CP15

SEMESTER 5
CNC Technology

Prepared by: Mr. Sugumaran P [VTC] & Mrs. Nikita S [DTC]

Verified by: Mr. Surendhar Kumar K.
Approved by: Mr. Shankar G.
Rev No : 02
Released Date : 01/12/2021
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Contents
1.0 INTRODUCTION TO COMPUTERISED NUMERICAL CONTROL........................................................................ 3
1.1 Computer Numerical Control ............................................................................................................................ 4
1.2 Applications of CNC Machines .......................................................................................................................... 7
2.0 CNC CONTROL SYSTEM............................................................................................................................... 9
2.1 Feed back Control System ................................................................................................................................. 9
2.2 Motion Control System ................................................................................................................................... 10
3.0 ELEMENTS OF CNC MACHINE.................................................................................................................... 13
3.1 Spindle Drives .................................................................................................................................................. 13
3.2 Feed Drives ...................................................................................................................................................... 14
3.3 Recirculating Ball Screw .................................................................................................................................. 15
3.4 Feed Back Devices ........................................................................................................................................... 16
3.5 The Machine Control Unit for CNC .................................................................................................................. 21
3.6 Automatic Tool Changer .................................................................................................................................. 23
3.7 Automatic Pallet Changer................................................................................................................................ 25
3.8. Automatic Swarf Removal Mechanism .......................................................................................................... 26
3.9 Tool Holding Devices ....................................................................................................................................... 27
3.10 Work Holding Devices ................................................................................................................................... 28
4.0 NOMENCLATURE OF LATHE TOOL ............................................................................................................. 29
4.1 Nomenclature of Lathe Tool............................................................................................................................ 29
4.2 Tool Holders .................................................................................................................................................... 33
4.3 Selection of Tools, Feeds, and Speeds............................................................................................................. 34
4.4 Cutting Tool Materials ..................................................................................................................................... 36
5.0 CNC OPERATING MODES .......................................................................................................................... 38
5.1 Manual Operating Mode ................................................................................................................................. 38
5.2 Jog Mode ......................................................................................................................................................... 42
5.3 Jogging the Axes .............................................................................................................................................. 43
5.3.1 Continuous Jog ............................................................................................................................................. 43
5.3.2 Incremental Jog ............................................................................................................................................ 44
5.3.3 Jogging the axes with handwheels ............................................................................................................... 45
5.4 Arbitrary Angle Jog. ......................................................................................................................................... 46
5.5 Jog Offset ......................................................................................................................................................... 47
5.6 Over travel Protaction : ................................................................................................................................... 47
5.7 Mechanical Handle Feed - (Servo Off) ............................................................................................................ 49
5.8 Removing an Axis - (Axis Detach) .................................................................................................................... 49
5.9 Manual Machine Homing ................................................................................................................................ 49

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6.0 CNC PROGRAMMING ............................................................................................................................... 51

6.1 Axis Nomenclature .......................................................................................................................................... 51
6.2 Coordinate System .......................................................................................................................................... 55
6.3 Tool Length Compensation ............................................................................................................................. 58
6.4 Cutter Radius Compensation........................................................................................................................... 60
6.5 Preparatory and Miscellaneous Functions for Milling .................................................................................... 62
6.6 Preparatory and Miscellaneous Functions for Turning ................................................................................... 65
6.7 Program Format .............................................................................................................................................. 67
6.8 Exercise on Part Programming in Milling ........................................................................................................ 69
6.9 Exercise on Part Programming in Turning ....................................................................................................... 71
7.0 CNC MAINTENANCE AND TROUBLESHOOTING .......................................................................................... 74
7.1 Coolant - Function, Types, Maintenance and Application. ............................................................................. 74
7.2 Understanding and Responding to Alarms in CNC. ......................................................................................... 76
7.3 Machine Maintenance. ................................................................................................................................... 77
7.4 Tools and Accessories required for CNC Machine Maintenance. ................................................................... 80
7.5 Causes for the failure of Electronic System in CNC ......................................................................................... 80
7.6 Deviations from Normal Performance in CNC Machine.................................................................................. 82
7.7 Backlash ........................................................................................................................................................... 83
7.8 Checklist for CNC Maintenance ....................................................................................................................... 83
7.9 Best Maintenance Practices ............................................................................................................................ 85
7.10 Troubleshooting - Causes and Remedies ...................................................................................................... 85

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1.0 INTRODUCTION TO COMPUTERISED NUMERICAL CONTROL

Introduction

Production is a process of converting raw material into finished products. The

process of production is achieved by the collective efforts of man and machine using
materials and tools. It requires information and energy to accomplish production by
machining.

Over a period of time, several techniques and methods are used in the process. The
evolution of new methods of production saw the increasing involvement of machines in
providing the information and energy required for production and the role played by the
humans declined.

Prepared programs consisting of informations and instructions took the role of

controling the machines instead of manual control. This has led to a manufacturing system
of higher production at lower cost with more accuracy.

Numerical Control

Numerical control can be defined as a system in which actions of a machine tool are
controlled by recorded informations in the form of numerical data. Data is sent to the
machine tool by means of punch cards or tapes. The reader at the machine performs no
calculations or interpolations.

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1.1 Computer Numerical Control

When the activities of a Numerical Control machine is administered by a dedicated

computer, it is known as Computer Numerical Control machine tool. The functions of the
machine tool are controlled by the instructions stored as programs in the computer

CNC stands for Computer Numerical Control. When computers are used to control a
Numerical Control (NC) machine tool than the machine is called CNC machine. In other
words, the use of computers to control machine tools like lathe, mills, slotter, shaper etc is
called CNC machine.

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The cutting operations performed by the CNC is called CNC machining. The Various
machining services in which CNC machine is used are known as CNC machining services.
In CNC machine shops, programs are designed or prepared first, and then it is fed to the
CNC machine. According to the program, the CNC controls the motion and speed of the
machine tools.

Block diagram of the CNC Machine

The main parts of the CNC machine are

(i) Input Devices: These are the devices which are used to
input the part program in the CNC machine. The modern
CNC machines have keyboards to enter the data /
program directly. They also have TCP/IP connector, hence
can be connected to computer through internet / intranet.
Some CNC machines have USB reader to take data from
flash memory. Some of the older machines may have
punch tape reader, magnetic tape reader and computer
via RS-232-C communication.

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(ii) Machine Control Unit (MCU): It is the heart of the CNC machine. It performs all the
controlling action of the CNC machine, the various functions performed by the MCU are

▪ It reads the coded instructions fed into it.

▪ It decodes the coded instruction.
▪ It implements interpolation ( linear, circular and helical ) to generate axis motion
commands.
▪ It feeds the axis motion commands to the amplifier circuits for driving the axis
mechanisms.
▪ It receives the feedback signals of position and speed for each drive axis.
▪ It implements the auxiliary control functions such as coolant or spindle on/off and
tool change.

(iii) Machine Tool: A CNC machine tool

always has a slide table and a spindle to
control the position and speed. The
machine table is controlled in X and Y axis
direction and the spindle is controlled in
the Z axis direction.

(iv) Driving System: The driving system of

a CNC machine consists of amplifier
circuits, drive motors and ball lead screw.
The MCU feeds the signals (i.e. of
position and speed) of each axis to the
amplifier circuits. The control signals are than augmented (increased) to actuate the drive
motors. And the actuated drive motors rotate the ball lead screw to position the machine
table.

(v) Feedback System: This system consists of transducers that act as sensors. It is also
called a measuring system. It contains position and speed transducers that continuously
monitor the position and speed of the cutting tool located at any instant. The MCU
receives the signals from these transducers and it uses the difference between the
reference signals and feedback signals to generate the control signals for correcting the
position and speed errors.

(vi) Display Unit: A monitor is used to display the programs, commands and other useful
data of CNC machine.
[Link]

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1.2 Applications of CNC Machines

1. Metal cutting machines.

2. Metal forming machines.
3. Tool handling system.
4. Work handling system.
5. Inspection and quality control system.
6. Welding machines.
7. Heat treatment equipment.
8. Assembly, testing and dispatch equipment.

Machines employing nontraditional machining such as EDM, plasma arc, Laser beam , Ion
beam, Ultrasonic, high speed water jet machining etc.

Advantages

▪ It can produce jobs with the highest accuracy and precision than any other manual
machine.
▪ It can be run for 24 hours a day.
▪ The parts produced by it have the same accuracy. There is no variation in the parts
manufactured.
▪ A highly skilled operator is not required to operate it. A semi-skilled operator can also
operate accurately and more precisely.
▪ Operators can easily make changes and improvements and reduce the delay time.
▪ It has the capability to produce complex designs with high accuracy in minimum
possible time.
▪ The modern design software, allows the designer to simulate the manufacturer of
his/her idea. And this removes the need for making a prototype or model and saves
time and money.
▪ Fewer workers are required to operate a CNC and save labor costs.

Disadvantages
Despite of having so many advantages, It has some disadvantages too. And these are:
▪ The cost of the CNC machine is very high as compared with a manually operated
machine.
▪ The parts of the CNC machines are expensive.
▪ The maintenance cost in the case of CNC is quite high.
▪ It does not eliminate the need for costly tools.

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Development – Economy

CNC machinery has played a vital role in the history of the manufacturing industry.
However, these advanced machines have also taken part in the transformation of the
economy since their invention, and have even served to have an impact upon our society as
well. Here’s an in depth look at the correlation between CNC machines, the economy, and
society.

CNC machinery triggers economic growth: Just about every sector that has been somehow
touched by CNC machinery over the years has experienced a boom in their industrial
economy and a significant boost in their overall production speed, quality and a reduction in
operational costs.
From the dress making industry to companies that are dedicated to producing machines for
cars, CNC machinery often has a direct impact upon profitability and production costs in
general.

Essentially, CNC machines have aided skilled laborers in various industries and reduced the
amount that companies have to spend on man power. Therefore, they can be partly
credited with triggering economic growth on a global scale.

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2.0 CNC CONTROL SYSTEM

2.1 Feed back Control System
The CNC systems require motor drives to control both the position and the velocity
of the machine axis. Each axis must be driven separately and follow the command signal
generated by the Numerical Control (NC). There are two ways to activate the servo drives:
1. Open-loop system.
2. Closed-loop system.
[Link] loop system
In an open-loop CNC system, programmed instructions are fed into
the controller through an input device. These instructions are then converted to electrical
signals by the controller and sent to the servo amplifier to drive the servo motors. The
cumulative number of electrical pulses determines the distance each servo drive will
move, and the signal frequency determines the velocity of movement.
The primary characteristic of the open-loop system is
that there is no feedback system to check whether the
desired position and velocity has been achieved. When a NC
system does not have any feedback arrangement, it is
known as open loop system. Actual output movement is not
directly measured and checked with the desired movement.
The primary drawback of the open-loop system is
that there is no feedback system to check whether the
program position and velocity has been achieved. If the
system performance is affected by load, temperature,
humidity, or lubrication then the actual output could deviate from the desired output.

[Link] loop system

In this system, the final movements (spindle speed and slide
displacement) are compared and balanced with the values given through the input
commands. The movements of spindle and slides are measured by feedback devices like
velocity transducers and position transducers and sent back to control unit for comparing.
If the feedback values do not match with desired output position, the difference is

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corrected. This system is adopted where highest

positional accuracy is required.
The closed-loop system has a feedback
subsystem to monitor the actual output and correct
any discrepancy from the input programmed. The
feedback system could be either analog or digital.
The analog systems measure the variation of
physical variables such as position and velocity in
terms of voltage levels. Digital systems monitor
output variations by means of electrical pulses

Closed-loop systems are very powerful and

accurate because they are capable of monitoring operating conditions through feedback
subsystems and automatically compensating for any variations in real-time.

2.2 Motion Control System

The CNC Motion control System works

together with a series of motors and drive
components to move and control the machine
axes, executing the programmed motions. On the
industrial machines there is usually a
sophisticated feedback system that constantly
monitors and adjusts the cutter's speed and
position.

