CNC FUNDAMENTALS

AND
PROGRAMMING
NE  REVISED
W By & ENLARGED
P. M. Agrawal, DR. V. J. Patel

Edition : 2nd Revised and Enlarged Edition: 2017 (First Reprint)

ISBN : 9789380358871
Size : 170 mm × 235 mm
Binding : Paperback
` 200.00 BUY Pages : 292 + 16 = 308

ABOUT THE BOOK CONTENT

This text-book explains the fundamentals of NC/CNC machine tools, operations and part   1 : INTRODUCTION TO NC/CNC MACHINE TOOLS
programming which form essential portion of course on Computer Aided Manufacturing (CAM).   2 : BASICS OF NC/CNC MACHINE TOOLS
This book also covers advanced topics such as Macro programming, DNC and Computer Aided   3 : CNC MACHINE TOOLS – STRUCTURE AND ELE-
Part Programming (CAPP) in detail. MENTS
In this second revised and enlarged edition, all the chapters are reviewed and relevant topics,   4 : BASICS OF CNC PROGRAMMING
examples, part programs, sketches, review questions and exercises have been added to   5 : BASICS OF TURNING CENTER PROGRAMMING
enhance the utility of the book.   6 : SINGLE PASS CANNED CYCLE FOR TURNING
This book is divided into 6 major areas. CENTERS
  7 : MULTIPASS CANNED CYCLES IN TURNING
Chapter 1 to 4 cover the history, fundamentals and structure of NC/CNC machine tools.
  8 : BASICS OF MACHINING CENTER PROGRAMMING
Chapter 5, 6 and 7 cover turning center programming in detail. Various turning canned cycles
  9 : DRILLING CANNED CYCLES IN MACHINING CENTER
are discussed in depth with the help of illustrative examples.
10 : SUBPROGRAMMING
Chapter 8 and 9 are devoted to machining center programming. Drilling canned cycles are 11 : MACRO PROGRAMMING
discussed in detail with relevant examples.
12 : DNC AND DATA COMMUNICATION
Chapter 10 and 11 cover advanced topics of subprogramming and macro programming. 13 : APT PROGRAMMING
Chapter 12 deals with the communications and networking of NC/CNC machine tools. 14 : CAD/CAM INTEGRATION
Chapter 13 and 14 explain the advanced programming using APT and CAD/CAM based APPENDIX I : MULTIPLE CHOICE QUESTIONS
programming respectively. APPENDIX II : NC/CNC MANUAL PART PROGRAMMING
CODES
The book contains:
INDEX
* 258 Self explanatory and neatly drawn drawings
*   62 Solved part programming examples
*   37 Part programming exercises
* 173 Review questions at the end of all the chapters
* 101 Multiple choice questions.
It is the fervent hope of the authors that book will satisfy the needs of the Mechanical, Production,
Mechatronics and Automobile Engineering students preparing for the B.Tech/B.E. examinations
of all the Indian Universities, Diploma examinations conducted by various Boards of Technical
Education, Certificate course as well as for the A.M.I.E., U.P.S.C., G.A.T.E., I.E.S. and other
similar competitive and professional examinations. It should also be of an immense help to the
practising Mechanical Engineers.

