CNC Machining Simulation Lab

Tutorial

Work Integrated Learning Program

WISE Simulation Lab
Birla Institute of Technology & Science, Pilani
 Errors to IGNORE During the tutorial

While creating new

project software will
ask you to save the NC
file, if you say YES then
After cycle start you may get
the above error
this error dialogue box, ignore
message may appear. this error, click CLOSE and
Ignore this error continue. If the error continues,
message just Click OK Ignore the floating decimals in
While switch ON the controller above error
and continue to your origin while editing in the
may appear, just ignore this error and
next steps. program. Just enter the
proceed with next steps. reference value as whole
numbers without any decimal
You may get these ignorable error messages during any tutorial. points
Collision and Over Travel error because of your wrong inputs

 “Collision Occur” is a common error message you will get because of your wrong input parameters. This
indicates that your input parameters are leading the spindle in wrong path instead of proper material
removal and collision occurs between the tool, work piece clamping fixture or the table

 Reasons for Collision and Over Travel

 Wrong work part origin reference value in NC program and
 Wrong tool dimensions

 Remedy
 Enter correct reference value as mentioned in the TUTORIAL Manual
 Enter correct tool nomenclatures as mentioned in the TUTORIAL Manual
Problems

Sl. No. Operation Workpiece size Tool used Controller

Vertical Milling
1. □ 100 x 100 x 20 Flat end mill ∅16 H 100 Siemens - Sinumeric
(Linear Interpolation)
Vertical Milling
2. □ 80 x 80 x 20 Flat end mill ∅24 H 100 Siemens – Sinumeric
(Profiling)
Vertical Milling
3. □ 80 x 80 x 20 Flat end mill ∅16 H 100 Fanuc 21i-MB5
(Profiling)
Flat end mill ∅ 20 H 100
Vertical Milling Central Drill -∅3 H 100
4. □ 100 x 100 x 20 Fanuc 21i-MB5
(Profiling) Drill ∅8.5 H95
Tap D10 H100
Horizontal Milling
5. □ 205 x 155 x 100 Ball End Mill D8 H100 Siemens – Sinumeric
(Profiling)
Problem 1: Vertical Machining-Linear Interpolation

Lab Perquisites: Basics of NC code in connection with vertical machining is required. Knowledge about face

end mill tool and their corresponding nomenclatures is mandatory before entering to this example.

Workpiece size: Rectangular piece (100 x 100 x 20 mm)

Mounting details: Length : 50mm & Height : 35 mm

Tool required: V-CNC Pro

Goal: To do the basic facing and profiling on the above workpiece in Siemens machining center.

At the end of this example students will understand how to do the machining operation in Siemens 840 D

controller and further a student shall interpret the NC code.

Problem 1: Vertical Machining-Linear Interpolation

Given work part diagram

Problem 1: Vertical Machining-Linear Interpolation

Desired work part diagram

Problem 1: Vertical Machining-Linear Interpolation

Experiment Outline
Part I : Set up the workpiece and machine Part II : Set up the controller and cycle start
 Open V-CNC Pro Mill Software  Simulation environment settings
 Save Project  Set collision check
 Open wizard floating menu  Type NC code in Controller
 Select machine  Offset Settings
 Select controller  Spindle Zero Return
 Open NC File  Start the machining process
 Create work part
 Load work part
 Edit Magazine & Tool
 Set origin of the work part
Problem 1: Vertical Machining-Linear Interpolation

Experiment Outline (Contd.,)

Part III – Verification
 Verification of Machined component window open
 Verification of Machined component: Tool path
 Verification of Machined component: Gouge check
 Verification of Machined component: View sections
 Verification of Machined component: Work part drawing preparation
 Verification of Machined component : Save Work part diagram
 Save and close the project
Problem 1: Vertical Machining-Linear Interpolation

Shortcuts to represent various mouse shortcuts in the tutorial for convenience.

