Himson Engg Training Report

MAHARANA PRATAP UNIVERSITY OF AGRICULTURE AND

TECHNOLOGY

UDAIPUR (RAJ.)

TRAINING REPORT

ON

CNC Machine

SUBMITTED TO SUBMITTED BY

DR. M.A. SALODA Sir ALOK KUMAR

MECHANICAL ENGG. DEPARTMENT [email protected]

[email protected]

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ACKNOWLEDGEMT

I would like to thank HIMSON ENGINEERING PVT. LTD. SURAT for providing

me an opportunity to work with them. The support and the environment provided to me

during my project was more than what anyone would have expected.

I owe my profound gratitude to Mr. MADHUKAR AJGAONKAR who granted me

the opportunity of working as a summer trainee at mechanical Division.

I would also like to thanks Mr. ASHOK PATEL (G.M.) without his support I

would not be able to perform such a delightful job.

And at last I would like to thanks all the people involve in the training who help

me out in accomplishing it in such a wonderful way.

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INDEX

1. ABOUT THE COMPANY

2. Introduction of CNC Machine

3. Types of tools

4. Tool Material

5. Tool Geometry

6. Tool Holding

7. WORK Holding Device

8. Material Handling

9. Automatic Tool changer

10. Operation of CNC

11. List of G-Codes

12. List of M -Codes

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About the company Himson Engineering Pvt.Ltd. is the flagship company of the Himson

Bhogibhai Group. It is one of the largest manufacturer of textile machinery in India with

the experience of more than 3 decades.

The engineering activities of the group are carried out under the direct control

of Head-Quarters located at Ashwanikumar Road premises at Surat, India.

Initially, in the year 1978, HIMSON tied up with Earnest Scragg Sons Ltd., UK to

manufacture Draw-Texturising Machines in India. Since then, the strategy has been to

acquire the best available technology from the reputed and innovative internationally

leading companies and upgrade the same with help of the experts around the world in

conjuction with our in-house development experts and considerably long machine-

building experience. This strategy has worked very well and eventually, made the

company successful in its field in India & Abroad.

Today, the company enjoys significant market share of Synthetic Yarn

Processing Machinery in India. (Supplied more than 3000 Draw-Texturising machines)

the fast growth has been sustained on continuous upgradation & design and manufacturing

facilities by installing most modern CNC machining centers, fabrication units and metal

finishing shop in-house together with the latest Design and Development Center equipped

with modern CAD/CAM facilities and latest state-of-the art designing software’s to

achieve highest accuracy and maintaining stringent quality standards, benchmarked

against the best in the world. Himson Engineering Pvt Ltd is accredited with ISO

9001:2000 Certification. Today, HIMSON enjoys high reputation for in-house research

and technology developments and an efficient and reliable After-Sales-Services.

In year 1998, HIMSON entered into a technical collaboration with M/s.

Teijin Seiki Textile Machinery Co. Ltd., Japan to manufacture High Speed Draw-

Texturising Machines with Energy Conserving Short Heaters and Auto Doffing.

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Himson Engineering enjoys a very respectful image as supplier of world

class textile machines and is the leader in almost all the products that it manufactures.

Many of the products are exported to developed as well as developing countries. The

manufacturing facilities are now also offered to the Indian & International industries, to

fully exploit the capacities which has been generates over the years.

In the year 2008, Himson Engineering Pvt Ltd also received a prestigious

order from Alok Industries Ltd, one of the leading textile unit in India for supply of Auto

– Doffing Draw Texturising Machine. Himson Engineering Pvt Ltd has executed this

prestigious order for supply of Himson TMT Draw Texturising Machine Model ATH – 12

F/V each with 288 spindles in joint corporation with world re-known TMT Japan (TMT

Machinery , Inc Japan)

This is the 1st time in India Auto Doffing Machines are manufactured and

installed also, this the 1st time in world to supply this machine with 288 spindles.

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INTRODUCTION

Numerical control (NC) refers to the automation of machine tools that are operated by

abstractly programmed commands encoded on a storage medium, as opposed to manually

controlled via hand wheels or levers, or mechanically automated via cams alone. The first NC

machines were built in the 1940s and 1950s, based on existing tools that were modified with

motors that moved the controls to follow points fed into the system on punched tape. These

early servomechanisms were rapidly augmented with analog and digital computers, creating

the modern computer numerical control (CNC) machine tools that have revolutionized the

manufacturing process.

