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DSCEBangalore – 78
MANUALDepartment of Mechanical
EngineeringCIM & AUTOMATION LAB: 10MEL78
CONTENTSPage No.
1. Introduction to CNC Turning, programs on turning 2
2. Introduction to CNC Milling, programs on Milling 32
3. CapsTurn and CapsMill 46
4. Simulation of Hydraulic and pneumatic circuits using LMS Image
Lab (AMESim) Software. 48
5. Exercise Problems 50
6. Definitions of FMS and ASRS 52
1
DSCEBangalore – 78
MANUALDepartment of Mechanical
EngineeringCIM & AUTOMATION LAB: 10MEL78
1. INTRODUCTION TO CNC TURNING, PROGRAMS ON TURNING
NC TECHNOLOGY
1.1 Numerical Control (NC):
It is the acronym for ‘Numerical Control’. Numerical Control refers to the use of coded
numerical information in the automatic control of equipment. NC can be defined as a kind of
programmable automation in which the process is controlled by numbers, letters & symbols. The
numbers letters & symbols are arranged as a ‘program of instructions’ for a particular job. Such a
program is called a part program.
NC can be applied to various operations in engineering, like drafting, machining, assembly,
inspection, etc. The main area of NC application is metal machining operations.
1.2 Basic Components of an NC System:
An NC system consists of three basic components.
1. Program of instructions
2. Machine control unit
3. Machine tool
Above Figure shows the block diagram of an NC machine. The program of instructions sends
commands to the Machine Control Unit, which in turn controls the machine tool.
1.3 NC Coordinate systems:
The relative movement of the machine tool spindle & worktable is due to the individual slides
being operated by instructions from the part program.
Normally, three slides are required in a NC machine tool.
Longitudinal
Vertical
Transverse
2
PROGRAM OF INSTRUCTIONS
MACHINE CONTROL UNIT MACHINE TOOL
DSCEBangalore – 78
MANUALDepartment of Mechanical
EngineeringCIM & AUTOMATION LAB: 10MEL78
The position and direction of movement of each slide is given by the right hand coordinate
system. Here we have three axes X, Y & Z mutually perpendicular to each other.
Position of axes: Usually the Z axis is located (positioned) along the machine tool spindle. The
X axis is positioned parallel to the machine worktable and perpendicular to the Z axis. The Y
axis is perpendicular to both Z & X axis.
Direction of axes: If the movement of the slide is such that the tool moves away from the work
piece, the direction of that slide axis is positive (+ ve). Similarly, if the movement of the slide is
such that the tool moves nearer to or into the work piece, the direction of that slide axis is
negative ( - ve).
Zero points & Reference points:
The accurate position of the machine tool slides with the machine tool is established by the ‘Zero
Point’. The Zero Points may be (a) Machine Zero Point & (b) Work Zero Point.
Machine Zero Point is specified by the manufacturer of the machine. This is the zero point for
the coordinate systems and other reference points in the machine.
Workpiece Zero Point determines the workpiece coordinate system in relation to the machine
zero point. This point is chosen by the programmer, and input into the CNC system when setting
up the machine. The position of this point can be freely chosen by the programmer within the
workpiece envelope of the machine. Its position is chosen such that the dimensions in the
workpiece drawing can be conveniently converted into coordinate values and also to effectively
take care about the clamping/chucking, setting up, etc.
Reference Point or Home Position serves for calibrating and controlling the measuring systems
of the slides and tool traverses. The position of the reference point is accurately predetermined in
every traverse axis by the trip dogs and the limit switches. Therefore the reference point
coordinates always have the same precisely known numerical values in relation to the machine
zero point. After initiating the control system, the reference point must always be approached
from all axes to calibrate the traverse measuring system.
Dimension System: Dimensional information in the work piece drawing can be stated in 2
methods – Absolute Dimensioning & Incremental Dimensioning.
In Absolute dimensioning, the coordinate data are taken with respect to a fixed reference point on
the workpiece drawing (usually the workpiece zero).
3
DSCEBangalore – 78
MANUALDepartment of Mechanical
EngineeringCIM & AUTOMATION LAB: 10MEL78
In Incremental Dimensioning, the coordinate data are taken with respect to the previous
coordinate value. i.e., every coordinate programmed will be the origin for the next coordinate to
be programmed.
1.4 NC & CNC: During the early period of NC technology, most of the control activities in the
controller were performed by electronic hardware devices like diode valves. The electronics
consisted of many mechanical devices which frequently posed problems of non-contact. The
machine tools and processes then controlled by such controllers were called as NC Machines.
With the improvement of technology and with the evolution of ‘integrated circuits’ mechanical
problems with electronic devices were solved. Also with the very fast development of
computers, almost all the control activities, performed by the hardware of the controller unit,
could then be tackled by software (programs). The machine tools and processes presently being
controlled by powerful computers is termed as CNC Machines. CNC is the acronym for
‘Computer Numerical Control’.
1.5 CNC Part Program:
It consists of a set of properly arranged sequence of instructions which when executed
initiates the controller to send various signals to different machine tool drives in accordance with
the program sequence so as to perform the desired work/job.
The CNC program (also called as the CNC part program) is made up of number of ‘lines of
instructions’. Each ‘line of instruction’ is called a Block. Each Block in turn consists of a few
‘alpha-numeric words’ called as ‘CNC Words’
Figure here shows a sample part program depicting the ‘Blocks’ and ‘CNC Words’.
Also, it may be noted that each CNC word starts
with a Word Address (upper-case alphabet) followed
by a numeric data.
Such a CNC program format is called ‘Word
Address Format’.
CNC Words: The different types of CNC words
used in CNC programming are as follows.
