CNC Basics

MTS TeachWare Students Book

MTS Mathematisch Technische Software-Entwicklung GmbH Kaiserin-Augusta-Allee 101 D-10553 Berlin

Phone: +49 / 30 / 349 960 - 0 Fax: +49 / 30 / 349 960 -25 World Wide Web: http://www.mts-cnc.com email: [email protected]

CNC-Basics
MTS TeachWare Students Book
MTS Mathematisch Technische Software-Entwicklung GmbH
Kaiserin-Augusta-Allee 101 D-10553 Berlin
Phone: +49 / 30 / 349 960 - 0
Fax: +49 / 30 / 349 960 - 25
eMail: [email protected]
World Wide Web: http://www.mts-cnc.com
Created by BK & BM, 2005.

All rights reserved, including photomechanical reproduction and storage on electric media

Contents
Introduction into CNC Technology .................................................................................. 9
1.1

History and Development of CNC Technology ................................................................................9

From conventional machine tool to Computer Integrated Manufacturing (CIM) ..............................9

1.2

Conventional vs. CNC Machine Tool .............................................................................................11

Machine Structure ..........................................................................................................................11
Function ..........................................................................................................................................11
Productivity .....................................................................................................................................12

1.3

Characteristics of modern CNC machine tools ..............................................................................13

Controllable feed and rotation axis.................................................................................................13
Path measuring systems ................................................................................................................15
Main drive and work spindle...........................................................................................................17
Work part clamping devices ...........................................................................................................17
Tool change facilities ......................................................................................................................18
Security precautions on CNC machine tools..................................................................................19

Control test CNC Basics.........................................................................................................................21

Basic Geometry for CNC Machining .............................................................................. 23

2.1

Coordinate systems on CNC machine tools ..................................................................................23

Types of coordinate systems..........................................................................................................23
Cartesian coordinate system..........................................................................................................23

CNC-Exercise ...........................................................................................................................................28
Feed and Turning Axes on CNC Machines....................................................................................31

CNC-Demo........................................................................................................................ 34
CNC milling ...............................................................................................................................................34
CNC turning ..............................................................................................................................................35
2.2

NC Mathematics .............................................................................................................................36
Basics of coordinate point calculations ..........................................................................................36
Calculation of NC coordinates........................................................................................................39

2.3

Zero and reference points on CNC machine tools .........................................................................41

Types of zero and reference points................................................................................................41
Setting the work part zero point W on a CNC lathe .......................................................................44
Setting the work part zero point W on a CNC milling machine ......................................................45

CNC exercise............................................................................................................................................47
2.4

Numeric Controls on CNC Machine Tools .....................................................................................53

Control chain and control loop........................................................................................................53
CNC Control ...................................................................................................................................53
Types of CNC controls ...................................................................................................................56
DNC operation................................................................................................................................60

2.5

Tool Compensations for CNC Machining.......................................................................................62

Inhalt
Using tool compensation values.................................................................................................... 62
Tool length compensation for milling and turning.......................................................................... 62
Tool radius compensations............................................................................................................ 63
Tool measuring and adjusting with an adjusting device ................................................................ 69
Tool measuring and setup using the CNC machine...................................................................... 71
2.6

Path Measuring Systems............................................................................................................... 75

Infeeds, position control and position adjustment of the NC axis.................................................. 75
Path measuring.............................................................................................................................. 75

CNC exercise ........................................................................................................................................... 77

Control test Basic Geometry .......................................................................................83

3

Technological Basics for CNC Machining...............................................................85

3.1

CNC tool systems for turning and milling ...................................................................................... 85

Tool carriers ................................................................................................................................... 85
Tool holder ..................................................................................................................................... 85
Tungsten carbide indexable inserts............................................................................................... 86

3.2

Structure and use of lathe tools for CNC machining ..................................................................... 87

Types of lathe tools and the corresponding ISO designation........................................................ 87
Cutting materials ............................................................................................................................ 88
Cutting edge geometry .................................................................................................................. 90
Abrasion and cutting edge ............................................................................................................. 91
Cutting value .................................................................................................................................. 92
Examples: Calculating technological values for CNC machining.................................................. 94

3.3

Structure and application of milling tools for CNC machining ....................................................... 95

Milling and milling operations......................................................................................................... 95
Types of milling tools ..................................................................................................................... 97
Cutting edge materials................................................................................................................... 99
Cutting geometry ......................................................................................................................... 100
Cutting values .............................................................................................................................. 102
Calculation examples of technological values for CNC machining ............................................. 104

3.4

Calculation of technological data for CNC machining ................................................................. 107

Calculation examples of technological data for CNC turning ...................................................... 107
Calculation examples of technological data for CNC milling ....................................................... 115

3.5

CNC clamping systems ............................................................................................................... 119

Types of clamping systems ......................................................................................................... 119
Types and characteristics of clamping devices for turning.......................................................... 123
Types and characteristics of clamping devices for milling .......................................................... 132

Control test Technological Basics............................................................................137

MTS TeachWare CNC-Grundlagen Students Book

Contents

Introduction into NC programming........................................................................ 139

4.1

Work organization and flow of manual NC programming ............................................................139

Comparison of work preparation of conventional and CNC machining .......................................139
Organizing the steps of NC programming....................................................................................140
Programming procedure for manual NC programming at programming seat..............................143
Quality assurance during CNC production...................................................................................145

4.2

NC programming basics...............................................................................................................146
NC programming standards (ISO)................................................................................................146
Structure of an NC program .........................................................................................................146
Structure of a program block ........................................................................................................147
Structure of a program word.........................................................................................................147
Comparison of programming codes/keys of various CNC controls .............................................149

4.3

Introduction to manual NC programming .....................................................................................156

Procedure for manual NC programming ......................................................................................156
Manual NC programming Turning ................................................................................................159
Manual NC programming Milling ..................................................................................................180

2.

Control test Introduction into NC programming ............................................... 195

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Instroduction into CNC technology

2.

Introduction into CNC Technology

1.1

History and Development of CNC Technology

From conventional machine tool to Computer Integrated Manufacturing (CIM)

The idea of numerical control (NC) of machine tools emerged in 1949/50 at the MIT (Massachusetts Institute
of Technology, Cambridge, USA) as a result of a US Air Force order to manufacture important airplane parts
from full material rather than by riveting and welding material together.
The templates and patterns needed for form cutting were however very complicated and could only be
manufactured with a considerable time and cost increase when using conventional technology. Since however the contours of the large parts could easily be represented as mathematical functions it was decided to
develop a control to control a milling machine on this basis.

CIM
CAD / CAM
CAD
FFS
CNC
NC

NC

CNC Numerical control with integrated computer

FFS Flexible manufacturing system
CAD Computer aided drawing/design
CAM Computer aided manufacturing
CIM

1950

1960

Numerical control

1970

1980

1990

Computer integrated manufacturing with planning, design and manufacturing

Figure 1
Development into CIM technology
The technical realization of this idea required a control which interprets binary and digital entries for travel
paths and switching operations in such a way that they could be understood and processed by the milling
machine. Herewith the basic principle was formulated for the application of numerical controls. The rapid
development of electronic data processing then enabled the practical realization.
First a corresponding NC control was developed for a vertical milling machine. The machining path and
switching information necessary for manufacturing was given on punch card. The idea was to control the
infeed axis of the milling machine so that separately working motors control the axis movements of the tool
carrier. The sequence of the travel path and switching information in form of code letters and numbers was
called a NC program.
This first NC machine tool already showed all the characteristics of the NC machines to be developed later
on:
Entry unit with numerical starting value for the travel path and switch information on a punch card.
Computer control to process the travel path and switch information.
Separate power supply for each infeed axis and spindle to control the movements of the tool and tool
carrier.
Measuring and control systems returning feedback to the controlling computer regarding the tool positions.

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Instroduction into CNC technology

In the mid 50s almost all machine tool manufacturers began developing and manufacturing numerically controlled milling machines which were soon followed by NC lathes. The rapid development of new microeletronic components, such us micro processors and micro computers, enhanced the development of NC controls to CNC (computerized numerical control) controls in the mid 70s.
With the increased contribution of high-performance microprocessors it was possible to extend the operations of the computer controlled machine tools. The current microcomputers and CNC controls as well as the
PLC (programmable logic controller) of the machine tools have improved NC programming efficiency. Contour precision and machining speed of the tools as well as cutting power have continuously improved. Modern CNC controls additionally offer a multitude of further characteristics. This has made it possible, for instance, to program complex tool geometries without using mathematical calculations.
The continuous further development of CNC machine tools takes place in a reciprocal innovation exchange
between the manufacturers of microelectronic components, CNC controls, tools and machine tools. Users
also facilitate this increasingly rapid development by continuously demanding new and improved solutions.
CNC machining centers, flexible production systems (FFS) and fully automated manufacturing (CIM) mark
significant stages of this development which started in the 50s.
The following list shows some of the current user requirements:
interfaces with high performance for more rapid transfer of constantly increasing data
complete machining centers with high precision, e.g. CNC lathes with 7-32 NC axis, several spindles and
live milling tools for turning
high speed machining for turning, milling and boring with maximum dynamic travel path accuracy
development of servo motors whose scanning rate for defining the manufacturing dimensions becomes
smaller and smaller (presently the scanning speed is already less than 1ms)
minimizing the programming effort for the individual manufacturing tasks
simple, high-performance NC programming systems with dynamic-interactive simulation of the machining
processes
graphic control error diagnosis of the CNC machine tool or of the complete machining system

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Introduction into CNC Technology

1.2

Conventional vs. CNC Machine Tool

Machine Structure
The CNC machine tools are basically built in the same way as conventional machine tools. The difference
lies in the fact that the machine components relevant for turning and milling processes are controlled by
computers.
The movement directions of the components of a CNC controlled machine tool are specified by a coordinate
system, which refers to the work part to be machined and shows axes located parallel to the main linear
movement. The movements necessary for machining the individual machine tool assemblies (table, turret
and others) are calculated, controlled and tested by a computer. For this purpose each machining direction
has a separate measuring system to calculate the corresponding positions of the machine tool assemblies
and to return this information to the control.

Function
In the following overview conventional, NC and CNC machine tools are compared in their basic functionality:

Conventional
Machine Tools

NC Machine Tools

CNC Machine Tools

Entry:
Entry:
The qualified worker manually The NC program is transmitted to
adjusts the machine tool according the NC control using a punch card.
to the drawing, clamps the raw part
as well as the tools and aligns
them.

Entry:
NC programs can be entered into
the CNC control either using a
keyboard, disks or data interface
(serial, Bus). Several NC programs
are stored in an internal storage,
whereby modern controls also use
hard disks.

Manual control:
The qualified worker manually sets
the machining values (number of
rotations, infeed) and controls the
machining using hand wheels.

NC control:
The NC control processes the path
and feed information of the NC
program and passes the corresponding control signals to the
components of the NC machine.

CNC control:
The micro computer integrated in
the CNC control and the corresponding software take over all
control functions of the CNC machine. Hereby internal storage are
used for programs and subprograms, machine data, tool and
compensation values and fixed
and free cycles. Frequently, error
monitoring software is integrated in
the CNC control.

Dimension control:
The qualified worker manually
measures and verifies the dimensions of the work part and, if necessary, must repeat the machining
process.

NC machine:
The NC machine ensures the dimensional stability of the work part
already during the machining
process with the continuous feedback from the measuring system
and the servo motors.

CNC machine:
The CNC machine ensures the
dimensional stability of the work
part already during the machining
process with the continuous feedback from the measuring system
and the servo motor, which is controlled by the number of rotations.
Integrated measuring sensors
make it possible to control the
dimensions during the machining.
In parallel to active machining it is
possible to continue work on the
CNC control, e.g. to test and optimize new NC programs.

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Instroduction into CNC technology

Productivity
Advantages of the CNC machine tool
1. The higher machining speed of the CNC machine tool as well as decreased basic, auxiliary, preparation
and finishing times on the machine increases productivity. The following factors are especially influential:
programming directly on the machine tool with manual entries
shared responsibility in a department responsible for work preparation for programming, materials and
tools and due entry of the data at the CNC work seat
storing recurrent machining processes of a tool specific program in form of subprograms
optimizing NC programs on the control
description of the work part shapes to be machined with simple geometry entries
automatic infeed of the tool until the required dimension has been reached
automatic initiation of all functions of the machine and direct intervention when identifying errors or
disturbances
automatic monitoring of the production through the CNC control (automatic measuring and testing)
universal application of tools in tool clamping systems
possibility to preset the tools outside of the machine tool without influencing machine run-time
2. Constant quality of the work part and less scrap.
3. Increased dimension precision of the work part through high basic precision of the machine tool
(1/1000 mm)
4. Short run-through-times through product organization and combination of split machining processes
5. Improved machine utilization and rentability
6. Improved production flexibility through machining systems and correspondingly rational production of
small lots or single work parts with high complexity
Due to the advantages mentioned above the CNC machine tools are prevalent in cutting production. The
wide application field (see figure 2) is a typical characteristic of the CNC machine tools.

larger lot sizes

increased complexity and
production precision

CNC machine tools

conventional machine tools

Figure 2
Application field of CNC machine tools
Requirements for using CNC machine tools
To operate and program CNC machine tools the machine operator needs a higher qualification. Experience
from conventional machining can not necessarily be transferred.

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Introduction into CNC Technology

1.3

Characteristics of modern CNC machine tools

Controllable feed and rotation axis

Work part machining on CNC machine tools requires controllable and adjustable infeed axes which are run
by the servo motors independent of each other. The hand wheels typical of conventional machine tools are
consequently redundant on a modern machine tool.
CNC lathes (see figure 3) have at least 2 controllable or adjustable feed axes marked as X and Z.

Figure 3
Controllable NC axes on an automatic lathe
CNC- milling machines (see figure 4) on the other hand have at least 3 controllable or adjustable feed axes
marked as X, Y, Z.

Figure 4
Controllable NC axes on a milling machine
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In addition to the linear movements along the X, Y and Z axes it is possible to control rotation around each
axis.
These controllable rotation axes are marked with A, B and C (see figure 5).
+Y

+B

+A
+X

+C

+Z

Figure 5
Feed and rotation axes
in Cartesian coordinate system
Often further controllable feed axes are needed. These are then marked as U, V, W. Additionally there are
the adjustable rotation axes around which the machining table, head stock and tool holder can rotate independent of the feed axes. They are marked as A, B and C.
The required tool and work part carriers are moved by feed drives. The feed drives meet the highest requirements due to high machining and iteration precision. The individual axis movements must be carried
out with maximum feed speed and minimum positioning time. To meet these requirements a modern feed
drive (see figure 6) consists of the following components:
motor, mechanical gears against overload as well as electronic control
ball screw drive for power transfer free from play
sensor as path measuring system, mostly located at the free end of the axis
power amplifier with analog or digital interfaces for CNC control
For exact positioning the feed drives are connected with the measuring facilities. Each controllable axis of a
CNC machine needs a path measuring system with automatic interpretation of the measuring signal. The
most frequently used resolution for length measuring is 0.001 mm, however for the X axis of the lathe (diameter dimension) 0.0005 and for the precision grinding machine up to 0.0001 are customary.

2
1

feed drive
work table
measuring system

ball screw

Figure 6
Feed drive for carrier with ball screw drive
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ball screw nut

Introduction into CNC Technology

The embodiment of the measure is usually a ball circulating screw. If the spindle is set in motion by the motor, then the spherical thread nut, which works almost free of play, moves in longitudinal direction and
pushes the corresponding tool or work part carrier along the carrier track (see figure 7). The almost frictionfree transfer of power from the spindle to the carrier is achieved through a system of balls. To guarantee the
minimum of thread play the two halves of the ball thread nut are clamped against each other to achieve high
and reproducible accuracy of production. Eventual pitch errors of the spherical contour spindle can be automatically rectified by the CNC control through the spindle pitch error compensation. Further mechanical possibilities are for instance the rack/pinion and spindle/nut. If less accuracy is sufficient hydraulic drives are
used as well.

2
ball screw nut

Clamping ring
balls
Drive spindle

3
4

Figure 7
ball screw drive with play-free double nut
The manufacturing tolerances resulting from the manufacturing process of the ball screw drive can be rectified by modern CNC controls using the spindle pitch error adjustment. For this purpose the tolerances are
measured by laser measuring systems and stored in the CNC control.

Path measuring systems

Depending on the applied measuring device or scale direct and indirect position measuring are differentiated
as well as absolute and incremental position measuring. The most accurate measuring values are achieved
with direct measuring scales.
In direct position measuring (see figure 8) the measuring scale is given in the carrier or on the machine
table so that inaccuracies on spindle and drive connection have no influence on the value measured.
The measuring values are specified by an optical pick-up on a scanning pattern of the measuring scale. The
pick-up converts these values into electrical signals and transfers them to the control.

pick-up

glass ruler with scale

1
2
Figure 8
Direct position measuring

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In indirect position measuring (see figure 9) the travel path is specified using the rotation of the ball circulating screw, which is equipped with a pulse disk as a measuring scale. A signal generator registers the rotations of the pulse disk and transfers them to the control. The control then calculates the exact carrier movements or its present positions based on the rotation pulses.
1

carrier

pulse disk as a measuring scale

spindle
signal generator

Figure 9
Indirect position measuring
In absolute position measuring (see figure 10) a coded measuring scale immediately shows the position
of the carrier with reference to one fixed orientation point on the machine. This point is the machine zero
point, which is specified by the machine manufacturer. This method presupposes that the reading-in area of
the measuring scale is as large as the machining area and that the coding of the measuring scale is binary.
This is to enable the control to allocate a numerical value to each read-in position.

012345678

2
binary-coded measuring scale
current tool carrier position

Figure 10
Absolute position measuring
In incremental position measuring (see figure 11) a measuring scale with a simple grating consisting of
light and dark fields is used. For a feed movement passing the sensor the sensor counts the number of light
and dark fields and calculates the current carrier position based on the difference from the last carrier position.

4
ruled grating
previous carrier position
current carrier position
carrier on reference point

Figure 11
Incremental position measuring
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Introduction into CNC Technology

The control has once to be given one absolute position, which it then uses as a reference point when calculating the current carrier position using incremental position measuring. Therefore, it is necessary to go to
this absolute point once the control is started. This absolute point is called the reference point on the machine. Each axes movement, even when traveled manually using the hand wheel or buttons, needs to be
registered by the control.
Since the control loses the control/information on mechanical movements when switched off the reference
point has to be returned to each time the control is switched on.