Some CNC processes like drilling and spot welding are performed at discrete
locations on the workpart. Other processes such
as turning, milling etc are carried out while the
workhead is moving. If the workhead is moving, it
may be required to follow a straight line path or a
circular or other curvilinear predefined path.
These different types of movement are
accomplished by the motion control system.

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Motion control systems for NC are of three types:

1. Point-to-Point control system.
2. Straight path control system.
3. Contour (or) Continuous Path control system.

1. Point to Point system

Point-to-point (PTP) is also called a positioning system. Operations like drilling is

carried out specific locations on the work piece. The tool is moved to that precise location
and then the drilling operation is carried out. During the operation the position of the tool
does not change. Machining is performed only after the cutting tool and the work are
located at defined positions and there will not be any change in their positions during
machining.
Once the machining at the particular position is over, the cutting tool (or) the work
(or) both are moved to next location for subsequent machining. The positioning may be
linear in the x-y plane or linear and rotary if the machine has a rotary table.

The NC machines with point to point system are simple in construction and are
cheaper. They are adapted for drilling, jig boring and spot welding machines.

2. Straight line Path

Straight line or straight cut system is an extension of point-to-point
control system with the provision of machining along a straight line as in case of milling
and turning operations.

This is obtained by providing movement of cutting tool or the work piece at

constant speed ie. controlled feed rate along the axis in the line of motion. It is possible to
machine along diagonal lines with movement in two axis at a controlled feed rate.

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In such cases the

control system must be
capable of calculating
and displacing the slides
simultaneously at
suitable feed rates to
reach the desired points
because in this case the
feed rates along
different axis will have
to be different.

3. Contour (or) continuous path system

In this system, both the cutting tool and the work
change their positions during machining. The movement of the cutting tool and the work
is simultaneous in all axes and in all planes each at different speed. This system is also
called as contouring system and is mainly used in milling machine.

Most modern closed-loop CNC systems are

able to provide very close resolution of 0.0001 of an
inch. Closed-looped systems would, naturally,
require more control devices and circuitry in order
for them to implement both position and velocity
control. This, obviously, makes them more complex
and more expensive than the open-loop system.

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3.0 ELEMENTS OF CNC MACHINE

3.1 Spindle Drives
In view of the large material removal rates used in the CNC machines, large power motors
are used. Further, the speed is generally infinitely variable. Hence to provide such a control
generally AC servomotors are used.

Servo drive is a type of electronic

amplifier that is used to power
electrical mechanisms connected to the
drive. The drive will automatically and
constantly adjust itself based on
feedback signals from connected
mechanisms to account for variations in
operation. It will also make adjustments
when the feedback received is a deviation from the desired operations.

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A servo system consists of several key components, including the:

a. Servo Motor.
b. Servo Drive.
c. Encoder.
d. Controller.

The encoder is the device that provides

feedback to the servo drive. The controller is
the component that regulates the programming
and instructions on what the servo motor must
do and when it should do it. The controller also
regulates the servo drive to ensure the right
amount of electrical power is delivered to the motor to perform the desire operations.

Essentially, the controller sends a command signal to the drive after it has calculated the
necessary operations. The drive then sends the necessary power to the motor so that it can
operate at the desired speed and perform the desired functions.

3.2 Feed Drives

These are used to drive the slide or a table. The feed motor needs to operate with
constant torque characteristics to overcome friction and working forces. Feed drives
are used to position the machine tool components carrying the cutting tool and workpiece
to the desired location; hence their positioning accuracy and speed determine the quality
and productivity of machine tools.

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A feed drive consists of a feed servomotor and an electronic controller. Unlike a spindle
motor, the feed motor has certain special characteristics, like constant torque and
positioning. Also, in contouring operations, where a prescribed path has to be followed
continuously, several feed drives have to work simultaneously. This requires a sufficiently
damped servo-system with fast response. The drive speed should be extremely variable
with a speed range of about 1: 20000, which means it should have a maximum speed of
around 2000 rpm and at a minimum speed of 0.1 rpm. The feed motor must run smoothly.
Positioning of smallest position increments like 1-2 μm should be possible. For a feed motor
this represents an angular rotation of approximately 2-5 angular minutes.
(one degree = 60 angular minutes)
The drive should have extremely small positioning resolution. Other requirements
include high torque to weight ratio, low rotor inertia and quick response in case of
contouring operation where several feed drives have to work simultaneously. However
nowa-days AC feed drives are being used.

Types of Feed Drives

Variable speed dc feed drives are very common in machine tools because of their
simple control techniques. However, with the advent of the latest power electronic devices
and control techniques ac feed drives are becoming popular due to certain advantages.

3.3 Recirculating Ball Screw

The ball screw assembly consists of a

screw and a nut, each with matching helical
grooves, and balls which roll between these
grooves providing the only contact
between the nut and the screw. As the
screw or nut rotates, the balls are deflected
by the deflector into the ball return system
of the nut and they travel through the
return system to the opposite end of the
ball nut in a continuous path. The balls then
exit from the ball return system into the
ball screw and nut thread raceways
continuously to recirculate in a closed
circuit .

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The External Ball Return System. In this type of return system, the ball is returned to the
opposite end of the circuit through a ball return
tube which protrudes above the outside diameter of
the ball nut.

The Internal Ball Return System In this type of

return system, the ball is returned to the opposite
end of the circuit through or along the nut wall, but
below the outside diameter through a "V" cap.
• These are virtually wear free.
• They require Less starting torque.
• No heat generation during operation.
• They can be used for high speed operations.

Applications of Ball Screws

a. CNC Machinary-CNC machine centre, CNC lathe, CNC milling machine, CNC EDM, CNC
grinder, boring machine, etc.
b. Percision machine tools-Milling machine, Grinder, Gear manufacturing, Planer.
c. Industrial Machinary-Printing machine, Paper processing machine , Textile machine,
Special purpose machine, etc.
d. Electronic machinery-Robot measuring instrument, X-Y tables, medical equipments,
Factory automation equipments, etc.
e. Aerospace industry-Aircraft flaps, thrust openclose reverser, fin actuator, etc.

Recirculating ball screw - [Link]

3.4 Feed Back Devices

The CNC machine tools
use closed loop control system
with an appropriate feedback
to provide accurate control to
the movement of the axes. A
large variety of sensors have
been used in CNC machine
tools with varying success for
providing the necessary
measurement of the
displacement (current position
of the axis).

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CNC systems depend on a combination of speed, accuracy and repeatability more

than any other machine tool—especially in the age of multi-axis. A metalworking operation
is only as strong as its weakest link. One defective part not only inflicts added material costs,
but also often affects the productivity and schedule of every process downstream from it.
More than maybe any other instrument in a machine tool, encoders ensure the
proper combination of speed, accuracy and repeatability by providing positional feedback to
the control. In other words, they encode position or movement in a language CNC controls
and, in turn, operators can understand.
The sensors that have become more common in the present day CNC machine tools are
the following.
a. Encoders.
b. Linear scales.
There are many different types of encoders but they basically fall into two main sensing
techniques. Those being:
i. Linear.
ii. Rotary.
Within those categories, there are differing encoder measurement types such as:
i. Absolute.
ii. Incremental.

Each type of encoder monitors a different motion element of a machine depending on

factors like the accuracy required and directional variety. The performance of a machine
tool depends heavily on these different encoder instruments providing accurate,
synchronized feedback readings.
a. Encoder

Encoder is a sensor of mechanical motion that generates digital signals in response to

motion. As an electro-mechanical device, an encoder is able to provide motion control
system users with information concerning
position, velocity and direction. There are
two different types of encoders.

1. Linear Encoder: The Linear Encoder uses

a transducer to measure the distance
between two points. These encoders can
use a rod or a cable that is run between the
encoder transducer and the object that will

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be measured for movement. In machine tool applications, positioning is a much more

important consideration than speed, since loads are typically being moved such short
distances. Another distinction is between exposed and enclosed encoders. The enclosed
option is the only choice for the extreme conditions in a machining center’s work area. Its
sealed unit is mounted on a small carriage that is connected directly to the machine slide,
moving with the table, protecting its sensitive scales and scanning instruments from chips
and coolant and feeding precise location to the control.
As the object moves, the transducer’s data collected from the rod or cable creates an
output signal that is linear to the object’s movement.

As the distance is measured, the Linear Encoder uses this information to determine
the position of the object. An example of where a Linear Encoder may be used is for
a CNC milling machine where precise movement measurements are required for accuracy in
manufacturing.

2. Rotary (Shaft) Encoder: A Rotary Encoder

collects data and provides feedback based on
the rotation of an object or in other words, a
rotating device.
Rotary Encoders are sometimes called
“Shaft Encoders”. This encoder type can
convert an object’s angular position or motion
based on the rotation of the shaft, depending
on the measurement type used.

3. Position Encoder: The next encoder, which is a “Position” Encoder, is used to determine
the mechanical position of an object. This
mechanical position is an “absolute position”.
They may also be used to determine a change
in position between the encoder and object as
well. The change in position in relation to the
object and encoder would be an incremental
change.

Position Encoders are widely used in the

industrial arena for sensing the position of
tooling and multi-axis positioning.

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4. Optical Encoder: Optical” Encoders

interpret data in pulses of light which can
then be used to determine such things as
position, direction, and velocity.

The shaft rotates a disc with opaque

segments that represent a particular
pattern.

These encoders can determine the movement of an

object for “rotary” or “shaft” applications while
determining exact position in “linear” functions. The
optical encoder has an LED light source, a light detector,
a “code” disc/wheel mounted on the shaft, and output
signal processor. The disc has alternating opaque and
transparent segments and is placed between the LED
and detector so it intermittently interrupts the LED’s
beam as it rotates.

The detector responds to the series of light pulses it receives and sends that information to
the processor, which actually extracts the motion information (both amount of rotation and
direction).
Optical encoders are used in various applications such as printers, CNC milling machines,
and [Link], these encoders may be Absolute or Incremental.

Types of encoder depends on measurement

a. Absolute Encoders can measure angula positions.
b. Incremental Encoders can measure things such as distance, speed, and position.

a. Absolute Encoders: An
absolute encoder contains
components also found in
incremental encoders. They
implement a photodetector and
LED light source but instead of a
disk with evenly spaced lines on
a disc, an absolute encoder uses
a disk with concentric circle
patterns.

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Absolute encoders utilize stationary mask in between the photodetector and the encoder
disk as shown below. The output signal generated from an absolute encoder is in digital bits
which correspond to a unique position. The bit configuration is produced by the light which
is received by the photodetector when the disk rotates.
The light configuration received is translated into gray code. As a result, each position
has its own unique bit configuration.

b. Incremental Rotary Encoders: They utilize a transparent disk which contains opaque
sections that are equally spaced to determine movement.

A light emitting diode is used to pass through the glass disk and is detected by a photo
detector. This causes the encoder to generate a train of equally spaced pulses as it rotates.
The output of incremental rotary encoders is measured in pulses per revolution which is
used to keep track of position or determine speed. The quadrature encoder can detect
direction of rotation also.

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What is an ENCODER - Linear and Rotary

encoder - Incremental and Absolute
encoder
[Link]
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What is the Difference between Absolute
and Incremental Encoders?
[Link]
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b. Linear scales
In order to read the motion along the path of the scale, a linear scale uses a
transducer to measure the distance between point A and point B. The transducer travels
along a rod or cable that sits between the transducer and
the object being measured. As it does so, the encoder
sends an electrical output signal that is linear to the
movement of the object. The scale uses the change in
distance to determine the position of the object.

When the encoder reads the distance traveled, it

translates the linear motion into a digital signal which
shows measurements like speed, angle, or position. By
measuring the moving parts, the linear scale allows you
to control the motions of an operating device to get
reliable accuracy. This type of exact control is often used in equipment like milling machines
or printers.

3.5 The Machine Control Unit for CNC

The machine control unit (MCU) is the heart of a CNC system. Machine control unit
comprises of a machine operations panel and a control panel. The group of CNC machine
controls that allows operators to manually control the machine. The machine operations
panel, or machine panel, directly guides tool movement and the operation of machine
components.
MCU performs the following functions:
a. To read the coded instructions.
b. To decode the coded instructions.
c. To implement interpolations (linear, circular, and helical) to generate axis
motion commands.

