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Mill CNC Prog ramming powered by I immersive.b 01000 G54 G90 G80 G40 GO X-1.0 Y-1.0 T1 M6 (1/2 END MILL) 83200 M3 An introduction to codes and programming, this manual is G43 H1 ZO.1 M8 designed for beginner to intermediate level mill CNC G1 Z-0.050 F20.0 operators and programmers. The content and sample G41 01 XO programs provided cover a broad range of CNC Y3.0 7.000 programming requirements. X2.0 Y4.5 Basic mathematics and formulas are used. X3.0 X5.0 Y2.0 learning materials may be used in conjunction with optional YO Virtual Training Environment for CNC including virtual CNC X-1.0 panels and 3D machines. Details provided in manual. G40 Y-1.0 M9 G28 G91 GO ZO M30 I LEVEL 11 I + 1.248.865.2001 www.immersive.biz learrting Productivity Tools ISBN-13: 978-0-9816982-0-5  Virtual Training Environment powered by Immersive.biz I j CNC Machining Flight Simulator Technology The Virtual Training Environment for CNC Machining combines powerful "flight-simul'ator" technology with a Mimic Reality flexible Internet-based learning content management system to deliver a truly innovative learning experience. Virtual mills and lathes Industrial control panels Edit, load, run and Real-time material removal save NC programs Set tool and work offsets Touch probes Stock material removal Canned cycles Simulated 3D machine models Control alarms Learning Productivity Tool Mill and lathe touch probes Unlimited access to train and rehearse in -the Virtual Training Environment for CNC machining enables learners to develop greater confidence and X l O.GOOOiI'I o.oOOOln proficiency prior to performing actual procedures and operating equipment. Learn at Your Convenience! Learn CNC machine setup and program- ming with popular HAAS control panels! Major Benefits.Cost-effective and safe.24/7 access at your convenience.Track and measure learner progress.Reduce risk to people and equipment.Increase control panel training contact-time.Learn with virtual controls and 3D machines Popular HAAS control panels Lathe applications + 1.248.865.2001 www.immersive.biz learn ing Productivity Tools  Additional Products " powered by Immerslve.biz I j Online Learning Courses and Virtual 3D CNC Machine Mill and Lathe CNC online courses provide the learner with comprehensive learning content, interactive exercises and virtual CNC panels and 3D machines. Depending on the course selected learning modules may include: Absolufo Worlrsheel 8calT"'Clo:talt"""'.,..irF./.J",Kt'j Machine Motion Description li.J:qlo::l': 1 ' ~--r-~.. D~':"'''''''.t'..lc&:.ko;'l.ll«l ToJ1>;~fI\>d''''~~Icl:''''Il CNC Panel Interface x. ~.cir,"~rool"t.otOO' ,,~ilt'O"8ftlO",",; "'OlFMllO CXil-H·U Program Structure (. Ulz.z_~ G_G4.ln'·,..... _. Cartesian Coordinates System Cutter Compensation '''-,.-...... ~:.'."..... ,__ - Tool Nose Radius Compensation Circular Interpolation Hole Manufacturing Programming Labs Interactive online courses Color Manuals, Exercises and Projects Mill CNC Programming Levell An introduction to codes and programming, this manual is designed for beginner to intermediate level Mill CNC operators Other Products and programmers. The content and sample programs provided cover a broad range of CNC programming requirements. Basic and Services mathematics and formulas are used. Robotic simulation eNC lathe Programmin9 Lathe CNC Programming Levell Learning content An introduction to codes and programming, this manual is management system