Main drive and work spindle

The main drive of a CNC machine needs to transmit the necessary power output for machining the current
work part. This power output is transmitted from the main drive to the drive of the corresponding work spindle. The friction loads of the mechanical parts of the machine are also to be considered. They ultimately
determine the efficiency of the CNC machine. It is necessary to have a drive with high stability, i.e. the moment of rotation has to be so that the current machining position remains unchanged even if the machining
loads are high. In addition to this, the drive has to possess sufficient dynamics to master speed changes
rapidly and without overshooting.
The work spindle and the eventually available counter spindle were previously driven by a direct-current
motor. To keep the cutting speed constant a stepless regulation of the rotation speed of these motors within
a wide range, for instance to turn various diameters, is required. A disadvantage of the direct-current motor
is the abrasion of the carbon brushes, which need to be regularly checked and changed if necessary.
Thanks to the progressive development of microelectronic components three-phase motors are now mostly
used. Their disadvantage, the complicated control of the number of rotations, has become irrelevant due to
the price development in electronic controls.
There are two types of three-phase motors: asynchronous and synchronous motors. They have considerable advantages compared with direct-current motors. With identical dimensions higher rotation moments
are achieved. Furthermore, up to three times higher number of rotation and much better power output is
possible. These motors work without carbon brushes, without collectors or collecting rings and are correspondingly maintenance free.
The spindle head of the work spindle is standardized to guarantee the maximum possible exchange of
clamping devices. In CNC machines, the work spindle as well as many other parts are more solidly built than
in conventional machine tools because of the considerably higher acceleration rate (10 to 40m/s) and higher
machining performance.

Work part clamping devices

Work part clamping devices hold the work part in the correct and exact position on the work spindle for turning or on the work table for milling. The work part must be clamped so that it is absolutely free from play,
positioned correctly and exactly, and fully resistant to dynamic stresses. A multitude of work part clamping
devices are available.
In milling, loading and withdrawal of work parts will automatically be done by charging robots in the future
(see MTS robot simulator ROBIN). For turning, mostly controllable jaw chucks of different types are used.
These chucks are designed to allow pneumatically or hydraulically controlled automatic charging and approach of the chucks. The clamping powers are adjustable. Depending on weight, material, length/diameter
relation, clamping depth and other machining conditions the clamping powers have to be adjusted higher or
lower.
Chuck jaws for high number of rotations have a centrifugal force compensation so that the clamping power is
not reduced by the contrary centrifugal force. This centrifugal force is realized for instance by compensation
weights, which are connected with the clamping jaws by a lever. The centrifugal force of the compensation
weight exerts then an opposite force to the centrifugal force of the chuck jaws. The clamping power is kept
constant with this compensation. For machining between centers mostly drivers, face drivers and controllable live turrets are used. For clamping small parts controllable collet systems are commonly used.

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Instroduction into CNC technology

In CNC milling the main function of the work part clamping devices is the correct positioning of the work
parts. The work part clamping should allow a work part change which is as quick, easy to approach, correctly and exactly positioned, reproducible as possible. For simple machining controllable, hydraulic chuck
jaws are sufficient. For milling on all sides the complete machining should be possible with as few reclamping as possible. For complicated milling parts milling fixtures, also with integrated automatic rotation,
are being manufactured or built out of available modular systems to allow, as far as possible, complete machining without re-clamping. Work part pallets, which are loaded with the next work part by the operator outside the work room and then automatically taken into the right machining position, are increasingly being
used.

Tool change facilities

CNC tool machines are equipped with controllable
automatic tool change facilities. Depending on the
type and application area these tool change facilities
can simultaneously take various quantities of tools
and set the tool called by the NC program into working position. The most common types are:
the tool turret
the tool magazine.
The tool turret (see figure 12) is mostly used for
lathes and the tool magazine for milling machines.
If a new tool is called by the NC program the turret
rotates as long as the required tool achieves working
position. Presently such a tool change only takes
fractions of seconds.

Figure 12
Example of a turret
Depending on the type and size, the turrets of the CNC machines have 8 to 16 tool places. In large milling
centers up to 3 turrets can be used simultaneously. If more than 48 tools are used tool magazines of different types are used in such machining centers allowing a charge of up to 100 and even more tools. There are
longitudinal magazines, ring magazines, plate magazines and chain magazines (see figure 13) as well as
cassette magazines.

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Introduction into CNC Technology

Figure 13
Example of a chain magazine

milling tools

tool gripper (tool changer)

work spindle
tool magazine

3
4

Figure 14
Automatic tool change facility
In the tool magazine the tool change takes place using a gripping system also called tool changer (see figure
14). The change takes place with a double arm gripping device after a new tool has been called in the NC
program as follows:

Positioning the desired tool in magazine into tool changing position

Taking the work spindle into changing position
Revolving the tool gripping device to the old tool in the spindle and to the new tool in the magazine
Taking the tools into the spindle and magazine and revolving the tool gripping device
Placing the tools into the spindle sleeve or magazine
Returning the tool gripping device into home position

The tool change procedure takes between 6 to 15 seconds, whereby the quickest tool changers are able to
make the tool change in merely one second.

Security precautions on CNC machine tools

The target of work security is to eliminate accidents and damages to persons, machines and facilities at work
site.
Basically the same work security precautions apply to working on CNC machines as to conventional machine tools. They can be classified in three categories:
Danger elimination
Defects on machines and on all devices necessary for work need to be registered at once.
Emergency exits have to be kept free.
No sharp objects should be carried in clothing.
Watches and rings are to be taken off.
Screening and marking risky areas:
The security precautions and corresponding notifications are not allowed to be removed or inactivated.
Moving and intersecting parts must be screened.
Eliminating danger exposure
Protective clothing must be worn to protect from possible sparks and flashes.
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Instroduction into CNC technology

Protective glasses or protective shields must be worn to protect the eyes.
Damaged electrical cables are not allowed to be used.
When setting up and operating CNC machines the following is to be taken into consideration:
In general, setting-up is allowed only on a machine which has been switched off. The only exceptions
being the operations which required the machine power to be switched on, such as re-setting the work
part with tools.
The operator should not go to the rotation or work area of the machine since within this area the machine can automatically rotate the turrethead or feed the tool carrier.
The specific security precautions of the machine manufacturer have to be followed.
The following security precautions are to be followed as well:
Blocking system against loose parts or parts which have not been allocated correctly, against autogenerated movement of not fixed elements and against starting an automatic machining procedure
before setting-up work has been completed.
Blocking system of the work part clamping device when charging the CNC machine manually.
Keeping the security distance between the parts of the neighbouring CNC machines coming closest to
the machine in a system where CNC machines are connected with each other and
protection against chips and coolant splashes.
Sucking off the machine room air.

Workshop
Clarification of machine parts of CNC machines in the workshop.
The parts of machine tools should be shown and explained on the available machine tools. Similarities and
differences between conventional machine tools and CNC machine tools are to be emphasized.

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Control test CNC Basics

1.

Discuss relevant differences between CNC machine tools and conventional machine tools.

1.

Name characteristic features of numerically controlled machine tools!

1.

What are the advantages of CNC machine tools compared with conventional machine tools?

1.

Why is it necessary to have adjustable feed axes on CNC machines?

1.

Which components make up a modern feed drive?

1.

How many feed axes at minimum should be available on a CNC lathe?

1.

What are the feed axes called?

1.

How many feed axes at minimum should be available on a CNC milling machine?

1.

What are the feed axes called?

1.

Give some examples of controllable rotation axes on CNC machines!

1.

Which operations can be achieved by controllable rotation axes on CNC lathes?

1.

Which operations can be achieved by controllable rotation axes on CNC milling machines?

1.

Discuss the significance and function of a ball screw!

1.

Discuss the difference between direct and indirect position measuring?

1.

Discuss the difference between absolute and incremental position measuring?

1.

What are the advantages of main drive motors with controllable number of rotations?

1.

Which automatic tool installations are available on CNC machine tools?

1.

Which types of tool magazines are available on CNC milling machines?

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Basic Geometry for CNC Machining

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Basic Geometry for CNC Machining

3.

Basic Geometry for CNC Machining

2.1

Coordinate systems on CNC machine tools

Types of coordinate systems

Coordinate systems enable the exact description of all points on a work plane or room. Basically there are
two types of coordinate systems:
Cartesian coordinate system and
polar coordinate system.

Cartesian coordinate system

A Cartesian coordinate system, also called rectangular coordinate system includes for the exact description
of the points
two coordinate axes (two-dimensional Cartesian coordinate system) or also
three coordinate axes (three-dimensional Cartesian coordinate system),
located vertically to each other.
In the two-dimensional Cartesian coordinate system, e.g. in the X, Y coordinate system, each point on the
plane is explicitly defined (see figure 15). The distance from the Y axis is called the X coordinate and the
distance from the X axis is called Y axis. These coordinates can either have a positive or a negative sign.

Example:

P2
P1
X

P1

X= 80

Y= 40

P2

X= -80

Y= 70

P3

X= -50

Y= -40

P4

X= 40

Y= -70

P3
P4
Figure 15
Cartesian coordinate system with 2 axis (X;Y)
If a work part drawing is placed in this coordinate system all important work points can be determined. Depending on where the zero point of the work part is placed, it is possible to exactly define the points either
with positive or also with negative coordinates.
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The three-dimensional Cartesian coordinate system is necessary for the description and location specification of three-dimensional work parts, e.g. milling parts. To describe a point in space three coordinates are
required. These are called X, Y or Z according to the corresponding axis (see figure 16).
Such three-dimensional coordinate systems with positive and negative areas of the coordinate axis enable
the exact description of all points, for instance in the operating space of a milling machine, regardless of
where the zero point of the work part is positioned.

P1

Example:

P1

X= 30

Y= 20

Z=

P2

X= 30

Y=

Z= -10

X
P2

Figure 16
Cartesian coordinate system with 3 axes (X,Y,Z)
The specifications of the three axes as well as the three coordinates is done as a so-called clockwiserotating system and follows the right-hand-rule (see figure 17). The fingers of the right hand always show to
the positive direction of each axis.
This system is also called the clockwise-rotating coordinate system.

+Y

+X

+Z
Figure 17
Right-hand-rule
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Polar coordinate system
In the Cartesian coordinate system a point is described, for instance, by its X and Y coordinates. For rotation
symmetrical contours, such as circular boring patterns, calculating the needed coordinates requires extensive computing.
In the polar coordinate system a point is specified by its distance (radius r) to the point of origin and its angle
() to a specified axis. The angle () refers to the X axis in the X,Y coordinate system. The angle is positive,
if it is measured counterclockwise starting from the positive X axis (see figure 18). In the opposite direction it
is negative (see figure 19).

Figure 18
Polar coordinate system (positive angle )

Figure 19
Polar coordinate system (negative angle )

Rotation angle of axis

Each of the 3 main axes X, Y and Z also have a rotation axis revolving around the corresponding angle.
These rotation angles of the axes are indicated with A, B, C, whereby A rotates on the X, B on Y and C on Z
axis (see figure 20).
The rotation direction is positive if the rotation is clockwise when seen from the coordinate zero point in the
positive coordinate direction (corresponds to the rotation of a screw with a right-hand thread or the rotation
direction of a corkscrew).
The specification of the angles A, B and C of the polar coordinates can be derived from figure 20. If the point
which is to be approached is located on the X/Y plane of the coordinate system, then the polar coordinate
angle corresponds to the rotation angle on the Z axis, i.e. C. On the Y/Z plane the polar coordinate angle
corresponds to the rotation angle on X axis, i.e. A. In the X/Z plane it corresponds to the rotation angle Y, i.e.
B.

Figure 20

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Axis angle of rotation with rotation direction
Coordinate system definition with reference to machine or work part
Machine coordinate system
The machine coordinate system of the CNC machine tool is defined by the manufacturer and cannot be
changed. The point of origin for this machine coordinate system, also called machine zero point M, cannot
be shifted in its location (see figure 21).
Work part coordinate system
The work part coordinate system is defined by the programmer and can be changed. The location of the
point of origin for the work part coordinate system, also called work part zero point W, can be specified as
desired (see figure 22).

Y
M

M Machine zero point

Figure 21
Machine coordinate system

Work part zero point

Figure 22
Work part coordinate system

CNC milling machine

The design of the CNC machine specifies the definition of the respective coordinate system. Correspondingly, the Z axis is specified as the working spindle (tool carrier) in CNC milling machines (see figure 23),
whereby the positive Z direction runs from the work part upwards to the tool.

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The X axis and the Y axis are usually parallel to
the clamping plane of the work part.
When standing in front of the machine the positive
X direction runs to the right and the Y axis away
from the viewer.
The zero point of the coordinate system is recommended to be placed on the outer edge of the
work part.

Figure 23
Milling part in three-dimensional Cartesian coordinate
system
For an easier calculation of the points needed for programming it is advisable to use the outer edges of the
upper (see figure 24) or the lower area (see figure 25).

Z
Y

Figure 24
Work part zero point in the upper left outer edge

Figure 25
Work part zero point in the lower left outer edge

CNC lathes
In the CNC lathes the working spindle (tool carrier) is specified as Z axis. This means the Z axis is identical
to the rotation axis (see figure 26 and 27). The direction of the Z axis is specified so that the tool withdraws
from the work part when moving to the positive axis direction.
The X axis is located in a right angle to the Z axis. However, the direction of the X axis always depends on if
the tool is located in front of (see figure 26) or behind (see figure 27) the rotation center.

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+X

+Z

+Z
W

+X

Figure 26
Milling work part in Cartesian coordinate system
with 2-axis tool in front of the rotation center

Figure 27
Milling work part in Cartesian coordinate system
with 2-axis tool behind the rotation center

CNC-Exercise
Working with different coordinate systems

Enter the coordinates of the points in the table.

a

X
a
X
d
c

28

b
c
d

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Y

Enter the following points in the diagram.

Z
Y
a

10

20

-80

-30

40

-70

-30

50

Enter the Cartesian coordinates of the points a to d in the

table.
X

a
b

c
d

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Enter the Cartesian coordinates of the points a to h in the table.

a
b

d
e

f
g
h

In a drawing milling work parts are specified by their diameter. Therefore, the diameter is also included for
programming.
Enter the Cartesian coordinates of the points a to g in the table. Determine the corresponding diameter values of the X coordinates!

b
a

d
e
f
g

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Feed and Turning Axes on CNC Machines

Location and Designation of the NC axes
CNC milling machines differ in their design with respect to the layout of the working spindles and the location
of the NC axes (see figure 28 and 29). The Z axis is identical with the rotation axis of the working spindle.
The positive Z direction is specified to run from the work part to the tool. Since a three-dimensional Cartesian
coordinate system is used, the other two coordinate axes can be determined by the right-hand-rule.

+Z

+Y
-Z

-Y
-X

+X

-X
+X
-Y

+Z

+Y

-Z

Figure 28
Axis on the vertical milling machine

Figure 29
Axis on the horizontal milling machine

In a CNC lathe the working spindle is defined as the Z axis (see figure 30). The positive Z direction runs from
the work part to the tool. The X axis is vertical to the Z axis. The positive direction of the X axis runs here to
the rear (tool behind the rotation center). One rotation axis - the C axis - is available when the working spindle is approached..

+X

+Z

Figure 30
Axes on the lathe

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Directions of motion on CNC machine tools
During machining relative motions between the work part and tool have to take place on the available axes.
The axes of CNC machine tools are specified by their design (see chapter Location and marking of the NC
axis). They refer to the work part, whereby a three-dimensional Cartesian coordinate system is used. It is
always assumed that only the tool moves, even though tool carrier of the vertical milling machine shown
below moves along the X and Z axes (see figure 31).

+Y
+Z
+X

Figure 31
Directions of motion on a milling machine
To be able to program regardless of machine, the following definition is introduced.
During programming it is always assumed that the tool moves. The coordinate
system always refers to the work part.
Using this definition the work part coordinates can always be applied to generate the NC program.
NC compatible dimensioning
Two different types of dimensioning are used in NC programming:
absolute dimensioning and
incremental dimensioning (incremental values).
Absolute dimensioning always refers to the work part zero point, i.e. reference dimensions are used
(see figure 32). In contrast, incremental dimensioning uses incremental values which are always measured
from the current point to the next point (see figure 33).
When turning, the X values for absolute dimensioning are diameter values, whereas for incremental dimensioning they refer to radius values.

+X

+X

-Z

-Z

Figure 32
Example for absolute dimensioning

32

Figure 33
Example for incremental dimensioning

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Basic Geometry for CNC Machining

Absolute dimensioning is recommended for programming, because of the following advantages compared
with incremental dimensioning:

measuring tolerances do not cumulate,

changes of individual values do not necessarily influence the subsequent dimensions,
one incorrect value does not lead to subsequent errors,
absolute coordinates indicate the current traverse path distance from the tool, so that single program
steps can be traced back more easily.

NC compatible drawings should therefore avoid incremental values and use coordinate values referring to
one reference point.
Despite these advantages it is not always possible to avoid incremental dimensioning in programming. It is,
for example, an advantage when several identical contour parts, such as recesses, are consecutively machined.

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4.

CNC-Demo

Controllable NC axes on the CNC simulator

Similar to a real CNC machine tool, the CNC simulator also permits manual travel along the NC axes. Subsequently, the necessary steps on a CNC simulator are described.
When entering data, only the indicated keys are to be pressed (for example, F5 corresponds to the function
key F5)

CNC milling
Description

Entry

1. Call CNC milling in the main menu.

F2 (Milling)

2. Select setup mode.

F3 (Setup mode) (NUM keyboard ON)

3. Go to X, Y or Z axis and check the travel path.

+Z

Pos 1

-X

-Y

Ende

2
-Z

Einfg

+Y

Bild

+X

Press the corresponding key on the numerical

keyboard.
Travel directions available:

( + X - direction )

( - X - direction )

( + Y - direction )

( - Y - direction )

Bild

Ende

Bild

( + Z - direction )

( - Z - direction )

Entf

The travel path can be checked using the displayed

axis coordinates.

