Computer Numerical Control (CNC) Name: ___________________________

(File location: http://techweb.bsu.edu/jcflowers1/rlo/NCLathe.docx)

Note: This packet contains instructional materials we will use to aid in learning to create
and interpret Numerical Control (NC) programs, and in learning to program and operate
our NC lathe and NC milling machine. It should be brought to lectures, demonstrations,
and lab sessions. (There could be an initial zero, so G01 = G1).

Some Common NC Codes: Hints (not listed on final exam):

G0 Rapid traverse; point-to-point Think: GO! Moves fast, not straight. No cuts.
After G0, list the destination coordinates.
G1 Linear interpolation Cuts in a straight line at a given feed rate
After G1, list the destination coordinates.
G2 Circular interpolation arc CW Cuts circular CW arcs from Starting Point
After G2, list end, then IJK of the center
G3 Circular interpolation arc CCW Cuts circular CCW arcs from Starting Point
After G3, list end, then IJK of the center
G4 Dwell e.g., To allow spindle to reach speed
After G4 list F then # of seconds: G4F2
G5 Pause Allows keyboard resume with F5 key

G90 Absolute dimension input All later references are based on the origin

G91 Incremental dimension input Each reference based on current position

M1 Program stop Halts the program

M2 End of program Ends the program. Include on final line.

M3 Spindle on CW Turns the spindle on at a set feed RPM

After M3, list S then the RPM: M3S2000
M5 Spindle off Turns the spindle off
Allows winding down the RMP at the end.
M6 Tool change Switches turret tools; move safe before M6.
After M6 list T then new tool: M6T3
N Block number Precedes program line numbers
You can renumber automatically.
F Feed rate (usually in IPM) Speed of the tools relative motion during cuts
After F, specify rate in inches per min.: F2
S Spindle speed RPM of the spindle. Use dwell to allow time.
After S indicate RPM: M3S2000
T Tool selection New tool number from the turret.
After M6, write T and the new tool #: M6T7
R Radius Alt. to IJK in Circ. Interpolation: G2X1Z2R.3

For a fuller description of NC codes and syntax, please consult the CNC lathe or mill
operators manuals located next to those machines (or in Blackboard).
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Procedure for a typical NC lathe project (For a fuller description with some
illustrations, see
http://techweb.bsu.edu/jcflowers1/rlo/cncturning.htm)

A. Design the Part

1. Determine machine limitations. Our lathe is not set up to machine steel, or very
large or long material. Make sure that our lathe can machine the part you want to
create.

2. Determine cutting tool limitations. Notice the particular cutting tools that are
installed in the turret, and their geometry. It may be impossible to machine certain
designs with these tools.

3. Determine stock limitations. There are some materials on-hand, including some
brass, aluminum, and hardwood. But we might not have the particular material you
want in the size you want. Check first to see if we do, or purchase the material on
your own. Do not purchase steel for this activity.

4. Use graph paper and sketch the part profile.

5. Add the collet or chuck to the drawing with at least 1/2" of material inside the
collet.

6. Label the origin. Make the x origin the center axis of the part, and the z origin the
face of the collet or chuck.

7. Label the (x,z) coordinates of each critical point in your drawing.

8. Show your design to the instructor or lab supervisor for approval.

9. Once the design is approved, cut your stock to length. Do not cut round stock on
a bandsaw.

B. Prepare the NC Code

10. Determine the recommended maximum depth of cut and feed rate for the
material you have chosen at the diameter to be machined.

11. Determine the best sequence of operations. Make believe your pencil is the
cutting tool, and use your drawing to plan out the sequence of cuts and feeds. Make
sure you both begin an end at the same safe location (called your Start Point)

12. Use the lathe simulator or any text editor to write the NC code for your part. Add
remarks as needed to the body of your NC code. Please include the following
information in the introductory lines as remarks:

The name of the part

The version number
The file name
 Your first and last name
The date
The type of material, its initial diameter and length
The amount of the material that is to be sticking out of the collet or chuck at
the beginning of the job.
The initial tool for the job
The starting point of the initial tool
Any special notes or instructions

13. Do not machine within 1/2" of the collet. That means no absolute coordinate
should have a z value less than +0.5. The only exception is that the cutoff tool can
machine to as close as +0.4. (This is a laboratory safety issue, and it is not
standard industrial practice.) Do not machine any closer than 1 inch from the collet
with the left-hand tool that cuts from left to right, since the heel of that tool sticks out
to the left over a half inch.

