lOMoARcPSD|34339280

CM4151 UNIT-3 - CAM

Master of Computer Applications (Anna University)

Studocu is not sponsored or endorsed by any college or university

Downloaded by Antony Rufeena ([email protected])
 lOMoARcPSD|34339280

UNIT-3

PROGRAMMING OF CNC MACHINES

STRUCTURE OF CNC PROGRAM
A CNC program is composed of a series of sequential instructions related to the
machining of a part. Each instruction is specified in a format the CNC system can
accept, interpret and process. Each instruction must also conform to the machine tool
specifications.

CNC Programming has a defined structure which machine can read the codes without
errors. NC Programming can be categorized into 3 parts:

 Main Program.

 Part program.

 Sub program.

Main Program Structure

The main program is first read or accessed on machine tool when the entire part
program sequence is run. Normally, the controller operates according to one program.
In this case the main program is also the part program. This controlling program can
then call a number of smaller programs into operation. These smaller programs, called
Sub Programs. These subprograms are generally used to perform repeat tasks, before
returning control back to the main program.

Each block, or program line, contains addresses which appear in this order:

N, G, X, Y, Z, F, M, S, T;

This order should be maintained throughout every block in the program, although
individual blocks may not necessarily contain all these addresses.

Meaning of addresses:

N - Refers to the block number.

G - Refers to the G code (Preparatory function).

Downloaded by Antony Rufeena ([email protected])

 lOMoARcPSD|34339280

X - Refers to the distance travelled by the tool in the X axis direction.

Y - Refers to the distance travelled by the tool in the Y axis direction.

Z - Refers to the distance travelled by the tool in the Z axis direction.

F - Refers to the feed rate.

M - Refers to the M code (Miscellaneous function).

S - Refers to the spindle speed.

T - Refers to the tooling management.

PART PROGRAM STRUCTURE

A part program is a list of coded instructions with series of letters and numbers. The part
program includes all the geometrical and technological data to perform the required
machine functions and movements to manufacture the part.

The part program can be further broken down into separate lines of data, each
line describing a particular set of machining operations. These lines run in sequence,
are called blocks. A block of data contains words which is called codes. Each word
refers to a specific cutting/movement command or machine function. The programming
language recognized by the CNC, the machine controller, is an I.S.O. code, which
includes the G-Code and M-code groups. Each program word is composed from a
letter, called the address, along with a number.

Downloaded by Antony Rufeena ([email protected])

 lOMoARcPSD|34339280

BLOCK EXAMPLE: N010 G01 X50 Y100 F100

Word Example: G01

Address Example: G

The part program can contain a number of separate programs, which together describe
all the operations required to manufacture the part.

SUB PROGRAM STRUCTURE

In order to simplify the main Program in case of repeated patterns or fixed sequences
the Sub program is called in between the main program. The Sub program always ends
with M99 which indicates the end of sub program. Sub program can be called any
number of times in a main program. When the main program calls one sub program into
operation, the process is called a one-loop sub program call. It is possible to program a
maximum four loop sub program call within the main program. Shown below is an
illustration of a two-loop sub program call.

COORDINATE SYSTEM
Nearly all CNC machine uses a Cartesian coordinate system based on an X, Y, and Z-
axis. This system allows a machine to move in a specific direction along a specific
plane. Reduce the Cartesian system to its basics, and you have a familiar number line.
One point on the line gets designated as the Origin.

Downloaded by Antony Rufeena ([email protected])

 lOMoARcPSD|34339280

The real parts of a CNC program involves the input of co-ordinates of the tool
endpoint to produce any machining profile, subsequently it is necessary to follow a
proper co-ordinate system.

All the machine tools make use of the Cartesian coordinate system for the purpose
of simplicity. The guiding coordinate system followed for assigning the axes is the
familiar right hand coordinate system. The fundamental axes to be assigned are the
rectangular axes and the rotary axes. One could use his right hand to arrive at these
alternate variable positions of the same right hand coordinate system.