4. Quit the setup menu

F8 (Quit)

CNC-Exercise: With the CNC simulator each student practices moving along the NC axes.

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CNC turning
Description

Entry

1. Call CNC turning in the main menu.

F1 (Turning)

2. Select setup mode.

F3 (setup mode) (NUM keyboard ON)

3. Go to the X or Z axis and check the travel

path.

Press the corresponding key on the numerical

keyboard.
Travel directions available:

+X

Pos 1

-Z

8
5
2

-X

Einfg

6
3

+Z

( + Z - direction )

( - Z - direction )

( + X - direction )

( - X - direction )

Bild

Entf

The travel path can be checked using the displayed

axis coordinates.

4. Quit the setup menu.

F8 (Quit)

CNC-Exercise: With the CNC simulator each student practices moving along the NC axes.

Workshop
Using the CNC machines available the students move along the controllable NC axes. Hereby the corresponding operation instructions of the machine have to be followed.
Exercise: With the CNC simulator each student practices moving along the NC machine tool.

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2.2

NC Mathematics

Basics of coordinate point calculations

When programming a CNC program the corresponding points of the contour to be machined have to be
entered. In most cases it is possible to directly take these point from the drawing, providing the drawing dimensions are NC compatible. In some cases it is however necessary to calculate coordinate points.
Characteristic values of a triangle
To calculate the missing coordinates the relations within a triangle are very helpful. There are various possibilities to describe a triangle. Some of the following characteristic values, such as corner points, angles or
sides are used (see figure 34).
Corner points
A, B and C mark the three corner points of a
triangle.

Angles
, and are the corresponding angles in
the corners of the triangle.
Sides
a, b and c mark the sides of the triangle opposite to the corners A, B and C.

The component parts of the triangle are always marked counterclockwise.

Figure 34
Characteristic values of a triangle
Angles of the triangle
The angles of the triangle specify the type of the triangle. Depending on the sizes of the triangle angles the
triangle is either an acute-angled, obtuse or right-angled triangle (see figure 35 - 37)

C
b

Figure 35
Acute-angled triangle
All angles are smaller than 90.

Figure 36
Obtuse triangle
One angle is larger than 90.

Figure 37
right-angled triangle
One angle is 90.

For a triangle the relation applies: the sum of the triangle angles , and is always 180.

+ + = 180o
With this formula it is possible to calculate one unknown angle if the other two angles are known.

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Right-angled triangle
The right-angled triangle (see figure 38) has a special significance in analytical geometry, since the sides of
such a triangle stand in a certain mathematical relation to each other. The sides of a right-angled triangle
have specific names:
The longest side is located opposite the right angle and is called hypotenuse.
The two sides of the triangle forming the right angle are each called cathetus
or together the legs of the right-angled triangle.
The side which is located opposite the angle is called counter cathetus.
The side located adjacent to the angle is called adjacent cathetus.
In a right-angled triangle the right angle (see figure 38) is described by a quarter circle and a point within the
angle.

counter cathetus

adjacent cathetus
1

hypotenuse

right angle

Figure 38
Right-angled triangle
The following applies for a right-angled triangle:
In a right-angled triangle it is possible to calculate the length of an unknown side if the other two side lengths
are known. For this, the Pythagorean theorem (see figure 39) is used.
The Greek Pythagoras (approx. 580 - 496 BC) was
the first to verify the following mathematical relation
which was called after him
the Pythagorean theorem

b
b

The sum of the squares of the legs

of a right triangle is equal to the
square of the length of the hypotenuse.
or expressed as an equation:

a2 + b2 = c 2
c

With the corresponding transformation the sides of

the triangle can be calculated as follows:

a = c 2 b2
b = c 2 a2

Figure 39
The Pythagorean theorem

c = a2 + b2

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Trigonometric functions
The trigonometric functions describe the relation between the angle and the sides of the right angle. With
these trigonometric functions it is possible to calculate unknown side lengths if one angle and the length of
one side is known. The choice of the trigonometric function between sine function (see figure 40), cosine
function (see figure 41) or the tangent function (see figure 42) depends on which side and angle are known.
counter cathetus

hypotenuse

sin =

counter cathetus
hypotenuse

Figure 40
Sine function
adjacent cathetus

hypotenuse

cos =

adjacent cathetus
hypotenuse

Figure 41
Cosine function
counter cathetus

adjacent cathetus

tan =
2

counter cathetus
adjacent cathetus

Figure 42
Tangent function
When calculating the unknown side the corresponding equations need to be transformed according to the
following example:
known values:

the angle and the length of the adjacent cathetus

unknown value:

the length of the counter cathetus

equation:

tan =

counter cathetus (see figure 42), resulting in:

adjacent cathetus

counter cathetus = adjacent cathetus tan

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Calculation of NC coordinates
Work part drawings are not always dimensioned NC-compatible. In addition to incremental values, angle
values are also frequently given in drawings. Consequently, when programming manually the programmer
has to calculate unknown Cartesian coordinates using the points to be programmed.
In the following drawing the coordinates of the points b, c and f need to be calculated. The other points are
known.

Y
f
e

25

g
c

15

15

15

35

85

35

85

85

85

15

65

25

X
Calculation of the point b:
known :

x from center point = 65 mm

unknown : x from point b = ?

25

solution : x = 65 mm - dx
dx = radius of the arc

dx

dx = 25 mm

x = 65 mm - 25 mm
x = 40 mm

Calculation of the point c:

known :

radius of the arc r = 25 mm

dy

25

dx

x from center point = 65 mm

dy = 35 mm - 15 mm = 20 mm

unknown : x from point c = ?

solution : x = 65 mm + dx
equation: dx = r 2 dy 2

dx = ( 25mm ) ( 20mm )
dx = 225mm 2
dx = 15mm
2

x = 65 mm + 15 mm
x = 80 mm

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known :

x from the beginning of the incline = 15 mm

angle of the incline = 25
dy = 85 mm - 65 mm = 20 mm

unknown : x from point f = ?

dx

solution : x = 15 mm + dx
equation: counter cathetus = adjacent cathesis * tan
dx = 20 mm * tan 25
dx = 20 mm * 0.4663
dx = 9.326 mm
x = 15 mm + 9.326 mm

dy

f
25

x = 24.326 mm
CNC exercise
Enter the Cartesian coordinates from the center points of the drillings a to h in the table. Give all values
rounded to three decimal points.

Y
X

60

100

c
d

h
g

e
50

50

f
g
h

100

Calculate the unknown coordinates in the following examples.

85
70
50

unknown : Y coordinate

40

80

30

85

35

90
80

unknown: Y coordinate

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2.3

Zero and reference points on CNC machine tools

Types of zero and reference points

M

machine zero point

work part zero point

reference point

tool reference point

tool setup point

tool shank point

tool change point

Machine zero point M

R
E
N

Each numerically controlled machine tool works with

a machine coordinate system. The machine zero
point is the origin of the machine-referenced coordinate system. It is specified by the machine manufacturer and its position cannot be changed. In general,
the machine zero point M is located in the center of
the work spindle nose for CNC lathes and above the
left corner edge of the work part carrier for CNC vertical milling machines.

Figure 43
Location of the zero and reference points for turning
Reference point R

R
M

A machine tool with an incremental travel path measuring system needs a calibration point which also
serves for controlling the tool and work part
movements. This calibration point is called the reference point R. Its location is set exactly by a limit
switch on each travel axis. The coordinates of the
reference point, with reference to the machine zero
point, always have the same value. This value has a
set adjustment in the CNC control. After switching the
machine on the reference point has to be approached from all axes to calibrate the incremental
travel path measuring system.

Figure 44
Location of the zero and reference point for milling

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Work part zero point W

+X

+Z
W

+Z

The work part zero point W is the origin of the work

part-based coordinate system. Its location is specified by the programmer according to practical criteria.
The ideal location of the work part zero point allows
the dimensions to be directly taken from the drawing.
In case of turning the work part zero point is generally in the center of the left or right side of the completed part, depending on which side the dimensioning was started from.
The work part zero point can be shifted in the NC
program, e.g. when a turned part is to be completely
machined between centers on two sides. In this case
it is advisable to alternately shift the work part zero
point to the right or left side of the machined part.

+X

Figure 45
Work part zero point of the turned part

Z
Y

For milling, the outer corner point is usually chosen

as the work part zero point, depending on which corner point is selected as the reference point when
dimensioning the work part.

Figure 46
Work part zero point of a milled part.
Tool reference point E
A further important point in the machine work space is the tool reference point E. The tool reference point E
of a CNC lathe is a fixed point on its tool carrier. On a CNC milling machine the tool reference point E is located on the tool spindle.
The CNC control refers first to the tool reference point for all target point coordinates. When programming
the target coordinates either the tool tip of the turning tool or the center of the milling tool is referred to. To be
able to control exactly the tool tip in turning or the tools in milling along the desired machining travel path
they have to be measured precisely. It is possible to measure the tools either outside the machine with a
preset device or directly on the machine using special optics. When using an optic, the measured values are

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directly entered into the machine storage. If however the preset device is used the measured values need to
be entered manually for each tool into the corresponding compensation value storage of the control.
Two additional points are needed to preset the tool outside the CNC machine. These are the tool setup point
B and the tool shank point A.
Location of the tool setup point B
on a turning tool
B
L

tool setup point

length = distance of the cutter tip to the tool setup
point in X
Q overhang = distance of the cutter tip to the tool
setup point in Z
R cutter radius

Figure 47
Tool setup point of a turning tool
Location of the tool setup point at B
of a milling tool
B
L

tool setup point

length = distance of the cutter tip to the tool setup
point in Z
radius of the milling tool

R
Figure 48
Tool setup point of a milling tool
Location of the toolholding point A
on a turret
A

toolholding point

Figure 49
Toolholding point of a turret
If the tool system (tool post with tool) is placed into the tool carrier (i.e. a turret), then the tool setup point B
and the toolholding point A fall together and make up the tool reference point E.
Tool change point N
The tool change point N is the point in the CNC machine work space on which the tools can be changed
without collision. In most CNC controls the tool change point can be configured.

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Setting the work part zero point W on a CNC lathe

Setting the work part zero point W coordinates the work part zero point with the drawing zero point. The
drawing dimensions can then be used directly for programming.
Setting the work part zero point is done with reference to the machine zero point M of the CNC machine.

The machine zero point of a lathe is generally located

on the rotation axis of the main spindle on the plane
surface of the spindle flange on which the jaw chuck
is flanged (see figure 50).
Using the operation functions described below the
distance between the machine zero point M and the
work part zero point W is specified. This value zw,
also called the zero point shift, is then entered into
the CNC control.

zw
Figure 50
Setting the work part zero point on a CNC lathe
Procedure
Starting situation: All machining tools have been measured and are available on the turret head.
The clamping device is prepared and the work part has been correctly clamped.
1. Switch on the spindle (counterclockwise rotation).
1. Change the tool to set the work part zero point, i.e. rotate the turret head to the corresponding position,
for instance T02.
Note:

The rotation area of the turret has to be checked first to avoid collision during rotation.

3. Touch the front plane area of the work part:

carefully move with the tool using the hand wheel
or using the corresponding arrow keys of the keyboard of the CNC control
until the cutting edge reaches a marking on the work part.
3. Enter the desired plane area allowance (e.g. 0.5 mm) on the CNC control.
Actuate with the zero key.
(The dimensions are used to face the front surface in z=0)
3. The CNC control then stores the value of the zero point shift zw.
The work part zero point W is clearly specified since the X coordinate zero is located on the rotation axis.
3. Because of eventual allowance the front side needs to be faced. This needs to be considered when programming the NC program.

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Setting the work part zero point W on a CNC milling machine

Similar to a lathe the work part zero point corresponds with the drawing zero point when the work part zero
point W is set on a CNC milling machine. This allows the drawing data to be directly used for programming.
The work part zero point is set with reference to the
machine zero point M. In most cases the machine
zero point of a CNC vertical milling machine is located above the left corner edge of the machine table
(see figure 51).

R
M

With the operations described below the distance is

specified between the machine zero point M and the
work part zero point W in the three coordinates X, Y
and Z. These values are then entered into the CNC
control.
Procedure
Starting situation:
The work part is adjusted and firmly clamped in the
machine table. All tools are gauged to each other.
The corresponding compensation values were entered into the CNC control. The zero setting tool is
clamped and the spindle rotation is switched on.
1. Resetting Z direction

Figure 51
Setting the work part zero point on a CNC milling
machine
Z

The machine table with the clamped work part is

moved below the work spindle (in X and Y) in which
the reset tool is clamped.
Now the tool is recessed in Z direction to the work
part surface (X, Y plane), with the spindle switched
on (see figure 52), until a small marking is made on
the work part (touching the work part) surface.
After this the Z axis is reset and the Z value of the
work part zero point W is transferred and stored into
the CNC control using the IST key.
2. Resetting in X direction

Figure 52
Resetting in Z
Z

Figure 53
Resetting in X

The tool is raised again and taken into the new resetting position for the X axis. With the spindle switched
on it is moved along the side surface of the work part
(Y, Z plane) in the X direction (see figure 53) until a
small marking is made on the work part surface
(touching the work part).
When touching the work part in X axis the radius of
the applied tool has to be considered when confirming the value with the IST key, since the center point
coordinates of the tool are always used in NC programming.
If the milling tool of the adjacent figure has, for instance, a radius of 15 mm, then the value X=-15 is
entered into the NC control and confirmed with IST.
.

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3. Resetting in Y direction

Figure 54
Resetting in Y

46

The last step is to take the tool to resetting position

for the Y axis. With the spindle switched on, the tool
is taken into Y direction (see figure 54), to the side
surface of the work part (X, E Plane) until a small
marking is done on the work part surface (touching
the work part).
When touching the work part in X axis the radius of
the applied tool has to be considered when confirming the value with the IST key, since the center point
coordinates of the tool are always used in NC programming.
If the tool of the adjacent figure has, for instance, a
radius of 15 mm then the value Y=-15 is entered into
the CNC control and confirmed with IST.

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CNC exercise
Setting the work part zero point W in the CNC simulator Turning
By setting the work part zero point W the relation between the machine based and work part based coordinate system is created. The work part zero point corresponds to the drawing zero point. Consequently, the
drawing dimensions can be used in programming. Using the operation steps described below the distance
between the machine zero point M and the work part zero point W can be specified. This Z value is also
called the zero shift zw.
Starting situation:
All machining tools are dimensioned and available
on the turret head.
The work part is clamped in chuck jaws.
The work part zero point is located on the front
plane surface, whereby an allowance of 1mm has
to be considered.

zw

Description

Entry

1. Call CNC turning in the main menu.

F1 (Turning)

2. Select setup mode.

F3 (Setup mode)

3. Switch on the spindle in counterclockwise

rotation.

Type M04 using the keyboard and

4. Change the tool for the definition of the work

part zero point.

Type T0404 using the keyboard and confirm.

5. Move the lathe tool in rapid speed so that it is

located in front of the front plane surface with
a distance of approx. 5mm to the front plane
surface.

Using the numeric keyboard press the corresponding arrow key simultaneously with the
shift key:

confirm.

+X

+ 4

for rapid speed in -Z direction

+ 2

for rapid speed in -X direction

+Z
Travel direction options:

+X

Pos 1

-Z

2
0

Einfg

-X

6
3

Bild

+Z

( + Z - direction )

( - Z - direction )

( + X - direction )

( - X - direction )

Entf

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6. Switch the increment from 1mm to 0,1mm or

0,01 mm for further machining. .

F3 (Technology)
F5 (Increment)
F2 (Increment 0.1)

7 Move the lathe tool in negative Z-direction

until it touches the plane surface of the work
part .

Press the arrow key on the numeric keyboard.

4
ESC

Then press
and

F8 (Quit).
8. Set the work part zero point in Z.

F4 (Tool datum)
F4 (Set datum)
F1 (Set Z coord.)
Type z+1using the keyboard and confirm

F8 with (allowance of 1mm).

The Z value can be checked for the current zero
point using the displayed coordinates.

9. Take the tool off in +Z direction and in

+X direction .

10. Quit the setup mode

Using the numeric keyboard press the arrow

key together with the shift key:
+ 6

for rapid speed in +Z direction

+ 8

for rapid speed in +X direction

F8 (Quit)
F8 (Quit)
F8 (Quit)

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Setting the work part zero point W in the CNC simulator milling
In milling, setting the work part zero point W coordinates the work part zero point with the drawing zero point.
Please note that only the tool moves in the MTS simulator!
Using the operation steps described below the distance between the machine zero point M and the work
part zero point W in the three coordinates X, Y and Z is defined.
Starting situation:

All machining tools are dimensioned and available in the magazine.

The work part is adjusted and clamped on the
machine table in the simulator.
The location of the work part zero point should
be the left top corner of the work part.

Description

Entry

1. Call CNC milling in the main menu.

F2 (Milling)

2. Select the setup mode.

F3 (Setup mode)

3. Switch on the spindle in clockwise rotation.

Type M03 using the keyboard and

confirm.

4. Change the tool to define the work part zero

point.

Type T0202 using the keyboard and

5. Setting the zero point in Z direction

Move the tool in rapid speed to a position
approx. 5mm above the work part surface.

Using the numeric keyboard press the corresponding arrow key together with the shift
key:

confirm.

Z
W

Pos 1

+Y

for rapid speed in -Z direction.

Bild

Further travel direction options:

6

+X

Bild

-Y

+ 2

X
+Z

-X

Ex.:

Ende

Einfg

2
-Z

Bild

Ende

8
2

( + X direction )
( - X direction )
( + Y direction )
( - Y direction )
( + Z direction )
( - Z direction )

Entf

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6. Switch the increment from 1mm to 0,1mm or

0,01mm for further machining.

F3 (Technology)
F5 (Increment)
F2 (Increment 0.1)

7 Move the tool in negative Z direction until it

touches the surface of the work part.

Press the arrow key on the numeric keyboard

2
ESC

Then press
and

F8 (Quit).
8. Set the work part zero point in Z.

F4 (Tool/ Datum)
F4 (Set Datum)
F3 (set Z coord.)
Type in the data on the keyboard 0 and

F8 confirm it.
Check Z by setting the zero point and using the displayed coordinate values.

