KALAIGNAR KARUNANIDHI INSTITUTE OF

TECHNOLOGY Coimbatore -641 402

Academic year 2014-2015

DEPARTMENT OF MECHANICAL
ENGINEERING
ME2309

CAD/CAM Laboratory

Laboratory Manual

SYLLABUS

LIST OF EXPERIMENTS

CAD MODELING EXERCISES

1.
2.
3.
4.
5.

Creation of a 3D Model Using Extrude

Creation of a 3D Model Using Revolve
Creation of Simple Machine Components
Assembly of a Knuckle Joint in 3D Modeling
Assembly of a Screw Jack in 3D Modeling

CAM EXERCISES
1.
2.
3.
4.
5.
6.
7.
8.
9.

Part
Part
Part
Part
Part
Part
Part
Part
Part

Program
Program
Program
Program
Program
Program
Program
Program
Program

for Step Turning

for Step and Taper Turning
for Circular Arc Cutting and Taper Turning
using multiple turning cycle
for Grooving and Thread Cutting
for Contour Milling
for Pocket Milling
for Mirroring cycle
for Drilling cycle

Introduction to CAD
1. Introduction
Computer-aided design (CAD) is the use of computer systems to assist in the creation,
modification, analysis, or optimization of a design. CAD software is used to increase the
productivity of the designer, improve the quality of design, improve communications through
documentation, and to create a database for manufacturing. CAD output is often in the form
of electronic files for print, machining, or other manufacturing operations.

The benefits derived from the use of CAD system are numerous some are enumerated below
thus;
Improved quality
Designers can monitor the progress of a problem solution and terminate the run or
modify the input data as required.
Reduction of rafting labour
Reduction of turnaround time
The designer can make subjective decisions at critical branch points, which guide the
computer in continuing the problem solution
Reduction in the number of drawings required:
Direct cost savings

High accuracy (to-one-millionth of a unit)

Improvement in the general flow of information through a company
Provision of more reliability in design work by having relevant informations
The drawing speed increased up to three times faster drafters using traditional tool
Evaluation of alternative design
Use of standard libraries copy repeats
Modification of the CAD is quick and easy
Generation of rotations, bills of materials, and materials and symbols be placed on
drawing savings valuable time: and
Designers can immediately see and correct any gross errors in their drawings.

1.1 Computer Aided Design CAD

CAD is technology concerned with using computer systems to assist in the creation,
modification, analysis, and optimization of a design. Any computer program that embodies
computer graphics and an application program facilitating engineering functions in design
process can be classified as CAD software.
The most basic role of CAD is to define the geometry of design a mechanical part, a
product assembly, an architectural structure, an electronic circuit, a building layout, etc. The
greatest benefits of CAD systems are that they can save considerable time and reduce errors
caused by otherwise having to redefine the geometry of the design from scratch every time it
is needed.

2.1 BRIEF HISTORY OF CAD/CAM DEVELOPMENT

The roots of current CAD/CAM technologies go back to the beginning of civilization
when engineers in ancient Egypt recognized graphics communication. Orthographic
projection practiced today was invented around the 1800s. The real development of
CAD/CAM systems started in the 1950s. CAD/CAM went through four major phases of
development in the last century. The 1950s was known as the era of interactive computer
graphics. MITs Servo Mechanisms Laboratory demonstrated the concept of numerical
control (NC) on a three-axis milling machine. Development in this era was slowed down by
the shortcomings of computers at
the time. During the late 1950s the development of Automatically Programmed Tools (APT)
began and General Motors explored the potential of interactive graphics.
The 1960s was the most critical research period for interactive computer graphics.
Ivan Sutherland developed a sketchpad system, which demonstrated the possibility of
creating drawings and altercations of objects interactively on a cathode ray tube (CRT). The
term CAD started to appear with the word design extending beyond basic drafting concepts.
General Motors announced their DAC-1 system and Bell Technologies introduced the
GRAPHIC 1 remote display system.

During the 1970s, the research efforts of the previous decade in computer graphics
had begun to be fruitful, and potential of interactive computer graphics in improving
productivity was realized by industry, government and academia. The 1970s is characterized
as the golden era for computer drafting and the beginning of ad hoc instrumental design
applications. National Computer Graphics Association (NCGA) was formed and Initial
Graphics Exchange Specification (IGES) was initiated.
In the 1980s, new theories and algorithms evolved and integration of various
elements of design and manufacturing was developed. The major research and development
focus was to expand CAD/CAM systems beyond three-dimensional geometric designs and
provide more engineering applications.
The present day CAD/CAM development focuses on efficient and fast integration and
automation of various elements of design and manufacturing along with the development of
new algorithms. There are many commercial CAD/CAM packages available for direct usages
that are user-friendly and very proficient.

Below are some of the commercial packages in the present market.

AutoCAD and Mechanical Desktop are some low-end CAD software systems, which are
mainly used for 2D modeling and drawing.
NX, Pro-E, CATIA and I-DEAS are high-end modeling and designing software systems that
are costlier but more powerful. These software systems also have computer aided
manufacturing and engineering analysis capabilities.
Ansys, Abaqus, Nastran, Fluent and CFX are packages mainly used for analysis of
structures and fluids. Different software are used for different proposes. For example, Fluent
is used for fluids and Ansys is used for structures.
Alibre and CollabCAD are some of the latest CAD systems that focus on collaborative
design, enabling multiple users of the software to collaborate on computer-aided design over
the Internet.

3.1 GEOMETRIC MODELING

Computer representation of the geometry of a component using software is called a
geometric model. Geometric modeling is done in three principal ways. They are:
i.

Wire frame modeling

ii.

Surface modeling

iii.

Solid modeling

These modeling methods have distinct features and applications.

3.1.1 WIRE FRAME MODELING

In wire frame modeling the object is represented by its edges. In the initial stages of
CAD, wireframe models were in 2-D. Subsequently 3-D wire frame modeling software was
introduced.
Thus in the case of complex parts wire frame models can be confusing. Some clarity
can be obtained through hidden line elimination. Though this type of modeling may not
provide unambiguous understanding of the object, this has been the method traditionally used
in the 2-D representation of the object, where orthographic views like plan, elevation, end
view etc are used to describe the object graphically.

Fig 1

Ambiguity in Wire Frame Modeling

A comparison between 2-D and 3-D models is given below

2 - D Models

3-D Wire Frame Models

Ends (vertices) of lines are represented by Ends of lines are represented by their X, Y
their X and Y coordinates
and Z coordinates.
Curved edges are represented by circles,
ellipses, splines etc. Additional views and
sectional views are necessary to represent a
complex object with clarity

Curved surfaces are represented by suitably

spaced generators. Hidden line or hidden
surface elimination is a must to interpret
complex components Correctly.

3-D image reconstruction is tedious.

2-D views as well as various pictorial views

can be generated easily.

Uses only one global coordinate system

May require the use of several user

coordinate systems to create features on
different faces of the component.

3.1.2 SURFACE MODELING

In this approach, a component is represented by its surfaces which in turn are
represented by their vertices and edges. For example, eight surfaces are put together to create
a box, as shown in Fig. Surface modeling has been very popular in aerospace product design
and automotive design. Surface modeling has been particularly useful in the development of
manufacturing codes for automobile panels and the complex doubly curved shapes of
aerospace structures and dies and moulds.

Fig 2

Surface Representation

Apart from standard surface types available for surface modeling (box, pyramid,
wedge, dome, sphere, cone, torus, dish and mesh) techniques are available for interactive
modeling and editing of curved surface geometry. Surfaces can be created through an
assembly of polygonal meshes or using advanced curve and surface modeling techniques like
B-splines or NURBS (Non-Uniform Rational B-splines). Standard primitives used in a
typical surface modeling software are shown in Fig. Tabulated surfaces, ruled surfaces and
edge surfaces and revolved are simple ways in which curved geometry could be created and
edited.

Fig 3 Typical Approaches in Surface Modeling

3.1.3 SOLID MODELING

The representation of solid models uses the fundamental idea that a physical object
divides the 3-D Euclidean space into two regions, one exterior and one interior, separated by
the boundary of the solid. Solid models are:
bounded
homogeneously three dimensional
finite
In most of the modeling packages, the approach used for modeling uses any one of the
following three techniques:
a) Constructive solid geometry (CSG or C-Rep)
b) Boundary representation (B-Rep)
c) Hybrid method which is a combination of B-Rep and CSG.
a) Constructive Solid Geometry (CSG)
In a CSG model, physical objects are created by combining basic elementary shapes
known as primitives like blocks, cylinders, cones, pyramids and spheres. The Boolean
operations like union (), difference () and intersection (are used to carry out this task.
For example, let us assume that we are using two primitives, a block and a cylinder which are
located in space as shown in Fig.

Fig 4 CSG Operation

A union operation (A B) will combine the two to convert them into a new solid. (Fig. (c))
The difference operation (A B) will create a block with a hole (Fig. (D)). An intersection
operation (A B) will yield the portion common to the two primitives. (Fig. (E)).

b) Boundary Representation
Boundary representation is built on the concept that a physical object is enclosed by a set
of faces which themselves are closed and orientable surfaces. Fig. shows a B-rep model of an
object. In this model, face is bounded by edges and each edge is bounded by vertices.
The entities which constitute a B-rep model are:

Fig 5

B-Rep Model

A solid model is a 3-D representation of an object. It is an accurate geometric

description which includes not only the external surfaces of part, but also the parts internal
structure. A solid model allows the designer to determine information like the objects mass
properties, interferences, and internal cross sections.
Solid models differ from wire frame and surface models in the kind of geometric
information they provide. Wire frame models only show the edge geometry of an object.
They say nothing about what is inside an object. Surface models provide surface information,
but they too lack information about an objects internal structure. Solid models provide
complete geometric descriptions of objects.
Solid models can be used for quick and reliable design analysis. Solid models apart
from geometric information provide important data such as volume, mass, mass properties
and centre of gravity. The designer can also export models created to other applications for
finite element analysis (FEA), rapid prototyping and other special engineering applications.
Finally designers can generate detailed production drawings directly from the solid
model. This capability increases design productivity considerably. Another important feature
of solid modeling is associativity. Detailed drawings are linked to solid model through the
associativity feature. In bidirectional associativity, any modifications made to geometry in the
drawing are reflected in the model. In more advanced design and manufacturing
environments, solid models are used for rapid prototyping and automated manufacturing
applications.

FEATURE-BASED DESIGN
The most fundamental aspect in creating a solid model is the concept of feature-based
design. In typical 2-D CAD applications, a designer draws a part by adding basic geometric
elements such as lines, arcs, circles and splines. Then dimensions are added. In solid
modeling a 3-D design is created by starting a base feature and then adding other features,
one at a time, until the accurate and complete representation of the parts geometry is
achieved.
A feature is a basic building block that describes the design, like a keyway on a shaft.
Each feature indicates how to add material (like a rib) or remove a portion of material (like a
cut or a hole). Features adjust automatically to changes in the design thereby allowing the
capture of design intent.

Features/available in typical solid modeling software are:

Extrude
Blend
Protrusion
Hole
Chamfer
Draft
Offset
Pipe

Revolve
Slot
Shaft
Flange
Push
Ear
Lip
Sweep

Thin
Cut
Round
Rib
Dome
Shell

Basic Features:
Extrude (Linear Sweep)
Simple 3-D objects can be created by extruding 2-D images in the third dimension.
The extrusion thickness can be specified by an appropriate command. The objects extruded
will have uniform thickness in the Z direction. Fig. 6.20 (a) shows a triangle extruded in the
third dimension and Fig. shows the extrusion of a complex plane.

Revolve
Wire frame images can be created by revolving an entity about an axis. In Fig. a set of
entities are revolved about an axis through 270 to create a wire frame object. Rotation
through 360 will produce complete objects.

Sweep
Extrusion of a cross section along a path

Blend / Loft
Blending of different cross sections along a path

Editing Features in Part Modeling

Round

Modify the sharp edge to curved edge

Chamfer

Modify the sharp edge to flat edge

Shell

Removes a surface or surfaces from the solid then hollows out the
inside of the solid, leaving a shell of a specified wall thickness.

Rib

Special type of protrusion to create a thin fin or web

Cut

Remove the undesirable portion from the basic part

Hole

Remove cylindrical portion from the basic part

Pattern

Create instances of the selected feature by varying some specified

dimensions

Study of Various types of Drawings

1.

Machine Drawing:

It is pertaining to machine parts or components. It is presented through a number of

orthographic views, so that the size and shape of the component is fully understood. Part
drawings and assembly drawings belong to this classification. An example of a machine
drawing is given in Fig. 1.1

2.

Production Drawing

A production drawing, also referred to as working drawing, should furnish all the
dimensions, limits and special finishing processes such as heat treatment, honing, lapping,
surface finish, etc., to guide the craftsman on the shop floor in producing the component. The
title should also mention the material used for the product, number of parts required for the
assembled unit, etc.

3.

Part Drawing:

Component or part drawing is a detailed drawing of a component to facilitate its

manufacture. All the principles of orthographic projection and the technique of graphic
representation must be followed to communicate the details in a part drawing. A part drawing
with production details is rightly called as a production drawing or working drawing.
4.

Assembly Drawing

A drawing that shows the various parts of a machine in their correct working locations
is an assembly drawing (Fig. 1.3). There are several types of such drawings.

4.1 Exploded Assembly Drawing

In some cases, exploded pictorial views are supplied to meet instruction manual
requirements. These drawings generally find a place in the parts list section of a company
instruction manual. Figure 1.4 shows drawings of this type which may be easily understood
even by those with less experience in the reading of drawings; because in these exploded
views, the parts are positioned in the sequence of assembly, but separated from each other.

4.2 Schematic assembly drawing:

1.
It is very difficult to understand
the operating principles of complicated machinery,
merely from the assembly drawings. Schematic representation of the unit facilitates easy
understanding of its operating principle. It is a simplified illustration of the machine or of a
system, replacing all the elements, by their respective conventional representations. Figure
1.5 shows the schematic representation of a gearing diagram.

1.

4.3 Machine Shop Drawing:

Rough castings and forgings are sent to the machine shop for finishing operation (Fig.
1.6). Since the machinist is not interested in the dimensions and information of the previous
stages, a machine shop drawing frequently gives only the information necessary for
machining. Based on the same principle, one may have forge shop drawing, pattern shop
drawing, sheet metal drawing, etc.

1.
6

Study of Geometric Dimensioning & Tolerancing

Introduction:
Geometric dimensioning and tolerancing (GD&T) is a system for defining and
communicating engineering tolerances. It uses a symbolic language on engineering drawings
and computer-generated three-dimensional solid models that explicitly describes nominal
geometry and its allowable variation. It tells the manufacturing staff and machines what
degree of accuracy and precision is needed on each controlled feature of the part. GD&T is
used to define the nominal (theoretically perfect) geometry of parts and assemblies, to define
the allowable variation in form and possible size of individual features, and to define the
allowable variation between features.

Dimensioning specifications define the nominal, as-modeled or as-intended geometry.

One example is a basic dimension.
Tolerancing specifications define the allowable variation for the form and possibly the
size of individual features, and the allowable variation in orientation and location
between features. Two examples are linear dimensions and feature control frames
using a datum reference.

Fig Drawing without GD & T

Fig Drawing with GD & T

There are several standards available worldwide that describe the symbols and define
the rules used in GD&T. One such standard is American Society of Mechanical Engineers
(ASME) Y14.5-2009. The Y14.5 standard has the advantage of providing a fairly complete
set of standards for GD&T in one document. The ISO standards, in comparison, typically
only address a single topic at a time. There are separate standards that provide the details for
each of the major symbols and topics below (e.g. position, flatness, profile, etc.).
Dimensioning and tolerancing philosophy
According to the ASME Y14.5-2009 standard, the purpose of geometric dimensioning
and tolerancing (GD&T) is to describe the engineering intent of parts and assemblies. This is
not a completely correct explanation of the purpose of GD&T or dimensioning and
tolerancing in general.
The purpose of GD&T is more accurately defined as describing the geometric
requirements for part and assembly geometry. Proper application of GD&T will ensure that
the allowable part and assembly geometry defined on the drawing leads to parts that have the
desired form and fit (within limits) and function as intended.
There are some fundamental rules that need to be applied

All dimensions must have a tolerance. Every feature on every manufactured part is
subject to variation; therefore, the limits of allowable variation must be specified. Plus
and minus tolerances may be applied directly to dimensions or applied from a general
tolerance block or general note. For basic dimensions, geometric tolerances are
indirectly applied in a related Feature Control Frame. The only exceptions are for
dimensions marked as minimum, maximum, stock or reference.
Dimensioning and tolerancing shall completely define the nominal geometry and
allowable variation. Measurement and scaling of the drawing is not allowed except in
certain cases.

Engineering drawings define the requirements of finished (complete) parts. Every

dimension and tolerance required to define the finished part shall be shown on the
drawing. If additional dimensions would be helpful, but are not required, they may be
marked as reference.

Dimensions should be applied to features and arranged in such a way as to represent

the function of the features. Additionally, dimensions should not be subject to more
than one interpretation.

Descriptions of manufacturing methods should be avoided. The geometry should be

described without explicitly defining the method of manufacture.

If certain sizes are required during manufacturing but are not required in the final
geometry (due to shrinkage or other causes) they should be marked as non-mandatory.

All dimensioning and tolerancing should be arranged for maximum readability and
should be applied to visible lines in true profiles.

When geometry is normally controlled by gage sizes or by code (e.g. stock materials),
the dimension(s) shall be included with the gage or code number in parentheses
following or below the dimension.

Angles of 90 are assumed when lines (including center lines) are shown at right
angles, but no angular dimension is explicitly shown. (This also applies to other
orthogonal angles of 0, 180, 270, etc.)

Dimensions and tolerances are valid at 20 C / 101.3 kPa unless stated otherwise.

Unless explicitly stated, all dimensions and tolerances are only valid when the item is
in a free state.

Dimensions and tolerances apply to the full length, width, and depth of a feature
including form variation.

Dimensions and tolerances only apply at the level of the drawing where they are
specified. It is not mandatory that they apply at other drawing levels, unless the
specifications are repeated on the higher level drawing(s).