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 CNC FUNDAMENTALS AND PROGRAMMING
DETAILED CONTENTS
Chapter 1 INTRODUCTION TO NC/CNC MACHINE TOOLS Chapter 2 BASICS OF NC/CNC MACHINE TOOLS
1-1. History of NC machines 2-1. Axes designation
1-2. Introduction to numerical control (NC) machine tools 2-1-1. Coordinate system
Definition 2-1-2. Designating the axes
1-3. CNC (Computer Numerical Control) 2-2. Axes system of different machine tools
Machine control unit 2-2-1. Turning center
1-4. Differences between NC and conventional machine tools 2-2-2. Vertical machining center (VMC)
  (1) Spindle drives 2-2-3. Horizontal machining center
 (2) Guideways 2-2-4. Turn mill center
  (3) Motion transmission 2-2-5. Three axes planer
  (4) Feed drives 2-2-6. Four axes machining center
  (5) Machine tool structure 2-2-7. Five axes horizontal boring machine
  (6) Control unit 2-2-8. Five axes vertical machining center
  (7) Feedback unit 2-3. Reference points
  (8) Automatic tool changer (ATC) 2-3-1. The grid system
  (9) Automatic pallet changer (APC) 2-3-2. Machine origin or machine zero
1-5. Advantages of CNC over NC
2-3-3. Part origin or part zero
 (1) Controller
2-3-4. Tool reference point
 (2) Memory
2-4. CNC control systems
  (3) Part program editing
2-4-1. Point-to-Point control (P-type)
  (4) Cutter compensation
(1) Axial path
  (5) Multipass canned cycles
(2) 45° path
  (6) Advance part programming
(3) Linear Path
  (7) Tool path simulation
  (8) Conversational programming 2-4-2. Line control/straight cut control (L-type)
 (9) Diagnostic 2-4-3. Continuous path control (C-type)
1-6. Advantages of NC and CNC over Conventional machine tools (1) 2-D contouring control
  (1) Increased flexibility (2) 2 1 -D contouring control
2
  (2) More complex geometry (3) 3-D contouring control
  (3) Higher production rate (4) 4-D contouring control
(i) Reduced set-ups 2-4-4. Example of P, L and C type controls
(ii) Reduced lead time 2-5. Automatic tool changer (ATC)
(iii) Reduced non-machining time 2-6. Automatic pallet changer
  (4) Higher accuracy and repeatability Review questions 2
  (5) Reduced inspection Chapter 3 CNC MACHINE TOOLS – STRUCTURE AND
  (6) Reduced operator skill ELEMENTS
  (7) Reduced scrap 3-1. Machine tool structure
  (8) Reduced work-in-process inventory 3-2. Machine tool spindle
  (9) Elimination of profile tools (1) Belt driven spindle
(10) Simpler fixtures (2) Integral motor-spindle
(11) Optimum cutting conditions 3-3. Spindle bearings
1-7. Limitations of NC/CNC machine tools 3-4. Guideways
 (1) Cost 3-5. Transmission system
  (2) High maintenance costs
3-5-1. Recirculating ballscrews
  (3) Not cost effective for low production levels
(1) Double nut preloading
  (4) Programming skill
(2) Single nut preloading
1-8. Specifications of a typical turning center
3-5-2. Roller screw
  (1) Axes system
3-6. Drives
  (2) Main spindle
3-6-1. Stepper motor
  (3) Tool turret
3-6-2. AC/DC rotary servo motor
  (4) Tail stock (with hydraulic quill)
  (5) Other Features 3-6-3. Linear motor
1-9. Specifications of a typical vertical machining center (VMC) 3-7. Open loop and closed loop control systems
  (1) Axes system 3-7-1. Open loop control system
 (2) Table 3-7-2. Closed loop control system
 (3) Headstock 3-8. Feedback devices
  (4) ATC system 3-8-1. Incremental optical encoders
  (5) Special features 3-8-2. Absolute optical encoders
1-10. Role of NC/CNC technology in modern manufacturing (1) Pure binary code
 (1) Machining (2) Gray code
  (2) Unconventional machining (3) Gray excess code
  (3) Fabrication and welding 3-9. CNC Tooling
  (4) Press work 3-9-1. Qualified tool
  (5) Material handling and assembly 3-9-2. Preset tools/semi-qualified tools
  (6) Inspection and measurement 3-9-3. Tool presetters
  (7) Wood working 3-9-4. Tool holders
1-11. Multi-tasking machine tools Review questions 3
Review questions 1 Exercise 3