designed for beginner to intermediate level Lathe CNC operators and programmers. The content and sample programs provided Online evaluation tools cover a broad range of CNC programming requirements. Basic mathematics and formulas are used. Content development Onsite training Mill CNC Programming and Applied Mathematics Level 2 This intermediate to expert level manual provides much more CNC programming advanced application of codes, programming, and use of canned cycles. The content and sample programs provided cover a broac range of CNC programming requirements. Advanced mathematics and formulas including applied shop floor trigonometry and geometry are used. + 1.248.865.2001 www.immersive.biz Learning Productivity To Immersive Engineering, Inc. and Powered by lmmersive.biz are registered trademarks. All product names used herein are for identification purposes only and may be trademarks of their respective owners. Immersive Engineering. Inc. disclaims any and all rights in those marks. Copyright Immersive Engineering. Inc.  Table of Contents CNC Mill Programming Levell History of CNC 2 Cartesian Coordinate System :............ 4 CNC Program Structure 25 Hole Manufacturing using Canned Cycles ' 34 Linear Interpolation...................................................................... 44 Tool On, Inside, and Outside 48 Climb vs. Conventional Machining 49 Cutter Compensation 51 Linear Exercises 59 Circular Interpolation with R 67 Circular Exercises 71 Feed rate and Spindle Speed....................................................... 74 Lead In and Lead Out 82 Circular Interpolation with I J 88 CNC Mill Programming Projects 97 Answers and Programs 107 Copyright © Immersive Engineering 000220081 CNC Mill Programming Levell  History of CNC Objectives 1. The student will know the definition of CNC. 2. The student will know the purpose of CNC machining. 3. The student will know the year NC was invented, and by whom. 4. The student will know the benefits of CNC technology. Copyright © Immersive Engineering 000220081 2 CNC Mill Programming Levell  History of CNC HISTORY: In 1949 the Air Force asked John Parsons to develop a machine that would move each axis to specified point location automatically. John then asked Massachusetts Institute of Technology (MIT) to develop a motor that could control the axis of the motion. This.became the servo. This combined technology became known as Numerical Control. NC technology was instrumental in the machining of airfoils for the Air Force. Later, with the invention of the computer and transistor circuitry, Computer Numerical Control (CNC) was born. Although the software and hardware technology have drastically improved over the years, the basic principles today remain the same. CNC technology offers many benefits over manual machining. Simple benefits include the ability to machine more than one part with consistency, and to contour circular features-something difficult to do manually. Complex benefits include High Speed Machining, Hard Milling and Turning, and multi-axis programming-all leading towards total automation. Copyright © Immersive Engineering 000220081 3 CNC Mill Programming Levell  Chapter 1 Cartesian Coordinate System Copyright © Immersive Engineering 000220081 CNC Mill Programming Levell 4  Objectives 1. The student will know the Cartesian Coordinate System and nomenclature. 2. The student will know the signs (+/-) of coordinates in four quadranfs. 