9. Setting the zero point in X direction

Withdraw the tool in +Z direction.

Using the numeric keyboard press the arrow

key together with the shift key:
+ 8

10. Move the tool in rapid speed to the new zero

setting position approx. 5mm off the side surface.

1
Z

Press the corresponding arrow key on the

numeric keyboard
together with the shift key:
1) in -X direction

+ 4

50

for rapid speed in -X direction

2) in -Z direction
+ 2

for rapid speed in +Z direction

for rapid speed in -Z direction

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11. Move the tool in positive X direction until it

touches the left side of the work part.

Press the arrow key on the numeric keyboard.

6
ESC

Then press
and

F8 (return).
12. Set the work part zero point in X.

F4 (tool, zero point)

Please note the tool radius!

So, enter for the X coordinate the negative
value of the radius of the applied tool, for instance -10.

F4 (set datum)
F1 (set X coordinate)
Type -10 using the keyboard and confirm.

F8
Check the X by setting the zero point using the displayed coordinate values.

13. Setting the zero point in Y direction

Take off the tool in -X direction and then in +Z
direction.

14. Take the tool in rapid speed to the new resetting position approx. 5mm off the front side.

Z
W

1
3

Using the numeric keyboard press the arrow

key together with the shift key:
+ 4

for rapid speed in -X direction then

+ 8

for rapid speed in +Z direction.

Using the numeric keyboard press the corresponding arrow key together with the shift
key:
1) in +X direction
+ 6

for rapid speed in +X direction

2) in -Y direction

1 for rapid speed in -Y direction

+ Ende

3) in -Z direction
+ 2

for rapid speed in -Z

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15. Take the tool in positive Y direction until it

touches the front of the work part.

Press the arrow key on the numeric keyboard.

Bild

ESC

Then press
and

F8 (Quit).
16. Set the work part zero point in Y.
Please, note the tool radius!
So, enter for the Y coordinate the negative
value of the radius, for instance -10.

F4 (Tool/Datum)
F4 (set Datum)
F2 (set Y coord.)
Type -10 using the keyboard and confirm

F8 key.
Check the Y by setting the zero point using the displayed coordinate values.

17. Withdraw the tool in -Y and then in +Z direction.

use the numeric keyboard and press the arrow key together with the shift key:

1 for rapid speed in -Y direction, then

+ En
de
+ 8
18.

F8 (Quit)

19. Quit the setup mode menu.

F8 (Quit)

52

for rapid speed in +Z

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2.4

Numeric Controls on CNC Machine Tools

Control chain and control loop

The current controls of the numeric-controlled machine tools are CNC controls. For the control it is
characteristic to have an open movement path (see figure 55). The control gives the set value to the
machine tool without controlling it directly. This is called a control chain.
1

input value (set value)

output value (actual value)

disturbance value
control path
3

Figure 55
Function principle of a control chain
Since such a control chain generates an incorrect output value it is connected with the control. The control is
a sequence of operations which constantly recalculates and adjusts the actual value to reach the required
value.This closed sequence of operations is called a control loop (see figure 56)..
1

2
4

entry value (set value)

output value (actual value)
disturbance value

control path

measuring equipment
5

output value (actual value)

Figure 56
Function principle of a control loop
In a CNC machine tool the principle of a control loop is applied as a position control for the axis.

CNC Control
Structure and function
The CNC control is designed to decode a NC program and to process it as geometrical and technological
information. Using CNC control it is possible to control or check the corresponding components of the CNC
machine tool so that the desired work part is formed. The functions of the CNC control can be classified as
data entry, data processing or data output (see figure 57).
Data entry and data processing
The data entry is done using the control panel consisting of a keyboard and monitor. Here the NC programs
can be generated and managed, data can be entered or program simulations can be called . The NC programs can also be read in or stored using external data carriers, such as data cassettes. It is also possible

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Basic Geometry for CNC Machining

to have an external data transmission to a computer (DNC operation) via serial interfaces or network input
ports. It is then possible to generate (MTS system) and manage NC programs on this computer.
CNC control

technological
processing

geometrical
processing

adjustment control

X,Y,Z

axis control

actual position
value
data entry

data processing

data output

Figure 57
Structure of a CNC control
The data needed by the CNC machine tool to operate and machine the work part is generated out of the NC
data by the data processing of the CNC control.
The technological data is used e.g. for tool selection, for adjusting the spindle rotation speed, for selecting
the spindle direction of rotation or for switching the coolant on and off. They are transmitted through the adjustment control to the corresponding component of the CNC machine tool.
The geometrical information of a NC program is translated from the CNC control into set values for the different axial drives under consideration of the infeed values. The travel movements which are so created are
continuously controlled by the position control loop of the feed axis.
Travel movement using interpolation
In technical applications by far all contour lines can be classified in straight lines and circular elements. This
is the reason why the majority of the CNC controls manufactured today are equipped only with straight line
and circular interpolation. In our CNC controls interpolations of parabolas and cubic parabolas, helical interpolations and spline interpolations are also available.
If a tool goes from the starting point to a target point which is not parallel to the axis it is a question of a
straight line interpolation. To achieve a straight tool path the relevant axes have to be correspondingly adjusted to each other. The relation of the axis feeds defines then the direction of the straight lines
(see figure 58 and 59).

Y
1
1

1
2

1
X

aimed travel movement

Figure 58
Relation of axial feeds

54

X
aimed travel movement
Figure 59
Relation of axial feeds

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The best way to demonstrate the principle of tool feed along curves, lines and arcs on a plane is to use a
plotter with a step motor. A step motor is controlled by current pulses. A positive or negative current pulse
rotates the wave of the step motor with a jerk in a certain angle to the right or to the left. As a result, each of
the two plotter axes can reach only a certain axial value. Therefore the plotter can only go to the points of a
tight grid on its drawing area. Just like on a monitor screen an incline is drawn through the axis-parallel
movement of the plotter (see figure 60).

aimed plotter movement

movement in the X axis
movement in the Y axis

Figure 60
Travel path of a plotter pen
The same principle is used for the interpolator of a CNC control. It calculates the intermediate values needed
for interpolation and transmits them as set values to the position control circles.
In straight line interpolation two or three axes move simultaneously (see figure 61), whereby their travel
movements are adjusted to each other in a certain relation.
If the tool moves in a circular path from the starting point it is a question of a circular interpolation
(see figure 62). The tool moves here either in clockwise or in counterclockwise direction. To achieve a circular tool path the travel movements of both axes, also depending on the path already traveled, have to be
adjusted to each other. The axis movement corresponds to a sine or cosine curve. The overlay of the two
axis makes out the arc.
Z

Travel path of a plotter pen

Figure 61
Straight line interpolation

Travel path of a plotter pen

Figure 62
Circular interpolation

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Types of CNC controls

The axis of the CNC machine tool receive their travel signals (commands) from the CNC control. These signals are coded and are based on the entered NC program. They are evaluated by the control and transmitted to the feed motor. The travel paths of the tools are exactly set. Depending on the type of the travel paths
the following control type classification is used:
point control
line control
path control:

- 2D path control
- 2 D path control
- 3D path control
Point control
It is the simplest control type. In case of a point control a target point is approached in rapid speed and a
machining operation is carried out at the target point
(see figure 63). In the same way several target points
can be approached one after an other.
The point control can be applied to work parts for
which machining is made only at certain points, e.g.
for machining surfaces by boring, reaming, recessing, threading, spot welding, punching.

Figure 63
Point control
Line control
With the line control only tool travel paths which are
parallel to axes and which have programmed infeed
values can be controlled (see figure 64).
The generated work part contours can only be parallel to axis.
The line control can be applied in cases where machining is supposed to take place only on planes
parallel to the guideways of the machine, e.g. for
simple plane and straight turning, plane parallel milling or breakthrough milling where machining takes
place in one direction at a time.

Figure 64
Line control

Path control
In path control it is possible to control any travel
paths (straight, inclines, circular, splines) of the tool
applied on planes or in space.
It is possible to achieve any contour line
(see figure 65) through the controlled interaction of
two or more infeed motors.

Figure 65
Path control on a CNC machine

56

To be able to carry out the movements simultaneously on all machine axes all intermediate values
located on the mathematically specified curve between the starting and end point need to be first calculated by the CNC control.

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Path controls are further classified depending on the number of axes which can be simultaneously controlled:
2 D path control
With the older 2 D path control it is possible to simultaneously control two axes. So it is possible to carry
out straight and circular tool movements on one
plane (see figure 65).
If, for example, a 3 axes CNC milling machine has a
2 D path control it means that it is possible to mill
contours in two axes. The third axes has to be entered separately.

Figure 66
2D path control

2 D path control
The 2 D path control makes it possible to carry out tool movements on several planes by switching the
interpolation in each case on one of the three main planes. All three axes are controllable in 2 D path control, however in every plane only two axes simultaneously. The third axes is the so-called infeed axis.
Depending on the selected machining plane different
axis can be controlled simultaneously so that it is
possible to travel in the following directions:
- X/Y plane (see figure 67),
- X/Z plane (see figure 68),
- Y/Z plane (see figure 69).

Figure 67
2D path control (X/Y plane)

Figure 68
2D path control (X/Z plane)

Figure 69
2D path control (Y/Z plane
3 D path control
In 3 D path controls three axes are interpolated simultaneously. Herewith it is possible to realize threedimensional tool movements.
It enables complicated contours, e.g. in tool construction, especially in molded construction, to be machined in one clamping.

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DNC operation
Characteristics of DNC operation
DNC is the abbreviation of direct numerical control. It is the name of an operation mode in which several NC
and CNC machines as well as further devices are connected with each other. These devices can be for instance tool presetting machines, measuring machines, programming seats and a central material and tool
management (see figure 70).

CAD

NC-Programming

PPS

...

Local area
Network (LAN)

Tool presetting machines

Master
computer
Measuring machines

NC
archive

...

Figure 70
Structure of a DNC system
The connection between the components of a DNC system is realized by a data bus. This direct data transmission makes the conventional data carriers such as punch cards, magnetic stripes, discs as well as the
corresponding recording and read-in instruments unnecessary.
The significant characteristic of the DNC operation is the management and timely disposition of the information. To be able to calculate and distribute this information to the right position, interfaces are needed.
Through the interfaces all the integrated parts of the DNC net are connected with the master computer. The
master computer is able to calculate machine and production data, switch operation modes, address, read-in
and record the correct storage location as well as automatically transmit them to the machine upstream computers.
Data input and data processing in DNC operation
Through the structure of a DNC system (see figure 70) it is possible to enter data into different devices.
These devices can be located far away from each other.
Small NC programs can be written directly on the CNC machine tool. For writing extensive or complicated
NC programs it is better to use an external programming work station.
A DNC system generally includes the following basic functions.
storage and management of NC programs
correct distribution of NC programs to the machines
re-transmission of the corrected and optimized NC programs from the machine to the master data
storage medium
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For this purpose there is a central management of the NC programs in the DNC system. The generated and
optimized NC programs are transmitted to the corresponding computers through data links. In case the CNC
machine tool is not equipped with a special DNC port a DNC terminal controls the organization of the data
transmission between the CNC control and master computer.
Depending on the model of a DNC system the following additional functions can be available:
central tool management and tool compensation data
interface for tool presetting devices
work part management
set time value and definition of working sequences
control of the material flow
central storage of the current data bases
central cooperation data and machine data acquisition (BDE, MDE) with graphical evaluation
NC programming with postprocessor conversion
graphical simulation with representation of the tool, clamping device and work part contour
Advantages of the DNC operation system
A DNC operation system has the following advantages compared with a solution with non-integrated CNC
machine tools:
improved workshop organization
immediate availability of programs and additional information
minimal standstill times of the CNC machine through the continuous provision of NC programs,
tools and material
reduced data entry errors
operating data and machine data acquisition (BDE, MDE) enable the user to control and record at
any time the production data (machine operating times, out-of-service-times, down times, etc.),
maintenance information and information on reasons for out-of-service-times

Workshop
The different CNC control types are demonstrated on the CNC machine tools available.
If no CNC machine tools are available for point or line control these CNC control types can be simulated with
the help of the corresponding work parts.
Example:
point control
milling machine: go to boreholes
line control
milling machine: travel parallel to axis
lathe: travel parallel to axis
2D path control
milling machine: travel linear on two axis
milling machine: travel in a circle
lathe: machine a cone or rounding
2 D path control
milling machine: travel on various planes
milling machine: travel in a circle on various planes
3 D path control
milling machine: travel linear on two axis
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milling machine: travel on a circle in space

2.5

Tool Compensations for CNC Machining

Using tool compensation values

Using the tool compensation values it is easy to program a work part without consideration of the actually
applicable tool lengths or tool radii. The available work part drawing data can be directly used for programming. The tool data, lengths as well as radii of the milling machines or indexable inserts are automatically
considered by the CNC control.

Tool length compensation for milling and turning

A tool length compensationregarding the reference point enables the adjustment between the set and actual
tool length, as in case of tool finishing. This tool length value has to be available for the control. For this it is
necessary to measure the length L, i.e. the distance between the tool setup point B and the cutting tip, and
to enter it into the control (see chapter on tool measuring page 69 ff.).
In case of milling tools the length is defined in Z direction (see figure 71).
B

tool setup point

length = distance of the cutting tip to the tool

setup point in Z

radius of the milling tool

R
Figure 71
Tool compensation values on a cutting tool
In case of lathe tools the length L is defined in Z direction (see figure 72).

tool setup point

length = distance of the cutting tip to the tool

set-in point in Z

overhang = distance of the cutting tip to the

tool setup point in X

cutting radius

Figure 72
Tool compensation values on a lathe tool
In the CNC control these tool compensation values are stored in the compensation value storage, whereby
in most CNC controls it is possible to describe up to 99 tools. These values have to be activated during ma-

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chining. This is done by calling the data within the NC program, e.g. with the address H or by specific places
in the T word.

Tool radius compensations

The CNC controls have an integrated cutter radius compensation for milling machines and tool tip compensation for lathes. Using these aids it is possible to directly program the finished contour of the work part.

Cutter radius compensation (milling)

To enable the tool to generate the programmed contour with high precision the tool center point has to travel
on a path running parallel to the programmed path. This tool center point path is called equidisant
(see figure 73).

Milling center point paths (equidisant)

work part contour

Figure 73
Milling center point paths (equidisants)
One equidisant is the tool center point path running in constant distance to the programmed path (contour) of
the work part. In discontinuous path transitions, i.e. in the inner and outer corners (see figure 74 and 75),
the transitions become equidisants, for instance, through insertion of arcs, in accordance with the controlspecific rules.

2
1

programmed path

programmed path

tool travel path

tool travel path

Figure 74
Inner corner in milling

Figure 75
Outer corner in milling

In case of inner corners an arc corresponding to the

radius of the milling machine is created.

In case of outer corner the tool makes a compensating arc.

The CNC control calculates the contour-parallel milling center point path necessary for machining. The calculations are based on the radius value of the current milling tool, which is stored in the tool compensation

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value storage. The radius is not given in the NC program as such, the corresponding compensation switch is
instead called.
Due to the fact that machining can be done in two ways the NC control has to be informed if machining is to
take place on the left or right of the programmed contour (see figure 76).

2
left of the contour
right of the contour

programmed contours

Figure 76
Machining directions in milling radius correction
The following figures demonstrate the selection of the milling radius compensation which depends on the
position of the tool with reference to the contour to be machined
outside machining (see figure 77) and in
inside machining (see figure 78).

2
1

1
2

left of the contour

left of the contour

right of the contour

right of the contour

programmed contour

programmed contour

Figure 77
Milling radius compensation in outside machining

64

Figure 78
Milling radius compensation in inside machining

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If subsequent travel movements without milling radius compensation are to be done, for instance in borings,
these have to be entered to the CNC control with the corresponding command.
Tool nose compensation (turning)
In milling, milling radius compensation is used and in turning, tool nose correction, due to the fact that the
control calculates the travel paths based on a theoretical tool nose of the lathe tool. This theoretical tool nose
moves along the programmed path.
Since the actual tool dimensions, i.e. tool nose radius of the lathe tool, are not considered errors are unavoidable. Consequently, as a rule, roundings remain in inside corners or the contours (see figure 79). In
tool movements which are not parallel to X or Z axis considerable dimension and form deviations are the
result (see figure 80). These errors can be avoided by using tool nose correction, also called tool nose
compensation, in the CNC control.
3

3
2

5
2

Figure 79
Unavoidable error in turning:
contour inside corner remains

Figure 80
Error in turning: cone is not true-to-size
according to the programmed contour

programmed contour

programmed contour

theoretical cutting point

theoretical cutting point

theoretical tool tip

theoretical tool tip

actual tool tip

actual tool tip

contour corner remains unmachined

because of the cutter radius

incorrect deviation from the programmed

contour

The location of the actually traveled tool paths (equidisant see figure 81) is automatically calculated by the
cutter radius compensation in modern CNC controls.The following three facts have to be considered:
1. The radius of the tool tip has to be available in the compensation value storage of the CNC control.
1. The location of the tool tip (cutter compensation value vector) has to be available for the CNC control.
1. The machining direction of the tool with reference to the contour has to be correspondingly
programmed in NC programming.

programmed contour path

2

the center point path (equidisant) calculated by the CNC control on which the
tool travels during machining

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Figure 81
Equidisant in turning
To enable the control to correctly calculate the actual cutting point the so-called cutting tip is described for
each tool by the cutter compensation vector (SRK vector). Hereby the SRK vector gives the position of the
cutter tip in I and K (X and Y direction) with reference to the cutter center point (see figure 82). The SRK
vector is defined in advance for each tool in the tool management of the MTS CNC simulator.

theoretical cutting edge

theoretical cutting tip

theoretical cutting tip

cutting radius compensation value vector

1
R

cutting radius

Figure 82
Cutting radius compensation value vector
Different cutting radius compensation value vectors have to be entered into the control depending on the fact
in which machining quadrant the applied tools are located (see figure 83). When entering the compensation
values I and K the signs of the resulting value have to be considered.
8
4

2
6

For the cutting radius R the value of the current

tool has to be entered.
1. quadrant:

K=R

I=R

2. quadrant:

K = -R

I=R

3. quadrant:

K = -R

I = -R

4. quadrant:

K=R

I = -R

5. quadrant:

K=R

I=0

6. quadrant:

K=0

I=R

7. quadrant:

K = -R

I=0

8. quadrant:

K=0

I = -R

Figure 83
Values for the cutting radius compensation value vector
which depend on the current machining quadrant of the
tool.
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The following example demonstrates how to define the compensation values I and K (see figure 84).
cutting edge in machining quadrant 3
cutting edge radius R = 0,8 mm
The values I and K are as follows:
K = -0,8

= -0,8

K
Figure 84
Example: Cutting edge radius compensation value

When calling the cutting edge radius compensation in the program the location of the turning tool in travel
direction has to be entered into the CNC control by using the corresponding command:
turning tool is located left of the contour in travel direction or
turning tool is located right of the contour in travel direction
The following figures demonstrate the programming of the cutting radius compensation in dependence upon
the location of the tool with reference to the contour to be machined in case of
outside machining (see figure 85 and figure 86) and in case of
inside machining (see figure 87 and figure 88).

Figure 85
Cutting radius compensation in case of outside machining
left of the contour
machining direction of the tool
left of the contour

Figure 86
Cutting radius compensation in case of outside machining
right of the contour
machining direction of the tool
right of the contour

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programmed contour

programmed contour

Figure 87
Cutting radius correction, inside machining,
left of the contour.

Figure 88
Cutting radius correction, inside machining,
right of the contour

machining direction of the tool

left of the contour

machining direction of the tool

right of the contour

programmed contour

programmed contour

Just like programming a milling work part it is possible to directly program the contour to be machined using
the work part drawings data without data conversion. In turning as well, the selected cutting edge radius
compensation has to be switched off with the corresponding command.

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Tool measuring and adjusting with an adjusting device

To guarantee efficient CNC machine capacity utilization the tool measurement (tool set-up) generally takes
place outside the CNC machine. For this a universal tool measuring and setup device is used. The term
universal refers here to the fact that turning and milling tools are measured with different tool holders to
define the corresponding setup values. Modern tool measuring and adjusting devices convey the calculated
data directly to the CNC control or to an other data carrier or a printer via DNC for an output.
Structure and function of a tool setup device
A tool setup device is used to define the compensation values of turning or milling tools. It is not possible to
correctly program a work part contour without the tool compensation values (see chapter on the milling radius compensation p.63 ff. or the tool nose compensation p. 65 ff).

Figure 89
Universal tool measuring and setup device
A tool setup device consists in general of four main components:

the base plate,

the compound slide rest,
the tool holder
the tool shank

In addition to this, an electronic measuring device for measuring the tool compensation values and a storage
medium for storing data, e.g. the milling radius R and length L, are available.

Tool measuring and setup

The following describes how to measure a turning tool using a tool setup device.

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The target is to precisely define the length L and the overhang Q (see figure 90) of the turning tool to be
able to give the CNC control the corresponding compensation values in X and Z.

B
L

tool set-up point

length = distance of the cutting edge tip
to the tool set-up point in Z
overhang = distance of the cutting edge tip to the
tool setup point in X

L
Figure 90
Measuring a turning tool

Clamp the turning tool to be measured in the tool shank corresponding to the current turret.
Switch on and adjust the tool measuring and setup device.
Measure the lathe tool.
Using the control desk of the tool setup device the compound slide rest is moved with the lathe tool to
be measured in X and Z (see figure 91).

Figure 91
Display crosslines of a tool setup device
with exact positioning of the tip of the turning tool
The aim of the infeed is to adjust the tool cutting edge exactly on the display crosslines of the measuring device.
Now the length L and the overhang Q of the lathe tool on the tool setup device display can be read-in.
These values correspond to the compensation values of the clamped lathe tool in X and Z.
Store the measured compensation values
The compensation values are now either manually listed for a later entry into the CNC machine, or
they are directly carried into the CNC machine through a data link between the tool set-up device and
the CNC control in DNC mode.
Declamp the turning tool
The turning tool can now be declamped from the tool set-up device to allow a further tool to be measured.

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Tool measuring and setup using the CNC machine

Direct tool measuring on the CNC lathe
Measuring the tools directly on the CNC machine tool is only customary for CNC lathes.
For direct tool measuring the work part is clamped together with the tool in any position (for instance machining a cylinder). The work part is then measured with reference to the machine zero point M. The measured
values are entered in the tool compensation register of the CNC control.
After that, the second tool is clamped, the tool slide is taken into the same position as it was for the first tool
and the machined work part contour is worked out again. The control then calculates the compensation values for the second tool based on the new actual position of the tool slide.
Direct tool measuring is time-consuming, requires however no additional investments.
Defining the deviation between target and actual value with various aids
Tool measuring using so-called zero tools on the CNC milling machine
A commonly applied method for tool measuring on CNC milling machine uses a zero tool to define the different lengths of the milling tools. The radius compensations of all tools have been defined and entered into the
CNC control in advance.
Procedure:
With the first tool, also called zero tool, an area on the clamped work part is machined. For this tool the
measured Z value is set zero.
The next tool is clamped and then moved as far as to touch the work part surface. The current Z position can
now be entered into the compensation register including its sign. Herewith the compensation values of the
tool length become the deviation values of the zero tool length.
This procedure will be repeated for all further tools.
Tool measuring on the display of a CNC lathe
In the machining room of some CNC machines there is an optical system installed on a fixed point, whose
position is known to the machine. The coordinates have been stored in the CNC control as parameters.
The tools to be measured are clamped in any position and are taken one after the other to the center of the
crosslines of the optical system using an electronic hand wheel (see figure 92). The control then calculates
without further data entry the value overhang Q as well as the length L and stores these values in the tool
compensation value register.

Figure 92

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Inside optical measuring
Advantages and disadvantages of direct tool measuring on CNC machine
Advantages

Disadvantages

increased flexibility
improved design of machine work places
reduced investment since
- tool setup devices
- complicated tool holder systems
are not needed

machine stand-still during measuring

high precision cannot be achieved

CNC exercise
Working with tool compensation values in the MTS simulation
The MTS software, just like a real CNC machine tool, allows the user to allocate one or several compensation switches to each tool. With these switches the tool compensation values of the tool are called.
Exercise:
The following work part is to be machined, including rough turning and final turning, using a left corner turning tool and the set compensation switches. The corner turning tool
T05

LEFT CORNER TOOL

CL-SDJCL-2020/L/1204 ISO30

is applied with the setting value for overhang Q and the length L to be entered in the compensation value
register D25.

It is assumed:
Setting-up the MTS simulator according to the following set-up data:
PART
CYLINDER D060.000 L082.000
MATERIAL C 45 W-Nr: 1.0503
DENSITY 007.90
MAIN SPINDLE WITH WORKPART
CHUCK KITAGAWA B-208
STEP JAW KITAGAWA-1
CHUCKING DEPTH E32.000
RIGHT SIDE OF THE PART: Z+209.500
TOOLS
T05 LEFT CORNER TOOL
CL-SDJCL-2020/R/1204 ISO30

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Procedure:
Description

Entry

1. Call CNC turning in the main menu.

F1 (Turning)

2. Select setup mode.

F3 (Setup mode)

3. Select menu for the compensation value register.

F4 (Tool data)
F2

4. Setting the additional compensation register

No. 25.

(Turret display)
Enter on the keyboard 25 using

F1 (change values) confirm.

Cutting point:

Z: +43.0
X: +60.5

Cutting radius:

R:

0.4

Size:

G:

0.0

Recessing angle:

E: 32.178

Compensation:

K:
I:

-0.4
-0.4

The quadrant Q3 is automatically set by MTS when

or the tabulator key
has been
the arrow key
actuated subsequent to the entry of the values! Only
then it is possible to accept/confirm the data.

5. Enter the data for the compensation register

No. 25.

Use the keyboard to enter the data by pressing

or
by selecting the data one by one.

6. Quit the compensation register menu.

F8 (Quit)
F8 (Quit)
F8 (Quit)

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Now the NC program BOLZEN can be simulated either in single step or in automatic run.
NC program: BOLZEN

Drawing

N010
N015
N020
N025
N030
N035
N040
N045
N050
N055
N060
N065
N070
N075
N080
N085
N090
N095
N100
N105
N110
N115
N120
N125
N130
N135
N140
N145
N150
N155

G90
G54 X+000.000 Z+207.500
F000.300 T0101 M04
G96 S0180
G92 S3000
G00 X+062.000 Z+000.000
G01 X-001.000 M08
Z+002.000
G00 X+120.000 Z+040.000 M09
F000.300 T0525 M04
G00 X+050.000 Z+002.000
G01 Z-044.800 M08
X+061.000
G00 Z+002.000
X+040.000
G01 Z-044.800
X+051.000
G00 Z+002.000
X+030.000
G01 Z-014.800
X+042.000
G00 Z+002.000
T0505 M04 F000.160
G00 X+030.000
G01 Z-015.000
X+040.000
Z-045.000
X+062.000
G00 X+120.000 Z+040.000 M05 M09
M30

Workshop
Working with tool setup devices
The students should individually define the compensation values of the tool on a real tool setup machine.
The necessary operation steps can be found in the operating manual of the applied tool setup machine.
Optical measuring of tools on the CNC machine
Direct dimension measuring using the CNC machine
The students should individually measure turning and milling tools on the CNC machine tools in workshop.
The details of this procedure are given in the chapter Tool measuring and setup using the CNC machine.
The operation steps on the CNC machine are given in the respective operation.

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2.6

Path Measuring Systems

Infeeds, position control and position adjustment of the NC axis

The CNC control invocates the travel movements of the tool or tool carriage using the NC program commands. Hereby the programmed coordinates have to be approached on the axis on a preset path (position)
using the preset speed (infeed) in highest precision.
The exact spatial position of the controllable and moving machine parts has to be constantly fed back to the
CNC control. This is done by the position sensor whose data is fed into the position control loop
(see figure 93).
On the CNC machine tool the position of the tool carriage is constantly measured. Based on the change of
time along the path, the current path position (actual value) as well as the path speed is calculated and compared with the programmed path (set value).
For instance the machining forces as well as friction and play in guidance influence the feedback loop. They
are called disturbance variables and are to be compensated by the control (CNC control).
Approximately every millisecond the control delivers a new position set value to the position feedback loop,
which the control aims for. Considering the high clock rate the control receives a new set value even before
the previous set value has been achieved. This phenomenon of the position feedback loop is based on
physical facts (i.e. too high infeed) and creates the so-called lag error.

2
5

input variable (set position

value)
output variable (actual position
value)
disturbance variables

7
3

motor
ball screw
measuring equipment

Figure 93
Position feedback loop

output value (actual position

value)

Path measuring
To define the current position of the tool carriage (actual value of the position feedback loop) there is a path
measuring system available for each travel axis of the CNC machine tool. Depending on the travel path different path measuring methods are applied.
Absolute and incremental path measuring
For absolute path measuring (see figure 94) each pitch of the binary coded measuring scale indicates the
exact numerical value. This value corresponds to an exact position of the tool slide opposite to the machine
zero point M. This means that the current tool slide position can be directly conveyed to the CNC control at
any time. The fact that the read-in area of the measuring scale has to be as large as the machining area is a
disadvantage. In connection with the binary coding this results in large, technically complicated measuring
scales.

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For incremental path measuring (see figure 95) counting pulses result from the constant change of light and
dark fields of the ruled grating during the travel movement. These pulses are constantly added or subtracted
by the CNC control. The current tool slide position is the difference of the new position to the last position.
Therefore, after the CNC control has been switched on, the tool slide has to go once to an absolute point,
the reference point, to enable the CNC control to calculate the absolute coordinates.

012345678

binary coded measuring scale

ruled grating

current tool slide position

last tool slide position

current tool slide position
tool slide on the reference point

Figure 94
absolute path measuring

Figure 95
incremental path measuring

In general, only incremental path measuring is applied in CNC machine tools due to the fact that the reference point can be gone to at any time.
In case of welding line robots, however, collisions can occur with the work parts when going to the reference
point. Therefore, absolute path measuring is required here.

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CNC exercise
Moving to the reference point
CNC turning
Procedure:
Description

Entry

1. Call CNC turning in the main menu.

F1 (turning)

2. Select setup mode.

F3 (setup mode)

3. Select go to reference point.

F2 (reference point)

Message: enter default value for the travel

axis.
4. Select the order of the travel axis.

X
Z

(first the X then the Z axis) or

(first the Z and then the X axis) confirm

The system goes to the reference point automatically on both axes.

The position can be read-in using the displayed axis
coordinates.

5. Quit the setup mode.

F8 (Quit)

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Moving to the reference point
CNC milling
Procedure:
Description

Entry

1. Call CNC milling in the main menu.

F2 (milling)

2. Select the setup mode.

F3 (setup mode)

3. Select go to reference point.

F2 (reference point)

Message: Enter default value for the travel

path.
4. Select the order of the travel axis.

(1. the X , 2. the Y then the Z axis) or

(1. the Y , 2. the X then the Z axis) or

(1. the Z , 2. the X then the Y axis).

The system goes to the reference point automatically on both axes.

The position can be read-in using the displayed axis
coordinates.

5. Quit the setup mode menu.

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Touching the turning tool on the plane surface
Procedure:
Description

Entry

1. Call CNC turning in the main menu.

F1 (turning)

2. Select setup mode.

F3 (setup mode)

3. Switch on the spindle in counterclockwise

rotation.

Use the keyboard to enter M04 and

4. Change the tool to define the work part zero

point.

Use the keyboard to enter T0404 and confirm.

5. Move the lathe tool in rapid speed so that it is

located in front of the front plane surface with
a distance of approx. 5mm to the front plane
surface.

Use the numeric keyboard to press the arrow

key together with the shift key:

confirm.

+X

+ 4

for rapid speed in -Z direction

+ 2

for rapid speed in -X direction

+Z
Further travel direction options:

+X

Pos 1

-Z

-X

Einfg

+Z

Bild

( + Z direction )

( - Z direction )

( + X direction )

( - X direction )

Entf

6. Switch the increment from 1mm to 0,1mm or

0,01 mm for further machining.

F3 (technology)
F5 (increment)
F2 (increment 0.1)

7 Move the lathe tool in negative Z direction

until it touches the plane surface of the work
part.

Now first press the arrow key on the numeric

keyboard.

ESC

F8

and then
press (Quit).

8. Quit the setup mode.

F8 (Quit)

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Touching the milling tool on the upper side
Procedure:
Description

Entry

1. Call CNC milling in the main menu.

F2 (milling)

2. Select the setup mode.

F3 (setup mode)

3. Switch on the spindle in clockwise rotation.

Enter M03 using the keyboard and

confirm.

4. Change the tool to define the work part zero

point.

Enter T0202 using the keyboard and

5. Move the tool in rapid speed to a position

approx. 5mm off the work part surface.

Use the numeric keyboard to press the arrow

key together with the shift key:

confirm.

Z
W

Pos 1

+Y

for rapid speed in - Z direction.

Bild

Further travel direction options:

6

+X

Bild

-Y

+ 2

X
+Z

-X

Ex.:

Ende

2
-Z

Einfg

Bild

Ende

8
2

( + X direction )
( - X direction )
( + Y direction )
( - Y direction )
( + Z direction )
( - Z direction )

Entf

6. Switch the increment from 1mm to 0,1mm or

0,01mm for further machining.

F3 (technology)
F5 (increment)
F2 (increment 0.1)

7 Move the tool in negative Z direction until it

touches the surface of the work part.

2
ESC

F8

Now press the arrow key on the numeric keyboard,

then press
and
(Quit).

8. Quit the setup mode.

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Touching the milling tool on the lateral side
Procedure:
Description

Entry

1. Call CNC milling in the main menu.

F2 (milling)

2. Select the setup mode.

F3 (setup mode)

3. Switch on the spindle in clockwise rotation.

Enter M03 using the keyboard and

confirm.

4. Change the tool to define the work part zero

point.

Enter T0202 using the keyboard and

5. Take the tool in rapid speed to the new resetting position approx. 5mm off the side surface.

Press the corresponding arrow key on the

numeric keyboard

confirm.

1) in -X direction

together with the shift key:

+ 4

for rapid speed in - X direction

2) in -Z direction
+ 2

X
+Z

Pos 1

-X

+Y

Bild

Further travel direction options:

+X

Bild

-Y

for rapid speed in -Z direction

Ende

2
-Z

Einfg

Bild

Ende

8
2

( + X direction )
( - X direction )
( + Y direction )
( - Y direction )
( + Z direction )
( - Z direction )

Entf

6. Switch the increment from 1mm to 0,1mm or

0,01mm for further machining.

F3 (technology)
F5 (increment)
F2 (increment 0.1)

7. Move the tool in positive X direction until it

touches the left side of the work part.

Now press the arrow key on the numeric keyboard,

ESC

then press

F8

and
(return) key.

8. Quit the Setup mode.

F8 (Quit)

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Touching the milling tool on the front side
Procedure:
Description

Entry

1. Call CNC milling in the main menu.

F2 (milling)

2. Select the setup mode.

F3 (Setup mode)

3. Switch on the spindle in clockwise rotation.

Type M03 using the keyboard and

confirm.

4. Change the tool to define the work part zero

point.

Type T0202 using the keyboard and

5. Take the tool in rapid speed to the new resetting position approx. 5mm off the front side.

Use the numeric keyboard to press the arrow

key together with the shift key:

1) in +X direction
+ 6

confirm.

2) in -Y direction

1 for rapid speed in -Y direction

+ En
de
3) in -Z direction

X
+Z

Pos 1

-X

+Y

+X

-Y

Ende

2
-Z

Einfg

Bild

for rapid speed in -Z

Further travel direction options:

6

Bild

+ 2

Bild

for rapid speed in +X direction

Ende

8
2

( + X direction )
( - X direction )
( + Y direction )
( - Y direction )
( + Z direction )
( - Z direction )

Entf

6. Switch the increment from 1mm to 0,1mm or

0,01mm for further machining.

F3 (Technology)
F5 (Increment)
F2 (Increment 0.1)

7. Take the tool in positive Y direction until it

touches the front of the work part.

Press the arrow key on the numeric keyboard.

Bild

ESC

Then press
and

F8 (Quit) key.
8. Quit the Setup mode.

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5.