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 CNC FUNDAMENTALS AND PROGRAMMING
DETAILED CONTENTS
Chapter 4 BASICS OF CNC PROGRAMMING Chapter 7 MULTIPASS CANNED CYCLES IN TURNING
4-1. Coding systems 7-1. Rough turning cycle (G71)
(1) Fixed sequential format 7-2. Face roughing cycle (G72)
(2) Tab sequential format 7-3. Pattern repeating cycle (G73)
(3) Word address format 7-4. End face peck drilling cycle (G74)
(i) Alphabet 7-5. Outer diameter grooving cycle (G75)
(ii) Digits 7-6. Multi-pass thread cutting cycle (G76)
(iii) Operators Review questions 7
(iv) Special characters Exercise 7
4-2. Punched paper tapes Chapter 8 BASICS OF MACHINING CENTER PROGRAMMING
(1) ISO code 8-1. Rapid traverse (G00)
(2) EIA code 8-2. Linear interpolation (G01)
4-3. Punched tape readers 8-3. Circular interpolation (G02/G03)
(1) Electromechanical tape reader 8-3-1. Circular interpolation for arcs greater than 180°
(2) Photoelectric tape reader 8-3-2. Programming of full circle in one block
(3) Pneumatic tape reader (1) Radius of arc programming
(4) Magnetic tapes (2) Center of arc programming
4-4. Types of codes 8-4. Profile milling
(1) Sequence or block number 8-5. Cutter compensations
(2) Preparatory code 8-5-1. Cutter radius compensation
(1) Offset plane selection and offset vector
(3) Miscellaneous code
(2) Cutter radius compensation to the left (G41)
(4) Axis words
(3) Cutter radius compensation to the right (G42)
(5) Feed word
(4) Ramp on move
(6) Speed word
(5) Ramp off move
(7) Tool number (6) Tool movements in offset mode
4-4-1. Preparatory codes (7) Change of the cutter compensation value
4-4-2. Miscellaneous codes 8-5-2. Tool length compensation
4-4-3. Modal and Non-modal codes 8-5-3. Tool wear compensation
4-5. Decimal point programming 8-6. Automatic reference point return (G28)
4-6. Absolute and incremental positioning Review questions 8
4-6-1. Absolute programming or positioning Exercise 8
4-6-2. Incremental/relative programming or positioning
Chapter 9 DRILLING CANNED CYCLES IN MACHINING
4-7. Diameter and radius programming
CENTER
4-8. Programming functions
9-1. Syntax of drilling canned cycles
4-8-1. Data input units
(1) Return to the initial level (G98)
4-8-2. Spindle speed control
(2) Return to R level (G99)
(1) Direction
9-2. Cancel the drilling canned cycle (G80)
(2) Spindle speed 9-3. Spot drilling cycle (G81)
4-8-3. Feedrate control 9-4. Counter boring cycle (G82)
4-8-4. Coordinate system preset 9-5. Deep hole peck drilling cycle (G83)
4-8-5. Tool and tool offset 9-6. High speed peck drilling cycle (G73)
4-8-6. Program control 9-7. Right-hand tapping cycle (G84)
(1) M00: Program stop 9-8. Left-hand tapping cycle (G74)
(2) M01: Optional stop 9-9. Boring cycles (G85,G86)
(3) M02: End of program 9-10. Back boring cycle (G87)
(4) M30: Program stop and rewind 9-11. Boring cycle with manual retraction (G88)
Review questions 4 9-12. Boring cycle with dwell (G89)
Chapter 5 BASICS OF TURNING CENTER PROGRAMMING 9-13. Fine boring cycle (G76)
5-1. Rapid traverse (G00) 9-14. Polar coordinate system
5-2. Linear interpolation (G01) 9-15. Local coordinate system using datum shift (G52)
5-3. Circular interpolation (G02/G03) Review questions 9
(1) Cutting direction (G02 or G03) Exercise 9
(2) Arc end point coordinates Chapter 10 SUBPROGRAMMING
(3) Radius of arc or center of arc 10-1. Writing a subprogram
5-4. Tool compensations 10-2. Multiple operations on specific set of hole locations
(1) Geometry offsets 10-3. Pattern repeating
(2) Wear offsets 10-4. Coordinate system mirroring
(3) Tool nose radius compensation 10-5. Coordinate system rotation
5-4-1. Geometry offsets 10-6. Scaling
5-4-2. Wear offset Review questions 10
5-4-3. Tool nose radius compensation Exercise 10
5-5. Automatic reference point return (G28) Chapter 11 MACRO PROGRAMMING
5-6. Dwell 11-1. Applications of macros
Review questions 5 (1) Part family
Exercise 5 (2) Development of canned cycles
(3) Complex interpolations
Chapter 6 SINGLE PASS CANNED CYCLE FOR TURNING (4) Controlling optional devices
CENTERS 11-2. Variables
6-1. Rectangular turning cycle (G90) (1) As arguments
6-2. Thread cutting cycle (G92) (2) In calculations
6-3. Face turning cycle (G94) (1) Local variables [#1 – #33]
Review questions 6 (2) Common variables [#100 – #149] [#500 – #532]
Exercise 6 (3) System variables [#1000 onwards]

