NUMERICAL CONTROL OF MACHINE TOOL (DE)

ME453
UNIT 3

1
 Unit 3
• CNC: Introduction, Components of CNC system –
Types of CNC systems
• DNC : Introduction, Types of DNC systems
• Adaptive control
• Manual part programming, preparatory &
miscellaneous functions
• Formats, coding

2
 PROBLEM WITH NC MACHINE
• Part programming mistakes:
– In preparing the punched tape, part programming mistakes are
common.
– The mistakes can either be syntax or numerical errors.
• Non optimal speeds and feeds:
– In NC machines the control system does not provide the opportunity
to make changes in speeds and feeds during the cutting process.
• Punched tape:
– Another problem related to programming is the tape itself.
• Tape reader:
– The tape reader that interprets the punched tape is the least
reliable hardware component of the machine.
• Controller:
– The NC controller unit is hard wired. This means that its control features
cannot be easily alerted to incorporate improvements into the unit.
3
 INTRODUCTION: CNC MACHINES
• What is a CNC Machine?

• CNC : Computer and Numeric Control

• Conventionally, an operator decides and adjusts various
machines parameters like feed , depth of cut etc. depending on
type of job , and controls the slide movements by hand.

• In a CNC Machine, functions and slide movements are controlled

by motors using computer programs.
 INTRODUCTION: CNC MACHINES

• Computer numerical control is an NC system that utilizes

a dedicated, stored program computer to perform some
or all of the basic numerical control functions.

• By integrating a computer processor, computer

numerical control, or “CNC” as it is now known, allows
part machining programs to be edited and stored in the
computer memory as well as permitting diagnostics and
quality control functions during the actual machining.
5
 INTRODUCTION: CNC MACHINES 16.09.2017

CNC machines offer the following advantages in manufacturing.

• Higher flexibility: This is essentially because of programmability, programmed
control and facilities for multiple operations in one machining center.

• Increased productivity: Due to low cycle time achieved through higher

material removal rates and low set up times achieved by faster tool
positioning, changing, automated material handling etc.

• Improved quality: Due to accurate part dimensions and excellent surface finish
that can be achieved due to precision motion control and improved thermal
control by automatic control of coolant flow.

• Reduced scrap rate: Use of Part programs that are developed using
optimization procedures

• Reliable and Safe operation: Advanced engineering practices for design and
manufacturing, automated monitoring, improved maintenance and low human
interaction
6
 INTRODUCTION: CNC MACHINES

On the other hand, the main disadvantages of CNC systems are

• Relatively higher cost compared to manual versions

• More complicated maintenance due to the complex nature of the

technologies

• Need for skilled part programmers.

• The above disadvantages indicate that CNC machines can be

gainfully deployed only when the required product quality and
average volume of production demand it.

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 CNC MACHINES
COMPONENTS OF CNC SYSTEMS

Any CNC system consists of following components:

1. Part program

2. Program input device

3. Machine control unit

4. Drive system

5. Machine tool

6. Feedback system

8
 CNC MACHINES
COMPONENTS OF CNC SYSTEMS
1. Part program
• A part program is series of coded instruction that are required to
the movement of the machine tools.

• It also includes the ON/OFF controls of auxiliary functions such as

spindle rotation and coolant for producing a part.

• The basic commands of coded instructions are G-codes, M-

codes, T-function, F-function and S-function.

• Any part program, simple or complicated, is coded from these

instructions.

• A word is the basic building unit of the part program. 9

 CNC MACHINES
COMPONENTS OF CNC SYSTEMS

1. Part program
There are four methods of generating CNC part programs, namely:

• Manual programming method - Writing G-M codes manually

block-by-block.
• Computer-assisted programming method - A computer program
allows the programmer to pre-define part-geometry, tool-path
movements and auxiliary functions.
• Conversational programming method - Provide conversational
programming function to allow part-programmers to interact with
the control for generating part programs.
• CAD/CAM programming method - Consists of three components
CAD, CAM, and post processor.
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 CNC MACHINES
COMPONENTS OF CNC SYSTEMS

2. Program input device

The program input device is the mechanism used to enter the part
program into the CNC control.

Computer via RS-232-C communication NIC card for network

communication.