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d. To feed the axis motion commands to the amplifier circuits for driving the axis
mechanisms.
e. To receive the feedback signals of position and speed for each drive axis.
f. To implement auxiliary control functions such as coolant or spindle on/off and
tool change.

Let us now look at various parts of MCU

Input reading unit: The main functions

of a input reading unit are
a. To accept the input media like
punched cards, punched tapes,
magnetic tapes floppy disks.
b. To send them into a reading unit to
extract the information stored in
them.
c. To process the collected information.
d. To collect the input media to be used
again.
Memory unit: A block of information received from the input media consists of words and
codes. Sequential informations are arranged in a desired order as separate blocks. These
blocks of informations are stored in a temporary memory known as buffer memory. The
memory unit will provide the information blocks to the processing unit in the desired
sequence.

Processing unit: The processing unit serves as a link between the memory unit and output
channels. The processor does the duty of co-ordinating and controlling the other units of
the MCU. The informations received from the buffer are processed here and appropriate
signals are given to various units at particular points of time. processors are driven by ICs.

Output channels: Mostly output channels are the pins found on ICs or the wires coming
out of processors. These channels emit electric pulses of very low voltage / current. The
pulses are the result of processed information based on the NC program. In order to drive
or actuate various slides of the machines, the pulses are amplified by means of electronic
or electro - magnetic amplifiers or thyristors.

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Feedback unit: Feedback unit consists of some electrical or electronic hardware. This is
used for converting physical quantities like displacement or velocity into electrical pulses.
This system is used in a NC system to check whether the operations are carried out in
accurate manner.

3.6 Automatic Tool Changer

An Automatic tool changer or ATC is used to improve the production

and tool carrying capacity of the machine. ATC changes the tool very
quickly, reducing the non-productive time. Generally, it is used to
improve the capacity of the machine to work with a number of tools.
It is also used to change worn out or broken tools. It is one more
step towards complete automation.

The tools from the magazines and spindle are exchanged by a tool
changer arm.

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The tool change activity requires the following motions:

▪ The spindle stops at the correct orientation for the tool change arm to pick the tool
from the spindle.
▪ Tool change arm moves to the spindle.
▪ Tool change arm picks the tool from the spindle.
▪ Tool change arm indexes to reach the tool magazine.
▪ Tool magazine indexes so that the tool from the spindle can be placed.
▪ The tool is placed in the tool magazine.
▪ The tool magazine indexes to bring the required tool to the tool change position.
▪ Tool change arm picks the tool from the tool magazine.
▪ Tool change arm indexes to reach the spindle.
▪ New tool is placed in the spindle. k. Tool change arm moves back to its parking
position

Advantages of automatic tool changer

▪ Increase in operator safety by changing tools automatically
▪ Changes the tools in seconds for maintenance and repair
▪ Increases flexibility
▪ Heavy and large multi-tools can easily be handled
▪ Decreases total production tim
Automatic Tool Changer - [Link]

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Tool Magazines

Tool Turret: Turning centres are available with the tool turret containing 8-12 tools. As the
tool change command is received by the control system, the tool turret moves to a fixed
tool change position and the required tool comes to the cutting position.

Drum type magazine: Drum or Disc type tool magazine The drum rotates for the purpose
of tool change to bring the required tool to 84 the tool change arm. As the number of tools
in the magazine increases its diameter becomes too large.

Chain type tool magazine: For storing large number of tools a chain type tool magazine
provides The necessary flexibility. The capacity may be as small as 30 to and as high as

Tool Turret Disk (or) Drum Chain

Tools Less than 12 More than 12 upto 50 More than 50
Cost Low Expensive More Expensive
Productivity Less High High

Tool Magzines - [Link]

3.7 Automatic Pallet Changer

Machining centers are generally equipped with two or more separate pallets. A
pallet may be considered as a small table having standard dimensions. While machining is
performed on the work piece with one pallet in position at the machine, the other pallets
are in a safe location away from the spindle. In this safe location the operator can unload
the finished part from the prior cycle and then fix raw work piece for the next cycle, thus
not disturbing the machining operation. An automatic pallet changer is used to move
these pallets.

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The automatic pallet change operations take place following the sequence
presented in Figure. In the first operation the machining centre’s table brings the pallet 2
over the pallet changer’s arm and performs the unclamp and cleaning (the lower side of
the pallet) operations. The following operation consists in lifting the automatic pallet
changer’s arm along with the pallet 1 from the loading station and the pallet 2 from the
machine table. The third operation performs the pallet exchange, moving the pallet from
the machining centre’s table to the loading station and the pallet from the loading station
to the machining centre’s table. The fourth operation consists in lowering the exchanged
pallets on the machine table, respectively on the loading station and the fifth operation is
the pallet clamp on the machine table.

3.8. Automatic Swarf Removal Mechanism

One of the main problems of the CNC
machine tools is the amount of chips generated.
Since these machines are designed to be
operated 24 hours a day and also have
considerable amount of metal removal
capability, the working area of the machine tool
gets clogged by the amount of chips if they are
not removed quickly. Most of the machines
therefore would be provided with some type of
chip handling capability either standard or
optional. typical chip removal facilities in turning
centers and machining centers.

In the case of turning centers the slant bed allows for the chip to be accumulated at
the bottom, away from the machining zone. From there the chips need to be transported
by a conveyor into a collection bin, which can be removed periodically.

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3.9 Tool Holding Devices

Milling tool holders: A device that acts as an interchangeable interface between a
machine tool spindle and cutting tool.

A tool holder is a machining component that holds the end mill in place. Its purpose
is to hold the tool in place as precisely and firmly as possible, as a barely perceptible
increase in runout can ruin your project or break your cutting tool.

Lathe Tool Holders: It is essential that the insert

be supported in a strong, rigid manner to
minimize deflection and possible vibration.
Consequently, turning tools are supported in
various types of heavy, forged steel tool
holdersThe turning tool body generally does not
feature quite so much engineering as the insert,
but even here there are a range of choices for
fine-tuning the process. Quick-change tools
involve modular bodies that allow replacement
tool bodies to be swapped in and out and locked
in place quickly to minimize setup time. The
turning tool body can also channel high-pressure
coolant more effectively to the cutting edge of
the tool.

The ANSI numbering system for turning tool holders has assigned letters to specific
geometries in terms of lead angle and end cutting edge angle. The primary lathe
machining operations of turning, facing, grooving, threading and cutoff are covered by one
of the seven basic tool styles outlined by the ANSI system. The designations for the seven
primary tool styles are A, B, C, D, E, F and G.

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3.10 Work Holding Devices

It is necessary that the work should be properly and securely held on the milling
machine table for effective machining operations. The cutting pressure exhorted by milling
cutter is quite high comparing the single point tool of a lathe machine. Therefore the
workpiece has to be secured rigidly to avoid any vibration. The following are the usual
methods of holding work on the milling machine.
▪ T-bolts and clamps
▪ Angle Plates
▪ V – Block
▪ Machine Vices
▪ Dividing Head
▪ Special Fixture
▪ Circular Table or Indexing Table
▪ Parallels
▪ Magnetic chuck / Vacuum chuck / Collet chuck

Bulky workpieces of irregular shapes are clamped directly on the milling machine table
by using T- bolts and clamps. Different types of clamps are used for different patterns of
work.

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4.0 NOMENCLATURE OF LATHE TOOL

4.1 Nomenclature of Lathe Tool

Turning generates axially symmetric shapes with a single-point tool. A single-point
tool removes material by means of one cutting edge.
In most cases the tool is held in a fixed position with
the workpiece rotating about a turning axis. There are
also tools held on the spindle centerline (drills,
reamers, taps) for hole-making applications that have
speed and feed limitations.

ANSI Insert Designations The American National

Standards Institute (ANSI) has developed a coding
system of numbers and letters to describe the shape,
dimensions, and important parameters of turning
inserts.

1. Insert Shape
Turning inserts are
manufactured in a variety of shapes,
sizes and thicknesses. The shape can
be round to maximize edge strength,
diamond-shaped to allow a sharp
point to cut fine features, square, or
even octagonal to increase the
number of separate edges that can be
applied as one edge after another
wears out.

• A = parallelogram 85 •
B=parallelogram 82 • C = diamond
80 • D = diamond 55 • E = diamond
75 • H = hexagon • K = diamond 55
• L = rectangle • M = diamond 86 • O = octagon • P = pentagon • R = round • S = square •
T = triangle • V = diamond 35 • W - trigon 80

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C and W type turning inserts are often used for rough machining due to their larger point
angle, which makes them more rigid. Inserts with a smaller point angle, such as D and V,
are often used for finish machining. Although they have less strength, the smaller angle
can reach more part details.
Large point angle:
▪ Stronger cutting edge
▪ Higher feed rates
▪ Increased cutting forces
▪ Increased vibration

Small point angle:

▪ Weaker cutting edge
▪ Increased access to part details
▪ Decreased cutting forces
▪ Decreased vibration

2. Clearance
Most inserts have drafted faces
on the walls. Clearance prevents the
walls of the insert from rubbing
against the part, which will give poor
machining. However, a turning insert
with a 0° clearance angle is mostly
used for rough machining.

3. Tolerance

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4. Type
The turning insert hole shape and chip breaker type

A = Cylindrical hole
B = 70-90° countersink hole
C = Double countersink
F = No hole; Double-sided chip breaker
G = Cylindrical; Double-sided chip breaker
H = 70-90° countersink; Singlesided
J = Double countersink; Double-sided
M = Cylindrical; Single-sided
N = No hole; No chip breaker
P = Cylindrical; Hi-DoublePositive Chip breaker
Q = 40-60° Double Countersink; No chip
breaker
R = No hole; Single-sided
S = Cylindrical; Hi-double positive
T = 40-60° double countersink; Single-sided
U = 40-60° double countersink; Double-sided
W = 40-60° double countersink
X = Special Desig

5. Size
This numeric value tells us the cutting edge length of the turning insert.

For equal sided inserts 1/4” I.C. or over: Size = Number of 1/8” increments.
Examples:
2 = 1/4"
3 = 3/8”
4 = 1/2"

For equal sided inserts less than 1/4” I.C.: Size = Number of 1/32” increments.
Examples:
2 = 1/16"
3 = 3/32”
4 = 1/8"

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For rectangles and parallelograms, 2 digits are necessary (Width and Length). Digit 1:
Width in 1/8” increments Digit 2: Length in 1/4” increments.
Example: 12 = 1/8” x 1/2"

6. Thickness
This value tells us the thickness of the insert. For inserts 1/4” I.C. or over: Thickness
in 1/16” increments For inserts less than 1/4” I.C.: Thickness in 1/32” increments.

7. Corner
Form on the corner in 1/16” increments for inserts with a corner radius. To reduce
vibration, it is often an advantage to choose a nose radius that is smaller than the depth of
cut.

Large nose radius:

▪ Increased feed rates
▪ Large depths of cut
▪ Strong edge security
▪ Increased radial pressures

Small nose radius:

▪ Small cutting depths
▪ Reduced vibration
▪ Weak cutting edg

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4.2 Tool Holders

The turning tool body generally does

not feature quite so much engineering as
the insert, but even here there are a range
of choices for fine-tuning the process.

Quick-change tools involve modular

bodies that allow replacement tool bodies
to be swapped in and out and locked in
place quickly to minimize setup time. The
turning tool body can also channel high-
pressure coolant more effectively to the
cutting edge of the tool.

It is essential that the insert be

supported in a strong, rigid manner to
minimize deflection and possible vibration. Consequently, turning tools are supported in
various types of heavy, forged steel tool holders.