Tolerances:
The term tolerances refers to the permissible deviation of a dimension from the
specified basic size.

Type of Tolerances
1) Unilateral: It is the tolerance in which variation is permitted in on direction only from the
design size
2) Bi- Lateral type: It is the tolerance in which variation is permitted in both directions from
the design size.
Geometric Tolerancing chart:

CAD Modeling
Exercises

Ex. No:1
Date:

Creation of a 3D model using Extrude

Aim :
To model the given object using the Extrusion feature as per the dimensions given.
Software Used:

Procedure:
1. Select a sketch plane.(Front, top or Side)
2. Sketch a 2D profile of the model.
3. Dimension the model using Smart Dimension icon.
4. Check the sketch is fully defined.
5. Extrude the sketch perpendicular to sketch plane.
6. Use extruded cut feature to cut the solid as given in the drawing.

Result:
Thus the given model is extruded.

Ex. No:
Date:

Creation of solid model using Revolve

AIM:
To model the given object using the Revolve feature as per the dimensions given.
Software Used:

Procedure:
1. Select a sketch plane.(Front, top or Side)
2. Sketch a 2D profile of the model.
3. Dimension the model using Smart Dimension icon.
4. Check the sketch is fully defined.
5. Revolve the sketch.

Result:
Thus the given model is drawn using revolve feature.

Ex. No:
Date:

Creation of Simple Machine Components

AIM:
To model the given object using various features as per the dimensions given.
Software Used:

Procedure:
1. Select a sketch plane.(Front, top or Side)
2. Sketch a 2D profile of the model.
3. Dimension the model using Smart Dimension icon.
4. Check the sketch is fully defined.
5. Create the part.
6. Save the model.

Result:
Thus the given model is drawn using various features.

ADDITIONAL MACHINE COMPONENTS EXERCISES

Ex. No:
Date:

Assembly of a Knuckle Joint in 3D Modeling

AIM:
To create an assembly of a knuckle joint as per the given dimensions.

Software Used:

Procedure:
1. Select a sketch plane.(Front, top or Side)
2. Sketch a 2D profile of the model.
3. Dimension the model using Smart Dimension icon.
4. Check the sketch is fully defined.
5. Create the parts.
6. Assemble the parts.
7. Save the assembly.

Result:
Thus the given model is drawn using various features and assembly is made.

Ex. No:
Date:

Assembly of a Screw Jack in 3D Modeling

AIM:
To create an assembly of a Screw Jack as per the given dimensions.

Software Used:

Procedure:
1. Select a sketch plane.(Front, top or Side)
2. Sketch a 2D profile of the model.
3. Dimension the model using Smart Dimension icon.
4. Check the sketch is fully defined.
5. Create the parts.
6. Assemble the parts.
7. Save the assembly.

Result:
Thus the given model is drawn using various features and assembly is made.

STUDY OF CNC MACHINES

INTRODUCTION TO CNC MACHINES

COMPUTER NUMERICAL CONTROL:
Numerical Control (NC) is a form of programmable automation in which
the processing equipment is controlled by means of numbers, letters, and other symbols. The
numbers, letters, and symbols are coded in an appropriate format to define the program of
instructions for a particular job.
Computer Numerical Control (CNC) is a reprogrammable
microprocessor based control system that accepts a set of programmed instructions, processes
and sends O/P control information to a machine tool ,accepts feedback information to a
machine tool from a transducer and based on the instructions and feedback it assures that
proper motion, speed and operation occurs.

A CNC system may be characterized in terms of three major elements, hardware, software
and information.
HARDWARE: CNC hardware includes the microprocessors that effect control system
functions and peripheral devices for data communication, machine tool interfacing and
machine tool status monitoring. In addition to, certain elements of the machine tool like
transducers, actuators can be considered part of the CNC system
SOFTWARE: CNC software includes the programs that are executed by the system
microprocessors. These programs process input and output instructions and control
information ,make all necessary computations for machine functions, coordinate the functions
of these machines and accessories and provide the communication links with other levels of
manufacturing automation .The instructions that drive a CNC system are frequently generated
using special programming languages like APT based CNC programming systems.
INFORMATION: CNC operation requires data such as cutter location data, machining data
information regarding the dynamic characteristics of the machine and many other information
pertaining to the process.

TYPES OF CNC MACHINES

1. Vertical Machining Centers (VMC)

2. Horizontal Machining Centers (HMC)
3. Multi-axis machining centers
4. Milling machines
5. Drilling machines
6. Surface Grinders
7. Cylindrical grinders
8. Tool and cutter grinders
9. Fixed RAM Electro Discharge machines (EDM)
10. Wire EDM
11. Punching and nibbling machines with plasma arc or laser beam machining
12. Forming machine
13. Gear cutting machines
14. Coordinate Measuring Machines (CMM)

REQUIREMENTS OF FLEXIBILITY

1. Uses of Flexible Manufacturing systems

2. Efficiency: Can be met by 1. Adaptive control. 2. Developments in material
and geometry of cutting tools.
3. Quality: Adaptive control for quality, i.e. on-line and active quality control.

STUDY OF CNC TURING CENTER

CNC controlled by the modular FANUC O.T.C

The CNC lathe is designed for chuck, bar and between centre works. It is normally
controls of the CNC system and the machine control itself are contained in a single control
desk. In turn, this desk consists of a control panel for the machine and a control panel for the
CNC system.
The machine control panel incorporates a CRT screen, which displays the
computer dialogue, the image sequences relating to the various modes of operation and work
piece programming.