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 CNC MACHINES
COMPONENTS OF CNC SYSTEMS
3. Machine Control Unit
The machine control unit (MCU) is the backbone of CNC systems.
Following six functions are being done by MCU:
• Read coded instructions
• Decode coded instructions
• Implement interpolations to generate axis motion commands
• Feed axis motion commands to amplifier circuits to drive axis
mechanisms
• Receive the feed back signals of position and speed for each drive
axis
• Implement auxiliary control functions such as coolant ON/OFF,
spindle ON/OFF, and tool change

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 CNC MACHINES
COMPONENTS OF CNC SYSTEMS

4. Drive System
• Amplifier circuits, drive motors, and ball lead screws are
main component of a drive systems.

• Control signals i.e. position and speed of each axis is fed to

amplifier circuits from MCU.

• The control signals are augmented to actuate drive motors

that in turn rotate ball lead-screws to position the
machine table.

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 CNC MACHINES
COMPONENTS OF CNC SYSTEMS

5. Machine Tool
• CNC controls are used to control various types of machine
tools.

• Irrespective of type of machine tool is to be controlled, a

machine consists of one or two motion axes (X and/or Y)
perpendicular to the work head and one motion axis (Z)
parallel to the work head.

• Some machines are equipped with index tables that allow

rotary motions (A, B, or C) around the linear axes (X, Y, or Z).

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 CNC MACHINES
COMPONENTS OF CNC SYSTEMS

6. Feedback System

• A feed back system is also referred to as a measuring system.

• It uses position and speed transducers to continuously monitor

the position of the cutting tool at any particular time.

• The MCU uses the difference between reference signals and

feedback signals for correcting position and speed errors.

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16
 CNC MACHINES
FUNCTIONS:

• The principles function of CNC are:

– Machine Tool Control

– In-process compensation
– Improved programming and operating features
– Diagnostics

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 CNC MACHINES
FUNCTIONS: Machine Tool Control
• The primary function of the CNC system is control of the machine
tool.
• This involves conversion of the part program instructions into
machine tool motions through the computer interface and servo-
system.
• The capability to conveniently incorporate a variety of control
features into the soft-wired controller unit is the main advantage
of CNC.
• Some of the control function, such as circular interpolation can be
accomplished more efficiently on the hard-wired circuits from the
computer.
• This fact has lead to the development of two alternative controller
designs to CNC .
– Hybrid CNC
– Straight CNC 18
 CNC MACHINES
FUNCTIONS: Machine Tool Control: Hybrid CNC
• In Hybrid CNC system, the controller consists of soft-wired
computer plus hard wired logic circuits.
• In hard-wired components perform the function which they do
best such as feed rate generation and circular interpolation.
• Use of these hard-wired circuits saves the computer from
performing less calculation and hence less expensive computer is
required in hybrid CNC controller.

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 CNC MACHINES
FUNCTIONS: Machine Tool Control: Straight CNC
• It uses a computer to perform all the CNC functions.
• The only hard-wired elements are those required to interface the
computer with machine tool and the operator’s console.
• Interpolation, tool position feedbacks and all other functions are
performed by computer software.
• Hence the computer required in a straight CNC system must be
more powerful than that needed for a hybrid system.
• The advantage gained in the straight CNC configurations is
additional flexibility.

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 CNC MACHINES
FUNCTIONS: In-process compensation
• This involves the dynamic correction of the machine tool motions
for changes or errors which occur during processing.

• Some of these in-process compensation are:

– Adjustments for errors sensed by in-process inspection probe and gauges.

– Re-computation of axis positions when an inspection probe is used to

locate a datum reference on a work piece.

– Offsets adjustments for tool radius and length.

– Adaptive control adjustments to speed and/or feed.

– Computation of predicted tool life and selection of alternate tooling when

indicated. 21
 CNC MACHINES
FUNCTIONS: Improved programming and operating features
• The flexibility of the soft-wired has permitted the introduction of
many convenient programming and operating features.

• Some of these are:

– Editing of part program on the machine.

– Graphic display of the of the tool path to verify the tape.
– Use of especially written subroutine.
– Manual data input (MDI).

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 CNC MACHINES
FUNCTIONS: Diagnostics

• CNC machine tools are complex and expensive system.

• The complexity increases the risk of component features which

lead to system down time.