4
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MANUALDepartment of Mechanical
EngineeringCIM & AUTOMATION LAB: 10MEL78
a) Sequence Number (N-word): It is used to identify a block.
b) Preparatory function word (G-code): This command prepares the machine controller to
follow a given instruction. E.g. G00 stands for Rapid Movement (point-to-point position)
c) Coordinate Data(X, Y & Z words): These words specify the coordinate position of the
cutting tool. E.g. X15, Y-40, Z-2
Coordinate Data may also contain the I, J & K words which specify the coordinate values
of the arc. I, J & K values are also called as the ‘interpolation parameters’.
d) Arc Radius (R-word): Instead of programming the interpolation parameters (arc-center-
coordinates) I, J & K, the arc radius can be programmed using the R-word.
e) Feed Rate (F-word): These words specify the feed rate of the tool in a machining
operation. It is usually expressed in mm/min. E.g. F30
f) Cutting Speed (S-word): These words specify the cutting speed of the tool/spindle
rotation in RPM. E.g. S1200
g) Tool Selection (T-word): This command is used to access a required tool from a tool
turret or an automatic tool changer. This command is usually used in CNC machines with
Automatic Tool Changing facility. E.g. T10 may specify that a 10 mm drill must be
selected from position number 10 of a tool magazine (holder).
h) Miscellaneous Functions (M-code): These are used to specify certain miscellaneous or
auxiliary functions (coolant on, coolant off, spindle on CW/CCW, spindle stop, etc)
available on the given machine.
NC LATHE
5
Z +Z –
Length
Dia
Face
(0,0)
X
Z
Chuck
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MANUALDepartment of Mechanical
EngineeringCIM & AUTOMATION LAB: 10MEL78
1.6 Dimensional Notations used in CNC lathe are:
1. Absolute Dimensioning – X & Z are used.
2. Incremental Dimensioning – U & W are used.
PointABSOLUTE INCREMENTAL
X Z U W
P1 20 0 20 0
P2 20 -25 0 -25
P3 25 -25 5 0
P4 25 -55 0 -30
P5 30 -55 5 0
P6 30 -80 0 -25
Note: Incremental program is easy to program but tedious to change values in between. Error
committed in any block is carried over to the consecutive blocks. Whereas, absolute
programming is a bit inconvenient as all coordinates are measured from a fixed point. Error
committed in any block will affect only that block. Consecutive blocks are not affected.
6
P1P2
P3P4
P5P6
30
25
20
25 30 25
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MANUALDepartment of Mechanical
EngineeringCIM & AUTOMATION LAB: 10MEL78
1.7 Zero points & Reference points on a CNC lathe:
Above figure shows the location and the relationship between Zero Points & Reference Point on
a CNC lathe.
1.8 Commonly used G-codes on the XLTURN machine:
G00 Positioning(Rapid Feed)
G01 Linear Interpolation(Cutting Feed)
G02 Circular Interpolation CW
G03 Circular Interpolation CCW
G04 Dwell
G17 XY Plane
G18 ZX Plane
G19 YZ Plane
G20 Inch Mode Input
G21 Metric Mode Input
G28 Return To Reference Point(Homing)
G70 Finishing Cycle
G71 Profile Turning Cycle
G72 Profile Facing Cycle
G74 Drilling Cycle
G75 Grooving Cycle
G76 Threading cycle
G90 Turning Cycle
G92 Treading Cycle
G94 Facing Cycle
(0,0)
X
Z
Max Z
Max
X
WM
R
M: Machine Zero Point W : Workpiece(Program) Zero Point
R: Reference point OR Home Position
7
DSCEBangalore – 78
MANUALDepartment of Mechanical
EngineeringCIM & AUTOMATION LAB: 10MEL78
G98 Feed per Minute
G99 Feed per Revolution
1.9 Commonly used M-codes on the XLTURN machine:
M00 Program Stop
M01 Optional Stop
M02 Program Reset
M03 Spindle Forward
M04 Spindle Reverse
M05 Spindle Stop
M06 Auto Tool Change
M08 Coolant ON
M09 Coolant OFF
M13 Spindle Forward and Coolant ON
M14 Spindle Reverse and Coolant ON
M98 Sub Program Call
M99 Sub Program Exit
M30 Program Reset and Rewind
G00 Rapid traverse
When the tool being positioned at a point preparatory to a cutting motion, to save time it is
moved along a straight line at Rapid traverse, at a fixed traverse rate which is pre-programmed
into the machine's control system. Typical rapid traverse rates are 10 to 25 m /min., but can be as
high as 80 m/min.
Format
N_ G00 X_ Z_
8
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MANUALDepartment of Mechanical
EngineeringCIM & AUTOMATION LAB: 10MEL78
G01 Linear interpolation (feed traverse)
The tool moves along a straight line in one or two axis simultaneously at a programmed linear
speed, the feed rate.
Format
N__ G01 X__ Z__ F__
G02/03 Circular interpolation
Format
N__ G02/03 X__ Z__ I__ K__ F__ using the arc center
OR
N__ G02/03 X__ Z__ R__ F__ using the arc radius
G02 moves along a CW arc
G03 moves along a CCW arc
Arc center
The arc center is specified by addresses I and K. I and K are the X and Z co-ordinates of the arc
center with reference to the arc start point.
9
DSCEBangalore – 78
MANUALDepartment of Mechanical
EngineeringCIM & AUTOMATION LAB: 10MEL78
I =(X coord. of center - X coord. of start point)/2
K = Z coord. of center - Z coord. of start point
I and K must be written with their signs.
Arc radius
The radius is
Specified with address R.
G02 X__ Z__ R__ F__
N__ G03 X__ Z__ R__ F__
If the radius is used, only arcs of less than 180 deg. can be programmed in a block. An arc with
included angle greater than 180 deg. must be specified in two blocks.
1.10 Canned cycles
A canned cycle simplifies a program by using a few blocks containing G-codes functions to
specify the machining operations usually specified in several blocks
I. Turning Cycle - G71
Format
G71 U (d) R (e)
G71 P(n) Q(n) U(u) W(w) F(f)
N (n) _ _ _ _
_ _ _ _ _ _ _
_ _ _ _ _ _ _
N (n) _ _ _ _
d = Depth of cut
10
DSCEBangalore – 78
MANUALDepartment of Mechanical
EngineeringCIM & AUTOMATION LAB: 10MEL78
e = Retract amount
n = Number of the first block of the shape
n = Number of the last block of the shape
u = Finishing allowance in X
w =Finishing allowance in Z
f = Feed rate
II. Step Facing Cycle (G94 Cycle):
It is a ‘Box type’ cutting cycle.
SYNTAX:
G94 X… (U….) Z….. (W…..) F…..
Where,
X is the diameter to which the movement is being made OR U is the incremental distance from
the current tool position to the required final diameter.
Z is the Z axis coordinate to which the movement is being made OR W is the incremental
distance from the current tool position to the required Z axis position.
F is the feed rate.
TP-1. Write a program to perform the step facing of the component as shown in the figure:
O1001
([BILLET X30 Z70)
G21 G98
G28 U0 W0
M06 T0101
M03 S1200
G00 X31 Z0
G94 X10 Z-0.5 F30
Z-1
Z-1.5
Z-2
Z-2.5
X20 Z-3
Z-3.5
11
F R
R
F
Tool Entry point
30
20
10
2.5 2.5
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MANUALDepartment of Mechanical
EngineeringCIM & AUTOMATION LAB: 10MEL78
Z-4
Z-4.5
Z-5
G28 U0 W0
M05
M30
12
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MANUALDepartment of Mechanical
EngineeringCIM & AUTOMATION LAB: 10MEL78
III. Step Turning Operation using the Box Turning Cycle (G90):
The Step Turning Operation can be performed by using the “Box Turning Cycle – G90 Cycle” as
below.
SYNTAX:
G90 X…..Z……F…….
Where,
X is the diameter to which movement is being made
Z is the Z axis coordinate to which the movement is being made
F is the feed rate being used
TP-2 Using the G90 Cycle; write a part program to step turn a work piece as shown below:
O1003
G21 G98
G28 U0 W0
M06 T0101
M03 S1200
G00 X30 Z1
G90 X30 Z-55 F30
X29
X28
X27
X26
X25
G00 X25 Z1
G90 X25 Z-25 F30
X24
X23
X22
X21
X20
G28 U0 W0
13
Tool Entry point
30
25
20
30 25
F
R
R
F
Tool Entry
Point
DSCEBangalore – 78
MANUALDepartment of Mechanical
EngineeringCIM & AUTOMATION LAB: 10MEL78
M05
M30
14
DSCEBangalore – 78
MANUALDepartment of Mechanical
EngineeringCIM & AUTOMATION LAB: 10MEL78
IV. Taper Turning Cycle (G90 Cycle):
The above taper turning operation can be performed by the standard “G90 Taper Turning
Cycle”. Its syntax is:
G90 X….Z….R…..F…..
Where,
X is the diameter to which the movement is being made.
Z is the Z axis coordinate to which the movement is being made.
R is the difference in incremental of the cut start radius value and the cut finish radius value.
TP-3 Write a part program to perform the taper turning operation using the “G90 Taper Turning
Cycle (R –ve)” for the work part shown in figure.
O1004
G21 G98
G28 U0 W0
M06 T0101
M03 S1200
G00 X30 Z1
G90 X30 Z-10 R0 F50 [(30-30)/2 = 0]
X30 R-0.5 [(29-30)/2 = -0.5]
X30 R-1 [(28-30)/2 = -1]
X30 R-1.5 [(27-30)/2 = -1.5]
X30 R-2 [(26-30)/2 = -2]
X30 R-2.5 [(25-30)/2 = -2.5]
G28 U0 W0
M05
M30
15
Tool Entry point
30
25
10
DSCEBangalore – 78
MANUALDepartment of Mechanical
EngineeringCIM & AUTOMATION LAB: 10MEL78
TP-4. Write a part program to perform the taper turning operation using the “G90 Taper Turning
Cycle (R +ve)” for the work part shown in figure.
O1005
G21 G98
G28 U0 W0
M06 T0101
M03 S1200
G00 X30 Z1
G90 X30 Z-10 R0 F50 [(30-30)/2 = 0]
X29 R0.5 [(30-29)/2 = 0.5]
X28 R1 [(30-28)/2 = 1]
X27 R1.5 [(30-27)/2 = 1.5]
X26 R2 [(30-26)/2 = 2]
X25 R2.5 [(30-25)/2 = 2.5]
G28 U0 W0
M05
M30
V. Multiple Turning Cycle (G71 Cycle):
The Multiple Turning Cycle is used when the major direction of cut is along the Z axis. This
cycle causes the profile to be roughed out by turning. Two G71 blocks are needed to specify all
the values.
Syntax: G71 U……R……
G71 P…..Q……U…..W…..F……
VI. Finishing Cycle (G70 Cycle):
16
Tool Entry point
30
25
10
X29X28X27X26
X25
Tool Entry Point
Tool Entry Point
U is the depth of cut.R is the relief or retract amount
P is the block number of the start of the final profile
Q is the block number of the end of the final profile.
U is the finishing allowance for the X axisW is the finishing allowance for the Z axis
F is the feed rate
DSCEBangalore – 78
MANUALDepartment of Mechanical
EngineeringCIM & AUTOMATION LAB: 10MEL78
On completion of any roughing operation, the material left as finishing allowance is removed
using the ‘Finishing Cycle’. The same tool path used in the roughing operation is used in the
G70 cycle. The G70 Cycle causes a range of specified blocks to be executed, then control passes
on to the block after the G70 Cycle.
Syntax: G70 P….Q….F…..
Where, P is the block number of the start of the final profile
Q is the block number of the end of the final profile.
TP-5 Write a part program for Multiple Turning operation for the component shown in the
figure.
O1006
G21 G98
G28 U0 W0
M06 T0101
M03 S1200
G00 X30 Z1
G71 U0.5 R1
G71 P1 Q10 U0.5 W0.5 F50
N1 G01 X7
N2 X9 Z-2
N3 Z-15
N4 G02 X14 Z-22 R8
N5 G01 X17 Z-27
N6 Z-32
N7 G03 X22 Z-39 R8
N8 G01 X24
N9 X28 Z-44
N10 X30
G70 P1 Q10 F50
POINT X Z
P1 7 0
P2 9 -2
P3 9 -15
P4 14 -22
P5 17 -27
P6 17 -32
P7 22 -39
P8 24 -39
P9 28 -44
P10 30 -4417
Tool Entry point
30 28
22
17
14
9
R 8
R 8
13 275575
24
P1P2P3
P4
P5P6
P7P8
P9
P10
7
DSCEBangalore – 78
MANUALDepartment of Mechanical
EngineeringCIM & AUTOMATION LAB: 10MEL78
G28 U0 W0
M05
M30
18
DSCEBangalore – 78
MANUALDepartment of Mechanical
EngineeringCIM & AUTOMATION LAB: 10MEL78
TP-6 Write a part program for Multiple Turning operation for the component shown in the
figure. Use a finishing tool for the finishing cycle.