In modern CNC systems, end-to-end component design is highly automated

using computer-aided design (CAD) and computer-aided manufacturing (CAM) programs.

The programs produce a computer file that is interpreted to extract the commands needed to

operate a particular machine via a postprocessor, and then loaded into the CNC machines for

production. Since any particular component might require the use of a number of different

tools-drills, saws, etc., modern machines often combine multiple tools into a single "cell". In

other cases, a number of different machines are used with an external controller and human or

robotic operators that move the component from machine to machine. In either case, the

complex series of steps needed to produce any part is highly automated and produces a part

that closely matches the original CAD design.

Conventional machining, one of the most important material removal methods, is a

collection of material-working processes in which power-driven machine tools, such as

saws, lathes, milling machines, and drill presses, are used with a sharp cutting tool to

mechanically cut the material to achieve the desired geometry. Machining is a part of the

manufacture of almost all metal products, and it is common for other materials, such as wood

and plastic, to be machined. A person who specializes in machining is called a machinist. A

room, building, or company where machining is done is called a machine shop. Much of

modern day machining is controlled by computers using computer numerical control (CNC)

machining. Machining can be a business, a hobby, or both.

The precise meaning of the term "machining" has evolved over the past 1.5 centuries

as technology has advanced. during the machine age, it referred to

as turning, boring, drilling, milling, broaching, sawing, shaping, planning, reaming, and

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tapping, or sometimes to grinding. since the advent of new technologies such as electrical

discharge machining, electrochemical machining, electron beam machining, photochemical

machining and ultrasonic machining, the retronym"conventional machining" can be used to

differentiate the classic technologies from the newer ones. The term "machining" without

qualification usually implies conventional machining

 ADVANTAGES OF CNC MACHINE

Higher flexibility

1Increased productivity

Consistent quality

Reduced scrap rate

Reliable operation

Reduced non productive time

Reduced manpower

Shorter cycle time

High accuracy

Reduced lead time

Just in time (JIT) manufacture

Automatic material handling

Lesser floor space

Increased operation safety

Machining on advanced material

CNC Computer Numerical Control (CNC) - A numerical control system in which the data

handling, control sequences, and response to input is determined by an on-board computer system at the machine tool. 

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SPECIFICATIONS OF THE CNC MACHINE USED IN COMPANY:

FEELER PVT. LTD.

Model No.-FV600 APC

Serial No.-AP036

APC- Automatic pallet change (Work on the Hydraulic Pressure)

Software used inside of the System : Fanuc Series 0-M

Magazine: It contains 18 tools (maximum) in its pocket at a time.

RPM of spindle:

MAX - 10,000

Generally work on 1200 to 2500.

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Center Drill Size :

BS-3 to BS-14 (used as per required diameter.)

Drill Size Diameter:

MIN:2.5 mm

MAX:30 mm

Generally , ALUMINIUM metal compnents are manufactured by this machine.

Requirements of CNC Toolingi. Higher control on reshaping and inspection should be practiced and repeatable

performances.

ii. Higher control should be exercised on the run out of the multi teeth cutter for better

size control.

iii. Cutting tool should be selected from improves design for improved quality of

workpiece and spade drills, carbide drills, care drills with carbide inserts, reamers,

coated inserts etc.

Construction Features of CNC ToolingThe tools for CNC machines should,

i. Be present and reset outside the machine.

ii. Be quickly changeable to deduce non cutting time.

iii. Have high degree of interchangeability.

iv. Have increased reliability because of high automation and unmanned machining.

Types of CNC Tooling

In order to reduce non productive time to zero level, quickly changeable tool such as

present and qualified must be used. These tool have emerged to reduce the non productive to

the minimum. There are two types of CNC tools

a) Preset tools

b) Qualified tools

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A.)Preset toolsA presetting device is used to present axial and radial position of the tool tip on the tool

holder. Once this is done, the tool holder is ready to be mounted on the machine and produce

a non dimension. Presetting device to various level of sophistication is available. Tool offset,

tool length, and tool diameter compensation facilities available in the present day CNC

machines have brought down the importance by presetting. Accuracy in the order of from -

0.0002 to +0.0002mm can be quickly and easily maintained.