14. Save your file as a DOS text file with the extension .nc and any other filename
requirements that have been made. (You might have been asked, for example, to
use your last name to begin the filename.)

C. Verify the Code

15. Use a computer that has CNCBase for ProLight 3000 software installed. Open
that software, and click File then Open to load your nc file.

16. If the NC code screen has a grey background, click Edit, Lock, to unlock it and
allow editing. Rearrange the windows as needed.

17. If your computer is not physically connected to a lathe, you will be working in
Simulation mode. If it is the computer connected to the lathe, you will have to turn
on the lathe's power supply and to make sure the emergency stop is disengaged,
which you do by pulling gently straight out.

18. There are specific tools installed in the lathe. Please do not change these
without permission from the lab supervisor, since there is an in-depth process for
re-setting the tool offsets. Note the tools in the lathe. Your software should show
these same tools when you click Tools, Setup Library. If you are working at the
computer with the lathe, please do not change these settings, but instead discuss it
with the lab supervisor. If you are working at a different computer, you may change
these settings, adding the correct tool for each tool number.

19. To verify your program, begin by clicking the Verify button. This brings you
Verify Program dialog box. Please click on Verify Settings.

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 20. Please change the stock length to indicate how much is sticking out of the
collet. This is not the length of the actual piece of material. Also, indicate the
diameter of the material. Next, indicate the starting tool position. Remember that the
x value here is a radius measurement, not a diameter.

21. Back in the Verify Program dialog box, click Verify Program. As the computer
goes through each line of your program, it shows the virtual machining in the
verification window. You can use different controls at the top of that window to
change the size, to move the object left or right in the window, and to slow or speed
up the verification.

22. Please correct errors.

23. Re-verify the program, correcting errors and re-saving it, until you are confident
it correctly machines the part with no error messages, no excessive cuts, and no
unreasonable motions.

D. Prepare the Lathe

24. Safety glasses are required in AT 141. Turn on the ProLight 3000 Turning
Center's power supply box and the computer that controls it. Open CNCBase for
ProLight 3000 and load your verified program.

25. Press the red emergency stop button in.

26. Raise the cover and install your material into the headstock of the lathe. Use the
appropriate collet or chuck and make sure your piece is held securely. Measure the
stock to ensure the exact amount is sticking out of the collet and at least 1/2" is
inside the collet. Make sure there is no stock protruding from the left of the collet
tool.

27. Close the cover and disengage the emergency stop button on the lathe.

E. Prepare the CNCBase Software Environment

28. Select Tools, Configure Turret, and then click on each of the tools to select the
correctly numbered tool for that turret location.

29. Make sure there is no stock in the way of the turret if it were to turn or move to
home.

30. Select Tools, Operate Turret, and click the Home icon in the window that
opens. After the turret is homed, click Done.

31. Select Setup, Set/Check Home, or click the Home icon that appears near the
top of the screen. In the window that opens, click the Home button.

32. Click Tools, Select Tool, find the correct tool and choose Select Tool.
F. Establish Known Coordinates

33. Using the computer's controls and the spindle turned off, move the tool near the
stock, and scratch on a place to later be machined. Manually rotate the spindle as
the tool nears. When the scratch goes 1/3 around, measure the Z distance of the
scratch. Right click the position window and choose Set Position. Enter the new X
and Z coordinates. You can find the Z coordinate by measuring the distance
between the collet and the center of the scratch. For the X coordinate, enter the
radius of the stock at the place where it was scratched, not the diameter.

34. For multiple tool programming, check the tool offsets for all tools to be used.

G. Make Final Preparations

35. Close the cover, back off the tool, then safely move it to its starting position.

36. Make sure the spindle speed on the lathe is set to Computer, the shield is
down, and you are wearing eye safety.

37. Visually check the code of your file. Save a copy of the file on the Lathe Control
Computer in the appropriate directory.

