CNC Machinery. Module 5: CNC Programming / Milling. IAT Curriculum Unit PREPARED BY. August 2009

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1 CNC Machinery Module 5: CNC Programming / Milling PREPARED BY IAT Curriculum Unit August 2009 Institute of Applied Technology, 2009

2 ATM313-CNC Module 5: CNC Programming / Milling Module Objectives: 1. Utilize both preparatory functions (G-codes) and miscellaneous functions (M-codes) in milling. 2. Demonstrate the ability to write a program to manufacture a simple workpiece using the MTS simulator. 3. Verify the program graphically on the computer. Module Contents: 1 Instructions 3 2 G41 and G Chamfer and round programming 5 4 Prepare a setup sheet 6 5 Practical Tasks 8 6 Work sheet 28 2 Module 5: Milling

3 ATM313 - CNC 1. Instructions Four groups of instructions can be differentiated: 1.1 Coordinates (X, Y & Z): same as turning. 1.2 Additional and switching functions: same as turning. 1.3 G-functions: G00, G01, G02, G03, G04, G54, G90, G91, G94 and G95 Are the same as explained in module 4. New important G codes are in the table below: Function G17,G18, and G19 G40 G41 G42 G70 G71 G111 G147 G148 G247 G248 Description Working plane selection Cutter radius compensation OFF. Cutter radius compensation ON Left. Cutter radius compensation ON Right. Input system inch Input system metric Polar coordinate interpolation Approach with a straight line. Leave in a straight line. Approach with a quarter a circle. Leave with a quarter a circle. Module 5: Milling 3

4 ATM313-CNC 1.4 Cycles A cycle allows performing a complete machining operation by entering the needed parameters for this operation. After receiving all needed data from the programmer, MTS generates automatically the suitable instructions to perform the operation. Cycle Cycle 81 Cycle 83 Pocket Holes Description Drilling; to make a hole in one phase. Deep Drilling; to make a deep hole, which requires introducing the tool with several phases. (Chip-breaking and chip removal) To engrave a circular or rectangular area on a surface. To repeat a drilling operation following circular or linear contours. 2. G41 and G42: G41: Cutter radius compensation ON Left. (See Fig. 5.1) Fig. 5.1: G41 G42: Cutter radius compensation ON Right. (See Fig. 5.2) Fig. 5.2: G42 4 Module 5: Milling

5 ATM313 - CNC 3. Chamfer and round programming: Chamfer programming. G1 X Y Z CHF=6 Or G1 X Y Z CHR=11 See Fig.5.3 Fig. 5.3: Chamfer Round programming. G1 X Y Z RND=5 See Fig. 5.4 Fig. 5.4: Round Module 5: Milling 5

6 ATM313-CNC 4. Preparing a Setup Sheet In order to set the machine, a setup sheet is created. This is done by clicking on setup dialog in the bottom menu. At this stage, the software ask for a name for this program e.g. example_1. By clicking on open, the setup sheet preparation procedure begins, where the following has to be mentioned: o Chuck device; Fig. 5.5 Vice orientation Chucking depth (E) Shift of the work part relative to the work part position (V) Shift of the work part on the machine table (Vx, Vy) Fig. 5.5 Chuck device 6 Module 5: Milling

7 ATM313 - CNC o Blank / Zero Point; Fig. 5.6 Blank part s dimensions Material; same like Top Turn material selection Zero point shift Fig. 5.6 Blank / Zero point o Tools The Tools are selected in the same way used in Top Turn. Module 5: Milling 7

8 ATM313-CNC Practical Tasks Practical Task (1) Title: Facing Create an NC program making 2 mm facing. The work part shown in the drawing below is the finished part. 30 mm 50 mm 50 mm Parameters: o Chuck type: RS 110 WS min.10 max.110 Et=32 o E= 15mm o V= 15mm o Vx= 150 mm o Vy= 150 mm o Material: Aluminum Almg1 o Zero point: top side left front work part corner o Zero point shift in Z = -2 mm o Tool: Shell End Mill, MW HSS ISO2586 o Feed rate: 250 mm/min o Spindle speed: 500 RPM o Spindle rotation: clockwise 8 Module 5: Milling

