CNC Machining Report - Wheel Centre

Abstract: This work involved the formulation and analysis of the machining process plan to complete
the fabrication of a ‘wheel centre’ with Computer Numerical Controlled (CNC) machinery. This is
further augmented with a Numerical Control (NC) program written in ISO G-code, to machine the part
utilising CNC turning techniques.
Table of Contents

1
 INTRODUCTION
 1

2
 NC/CNC
FUNDAMENTALS
 2

3
 PART
ANALYSIS
 3

3.1
 Geometry
Features
and
Dimensions
 3

3.2
 Roughness
and
Accuracy
 4

3.3
 Dimensional
Tolerances
 4

3.4
 Machining
Material
 4

3.5
 Compatible
Machining
Components
 5

3.6
 Stock
Material
(Billet)
 5

4
 PROCESS
PLANNING
 6

4.1
 Work
Holding
Strategy
 7

4.2
 Datum
Point
 8

4.3
 Machining
Operations
 10

4.4
 Operation
Sequencing
 11

5
 CNC
ISO
G‐CODE
MACHINING
PROGRAM
 12

5.1
 Coordinate
Systems
Choice
 12

5.2
 Choice
of
Fixture
 13

5.3
 CNC
Machine
Specifications
 13

5.4
 Cutting
Tool
Parameters
and
Accuracy
 14

6
 CONCLUSION
 15

A.
 SCHEMATIC
OF
MACHINED
WORK‐PIECE.
 17

B.
 G‐CODE
MACHINING
PROGRAM
 18


i
Table of Figures

Figure
1:
Supplied
schematic
of
wheel
centre
 1

Figure
4:
Schematic
of
the
proposed
billet.
 5

Figure
5:
Pro/E
sketch
before
revolving
by
360º
around
the
vertical
datum
on
the
left.
 6

Figure
6:
Pro/E
model
of
machined
work­piece.
 6

Figure
7:
Solid
and
wireframe
model
of
the
work
holding
strategy
(side
view).
 7

Figure
8:
Datum
point
of
work­piece
shown
on
the
chuck­mounted
billet
(top­down
view).

 8

Figure
 9:
 Datum
 point,
 shown
 on
 image
 on
 the
 right,
 on
 machining
 schematic
 (top­down

view).
 9

Figure
10:
Typical
turning
centre
configuration
with
spindle
face
as
the
X­axis
and
spindle

centre
line
forming
the
Z­axis
(left
image,
top­down
view).

Notice
the
cutting
tool
is

located
behind
the
centre
line
in
both
images.
 12

Figure
11:
Defining
characteristics
of
a
CNC
machine.
 13


ii
1 INTRODUCTION

The primary objective of this report is the formulation and analysis of the machining
process plan to complete the fabrication of the wheel centre, shown in Figure 1, with
Numerical Control (NC)/Computer Numerical Controlled (CNC) machinery.

Figure 1: Supplied schematic of wheel centre

Most of the engineering schematics and 3D modelling produced in this report has
been performed utilising Pro/Engineer (Pro/E) Wildfire 4.0 developed by the
Parametric Technology Corporation.

The methodology used in the analysis includes research into the history of NC/CNC
fundamentals, part analysis and process planning and sequencing. Ultimately a NC
program is developed using ISO G-code for the above wheel centre to be machined in
a typical University metal workshop, and is located in Appendix B.

1
2 NC/CNC FUNDAMENTALS
The creation of Numeric Control (NC) is credited to John Parsons, who was a
machinist and salesman of Parsons Corporation, which belonged to his father. After
much tribulation, in 1949 the United Stated (US) Air Force funded the development
for the design a machining system to aid in the machining of wings for helicopters
and aircraft (Quesada, 2004)xiii. Parsons decided to contact the Servomechanisms
Laboratory at Massachusetts Institute of Technology (MIT), pioneers in the field of
mechanical computing and motor control systems that implemented feedback so as to
ensure constant driving speed and torque under a load.

On the 14th of August 1952, MIT filed a patent with the US Patent office for a
“Numerical Control Servo-System” – this was the birth of NC. With NC systems, the
commands for experimental metal work had to be performed by hand so as to create
“punch tapes”. A gentleman by the name of John Runyon thought of having a
computer handle all the ‘input’ and this once again resulted in funding from the US
Air Force for the development of a programming language for NC – this was the
creation of Computer Numeric Control (CNC) (Sing, 1996)x.

The metal cutting tasks required were as follows:

1. Determining the location where the machining was to be performed.

2. Controlling the path during the motion of the tool or work-piece.
3. Controlling the rate at which this path was traversed.
4. Controlling the rate at which the tool was fed in into the work-piece.

These are known in NC as: (1) the datum point, a point of reference from which all
Euclidean distances are measured, (2) control is established by the means of linear or
circular interpolation in general, (3) and (4) is known as the feed rate.

2
NC blocks are formed of words that are split into 5 categories of commands (with
examples included):

1. Preparatory functions
2. Axis motion commands: X, Y, and Z commands.
3. Feed rate and speed commands: Address words F and S.
4. Identification commands: N or T word.
5. Miscellaneous commands: ‘M’ words (M03, M08)

Linear programming is achieved with the G01 command and referencing the intended
destination location in (X, Y, Z). Contouring is achieved by incorporating G01
commands with the circular interpolation commands G02 (CW direction) and G03
(CCW). It should be noted that rapid control over tool positioning is managed by the
G00 and F commands (Sing, 1996)x.

3 PART ANALYSIS
3.1 GEOMETRY FEATURES AND DIMENSIONS
The part has been described as a ‘wheel centre’ in the supplied schematic, and as such
this geometry is revolute and symmetrical.

The noticeable features of the part in Figure 1 are:

• Base has a thickness of 8 mm and diameter of 240 mm.

• Second layer has a thickness of 8 mm and diameter of 210 mm.
• From the base, along its central symmetrical axis, to its tallest point is 20 mm.
• There is a tapered contour from the second layer to its tallest point at the
forefront of the part; this tapering accounts for a thickness of 4 mm that
follows from the 210 mm diameter of the second layer to the diameter of its
tallest point (90 mm) which is symmetrical about its revolute axis as well.

The centres of the diameters of 240 mm, 210 mm and 90 mm are aligned with the
symmetrical axis.

3
 The dimensions of the part are significant due to the extremely fine taper. The overall
thickness of the part to its total diameter has a ratio of 1:12, i.e. each increase in
thickness by a mm accounts for an increase in diameter by 12 mm.

3.2 ROUGHNESS AND ACCURACY

Roughness parameters are calculated to describe the granularity in the smoothness of
the surface (or lack thereof). Of most of the roughness parameters in use, Ra, is by far
the most widely encountered (Kalpakjian and Schmid, 2005)iv as it is the arithmetic
mean of absolute values of vertical deviations of the surface, where it is simply
defined (typically in micrometres) as,

1 n
Ra = ∑ yi
n i=1
(1)

Although the supplied schematic (Appendix A) specifically states that all dimensions
€
are in millimetres (mm), it is typical for surface finish (Ra) to be indicated in
micrometres (µm) with a Ra value of 12.5 µm resulting in visible tool marks.
Therefore the value marked in ‘green’ in Figure 1 is understood as 0.8 µm, which
needs to be finished to similar smoothness as that of a bearing surface.

3.3 DIMENSIONAL TOLERANCES

The required tolerances for all dimensions are taken as ± 0.5 mm, although this may
be considered as too conservative. This means that for example the top surface of Ø
90 mm will be machined to 90 ± 0.5 mm and thus the diameter will vary anywhere
between 89.5 mm and 90.5 mm. This liberty has been taken as the supplied
specification (Appendix A) has indicated most of the dimensions accurate to, at most,
1 or 2 significant digits.

