 G01 X35 Y65
N10 G01 Y75
N11 G03 X45 Y85 R10 F35
N12 G02 X55 Y95 R10 F35
N13 G01 X85 F40
N14 G02 X95 Y85 R10 F35
N15 G01 Y35 F40
N16 G02 X85 Y25 R10 F35
N17 G01 X35
N18 G02 X25 Y35 R10 F35
N19 G00 Z5
N20 M05
N21 G28 X0 Y0 Z0
N22 M30
PROBLEM NO 2:

R3
0
75

25
15
80
100

O02
BILLET 150 X 150 X 30 MM

N01 G21 G94 G90

N02 G28 X0 Y0 Z0
N03 M06 T01
G43 H01
N04 M03 S1500 M08
N05 G00 X0 Y0 Z5
N06 G00 X25 Y25 Z5
N07 G01 Z-10 F40
N08 G01 X25 Y100
N09 G02 X85 Y100 R30 F30
N10 G01 X105 Y50 F40
N11 G01 X125 Y40
N12 G01 Y25
N13 G01 X25 Y25
N14 G00 Z5
N15 M05 M09
N16 G28 X0 Y0 Z0
N17 M30
PROBLEM NO 3:

100

50

8
R

100
16
O
50

30

30 30
150

O03
BILLET 200 X 150 X 30 MM

N01 G21 G94 G90 G40 N16 G01 Y25

N02 G28 X0 Y0 Z0 N17 G01 X25 Y25
N03 T01 N18 G00 Z5
G43 H01 N19 M05
N04 M03 S1500 M08 N20 G28 X0 Y0 Z0
N05 G00 X0 Y0 Z5 N21 T02
N06 G00 X25 Y25 G43 H02
N07 G01 Z-15 F40 N22 G00 X55 Y50 Z3
N08 X25 Y75 N23 G01 Z-10
N09 G01 X67 Y75 N24 G00 Z3
N10 G03 X75 Y83 R8 F30 N25 G00 X145 Y50
N11 G01 Y125 F40 N26 G01 Z-10
N12 G01 X125 N27 G00 Z3
N13 G01 X125 Y83 N28 M05 M09
N14 G03 X133 Y75 R8 F30 N29 G28 X0 Y0 Z0
N15 G01 X175 N30 M30

PROBLEM NO 4:
O04
BILLET 100 X 100 X 30 MM

CANNED CYCLES USED: G81 & G85

25
50
25

25

25 50 25

N01 G21 G94 G90 N17 G00 X25 Y25

N02 G28 X0 Y0 Z0 N18 G99 G85 Z-10 R3 F75
N03 M06 T0101 N19 Y75
G43 H01 N20 X75
N04 M03 S1500 M08 N21 Y25
N05 G00 X0 Y0 Z5 N22 X50 Y50
N06 G00 X25 Y25 N23 G80 M09 M05
N07 G99 G81 Z-10 R5 F100 N24 G28 X0 Y0 Z0
N08 Y75 N25 M06 T03
N09 X75 N26 M30
N10 Y25
N11 X50 Y50
N12 G80 M09 M05
N13 G28 X0 Y0 Z0
N14 M06 T02
N15 G43 H02
N16 M03 S750 M08
PROBLEM NO 5:

O05
BILLET 120 X 120 X 30 MM

CANNED CYCLES USED: G83

30
120

80

30
30 30

25
120

N01 G21 G94 G90

N02 G28 X0 Y0 Z0
N03 M06 T01
G43 H1
N04 M03 S1500 M08
N05 G00 X0 Y0 Z5
N06 G00 X25 Y25
N07 G99 G83 Z-40 Q5 R5 F100
N08 Y105
N09 X105
N10 Y25
N11 G80 M09 M05
N12 G28 X0 Y0 Z0
N13 M06 T02
G43 H2
N14 M03 S1500 M08
N15 G00 X0 Y0 Z5
N16 G00 X30 Y65
N17 G99 G83 Z-40 Q5 F100
N18 X60 Y95
N19 X90 Y65
N20 X60 Y35
N21 G80 M09 M05
N22 G28 X0 Y0 Z0
N23 M30.

PROBLEM NO 6:

O06
BILLET 350 X 250 X 30 MM

CANNED CYCLES USED: G81 & G86

50

75
R
50

R5
0
50

75 125

N01 G21 G94 G90

N02 G28 X0 Y0 Z0
N03 M06 T01
N04 G43 H01
N05 M03 S1500 M08
N06 G00 X0 Y0 Z10
N07 G01 X25 Y75 F100
N08 G01 Z-10
N09 G01 Y125
N10 X100 Y175
N11 X225
N12 G02 X225 Y25 R75 F70
N13 G01 X100
N14 G01 X25 Y75
N15 G01 Z5
N16 M05 M09
N17 G28 X0 Y0 Z5
N18 M06 T02
G43 H02
N19 M03 S1000 M08
N20 G00 X225 Y50 Z5
N21 G99 G81 Z-10 R5 F100
N22 G00 X275 Y100
N23 X225 Y137.5
N24 G80 M09 M05
N25 G28 X0 Y0 Z5
N26 M06 T03
G43 H03
N27 M03 S500 M08
N28 G00 X225 Y50 Z5
N29 G99 G86 R5 Z-10 F75
N30 G00 X275 Y100
N31 X225 Y137.5
N32 G80 M09 M05
N33 G28 X0 Y0 Z5
N34 M30
N35 M30
 CAPSturn and CAPSmill

CAPS turn and CAPS mill are the CADEM softwares available to create
complicated designs and models for turning & milling related operations. It can also be
utilized as a tool to generate a part and in turn to generate the NC part programme for the
part generated. Writing a manual part programme involves designing the part and writing
programme. But by using CAPSturn & CAPSmill, the part programme will generate by
itself for the part drawn by the operator. It is also possible to interface this software
directly to a CNC machine where in the part designed can be machined.

The programming process of CAPSturn & CAPSmill includes the following 8 steps

Steps Operation Menu option

1 Start a new programme File
2 Define a work setup
3 Draw the part Geometry
4 Define Blank Geometry
5 Perdorm Machining Machining
6 Select Machine Machines
7 View tool path Tool path
8 Generate NC program NC program
CAPS Turn Exercise:

This problem illustrates

• Creating geometry.
• Selecting tools.
• Performing Roughing and Finishing operations.
• Viewing tool path.
• Generating documents.

Part drawing

All Dimensions are in mm.

CAPS Mill Exercise: