CNC Machining Simulation Lab

Tutorial

Work Integrated Learning Program

WISE Simulation Lab
Birla Institute of Technology & Science, Pilani
 Errors to IGNORE During the tutorial

While creating new

project software will
ask you to save the NC
file, if you say YES then
After cycle start you may get
the above error
this error dialogue box, ignore
message may appear. this error, click CLOSE and
Ignore this error continue. If the error continues,
message just Click OK Ignore the floating decimals in
While switch ON the controller above error
and continue to your origin while editing in the
may appear, just ignore this error and
next steps. program. Just enter the
proceed with next steps. reference value as whole
numbers without any decimal
You may get these ignorable error messages during any tutorial. points
Collision and Over Travel error because of your wrong inputs

 “Collision Occur” is a common error message you will get because of your wrong input parameters. This
indicates that your input parameters are leading the spindle in wrong path instead of proper material
removal and collision occurs between the tool, work piece clamping fixture or the table

 Reasons for Collision and Over Travel

 Wrong work part origin reference value in NC program and
 Wrong tool dimensions

 Remedy
 Enter correct reference value as mentioned in the TUTORIAL Manual
 Enter correct tool nomenclatures as mentioned in the TUTORIAL Manual
Problems

Sl. No. Operation Workpiece size Tool used Controller

Vertical Milling
1. □ 100 x 100 x 20 Flat end mill ∅16 H 100 Fanuc 0iMD
(Linear Interpolation)
Vertical Milling
2. □ 80 x 80 x 20 Flat end mill ∅16 H 100 Fanuc 0iMD
(Profiling)

Flat end mill ∅20 H 75

Flat end mill ∅12 H 100
Vertical Milling
3. □ 100 x 100 x 20 Flat end mill ∅12 H 85 Fanuc 18i-MB5
(Profiling) Drill ∅10 H100
Central Drill - ∅04 H 100

Flat end mill ∅20 H 100

Horizontal Milling Central Drill - ∅3 H 100
4. □ 150 x 100 x 100 Fanuc 18i-MB5
(Step milling) Drill ∅8.5 H95
Tap D10 H100
Horizontal Milling
5. □ 205 x 155 x 100 Ball end mill ∅20 H 100 Mitsubishi
(Curvature profiling)
Problem 1: Vertical Machining-Linear Interpolation

Lab Perquisites: Basics of NC code in connection with vertical machining is required. Knowledge about flat

end mill tool and their corresponding nomenclatures is mandatory before entering to this example.

Workpiece size: Rectangular piece (100 x 100 x 20 mm)

Mounting details: Length : 50mm & Height : 35 mm

Tool required: V-CNC Pro

Goal: To do the basic facing and profiling on the above workpiece in Fanuc 0iMD machining center.

At the end of this example students will understand how to do the machining operation in Fanuc 0iMD

machining center and further a student shall interpret the NC code.

Problem 1: Vertical Machining-Linear Interpolation

Given work part diagram

Problem 1: Vertical Machining-Linear Interpolation

Desired work part diagram

Problem 1: Vertical Machining-Linear Interpolation

Experiment Outline
Part I : Set up the workpiece and machine Part II : Set up the controller and cycle start
 Open V-CNC Pro Mill Software  Simulation environment settings
 Create new project  Set collision check
 Save Project  Power on the controller
 Open wizard floating menu  Spindle Zero Return
 Select machine  Cutter Compensation
 Select controller  Start the machining process
 Open NC File
 Create work part
 Load work part
 Edit Magazine & Tool
 Set origin of the work part
Problem 1: Vertical Machining-Linear Interpolation

Experiment Outline (Contd.,)

Part III – Verification
 Verification of Machined component window open
 Verification of Machined component - Tool path
 Verification of Machined component - Gouge check
 Verification of Machined component - View sections
 Verification of Machined component - Work part drawing preparation
 Verification of Machined component - Save Work part diagram
 Save and close the project
Problem 1: Vertical Machining-Linear Interpolation

Shortcuts to represent various mouse shortcuts in the tutorial for convenience.