LMB: Left Mouse Button Single click RMB: Right Mouse Button click once

DLMB: Left Mouse Button Double click

 Problem 1: Vertical Machining-Linear Interpolation

Experiment Outline
Part I : Set up the workpiece and machine
Step 1: Open V-CNC Pro Mill Software
 Once log in to the citrix server, click
VCNCProStart.
 VCNCProStart window will appear
 Click Machining Center in the
window and wait for some time, then
you can see VCNC Promill software
window open in your system.

V-CNC Pro Mill Software Interface

Part 1: Set up the workpiece and machine

 Problem 1: Vertical Machining-Linear Interpolation

Step 2: Reset the toolbar

 View (LMB)
Toolbars (LMB)
Init Toolbar (LMB)

Note: There may not be any changes in the screen after this step, proceed to next step.
Part 1: Set up the workpiece and machine
 Problem 1: Vertical Machining-Linear Interpolation
Step 3: Save project
 File (LMB)
Project save(LMB)
 Save as project file window will pop up
LMB the drop down menu (Save in:)
Personal Directory (P:) (LMB)
Create new folder inside the
personal directory and name it as your
BITS ID (for example 201518… )
 DLMB the created folder
 Type File name”Tutorial1”
 Save (LMB)

Part 1: Set up the workpiece and machine

Problem 1: Vertical Machining-Linear Interpolation

Step 4: Open wizard floating menu

 Settings (LMB)
 Wizard (LMB)
 Now you can see the floating window
included the steps, Set User
Information, Select Machine and so on.

Part 1: Set up the workpiece and machine

Problem 1: Vertical Machining-Linear Interpolation

Step 5: Select Machine

 Select Machine (LMB) (in wizard)
 Now Select Machine window will Tool Magazine
pop up.
 1_Vertical M-C (LMB) Tool Head
 Apply (LMB)
Tool Assembly

Work part and

Fixture
Table
Rotate, Move and other icons

Directions in vertical
machining center

Part 1: Set up the workpiece and machine

Problem 1: Vertical Machining-Linear Interpolation

Step 6: Select Controller

 Select Controller (LMB) (in wizard)
 Now Select Controller window will
pop up.
 Commercial controllers (LMB)
 Among the list of controllers
select Siemens 840D(M/C) (LMB)
 Apply (LMB)
 Controller interface window will
pop up now.
 Maximize the controller interface
to have a better view. (Refer next
page for the maximized controller
interface)

Part 1: Set up the workpiece and machine

Problem 1: Vertical Machining-Linear Interpolation

Part 1: Set up the workpiece and machine

Problem 1: Vertical Machining-Linear Interpolation

CRT Screen

Part 1: Set up the workpiece and machine

Problem 1: Vertical Machining-Linear Interpolation

Control Panel

Part 1: Set up the workpiece and machine

Problem 1: Vertical Machining-Linear Interpolation

Control Panel

Part 1: Set up the workpiece and machine

Problem 1: Vertical Machining-Linear Interpolation

Control Panel

Part 1: Set up the workpiece and machine

Problem 1: Vertical Machining-Linear Interpolation

Key Pad

Part 1: Set up the workpiece and machine

Problem 1: Vertical Machining-Linear Interpolation

Soft Key Screen

Part 1: Set up the workpiece and machine

Problem 1: Vertical Machining-Linear Interpolation

Part 1: Set up the workpiece and machine

Problem 1: Vertical Machining-Linear Interpolation

Part 1: Set up the workpiece and machine

 Problem 1: Vertical Machining-Linear Interpolation
Step 7: Create Work Part
 Create Work Part (LMB) (in wizard)
 Create work-part window will appear
 Type 100 in W(width) and D(depth) box
 Type 20 in H(height) box
 Let the material be unchanged
 Reload (LMB)
 Wait for a moment, work part will be reloaded
in the fixture.
 Now the work part will be loaded in the fixture.