B.)Qualified ToolsThese are tools in which the cutting tip or edge is maintained at a fixed distance within a

tolerance (from-0.05to+0.05) with respect to the reference surface of the folder. In these types

of tools no presetting device is used, therefore investment is less. Rough cuts can be taken

without a trial cut. Control dimensions of the tool are nominal and fixed, hence programming

is easy. Set up time is reduced as elaborate organizing and planning as in preset tool is not

needed. The tool need not be measured individually.

Tool materials

Tooling, surprisingly enough, is often the least understood aspect of CNC equipment.

Given that it is the one element that will most affect the quality of cut and the cutting speed,

operators should spend more time exploring this subject. Cutting tools usually come in three

different materials; high speed steel, carbide and diamond.

High Speed Steel (HSS)HSS is the sharpest of the three materials and the least expensive; however, it wears

the fastest and should only be used on nonabrasive materials. it requires frequent changes and

sharpening and for that reason it is used mostly in cases where the operator will need to cut a

custom profile in-house for a special job.

Solid carbideCarbide tools come in different forms: carbide tipped, carbide inserts and solid

carbide tools. Bear in mind that not all carbide is the same as the crystalline structure varies

greatly between makers of these tools. As a result, these tools react differently to heat,

vibration, and impact and cut loads. Generally, low cost generic carbide tools will wear and

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chip more rapidly than higher priced name brands. Silicon carbide crystals are embedded in a

cobalt binder to form the tool. When the tool is heated, the cobalt binder loses its ability to

hold on to the carbide crystals and it becomes dull. At the same time the hollow space left by

the missing carbide fills up with contaminants from the material being cut, amplifying the

dulling process.

PCBN (Poly Crystalline Cubic Boron Nitrate)

The PCBN tools are used for finishing heat treated alloy steels, tool steels, cast iron,

powered metal, cobalt based alloy, and nickel based super alloys.

PCD (Poly Crystalline Diamond)The PCD tools provides outstanding wear resistance and good surface finish, when

machining highly abrasive non ferrous material such as aluminum, aluminum alloy, cooper

alloys, and carbon and epoxy composites, hard rubber, wood, fiber glass, and plastics.

Summary of application for various cutting tool materialTool material Work material Remark

Carbon steel Low strength, softer material,

non ferrous alloys, plastics

Low cutting speed, low

strength material

Low/medium alloy steel Low strength, softer material,

non ferrous alloys, plastics

Low cutting speed, low

strength material

HSS All material of low and

medium strength and

hardness

Not suitable for low speed

application

Cemented carbide Cast iron, alloy steel,

stainless steel, super alloy

Not for titanium alloys, not

for non ferrous alloys as the

coated grades don’t offer

additional benefits over un

coated.

Ceramics Cast iron, nickel base super

alloys, non ferrous alloys,

plastics

Not for low speed operations

or interrupted cutting. Not for

machining Al, Ti alloys.

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TOOL GEOMETRY

Figure .tool geometry

Tool geometry consists following parameters as -

ShankThe shank is the part of the tool that is held by the tool holder. It is the part of the tool

that has no evidence of machining. The shank must be kept free of contamination, oxidation

and scratching.

Cut diameterThis is the diameter or the width of the cut that the tool will produce.

Length of cutThis is the effective cutting depth of the tool or how deep the tool can cut into the material.

FlutesThis is the part of the tool that augers out the cut material. The number of flutes on a

cutter is important in determining the chip load.

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WORK HOLDING

In order to machine a part on a CNC router the part must be held securely in place.

This seems obvious; however, this is the one area that often causes major headaches. Another

term used for part holding is fixturing. The hold-down system has a significant impact on part

accuracy, quality of finish and on feed speeds and tooling life. Keep in mind that holding the

part securely is important and there is no one system that will properly hold all parts. There

are two fundamentally different types of parts that must be held in place. The first is a flat

part or a sheet of material and the second is a three-dimensional object. The fixturing systems

for each are similar; however, the three-dimensional part normally requires somewhat more

complex arrangements. Some materials require higher cutting forces than others and these

materials will require a more rigid hold-down system. Some materials will vibrate or chatter

when cut.