The designations for the tool holders are :

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Tool Holders for Insert Shape(A – G)

▪ A = 0° side-cutting edge angle, straight shank

▪ B = 15° side-cutting edge angle, straight shank
▪ C = 0° end-cutting edge angle, straight shank (for cutoff and
grooving operations)
▪ D = 45° side-cutting edge angle, straight shank
▪ E = 30° side-cutting edge angle, straight shank (for threading
operations)
▪ F = 0° end-cutting edge angle, offset shank (for facing
operations)
▪ G = 0° side-cutting edge angle; offset shank (this tool is an 'A'
style tool with additional clearance built in for turning
operations close to the lathe chuck

4.3 Selection of Tools, Feeds, and Speeds

Cutting tool selection has a direct impact on the proper programming of feeds and speeds
at the machine. However, many other variables that affect feeds and speeds are:
▪ Workpiece material class and condition
▪ Workpiece diameter
▪ Cutter material
▪ Cutter geometry
▪ Type of cut
▪ Depth of cut
▪ Condition of the machine.

Cutting Speed
Cutting speed is the speed that the material moves past the cutting edge of the tool.
Cutting speed can be defined as revolutions per minute (RPM) or as surface feet per
minute (SFM).

RPM mode is useful for:

▪ Center cutting operations (drilling).
▪ When the diameter at the beginning and end of a cut only differs slightly.
▪ During threading to allow the perfect synchronization between spindle revolution
and Zaxis motion to allow precise thread.

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Surface Feet Per Minute (SFM) mode is useful for:

▪ It is a combination of the cut diameter and RPM.
▪ The faster the spindle turns, and/or the larger the part diameter, the higher the SFM.
▪ If two round pieces of different sizes are turning at the same revolutions per minute,
the larger piece has a greater surface speed because it has a larger circumference
and has more surface area.

Most CNC lathes have CSS (Constant Surface Speed).

SFM is a constant, with RPM as a variable based upon cut diameter.
When the SFM constant is known for a specific material, the formulas below can be used
to determine spindle speed:
RPM = SFM x (12/π) / Cut Diameter
So, for an SFM of 400 and a cut diameter of 5 inches , RPM can be found:
RPM = 400 x 3.82 / 5 = 306
When RPM is known, SFM can be found as follows:
SFM = RPM x Cut Diameter x π/12 For
example, if you have a cut diameter of 5” and a spindle speed of 306 RPM, then:
SFM = 306 x 5 x .262 = 400 SFM.

Feed Rate

Feed rate is the velocity at which the cutter is advanced along the workpiece. Feed rate is
expressed as units of distance (inch) per minute or per single revolution.
Values for IPR and IPM are easily converted with the following formulas:
IPM = IPR x RPM
For a spindle speed of 306 RPM and a feed rate of .01 IPR, the IPM can be calculated as
follows:
IPM = .01 x 306 = 3 IPM.

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4.4 Cutting Tool Materials

SI NO. Tool materials Work materials Remarks
Low strength, softer
Low cutting
materials, non
1. Carbon steel speeds, low
ferrous alloys,
strength materials
plastics
Low strength, softer
Low cutting
Low/medium materials, non
2. speeds, low
alloy steels ferrous alloys,
strength materials
plastics
Low to medium
cutting speeds, low
All materials of low
to medium
and medium,
3. HSS strength materials
strength and
Not suitable for
hardness
low speed
application

Not for titanium

Cemented
alloys, not for non-
carbides
Cast iron, alloy ferrous alloys as
4. steels, stainless the coated grades
steels, super alloys do not offer
Coated
additional benefits
carbides
over uncoated

Not for low speed

Cast iron, Ni-base
operation or
super alloys, non
5. Ceramics interrupted cutting.
ferrous alloys,
Not for machining
plastics
Al, Ti alloys.

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Insert Materials

Insert material is typically carbide, though ceramic, cermet or diamond inserts can be
applied to more demanding applications. A variety of protective coatings also help these
insert materials cut faster and last longer.
Insert Material Characteristics
The most common material used in the industry
Cemented carbide (HW, HC)
today. It is offered in several “grades” containing
▪ HW: Uncoated
different proportions of tungsten carbide and binder
▪ HC: Coated
(usually cobalt). High resistance to abrasion.

Cermets (HT, HC) Cermet containing Another cemented material, based on titanium
primarily titanium carbides (TiC) or carbide (TiC). Binder is usually nickel. It provides
titanium nitrides (TiN) or both higher abrasion resistance compared to tungsten
▪ HT: Uncoated carbide at the expense of some toughness. Extremely
▪ HC: Coated high resistance to abrasion

Ceramics (CA, CM, CN, CC)

CA - Oxide ceramics containing
primarily aluminum oxide (Al2O3)
CM - Mixed ceramics containing Chemically inert and extremely resistant to heat,
primarily aluminum oxide (Al2O3) but ceramics are usually desirable in high speed
containing components other than applications, the only drawback being their high
oxides fragility. The most common ceramic materials are
CN - Nitride ceramics containing based on alumina (aluminium oxide), silicon nitride
primarily silicon nitride (Si3N4) and silicon carbide
CC - Nitride ceramics containing
primarily silicon nitride (Si3N4), but
coated

The second hardest substance. It offers extremely high

resistance to abrasion at the expense of much
toughness. It is generally used in a machining process
Cubic boron nitrides (BN)
called "hard machining", which involves running the
tool or the part fast enough to melt it before it
touches the edge, softening it considerably.

The hardest substance. Superior resistance to abrasion

Polycrystalline diamonds (DP, HC) but also high chemical affinity to iron which results in
▪ DP : Uncoated being unsuitable for steel machining. It is used where
▪ HC : Coated abrasive materials would wear anything else.

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5.0 CNC OPERATING MODES

5.1 Manual Operating Mode
To go into the manual
mode, select MANUAL under . If you are
not equipped with a button or switch,
press the {FRONT PANEL} softkey
followed by the left/right arrow key to
select the mode .
In manual mode, the control displays
both the axis position data and any
currently active part program in the data
display area if the normal display is used
for softkey level 1. Normally you can
press to abort manual operations.

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Function of CNC Control Panel Keys

Address and Numeric keys

1. A to Z (Address key ) - This key is used to type the address code into the program
2. Number keys - These keys allow numeric entry. Normally located close to the letter
keypad, most CNC controls have number keys positioned.
3. EOB - This key is used when complete the one block with a symbol at the end(;) .
4. CAN -This KEY is used to cancelled the missed code while typing the program.
5. DELETE - This key is used to remove the code or block from the program.
6. INSERT - This key is used to put the typed code into the program in write mode .
7. ALTER - This key is used to replace the other code with the one in the program.
8. SHIFT - This key is used to hold the lowercase letter on the address key . That is, if
we assume that we want the small letter V in the Y tab above the address key,then
we have to press Shift + Y= V.
9. INPUT TAB - This key is used to input the parameter of offset or setting.
[Link] UP /DOWN KEY - This key is used to move the cursor up & down within
the program
[Link] UP/ DOWN KEY - If the program is of multiple pages, then this key is used
to jump to the top or bottom page.

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[Link] - This key is used to clear the alarm when typing a program.
[Link] - This key is use ,when an alarm arrives, it checks to see which
message the system came from.

Function Keys:
1. POS - Use this key to check the machine's axis position.
2. PROG(Program) -This key is used to view the store program or to
insert it into the new program system.
3. OFFSET - Use this key to set offset all types of tool jobs.
4. SYSTEM - This key is used to view files in the system.
5. GRAPH- - Use this key to test the program or to test the tool path
througH a graph.

Mode Keys:

Power and control switch for the main power and control
1. ON / OFF switch
unit.

2. Cycle Start Starts program execution or MDI command.

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Stops all machine activity and turns off power to the control
3. Emergency Stop
unit

5. Single Block Allows program run one block at a time

Temporarily stops program execution (M01 required in

6. Optional Stop
program)

Block Skip Ignores blocks preceded with a forward slash ( / ) in the

7.
program
Enables program testing at fast feedrates (without a
8. Dry Run
mounted part)

Spindle Override Overrides programmed spindle speed, usually within 50-

9.
120% range

Overrides programmed feedrate, usually within 0-200%

10. Feedrate Override
range.

Shows current status of the chuck clamping (Outside / Inside

11. Chuck Clamp
clamping)

12. Table Clamp Shows current status of table clamping

13. Coolant Switch Coolant control ON / OFF / AUTO

Gear Selection :
14. Spindle Rotation Shows current status of working gear range selection

Spindle Indicates spindle rotation direction (clockwise or

15. Orientation
counterclockwise)

16. Tool Change Switch allowing a manual tool change

Switches and lights relating to setup of machine, from

17. Reference Position
reference position.

Watch and learn “Various modes of CNC machine.

[Link]

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5.2 Jog Mode

JOG mode is also called jogging mode. In this mode,

the CNC machine is used to operate manually. This
mode is used to make the CNC machine much faster.
In this mode, the CNC machine carriage can be travel.

This the mode is used to manually perform the

Mainly Three function:
1. Movement of Axis.
2. Tool Indexing.
3. Spindle rotation.

[Link] Of Axis – In this, we have the CNC lathe used to

move the X and Z axis in the machine as well as the X, Y and Z
axis in the milling machine. We will see below how this is done.

To move simply

Step 1- Press “ JOG” Key

Step 2- Press axis “ +X/+Y/+Z or –X/-Y/-Z “ if you want to move.

some machine it can be only “ X/Y/Z” not give in + or -. That
time we have need following step 3 after pressing axis.

Step 3- Press “ + OR –“ to move the axis

To move rapidly

Step 1 – Press “JOG” key.

Step 2 – Press “ Rapid + (+X/+Y/+Z or –X/-Y/-Z)”.Some machine it can

be only “ X/Y/Z” not given + or - . That time we have need
following step 3 after pressing axis.

Step 3 - Press “ + OR –“ to move the axis

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2. Tool Indexing - In MDI mode we used tool no. and tool offset no .(T0100 OR T0202).
But in this case, we can change tool directly.

Step 1 – Press “ JOG” key.

Step 2 – Press “ TOOL” key.

3. Spindle Rotation - In MDI mode we used programmable code

(G97 S200 M03). But in this case we can rotate spindle directly

Step 1 – Press “ JOG” key.

Step 2 – Press “SPDL CW / SPDL CCW” (spindle clockwise/ counter clockwise)

5.3 Jogging the Axes

The axes of the machine can be moved in the following ways:

1. Continuous jog.
2. Incremental jog.
3. Jogging with an electronic handwheel.
4. Jogging to a programmed position.

5.3.1 Continuous Jog

Continuous movement should be done axis to axis. To do this press the JOG key for the
direction of the axis to be moved.
The axis moves with a feedrate equal to the percentage (0% to 120%) of the «F»
feedrate selected.
If during movement the key in the "G00FEED" axis machine parameter. This
feedrate will be applied as long as said key ispressed, and when released the previous
feedrate will be resumed.

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The movement will be made in one of the following ways:

• The axis will only move while the relevant JOG key is pressed.
• The axis will start moving when the JOG key is pressed and will not stop until said
JOG key or another JOG key is pressed again, and in this case the movement is
transferred to what is indicated by the next key pressed.

To jog an axis continuously

1. Select CONTINUOUS under <JOG SELECT>.
2. Select the feedrate for continuous jog under <SPEED/MULTIPLY>.
3. Press the <AXIS/DIRECTION> button for the axis and direction to [Link] axis moves
while the button is held down.
Important: You can jog more than one axis at a time. To jogmultiple axes, press and hold
more than one axis direction [Link] selected axes drive at the feedrate chosen with the
<SPEED/MULTIPLY> switch. If the selected feedrate is above aspecific axis maximum
allowable feedrate, that axis drives at its maximum feedrate. The feedrate for the other
selected axes is not affected.

5.3.2 Incremental Jog

Incremental movement must be done axis to axis. To do this press the JOG key for the
direction of the axis to be [Link] time a key is pressed, the corresponding axis moves
the amount set by the switch. This movement effects the «F» feedrate selected.