• CNC machines are often equipped with a diagnostics capability to

assist in maintaining and repairing the system.

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 CNC MACHINES
TYPES OF CNC MACHINES

In every aspects of manufacturing CNC machines are used. It can be

mainly classified in eight classes.
1. Mills and Machining centers
2. Lathes and Turning centers
3. EDM Machines
4. Grinding machines
5. Cutting Machines
6. Fabrication Machines
7. Welding Machines
8. Coordinate Measuring Machines

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 PARTS SUITABLE FOR CNC MACHINES
• The following parts are usually made in practice on the CNC
Machines:
• Aerospace equipments.
• Automobile Parts.
• Complex shapes.
• Electronic industry uses CNC e.g. Printed circuit board.
• Electrical industry uses CNC e.g. Coil winding.
• For small to medium batch quantity.
• Where the set-ups are very large.
• Where the tool storage is a problem.
• Where much metal needs to be removed.
• When the part geometry is so complex.
• The operations are very complex. 25
Spur Gear 26
 DIRECT NUMERICAL CONTROL : DNC
The EIA definition of DNC.

A system connecting a set of numerically controlled machines to a

common memory for part program or machine program storage
with provision for on-demand distribution of data to machines.

•In principle , one large computer can be used to control more than
100 separate machines.
•The DNC computer is designed to provide instructions to each
machine tool on demand.
•When the machines needs control commands, they are
communicated to it immediately.
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 DNC
Direct Numerical Control (DNC)
• Direct Numerical Control Software (DNC) solution is a multi-
threaded communications and file management system that
allows for simultaneous upload and download of multiple CNC
controls.

• It remotely uploads and downloads directly from the CNC control,

and files are automatically named, saved, and stored in the
correct folder.

• DNC Software is easily connected to CAD/CAM systems over

industry standard networks and is available in a Client-Server
configuration.

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 DNC
Components of a DNC system
• Central computer
• Bulk memory, which stores the part program
• Telecommunication lines
• Machine tools

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 DNC
• The computer calls the part program instructions from bulk
storage an d sends them to the individual machines as the need
arises.
• It also receives data back from the machines.
• The two way information flow occurs in real time, which means
that each machine’s requests for instructions must be satisfied
almost instantaneously.
• Similarly computer must always be ready to receive information
from the machine and to respond accordingly.

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 DNC
• Depending on the number of machines and the computational
requirements that are imposed on the computer, it is sometimes
necessary to make use of satellite computers.
• These satellites are minicomputers, and they serve to take some of the
burden off the central computer. Each satellite computer controls
several machines.
• Group of of part program instructions are received from the central
computer and stored in buffers.
• They are then dispensed to the individual machines as required.
• Feedback data from the machines are also stored in the satellite's
buffer before being collected at the central computer.

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 DNC

Direct numerical control (DNC)

Control of multiple machine tools by a single (mainframe) computer
through direct connection and in real time
• 1960s technology
• Two way communication

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 DNC
Distributed Numerical Control Configurations
Network consisting of central computer connected to machine
tool MCUs, which are CNC
• Present technology
• Two way communication

Switching
network

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 TYPES OF DNC
Two types:
1. Behind the Tape Reader (BTR) 2. Special Machine Control Unit
1. Behind the tape Reader (BTR)
•Computer is linked directly to
regular NC controller unit.

•The connection is made behind

the tape reader.

•Two temporary storage buffers.

While one buffer is receiving a
block of data, the other is
providing control instructions to
the machine tool.

•Less cost. 34
 TYPES OF DNC
2. Special Machine Control Unit
• In this configuration the
regular NC controller is
replace with special MCU.
• This special MCU is a device
that is specifically designed to
facilitate communication
between the machine tool
and the computer.
• One area where this
communication link is
important is in circular
interpolation of the cutter
path.
• The special MCU is soft-wired
and, while the conventional
NC controller is hard–wired. 35
NC, CNC AND DNC COMPARISON 05.10.2017

36
Advantages of DNC
1. Elimination of punched tape and tape reader
2. Greater computational capability and flexibility
3. Convenient storage of NC part programs in computer files
4. Programs stored as CLFILE
5. Reporting of shop performance
6. Establishes the framework for evolution of future computer
automated factory (CIM)
7. 2-5 % increase in operational efficiency of CNC machine tools.
Cost of DNC installation can be recovered quickly.

