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STUDY OF THE CNC MACHINE

Computer-aided manufacturing:
Computer-aided manufacturing (CAM) is the use of computer-based software tools
that assist engineers and machinists in manufacturing or prototyping product components. Its
primary purpose is to create a faster production process and components with more precise
dimensions and material consistency, which in some cases, uses only the required amount of
raw material (thus minimizing waste), while simultaneously reducing energy consumption.
CAM is a programming tool that makes it possible to manufacture physical models using
computer-aided design (CAD) programs. CAM creates real life versions of components
designed within a software package
CNC Technology
Numerical Control (NC) is a software-based machine tool control technique
developed at Massachusetts Institute of Technology (MIT) in early 1960s. It has now evolved
into a mature technology known as Computer Numerical Control (CNC). Although major
applications of CNC even today continue to be in machining, it finds applications in other
processes such as sheet metal working, non-traditional machining and inspection. Robots and
Rapid Prototyping machines are also CNC controlled. In fact, any process that can be
visualized as a sequence of motions and switching functions can be controlled by CNC.
These motions and switching functions are input in the form of alphanumeric instructions.
CNC is the basis of flexible automation which helps industries cut down time-to-market and
enables launch of even low volume products. Unlimited muscle power, unmanned operation,
independent axes coordinated through software, simplified generic tooling even for the most
complex jobs and accurate construction are some of the salient features of CNC.
CNC Machining
Automats and Special Purpose Machines (SPMs) require special cams/ templates and
clutch settings for each part. Manufacture of these cams/ templates is costly and slow.
Furthermore, changing over from one part to the other on these machines also consumes
considerable time. The high cost and long time of these hard automated machines to produce
parts can be justified only in mass production. With the advent of fast, rigid and accurate
CNC machines and sophisticated CAM packages, generation of NC programs and change
over from one product to the other are easy and fast as it does not require any mechanical
change. These in conjunction with advanced cutting tools have made High Speed Cutting
(HSC) of hard materials a reality. Therefore, CNC machining has become a standard means
to produce dies and molds; tool makers today require EDM only for producing inaccessible
regions, sharp corners, tiny features and desired surface quality. Intricate aerospace parts are
realized through 5 axis CNC machining. Internet technology in a global village enables
designing in one place, NC programming and verification in another place and actual
machining in yet another place.

Advantages of CNC
 Flexibility
 Accuracy
 Speed
 Simplified fixturing and generic cutting tools
 Storage of machining skill in NC programs
 Less skilled operators will do
 Less fatigue to the operators

G-codes
G-Code, or preparatory code or function, are functions in the Numerical control
programming language. The G- codes are the codes that position the tool and do the actual
work, as opposed to M-codes, that manages the machine; T for tool-related codes. S and F are
tool-Speed and tool-Feed, and finally D-codes for tool compensation. The programming
language of Numerical Control (NC) is sometimes informally called G-code. But in actuality,
G-codes are only a part of the NC programming language that controls NC and CNC machine
tools.