Fig. Toggle clamp

Types of work holding-

Manual

The most cost effective way to hold down parts to a table is to screw, nail or to bolt

the part to the work table. Other good methods of manually holding parts down are to glue

the part down with regular or thermo fusible glue or with double sided tape. in the case where

a prototype or a single piece will be cut, it might not be cost effective to build a holding

fixture. For short production runs or for fixturing prototypes, another useful method is to use

a toggle clamp. These come in many different configurations and sizes are easy to adjust and

to setup on a jig. One must be careful not to crash the tool or the spindle into the clamp when

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using this kind of device. it is always a good idea to test the program in a dry run at low

speeds before putting such a fixture into production.

VacuumThe most common system for holding down parts on the CNC router is conventional

vacuum. Vacuum is simply the absence of air. the 45 km thick layer of air surrounding the

earth weighs about 14 psi or 29.92" of mercury (hg) or 100 kilopascals (k pa) at sea level.

This column of air pushes down equally on everything in all directions so that no resultant

force is felt on the objects around us. When the air is removed from one side of an object, the

air on the other side now pushes against the object with a force proportional to the absence of

air on the opposite side. This is the basis of vacuum hold-down.the part to be machined is

sealed against the tabletop or a fixture and then the air inside the seal is removed using a

vacuum pump. The air on the outside then pushes the part against the fixture. The vacuum

pressure is not the only thing holding the part against the table. Since lateral pressure is

exerted by the cutter when it is machining the part, the coefficient of friction between the part

and the fixture plays an important part as well. A perfect vacuum is not possible with current

technology, no matter which kind of vacuum pump is used.

Types of Vacuum Work Holding Methods;

a) Conventional vacuum fixturingThis method is mostly used in 5-axis production when trimming molded parts. Since

these parts are almost never flat, special vacuum fixtures are made using plaster to conform to

the part and a rubber seal is used around the vacuum ports.

b) Pod and rail

This vacuum cup type of hold-down is a widespread method of holding parts on a

CNC machine. This is well indicated when one part at a time needs to be machined. There are

many different configurations of pods for different applications and as it takes time to adjust

the pods to different configurations and part sizes, this can be an inefficient way to work. Pod

systems are not the universal solution that some manufacturers advertise.

c) Combination pod/flat tableTable using conventional vacuum is often found. on lower-priced or older systems, a

combination of pods on a flat rotary vane vacuum pumps are relatively inexpensive as they

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are small and are not required to pull a great volume of air. This system works well when

there is a good seal with the part

d) High flow vacuumThis method is often associated with nested based systems. a sacrificial board

otherwise known as a spoil board made particleboard sits atop a vacuum plenum on the

worktable. Flow is so high that a low-pressure area is created on the surface. a flat part that is

laid on this table will be held in place in this low-pressure area without the need for fixtures

or seals.

e) Roller hold-downOther methods of material holding have surfaced in response to specific industry needs.

Roller hold-down systems are often seen in upholstery shops. This method isused to hold

rough and often warped plywood that could not otherwise be held in place by a high flow

vacuum.

Capacity of vacuumThe capacity for vacuum pumps is specified in a couple of different ways, depending

on the type of vacuum pump and the manufacturer. It is important to know the scfm rating of

the pump. It expresses the “actual cubic feet per minute” inlet capacity at a specific vacuum

level. Capacities expressed in cfm or scfm (standard cubic feet per minute) can be very

misleading because one has to take into consideration the volumetric efficiency of the pump

at a specific vacuum level. Rotary vane pumps are generally rated in cfm of free air

displacement, which is the theoretical displacement at 0" hg vacuum. the requirements in

vacuum flow or the capacity of the pump will be different whether vacuum cups, clamps or

high flow universal vacuum tables are being used. A vacuum hold-down where the part rests

on rubber seals may allow thepart to move or wiggle slightly on the soft seals.

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MATERIAL HANDLINGManual material handling is often the norm in furniture and cabinet shops. This

oversight is often at the expense of the manufacturer since the time spent loading and

unloading machines often makes up most of the wasted time in a day. Often, CNC owners

will try to trim seconds off a program or even try to run parts at much faster speeds. This will

result in marginal savings in time and most often result in poor cut quality. Often they

overlook parts and machine idleness and unnecessary material handling in their time analysis.