 Skip the NC code step, hence we are going to type the

problem in controller.

Part 1: Set up the workpiece and machine

 Problem 1: Vertical Machining-Linear Interpolation
Step 8: Load Work Part
 Load Work Part (LMB) (in wizard)
 Load work-part window will appear
 Type 50 in Mounting Length box
 Type 35 in Mounting Height box
 Load (LMB)
 Create Work Part (LMB)
 Reload (LMB)
 Wait for a moment, work part will be reloaded
in the fixture.
 Now the work part will be loaded with the
specified mounting height and length in the
fixture.
Part 1: Set up the workpiece and machine
 Problem 1: Vertical Machining-Linear Interpolation
Step 9: Edit Magazine & Tool
 Edit Magazine & Tool (LMB) (in wizard)
 Magazine window will appear
 Flat end mill (LMB)
 Modify Tool (LMB) below window will appear
 Edit the Tool Dia. 10 into 16.
 (DLMB the tool dia text box and delete value
10 & type 16, then press ENTER)
 OK (LMB)

Part 1: Set up the workpiece and machine

 Problem 1: Vertical Machining-Linear Interpolation
Step 9: Edit Magazine & Tool (Contd.,)
 Now Tool library manager window will disappear
and magazine window will appear.
 Add tool (LMB) in magazine window Spindle
 OK (LMB). Tool no
 Now do you want to save pop up window will
appear press Yes.

Spindle Tool No.

Edited tool should be
add in Spindle tool
no “1”. If you see any
other number in the
spindle number use
<<Prev tool and
Next Tool>> to swap
tools. Swap to “1”
and add the edited
tool.

Part 1: Set up the workpiece and machine

 Problem 1: Vertical Machining-Linear Interpolation
Step 9: Edit Magazine & Tool (Contd.,)
 LMB the drop down menu (Save in:)
 Personal Directory (P:) (LMB)
 Your folder DLMB
 Type File name”Tutorial1-Tool”
 Save (LMB)
 Tool library has been saved
confirmation window will appear
click ok.

Part 1: Set up the workpiece and machine

 Problem 1: Vertical Machining-Linear Interpolation
Step 10: Set origin work part
 Set origin work part (LMB) (in wizard)
 Work-Part origin setting (auto) window will appear
 Click the corner of the rectangle as shown
 In Work-Part drop down box click Hexahedron
 Apply (LMB).
 Close (LMB)

Part 1: Set up the workpiece and machine

 Problem 1: Vertical Machining-Linear Interpolation
Part II : Set up the controller and cycle start
Step 1: Simulation Environment settings
 Settings (LMB)
 Environment setting (LMB)
 Environment Setting window will appear
 Reduce the simulation speed to 50% (drag the
horizontal bar towards left)
  Simulation On is selected.
  Select High speed mode not use
  Give Tool Tolerance of 0.05
  Select the Show tool path option
  Click OK.

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Step 2: Set collision check
 Settings (LMB)
 Set collision check (LMB)
 Collision Setting window will appear
 Select Stop
 Apply (LMB)

When there is a collision occurs between tool,

table, or any other components machining
operation will be stopped.

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Step 3: Type NC code in Controller
 Maximize the controller window
 Machine Area Key (LMB)
 Menu Selection Key (LMB)
 AUTO Softkey (LMB)
 Machine Area Key (LMB)
 Correct Program Softkey (LMB)
 Correct’n Block editor window will open as
shown in below figure.

