CNC PROGRAMMING WORKBOOK. Sample not for. Distribution TEACHER KIT MILL AND LATHE. By Matthew Manton and Duane Weidinger

Transcription

1 CNC PROGRAMMING WORKBOOK TEACHER KIT MILL AND LATHE By Matthew Manton and Duane Weidinger

2 CNC Programming Teacher Kit Published by CamInstructor Incorporated 330 Chandos Crt. Kitchener, Ontario N2A 3C2 Date: June 1, 2013 Author: Matthew Manton and Duane Weidinger ISBN: Copyright 2013 CamInstructor Inc. - All rights reserved. This book is protected under the copyright laws of Canada and the United States. All rights are reserved. This document may not, in whole or part, be copied, photocopied, reproduced, translated or reduced to any electronic medium or machine-readable form without prior consent, in writing, from CamInstructor Inc. National Library of Canada Cataloguing in Publication To order additional copies of the book contact: CamInstructor Inc. 330 Chandos Crt, Kitchener, ON, N2A 3C2 Phone Fax [email protected] Limit of Liability/Disclaimer of Warranty: While the Publisher and Author have used their best efforts in preparing this book, they make no representations or warranties with respect to the accuracy or completeness of the contents of this book and specifically disclaim any implied warranties of merchantability or fitness for a particular purpose. No warranty may be created or extended by representatives. The advice and strategies contained in this book may not be suitable for the readers or users situation. Neither the publisher nor author shall be liable for any damage, loss or any other damages, including but not limited to special, incidental, consequential, or other damages including personal. Notice CamInstructor Inc. reserves the right to make improvements to this book at any time and without notice. Trademarks All brands are the trademark of their respective owners. Printed in Canada Requirements Use of the Multi-media CD/DVD requires a computer with speakers, and CD/DVD ROM. June 18, 2013

3 How to Use The Programming Workbook The CNC Programming Student Workbook includes a DVD with the following Videos and support files on it. 1. Self-Learning Videos 2. Discriminator BackPlot Installation Software To view what s on the DVD just follow the instructions below. We encourage you to take a few moments to watch the Getting Started video on the DVD as it provides an overview of how the system works. Just pop the DVD into your computer, the autorun feature should display the AutoPlay window. Click on the Run CNC-Mill.exe file as shown below. Note, if this window is not displayed after putting the DVD into your computer, go to the file manager feature on your computer and select the DVD drive and double click on the Run CNC-Mill.exe file. The following Menu Screen should appear; How to Use The Programming Workbook Page - 1

4 The Menu is your easy access to the Instructional Videos that will guide you through the content and provide you with all the information you need to get through this workbook. You will notice that there are 10 Lessons and a Getting Started link. Each Lesson matches the corresponding lesson in this workbook. Be sure to watch the video first, it will guide you to information in the workbook. Step 1: Watch the Getting Started Video. Don t worry about taking notes or filling out anything in the workbook while you watch the Getting Started Video, it is just a preview of what to expect. Step 2: The second item on the DVD is the Discriminator installation file. We have provided this to you free of charge so you can install Discriminator onto your computer. Discriminator Software enables you to type in the CNC Code (G Code) and watch what it will do. It is a handy tool to see if your CNC Programs are correct. 1. To access the Discriminator installation file put the DVD into your computer and locate the Discriminator folder as shown below. 2. Double click on the Discriminator folder as shown above and then double click on the Discriminator21017.exe file as shown below and follow the onscreen instructions. How to Use This Guide Page - 2

5 TABLE OF CONTENTS-MILL LESSON-1..ABSOLUTE & INCREMENTAL POSITIONING...1 EXERCISES 1 THROUGH 4 ABSOLUTE & INCREMENTAL... 2 LESSON-2.. INTRODUCTION TO CNC CODES...7 AUTOMATIC TOOL CHANGER STANDARD TOOL CAROUSEL... 8 COMMONLY USED PREPARATORY G-CODES... 9 COMMONLY USED MISCELLANEOUS M-CODES EXAMPLE OF PROGRAM START-UP BLOCKS EXAMPLE OF PROGRAM END BLOCKS EXAMPLE OF PROGRAM TOOL CHANGE BLOCKS RAPID (G00) AND LINEAR (G01) INTERPOLATION CNC PART #1 SPOT DRILLING SAMPLE PROGRAM LESSON-3.. CREATING CNC PROGRAMS - CNC PART # CNC PART #1 SPOT AND DRILLING SAMPLE PROGRAM LESSON-4.. DRILLING USING CANNED CYCLES...21 DRILLING CANNED CYCLES CNC PART #1 SPOT AND DRILLING PROGRAM USING G CNC PART #1 WHAT COULD GO WRONG?... 26

6 TABLE OF CONTENTS LESSON-5.. DRILLING USING CANNED CYCLES...27 CNC PART #2 - SPOT AND DRILLING PROGRAM USING G CNC PART #2 - CREATE THE PROGRAM TO SPOT AND DRILL CNC - PART #2 - TYPING UP YOUR PROGRAM USING WINDOWS NOTEPAD CNC - PART #2 - BACKPLOTTING CNC - PART #3 - CREATE THE PROGRAM CNC - PART #3 - BACKPLOTTING CNC - PART #4 - CREATE THE PROGRAM LESSON-6.. STRAIGHT LINE MILLING LINEAR INTERPOLATION...47 EXERCISE #1 - ABSOLUTE & INCREMENTAL POSITIONING CNC PART #5 STRAIGHT LINE MILLING SAMPLE PROGRAM CNC PART #6 STRAIGHT LINE MILLING SAMPLE PROGRAM CNC PART #7 CREATE THE PROGRAM CNC PART #8 CREATE THE PROGRAM LESSON-7.. CIRCULAR INTERPOLATION...61 CIRCULAR INTERPOLATION EXERCISES CIRCULAR INTERPOLATION SAMPLE PROGRAMS LESSON-8.. CIRCULAR INTERPOLATION...75 CNC PART #9 CIRCULAR INTERPOLATION CREATE THE PROGRAM CNC PART #10 - CIRCULAR INTERPOLATION CREATE THE PROGRAM Table of Contents - 2

7 TABLE OF CONTENTS LESSON-9.. CIRCULAR INTERPOLATION...89 CNC PART #11 - CIRCULAR INTERPOLATION CREATE THE PROGRAM CNC PART #12 - CIRCULAR INTERPOLATION CREATE THE PROGRAM LESSON-10 CUTTER COMPENSATION INTRODUCTION TO CUTTER COMPENSATION CNC PART #13 - CUTTER COMPENSATION CREATE THE PROGRAM CNC PART #14 - CUTTER COMPENSATION CREATE THE PROGRAM APPENDIX EXTRA CNC PROGRAMMING EXERCISES PREPATORY FUNCTIONS G-CODES MISCELLANEOUS FUNCTIONS M-CODES STANDARD DRILL SIZES INCHES INCH TAP DRILL SIZES METRIC TAP DRILL SIZES DISCRIMINATOR SOFTWARE INSTALLATION Table of Contents - 3

8 Table of Contents - 4

9 CNC PROGRAMMING WORKBOOK LESSON-1 ABSOLUTE & INCREMENTAL POSITIONING NOTE: Teacher s Solutions are in shaded cells throughout this book. Page 1

10 LESSON-1 EXERCISE #1 - ABSOLUTE & INCREMENTAL POSITIONING G90 ABSOLUTE PROGRAMMING All axis motions are based on a fixed zero reference point, known as ABSOLUTE ZERO (part zero). Each coordinate is in relation to this absolute zero using Cartesian Co-ordinates. G91 INCREMENTAL PROGRAMMING All axis motions are based on the distance to the next location. Each coordinate is based on how far the cutter is to move from start to finish. STARTING AT THE POINT O (ORIGIN), DESCRIBE THE PATH FROM O THROUGH ALL 9 POINTS AND BACK TO THE POINT O USING G90 & G91 G90 X Y G91 X Y O (Origin) 0 0 O O -7 3 Page 2 TK-Mill Lesson 1-2

11 LESSON-1 EXERCISE #2 - ABSOLUTE & INCREMENTAL POSITIONING G90 ABSOLUTE PROGRAMMING All axis motions are based on a fixed zero reference point, known as ABSOLUTE ZERO (part zero). Each coordinate is in relation to this absolute zero using Cartesian Co-ordinates. G91 INCREMENTAL PROGRAMMING All axis motions are based on the distance to the next location. Each coordinate is based on how far the cutter is to move from start to finish. STARTING AT THE POINT O (ORIGIN), DESCRIBE THE PATH FROM O THROUGH ALL 9 POINTS AND BACK TO THE POINT O USING G90 & G91 G90 X Y G91 X Y O (Origin) 0 0 O O -7 3 TK-Mill Lesson 1-3 Page 3

12 LESSON-1 EXERCISE #3 - ABSOLUTE & INCREMENTAL POSITIONING G90 ABSOLUTE PROGRAMMING All axis motions are based on a fixed zero reference point, known as ABSOLUTE ZERO (part zero). Each coordinate is in relation to this absolute zero using Cartesian Co-ordinates. G91 INCREMENTAL PROGRAMMING All axis motions are based on the distance to the next location. Each coordinate is based on how far the cutter is to move from start to finish. STARTING AT THE POINT O (ORIGIN), DESCRIBE THE PATH FROM O THROUGH ALL 9 POINTS AND BACK TO THE POINT O USING G90 & G91 G90 X Y G91 X Y O (Origin) 0 0 O O -3 2 Page 4 TK-Mill Lesson 1-4

13 LESSON-1 EXERCISE #4 - ABSOLUTE & INCREMENTAL POSITIONING STARTING AT THE POINT O (ORIGIN), DESCRIBE THE PATH FROM O THROUGH ALL 9 POINTS AND BACK TO THE POINT O USING G90 & G91 G90 X Y G91 X Y O (Origin) 0 0 O O TK-Mill Lesson 1-5 Page 5

14 Page 6 TK-Mill Lesson 1-6

15 CNC PROGRAMMING WORKBOOK CODE FUNCTION G00 G01 G02 G03 G04 G17 G20 G21 G28 G40 Rapid traverse motion; This is used for non-cutting rapid moves of the machine axis, or rapid retract moves after cuts have been completed. Maximum rapid motion (I.P.M.) of a CNC Machine will vary dependent on machine model. Linear interpolation motion; Used for cutting in a straight line under a controlled feedrate. Maximum feed rate (I.P.M.) of a CNC Machine will vary depending on the model of the machine. Circular Interpolation, Clockwise Circular Interpolation, Counterclockwise Dwell Circular Motion XY Plane Selection Verify Inch Coordinate Positions Verify Metric Coordinate Positions Machine Home (Rapid traverse) G91 is required for rapid move to the G28 reference point. LESSON-2 Cutter Compensation CANCEL INTRODUCTION TO CNC CODES NOTE: Teacher s Solutions are in shaded cells throughout this book. Page 7

16 LESSON-2 - INTRODUCTION TO CNC CODES AUTOMATIC TOOL CHANGER STANDARD TOOL CAROUSEL The CNC Machining Center used in this text is set-up with following tools. All program examples and exercises in this workbook are using the tools and tool numbers listed below. Carousel # Diameter Flat End Mill Diameter Flat End Mill Diameter Flat End Mill Diameter Flat End Mill Diameter Flat End Mill Diameter Spot Drill Diameter Drill Tool Description Diameter Drill Number 7 drill UNC Tap 10 #4 Center Drill Page 8 TK-Mill Lesson 2-2

17 COMMONLY USED PREPARATORY G CODES CODE FUNCTION G00 G01 G02 G03 G04 G17 G20 G21 G28 G40 G41 G42 G43 G49 Rapid traverse motion; This is used for non-cutting rapid moves of the machine axis, or rapid retract moves after cuts have been completed. Maximum rapid motion (I.P.M.) of a CNC Machine will vary dependent on machine model. Linear interpolation motion; Used for cutting in a straight line under a controlled feedrate. Maximum feed rate (I.P.M.) of a CNC Machine will vary depending on the model of the machine. Circular Interpolation, Clockwise Circular Interpolation, Counterclockwise Dwell Circular Motion XY Plane Selection Verify Inch Coordinate Positions Verify Metric Coordinate Positions Machine Home (Rapid traverse) G91 is required for rapid move to the G28 reference point. Cutter Compensation CANCEL Cutter Compensation LEFT of the programmed path Cutter Compensation RIGHT of the programmed path Tool Length Compensation Tool Length Compensation CANCEL G53 G54 G80 G81 G82 G83 G84 G90 G91 G98 G99 Positions the machine axis relative to Machine Home. It is non modal. Work Coordinate #1 (Part zero offset location) Canned Cycle CANCEL Drill Canned Cycle Spot Drill Canned Cycle Peck Drill Canned Cycle Tapping Canned Cycle Absolute Programming Positioning Incremental Programming Positioning Canned Cycle Initial Point Return Canned Cycle Rapid (R) Plane Return TK-Mill Lesson 2-3 Page 9

18 COMMONLY USED MISCELLANEOUS M CODES CODE FUNCTION M00 The M00 code is used for a Program Stop. The spindle stops and the coolant is turned off. Pressing CYCLE START again will continue the program. M01 M03 M04 M05 M06 The M01 code is used for an Optional Program Stop command. Pressing the OPT STOP key on the control panel signals the machine to perform a stop command when the control reads an M01 command. It will then perform like an M00. Optional stops are useful when machining the first part to allow for inspection of the part as it is machined. Starts the spindle CLOCKWISE used for most machining. Must have a spindle speed defined. The M03 is used to turn the spindle on at the beginning of program or after a tool change. Starts the spindle COUNTERCLOCKWISE. Must have a spindle speed defined. STOPS the spindle. The M05 is used to turn the spindle off at the end of program or before a tool change. If the coolant is on, the M05 will turn it off. The tool change command along with a tool number will action a tool change. This command will automatically stop the spindle, Z-axis will move up to the machine zero position and the selected tool will be put in the spindle. The coolant pump will turn off right before executing the tool change. M08 M09 M30 Coolant ON command. Coolant OFF command. Program End and Reset to the beginning of program. Note: Only one M code can be used per line. And the M-codes will be the last command to be executed in a line, regardless of where it is located in that line. Page 10 TK-Mill Lesson 2-4

19 EXAMPLE OF PROGRAM START-UP BLOCKS % O00023 Programs must begin and end with % depending on the type of control. Letter O and up to a five digit program number. Blocks are always terminated by the ; symbol: End of Block (EOB) N10 G20 N20 G00 G17 G40 G49 G80 G90 N30 T8 M06 N40 G00 G90 G54 X1.0 Y1.0 S4000 M03 N50 G43 H8 Z2. 0 Nnn - Sequence Number G20 - Verify Inch G00 - Rapid Traverse G17 - X, Y Circular Plane Selection G40 - Cutter Compensation Cancel G49 - Tool Length Compensation Cancel G80 - Canned Cycle Cancel G90 - Absolute Programming Startup Block (Machine Default Setting) T8 - Tool number #8 to be loaded into the spindle. M06 - Tool Change G00 - Rapid Traverse G90 - Activates control to be in ABSOLUTE. G54 - Selects work coordinate offset system No. 1 X - Axis move to initial X position. Y - Axis move to initial Y position. S Spindle speed 4000 RPM for this tool. M03 - Turns the spindle on in a clockwise direction G43 - Tool Length Compensation: Recognizes the tool length offset value stored in the Hnn code offset display register in the offset length display. H8 - Defines to the control the offset register the tool offset value is stored in. * Tool Length offset # = Tool # Z2.0 - Informs the control to move from full spindle retract to this Z value and apply the tool length offset. TK-Mill Lesson 2-5 Page 11

20 EXAMPLE OF PROGRAM END BLOCKS N200 G00 Z2.0 N210 M05 G00 - Rapid Traverse Z2.0 Retracts tool to 2.0 above part zero M05 Turn off spindle N220 G28 G91 Z0 * N220 G53 Z0 N230 G28 X0 Y0 * N230 G53 X0 Y0 N240 M30 N100 G00 Z2.0 G91 - Incremental Programming G28 - Machine Zero Return Z0 - Z axis in the up direction to machine zero G28 - Machine Zero Return X0 - X axis to machine zero Y0 - Y axis to machine zero M30 End of Program and Reset EXAMPLE OF PROGRAM TOOL CHANGE LINES N110 M05 Send to machine zero Z-axis first to avoid any crash. *G53 is another way to return to machine zero Rapid Traverse and Retracts tool to 2.0 above part zero M05 Turn off spindle N120 G28 G91 Z0 ; / *N120 G53 Z0 Machine Zero Return - Z axis Send to machine zero Z-axis first to N130 G28 X0 Y0 / *N130 G53 X0 Y0 Machine Zero Return - X, Y axis avoid any crash. N140 M01 Optional Program Stop N150 T9 M06 Tool Change - Tool # 9 N160 G00 G90 G54 X1.0 Y1.0 S4000 M03 Turn on the spindle and Rapid traverse to X1. Y1. N170 G43 H9 Z2.0 Tool Length compensation for Tool #9 (H9) *G53 - Positions the machine axis relative to Machine Home. It is non modal. Page 12 TK-Mill Lesson 2-6

21 RAPID G00 AND LINEAR G01 INTERPOLATION G00 RAPID TRAVERSE This code is used for rapid motion of the cutter in air to traverse from one position to another as fast as possible. This code will work for all axis motion up to three axes at once. This G00 code is modal and causes all the following blocks to be in rapid motion until another Group 01 code is specified. The actual rapid federate is dependent on the machine. Generally, rapid motions "will not" be in a straight line. All the axes specified are moved at the maximum speed and will not necessarily complete each axis move at the same time. It activates each axis drive motor independently of each other and, as a result, the axis with the shortest move will reach its destination first. So you need to be careful of any obstructions to avoid with this type of rapid move. G00 is used when you are positioning the cutter in fresh air. Retracting from a hole you have drilled. Rapid traverse is not used when cutting the part. Used incorrectly, rapid traverse will break a cutter very easily. G01 LINEAR INTERPOLATION This G code provides for straight line (linear) motion with programmed feedrate for all axis motions from point to point. Motion can occur up to three axes at once. All axes specified will start at the same time and proceed to their destination and arrive simultaneously at the specified feedrate. To program a feedrate, the F command is used. The F command is modal and may be specified in a previous block. G01 is used for Drilling a hole Machining a slot Machining a profile TK-Mill Lesson 2-7 Page 13

22 LESSON-2 - CNC - PART #1 Page 14 TK-Mill Lesson 2-8

23 LESSON-2 - CNC - PART #1 WORK OUT THE X AND Y COORDIANTES FOR HOLES 1,2 AND 3 X0Y0 is at the centre of the part G90 X Y TK-Mill Lesson 2-9 Page 15

24 LESSON-2 - CNC - PART #1 PROGRAM TO SPOT DRILL THE THREE HOLES ONLY USING A COMBINATION OF G00 AND G01 (CANNED CYCLE DRILL WILL BE USED LATER) Below is the program to spot drill the three holes with an explanation of each block Use a diameter Spot Drill Tool # 6 Spindle Speed = 2750 Feed rate = 11 IPM Spot Drill Depth = Z X0Y0 is at the centre of the part Z=0 is the top of the part. Information inside the parenthesis ( ) is a comment. The CNC control will ignore all text between the parenthesis % (Program must begin and end with a %) O1 ( Program #1 - CNC-PART-1-SPOT DRILLING ONLY ) N10 G20 (Inch programming) N20 G00 G17 G40 G49 G80 G90 (MACHINE DEFAULT SETTING) N30 T06 M06 (T6-Select tool number 6 to be loaded M06-Activates the tool changer) N40 G00 G90 G54 X-1.0 Y S2750 M03 (Rapid to the X and Y position and turn on the spindle at 2750 RPM) N50 G43 H06 Z0.1 (G43 - Activate the tool offset value stored in H06 and rapid to Z0.1) N60 G01 Z-0.15 F11.0 (Hole #1 - Feed down to Z depth at 11 inches per minute) N70 G00 Z0.1 (G00- Retract out of hole #1 at rapid to 0.1 above the top of the work piece) N80 X0 Y0 (G00 is modal - Move at rapid in the X and Y axis to hole #2) N90 G01 Z-0.15 N100 G00 Z0.1 (Hole #2 - Feed down to Z depth at 11 inches per minute, Feed rate is modal) (G00- Retract out of hole #2 at rapid to 0.1 above the top of the work piece) N110 X1.0 Y0.875 (G00 is modal - Move at rapid in the X and Y axis to hole #3) N120 G01 Z-0.15 (Hole #3 - Feed down to Z depth at 11 inches per minute, Feed rate is modal) N130 G53 G00 Z0 M05 (G53 Machine Zero positioning, non modal. Rapid to machine zero in Z, switch spindle off) N140 G53 X-15.0 Y0 (G53 Rapid in relation to machine zero X-15.0 and Y0) N150 M30 (Program end rewind program to the beginning) % (Program must begin and end with a %) Page 16 TK-Mill Lesson 2-10

25 CNC PROGRAMMING WORKBOOK LESSON-3 CREATING CNC PROGRAMS - CNC PART #1 Page 17

26 LESSON-3 - CNC - PART #1 PROGRAM TO SPOT AND DRILL THE THREE HOLES USING A COMBINATION OF G00 AND G01 (CANNED CYCLE WILL BE USED LATER) Below is the program to spot and drill the three holes with an explanation of each block Use a diameter Spot Drill Tool # 6 Spot Drill Spindle Speed = 2750 Feed rate = 11 IPM Use a diameter Drill Tool # diameter Drill Spindle Speed = 4500 Feed rate = 15 IPM Spot Drill Depth = Z Drill Depth = Z X0Y0 is at the centre of the part Z=0 is the top of the part. % (Program must begin and end with a %) O2 ( Program #2 - CNC-PART-1-SPOT AND DRILLING ) N10 G20 (Inch programming) N20 G00 G17 G40 G49 G80 G90 (MACHINE DEFAULT SETTING) (SPOT DRILL 0.25 HOLES) N30 T06 M06 (T6-Select tool number 6 to be loaded M06-Activates the tool changer) N40 G00 G90 G54 X-1.0 Y S2750 M03 (Rapid to the X and Y position of Hole #1 and turn on the spindle at 2750 RPM) N50 G43 H06 Z0.1 (G43 - Activate the tool offset value stored in H06 and rapid to Z0.1) N60 G01 Z-0.15 F11.0 (Hole #1 - Feed down to Z depth at 11 inches per minute) N70 G00 Z0.1 (G00- Retract out of hole #1 at rapid to 0.1 above the top of the work piece) N80 X0 Y0 (G00 is modal - Move at rapid in the X and Y axis to Hole #2) N90 G01 Z-0.15 N100 G00 Z0.1 (Hole #2 - Feed down to Z depth at 11 inches per minute, Feed rate is modal) (G00- Retract out of hole #2 at rapid to 0.1 above the top of the work piece) N110 X1.0 Y0.875 (G00 is modal - Move at rapid in the X and Y axis to hole #3) N120 G01 Z-0.15 (Hole #3 - Feed down to Z depth at 11 inches per minute, Feed rate is modal) N130 G53 G00 Z0 M05 (G53 Machine Zero positioning, non modal. Rapid to machine zero in Z, switch spindle off) N140 G53 X-15.0 Y0 (G53 Rapid in relation to machine zero X-15.0 and Y0) (DRILL 0.25 HOLES) N160 T07 M06 (T7-Select tool number 7 to be loaded M06-Activates the tool changer) N170 G00 G90 G54 X-1.0 Y S4500 M03 (Rapid to the X and Y position of Hole #1 and turn on the spindle at 4500 RPM) N180 G43 H07 Z0.1 (G43 - Activate the tool offset value stored in H07 and rapid to Z0.1) N190 G01 Z-0.35 F15.0 (Hole #1 - Feed down to Z depth at 15 inches per minute through part) N200 G00 Z0.1 (G00- Retract out of hole #1 at rapid to 0.1 above the top of the work piece) Page 18 TK-Mill Lesson 3-2

27 LESSON-3 - CNC - PART #1 - Continued N210 X0 Y0 (G00 is modal - Move at rapid in the X and Y axis to hole #2) N220 G01 Z-0.35 N230 G00 Z0.1 (Hole #2 - Feed down to Z depth, at 15 inches per minute, Feed rate is modal) (G00- Retract out of hole #2 at rapid to 0.1 above the top of the work piece) N240 X1.0 Y0.875 (G00 is modal - Move at rapid in the X and Y axis to hole #3) N250 G01 Z-0.35 (Hole #3 - Feed down to Z depth at 15 inches per minute, Feed rate is modal) N260 G53 G00 Z0 M05 (G53 Machine Zero positioning, non modal. Rapid to machine zero in Z, switch spindle off) N270 G53 X-15.0 Y0 (G53 Rapid in relation to machine zero X-15.0 and Y0) N270 M30 (Program end rewind program to the beginning) % (Program must begin and end with a %) TK-Mill Lesson 3-3 Page 19

29 CNC PROGRAMMING WORKBOOK LESSON-4 DRILLING USING CANNED CYCLES

30 LESSON-4 DRILL CANNED CYCLE G81 G80 CANCEL CANNED CYCLE A canned cycle permits multiple function programming on one block. A canned cycle is canceled with G80. G81 CANNED CYCLE DRILL X Y Z R F Format: G99 G81 Z R0.1 F10. Rapid X location (Optional) Rapid Y location (Optional) Z-depth (Feed to Z-depth starting from R Plane) R-Plane (Rapid point to start feeding) Feed rate in inches/min This G code permits the inclusion of multiple axis motions on one block of program. It is used to reduce the length of program. The figure below shows the axis motions that are included with a Canned Cycle Drill. All Z axis motions are in ABSOLUTE with any other axis motions unaffected. In a canned cycle drill, the cutter moves at rapid to the X and Y, then to a height above the part at rapid rate to the R Plane, which is a point above the work surface. From the R Plane the cutter feeds to the Z-depth at the specified feedrate. When the cutter reaches the Z depth, it retracts at rapid rate to the R Plane. G99 returns the tool to the R Plane after each hole, G98 returns the tool to the initial starting plane. TK-Mill Lesson 4-2

31 DEEP HOLE PECK DRILL CANNED CYCLE G83 G83 DEEP HOLE PECK DRILL CANNED CYCLE Format : G99 G83 Z-2.5 Q0.5 R0.1 F10. / G99 G83 Z-2.18 I0.5 J0.1 K0.2 R0.1 F9. X* Rapid X-axis location Y* Rapid Y-axis location Z Z-depth (feed to Z-depth starting from R plane) Q* Pecking equal incremental depth amount (if I, J and K are not used) I* Size of first peck depth (if Q is not used) J* Amount reducing each peck after first peck depth (if Q is not used) K* Minimum peck depth (if Q is not used) P Dwell time at Z-depth R R-plane (rapid point to start feeding) F Feed rate in inches (mm) per minute * Indicates optional This G code is similar to G81 but is used for drilling when the tool must be withdrawn periodically to allow chips to be removed from the hole. This cycle allows the tool to rapid to the R Plane, feeds towards the Z depth in increments (traversing to the R Plane and back to the point where drilling was interrupted after each increment) until the tool reaches the final Z depth. TK-Mill Lesson 4-3

32 LESSON-4 - CNC - PART #1 CREATE THE PROGRAM TO SPOT AND DRILL THE THREE HOLES USING CANNED CYCLE G81 Use a diameter Spot Drill Tool # 6 Spot Drill Spindle Speed = 2750 Feed rate = 11 IPM Use a diameter Drill Tool # diameter Drill Spindle Speed = 4500 Feed rate = 15 IPM Spot Drill Depth = Z Drill Depth = Z X0Y0 is at the centre of the part Z=0 is the top of the part. % (Program must begin and end with a %) O3 ( Program #3 - CNC-PART-1-SPOT AND DRILLING USING CANNED CYCLE DRILL G81 ) N10 G20 (Inch programming) N20 G00 G17 G40 G49 G80 G90 (MACHINE DEFAULT SETTING) N30 T06 M06 N40 G00 G90 G54 X-1.0 Y S2750 M03 N50 G43 H06 Z0.1 (T6-Select tool number 6 to be loaded M06-Activates the tool changer) (Rapid to the X and Y position of Hole #1 and turn on the spindle at 2750 RPM) (G43 - Activate the tool offset value stored in H06 and rapid to Z0.1) N60 G99 G81 Z-0.15 R0.1 F11.0 (Hole #1 G81 - Feed down to Z depth at 11 inches per minute, and then retract at rapid to Z0.1, this is the R0.1 value. G99 returns the drill tip to the R value after drilling each hole) N70 X0. Y0. (Hole #2 - Move at rapid in the X and Y axis to Hole #2. Feed down to Z depth at 11 inches per minute and then retract at rapid to Z0.1) N80 X1.0 Y.875 (Hole #3 - Move at rapid in the X and Y axis to Hole #3. Feed down to Z depth at 11 inches per minute and then retract at rapid to Z0.1) N90 G80 (Cancel Canned Cycle Drill) N100 G53 G00 Z0 M05 (G53 Rapid to machine zero in Z, switch spindle off) N110 G53 X-15.0 Y0 (G53 Rapid in relation to machine zero X-15.0 and Y0) (DRILL 0.25 HOLES) N120 T07 M06 (T7-Select tool number 7 to be loaded M06-Activates the tool changer) N130 G00 G90 G54 X-1.0 Y S4500 M03 (Rapid to the X and Y position of Hole #1 and turn on the spindle at 4500 RPM) N140 G43 H07 Z0.1 (G43 - Activate the tool offset value stored in H07 and rapid to Z0.1) TK-Mill Lesson 4-4

33 LESSON-4 - CNC - PART #1 - Continued N150 G99 G81 Z-0.35 R0.1 F15.0 (Hole #1 G81 - Feed down to Z depth at 15 inches per minute, and then retract at rapid to Z0.1, this is the R0.1 value. G99 returns the drill tip to the R value after drilling each hole) N160 X0. Y0. (Hole #2 - Move at rapid in the X and Y axis to Hole #2. Feed down to Z depth at 15 inches per minute and then retract at rapid to Z0.1) N170 X1.0 Y.875 (Hole #3 - Move at rapid in the X and Y axis to Hole #3. Feed down to Z depth at 15 inches per minute and then retract at rapid to Z0.1) N180 G80 (Cancel Canned Cycle Drill) N190 G53 G00 Z0 M05 (G53 Rapid to machine zero in Z, switch spindle off) N200 G53 X-15.0 Y0 (G53 Rapid in relation to machine zero X-15.0 and Y0) N210 M30 (Program end rewind program to the beginning) % (Program must begin and end with a %) TK-Mill Lesson 4-5

34 LESSON-4 WHAT COULD GO WRONG? IDENTIFY SOME OF THE COMMON PROBLEMS THAT COULD RESULT IN A SCRAPPED PART Do you have X0 Y0 Z0 in the correct position? Is the spindle switched on and off at the appropriate time Did you use the correct X and Y coordinates for the holes? Did you use the correct tool numbers? Did you use the correct tool length offset number (H??) for the tool? Did you cancel any canned cycles with G80? Are the feed-rates correct? Is the Z depth in the canned cycle block set to a negative value? Is the R value in the canned cycle block set to a positive value? What is the difference between Z2 and Z2.0? No decimal point??? What is the difference between F10 and F10.0? No decimal point??? What else? TK-Mill Lesson 4-6

35 CNC PROGRAMMING WORKBOOK LESSON-5 DRILLING USING CANNED CYCLES - CONTINUED NOTE: Teacher s Solutions are in shaded cells throughout this book.