FEATURES OF CNC TURNING MACHINES

1. High powered drives and wide speed range

2. Simultaneous 2 tool operation with 4 axis machines
3. High duty drums type turrets capable of accommodating internal as well as
external turning tools.
4. Automatic tool changer(ATC) facility
5. Off axis machining facility
6. Probes for work piece size monitoring, tool condition monitoring, inspection of
tools and setting of automatic tool offsets
7. Programmable tail stock

STUDY OF PART PROGRAMMING

The part programming method includes a variety of procedures ranging from highly
manual to highly automated. The types of part program are
1. Manual Part Programming
2. Computer assisted part programming
3. Computer automated part programming
4. NC programming using CAD/CAM
Manual Part Programming:
In Manual Part Programming the programming instructions are documented on a form
called a part programming manuscript. The manuscript is a listing of the positions of the tool
relative to the work piece that the machine must follow in order to perform the processing.
The listing may include other commands such as speeds, feeds, tooling and so on. A punched
tape is then prepared from the manuscript.
Computer Assisted Part Programming:
In computer assisted part programming much of the tedious computational work
required in manual part programming is performed by computer. For complex work part jobs
with many processing steps, use of the computer results in significant savings time . when
computer assisted part programming is used the programmer prepares the set of processing
instructions in a higher level computer language. The high level language commands are
interpreted by the computer and the required data calculations and data processing are
accomplished to prepare the NC program.
NC Programming using CAD/CAM:
NC programming using CAD/CAM is an advanced form of computer assisted part
programming in which an interactive graphics system equipped with NC programming
software is used to facilitate the part programming task. In this method the programmer
works on a CAD/CAM workstation to enter the machining commands .The actions indicated
by the commands are displayed on the graphics monitor, which provides visual feedback to
the programmer .Also certain portions of the programming cycle are automated by the NC
programming software to reduce the total programming time required.
Computer Automated Part Programming:
Computer automated part programming extends the notion of automating certain
portions of the NC part programming procedure to its logical conclusion. It automates the
complete part programming task using software that is capable of making logical even quasi
intelligent decisions about how the part should be machined.

PREREQUISITES
For writing CNC programming the required data are

Dimension of the work pieces

Finished dimension with tolerance of the final component

Sequence of the operations to be performed

Types of tools to be used

Optimum cutting speed & feed at each stage

Method of clamping / chucking of job

Mounting of tools

The process of putting all these data into the proper order and translating them into a
language that the machine control system can understand is called part programming.
Therefore a part program is the set of (alpha- numeric) coded form of step by step
instructions in a pre determined sequence that are entered into the control system of CNC.
Just like any other language, the part program consists of sentences, called blocks, which
in turn are made up of words. The words used in this language are the programming
commands, the command for the machine.

NC Words
The lists of addresses used in the words are
CHARACTER

FUNCTION

Rotating about X axis

Rotating about Y axis

Rotating about Z axis

D&E

Rotating about additional axis

Feed

Preparatory function, identifying the action to be executed

Unassigned

Interpolation parameter / Thread pitch parallel to X axis

Thread pitch parallel to Y axis

Thread pitch parallel to Z axis

Unassigned

Auxiliary function

Block number

Prefix add the program no

P,Q,R

Thread movement parallel to X,Y & Z axes respectively. P&Q are

also used as parameters in cycles

Spindle speed

Tool No

U,V,W

Second Movement parallel to X,Y,Z respectively

Movement in X axis

Movement in Y axis

Movement in Z axis

PREPARATORY FUNCTION (G-FUNCTION) FOR CNC MACHINES

The preparatory function (also called as G-code) is those, which decides the
mode of tool movement operation. The purpose of G-code is to initiate motion
command, canned cycles, various machine functions, and other control capabilities.
More than one G-code may be specified per block .If conflicting G-code are
specified on a block, an error message will appear.
G Codes (Preparatory Function)
GODE

FUNCTIONS
CNC MILLING

CNC LATHE

G00

Rapid traverse

Rapid traverse

G01

Linear cutting

Linear cutting

G02

Circular cutting clock wise

Circular cutting clock wise

G03

Circular cutting anti clock wise

Circular cutting anti clock wise

G04

Dwell time

Dwell time

G20

Inch command input

Inch command input

G21

Metric input

Metric input

G28

Automatic zero return

Automatic zero return

G40

Cutter radius offset cancel

Cutter radius offset cancel

G41

Cutter radius offset LEFT

Cutter radius offset RIGHT

G42

Cutter radius offset RIGHT

Cutter radius offset LEFT

G70

--

Multiple turning finishing cycle

G71

--

Multiple turning roughing cycle

G73

Peck drilling

Pattern repeating cycle

G74

Reverse tapping cycle

End face peck drilling

G75

--

Grooving cycle

G76

Fine boring cycle

Multiple threading cycle

G80

Canned cycle cancel

Canned cycle cancel

G81

Spot drilling cycle

Drilling cycle

G82

Counter boring cycle

Counter boring cycle

G83

Peck drilling cycle

Peck drilling cycle

G84

Tapping cycle

Tapping cycle

G87

Back boring cycle

Back boring cycle

G90

Absolute command

Turning cycle

G91

Incremental command

Incremental command

G94

Feed in mm/min

Facing cycle

G95

Feed in rev/min

Feed in rev/min

G98

Initial point level return

Feed in mm/min

G99

Point R level return

Point R level return

M Codes (Miscellaneous Codes)

GODE

FUNCTIONS
CNC LATHE

CNC MILLING

M00

Program stop

Program stop

M01

Optional stop

Optional stop

M02

Program end

Program end

M03

Spindle rotation Clock wise

Spindle rotation Clock wise

M04

Spindle rotation
wise

Spindle rotation anti clock wise

M05

Spindle rotation stop

Spindle rotation stop

M06

Automatic Tool changing

Automatic Tool changing

M08

Coolant ON

Coolant ON

M09

Coolant OFF

Coolant OFF

M30

Program End and Rewind

Program End and Rewind

M70

X axis mirror image ON

--

M71

Y axis mirror image ON

--

M80

X axis mirror image OFF

--

M81

Y axis mirror image OFF

--

M98

Sup program call

Sup program call

M99

Sup program call

Sup program call

anti clock

CNC Turning
Exercises

Program
O0001;
[BILLET X50 Z80
G28 U0 W0;
N1 G50 S3000;
T0101;
G96 S500 M03;
G00 X55 Z5;
G01 X0 Z0 F1.0;
G01 X26 Z0 F0.25;
X26 Z-20;
X34 Z-20;
X34 Z-35;
X42 Z-35;
X42 Z-50;
X50 Z-50;
X50 Z-70;
G00 X55 Z5;
M05;
G28 U0 W0;
M01;
M30;

Ex. No:

PART PROGRAM FOR STEP TURNING

Date:
Aim:

To write and execute a part program for step turning.