G & M CODES

M code is the machine control language that controls the overall program, often called
G code. While G commands describe positions, M code directs the machine's actions.
While M represents miscellaneous codes, some refer to it as machine code because it
controls particular operations of the equipment.

M-code controls miscellaneous functions, and typically these can be thought of as non-
geometry machine functions. Examples include spindle rotation start and stop, coolant
on and off, pallet change, etc. Some of these functions may vary by the specific
machine.

CUTTER RADIUS
COMPENSATION
Cutter compensation or sometimes referred
to as “cutter comp”, is an offset or shift from
center line of the tools shaft to the cutters
edge along a programmed path. The
advantage of cutter compensation is the
use of geometry based offsets rather than
tool center point, allowing for the same program to use different diameter tools.

Downloaded by Antony Rufeena ([email protected])

 lOMoARcPSD|34339280

Command names for cutter compensation:

 Tool cutter compensation

 CNC cutter compensation
 G41 G42 cutter compensation
 Cutter diameter compensation
 Cutter radius compensation
 CRC
 Line left
 Line Right

TOOL NOSE RADIUS COMPENSATION

Tool nose radius compensation provides a way to perform precise cutting with a tool
that doesn't end in a perfect point. Since no tool has a perfect point, the sharpness of
the point be expressed in the radius of the tool nose (the smaller the radius, the sharper
the point).
When programming a CNC machine with a turning tool that has a rounded tip, errors in
cutting can occur on tapered edges and circular contours. This is corrected

Downloaded by Antony Rufeena ([email protected])

 lOMoARcPSD|34339280

automatically by Feature CAM or alternatively using a Tool Nose Radius (TNR)

compensation command in a CNC control.

Tool Nose Radius Compensation G40, G41, G42

Tool Nose Radius compensation in Feature CAM

When programming a CNC machine with a turning tool that has a rounded tip, errors in
cutting can occur on tapered edges and circular contours. This is corrected
automatically by Feature CAM or alternatively using a Tool Nose Radius (TNR)
compensation command in a CNC control.

The attached file contains NC code and a Feature CAM part file that will be referenced
in the explanation below (remember to use tools from last save). Feel free to follow
along.

Feature CAM adjusts for the tool nose radius that is entered in the tool properties
automatically.

TOOL WEAR COMPENSATION

Cutter compensation (cutter comp), also sometimes called Cutter Diameter
Compensation (CDC), provides a way to adjust the tool path at the machine to
compensate for tool size, tool wear, and tool deflection.

Downloaded by Antony Rufeena ([email protected])

 lOMoARcPSD|34339280

Tool compensation determines the machining precision and quality . There are tool
length compensation, tool radius compensation and corner radius compensation in CNC
system . The parameters of these compensation are all static.

Alternative tool wear compensation modules employing drawbar actuated tool position
adjustment or electrically activated solid-state prime mover adjustment including means
for physically sensing and verifying the extent of adjustment without awaiting the gaging
of successive work piece dimensions following compensation adjustment. In one
embodiment, a piezoelectric stack is employed with a flexure unit mounted tool to
produce adjustment deflection through controlled voltage applied to the piezoelectric
stack.

CANNED CYCLES
A canned cycle is a combination of machine movements that perform machining
operation like drilling, milling, boring and tapping. This cycle simplifies the program by
using a single block with a G-code to specify the machining operations usually specified
in several blocks. This cycle is also called as fixed cycle. Canned cycles are traditionally
used in making the holes on the complex parts of air crafts and aerospace component
manufacturing, electronics instruments, optical or mold making industry.

A canned cycle is a way of conveniently performing repetitive CNC machine operations.

Canned cycles automate certain machining functions such as drilling, boring, threading,
pocketing, etc... Canned cycles are so called because they allow a concise way to
program a machine to produce a feature of a part.

Canned cycles are so called because they allow a concise way to program a machine to
produce a feature of a part. A canned cycle is also known as a fixed cycle. A canned
cycle is usually permanently stored as a pre-program in the machine's controller and
cannot be altered by the user.