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 ADAPTIVE CONTROL: AC
Adaptive Control

• A control system that measures certain output process variables

like spindle deflection, force, torque, cutting temperature,
vibration amplitude, horse power and uses them to control
speed or feed.

• CNC reduces non productive time in a machining operation

whereas, AC determines proper speeds and feeds during
machining as a function of variation in work piece hardness,
width or depth of cut, air gaps in part geometry etc.

• The typical measures of performance in machining have been

metal removal rate and reduced cost per volume of metal
removed
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 ADAPTIVE CONTROL
• In CNC mechanism the cutting speed and feed rates are
prescribed by the part programmer.

• The determination of these operating parameters depends on the

knowledge and experience regarding the work piece, tool
materials, coolant conditions and other factors.

• By contrast in adaptive control machining, there is improvement

in the production rate and reduction in the machining cost as a
result of calculating and setting of optimal parameters during
machining.

• This calculation is based on measurements of process variables in

real time and followed by a subsequent on-line adjustments of
the parameters subjected to machining constraints in order to
optimize the performance of the overall system.
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 ADAPTIVE CONTROL

• Adaptive control possesses attributes of both feedback

control and optimal control.

• Like a feedback system measurements are taken on

certain process variables whereas in an optimal system,
an overall measure of performance is used.

• In adaptive control, this measure is called the index of

performance (IP).

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 ADAPTIVE CONTROL
Where to use adaptive control?

Adaptive control is not appropriate for every operation situation.

In general, the following characteristics can be used to identify
situations where adaptive can be beneficially applied.

1. In-process time consumes significant portion of the machining

cycle time. (>40%)
2. Significant sources of variability in the job
3. Higher cost of operation of machine tool
4. Work material – steel, titanium, high strength alloys

41
 ADAPTIVE CONTROL
Sources of variability in machining.

•Variable geometry of cut in the form of changing depth or width of

cut (profile milling or contouring operations).
The feed rate is usually compensated for the variability.

•Variable work piece hardness and variable machineability.

Either speed or feed is reduced to avoid premature failure of
the tool.

• Variable work piece rigidity.

If the work piece deflects as a result of insufficient rigidity in
the setup, the feed rate must be reduced to maintain accuracy
in the process.

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 ADAPTIVE CONTROL
Sources of variability in machining

•Toolwear
As tool wears, cutting forces increases and AC will reduce the
feed rate.

•Air gap during cutting.

If the tool continue feeding through te air gaps at the same
rate , time would be lost. Accordingly, the typical procedure is
to increase the feed rate when the gaps are encountered.

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 ADAPTIVE CONTROL

Functions of adaptive control

The three functions of adaptive control are:
1. Identification function
2. Decision function
3. Modification function

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 ADAPTIVE CONTROL
Identification function.
• This involves determining the current performance of
the process or system.
• Normally, the performance quality of the system is
defined by some relevant index of performance.
• The identification function is concerned with
determining the current value of this performance
measure by making use of the feedback data from the
process.
• Since the environment will change overtime, the
performance of the system will also change.
• Identification of the system may involve a number of
possible measurements activities.
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 ADAPTIVE CONTROL

Decision function
• Once the system performance is determined, the next
function is to decide how the control mechanism should
be adjusted to improve process performance.
• The decision procedure is carried out by means of a pre-
programmed logic provided by the designer.
• Depending upon the logic the decision may be to
change one or more of the controllable process.
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 ADAPTIVE CONTROL
Modification function

• The third AC function is to implement the decision.

While the decision function is a logic function,
modification is concerned with a physical or mechanical
change in the system.
• The modification involves changing the system
parameters or variables so as to drive the process
towards a more optimal state.
• The process is assumed to be influenced by some time
varying environment.
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 06.10.2017
ADAPTIVE CONTROL
Modification function

• The adaptive system first identifies the current

performance by taking measurements of inputs and
outputs.

• Depending on current performance, a decision

procedure is carried out to determine what changes are
needed to improve system performance.

• Actual changes to the system are made in the

modification function.
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 ADAPTIVE CONTROL

Types of Adaptive Control

There are basically two groups of adaptive control.
1. Geometrical adaptive control.
2. Technological adaptive control.