3. The student will know the right-hand rule. 4. The student will know Program Part Zero (origin). 5. The student will know how to map drawing coordinates to CNC coordinates using Absolute and Incremental coordinates. Copyright © Immersive Engineering 000220081 5 CNC Mill Programming Levell  Cartesian Coordinate System By adopting the Cartesian Coordinate System-commonly referred to as the Rectangular Coordinate System-drawing coordinates can be mapped to the machine tool table. - Part Zero (origin) is located at the intersection of two axes. The horizontal axis is labeled X. The vertical axis is label Y...... 1-1 '11II - I-\. x-~.1- ~- 'IJ il-\. ~ y- y+ X-axis i"\Ih Y J x+ ~ rfj ~ ~ Copyright © Immersive Engineering 000220081 6 CNC Mill Programming Levell  Quadrants The Cartesian Coordinate System is divided into four quadrants. Motion to the right of Part Zero (origin) is positive (X+). Motion to the left of part Part Zero (origin) is negative (X-). Motion above (north) part Part Zero (origin) is positive (Y+), while motion below (south) part Part Zero (origin) is negative (Y-). Y+ -. -- I ·...".1-..1- l-t--~-". I·'"10- ~.-..",~"..- · - Quadrant +X -X +X -..- -- · +Y +Y -y· ·4 · I I x-+· · XOYO Quadrant 1 ~Y- Copyright © Immersive Engineering 000220081 7 CNC Mill Programming Levell  Right Hand Rule The right-hand rule is used to remind you of the primary axes: X, Y, and Z. This rule applies to both horizontal and vertical machines. Your thumb represents the X-axis. Your index finger represents the Y-axis. Your middle finger represents the Z-axis. y+ Z I~ +, ·~··.I~ ~, ~!f ·I~· ~I. " I ~----~ "I. j4~ XOYOZO X-Axis X+ Copyright © Immersive Engineering 000220081 CNC Mill Programming Levell 8  Machine Part Print CNC Program Machine Tool XOYO 4.5 01000 ,[~I L" '\~ ~ ~I. 3 , / (Part Zero: Lower Left ) G54 G90 GO X-1.0 Y-1.0 T1 M6 'liII ~4.~ /' I 2--- j 1 83200 M3 G43 HI 2.1 G 1 2-0.050 F20.0 G1 G41 D1 XO F50.0 o Datum 0 (I Y3.0 X2.0Y4.5 X3.0 G x- y~G54 023 5 X5.0Y2 Program XOYO YO X-1.0 The machine operator places Drawing dimensions are G40Y-1.0 the part onto the table, positions relative to datum features, G28 G91 GO 20 the XY axes to the datum chosen by the product M30 feature, and labels this 054. designer. For example, it's CNC programs map the - The distance from the machine's home to important that all part print dimensions to this datum feature is stored in a work features be machined within offset register. Work offsets allow parts to ProgramXY tolerance-relative to a coordinates-which. be located anywhere on the table, and essentially move program XOYOto a more particular baseline feature, relate back to the print. convenient location than machine home. such as a dowel pin hole, or XY coordinates become easier to read - G54 references the work a comer. because they're relative to the part print. offset. Copyright © Immersive Engineering 000220081 CNC Mill Programming Levell 9  Program Part Zero (Origin) · Program Part Zero (origin) defines XO YO ZO on the physical part relative to machine zero (Home). - Part Zero can be located anywhere the' programmer desires-usually dictated by the part pri nt.. - The operator locates this point on the machine and defines the Part Zero using a work offset G54 - G59. · There is usually one Part Zero per setup. - The operator picks up the Part Zero using an edge finder, dial indicator, or probing device. 