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Step 3: Type NC code in Controller (contd.,)
 Type the below NC code in the block editor.
 Verify the program once and click Close editor
softkey

O 0002 N10 X2.;

N1 G71 G40; N11 Y2.;
N2 M6 T1; N12 G42 Y20. D1;
N3 G54 G90 X0 Y0 Z100 G00; N13 X80.;
N4 M8; N14 Y80.;
N5 G0 X-12. Y2.; N15 X20.;
N6 G43 Z20. S700 M03; N16 Y16.;
N7 G1 Z-6. M8 F200; N17 G40 X-12.;
N8 G1 X98. ; N18 G0 Z50. M09;
N9 Y98.; N19 M05;
N20 M30;

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Step 4: Cutter compensation
 Maximize the controller window
 Machine Area Key (LMB)
 Menu Selection Key (LMB)
 Parameter Softkey (LMB)
 Parameter window will appear as
shown below

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Step 4: Cutter compensation (Contd.,)
 Enter 6 in Radius
 Make sure that the Tool number and
compensations number is set to “1”

 Use Tool + or – to adjust the tool

number and D + or – to adjust the
compensation number.

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Step 5: Reference axis offset
 Click Zero offset softkey
 Make sure that the G54 reference
offset is set in zero offset.
 Cross check the axis offset values
with the origin values (Part I step 14)
 Save softkey (LMB)
 Menu Selection Key (LMB)

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Step 6: Spindle Zero return
 JOG mode (LMB)
 Ref Pos (LMB)
 Cycle Start (LMB)
 Spindles Softkey (LMB) to check the spindle
position.

 Make sure that the spindle position reached

machine reference (0,0,0). Since the machine
reference return is not mentioned in the NC
code it is mandatory to move the spindle
position to the origin position to avoid
accidents during tool change.

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Step 6: Start the machining process
 Auto (LMB) Green led should glow
 Single block (LMB)
 Press the cycle start
 Now, press cycle start to execute each and
every block.
 Square embossing operation is done on the
rectangular work piece of 100 x 100 x 20 mm.
 Next, the dimension of the machined
component should be verified.

 If any error occur during cycle start, do the zero

return process once again, check the feed rate
(should be 100) and rerun the above step.
 Check the current block and the corresponding
position changes in the CRT screen.

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Start the machining process (Single block
positions)
 Click cycle start for executing each block.
 Positions of machining will be changing for
each blocks.
 Below figure illustrates the position after block
7.

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Start the machining process (Single block
positions) Contd.,
 After 8 th Block

Table moves from -652 mm (previous block

position) to -542 mm in X - AXIS
Relative coordinate movement = 110 mm

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Start the machining process (Single block
positions) Contd.,
 After 9 th Block

Table moves from -312 mm (previous block

position) to -216 mm in Y- AXIS
Relative coordinate movement = 96 mm

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Start the machining process (Single block
positions) Contd.,
 After 10 th Block

Table moves from -542 mm (previous block

position) to -638 mm in X - AXIS
Relative coordinate movement = 96 mm

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Start the machining process (Single block
positions) Contd.,
 After 11 th Block

Table moves from -216 mm (previous block

position) to -312 mm in Y - AXIS
Relative coordinate movement = 96 mm

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Start the machining process (Single block
positions) Contd.,
 After 12 th Block

Table moves from -312 mm (previous block

position) to -300 mm in Y - AXIS
Relative coordinate movement = 12 mm

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Start the machining process (Single block
positions) Contd.,
 After 13 th Block

Table moves from -638 mm (previous block

position) to -554 mm in X - AXIS
Relative coordinate movement = 84 mm

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Start the machining process (Single block
positions) Contd.,
 After 14 th Block

Table moves from -300mm (previous block

position) to -228 mm in Y - AXIS
Relative coordinate movement = 72 mm

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Start the machining process (Single block
positions) Contd.,
 After 15 th Block

Table moves from -554 mm (previous block

position) to -626 mm in Y - AXIS
Relative coordinate movement = 72 mm

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Start the machining process (Single block
positions) Contd.,
 After 16 th Block

Table moves from -228 mm (previous block

position) to -298 mm in Y - AXIS
Relative coordinate movement = 70 mm

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Start the machining process (Single block
positions) Contd.,
 After 17 th Block

Table moves from -626 mm (previous block

position) to -652 mm in Y - AXIS
Relative coordinate movement = 27 mm

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Start the machining process (Single block
positions) Contd.,
 After 18 th Block

Spindle moves from -345 mm (previous

block position) to -285 mm in Z - AXIS
Relative coordinate movement = 60 mm

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Part III – Verification
Step 1: Verification of Machined
component window open
 Inspection (LMB)
 Verification
 Separate verfication module page
will open as shown.
 In Move Work-Part dialouge box
enter 0,0,0 in X, Y and Z then click
Move.

