CNC Machinery Module 5: CNC Programming / Milling PREPARED BY IAT Curriculum Unit August 2009 © Institute of Applied Technology, 2009
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CNC Machinery
Module 5: CNC Programming / Milling
PREPARED BY
IAT Curriculum Unit
August 2009
© Institute of Applied Technology, 2009
ATM313-CNC
Module 5: Milling 2
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 G42 4
3 Chamfer and round programming 5
4 Prepare a setup sheet 6
5 Practical Tasks 8
6 Work sheet 28
ATM313 - CNC
Module 5: Milling 3
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 Description
G17,G18, and G19 Working plane selection
G40 Cutter radius compensation OFF.
G41 Cutter radius compensation ON Left.
G42 Cutter radius compensation ON Right.
G70 Input system inch
G71 Input system metric
G111 Polar coordinate interpolation
G147 Approach with a straight line.
G148 Leave in a straight line.
G247 Approach with a quarter a circle.
G248 Leave with a quarter a circle.
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Module 5: Milling 4
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 Description
Cycle 81 Drilling; to make a hole in one phase.
Cycle 83 Deep Drilling; to make a deep hole, which requires
introducing the tool with several phases. (Chip-breaking
and chip removal)
Pocket To engrave a circular or rectangular area on a surface.
Holes To repeat a drilling operation following circular or linear
contours.
2. G41 and G42:
G41:
Cutter radius compensation ON Left.
(See Fig. 5.1)
G42:
Cutter radius compensation ON Right.
(See Fig. 5.2)
Fig. 5.1: G41
Fig. 5.2: G42
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Module 5: Milling 5
3. Chamfer and round programming:
Chamfer programming.
G1 X… Y… Z… CHF=6
Or
G1 X… Y… Z… CHR=11
See Fig.5.3
Round programming.
G1 X… Y… Z… RND=5
See Fig. 5.4
Fig. 5.3: Chamfer
Fig. 5.4: Round
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Module 5: Milling 6
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
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Module 5: Milling 7
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.
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Module 5: Milling 8
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-040 020 HSS ISO2586
o Feed rate: 250 mm/min
o Spindle speed: 500 RPM
o Spindle rotation: clockwise
ATM313 - CNC
Module 5: Milling 9
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
ATM313-CNC
Module 5: Milling 10
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-063 040 HSS ISO2586.
Pos#2: Drill, DR-02.50 030 HSS ISO 235.
Pos#3: Drill, DR-12.00 101 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
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Module 5: Milling 11
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
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Module 5: Milling 12
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.
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Module 5: Milling 13
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Module 5: Milling 14
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.
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Module 5: Milling 15
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-063 40 32 HM 90
2. Slot Milling tool MS-20.0 038K HSS ISO 1641
3. Slot Milling tool Finishing MS-20.0 038K HSS ISO 1641
4. Slot Milling tool MS-10.0 022K HSS ISO 1641
5. Slot Milling tool Finishing MS-10.0 022K HSS ISO 1641
6. Spotting drill DC-08.0 090 HSS ISO 3294
7. Tool No. 7: DR-10.00 087 HSS ISO 235
8. Tool No. 8: DR-5.00 052 HSS ISO 235
o Feed rate: 250 mm/min
o Spindle speed: 500 RPM
o Spindle rotation: clockwise
Top View Front View
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Module 5: Milling 16
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
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Module 5: Milling 17
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
ATM313-CNC
Module 5: Milling 18
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
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Module 5: Milling 19
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
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Module 5: Milling 20
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
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Module 5: Milling 21
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)
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Module 5: Milling 22
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
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Module 5: Milling 23
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-040 020 HSS ISO2586
Pos#2: Slot Milling tool, MS-14.0 026K 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
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Module 5: Milling 24
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
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Module 5: Milling 25
Student's Notes
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ATM313-CNC
Module 5: Milling 26
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Module 5: Milling 27
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
ATM313-CNC
Module 5: Milling 28
4. Complete the following table:
Cycle 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. ……………………………………
ATM313 - CNC
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
No. Description
1
2
3
4
5
ATM313-CNC
Module 5: Milling 30
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
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Module 5: Milling 31
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 ________________________
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Module 5: Milling 32
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
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