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 CNC FUNDAMENTALS AND PROGRAMMING
DETAILED CONTENTS
11-3. Arithmetic expressions (1) Tolerance specifications
11-4. Flow control statements (2) Startup and positioning statements
11-4-1. Unconditional branching (3) Part, drive and check surfaces
11-4-2. Conditional branching (4) Startup statements
11-4-3. Looping (5) Point to point motion statements
11-5. Calling a macro 13-5. Machining center canned cycles
Review questions 11 13-6. Macro programming
Exercise 11 13-7. Repetitive programming
(1) Tracut
Chapter 12 DNC AND DATA COMMUNICATION
(2) Looping and branching
12-1. History
Review questions 13
12-2. Direct numerical control
Exercise 13
12-3. Distributed numerical control
12-4. DNC software features Chapter 14 CAD/CAM INTEGRATION
(1) File transfer 14-1. CAD/CAM systems
(2) File management (1) Standalone CAD/CAM systems
(3) NC editor (2) Integrated CAD/CAM/CAE systems
(4) Report generation (1) Input of geometrical and technological data
(5) Access control (2) Calculation of the tool path and creation of the
12-5. Advantages of DNC tool paths
12-6. DNC communications (3) Translation of the tool paths to a part program
12-6-1. Parallel communications Step 1: Create the manufacturing model
12-6-2. Serial communications Step 2: Setup the manufacturing data base and operations
(1) Synchronous serial communication (1) Tooling data
(2) Asynchronous serial communication (2) Machine tools/work cells
12-7. Networking (3) Fixture setups
12-7-1. Networking components (4) Operation setup
(1) Coaxial cables Step 3: Define the NC-sequences
(2) Twisted pair cables (1) Defining the machining features
(3) Optical fiber cables (2) Define the sequence of machining features
12-7-2. Network topologies Step 4: Create the toolpath (cutter location files)
(1) Physical topology Step 5: Post-processing
(2) Logical topology 14-2. Evaluation of CAM software
(1) Bus network topology 14-2-1. Turning
(2) Ring network topology (1) 2-axis turning
(3) Star network topology (i) Contouring
(4) Mesh network topology (ii) Hole making
(5) Tree network topology (iii) Roughing
12-8. Networking of CNC machine tools (iv) Copy roughing
(1) Wired DNC Networks (v) Grooving
(i) RS232 DNC system (vi) Threading
(ii) Ethernet DNC system (2) Multi-spindle and multi-turret turning
(2) Wireless DNC networks 14-2-2. Milling
(i) Ethernet wireless DNC system (1) Simple milling
(ii) Bluetooth wireless DNC system (i) Pocketing
Review questions 12 (ii) Facing
Chapter 13 APT PROGRAMMING (iii) Hole making
13-1. Introduction (iv) Profiling
(1) Arithmetic calculations (v) Thread milling
(2) Cutter offset computation (2) Advanced milling
(3) Postprocessing (i) Rotary axis
13-2. Coordinate system (ii) Machining using 4th and 5th axis
13-3. Language features (3) Machining of 3D freeform shapes
13-3-1. Keywords 14-3. Conversational programming
(1) Major words (1) Initialization module
(2) Minor words (2) Machining cycle module
13-3-2. Symbols (3) Contour module
Subscripted symbols (4) Tool module
13-3-3. Other features (5) Toolpath simulation module
(1) Numbers (6) Utility module
(2) Angles 14-4. Part program verification
(3) Arithmetic operators 14-4-1. The purposes of part program verification
(4) Library functions (1) To detect geometric errors of the cutter path
13-4. APT statements (2) To detect potential tool interference
13-4-1. Postprocessor statements (3) To detect incorrect cutting conditions
13-4-2. Auxiliary statements 14-4-2. Part program verification methods
13-4-3. Geometry statements (1) Dry run
(1) Point (2) Machine a prototype
(2) Line (3) CAD-based verification software
(3) Circle Review questions 14
(4) Plane
(5) Patern Appendix I MULTIPLE CHOICE QUESTIONS
(6) Vector Appendix II NC/CNC MANUAL PART PROGRAMMING CODES
(7) Zsurf
13-4-4. Motion statements Index

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