O1007
[BILLET X30 Z70
G21 G98
G28 U0 W0
M06 T0101 (Select roughing tool)
M03 S1200
G00 X30 Z1 (Select Entry Point)
G71 U0.5 R1
G71 P10 Q20 U0.5 W0.5 F50
N10 G01 X8
X10 Z-2
Z-15
G03 X20 Z-25 R10
N20 G01 X30 Z-35
G28 U0 W0
M06 T0303
M03 S1450
G00 X30 Z1
G70 P10 Q20 F40
G28 U0 W0
M05
M30
Note: Whenever a tool change is to be made, current tool must be sent to ‘Home Position’ by
using the G28 command, so as to ensure that turret indexing will not interfere with workpiece or
machine tool parts (work table).
19
Select Finishing Tool
30
20
10 8
R 10
10 13 210
DSCEBangalore – 78
MANUALDepartment of Mechanical
EngineeringCIM & AUTOMATION LAB: 10MEL78
TP-7 Write a part program for Multiple Turning operation for the component shown in the
figure. Note that it is the same component as shown above except that there is an extra taper
before the circular interpolation.
It should be noted that the G71 cycle works only for continuously increasing (for external
operation) or decreasing (for internal operations) dimensions only. Hence the shaded portion in
the figure must be removed separately (by using the G90 R +ve cycle) after using the G71 cycle.
O1008
G21 G98
G28 U0 W0
M06 T0101
M03 S1200
G00 X30 Z1
G71 U0.5 R1
G71 P10 Q20 U0.5 W0.5 F50
N10 G01 X8
X10 Z-2
Z-15
G03 X20 Z-25 R10
N20 G01 X30 Z-35
G00 X10 Z-2
G90 X10 Z-15 R0 F30
X9 R0.5
X8 R1
X7 R1.5
X6 R2
X5 R2.5
G28 U0 W0
M05
M30
20
Tool Entry point
G90 Cycle to machine the taper.
DSCEBangalore – 78
MANUALDepartment of Mechanical
EngineeringCIM & AUTOMATION LAB: 10MEL78
1.12 Subprogram:
A CNC program is divided into a main program & a subprogram. Normally the CNC operates
according to the main program but when a command calling a subprogram is encountered in the
main program, control is passed to the subprogram. When a command indicating a return to the
main program is encountered in the subprogram, control is returned to the main program. The
first block of the main program & sub program must contain a program number starting with
letter ‘O’.
Use of subprogram: When a program contains certain fixed sequences or frequently repeated
patterns, these sequences or patterns can be entered into the memory as a subprogram to simplify
programming. If a subprogram can call another subprogram, it is regarded as a one loop sub
program call.
Syntax: M98 P0000000
M99
21
Subprogram No.
No. of repetitions
Subprogram call
Command used in main program
Command used in Subprogram
O0001
……..
……..
M980012222
……..
……..
……..
M30
Main ProgramO2222
……..
……..
M980013333
……..
……..
……..
M99
O3333
……..
……..
……..
……..
……..
……..
M99
Subprogram Subprogram
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MANUALDepartment of Mechanical
EngineeringCIM & AUTOMATION LAB: 10MEL78
Note: If the Number of repetition is omitted, the called subprogram is executed only once.
22
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MANUALDepartment of Mechanical
EngineeringCIM & AUTOMATION LAB: 10MEL78
TP-8. Write a part program to machine the component shown in the figure making use of a sub
program.
O1009
[BILLET X22 Z70
G21 G98
G28 U0 W0
M06 T0101
M03 S1200
G00 X22 Z1
G90 X22 Z-40 F50
X21
X20
G00 X20 Z0
M98 P0032000
G00 X20 Z-30
G90 X20 Z-40 F50
X19
X18
X17
X16
X15
G28 U0 W0
M05
M30
Note: (1) While writing the subprogram, incremental dimensioning is normally used.
Dimensions which remain constant in every pass can be programmed as absolute dimensions.
(2) Main program and sub-programs are written in separate files
Subprogram Nesting: When one subprogram calls for another subprogram, subprogram nesting
is said to be done.
23
22
15
20
10 5 5 5 5 5 5
Tool Entry point
O2000G90 X20 W-5 R0 F30
X20 R-0.5X20 R-1X20 R-1.5X20 R-2X20 R-2.5
G00 X20 W-5G90 X20 W-5 R0 F30
X19 R0.5X18 R1X17 R1.5X16 R2X15 R2.5
G00 X20 W-5M99
DSCEBangalore – 78
MANUALDepartment of Mechanical
EngineeringCIM & AUTOMATION LAB: 10MEL78
TP-9 Write a part program for the component shown in figure making use of the ‘Subprogram
Nesting’.
O1010
[BILLET X22 Z70
G21 G98
G28 U0 W0
M06 T0101
M03 S1200
G00 X22 Z1
G90 X22 Z-60 F50
X21
X20
G00 X20 Z0
M98 P0012020
M98 P0012020
M98 P0012020
G28 U0 W0
M05
M30
O2020
G90 X20 W-5 R0 F30
X20 R-0.5
X20 R-1
X20 R-1.5
X20 R-2
X20 R-2.5
G00 X20 W-10
G90 X20 W-5 R0 F30
X19 R0.5
X18 R1
24
22
15
20
5 5 5 5 5 5 55 5 5 55
Tool Entry point
O2030
G90 X20 W-5 F50
X19
X18
X17
X16
X15
G00 X20 W-5
M99
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MANUALDepartment of Mechanical
EngineeringCIM & AUTOMATION LAB: 10MEL78
X17 R1.5
X16 R2
X15 R2.5
G00 X20 W-5
M98 P0012030
M99
VII. External Grooving (G81 Cycle):
Syntax: G81 X….Z…..F…..
Where,
X is the diameter up to which the grooving must be done.
Z is the Z-axis coordinate where the grooving must be done.
F is the feed rate.
TP-10 Write a part program for performing the external grooving operation for the component
shown in figure.
O1011
[BILLET X22 Z70
G21 G98
G28 U0 W0
M06 T0101
M03 S1200
G00 X22 Z1
G71 U0.5 R1
G71 P10 Q20 U0.5 W0.5 F40
N10 G01 X10
X12 Z-2
X12 Z-20
G02 X18 Z-27
G01 X18 Z-37
N20 X22 Z-45
25
Tool Entry point
3 mm
Note: The required grooves are 4 mm wide whereas the width of the tool tip is only 3mm. Hence, the sequence of G81 cycles are used twice, during the second set, tool is made to move by 1 mm so that the final groove width will be 4 mm.
22
18
10
R 7
8 27 510 13
12 10
15
4
5
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MANUALDepartment of Mechanical
EngineeringCIM & AUTOMATION LAB: 10MEL78
G28 U0 W0
M06 T0303
M03 S800
G00 X12 Z-15
G81 X11.5 Z-15 F30
X11
X10.5
X10
26
Call grooving tool
DSCEBangalore – 78
MANUALDepartment of Mechanical
EngineeringCIM & AUTOMATION LAB: 10MEL78
G00 X13 Z-15
G81 X11.5 Z-14 F30
X11
X10.5
X10
G00 X19
Z-37
G81 X18.5 Z-37 F30
X18
X17.5
X17
X16.5
X16
X15.5
X15
G00 X19
Z-36
G81 X18.5 Z-36 F30
X18
X17.5
X17
X16.5
X16
X15.5
X15
G00 X19
G28 U0 W0
M05
M30
27
DSCEBangalore – 78
MANUALDepartment of Mechanical
EngineeringCOMPUTER INTEGRATED MANUFACTURING: 06MEL77
VIII. External Threading: The threading operation can be performed by using the ‘Box
Threading Cycle-G92 Cycle’.
Syntax: G92 X…..Z…..F…..
Where, X is the diameter up to which the thread must be cut.
Z is the Z axis coordinate up to which the thread must be cut.
F is the pitch.
ISO Metric Thread Parameters:
For Metric Thread, (60o tool
angle), given the major diameter and pitch, the thread height can be given by:
h = (pitch) × 0.61343
Then the Core (Minor) Diameter can be given as:
Core Diameter = (Major diameter) – 2(h)
Commonly used thread parameters for ISO metric thread:
Major Diameter
(mm)
Pitch
(mm)
Major Diameter
(mm)
Pitch
(mm)
M 2.5 0.45 M 12 1.75
M 3 0.5 M 16 2
M 4 0.7 M 20 2.5
M 5 0.8 M 24 3
M 6 1 M 30 3.5
M 8 1.25 M 33 3.5
M 10 1.5 M 36 428
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MANUALDepartment of Mechanical
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TP-11 Write a part program to perform the threading operation on the component as shown
in the figure.
O1012
[BILLET X22 Z70
G21 G98
G28 U0 W0
M06 T0101
M03 S1200
G00 X22 Z1
G71 U0.5 R1
G71 P10 Q20 U0.5 W0.5 F50
N10 G01 X8
X10 Z-2
Z-25
N20 X22 Z-35
G28 U0 W0
M06 T0303
M03 S800
M98P0022040
G28 U0 W0
M06 T0505
M03 S800
G00 X15 Z2
G92 X10 Z-23 F1.5
X9.75
X9.50
X9.25
X9.00
X8.75
X8.50
X8.25
X8.159
Tool Entry point
O2040
G81 X10 W0 F30
X9.5
X9
X8.5
X8
X7.5
X7
G00 X11
W1
M99
Calculation of Core dia:
Thread height = h = (pitch) × 0.61343
= 1.5 × 0.61343
= 0.920 mmCall grooving tool
Call threading tool
22
10 8 7
2510
4
M10 × 1.5
2
29
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MANUALDepartment of Mechanical
EngineeringCOMPUTER INTEGRATED MANUFACTURING: 06MEL77
G28 U0 W0
M05
M30
Exercise Programs:
EXTRA CLASS
Internal Operation: The motion commands G00, G01, G02 & G03 as well as some of the
cycles G90 (Linear & Taper), G71, G81, etc. can be performed as internal operations also.
Pilot Hole Drilling (G74 Cycle): The Pilot hole required to perform any other internal
operations can be performed by using the G74 Cycle.
Syntax: G74 R……
G74 X…..Z…..Q…..F……
Where, R is the relief or retract amount
X is the diametral position of the hole
Z is length of the hole
Q is the peck increment (in microns, where, 1 mm = 1000 microns)
F is the feed rate
TP-12 Write a part program to perform the ‘Pilot Hole Drilling’ on the component as shown
in the figure.
O1013
[BILLET X30 Z70
G21 G98
G28 U0 W0
M06 T0505
M03 S1200
G00 X0 Z1
G74 R1
G74 X0 Z-8 Q500 F50
G28 U0 W0
M05
M30
Tool Entry point
Call 8 mm center drill
8
8
CENTER DRILL
8
8
30
30
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MANUALDepartment of Mechanical
EngineeringCOMPUTER INTEGRATED MANUFACTURING: 06MEL77
TP-13 Write a part program to perform the internal step turning operation (internal boring)
on the component as shown in the figure.
O1014
[BILLET X30 Z70
G21 G98
G28 U0 W0
M06 T0505
M03 S1200
G00 X0 Z1
G74 R1
G74 X0 Z-8 Q500 F50
G28 U0 W0
M06 T0707
M03 S800
G00 X0 Z2
G74 R1
G74 X0 Z-75 Q500 F30
G28 U0 W0
M06 T0101
M03 S1200
G00 X12 Z2
G90 X12 Z-6 F50
X13
X14
X15
X16
X17 Z-40
X18
X19
X20
X21
12
30
16 22
28
16 20 20 20Tool Entry point
Call 8 mm center drill
Call 12 mm center drill
Call 10 mm boring bar
10
10 mm boring bar
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MANUALDepartment of Mechanical
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X22
X23 Z-20
X24
X25
X26
X27
X28
G28 U0 W0
M05
M30
TP-14 Write a part program to perform the internal contouring operation on the component
as shown in the figure.