Most of the efficiencies that can be gained at a CNC work stationary in handling material.

Whether talking about the methods used to handle material or the strategies used to deal with

material handling, large quantities of inventory or work in progress can usually be found all

around the shop. Ensuring that raw material gets to the shipping door as a finished product in

the best possible time will always have the greatest impact on a manufacturer’s bottom line.

Material handling equipment

Scissor lifts

A simple scissor lift at the end of the worktable is often enough when mostly the same

material is being processed all day. When more than one material is used, manufacturers

often pre-stage lifts with the right combination of material so the operator can slide the right

sheet on to the worktable. Care must always be taken when dragging sheet sacross each other

as this can ruin the surface of the sheet below.

Vacuum lifts

Vacuum lifts are a little more expensive than a scissor lift but are also more versatile.

They can pick up sheets from different piles around the CNC and give the added ability of

removing larger parts from the work table once the machining is done .They are usually

mounted on a crane bolted to the floor or wall. Some use high flow vacuum for both the

holding and the lifting, while others use an electric winch for lifting and an air vacuum on a

suction cup for holding.

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Automatic material handling

Automated material handling equipment is mostly found in very largeproduction

plants.Automation can vary from a mechanized conveyorsystem to robotic arms doing most

of the loading and unloading ofthe work.

AUTOMATIC TOOL CHANGER(ATC)

During the operation of a machine tool, considerable amount of time is spent in idle

movement of tool such as tooling engagement and disengagement, tool change in tool setup.

To improve the machine utilization, it is necessary to minimize these idle motions. To that

extent automatic tool changers or ATC as is popular called, plays a very important role.

These are particularly useful in machining operations where a number of tools are to be used

for finishing the job. Though there are still some CNC machine tools which are sold ATC.

For an ATC, it is necessary to have the following statement-

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a) A tool magazine where sufficient number of tools can be stored.

b) The tool adapter that has a provision for pick up by the tool change arm.

c) The ability in the control to perform the tool change function.

d) Tool change procedure.

Tool changing

In the case of turret the tool changing is relatively simple, because of the turret

indexing. However in the case of other tool magazine, it is necessary to have a tool changing

arm which can provide the necessary tool transfer. Generally the tool magazine is placed

closed to the spindle such that the actual tool transfer does consume a lot of time. Typically

tool change time quoted by the various machine tools manufactured range from as low 2 to a

maximum of 10 seconds. The tool change activity requires various motions.

Tool magazine

Tool magazine is to be used have to be considered in terms of following attributes;

Storage capacity

Type and shapes

Tool change procedure

Storage capacity typically starts with about 12 and goes as high as 200 while 30-60 appears to

be most common capacity of the tool magazines. The simplest type of tool magazine is a

turret as shown in figure.

The method combinations tool storage with the tool change procedure, without the

need for a tool change arm. The turret simply indexes to bring the tool in the position of the

machining. Since the spindle is combined with the tool turret as shown in figure. The main

advantages of the system is that the tool is identifies directly with the pocket position and

hence does not require a separate identification. Through it is a relatively simple method, the

time taken for actual tool change is normally more except in the case of a tool in the adjacent

pocket. Further the turret should have the capacity of indexing in both directions to minimize

the change time. The next type of tool magazine is – Drum or disc type magazine. The drum

rotates for the purpose of tool change to bring the required tool to tool change arm and

another type is chain type magazine.

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Operations of CNC

Straight Turning

Drilling

Step Turning

Bearing

Taper Turning

Polishing

Eccentric Turning

Tapping

Chamfering

Parting 0ff

Thread Cutting

Reaming

Facing

Counter Boaring

Spinning

Under Cutting

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List of G-codes commonly found on Feeler CNC Machine:

Code Description

G00 Rapid positioning

G01 Linear interpolation

G02 Circular interpolation, clockwise

G03 Circular interpolation, counterclockwise

G04 Dwell

G05P10000 High-precision contour control (HPCC)