49
 ADAPTIVE CONTROL

Geometrical Adaptive Control

• This type of adaptive control is concerned with

monitoring the shape and dimension of a machined
component.

• The index of performance of such a system is the final

dimension and shape of the component.

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 ADAPTIVE CONTROL

Technological Adaptive Control System

Under the umbrella of technological AC two distinct
systems are grouped:
1. Adaptive control optimization (ACO)
2. Adaptive control constraint (ACC)

51
 ADAPTIVE CONTROL
Adaptive control optimization (ACO)
• In this form of adaptive control , an index of performance is
specified for the system.
• The performance index is a measure of overall process
performance, such as production rate or cost per volume of
metal removed.
• The objective of the adaptive controller is to optimize the
index of performance by manipulating speed and/or feed in
the operation.
• Most adaptive control optimization system attempt to
maximize the ratio of work material removal rate to tool wear
rate.
IP= a function of MRR/TWR
MRR=Material removal rate; TWR= Tool wear rate 52
 ADAPTIVE CONTROL
Adaptive control optimization (ACO)
• Tool Wear Rate cannot be measured on line with today’s
measurement technology.
• Hence the IP cannot really be monitored doing the process,
eventually, sensors are used.
• However due to sensor problems , nearly all adaptive control
machining is of adaptive control constraint system.

Adaptive control constraint (ACC)

• The production adaptive control system utilize constraint limits
imposed on certain measured process variable.
• The objective in these systems is to manipulate feed and/or
speed so that these measured process variable are maintained at
or below the constraint limit value.
53
FORCE INCREASES COMPENSATED BY REDUCE FEED RATE

DUE TO INCREASED
WORKPIECE HARDNESS OR
DEPTH OR WIDTH OF CUT

FEED RATE IS
DUE TO DECREASE IN INCREASED
WORKPIECE HARDNESS
FORCE DECREASES OR DEPTH OR WIDTH OF
CUT OR AIR-GAPS

Objective : To maximize the metal

removal rate 54
55
• The figure shows the air-gap override feature which
monitors the cutter force and determines if the cutter is
moving through the air or through metal.
• This is usually sensed by means of a low threshold value
of cutter force.
• If the actual cutter force is below this threshold value
level, the controller assumes that the cutter is passing
through an air-gap.
• When the air-gap is sensed , the feed rate is doubled or
tripled to minimize the time wasted travelling across the
air-gap.
• When the cutter reengages metal on the other side of
the gap, the feed reverts back to the cutter force mode
of control.
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 ADAPTIVE CONTROL

Benefits of AC

1. Increased production rate

2. Increased tool life
3. Greater part protection
4. Increases machine life
5. Less operator intervention
6. Easier part programming
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• Manual part programming, preparatory &
miscellaneous functions

• Formats, coding

58
• The part program is a sequence of instructions, which
describe the work, which has to be done on a part, in
the form required by a computer under the control of a
numerical control computer program.

• It is the task of preparing a program sheet from a

drawing sheet.

• All data is fed into the numerical control system using a

standardized format.

• Programming is where all the machining data are

compiled and where the data are translated into a
language which can be understood by the control
system of the machine tool. 59
The machining data is as follows :

• Machining sequence classification of process, tool start

up point, cutting depth, tool path, etc.

• Cutting conditions, spindle speed, feed rate, coolant,

etc.

• Selection of cutting tools.

While preparing a part program, one need to perform the

following steps:

(a) Determine the startup procedure, which includes the

extraction of dimensional data from part drawings and
data regarding surface quality requirements on the
machined component.
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(b) Select the tool and determine the tool offset.
(c) Set up the zero position for the workpiece.
(d) Select the speed and rotation of the spindle.
(e) Set up the tool motions according to the profile required.
(f) Return the cutting tool to the reference point after
completion of work.
(g) End the program by stopping the spindle and coolant.

Hence the methods of part programming can be of two types

depending upon the two techniques as below :

(a) Manual part programming, and

(b) Computer aided part programming.
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 Manual Part Programming

• The programmer first prepares the program manuscript in

a standard format.

• Manuscripts are typed with a device known as flexo writer,

which is also used to type the program instructions.

• After the program is typed, the punched tape is prepared

on the flexo writer.