O1015
[BILLET X30 Z70
G21 G98
G28 U0 W0
M06 T0505
M03 S1200
G00 X0 Z1
G74 R1
G74 X0 Z-8 Q500 F50
G28 U0 W0
M06 T0707
M03 S800
1520 10 8 10 7 5
17
13
22
28
30
12
R 6
R 5
Tool Entry point
Call 8 mm center drill
Call 12 mm center drill
32
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MANUALDepartment of Mechanical
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G00 X0 Z2
G74 R1
G74 X0 Z-75 Q500 F30
G28 U0 W0
M06 T0101
M03 S1200
G00 X12 Z2
G71 U0.5 R1
G71 P10 Q20 U0.2 W0 F50
N10 G01 X30
X28 Z-5
G02 X22 W-7 R5
X17
W-10
G03 X13 W-8 R6
G01 W-10
N20 G01 X12 W-15
G70 P10 Q20 F50
G28 U0 W0
M05
M30
Call 10 mm boring bar
10
10 mm boring bar
33
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MANUALDepartment of Mechanical
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2. INTRODUCTION TO CNC MILLING, PROGRAMS ON MILLINGCNC MLL
In CNC Mill we have 3 axes – X axis (along length), Y axis (along breadth) & Z axis (along
thickness). The position of the Z axis is along the spindle axis and it is +ve in a direction
away from the workpiece. The position of the X & Y axis is parallel to and on the worktable.
X axis is along the length and Y axis is along the breadth of the table. X and Y axes are +ve
in directions moving away from the workpiece.
2.1 Automatic Tool Changer (ATC): It is a facility or device provided on the CNC Mill for
automatically indexing the tool magazine and making the required tool change as indicated in
the CNC program.
2.2 Automatic Pallet Changer (APC): It is a time saving facility provided on the CNC Mill
for automatically loading and unloading the pallets. Pallets are portable work holding
devices. While a loaded pallet is being used, a machined-component may be unloaded from
the pallet and a to-be-machined workpiece may be loaded on to the pallet.
2.3 Dimensional Notations used in CNC Mill are:
X Coordinate value along the length of the table
Y Coordinate value along the breadth of the table
Z Coordinate value along the vertical to the table
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2.4 Programming Method - Absolute & Incremental Programming:
Absolute programming is specified by the G code G90 and incremental programming by
G91. In absolute programming, coordinate values are measured from the program zero point.
In incremental programming, the coordinate values are measured from the previous
programmed point
Point
ABSOLUTE (G90) INCREMENTAL
(G91)
X Y X Y
P1 0 0 0 0
P2 0 100 0 100
P3 60 100 60 0
P4 60 70 0 -30
P5 100 70 40 0
P6 100 30 0 -40
P7 20 30 -80 0
P8 20 0 0 -30
P1 0 0 -20 0
Note: Incremental program is easy to program but tedious to change values in between. Error
committed in any block is carried over to the consecutive blocks. Whereas, absolute
programming is a bit inconvenient as all coordinates are measured from a fixed point. Error
committed in any block will affect only that block. Consecutive blocks are not affected.
P1
P2
P3
P5
P6
P7
P8
60
40
3 04 0
3 0
20
80
P4
35
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MANUALDepartment of Mechanical
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2.5 Commonly used G-codes on the FANUC Controller CNC Mill
G00
Rapid Traverse (Tool moves at a predetermined rapid speed
without making contact with the workpiece).
G01
Linear interpolation (Tool moves at a speed specified in the feed
word)
G20 Inches programming
G21 Metric programming
G28 Return to reference point OR home position
G02 Circular Interpolation CW
G03 Circular Interpolation CCW
G90 Absolute Programming
G91 Incremental Programming
G94 Feed programmed in mm/min
G95 Feed programmed in mm/rev
2.6 Commonly used M-codes on the FANUC Controller CNC Mill
M01 Optional stop
M02 Program end
M03 Spindle ON CW
M04 Spindle ON CCW
M05 Spindle OFF
M06 Tool change
M08 Coolant ON
M09 Coolant OFF
M30 Program stop & rewind
M70 X Mirror ON
M71 Y Mirror ON
M80 X Mirror OFF
M81 Y Mirror OFF
M98 Subprogram Call
M99 Subprogram end
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MANUALDepartment of Mechanical
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2.7 Subprogram:
A CNC program is divided into a main program & a subprogram. Normally the CNC
operates according to the main program but when a command calling a subprogram is
encountered in the main program, control is passed to the subprogram. When a command
indicating a return to the main program is encountered in the subprogram, control is returned
to the main program. The first block of the main program & sub program must contain a
program number starting with letter ‘O’.
Use of subprogram: When a program contains certain fixed sequences or frequently
repeated patterns, these sequences or patterns can be entered into the memory as a
subprogram to simplify programming. If a subprogram can call another subprogram, it is
regarded as a one loop sub program call.
Syntax: M98 P0000000
M99
Subprogram No.
No. of repetitions
Subprogram call
Command used in main program
Command used in Subprogram
O0001
……..
……..
M980012222
……..
……..
……..
M30
Main ProgramO2222
……..
……..
M980013333
……..
……..
……..
M99
O3333
……..
……..
……..
……..
……..
……..
M99
SubProgram SubProgram
37
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MANUALDepartment of Mechanical
EngineeringCOMPUTER INTEGRATED MANUFACTURING: 06MEL77
MP 1. Write a part program to perform the contour slotting operation on the component as
shown in the figure. The slot should have a width of 8 mm and a depth of 1 mm.
O0003
([BILLET X100 Y100 Z10)
([TOOLDEF T01 D8)
([EDGEMOVE X0 Y0)
G21 G94
G91 G28 Z0
G28 X0 Y0
G90
M06 T01
M03 S1200
G00 X20 Y10 Z5
G01 Z-1 F50 (P1)
G03 X10 Y20 R10 (P2)
G01 X10 Y80 (P3)
X20 Y90 (P4)
X80 Y90 (P5)
G02 X90 Y80 R10 (P6)
G01 X90 Y10 (P7)
X20 Y10 (P1)
G00 Z5
G91 G28 Z0
G28 X0 Y0
G90
M05
M30
X Y
P1 20 10
P2 10 20
P3 10 80
P4 20 90
P5 80 90
P6 90 80
P7 90 10
P1 20 10
70
20
80 060 010
20
P1
P2
P3
P4 P5
P7
P6
10 60
10
10
R 10
R 10
Billet Size 100 x 100 x 10 mm
Cutter Dia: 8 mm
38
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MANUALDepartment of Mechanical
EngineeringCOMPUTER INTEGRATED MANUFACTURING: 06MEL77
MP 2. Write a part program to perform the contour slotting operation on the component as
shown in the figure for program MP 1. The slot should have a width of 8 mm and a depth of 5
mm. Use subprogram with a maximum depth of cut of 1 mm per pass.