G05.1 Q1. Ai Nano contour control

G06.1 Non Uniform Rational B Spline Machining

G07 Imaginary axis designation

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G09 Exact stop check

G10 Programmable data input

G11 Data write cancel

G12 Full-circle interpolation, clockwise

G13 Full-circle interpolation, counterclockwise

G17 XY plane selection

G18 ZX plane selection

G19 YZ plane selection

G20 Programming ininches

G21 Programming inmillimeters (mm)

G28 Return to home position (machine zero, aka machine reference point)

G30 Return to secondary home position (machine zero, aka machine reference point)

G31 Skip function (used for probes and tool length measurement systems)

G32 Single-point threading, longhand style (if not using a

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cycle, e.g., G76)

G33 Constant-pitchthreading

G33 Single-point threading, longhand style (if not using a cycle, e.g., G76)

G34 Variable-pitch threading

G40 Tool radius compensation off

G41 Tool radius compensation left

G42 Tool radius compensation right

G43 Tool height offset compensation negative

G44 Tool height offset compensation positive

G45 Axis offset single increase

G46 Axis offset single decrease

G47 Axis offset double increase

G48 Axis offset double decrease

G49 Tool length offset compensation cancel

G50 Define the maximum spindle speed

G50 Scaling function cancel

G50Position register (programming of vector from part zero to tool tip)

G52 Local coordinate system (LCS)

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G53 Machine coordinate system

G54 to G59 Work coordinate systems (WCSs)

G54.1 P1 to P48 Extended work coordinate systems

G70 Fixed cycle, multiple repetitive cycle, for finishing (including contours)

G71 Fixed cycle, multiple repetitive cycle, for roughing (Z-axis emphasis)

G72 Fixed cycle, multiple repetitive cycle, for roughing (X-axis emphasis)

G73 Fixed cycle, multiple repetitive cycle, for roughing, with pattern repetition

G73 Peck drilling cycle for milling - high-speed (NO full retraction from pecks)

G74 Peck drilling cycle for turning

G74Tapping cycle for milling, lefthand thread, M04 spindle direction

G75 Peck grooving cycle for turning

G76 Fine boring cycle for milling

G76 Threading cycle for turning, multiple repetitive cycle

G80 Cancel canned cycle

G81 Simple drilling cycle

G82 Drilling cycle with dwell

G83 Peck drilling cycle (full retraction from pecks)

G84 Tapping cycle,righthand thread,M03 spindle direction

G84.2 Tapping cycle, righthand thread,M03 spindle direction,

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rigid toolholder

G90 Absolute programming

G90 Fixed cycle, simple cycle, for roughing (Z-axis emphasis)

G91 Incremental programming

G92 Position register (programming of vector from part zero to tool tip)

G92 Threading cycle, simple cycle

G94 Feedrate per minute

G94 Fixed cycle, simple cycle, for roughing (X-axis emphasis)

G95 Feedrate per revolution

G96 Constant surface speed (CSS)

G97 Constant spindle speed

G98 Return to initial Z level in canned cycle

G98 Feedrate per minute (group type A)

G99 Return to R level in canned cycle

G99 Feedrate per revolution (group type A)

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List of M-codes commonly found on Filler CNC Machine :

Code   Description

M00 Compulsory stop

M01 Optional stop

M02 End of program

M03 Spindle on (clockwise rotation)

M04 Spindle on (counterclockwise rotation)

M05 Spindle stop

M06 Automatic tool change (ATC)

M07 Coolant on (mist)

M08 Coolant on (flood)

M09 Coolant off

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M10 Pallet clamp on

M11 Pallet clamp off

M13 Spindle on (clockwise rotation) and coolant on (flood)

M19 Spindle orientation

M21 Mirror, X-axis

M21 Tailstock forward

M22 Mirror, Y-axis

M22 Tailstock backward

M23 Mirror OFF

M23 Thread gradual pullout ON

M24 Thread gradual pullout OFF

M30 End of program with return to program top

M41 Gear select - gear 1

M42 Gear select - gear 2

M43 Gear select - gear 3

M44 Gear select - gear 4

M48 Feedrate override allowed

M49 Feedrate override NOT allowed

M52 Unload Last tool from spindle

M60 Automatic pallet change (APC)

M98 Subprogram call

M99 Subprogram end

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BIBLIOGRAPHY

www.wikinpedia.org www.google.co.in (for images) www.himpson.in CTAE library

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