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Incremental jog manually moves an axis a predetermined amount each time you press the
<AXIS DIRECTION> button. To use incremental jog:

1. Select INCREMENTAL under <JOG SELECT> .

2. Select the jog increment under <SPEED/MULTIPLY>. The jog increment is equal to
an amount specified in AMP for each selection under <SPEED/MULTIPLY>.
3. Press the <AXIS/DIRECTION> button for the axis and direction to jog.
The control makes one incremental move each time it recognizes the <AXIS/DIRECTION>
button. Until the control completes the execution of the incremental move, no other jog
moves are recognized on tha axis. This includes attempts to perform other incremental
moves on that axis.

Important: You can jog more than one axis at a time. To jog multiple axes, press more than
one axis direction button. The selected axes drive a the feedrate chosen under
<SPEED/MULTIPLY>. If the selected feedrate is above a specific axis maximum allowable
feedrate, that axis drives at its maximum feedrate. The feedrate for the other selected
axes is not affected

5.3.3 Jogging the axes with handwheels

Up to three electronic handwheels may be used to move the axes.

Depending on configuration, there may be a general handwheel to move any axis or

an individual handwheel per axis that will only move its associated axis.

To move the axes with the handwheels, turn the jog selector switch(a)of the
operatorpanel to one of the handwheel positions. Every position indicates the
multiplyingfactor applied to the handwheel pulses; the typical values are the following.

Once the desired resolution has been selected and depending on the type of
handwheel being used, general or individual, proceed as
follow
s.

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There are 3 operating modes with handwheels:

1. Standard handwheel:
2. Path handwheel:
3. Feed handwheel

Standard handwheel: With the general handwheel, select the axis to be moved and turn
the handwheel. With individual handwheels, turn the handwheel associated with the axis
to be Moved.

Path handwheel : For chamfering and rounding corners. 2 axes are moved along a
selected path (chamfer or rounding) by moving a single handwheel. This feature must be
activated via PLC. The general handwheel is assumed as the "path handwheel" or the
individual handwheel associated with the X axis (MCO model) or Z (TCO model).

Feed handwheel: To control the feedrate of the machine. This feature must be activated
via PLC

5.4 Arbitrary Angle Jog.

When you activate this feature, the operator selects two different axes to define a plane
for the arbitrary angle jog to take place in. Then an angle is selected (between 0° and 360°)
to define a vector for the jog. This angle is referenced from the first axis chosen to define
the current plane. Your system installer has the option to predefine this plane and vector
in PAL.
Once this vector has been defined, a jog move can be made along the defined vector by
selecting either HPG, incremental, or continuous jogging modes in the normal fashion The
direction that the wheel travels along the defined vector is determined by your system
installer in PAL.
The feedrate of the wheel is equal to the current feedrate as determined by
<SPEED/MULTIPLY> and <FEEDRATE OVERRIDE>.
This feedrate is the vectorial feedrate for the grinding wheel. Individual axis feedrates
automatically adjust to produce the designated vectorial feedrate. To jog at the maximum
feedrate as set in AMP, hold the <TRVRS> button down while jogging in continuous mode.
Watch and learn “Various modes of CNC machine.
[Link]

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5.5 Jog Offset

The control may be equipped with an optional jog offset feature, activated by a switch
installed by the system installer. When this function is active, all jog moves made are
added as offsets to the current work coordinate system.
Normally, jogging occurs in the manual mode. The system installer has the option to
enable a “Jog on the Fly” feature that will allow jogging in automatic or MDI mode for the
purpose of jogging an offset. To jog in automatic or MDI mode both the “Jog on the Fly”
and jog offset features must be active. Normally, the system installer will enable both of
these features with the same switch. “Jog on the Fly” can be performed at any time during
automatic operation, even while blocks are being executed.
To use this feature, follow these directions:
1. Turn on the switch to activate the jog offset function. Refer to documentation
provided by the system installer.
2. Change to manual mode unless the control is equipped for the “Jog on the Fly”
feature which allows jogging in MDI and Automatic modes. If equipped with “Jog on
the Fly,”turn on the switch to activate it. For details, refer to documentation
prepared by the system installer.
3. Jog the axis by using any of the available jog types, with the exception of homing, as
described on page 4-8. The control adds the amount of the jog move as offsets to
each jogged axis immediately when the jog takes place

5.6 Over travel Protaction :

Overtravel protection must be employed to prevent the damage to the machine due to
the overtravel of the X, Y, or Z axis.

1. Hardware overtravel protection

2. Software overtravel protection
3. Programmable Zone Overtravel.

[Link] overtravel protection: The

overtravel limit switches are fixed at the
positive and negative maximum stroke of the
machine X, Y, Z axis respectively. If the
overtravel occurs, the moving axis slows
down and stops after it touches the limit
switch. And the overtravel alarm is issued.

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In Auto mode, if the tool contacts the stroke limit switch during moving along an axis, all
the axes movement are slowed down to stop with the overtravel alarm being issued. The
program execution is stopped at the block where the overtravel occurs.

In JOG mode, any axis contacts the stroke limit switch, all axes will slow down immediately
and stop.

2. Software Overtravel Protection : The software strokes of the machine are set by the
number parameters, which refers to machine coordinate values.
Overtravel alarm occurs if the machine position (coordinate) exceeds the setting software
stroke. The alarm issued before or after overtravel for software limit overtravel is set by
bit parameter.

During the overtravel alarm, move the axis reversely in JOG mode, the alarm will be
cancelled after the axis is moved out of the overtravel range.

Overtravel Condition Cause

The axes reach a travel limit, usually set by a limit switch or
hardware overtrave sensor mounted on the axis. Hardware overtravels are always
active

Commands cause the grinding wheel to pass a software

travel limit.
software overtravel Software overtravels are active only after the axis has been
homed, provided the feature has been activated in AMP by your
system installer.

The axes reach a travel limit established by ndependent

programmable zone programmable areas.
overtravel Programmable zones are activated through programming the
appropriate G--code.

When a software or zone overtravel has taken place, you cannot move the axis in the
same direction as the overtravel. Only axis motion in the reverse direction is possible
Watch and learn “Various modes of CNC machine .
[Link]

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5.7 Mechanical Handle Feed - (Servo Off)

This feature lets you disable the servo drives and move the axes by external means, such
as a hand crank attached to the ball screw, without requiring the control to be in E-Stop.
When you enable this feature, all position displays get updated as the axes are moved. You
can only enable this feature when the control is in the cycle stop state and the axes are
not being jogged at the time of request.

5.8 Removing an Axis - (Axis Detach)

Use this feature to remove a rotary table or other axis attachment from a grinder without
reconfiguring the system. When activated, the control ignores messages that may occur
resulting from the loss of feedback from a removed axis such as servo errors, etc.
Important: This feature removes the selected axis from the control as an active axis. Any
attempt to move the removed axis results in an error. This means that part programs that
use the removed axis name cannot be executed. Jog moves and MDI commands that
attempt to move the removed axis also result in an error. This feature can only be enabled
in AMP. You must select the axis as “detached.” See your system installer’s documentation
for the necessary steps involved in physically removing axis hardware from a specific
machine.

5.9 Manual Machine Homing

The machine home return operation means the positioning of a specified
linear or rotary axis to a machine-dependent fixed
position, which is called the machine home. This
position is established via a home limit switch
mounted on the machine and the marker on your
feedback device.
The execution of machine home establishes the
machine coordinate system. Since all of the AMP
assigned work coordinate systems and all of the
programmable zones are referenced from the zero point of the machine coordinate
system, none of these features are available until you have conducted the machine
homing operation. Homing the axis should be the first operation done on the control after
power has been turned on.
Important: When a homing request is made the feedback device for the axis (typically an
encoder) must encounter at least one marker beforetripping the homing limit switch. If

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the axis is close to the home limit switch you should jog the axis away from this switch
before attempting a homing operation.

Important: An automatic homing feature is available and is executed by programming a

G28 code.

To execute the manual return to machine home position

1. Select HOME under <JOG SELECT>.
2. Place the control in manual mode .
3. Determine the direction that each axis must travel to reach the home limit switch.
See documentation prepared by your system installer on the location of the home
limit switch on your specific machine.
4. Press the <AXIS/DIRECTION> button for the axis and direction to home. You can
select more than one axis at one time. The axis selected moves at the feedrate under
<SPEED/MULTIPLY>.

Important: If you choose a wrong direction for an axis, it continues to travel in the
selected direction until it contacts a hard limit and an overtravel occurs.

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6.0 CNC PROGRAMMING

6.1 Axis Nomenclature
CNC (computer numerical control) machining is a process in manufacturing where
programmed computer software directs the motions of plant machinery and tools.
Instructions are fed into the CNC machine through a CAD file and transposed into a precise
set of sequential instructions. The CNC machine uses these programmed commands to
operate automatically without a physical operator.
The reference to axes is used to describe CNC machines which operate along multiple
axis points. CNC machining is the process of removing material from a workpiece until the
desired shape is configured. These machines have at least a 3 axes and operate along an XYZ
plane. The number of axes on a CNC machine determines the type of work it can do, the
level of detail it can cut, and the workpiece locations it can manipulate.
Different types of Axis performed in the CNC Machines:
a. 3 Axis
b. 4 Axis
c. 5 Axis

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3 - AXIS
3 axis machining implies that the workpiece remains in the same position while the
cutting tool operates along the XYZ plane to remove a material. They are great for fast and
efficient material removal and making flat or
planar surfaces. While many machines have a
moving bed, the 3 axis milling centers are still
while the cutter itself operates.
3 axis machining is most commonly used to
produce mechanical components and is best
suited for:
▪ Automatic/interactive operation
▪ Milling slots
▪ Drilling holes
▪ Cutting sharp edges

4 - AXIS
A 4-axis CNC machine operates on the X, Y and Z axes like a 3-axis machine, but it
also includes rotation around the X-axis, which is called the A-axis.
4-axis milling is useful when
holes and cut-outs need to be
made in the side of a piece or
around a cylinder. They can
provide quick and efficient work
based off computer numerical
inputs for precise results.
4 axis machining is
multifunctional and can be used
for: Intermittent cutting,
Continuous cutting, Engraving
curved surfaces

5 - AXIS
5-axis machining involves all the axes of 4-axis machining, with an additional
rotational axis. The 5th axis in 5-axis milling machine is around the B-axis, which rotates
around the Y-axis in the X-Y-Z plane.
This multidimensional rotation and tool movement allows for B-axis unparalleled
precision, finish and speed in the production of a piece.

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5 axis machining requires greater

CNC programming preparation time to
accommodate complex rotatory
movement, but allows one workpiece to
be worked on all five sides during one
operation.
5-axis milling machines are the best
CNC milling machines available today,
capable of creating precise and intricate
parts for artificial bones, aerospace
products, titanium pieces, oil and gas
machine parts, car molds, medical,
architectural, and military products.

Axes Movements:
X axis – left to right
Y axis – front to back
Z axis – up and down
A axis – 180° rotation around the X axis
B axis – 180° rotation around the Y axis
C axis - 180° rotation around the Z axis

Comparison of 3Axis , 4Axis and 5Axis CNC Machines:

[Link] 3-Axis 4-Axis 5-Axis

5 axis CNC machine has

Number & 3 axis CNC machine 4 axis CNC Machine
two rotational axes.
movement moves up and down and has one rotational axis,
of axis (X-Y-Z-A-B; X-Y-Z-A-C;
side to side. (X,Y,Z) (X,Y,Z,A)
X-Y-Z-B-C)

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4 axis CNC mill can do

this with the added
benefit of being
5 axis machine can carry
3 axis CNC machines are suitable for working
out much more intricate
widely used for making with cylindrical
and complex work.
Application mechanical parts surfaces and 3D
s
Eg.,
Eg., Milling slots objects
Artificial bones, aerospace
Drilling holes Eg., Intermittent
products.
Cutting sharp edges cutting
Sculpture design work.
Continuous cutting
Engraving curved
surfaces

Cost Low Expensive More Expensive

Maching

Additional Information – Not part the examination

6 Axis CNC Machine:
A 6-axis CNC machine is one of the quite a cutting-edge and efficient solution,
especially for the tools and components that are complicated and require high precision.
The uses of 6-axis CNC machines enable some difficult works like drilling holes of different
diameters and have different cutting patterns and speed. It also contains a smoother
application process. Even, the quality of its final product is extremely superior to other
CNC machines.
The 6 axis machines are mainly designed for volume machining of steel, aluminum,
cast iron and also model making materials. The machine utilizes the unique 3 axis milling
head for allowing simultaneous 6-axis CNC machining, which cuts production times by as
much as 75%.
To understand the CNC Axis Machining; please click the link below
[Link]

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6.2 Coordinate System

The Cartesian coordinate system is the fundamental system used to describe the
motion of the tool and workpiece within a three-dimensional space. CNC machines use
numbers to locate a particular point along the X, Y, and Z-axes. They perform a series of
instructions, one after another, to machine the workpiece and create incredibly
accurate dimensions. When describing a machine operation, the programmer always
calculates tool movements relative to the coordinate system of the stationary workpiece.
For example, you may have a CNC machine on which the tool is always stationary;
however, the workpiece will move in various directions to achieve a finished part.
In this example, when describing the tool motion or coordinate system, you
describe the tool moving relative to the workpiece.
An easy way to understand the Cartesian coordinate system in relation to your CNC
machine is using the Right Hand Rule.