• Complex shaped components require tedious calculations.

• This type of programming is carried out for simple

machining parts produced on point-to-point machine tool.
62
To be able to create a part program manually, need the
following information :

(a) Knowledge about various manufacturing processes

and machines.

(b) Sequence of operations to be performed for a given

component.

(c) Knowledge of the selection of cutting parameters.

(d) Editing the part program according to the design

changes.

(e) Knowledge about the codes and functions used in

part programs.
63
 Computer Aided Part Programming
• If the complex-shaped component requires calculations
to produce the component are done by the
programming software contained in the computer.

• The programmer communicates with this system

through the system language, which is based on words.

• There are various programming languages developed in

the recent past, such as APT (Automatically
Programmed Tools), ADAPT, AUTOSPOT, COMPAT-II,
2CL, SPLIT is used for writing a computer programme,
which has English like statements.

• A translator known as compiler program is used to

translate it in a form acceptable to MCU. 64
The programmer has to do only following things :
• Define the work part geometry.
• Defining the repetition work.
• Specifying the operation sequence.

• Over the past years, lot of effort is devoted to automate

the part programme generation.

• With the development of the CAD (Computer Aided

Design)/CAM (Computer Aided Manufacturing) system,
interactive graphic system is integrated with the NC part
programming.
• Graphic based software using menu driven technique
improves the user friendliness.
65
• The part programmer can create the geometrical
model in the CAM package or directly extract the
geometrical model from the CAD/CAM database.

• Built in tool motion commands can assist the part

programmer to calculate the tool paths automatically.

• The programmer can verify the tool paths through the

graphic display using the animation function of the
CAM system.

• It greatly enhances the speed and accuracy in tool

path generation.
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 Computer Aided Part Programming
Software programs can automatic generation of CNC data

Define Tool

CNC data

Make 3D model
Simulate
cutting

67
 CNC Programming Basics
• Binary digit is called BITS (1,0)

• Out of one ROW- CHARACTER is formed

• Out of sequence of CHARACTER, a WORD is formed

• Out of collection of WORDS, a BLOCK is formed

• BLOCK is one complete NC instructions

68
 L6: 28.02.2017

Block Configurations

N G X Y Z I J K F S T M EOB

End
tool of Block
center of circle spindle speed
destination coordinates feed rate miscellaneous
preparatory function function

sequence no

69
 N CODES

• Gives an identifying number for each block of

information.

• It is generally good practice to increment each block

number by 5 or 10 to allow additional blocks to be
inserted if future changes are required.

Block Configurations

N G X Y Z I J K F S T M EOB

70
 G CODES
• The most common codes used when programming NC
machines tools are G-codes (preparatory functions).
• G-code specifies certain machine preparations such as inch
or metric modes, or absolutes versus incremental modes.
• G-codes are sometimes called cycle codes because they
refer to some action occurring on the X, Y, and/or Z-axis of a
machine tool.
• Generally it is a code telling the machine tool what type of
action to perform such as:
• Rapid move
• Controlled feed move in a straight line or arc
• Series of controlled feed move- profile shape
• Set tool information
71
 X,Y, AND Z CODES
• X, Y, and Z codes are used to specify the coordinate
axis.

• Number following the code defines the coordinate

at the end of the move relative to an incremental or
absolute reference point.

Block Configurations

N G X Y Z I J K F S T M EOB

72
 I, J, AND K CODES

• I, J, and K codes are used to specify the coordinate

axis when defining the center of a circle.

• Number following the code defines the respective

coordinate for the center of the circle.

Block Configurations

N G X Y Z I J K F S T M EOB

73
 F, S, AND T CODES
• F-code: used to specify the feed rate

• S-code: used to specify the spindle speed

• T-code: used to specify the tool identification

number associated with the tool to be used in
subsequent operations.

Block Configurations

N G X Y Z I J K F S T M EOB

74
 M CODES
M-code specifies miscellaneous machine functions and
work like on/off switches for coolant flow, tool
changing, or spindle rotation. Other letter addresses
are used to direct a wide variety of other machine
commands.