3.4 MACHINING MATERIAL

The Vickers hardness of pure aluminium is 167 MPa when compared with that of iron
at 608 MPa, or Tungsten Carbide (the material out of which most cutting tools are
manufactured in) at 22 GPa (Gere and Goodno, 2008)iii. Considering an aluminium
alloy is used as the billet material, the substances it is alloyed with can greatly vary.

4
However, it should still the primary characteristic of machine-shop grade aluminium
that is machining friendly.

3.5 COMPATIBLE MACHINING COMPONENTS

As per the analysis above, it is apparent that the machining needs to be performing on
a turning centre as circular and symmetrical part geometries are ideally machined
using lathing operations on turning centres.

Minimum of two tools are required: (i) for profiling the features and (ii) for vertical
slicing through the work-piece material. The accuracy of these tool-tips will
determine the smoothness of the cut (depending on other factors such as spindle
speed, feed rate etc.).

Typical lathing operations will be able to machine the final part from the supplied
billet. These turning operations need to be sequenced carefully to ensure correct
machining of the part, down to the correct level of surface finishing and compensating
for tool radius during profiling and cutting.

3.6 STOCK MATERIAL (BILLET)

The supplied schematic (Appendix A) states that the billet has a diameter of 250 mm
with a length of 25 mm. To satisfy the possibility of machining a one part set and
multiple parts set on the same NC/CNC turning centre, it is proposed that the
aluminium alloy is formed of a rod 500 mm (0.5m) in length.

Figure 2: Schematic of the proposed billet.

5
4 PROCESS PLANNING

‘Process Planning, as the name simply implies, is a means for systematically

identifying and specifying the needed machining operations to machine the final part
from the billet. Since the ‘Part Analysis’ has already been completed, it has been
decided to implement lathing operations to machine the final part.

The aid in visualising the particular problem at hand, the supplied schematic was
sketched as a 2D part in Pro/E and was made into a solid part by revolving the sketch
by 360º around the vertical datum on the left (Toogood, 2007)xii.

Figure 3: Pro/E sketch before revolving by 360º around the vertical datum on the left.

‘Rounds’ with a radius of 2 mm were applied (Lamit, 2001)vii to the three edges
shown in the supplied schematic (Appendix A). The modelled wheel centre is shown
below,

Figure 4: Pro/E model of machined work-piece.

6
4.1 WORK HOLDING STRATEGY
Since the work-piece is to be machined using lathing operations, the work holding
strategy simply reduces to utilising a chuck, which is a specialized type of clamp used
to hold rotating tools or materials. Lathing centres tend to have three or four-jaw
chucks, however, other types may be encountered (Bray, 2003)i.

To further explain how the work-piece is to be machined, a simple model of a

‘hypothetical’ chuck (Wikipedia, 2009)xiv with billet (held in place by tightening
screws that have not been modelled for the sake of simplicity) was rendered (Kelley,
2008)v in Pro/E and is shown below,

Figure 5: Solid and wireframe model of the work holding strategy (side view).

For the purposes of running the developed G-code, the billet needs to be locked into
place so as to protrude 100 mm (10 cm) from the vertical face of the chuck or jaw-
type chuck. The diameter of the pre-fabricated billet is 250 mm, as defined in the
supplied schematic (Appendix A).

Although there is material wastage working from a larger than necessary diameter,
this allows for the machining process to remove any surface oxidation and ensures
that the entire part is worked out of ‘freshly’ cut metal. This could be important if
there are further stages involving metal treatment, such as anodizing for example.

7
4.2 DATUM POINT
In the diagram below, the datum point of the work-piece has been indicated on the
mounted billet, with a Euclidean distance of 75 mm along the Z-axis taken from the
foremost surface of the chuck.

Figure 6: Datum point of work-piece shown on the chuck-mounted billet (top-down view).

This datum point will be referenced as (0, 0) in the developed machining system and
as such great care is needed for any negative motion along the Z-axis to prevent
damaging the tools, and the lathe itself.