Control test Basic Geometry

1.

Indicate the possible travel movements for turning in a coordinate system.

1.

Indicate the possible travel movements for milling in a coordinate system.

1.

For which applications is it reasonable to use the polar coordinate system in milling?

1.

Give two examples of control types on CNC milling machines.

1.

Which types of 2 D path controls can be differentiated on CNC milling machines?

1.

How can the different possibilities of 2 D path control be explained?

1.

Explain the zero and reference point on numerically controlled machine tools.

1.

Where should the work part zero point, which is set by the user, be positioned?

1.

What are the advantages of absolute programming?

1.

Why is incremental programming sometimes unavoidable?

1.

Incrementally dimension the sketched milling work part with absolute dimensions:

12.

What is the main difference between the principle of a control chain and a feedback loop?

12.

Discuss the control as an operation.

12.

Why is it necessary to have milling radius compensation in milling?

12.

Which values are considered by the tool compensation in milling?

12.

Why is it necessary to have cutting radius compensation in turning?

12.

Which values are considered by the tool compensation in turning?

12.

What is the significance of the working quadrants of the turning tool edge?

12.

List the different types of tool dimensioning.

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6.

3 Technological Basics for CNC Machining

3.1

CNC tool systems for turning and milling

CNC machine tools use special NC tools. These tools meet the following criteria:
better milling performance with high stand still times
short changing and setup times to enable economical production of small production lots
standardized and rationalized tools
improved tool management and flexible production
The NC tools are either a single tool or they are put together of the cutter edge holder and tool holder. To
enable a quick tool change and to secure good exchangeability of the NC tools the tool carriers are standardized.

Tool carriers
Special forms have been stablished for tool carriers. They differ from each other in their machining method.
For turning tools a straight shank with toothing (see figure 96) is mostly used and for cutting tools a steepangle taper (see figure 97). Both tool shanks can be used with automatic and/or quick manual tool change.

Figure 96
Straight shank with toothing

Figure 97
Steep-angle taper

Tool holder
Many lathe and milling tools are a combination of several components. Indexable inserts are used which are
attached, for example with clamping devices (see figure 98).

1
Clamping finger

indexable insert

pin

Insert

indexable insert carrier

Figure 98
Example of a clamping system

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The main components of a modern lathe tool are the clamping holder or indexable insert holder, the indexable insert and the clamping device. The indexable inserts are placed in the holder which has two supporting
edges and an insert. The insert serves to convey larger cutting forces and to protect the holder from damage
in case of an eventual breach in the indexable insert.
Since the indexable inserts are exposed to the cutting forces of the lathe and to the centrifugal forces of the
milling machine, there is the danger of loosening supports or slipping tools. Clamping and screw clamping
fixtures are therefore used to accurately fix and position the indexable inserts.
The clamping fixtures and the indexable inserts are standardized to a large extent.

Tungsten carbide indexable inserts

In CNC technology indexable inserts are increasingly being used since they achieve very high stand-still
times and are easy to change. Indexable inserts have several cutting edges. This allows the insert to be
rotated or turned when one edge of the insert becomes dull.
Indexable inserts are made either of tungsten carbide or cutting ceramics (see chapter cutting materials
pp. 88 ff.).They are sintered. This production method, in which metal powder is first pressed and then heat
treated, enables economical indexable inserts to be manufactured in various designs (see figure 99).

Figure 99
Forms of indexable inserts
Indexable inserts are classified according to their basic form, angles, cutting edges, tolerance class as well
as their clamping system and main dimensions. Based on a norm sheet ISO 1832 / DIN-4987 the following
example (see figure 100) shows the norm title of an indexable insert.

indexable insert ISO 1832 - ECMT 09 T3 08 FR - P10

1)
2)
3)
4)
5)
6)
7)
8)
9)
10)

Designation

Example

Norm main number

basic form
normal-clearance angle
tolerance class
face and clamping characteristics
insert size
insert thickness
cutting edge radius
cutting edge characteristics
cutting direction
cutting edge material

DIN 4987
E = orthorhombic 75
C = 7
M
T = counterborehole
60on face
side length: 9,52 mm
s = 3,97mm
r = 0,8mm
F = sharp edged
R = right
tungsten carbide P10

Figure 100
Description of an indexable insert

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3.2

Structure and use of lathe tools for CNC machining

Types of lathe tools and the corresponding ISO designation

The lathe tools, also called cutting tools, can be classified according to the following criteria:
according to the cutting material:
cutting tool edges out of high-speed steel,
cutting tool edges out of tungsten carbide,
cutting tool edges out of ceramics or
cutting tool edges out of diamond;
according to the location of the application area:
cutting tool for outer machining or
cutting tool for inner machining;
according to their form:
straight cutting tool,
offset cutting tool,
cranked cutting tool,
sharp cutting tool or
wide cutting tool;
according to the location of the major cutting edge
left cutting tool,
right cutting tool or
neutral cutting tool;
according to the application purpose e.g.:
recessing tool,
corner cutting tool or
tapping tool.
Details of the cutting tools are described in the corresponding norms (ISO 243, 504 or 514).
A selection of commonly used cutting tools is listed in the below table 101 according to their application area.
These cutting tools are stored with all their dimensions in the tool management of the MTS turning simulator.
They can be called from there for simulaton on the MTS turning simulator.

outer

inner

cutting tool
corner cutting tool
(right cutting)
corner cutting tool (left
cutting)
copying lathe tool
outer cutting tool (round
cutting edge)
inner cutting tool (preaxial)
inner cutting tool
(postaxial)

thread cutting tool

outer tapping tool (right
cutting)
outer tapping tool (left cutting)

recessing tool
outer recessing tool

inner recessing tool

(preaxial)
inner tapping tool (postaxial) inner recessing tool
(postaxial)
axial recessing tool

boring tool

inner tapping tool (preaxial)

axial

centering drill
twist drill
indexable insert
reamer

Figure 101
Classification of cutting tools

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Cutting materials
Hard metals are primarily used as the cutting material for lathe tools. For certain types of cutting high-speed
steels (HSS steels) are used. Their cutting surface is usually coated. In special cases ceramic materials
(cutting ceramics) are used as indexable inserts and in some cases industrial diamonds as well.
High-speed steels
High-speed steel is a high-alloyed tool steel (HSS = high-speed steel). It is highly durable and can therefore
easily take impact loads. The cutting speed is considerable lower compared with hard metals and cutting
ceramics.
It is used for tools whose form, for instance boring and reaming tools, do not allow the use of indexable inserts or machining of thermoplastic plastics and light alloys. HSS tools are frequently coated with a hard coat
of titanium nitrid TiN. This extremely hard, golden colored coating increases the abrasion resistance and
allows higher cutting speeds.
Hard metals
Hard metals are materials which are cintered as indexable inserts using hardening materials and a binding
agent. In most cases the hardening materials are tungsten, titanium or tantalum carbide. Cobalt is used as a
binding agent.
Hard metals are considerably harder than HSS steels. They are extremely abrasion-resistent and allow very
high working temperatures. They do, however, tolerate far less temperature fluctuation and impact exposure
than the HSS steels.
Hard metals can be classified according to the main cutting groups and cutting application groups.
Main cutting
groups

Cutting application groups

Abbreviation

Materials

P01

P
blue

P10
P20
P30
P40

K
red

steel
cast steel
malleable cast iron short
shipping

M10

steel

M20
M30
M40

hard steel
cast iron
non-iron metals

K01
K10
K20

hard cast iron

cast iron
malleable cast iron short
shipping
plastics
wood

K30
K40

high abrasion resistance

high cutting speed

precision machining,
high cutting speed

P50

M
yellow

Applications
superfinish turning,
high surface quality

medium cutting speed

rough cutting
interrupted cutting
precision machining
high cutting speed

high hardness
high infeeds
high abrasion resistance
high cutting speed

medium cutting speed

rough cutting
interrupted cutting
precision machining

high hardness
high infeeds
high abrasion resistance
high cutting speed

rough cutting
interrupted cutting

high hardness
high infeeds

Figure 102
Application areas of hard metals
The abrasion resistance of hard metals can be increased with a corresponding coating. As coating materials
titanium nitrid, titanium carbide and aluminium oxide are applied in several layers in vacuum in a temperature of 1000C
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Cutting ceramics
Ceramic materials which are even harder than hard metals are used as cutting ceramics. Cutting ceramics
allow a working temperature up to 1200C. They are very brittle and sensitive to fluctuating cutting forces.
Cutting ceramics are manufactured as indexable inserts and are clamped in the tool holder just like hard
metals.
Cutting ceramics are applied for cutting with constant cutting conditions, without coolant application. The
cutting speed is higher than that of hard metals. They are ideal for cutting iron materials since they do not
create built-up edges. They, however, cannot be used for aluminium alloys.
The applicable cutting ceramics can be classified in the three following groups:
oxide ceramics
mixed ceramics
nitrid ceramics
Cutting ceramics alloys of pure Al2O3 are called oxide ceramics. They have no metallic binding agent. They
are especially ideal for cutting iron alloys since they are highly abrasion resistant to them.
In case of mixed ceramics hard materials are added to the Al2O3 such as titanium carbide. Mixed ceramics
are used for finishing gray-cast iron or steel as well as for cutting hardened iron materials.
Nitrid ceramics are based on silicium nitrid Si3N4. This non-oxide cutting material is extremely brittle and
sensitive to temperature fluctuations. High abrasion in cutting steel is a disadvantage. The nitrid ceramics is
applied for machining gray cast iron.

Diamond
Diamands are harder than all other materials. They are extremely sensitive to impact, however create no
built-up edges during machining.
They are used for cutting non-iron materials and their alloys as well as for composite materials (GRP), hard
metal, gas and ceramics.
Diamands cannot be applied for machining steel. Here they have very high abrasion since the carbon atoms
of diamonds are given off to the iron (diffusion abrasion).

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Cutting edge geometry

Each machining process requires its cutting edge geometry. Only this can guarantee ideal production times,
long cutting-edge life and high surface quality. The angles of the tool cutting edge play a decisive role here
(vgl. Abbildung 103).

clearance angle

wedge angle

angle of rake

angle of point

angle of inclination

adjustment angle

r
Figure 103
Cutting geometries in turning
Clearance angle : The clearance angle reduces friction and heating up of the tool edge and the work
part.
Wedge angle :

The size of the wedge angle depends on the hardness and toughness of the work
part. The smaller the wedge angle the lighter the cutting, however, the larger the edge
abrasion and the shorter the cutting edge life.

Angle of rake :

The angle of rake has an influence on chip building and cutting forces. The larger the
angle of rake the smaller the cutting force, however, cutting edge breach and abrasion
are increased because of total decarburization. Solid, medium hard materials require
an angle of rake of approx. 10. Hard and brittle materials require a small or even a
negative angle of rake.

Adjustment angle : In the first place the entering angle has an influence on infeed force, on the forces
against the work part clamping and work part as well as on the cutting width and
thickness. In case of solid clamping situation an entering angle of 30 to 60 is selected. Only for thin shafts or right angled offsets 90 is selected for the adjustment
angle.
Inclination angle : For finishing a positive, for roughing a negative inclination angle is frequently selected.
When negative angles of rake are used the cutting edge tip is exposed to less stress.
When positive inclination angle is used the chip flow is directed away from the work
part.
Angle of point :

90

The larger the angle of point the better the stability of the tool edge and the better the
heat removal.

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Abrasion and cutting edge

During cutting the tools are subject to wear, also called abrasion. This is due to the cutting friction, the diffusion in high temperatures as well as to the chip flow.
Due to the high temperature of the tool cutting edge small work part particles can be welded on to the tool
face. A built-up edge can be created (see figure 105).

Figure 104
New lathe tool

Figure 105
Built-up edge

During the cutting process material particles continuously break off from the lathe tool. Correspondingly, the
geometry of the tool cutting edge changes with the time. Depending on the choice of the tool cutting edge
angle the abrasion can take different forms (see figure 106 to 109).

Figure 106
Open cutting edge wear

Figure 107
Chip surface wear

Figure 108
Crater wear

Figure 109
Edge rounding

Due to tool wear the surface quality of the machining as well as the dimensional stability of the work part are
reduced. As soon as the required surface quality or dimensional stability are not maintained any more the
cutting-edge life of the tool has been reached.
Cutting-edge life is the time during which the cutting edge is in operation and the following requirements are
met:
Generation of required surface quality
Dimensional stability within the required tolerances
When cutting-edge life has been reached it is necessary to change the tool or to resharpen it. When using
indexable inserts the insert can be turned or changed. Prior to using the tool again tool dimensioning has to
be done.

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Cutting value
Turning is a cutting operation with a circular cutting movement and an infeed which can be in any relation to
the cutting direction. In most cases the cutting movement is made by the rotation of the work part and the
infeed of the tool (see figure 110). The
cutting speed vc and the
infeed speed vf
overlap and result in a continuous cutting process.
Cutting speed vc
Cutting speed is the movement between the tool and the work part causing only a single chip removal during
one rotation without infeed. The symbol for cutting speed is vc and is indicated in m/min.
In general the speed indicates the traversed path s within a certain period of time t. It is calculated as follows:

v=

s
t

in path/time

The traversed path s for a work part rotation can be generated in turning using the work part diameter d on
the cutting edge tip and the constant :

s = *d

in m

The starting point for the calculation of the cutting speed is now a time unit t = 1 min. The result is herewith
cutting speed vc :

vc =

*d
t

in m/min

The number or work part rotations in one minute is indicated as a number of rotations n (in rotations per
minute):

t=

1
n

in min

As a result the following formula is achieved for the calculation of the cutting speed vc:

vc = * d * n

in m/min

vc
n

vf

number of rotations

in U/min

vf

infeed speed

in mm/

vc

cutting speed

in m/min

vc

=*d*n

Figure 110
Cutting values in turning

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Infeed speed vf
Together with the cutting movement Infeed allows a continuous chip removal during several rotations. The
infeed speed vf is indicated in mm/min.
Often the infeed f is given in mm per rotation as well. The infeed f is the path the lathe tool makes in the infeed fixture during one spindle rotation. The following relation exists between these two forms:

vf = n *f

in mm / min

For each cutting process a certain infeed is required. Together with the spindle number of rotations n it defines the machining time for each travel path. Its value has a decisive influence on an ideal cutting force and
on the sufrace quality of the machined surface.
Chip size
The chip diameter A describes the material diameter, which is cut in one cut (see figure 111). Its size largely
defines the cutting force created.
Without considering the cutting edge radius, the chip diameter A is the product of the cutting depth a and
infeed f. It is given in mm2. The cutting depth a, i.e. the depth of the tool cutting, is the value to be fed in step
by step.

A = a *f

in mm2

Using the entering angle it is possible to calculate the width b and the thickness h of the chip.

h = f *sin
b=

in mm

a
sin

in mm

cutting depth

adjustment angle

infeed per rotation

chipping width

chipping thickness

Figure 111
Chipping sizes
The following cutting values have to be selected always considering the specific appliction, and the lathe is
to be correspondigly set up.
cutting speed vc
infeed f
cutting depth a
This requires extensive experience. As a support standard value tables are therefore available indicating the
cutting values regarding the material to be cut and the cutting edge material.

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Examples: Calculating technological values for CNC machining

Cutting speed vc

vc = * d * n

in m/min

1. Example:
What is the cutting speed in plain turning if the cutting is done with a 60 mm diameter and number of rotations of 1500 1/mm.
datum:

d = 60 mm
n = 1500 1/min

unknown:

vc in m/min

valid :

vc = * d * n
vc = * 0,06 m 1500 1 min

solution:

vc = 283

m
min

2. Example:
How many number of rotations are required if the smallest diameter to be machined on the same work
part with this cutting speed is 12mm?

datum:

vc = 283 m/min
d = 12 mm

unknown:

n in 1/min

valid :

vc = *d * n

solution:

94

or

n=

vc
*d

n=

283m
* min* 0,012m

n = 7511 1 min

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Technological Basics for CNC Machining

3.3

Structure and application of milling tools for CNC machining

Milling and milling operations

Milling is a cutting operation with a geometrically specified cutting edge in which the tool makes the rotating
main movement, and the feed as well as the infeed movement are generally made by the work part
(see figure 112).

rotation of the milling tool

work part feed

2
Figure 112
Milling
Milling operations are classified according to the position of the milling axis towards the work part, i.e. between face milling and peripheral milling.
In case of face milling the milling axis is located vertically to the machining area (see figure 113). The work
part surface is machined by the main cutting edges. Also, the work part surface is further finished with auxiliary cutting edges.
In case of peripheral milling the milling axis is located parallel to the machining axis (see figure 114). The
milling tool machines the work part surface with the main cutting edges (the peripheral cutting edges). Furthermore, a difference is made between synchronous and conventional milling.

Figure 113
Face milling

Figure 114
Plain-milling
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Additionally, synchronous and conventional milling (see figure 115 and 116) are differentiated.
In case of conventional milling the rotation direction of the milling tool is opposite to the feed direction of
the work part (see figure 115).
The milling tool chamfer edge starts with chip thickness zero. The milling tool cutting edge slides in front of
the chip chamfer edge until the required minimum chip thickness has been achieved for chip building.
The friction created by sliding results in high abrasion of the tool flanks and in hardening of the work part
surface. This leads to a shorter cutting edge life of the tool compared with synchronous milling.
Conventional milling is recommended to be used for machining work parts with hard surfaces (cast material)
since the hard surface is cut through from inside.
For synchronous milling the rotation direction of the milling tool and the feed movement of the work part
are parallel (see figure 116).
The tooth of the milling cutter immediately penetrates into the work part. Since the milling tool cutting edge is
exposed to impact forces the feed drive needs to be playfree. Several cutters should always be in operation.
The surface quality is flatter and duller when synchronous milling is used. Compared with conventional milling higher feed movements and cutting speeds within the same cutting edge life can be achieved.