LMB: Left Mouse Button Single click RMB: Right Mouse Button click once

DLMB: Left Mouse Button Double click

 Problem 1: Vertical Machining-Linear Interpolation

Experiment Outline
Part I : Set up the workpiece and machine
Step 1: Open V-CNC Pro Mill Software
 Once log in to the citrix server, click
VCNCProStart.
 VCNCProStart window will appear
 Click Machining Center in the
window and wait for some time, then
you can see VCNC Promill software
window open in your system.

V-CNC Pro Mill Software Interface

Part 1: Set up the workpiece and machine

 Problem 1: Vertical Machining-Linear Interpolation

Step 2: Reset the toolbar

 View (LMB)
Toolbars (LMB)
Init Toolbar (LMB)

Note: There may not be any changes in the screen after this step, proceed to next step.
Part 1: Set up the workpiece and machine
 Problem 1: Vertical Machining-Linear Interpolation
Step 3: Save project
 File (LMB)
Project save(LMB)
 Save as project file window will pop up
LMB the drop down menu (Save in:)
Personal Directory (P:) (LMB)
Create new folder inside the
personal directory and name it as your
BITS ID (for example 201518… )
 DLMB the created folder
 Type File name”Tutorial2”
 Save (LMB)

Part 1: Set up the workpiece and machine

Problem 1: Vertical Machining-Linear Interpolation

Step 4: Open wizard floating menu

 Settings (LMB)
Wizard (LMB)
 Now you can see the floating window
included the steps, Set User
Information, Select Machine and so on.

Part 1: Set up the workpiece and machine

Problem 1: Vertical Machining-Linear Interpolation

Step 5: Select Machine

 Select Machine (LMB) (in wizard)
 Now Select Machine window will Tool Magazine
pop up.
1_Vertical M-C (LMB) Tool Head
Apply (LMB)
Tool Assembly

Work part and

Fixture
Table
Rotate, Move and other icons

Directions in vertical
machining center

Part 1: Set up the workpiece and machine

Problem 1: Vertical Machining-Linear Interpolation

Step 6: Select Controller

 Select Controller (LMB) (in wizard)
 Now Select Controller window will
pop up.
Commercial controllers (LMB)
Among the list of controllers
select Fanuc 0iMD (M/C) (LMB)
Apply (LMB)
 Fanuc 0iMD controller interface
window will pop up now.
 Maximize the controller interface
to have a better view. (Refer next
page for the maximized controller
interface)

Part 1: Set up the workpiece and machine

 Problem 1: Vertical Machining-Linear Interpolation

Power
ON
MDI Mode
Remote Single
Display Block
Edit Mode
Auto Mode Machine
Lock

Zero
Cycle Start Cycle Stop return
Feed
Override
Reset
Spindle
Position Override

Emergenc
Set Offset y Stop

Fanuc 0i-MD Controller Interface Part 1: Set up the workpiece and machine
 Problem 1: Vertical Machining-Linear Interpolation
Step 7: Open NC File (Numerical Code)
 Before starting this step, Minimize (find in
right top) the controller down
 Open NC File (LMB) (in wizard)
 Now Open window will appear
 In the Look in drop down menu select
Tutorial Share (T:), Scroll down and find V-
CNC Pro Tutorial Folder. DLMB the folder. You
can find NC Files (DLMB), find “Tutorial 1”
folder. DLMB the same folder.
Tutorial1 notepad file (LMB)
Open (LMB)

Part 1: Set up the workpiece and machine

 Problem 1: Vertical Machining-Linear Interpolation
Step 8: Create Work Part
 Create Work Part (LMB) (in wizard)
 Create work-part window will appear
Type 100 in W(width) and D(depth) box
Type 20 in H(height) box
 Let the material be unchanged
 Reload (LMB)
 Wait for a moment, work part will be reloaded
in the fixture.
 Now the work part will be loaded in the fixture.