Codes used:
Billet

Specify jobs dimensions

G21

Selects metric systems (.001 mm)

G96

Constant surface speed (CSS)

M06

Tool change

M03

Spindle on

G00

Rapid traverse

G01

Linear cutting

G28

Home position

M05

Spindle stop

M30

Program stop and rewind

Part program:

Result:
The part program is created and executed and the output is verified.

Program
O0002;
[BILLET X50 Z80
G28 U0 W0;
N1 G50 S3000;
T0101;
G96 S500 M03;
G00 X55 Z5;
G01 X0 Z0 F1.0;
G01 X26 Z0 F0.25;
X34 Z-15;
X34 Z-25;
X42 Z-45;
X42 Z-55;
X50 Z-75;
G00 X55 Z5;
M05;
G28 U0 W0;
M01;

M30;

Ex. No:

PART PROGRAM FOR STEP AND TAPER TURNING

Date:
Aim:

To create the part program to step turn & taper turn a cylindrical job.
Codes used:
Billet

Specify jobs dimensions

G21

Selects metric systems

G96

Constant surface speed (CSS)

M06

Tool change

M03

Spindle on clockwise

G00

Rapid traverse

G01

Linear cutting

G28

Home position

M05

Spindle stop

M30

Program stop and rewind

Part program:

Result:
The part program is created & executed and output is verified.

Program
O0003;
[BILLET X25 Z40
G28 U0 W0;
N1 G50 S3000;
T0101;
G96 S500 M03;
G00 X30 Z5;
G01 X0 Z0 F1.0;
G01 X10 Z0 F0.25;
X14 Z-5;
X14 Z-10;
G02 X17 Z-13 R3;
G03 X20 Z-16 R3;
G01 X20 Z-24;
G00 X25 Z-29;
M05;
G28 U0 W0;
M01;
M30;

Ex. No:

PART PROGRAM FOR CIRCULAR ARC CUTTING, STEP

AND TAPER TURNING

Date:
Aim:

To create a part program to cut circular arcs & taper turn a cylindrical work piece.
Codes used:
Billet

Specify jobs dimensions

G21

Selects metric systems

G96

Constant surface speed (CSS)

M06

Tool change

M03

Spindle on

G00

Rapid traverse

G01

Linear Cutting

G02

Circular arc clockwise

G03

Circular arc counter clockwise

G28

Home position

M05

Spindle stop

M30

Program stop and rewind

Part Program:

Result:
The part program is created and executed & output is verified.

G71 Turning cycle

Example
G71 U4.0 R2.0
G71 P1 Q7 F0.1 U0.5 W0.2
LINE 1
G71 - Is the cycle type
U4.0 - is the depth of cut in mm
R2.0 - is the clearance of the X axis when rapid traversing back for the next cut in mm
F0.1 - is the feed rate (either in mm/rev or mm/min depending on your feed type)
LINE 2
G71 - Is the cycle type
P1 - is the first profile line sequence number
Q7 - is the last profile line sequence number
U0.5 - is the amount of material to be left on the OD (X) incremental
W0.2 - is the material to be left on the shoulders (Z) incremental
Program
O0004;
[BILLET X25 Z40
G28 U0 W0;
N1 G50 S3000;
T0101;
G96 S500 M03;
G00 X27 Z5;
G71 U2 R2;
G71 P10 Q20 F0.25 R2 U0.2 W0.1;
N10 G00 X0;
G01 Z0 F1.0;
G03 X10 Z-5 R5;
G01 X10 Z-15;
X15 Z-20;
X15 Z-28;
N20 X22 Z-28;
G70 P10 Q20;
M05;

G28 U0 W0;
M01;
M30;

Ex. No:

PART PROGRAM USING MULTIPLE TURNING CYCLE

Date:
Aim:

To create the part program using multiple turning cycle for the given job.
Codes used:
Billet

Specify jobs dimensions

G21

Selects metric systems

G96

Constant surface speed (CSS)

M06

Tool change

M03

Spindle on clockwise

G00

Rapid traverse

G01

Linear cutting

G70

Finishing cycle

G71

Stock removal in turning

G28

Home position

M05

Spindle stop

M30

Program stop and rewind

Part program:

Result:
The part program is created & executed and output is verified.

G75 Grooving cycle

Format
G75 R
G75 X Z P Q R

G75 First CNC Programming Block

R Return amount
G75 Second CNC Programming Block
X Groove Depth (Groove end position in x-axis)
Z Last groove position in z-axis (End Position in z-axis)
P *Peck increment in x-axis (depth of each cut in x-axis)
Q Stepping in z-axis. R = Relief amount at end of the cut.

G76 Threading cycle

Example
G76 P010060 Q100 R0.05
G76 X30 Z-20 P1024 Q200 F2

P : P actually consists of multiple values which control the thread behavior,

01 : Number of spring passes or spring cuts.
00 : Thread run out at 45 degree
60 : Flank angle or Infeed angle
Q : Depth of normal cut ( these values are given in hundreds, so the depth of cut will be 0.1 ).
R : Depth of Last or Finish cut

Second block of the G76 Threading cycle

G76 : G code of the threading cycle.
X : The end value in x-axis.
Z : The end value in z-axis.

P : Thread depth ( as radius value ).

Q : Depth of first cut.
F : Thread Pitch
R : Thread Taper

Ex. No:

PART PROGRAM FOR GROOVING AND THREAD CUTTING

Date:
Aim:

To create the part program of grooving and thread cutting using cycles for the given
job.
Codes used:
Billet

Specify jobs dimensions

G21

Selects metric systems

G96

Constant surface speed (CSS)

M06

Tool change

M03

Spindle on clockwise

G00

Rapid traverse

G01

Linear cutting

G70

Finishing cycle

G71

Turning cycle (Stock removal in turning)

G75

Grooving cycle

G76

Threading cycle

G28

Home position

M05

Spindle stop

M30

Program stop and rewind

Part program:

Result:
The part program is created & executed and output is verified.