Part III: Verification

 Problem 1: Vertical Machining-Linear Interpolation
Step 2: Verification of … Tool path without machining ___ Tool path during machining
Machined component :
Tool Path
 View(LMB)
 Tool Path N11
 Machining Path NC
Codes
N9G01 X98. ; N10
N10Y98.;
N11X2.;
N12Y2.;
N13G42 Y20. D01;
N14X80.;
N12
N15Y80.;
N16X20.;
N17Y16.; N9
N18G40 X-12.;

Note: Cutter compensation will be added during interpolation Part III: Verification
 Problem 1: Vertical Machining-Linear Interpolation
Step 3: Verification of Machined
component : Gouge Check
 Gouge check (LMB)
 Open Model File(o) LMB
 In the Look in drop down menu
select Tutorial Share (T:), Scroll down
and find V-CNC Pro Tutorial Folder.
DLMB the folder. You can find Phase
2STL Files folder (DLMB), find
“Tutorial 1” folder. DLMB the same
folder.
 Tutorial1 STL file (LMB) Open (LMB)
 Machined component is overlapped
with the final component to check the
undercut and overcut.
 Green color portion indicates that
there is no under cut in the model.
 If the machining is not properly done,
then blue/red colored portion may
visible.
 Finish gouge check (LMB)
Part III: Verification
 Problem 1: Vertical Machining-Linear Interpolation
Step 4: Verification of Machined
component : View Section
 Measure (LMB)
 View section
 Select the points as shown in the
Fig.
 OK (LMB)
 View Section window will appear
 In the view Section window, click
next to cross check the
coordinates. (This will help us to
Point
cross verify geometry of the
selected
complex curvature geometry)
 Close the View Section window

Part III: Verification

 Problem 1: Vertical Machining-Linear Interpolation
Step 5: Verification of Save image Settings Dimensioning
Machined component : Work
Part diagram
 Measure (LMB)
 Work Part Diagram (LMB)
 Separate CbDrawer window Coordinate
will appear. value
 Click at the corner as shown in
the Fig and press OK.

 Continue in the next page…

Part III: Verification

 Problem 1: Vertical Machining-Linear Interpolation
Step 6: Verification of Machined
component : Work Part diagram
 Give the dimensions as shown.
 Horizontal direction icon (LMB)

Part III: Verification

 Problem 1: Vertical Machining-Linear Interpolation
Step 7: Verification of Machined
component : Work Part diagram
 Give the dimensions as shown.
 Vertical direction icon (LMB)

Part III: Verification

 Problem 1: Vertical Machining-Linear Interpolation
Step 8: Verification of Machined
component : Save Work part
diagram
 Save image icon (LMB)
 In the Save in drop down menu click
Personal Directory (P:)
 DLMB – Folder created in the first
step.
 Give File name in the text box
 Save (LMB)
Step 29: Save and close the project
 Workpart Diagram window (Close)
 Verification window (close)
 File (LMB) in VNC PRO Mill Software
page
 Project Save (LMB)
 File (LMB)
 Exit (LMB)
 Save the program alert (Click save)
Part III: Verification
Contact us if you have any queries

Work Integrated Learning Program

WISE Simulation Lab
Birla Institute of Technology & Science, Pilani

Email : wise@wilp.bits-pilani.ac.in
Text @ Hangout : wise@wilp.bits-pilani.ac.in