Block Configurations

N G X Y Z I J K F S T M EOB

75
 RESTRICTIONS ON CNC BLOCKS

• Each may contain only one tool move

• Each may contain any number of non-tool move G-

codes

• Each may contain only one feed rate

• Each may contain only one specified tool or spindle

speed

• The block numbers should be sequential

• The data within a block should follow the sequence

shown in the above sample block
76
 G CODES (PREPARATORY FUNCTION)
The total numbers of these codes are 100, out of which
some of important codes are given as under :
• G40 Cutter compensation –
• G00 Rapid positioning cancel
• G01 Linear interpolation • G41 Cutter compensation –left
• G02 Circular interpolation, • G42 Cutter compensation- right
CW • G80 Fixed-cycle cancel
• G03 Circular interpolation, • G81-G89 Fixed cycles
CCW
• G90 Absolute dimensions
• G04 Dwell
• G91 Incremental dimensions
• G20 Inch Units (G70)
• G94 feed (mm/min)
• G21 Metric Units (G71)
• G95 feed (mm/rev)
• G33 Thread cutting
• G96 Constant surface speed ON
• G97 Constant surface speed
cancel
On some machines and controls, some may differ. 77
 M Codes
M or miscellaneous codes are used to either turn ON or OFF
different functions, which control certain machine tool
operations. Some of important codes are given as under with
their functions:
• M00 Program stop • M09 Coolant off
• M01 Optional • M10 Clamps on
program stop • M11 Clamps off
• M02 Program end • M30 Program stop,
• M03 Spindle on reset to start
CW
• M98 Transfer to
• M04 Spindle on
CCW subprogram
• M05 Spindle stop • M99 End of
• M06 Tool change subprogram
• M08 Coolant on 78
EXPLANATION OF COMMONLY USED G CODES

79
 Positioning (Rapid traverse); G00
G00 – Preparatory code to control final position of the tool and not
concerned with the path that is followed in arriving at the final
destination.

This command is accompanied by coordinate words. It positions the

tool along a linear or non-linear path from the present point as the
start point to the end point which is specified by the coordinate
words.

Command format
G00 Xx Yy Zz
x, y, z, : Represent coordinates, and could be either absolute values
or incremental values, depending on the setting of G90/G91.

80
 Linear interpolation; G01

It makes the tool move (interpolate) linearly from its present

position to the end point specified by the coordinate words at the
feed specified by address F.

In this case, the feed rate specified by address F always acts as a

linear speed in the tool nose center advance direction.

Command format
G01 Xx Yy Zz Ff

x, y, z, : Coordinate values and may be an absolute position or

incremental position depending on the G90/G91 state.
f :Value that indicates the feed data (G94/G95).
81
 Circular interpolation; G02, G03

G02 : Clockwise (CW)

G03 : Counterclockwise (CCW)

Command format
G02 (G03) Xx Yy ZZ Ii Jj Kk Ff;
Xx, Yy ZZ: End point
Ii, Jj, Kk : Arc center
Ff : Feed rate

For the arc command, the arc end point coordinates are assigned
with addresses X, Y or Z, and the arc center coordinate value is
assigned with addresses I, J or K).
Either an absolute value or incremental value can be used for the
arc end point coordinate value command, but the arc center
coordinate value must always be commanded with an incremental
value from the start point. 82
The G02 command requires an
endpoint and a radius in order to
cut the arc.
I, J, and K are relative to the start
point.

N1 G02 X2 Y1 I0 J-1 F10

or
N1 G02 X2 Y1 R1

N2 G03 X1 Y2 I-1 J0 F10

83
 G04 Dwell
Format: N_ G04 P_; P=1/1000 seconds
N_ G04 X_; X= time in seconds
N_ G04 U_; U=Preferred on lathe (seconds)
N30 G04 U2 (Dwell for 2 seconds)
The G04 command is a
non modal dwell
command that halts all
axis movement for a
specified time while the
spindle continues
revolving at the specified
rpm.
A dwell is used largely in
drilling operations and
after plunge moves,
which allows for the
clearance of chips .
 Inch/metric command change; G20/G70, G21/G71
G20/G70; G21/G71;

G20/70 : Inch command

G21/71 : Metric command

G20/70 and G21/71 selection is meaningful only for linear

axes and it is meaningless for rotary axes.