36 LESSON-5 - CNC - PART #2 TK-Mill Lesson 5-2

37 LESSON-5 - CNC - PART #2 WORK OUT THE ABSOLUTE COORDINATES FOR THE NINE HOLES X0Y0 is at the centre of the part G90 X Y TK-Mill Lesson 5-3

38 LESSON-5 - CNC - PART #2 CREATE THE PROGRAM TO SPOT AND DRILL THE NINE HOLES USING CANNED CYCLE G81 Use a diameter Spot Drill Tool # 6 Spot Drill Spindle Speed = 2750 Feed rate = 11 IPM Use a diameter Drill Tool # diameter Drill Spindle Speed = 4500 Feed rate = 15 IPM Spot Drill Depth = Z Drill Depth = Z X0Y0 is at the centre of the part Z=0 is the top of the part. Type up your program and check it for correctness using Discriminator % O4 ( Program #4 - CNC-PART-2-SPOT AND DRILLING USING CANNED CYCLE DRILL G81 ) N10 G20 N20 G00 G17 G40 G49 G80 G90 N30 T06 M06 N40 G00 G90 G54 X0 Y0 S2750 M03 N50 G43 H6 Z0.1 N60 G99 G81 Z-0.15 R0.1 F11.0 N70 Y1.0 N80 X-1.0 N90 Y0 N100 Y-1.0 N110 X0 N120 X1.0 N130 Y0 N140 Y1.0 N150 G80 N160 G53 G00 Z0 M05 N170 G53 X-15.0 Y0 TK-Mill Lesson 5-4

39 LESSON-5 - CNC - PART #2 - Continued (DRILL 0.25 HOLES) N180 T07 M06 N190 G00 G90 G54 X0 Y0 S4500 M03 N200 G43 H07 Z0.1 N210 G99 G81 Z-0.35 R0.1 F15.0 N220 Y1.0 N230 X-1.0 N240 Y0 N250 Y-1.0 N260 X0 N270 X1.0 N280 Y0 N290 Y1.0 N300 G80 N310 G53 G00 Z0 M05 N320 G53 X-15.0 Y0 N330 M30 % TK-Mill Lesson 5-5

40 LESSON-5 - CNC - PART #2 TYPING UP YOUR PROGRAM USING WINDOWS NOTEPAD Use Windows Notepad to type up your CNC program 1. Launch Windows Notepad Start>All Programs>Accessories>Notepad. 2. Select File Save As 3. Browse to where you would like to save this file. 4. Open up the Save as type drop down and change to All files. 5. Encoding should be set to ANSI. 6. In the File name section enter CNC-PART-2.NC This will give this file an extension of.nc 7. Click on the Save button 8. Start typing your program, ALL CAPITALS for the CNC program codes. Please note on the second line of this program O4 this is a letter O. TK-Mill Lesson 5-6

41 LESSON-5 - CNC - PART #2 TYPING UP YOUR PROGRAM USING WINDOWS NOTEPAD 9. When you have completed typing your program Save your file, File>Save or the shortcut Ctrl+S. Now you can check for any Letter O s in your CNC program. Please Note there should not be any letter O s in your CNC program, G00 is G Zero Zero not G Letter O! 10. Select Edit>Find. 11. Type in the Letter O in the Find what: space. Now hit the Find Next button. There will be some letter O s in your program, for example the Letter O in the program number at the start of the program and any notes you have in your program enclosed by parenthesis ( ). But for the coding no letter O s. 12. I f you do find any letter O s change them to a Zero. TK-Mill Lesson 5-7

42 LESSON-5 - CNC - PART #2 TYPING UP YOUR PROGRAM USING WINDOWS NOTEPAD 13. When you have checked your program select File>Save your file or the shortcut Ctrl+S. 14. You may require a print of your CNC program to do this select File>Print or the shortcut Ctrl+P. 15. Select which printer you wish to send the file to and then hit the Print button 16. To open your CNC program at a later date launch Windows Notepad. Start>All Programs>Accessories>Notepad. 17. Select File>Open. 18. Change the Files of type: to All Files and browse for your CNC program. TK-Mill Lesson 5-8

43 LESSON-5 - CNC - PART #2 - BACKPLOTTING Use Discriminator Backplot Software to check for correctness Note: If you do not have Discriminator installed on your computer please go to the last page of the appendix for installation instructions. 1. After typing up your program in Notepad launch the Discriminator application by clicking on the icon on your desktop or Start>All Programs>Discriminator> Discriminator 2. Click OK to any warnings you receive. 3. Click on File>Open and browse to your file location and select the CNC file to plot. 4. After selecting the CNC file it opens up in a separate window. 5. Now click on the show graphics icon at the toolbar at the top of the screen to launch a plot of your CNC file. TK-Mill Lesson 5-9

44 6. When the plot screen opens up hit the Maximize button. 7. On the top toolbar select the icon to View Fit. 8. You plot should appear as below. The point on the left of the screen shot below is the G53 X-15.0 Y0 movement in the program. TK-Mill Lesson 5-10

45 9. Click the right mouse button on the main graphics plot screen and select Views>Front. 10. Return to a Top view by clicking the right mouse button on the main graphics plot screen and select Views>Top. 11. Experiment with the various display functions at the top right of the screen. 12. Review and experiment with the various toolbar options. 13. You can use Discriminator instead of Windows Notepad to type up your CNC program. Select the New document icon to create a new file and type up your program in the new document window. TK-Mill Lesson 5-11

46 LESSON-5 - CNC - PART #3 PART #3 IS SIMILAR TO PART #2 BUT HAS DIFFERENT DIMENSIONS FOR THE HOLE CENTRES TK-Mill Lesson 5-12

47 LESSON-5 - CNC - PART #3 WORK OUT THE ABSOLUTE COORDINATES FOR THE NINE HOLES X0Y0 is at the centre of the part G90 X Y TK-Mill Lesson 5-13

48 LESSON-5 - CNC - PART #3 CREATE THE PROGRAM TO SPOT AND DRILL THE NINE HOLES USING CANNED CYCLE G81 Use a diameter Spot Drill Tool # 6 Spot Drill Spindle Speed = 2750 Feed rate = 11 IPM Use a diameter Drill Tool # diameter Drill Spindle Speed = 4500 Feed rate = 15 IPM Spot Drill Depth = Z Drill Depth = Z X0Y0 is at the centre of the part Z=0 is the top of the part. Type up your program and check it for correctness using Backplot Software % O5(CNC-PART-3) ( T6 3/8 SPOTDRILL H6 ) ( T7 1/4 DRILL H7 ) N5 G20 N10 G0 G17 G40 G49 G80 G90 N15 T6 M6 N20 G0 G90 G54 X0 Y10 S2750 M3 N25 G43 H6 Z2. N30 Z.1 N35 G99 G81 Z-.15 R.1 F11. N40 Y1.0 N45 X Y1.0 N50 Y0 N55 Y-1.0 N60 X0 N65 X1.125 N70 Y0 N75 Y1.0 N80 G80 N85 Z2. N90 G53 G00 Z0 M05 N95 G53 X-15.0 Y0 N100 T7 M6 N105 G0 G90 G54 X0 Y0 S4500 M3 N110 G43 H7 Z2. N115 Z.1 N120 G99 G81 Z-.35 R.1 F15. TK-Mill Lesson 5-14

49 LESSON-5 - CNC - PART #3 - Continued N125 Y1.0 N130 X Y1.0 N135 Y0 N140 Y-1.0 N145 X0 N150 X1.125 N155 Y0 N160 Y1.0 N165 G80 N170 Z2. N175 G53 G00 Z0 M05 N180 G53 X-15.0 Y0 N185 M30 % TK-Mill Lesson 5-15

50 LESSON-5 - CNC - PART #3 - BACKPLOTTING Use Discriminator to check for correctness After typing up your program in Notepad launch the Discriminator application by clicking on the icon on your desktop or Start>All Programs>Discriminator> Discriminator Click OK to any warnings you receive. Click on File>Open and browse to your file location and select the CNC file to plot. After selecting the CNC file it opens up in a separate window. Now click on the show graphics icon at the toolbar at the top of the screen to launch a plot of your CNC file. When the plot screen opens up hit the Maximize button and selects the icon to View Fit. You plot should appear as below. The point on the left of the screen shot below is the G53 X-15.0 Y0 movement in the program. TK-Mill Lesson 5-16

52 LESSON-5 - CNC - PART #4 WORK OUT THE ABSOLUTE COORDINATES FOR THE ELEVEN HOLES X0Y0 is at the centre of the part Use Trigonometry to work out the center positions of the holes or draw the part up on a CAD system and then identify the center positions of each hole. G90 X Y TK-Mill Lesson 5-18

53 LESSON-5 - CNC - PART #4 CREATE THE PROGRAM TO SPOT AND DRILL THE ELEVEN HOLES USING CANNED CYCLE G81 Use a diameter Spot Drill Tool # 6 Spot Drill Spindle Speed = 2750 Feed rate = 11 IPM Use a diameter Drill Tool # diameter Drill Spindle Speed = 4500 Feed rate = 15 IPM Spot Drill Depth = Z Drill Depth = Z X0Y0 is at the centre of the part Z=0 is the top of the part. Type up your program and check it for correctness using Backplot Software. % O99( CNC-TEXT-PART-4 ) ( T6 3/8 SPOTDRILL H6 ) ( T7 1/4 DRILL H7 ) N5 G20 N10 G0 G17 G40 G49 G80 G90 N15 T6 M6 N20 G0 G90 G54 X0. Y0. A0. S2750 M3 N25 G43 H6 Z.1 N30 G99 G81 Z-.15 R.1 F11. N35 X1. N40 X.809 Y.5878 N45 X.309 Y.9511 N50 X-.309 N55 X-.809 Y.5878 N60 X-1. Y0. N65 X-.809 Y N70 X-.309 Y N75 X.309 TK-Mill Lesson 5-19

54 LESSON-5 - CNC - PART #4 - Continued N80 X.809 Y N85 G80 N90 G53 G00 Z0 M05 N95 G53 X-15.0 Y0 N100 T7 M6 N105 G0 G90 G54 X0. Y0. A0. S4500 M3 N110 G43 H7 Z.1 N115 G99 G81 Z-.35 R.1 F15. N120 X1. N125 X.809 Y.5878 N130 X.309 Y.9511 N135 X-.309 N140 X-.809 Y.5878 N145 X-1. Y0. N150 X-.809 Y N155 X-.309 Y N160 X.309 N165 X.809 Y N170 G80 N175 G53 G00 Z0 M05 N180 G53 X-15.0 Y0 N185 M30 % TK-Mill Lesson 5-20

55 CNC PROGRAMMING WORKBOOK LESSON-6 STRAIGHT LINE MILLING LINEAR INTERPOLATION NOTE: Teacher s Solutions are in shaded cells throughout this book.

56 LESSON-6 STRAIGHT LINE MILLING LESSON-6 EXERCISE #1 - ABSOLUTE & INCREMENTAL POSITIONING STARTING AT THE POINT O (ORIGIN), DESCRIBE THE ENDMILL PATH FROM O THROUGH ALL THE POINTS AND BACK TO THE POINT O USING G90 & G91. CUTTER DIAMETER = 0.5 RADIUS = 0.25 G90 X Y G91 X Y O 0 0 O O O 0 0 DIRECTION OF CUT CW TK-Mill Lesson 6-2

58 LESSON-6 - CNC - PART #5 WORK OUT THE ABSOLUTE COORDINATES FOR POSITION 1, 2 AND 3 X0Y0 is at the lower left corner of the part These X and Y coordinates will be used to machine the L shaped slot G90 X Y TK-Mill Lesson 6-4

59 LESSON-6 - CNC - PART #5 PROGRAM TO MACHINE THE L SHAPED SLOT Use a 0.5 diameter End Mill Tool # 4 Speed = 3050 Feed rate =20 IPM X0Y0 is at the lower left corner of the part Z=0 is the top of the part. The slot depth is Enter the part at Position 1 and sink to depth using linear interpolation G01 Then move to Position 2 and finally Position 3 % (Program must begin and end with a %) O6 ( T4-1/2 FLAT ENDMILL - H4 ) N10 G20 ( Program #6 Part #5 STRAIGHT LINE MILLING) (Inch programming) N20 G00 G17 G40 G49 G80 G90 (MACHINE DEFAULT SETTING) N30 T4 M6 (T4-Select tool number 4 to be loaded M06-Activates the tool changer) N40 G00 G90 G54 X0.75 Y2.5 S3050 M3 (Rapid to the X and Y to Position #1 and turn on the spindle at 3050 RPM) N50 G43 H04 Z0.1 N70 G1 Z F10. N80 Y0.75 F20.0 N90 X2.375 N100 Z0.1 F10.0 N120 M05 (G43 - Activate the tool offset value stored in H04 and rapid to Z0.1) (Position #1 - Feed down to Z depth at 10 inches per minute) (Move to Position #2 - at 20 inches per minute) (Move to Position #3 - at 20 inches per minute) (Retract out of the part at feedrate to 0.1 above the top of the work piece) (Spindle off) N130 G00 G91 G28 Z0 (G28 Machine Zero positioning. Rapid to machine zero in Z) N140 G28 X0 Y0 (G28 Rapid in relation to machine zero X0 and Y0) N150 G90 N160 M30 (RETURN TO ABSOLUTE PROGRAMMING) (Program end rewind program to the beginning) % (Program must begin and end with a %) In earlier programs we used G53 to return the machine to coordinates in relation to the Machine Zero (home position). G28 is another code that will accomplish this. G28 is a more common way to send the machine to machine zero, it will work on many different types of CNC machines. As you can see above at block N130, G28 is activated in G91 incremental mode, and then at block N150 the program is returned to G90 absolute mode. TK-Mill Lesson 6-5

61 LESSON-6 - CNC - PART #6 WORK OUT THE ABSOLUTE X AND Y COORDINATES FOR THE VARIOUS POSITIONS TO MACHINE THE CONTOUR X0Y0 is at the lower left corner of the part Use a 0.5 diameter End Mill Tool # 4 Start at X-0.5 Y3.125 and machine the contour in a clockwise direction climb milling G90 X Y TK-Mill Lesson 6-7

62 LESSON-6 - CNC - PART #6 PROGRAM TO MACHINE THE CONTOUR Use a 0.5 diameter End Mill Tool # 4 Speed = 3050 Feed rate =20 IPM X0Y0 is at the lower left corner of the part Z=0 is the top of the part. Machine the contour at a depth is % (Program must begin and end with a %) O8 ( Program #8 - CNC-PART-6 - STRAIGHT LINE MILLING) ( T4-1/2 FLAT ENDMILL - H4 ) N10 G20 (Inch programming) N20 G00 G17 G40 G49 G80 G90 (MACHINE DEFAULT SETTING) N30 T4 M6 N40 G00 G90 G54 X-0.5 Y S3050 M3 N50 G43 H04 Z0.1 N60 G1 Z F10. N70 X1.375 F20.0 N80 Y1.75 (Move to Position #3) N90 X1.5 (Move to Position #4) N100 Y3.125 (Move to Position #5) N110 X2.875 (Move to Position #6) N120 Y1.75 (Move to Position #7) N130 X3.125 (Move to Position #8) N140 Y0 (Move to Position #9) N150 X0.125 (Move to Position #10) N160 Y3.375 (Move to Position #11) N170 Z0.1 F10.0 (T4-Select tool number 4 to be loaded M06-Activates the tool changer) (Rapid to the X and Y to start Position #1 and turn on the spindle at 3050 RPM) (G43 - Activate the tool offset value stored in H04 and rapid to Z0.1) (Position #1 - Feed down to Z depth at 10 inches per minute) (Move to Position #2 - at 20 inches per minute) N180 M05 (Retract out of the part at feedrate to 0.1 above the top of the work piece) (Spindle off) N190 G00 G91 G28 Z0 (G28 Machine Zero positioning. Rapid to machine zero in Z) N200 G28 X0 Y0 (G28 Rapid in relation to machine zero X0 and Y0) N210 G90 N220 M30 (RETURN TO ABSOLUTE PROGRAMMING) (Program end rewind program to the beginning) % (Program must begin and end with a %) TK-Mill Lesson 6-8

64 LESSON-6 - CNC - PART #7 WORK OUT THE ABSOLUTE X AND Y COORDINATES FOR THE VARIOUS POSITIONS TO MACHINE THE CONTOUR X0Y0 is at the lower left corner of the part Use a 0.5 diameter End Mill Tool # 4 Start at X-0.5 Y3.0 and machine the contour in a clockwise direction climb milling G90 X Y TK-Mill Lesson 6-10

65 LESSON-6 - CNC - PART #7 CREATE THE PROGRAM TO MACHINE THE CONTOUR Use a 0.5 diameter End Mill Tool # 4 Speed = 3050 Feed rate =20 IPM X0Y0 is at the lower left corner of the part Z=0 is the top of the part. Machine the contour at a depth is Start at X-0.5 Y3.0 and machine the contour in a clockwise direction climb milling Type up your program and check it for correctness using Backplot software. % O9( CNC-PART-7 ) ( T4 1/2 FLAT ENDMILL H4 ) N5 G20 N10 G0 G17 G40 G49 G80 G90 N15 T4 M6 N20 G0 G90 G54 X-.5 Y3. A0. S3050 M3 N25 G43 H4 Z.1 N30 G1 Z-.125 F20. N35 X0. N40 X1.25 N45 Y2. N50 X1.375 N55 Y3. N60 X2.875 N65 Y1.25 N70 X3.125 N75 Y0. N80 X0. N85 Y3. N90 Y3.25 N95 G0 Z.1 N100 M5 N105 G91 G28 Z0. N110 G28 X0. Y0. A0. N115 M30 % TK-Mill Lesson 6-11

67 LESSON-6 - CNC - PART #8 WORK OUT THE ABSOLUTE X AND Y COORDINATES FOR THE VARIOUS POSITIONS TO MACHINE THE CONTOUR X0Y0 is at the lower left corner of the part Use a 0.5 diameter End Mill Tool # 4 Start at X0 Y and machine the contour in a clockwise direction climb milling G90 X Y TK-Mill Lesson 6-13

68 LESSON-6 - CNC - PART #8 CREATE THE PROGRAM TO MACHINE THE CONTOUR Use a 0.5 diameter End Mill Tool # 4 Speed = 3050 Feed rate =20 IPM X0Y0 is at the lower left corner of the part Z=0 is the top of the part. Machine the contour at a depth is Start at X-0.5 Y3.0 and machine the contour in a clockwise direction climb milling Type up your program and check it for correctness using Backplot software. % O101( CNC-PART-8 ) ( T4 1/2 FLAT ENDMILL H4 ) N5 G20 N10 G0 G17 G40 G49 G80 G90 N15 T4 M6 N20 G0 G90 G54 X-.5 Y3.15 A0. S3050 M3 N25 G43 H4 Z.1 N30 G1 Z-.125 F20. N35 X.5 N40 X3. N45 Y1.25 N50 X1.5 N55 Y1.125 N60 X3. N65 Y.125 N70 X0. N75 Y2.875 N80 X.5 N85 Y3.275 N90 G0 Z.1 N95 M5 N100 G91 G28 Z0. N105 G28 X0. Y0. A0. N110 M30 % TK-Mill Lesson 6-14

69 CNC PROGRAMMING WORKBOOK LESSON-7 CIRCULAR INTERPOLATION NOTE: Teacher s Solutions are in shaded cells throughout this book. Page 61

70 LESSON-7 - CIRCULAR INTERPOLATION - G02 & G03 In the next series of circular interpolation exercises you will explore how to machine arcs and complete circles. G02 and G03 allow the machining of circles and arcs When the machine is required to move in a straight line under a controlled federate, linear interpolation is used G01. When it is necessary to machine in a circular motion in any plane (XY, YZ, XZ) circular interpolation is used G02 and G03. All circular interpolation moves are defined using three pieces of information. 1. DIRECTION OF TRAVEL: CLOCKWISE G02, COUNTER CLOCKWISE G03 2. PROGRAMMED END POINT OF THE ARC 3. ARC CENTER: INCREMENTAL DISTANCE FROM START POINT TO ARC CENTER (I, J, K OR R FOR RADIUS, I,J AND K ARE NOT USED) When trying to figure out a circular interpolation move answer these three questions: I. What is the direction of travel, clockwise or counterclockwise G02 or G03? II. Where is the programmed end point? III. What is the incremental distance from the start of the arc to the center of the arc being machined I and J values? G02 X4.25 Y3. I 0. J-1.25 G03 X2.25 Y1. I 0. J-.75 G02 & G03 Circular Interpolation Format XY PLANE Page 62 TK-Mill Lesson 7-2

71 CIRCULAR INTERPOLATION - DIRECTION OF TRAVEL G02 -Clockwise or G03 Counter Clockwise? What are the circular interpolation movements G02 or G03? 1. A to B Circular Interpolation (CW) G02 2. A to C Circular Interpolation (CW) G02 3. D to C Circular Interpolation (CCW)? Solution - G03 4. D to B Circular Interpolation (CCW)? Solution - G03 5. A to A Circular Interpolation (CW)? Solution - G02 TK-Mill Lesson 7-3 Page 63

72 CIRCULAR INTERPOLATION - PROGRAMED END POINT 1.0 Diameter End Mill Radius = What are the coordinates at the center of the cutter for A, B, C, and D A: X 0 Y 3.0 B: X 3.0 Y 0 C: X 0 Y-3.0 D: X -3.0 Y 0 Page 64 TK-Mill Lesson 7-4

73 CIRCULAR INTERPOLATION - ARC CENTER I, J and K Values are measured from the tool start to the center of the arc I, J and K values are INCREMENTAL I= X Axis J = Y Axis K= Z Axis 1.0 Diameter End Mill Radius = What are the incremental distances from the start of cut to the center of the programmed arc? I = The Incremental distance along the X axis from the start of the arc to the center of the programmed arc J = The Incremental distance along the Y axis from the start of the arc to the center of the programmed arc A to the centre of the circle: I 0 J-3.0 B to the centre of the circle: I -3.0 J 0 C to the centre of the circle: I 0 J3.0 D to the centre of the circle: I 3.0 J 0 TK-Mill Lesson 7-5 Page 65

74 LESSON-7 - CIRCULAR INTERPOLATION - G02 & G03 What does the block of code look like moving from D to B clockwise? G02 X3.0 Y0 I3.0 J0 What does the block of code look like moving from A to D counterclockwise? G03 X-3.0 Y0 I-3.0 J0 1.0 Diameter End Mill Radius = 0.5 When trying to figure out a circular interpolation move answer these three questions: I. What is the direction of travel, clockwise or counterclockwise G02 or G03? II. Where is the programmed end point? III. What is the incremental distance from the start of the arc to the center of the arc being machined I and J values? Work out the following circular interpolation blocks C to D Clockwise: G02 X-3.0 Y0 I0 J3.0 D to C Counterclockwise: G03 X0 Y-3.0 I-3.0 J0 A to A Clockwise: G02 X-3.0 Y0 I0 J-3.0 B to C Counterclockwise: G03 X0 Y-3.0 I-3.0 J0 Page 66 TK-Mill Lesson 7-6

75 LESSON-7 - CIRCULAR INTERPOLATION - G02 & G03 The center of the circle has now been changed to X5.0 Y5.0 What does the block of code look like moving from D to B clockwise? G02 X8.0 Y5.0 I3.0 J0 What does the block of code look like moving from A to D counterclockwise? G03 X2.0 Y5.0 I-3.0 J0 1.0 Diameter End Mill Radius = 0.5 When trying to figure out a circular interpolation move answer these three questions: I. What is the direction of travel, clockwise or counterclockwise G02 or G03? II. Where is the programmed end point? III. What is the incremental distance from the start of the arc to the center of the arc being machined I and J values? Work out the following circular interpolation blocks C to D Clockwise: G02 X2.0 Y5.0 I0 J3.0 D to C Counterclockwise: G02 X5.0 Y2.0 I3 J0 A to A Clockwise: G02 X-3.0 Y0 I0 J-3.0 X5.0 Y5.0 B to C Counterclockwise: G03 X5.0 Y2.0 I-3.0 J0 To cut a complete circle of 360, you do not need to specify an end point X, Y, or Z. Just program I, J, or K to define the centre of the circle. TK-Mill Lesson 7-7 Page 67

76 LESSON-7 - CIRCULAR INTERPOLATION - G02 & G03 Work out the following circular interpolation blocks PROGRAM CIRCULAR INTERPOLATION USING ABSOLUTE AND INCREMENTAL IN DIRECTION SHOWN Y + ABSOLUTE X - START R=2 Y + X - START/ FINISH (-10, -5) ABSOLUTE D=10 Y - FINISH (0, 0) Y - X + INCREMENTAL Y + FINISH X - (5, 2) R=1.414 START Y - X + X + START POINT X -4.0 Y -2.0 END POINT X 0.0 Y G02 X0.0 Y-2.0 I 2.0 J 0.0 INCREMENTAL START POINT X -4.0 Y -2.0 END POINT X 4.0 Y 0.0. G02 X 4.0 Y 0.0 I 2.0 J 0.0. ABSOLUTE (COUNTER CLOCKWISE DIRECTION) START POINT X Y -5.0 END POINT X Y G 03 X Y -5.0 I 0 J INCREMENTAL (CLOCKWISE DIRECTION) START POINT X Y -5.0 END POINT X 0 Y 0. G 02 X 0 Y 0 I 0 J ABSOLUTE START POINT X 5.0 Y END POINT X Y 2.0. G 03 X Y 2.0 I J 0. INCREMENTAL START POINT X 5.0 Y END POINT X Y G 03 X Y I J 0. Page 68 TK-Mill Lesson 7-8

77 LESSON-7 CIRCULAR INTERPOLATION G02 Review the CNC program below that machines the contour. The cutter being used is a 0.5 diameter end mill. X0 Y0 is the lower left corner of the part. Start position lower left corner, machines clockwise. The blocks of CNC code are made up of G01 and a G02 moves. Note that the G02 move to machine the 0.5 and 0.25 radius can use either I and J values or R for the radius. All circular interpolation moves are defined using three pieces of information. 1. DIRECTION OF TRAVEL: CLOCKWISE G02, COUNTER CLOCKWISE G03 2. ARC END POINT 3. ARC CENTER: INCREMENTAL DISTANCE FROM START POINT TO ARC CENTER (I, J, K) N160 G1 X-.25 Y-.25 (start position) N170 Y1.5 N180 G2 X.5 Y2.25 I.75 J0. (OR R0.5) N190 G1 X2.75 N200 Y.25 N210 G2 X2.25 Y-.25 I-.5 J0. (OR R0.25) N220 G1 X-.25 I = The Incremental distance along the X axis from the start of the arc to the center of the programmed arc J = The Incremental distance along the Y axis from the start of the arc to the center of the programmed arc TK-Mill Lesson 7-9 Page 69

78 LESSON-7 CIRCULAR INTERPOLATION G02 Review the CNC program below that machines the contour. The cutter being used is a 0.5 diameter end mill. X0 Y0 is the center of the part. Start position is the upper right, machines clockwise. The blocks of CNC code are made up of G01 and a G02 moves. Note that the G02 move to machine the radii can use either I and J values or R for the radius. Using I and J Values Using R for Radius Values N160 G1 X1.5 Y1.0 (start position) N160 G1 X1.5 Y1.0 (start position) N170 Y-.25 N170 Y-.25 N180 G2 X.25 Y-1.5 I-1.25 J0. N180 G2 X.25 Y-1.5 R1.25 N190 G1 X-.75 N190 G1 X-.75 N200 G2 X-1.5 Y-.75 I0. J.75 N200 G2 X-1.5 Y-.75 R.75 N210 G1 Y.875 N210 G1 Y.875 N220 G2 X-.875 Y1.5 I.625 J0. N220 G2 X-.875 Y1.5 R.625 N230 G1 X1. N230 G1 X1. N240 G2 X1.5 Y1. I0. J-.5 N240 G2 X1.5 Y1. R.5 To cut a complete circle of 360, you do not need to specify an end point X, Y, or Z. Just program I, J, or K to define the centre of the circle. Page 70 TK-Mill Lesson 7-10