O0004
G21 G94
G91 G28 Z0
G28 X0 Y0
G90
M06 T01
M03 S1200
G00 X20 Y10 Z5
G01 Z0 F30
M98 P0051155
G01 Z5
G91 G28 Z0
G28 X0 Y0
G90
M05
M30
O1155
G91 G01 Z-1 F40 (P1)
G90
G03 X10 Y20 R10 (P2)
G01 X10 Y80 (P3)
X20 Y90 (P4)
X80 Y90 (P5)
G02 X90 Y80 R10 (P6)
G01 X90 Y10 (P7)
X20 Y10 (P1)
M99
39
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MANUALDepartment of Mechanical
EngineeringCOMPUTER INTEGRATED MANUFACTURING: 06MEL77
2.8 Slab Milling
MP 3. Write a part program to perform the square slab milling operation on a workpiece of
dimensions 100mm100mm10 mm. The slab’s dimension is 64mm64mm6mm and is
located at the centre of the workpiece. Use a cutter diameter of 10 mm. Take program zero at
the left bottom end of the workpiece.
O1122
G21 G94
G91 G28 Z0
G28 X0 Y0
G90
M06 T01
M03 S1000
G00 X0 Y0 Z5
G01 Z0 F30
M98 P0063456
G01 Z5
G91 G28 Z0
G28 X0 Y0
G90
M05 M30
O3456
G91 G01 Z-1 F30
G90
G01 X100 Y0
X100 Y100
X0 Y100
X0 Y0
X5 Y5
X95 Y5
X95 Y95
X5 Y95
X5 Y5
X10 Y10
X90 Y10
X90 Y90
X10 Y90
X10 Y10
G42 G01 X18 Y18
X82 Y18
X82 Y82
X18 Y82
X18 Y18
X50 Y18
64 mm
64 m
m
100
mm
10 m
m6 mm
100 mm
40
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MANUALDepartment of Mechanical
EngineeringCOMPUTER INTEGRATED MANUFACTURING: 06MEL77
X50 Y10
G40
G01 X0 Y0
M99
2.9 Circular Pocket Milling
MP 4.Write a part program to perform the Circular Pocket Milling operation on a workpiece
of dimensions 100mm100mm10 mm. The pocket’s dimension is R376mm depth and is
located at the centre of the workpiece. Use a cutter diameter of 10 mm. Take program zero at
the top face center of the workpiece.
O1123
G21 G94
G91 G28 Z0
G28 X0 Y0
G90
M06 T01
M03 S1000
G00 X0 Y0 Z5
G01 Z0 F30
M98 P0065973
G01 Z5
G91 G28 Z0
G28 X0 Y0
G90
M05
M30
O5973
G91 G01 Z-1 F30
G90
G01 X5 Y0
G03 X-5 Y0 R5
X5 Y0 R5
G01 X10 Y0
G03 X-10 Y0 R10
X10 Y0 R10
G01 X15 Y0
G03 X-15 Y0 R15
X15 Y0 R15G01 X20 Y0
G03 X-20 Y0 R20
X20 Y0 R20
G01 X25 Y0
G03 X-25 Y0 R25
X25 Y0 R25
G01 X30 Y0
G03 X-30 Y0 R30
X30 Y0 R30 41
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MANUALDepartment of Mechanical
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G41 G01 X37 Y0
G03 X-37 Y0 R37
X37 Y0 R37
X0 Y37 R37
G01 X0 Y25
G40
G01 X0 Y0
M99
2.10 Square Pocket Milling
MP 5.Write a part program to perform the Square Pocket Milling operation on a workpiece
of dimensions 100mm100mm10 mm. The pocket’s dimension is 57mm57mm8mm
and is located at the centre of the workpiece. Use a cutter diameter of 10 mm. Take program
zero at the top face center of the workpiece.
O1124
G21 G94
G91 G28 Z0
G28 X0 Y0
G90
M06 T01
M03 S1000
G00 X0 Y0 Z5
G01 Z0 F30
M98 P0087061
G01 Z5
G91 G28 Z0
G28 X0 Y0
G90
M05
M30
O7061
G91 G01 Z-1 F30
G90
G01 X5 Y0
X5 Y5
X-5 Y5
X-5 Y-5
X5 Y-5
X5 Y0
X10 Y0
X10 Y10
X-10 Y10
X-10 Y-10
X10 Y-10
X10 Y0
X15 Y0
100mm
57 mm
57 m
m
100
mm
8 mm
10 mm
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MANUALDepartment of Mechanical
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X15 Y15
X-15 Y15
X-15 Y-15
X15 Y-15
X15 Y0
G41 G01 X21.5 Y0
X21.5 Y21.5
X-21.5 Y21.5
X-21.5 Y-21.5
X21.5 Y-21.5
X21.5 Y10
X15 Y10
G40
G01 X0 Y0
M99
2.11 Rectangular Pocket Milling
MP 6.Write a part program to perform the Rectangular Pocket Milling operation on a
workpiece of dimensions 100mm100mm10 mm. The pocket’s dimension is
73mm61mm5mm and is located at the centre of the workpiece. Use a cutter diameter of
10 mm. Length of the pocket is parallel to X axis. Take program zero at the top face center of
the workpiece.