Different Types of Canned Drilling Cycles and Their Uses

G Code Purpose Retract
G73 High-speed Peck Drilling for Shallow Depths Rapid
G74 Left-hand Tapping Cycle Feed
G76 Fine Boring Cycle Rapid
G81 Drilling Cycle without Peck, Drill Depths <= 3 Diameters Rapid

Downloaded by Antony Rufeena ([email protected])

 lOMoARcPSD|34339280

Mirroring Features
Mirror image is a function through which can machine the same trace in other place of
the work-piece, not only saving the tool setting time but also simplifying the edit of
program.

By this way, product could have good accuracy and interchangeability. However,
researches aimed at mirror function based on PMAC is rare. This paper analyzed the
principle of mirror image, combined with coordinate transformation and G-code
development way, a method to deliver the mirror function G-code has been put forward,
which has already used in the independent R&D project single-point diamond ultra-
precision CNC system.

In addition, this article introduced an upper computer software of CNC system based
on Qt and listed the program code of mirror function. The method is available to any
CNC system based on PMAC, offering good versatility.

Manual Part Programming in CNC

Manual programming involves numerous calculations and verifications without the use
of a computer. The programmer must program in the same language the CNC machine
will execute, creating a step-by-step order of commands that make the machine run
accordingly.

In manual part programming, the processing instructions are documented on a form

called a part program manuscript. The manuscript is a listing of the positions of the tool
relative to the work piece that the machine must follow in order to perform the
processing.

Machining center
Machining centers are widely used in manufacturing sites. Machining centers are critical
equipment for machining metal parts and components in addition to their primary
purpose of die manufacture.

As an example, machining centers in the automobile industry are used for efficient
grinding and drilling of engine parts as well as for making dies for body components.
Many other products commonly used in daily life and in industrial settings are
manufactured in machining centers.

Machining centers feature a computerized automatic tool change function. In general,

an operator must exchange the tools on an NC machine tool. Machining centers,
however, have a change arm that automatically retrieves and exchanges tools from a

Downloaded by Antony Rufeena ([email protected])

 lOMoARcPSD|34339280

tool magazine where the tools are stored during the machining of work-pieces. This
saves time and effort required for standard tool changeovers, and consequentially
enables automated and power-saving operations while reducing costs.

In recent years, the emergence of five-axis machining centers, equipped with two
rotational axes in addition to the conventional three axes, has enabled machining of
shapes with even greater complexity.

WIRE ELECTRIC DISCHARGE MACHINING

Wire EDM is also known as: wire-cut EDM, wire cutting, EDN cutting, EDM wire cutting,
wire burning, wire erosion, wire eroding, wire cut electric discharge machining, and
‘cheese-cutter’ EDM.

Wire electrical discharge machining (WEDM) uses a metallic wire to cut or shape a
work-piece, often a conductive material, with a thin electrode wire that follows a
precisely programmed path. Typically the electrode diameters range from .004″ – .012″
(.10mm – .30mm), although smaller and larger diameters are available.

During the wire cutting process there is no direct contact between the wire and the
work-piece which allows for machining without causing any distortion in the path of the
wire, or the shape of the material. To accomplish this, the wire is very rapidly charged to
a desired voltage. The wire is also surrounded by deionized water. When the voltage
reaches the correct level, a spark jumps the gap and melts a small portion of the work
piece. The deionized water cools and flushes away the small particles from the gap.

The hardness of the work piece material has no detrimental effect on the cutting
speed. Extrusion dies and blanking punches are very often machined by wire cutting.

EDM cutting is always through the entire work-piece. To start wire machining it is first
necessary to drill a hole in the work-piece or start from the edge. On the machining
area, each discharge creates a crater in the work-piece and an impact on the tool. The
wire can be inclined, thus making it possible to make parts with taper or with different

Downloaded by Antony Rufeena ([email protected])

 lOMoARcPSD|34339280

profiles at the top and bottom. There is never any mechanical contact between the
electrode and work-piece (see above). The wire is usually made of brass or stratified
copper, and is between 0.1 and 0.3 mm diameter.