79 LESSON-7 CIRCULAR INTERPOLATION G03 Review the CNC program below that machines the contour around the inside of the pocket. The cutter being used is a 0.5 diameter end mill. X0 Y0 is the center of the part. Start position is the upper right, machines contour counter clockwise. The blocks of CNC code are made up of G01 and a G03 moves. Note that the G03 move to machine the radii can use either I and J values or R for the radius. Using I and J Values N40 G0 G90 G54 X.75 Y1. A0. S2500 M3 N50 G43 H4 Z.35 N60 G1 Z.125 F15. N70 X-.875 N80 G3 X-1. Y.875 I0. J-.125 (0.375 Radius) N90 G1 Y-.75 N100 G3 X-.75 Y-1. I.25 J0. (0.5 Radius) N110 G1 X.25 N120 G3 X1. Y-.25 I0. J.75 (1.0 Radius) N130 G1 Y.75 N140 G3 X.75 Y1. I-.25 J0. (0.5 Radius) N150 G0 Z.35 Using R for Radius Values N40 G0 G90 G54 X.75 Y1. A0. S2500 M3 N50 G43 H4 Z.35 N60 G1 Z.125 F15. N70 X-.875 N80 G3 X-1. Y.875 R.125 (0.375 Radius) N90 G1 Y-.75 N100 G3 X-.75 Y-1. R.25 (0.5 Radius) N110 G1 X.25 N120 G3 X1. Y-.25 R.75 (1.0 Radius) N130 G1 Y.75 N140 G3 X.75 Y1. R.25 (0.5 Radius) N150 G0 Z.35 TK-Mill Lesson 7-11 Page 71

80 LESSON-7 CIRCULAR INTERPOLATION G02 & G03 Review the program to machine the contour shown below. Material: Aluminum 6061 Surface Feet Minute= 400 Tool #4 (Ø.500 Flat End Mill) Mill the profile Spindle Speed RPM = 3.82xSFM/D= 3.82x400/0.5 =3056 Depth of Cut = Z Feed Per Tooth (FPT) = Flute Cutter Feed Per Minute = FPT x 2 Flutes x RPM = Start from the top left corner % O11 ( G02-G03-EXAMPLE ) N60 X4.25 N10 G20 N65 Y0. N15 G0 G17 G40 G49 G80 G90 N70 G2 X3. Y-1.25 I-1.25 J0. N20 T4 M6 N75 G1 X-.25 N25 G0 G90 G54 X-.25 Y.25 S3056 M3 N80 Y.25 N30 G43 H4 Z2. N85 G0 Z2. N35 Z.1 N90 M5 N40 G1 Z-.2 F18. N95 G91 G28 Z0. N45 X2.5 N100 G28 X0. Y0. N50 G3 X2.75 Y.5 I0. J.25 N105 M30 N55 G1 Y1.75 % Page 72 TK-Mill Lesson 7-12

81 LESSON-7 CIRCULAR INTERPOLATION G02 & G03 Create the program to machine the contour shown below. Tool #4 (Ø.500 Flat End Mill) Mill the profile Spindle Speed RPM = 3.82xSFM/D= 3.82x400/0.5 =3056 Material: Aluminum 6061 CS= 400 ft/min Feed Per Tooth (FPT) = Flute Cutter Feed Per Minute = FPT x 2 Flutes x RPM = Depth of Cut = Z Start from the top right hand corner TK-Mill Lesson 7-13 Page 73

82 LESSON-7 CIRCULAR INTERPOLATION G02 & G03 % N100 G20 N110 G0 G17 G40 G49 G80 G90 N120 T4 M6 N130 G0 G90 G54 X.25 Y.25 A0. S3056 M3 N140 G43 H239 Z.25 N150 Z.2 N160 G1 Z0. F6.4 N170 X0. F18. N180 X-2.5 N190 G3 X-3.25 Y-.5 I0. J-.75 N200 G1 Y-2.75 N210 G3 X-2.75 Y-3.25 I.5 J0. N220 G1 X-1. N230 G3 X.25 Y-2. I0. J1.25 N240 G1 Y0. N250 G3 X0. Y.25 I-.25 J0. N260 G1 Z.2 F6.4 N270 G0 Z.25 N280 M5 N290 G91 G28 Z0. N300 G28 X0. Y0. A0. N310 M30 % Page 74 TK-Mill Lesson 7-14

83 CNC PROGRAMMING WORKBOOK MILL-LESSON-8 CIRCULAR INTERPOLATION - CONTINUED NOTE: Teacher s Solutions are in shaded cells throughout this book. Page 75

85 LESSON-8 - CNC - PART #9 The Machining Process Ø.500 Endmill - Tool # RPM Feedrate 18 IPM Machine the 2.25 square with the corner radii depth Machine the circular 2.25 and 1.25 diameter circular profile depth Ø.125 Endmill - Tool # RPM Feedrate 7 IPM Drill the Ø.125 holes through the part (4 places) Note: The Ø.125 Endmill is designed for center cutting machining. No center drilling or pilot hole is required. TK-Mill Lesson 8-3 Page 77

86 LESSON-8 - CNC - PART #9 WORK OUT THE ABSOLUTE X AND Y COORDINATES FOR THE VARIOUS POSITIONS TO MACHINE THE PART X0Y0 is at the center of the part Use a 0.5 diameter End Mill Tool # 4 and a diameter End Mill Tool # 1 Climb mill the inside contours WORK OUT THE ABSOLUTE X AND Y COORDINATES FOR THE FOUR HOLES G90 X Y Page 78 TK-Mill Lesson 8-4

87 LESSON-8 - CNC - PART #9 WORK OUT THE ABSOLUTE X AND Y COORDINATES FOR THE VARIOUS POSITIONS TO MACHINE THE PART X0Y0 is at the center of the part Use a 0.5 diameter End Mill Tool # 4 and a diameter End Mill Tool # 1 Climb mill WORK OUT THE ABSOLUTE X AND Y COORDINATES FOR THE VARIOUS POSITIONS OF THE 0.5 DIAMETER END MILL G90 X Y TK-Mill Lesson 8-5 Page 79

88 LESSON-8 - CNC - PART #9 CREATE THE PROGRAM TO MACHINE THE PART Use a 0.5 diameter End Mill Tool # 4 Speed = 3050 Feed rate =20 IPM Use a diameter End Mill Tool # 1 Speed = 5000 Feed rate =7 IPM X0Y0 is at the center of the part Z=0 is the top of the part. Climb mill Type up your program and check it for correctness using Backplot software. % O4( CNC-PART-9 ) ( T4 1/2 FLAT ENDMILL H4 ) ( T1 1/8 FLAT ENDMILL H1 ) N5 G20 N10 G0 G17 G40 G49 G80 G90 N15 T4 M6 N20 G0 G90 G54 X0. Y.875 S3050 M3 N25 G43 H4 Z.1 N30 G1 Z F10. N35 X-.75 F20. N40 G3 X-.875 Y.75 I0. J-.125 N45 G1 Y-.75 N50 G3 X-.75 Y-.875 I.125 J0. N55 G1 X.75 N60 G3 X.875 Y-.75 I0. J.125 N65 G1 Y.75 N70 G3 X.75 Y.875 I-.125 J0. N75 G1 X0. N80 Z.1 F10. N85 Z-.125 Page 80 TK-Mill Lesson 8-6

89 LESSON-8 - CNC - PART #9 - Continued N90 G3 X-.875 Y0. I0. J-.875 F20. N95 X0. Y-.875 I.875 J0. N100 X.875 Y0. I0. J.875 N105 X0. Y.875 I-.875 J0. N110 G1 Z.1 F10. N115 M5 N120 G91 G0 G28 Z0. N125 T1 M6 N130 G0 G90 G54 X0. Y.875 S5000 M3 N135 G43 H1 Z2. N140 Z.1 N145 G99 G81 Z-.28 R.1 F7. N150 X-.875 Y0. N155 X0. Y-.875 N160 X.875 Y0. N165 G80 N170 Z2. N175 M5 N180 G91 G28 Z0. N185 G28 X0. Y0. N190 M30 % TK-Mill Lesson 8-7 Page 81

91 LESSON-8 - CNC - PART #10 The Machining Process Ø.500 Endmill - Tool # RPM Feedrate 18 IPM Machine the open slot with the fillet radii depth Ø.125 Endmill - Tool # RPM Feedrate 7 IPM Drill the Ø.125 holes through the part (4 places) Note: The Ø.125 Endmill is designed for center cutting machining. No center drilling or pilot hole is required. TK-Mill Lesson 8-9 Page 83

92 LESSON-8 - CNC - PART #10 WORK OUT THE ABSOLUTE X AND Y COORDINATES FOR THE VARIOUS POSITIONS TO MACHINE THE PART X0Y0 is at the center of the part Use a 0.5 diameter End Mill Tool # 4 and a diameter End Mill Tool # 1 WORK OUT THE ABSOLUTE X AND Y COORDINATES FOR THE FOUR HOLES G90 X Y Page 84 TK-Mill Lesson 8-10

94 LESSON-8 - CNC - PART #10 CREATE THE PROGRAM TO MACHINE THE PART Use a 0.5 diameter End Mill Tool # 4 Speed = 3050 Feed rate =20 IPM Use a diameter End Mill Tool # 1 Speed = 5000 Feed rate =7 IPM X0Y0 is at the center of the part Z=0 is the top of the part. Climb mill Type up your program and check it for correctness using Backplot software. % O303( CNC-PART-10 ) ( T4 1/2 FLAT ENDMILL H4 ) ( T1 1/8 FLAT ENDMILL H1 ) N5 G20 N10 G0 G17 G40 G49 G80 G90 N15 T4 M6 N20 G0 G90 G54 X Y.875 S3050 M3 N25 G43 H4 Z.1 N30 G1 Z-.125 F20. N35 X-1.5 N40 X.75 N45 G2 X.875 Y.75 I0. J-.125 N50 G1 Y-.75 N55 G2 X.75 Y-.875 I-.125 J0. N60 G1 X N65 Y-.75 N70 X0. N75 G3 X.75 Y0. I0. J.75 N80 G3 X0. Y.75 I-.75 J0. N85 G1 X-1.5 N90 X N95 G0 Z.1 N100 M5 Page 86 TK-Mill Lesson 8-12

95 LESSON-8 - CNC - PART #10 N105 G91 G28 Z0. N110 T1 M6 N115 G0 G90 G54 X.7071 Y.7071 A0. S5000 M3 N120 G43 H1 Z.1 N125 G99 G81 Z-.28 R.1 F7. N130 X N135 Y N140 X.7071 N145 G80 N150 M5 N155 G91 G28 Z0. N160 G28 X0. Y0. N165 M30 % TK-Mill Lesson 8-13 Page 87

97 CNC PROGRAMMING WORKBOOK LESSON-9 CIRCULAR INTERPOLATION - CONTINUED NOTE: Teacher s Solutions are in shaded cells throughout this book. Page 89

99 LESSON-9 - CNC - PART #11 The Machining Process Ø.500 Endmill - Tool # 4 Machine the profile with the.125 radii at Z.125 deep 1 Cut Machine the circular 2.5 diameter circular profile 1 Cut Ø.125 Endmill - Tool # 1 Drill the Ø.125 holes through the part (4 places) Note: The Ø.125 Endmill is designed for center cutting machining. No center drilling or pilot hole is required. TK-Mill Lesson 9-3 Page 91

100 LESSON-9 - CNC - PART #11 WORK OUT THE ABSOLUTE X AND Y COORDINATES FOR THE VARIOUS POSITIONS TO MACHINE THE PART X0Y0 is at the center of the part Use a 0.5 diameter End Mill Tool # 4 and a diameter End Mill Tool # 1 WORK OUT THE ABSOLUTE X AND Y COORDINATES FOR THE FOUR HOLES G90 X Y Page 92 TK-Mill Lesson 9-4

102 LESSON-9 - CNC - PART #11 CREATE THE PROGRAM TO MACHINE THE PART Use a 0.5 diameter End Mill Tool # 4 Speed = 3050 Feed rate =20 IPM Use a diameter End Mill Tool # 1 Speed = 5000 Feed rate =7 IPM X0Y0 is at the center of the part Z=0 is the top of the part. Climb mill Type up your program and check it for correctness using Backplot software. % O6( CNC-PART-11 ) ( T4 1/2 FLAT ENDMILL H4 ) ( T1 1/8 FLAT ENDMILL H1 ) N5 G20 N10 G0 G17 G40 G49 G80 G90 N15 T4 M6 N20 G0 G90 G54 X Y1.5 S3050 M3 N25 G43 H4 Z.1 N30 G1 Z-.125 F20. N35 X N40 X0. N45 X1.125 N50 G2 X1.5 Y1.125 I0. J-.375 N55 G1 Y0. N60 Y N65 G2 X1.125 Y-1.5 I-.375 J0. N70 G1 X0. N75 X N80 G2 X-1.5 Y I0. J.375 N85 G1 Y0. N90 Y1.125 N95 G2 X Y1.5 I.375 J0. N100 G1 Z.1 N105 G0 X0. Page 94 TK-Mill Lesson 9-6

103 LESSON-9 - CNC - PART #11 - Continued N110 G1 Z N115 G2 X1.5 Y0. I0. J-1.5 N120 X0. Y-1.5 I-1.5 J0. N125 X-1.5 Y0. I0. J1.5 N130 X0. Y1.5 I1.5 J0. N135 G1 Z.1 N140 M5 N145 G91 G0 G28 Z0. N150 T1 M6 N155 G0 G90 G54 X Y1.125 S5000 M3 N160 G43 H1 Z.1 N165 G99 G81 Z-.28 R.1 F7. N170 X1.125 N175 Y N180 X N185 G80 N190 M5 N195 G91 G28 Z0. N200 G28 X0. Y0. N205 M30 % TK-Mill Lesson 9-7 Page 95

105 LESSON-9 - CNC - PART #12 The Machining Process Ø.500 Endmill - Tool # RPM Feedrate 20 IPM Machine the profiles with the.125 and.25 radii. Machine the circular diameter through hole. Sink to depth at center and use circular interpolation to finish the bore. Ø.125 Endmill - Tool # RPM Feedrate 7 IPM Drill the Ø.125 holes through the part (8 places) Note: The Ø.125 Endmill is designed for center cutting machining. No center drilling or pilot hole is required. TK-Mill Lesson 9-9 Page 97

106 LESSON-9 - CNC - PART #12 WORK OUT THE ABSOLUTE X AND Y COORDINATES FOR THE VARIOUS POSITIONS TO MACHINE THE PART X0Y0 is at the center of the part Use a 0.5 diameter End Mill Tool # 4 and a diameter End Mill Tool # 1 WORK OUT THE ABSOLUTE X AND Y COORDINATES FOR THE HOLES G90 X Y Page 98 TK-Mill Lesson 9-10

107 LESSON-9 - CNC - PART #12 WORK OUT THE ABSOLUTE X AND Y COORDINATES FOR THE VARIOUS POSITIONS TO MACHINE THE PART X0Y0 is at the center of the part Use a 0.5 diameter End Mill Tool # 4 and a diameter End Mill Tool # 1 Climb mill WORK OUT THE ABSOLUTE X AND Y COORDINATES FOR THE VARIOUS POSITIONS OF THE 0.5 DIAMETER END MILL Square Coordinates 2.0 Square Coordinates G90 X Y G90 X Y TK-Mill Lesson 9-11 Page 99

108 LESSON-9 - CNC - PART #12 CREATE THE PROGRAM TO MACHINE THE PART Use a 0.5 diameter End Mill Tool # 4 Speed = 3050 Feed rate =20 IPM Use a diameter End Mill Tool # 1 Speed = 5000 Feed rate =7 IPM X0Y0 is at the center of the part Z=0 is the top of the part. Climb mill Type up your program and check it for correctness using Backplot software. % O999( CNC-PART-12 ) ( T4 1/2 FLAT ENDMILL H4 ) ( T1 1/8 FLAT ENDMILL H1 ) N5 G20 N10 G0 G17 G40 G49 G80 G90 N15 T4 M6 N20 G0 G90 G54 X Y S3050 M3 N25 G43 H4 Z.1 N30 G1 Z-.125 F20. N35 X N40 X N45 G2 X Y I0. J-.5 N50 G1 Y N55 G2 X Y I-.5 J0. N60 G1 X N65 G2 X Y I0. J.5 N70 G1 Y N75 G2 X Y I.5 J0. N80 G1 Z.1 N85 G0 X Y1.25 N90 G1 Z N95 X-.875 N100 X.875 N105 G2 X1.25 Y.875 I0. J-.375 N110 G1 Y-.875 N115 G2 X.875 Y-1.25 I-.375 J0. Page 100 TK-Mill Lesson 9-12

109 LESSON-9 - CNC - PART #12 - Continued N120 G1 X-.875 N125 G2 X-1.25 Y-.875 I0. J.375 N130 G1 Y.875 N135 G2 X-.875 Y1.25 I.375 J0. N140 G1 Z.1 N145 G0 X0. Y0. N150 G1 Z-.26 F10. N155 Y.0625 F20. N160 G3 X Y0. I0. J N165 X0. Y I.0625 J0. N170 X.0625 Y0. I0. J.0625 N175 X0. Y.0625 I J0. N180 G1 Y0. N185 G0 Z.1 N190 M5 N195 G91 G28 Z0. N200 T1 M6 N205 G0 G90 G54 X Y S5000 M3 N210 G43 H1 Z.1 N215 G99 G81 Z-.28 R.1 F7. N220 X N225 Y N230 X N235 X-.875 Y-.875 N240 Y.875 N245 X.875 N250 Y-.875 N255 G80 N260 M5 N265 G91 G28 Z0. N270 G28 X0. Y0. N275 M30 % TK-Mill Lesson 9-13 Page 101

111 CNC PROGRAMMING WORKBOOK LESSON-10 CUTTER COMPENSATION NOTE: Teacher s Solutions are in shaded cells throughout this book. Page 103

112 LESSON-10 - G40, G41, & G42 CUTTER COMPENSATION Cutter Compensation is used to offset the center of the cutter and move the cutter either to the left or right the distance of the cutter radius. When cutting angled geometry, substantial computations are required to determine the center of the cutter. Using Cutter Compensation, you can program the part as if the center of the cutter will be travelling along the geometry. G40 CUTTER COMPENSATION CANCEL G40 will cancel the G41 or G42 cutter compensation commands. G41 CUTTER COMPENSATION LEFT G41 will action cutter compensation left. The tool is moved to the left of the programmed path to compensate for the radius of the tool. A Dnn must also be programmed to select the correct tool size from the DIAMETER/RADIUS offset display register. G42 CUTTER COMPENSATION RIGHT G42 will action cutter compensation right. The tool is moved to the right of the programmed path to compensate for the size of the tool. G41 Left of the Line G41 G42 Right of the Line G41 : Tool is moved to the left of the profile (e.g. Outside Profile shown as above) G42 : Tool is moved to the right of the profile (e.g. Inside Profile shown as above) G41 Page 104 TK-Mill Lesson 10-2

113 LESSON-10 - G40, G41, & G42 CUTTER COMPENSATION Without Cutter Compensation % O10011 N1 T12 M06 (3/4 Flat Endmill) N2 G90 G54 G00 X-.575 Y-.200 S1500 M03 N3 G43 H12 Z2. N4 Z.1 N5 G01 Z-.25 F10. N6 X-.375 (Point B) N7 Y?.???? (Point C) N8 X?.???? Y2.375 (Point D) N9 X2.875 (Point E) N10 M05 N11 G00 Z2. N12 G91 G28 Z0. (Machine Home Z-Axis) N13 G28 X0. Y0. (Machine Home X,Y-Axis) N14 M30 % Using Cutter Compensation % O10012 N1 T12 M06 (3/4 Flat Endmill) N2 G90 G54 G00 X-.575 Y-.200 S1500 M03 N3 G43 H12 Z2. N4 Z.1 N5 G01 Z-.25 F10. N6 G41 X0. D12 (Origin) N7 Y1.0 (P1) N8 X1.732 Y2.0 (P2) N9 X2.875 N10 G40 M05 N11 G00 Z2. N12 G91 G28 Z0. (Machine Home Z-Axis) N13 G28 X0. Y0. (Machine Home X,Y-Axis) N14 M30 % The Cutter Compensation (G41) will reflect the actual part geometry (O, P1, P2..) instead of Cutter Centers (Point B,C,D & E) TK-Mill Lesson 10-3 Page 105

115 LESSON-10 - CNC - PART #13 The Machining Process Ø.750 Endmill - Tool # 6 Machine the profile and pocket using cutter compensation diameter end mill Spindle Speed = 2100 Feed rate = 25 IPM Ø.375 Spot Drill - Tool # 6 Spot Drill Spindle Speed = 2750 Feed rate = 11 IPM Ø.201 Drill - Tool # diameter Drill Spindle Speed = 4500 Feed rate = 15 IPM Ø UNC Tap - Tool # UNC Tap Spindle Speed = 1000 Feed rate = 50 IPM TK-Mill Lesson 10-5 Page 107

116 LESSON-10 - CNC - PART #13 WORK OUT THE ABSOLUTE X AND Y COORDINATES FOR THE VARIOUS POSITIONS TO MACHINE THE PART X0Y0 is at the lower left corner of the part WORK OUT THE ABSOLUTE X AND Y COORDINATES FOR THE TWO HOLES G90 X Y Page 108 TK-Mill Lesson 10-6

117 LESSON-10 - CNC - PART #13 WORK OUT THE ABSOLUTE X AND Y COORDINATES FOR THE VARIOUS POSITIONS TO MACHINE THE PART - CONTOUR X0Y0 is at the lower left of the part WORK OUT THE ABSOLUTE X AND Y COORDINATES FOR THE VARIOUS POSITIONS OF THE 0.75 DIAMETER END MILL TO MACHINE THE CONTOUR G90 X Y G90 X Y TK-Mill Lesson 10-7 Page 109

118 LESSON-10 - CNC - PART #13 WORK OUT THE ABSOLUTE X AND Y COORDINATES FOR THE VARIOUS POSITIONS TO MACHINE THE PART - POCKET X0Y0 is at the lower left of the part WORK OUT THE ABSOLUTE X AND Y COORDINATES FOR THE VARIOUS POSITIONS OF THE 0.75 DIAMETER END MILL TO MACHINE THE POCKET G90 X Y Page 110 TK-Mill Lesson 10-8

119 LESSON-10 - CNC - PART #13 CREATE THE PROGRAM TO MACHINE THE PART The Machining Process Ø.750 Endmill - Tool # 6 Machine the profile and pocket using cutter compensation diameter end mill Spindle Speed = 2100 Feed rate = 25 IPM Ø.375 Spot Drill - Tool # 6 Spot Drill Spindle Speed = 2750 Feed rate = 11 IPM Ø.201 Drill - Tool # diameter Drill Spindle Speed = 4500 Feed rate = 15 IPM Ø UNC Tap - Tool # diameter Drill Spindle Speed = 1000 Feed rate = 50 IPM % O888( PART-13-CUTTER-COMP ) N10 ( X0Y0 LOWER LEFT CORNER OF PART ) N15 ( Z ZERO TOP OF PART) N20 ( T5 3/4 FLAT ENDMILL H5 D5 CONTROL COMP TOOL DIA ) N25 ( T6 3/8 SPOTDRILL H6 ) N30 ( T8 NO. 7 DRILL H8 ) N35 ( T9 1/4-20 TAPRH H9 ) N40 G20 N45 G0 G17 G40 G49 G80 G90 N50 T5 M6 N55 G0 G90 G54 X-0.65 Y S2100 M3 N60 G43 H5 Z0.1 N65 G1 Z F25.0 N70 G41 D5 X0.1 N75 Y1.0 N80 X0.5 N85 G3 X1.0 Y1.5 I0. J0.5 N90 G1 Y1.75 N95 G3 X0.5 Y2.25 I-0.5 J0. N100 G1 X0.1 N105 Y2.5 N110 X1.0 Y2.75 N115 X2.375 N120 X2.875 Y2.5 N125 Y0.5 N130 G2 X2.625 Y0.25 I-0.25 J0. N135 G1 X1.0 TK-Mill Lesson 10-9 Page 111

120 LESSON-10 - CNC - PART #13 - Continued N140 X0.1 Y0.75 N145 G40 X-0.65 N150 G0 Z0.1 N155 (RAMP INTO POCKET) N160 X2.0 Y0.875 N165 G1 Z0. F10.0 N170 Y1.5 Z N175 G41 D5 Y2.5 F25.0 N180 X1.875 N185 G3 X1.375 Y2.0 I0. J-0.5 N190 G1 Y1.0 N195 G3 X1.875 Y0.5 I0.5 J0. N200 G1 X2.125 N205 G3 X2.625 Y1.0 I0. J0.5 N210 G1 Y2.0 N215 G3 X2.125 Y2.5 I-0.5 J0. N220 G01 X1.875 N225 G40 X2.0 Y2.0 N230 G0 Z0.1 N235 M5 N240 G91 G28 Z0. N245 T6 M6 N250 G0 G90 G54 X1.0 Y1.0 S2750 M3 N255 G43 H6 Z0.1 N260 G99 G81 Z-0.14 R0.1 F11.0 N265 Y2.25 N270 G80 N275 M5 N280 G91 G28 Z0. N285 T8 M6 N290 G0 G90 G54 X1.0 Y2.25 S4500 M3 N295 G43 H8 Z0.1 N300 G99 G83 Z-0.35 R0.1 Q0.15 F15.0 N305 Y1.0 N310 G80 Page 112 TK-Mill Lesson 10-10

121 LESSON-10 - CNC - PART #13 - Continued N315 M5 N320 G91 G28 Z0. N325 T9 M6 N330 G0 G90 G54 X1.0 Y1.0 S1000 M3 N335 G43 H9 Z0.1 N340 G99 G84 Z-0.6 R0.1 F50.0 N345 Y2.25 N350 G80 N355 M5 N360 G91 G28 Z0. N365 G28 X0. Y0. N370 G90 N375 M30 % TK-Mill Lesson Page 113

123 LESSON-10 - CNC - PART #14 The Machining Process Ø.750 Endmill - Tool # 6 Machine the profile and pocket using cutter compensation diameter end mill Spindle Speed = 2100 Feed rate = 25 IPM Ø.375 Spot Drill - Tool # 6 Spot Drill Spindle Speed = 2750 Feed rate = 11 IPM Ø.201 Drill - Tool # diameter Drill Spindle Speed = 4500 Feed rate = 15 IPM Ø UNC Tap - Tool # diameter Drill Spindle Speed = 1000 Feed rate = 50 IPM TK-Mill Lesson Page 115

124 LESSON-10 - CNC - PART #14 WORK OUT THE ABSOLUTE X AND Y COORDINATES FOR THE VARIOUS POSITIONS TO MACHINE THE PART X0Y0 is at the lower left of the part WORK OUT THE ABSOLUTE X AND Y COORDINATES FOR THE TWO HOLES G90 X Y Page 116 TK-Mill Lesson 10-14

125 LESSON-10 - CNC - PART #14 WORK OUT THE ABSOLUTE X AND Y COORDINATES FOR THE VARIOUS POSITIONS TO MACHINE THE PART - CONTOUR X0Y0 is at the lower left of the part WORK OUT THE ABSOLUTE X AND Y COORDINATES FOR THE VARIOUS POSITIONS OF THE 0.75 DIAMETER END MILL TO MACHINE CONTOUR G90 X Y G90 X Y TK-Mill Lesson Page 117

126 LESSON-10 - CNC - PART #14 WORK OUT THE ABSOLUTE X AND Y COORDINATES FOR THE VARIOUS POSITIONS TO MACHINE THE PART - POCKET X0Y0 is at the lower left of the part WORK OUT THE ABSOLUTE X AND Y COORDINATES FOR THE VARIOUS POSITIONS OF THE 0.75 DIAMETER END MILL TO MACHINE POCKET G90 X Y Page 118 TK-Mill Lesson 10-16

127 LESSON-10 - CNC - PART #14 CREATE THE PROGRAM TO MACHINE THE PART The Machining Process Ø.750 Endmill - Tool # 6 Machine the profile and pocket using cutter compensation diameter end mill Spindle Speed = 2100 Feed rate = 25 IPM Ø.375 Spot Drill - Tool # 6 Spot Drill Spindle Speed = 2750 Feed rate = 11 IPM Ø.201 Drill - Tool # diameter Drill Spindle Speed = 4500 Feed rate = 15 IPM Ø UNC Tap - Tool # diameter Drill Spindle Speed = 1000 Feed rate = 50 IPM % O5643( CNC-PART-14 ) ( T5 3/4 FLAT ENDMILL H5 D5 CONTROL COMP TOOL DIA ) ( T6 3/8 SPOTDRILL H6 ) ( T8 NO. 7 DRILL H8 ) ( T9 1/4-20 TAPRH H9 ) N5 G20 N10 G0 G17 G40 G49 G80 G90 N15 T5 M6 N20 G0 G90 G54 X-.65 Y-.375 S2100 M3 N25 G43 H5 Z.1 N30 G1 Z-.125 F25. N35 X N40 G41 D5 Y2.25 N45 G2 X.625 Y2.75 I.5 J0. N50 G1 X1.125 N55 Y2.5 N60 G3 X1.625 Y2. I.5 J0. N65 G1 X1.75 N70 G3 X2.25 Y2.5 I0. J.5 N75 G1 Y2.625 N80 X2.625 N85 G2 X2.875 Y2.375 I0. J-.25 N90 G1 Y.5 N95 X2.5 Y.25 N100 X.75 N105 X.125 Y.5 TK-Mill Lesson Page 119