9 ATM313 - CNC Possible Solution: N10 G54 N20 G94 F250 S500 M3 N30 T1 D1 M6 N40 G00 X-23 Y18 Z10 N50 G01 Z0 N60 G01 X73 Y18 N70 G01 Y56 N80 G01 X-23 N90 G00 Z10 N100 G00 X100 Y100 N110 M30 Practical Task (2) Title: Drilling using cycle81 and cycle83 Create an NC Program making the finished work part shown in the drawing below. It is needed to make a 2 mm facing operation prior to drilling. o Small holes depth = 12 mm. o Large holes depth = 50 mm. o Finished part thickness = 50 mm. o All dimensions are in mm. Top View Front View Module 5: Milling 9

10 ATM313-CNC Parameters: o Chuck type: RS 110 WS min.10 max.110 Et=32 o E= 15mm o V= 15mm o Vx= 150 mm o Vy= 150 mm o Material: Aluminum Almg1 o Zero point: top side left front work part corner o Tools: Pos#1: Shell End Mill, MW HSS ISO2586. Pos#2: Drill, DR HSS ISO 235. Pos#3: Drill, DR HSS ISO 235. o Feed rate for facing: 250 mm/min o Feed rate for drilling: 100 mm/min o Spindle speed for facing: 500 RPM o Spindle speed for drilling: 1500 RPM o Spindle rotation: clockwise Possible solution N10 G54 N15 G94 S500 F250 M3 N20 T1 D1 M6 N25 G00 X-35 Y30 Z10 N30 G01 Z0 N35 G01 X165 N40 G01 Z10 N45 G94 S1500 F100 M3 N50 T2 D1 M6 N55 G00 X10 Y10 Z5 N60 G01 Z-12 N65 G01 Z5 N70 G00 X10 Y30 Z5 10 Module 5: Milling

11 ATM313 - CNC N75 G01 Z-12 N80 G01 Z5 N85 G00 X10 Y50 Z5 N90 G01 Z-15 N95 G01 Z5 N100 MCALL CYCLE81(5,0,2,-12) Cycle 81 Drilling Cycle To make a hole in one phase RTP retraction plane absolute ReTraction Plane After the cycle the tool is placed on this height. RTP must be higher than the reference plane. RFP reference plane absolute ReFerence Plane Height of the workpiece surface most time the workpiece reference point is on the surface (RTF=0) SDIS safety distance without sign Safety DIStance The tool traverse without rapid feed until SDIS over reference plane and then changing the working feed DP end depth absolute DePth Depth of the hole related to the workpiece reference point DPR end depth relative to reference plane DePth Relative Module 5: Milling 11

12 ATM313-CNC N105 HOLES1(90,10,90,0,20,3) N110 MCALL N115 G01 Z5 N120 G00 X100 Z100 Y100 N125 T3 D1 M6 N130 G00 X50 Y10 Z5 N135 MCALL CYCLE83(5,0,2,-55,,-5,,2,1,1,1,1) Cycle 83-deep drilling cycle Function : The tool drills up to the requested final drilling depth at the programmed spindle speed and feed rate. The deep hole is machined by repeated incremental plunging depths the maximum value can be determined - until the total depth is reached. After every plunging depth the drill can be either retracted to the reference plane in addition to a safety distance for chip removal or it can be retracted by 1 mm each time for chip breaking. 12 Module 5: Milling