38. Verify the code one more time. Make sure that "Single Step" is not selected in
the run parameters.

39. Get the lab supervisors approval to machine before you run the program.

H. Run the Program, Clean Up & Power Down

40. If you have received the lab supervisor's permission and you are confident in
your work, then click on the green Run button. As soon as you do, please make
sure your hand is covering the Red Emergency Stop button on the lathe itself and
you can press it if anything goes wrong (like if you see the stock work lose, if a tool
insert is lost, if the spindle stops, or if you believe the tool will become damaged.

41. When the lathe has come to a complete stop at the very end of your program,
press in the Red Emergency Stop button, lift the cover, and remove your part.
Repeat as needed for additional parts.

42. When you are done for the day, please clean the lathe. Vacuum out the debris.
Put all tools and materials away. Power-down the computer and the lathe power
supply/controller box.

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 Lathe Feed Rates and Maximum Depths of Cut Recommended by Light
Machines Corporation for the ProLight 3000.
Material Cut Type Dia. Feed IPM Max. Depth of Spindle RPM
Cut
Aluminum Finish .375-.5 2 .008 2000
.75 2 .005 2000
1.5 2 .003 2000
Rough .375-.5 2 .020 2000
.75 2 .010 2000
1.5 2 .006 2000
Brass Finish .375-.5 2 .010 2000
.75 2 .006 2000
1.5 2 .003 2000
Rough .375-.5 3 .022 2000
.75 3 .014 2000
1.5 3 .007 2000

For other materials, use an experimental approach to optimize settings safely, and do not
exceed .05 for a maximum depth of cut.

Sample Lathe Problem: Shaft 5

Close-up for Shaft 5

Lathe: Bishop Project

A piece of diameter brass was cut to 2 in length, and of that length was placed into
a collet on an NC lathe to machine the following piece. The part is to be cut off at a length
of 1. The grid below has 0.05 spacing and critical points circled.

1. Label the XZ coordinates for each critical point circled on the drawing below.

2. Beneath the grid, write the lines of NC code beginning at Block N65 for the finish pass
only, prior to cutoff. Begin at X0Z1.51, and assume that all the roughing cuts have been
made. Assume Tool T1 feeds right to left at a feed rate of 2 inches per minute.

N65G0X0Z1.51
N66

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 N32G0X.162
N33G1Z1.35
N34G1X.172
X.25Z0 X.2Z.5 X.2Z1.05 CP=X0Z1.35 N35G0Z1.6;
X0Z0 X.25Z.5 X.2Z.75 X0Z1.5 N36G0X0; Reposition for end arc
N37G1Z1.5
N38G1X.14
X=0 N39G2X.15Z1.49I0K1.35; First pass
.1 N40G0Z1.51; Four line sequence to rough arc
.2 N41G0X.12
N42G1Z1.5
N43G2X.15Z1.47I0K1.35
N44G0Z1.51
N45G0X.10
Z=0 .5 1 1.5 N46G1Z1.5
X.15Z1.35 CP=X.5Z.9 X.25Z1.5 SP=X.25Z1.6
N47G2X.15Z1.45I0K1.35
N48G0Z1.51
Sample program with documentation:
N49G0X.08
Bishop N50G1Z1.5
N51G2X.15Z1.43I0K1.35
N1; Part Name: Bishop N52G0Z1.51
N2; Author: Jim Flowers N53G0X.06
N3; Filename: FlowersJ6.nc N54G1Z1.5
N4; Class: TDPT 280 and TMFG 585 N55G2X.15Z1.41I0K1.35
N5; Date: 2/11/2015 N56G0Z1.51
N6; Material: Free-Machining Brass N57G0X.04
N7; Dia: .5" N58G1Z1.5
N8; Length: .2" N59G2X.15Z1.39I0K1.35
N9; Amount Right of Collet: 1.5" N60G0Z1.51
N10; Starting Point: X.25Z1.6 N61G0X.02
N11; Tool 1 Right Hand Tool (Initial) N62G1Z1.5
N12; Tool 3: Cutoff Tool N63G2X.15Z1.37I0K1.35
N13; Est. Minutes:Seconds: 3:08 N64G0Z1.51
N14G90; Absolute Dimensioning N65G0X.0
N15M3S2000G4F3; Spindle CW at 2000 RPM N66G1Z1.5
N16G0X.25Z1.6; Safety move to Start N67G2X.15Z1.35I0K1.35F2; Begin final pass
N17G0X.228; Plunge N68G1X.2Z1.05
N18G1Z.5F3; Feed at 3 IPM N69G3X.2Z.75I.5K.9
N19G1X.26; Withdraw N70G1Z.5
N20G0Z1.6; Back to starting Z N71G1X.26
N21G0X.206; N72G0X2Z2; Move safe to rotate turret
N22G1Z.5 N73M6T3; Cutoff Tool
N23G1X.26 N74G0X.26Z.4;
N24G0Z1.05; Position to rough out left arc N75G1X0F1; Cutoff
N25G0X.21 N76G1X.26F2; Back straight out
N26G3X.21Z.75I.5K.9; CCW circular N77M05; Spindle off
N27G0Z1.6 N78G0X2Z2; Move safe to rotate turret
N28G0X.184; Four-line sequence to rough taper N79M6T1; Right to Left Tool
N29G1Z1.2 N80G0X.25Z1.6; Back to Start
N30G1X.194 N81M02; Program end
N31G0Z1.6
Lathe Practice Problem 1