128 LESSON-10 - CNC - PART #14 - Continued N110 X-0.65 Y.5 N115 G40 N120 G0 Z.1 N125 X1.0 Y1.125 N130 G1 Z0 N135 X1.75 Y1.125 Z N140 G41 D5 X2.5 N145 Y1.25 N150 G3 X2. Y1.75 I-.5 J0. N155 G1 X1. N160 G3 X.5 Y1.25 I0. J-.5 N165 G1 Y1. N170 G3 X1. Y.5 I.5 J0. N175 G1 X2. N180 G3 X2.5 Y1. I0. J.5 N185 G1 X2.5 Y1.125 N190 G1 X2.0 Y1.125 N195 G00 Z.1 N200 G40 N205 M5 N210 G91 G28 Z0. N215 T6 M6 N220 G0 G90 G54 X2. Y1.25 S2750 M3 N225 G43 H6 Z.1 N230 G99 G81 Z-.14 R.1 F11. N235 X1. Y1. N240 G80 N245 M5 N250 G91 G28 Z0. N255 T8 M6 Page 120 TK-Mill Lesson 10-18

129 LESSON-10 - CNC - PART #14 N260 G0 G90 G54 X1. Y1. S4500 M3 N265 G43 H8 Z.1 N270 G99 G83 Z-.35 R.1 Q.1 F15. N275 X2. Y1.25 N280 G80 N285 M5 N290 G91 G28 Z0. N295 T9 M6 N300 G0 G90 G54 X2. Y1.25 S1000 M3 N305 G43 H9 Z.1 N310 G99 G84 Z-.35 R.1 F50. N315 X1. Y1. N320 G80 N325 M5 N330 G91 G28 Z0. N335 G28 X0. Y0. N340 M30 % TK-Mill Lesson Page 121

131 CNC PROGRAMMING WORKBOOK - MILL APPENDIX Page 123

132 Appendix Extra CNC Programming Exercises Exercise #1 Page 124 TK-Mill Appendix - 2

133 Extra CNC Programming Exercise #2 TK-Mill Appendix - 3 Page 125

134 Extra CNC Programming Exercise #3 Page 126 TK-Mill Appendix - 4

136 Extra CNC Programming Exercise #5 Page 128 TK-Mill Appendix - 6

138 Extra CNC Programming Exercise #7 Instructions: 1. Create your own design. 2. The material size: 6 x 1.5 x.125 Aluminum 3. The part is held in the vise. 4. Locate the part flush with the left hand side of the vise jaw. 5. X0 Y0 is the top left hand corner of the material. 6. Z0 is the top of the material. 7. Center Drill is used as an engraving tool to machine the letters. 8. Spindle Speed: 5000 rpm 9. Feedrate: 12 in/min 10. Depth of Cut : Center Drill 2 mounting holes using Canned Cycle 12. Depth of Cut: Minimum of five letters 14. You can use the suggested letter shapes & size or create your own lettering design. Suggested Lettering: Page 130 TK-Mill Appendix - 8

139 Appendix Preparatory Functions G-Codes G00 RAPID POSITIONING MOTION G01 LINEAR INTERPOLATION MOTION G02 CIRCULAR INTERPOLATION MOTION - CLOCKWISE G03 CIRCULAR INTERPOLATION MOTION - COUNTECLOCKWISE G04 DWELL G09 EXACT STOP G10 PROGRAMMABLE OFFSET SETTING G12 CW CIRCULAR POCKET MILLING G13 CCW CIRCULAR POCKET MILLING G17 CIRCULAR MOTION XY PLANE SELECTION (G02 or G03) G18 CIRCULAR MOTION ZX PLANE SELECTION (G02 or G03) G19 CIRCULAR MOTION YZ PLANE SELECTION (G02 or G03) G20 VERIFY INCH COORDINATE POSITIONING G21 VERIFY METRIC COORDINATE POSITIONING G28 MACHINE ZERIO RETURN THRU REF. POINT G29 MOVE TO LOCATION THROUGH G28 REF. POINT G31 FEED UNTIL SKIP FUNCTION G35 AUTOMATIC TOOL DIAMETER MEASUREMENT G36 AUTOMATIC WORK OFFSET MEASUREMENT G37 AUTOMATIC TOOL LENGTH MEASUREMENT G40 CUTTER COMPENSATION CANCEL G41/G42/G141 G41 2D CUTTER COMPENSATION, LEFT (X, Y, D) G42 2D CUTTER COMPENSATION, RIGHT (X, Y, D) G43 TOOL LENGTH COMPESATION POSITIVE (H, Z) G44 TOOL LENGTH COMPENATION NEGATIVE (H, Z) TK-Mill Appendix - 9 Page 131

140 Appendix Preparatory Functions G-Codes G47 TEXT ENGRAVING (X, Y, Z, R, I, J, P, E, F) G49 TOOL LENGTH COMPENSATION CANCEL G43/G44/G143) G50 SCALING G51 CANCEL G51 SCALING (X, Y, Z, P) G52 WORK OFFSET COORDINATE POSITING G52 GLOBAL WORK COORDINATE OFFSET SHIFT G52 GLOBAL WORK COORDINATE OFFSET SHIFT G53 MACHINE COORDAINTE POSITIONING, NON-MODAL (X, Y, Z, A, B) G54 WORK OFSET COORDIANTE POSITIONING #1 G55 WORK OFSET COORDIANTE POSITIONING #2 G56 WORK OFSET COORDIANTE POSITIONING #3 G57 WORK OFSET COORDIANTE POSITIONING #4 G58 WORK OFSET COORDIANTE POSITIONING #5 G59 WORK OFSET COORDIANTE POSITIONING #6 G60 UNI-DIRECTIONAL POSITIONING (X, Y, Z, A, B) G61 EXACT STOP, MODAL (X, Y, Z, A, B) G64 EXACT STOP G61 MODE CANCEL G65 MACRO SUB-ROUTINE CALL G68 ROATION (G17, G18, G19, X, Y, Z, R) G69 ROTATION G68 CANCEL G70 BOLT HOLE CIRCLE with a CANNED CYCLE (I, J, L) Page 132 TK-Mill Appendix - 10

141 Appendix Preparatory Functions G-Codes G71 BOLTHOLEARC with a CANNED CYCLE (I, J, K, L) G72 BOLT HOLES ALONG AN ANGLE with a CANNED CYCLE (I, J, L) G73 HIGH SPEED PECK DRILL CANNED CYCLE (X, Y, A, B, Z, I, J, K, Q, P, R, L, F) G74 REVERSE TAPPING CANNED CYCLE (X, Y, A, B, Z, J, R, L, F) G76 FINE BORING CANNED CYCLE (X, Y, A, B, Z, I, J, P, Q, R, L, F) G77 BACK BORE CANNED CYCLE (X, Y, A, B, Z, I, J, Q, R, L, F) G80 CANCEL CANNED CYCLE G81 DRILL CANNED CYCLE (X, Y, A, B, Z, R, L, F) G82 SPOT DRILL/COUNTERBORE CANNED CYCLE (X, Y, A, B, Z, P, R, L, F) G83 PECK DRILL CANNED CYCLE (X, Y, A, B, Z, I, J, K, Q, P, R, L, F) G84 TAPPING CANNED CYCLE (X, Y, A, B, Z, J, R, L, F) G85 BORE IN, BORE OUT CANNED CYCLE (X, Y, A, B, Z, R, L, F) G86 BORE IN, STOP, RAPID OUT CANNED CYCLE (X, Y, A, B, Z, R, L, F) G87 BORE IN AND MANUAL RETRACT CANNED CYCLE (X, Y, A, B, Z, R, L, F) G88 BORE IN, DWELL, MANUAL RETRACT CANNED CYCLE (X, Y, A, B, Z, P, R, L, F) G89 BORE IN, DWELL, BORE OUT (X, Y, A, B, Z, P, R, L, F) G90 ABSOLUTE POSITIONING G91 INCREMENTAL POSITIONING G92 GLOBAL WORK COORDINATE SYSTEM SHIFT (FANUC) (HAAS) G92 SET WORK COORDINATE VALUE (YA SNAC) G93 INVERSE TIME FEED MODE ON G94 INVERSE TIME FEED MODE OFF/FEED PER MINUTE ON G98 CANNED CYCLE INITIAL POINT RETURN G99 CANNED CYCLE R PLANE RETURN TK-Mill Appendix - 11 Page 133

142 Appendix Miscellaneous Functions M-Codes M00 PROGRAM STOP M01 OPTIONAL PROGRAM STOP M02 PROGRAM END M03 SPINDLE ON CLOCKWISE M04 SPINDLE ON COUTERCLOCKWISE M05 SPINDLE STOP M06 TOOL CHANGE M08 COOLANT ON M09 COOLANT OFF M19 ORIENT SPINDLE (P, R) M21-M28 OPTIONAL USER M CODE INTERFACE WITH M-FIN SIGNAL M30 PROGRAM END AN RESET M31 CHIP AUGER FORWARD M32 CHIP AUGER REVERSE M33 CHIP AUGER STOP M34 COOLANT SPIGOT POSITION DOWN, INCREMENT M35 COOLANT SPIGOT POSITION UP, DECREMENT M36 PALET PART READY M39 ROTATE TOOL TURRET M41 SPINDLE LOW GEAR OVERRIDE M42 SPINDLE HIGH GEAR OVERRIDE M50 EXECUTE PALLET CHANGE Page 134 TK-Mill Appendix - 12

143 Appendix Miscellaneous Functions M-Codes M51-M58 OPTIONAL USER M CODE SET M59 OUTPUT RELAY SET (N) M61-M68 OPTIONAL USER M CODE CLEAR M69 OUTPUT RELAY CLEAR (N) M75 SET G35 OR G136 REFERENCE POINT M76 CONTROL DISPLAY INACTIVE M77 CONTROL DISPLAY ACTIVE M78 ALARM IF SKIP SIGNAL FOUND M79 ALARM IF SKIP SIGNAL NOT FOUND M80 AUTOMATIC DOOR OPEN M81 AUTOMATIC DOOR CLOSE M82 TOOL UNCLAMP M83 AUTO AIR JET ON M84 AUTO AIR JET OFF M86 TOOL CLAMP M88 COOLANT THROUGH SPINDLE ON M89 COOLANT THROUGH SPINDLE OFF M93 AXIS POS CAPTURE START (P, Q) M94 AXIS POS CAPTURE STOP M95 SLEEP MODE M96 JUMP IF NO SIGNAL (P, Q) M97 LOCAL SUB-PROGRAM CALL (P, L) M98 SUB-PROGRAM CALL (P, L) M99 SUB-PROGRAM/ROUTINE RETURN OR LOOP M109 INTERACTIVE USER INPUT (P) TK-Mill Appendix - 13 Page 135

144 Standard Drill Sizes - Inches Drill. Decimal Drill.. Decimal Drill.. Decimal Drill.. Decimal Size Equiv. Size Equiv. Size Equiv. Size Equiv. 80 = = = /64 = = = =.201 X =.397 1/64 = /32 = /64 =.2031 Y = = = = /32 = = = =.2055 Z = = = = /64 = = = =.213 7/16 = = =.104 7/32 = /64 = = = = /32 = =.025 7/64 = = /64 = = =.110 A =.234 1/2 = = = /64 = /64 = = =.113 B = /32 = = =.116 C = /64 = /32 = =.120 D =.246 9/16 = =.032 1/8 = /4 (E) = /64 = = =.1285 F = /32 = = =.136 G = /64 = = = /64 = /8 = =.037 9/64 =.1406 H = /64 = = =.144 I = /32 = = =.147 J = /64 = = =.1495 K = /16 = = =.152 9/32 = /64 = = =.154 L = /32 = =.043 5/32 =.1563 M = /64 = = = /64 = /4 =.750 3/64 = =.159 N = /64 = = =.161 5/16 = /32 = = =.166 O = /64 = = =.1695 P = /16 = /16 = /64 = /64 = /64 = = =.173 Q = /32 = = =.177 R = /64 = = = /32 = /8 = = =.182 S = /64 = = =.185 T = /32 = /64 = /16 = /64 = /64 = = =.189 U = /16 = = =.191 3/8 = /64 = = =.1935 V = /32 = = =.196 W = /64 =.9844 Page 136 TK-Mill Appendix - 14

145 Inch Tap Drill Sizes INCH SIZES - NATIONAL COARSE UNC TAP DRILL SIZE SIZE #1-64 #53 #2-56 #51 #3-48 5/64" #4-40 #43 #5-40 #39 #6-32 #36 #8-32 #29 #10-24 #25 #12-24 #17 1/4-20 #7 5/16-18 F 3/8-16 5/16 7/16-14 U 1/ /64 9/ /64 5/ /32 3/ /32 7/8-9 49/64 1"-8 7/8 1-1/8-7 63/64 1-1/ /64 1-1/ /32 1-3/ /64 2"-4-1/2 1-25/32 INCH SIZES - NATIONAL FINE UNF TAP DRILL SIZE SIZE #0-80 3/64" #1-72 #53 #2-64 #50 #3-56 #46 #4-48 #42 #5-44 #37 #6-40 #33 #8-36 #29 #10-32 #21 #12-28 #15 1/4-28 #3 5/16-24 I 3/8-24 Q 7/16-20 W 1/ /64 9/ /64 5/ /64 3/ /16 7/ /16 1"-14 15/16 1-1/ /64 1-1/ /64 1-1/ /64 1-3/ /64 2" /64 TK-Mill Appendix - 15 Page 137

146 Metric Tap Drill Sizes METRIC COARSE SIZES TAP DRILL SIZE SIZE mm x.25.75mm 1.1 x x x x x x x x x x x x x x x x x x x x x x x x x x x x x METRIC FINE SIZES TAP DRILL SIZE SIZE mm x mm 4 x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x 2 28 Page 138 TK-Mill Appendix - 16

147 CENTER DRILLING CENTER DRILLING Before most drilling operations take place a starting drill must be programmed to make a small hole for the larger drill that will follow. The tool used to make the starting hole is known as a center drill, sizes of center drills vary and the use of the different sizes is governed by the size of the drill that will be used after. The following is a chart that will assist in choosing the proper size of the center drill and programming the correct Z depth. DRILL POINT LENGTH On most engineering drawings the finished depth of the hole will be given from the front edge of the part to the end of the parallel part of the hole (not including the drill point). This poses a programming problem because we program from the point of the drill so any Z depth we specify has to include the length of the drill point. To do this we have a calculation to perform based on the diameter of the drill and the angle of the drill point (usually 118 ). Quite simply the calculation is as follows: Drill Point Length = Diameter x Constant Where DIA. refers to the drill diameter and the constant is stated in the following chart DRILL ANGLE CONSTANTS 60 = = = = = = = = = = = = TK-Mill Appendix - 17 Page 139

148 Discriminator Installation Instructions Installation Instructions for Workbook users: 1. Locate the DVD/CD that came with the workbook (fixed to the back cover). 2. Insert the disc into the DVD/CD ROM tray of your computer. 3. When the AutoPlay window is displayed select Open folder to view files as shown below: 4. Double click or open the folder Discriminator_v1_2 as shown below: Page 140 TK-Mill Appendix - 18

149 Discriminator Installation Instructions Continued 5. Double-click the Discriminator.exe file as shown below. This will start the installation process. Follow the instructions on the screen to complete the installation. Installation Instructions for Online Course users: 1. Go to the Course Intro page of the Online Course as shown below: 2. Locate the What you need to complete this course section on this page and click on the Discriminator link to download the Discriminator installation file. Make sure you save the file to a place on the hard drive that you can be easily located. 3. Once the file has downloaded locate it and double-click the Discriminator.zip file to extract the installation files onto your hard drive. Make sure you extract the files into a new folder on your hard drive and remember where the folder is located. 4. Open the folder the files were extracted to and double click on Discriminator21017.exe. 5. Follow the instructions on the screen. TK-Mill Appendix - 19 Page 141

150 Page 142

151 CNC PROGRAMMING TEACHER KIT LATHE By Matthew Manton and Duane Weidinger

152

153 TABLE OF CONTENTS-LATHE LESSON-1..ABSOLUTE & INCREMENTAL POSITIONING...1 ABSOLUTE & INCREMENTAL POSITIONING - EXERCISE # ABSOLUTE & INCREMENTAL POSITIONING - EXERCISE # ABSOLUTE & INCREMENTAL POSITIONING - EXERCISE # ABSOLUTE & INCREMENTAL POSITIONING - EXERCISE # ABSOLUTE & INCREMENTAL POSITIONING - EXERCISE # LESSON-2..INTRODUCTION TO CNC CODES...7 LATHE TOOLS... 8 COMMONLY USED PREPARATORY G CODES... 9 COMMONLY USED MISCELLANEOUS M CODES RAPID G00 AND LINEAR G01 INTERPOLATION EXAMPLE OF PROGRAM START-UP BLOCKS MOVING TO MACHINE ZERO G28 AND G G40, G41, & G42 TOOL NOSE COMPENSATION LESSON-3..DRILLING...19 DRILLING ON CENTERLINE EXAMPLE DRILLING CANNED CYCLES DRILLING ON CENTERLINE EXERCISE # LESSON-4..LINEAR INTERPOLATION...27 FACING EXAMPLE LINEAR INTERPOLATION - EXAMPLE LINEAR INTERPOLATION LESSON-4 EXERCISE #

154 TABLE OF CONTENTS LESSON-5..TURNING CANNED CYCLES...39 ROUGH TURNING CANNED CYCLE EXAMPLE ROUGH BORING CANNED EXAMPLE LESSON-6..CIRCULAR INTERPOLATION...49 CIRCULAR INTERPOLATION - EXERCISE # CIRCULAR INTERPOLATION BORING - EXERCISE # CIRCULAR INTERPOLATION TURNING AND BORING -EXERCISE # CIRCULAR INTERPOLATION TURNING AND BORING -EXERCISE # LESSON-7..TOOL NOSE COMPENSATION...73 TOOL NOSE COMPENSATION (G40, G41, & G42) CNC PROGRAMMING G42 EXAMPLE CNC PROGRAMMING BORING EXAMPLE G LESSON-8..GROOVING/PARTING OFF...79 GROOVING EXAMPLE PART-OFF EXAMPLE GROOVING CYCLE-MULTIPLE PASS GROOVING CYCLE-SINGLE PASS FOR CUT-OFF GROOVING & PART OFF EXERCISE # TK-Table of Contents - 2

155 LESSON-9 THREADING HAAS-G76 O.D/I.D THREAD CUTTING CYCLE HAAS-G92 THREAD CUTTING CYCLE HAAS-M24 THREAD CHAMFER OFF THREADING OVERVIEW THREADING EXAMPLE DRAWING THREADING EXERCISE APPENDIX EXTRA CNC PROGRAMMING EXERCISES PREPATORY FUNCTIONS G-CODES MISCELLANEOUS FUNCTIONS M-CODES STANDARD DRILL SIZES INCHES INCH TAP DRILL SIZES METRIC TAP DRILL SIZES DISCRIMINATOR SOFTWARE INSTALLATION TK-Table of Contents - 3

156 TK-Table of Contents - 4

157 CNC PROGRAMMING WORKBOOK LESSON-1 ABSOLUTE AND INCREMENTAL POSITIONING NOTE: Teacher s Solutions are in shaded cells throughout this book. Page 1

158 LESSON-1 EXERCISE #1 - ABSOLUTE & INCREMENTAL POSITIONING ABSOLUTE PROGRAMMING All axis motions are based on a fixed zero reference point, known as ABSOLUTE ZERO (part zero). Each coordinate is in relation to this absolute zero using Cartesian or Rectangular Co-ordinates. INCREMENTAL PROGRAMMING All axis motions are based on the distance to the next location. Each coordinate is based on how far the tool is to move from start to finish. For an incremental move in X axis, we use U and for an incremental move in the Z axis we use W. G91 is not used. STARTING AT THE POINT O (ORIGIN), DESCRIBE THE PATH FROM O THROUGH ALL 9 POINTS AND BACK TO THE POINT O USING ABSOLUTE & INCREMENTAL POSITIONING ABSOLUTE X Z INCREMENTAL U W O (Origin) 0 0 O O 3-7 Page 2 TK-Lathe Lesson 1-2

159 LESSON-1 EXERCISE #2 - ABSOLUTE & INCREMENTAL POSITIONING ABSOLUTE PROGRAMMING All axis motions are based on a fixed zero reference point, known as ABSOLUTE ZERO (part zero). Each coordinate is in relation to this absolute zero using Cartesian or Rectangular Co-ordinates. INCREMENTAL PROGRAMMING All axis motions are based on the distance to the next location. Each coordinate is based on how far the tool is to move from start to finish. For an incremental move in X axis, we use U and for an incremental move in the Z axis, we use W. G91 is not used. STARTING AT THE POINT O (ORIGIN), DESCRIBE THE PATH FROM O THROUGH ALL 9 POINTS AND BACK TO THE POINT O USING ABSOLUTE & INCREMENTAL POSITIONING ABSOLUTE X Z INCREMENTAL U W O (Origin) 0 0 O O 3 7 TK-Lathe Lesson 1-3 Page 3

160 LESSON-1 EXERCISE #3 - ABSOLUTE & INCREMENTAL POSITIONING ABSOLUTE PROGRAMMING All axis motions are based on a fixed zero reference point, known as ABSOLUTE ZERO (part zero). Each coordinate is in relation to this absolute zero using Cartesian Co-ordinates. INCREMENTAL PROGRAMMING All axis motions are based on the distance to the next location. Each coordinate is based on how far the tool is to move from start to finish. For an incremental move in X axis, we use U and for an incremental move in the Z axis, we use W. G91 is not used. STARTING AT THE POINT O (ORIGIN), DESCRIBE THE PATH FROM O THROUGH ALL 9 POINTS AND BACK TO THE POINT O USING ABSOLUTE & INCREMENTAL POSITIONING ABSOLUTE X Z INCREMENTAL U W O (Origin) 0 0 O O 2-3 Page 4 TK-Lathe Lesson 1-4

161 LESSON-1 EXERCISE #4 - ABSOLUTE & INCREMENTAL POSITIONING OD STARTING AT THE POINT A (ORIGIN), DESCRIBE THE TOOLPATH THROUGH ALL THE POINTS USING ABSOLUTE & INCREMENTAL POSITIONING ABSOLUTE X Z INCREMENTAL U W A 0 0 A B B B C C C D D D E E E F F F G G G H H H I I TK-Lathe Lesson 1-5 Page 5

162 LESSON-1 EXERCISE #5 - ABSOLUTE & INCREMENTAL POSITIONING OD BEGIN AT START POINT SP (X3.75, Z0.25), DESCRIBE THE PATH FROM SP THROUGH POINTS A-K AND BACK TO POINT SP, USING ABSOLUTE & INCREMENTAL POSITIONING ABSOLUTE X Z INCREMENTAL U W SP (START POINT) SP A A A B B 0 0 B C C C D D D E E E F F F G G G H H H I I I J J J K K K SP SP Page 6 TK-Lathe Lesson 1-6

163 CNC PROGRAMMING WORKBOOK CODE G00 FUNCTION Rapid traverse motion; Used for non-cutting rapid moves of the machine axis to a location to be machined, or rapid retract moves after cuts have been completed. Maximum rapid motion (I.P.M.) of a CNC Machine will vary on machine model. G01 G02 G03 G04 G18 G20 G21 G28 G40 G41 G42 Linear interpolation motion; Used for actual machining and metal removal. Governed by a programmed feedrate in inches (or mm) per minute. Maximum feed rate (I.P.M.) of a CNC Machine will vary depending on the model of the machine. Circular Interpolation, Clockwise Circular Interpolation, Counterclockwise Dwell- Used with an X value for time of dwell in seconds ZX Plane Selection Verify Inch Coordinate Positions Verify Metric Coordinate Positions Machine Home (Rapid traverse) Tool Nose Radius Compensation CANCEL Tool Nose Radius Compensation LEFT of the programmed path G50 G52 G53 Tool Nose Radius Compensation RIGHT of the programmed path Max RPM Preset Local Coordinate system setting Machine Zero Positioning Coordinate Shift G54-59 Select Coordinate System #1 - #6 LESSON-2 INTRODUCTION TO CNC CODES Page 7

164 LESSON-2 INTRODUCTION TO CNC CODES LATHE TOOLS The CNC Lathe used in this text is set-up with following tools. All program examples and exercises in this workbook are typically using the same tools. Turret # Tool Description 1 O.D. Right Hand Roughing Tool 80 2 O.D. Right Hand Finishing Tool 55 3 O.D. Profiling Tool 35 4 Right Hand Parting Tool Width O.D. Thread Tool 6 # 4 Centre Drill 7 1/4 Diameter Drill 8 Boring Tool Page 8 TK-Lathe Lesson 2-2

165 CODE G00 G01 G02 G03 G04 G18 G20 G21 G28 G40 G41 G42 G50 G52 G53 G54-G59 G70 G71 COMMONLY USED PREPARATORY G CODES FUNCTION Rapid traverse motion; Used for non-cutting rapid moves of the machine axis to a location to be machined, or rapid retract moves after cuts have been completed. Linear interpolation motion; Used for actual machining and metal removal. Governed by a programmed feedrate in inches (or mm) per minute. Circular Interpolation, Clockwise Circular Interpolation, Counterclockwise Dwell- Used with an X value for time of dwell in seconds ZX Plane Selection Verify Inch Coordinate Positions Verify Metric Coordinate Positions Machine Home (Rapid traverse) Tool Nose Radius Compensation CANCEL Tool Nose Radius Compensation LEFT of the programmed path Tool Nose Radius Compensation RIGHT of the programmed path Max RPM Preset Local Coordinate system setting Machine Zero Positioning Coordinate Shift Select Coordinate System #1 - #6 (Part zero offset location) Profile Finish Turning fixed cycle Profile Rough Turning fixed cycle Z axis direction G72 G73 G74 G75 G76 G80 G81 G96 G97 G98 G99 Profile Rough Turning fixed cycle X axis direction Pattern Repetition cycle Drilling Cycle Grooving cycle Threading cycle Cancel Canned Cycle Drill Canned Cycle Constant Surface Speed (CSS) Direct RPM Input Mode (cancels CSS mode) Feed Rate per Minute Feed Rate per Revolution TK-Lathe Lesson 2-3 Page 9

166 PROGRAMMING NOTE As you may have noticed, there are no Incremental or Absolute modes included in the Preparatory Commands (G codes). On a CNC turning center or Lathe, the mode is always set to Absolute and diameter, if an Incremental movement is required the letters U or W are used for X or Z respectively. X OVERCUT Most lathe tools have a radius on the front or cutting edge; it is referred to as Tool Nose Radius. This radius must be compensated for in the calculation of the tool path much like the tool radius offset in milling operations, this offset is known as Tool Nose Radius Compensation. We will discuss this later on in this book but for now, know that when we program a facing operation we must account for the radius in our final X position of the facing move to create a flat surface. This extra value that we program is sometimes referred to as overcut. Page 10 TK-Lathe Lesson 2-4

167 COMMONLY USED MISCELLANEOUS M CODES CODE FUNCTION M00 M01 M03 M04 M05 M08 M09 M10 M11 M12 M13 M17 M18 The M00 code is used for a Program Stop command on the machine. It stops the spindle, turns off coolant and stops look-a-head processing. Pressing CYCLE START again will continue the program on the next block of the program. The M01 code is used for an Optional Program Stop command. Pressing the OPT STOP key on the control panel signals the machine to perform a stop command when the control reads an M01 command. It will then perform like an M00. Optional stops are useful when machining the first part to allow for inspection of the part as it is machined. Starts the spindle CLOCKWISE for most machining. Must have a spindle speed defined. The M03 is used to turn the spindle on at the beginning of program or after a tool change. Starts the spindle COUNTERCLOCKWISE. Must have a spindle speed defined. STOPS the spindle. If the coolant is on, the M05 will turn it off. Coolant ON command. Coolant OFF command. Open Chuck Close Chuck Tailstock Quill IN Tailstock Quill OUT Turret Indexing Forward Turret Indexing Reverse M19 M21 M22 M23 M24 M30 M41 Spindle Orientation Tailstock Forward Tailstock Backward Thread Gradual pullout ON Thread Gradual pullout OFF Program End and Reset to the beginning of program. Low Gear selection M42 Medium Gear selection 1 M43 Medium Gear selection 2 M44 High Gear selection NOTE: On the Haas lathe only one "M" code can be used in each block. The "M" codes will be the last command executed in a line, regardless of where it's located in that block. TK-Lathe Lesson 2-5 Page 11

168 RAPID G00 AND LINEAR G01 INTERPOLATION G00 RAPID TRAVERSE This code is used for rapid motion of the tool in air to traverse from one position to another as fast as possible. This code will work for both axis motions at once. This G00 code is modal and causes all the following blocks to be in rapid (up to 1000 in./min.) motion until another Group 01 code is specified, for example G01 linear interpolation. Generally, rapid motions "will not" be in a straight line. All the axes specified are moved at the maximum speed and will not necessarily complete each axis move at the same time. It activates each axis drive motor independently of each other and, as a result, the axis with the shortest move will reach its destination first. So you need to be careful of any obstructions to avoid with this type of rapid move. G00 is used when you are positioning the tool in fresh air. Retracting from a hole you have drilled. Rapid traverse is not used when cutting the part. Used incorrectly, rapid traverse will break a tool very easily and possibly remove the part from the chuck. G01 LINEAR INTERPOLATION This G code provides for straight line (linear) motion with programmed feedrate for all axis motions from point to point. Motion can occur with both axes at once. All axes specified will start at the same time and proceed to their destination and arrive simultaneously at the specified feedrate. To program a feedrate, the F command is used. The F command is modal and may be specified in a previous block. G01 is used for Drilling a hole Turning a diameter Machining a profile I.D and O.D. Grooving I.D and O.D. Page 12 TK-Lathe Lesson 2-6

169 EXAMPLE OF PROGRAM START-UP BLOCKS N10 G18 G20 G40 G54 G80 G97 G99 Many programs have a G code default line or Safety Block at the beginning of the program, this is to ensure the machine control is in a safe start condition before proceeding with the program. If the previous program had failed to cancel certain function this Safety Block would help ensure that the new program starts with the appropriate settings. For example the G codes below would perform the following at the start of the program: G18 - ZX Plane Selection G20 - Inch Programming G40 - Cancel Tool Nose Compensation G54 - Work Offset Command G80 - Cancels Canned Cycles G97 - Constant Non-Varying Spindle Speed G99 - Feed Per Revolution MACHINE DEFAULTS When the machine tool is powered on the control automatically recognizes a series of codes. On the Haas lathe the G codes listed below are set when the lathe is powered up: G00 Rapid Traverse G18 XZ Circular Plane Selection G40 Cutter Compensation Cancel G54 Work Coordinate Zero #1 G64 Exact Stop Cancel G80 Canned Cycle Cancel G97 Constant Surface Speed Cancel G99 Feed Per Revolution TK-Lathe Lesson 2-7 Page 13