Program:
O0005;
[BILLET X32 Z70
G28 U0 W0;
N1 G50 S3000;
T0101; (Turning tool)
G96 S500 M03;
G00 X35 Z5;
G71 U2 R2;
G71 P10 Q20 F0.25 R2 U0.2 W0.1;
N10 G00 X18;
G01 Z0 F1.0;
X18 Z0;
X22 Z-2;
X22 Z-20;
X32 Z-40;
N20 G00 X35;
G70 P10 Q20;
M05;
M01;
N2 G50 S3000;
G28 U0 W0;
T0606; (Grooving tool)
G96 S400 M03;
G00 X25 Z-18;
G75 R1;
G75 X18 Z-20 P1000 Q1000 R0 F0.1;
M05
G28 U0 W0;
M01;
N2 G50 S3000;
G28 U0 W0;
T0505; (Threading tool)
G96 S400 M03;
G00 X22 Z5;
G76 P010060 Q100 R0.05;
G76 X18 Z-16 P2000 Q200 F2;
M05
G28 U0 W0;
M01;
M30;

1. Single Turning Cycle: Billet size: - 25 x 70 mm

2. Multiple Turning Cycle: Billet size: - 22 x 65 mm

ADDITIONAL TURNING EXERCISE

3. Single Facing Cycle: Billet size: - 20 x 75 mm

4. Single Grooving: Billet size: - 22 x 70 mm (3mm width grooving tool)

CNC Milling
Exercises

STUDY OF CNC MILLING

CNC Machining Center

The machining centre is normally controlled by the FANUC OM or similar
controls. All the operating controls of the CNC system and the machine control itself are
contained in a single control panel. The machine control incorporates a CRT screen, which
displays the computer dialogue, the image sequences relating to the various modes of
operation and work piece programming. Some machining centers have Automatic Tool
Changer Facility.
Construction:
Bed

Function as a base for all machine components, including the column, saddle,
table, etc.

Column:

Installed on the bed and carries the head.

Saddle :

Installed on the slide ways of the bed and traverses back and forth.

Table :

Traverse left and right on the saddle sideways moves along the column slide
ways.

Head :

Composed of the spindle, spindle drive motor, etc. and vertically.

ATC

Composed of tool magazine, cylinder, etc. and changes tool.

Representation of working planes:

Working planes in a machining center is represented as shown in the figure
below.

Cutter Compensations:
The principle behind the various cutter compensations are shown in the

following figures.

The above figure represents the tool length compensation for the various tools
mounted in a tool magazine.
In order to achieve the correct dimension values and to ease the process of
part programming following cutter compensation are to be given

CANNED CYCLES
Canned cycles make it easier for the programmer to create programs. With a
canned cycle, a frequently used machining operation can be specified in single block
with G function. Without canned cycles, normally more than one block is required. In
addition, the use of canned cycles can shorten the program to save memory.

Directives
[BILLET

- Define Billet Size

[EDGEMOVE- Offset from the program zero to the lower left corner of the billet
[TOOLDEF

- Define diameter and length of a tool

[STEP

- Step by step execution of program

[NOSTEP

- Cancel step by step execution of program

[SHOW

- Show the operation being simulated

[NOSHOW

- Stop the operation being simulated

! TUTORIAL - To display user interactive message at the bottom

[CLEAR

- It will clear the interactive message display

General Notations
X

X coordinate value

Y coordinates value

Z coordinates value

Diameter of tool

Tool Number

Feed rate

Spindle speed

Radius of arc

Function
G00
G01
G02
G03
G04
G20
G21
G28
G40
G41
G42
G49
G90
G91
G92
G94
G95
G170-G171
G172-G173

G Functions
Operation
Positioning (Rapid traverse)
Linear interpolation (Cutting feed)
Circular interpolation / Helical CW
Circular interpolation / Helical CCW
Dwell Exact stop
Imperial units (inches)
Metric units (mm)
Return to reference point
Tool radius compensation cancel
Left hand radius compensation
Right hand radius compensation
Tool length compensation cancel
Absolute command
Incremental command
Set datum
Feed per minute
Feed per rotation
Circular Pocketing
Rectangular Pocketing

Function
M00
M02
M03
M04
M05
M06
M70
M71
M80
M81
M98
M99

M Functions
Operation
Program Stop
Program End
Spindle Forward
Spindle Reverse
Spindle Stop
Tool Change
X Mirror on
Y Mirror on
X Mirror Off
Y Mirror Off
Subprogram Call
Subprogram Exit

Contour Milling:

Billet size: - 100 x 100 x 10 mm; Depth of cut 1 mm

Program
O2000
[BILLET X100 Y100 Z10;
[TOOLDEF T1 D5;
[EDGEMOVE X-50 Y-50;
N10 G21 G40 G94;
N20 G50 S2000;
N30 G91 G28 Z0;
N40 G28 X0 Y0;
N50 M06 T0101;
N60 G90;
N70 G00 X-25 Y0;
N75 Z1;
N80 M03 S1000;
N90 G01 Z-1 F35;
N100 G01 X-25 Y15;
N110 G02 X-15 Y25 R10 F25;
N120 G01 X15 Y25 F35;
N130 G03 X25 Y15 R10 F25;
N140 G01 X25 Y-15 F35;
N150 G02 X15 Y-25 R10 F25;
N160 G01 X-15 Y-25 F35;
N165 G03 X-25 Y-15 R10;
N166 G01 X-25 Y0;
N170 G00 Z1;
N175 M05;
N180 G91 G28 Z0;
N190 G28 X0 Y0;
N200 M01;
N210 M30;

Ex. No:

PART PROGRAM FOR CONTOUR MILLING

Date:
Aim:

To create a part program to slot mill the required pattern on the job.
Codes used:
Billet

Specify jobs dimensions

Tool def

Tool specifications

Edge move

Initial position

G00

Rapid traverse

G01

Cutting

G90

Metric system (absolute)

G91

Imperial system on

G21

Metric units

G94

Per minute feed

G40

Cancel tool radius compensation

G80

Cancel canned cycles

G28

Home position

M06

Tool change

M03

Spindle on

M05

Spindle stop

M30

Program stop and rewind

Part program:

Result:
The part program is created & executed and output is verified.
Pocket Milling:

Billet size: - 90 x 90 x 10 mm; Depth of cut 3 mm

All Dimensions are in mm

The syntax for rectangular pocketing is given below:

G172 I30 J50 K0 P0 Q.5 R0 X10 Y10 Z-5
G173 I0 K0 P75 T1 S1000 R35 F45 B1500 J15 Z5
Where
I,J
- Length of pocket in X, Y directions
K
- Corner radius
P
- Roughing (0) / Finishing (1)
Q
- Depth of cut for each pass
R
- Absolute depth from the surface
X & Y - Pocket corner coordinates
Z
- Base of pocket
I,K
- Pocket side and base finish allowance
P
- Cutter width percentage
T
- Tool number
S
- Roughing spindle speed
R
- Roughing feed in Z direction
F
- Roughing feed in XY directions
B
- Finishing spindle speed
J
- Finishing feed

Ex. No:

PART PROGRAM FOR POCKET MILLING

Date:
Aim:

To create a part program to slot mill the required pattern on the job.
Codes used:
Billet
Tool def
Edge move
G00
G01
G90
G91
G21
G94
G40
G80
G28
M06
M03
M05
M30

Specify jobs dimensions

Tool specifications
Initial position
Rapid traverse
Cutting
Metric system (absolute)
Imperial system on
Metric units
Per minute feed
Cancel tool radius compensation
Cancel canned cycles
Home position
Tool change
Spindle on
Spindle stop
Program stop and rewind

Part program:
O2002;
[BILLET X80 Y70 Z10;
[TOOLDEF T1 D10;
[EDGEMOVE X0 Y0;
N10 G21 G40 G94;
N20 G91 G28 Z0;
N30 G28 X0 Y0;
N40 M06 T0101;
N50 M03 S2000;
N60 G90 G00 X0 Y0;
N70 Z5;
N80 G172 I40 J30 K0 P0 Q1.5 R0 X20 Y15 Z-3.;
N90 G173 I0 K0 P75 T1 S2000 R75 F275 B2500 J200 Z3
N100 M05;
N110 G91 G28 Z0;
N120 G28 X0 Y0;
N130 M30;

Result:
The part program is created & executed and output is verified.
Mirroring Cycle:

Billet size:-100 x 100 x 10 mm, Depth of cut 1 mm

All Dimensions are in mm
Subprogram
O8000;
N10 G90 G00 X15 Y15 Z1;
N20 G01 Z-1 F35;
N30 G01 X25 Y15;
N40 G01 X15 Y25;
N50 G01 X15 Y15;
N60 G00 Z1;
N70 G00 X0 Y0;
N80 M99;
** save the file as 4 digit number 8000.

Main Program
O2004;
[BILLET X100 Y100 Z10;
[EDGEMOVE X-50 Y-50;
[TOOLDEF T1 D5;
N10 G21 G94 G40;
N20 G91 G28 Z0;
N30 G28 X0 Y0;
N40 M06 T0101;
N50 M03 S1000;
N60 G90 G00 X0 Y0 Z5;
N70 M98 P0018000;
PROFILE 1
N80 M70;
X
Mirror On
N90 M98 P0018000;
PROFILE 4
N100 M71;
Y
Mirror On
N110 M98 P0018000;
PROFILE 3

N120 M80;
X
Mirror Off
N130 M98 P0018000;
PROFILE 2
N140 M81;
Y
Mirror Off
N150 G91 G28 Z0;
N160 G28 X0 Y0;
N170 M05;
N180 M30;

Ex. No:

PART PROGRAM FOR MIRRORING CYCLE

Date:
Aim:

To create a part program to slot mill the required pattern on the job.
Codes used:
Billet

Specify jobs dimensions

Tool def

Tool specifications

Edge move

Initial position

G00

Rapid traverse

G01

Cutting

G90

Metric system (absolute)

G91

Imperial system on

G21

Metric units

G94

Per minute feed

G70

X - Mirror ON

G71

Y - Mirror ON

G80

X - Mirror OFF

G81

Y - Mirror OFF

M98

Call sub-program

M99

Return from sub-program

G28

Home position

M06

Tool change

M03

Spindle on

M05

Spindle stop

M30

Program stop and rewind

Part program:

Result:
The part program is created & executed and output is verified.
Drilling Cycle:

G83 Peck Drilling Cycle

Command Format
G83 X _ Y_ Z _ R _ Q _ K _ F _;
Argument Instruction
X__Y__
- Coordinate of hole position (mm).
Z__
- Coordinate of hole bottom (mm).
R__
- Coordinate of R point (i.e. retraction point) (mm).
Q__
- Cutting feed per time (mm).
K__
- Times of iteration.
F__
- Feedrate (G94 mm/min) (G95 mm/rev)

Ex. No:

PART PROGRAM FOR DRILLING CYCLE

Date:
Aim:

To create a part program to slot mill the required pattern on the job.
Codes used:
Billet
Tool def
Edge move
G00
G90
G91
G21
G94
G81
G83
G04
G80
G28
M06
M03
M05
M30

Specify jobs dimensions

Tool specifications
Initial position
Rapid traverse
Metric system (absolute)
Imperial system on
Metric units
Per minute feed
Spot drilling cycle
Peck drilling cycle
Dwell time
Cancel canned cycles
Home position
Tool change
Spindle on
Spindle stop
Program stop and rewind

Part program:
O2005;
[BILLET X100 Y100 Z20;
[TOOLDEF T1 D10;
[EDGEMOVE X-50 Y-50;
N10 G21 G94 G41;
N20 G91 G28 Z0;
N30 G28 X0 Y0;
N40 M06 T0101;
N50 M03 S1000;
N60 G90 G00 X25 Y25 Z5;
N70 G83 X25 Y25 Z-10 Q2.5 R1 F35;
N80 X25 Y-25;
N90 X-25 Y-25 ;
N100 X-25 Y25;
N110 G80;
N120 G91 G28 Z0;
N130 G28 X0 Y0;
N140 M05;
N150 M30;

Result:
The part program is created & executed and output is verified.

ADDITIONAL TURNING EXERCISE

1. Circular Pocketing: : Billet size: - 90 x 90 x 10 mm; Depth of cut 3 mm

2. Contour Milling: Billet size: - 100 x 100 x 10 mm; Depth of cut 1 mm

3. Drilling & Boring Using Absolute Co-ordinates: :

Billet size : 100 x 100 x 10 mm
Drilling Tool : 6
Boring Tool : 10