As per Figure 7, the datum point is shown placed upon its symmetrical axis flush with
its base, which has a 240 mm diameter. This schematic also clearly depicts all the
dimensions of the final product (apart from the surface roughness attribute of the 90
mm diameter frontal plane).

The developed G-code was based upon the features and dimensions shown in Figure
7.

8
 Figure 7: Datum point, shown on image on the right, on machining schematic (top-down view).

The X and Z-axes have been indicted above for clarity, as much referencing will be
made to coordinate systems operating in these two orthogonal planes. All lathing
operations are achieved with the cutting tool advancing towards the work-piece along
the X-axis whilst parallel with the Z-axis (Quesada, 2004)xiii.

The datum point on the mounted work-piece has been chosen to be located 75 mm
along the Z-axis (Figure 6), as this allows for 5 mm of excess in finishing the front
profile to the roughness tolerance indicated in the supplied schematic (Appendix A).

9
4.3 MACHINING OPERATIONS
Based upon the features of Figure 7, the task of machining the part has been reduced
to a particular sequence of the following three lathing operations (Conover, 2001)ii,

Straight Turning: • RECOMMENDED MACHINE TOOL: turning centre.

• CUTTING TOOLS: side-tool (1) with tool-tip radius for
rough profiling and (2) with sharp profile for finishing.
• FIXTURES: turning centre chuck.
• CUTTING PARAMETERS: rough and finishing profiles.
Image Source: (Sing, 2000)x
• NC/CNC MACHINE: CNC

Taper turning: • RECOMMENDED MACHINE TOOL: turning centre.

Image Source: (Sing, 2000)x
• CUTTING TOOLS: side-tool (1) with tool-tip radius for
rough profiling and (2) with sharp profile for finishing.
• FIXTURES: turning centre chuck.
• CUTTING PARAMETERS: rough and finishing profiles.
• NC/CNC MACHINE: CNC

Cutting off: • RECOMMENDED MACHINE TOOL: turning centre.

Image Source: (Sing, 2000)x
• CUTTING TOOLS: parting-tool (1) with tool-tip radius for
rough cutting and (2) with sharp profile for finish
cutting.
• FIXTURES: turning centre chuck.
• CUTTING PARAMETERS: rough and finishing profiles.
• NC/CNC MACHINE: CNC

All three operations are to be run on CNC machine (Wikipedia, 2009)xv as it will
ensure the work-pieces can be turned on a single machine-tool, considering the
benefits of CNC. CNC is far more flexible than NC machines due to its inherent
integration with computer control and software to greatly extend the capabilities of
the system past that of simple Microcontroller control (Morton, 2005)ix.

10
4.4 OPERATION SEQUENCING
The sequencing of operations to machine the final part, are defined as follows with
the notation of (Z [mm], X [mm]) used with respect to the location of the datum point.

Safe tool starting Position the tool tip at a safe distance away from the work-
0.
& resting position piece (40, 140). Load the parting-tool into the tool holder.
Cutting off Cut from (20, 140) along the vertical X-plane to (20, -140)
1.
(rough profile) with TNR compensation for rough profile.
Cutting off Finishing cut from (20, 140) along the vertical X-plane to
2.
(finishing profile) (20, -140)). Change to the side-tool via manual swap.
Straight turning Turn first layer; rough profile of r = 120 mm (Ø 240 mm)
3.
(rough profile). with TNR compensation for rough profile.
Straight turning Finishing profile of r = 120mm (Ø 240 mm) with TNR
4.
(finishing profile). compensation for smooth profile.
Straight turning Turn second layer to 10 mm thickness; rough profile of r =
5.
(rough profile). 107 mm (Ø 214 mm)
Straight turning Finish layer with 8 mm thickness and profile of r = 105
6.
(finishing profile) mm (Ø 210 mm)
Taper turning Taper from of r = 47 mm (Ø 94 mm) to r = 107 mm (Ø 214
7.
(rough profile) mm); taper has an excess of 2mm thickness.
Taper turning Finish taper from of r = 45 mm (Ø 90 mm) to r = 105 mm
8.
(finishing profile) (Ø 210 mm); taper has an excess of 2mm thickness.
Starting from (20, -105), perform linear interpolation
Straight turning
10. vertically along the X-plane to finish the foremost face
(finishing profile)
smoothly to rest at (20, 105).
Starting from (16, 103) round the three edges located at: (i)
Straight turning (16, 105), (ii) (8, 105) and (iii) (8, 120) with circular
9.
(finishing profile) interpolation (with radius 2 mm for each ‘round’). Change
to the parting-tool via a manual swap.
Position the tool-tip vertically centred above the datum
Cutting off
11. point (0, 140). Cut through the vertical X-plane to (0, -
(finishing profile)
140), with TNR (left) compensation for parting-tool radius.