170 EXAMPLE OF PROGRAM START-UP BLOCKS % Programs must begin and end with % (depending on the type of control.) O00023 Letter O and up to a five digit program number. N10 G18 G20 G40 N20 G80 G97 G99 N30 T0100 M41 N40 G97 S500 M03 N50 G00 G54 G41 X2.0 Z0.3 T0101 M08 N60 G96 S450 Nnn - Sequence Number G18 - ZX Plane Selection G20 - Verify Inch G40 Tool Nose Radius Compensation Cancel G80 - Canned Cycle Cancel G97 - Constant Non-Varying Spindle Speed G99 - Feed Per Revolution T Tool number #1 to be loaded into the cutting position with no offset call. M41 Select low gear if required Safety Startup Block G97 - constant surface speed off / revolution per minute on spindle speed is set to 500 RPM M03 - Starts the spindle in a clockwise direction G00 Rapid feed engagement. G54 - Select Coordinate System #1 G41 Tool nose radius compensation to the left of the programmed tool path. X2.0 Tool will rapid to a position of 1.0 units from center line of part. Z0.3 Tool will rapid to a position 0.3 units from finished face of part (finished face of part is usually set to Z0). T0101 Confirms tool #1 and assigns offset #1 M08 Start coolant pump G96 - Constant surface speed on. Spindle will turn at S450 surface feet per minute. Surface speed is determined by adjusting the spindle speed based on the radius of cut. S450 - Cutting speed selection of 450 ft/min. Page 14 TK-Lathe Lesson 2-8

171 EXAMPLE OF PROGRAM ENDING BLOCKS N200 G00 U0.05 W0.05 N210 M05 G00 - Rapid Traverse U0.05 Rapids tool 0.05 incrementally above last X position W0.05 Rapids tool 0.05 incrementally away from last Z position M05 Turn off spindle N220 G28 U0. N230 G28 W0. N240 M30 G28 - Machine Zero Return U0 - X axis in the up direction to machine zero G28 - Machine Zero Return W0 - Z axis to machine zero M30 End of Program and Reset Send to machine zero X-axis first to avoid any crash. Note: Depending on the setup of the lathe and to avoid any crashes while returning to machine zero it is usually best to move to machine zero in only one axis first. You need to be aware of where the tool is located and on its journey to machine zero, will it collide with anything? TK-Lathe Lesson 2-9 Page 15

172 MOVING TO MACHINE ZERO G28 and G53 G28 - FANUC RETURN TO MACHINE ZERO THROUGH REFERENCE POINT The G28 code is used to return to the machine zero position on all axes. If you program G28 on its own the machine will move in the X and Z axis simultaneously to machine zero. To command only the turret to return to machine zero, and not the tailstock if one is being used, program in G28 U0 W0 to send only the X and Z axes home and the tailstock will remain in place. G00 G28 X3.00 Z2.00 The above command would position the tool from the current position to the absolute position of X3.00 and Z2.00, and then to the X and Y axis machine zero point. This is a movement through an absolute intermediate point. This can be used as a way to move to a clearance point and then return to machine zero. Haas has a G53 program code that works similar to G28. Example: G53 G00 X-2.0 Z-4.0 The machine will move negative 2.0 inches from the machine zero position in the X axis, and negative 4.0 inches from home position in the Z axis. G53 G00 X0 Z0 This block will send the turret to machine Zero. Page 16 TK-Lathe Lesson 2-10

173 G40, G41, & G42 TOOL NOSE COMPENSATION When a program is created it is done so using the insert s command or reference point (see figure below). Tool Nose Compensation is used to offset the tool by a distance that will bring the cutting edge of the insert to the proper position in relation to the specific radius of the insert being used. The radius of the tool must be input into the controller and it will calculate the proper offset known as Tool Nose Compensation. G40 TOOL COMPENSATION CANCEL G40 will cancel the G41 or G42 tool compensation commands that are in effect at the time. G41 TOOL COMPENSATION LEFT (BORING) G41 will select tool compensation to the LEFT of the contouring direction; generally G41 is used for boring. The tool is compensated for the radius of the tool tip. The value of the compensation (tool radius) must be entered in the controller registry during set-up. G42 TOOL COMPENSATION RIGHT (TURNING) G42 will select tool compensation to the RIGHT of the contouring direction; generally G42 is used for turning. The tool is compensated for the radius of the tool tip. The value of the compensation (tool radius) must be entered in the controller registry during set-up. TK-Lathe Lesson 2-11 Page 17

174 Page 18 TK-Lathe Lesson 2-12

175 CNC PROGRAMMING WORKBOOK LESSON-3 DRILLING NOTE: Teacher s Solutions are in shaded cells throughout this book. Page 19

176 LESSON-3 CENTER DRILL & DRILLING CENTER DRILLING Before most drilling operations take place a starting drill must be programmed to make a small hole for the larger drill that will follow. The tool used to make the starting hole is known as a center drill, sizes of center drills vary and the use of the different sizes is governed by the size of the drill that will be used after. The following is a chart that will assist in choosing the proper size of the center drill and programming the correct Z depth. DRILL POINT LENGTH On most engineering drawings the finished depth of the hole will be given from the front edge of the part to the end of the parallel part of the hole (not including the drill point). This poses a programming problem because we program from the point of the drill so any Z depth we specify has to include the length of the drill point. To do this we have a calculation to perform based on the diameter of the drill and the angle of the drill point (usually 118 ). Quite simply the calculation is as follows: Drill Point Length = Diameter x Constant Where DIA. refers to the drill diameter and the constant is stated in the following chart DRILL ANGLE CONSTANTS 60 = = = = = = = = = = = = Page 20 TK-Lathe Lesson 3-2

177 DRILLING ON CENTRELINE EXAMPLE Tool #8 (#4 CENTRE DRILL) FACE MUST BE CENTRE DRILLED BEFORE DRILLING Tool #11 (Ø 0.25 DRILL) DRILL HOLE 0.75 DEEP Material: Al CS= 700 ft/min Z ZERO RIGHT FACE OF PART Spindle Speed RPM = 4xCS/D= Feed = in/min % O00084 (PROGRAM NAME, CENTRE DRILL AND DRILLING EXERCISE) N3G18 G20 G40 G54 G80 G97 G99 (SAFETY BLOCK) N5T0800 M41 (C/DRILL TOOL CALL NO OFFSETS AND GEAR RANGE) N9S2500 M03 (START SPINDLE, CLOCKWISE ROTATION) N11G00 X0 Z1.0 T0808 M08 (X CENTRE OF PART, Z SAFE DISTANCE FROM FRONT FACE OF PART) N13Z0.05 (RAPID TO 0.05 FROM FRONT FACE OF THE PART, NON-CUTTING MOVE) N15G98 (FEEDRATE PER MINUTE) N17G01 Z F15.0 (FEED TOOL TO C'DRILL DEPTH, FEEDRATE=15.0" / MIN.) N19G00 Z.1 (RAPID RETRACT) N21G00 X0 Z1.0 (T0800 RAPID TO ORIGINAL START POSITION) N23G28 U0 M09 (SEND TOOL TO HOME POSITION IN X AXIS) N25G28 W0 (SEND TOOL TO HOME POSITION IN Z AXIS) N27M01 (OPTIONAL STOP) N29T1100 M41 (0.25 DRILL TOOL CALL NO OFFSETS AND GEAR RANGE) N33S2000 M03 (START SPINDLE,CLOCKWISE ROTATION) N35G00 X0 Z1.0 T1111 M08 (X CENTRE OF PART, Z SAFE DISTANCE FROM FRONT FACE) N37Z0.05 (RAPID TO 0.05 FROM FRONT FACE OF THE PART, NON-CUTTING MOVE) N39G01 Z F15.0 (1st PECK FEED TOOL TO DRILL DEPTH, FEEDRATE=15.0" / MIN. ) N41G00 Z.05 (RAPID RETRACT TO CLEAR CHIPS) N43Z-.35 (RAPID BACK INTO HOLE) N45G01 Z (2nd PECK FEED TOOL TO DRILL DEPTH) N47G00 Z.05 (RAPID RETRACT OUT OF HOLE) N49 G00 X0 Z1.0 T1111 (RAPID TO ORIGINAL START POSITION) N51G28 U0. (SEND TOOL TO HOME POSITION IN X AXIS) N53G28 W0. (SEND TOOL TO HOME POSITION IN Z AXIS) N55M30 (PROGRAM END) % TK-Lathe Lesson 3-3 Page 21

178 LESSON-3 DRILL CANNED CYCLE G81 G80 CANCEL CANNED CYCLE A canned cycle permits multiple function programming on one block. A canned cycle is canceled with G80. G81 CANNED CYCLE DRILL X Z R F Format: G81 X0 Z R0.1 F10. Rapid X location (Optional) Z-depth (Optional - Feed to Z-depth starting from R Plane) R-Plane (Rapid point to start feeding) Feed rate This G code permits the inclusion of multiple axis motions on one block of program. It is used to reduce the length of program. All Z axis motions are in ABSOLUTE with any other axis motions unaffected. In a canned cycle drill, the cutter moves at rapid to the X and Z axis specified, then to a Z value in front of the hole at rapid rate to the R Plane, which is a point clear of the work piece. From the R Plane the drill feeds to the Z-depth at the specified feedrate. When the cutter reaches the Z depth, it retracts at rapid rate to the R Plane. Example of G81: % O00187 (G81 Drilling) N1 G28 (Return to Machine Zero) N2 T101 (1/2 DIA. DRILL - Tool 1 Offset 1) N3 G97 S1500 M03 N4 G54 G00 X0. Z1. M08 (Rapid to Initial Start Point) N5 G81 Z R0.1 F0.005 (G81 Drilling Cycle) N6 G80 G00 Z1. M09 N7 G28 N8 M30 % Page 22 TK-Lathe Lesson 3-4

179 DEEP HOLE PECK DRILL CANNED CYCLE G83 G83 DEEP HOLE PECK DRILL CANNED CYCLE Format : G83 Z-2.5 Q0.5 R0.1 F10. X* Rapid X-axis location Z Z-depth (feed to Z-depth starting from R plane) W* Incremental Z-depth (feeding to Z-depth starting from R-plane) Q* Pecking equal incremental depth amount (if I, J and K are not used) I* Size of first peck depth (if Q is not used) J* Amount reducing each peck after first peck depth (if Q is not used) K* Minimum peck depth (if Q is not used) P Dwell time at Z-depth R R-plane (rapid point to start feeding) F Feed rate in inches (mm) per minute * Indicates optional This G code is similar to G81 but is used for drilling when the tool must be withdrawn periodically to allow chips to be removed from the hole. This cycle allows the tool to rapid to the R Plane, feeds towards the Z depth in increments (traversing to the R Plane and back to the point where drilling was interrupted after each increment) until the tool reaches the final Z depth. TK-Lathe Lesson 3-5 Page 23

180 DEEP HOLE PECK DRILL CANNED CYCLE G83 Example of G83 using Q to define peck amount: In the example below Q is set to 0.2. When using G83 to peck drill a hole every pass will cut in by the Q amount 0.2, then rapid out to the R plane to clear chips and then rapid into hole for the next Q peck amount until Z depth is reached. % O00121 (G83 Peck Drilling) N1 G28 N2 T303 (1/2 DIA. DRILL - Tool 3 Offset 3) N3 G97 S1900 M03 N4 G54 G00 X0. Z1. M08 (Rapid to Initial Start Point) N5 G83 Z-1.5 Q0.2 R0.1 F0.005 (G83 Peck Drilling Cycle with Q) N6 G80 G00 Z1. M09 N7 G28 N8 M30 % Page 24 TK-Lathe Lesson 3-6

181 DRILLING ON CENTRELINE - LESSON-3 - EXERCISE #1 CREATE A DRILLING PROGRAM USING G83 Tool #8 (#4 CENTRE DRILL) FACE MUST BE CENTRE DRILLED BEFORE DRILLING Tool #11 (Ø 0.25 DRILL) DRILL HOLE 0.75 DEEP Material: Al CS= ft/min Z ZERO RIGHT FACE OF PART Spindle Speed RPM = 4xCS/D= Feed = in/min Depth of Peck = Total Distance traveled/# of Pecks = # of pecks = 4 % O891 (LESSON-3-EXERCISE 1, CENTRE DRILL AND DRILLING EXERCISE) N1 G18 G20 G40 G54 G80 G97 G99 (SAFETY BLOCK) N3 T0800 M41 (C/DRILL TOOL CALL NO OFFSETS AND GEAR RANGE) N5 S2500 M03 (START SPINDLE, CLOCKWISE ROTATION) N7 G00 X0 Z1.0 T0808 M08 (X CENTRE OF PART, Z SAFE DISTANCE FROM FRONT FACE OF PART) N9 Z0.1 (RAPID TO 0.1 FROM FRONT FACE OF THE PART, NON-CUTTING MOVE) N11 G98 (FEEDRATE PER MINUTE) N13 G81 Z R0.1 F7.0 (G81 DRILLING CYCLE) N15 G80 G00 X0 Z1.0 (CANCEL CYCLE RAPID TO ORIGINAL START POSITION) N17 G28 U0 M09 (SEND TOOL TO HOME POSITION IN X AXIS) N19 G28 W0 (SEND TOOL TO HOME POSITION IN Z AXIS) N21 M01 (OPTIONAL STOP) N23 T1100 M41 (0.25 DRILL TOOL CALL NO OFFSETS AND GEAR RANGE) N25 S2000 M03 (START SPINDLE,CLOCKWISE ROTATION) N27 G00 X0 Z1.0 T1111 M08 (X CENTRE OF PART, Z SAFE DISTANCE FROM FRONT FACE) N29 Z0.1 (RAPID TO 0.1 FROM FRONT FACE OF THE PART, NON-CUTTING MOVE) N31 G83 Z Q0.375 R0.1 F10.0 (G83 PECK DRILLING CYCLE WITH Q) N33 G80 G00 X0 Z1.0 T1111 (RAPID TO ORIGINAL START POSITION) N35 G28 U0. (SEND TOOL TO HOME POSITION IN X AXIS) N37 G28 W0. (SEND TOOL TO HOME POSITION IN Z AXIS) N39 M30 (PROGRAM END) TK-Lathe Lesson 3-7 Page 25

182 Page 26 TK-Lathe Lesson 3-8

183 CNC PROGRAMMING WORKBOOK LESSON-4 LINEAR INTERPOLATION NOTE: Teacher s Solutions are in shaded cells throughout this book. Page 27

184 RAPID G00 AND LINEAR G01 INTERPOLATION G00 RAPID TRAVERSE This code is used for rapid motion of the tool in air to traverse from one position to another as fast as possible. This code will work for both axis motions at once. This G00 code is modal and causes all the following blocks to be in rapid (up to 1000 in./min.) motion until another Group 01 code is specified, for example G01 linear interpolation. Generally, rapid motions "will not" be in a straight line. All the axes specified are moved at the maximum speed and will not necessarily complete each axis move at the same time. It activates each axis drive motor independently of each other and, as a result, the axis with the shortest move will reach its destination first. So you need to be careful of any obstructions to avoid with this type of rapid move. G00 is used when you are positioning the tool in fresh air. Retracting from a hole you have drilled. Rapid traverse is not used when cutting the part. Used incorrectly, rapid traverse will break a tool very easily and possibly remove the part from the chuck. G01 LINEAR INTERPOLATION This G code provides for straight line (linear) motion with programmed feedrate for all axis motions from point to point. Motion can occur with both axes at once. All axes specified will start at the same time and proceed to their destination and arrive simultaneously at the specified feedrate. To program a feedrate, the F command is used. The F command is modal and may be specified in a previous block. G01 is used for Drilling a hole Turning a diameter Machining a profile I.D and O.D. Grooving I.D and O.D. Page 28 TK-Lathe Lesson 4-2

185 FACING FACING After a work piece has been loaded into a lathe the first operation should be to face the end of the part to make it flat. This will allow the later turning and boring operations to start the cut without having a sometimes large interrupted cut due to an uneven face. There are fixed or canned cycles that can be programmed to do this but for now we will talk about manually programming this operation. A safe starting position away from the Outside Diameter (OD) of the rough material should be determined, as well as from the uneven front face of the raw material (X and Z). Depth of the face cut should be made from the safe position to the Z position required, then program the X cut along the face as linear interpolation. If the material has a rough bore the X coordinate for facing should be programmed a sufficient amount smaller than the Inside Diameter (ID) of the bore, as there is no need to go to X0 this will eliminate fresh air cutting. Don t forget the overcut! The usual amount of the overcut is not much more than the radius of the facing insert, if too much overcut is programmed damage to the insert itself may occur due to rubbing of the cutting edge on the material. PROGRAMMING EXAMPLE FACING STOCK DIAMETER % O43 (Program number) N1 G20 (Verify inch units) N2 G40 G54 G80 G97 G99 (Safety block) N3 T0100 M41 (Tool call T01 with gear selection) N4 G50 S1200 (Specify maximum RPM to 1200) N5 G97 S500 M03 (Start spindle 500 RPM CW) N6 G00 G54 X1.7 Z0.25 T0101 M08 (Rapid to X1.7 Z0.25 safe position) N7 G96 S700 (Specify constant surface speed 700 SFM) N8 G01 Z0 F0.012 (Feed to Z0 finish front face of part) N9 X-0.05 (Program tool to X-0.05 overcut by 0.05) N10 U0.05 W0.05 (Incremental pull off from part face X0.05 Z0.05) N11 G00 X1.7 Z0.25 (Rapid back to safe position) N12 G28 U0 (Return to X machine home position) N13 G28 W0 M05 (Return to Z machine home position) N14 M01 (Optional stop) N15 T0100 (Tool offset compensation canceled) N16 M30 (Program End) % TK-Lathe Lesson 4-3 Page 29

186 FACING EXAMPLE % Example program to only face rough material (shown as a dashed line diameter) This example takes 2 face passes The first rough face pass away from the finish face. For the second finish pass face at Z0. Z0 = finished face of part. Tool T01 is being used. O43 (Program number) N1 G20 N3 G40 G54 G80 G97 G99 N5 T0100 M41 (Verify inch units) (Safety block) (Tool call T01 with gear selection) N7 G50 S1200 (Specify maximum RPM to 1200) N9 G97 S500 M03 (Start spindle 500 RPM CW) N11 G00 G54 X1.7 Z0.25 T0101 M08 (Rapid to Safe position, coolant on) N13 G96 S700 (Specify constant surface speed 700 SFM) N15 G99 G01 Z0.005 F0.012 (G99=Feed per revolution) N17 X-0.05 (Move tool to X-0.05, overcut by 0.05) N19 U0.05 W0.05 N21 G00 X 1.5 N23 Z0 (Incremental pull off from part face X0.05 Z0.05) (Rapid out for second finish facing cut) (Move to Z Zero for final facing cut) N25 G01 X-0.05 (Move tool to X-0.05, overcut by 0.05) N27 U0.05 W0.05 N29 G00 X1.7 Z0.25 M09 N31 G28 U0 N33 G28 W0 M05 N34 T0100 N35 M30 % (Incremental pull off from part face X0.05 Z0.05) (Rapid back to safe position, coolant off) (Return to X machine home position) (Return to Z machine home position) (Tool offset compensation canceled) (Program End) Page 30 TK-Lathe Lesson 4-4

187 LINEAR ROUGH TURNING EXAMPLE LINEAR ROUGH TURNING EXAMPLE - ROUGHING TOOLPATH This Example program faces the front of the part, one rough cut, one finish cut. After facing the front of the bar stock the diameters are rough turned, leaving a small amount of material for a finish pass. For this example a maximum cut of 0.25 off the diameter is being taken, leaving 0.03 on the diameter and on all Z faces. A finishing pass will be programmed in the next exercise. The bar stock is 1.5 diameter X0 is centerline of the part, Z0 is the front face (far right) of the part All X positions are diameter, all Z positions past the front face are Z- After facing the tool is retracted in X&Z (U&W) a small amount (0.05 ) then rapids to the X diameter of the first Z feed across the rough OD of the part. The tool is once again retracted in X&Z (U&W) then rapids back to a safe position in Z, and then brought to the next position in X diameter for the next feed across and so on. The x 45 chamfers will be added later in the finishing tool path In this example the rough turning passes will machine past the left end of the part by 0.2. The reason for this is to remove material prior to the parting off operation; this will leave less material for the parting tool to remove. TK-Lathe Lesson 4-5 Page 31

188 LINEAR ROUGH TURNING EXAMPLE % O00081 (PROGRAM NAME, ROUGH TURNING EXERCISE) N1 G20 (Verify inch units) N3 G40 G54 G80 G97 G99 (Safety block) N5 T0100 M41 (Tool call T01 with gear selection) N7 G50 S3500 (Specify maximum RPM to 3500) N9 G97 S500 M03 (Start spindle 500 RPM CW) N11 G00 G41 G54 X1.7 Z0.25 T0101 M08 (Rapid to Safe position, tool nose compensation (TNC), coolant on) N13 G96 S600 (Specify constant surface speed 600 SFM) N15 G99 G01 Z0.005 F0.010 (Feed to Z from finish front face of part G99=Feed per revolution) N17 X-0.05 (Move tool to X-0.05, overcut by 0.05) N19 U0.05 W0.05 (Incremental pull off from part face X0.05 Z0.05) N21 G00 X1.7 (Rapid out for second finish facing cut) N23 Z0 (Move to Z Zero for final facing cut) N25 G01 X-0.05 (Move tool to X-0.05, overcut by 0.05) N27 U0.05 W0.05 (Incremental pull off from part face X0.05 Z0.05) N29 G00 X1.7 Z0.25 (Rapid back to safe position for start of rough turning) N31 G96 S700 (Constant surface speed engaged at 700 SFM) N33 G42 X1.405 (Move to the first X diameter cutting position, TNC right) N35 G01 Z-2.2 (Feed to full length of part plus another 0.2 to allow for the parting tool) N37 U0.05 W0.05 (Retract off part in feed mode) N39 G00 Z0.25 (Rapid to safe position in front of part) N41 X1.250 (Move to the second X diameter cutting position) N43 G01 Z (Feed to length of 0.5" shoulder, leaving for finish) N45 U0.05 W0.05 (Retract off part in feed mode) N47 G00 Z0.25 (Rapid to safe position in front of part) N49 X1.0 (Move to the third X diameter cutting position) N51 G01 Z (Feed to length of 0.5" shoulder, leaving for finish on z) N53 U0.05 W0.05 (Retract off part in feed mode) N55 G00 Z0.25 (Rapid to safe position in front of part) N57 X0.905 (Move to the fourth X diameter cutting position, plus 0.030" on 0.875" diameter) N59 G01 Z (Feed to length of 0.5" shoulder, leaving for finish) N61 U0.05 W0.05 (Retract off part in feed mode) N63 G00 Z0.25 (Rapid to safe position in front of part) N65 X0.655 (Move to the fifth X diameter cutting position, plus 0.030" on 0.625" diameter) N67 G01 Z (Feed to length of 0.375" shoulder, leaving for finish on Z) N69 U0.05 W0.05 (Retract off part in feed mode) N71 G00 Z0.25 (Rapid to safe position in front of part) N73 G40 G00 X1.7 Z0.25 (Cancel TNC offset, rapid to original start position) N75 G28 U0 (Rapid to X machine home position) N77 G28 W0 M05 (Rapid to Z machine home position) N79 M30 (Program end) % Page 32 TK-Lathe Lesson 4-6

189 CONTOUR THE FINISH PROFILE LINEAR FINISH TURNING EXAMPLE In the previous Example the part was rough turned, now we will add the finishing tool path to the rouging program. The continuation of this program is show below The first part of the program rough turns the part and then a tool change takes place to load up the finish tool The tool used to finish the contour will be a carbide insert with a tool nose radius - Tool # 2 (End of roughing tool path on previous page - continue finish cut here) N73 G40 G00 X1.7 Z0.25 (Cancel tool nose radius offset, rapid to original start position) N75 G28 U0 (Rapid to x machine home position) N77 G28 W0 M05 (Rapid to z machine home position) N79 T0202 (O.D. Right Hand Finishing Tool 55 ) N81 G50 S3500 (Specify maximum RPM to 3500) N83 G97 S800 M03 (Start spindle 800 RPM CW) N85 G00 G42 G54 X1.7 Z0.25 T0202 M08 (Rapid to Safe position, TNC, coolant on) N87 G96 S700 N89 G99 G01 X Z0.05 F0.006 N91 X0.625 Z N93 Z N95 X0.875 N97 Z-1.5 N99 X N101 X1.375 Z N103 Z-2.2 (Specify constant surface speed 700 SFM) (Feed to Z0.05 from finish front face of part & 0.05 below chamfer) (Cut chamfer at front of part) (Cut chamfer at left of part) TK-Lathe Lesson 4-7 Page 33

190 LINEAR FINISH TURNING EXAMPLE - CONTINUED N105 X1.625 N107 G00 Z0.25 N109 G40 G00 X1.7 Z0.25 N111 G28 U0 N113 G28 W0 M05 N115 M30 % (Rapid to safe position in front of part) (Cancel tool nose radius offset, rapid to original start position) (Rapid to X machine home position) (Rapid to Z machine home position) (Program end) Page 34 TK-Lathe Lesson 4-8

191 LINEAR INTERPOLATION - LESSON-4 - EXERCISE #1 PROFILE TURNING and DRILLING EXERCISE Use the previous sample programs as a guide to complete the part shown below Z Zero is at the right face of the part Make from 1.5 diameter bar stock. Material: Alum T6061 TK-Lathe Lesson 4-9 Page 35

192 % O49 (LESSON 4 EXERCISE #1) (Face Front of Part one cut) N1 G20 (Verify inch units) N3 G40 G54 G80 G97 G99 (Safety block) N5 T0100 (Tool call T01) N7 G50 S3500 (Specify maximum RPM to 3500) N9 G97 S500 M03 (Start spindle 500 RPM CW) N11 G00 G41 G54 X1.5 Z0.25 T0101 M08 (Rapid to Safe position, tool nose compensation- TNC, coolant on) N13 G96 S600 (Specify constant surface speed 600 SFM) N15 G99 G01 Z0 F0.010 (Feed to Z from finish front face of part G99=Feed per revolution) N17 X-0.05 (Move tool to X-0.05, overcut by 0.05) N19 U0.05 W0.05 (Incremental pull off from part face X0.05 Z0.05) N21 G00 G40 X1.5 Z0.25 (Rapid back to safe position for start of rough turning) (Rough Turn) N23 X1.480 N25 G01 Z-2.2 N27 U0.05 W0.05 N29 G00 Z0.25 (Rapid to safe position in front of part) N31 X1.375 N33 G01 Z N35 U0.05 W0.05 N37 G00 Z0.25 (Rapid to safe position in front of part) N39 X1.25 N41 G01 Z N43 U0.05 W0.05 N45 G00 Z0.25 (Rapid to safe position in front of part) N47 X1.125 N49 G01 Z N51 U0.05 W0.05 N53 G00 Z0.25 (Rapid to safe position in front of part) N55 X1.030 N57 G01 Z N59 U0.05 W0.05 N61 G00 Z0.25 (Rapid to safe position in front of part) N63 X0.905 N65 G01 Z N67 U0.05 W0.05 N69 G00 Z0.25 (Rapid to safe position in front of part) N71 X0.750 N73 G01 Z N75 U0.05 W0.05 N77 G00 Z0.25 (Rapid to safe position in front of part) N79 X0.625 N81 G01 Z N83 U0.05 W0.05 N85 G00 Z0.25 (Rapid to safe position in front of part) N87 X0.530 N89 G01 Z N91 U0.05 W0.05 Page 36 TK-Lathe Lesson 4-10

193 N93 G00 Z0.25 (Rapid to safe position in front of part) N95 G40 G00 X1.5 Z0.25 (Cancel TNC offset, rapid to original start position) N97 G28 U0 (Rapid to X machine home position) N99 G28 W0 M05 (Rapid to Z machine home position) (Finish Cut) N101 T0202 (O.D. Right Hand Finishing Tool 55 ) N103 G50 S3500 (Specify maximum RPM to 3500) N105 G97 S800 M03 (Start spindle 800 RPM CW) N107 G00 G42 G54 X1.5 Z0.25 T0202 M08 (Rapid to Safe position, TNC, coolant on) N109 G96 S700 (Specify constant surface speed 700 SFM) N111 G99 G01 X Z0.05 F0.006 (Feed to Z0.05 from finish front face of part & 0.05 below chamfer) N113 X0.5 Z (Cut chamfer at front of part) N115 Z N117 X0.875 N119 Z N121 X1.0 Z-1.5 N123 Z-1.75 N125 X1.45 N127 Z-2.2 N129 U0.05 W0.05 (Incremental pull off from part face X0.05 Z0.05) N131 G00 Z0.25 (Rapid to safe position in front of part) N133 G40 G00 X1.5 Z0.25 (Cancel TNC offset, rapid to original start position) N135 G28 U0 (Rapid to X machine home position) N137 G28 W0 M05 (Rapid to Z machine home position) (Centre Drill - G81 Canned Cycle Drill) N139 T0800 (Tool call T08) N141 G50 S3500 (Specify maximum RPM to 3500) N143 G97 S2500 M03 (Start spindle 2500 RPM CW) N145 G00 G54 X1.5 Z0.25 T0808 M08 (Rapid to Safe position,coolant on) N147 G00 X0 Z0.25 N149 G98 G81 Z-0.2 R0.1 F7.0 (G81 Drilling Cycle) N151 G80 (Drill 1/4" - G83 Canned Cycle Peck Drill) N153 G28 N155 T1111 (1/4 DIA. DRILL - Tool 11) N157 G97 S2500 M03 N159 G00 G54 X1.5 Z0.25 T1111 M08 (Rapid to Safe position,coolant on) N161 G00 X0 Z0.25 N163 G98 G83 Z Q0.25 R0.1 F10.0 N165 G80 N167 G28 N169 M30 (Program end) % TK-Lathe Lesson 4-11 Page 37