Depending on the accuracy and surface finish needed, a part will either be one cut or it
will be roughed and skimmed. On a one cut the wire ideally passes through a solid part
and drops a slug or scrap piece when it is done. This will give adequate accuracy for
some jobs, but most of the time, skimming is necessary.
A wire EDM machine is a type of CNC machine that can move along four independent
axes to generate taper cuts. For example, a stamping die can be machined with 1/4
degree taper or a mold with one degree taper in some areas and two degrees in
another with precision. Extrusion dies or nozzles and horns can be cut with constantly
changing tapers. For example, a detailed shape on the top of the work piece can
transition to a simple circle on the bottom.

Applications

 Thick parts requiring good finishes and/or accuracies.

 Complex shapes or narrow slots
 Larger parts that need to hold accurate tolerances
 Delicate, hard, exotic/expensive or weak materials

ABRASIVE WATER JET MACHINING

Abrasive water jet machining (AWJM) is a very useful non-conventional machining for
the cutting of dissimilar materials at once.

It is a flexible process that generates low thermal damage to the machined surface as
there is no continuous tool-material con- tact along the machining process.

It is an advanced Water Jet Machining Process that includes Abrasives as a medium.

To overcome the disadvantage of water jet machining, the abrasive particles will be
added into the water so that the abrasive particles along with water also come out from
the nozzle at a very high velocity to remove the material from the surface of a workpiece
to get desired shape and size at high accuracy.

CONSTRUCTIONS OF AWJM

Downloaded by Antony Rufeena ([email protected])

 lOMoARcPSD|34339280

The main parts of the Abrasive Water jet Machining Process are as follows. Some of the
parts of the water jet machining process are also included in the setup because the
AWJM process is the advance of the WJM process.

Reservoir:

The reservoir will act as a basic part for storing water and this water is sent to all the
other parts of the system to work properly.

Hydraulic Pump:

The hydraulic pump is generally used to pump the fluid from one place to another place
whereas here in this unit, it acts as a mediator between the reservoir and the Intensifier.
It sucks the water from the reservoir and sends it to the Intensifier.

Hydraulic Intensifier:

It is connected after the hydraulic pump and is used to increase the pressure of the
water.

Accumulator:

The accumulator is used to store the water temporarily and supplies the water in the
system when there is either a pressure drop or high-pressure water required in the
system.

Control Valves:

 The duty of the pressure control valve is to control the pressure of water and
also the direction of water.
 A flow regulator valve is used to regulate the flow of water into the system.

Flow regulator:

As the name flow regulator, it is used to regulate the flow of water which was arrived
from the control valve and send that water towards the nozzle.

Abrasive Tank:

Abrasive particles play a vital role in this process. As we know that water jet machining
process is used to cut soft materials whereas, in order to cut the hard materials, just
water is not sufficient. In addition to water, Abrasives are also added so that the material
can cut at a faster rate. The commonly used Abrasive particles are aluminum oxides,
sand, garnet, glass particles, etc.

Downloaded by Antony Rufeena ([email protected])

 lOMoARcPSD|34339280

Mixing Chamber:

In the water jet machining process, only water is used as a cutting medium whereas, in
the Abrasive Water Jet Machining process, 70% water and 30% Abrasive particles are
used and they are mixed in the mixing chamber.

Nozzle:

The duty of the nozzle is to convert high-pressure water into kinetic energy(K.E) and
this K.E. is increased due to the decrease in the nozzle area. This high K.E. water along
with the abrasive particles is impinged onto the surface of the workpiece to get the
desired shape and size at a faster rate.

Drain system:

The main duty of the drain is to collect the water coming away from the work region and
is supplied back to the reservoir via the pump and the filter

WORKING PRINCIPLE OF AWJM

The water from the reservoir is to be passed to all the parts of the system starting from
the reservoir to the drain system. Firstly, the water is passed through the hydraulic
intensifier where the pressure of the water increases and is to be sent to the
accumulator for storing the water on a temporary basis.