A basic list of `G' operation codes is given below. These direct motion of the tool.
1. G00 - Rapid move (not cutting)
2. G01 - Linear move
3. G02 - Clockwise circular motion
4. G03 - Counterclockwise circular motion
5. G04 - Dwell
6. G05 - Pause (for operator intervention)
7. G08 - Acceleration
8. G09 - Deceleration
9. G17 - x-y plane for circular interpolation
10. G18 - z-x plane for circular interpolation
11. G19 - y-z plane for circular interpolation
12. G20 - turning cycle or inch data specification
13. G21 - thread cutting cycle or metric data specification
14. G24 - face turning cycle
15. G25 - wait for input #1 to go low (Prolight Mill)
16. G26 - wait for input #1 to go high (Prolight Mill)
17. G28 - return to reference point
18. G29 - return from reference point
19. G31 - Stop on input (INROB1 is high) (Prolight Mill)
20. G33-35 - thread cutting functions (Emco Lathe)
21. G35 - wait for input #2 to go low (Prolight Mill)
22. G36 - wait for input #2 to go high (Prolight Mill)
23. G40 - cutter compensation cancel
24. G41 - cutter compensation to the left
25. G42 - cutter compensation to the right
26. G43 - tool length compensation, positive
27. G44 - tool length compensation, negative
28. G50 - Preset position
29. G70 - set inch based units or finishing cycle
30. G71 - set metric units or stock removal
31. G72 - indicate finishing cycle (EMCO Lathe)
32. G72 - 3D circular interpolation clockwise (Prolight Mill)
33. G73 - turning cycle contour (EMCO Lathe)
34. G73 - 3D circular interpolation counter clockwise (Prolight Mill)
35. G74 - facing cycle contour (Emco Lathe)
36. G74.1 - disable 360 deg arcs (Prolight Mill)
37. G75 - pattern repeating (Emco Lathe)
38. G75.1 - enable 360 degree arcs (Prolight Mill)
39. G76 - deep hole drilling, cut cycle in z-axis
40. G77 - cut-in cycle in x-axis
41. G78 - multiple threading cycle
42. G80 - fixed cycle cancel
43. G81-89 - fixed cycles specified by machine tool manufacturers
44. G81 - drilling cycle (Prolight Mill)
45. G82 - straight drilling cycle with dwell (Prolight Mill)
46. G83 - drilling cycle (EMCO Lathe)
47. G83 - peck drilling cycle (Prolight Mill)
48. G84 - taping cycle (EMCO Lathe)
49. G85 - reaming cycle (EMCO Lathe)
50. G85 - boring cycle (Prolight mill)
51. G86 - boring with spindle off and dwell cycle (Prolight Mill)
52. G89 - boring cycle with dwell (Prolight Mill)
53. G90 - absolute dimension program
54. G91 - incremental dimensions
55. G92 - Spindle speed limit
56. G93 - Coordinate system setting
57. G94 - Feed rate in ipm (EMCO Lathe)
58. G95 - Feed rate in ipr (EMCO Lathe)
59. G96 - Surface cutting speed (EMCO Lathe)
60. G97 - Rotational speed rpm (EMCO Lathe)
61. G98 - withdraw the tool to the starting point or feed per minute
62. G99 - withdraw the tool to a safe plane or feed per revolution
63. G101 - Spline interpolation (Prolight Mill)
M-Codes
M-Codes control machine functions and these include,
1. M00 - program stop
2. M01 - optional stop using stop button
3. M02 - end of program
4. M03 - spindle on CW
5. M04 - spindle on CCW
6. M05 - spindle off
7. M06 - tool change
8. M07 - flood with coolant
9. M08 - mist with coolant
10. M08 - turn on accessory #1 (120VAC outlet) (Prolight Mill)
11. M09 - coolant off
12. M09 - turn off accessory #1 (120VAC outlet) (Prolight Mill)
13. M10 - turn on accessory #2 (120VAC outlet) (Prolight Mill)
14. M11 - turn off accessory #2 (120VAC outlet) (Prolight Mill) or tool change
15. M17 - subroutine end
16. M20 - tailstock back (EMCO Lathe)
17. M20 - Chain to next program (Prolight Mill)
18. M21 - tailstock forward (EMCO Lathe)
19. M22 - Write current position to data file (Prolight Mill)
20. M25 - open chuck (EMCO Lathe)
21. M25 - set output #1 off (Prolight Mill)
22. M26 - close chuck (EMCO Lathe)
23. M26 - set output #1 on (Prolight Mill)
24. M30 - end of tape (rewind)
25. M35 - set output #2 off (Prolight Mill)
26. M36 - set output #2 on (Prolight Mill)
27. M38 - put stepper motors on low power standby (Prolight Mill)
28. M47 - restart a program continuously, or a fixed number of times (Prolight Mill)
29. M71 - puff blowing on (EMCO Lathe)
30. M72 - puff blowing off (EMCO Lathe)
31. M96 - compensate for rounded external curves
32. M97 - compensate for sharp external curves
33. M98 - subprogram call
34. M99 - return from subprogram, jump instruction
35. M101 - move x-axis home (Prolight Mill)
36. M102 - move y-axis home (Prolight Mill)
37. M103 - move z-axis home (Prolight Mill)