194 LINEAR INTERPOLATION - LESSON-4 - EXERCISE #1 EXAMPLE OF CUT-OFF The program below shows how the Lesson-4 Exercise #1 part would be cut-off using a parting tool. (CUT OFF) N137 T404 N139 G97 S191 M03 (Cut-Off Tool wide) (Start spindle 191 RPM CW) N141 G00 X1.7 Z0.25 M8 (Rapid to safe position in front of part, Coolant on) N143 G50 S3000 (Specify maximum RPM to 3500) N145 G96 S200 N147 Z-2.0 N149 X1.6 N150 G99 N151 G01 X-0.02 F0.002 N153 G00 X1.7 N155 G28 U0 N157 G28 W0 M05 N169 M30 % (Specify constant surface speed 200 SFM) (Rapid move to Z-2.0, end of part) (Rapid move to X1.6, clearance away from part) (Feed Rate Per Revolution) (Feed to X-0.02 past center of part) (Rapid move to X1.7, clearance away from part) (Rapid to X machine home position) (Rapid to Z machine home position) (Program end) Page 38 TK-Lathe Lesson 4-12

195 CNC PROGRAMMING WORKBOOK LESSON-5 TURNING CANNED CYCLES Page 39

196 LESSON 5 - TURNING CANNED CYCLES G71, G72 and G70 G71-G72 ROUGH TURNING CYCLE A canned cycle, which permits multiple function programming in one code, is very helpful to the programmer for ease of programming and more compact programs. The G71 cycle allows for rough turning in the Z- direction (towards the chuck) The G72 cycle allows for rough facing in the X- direction (towards the centerline of the part) G71 CANNED CYCLE TWO LINE FORMAT Format: G71 U R G71 P Q U W F S First G71 block U Depth of roughing cut R Amount of retract after each cut Second G71 block P First block number of finish contour Q Last block number of finish contour U Amount of stock left for finish operation (diameter) X axis W Amount of stock left on all faces for finish operation Z axis F Feed rate in inches or mm /rev. S Spindle speed in ft or m /min. G72 CANNED CYCLE TWO LINE FORMAT Format: G72 W R G72 P Q U W F S First G71 block U Depth of roughing cut R Amount of retract after each cut Second G71 block P First block number of finish contour Q Last block number of finish contour U Amount of stock left for finish operation (diameter) X axis W Amount of stock left on all faces for finish operation Z axis F Feed rate in inches or mm /rev. S Spindle speed in ft or m /min. Page 40 TK-Lathe Lesson 5-2

197 LESSON 5 - TURNING CANNED CYCLES G71 G71 CANNED CYCLE HAAS ONE LINE FORMAT G71 O.D./I.D. STOCK REMOVAL CYCLE The type described below is a TYPE I geometry path and is when the X-axis of the programmed path does not change direction. This type of path is called monotonic. Format: G71 P Q U W F S P First block number of finish contour Q Last block number of finish contour U* Finish stock remaining with direction (+or -), X-axis diameter value W* Finish stock remaining with direction (+or -), Z-axis value I* Last pass amount with direction (+or -), X-axis radius value K* Last pass amount with direction (+or -), Z-axis value D* Depth of cut stock removal each pass, positive radius value (Setting 72) F Roughing passes feed rate throughout this cycle R1* YASNAC type II roughing (only if setting 33 is on Yasnac) S** Spindle speed in this cycle T** Tool and offset in this cycle * Indicates optional ** Rarely defined in a G71 line TK-Lathe Lesson 5-3 Page 41

198 LESSON 5 - FINISHING CANNED CYCLE G70 G70 FINISH TURNING/BORING CANNED CYCLE Format : G70 P Q F S P= First block number of the finish contour Q= Last block number of the finish contour F= Cutting feedrate for the finishing (overrides the feed in roughing contour) S= spindle speed (overrides speed in roughing contour) This canned cycle is used after the roughing canned cycle is finished. It does not have to be run directly after the roughing cycle but can be run in the same main program. The start and finish blocks of the original definition of the profile that was used in the rough cycle are used to define the contour of the finish cycle. It is recommended that the same start point is used for both rough and finish cycles to ensure safe tool paths of both operations. TYPICAL O.D. FINISH CANNED CYCLE N37 T0500 M42 N38 G96 S500 M03 N39 G42 X Z T0505 M08 N40 G70 P11 Q19 F12.0 N41 G00 G40 X Z T0100 N42 M01 TYPICAL I.D. FINISH CANNED CYCLE (OD FINISH TOOL & GEAR SEL.) (CSS. SPEED) (TOOL COMPENSATION & START POS.) (CALL LINES FOR FINISH COORDS) N43 T0700 M42 (ID FIN TOOL & GEAR SEL.) N44 G96 S475 M03 (CSS. SPD) N45 G00 G41 X Z T0707 M08 (TOOL COMPENSATION & START POS.) N46 G70 P27 Q34 F12.0 (CALL LINES FOR FIN. COORDS) N47 G00 G40 X Z T0700 N48 M01 Page 42 TK-Lathe Lesson 5-4

199 LESSON 5 EXAMPLE - ROUGH AND FINISH TURNING CANNED CYCLES In the previous lesson the part shown below was programmed as an exercise, the program in the previous lesson did not use canned cycles to rough the diameters. In this example program the part will be programmed using canned cycle G71 to rough the diameters of the part and G70 to Finish machine the contour Z Zero is at the right face of the part The part is being made from 1.5 diameter bar stock This Example program faces the front of the part, then a series of rough cuts and one finish cut. After facing the front of the bar stock the diameters are rough turned, leaving a small amount of material for a finish pass. For this example a maximum cut of 0.1 off the diameter is being taken, leaving 0.03 on the diameter and on all Z faces. In this example the rough turning passes will machine past the left end of the part by 0.2. The reason for this is to remove material prior to the parting off operation; this will leave less material for the parting tool to remove Material: Alum T6061 TK-Lathe Lesson 5-5 Page 43

200 LESSON 5 EXAMPLE - ROUGH AND FINISH TURNING CANNED CYCLES % O49 (Roughing Cycle Example - Lesson-5) (Face Front of Part one cut) N1 G20 (Verify inch units) N3 G40 G54 G80 G97 G99 (Safety block) N5 T0100 (Tool call T01) N7 G50 S3500 (Specify maximum RPM to 3500) N9 G97 S500 M03 (Start spindle 500 RPM CW) N11 G00 G41 G54 X1.7 Z0.25 T0101 M08 (Rapid to Safe position, TNC, coolant on) N13 G96 S700 N15 G99 G01 Z0 F0.010 (Specify constant surface speed 700 SFM) (Feed to Z from finish front face of part G99=Feed per revolution) N17 X-0.05 (Move tool to X-0.05, overcut by 0.05) N19 U0.05 W0.05 (Incremental pull off from part face X0.05 Z0.05) N21 G00 G40 X1.7 Z0.25 (Rough Turn O.D.) (Rapid back to safe position for start of rough turning) N23 G71 P25 Q47 U0.03 W0.005 D0.1 F0.010 (G71 Rough Turning Cycle) N25 G00 G42 X (P and G42 With the start of Geometry) N27 G99 G01 X Z0.05 F0.006 (Feed to Z0.05 from finish front face of part & 0.05 below chamfer) N29 X0.5 Z N31 Z N33 X0.875 N35 Z N37 X1.0 Z-1.5 N39 Z-1.75 N41 X1.45 N43 Z-2.2 N45 X1.6 N47 G40 G00 X 1.7 N49 G00 X1.7 Z0.25 N51 G28 U0 N53 G28 W0 M05 (Cut chamfer at front of part) (Q End of Geometry. Machine off of part and cancel compensation) (Rapid back to safe position) (Rapid to X machine home position) (Rapid to Z machine home position) Page 44 TK-Lathe Lesson 5-6

201 LESSON 5 EXAMPLE - ROUGH AND FINISH TURNING CANNED CYCLES (Finish Cut) N55 T0202 (O.D. Right Hand Finishing Tool 55 ) N57 G50 S3500 (Specify maximum RPM to 3500) N59 G97 S800 M03 (Start spindle 800 RPM CW) N61 G00 G42 G54 X1.7 Z0.25 T0202 M08 (Rapid to Safe position, TNC, coolant on) N63 G96 S700 (Specify constant surface speed 700 SFM) N65 G70 P25 Q47 ( G70 Finishing OD) N67 G28 U0 (Rapid to X machine home position) N69 G28 W0 M05 (Centre Drill - G81 Canned Cycle Drill) N71 T0600 (Tool call T08) (Rapid to Z machine home position) N73 G50 S3500 (Specify maximum RPM to 3500) N75 G97 S2500 M03 (Start spindle 2500 RPM CW) N77 G00 G54 X1.7 Z0.25 T0606 M08 (Rapid to Safe position, coolant on) N79 G00 X0 Z0.25 N81 G98 G81 Z R0.1 F7.0 N83 G80 (G81 Drilling Cycle) N85 G28 (Drill 1/4" - G83 Canned Cycle Peck Drill) N87 T0707 (1/4 DIA. DRILL - Tool 07) N89 G97 S2500 M03 N91 G00 G54 X1.7 Z0.25 T0707 M08 (Rapid to Safe position, coolant on) N93 G00 X0 Z0.25 N95 G98 G83 Z Q0.125 R0.1 F10.0 N97 G80 N99 G28 N101 M30 % (Program end) TK-Lathe Lesson 5-7 Page 45

202 LESSON 5 - EXAMPLE - ROUGH AND FINISH BORING CANNED CYCLES Material: Aluminium CS=700ft/min 1. 1/2 diameter drill has already been used to drill though the part, front face has been faced 2. Example shows below the Rough and Finish Boring Tool path using the above drawing 3. Use G71 (Roughing Towards The Chuck In Z Axis) G70 for finish cut 4. Leave on diameters, Leave on faces for finish cut 1. Spindle Speed RPM = 4xCS/D= 1. Feed =0.003 in per rev 1. Depth of Cut=0.030 % O67 N1 G20 N3 G40 G54 G80 G97 G99 N5 T0800 (Roughing and Finishing Cycles - Boring) (Verify inch units) (Safety block) (Tool call T08 - Rough Boring Tool) N7 G50 S3500 (Specify maximum RPM to 3500) N9 G97 S500 M03 (Start spindle 500 RPM CW) N11 G00 X1.7 Z0.25 T0808 M08 (Rapid to Safe position, coolant on) N13 G96 S700 N15 X0.490 Z0.1 (Specify constant surface speed 700 SFM) Page 46 TK-Lathe Lesson 5-8

203 LESSON 5 - EXAMPLE - ROUGH AND FINISH BORING CANNED CYCLES (Rough Bore) N17 G71 P19 Q31 U-0.01 W0.005 D0.03 F0.005 (G71 Rough Turning Cycle) N19 G00 G41 X0.875 Z0.1 (P and G41 With the start of Geometry) N21 G01 Z-0.25 N23 X0.625 N25 Z-0.5 N27 X0.52 N29 Z-0.65 (Bore past end of part) N31 G40 X0.49 (Q End of Geometry) (Finish Cut Same Boring Tool) N33 G96 S800 (Specify constant surface speed 800 SFM) N35 G70 P19 Q31 F0.004 (G70 Finishing OD) N37 G00 Z0.25 (Rapid to safe position in front of part) N39 G28 U0 N41 G28 W0 M05 N43 M30 % (Rapid to X machine home position) (Rapid to Z machine home position) (Program end) TK-Lathe Lesson 5-9 Page 47

204 LESSON 5 - TOOL TIP ORIENTATION Toolpaths are programmed using the coordinates of the true profile, much like a mill but because there are many possible positions of the tool point called the command point or Tool Tip Orientation. You have to enter the position from 1-9 in the tool (T) column on the offset page during part set-up. These are the eight possible tool positions, the ninth position is a neutral one, sometimes used when no tool offset is needed. Once the tool position has been determined, the position is entered as the appropriate number in the chart below in the T column. This chart is only a graphic representation of a lathe offset page. TOOL # X Y R T Page 48 TK-Lathe Lesson 5-10

205 CNC PROGRAMMING WORKBOOK LESSON-6 CIRCULAR INTERPOLATION NOTE: Teacher s Solutions are in shaded cells throughout this book. Page 49

206 CIRCULAR INTERPOLATION G02 & G03 G03 (CCW) U.125 W-.125 I0 K-.125 F15.0 G02 (CW) U.25 W-.25 I.25 K0 F15.0 G02 Clockwise G03 Counter Clockwise U.25 W-.25 Arc End Point (optional incremental) U.125 W-.125 Arc End Point (optional incremental) I 0.25 K0 Incremental Distance from the tool start point to the center of arc I 0. J-.125 Incremental Distance from the tool start point to the center of arc F15. Feed rate 15 in/min F15. Feed rate 15 in/min When the machine is required to move in a straight line under a controlled federate, linear interpolation is used (G01). When it is necessary to travel in the circular motion in any plane (XY, YZ, XZ), circular interpolation is used (G02, G03). The velocity at which the tool is moving is controlled by the feed rate (F) command. All circular interpolation moves are defined and machined by programming three pieces of information into the control. 1. DIRECTION OF TRAVEL: CLOCKWISE G02, COUNTER CLOCKWISE G03 2. ARC END POINT: X AXIS, Z AXIS XZ PLANE 3. ARC CENTER: INCREMENTAL DISTANCE FROM START POINT TO ARC CENTER (I AND K) Page 50 TK-Lathe Lesson 6-2

207 LESSON-6 EXERCISE #1 CIRCULAR INTERPOLATION-OD WORK OUT ALL THE VALUES When programming lathe coordinates only the top half of the part needs to be profiled, because the part is turning around, the full round part is machined. Don t forget to program in diameters and double the radii to calculate diameter positions The front finished face is Z0. Note that when programming fillets and radii for turning, most of the time it is easier to do so incrementally (U and W). POSITION X U Z W I K TK-Lathe Lesson 6-3 Page 51

208 LESSON-6 EXERCISE #1 CIRCULAR INTERPOLATION-OD (CONT.) Contour the profile as shown on the previous page. Start from machine home and rapid to a safe zone. Face the front of the part, don t forget the overcut! Program the contour using the above coordinates as a guide. Material: Aluminum 6061 & Use appropriate Spindle Speed and Feedrate. % O63 N1 G20 N2 G18 G40 G80 G99 N3 G0 T0202 N4 G50 S3500 N5 G97 S M03 (PROGRAM NUMBER) (VERIFY INCH MODE) (SAFETY LINE WITH FEED AS INCH\REV.) (TOOL CALL) (SET MAX. SPEED AT 3500 RPM) (START SPINDLE RPM CLOCKWISE ROTATION) N6 G00 G54 G41 X Z T0202 M08 (TOOL NOSE RADIUS OFFSET, SAFE POSITION, COOLANT ON) N7 G96 S N8 G1 X-.05 F.008 N9 G0 Z.1 N10 G01 G42 X0.2 (CONSTANT SURFACE SPEED ENGAGED) (FEED TO X0 + OVERCUT) (PULL OFF FROM PART) (FEED TO X0.2 ACTIVATE TOOL NOSE RADIUS OFFSET) N11 G01 Z0 F (FEED INTO FRONT FACE TO Z0) N12 X N13 G03 X Z K N14 G01 Z N15 G02 X Z I N16 G03 X Z K N17 G01 Z N18 G02 X Z I N19 G03 X Z K N20 G01 Z N21 U0.1 N22 G00 G40 X Z T0202 M09 N23 G28 U0. N24 G28 W0. M05. N25 M30 % (FEED UP FRONT FACE TO START OF FIRST RADIUS) (CUT FIRST RADIUS) (FEED ALONG DIA.) (CUT FIRST FILLET) (CUT SECOND RADIUS) (FEED ALONG DIA.) (CUT SECOND FILLET) (CUT THIRD RADIUS) (FEED ALONG FINAL DIA. 0.2 PAST END OF PART) (PART PULL OFF INCREMENTAL) (RAPID TO SAFE ZONE) (RAPID TO Z MACHINE HOME POSITION) (RAPID TO X MACHINE HOME POSITION) (PROGRAM END) Page 52 TK-Lathe Lesson 6-4

209 LESSON-6 EXERCISE #2 CIRCULAR INTERPOLATION ON THE FOLLOWING PAGES, CREATE A PROGRAM TO: 1. FACE. 2. TURN OUTSIDE DIAMETER ONE CUT. 3. DRILL 0.5 DIAMETER. 4. ROUGH AND FINISH THE BORE USING CANNED CYCLES AS USED IN LESSON CUT-OFF. 6. Z ZERO IS THE FRONT FACE OF THE PART 7. USE THE LESSON 6 VIDEOS TO GUIDE YOU THROUGH THE PROGRAMMING PROCESS. TK-Lathe Lesson 6-5 Page 53

210 LESSON-6 EXERCISE #2 CIRCULAR INTERPOLATION - DRAWING Page 54 TK-Lathe Lesson 6-6

211 LESSON-6 EXERCISE #2 CIRCULAR INTERPOLATION USE THE CHART BELOW TO WORK OUT THE COORDINATES OF THE TOOL AS IT MOVES AROUND THE BORE. I = INCREMENTAL DISTANCE ALONG THE X-AXIS FROM THE TOOL START POINT TO THE CENTER OF ARC (ARC PIVOT POINT) K = INCREMENTAL DISTANCE ALONG THE Z-AXIS FROM THE TOOL START POINT TO THE CENTER OF ARC (ARC PIVOT POINT) POSITION X U Z W I K Please refer to Lesson 6 Exercise #2.NC program on following pages for co-ordinates. TK-Lathe Lesson 6-7 Page 55

212 LESSON-6 EXERCISE #2 CIRCULAR INTERPOLATION PROGRAMMING NOTE BEFORE MACHINING A BORE IN A SOLID PIECE OF STOCK A HOLE WILL HAVE TO BE DRILLED TO ALLOW THE BORING BAR TO DO IT S JOB. COORDINATES TO DRILL POSITION X U Z W Please refer to Lesson 6 Exercise #2.NC program on following pages for co-ordinates. Page 56 TK-Lathe Lesson 6-8

213 LESSON-6 EXERCISE #2 CIRCULAR INTERPOLATION % O193(Face and Drill and bore - Lesson-6-Ex-2) (Face Front of Part - Turn OD one cut) N1 G20 (Verify inch units) N3 G18 G40 G54 G80 G97 G99 (Safety block) N5 T0100 (Tool call T01) N7 G50 S3500 (Specify maximum RPM to 3500) N9 G97 S500 M03 (Start spindle 500 RPM CW) N11 G00 G41 G54 X1.7 Z0.25 T0101 M08 (Rapid to Safe position, TNC, coolant on) N13 G96 S700 (Specify constant surface speed 700 SFM) N15 G99 G01 Z0 F0.010 (Feed to Z0. G99=Feed per revolution) N17 X-0.05 (Move tool to X-0.05, overcut by 0.05) N19 U0.05 W0.05 (Incremental pull off from part face X0.05 Z0.05) N21 G00 G40 X1.25 Z0.25 N23 G01 G42 X1.095 Z0 F0.005 N25 G03 X1.115 Z R0.01 N27 G01 Z-0.8 N29 X1.15 N31 G40 G00 X 1.7 N33 G28 U0 (Rapid to X machine home position) N35 G28 W0 (Rapid to Z machine home position) (Drill 1/2" - G83 Canned Cycle Peck Drill) N37 T0707 (1/2 DIA. END MILL - Tool 07) N39 G97 S2500 M03 N41 G00 G54 X1.7 Z0.25 T0707 M08 (Rapid to Safe position,coolant on) N43 G00 X0 Z0.25 N45 G98 G83 Z-0.80 Q0.05 R0.1 F4.0 N47 G80 N49 G28 (Roughing and Finishing Cycles - Boring - Pre Drilled Hole 0.5") N51 T0800 (Tool call T08 - Rough Boring Tool 0.008" TIP RADIUS) N53 G50 S3500 (Specify maximum RPM to 3500) N55 G97 S500 M03 (Start spindle 500 RPM CW) N57 G00 X1.7 Z0.25 T0808 M08 (Rapid to Safe position,coolant on) N59 G96 S700 (Specify constant surface speed 700 SFM) N61 G99 N63 G00 X0.490 Z0.1 (Rough Bore) N65 G71 P67 Q91 U-0.01 W0.005 D0.03 F0.005 (G71 Rough Turning Cycle) N67 G00 G41 X1.075 Z0.1 (P and G41 With the start of Geometry) N69 G01 Z0 N71 G02 X0.875 Z-0.1 I0 K-0.1 N73 G01 Z N75 G03 X0.795 Z-0.25 I-0.04 K0 TK-Lathe Lesson 6-9 Page 57

214 LESSON-6 EXERCISE #2 CIRCULAR INTERPOLATION N77 G01 X0.760 N79 G02 X0.700 Z I0 K-0.03 N81 G01 Z N83 G03 X0.620 Z I-0.04 K0 N85 G01 X0.600 N87 G02 X0.540 Z I0 K-0.03 N89 G01 Z (Bore past end of part) N91 G40 X0.49 (Q End of Geometry) (Finish Cut Same Boring Tool) N93 G96 S800 (Specify constant surface speed 800 SFM) N95 G70 P67 Q91 F0.004 ( G70 Finishing OD) N97 G00 Z0.25 (Rapid to safe position in front of part) N99 G28 (Rapid to machine home position) (CUT OFF) N101 G00 T404 N103 G97 S191 M03 N105 G00 X1.7 Z0.25 M8 N107 G50 S3000 N109 G96 S200 N111 Z N113 X1.3 N115 G01 X0.450 F0.002 N117 G00 X1.250 N119 G28 (Rapid to machine home position) N121 M30 (Program end) % Page 58 TK-Lathe Lesson 6-10

215 TK-Lathe Lesson 6-11 Page 59

216 LESSON-6 EXERCISE #3 CIRCULAR INTERPOLATION ON THE FOLLOWING PAGES, CREATE A PROGRAM TO: 1. FACE. 2. ROUGH TURN OUTSIDE DIAMETER ONE CUT USING CANNED CYCLES. 3. FINISH TURN OUTSIDE DIAMETER ONE CUT USING CANNED CYCLES. 4. DRILL 0.5 DIAMETER. 5. ROUGH AND FINISH THE BORE USING CANNED CYCLES AS USED IN LESSON CUT-OFF. 7. Z ZERO IS THE FRONT FACE OF THE PART 8. USE THE LESSON 6 VIDEOS TO GUIDE YOU THROUGH THE PROGRAMMING PROCESS. Page 60 TK-Lathe Lesson 6-12

217 LESSON 6 EXERCISE #3 G02/G03 - DRAWING TK-Lathe Lesson 6-13 Page 61

218 LESSON-6 EXERCISE #3 CIRCULAR INTERPOLATION USE THE CHART BELOW TO WORK OUT THE COORDINATES OF THE TOOL AS IT MOVES AROUND THE BORE. I = INCREMENTAL DISTANCE ALONG THE X-AXIS FROM THE TOOL START POINT TO THE CENTER OF ARC (ARC PIVOT POINT) K = INCREMENTAL DISTANCE ALONG THE Z-AXIS FROM THE TOOL START POINT TO THE CENTER OF ARC (ARC PIVOT POINT) POSITION X U Z W I K Please refer to Lesson 6 Exercise #3.NC program on following pages for co-ordinates. Page 62 TK-Lathe Lesson 6-14

219 LESSON 6 EXERCISE #3 G02/G03 PROGRAMMING NOTE BEFORE MACHINING A BORE (ID) IN A SOLID PIECE OF STOCK A HOLE WILL HAVE TO BE DRILLED TO ALLOW THE BORING BAR TO DO IT S JOB. COORDINATES TO DRILL POSITION X U Z W Please refer to Lesson 6 Exercise #3.NC program on following pages for co-ordinates. TK-Lathe Lesson 6-15 Page 63

220 LESSON 6 EXERCISE #3 G02/G03 (CONT.) % O187 (Face, Rough & Finish OD - Drill and Bore - Lesson-6-Ex-3) (Face Front of Part one cut) N1 G20 (Verify inch units) N3 G18 G40 G54 G80 G97 G99 (Safety block) N5 T0100 (Tool call T01) N7 G50 S3500 (Specify maximum RPM to 3500) N9 G97 S500 M03 (Start spindle 500 RPM CW) N11 G00 G41 G54 X1.7 Z0.25 T0101 M08 (Rapid to Safe position, TNC, coolant on) N13 G96 S700 (Specify constant surface speed 700 SFM) N15 G99 G01 Z0 F0.010 (Feed to Z0. G99=Feed per revolution) N17 X-0.05 (Move tool to X-0.05, overcut by 0.05) N19 U0.05 W0.05 (Incremental pull off from part face X0.05 Z0.05) N21 G00 G40 X1.125 Z0.25 (Rough Turn O.D.) N23 G71 P25 Q43 U0.010 W0.005 D0.1 F0.010 N25 G01 G42 X1.030 (P and G42 With the start of Geometry) N27 Z0 N29 G03 X1.050 Z R0.01 N31 G01 Z N33 G02 X1.100 Z-0.5 R0.025 N35 G01 X1.105 N37 G03 X1.115 Z R0.005 N39 G01 Z-0.8 N41 X1.15 N43 G40 G00 X 1.7 (Q End of Geometry) N45 G00 X1.7 Z0.25 (Rapid back to safe position) N47 G28 U0 (Rapid to X machine home position) N49 G28 W0 M05 (Rapid to Z machine home position) (Finish Cut) N51 T0202 (O.D. Right Hand Finishing Tool 55 ) N53 G50 S3500 (Specify maximum RPM to 3500) N55 G97 S800 M03 (Start spindle 800 RPM CW) N57 G00 G42 G54 X1.7 Z0.25 T0202 M08 (Rapid to Safe position, TNC, coolant on) N59 G96 S700 (Specify constant surface speed 700 SFM) N61 G70 P25 Q43 F0.004 ( G70 Finishing OD) N63 G28 U0 (Rapid to X machine home position) N65 G28 W0 M05 (Rapid to Z machine home position) Page 64 TK-Lathe Lesson 6-16

221 LESSON 6 EXERCISE #3 G02/G03 (CONT.) (Drill 1/2" - G83 Canned Cycle Peck Drill) N69 T0707 (1/2 DIA. END MILL - Tool 07) N71 G97 S2500 M03 N73 G00 G54 X1.7 Z0.25 T0707 M08 (Rapid to Safe position,coolant on) N75 G00 X0 Z0.25 N77 G98 G83 Z-0.8 Q0.05 R0.1 F4.0 N79 G80 N81 G28 (Roughing and Finishing Cycles - Boring - Pre Drilled Hole 0.5") N83 T0800 (Tool call T08 - Rough Boring Tool 0.008" TIP RADIUS) N85 G50 S3500 (Specify maximum RPM to 3500) N87 G97 S500 M03 (Start spindle 500 RPM CW) N89 G00 X1.7 Z0.25 T0808 M08 (Rapid to Safe position,coolant on) N91 G96 S700 (Specify constant surface speed 700 SFM) N93 G99 N95 X0.490 Z0.1 (Rough Bore) N97 G71 P99 Q123 U-0.01 W0.005 D0.02 F0.003 (G71 Rough Turning Cycle) N99 G00 G41 X1.0 (P and G41 With the start of Geometry) N101 G01 Z0 N103 G02 X0.900 Z-0.05 I0 K-0.05 N105 G01 Z -0.2 N107 G03 X0.800 Z-0.25 I-0.05 K0 N109 G01 X0.750 N111 G02 X0.7 Z R0.025 N113 G01 Z N115 G03 X0.600 Z-0.50 I-0.05 K0 N117 G01 X0.590 N119 G02 X0.540 Z R0.025 N121 G01 Z (Bore past end of part) N123 G40 X0.49 (Q End of Geometry) (Finish Cut Same Boring Tool) N125 G96 S800 (Specify constant surface speed 800 SFM) N127 G70 P99 Q123 F0.002 (G70 Finishing ID) N129 G00 Z0.25 (Rapid to safe position in front of part) N131 G28 U0 (Rapid to X machine home position) N133 G28 W0 M05 (Rapid to Z machine home position) TK-Lathe Lesson 6-17 Page 65

222 LESSON 6 EXERCISE #3 G02/G03 (CONT.) (CUT OFF) N135 G00 T404 N137 G97 S191 M03 N139 G00 X1.7 Z0.25 M8 N141 G50 S3000 N143 G96 S200 N145 Z N147 X1.3 N149 G01 X0.450 F0.002 N151 G00 X1.250 N153 G28 U0 (Rapid to X machine home position) N155 G28 W0 M05 (Rapid to Z machine home position) N157 M30 (Program end) % Page 66 TK-Lathe Lesson 6-18

223 LESSON-6 EXERCISE #4 CIRCULAR INTERPOLATION ON THE FOLLOWING PAGES, CREATE A PROGRAM TO: 1. FACE. 2. ROUGH TURN OUTSIDE DIAMETER ONE CUT USING CANNED CYCLES. 3. FINISH TURN OUTSIDE DIAMETER ONE CUT USING CANNED CYCLES. 4. DRILL 0.5 DIAMETER. 5. ROUGH AND FINISH THE BORE USING CANNED CYCLES AS USED IN LESSON CUT-OFF. 7. Z ZERO IS THE FRONT FACE OF THE PART 8. USE THE LESSON 6 VIDEOS TO GUIDE YOU THROUGH THE PROGRAMMING PROCESS. TK-Lathe Lesson 6-19 Page 67