Part 1: Set up the workpiece and machine

 Problem 1: Vertical Machining-Linear Interpolation
Step 9: Load Work Part
 Load Work Part (LMB) (in wizard)
 Load work-part window will appear
Type 50 in Mounting Length box
Type 35 in Mounting Height box
 Load (LMB)
 Create Work Part (LMB)
 Reload (LMB)
 Wait for a moment, work part will be reloaded
in the fixture.
 Now the work part will be loaded with the
specified mounting height and length in the
fixture.
Part 1: Set up the workpiece and machine
 Problem 1: Vertical Machining-Linear Interpolation
Step 10: Edit Magazine & Tool
 Edit Magazine & Tool (LMB) (in wizard)
 Magazine window will appear
Flat end mill (LMB)
Modify Tool (LMB) below window will appear
 Edit the Tool Dia. 10 into 16.
 (DLMB the tool dia text box and delete value
10 & type 16, then press ENTER)
 Add Tool (LMB)
 OK (LMB)

Part 1: Set up the workpiece and machine

 Problem 1: Vertical Machining-Linear Interpolation
Step 11: Edit Magazine & Tool (Contd.,)
 Now Tool library manager window will disappear
and magazine window will appear.
 Add tool (LMB) in magazine window Spindle
 OK (LMB). Tool no
 Now do you want to save pop up window will
appear press Yes.

Spindle Tool No.

Edited tool should be
add in Spindle tool
no “1”. If you see any
other number in the
spindle number use
<<Prev tool and
Next Tool>> to swap
tools. Swap to “1”
and add the edited
tool.

Part 1: Set up the workpiece and machine

 Problem 1: Vertical Machining-Linear Interpolation
Step 11: Edit Magazine & Tool (Contd.,)
 LMB the drop down menu (Save in:)
Personal Directory (LMB)
Your folder DLMB
 Type File name”Tutorial1Tool”
 Save (LMB)
 Tool library has been saved
confirmation window will appear
click ok.

Part 1: Set up the workpiece and machine

 Problem 1: Vertical Machining-Linear Interpolation
Step 12: Set origin work part
 Set origin work part (LMB) (in wizard)
 Work-Part origin setting (auto) window will appear
 Click the corner of the rectangle as shown
 In Work-Part drop down box click Hexahedron
 In NC Code drop down box select G92
 Shown X, Y and Z values are the origin point of the
component. NC code is generation for the same
origin.
X = 640
Y = 314
Z = 335

Ignore the minus sign.

Part 1: Set up the workpiece and machine

 Problem 1: Vertical Machining-Linear Interpolation
Part II : Set up the controller and cycle start
Step 1: Simulation Environment settings
 Settings (LMB)
Environment setting (LMB)
 Environment Setting window will appear
Reduce the simulation speed to 50% (drag the
horizontal bar towards left)
 Simulation On is selected.
 Select High speed mode not use
 Give Tool Tolerance of 0.05
 Select the Show tool path option
 Click OK.

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Step 2: Set collision check
 Settings (LMB)
Set collision check (LMB)
 Collision Setting window will appear
Select Stop
Apply (LMB)

When there is a collision occurs between tool,

table, or any other components machining
operation will be stopped.

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Step 3: Power ON the controller
 Maximize the controller window
 Power ON (LMB)
ignore any error messages in the display
 EDIT (LMB) (Green LED should glow)
 RESET (LMB)
 Edit the X, Y and Z values in Block
number “4” as (640, 314 and 335)
i.e., N4G90 G92 G00 X650. Y360. Z340.;
should be edited as below
N4 G90 G92 G00 X640. Y314. Z335.;

Make sure that the correct reference values are

entered in G92 reference. Wrong values will
lead to severe damage in the tool and work
piece.

Note: G92 value should be changed manually after reloading the work part. (Usual practice in machining industry)
Part II: Set up the controller and cycle start
 Problem 1: Vertical Machining-Linear Interpolation
Step 4: Spindle Zero return
 Move the controller window and
machine as shown in Figure using rotate
and pan options.
 MDI (LMB)
 In the program box type the following code.
G28 X0. Y0. Z0.;
 Press Cycle start green button.
 Above process will return the spindle to its
extreme origin position.
 Cross check the spindle position in the display
after each click.

Spindle Zero
Position

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Step 5: Cutter compensation
 Set offset button (LMB)
 Offset window will appear in
the desktop
 Enter 8 in GEOM (RADIUS
Compensation)

 Numerical value 8.000 in the

highlighted box.
 Don’t change the values
except the highlighted box.
Hence the compensation will
be added to the
corresponding H number (if
added in the NC code).