Right-Hand Rule
The machine coordinate system is described by the right-hand rectangular
coordinate system, that is, the rectangular Cartesian system.
Based on this system, the right-
hand rule governs how the primary axis
of a machine tool should be designated.
As shown in Figure, hold your
right hand with the thumb, forefinger,
and middle finger perpendicular to each
other. The thumb represents the X axis,
the forefinger the Y axis, and the middle
finger the Z axis. The other two fingers
are kept closed. The direction of each
finger represents the positive direction
of motion. The axis of the main spindle
is always Z, and the positive direction is
normally into the spindle.
There are three Coordinate system used in the Machines :
a. Machine coordinate system
b. Tool Reference point
c. Workpiece coordinate system.

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Machine coordinate system

The coordinate system set by machine zero taken as origin is called machine
coordinate system. It is set up by manual machine zero
return after power is on. Once set, it remains unchanged till
the power off, system reset or emergency stop. Every CNC
machine has its own internal origin point called Machine
Home. When the CNC first boots up, it has no idea where it
is in physical space and requires a calibration to get its
bearings. When this process occurs, all three axes of the
CNC move towards their maximum mechanical limit. Once a
limit is reached, a signal is sent to a controller which records
the home position for that particular axis. When this occurs
for all three axes, the machine is now “homed.”
The origin of coordinate system used by the workpiece (CAD drawing) may not be
the same as that of machine coordinate system.

Tool Reference point

Good tool setup is critical to good machining
environment. A good setup is important to all the
tools. Tool cutting edge has to be correctly oriented,
securely mounted and it has to be the right type. Its
reference point, used for setup, is also very critical. It
is a fixed point in machine coordinate system set by
machine builder. By reference point return, the tool
move to that position on start up. Generally this point
in CNC milling system coincides with the machine
zero, while the reference point of Machine Center is
usually the tool change point.

Workpiece coordinate system

The coordinate system used for workpiece at
machining is called workpiece coordinate system(or
part coordinate system), which is preset by CNC system. The workpiece-coordinate-
system is a Cartesian coordinate-system
whose origin is within the work piece or at a
corner of the workpiece.
How is coordinate system set if there
are multiple pallets? If there are several
workpieces on the pallet, it is sufficient to
know the workpiece geometry of one
workpiece. Only the zero point of a new pallet has to determined.
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Applications
CNC Milling
The three planes in the Cartesian coordinate
system:

The XY plane, XZ plane, and YZ plane.

The XY plane (G17) is the conventional standard.
G17 – Top Plane Reference
G18 – Side Plane Reference
G19 – Front Plane Reference

To understand the Milling Coordinate system ;

please click the link
[Link]

CNC Turning:
All CNC lathes are two-axis coordinate system. Basically, in CNC turning there is a
primary (horizontal) axis and a secondary (vertical) axis.
When measuring X and Z coordinates, use a central reference point. Start all
measurements at this reference point, the origin (X0, Z0).

For our purposes, the origin is located at the center right-hand endpoint of the workpiece.
Keep in mind that at times the center left-hand endpoint of the workpiece or even the
chuck face may be used.

To understand the Turning Coordinate system ; please click the link below
[Link]

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6.3 Tool Length Compensation

As the name suggests, tool length compensation
enables a cnc machine to compensate for many tools of different lengths .It allows a
machinist to set a Z axis datum on a part and use multiple tools without having to reset the
Z datum for each tool used.

Functions of Tool Length Compensaation:

This function is needed when a cnc machine
has a tool changer and a magazine that holds many different types of cutting tools. An
operator may need to use a lot of these tools in one program.

The machine can change tools automatically, enabling the machine to finish the part
quicker than if the tools were changed by an operator. All the tools are loaded in
interchangeable chucks or arbors with a standard taper clamping system that all cnc
machine tools use.

Different Tool Heights

G Codes used in Tool Length Compensation:

[Link] CODE FUNCTION

1. G43 Tool Length Compensation (Plus)

2. G44 Tool Length Compensation (Minus)

3. G49 Tool Length Compensation Cancel

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G43 code
The G43 Gcode is the most commonly used command to activate tool length
[Link] command will be accompanied with a “H” value to tell the machine
control software which compensation value to apply.
An example line of code : G43 H2 Z1.

G43 Activates the tool length stored in the “H” code offset number.

H2 H value number is usually associated with the tool number.

Informs the control to move from full spindle retract to this “Z” value and
Z1
apply the tool length offset.

The H value number is usually

associated with the tool number,
i.e. Tool 2 will have its tool length
stored in the H2 value block in the
tool offset page.

The H values are all positive so it

will compensate the Z axis position
in a positive direction, moving the machine the exact length of the tool away from the
workpiece.

Using multiple tools means the Z datum has to be set to the face of the spindle without
having any tool loaded

G44 code
This code selects tool length compensation in a negative direction. The tool
length offsets are subtracted from the commanded axis positions. A (Hnn) must be
programmed to select the correct entry from offsets memory.
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G44 is a rarely-used alternative to G43.

It tells the control to begin applying tool length compensation, by subtracting the current
length offset from all Z axis positions.

G49 code
G49 is a G-code that helps in the cancellation of both G43 and G44 tool length
compensation. If you use the offset amount as H00, it can also scrap the tool length
compensation.

G49 functions by canceling the current tool offset and helps it to go back to value zero.
During Automatic Tool Change (ATC), when we use the G43 code, it becomes a useful
code. This code does not require any extra parameters. It neutralizes the value by clearing
out both positive (G43) and negative (G44) shifts.

To understand the Tool Length Compensation ; please click the link below
[Link]

6.4 Cutter Radius Compensation

Cutter radius compensation compensates for the
radius of a cutting tool by causing the controller to maintain a constant offset that is
perpendicular to the programmed path in a two-dimensional plane. You can use this
feature to compensate for the diameter of a cutting tool or the width of a laser.

Functions of CRC :
If diameters of tools are stored in the CNC tool compensation list, the
tool can be moved by tool radius apart from the machining part figure by calling different
radius compensation according to program. This function is called tool radius
compensation.

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G Codes used in CRC:

CODE FUNCTION

G40 Tool radius compensation cancellation

G41 Tool radius compensation turning the Left mode ON

G42 Tool radius compensation turning the Right mode ON

G40 is used for cancelling the tool radius compensation mode. It is also valid for the fixed
cycles (like G77 – G79) and for the roughing cycles (like G70 to G73).

G41 Code
If the
programmed cutter path
needs to mill CLIMB
cutting, and it's a
standard right handed
tool, it will then be
programmed with G41
cutter LEFT of the
programmed path.

G42 Code
If the programmed
cutter path needs to mill with
CONVENTIONAL cutting, and it's
a standard right handed tool, it
will then be programmed with
G42 cutter RIGHT of the
programmed path.

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Format : G00/G01 G41/G42 D__ X__ Y__ F__

Offset value (D value)

The radius offset number is specified by D code, and the new moving instruction value is
obtained by the value of the offset number plusing or subtracting the moving value of the
program.

The offset value of the offset number can be saved into the offset memory in advance by
MDI panel. For the tool radius compensation the effectiveness of the offset value by D
code respecified.

To understand the Cutter Compensation ; please click the link below

[Link]

6.5 Preparatory and Miscellaneous Functions for Milling

Preparatory Function: G code

Preparatory function is represented by G code with the
number behind it, which defines the meaning of the block that contains it.

G-Code
This combination of letters and numerical values in order to perform a specific
machining operation is called as G-Code.
Eg., G00, G01 etc., G- Address ; 00 – Two digit number

G codes are Classified by the following two types:

Classification Meaning
Non-modal G code Effective in the block in which it is specified

Modal G code Effective till another G code of the same group is specified

Gcodes and their Function in Milling:

Gcode Functions
G00 Rapid Positioning (traverse)

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G01 Linear interpolation

G02 Circular interpolation (CW)
G03 Circular interpolation (CCW)
G04 Dwell
G15 Polar coordinate instruction cancel
G16 Polar coordinate instruction (ON)
G17 XY Plane Selection
G18 ZX Plane Selection
G19 YZ Plane Selection
G20 Inch input
G21 Metric input
G28 Reference point return
G40 Tool radius compensation cancel
G41 Left-hand tool radius compensation
G42 Right-hand tool radius compensation
G43 Positive tool length compensation
G44 Negative tool length compensation
G49 Tool length compensation cancel
G54 Workpiece coordinate system 1
G73 Peck drilling cycle
G74 Lef-hand tapping cycle
G76 Fine boring cycle
G80 Canned cycle cancel
G81 Drilling cycle(spot drilling cycle)
G82 Drilling cycle (counter boring cycle)
G83 Peck drilling cycle
G84 Tapping cycle
G85 Boring cycle
G86 Drilling cycle
G87 Back boring cycle
G90 Absolute programming

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G91 Incremental programming

G94 Feed per minute
G95 Feed per revolution
G96 Constant surface speed control(cutting speed）
G97 Constant surface speed control cancel（cutting speed）
G98 Return to initial point in canned cycle
G99 Return to point R level (in canned cycle)

M codes and their Function in Milling:

Mcode Functions
M00 Program dwell
M01 Program optional dwell
M02 Program ends and returns to program begining
M03 Spindle CCW
M04 Spindle CW
M05 Spindle stop
M06 Tool change
M07 Flood Coolant ON
M08 Mist Coolant ON
M09 Coolant Off
M19 Spindle orientation
M30 Program End
M98 Sub Program Call
M99 Sub Program End

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6.6 Preparatory and Miscellaneous Functions for Turning

Gcodes and their Function in Turning:

Gcode Functions
G00 Rapid Positioning (traverse)
G01 Linear interpolation
G02 Circular interpolation (CW)
G03 Circular interpolation (CCW)
G04 Dwell
G20 Inch input
G21 Metric input
G28 Reference point return
G40 Tool radius compensation cancel
G41 Left-hand tool radius compensation
G42 Right-hand tool radius compensation
G50 Maximum Spindle Speed
G54 Workpiece coordinate system 1
G70 Finishing Cycle
G71 Turning Cycle
G72 Facing Cycle
G73 Pattern Repeating Cycle
G74 Drilling Cycle
G75 Grooving Cycle
G76 Threading Cycle
G80 Canned Cycle Cancel
G83 Face Drilling Cycle
G84 Face Tapping Cycle
G85 Face Boring Cycle
G90 Absolute programming
G91 Incremental programming
G96 Constant surface speed control(cutting speed）

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G97 Constant surface speed control cancel（cutting speed）

G98 Feedrate Per Time
G99 Feedrate Per Revolution

M codes and their Function in Turning:

Mcode Functions
M00 Program stop
M01 Program optional stop
M02 Program ends and returns to program begining
M03 Spindle CCW
M04 Spindle CW
M05 Spindle stop
M06 Tool change
M07 Flood Coolant ON
M08 Mist Coolant ON
M09 Coolant Off
M68 Hydraulic chuck close
M69 Hydraulic chuck open
M78 Tailstock advancing
M79 Tailstock reversing
M98 Sub Program Call
M99 Sub Program End

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6.7 Program Format

1) Program number
• Functions as an addressing symbol for accessing the program.
• It is expressed by 4 digit numerals prefixed by the letter O.
• Numerals from 0001 to 9999 can be used.
Example : O 1234
2) Sequence number
• Used search or to call out the position being executed.
• It starts with the letter N followed by numerals up to 5 digits.
Example : N10 G00 X100 Y100
3) Address
• Expressed in alphabets.
Example : N10 G00 X100 Y100
4) Data
• Numerals succeeding the alphabets are called as data.
Example : N10 G00 X100 Y100
5) Word
• The minimum unit for specifying the functions.
• It consists of address and data.
Example : N10 G00 X100 Y100
6) Block
• The minimum command unit required to perform a process.
• It consists of words.
Example : N10 G00 X100 Y100
Program blocks
A cnc program block is normally written as

Eg.,N50 G01 X100 Y-50.02 F100 S1200

• N50 Block Number

• G01 Type of Movement
• X,Y Target Coordinates
• F Feedrate
• S Spindle Speed
Block structure

The sequence in which address codes appear in each block should remain

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consistent throughout the program. It is recommended that the order of these

Address codes follows the example shown below

Functions:
• Preparatory Function (G codes)
• Miscellaneous Function (M codes)
• Tool Function (T)
• Speed Function (S)
• Feed Function (F)

Gcode with Format

Gcode Format
G00 G00 X_Y_Z_
G01 G01 X_Y_Z_F_
G02 G02 X_Y_I_J_F_；(or) G02 X_Y_R_F_
G03 G03 X_Y_I_J_F_；(or) G03 X_Y_R_F_
G40 G17 G40 X_Y_
G41 G18 G41 X_Z_
G42 G19 G42 Y_Z_
G43 G43 H_ Z_ M08
G81 G81 X_Y_Z_R_F_；
G82 G82 X_Y_Z_R_P_F_；
G83 G84 X_Y_Z_R_P_F_；
G84 G85 X_Y_Z_R_F_；

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6.8 Exercise on Part Programming in Milling

[Link] a manual part program for Milling operationfor the component as shown in
drawing

CNC Part Program

N10 G00 G90 X70 Y25 Z1 S800 M3;

N20 Z-5;
N30 G01 X20 F150;
N40 G00 Z100 ;
N50 X-25 Y50 ;
N60 M30;

Explanation

1. N10 Spindle on clockwise rotation at 800 rev/min, tool rapid traverse to

P01
2. N20 Infeed in Z.
3. N30 Tool traverse P01 to P02, feedrate 150 mm/min.
4. N40/N50 Rapid traverse retraction
5. N60 End of program

[Link] a manual part program for Milling operationfor the component as shown in
drawing

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CNC Part Program:

O1000
T1 M6
(Linear / Feed - Absolute)
G0 G90 G40 G21 G17 G94 G80
G54 X-75 Y-75 S500 M3 (Position 6)
G43 Z100 H1
Z5
G1 Z-20 F100
X-40 (Position 1)
Y40 M8 (Position 2)
X40 (Position 3)
Y-40 (Position 4)
X-75 (Position 5)
Y-75 (Position 6)
G0 Z100
M30

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6.9 Exercise on Part Programming in Turning

1. Write a manual part program for Lathe operationfor the component as shown in
drawing

CNC PROGRAM

O0001
N05 G90 G94 G21 M06 T0101;
N10 G00 X0 Z0 M03 S600; [Link] a
N15 G01 X50 F30 M08; manual
N20 G01 Z-40; part
program
N25 G01 X60;
for Lathe
N30 G01 Z-60; operationf
N35 G01 X80; or the
N40 G01 Z-100; componen
N45 G00 X100; t as shown
N50 G00 Z10; in drawing
N55 M05;
N60 M30;

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O0001(Plain Turning);
N01 G40;
N02 G30 P3 U0 W0;
N03 G54 G92 S1000;
N04 G95 F0.2 T0101;
N05 G96 S250 M04;
N06 G00 Z3.0;
N07 G00 X56.0;
N08 G01 X50.0 M08;
N09 G01 Z-40.0;
N10 G1 X56.0;
N11 G00 X200 M09;
N12 G28 U0 W0;
N13 M01;
N14 M30;

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Explanation

N1 Sequence number.
G40 Cancelling G41 & G42
G30 P3 U0 W0 Home position P3-position,U=X axis,W=Y axis.
G54 Work coordinate.
G92 S1000 Limiting speed.
G95 F0.2 T0101 Feed & Tool.
G96 S250 M04 Cutting speed & spindle rotation.
G00 Z3.0 Safety distance for Z axis.
Tool will move rapidly to Z3.0.
That is tool will stop at a distance 3.0 from face.
G00 X56.0 Safety distance for X axis.
Tool will move rapidly to 56 diameter.
As the diameter of raw material is 54.
G01 X50.0 M08 Tool will move in feed to 50 diameter, Coolant ON
This is the turning movement of tool upto Z-40.0 as per
G01 Z-40.0
drawing
G01 X56.0 Tool will return to safety postion with feed
G00 X200 M09 Tool will move to a safety distance of 200 diameter
M09 Coolant ON.
G30 P3 U0 W0 Home position
M01 Optional stop
M30 Program stop

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7.0 CNC MAINTENANCE AND TROUBLESHOOTING

7.1 Coolant - Function, Types, Maintenance and Application.

Metal cutting generates heat due to friction and energy lost deforming the
material. During the machining process
is to cool and lubricate the ferrous or
non-ferrous metal being machined and
the tool. It helps extend tool life and
provide an improved surface finish of
the parts being machined.

If the machine coolant fails to control

the friction created by deformation,
one or both contact surfaces is
eroded. This is the start of the failure of the tools within the operation.

Types of Coolants

Coolants are grouped into four main categories and have a variety of different
formulations. Selecting coolant should be based on the overall performance it provides
centered around your machining application and materials used.

1. Soluble Oils.
2. Semi-synthetic.
3. Synthetic.
4. Straight Oils

Water is a good conductor of heat but has drawbacks as a cutting fluid. It boils easily,
promotes rusting of machine parts, and does not lubricate well.

Coolant Functions

• Reducing and removing the heat build-up in the cutting zone and workpiece.
• Provides lubrication to reduce friction between the tool and removal of the chips.
• Flushes away chips and small abrasive particles from the work area.
• Protects against corrosion.

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How Machine Coolant Systems Work

During the machining process, the coolant mixture floods over the work area. This process
also washes chips and particles away from the work area. Coolant collects in a sump at the
bottom of the machine. The coolant is pumped out of the sump and recirculated to the
work area.

Coolant Concentration

If appropriate concentration levels of coolant are not maintained, several issues can occur.
The most common problem is low concentration. If the concentration of coolant is below
the machine coolant supplier’s minimum ratio, there is a risk of:

▪ Machine and workpiece corrosion.

▪ Reduction in tool life.
▪ Bacterial growth.

Coolant Maintenance

▪ At the start of each day, the coolant should be checked to maintain an acceptable
concentration level.
▪ Hand refractometers are a great way to check cutting and grinding fluid
concentrations to maintain daily control of concentration levels.
▪ Machine coolant concentrations can change 5% to 20% every day from evaporation,
splashing, misting, and dragout.
▪ Keeping a daily log of concentration levels for each machine provides an
understanding of how the system is functioning and how much concentration levels
change from day-to-day.
▪ By selecting the right coolant for the type of machine and metals being machined,
and by maintaining the concentration levels, you extend the life of the coolant, the
tools, and your machine.

Advantages

▪ Achieving tighter tolerances.

▪ Improving surface finish of product.
▪ Maximizing life of the cutting tool.
▪ Evacuation of metal chips from work areas.
▪ Preventing rust to machined part surfaces.

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Disadvantages

▪ Cost related to fluid purchase, storage, maintenance , water fluid disposal.

▪ Environmental impact.
▪ Worker health hazards.

Applications

▪ In Drilling operations that generate discontinuous chips, the main cutting fluid
function is to carry the chips away from the cutting zone, what other wise could
cause chip jamming and, consequently, a possible tool breakage.
▪ Broaching, Milling, Threading with high speed steel tools are typical examples of
these operations where the use of cutting fluids is essential.
▪ In Grinding operations, used for coolants to get a better surface finish.

To understand the Coolant methods ; please click the link below

[Link]

7.2 Understanding and Responding to Alarms in CNC.

It supports a series of alarms that are displayed on the screen to alert you for system
related issues. These system alarms are an integrated part of the controller, they help you
diagnose problems and at the same time help your machine safely.

When an alarm is issued, “ALARM” is displayed at the bottom line of the LCD. Press the key
to display the alarm page,

There are 4 modes

▪ ALARM
▪ USER
▪ HISTORY
▪ OPERATE

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7.3 Machine Maintenance.

Maintenance is a routine and recurring activity of keeping a particular machine or facility

at its normal operating condition so that it can deliver its expected performance or service
without causing any loose of time on account of accidental damage or breakdown.

Objectives of Maintenance
a. The machines are always in an optimum working condition at the lowest possible cost.
b. The time schedule of delivering to the customers is not affected because of non
availability of machinery /service in working condition.
c. The performance of the machinery is dependable and reliable.
d. The performance of the machinery is kept to minimum to the event of the breakdown.
e. The maintenance cost is properly monitored to control overhead costs.

Types Of Maintenance

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Preventive Maintenance: “The maintenance carried at predetermined intervals or

corresponding to prescribed criteria and intended to reduce the probability of failure or
the performance degradation of an item.”

Running maintenance: Running Maintenance includes those maintenance activities that

are carried out while the machine or equipment is running and they represent those
activities that are performed before the actual preventive maintenance activities take
place.

Shutdown preventive maintenance : It is a set of preventive maintenance activities that

are carried out when the production line is in total stoppage situation.

Scheduled Maintenance: It includes those maintenance activities that are repetitive and
periodic in nature such as lubrication, cleaning, and small adjustment.

Corrective Maintenance: Maintaining action for correcting or restoring failed unit. Actions
doing like adjustment, minor repairs to redesign of equipments . Generally once taken and
completed fully.

Usually carried out in four steps :

1st step : collection of data, information and Analysis
2nd step : identifying the causes
3rd step : find out the best possible solution to illuminate likely causes
4th step : Implement those solution

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Breakdown Maintenance: Whenever the failure occurs, breakdown maintenance is

performed to mend the asset and make it return to its operational site again. This
approach is common where an equipment failure doesn’t affect productivity.

But mostly breakdown maintenance is carried out due to an unplanned accident.

For instance, when an important part of a machinery breaks, the maintenance is

performed due to the urgent need for that machine to operate again.

Some examples of breakdown maintenance are:

▪ When equipment cannot be repaired.

▪ When an asset has easy-to-replace parts.
▪ When the part to be repaired is non-critical piece of equipment like hand tools.
Causes of Breakdowns:

▪ Improper Maintenance
▪ Overuse of Machines
▪ Never Replacing Worn Parts
▪ Misaligned Fasteners
▪ Weather-related Issues
Predictive maintenance: Predictive maintenance (PdM) is a type of condition-based
maintenance that monitors the condition of assets using sensor devices. These sensor
devices supply data in real-time, which is used to predict when the asset will require
maintenance and prevent equipment failure.

To understand the CNC Maintenance ; please click the link below

[Link]

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7.4 Tools and Accessories required for CNC Machine Maintenance.

1. Digital millimeters.
2. Screw Driver, spanner and Allen Keys (Complete Set)
3. Megger (Insulation tester.)
4. Standard adapters for clamping the dial indicators while checking out of roundness
of run of spindle.
5. Standard mandrels for testing geometrical accuracies/alignment check.
6. Clip on meter to measure AC/DC current in electrical power cables.
7. Spare Parts List.
a. Contingency spares parts list (Fuses, Belts and standby work holding systems.)
b. Regular spare part list (Limited life time items like wiper, relays, soft jaws/collets,
and other spare for periodic replacements.