224 LESSON 6 EXERCISE #4 G02/G03 TURNING AND BORING - DRAWING Page 68 TK-Lathe Lesson 6-20

225 LESSON 6 EXERCISE #4 G02/G03 TURNING AND BORING PROGRAMMING NOTE BEFORE MACHINING A BORE (ID) IN A SOLID PIECE OF STOCK A HOLE WILL HAVE TO BE DRILLED TO ALLOW THE BORING BAR TO DO IT S JOB. COORDINATES TO DRILL POSITION X U Z W Please refer to Lesson 6 Exercise #4.NC program on following pages for co-ordinates. TK-Lathe Lesson 6-21 Page 69

226 LESSON 6 EXERCISE #4 G02/G03 TURNING AND BORING % O1345 (Face, Rough & Finish OD - Drill and Bore - Lesson-6-Ex-4) (Face Front of Part one cut) N1 G20 (Verify inch units) N3 G18 G40 G54 G80 G97 G99 (Safety block) N5 T0100 (Tool call T01) N7 G50 S3500 (Specify maximum RPM to 3500) N9 G97 S500 M03 (Start spindle 500 RPM CW) N11 G00 G41 G54 X1.7 Z0.25 T0101 M08 (Rapid to Safe position, TNC, coolant on) N13 G96 S700 (Specify constant surface speed 700 SFM) N15 G99 G01 Z0 F0.010 (Feed to Z0. G99=Feed per revolution) N17 X-0.05 (Move tool to X-0.05, overcut by 0.05) N19 U0.05 W0.05 (Incremental pull off from part face X0.05 Z0.05) N21 G00 G40 X1.125 Z0.25 (Rough Turn O.D.) N23 G71 P25 Q47 U0.03 W0.005 D0.1 F0.010 N25 G99 G01 G42 X0.965 (P and G42 With the start of Geometry) N27 Z0 N29 G03 X0.975 Z R0.005 N31 G01 Z N33 X1.025 Z-0.25 N35 Z N37 G02 X1.085 Z-0.5 R0.03 N39 G01 X1.105 N41 G03 X1.115 Z R0.005 N43 G01 Z-0.8 N45 X1.15 N47 G40 G00 X 1.7 (Q End of Geometry) N49 G00 X1.7 Z0.25 (Rapid back to safe position) N51 G28 U0 (Rapid to X machine home position) N53 G28 W0 M05 (Rapid to Z machine home position) (Finish Cut) N55 T0202 (O.D. Right Hand Finishing Tool 55 ) N57 G50 S3500 (Specify maximum RPM to 3500) N59 G97 S800 M03 (Start spindle 800 RPM CW) N61 G00 G42 G54 X1.7 Z0.25 T0202 M08 (Rapid to Safe position, TNC, coolant on) N63 G96 S700 (Specify constant surface speed 700 SFM) N65 G70 P25 Q47 F0.004 ( G70 Finishing OD) N67 G28 U0 (Rapid to X machine home position) N69 G28 W0 M05 (Rapid to Z machine home position) Page 70 TK-Lathe Lesson 6-22

227 LESSON 6 EXERCISE #4 G02/G03 (CONT) (Drill 1/2" - G83 Canned Cycle Peck Drill) N73 T0707 (1/2 DIA. END MILL - Tool 07) N75 G97 S2500 M03 N77 G00 G54 X1.7 Z0.25 T0707 M08 (Rapid to Safe position,coolant on) N79 G00 X0 Z0.25 N81 G98 G83 Z-0.8 Q0.05 R0.1 F4.0 N83 G80 N85 G28 (Roughing and Finishing Cycles - Boring - Pre Drilled Hole 0.5") N87 T0800 (Tool call T08 - Rough Boring Tool 0.008" TIP RADIUS) N89 G50 S3500 (Specify maximum RPM to 3500) N91 G97 S500 M03 (Start spindle 500 RPM CW) N92 G99 N93 G00 X1.7 Z0.25 T0808 M08 (Rapid to Safe position,coolant on) N95 G96 S700 (Specify constant surface speed 700 SFM) N97 X0.490 Z0.1 (Rough Bore) N99 G71 P101 Q125 U-0.01 W0.005 D0.02 F0.003 (G71 Rough Turning Cycle) N101 G00 G41 X0.935 Z0.1 (P and G41 With the start of Geometry) N103 G01 Z0 N105 G02 X0.875 Z-0.03 I0 K-0.03 N107 G01 Z N109 G03 X0.775 Z I-0.05 K0 N111 G01 X0.740 N113 G02 X0.700 Z I0 K N115 G01 Z N117 G03 X0.600 Z I-0.05 K0 N119 G01 X0.580 N121 G02 X0.540 Z R0.02 N123 G01 Z-0.80 (Bore past end of part) N125 G40 X0.49 (Q End of Geometry) (Finish Cut Same Boring Tool) N127 G96 S800 (Specify constant surface speed 800 SFM) N129 G70 P101 Q125 F0.002 ( G70 Finishing ID) N131 G00 Z0.25 (Rapid to safe position in front of part) N133 G28 U0 (Rapid to X machine home position) N135 G28 W0 M05 (Rapid to Z machine home position) TK-Lathe Lesson 6-23 Page 71

228 LESSON 6 EXERCISE #4 G02/G03 (CONT) (CUT OFF) N137 G00 T404 N139 G97 S191 M03 N141 G00 X1.7 Z0.25 M8 N143 G50 S3000 N145 G96 S200 N147 Z N149 X1.3 N151 G01 X0.450 F0.002 N153 G00 X1.250 N155 G28 U0 (Rapid to X machine home position) N157 G28 W0 M05 (Rapid to Z machine home position) N159 M30 (Program end) % Page 72 TK-Lathe Lesson 6-24

229 CNC PROGRAMMING WORKBOOK LESSON-7 TOOL NOSE COMPENSATION Page 73

230 G40, G41, & G42 TOOL NOSE COMPENSATION When a program is created it is done so using the insert s command or reference point (see figure below). Tool Nose Compensation is used to offset the tool by a distance that will bring the cutting edge of the insert to the proper position in relation to the specific radius of the insert being used. The radius of the tool must be input into the controller and it will calculate the proper offset known as Tool Nose Compensation. G40 TOOL COMPENSATION CANCEL G40 will cancel the G41 or G42 tool compensation commands that are in effect at the time. G41 TOOL COMPENSATION LEFT (BORING) G41 will select tool compensation to the LEFT of the contouring direction; generally G41 is used for boring. The tool is compensated for the radius of the tool tip. The value of the compensation (tool radius) must be entered in the controller registry during set-up. G42 TOOL COMPENSATION RIGHT (TURNING) G42 will select tool compensation to the RIGHT of the contouring direction; generally G42 is used for turning. The tool is compensated for the radius of the tool tip. The value of the compensation (tool radius) must be entered in the controller registry during set-up. Page 74 TK-Lesson 7-2

231 G40, G41, & G42 TOOL NOSE COMPENSATION Tool Nose Compensation is used to offset the tool by a distance that will bring the cutting edge of the insert to the proper position in relation to the specific radius of the insert being used. The radius of the tool must be input into the CNC controller and it will calculate the proper offset known as Tool Nose Radius Compensation. G40 is Tool Nose Radius Compensation CANCEL G41 is Tool Nose Radius Compensation LEFT of the programmed path G42 is Tool Nose Radius Compensation RIGHT of the programmed path The shift direction is based on the direction of the tool movement relative to the tool, and which side of the part it is on. When thinking about which direction the compensated shift will occur in tool nose compensation, imagine looking down the tool tip and steering the tool. Tool nose compensation works by shifting the Programmed Tool Path to the right or to the left. The programmer will usually program the tool path to the finished size. When tool nose compensation is used, the CNC control will compensate for the radius of the insert based on instructions written into the program. At the CNC machine Tool Nose Compensation accomplishes its job by reading ahead one or two blocks to determine how it must modify the current programmed block of code. This is done, so that the control can calculate in advance, how to position around radiuses and angles with a specified tool nose radius. This is referred to as Block Look-A-head Or Look-Ahead Processing. Tool nose compensation does not need to be used when the programmed cuts are solely along the X axis (diameters) or Z axis (faces). Cutter compensation comes into effect on angled cuts and radius cuts. TK-Lesson 7-3 Page 75

232 EXAMPLE PROGRAM USING G42 % EXAMPLE OF PROGRAMMING WITH TOOL NOSE RADIUS OFFSET O73 (PROGRAM NAME, FINISH TURNING EXERCISE) N1 G20 N3 G40 G54 G80 G97 G99 (Verify inch units) (Safety block) N5 T0200 (O.D. Right Hand Finishing Tool 55 ) N7 G50 S3500 (Specify maximum RPM to 3500) N9 G97 S800 M03 (Start spindle 800 RPM CW) N11 G00 G42 G54 X1.5 Z0.25 T0202 M08 (Rapid to Safe position, TNC, coolant on) N13 G96 S700 (Specify constant surface speed 700 SFM) N15 G99 G01 X Z0.05 F0.006 (Feed to Z0.05 from finish front face of part & 0.05 below chamfer) N17 X0.625 Z (Cut chamfer at front of part) N19 Z N21 X0.875 N23 Z-1.5 N25 X N27 X1.375 Z N29 Z-2.2 N31 X1.625 N33 G00 Z0.25 N35 G40 G00 X1.5 Z0.25 N37 G28 U0 N39 G28 W0 M05 N41 M30 % (Cut chamfer at left of part) (Rapid to safe position in front of part) (Cancel tool nose radius offset, rapid to original start position) (Rapid to X machine home position) (Rapid to Z machine home position) (Program end) Page 76 TK-Lesson 7-4

233 EXAMPLE PROGRAM USING G41 - BORING % EXAMPLE OF PROGRAMMING WITH TOOL NOSE RADIUS OFFSET - BORING O1345 (G41 - Finishing - Boring - Pre Drilled Hole 0.5") N1 G20 (Verify inch units) N3 G18 G40 G54 G80 G97 G99 (Safety block) N5 T0800 (Tool call T08 - Boring Tool 0.008" TIP RADIUS) N7 G50 S3500 (Specify maximum RPM to 3500) N9 G97 S500 M03 (Start spindle 500 RPM CW) N11 G99 N13 G00 X1.7 Z0.25 T0808 M08 (Rapid to Safe position, coolant on) N15 G96 S700 (Specify constant surface speed 700 SFM) N17 X0.490 Z0.1 N19 G00 G41 X0.935 Z0.1 N21 G01 Z0 N23 G02 X0.875 Z-0.03 I0 K-0.03 N25 G01 Z N27 G03 X0.775 Z I-0.05 K0 N29 G01 X0.740 N31 G02 X0.700 Z I0 K TK-Lesson 7-5 Page 77

234 EXAMPLE PROGRAM USING G41 - BORING - CONTINUED N33 G01 Z N35 G03 X0.600 Z I-0.05 K0 N37 G01 X0.580 N39 G02 X0.540 Z R0.02 N41 G01 Z-0.80 (Bore past end of part) N43 G40 X0.49 N45 G00 Z0.25 (Rapid to safe position in front of part) N47 G28 U0 (Rapid to X machine home position) N49 G28 W0 M05 (Rapid to Z machine home position) N51 M30 % (Program end) Page 78 TK-Lesson 7-6

235 CNC PROGRAMMING WORKBOOK LESSON-8 GROOVING/PART-OFF NOTE: Teacher s Solutions are in shaded cells throughout this book. Page 79

236 GROOVING GROOVING When a circular slot or groove is needed in a part a special shaped tool may be needed. A grooving tool is the tool that is most commonly used. It comes in many shapes and sizes but usually has one thing in common, which is that it feeds straight in along the X axis and plunges into the part. A grooving tool is typically used to plunge into the part and make a groove around the part, but some grooving inserts are designed to cut in the X and Z axis direction. EXAMPLE OF PROGRAMMING A GROOVING OPERATION O (TYPICAL GROOVING EXAMPLE) N1 G20... N90 T0900 M42 (TOOL CALL & GEAR SELECTION) N91 G97 S650 M03 N92 G00 X1.0 Z0.25 T0909 M08 N93 Z N94 G01 X0.675 F0.004 N95 G04 P0.5 N96 X1.0 F0.05 N97 G00 W N98 G01 X0.675 F0.004 N99 G04 P0.5 N100 X1.0 F0.05 N101 G00 X1.0 Z0.25 T0900 M09 N102 M01 (SET SPEED AND TURN CLOCKWISE) (RAPID TO SAFE POSITION & PICK-UP OFFSETS) (RAPID TO GROOVE POSITION) (FEED TO GROOVE DEPTH) (DWELL 0.5 SECOND) (FAST FEED OUT) (INCREMENTAL RAPID TO NEXT LOCATION) (FEED TO GROOVE DEPTH) (DWELL 0.5 SECOND) (FAST FEED OUT) (RAPID TO SAFE POSITION CANCEL OFFSETS) (OPTIONAL STOP) Page 80 TK-Lathe Lesson 8-2

237 PARTING-OFF PARTING-OFF Parting-off is very similar to grooving but instead of stopping at a required depth of groove, the part-off tool is able to go right to the center of the part to allow the finished part to fall away from the chuck of the lathe. The design of the tool may be similar but the intent is very different. EXAMPLE OF PROGRAMMING A PART-OFF OPERATION O (TYPICAL PART-OFF EXAMPLE) N1 G20... N90 T0900 M42 (TOOL CALL & GEAR SELECTION) N91 G99 G97 S500 M03 ( FEED PER REV., SET SPEED(RPM) AND TURN CLOCKWISE) N92 G00 X2.25 Z-2.0 T0909 M08 (RAPID TO SAFE POSITION & ACTIVATE OFFSET) N93 G96 S200 (SET C.S.S. 200 SF\M) N94 G01 X-0.05 F0.004 N95 X2.25 F0.05 N96 G00 Z0.25 T0900 M09 (FEED TO FINISH PART-OFF DEPTH) (FAST FEED OUT) (RAPID TO SAFE POSITION CANCEL OFFSETS) N97 G28 W0 (RAPID TO MACHINE HOME Z) N98 G28 U0 (RAPID TO MACHINE HOME X) N102 M01 (OPTIONAL STOP) TK-Lathe Lesson 8-3 Page 81

238 LESSON 8 GROOVING & PART OFF - EXAMPLE - DRAWING Page 82 TK-Lathe Lesson 8-4

239 LESSON 8 GROOVING & PART OFF - EXAMPLE - MACHINING PROCESS Machining Process 1. Face. 2. Turn outside diameter one cut. 3. Groove two slots 4. Dwell at bottom of each grooving cut. This ensures a clean cut at the bottom of the groove. 5. Cut-off. 6. Z zero is the front face of the part 7. The grooving\part-off tool is wide 8. Program right hand side of grooving\part-off tool 9. Machine to finish depth with every plunge 10. Material is ø1.125 aluminum TK-Lathe Lesson 8-5 Page 83

240 Face and Turn OD LESSON 8 GROOVING & PART OFF - EXAMPLE - PROGRAM % O186 (FACE FRONT OF PART - TURN OD ONE CUT) N1 G20 N3 G18 G40 G54 G80 G97 G99 (GROOVING & PART-OFF LESSON-8-EXAMPLE) (VERIFY INCH MODE) (SAFETY BLOCK) N5 T0100 (TOOL CALL T01) N7 G50 S3500 (SPECIFY MAXIMUM RPM TO 3500) N9 G97 S500 M03 (START SPINDLE 500 RPM CW) N11 G00 G41 G54 X1.5 Z0.25 T0101 M08 (RAPID TO SAFE POSITION, TNC, ACTIVATE OFFSET, COOLANT ON) N13 G96 S700 N15 G99 G01 Z0 F0.010 (SPECIFY CONSTANT SURFACE SPEED 700 SFM) (FEED TO Z0. G99=FEED PER REVOLUTION) N17 X-0.05 (MOVE TOOL TO X-0.05, OVERCUT BY 0.05) N19 U0.05 W0.05 N21 G00 G40 X1.25 Z0.25 N23 G01 G42 X1.100 Z0.1 F0.005 (INCREMENTAL PULL OFF FROM PART FACE X0.05 Z0.05) (RAPID TO SAFE POSITION, CANCEL TNC) (ACTIVATE TNC, FEED TO FINISH DIAMETER) N25 G01 Z (FEED TO LENGTH ) N27 X1.15 N29 G40 G00 X 1.5 N31 G28 U0 N33 G28 W0 ( PULL OFF FROM PART AT FEED RATE) (CANCEL TNC) (RAPID TO X MACHINE HOME POSITION) (RAPID TO Z MACHINE HOME POSITION) Page 84 TK-Lathe Lesson 8-6

241 Cut First Groove LESSON 8 GROOVING & PART OFF - EXAMPLE - PROGRAM (CUT FIRST GROOVE - FIRST CUT) (INSERT WIDTH = 0.118") (PROGRAM RIGHT HAND SIDE OF GROOVING\PART-OFF TOOL) N35 G00 T404 (TOOL CALL T04, ACTIVATE OFFSET) N37 G97 S191 M03 (START SPINDLE 191 RPM CW) N39 G00 X1.5 Z0.25 M8 (RAPID TO SAFE POSITION, COOLANT ON) N41 G50 S3000 (SPECIFY MAXIMUM RPM TO 3000) N43 G96 S200 (SPECIFY CONSTANT SURFACE SPEED 200 SFM) N45 Z (RAPID TO FIRST GROOVE POSITION) N47 X1.2 (RAPID TO X1.2 CLEAR OF PART BY 0.05 ) N49 G01 X0.750 F0.002 N51 G04 P2.0 (FEED TO GROOVE DEPTH) (DWELL 2.0 SECONDS) N53 X1.2 (FEED TO X1.2 CLEAR OF PART BY 0.05 ) (CUT FIRST GROOVE - SECOND CUT) N55 G00 Z (SECOND CUT INSERT WIDTH = 0.118") N57 G01 X0.750 N59 G04 P2.0 (FEED TO GROOVE DEPTH) (DWELL 2.0 SECONDS) N61 X1.2 (FEED TO X1.2 CLEAR OF PART BY 0.05 ) TK-Lathe Lesson 8-7 Page 85

242 Cut Second Groove LESSON 8 GROOVING & PART OFF - EXAMPLE - PROGRAM (CUT SECOND GROOVE - FIRST CUT) (INSERT WIDTH = 0.118") (PROGRAM RIGHT HAND SIDE OF GROOVING\PART-OFF TOOL) N63 G00 Z N65 G01 X0.875 N67 G04 P2.0 (RAPID TO SECOND GROOVE POSITION) (FEED TO GROOVE DEPTH) (DWELL 2.0 SECONDS) N69 X1.2 (FEED TO X1.2 CLEAR OF PART BY 0.05 ) (CUT SECOND GROOVE - SECOND CUT) N71 G00 Z (SECOND CUT INSERT WIDTH = 0.118") N73 G01 X0.875 N75 G04 P2.0 (FEED TO GROOVE DEPTH) (DWELL 2.0 SECONDS) N77 X1.2 (FEED TO X1.2 CLEAR OF PART BY 0.05 ) Page 86 TK-Lathe Lesson 8-8

243 LESSON 8 GROOVING & PART OFF - EXAMPLE - PROGRAM Cut-Off (CUT OFF) N79 G00 Z-1.25 (RAPID TO CUT-OFF POSITION) N81 G01 X-0.05 F0.002 N83 G00 X1.250 N85 G28 N87 M30 % (FEED TO FINISH PART-OFF DEPTH) (RAPID TO X1.25 CLEAR OF PART) (RAPID TO MACHINE HOME POSITION) (PROGRAM END) TK-Lathe Lesson 8-9 Page 87

244 HAAS G75 GROOVING CYCLE MULTIPLE PASS N49 G75 X0.750 Z I0.1 K0.03 F0.002 X X-axis absolute pecking depth, diameter value Z* Z-axis absolute location to the furthest peck U* X-axis incremental pecking depth, diameter value W* Z-axis incremental distance and direction (+or -) to the furthest peck I * X-axis pecking depth increment, radius value K* Z-axis shift increment between pecking cycles D* Tool shift amount when returning to clearance plane (Caution see NOTE) F Feed rate * Indicates optional The G75 canned cycle can be used for grooving an outside diameter with the added bonus of a chip break. A small retract move while cutting the groove allows the chip to break. The G75 cycle is non-modal. With G75 either a single pecking cycle can be performed, as for a single groove, or a series of pecking moves can be performed for multiple grooves. G75 can also be used to cut-off the part by using the single pass options. When a Z or W code is added to a G75 block and Z is not the current position, then a minimum of two pecking cycles will occur, one at the current location and another at the Z location. The K code is the incremental distance between Z axis pecking cycles. Adding a K will perform multiple evenly spaced, pecking cycles between the starting position and Z. When I is added to a G75 block, then pecking will be performed at each interval specified by I, the peck is a rapid move opposite the direction of feed and the peck distance is obtained from Setting 22 on the Haas control. Page 88 TK-Lathe Lesson 8-10

245 HAAS G75 GROOVING CYCLE SINGLE PASS - FOR CUT-OFF N61 G75 X I0.1 F0.002 At block 61 the grooving canned cycle G75 is being used to cut-off the part at the end of the machining operations. The X is the destination that the tool will arrive at along the X axis. This move is at a feed rate of per revolution. In this block the I value is set to 0.1, this is the X-axis pecking depth increment, a radius value. As the tool moves to the X position it will cut for 0.1 and then retract to break the chip. This retract move is a small amount and on the Hass lathe is governed by Setting 22. The Hass lathe used in the machining videos has Setting 22 set to 0.01 When the G75 cycle is complete it will return to the starting X position at rapid. TK-Lathe Lesson 8-11 Page 89

246 G75 GROOVING CYCLE LESSON 8 GROOVING & PART OFF - EXAMPLE - DRAWING Page 90 TK-Lathe Lesson 8-12

247 G75 GROOVING CYCLE LESSON 8 GROOVING & PART OFF - EXAMPLE - MACHINING PROCESS Machining Process 1. Face. 2. Turn outside diameter one cut. 3. Groove two slots using G75 Grooving Cycle 4. Cut-off using G75 Grooving Cycle. 5. Z zero is the front face of the part 6. The grooving\part-off tool is wide 7. Program right hand side of grooving\part-off tool 8. Machine to finish depth with every plunge 9. Material is ø1.125 aluminum TK-Lathe Lesson 8-13 Page 91

248 Face and Turn OD G75 GROOVING CYCLE LESSON 8 GROOVING & PART OFF - EXAMPLE - PROGRAM % O186 (FACE FRONT OF PART - TURN OD ONE CUT) N1 G20 N3 G18 G40 G54 G80 G97 G99 (GROOVING & PART-OFF LESSON-8-EXAMPLE) (VERIFY INCH MODE) (SAFETY BLOCK) N5 T0100 (TOOL CALL T01) N7 G50 S3500 (SPECIFY MAXIMUM RPM TO 3500) N9 G97 S500 M03 (START SPINDLE 500 RPM CW) N11 G00 G41 G54 X1.5 Z0.25 T0101 M08 (RAPID TO SAFE POSITION, TNC, ACTIVATE OFFSET, COOLANT ON) N13 G96 S700 N15 G99 G01 Z0 F0.010 (SPECIFY CONSTANT SURFACE SPEED 700 SFM) (FEED TO Z0. G99=FEED PER REVOLUTION) N17 X-0.05 (MOVE TOOL TO X-0.05, OVERCUT BY 0.05) N19 U0.05 W0.05 N21 G00 G40 X1.25 Z0.25 N23 G01 G42 X1.100 Z0.1 F0.005 (INCREMENTAL PULL OFF FROM PART FACE X0.05 Z0.05) (RAPID TO SAFE POSITION, CANCEL TNC) (ACTIVATE TNC, FEED TO FINISH DIAMETER) N25 G01 Z (FEED TO LENGTH ) N27 X1.15 N29 G40 G00 X 1.5 N31 G28 U0 N33 G28 W0 ( PULL OFF FROM PART AT FEED RATE) (CANCEL TNC) (RAPID TO X MACHINE HOME POSITION) (RAPID TO Z MACHINE HOME POSITION) Page 92 TK-Lathe Lesson 8-14

249 G75 GROOVING CYCLE LESSON 8 GROOVING & PART OFF - EXAMPLE - PROGRAM Cut First and Second Groove (CUT FIRST GROOVE - G75 - GROOVING CYCLE) (INSERT WIDTH = 0.118") (PROGRAM RIGHT HAND SIDE OF GROOVING\PART-OFF TOOL) N35 G00 T404 (TOOL CALL T04, ACTIVATE OFFSET) N37 G97 S191 M03 (START SPINDLE 191 RPM CW) N39 G00 X1.5 Z0.25 M8 (RAPID TO SAFE POSITION, COOLANT ON) N41 G50 S3000 (SPECIFY MAXIMUM RPM TO 3000) N43 G96 S200 N45 Z N47 X1.15 (SPECIFY CONSTANT SURFACE SPEED 200 SFM) (RAPID TO FIRST GROOVE POSITION) (RAPID TO X1.15 CLEAR OF PART) N49 G75 X0.750 Z I0.1 K0.03 F0.002 (G75 - GROOVING CYCLE) N51 X1.15 (CUT SECOND GROOVE - G75 - GROOVING CYCLE) N53 G00 Z (RAPID TO X1.15 CLEAR OF PART) (RAPID TO SECOND GROOVE POSITION) N55 G75 X0.875 Z I0.1 K0.03 F0.002 (G75 - GROOVING CYCLE) N57 X1.15 (RAPID TO X1.15 CLEAR OF PART) TK-Lathe Lesson 8-15 Page 93

250 G75 GROOVING CYCLE LESSON 8 GROOVING & PART OFF - EXAMPLE - PROGRAM Cut-Off (CUT OFF - SINGLE PASS GROOVING CYCLE) N59 G00 Z-1.25 (RAPID TO CUT-OFF POSITION) N61 G75 X I0.1 F0.002 N63 G00 X1.250 N65 G28 N67 M30 % (CUT OFF - G75 - SINGLE PASS GROOVING CYCLE) (RAPID TO X1.25 CLEAR OF PART) (RAPID TO MACHINE HOME POSITION) (PROGRAM END) Page 94 TK-Lathe Lesson 8-16

251 LESSON 8 GROOVING & PART OFF EXERCISE #1 TK-Lathe Lesson 8-17 Page 95

252 LESSON 8 GROOVING & PART OFF EXERCISE #1 Create a program for Exercise #1 to: 1. Face. 2. Finish turn outside diameter one cut. 3. Groove three places. 4. Cut-off. 5. Z zero is the front face of the part 6. Use the Lesson 8 videos to guide you through the programming process. Page 96 TK-Lathe Lesson 8-18

253 LESSON 8 GROOVING & PART OFF EXERCISE #1 % O186(Lesson-8-EXERCISE-1 - Grooving & Part-Off ) (Face Front of Part - Turn OD one cut) N1 G20 (Verify inch units) N3 G18 G40 G54 G80 G97 G99 (Safety block) N5 T0100 (Tool call T01) N7 G50 S3500 (Specify maximum RPM to 3500) N9 G97 S500 M03 (Start spindle 500 RPM CW) N11 G00 G41 G54 X1.5 Z0.25 T0101 M08 (Rapid to Safe position, TNC, coolant on) N13 G96 S700 (Specify constant surface speed 700 SFM) N15 G99 G01 Z0 F0.010 (Feed to Z0. G99=Feed per revolution) N17 X-0.05 (Move tool to X-0.05, overcut by 0.05) N19 U0.05 W0.05 (Incremental pull off from part face X0.05 Z0.05) N21 G00 G40 X1.25 Z0.25 N23 G01 G42 X1.100 Z0.1 F0.005 N25 G01 Z N27 X1.15 N29 G40 G00 X 1.5 N31 G28 U0 (Rapid to X machine home position) N33 G28 W0 (Rapid to Z machine home position) (CUT FIRST GROOVE - FIRST CUT) (INSERT WIDTH = 0.118") (PROGRAM RIGHT HAND SIDE OF GROOVING\PART-OFF TOOL) N35 G00 T404 N37 G97 S191 M03 N39 G00 X1.5 Z0.25 M8 N41 G50 S3000 N43 G96 S200 N45 Z N47 X1.2 N49 G01 X0.800 F0.002 N51 G04 P2.0 N53 X1.2 (CUT FIRST GROOVE - SECOND CUT) N55 G00 Z ( INSERT WIDTH = 0.118") N57 G01 X0.800 N59 G04 P2.0 N61 X1.2 TK-Lathe Lesson 8-19 Page 97

254 LESSON 8 GROOVING & PART OFF EXERCISE #1 (CUT SECOND GROOVE - FIRST CUT) N63 G00 Z-0.5 N65 G01 X0.850 N67 G04 P2.0 N69 X1.2 (CUT SECOND GROOVE - SECOND CUT) N71 G00 Z ( INSERT WIDTH = 0.118") N73 G01 X0.850 N75 G04 P2.0 N77 X1.2 (CUT THIRD GROOVE - FIRST CUT) N79 G00 Z N81 G01 X0.730 N83 G04 P2.0 N85 X1.2 (CUT THIRD GROOVE - SECOND CUT) N87 G00 Z ( INSERT WIDTH = 0.118") N89 G01 X0.730 N91 G04 P2.0 N93 X1.2 (CUT OFF) N95 G00 Z-1.25 N97 G01 X-0.05 F0.002 N99 G00 X1.250 N101 G28 (Rapid to machine home position) N103 M30 (Program end) % Page 98 TK-Lathe Lesson 8-20

255 LESSON 8 GROOVING & PART OFF EXERCISE #1 TK-Lathe Lesson 8-21 Page 99

256 LESSON 8 GROOVING & PART OFF EXERCISE #1 Page 100 TK-Lathe Lesson 8-22

257 CNC PROGRAMMING WORKBOOK LESSON-9 THREADING NOTE: Teacher s Solutions are in shaded cells throughout this book. Page 101