13 ATM313 - CNC Module 5: Milling 13

14 ATM313-CNC N140 HOLES1(50,10,90,0,20,3) N145 MCALL N150 G01 Z5 N155 G0 X100 Y100 Z50 N160 M30 Practical Task (3) Title: Contour Cutting: Using the MTS Simulation software, create an NC Program in order to manufacture the finished work part shown in the drawing below It is needed to make a 2 mm facing prior to the milling operation all dimensions are in mm. o Small holes diameter=5mm. o Small holes depth =16 mm. o Large hole diameter=10 mm. o Large hole depth=10 mm. o Finished part thickness = 38 mm. o All dimensions are in mm. 14 Module 5: Milling

15 ATM313 - CNC Top View Front View Parameters: o Chuck type: RS 110 WS min.10 max.110 Et=32 o E= 10 mm o V= 0 mm o Vx= 200 mm o Vy= 150 mm o Material: Aluminum Almg1 o Zero point: top side left front work part corner o Tools: 1. Face end mill MF HM Slot Milling tool MS K HSS ISO Slot Milling tool Finishing MS K HSS ISO Slot Milling tool MS K HSS ISO Slot Milling tool Finishing MS K HSS ISO Spotting drill DC HSS ISO Tool No. 7: DR HSS ISO Tool No. 8: DR HSS ISO 235 o Feed rate: 250 mm/min o Spindle speed: 500 RPM o Spindle rotation: clockwise Module 5: Milling 15

16 ATM313-CNC Possible solution N10 G54 N15 T1 D1 N20 M6 N25 G94 F250 S500 M3 N30 G0 X-40 Y0 Z2 N35 G0 Z0 N40 G1 X100 N45 G0 Y60 N50 G1 X-40 N55 T2 D1 N60 M6 N65 G94 F150 S475 M3 N70 G0 X-15 Y-15 Z2 N75 G41 G247 DISR=10 X5 Y5 Z-2 N80 G1 Y55 CHR=6 N85 G1 X55 RND=6 N90 G1 Y5 CHR=12 N95 G1 X5 16 Module 5: Milling

17 ATM313 - CNC N100 G40 G248 DISR=10 X-15 Y-15 N105 G41 G247 DISR=10 X5 Y5 Z-4 N110 G1 Y55 CHR=6 N115 G1 X55 RND=6 N120 G1 Y5 CHR=12 N125 G1 X5 Module 5: Milling 17

18 ATM313-CNC N130 G40 G248 DISR=10 X-15 Y-15 N135 G41 G247 DISR=10 X5 Y5 Z-6 N140 G1 Y55 CHR=6 N145 G1 X55 RND=6 N150 G1 Y5 CHR=12 N155 G1 X5 18 Module 5: Milling

19 ATM313 - CNC N160 G40 G248 DISR=10 X-15 Y-15 N165 G41 G247 DISR=10 X5 Y5 Z-8 N170 G1 Y55 CHR=6 N175 G1 X55 RND=6 N180 G1 Y5 CHR=12 N185 G1 X5 Module 5: Milling 19

20 ATM313-CNC N190 G40 G248 DISR=10 X-15 Y-15 N195 T6 D1 M6 N200 G94 S800 F75 M3 N205 G0 X30 Y30 Z10 N210 MCALL CYCLE81(5,0,2,- 4) N215 G0 X30 Y30 Z10 20 Module 5: Milling

21 ATM313 - CNC N220 HOLES2(30,30,20,0,90,4) N225 T7D1 N230 M6 N235 G94 F100 S2000 M3 N240 G0 X30 Y30 Z10 N245 G01 Z-20 N250 G0 X30 Y30 Z10 N255 T8 D1 M6 N260 MCALL CYCLE83(5,0,2,-16,,-5,,2,1,1,1,1) Module 5: Milling 21

22 ATM313-CNC N265 HOLES2(30,30,20,0,90,4) N270 MCALL N275 G00 X100 Y100 Z 50 N280 M30 Practical Task (4) Title: Contour cutting with arcs: Create an NC program making the finished part shown in the drawing below. It is needed to make a 2mm facing prior to slotting; all dimensions are in mm; depth of cut = 2mm and the finished work part thickness = 30 mm. Top View Front View 22 Module 5: Milling