7.5 Causes for the failure of Electronic System in CNC

1. Dust failing on the electronic components.

2. Corrosive fumes (coming from coolant interacting with the hot chips)
3. Oil/Coolant dripping through cables.
4. Condensation of moisture.
5. Insects.
6. Poor Ventilation.
7. Improper power supply.
8. Improper earthing.
9. Loose connections and bare control wirings.
10. Non conformance to EMI (Electro Magnetic Interference) guidelines.

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Precaution to be Observed
▪ Ensure proper sealing at the entry of the cables.
▪ Maintain right temperature of the A/C systems.
▪ Ensure that no insects and pests come near the machine tool.
▪ Ensure periodic cleaning of the filters of A/C Systems.
▪ Ensure periodic tightening of cable connections and avoiding bare wires.
▪ Ensure Proper Power Supply.
▪ Ensure Proper Earthing.

Ensure Proper Power Supply

▪ Ensure proper rating of protective switchgears as per the recommendation by the
manufacturer.
▪ Ensure proper rating/cross section of cables as per the recommendation by the
manufacturer.
▪ Ensure switching sequence as per the recommendation of the manufacturer.
▪ Do not mix, neutral and earth lines/wires.

Ensure Proper Earthing

▪ Do not loop earth wire

between the electronic
components.
▪ Ensure proper cross
section of the earth wire at
all the points.
▪ Ensure the earth
resistance at the incoming
terminals.
▪ Do not loop earthing
between different
machines.
• Ensure periodic maintenance of earthing pit.

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7.6 Deviations from Normal Performance in CNC Machine

▪ Size variation
▪ Taper formation.
▪ ovality (out of roundness or run out)
▪ Surface finish less than desirable.
▪ Decreased tool life.
▪ Installing of machine tool spindle.

Causes of Size Variation.

▪ Constant variation.
1. Defective or improper functioning of encoder and coupling.
2. Slippage/Backlash (Identify and measure the value)
3. Slippage of coupling or belt.
4. Variation in coolant flow.

▪ Erratic variation.
1. Cutting parameters change.
2. Present of Backlash.
3. Malfunctioning of encoder.
4. Slippage of couplings.
5. Improper turret clamping.
6. Wear out of guide ways

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7.7 Backlash
Backlash is non-movement of the cnc axis which
occurs on axis reversal. It is a deviation from the
actual position to the value displayed on the screen.

Causes of CNC Backlash

This play (backlash) might be due to
▪ Clearance which is kept in mechanical parts to
reduce friction.
▪ As mechanical parts get loose with time.
▪ As with time mechanical parts keep moving and rubbing each other and after long time
they lose their actual shape and size.

How to identify and measure backlash ?

Mount the dial indicator on turret face and set zero on dial, reverse the axis movement
and come back to the same point.
The dial will now indicate the difference in value which indicate there is a backlash error.

How to compose for the backlash error?

a. Check for ball screw preloading end nuts.

b. Adjust belt tension.
c. Prevent coupling slippage.

To understand the CNC Machine Backlash ; please click the link below
[Link]

7.8 Checklist for CNC Maintenance

Maintenance tasks for CNC machines fall into three general categories:
a. Daily inspections.
b. Jobs that need to be performed every 500 hours or every six months, and
c. Additional inspections to be done every 1000 hours or every year.

Especially if the machine is running around-the-clock or for extended shifts. Five 24-hour
days is 121 hours, meaning that machines which are in nearly constant use could require a
500-hour inspection almost every month.

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Daily Checklist for CNC Machines:

Points to be
Required value Action to be taken
checked
Oil Level Of Hydraulic
Oil level should above If Oil level is low then Top Up oil and
tank & Automatic
from half of Indicator. start the machine.
lubrication tank.
Cooling System of If not ,then inform maintenance
Check the [Link]
Hydraulic department./Check compressor and
should below 32°C.
Tank/Chiller Unit. blower fan.
If not then set the
Cooling system of
Below 25°C. temperature./Check compressor
PLC/Electrical panel.
,temperature sensor and blower fan.
Any leakage from
There should not be any If any leakage and inform to
Hydraulic power
leakage. maintenance department.
Pack/Valve.
Pressure should be
according to
Hydraulic Pressure. If not then set the pressure.
manual(Drawing) of
machine
Condition of Main
Belt should not slip
Spindle Change the belt if it slips.
during breaking.
/Chuck belt .
Any Abnormal sound
from main There should not be any Lubricate the [Link] check the oil
motor/Spindle sound from bearing. flow to bearing.
motor.
If vibration is more then tighten the
check nut of bearing adjustment.
Vibration in Spindle There shoild not be
(For milling head of milling machine)
or Chuck. vibration
For lathe machine check the bearing
of chuck.
Temperature of
If temperature is [Link] the
Spindle Temperature in spindle
[Link] to maintenance
/Chuck(Bearing should be less.
[Link] the bearing.
temp.)
Hydraulic Motor and
Power transmission If there is vibration or noise then
Pump Coupling
should smooth. check the coupling.
Condition.
Ratio of Coolant and water
should be [Link] it Change the coolant if a bad smell
Condition of Coolant. will damage the bed/rust the comes from it.
bed.
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7.9 Best Maintenance Practices

Following are some of the best maintenance practices to be adhered to while carrying out
maintenance of CNC machines.

1. Execution of maintenance activities as per TPM (Total Productive Maintenance) Chart.

2. “Solving” the “Cause” of the problem and not the “Symptom”.
3. Use of “Right” tools, fixtures, equipment and spares.
4. Understanding the accuracy class of bearing, grade of oil and their correct
specifications.
5. Understanding the working of the machine tools by studying the manuals, and circle
diagram supplied by the machine manufacturers.
6. Use of flow chart/cause and defect diagrams and the breakdown history for quick
repair and maintenance /trouble shooting.
7. As far as possible carryout reassembly in a clean room.
8. When the electrical cabinet is in open position do not allow the machine in the
running condition.
9. Do not bypass the interlocks.
10. Follow proper procedure and communication protocols when reporting
service/maintenance problems to the service staff of the CNC machine tool
manufacturing company.

7.10 Troubleshooting - Causes and Remedies

Troubleshooting is a systematic approach to problem solving that is often used to find and
correct issues with complex machines.

[Link] the Wrong Cutting Tools / Settings

Cause : Choosing the wrong cutting tool for the job may often result in poor quality
material finishes. This could be seen as rough edges, cutter marks on the surface, raised
marks, or burn marks on the material’s edges or corners. Extensive tool wear may result
from this error.

Poor material finishes could be due to either bluntness in the tool used, or improper feed
speed ratio. It may also be caused by the wrong dimensions of the tool for the job at hand
in terms of the sizes, quality or match with the material.

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Remedy: To resolve this, it is important to choose the right tool and setting for the job and
material.

2. Errors in Programming

Cause : These may come from a lack of understanding of the different G and M codes used
for the controller, wrong set-up, or inputting the wrong data variables into the CNC
controller.

Remedies : To resolve these errors, it is important for new operators to be adequately

trained in the different ways in which CNC machines can be programmed.

3. Poor Maintenance of CNC Machine Tool

Cause : Failure to clear away dirt, material and other debris could result in a build-up
which over time can result in inaccuracies in machining or even machine failures.

Remedies : To prevent this, it is crucial for machine operators to follow a detailed

maintenance regime for the machine tools in use. They should also regularly check levels
of coolants or airflow, e.g. air filters, to ensure that operations continue to be smooth and
uninterrupted.

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4. Clamping/ Unclamping Problem of Chucks and Fixtures

Cause : This can be a major issue when the piece to be worked on cannot be securely
gripped by the chuck, or if it shifts or vibrates during the machining process.

Remedies :
▪ Check if the part is correctly positioned to ensure secured clamping.
▪ Check if the hydraulic pump and the hydraulic pressure is adequately set-up.
▪ Check if the jaws used are correctly set and adequate for gripping the material.
Ensure a wider surface gripping instead of point gripping.
▪ If the chuck does not open / close, check to see if the foot switch is working – see if
the contacts are still working and that the wires are not broken.
▪ Check to see if the lubricant is adequate for the different parts of the chuck, and that
there isn’t dirt or debris affecting the movements.
▪ Check if the chuck is working based on the MDI M-code command.
▪ Check to see if the output of the solenoid is working. If it does, a broken wire at the
connector could be a problem.
▪ Check if the draw tube which connects the hydraulic cylinder and the chuck is
working, and if it is loose.

5. Power Supply Problems

Cause : Sometimes, the CNC machine tool’s display or different parts may not work due to
issues with the power supply.

Remdies : In most cases, machines have multiple power sources. If you aren’t sure which
one is causing the problem, try checking these locations:

▪ Behind the CRT screen

▪ Door interlock circuit
▪ I/O card
▪ Individual power supplies for the drives and spindle
▪ The external power supply

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[Link] Tool Changer Problems

Cause : The problem is occurring at some point during the automatic tool changing
process.

Remedies :
▪ This could be resolved by learning every step of the tool changing process, and
troubleshooting it by diagnosing what went wrong.
▪ Check that the base, the gripper arm, tool holder, support arm and tool magazines
are working properly and smoothly.
▪ Or examine the swivelling and mechanical arm action to see that they work
properly.
▪ Do also keep the automatic tool changer and tool holders clean of chips and coolant.

[Link] Vibration/ Chatter

Cause : When your CNC machine vibrates when it is doing its job, it could significantly
reduce the life of your tool, affect the durability of your CNC machine, or undermine the
quality of your machined part. You can detect this merely by listening to the noise
generated – this may sometimes be very loud!

Remedies : To resolve this, you need to diagnose if its workpiece chatter or tool chatter.
You can also adjust the RPM of your machining process, so that the frequencies of the
machining process will not resonate with the material frequency.

[Link] of Machine Tool:

Cause : For high volume and long durations of machining, overheating may sometimes
occur. Your CNC machine tool may hit temperatures of 150 degrees or more within. This
could negatively affect the result of your machining job, the tool used, as well as the CNC
machine itself.

Remedies : To avoid this, ensure that you regularly clear all channels and clean the
machine to be free of dirt, soil and material. Have a regular calendar of cleaning up all
metal shavings as well as the liquids used in cutting.
Overheating of a machine spindle comes mainly from extensive usage at highest rpm. A
spindle with Greased Lubrication cannot be used over extensive hours at full rpm. A
spindle with Air-Oil Lubrication is better, while an Oil-Jet Lubrication spindle, like what
Hwacheon is using, has no problem to run the longest hours even at maximum rpm.

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SNO TroubleShooting Possible Causes Remedy

Improper levelling Level the machine as per the chart
Machine Vibrates
1.
while running
Job not balanced Reduce speed.
Improper levelling Level the machine as per the chart
Improper tensioning Adjust the belt tension.
of belts
Clamping of tool is Check the chuck clamping and more
not rigid rigidly placed.
Workholding is not Check the vices and use proper
rigid clamping method
Chatter marks on Ram slide,Cross Tighten the jobs properly
2.
Workpiece slide,tool jibs may
be loose
Hydraulic clamping Ensure the pressure on hydraulic
is not rigid clamps in cross slide.
Wrong tool Check the tool material and
selection geometry.
Improper cutting Select proper feed rate and speed.
parameters
Machine cuts tapers Cross Slide Check the Machine leveland Ensure
3. on the facial runout misalignment the parallelism.
face
Reservoir fluid level Add fluid and check level of reservoir
4. Pump not delivering low to ensure pump in take line of
submerged pump.
Partly clogged Pump must receive intake fluid
intake line or freely or cavitation takes place.
restricted in take
5. Pump making noise pipe
Coupling Check for damaged shaft bearing on
Misalignment the other [Link] necessary replace
and realign the coupled shaft.

To understand the CNC Troubleshooting ; please click the link below

[Link]

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