Work part feed

Figure 115
Conventional milling

Work part feed

Figure 116
Synchronous milling

The tool cutting edge is subject to constant cutting interruptions in all milling operations. Due to the cutting
path comma-form chips are cut with a changing chip thickness (see figure 117).

cutting chip

Figure 117
Milling plan

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Types of milling tools

Milling tools can be classified according to the following criteria:
according to the type of the material to be cut in
tool type N (for normal steel),
tool type H (for soft, long-chipping materials),
tool type W (for hard, short-chipping materials),
according to the cutting material in
cutter with cutting edge of high-speed steel tool,
cutter with cutting edge of hardmetal,
cutter with cutting edge of ceramics or
cutter with cutting edge of diamond;
according to the type of the tool carrier
shell mill or;
end mill;
according to the milling form, for instance in
T slot cutter;
face milling cutter;
side mill or
form cutter;
according to the form of the milling tool tooth in
pointed teeth cutter or
back-off teeth cutter
Details of milling tools are given in the manufacturers catalogues and in the corresponding norm sheets.
A selection of common milling tools are shown below, classified according to their application field:
end mill
standard types

plain milling cutter

face milling cutter
counterbore

drills

drill

screw tap

indexable insert drill

reamer

stepped drill
radius form cutter
special forms
T slot mill
Figure 118
Classification of milling tools

angle cutter (form A)

concave cutter

angle cutter (form B)

side mill

The above milling tools including all their data are included in the MTS CNC milling simulator and can be
called by the user. These tools can be modified or extended to meet the users demand.
End mill / Slot drill

T-slot cutter

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Shell end mill

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Basic Geometry for CNC Machining

98

Face end cutter

Radius cutter

Angular cutter (type A)

Angular cutter (type B)

Tap drill

Drill

Step drill

Reversible tip drill

Reamer

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Technological Basics for CNC Machining

Countersink

Concave cutter

Side milling cutter

Cutting edge materials

In milling, the cutting edges are not in operation all the time. The milling cut is a discontinuous cut with a
changing cutting diameter. Therefore, the cutting edge is exposed to high impact forces. The cutting edge
material has to be tough and heat resistant.
Today, mostly indexable inserts made of hardmetal are used as milling tools. Only in case of small milling
machines soldered hardmetal cutting edges made of high-speed steel or coated high-speed steel tools are
used.

High-speed steel
High-speed steel is a high-alloyed tool steel. Due to its high toughness it is able to withstand impact forces.
The cutting speed is considerably lower compared with hardmetals or cutting ceramics.
It is used for drills, small milling tools and tools with a complicated form (profile cutter). Cutting tools made of
high-speed steel are used for cutting less tough materials, for profile cutting and for cutting with low cutting
speed.

Hardmetals
Hardmetals are materials which are sintered in form of indexable inserts by using hardening materials and
a binding agent. By increasing the binding agent proportion in hardmetal production it is possible to increase
the hardness of the material as required. The abrasion resistance of hardmetals can be increased by a titanium nitrid, titanium carbide or aluminium oxide coat.
Hardmetal cutting plates are soldered on the milling tool or screwed on it in form of indexable inserts.

Cutting ceramics
Cutting ceramics are rarely used for milling because of their brittleness and sensitivity to fluctuating cutting
forces. However, because of the high hardness aluminium oxide is used for machining hardcast materials
and hardened steel as well as silicon nitrid for grey cast. Both of these materials are used for cutting without
coolant application.
Like hardmetal, cutting ceramics are manufactured to be used in form of indexable inserts.

Diamond
Cutting plates made of polycrystalline diamonds are used to cut non-iron metals and plastics. The extraordinary hardness of the diamonds enables double as high cutting speeds with ten times longer cutting edge
lifes are achieved as compared with hardmetals.
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Diamonds cannot be used for cutting steel. Here they are exposed to high abrasion since the carbon atoms
of the diamond are given off to iron atoms (diffusion abrasion).

Cutting geometry

fz

Unlike lathe tools milling tools have several cutting edges (see figure 119). Typical of milling is the discontinuous cut as each cutting edge works only for a time.

diameter of the milling tool

z:

number of teeth

fz:

feed per tooth

ae:

entering point

S:

entering angle

0:

clearance angle

0:

wedge angle

0:

angle of rake

S:

angle of twist of the edges

ap:

cutting width

ae

d:

ap

0
s
Figure 119
Cutting geometry milling

Clearance angle : The clearance angle is to reduce the friction and consequently the heating of the cutting edge and of the work part.
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Wedge angle :

The size of the wedge angle depends on the hardness of the work part. The smaller
the wedge angle the lighter the cutting, however the greater the cutting abrasion and
the shorter the cutting edge life.

Angle of rake :

The angle of rake influences cutting chip formation and cutting forces. The larger the
angle of rake of the chip the smaller the cutting force, however the risk to breach as
well as abrasion of the cutting edge are increased due to erosion.

Entering angle S:

The entering angle indicates the machining path of the tool with reference to the circumference. It depend on the size of the entering point.

Inclination angle : The size of the inclination angle influences the process of chamfering and cutting-out.
Since the inclined cutting edges are consecutively engaged the milling tool runs with
increased quietness.

The configuration of the adjustment angle (see figure 120) is very important in milling. The adjustment angle
is the angle between the main cutting edge and the surface to be cut.
:

adjustment angle

Figure 120
Adjustment angle of milling tools
If the adjustment angle is 90, the highest radial forces are exposed. This angle value is therefore only recommended for right-angled contours. For most milling works an adjustment angle of 75 or 60 is ideal. For
long cutting materials the adjustment angle of = 45 is ideal.
If hardmetal indexable inserts are mostly used, then two cutting angles are available. They can be measured
using the reference lines:
radial cutting angle (reference line through the centerof the milling tool)
axial cutting angle (reference line parallel to milling axis)
In case of plain milling with a plain milling cutter the following combinations are mostly used (see figure 121):
double positive geometry
double negative geometry
positive-negative geometry

1
double positive geometry

double negative geometry

1
positive-negative geometry

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radial cutting angle
Figure 121
Cutting geometries on plain milling cutter

axial cutting angle

In case of double positive geometry only light driving power is required due to small cutting forces. It is therefore possible to machine thin-walled work parts as well. The spiral-form chips drop off from the tool easily. In
case of materials which tend to form built-up edge, for instance aluminium, this geometry is recommended.
Double negative geometry is used for machining hard steels and grey cast as well as for roughing. The high
cutting forces created hereby require strong driving power and high stability of the machine. Due to the geometry the chips curl on the tool. In case of long-chipping materials this can lead to a chip jam.
Positive-negative geometry makes large feeds and big cutting depths possible since the negative radial angle of rake contributes to high breaking strength of the indexable insert. Here the chipping is ideal since the
chips flow off from the tool. Tools with a positive-negative geometry are therefore applied for various situations.

Cutting values
Milling is a cutting operation with a rotating tool, whereby the cutting edges are not in operation all the time.
The cutting movement is caused by the rotation of the tool. Feed direction and cutting direction do not depend on each other. It is realized either by the tool or by the work part or by both of them (see figure 122).
The
cutting speed vc and the
feed speed vf
overlap each other and results in a continuous cutting operation.
Cutting speed vc
The cutting movement is the movement between the tool and the work part, generating only one nonrecurrent chip cut during one rotation without a feed movement. Cutting speed corresponds to circumferential speed of the milling tool on the current cutting edge. It is expressed as vc and m/min. Under consideration of the number of rotations of the spindle n the following formula is received

vc = * d * n

in m/min

The cutting speed of a cutting tool depends on the number of the rotations. The direction constantly changes
however during cutting operation (see figure 122

vc
vf

vc

vc

vc

number of rotation

vf

feed speed

vc

cutting speed

diameter of the cutting tool

vc

Figure 122
Cutting values for milling
Feed speed vf

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The feed movement together with the cutting movement enable a constant chip removal during several rotations. In milling, the feed can be indicated in three ways:
feed speed vf
feed per tooth fz
feed per milling rotation f

in mm / min
in mm
in mm

The calculation of the feed speed vf is based on the feed fz , i.e. the feed path per milling tooth. Under consideration ot the number of rotations n and the number or teeth z the formula is as follows:

v f = fz * n * z

in mm / min

The feed speed can be expressed with the following formula as well with reference to the feed per milling
rotation.

vf = f *n

in mm / min

Consequently, the following equivalence is valid:

v f = f * n = fz * n * z

in mm / min

Cutting width
Unlike in turning, a nonuniform chip is cut in milling (see figure 123). The average cutting thickness hm is
used as reference.

fz
1

actual chip
fz:

feed per tooth

h m:

average cutting thickness

hm
Figure 123
Cutting thickness
In plain milling, the cutting width ap is the penetration width of the tool into the work part. The working engagement ae is measured on an imagined plane of the working plane. The cutting and feed direction are
located on the working plane (see figure 124).

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ap

ae

ae

ap

working plane

ap: cutting plane

ae: entering point

ap: cutting depth

ae: entering point

Figure 124
Operating variables in milling
In face milling, ap is the cutting depth measured vertically to the working plane. The working engagement ap
is identical with the width of the milled surface.
The following cutting values must be selected case by case depending on the application and then entered
into the milling machine:

number of rotations n
feed f
working engagement ae
cutting depth or cutting width ap

This requires extensive experience. As a support standard value tables are therefore available containing
cutting values regarding the material to be cut and to the cutting edge material.

Calculation examples of technological values for CNC machining

Cutting speed vc

vc = * d * n

in m/min

Feed speed vf

v f = f * n = fz * n * z

in mm / min

1. Example:
Calculate the cutting speed for milling if the milling tool diameter d = 50 mm and the
number of rotations n = 520 1/min.
known:

d = 50 mm
n = 520 1/min

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unknown:

vc in m/min

it applies :

vc = *d * n
vc = * 0,05 m 520 1 min

solution:

vc 82

m
min

2. Example:
Calculate the number of rotations n of an end mill with a diameter of = 12 mm and cutting
speed of vc = 120m/min.
known:

d = 12 mm
vc = 120 m/min

unknown:

n in 1/min

it applies :

vc = *d * n

solution:

, or

n=

vc
*d

n=

120m
* min* 0,012m

n = 3183 1 min

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3. Example:
In plain milling with a face milling cutter a cutting speed of vc = 180 m/min has been scheduled
and the number of rotations should not exceed 400 1/min. What is the maximum diameter d of
the face milling cutter so that these values are not exceeded?
known:

n = 400 1/min
vc = 180 m/min

unknown:

d in mm

it applies :

vc = *d * n

Solution:

106

, or

d=

vc
*n

d=

180000mm * min
* min* 400

d = 143mm

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Technological Basics for CNC Machining

3.4

Calculation of technological data for CNC machining

Calculation examples of technological data for CNC turning

1. Example:

25

45

The cutting speed for roughing is vcv = 280 m/min and

for finishing vcf = 400 m/min.

70

On a CNC-lathe the sketched bolt is to be roughed as

well as finished in four cuts with cutting depths of 6; 6; 5
and 5 mm and a finishing allowance of 0,5 mm.

Calculate the number of rotations for each cut.

20
50
60

Calculating the number of rotations for roughing (Cut 1-4) and for finishing (Cut 5-6)
datum:

vcv = 280 m/min

vcf = 400 m/min

unknown:

n in 1/min

valid :

n=

vc
*d

1. Cut
= 58mm

2. Cut
vcv = 280 m/min

280m
* min* 0,058m
n1 = 1537 1 min

n1 =

3. Cut
= 36mm

vcv = 280 m/min

280m
* min* 0,036m
n 3 = 2476 1 min
5. Cut

280m
* min* 0,046m
n2 = 1938 1min
n2 =

= 26mm

vcv = 280 m/min

280m
* min* 0,026m
n4 = 3428 1min
n4 =

6. Cut
vcf = 400 m/min

400m
* min* 0,025m
n5 = 5393 1 min
n5 =

vcv = 280 m/min

4. Cut

n3 =

= 25 mm

= 46mm

= 45 mm

vcf = 400 m/min

400m
* min* 0,045m
n6 = 2830 1min
n6 =

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2. Example:

25

45

Because of the various specified roughness heights the

45 will be finished with a feed of ff1 = 0.07 mm and all
other surfaces with a feed of ff2 = 0.12 mm.

70

On a CNC-lathe the sketched bolt is to be roughed in

four cuts with cutting depths of 6; 6; 5 and 5 mm, a feed
of fv = 0,2 mm and a finishing allowance of 0,5 mm.

The lengths of the approach and retreat movements will

each be programmed with 2 mm.
20

The machining time for roughing thuv and for finishing thuf
as well as well as the entire machining time thu are to be
calculated.

50
60

Calculating the machining time for roughing thuv and for finishing thuf
The machining time for turning is calculated with the following formula:

th =

L *i
n *f

in min

The variables are:

L
i
n
f

Feed Path
Number of Cuts
Number of Rotations
Feed per Rotation

The feed path L is calculated from the path in which the cutting edge is operating (length l = feed motion in Z and X !) and possible approach / withdrawal paths (length la or lu) that are traveled in the feed.
The following feed paths result for each cut with consideration to 2mm for the approach / withdrawal
paths:
1.
1.
1.
1.
1.
1.

Cut
Cut
Cut
Cut
Cut
Cut
datum:

L = l + la + lu = 50mm + 6mm + 2mm + 2mm = 60mm

L = l + la + lu = 50mm + 12mm + 2mm + 2mm = 66mm
L = l + la + lu = 20mm + 5mm + 2mm + 2mm = 29mm
L = l + la + lu = 20mm + 10mm + 2mm + 2mm = 34mm
L = l + la + lu = 20mm + 1mm + 2mm + 2mm = 25mm
L = l + la + lu = 30mm + 12mm + 2mm + 2mm = 46mm
L = Feed Path
i =1

108

unknown:

th in min

valid :

th =

L *i
n *f

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Technological Basics for CNC Machining

Calculating the machining time for preturning thuv
2. Cut

1. Cut
L = 60mm

fv= 0.2 mm

n= 1537 1/min

L = 66mm

L *i
n *f
60mm * 1 min
th =
1537 * 0,2mm
t h = 0,195 min

n= 1938 1/min

L *i
n *f
66mm * 1 min
th =
1938 * 0,2mm
t h = 0,172 min

th =

th =

4. Cut

3. Cut
L = 29mm

fv= 0.2 mm

fv= 0.2 mm

n= 2476 1/min

L = 34mm

L *i
n *f
29mm * 1 min
th =
2476 * 0,2mm
t h = 0,059 min

fv= 0.2 mm

n= 3428 1/min

L *i
n *f
34mm * 1 min
th =
3428 * 0,2mm
t h = 0,050 min

th =

th =

t huv = 0,195 min+ 0,172 min+ 0,059 min+ 0,050 min

t huv = 0,476 min
Calculating the machining time thuf f for finishing
6. Cut

5. Cut
L = 25mm

fv= 0.12 mm

n= 5393 1/min

L = 46mm

L *i
n *f
25mm *1 min
th =
5393 * 0,12mm
t h = 0,039 min
th =

fv= 0.07 mm

n= 2830 1/min

L *i
n *f
46mm * 1 min
th =
2830 * 0,07mm
t h = 0,232 min
th =

t huf = 0,039 min+ 0,232 min

t huf = 0,271 min
Calculating the entire machining time thug

t hug = t huv + t huf

t hug = 0,476 min+ 0,271 min
t hug = 0,747 min
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Basic Geometry for CNC Machining

3. Example:

25

45

Because of the various specified roughness heights the

25 will be finish turned with a feed of ff1 = 0.07 mm
and all other surfaces with a feed of ff2 = 0.12 mm.

70

On a CNC-lathe the sketched bolt is to be preturned in

four cuts with cutting depths of 6; 6; 5 and 5 mm and
with a feed of fv = 0,2 mm.

The cutting speed for preturning is vcv =280 m/min and

for finishing vcf =400 m/min.
20

The cutting edge curve for the preturning tool is rv = 0.8

mm and for the finishing tool rf = 0.4 mm.

50

The attained roughness height are to be calculated.

60

Calculating the attained roughness heights Rt

The roughness height reached by turning is calculated with the following formula:

Rt =

f2
8* r

in mm

The variables are:

f
r

Feed per Rotation

Cutting Edge Radius

datum:

f = 0.07 mm
r = 0.4 mm

datum:

f = 0.12 mm
r = 0.8 mm

unknown:

Rt in mm

unknown:

Rt in mm

1. Calculating the roughness height Rt1.6 for 2. Calculating the roughness height Rt 6.3 for
the other surfaces
the surface 45

f 2 mm2
= mm

8 r 1 mm

2
0. 07
=
8 0. 4
0. 0049
=
3. 2

Rt1.6 =

Rt 6.3 =

Rt1.6

Rt 6.3 =

Rt1.6

Rt1.6 = 0,00153 mm

110

f2
8r

mm2

1 mm = mm

0.12 2
8 0.8
0. 0144
Rt 6.3 =
8 0. 8
0. 0144
Rt 6.3 =
mm
6. 4
Rt 6.3 = 0,00225 mm

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Technological Basics for CNC Machining

Calculating the cutting forces and the motor power

For operating a CNC-machine it is important that the skilled worker understands the relevant mechanisms of
the cutting force as well as the machining performance and the drive motor's rated power and actual output..
The multitude of variables influencing the cutting forces do not allow precise calculation with a formula.
Some of these factors can only be determined in tests. This has shown, for example, that every material to
be machined has a specific cutting force value which varies according to e.g consistency (hard or soft) or
machining duration (short or long). Moreover, the tool, its cutting material and its characteristics should be
considered. Also important are the programmed operation values, such as feed, number of rotations, cutting
speed, chip thickness, chip diameter, machining mechanisms as well as the cutting edge geometry, whereby
the angle of rake and the adjustment angle are especially relevant. The cutting edge wear also plays a role.
Example:
From a 60 mm shaft the sketched peg out of Ck 45 is to be preturned and then finish turned in one
cut.
Hard-metal corner cutting tools with indexable inserts are available (0=90, r=90).
The feeds are f v = 0. 2 mm and f f = 0.1mm ,
cutting speeds are vcv=200m/min and vcf=300m/min.
Allowance after preturning is 0.5 mm.
The output of the main drive motor is =0,8.
To be calculated:
1. the cutting force Fcv,
1. the cutting performance Pcv and
1. the required power output from the drive Pab .