23 ATM313 - CNC Parameters: o Chuck type: RS 110 WS min.10 max.110 Et=32 o E= 15mm o V= 15mm o Vx= 150 mm o Vy= 150 mm o Material: Aluminum Almg1 o Zero point: top side left front work part corner o Tools: Pos#1: Shell End Mill, MW HSS ISO2586 Pos#2: Slot Milling tool, MS K HSS ISO1641 o Feed rate for facing: 250 mm/min o Feed rate for slotting: 150 mm/min o Spindle speed for facing: 500 RPM o Spindle speed for drilling: 475 RPM o Spindle rotation: clockwise Possible Solution: N10 G54 N15 G94 S500 F250 M3 N20 T1 D1 M6 N25 G00 X-23 Y18 Z5 N30 G01 Z0 N35 G01 X123 N40 G01 Y56 N45 G01 X-23 N50 G01 Z5 N55 G94 S475 F150 M3 N60 T2 D1 M6 N65 G00 X-5 Y-10 Z5 Module 5: Milling 23

24 ATM313-CNC N70 G01 Z-2 N75 G41 X5 Y15 N80 G01 Y51 N85 G01 X91 N90 G01 Y9 N95 G01 X3 N100 G01 Z5 N105 G40 X3 Y-10 Z10 N110 G00 X5 Y-10 Z5 N115 G01 Z-4 N120 G41 X10 Y18 N125 G01 Y40 N130 G01 X40 N135 G02 X60 Y40 I10 J-20 N140 G01 X90 N145 G01 Y20 N150 G01 X60 N155 G02 X40 Y20 I-10 J20 N160 G01 X5 N165 G01 Z5 N170 G40 X5 Y-10 Z5 N175 G0 X150 Y100 Z70 N180 M30 24 Module 5: Milling

25 ATM313 - CNC Student's Notes Module 5: Milling 25

26 ATM313-CNC 26 Module 5: Milling

27 ATM313 - CNC Work Sheet 1. For the shown chamfer, the amount of CHR is : 2. From the picture below, the code and the compensation of the tool radius are: a) G43 left b) G41 right c) G41 left 3. From the picture below, the code and the compensation of the tool radius are: a) G42 left b) G42 right c) G41 left Module 5: Milling 27

28 ATM313-CNC 4. Complete the following table: Cycle.. Pocket. Description Drilling; to make a hole in one phase. Deep Drilling; to make a deep hole, which requires introducing the tool with several phases..... To repeat a drilling operation following circular or linear contours. 5. Write the correct code for tool radius compensation to do the cutting operations shown below: A. B. 28 Module 5: Milling

29 6. Use the following list and picture to fill the table below: Material Blank/zero point Tools Dimensions Zero point Zero point shift ATM313 - CNC No. Description Module 5: Milling 29

30 ATM313-CNC 7. Write the appropriate number from the following picture to match the correct description given in the table below: No. Description Vice orientation Shift of the workpart on the machine table Chuck device Vice selection Chucking depth Shift of the workpart in the free direction relative to the workpart position 30 Module 5: Milling

31 ATM313 - CNC 8. Write NC-program to drill the holes shown in the drawing below. Given: - Spindle Speed: 2000 RPM, F200 mm/min - Direction of rotation: Clockwise - Depth of the holes 10 mm. N15 G54 N20 N30 N40 N50 N55 N60 N70 N80 N90 N100 Module 5: Milling 31

32 ATM313-CNC 9. Write NC program to drill the holes shown below. Workpart dimensions are 100*60*20 mm. Holes diameter is 2.5 mm and depth of cut-10 mm. (Other parameters are the same as previous example) N10 N20 N30 N40 N50 N60 N70 N80 N90 References: Milling Programming Manual - MTS 32 Module 5: Milling

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