O9128
G21 G94
G91 G28 Z0
G28 X0 Y0
G90
M06 T01
M03 S1000
G00 X0 Y0 Z5
G01 Z0 F30
M98 P0058753
G01 Z5
G91 G28 Z0
G28 X0 Y0
G90
M05
M30
O8753
G91 G01 Z-1 F30
Y/X = Breadth / Length =61/73 = 0.8356
Y = (0.8356) X
X (mm) Y (mm)5 4.1781
10 8.356115 12.534220 16.712325 20.890430 25.0685
36.5 30.5
73 mm
100 mm
100
mm
61 m
m
5 mm
10 mm
43
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MANUALDepartment of Mechanical
EngineeringCOMPUTER INTEGRATED MANUFACTURING: 06MEL77
G90
G01 X5 Y0
X5 Y4.1781
X-5 Y4.1781
X-5 Y-4.1781
X5 Y-4.1781
X5 Y0
X10 Y0
X10 Y8.3561
X-10 Y8.3561
X-10 Y-8.3561
X10 Y-8.3561
X10 Y0
X15 Y0
X15 Y12.5342
X-15 Y12.5342
X-15 Y-12.5342
X15 Y-12.5342
X15 Y0
X20 Y0
X20 Y16.7123
X-20 Y16.7123
X-20 Y-16.7123
X20 Y-16.7123
X20 Y0
X25 Y0
X25 Y20.8904
X-25 Y20.8904
X-25 Y-20.8904
X25 Y-20.8904
X25 Y0
X30 Y0
X30 Y25.0685
X-30 Y25.0685
X-30 Y-25.0685
X30 Y-25.0685
X30 Y0
G41 G01 X36.5 Y0
X36.5 Y30.5
X-36.5 Y30.5
X-36.5 Y-30.5
X36.5 Y-30.5
X36.5 Y10
X25 Y10
G40
G01 X0 Y0
M99
44
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MANUALDepartment of Mechanical
EngineeringCOMPUTER INTEGRATED MANUFACTURING: 06MEL77
2.12 Mirroring: If symmetrical contours (symmetry about X axis only, symmetry about Y
axis only OR simultaneous symmetry about both X & Y axes) are to be machined on a
component, the mirroring feature in CNC programming can be selected to ease the task of
programming. Here, part program (usually a sub-program) is written only for one of the
contours of the symmetric pair. Part program for the other part of the pair can be appended by
just selecting the ‘Mirror On’ feature.
M codes that are used for selecting the ‘Mirror On’ feature are:
M70 X Mirror ON means all future X coordinates programmed
are taken with –ve values.
M71 Y Mirror ON means all future Y coordinates programmed
are taken with –ve values.
M80 X Mirror OFF to cancle X Mirroring
M81 Y Mirror OFF to cancle Y Mirroring
Note: (1) Simultaneous mirroring of X & Y values is possible by programming both M70 &
M71.
(2) Mirroring changes the CW arc tool movement to CCW and vice-versa. In other
words, G02 becomes G03 and G03 becomes G02
45
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MANUALDepartment of Mechanical
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MP 7.Write a part program to perform the mirroring operation on the component as shown in
the figure. Take cutter dia = 8 mm. Let the depth of the slot be 1 mm.
O0006
G21 G94
G91 G28 Z0
G28 X0 Y0
G90
M06 T02
M03 S1200
G00 X0 Y0 Z5
M98 P0017577
M70 X Mirror ON
M98 P0017577
M80 X Mirror OFF
M71 Y Mirror ON
M98 P0017577
M70 X Mirror ON
M98 P0017577
M80 X Mirror OFF
M81 Y Mirror ON
G91 G28 Z0
G28 X0 Y0
M05 M30
30
30
10
10
50
5010
10
Billet Size: 100 x 100 x 10 mm
O7577
G00 X10 Y10
G01 Z-1 F50
X10 Y40
X40 Y10
X10 Y10
Z5
G00 X0 Y0
M99
46
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MANUALDepartment of Mechanical
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3. CAPSTURN AND CAPSMILL
3.1 CAPS Mill EXERCISE:
Sequence
numberOperations Tool
1 Facing 50 mm dia face mill
2 Contour pocketing 20 mm dia end mill
3 Rectangular pocketing 20 mm dia end mill
4 Drilling 9.8 mm dia twist drill
5 Counter Sinking 5-20 mm Counter sink 120o
6 Tapping M10 1.5 pitch
M10
1
.5 p
itch,
6 h
oles
on
60
PCD,
60o p
itch,
30
mm
dee
p
All dimensions in mm
47
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MANUALDepartment of Mechanical
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3.2 CAPSTurn EXERCISE:
Sequence
numberOperations Tool
1 Plain Facing External facing tool
2 Contour turning External turning tool
3 Finish turning External finishing tool
4 Finish Facing External facing tool
5 Pilot hole drilling 8 mm dia center drill
6 Peck drilling 8.5 mm dia twist drill
All dimensions in mm
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MANUALDepartment of Mechanical
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4. SIMULATION OF HYDRAULIC AND PNEUMATIC CIRCUITS
USING LMS IMAGE LAB (AMESIM) SOFTWARE.
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MANUALDepartment of Mechanical
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5. Exercise Problems
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52
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MANUALDepartment of Mechanical
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6. DEFINITIONS OF FMS AND ASRS6.1 Flexible Manufacturing System (FMS)
An FMS can be defined as an integrated computer controlled configuration of NC machine
tools, other auxiliary production equipments, and a material handling system designed to
simultaneously manufacture low to medium volumes of a wide variety of high quality
products at low cost. An FMS is capable of processing a variety of different part styles
simultaneously at various workstations, the mix of part styles and quantities of production
can be adjusted in response to changing demand patterns. FMS is the most automated and
technologically sophisticated Group Technology cell. FMS is designed to produce parts (or
products) within a defined range of styles, sizes and processes. A typical FMS is shown in the
below illustration.
MC1- Machining center 1
MC2- Machining center 2
53
6.2 Automatic storage and Retrieval system
An automated storage and retrieval system (ASRS) can be defined as a storage system that
performs storage and retrieval operations with speed and accuracy under a defined degree of
automation. The performance of any manufacturing industry depends mostly on its material
handling and storage system. Generally, ASRS refers to a variety of computer-controlled
methods for automatically depositing and retrieving loads to and from defined storage
locations. Within an automated storage system environment, there are having several layouts
such as horizontal carousels, rotary carousels ,vertical carousels, vertical lift modules, and
fixed aisle storage and retrieval systems. A typical rotary carousels ASRS is show below.