The piece below is drawn at full scale, so measure it precisely in decimal inches. Assume
that the leftmost " of the stock shown below is placed in the collet or chuck. Use the
collet face as Z0.Write the annotated nc code to machine the right section of this piece
(between centers) from a hardwood dowel. Use a spindle speed of 2000 RPM and a feed
rate of 1 foot per minute. The maximum depth of cut is 1/8", and you are to use a right-cut
tool (which feeds from right to left). Please begin the tool even with the stocks
circumference and 1/8" to the right. Name your file LP1.nc, adding your last name first, so
mine would be FlowersLP1.nc. Verify your file and inform the instructor when it works. (15
pts)
1. Now begin by drawing the chuck face, labeling the origin, and labeling the (x,z)
coordinates for all critical points.
2. Next, use your pencil to simulate the cutting tool and plan out the moves.
3. Finally, write the NC code. If you use the lathe simulator, you can verify it as you
go. But it could instead be written using any text editor or word processor, as long
as it is saved as a DOS text file.
4. Verify your program. When it works, save a copy to your personal drive and tell the
instructor it verified correctly to receive credit.

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Lathe Practice Problem 2

Parameters: The drawing represents a 2.9" long piece of hardwood, 1" in diameter (not
necessarily drawn at full scale.) Assume the use of a right-cut tool (T1) with a maximum
depth of cut of 0.1", a spindle speed of 1500 RPM, and a feed rate of 3 inches per minute.
Assume " of the 2.9" length to be in the chuck, with the chuck face at Z=0. (The Y-axis
is labeled assuming " is in the chuck.) Start the tool even with the edge of the stock, and
0.1" to the right. Include a cut-off routine (T3, feed rate of 1 IPM) so the final piece is 1.9
long and return to the starting point at the end of the program.

Challenge: Write efficient NC code to machine the part on our lathe. First, use absolute
coordinates. Then write the control code again using relative coordinates. Two separate
programs are due. Call these files LP2A.nc and LP2R.nc, adding your last name to the
beginning of the filename. Verify them, and when they work, tell the instructor. (15 pts
each).

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Lathe Practice Problem 3: Hemisphere

You are to write the program that will use the right-cut tool which feeds right to left to cut a
hemisphere on the right end of a piece of " diameter oak, 2 inches long. The
hemisphere is to have a radius of 1/4". However, the maximum depth of cut is only 1/10",
and the feed is 4 inches per minute. Begin with " in the chuck, and the origin at the
chuck face. The tool is to start just even with the round edge of the stock, but 1/10" to the
right. Cut off the hemisphere with Tool 3. Show all of your work. You are to prepare:
1. a sketch of the part showing all critical point coordinates and all tool paths.
2. nc code using absolute dimensioning

Verify your work. Save this as LP3.nc, adding your name to the beginning of the filename.
Inform the instructor when the code has been verified without errors. (15 pts.)

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Lathe Practice Problem 4: Left and Right

The following piece is shown on a 0.1 grid with the origin indicated. Using those
coordinates, write the absolute dimensioning code to machine this part assuming that T1
is the tool that feeds right to left, and T5 feeds left to right. Use 0.1 as a maximum depth
of cut and 5 IPM as the feed. Call this LP4.nc adding your last name. Verify the code and
tell the instructor when it has been verified with no errors. (15 pts).

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