The control valves are placed in the system to control the pressure of water and the
directional flow of water. Next, the abrasive particles along with water in a percentage of
30 & 70 are mixed in the mixing chamber.

Downloaded by Antony Rufeena ([email protected])

 lOMoARcPSD|34339280

When these high-velocity Abrasive particles are impinging onto the hard work-
pieces, it is possible to produce plastic deformation fracturing in the hard work
materials.

As the percentage of abrasives is increasing, the material removal also increases but
the flow characteristics of the liquid mixture are coming down.

Therefore the optimum percentage of abrasives will be about 40 to 60%.

It is mainly developed for cutting granite and marble of complex shapes .

Abrasive Water Jet Machining Process Parameters

The parameters of the Abrasive Water Jet Machining process are as follows.

 Water flow rate

 Water Pressure
 Abrasive Flow rate
 Abrasive particle size
 Abrasive materials
 Nozzle diameter
 Traverse rate
 Stand-off distance
 Depth of cut
 Material properties.

Abrasive Particle size:

The most common usage of abrasive particles in the AWJM process is in the range of
100 to 150 grit.

Abrasive Materials:

The most used abrasive materials are Garnet(which is 30% more efficient than sand),
silicon carbide, and silica.

Traverse rate:

The depth of cut decreases when the traverse rate is increased. The Traverse speed
maintained is 100 mm/min to 5 m/min.

Downloaded by Antony Rufeena ([email protected])

 lOMoARcPSD|34339280

Stand-off distance:

If the stand-off distance is increased, the depth of the cut is decreased. The stand-off
distance maintained is 1-2mm.

Depth of cut:

The depth of cut maintained is in the range of 1 mm-250 mm.

ADVANTAGES
1. No heat-affected zone
2. No cutter induced distortion
3. Eliminates thermal distortion
4. Low cutting forces on work-pieces

DISADVANTAGES
1. High capital cost and high noise levels during machining.
2. It cannot cut the materials that degrade quickly with moisture.
3. Surface finish loses at higher cut speeds.

APPLICATIONS
1. It is highly used in the automotive, aerospace, and electronics industries.
2. In aerospace industries, parts such as engine components (aluminum, titanium,
and heat resistant alloys), aluminum body parts, titanium bodies for military
aircraft, etc. are made using abrasive water jet machining process.

Bulk and sheet metal forming

In ironing, characterized by combined tensile and compressive stress states, a hollow
work-piece is drawn over an ironing ring by an inner tool. As this process leads to
localized sheet thinning, caused by a three-dimensional stress state applied on a sheet
metal, it is a form of sheet-bulk metal forming.

Downloaded by Antony Rufeena ([email protected])

 lOMoARcPSD|34339280

Bulk metal forming

Bulk forming processes such as forging, extrusion and rolling are key processes of
modern industrial manufacturing. Especially for structural components and safety-critical
applications, forming components are essential due to their reliable mechanical
properties.

Sheet metal forming

Sheet metal forming involves various processes where force is applied to a piece of
sheet metal to plastically deform the material into the desired shape, modifying its
geometry rather than removing any material.

Sheet metal forming is used in almost every sector of industrial production, like the
automotive industry, the aircraft industry, the home appliance industry, the food industry
etc.

The three major categories of sheet-metal processes are

(1) cutting,

(2) bending, and

(3) drawing

Generation of CNC program using CAM softwares

Computer aided manufacturing (CAM) software is a tool/program that uses numerical
control (NC) to create detailed instructions (G-code) that drive CNC machines. CAM
software streamlines the machining process and automates actions like drilling and
cutting, which makes it ideal for high-quality manufacturing

Downloaded by Antony Rufeena ([email protected])

 lOMoARcPSD|34339280

CAM software is used to program tool paths and to generate the G-code that controls
CNC machines like mills, routers, lathes, and wire EDMs. CAD/CAM software, like
Master-cam, is used to take parts from design through production within a single, user
friendly interface.

Downloaded by Antony Rufeena ([email protected])