11
It should be noted that after each operation performed in the sequence above (except
for operation No. 10), the tool tip needs to be returned to a safe location away from
the spindle, chuck and work-piece

To ensure the basic profiling of the part is performed to a relatively high degree of
smoothness and finish, the layers and tapering operations have been sequenced in
pairs of rough and finish profiling. The finishing profiles are accompanied by a
higher spindle speed and low tool feed rate (Quesada, 2004)xiii.

5 CNC ISO G-CODE MACHINING PROGRAM

The developed CNC program in ISO G-Code is located in Appendix B.

5.1 COORDINATE SYSTEMS CHOICE

The coordinate system will be based upon operations in the X and Z-planes, as
previously shown, with regard to the datum point of the work-piece. This is ideally
suited for lathing operations, due to their inherent ‘symmetrical’ nature, and this
representation is commonly used in industry (Smid, 2007)xi.

Image Source: (Krar, Gill and Smid, 2000)vi

Image Source: http://www.mmsonline.com,

Date accessed 24 March 2009.

Figure 8: Typical turning centre configuration with spindle face as the X-axis and spindle centre
line forming the Z-axis (left image, top-down view). Notice the cutting tool is located behind the
centre line in both images.

12
5.2 CHOICE OF FIXTURE
Although some types of chuck designs tend to offer better work holding
characteristics and quick means for accessing and replacing the work-piece, the
choice of fixture has been chosen to be the standard adjustable chuck that is
commonly found on lathing systems, as discussed earlier during the Process Planning
phase.

5.3 CNC MACHINE SPECIFICATIONS

The three main characteristics of a CNC machine (Krar, Gill and Smid, 2000)vi are: (i)
the number of parts it is able of producing per hour, (ii) the material hardness that can
be machined and (iii) the level of surface finish required. Graphs of all these are
show in Figure 9 below.

Image(s) Source: http://www.mmsonline.com,

Date accessed 24 March 2009.
Figure 9: Defining characteristics of a CNC machine.

Based on the design requirements defined in the supplied schematic (Appendix A),
the machine of choice for profiling the part in question would have the following
characteristics:

1. MACHINE THROUGHPUT: 1 to 10 per hour (or less).

2. MATERIAL HARDNESS: standard (approx. Vickers 167 to 400 MPa)
3. SURFACE FINISH: performance

13
Further to the previously mentioned characteristics of the system, the following
criteria for selection need to be met as well:

• MACHINE-TOOL TYPE: turning centre.

• AXIS DRIVE:
• ACCURACY:
• TOOL HOLDING:
• I/O FUNCTIONS:
• FEED RATE:
• SPINDLE SPEED:
• MOTOR POWER:
motion in two orthogonal axes.
within ± 0.5 mm (as per supplied schematic).
manual change, single-tool holder.
spindle speed and coolant (mist) control
minimum 300 mm/min (5 mm/s)
minimum 1000 rev/min (16.67 rev/s)
minimum of 1.5 hp

Rather than selecting a system with a multiple tool holder, the CNC program has been
designed to work with manual changes of the tool in a single tool holder system.
However, this does not prevent the CNC program from being run on a system with a
multiple tool holder.