10 Copyright © Immersive Engineering 000220081 CNC Mill Programming Levell  Mapping Coordinates · Drawing coordinates are mapped (expressed) to the CNC machine in one of two methods: - Absolute (G90) coordinat.es are relative to Program Part Zero. This method-by far-is the most common method of programming. - Incremental (G91) coordinates are relative to the previous point location. This method is less commonly used. It's used when operations are repeated, such as four identical pockets located in different locations on the part. 11 Copyright © Immersive Engineering 000220081 CNC Mill Programming Levell  ~ero T 425316 -~ " Oy rt~) ~ Y -2.0 3.0 -2.0 1.0 (~2.0.J Xfrom the Part Mapping Zero. ABSOLUTE ~ y- ABSOULUTE coordinates are measured '-:;/ -'3' 1; -5.0 3.0 5.0 Y+- Part Print Coordinates.. 6) x- x+ Copyright © Immersive Engineering 000220081 CNC Mill Programming Levell 12  Mapping Worksheet 1 -1~ -. '" ~I!Il. -~,t\. - !"-....... va.~ I ~ 5) - -.;;;; Y+ -, xa 4; y- ~~ ~ x- x+ y INT 1 Fill 64253in the Absolute Values xPOINT ABSOLUTE REMEMBER! Each point is relative toXOYO. Copyright © Immersive Engineering 000220081 13 CNC Mill Pr9gramming Levell  --- I -- -,Mapping Worksheet 2 I I 2 ~..- J y+ OYO I I~ 5/ ~ - I I.1 - :::::j L\ ~{3)-=~ I Y- x ". ~ f~~ -, r ~i... -.- ~ x- x+ y OINT 1 Fill 42653in the Absolute Values xPOINT ABSOLUTE REMEMBER! Each point is relative to XOYO. Copyright © Immersive Engineering 000220081 14 CNC Mill Programming Levell  Mapping Worksheet 3.... _.- x- Fill in the Absolute Values ABSOLUTE X Y POINT 1 REMEMBER! POINT 2 Each point is relative POINT 3 to XO yo. POINT 4 POINT 5 POINT 6 15 Copyright © Immersive Engineering 000220081 CNC Mill Programming Levell  Mapping Worksheet 4 Y+......x--. - y- x+ _. -. Y X ABSOLUTE POINT 98710 11 12 Fill in the Absolute Values ABSOLUTE Copyright © Immersive Engineering 000220081 CNC Mill Programming Levell 16  Map each point using ABSOLUTE Coord inates relative to Part Zero. x___ x x x y_... L-.------1C( Y__ I Y 0 Y- 111. X Y- ~... \ /-_--6.F·····..... ¥. x ,i Y P '1~,(i~}··... I_-_.--... ··· l -" i -. -._.0._._. -" "ii' II ,f " --_.- I , \ , -4Ple;..-. ; xo YO. -----;------ "'" J. _ "_ "_ "",. x "'\ -".'--.. 2J)(:HJ Y -------- // \. " \\ x " 1111 '11i x Y Y _. '._.'.'.~.,'.j r- U @ ~ ~  Objectives 1. The student will know the benefits of Cutter Compensation. 2. The student will I- C- O U  Objectives 1. The student will know how to program arcs and circles using U coordinates for Fanuc compatible machines.. 2. The student will know how to program arcs and circles using U coordinates for non- Fanuc compatible machines. Copyright © Immersive Engineering 000220081 CNC Mill Programming Levell 89  CIRCULAR INTERPOLATION WITH !lU" Circular Interpolation with "U" allows you to machine arcs and full circles. - Greater than 0 degrees and less than or equal to 360 degrees Cutting Direction: - G2 = Clockwise motion - G3 = Counterclockwise motion I and J define the center of the arc or circle. There are two main styles of programming: U - FANUC (circle center defined incrementally from start to center) - Non-FANUC (Circle centers defined in absolute coordinates relative to Part Zero) Note: Both methods define the circle centers, but each is unique. Programs with eire-interpolation may be incompatible from machine to machine. CNC programmers must know the style of programming required for each machine. The style is commonly referred to as absolute VS. incremental centers. Copyright © Immersive Engineering 000220081 CNC Mill Programming Levell 90  FANUC Compatible Circular Interpolation with IJ G2X y I J '" J '" J Y Y @ Start Point of arc. @ ® @ End Point (destination) of arc or circle. ® Incrementa/location of arc center in X & Y, respectively, measured/rom Start Point to the Center Point. I represents the direction and distance along the X axis J represents the direction and distance along the Y axis EP------------+ t I I I I I G2 XO Y.5 1.5 JO I Copyright © Immersive Engineering 000220081 CNC Mill Programming Levell 91  FANUC STYLE Incremental IJ Circle Centers Fanuc, Haas, Fadal, Deckel, 2E)()(j._-- ----=~ G2 X3.0 YS.O R.S F' {}SOO I Mitsubishi/Meldas,Okuma ,1]\ -(\) >®---@",,,/' ,,' I I I I,. I../'.... , 1:'l""iDIC,~L , I r ,_" ~'I ~ ~ __ J D E..:;'-- XYR XYIJ 4-< o G2 XS.O Y4.S R.S GS4 G90 GO X-I. Y-L GS4 G90 GO X-I. Y-1. o s::: T2M6 T2M6 'B ~.G43 H2 GO 2.1 G43 H2 GO 2.1 a S1000 M3 S1000 M3 G1 2-.12S F10. M8 G1 2-.12S F10. M8 G2 X.S Y2.S R.S ~- ~ G3 X2.S Y3.0 R.S G41 D2 G1 XO FlO. G41 D2 G1 XO F10. r"'-"('I XOY2. XOY2. r:::-,I.),.,I"-',n I.' :cqpe-----'®.... /C G2 X.S Y2.S R.S (B) G2 x'S Y2.S 1.S JO (B) G1 X2.0 G1 X2.0 G3 X2.S Y3.0 R.S (C) 03 X2.S Y3.0 10 J.S (C) ~,.... h'('11"", _.'-}, '...... ' l-JB G1 Y4.S G2 X3.0 YS.O R.S (D) G1 Y4.S G2 X3.0 YS.O 1.S JO (D) G1 X4.S G1 X4.S $--, IG2 xoAY,S R.S.... I G2 XS.O Y4.S R.5 (E) G1Y,S G2 XS.O Y4.S IO J-.S (E) G1Y,S '1111 'Ill' G2 X4.S YO R.S (F) G2 X4.5 YO I-.S JO (F) Ixoyo~ _®. ---.. G2X4.5YOR.5 5.1,)1)1,) F;/ -~ G1 x'S G2 XO Y,S R.S (A) G1 x'S G2 XO Y,S 10 J.S (A) G40 G1 X-LO G40 G1 X-1.0 ®Start Point G28 G91 GO 20 028 G91 GO 20 ®End Point Copyright © Immersive Engineering 000220081 92 CNC Mill Programming Levell  NON-FANUC Compatible Circular Interpolation U G2X y I J \. J \.__ J @ Start Point of arc. @ Y y ® @ End Point (destination) of arc or circle. ® Absolute location of arc center in X & Y, respectively, measured from program Part Zero. t' I I I : G2 XO Y.5 10 JO I Copyright © Immersive Engineering 000220081 CNC Mill Programming Levell 93  NON FANUC COMPATIBLE Absolute IJ Circle Centers Boss, AoUam, Heid, Hurco, Fidia 2'.l)(J() G2 X3.0 Y5.0 R.5 F:'. "-,,r.::('(j I,) "_} ~_I',_, /®I @---.// '" II ,_.,' '.L"r.' (1\/Dlrr, A XYIJ.1111 ~ 1/" ~ I I.··· G54 G90 GO X-I. Y-I. ~ --.JD E""-- 4-< T2M6 o G2 X5.0 Y4.5 R.5 t:: G43 H2 GOZ.l o SlOOOM3 "-g Il) $-< Gl Z-.125 FlO. M8 C5 G4l D2 Gl XO FlO. G2 X.5 Y2.5 R.5 i-\If) G3 X2.5 Y3.0 R.5 XOY2. G2 X.5 Y2.5 1.5 J2. Gl X2.0 (B) S.OC:II') III i//wpl--------. "~ O"l 0'1 c.. 01 ~ J C) ,..... C)....J ~ Vl ~ a..rt:l 0'1.-...EN0;;0E z~OJ Q) r-.... OJ Q) 0 «  00 O"l ~" I o I I cen Z CL "- "- OJ I, U E ~ +-' u OJ.~ o -.- ~ c.. 00 oo N N oo o 0'\ C.;: Q) Q) I' C 0'\ C LJJ Q) (.2:: ~ Q) ~-----l E 6(~ I-1'-',: I:....L >.._- @ E.. J::: ('~~) f-- 0'\.~ C. o U  N o , " ~:=::' Ln o..L IfII,II ,-- (:=-:.: -z 001 > 01 , ])I, (... C....I rn E -- --q- " ~u (]) 0.. u... u....., OJ I~---'/' //' t.~ o..... ~ I.. -.- ~ c.. LL 00 :J:~.' -._ -.0,1,... ~. o o N N oo o I~~:~ 01 c ';: Q) Q) c 01 c UJ Q) ,::: ~ Q) E E @... ~ 01 ';: > Q. o U  Mill Project 201 ,3_()() l.se)..... ,'1", / \"1 :::~l.C)(~) --1-'1'........ ~~:,.,. ,I I 'I I', " \. F:' (', '. ('T'rF') -' 1.. ~-=-, ,_.,' ":1 l.. :)IJ ~. ,! "I, " ',I'; -0'\,---",. f Copyright © Immersive Engineering 000220081 CNC Mill Programming Levell 103  r- --=-.:: " ,- ----'4 =-~- N oN t t, Q) """T >Q) ,.,---., i'----"- I....J I 01 -.J C I E I E fIl... 01 I o... , 0... I ~ I u z u -.- I , I I " I ',' I -.-- '.. ;//'1'....J 01 I... C E t E rd "- 01 o "- Q.. ~ U Z --- U I I I 00 o o I N N o o I o r ~ cen ''::