 Cross verify whether H01 is used in the NC code. In this tutorial H value is used in 7th block (N7)
Part II: Set up the controller and cycle start
 Problem 1: Vertical Machining-Linear Interpolation
Step 6: Start the machining process
 Auto (LMB) Green led should glow
 Rotate the FEED OVERRIDE to 40% (108
mm/min)
 Press the cycle start
 Once the machining starts, press SINGLE
BLOCK (green LED should glow)
 Now, press cycle start to execute each and
every block.
 Once the simulation is completed redo step
17 again and take the spindle to its origin
position.
 Square pocketing operation is done on the
rectangular work piece of 100 x 100 x 20 mm.
 Next, the dimension of the machined
component should be verified.

Part II: Set up the controller and cycle start

 Problem 1: Vertical Machining-Linear Interpolation
Part III – Verification
Step 1: Verification of Machined
component window open
 Inspection (LMB)
Verification
 Separate verification module
page will open as shown.
In Move Work-Part dialogue
box enter 0,0,0 in X, Y and Z
then click Move.

Part III: Verification

 Problem 1: Vertical Machining-Linear Interpolation
Step 2: Verification of … Tool path without machining ___ Tool path during machining
Machined component -
Tool Path
 View(LMB)
Tool Path N11
 Machining Path NC
Codes
N9G01 X98. ; N10
N10Y98.;
N11X2.;
N12Y2.;
N13G42 Y20. D01;
N14X80.;
N12
N15Y80.;
N16X20.;
N17Y16.; N9
N18G40 X-12.;

Note: Cutter compensation will be added during interpolation Part III: Verification
 Problem 1: Vertical Machining-Linear Interpolation
Step 3: Verification of Machined
component - Gouge Check
 Gouge check (LMB)
 Open Model File(o) LMB
In the Look in drop down menu
select Tutorial Share(T:), Scroll down
and find V-CNC Pro Tutorial Folder.
DLMB the folder. You can find STL File
folder (DLMB), find “Tutorial 1” folder.
DLMB the same folder.
Tutorial1 STL file (LMB) Open (LMB)
 Machined component is overlapped
with the final component to check the
undercut and overcut.
 Green color portion indicates that
there is no under cut in the model.
 If the machining is not properly done,
then blue/red colored portion may
visible.
 Finish gouge check (LMB)

Part III: Verification

 Problem 1: Vertical Machining-Linear Interpolation
Step 4: Verification of Machined
component - View Section
 Measure (LMB)
View section
Select the points as shown in the
Fig.
OK (LMB)
 View Section window will appear
 In the view Section window, click
next to cross check the
coordinates. (This will help us to
Point
cross verify geometry of the
selected
complex curvature geometry)
 Close the View Section window

Part III: Verification

 Problem 1: Vertical Machining-Linear Interpolation
Step 5: Verification of Save image Settings Dimensioning
Machined component - Work
Part diagram
 Measure (LMB)
Work Part Diagram (LMB)
 Separate CbDrawer window Coordinate
will appear. value
 Click at the corner as shown in
the Fig and press OK.

 Continue in the next page…

Part III: Verification

 Problem 1: Vertical Machining-Linear Interpolation
Step 6: Verification of Machined
component - Work Part diagram
 Give the dimensions as shown.
 Horizontal direction icon (LMB)

Part III: Verification

 Problem 1: Vertical Machining-Linear Interpolation
Step 7: Verification of Machined
component - Work Part diagram
 Give the dimensions as shown.
 Vertical direction icon (LMB)

Part III: Verification

 Problem 1: Vertical Machining-Linear Interpolation
Step 8: Verification of Machined
component - Save Work part
diagram
 Save image icon (LMB)
 In the Save in drop down menu click
Personal Directory (P:)
 DLMB – Folder created in the first
step.
 Give File name in the text box
 Save (LMB)
Step 9: Save and close the project
 Workpart Diagram window (Close)
 Verification window (close)
 File (LMB) in VNC PRO Mill Software
page
Project Save (LMB)
 File (LMB)
 Exit (LMB)
 Save the program alert (Click save)
Part III: Verification
Contact us if you have any queries

Work Integrated Learning Program

WISE Simulation Lab
Birla Institute of Technology & Science, Pilani

Email : wise@wilp.bits-pilani.ac.in
Text @ Hangout : wise@wilp.bits-pilani.ac.in