5.4 CUTTING TOOL PARAMETERS AND ACCURACY

Particular attention has been paid to the positioning of the cutting tools and especially
the choice of coordinate system. Tool-Nose Radius (TNR) compensation has also
been employed to easily allow for the operator to compensate for variations that may
present themselves during machining without the need for directly modifying the
CNC program (Lynch, 1991)viii, but rather, the associated TNR value for the
particular tool being used.

Due to the class of a particular commercial grade tool, the thickness of a machined
work-piece tends to vary in size. The tool-tip radius largely determines the tool
accuracy and a tool with a .005 tool-tip radius would typically be employed for rough
cuts, whereas a tool-tip of 0.0002 radius would be more suited for finishing cuts.

TNR compensation further plays a vital role in contouring. Without TNR

compensation, much material may not be machined during this motion. It also allows
for the same tool trajectories to be utilised during both rough and finish profiling.

14
6 CONCLUSION
The machining quality for a single part set could offer a better finish depending on the
experience of the CNC operator and on his methodology in first testing the NC
program with no work-piece attached, and how well the TNR tolerances are
compensated for.

Multiple part sets are easily produced by repeatedly running the NC program with
constantly re-aligning the billet datum point for the machining to take place. With
sufficiently high spindle speeds and low tool feed rate it would be possible to finish
the work-piece to a very high degree.

The tolerance of the final part could even be taken as ± 0.1 mm as long as the CNC
system supports this. The quality of both the side-tool and parting-tool will also have
an impact on the resulting machined part.

15
REFERENCES
i
Bray, S. (2003) Metalworking Tools and Techniques, Wiltshire, UK: Crowood
Press.
ii
Conover, E. (2001) The Lathe Book: A Complete Guide to the Machine and its
Accessories, 2nd edition, Newtown, CT: The Taunton Press, Inc.
iii
Gere, J.M. and Goodno, B.J. (2008) Mechanics of Materials, 7th edition, Toronto,
Canada: Cengage Learning, Inc.
iv
Kalpakjian, S. and Schmid, S. (2005) Manufacturing, Engineering and
Technology, 5th edition, Upper Saddle River, NJ: Prentice Hall.
v
Kelley, D. (2008) Pro/Engineer Wildfire Instructor, 4th edition, New York, NY:
McGraw-Hill
vi
Krar, S., Gill, A. and Smid, P. (2000) Computer Numerical Control Simplified,
New York, NY: Industrial Press, Inc.
vii
Lamit, G. (2001) Pro/ENGINEER Wildfire™ 4.0, Toronto, Canada: Cengage
Learning, Inc.
viii
Lynch, M. (1991) Computer Numerical Control for Machining, New York, NY:
McGraw-Hill.
ix
Morton, J. (2005) The PIC Microcontroller: Your Personal Introductory Course,
3rd edition, Oxford, UK: Newnes.
x
Singh, N. (1996) Systems Approach to Computer-Integrated Design and
Manufacturing, Somerset, NJ: John Wiley & Sons, Inc.
xi
Smid, P. (2007) CNC Programming Handbook, 3rd edition, New York, NY:
Industrial Press, Inc.
xii
Toogood, R. (2007) Pro/ENGINEER Tutorial Wildfire 4.0, Mission, KS: Schroff
Development Corp.
xiii
Quesada, R. (2004) Computer Numeric Control: Machining and Turning Centres,
Upper Saddle River, NJ: Prentice Hall.
xiv
Wikipedia (2009) Lathe (metal), http://en.wikipedia.org/wiki/Lathe_(metal), Date
accessed 24 March 2009.
xv
Wikipedia (2009) Numerical Control, http://en.wikipedia.org/wiki/CNC, Date
accessed 24 March 2009.

16
A. Schematic of Machined Work-piece.

17
B. G-Code Machining Program
This program relies upon the TNR compensation information stored for tool 1 in
registers #1 and #2 to control rough and finish profiling of many of the surfaces
machined.