85
 Position command methods ; G90, G91
By using the G90 and G91 commands, it is possible to
execute the next coordinate commands using absolute
values or incremental values.
G90 :Absolute value command
G91 :Incremental command

(1) Regardless of the current position, in the

Absolute value mode, it is possible to move to
the position of the work piece coordinate
system that was designated in the program.
N 1 G90 G00 X0 Y0 ;

In the incremental value mode, the current position is the start point (0), and the
movement is made only the value determined by the program, and is expressed as an
incremental value.
N 2 G90 G01 X200. Y50. F100; N 2 G91 G01 X200. Y50. F100; 86
(2) For the next block, the last G90/G91 command that was given
becomes the modal.

(G90) N3 X100. Y100.;

The axis moves to the work piece

coordinate system X = 100mm and
Y = 100mm position.

(G91) N3 X–100. Y50.;

The X axis moves to -100. mm and the Y axis to +50.0 mm as an

incremental value, and as a result X moves to 100.mm and Y to
100.mm.

87
(3) Since multiple commands can be issued in the same block, it is
possible to command specific addresses as either absolute values or
incremental values.
N 4 G90 X300. G91 Y100.;

The X axis is treated in the absolute value mode, and with G90 is
moved to the work piece coordinate system 300 mm position. The Y
axis is moved +100.mm with G91.
As a result, Y moves to the 200.mm position. In terms of the next
block, G91 remains as the modal and becomes the incremental
value mode.

88
 Feed; G94, G95
Using the G95 command, it is possible to assign the feed
amount per rotation with an F code.
When the G94 command is issued the per-minute feed
rate will return to the designated per-minute feed mode.

Command format
G94;
G95;

G94 : Per-minute feed (mm/min) F1 = 1mm/min)

G95 : Per-revolution feed (mm/rev) feed) (F1 =
0.01mm/rev)
89
 G Codes: Canned Cycles
A canned cycle simplifies the program by replacing
complex machining sequences, programmed by several
blocks of information, with just one or two blocks.
• G73 - G89 – Canned cycles
• G73 - High speed peck drilling cycle G87- Rectangular
• G74 - Left hand tapping cycle pocket canned cycle
• G76 - Precision boring cycle G88- Circular pocket
• G80 – Cancel canned cycle canned cycle
• G81 – Drilling cycle G98 – The tool, after
• G83 – Peck drilling cycle the canned cycle is
• G84 – Right Hand Tapping cycle done, return to the
• G85 – Reaming cycle straight plane
• G86 – Boring cycle G99- return to the
reference plane
• NOTE: A canned cycle stays in effect until cancelled by a G80.
Modal commands:

Commands issued in the CNC program that will stay in

effect until it is changed by some other command, like,
feed rate selection, coolant selection, etc.

Nonmodal commands: Commands that are effective

only when issued and whose effects are lost for
subsequent commands, like, a dwell command which
instructs the tool to remain in a given configuration for
a given amount of time.

91
 Modal G-Code List
• G00 Rapid Transverse
• G01 Linear Interpolation
• G02 Circular Interpolation,
CW
• G03 Circular Interpolation,
CCW
• G20/G70 Inch units
• G21/G71 Metric Units
• G40 Cutter compensation
cancel
• G41 Cutter compensation
left
• G42 Cutter compensation
right
• G80 Cancel canned cycles
• G81 Drilling cycle
• G82 Counter boring cycle
• G83 Deep hole drilling cycle
• G90 Absolute positioning
• G91 Incremental
positioning
• G43 Tool length
compensation (plus)
92
 Structure of an NC Part Program

Commands are input into the controller in units

called blocks or statements.

Block Format:

1. Fixed sequential format

2. Tab sequential format
3. Word address format

93
 1. Fixed sequential format
N G X Y Z F M
50 00 +254 +125 +000 000
60 01 +254 +125 -100 500 08
70 00 +254 +125 +000 000 09

2. Tab sequential format

N G X Y Z F M
50 TAB 00 TAB +254 TAB +125 TAB +000 TAB TAB
60 TAB 01 TAB TAB TAB TAB TAB -100 TAB 500 TAB 08
70 TAB 00 TAB TAB TAB -000 TAB 000 TAB TAB TAB 09

3. Word address format

N50 G00 X25400 Y125 Z0 F0
N60 G01 Z-10000 F500 M08
N70 G00 Z0 M09

94
END OF 3rd UNIT

95