258 HAAS - G76 O.D./I.D. THREAD CUTTING CYCLE, MULTIPLE PASS N93 G76 X Z-0.8 K D F G76 O.D./I.D. THREAD CUTTING CYCLE, MULTIPLE PASS X* X-axis absolute thread finish point, a diameter value Z* Z-axis absolute distance, thread end point location U* X-axis incremental total distance to finish point, diameter W* Z-axis incremental thread length finish point K Thread height, radius value I * Thread taper amount, radius value D First pass cutting depth P Thread Cutting Method P1-P4 A* Tool nose angle, no decimal with A command (0 to 120 degrees, If not used then 0 degrees is assumed) F Feed rate (Threading feed rate, is the thread distance per revolution) * Indicates optional The G76 canned cycle can be used for threading both straight and tapered threads. G76 can be used to create multiple cutting passes along the length of a thread. The height of the thread is specified in K, this height is defined as the distance from the crest of the thread to the root. The calculated depth of the thread will be K less the finish allowance. On the Hass lathe Setting 86 (THREAD FINISH ALLOWANCE) is this stock allowance for a finish pass allowance, if required. The depth of the first cut of the thread is specified in D. This also determines the number of passes over the thread based on the value of K and the cutting method used. The depth of the last cut on the thread can be controlled with Setting 99 on the Hass lathe (THREAD MINIMUM CUT). The last cut will never be less than this value. The default value is.001 inches/.01 mm. The feed rate is the Lead of thread. The F feed rate in a G76 threading cycle is 1.0 divided by the number of threads per inch = F. (1.0 divided by 11 TPI = F ) Page 102 TK-Lathe Lesson 9-2

259 HAAS G92 THREAD CUTTING CYCLE N95 G92 X.5135 Z-0.8 F G92 THREAD CUTTING CYCLE X* Absolute X-axis target location Z* Absolute Z-axis target location U* Incremental X-axis target distance, diameter W* Incremental Z-axis target distance I * Distance and direction of X axis taper, a radius value F Feed rate (Threading feed rate, is the thread distance per revolution) * Indicates optional The G92 is a modal canned cycle. It can be used for simple threading. Since it is modal, you can do multiple passes for threading by just specifying a new X location for successive passes. For example: N16 G92 X.523 Z-0.8 F M24 N17 X.520 (Additional Pass) N18 X.515 (Additional Pass) N19 X.5135 (Additional Pass) (First Pass of a G92 O.D. Thread Cycle) Straight threads can be made by just specifying X, Z and F. By adding I a pipe or taper thread can be cut. TK-Lathe Lesson 9-3 Page 103

260 HAAS M24 - THREAD CHAMFER OFF N91 X0.650 M24 At the end of the thread an optional chamfer can be performed. The size and angle of the chamfer is controlled with Setting 95 (THREAD CHAMFER SIZE) and Setting 96 (THREAD CHAMFER ANGLE). The chamfer size is designated in number of threads, so that if is recorded in Setting 95 and the feed rate is.05, then the chamfer will be.05. If relief is provided for at the end of the thread, then the chamfer can be eliminated by specifying for the chamfer size in Setting 95. The default value for Setting 95 is and the default angle for the thread (Setting 96) is 45 degrees. A chamfer can improve the appearance and functionality of threads that must be machined up to a shoulder. As the Lesson-9 Example part has a wide undercut M24 will be programed as no chamfer is required. M23 commands chamfer on. M24 commands chamfer off. M23 is the default value. Page 104 TK-Lathe Lesson 9-4

261 THREADING THREADING The portion of the example CNC program below cuts the UNC thread on the Lesson-9 Example part, the drawing is shown below. At block N93 the G76 threading cycle is used to cut the thread in multiple passes. The G92 threading cycle is used at block N95 and N97 to perform spring passes. These spring passes are sometimes referred to as ghost passes. The threading tool is not moved any deeper but cuts along the path previously cut to clean up and get a good finish on the threads. (THREAD UNC) N85 T0505 N87 G97 S800 M03 EXAMPLE OF THREADING OPERATION (O.D. THREADING TOOL) (START SPINDLE 800 RPM CW) N89 G00 G54 X1.25 Z0.25 T0505 M08 (RAPID TO SAFE POSITION & PICK-UP OFFSETS) N91 X0.650 M24 (CHAMFER AT END OF THREAD IS OFF) N93 G76 X Z-0.8 K D F ( G76 OD THREADING CYCLE MULTIPLE PASSES) N95 G92 X.5135 Z-0.8 F N97 G92 X.5135 Z-0.8 F N99 G28 U0 N101 G28 W0 M05 (SPRING CUT) (SPRING CUT) TK-Lathe Lesson 9-5 Page 105

262 THREADING - G76 THREADING CYCLE THREADING - G76 THREADING CYCLE N93 G76 X Z-0.8 K D F At block N93 the G76 threading cycle is used to cut the thread in multiple passes. X is the root diameter of the UNC thread. The root diameter was identified in the Machinery s Handbook. Z-0.8 is the absolute Z-axis target location. This is past the end of the thread. K is the thread height, a radius value. This is / 2 = D is the first pass cutting depth. This determines how many cuts will be taken to reach the final depth. F is the feed rate. The threading feed rate is the thread distance per revolution. The calculation for this thread having 11 threads per inch is 1 divided by 11 which is equals to Page 106 TK-Lathe Lesson 9-6

263 THREADING G92 THREADING CYCLE THREADING G92 THREADING CYCLE N95 G92 X.5135 Z-0.8 F N97 G92 X.5135 Z-0.8 F At block N95 and N97 the G92 threading cycle is used after the G76 cycle to cut the thread in two single passes both at the same depth. G92 is being used in the Example program to perform two spring passes The G92 is a modal canned cycle. It can be used for simple threading. Once the first G92 block is input with all the relevant values, additional threading cuts can be made by just the input of the desired X value. X is the root diameter of the UNC thread. The root diameter was identified in the Machinery s Handbook. Z-0.8 is the absolute Z-axis target location. This is past the end of the thread. F is the feed rate. The threading feed rate is the thread distance per revolution. The calculation for this thread having 11 threads per inch is 1 divided by 11 which is equals to TK-Lathe Lesson 9-7 Page 107

264 LESSON 9 - THREADING - EXAMPLE - DRAWING Page 108 TK-Lathe Lesson 9-8

265 LESSON 9 - THREADING - EXAMPLE - MACHINING PROCESS Machining Process 1. Face. 2. Rough Turn OD 3. Finish Turn OD 4. Groove undercut for thread wide 5. Thread UNC. 6. Cut-off. 7. Z zero is the front face of the part 8. The grooving\part-off tool is wide 9. Program right hand side of grooving\part-off tool 10. Material is ø1.125 aluminum TK-Lathe Lesson 9-9 Page 109

266 LESSON 9 - THREADING - EXAMPLE - PROGRAM Face % O1294 (FACE FRONT OF PART) N1 G20 N3 G18 G40 G54 G80 G97 G99 (Lesson-9-Example) (Verify inch mode) (Safety Block) N5 T0100 (Tool call T01) N7 G50 S3500 (Specify maximum rpm to 3500) N9 G97 S500 M03 (Start spindle 500 RPM CW) N11 G00 G41 G54 X1.5 Z0.25 T0101 M08 (Rapid to safe position, TNC, activate offset) N13 G96 S700 N15 G99 G01 Z0 F0.010 (Specify constant surface speed 700 sfm) (Feed to Z0. G99=feed per revolution) N17 X-0.05 (Move tool to X-0.05, overcut by 0.05) N19 U0.05 W0.05 N21 G00 G40 X1.25 Z0.25 (Incremental pull off from part face X0.05 Z0.05) (Rapid to safe position, cancel TNC) Page 110 TK-Lathe Lesson 9-10

267 LESSON 9 - THREADING - EXAMPLE - PROGRAM Rough Turn OD (ROUGH TURN O.D.) N23 G71 P25 Q41 U0.03 W0.005 D0.1 F0.010 N25 G00 G42 X0.398 N27 G99 G01 X Z0.05 F0.006 N29 X0.623 Z N31 Z N33 X0.925 N35 X1.050 Z (G71 Rough Turning Cycle) (P and G42 with the start of geometry) (Feed to Z0.05 from finish front face, 0.05 below chamfer) (Turned undersize - cut chamfer at front of part) (Cut second chamfer) N37 Z-1.5 (Cut past end of part) N39 X1.25 (Pull away from part) N41 G40 G00 X 1.5 (Q end of geometry, machine off of part and cancel compensation) N43 G00 X1.25 Z0.25 (Rapid back to safe position) N45 G28 U0 N47 G28 W0 M05 (Rapid to x machine home position) (Rapid to z machine home position) TK-Lathe Lesson 9-11 Page 111

268 LESSON 9 - THREADING - EXAMPLE - PROGRAM Finish Turn OD (FINISH CUT) N49 T0202 (O.D. right hand finishing tool 55 ) N51 G50 S3500 (Specify maximum RPM to 3500) N53 G97 S800 M03 (Start spindle 800 RPM CW) N55 G00 G42 G54 X1.25 Z0.25 T0202 M08 (Rapid to safe position, TNC, coolant on) N57 G96 S700 N59 G70 P25 Q41 (Specify constant surface speed 700 SFM) (G70 finishing OD) N61 G28 U0 (Rapid to X machine home position) N63 G28 W0 M05 (Rapid to Z machine home position) Page 112 TK-Lathe Lesson 9-12

269 LESSON 9 - THREADING - EXAMPLE - PROGRAM Cut Groove (CUT.125 WIDE GROOVE ) (CUT GROOVE - G75 - GROOVING CYCLE) (INSERT WIDTH = 0.118") (PROGRAM RIGHT HAND SIDE OF GROOVING\PART-OFF TOOL) N65 G00 T404 N67 G97 S191 M03 N69 G00 X1.25 Z0.25 M8 (Tool call T04, activate offset) (Start spindle 191 RPM CW) (Rapid to safe position, coolant on) N71 G50 S3000 (Specify maximum rpm to 3000) N73 G96 S200 (Specify constant surface speed 200 SFM) N75 Z (Rapid to groove position) N77 X1.15 (Rapid to X1.15 clear of part) N79 G75 X0.50 Z I0.5 F0.002 (G75 Grooving Cycle) N81 X1.15 N83 G28 (Rapid to machine home position) TK-Lathe Lesson 9-13 Page 113

270 LESSON 9 - THREADING - EXAMPLE - PROGRAM Thread (THREAD UNC) N85 T0505 (Tool call T05, activate offset, O.D. threading tool) N87 G97 S800 M03 (Start spindle 800 rpm CW) N89 G00 G54 X1.25 Z0.25 T0505 M08 N91 X0.650 M24 (Rapid to safe position, TNC, coolant on) (Chamfer at end of thread is off) N93 G76 X Z-0.8 K D F ( G76 OD threading cycle) N95 G92 X.5135 Z-0.8 F (Spring cut) N97 G92 X.5135 Z-0.8 F (Spring cut) N99 G28 U0 (Rapid to X machine home position) N101 G28 W0 M05 (Rapid to Z machine home position) Page 114 TK-Lathe Lesson 9-14

271 LESSON 9 - THREADING - EXAMPLE - PROGRAM Cut-Off (CUT OFF) N103 G00 T404 N105 G97 S191 M03 N107 G00 X1.25 Z0.25 M8 N109 G50 S3000 N111 G96 S200 N113 Z N115 X1.15 N117 G75 X0.3 I0.1 F0.002 (Tool call T04, activate offset) (Rapid to cut-off position for rough cut) (Grooving Cycle Rough cut to 0.3 diameter) N119 Z (Position for chamfer on end of part) N121 G01 X1.05 N123 U W (Cut chamfer on end of part remove sharp edge) N125 X1.15 N127 Z-1.5 N129 G75 X-0.03 I0.1 F0.002 N131 G00 X1.250 N133 G28 N135 M30 % (Retract from groove) (Position for cut-off) (Grooving Cycle - Cut-Off to length) (Rapid to machine home position) (Program end) TK-Lathe Lesson 9-15 Page 115

272 LESSON 9 - THREADING EXERCISE Page 116 TK-Lathe Lesson 9-16

273 LESSON 9 - THREADING EXERCISE Create a program for the Lesson-9 Exercise to: 1. Face. 2. Rough Turn OD 3. Finish Turn OD 4. Groove undercut for thread wide 5. Thread UNC. 6. Cut-off. 7. Z zero is the front face of the part 8. The grooving\part-off tool is wide 9. Program right hand side of grooving\part-off tool 10. Material is ø1.125 aluminum TK-Lathe Lesson 9-17 Page 117

274 LESSON 9 - THREADING EXERCISE % O1294(Lesson-9-Example) (Face Front of Part) N1 G20 (Verify inch units) N3 G18 G40 G54 G80 G97 G99 (Safety block) N5 T0100 (Tool call T01) N7 G50 S3500 (Specify maximum RPM to 3500) N9 G97 S500 M03 (Start spindle 500 RPM CW) N11 G00 G41 G54 X1.7 Z0.25 T0101 M08 (Rapid to Safe position, TNC, coolant on) N13 G96 S700 (Specify constant surface speed 700 SFM) N15 G99 G01 Z0 F0.010 (Feed to Z0. G99=Feed per revolution) N17 X-0.05 (Move tool to X-0.05, overcut by 0.05) N19 U0.05 W0.05 (Incremental pull off from part face X0.05 Z0.05) N21 G00 G40 X1.25 Z0.25 (Rough Turn O.D.) N23 G71 P25 Q41 U0.03 W0.005 D0.1 F0.010 N25 G00 G42 X0.398 (P and G42 With the start of Geometry) N27 G99 G01 X Z0.05 F0.006 (Feed to Z0.05 from finish front face of part & 0.05 below chamfer) N29 X0.623 Z (TURNED UNDERSIZE - Cut chamfer at front of part) N31 Z N33 X0.925 N35 X1.050 Z (Cut second chamfer) N37 Z-1.5 N39 X1.25 N41 G40 G00 X 1.5 (Q End of Geometry) N43 G00 X1.25 Z0.25 (Rapid back to safe position) N45 G28 U0 (Rapid to X machine home position) N47 G28 W0 M05 (Rapid to Z machine home position) (Finish Cut) N49 T0202 (O.D. Right Hand Finishing Tool 55 ) N51 G50 S3500 (Specify maximum RPM to 3500) N53 G97 S800 M03 (Start spindle 800 RPM CW) N55 G00 G42 G54 X1.25 Z0.25 T0202 M08 (Rapid to Safe position, TNC, coolant on) N57 G96 S700 (Specify constant surface speed 700 SFM) N59 G70 P25 Q41 ( G70 Finishing OD) N61 G28 U0 (Rapid to X machine home position) N63 G28 W0 M05 (Rapid to Z machine home position) Page 118 TK-Lathe Lesson 9-18

275 LESSON 9 - THREADING EXERCISE (CUT.125 WIDE GROOVE ) (CUT GROOVE - G75 - GROOVING CYCLE) (INSERT WIDTH = 0.118") (PROGRAM RIGHT HAND SIDE OF GROOVING\PART-OFF TOOL) N65 G00 T404 N67 G97 S191 M03 N69 G00 X1.25 Z0.25 M8 N71 G50 S3000 N73 G96 S200 N75 Z N77 X1.15 N79 G75 X0.50 Z I0.5 F0.002 N81 X1.15 N83 G28 (Rapid to machine home position) (THREAD UNC) N85 T0505 (O.D. THREADING TOOL) N87 G97 S800 M03 (Start spindle 800 RPM CW) N89 G00 G54 X1.25 Z0.25 T0505 M08 (Rapid to Safe position, TNC, coolant on) N91 X0.650 M24 (CHAMFER AT END OF THREAD IS OFF) N93 G76 X Z-0.8 K D F ( G76 OD THREADING CYCLE) N95 G92 X.5135 Z-0.8 F (SPRING CUT) N97 G92 X.5135 Z-0.8 F (SPRING CUT) N99 G28 U0 (Rapid to X machine home position) N101 G28 W0 M05 (Rapid to Z machine home position) (CUT OFF) N103 G00 T404 N105 G97 S191 M03 N107 G00 X1.25 Z0.25 M8 N109 G50 S3000 N111 G96 S200 N113 Z N115 X1.15 N117 G75 X0.3 I0.1 F0.002 N119 Z N121 G01 X1.05 N123 U W N125 X1.15 N127 Z-1.5 N129 G75 X-0.03 I0.1 F0.002 N131 G00 X1.250 N133 G28 (Rapid to machine home position) N135 M30 (Program end) % TK-Lathe Lesson 9-19 Page 119

276 LESSON 9 - THREADING EXERCISE Page 120 TK-Lathe Lesson 9-20

277 CNC PROGRAMMING WORKBOOK LATHE APPENDIX Page 121

278 Appendix Extra CNC Programming Exercises Page 122 Lathe Appendix - 2

279 Appendix Extra CNC Programming Exercises Lathe Appendix - 3 Page 123

284 Appendix Extra CNC Programming Exercises Material: Aluminum 6061 CS= ft/min XZ PLANE 1. Tool #1 (OD Roughing Tool) Create A Toolpath To Rough The Above Profile Feed = Spindle Speed RPM = 4xCS/D= in/min Depth of Cut =0.1/side Use a G71 Canned Cycle 2. Tool #2 (OD Finishing Tool) Finish The OD Using The Profile Created In The First Operation Feed = Spindle Speed RPM = 4xCS/D= in/min Depth of Cut =0.02/side Use a G70 Canned Cycle 3. Tool #9 (0.125 Right Hand Groove Tool) Machine Both Grooves By Plunging In The Middle Of The Groove, Then Retract And Move Over To The Left And Right To Finish Feed = Spindle Speed RPM = 4xCS/D= in/min Start in the middle of grooves Page 128 Lathe Appendix - 8

285 % O00014; CNC PROGRAMMING EXERCISE (CONTINUED) Lathe Appendix - 9 Page 129

286 CNC PROGRAMMING EXERCISE (CONTINUED) Page 130 Lathe Appendix - 10

287 Appendix Preparatory Functions G-Codes G00 RAPID POSITIONING MOTION G01 LINEAR INTERPOLATION MOTION G02 CIRCULAR INTERPOLATION MOTION - CLOCKWISE G03 CIRCULAR INTERPOLATION MOTION - COUNTECLOCKWISE G04 DWELL G09 EXACT STOP G10 PROGRAMMABLE OFFSET SETTING G12 CW CIRCULAR POCKET MILLING G13 CCW CIRCULAR POCKET MILLING G17 CIRCULAR MOTION XY PLANE SELECTION (G02 or G03) G18 CIRCULAR MOTION ZX PLANE SELECTION (G02 or G03) G19 CIRCULAR MOTION YZ PLANE SELECTION (G02 or G03) G20 VERIFY INCH COORDINATE POSITIONING G21 VERIFY METRIC COORDINATE POSITIONING G28 MACHINE ZERIO RETURN THRU REF. POINT G29 MOVE TO LOCATION THROUGH G28 REF. POINT G31 FEED UNTIL SKIP FUNCTION G35 AUTOMATIC TOOL DIAMETER MEASUREMENT G36 AUTOMATIC WORK OFFSET MEASUREMENT G37 AUTOMATIC TOOL LENGTH MEASUREMENT G40 CUTTER COMPENSATION CANCEL G41/G42/G141 G41 2D CUTTER COMPENSATION, LEFT (X, Y, D) G42 2D CUTTER COMPENSATION, RIGHT (X, Y, D) G43 TOOL LENGTH COMPESATION POSITIVE (H, Z) G44 TOOL LENGTH COMPENATION NEGATIVE (H, Z) Lathe Appendix - 11 Page 131

288 Appendix Preparatory Functions G-Codes G47 TEXT ENGRAVING (X, Y, Z, R, I, J, P, E, F) G49 TOOL LENGTH COMPENSATION CANCEL G43/G44/G143) G50 SCALING G51 CANCEL G51 SCALING (X, Y, Z, P) G52 WORK OFFSET COORDINATE POSITING G52 GLOBAL WORK COORDINATE OFFSET SHIFT G52 GLOBAL WORK COORDINATE OFFSET SHIFT G53 MACHINE COORDAINTE POSITIONING, NON-MODAL (X, Y, Z, A, B) G54 WORK OFSET COORDIANTE POSITIONING #1 G55 WORK OFSET COORDIANTE POSITIONING #2 G56 WORK OFSET COORDIANTE POSITIONING #3 G57 WORK OFSET COORDIANTE POSITIONING #4 G58 WORK OFSET COORDIANTE POSITIONING #5 G59 WORK OFSET COORDIANTE POSITIONING #6 G60 UNI-DIRECTIONAL POSITIONING (X, Y, Z, A, B) G61 EXACT STOP, MODAL (X, Y, Z, A, B) G64 EXACT STOP G61 MODE CANCEL G65 MACRO SUB-ROUTINE CALL G68 ROATION (G17, G18, G19, X, Y, Z, R) G69 ROTATION G68 CANCEL G70 BOLT HOLE CIRCLE with a CANNED CYCLE (I, J, L) Page 132 Lathe Appendix - 12

289 Appendix Preparatory Functions G-Codes G71 BOLTHOLEARC with a CANNED CYCLE (I, J, K, L) G72 BOLT HOLES ALONG AN ANGLE with a CANNED CYCLE (I, J, L) G73 HIGH SPEED PECK DRILL CANNED CYCLE (X, Y, A, B, Z, I, J, K, Q, P, R, L, F) G74 REVERSE TAPPING CANNED CYCLE (X, Y, A, B, Z, J, R, L, F) G76 FINE BORING CANNED CYCLE (X, Y, A, B, Z, I, J, P, Q, R, L, F) G77 BACK BORE CANNED CYCLE (X, Y, A, B, Z, I, J, Q, R, L, F) G80 CANCEL CANNED CYCLE G81 DRILL CANNED CYCLE (X, Y, A, B, Z, R, L, F) G82 SPOT DRILL/COUNTERBORE CANNED CYCLE (X, Y, A, B, Z, P, R, L, F) G83 PECK DRILL CANNED CYCLE (X, Y, A, B, Z, I, J, K, Q, P, R, L, F) G84 TAPPING CANNED CYCLE (X, Y, A, B, Z, J, R, L, F) G85 BORE IN, BORE OUT CANNED CYCLE (X, Y, A, B, Z, R, L, F) G86 BORE IN, STOP, RAPID OUT CANNED CYCLE (X, Y, A, B, Z, R, L, F) G87 BORE IN AND MANUAL RETRACT CANNED CYCLE (X, Y, A, B, Z, R, L, F) G88 BORE IN, DWELL, MANUAL RETRACT CANNED CYCLE (X, Y, A, B, Z, P, R, L, F) G89 BORE IN, DWELL, BORE OUT (X, Y, A, B, Z, P, R, L, F) G90 ABSOLUTE POSITIONING G91 INCREMENTAL POSITIONING G92 GLOBAL WORK COORDINATE SYSTEM SHIFT (FANUC) (HAAS) G92 SET WORK COORDINATE VALUE (YA SNAC) G93 INVERSE TIME FEED MODE ON G94 INVERSE TIME FEED MODE OFF/FEED PER MINUTE ON G98 CANNED CYCLE INITIAL POINT RETURN G99 CANNED CYCLE R PLANE RETURN Lathe Appendix - 13 Page 133

290 Appendix Miscellaneous Functions M-Codes M00 PROGRAM STOP M01 OPTIONAL PROGRAM STOP M02 PROGRAM END M03 SPINDLE ON CLOCKWISE M04 SPINDLE ON COUTERCLOCKWISE M05 SPINDLE STOP M06 TOOL CHANGE M08 COOLANT ON M09 COOLANT OFF M19 ORIENT SPINDLE (P, R) M21-M28 OPTIONAL USER M CODE INTERFACE WITH M-FIN SIGNAL M30 PROGRAM END AN RESET M31 CHIP AUGER FORWARD M32 CHIP AUGER REVERSE M33 CHIP AUGER STOP M34 COOLANT SPIGOT POSITION DOWN, INCREMENT M35 COOLANT SPIGOT POSITION UP, DECREMENT M36 PALET PART READY M39 ROTATE TOOL TURRET M41 SPINDLE LOW GEAR OVERRIDE M42 SPINDLE HIGH GEAR OVERRIDE M50 EXECUTE PALLET CHANGE Page 134 Lathe Appendix - 14

291 Appendix Miscellaneous Functions M-Codes M51-M58 OPTIONAL USER M CODE SET M59 OUTPUT RELAY SET (N) M61-M68 OPTIONAL USER M CODE CLEAR M69 OUTPUT RELAY CLEAR (N) M75 SET G35 OR G136 REFERENCE POINT M76 CONTROL DISPLAY INACTIVE M77 CONTROL DISPLAY ACTIVE M78 ALARM IF SKIP SIGNAL FOUND M79 ALARM IF SKIP SIGNAL NOT FOUND M80 AUTOMATIC DOOR OPEN M81 AUTOMATIC DOOR CLOSE M82 TOOL UNCLAMP M83 AUTO AIR JET ON M84 AUTO AIR JET OFF M86 TOOL CLAMP M88 COOLANT THROUGH SPINDLE ON M89 COOLANT THROUGH SPINDLE OFF M93 AXIS POS CAPTURE START (P, Q) M94 AXIS POS CAPTURE STOP M95 SLEEP MODE M96 JUMP IF NO SIGNAL (P, Q) M97 LOCAL SUB-PROGRAM CALL (P, L) M98 SUB-PROGRAM CALL (P, L) M99 SUB-PROGRAM/ROUTINE RETURN OR LOOP M109 INTERACTIVE USER INPUT (P) Lathe Appendix - 15 Page 135

292 Standard Drill Sizes - Inches Drill. Decimal Drill.. Decimal Drill.. Decimal Drill.. Decimal Size Equiv. Size Equiv. Size Equiv. Size Equiv. 80 = = = /64 = = = =.201 X =.397 1/64 = /32 = /64 =.2031 Y = = = = /32 = = = =.2055 Z = = = = /64 = = = =.213 7/16 = = =.104 7/32 = /64 = = = = /32 = =.025 7/64 = = /64 = = =.110 A =.234 1/2 = = = /64 = /64 = = =.113 B = /32 = = =.116 C = /64 = /32 = =.120 D =.246 9/16 = =.032 1/8 = /4 (E) = /64 = = =.1285 F = /32 = = =.136 G = /64 = = = /64 = /8 = =.037 9/64 =.1406 H = /64 = = =.144 I = /32 = = =.147 J = /64 = = =.1495 K = /16 = = =.152 9/32 = /64 = = =.154 L = /32 = =.043 5/32 =.1563 M = /64 = = = /64 = /4 =.750 3/64 = =.159 N = /64 = = =.161 5/16 = /32 = = =.166 O = /64 = = =.1695 P = /16 = /16 = /64 = /64 = /64 = = =.173 Q = /32 = = =.177 R = /64 = = = /32 = /8 = = =.182 S = /64 = = =.185 T = /32 = /64 = /16 = /64 = /64 = = =.189 U = /16 = = =.191 3/8 = /64 = = =.1935 V = /32 = = =.196 W = /64 =.9844 Page 136 Lathe Appendix - 16

293 Inch Tap Drill Sizes INCH SIZES - NATIONAL COARSE UNC TAP DRILL SIZE SIZE #1-64 #53 #2-56 #51 #3-48 5/64" #4-40 #43 #5-40 #39 #6-32 #36 #8-32 #29 #10-24 #25 #12-24 #17 1/4-20 #7 5/16-18 F 3/8-16 5/16 7/16-14 U 1/ /64 9/ /64 5/ /32 3/ /32 7/8-9 49/64 1"-8 7/8 1-1/8-7 63/64 1-1/ /64 1-1/ /32 1-3/ /64 2"-4-1/2 1-25/32 INCH SIZES - NATIONAL FINE UNF TAP DRILL SIZE SIZE #0-80 3/64" #1-72 #53 #2-64 #50 #3-56 #46 #4-48 #42 #5-44 #37 #6-40 #33 #8-36 #29 #10-32 #21 #12-28 #15 1/4-28 #3 5/16-24 I 3/8-24 Q 7/16-20 W 1/ /64 9/ /64 5/ /64 3/ /16 7/ /16 1"-14 15/16 1-1/ /64 1-1/ /64 1-1/ /64 1-3/ /64 2" /64 Lathe Appendix - 17 Page 137

294 Metric Tap Drill Sizes Page 138 METRIC COARSE SIZES TAP DRILL SIZE SIZE mm x.25.75mm 1.1 x x x x x x x x x x x x x x x x x x x x x x x x x x x x x Tap Drill Sizes Lathe Appendix - 18 METRIC FINE SIZES TAP DRILL SIZE SIZE mm x mm 4 x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x 2 28

295 Discriminator Installation Instructions Installation Instructions for Workbook users: 1. Locate the DVD/CD that came with the workbook (fixed to the back cover). 2. Insert the disc into the DVD/CD ROM tray of your computer. 3. When the AutoPlay window is displayed select Open folder to view files as shown below: 4. Double click or open the Discriminator folder as shown below: Lathe Appendix - 19 Page 139

296 Discriminator Installation Instructions Continued 5. Double-click the Discriminator21017.exe file as shown below. This will start the installation process. Follow the instructions on the screen to complete the installation. Installation Instructions for Online Course users: 1. Go to the Course Intro page of the Online Course as shown below: 2. Locate the What you need to complete this course section on this page and click on the Discriminator link to download the Discriminator installation file. Make sure you save the file to a place on the hard drive that you can be easily located. 3. Once the file has downloaded locate it and double-click the Discriminator.zip file to extract the installation files onto your hard drive. Make sure you extract the files into a new folder on your hard drive and remember where the folder is located. 4. Open the folder the files were extracted to and double click on Discriminator21017.exe. 5. Follow the instructions on the screen. Page 140 Lathe Appendix - 20