%
N000 G90 G21 Absolute programming in metric units
Constant spindle RPM, feed rate in
mm/min, select tool 1 (parting-tool) and its
N010 G97 G94 M06 T0101
TNR value from register #1 for rough
profile.
N020 G00 Z40000 X140000 F0 Rapid move to safe tool start position.
N030 G00 Z20000 X140000 F0 Position above plane of cut.
Start spindle (clockwise) at 300 RPM, tool
N040 M03 S300 F250 M08 feed rate of 250 mm/min and enable
coolant.
N050 G42 Enable TNR compensation (right)
Utilise parting-tool to rough-cut through
N060 G01 Z20000 X-140000
billet.
N070 G40 Disable TNR compensation.
N080 G00 Z40000 X140000 F0 Rapid move to safe tool start position.
N090 G00 Z20000 X140000 F0 Position above plane of cut.
Spindle speed of 500 RPM and tool feed
N100 S500 F120
rate of 120 mm/min for finishing profile
Enable TNR compensation (right) and load
N110 G42 T0102 TNR value from register #2 for smooth
profile.
Utilise parting-tool to finish cut through
N120 G01 Z20000 X-140000
billet.
N130 G40 Disable TNR compensation.
Rapid move to safe tool start position for
G00 Z40000 X140000 F0 M09
N140 manual tool change, stop coolant and
M05
spindle.
Replace the parting-tool with the side-tool for straight turning. We now proceed to machine
the first layer.
Select tool 1 (side-tool) and its TNR value
N150 M06 T0101
from register #1 for rough profile.

18
N160 G00 Z40000 X140000 F0 Recalibrate safe tool start position.
Start spindle (clockwise) at 300 RPM, tool
N170 M03 S300 F250 M08 feed rate of 250 mm/min and enable
coolant.
N180 G00 Z40000 X120000 F0 Rapid move to align with pending profile
N190 G42 Enable TNR compensation (right)
Linear interpolate past vertical plane of
N200 G01 Z-20000 X120000 datum point (enough clearance to cut-off
part at the end).
N210 G40 Disable TNR compensation.
N220 G00 Z40000 X140000 F0 Rapid move to safe tool start position.
N230 G00 Z40000 X120000 F0 Rapid move to align with pending profile
Spindle speed of 500 RPM and tool feed
N240 S500 F120
rate of 120 mm/min for finishing profile
Enable TNR compensation (right) and load
N250 G42 T0102 TNR value from register #2 for smooth
profile.
Linear interpolate past vertical plane of
N260 G01 Z-20000 X120000
datum point (finishing profile).
N270 G40 Disable TNR compensation.
N280 G00 Z40000 X140000 F0 Rapid move to safe tool start position.

We now proceed to machine the second layer.

Spindle speed of 300 RPM and tool feed

N290 S300 F250
rate of 250 mm/min for rough profile
N300 G00 Z40000 X105000 F0 Rapid move to align with pending profile
Enable TNR compensation (right) and load
N310 G42 T0101 TNR value from register #1 for rough
profile.
Linear interpolate the rough profile of the
N320 G01 Z8000 X105000
second layer.
N330 G40 Disable TNR compensation.
N340 G00 Z40000 X140000 F0 Rapid move to safe tool start position.
N350 G00 Z40000 X105000 F0 Rapid move to align with pending profile
Spindle speed of 500 RPM and tool feed
N360 S500 F120
rate of 120 mm/min for finishing profile
Enable TNR compensation (right) and load
N370 G42 T0102 TNR value from register #2 for smooth
profile.

19
 Linear interpolate the finishing profile of the
N380 G01 Z8000 X105000
second layer.
N390 G40 Disable TNR compensation.
N400 G00 Z40000 X140000 F0 Rapid move to safe tool start position.

We now proceed to machine the tapered feature.

Spindle speed of 300 RPM and tool feed

N410 S300 F250
rate of 250 mm/min for rough profile
N420 G00 Z20000 X45000 F0 Rapid move to align with pending profile
Enable TNR compensation (right) and load
N430 G42 T0101 TNR value from register #1 for rough
profile.
Linear interpolate the rough profile of the
N440 G01 Z16000 X105000
tapered feature.
N450 G40 Disable TNR compensation.
N460 G00 Z40000 X140000 F0 Rapid move to safe tool start position.
N470 G00 Z20000 X45000 F0 Rapid move to align with pending profile
Spindle speed of 500 RPM and tool feed
N480 S500 F120
rate of 120 mm/min for finishing profile
Enable TNR compensation (right) and load
N490 G42 T0102 TNR value from register #1 for smooth
profile.
Linear interpolate the finishing profile of the
N500 G01 Z16000 X105000
tapered feature.
N510 G40 Disable TNR compensation.
N520 G00 Z40000 X140000 F0 Rapid move to safe tool start position.

Finish profile the foremost face (Ø 90 mm) with high precision side-tool.

N530 G00 Z40000 X-105000 F0 Rapid move to intermediate location.

N540 G00 Z20000 X-105000 F0 Rapid move to align with pending profile
Enable TNR compensation (right) and load
N550 G42 T0102 TNR value from register #2 for smooth
profile.
Linear interpolate vertically along the X-
N560 G01 Z20000 X105000
plane.

Perform ‘rounding’ the three edges located at: (i) (16, 105), (ii) (8, 105) and (iii) (8, 120)

N570 G01 Z16000 X103000 Arrive at the starting point of first ‘rounding’.
st
N580 G03 Z14000 X105000 I2000 Circular interpolation (CCW), 1 edge.

20
 K2000
N590 G01 Z10000 X105000 Linear interpolate to the next starting point.
G02 Z8000 X107000 I2000
nd
N600 Circular interpolation (CW), 2 edge.
K2000
N610 G01 Z8000 X118000 Linear interpolate to the next starting point.
G03 Z6000 X120000 I2000 Circular interpolation (CCW), last and final
N620
K2000 edge.
N630 G40 Disable TNR compensation.
Rapid move to safe tool start position for
G00 Z40000 X140000 F0 M09
N640 manual tool change, stop coolant and
M05
spindle.

Replace the side-tool with the parting-tool for separating the part from the reset of the billet.

Select tool 1 (parting-tool) and its TNR

N650 M06 T0102
value from register #2 for smooth profile.
N660 G00 Z40000 X140000 F0 Recalibrate safe tool start position.
Start spindle (clockwise) at 500 RPM, with
N670 M03 S500 F120 M08
tool feed rate of 120 mm/min
N680 G00 Z00 X140000 F0 Rapid move to align with pending profile
N690 G41 Enable TNR compensation (left)
Linear interpolate along vertical plane of
N700 G01 Z00 X-140000
datum point, to cut the machined part off.
N710 G40 Disable TNR compensation.
Rapid move to safe tool position and turn
N720 G00 Z40000 X140000 F0 M30
off all machine functions.
%

21
QUALITY CONTROL ID: 603001

WORD COUNT: ~3000

(EXCLUDING EQUATIONS, FIGURES, CAPTIONS, DATA, CODE, OUTPUT, TABLE OF
CONTENTS, LIST OF FIGURES, LIST OF TABLES, REFERENCES AND APPENDICES.)

15-20 REFERENCES/3K WORDS? 15 REFERENCES (INC. BOOKS, JOURNALS AND WEB)

WEB REFERENCES < 15%? 2 WEB REFERENCES

DATE COMPLETED: 24TH MARCH 2009 / 1551 HRS GMT

NOTES:

AMENDED AS PER THE REQUEST OF THE CLIENT TO 15 PAGES IN LENGTH FOR THE MAIN
REPORT TEXT. G-CODE LISTING HAS BEEN RELEGATED TO APPENDIX B.

DATE COMPLETED: 24TH MARCH 2009 / 1833 HRS GMT

NOTE: This document has been created with compatibility for Word 97 – 2004. It is recommended that
the Word document have all its fields, tables, cross-references updated if this document is subjected to
modification.