Datum:

turning length l = 50 mm
cutting depth ap = 4.5 mm
feed f v = 0.20 mm
cutting speed vcv=200m/min
adjustment angle r=90
output =0,8
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Basic Geometry for CNC Machining

1. The cutting force FC
The cutting force FC is calculated with the formula:

cutting force = chip diameter * specific cutting force

Fc = b h k c = a p f v k c , (with r=90)
if r is smaller than 90, then b is calculated with

b=

ap

sin r
h aus h = f sin r und
k N
kc = cm11c
,
h mm2
where kcl-1 is the kc-value based on the test conditions and mc
is a chip thickness index; kcl-1 and mc can be taken from the
following table.

Specific Cutting Force kc in N/mm by thickness of cut h in mm

Materials

However, the formula mentioned above is not sufficient for calculating the cutting force. Various compensation factors must first be taken into account. After these compensation factors are considered, the applicable
formula is as follows:

Fc = a p f v k c K o K v K sch K ver

[N ]

The compensation factors in the formula are:

K0 is the angle of rake variation factor. It is calculated from

K o = 1

o ok
66. 7

, whereby 0 is the given angle of rake and ok is the angle of rake used for de-

termining the kc-Werte.

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Kv is the cutting speed variation factor. The tabular values are only for the area between vc=90...125 m/min.
It is taken from the following Kv-vc-Diagram.

The identificated Kv - values are valid for:

Kv

Kv- vc - diagram:

v c in m/min
Example:
Ksch is the cutting edge variation factor for hard-metal to cutting ceramic, whereby hard-metal is 1 and cutting
ceramic is set between 0.9....0.95.
Kver is the cutting edge abrasion factor. It has to be estimated since the kc-values from the table only apply to
working sharp tools. For this reason a Kver-value of 1.3...1.5 is used.
Solution:
The compensation value Ksch conform with the table provisions and can be set with 1. aP and f v are given.
All other values must be determined:

kc11 N
h mc mm2
2220
kc =
0.20.14
N
kc = 2781
mm2
kc =

K o = 1

o ok

66.7
10 6
K o == 1
66.7
K o = 0,94

Selected as the compensation values:

Kver=1,3 and taken from the diagram
Kv=0,96. For the desired cutting force this yields:

Fc = a p f k c K 0 Kv Ksch Kver
Fcv = 4.5mm 0. 2 mm 2781 N / mm 2 0. 96 0. 94 1 1. 3
Fcv = 2936 N

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Basic Geometry for CNC Machining

2. The cutting performanc PC
The cutting performance PC is calculated with the equation

m 1 min Nm

Pc = Fc v c N

=
, using the values from the examples yields
min 60s 60s
m
Pcv = 2936 N 200
min
Nm
Pcv = 9786, 7
, da 1Nm/s = 1W (Watt) ist, sind 9786,7 Nm/s = 9,787 KW
s
Pcv = 9. 787 KW
3. The power output of the drive motor Pab
With known cutting performacne the power output of the drive motor Pab is calculated with the formula:

Pcv KW

= KW

9.787
Pab =
0.8
Pab = 12.23KW
Pab =

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Calculation examples of technological data for CNC milling

Calculating the infeed speed vf
For milling the infeed speed vf is usually calculated in mm per min. However, the feed per tooth fz is just as
important, since the skilled worker foremostly knows what feed a cutting edge can endure. This feed must be
distinguished from a feed attained in a milling cutter rotation.
infeed speed vf
feed per tooth
feed per rotation

vf in mm / min
fz in mm
f in mm

The following formulae are available for calculation:

v f = fz * n * z

in mm / min

vf = f *n

in mm / min

v f = f * n = fz * n * z

in mm / min

1. Example:
A plate made from C15 is to be milled in one cut using an end-face mill with indexable inserts.
The step is 10 mm high. The cutting speed vc is 160 m/min and the feed per cutter edge fz is
0,18 mm. The end-face mill with = 63 mm has four cutting edges.
How high is the infeed speed vf?
datum:

vc = 160 m/min
d = 63 mm
fz = 0,18 mm
z =4

unknown:

vf in mm/min

valid :

v f = fz * n * z

vc = * d * n

or

vc
, it follows:
*d
v
v f = c * fz * z
*d
160000mm
vf =
* 0,18mm * 4
* min* 63mm
v f = 582mm / min
n=

solution:

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2. Example:
Calculating thein feed speed vf
On a CNC-vertical milling cutter the slot of the sketched work part is to be milled in one cut with a two-edged
slot boring cutter of 12mm , n = 1800 1/min number of rotations and a feed f z of 0.12 mm. How high is the
infeed speed?
datum:

n = 1800

1
min

f z = 0.12 mm

z=2
unknown:

vf in mm/min

valid :

v f = fz * n * z

v f = 0,12mm * 1800
solution:

1
*2
min

v f = 432mm / min

3. Example
Calculating the number of rotations n
How high must the number of rotations be when the slot is machined with a boring feed of 0.1 mm per edge
and a longitudinal feed of 0.15 mm and with an infeed speed of 200 mm/min ?
datum:

unknown:

valid :

f b = 0.10mm
f z = 0.15mm
mm
v f = 200
min
nb in

1
min

z=2
unknown:

v
mm
nb = f
fb z min mm

200
0.1 2

nb = 1000

n = 1800

f z = 0.12 mm

1
min

nb =

116

datum:

1
min

valid :

nl in

1
min

vf
mm
fzl z min mm
200 1
nf =
. 2 min
015
1
nf = 667
min

nl =

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Technological Basics for CNC Machining

Calculating the cutting force and motor power

For calculating the cutting force, the same compensation factors are used for milling as in for turning..
ap
ae
b
Fcz

hm

fz

z
ze
D

kc
kc1-1
mc

cutting depth
entering point
chip width
cutting force per edge (mean)
entering angle
middle chip thickness
feed per edge
number of cutter edges
number of edges in operation
diameter of milling cutter
angle of twist of edges
adjustment angle of edges
specific cutting force
specific cutting force related to chip diameter b hm =1 mm
chip thickness index

These are either taken from a book of specifications or, as in the case of the angle of rake variation factor,
calculated with the formula K o = 1

o ok
66. 7

. For milling, the cutting force is:

Fc = Fcz ze N 1 = N . In this formula

z s
and
360
Fcz = b hm k c . Herewith are

ze =

b=

ae
mm and
cos

hm = f z sin

360ae
mm .
d s

=90- for milling cutters with angle of twist.

Taking into account the compensation factors, the cutting force can be calculated with the formula:

Fc = ze b h m kc K o K v K ver mm mm
= N and with ze , b , hm yields the formula
2
mm

Fc =

z s ae 360a p
f z sin k c K o Kv Kver

360 cos s d

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3.4

Calculation of technological data for CNC machining

Example:
As shown in the figure, a guide recess should be milled with a 4-edged end-face mill =40 mm into a guide
plate made of C35.
data :

miller diameter d = 40mm

milled width ae = 40mm
milled depth ap = 6mm
feed f z = 0.12 mm
angle of rake 0 = 10
angle of twist = 30
adjustment angle = 90
material C35
machine output M = 0.82
cutting speed vc=140mm/min

Calculating the cutting force Fc

Fc =

z s a e 360a p
N
mm mm

f z sin k c K o K v K ver 1

mm
1 = N

2
mm
360 cos s d
1 mm

Fc =

4 1
40
3606

0.12 sin 90k c K o Kv Kver ;

360 cos 30 1 40

the kc-value can not be taken directly from the table. It is calculated as follows:

kc =

k c11
,
h mc

kc11 with 1860 can be taken from the table as well as mc with 0.2. The hm-value is calculated as follows:

hm =

360a p

s d

f z sin

Consequently,

360 6
= 3. 87 mm and
44. 4 40
1860
N
kc =
= 1420
.
0.2
mm 2
3. 87
10 6
ok
K o = 1 o
= 1
= 0. 94
66. 7
66. 7

hm =

Kv with 0.97 is taken from the diagram. 1.3 is selected for the edge abrasion compensation value Kver. All

values for the cutting force are therefore established and can be calculated:

4 40 6 0.12 1
1420 0. 94 0. 97 1. 3
0. 866 40
Fc = 1782 N
Fc =

Calculating the cutting performance Pc

The following formula is used for calculating the cutting performance Pc:

Pc = Fc *v c

m
min
Nm
Pc = 1782 *140
60s
Pc = 415W
Pc = 1782N *140

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Calculating the required motor output Pab
The following formula is used for calculating the motor output Pab:

Pab =

Pc
M c

0,45KW
0,82
Pab = 055KW
Pab =

Calculating the machining time

In one cut the sketched base sheet made from ST50 (see fig. 1) is to be milled in 12 mm gradations with a
three-edged end mill of 32 mm and 16 mm cutting edge lengths. How long is the machining time of the
CNC-machine when milled with a feed of 0.12 mm per cutter edge and cutting speed of 120 mm/min? The
lenghth of the approach and retreat movements are 22 mm.
data:

material: ST50
miller diameter d =32 mm
feed per edge f z = 0.12 mm
cutting speed

v c = 120

m
min

approach and retreat movements =

22mm
cutting depth
ap = 12mm
work part length
Ll = 90mm
work part depth Lb = 50mm
The following formula is used for calculating the machining time tnu:

t nu =

t nu =

Lges i
f vc

(2L + 2L
l

f v= fz z
c

mm 1 mm min

=
=
= min
mm
mm

min
b

f vc

+ 2 A )

;; with

012
. 3 140
vc
mm
= f vc =
= f v = 501
yields:
c
0.032
d
min

2 110 + 2 70 + 2 22
501
t nu = 0.81 min
t nu =

3.5

CNC clamping systems

Types of clamping systems

A clamping system attaches the work part to the machine tool. It must fulfill two essential functions:

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3.5

CNC clamping systems

1. It must clearly determine the position of the work part.
1. It must detain all forces from the work part.

The clamping elements constrain the work part and the required force for this is called clamping power.
In order to keep the costs for the clamping system as well as for production low, further requirements are
made on the clamping system:

simple and quick handling

versatile usage
easy exchangeability of the clamping elements
high accuracy with repeated clamping

Clamping power generation

Manual clamping is usually used on conventional machine tools. This requires a high energy exertion by the
worker. Special clamping systems for individual clamping equipment has been developed to reduce auxiliary
times and ease clamping for the worker. Various methods are used for generating clamping power:

mechanical clamping power generators

hydraulic clamping power generators
pneumatic clamping power generators
electric clamping systems

Mechanical clamping power generators are usually in the form of wedge lever-type or bellcrank lever-type
power chucks. These types of force chucks are usually used for turning machines.

3
2

chuck
drawbar
wedge lever
jaws
Figure 125
wedge lever-type power chuck (mechanical)

chuck
drawbar
bellcrank lever
jaws
figure 126
Bellcrank lever-type power chuck (mechanical)

Hydraulic clamping fixtures generate the movement and power needed for clamping with hydraulically
powered pistons. These are usually manually controlled by the operator with valves. The clamping power
can be accurately controlled and is monitored on a display. Although hydraulic systems require high technical effort, they are quite reliable.

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Figure 127
Hydraulic actuating cylinders with through-hole Rhm SZ

Pneumatic clamping fixtures are operated with air pressure and function similiarly to hydraulic clamps.
Compressors are used for generating air pressure (compression).

Figure 128
Air actuating cylinders with through hole Rhm LHS

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3.5

CNC clamping systems

Electric clamps which rotate are used for force chucks with geared scroll systems. They enable a quick
adjustment to various work part diameters.
An electromagnetic clutch in the clamp blocks the spindle during the clamping and declamping process, so
that the full clamp torque is transmitted to the chuck.
Furthermore, there are electric clamps with stroke movements for operating clamping devices and force
chucks.

thread nut

thread spindle

tie bar

clutch

epicyclic gears

motor

Figure 129
Electric clamp with stroke movement

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Types and characteristics of clamping devices for turning

The different clamping devices for turning will be introduced in this section. In general, the following clamping
variations can be distinguished:
clamping in chucks
clamping with collets
clamping between centers
clamping on mandrels
clamping on faceplates
clamping with turning fixtures
clamping using steady rests
Clamping in chucks
Chucks are differentiated according to the number of jaws, i.e. two-, three- and four-jaw chucks. Selfcentering three-jaw chucks are most commonly used. They guarantee a quick, secure and centered mounting of round blanks. With a four-jaw chuck, four-, eight- or twelve sided blanks as well as round blanks can
be clamped.

Figure 130
Self-centering three-jaw chuck Rhm ZG-ZS

Figure 131
Self-centering four-jaw chuck Rhm ZG-ZS

The jaws are usually hardened and have increments. The jaws can be adjusted so that they can clamp parts
with various diameters. By exchanging jaws the turned parts can be either clamped from the inside or outside.
Clamping power transmission is usually based on the principal of geared scrolls or key bars.

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3.5

CNC clamping systems

Clamping power with a geared scroll

Chucks with geared scrolls are for lower clamping power. Only low force can be transmitted since the area
between the geared scroll and the jaw is so small.

Figure 132
Geared scroll chuck Rhm EG-ES

Figure 133
Jaw operating mechanism

The disadvantage of chucks with geared scrolls is that changing requires the chucks to be fully dismounted.
:

reversible top jaw

adjusting screw
spindle

base jaw

pinion

scroll

pinion holder screw

operating screw

adjusting key

Figure 134
Geared scroll chuck Rhm EG-ES
Operation:
The rotation of the pinion (4) causes the scroll (5) to turn. The base jaw (3) consequently moves towards the
turning axis and clamps the work part.

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Clamping power with a key bar
The key bar chuck enables a quick change of jaws and generates higher clamping power than chucks with
geared scrolls.

Components:
22

cover

33

indicator pin

51

body

23

drive ring

34

bearing

56

key bar with inner thread

24GB

base jaw

35

thrust ring

57

press pin

24EB

one-piece jaw

36

pressure spring

58

locking slide

25

reversible top jaw

37

pressure spring

76

chip guard

27

operating screw

38

taper key

90

key with toggle

28

slide

39-42

socket head cap screw

29

jaw retaining pin

44

straight pin

Figure 135
Chuck with thrust ring and key bars Rhm Duro
Operation
The tangentially arranged operating screw (27) engages the internal thread of the actuating key bar (56) to
move a slide (28) which in turn moves the drive ring (23). Two further slides in the drive ring (23) transmit the
force to the other key bars. The key bars are provided witch helical teeth which engages the teeth of the
base jaws (24GB) so that the work part is gripped accurately and concentrically.

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3.5

CNC clamping systems

Clamping with collets

Collets enable cylindrical work parts to be quickly and accurately clamped. The collet clamps the work part
from the outside. Collets are usually only applicable for one work part diameter or a component group since
it only has a minimal, radial range of adjustment.

work part

clamping bocy

spindle

clamping tube

Figure 136
Collet

Clamping between centers

Clamping between centers is applied for longer parts. The work parts must be cut to length and centered on
both sides.

Figure 137
Clamping between centers
The following possibilities for clamping between centers can be distinguished based on the maching specifications:
face drivers with revolving or fixed centers
driver with a vise chuck with clamping ring revolving or fixed centers

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Face drivers are generally contained by the main spindle. They are used when the entire surface is to be
machined. The work part is clamped between the face driver and the tailstock. A disadvantage is that only
low torques are transmitted.

Figure 138
Face driver Rhm 681
The revolving tailstock center is inserted into the tail spindle of the tailstock. Since the center can revolve on
its own, higher cutting speeds during turning operation are possible.

Figure 139
Revolving tailstock center Rhm 601

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3.5

CNC clamping systems

The application area of dead centers is very limited. They only enable minor cutting depths because they
warm up and wear too quickly.

Figure 140
Dead center Rhm 667

Figure 141
Dead center with half point Rhm 670
A vise chuck with clamping ring centers the work part and additionally radially clamps it with a clamping bolt.
Consequently, larger torques can be transmitted and a higher machining performance is reached.

driving disk

sleeve with clamping bolt

work part

Figure 142
vise chuck with clamping ring

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Clamping on mandrels
Work parts that have a bore hole, which can be very small, are clamped from the inside with clamping mandrels. Two types can be distinguished: fixed mandrels and expanding mandrels.
Fixed mandrels are minimally conical (cone 1:2000) and are clamped between centers. They are only used
for finish turning since only low cutting depths are possible. The rotary accuracy of the centers must be
checked before being used.
Expanding mandrels are inserted into the inner cone of the main spindle. Clamping is established by the
slotted clamping part of the mandrel according to the rotary accuracy as well as by an even grip on the work
part. Clamping is enabled by pressing in the taper plug.

Figure 143
Cartridge mandrels Rhm

clamping ring

clamping sleeve

Figure 144
Cartridge mandrel Rhm MZB
Expanding mandrels are clamped between centers and only have a minor clamping area. They operate by
expanding a thin-walled, non-slotted sleeve made from a plastic for elastic deformation.

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3.5

CNC clamping systems

Clamping on face plates

Face plates enable irregularly formed parts to be clamped. The four or more clamping pistons can individually be adjusted as well as be turned. The clamping areas are constructed so that outer and inner clamping
is possible. Attaching fixtures and compensating weights is possible with the available clamping slots.

Figure 145
Hydraulically operated 6-jaw pull-down finger chuck Rhm

Clamping with turning fixtures

The perforated disk with threaded borings offers a variety of clamping possibilities. However this clamping
method requires a careful gyrating mass compensation, because the spindle run will otherwise be imbalanced. This consequently leads to imprecise machining results and in the worst case, damage to the machine tool..

work part

clamping body

clamping bridge

gyrating mass compensation

Figure 146
Turning fixture

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Clamping with steady rests
Steady rests are used for clamping long, slim work parts in order to withstand work part bending caused by
cutting force and own weight.

Figure 147
Self-centering steady rests Rhm SLZ
The work part is clamped between centers and additionally supported by steady rests.

Figure 148
Fixed steady rest

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3.5

CNC clamping systems

Types and characteristics of clamping devices for milling

Various possibilities for clamping work parts on milling cutters are introduced in this section. The following
clamping variations can be distinguished.
Jaw Chucking
Magnetic Chucking
Modular Chucking
Jaw Chucking
1.

The vise can be turned in steps of 90 on

the machine table.

2.

Its position can be changed.

3.

The chucked part can be moved along

the x- and z-axes.

Magnetic Chucking
1.

The position of the part on the machine

table can be freely defined.

Modular Chucking
1.

The position of the part on the machine

table can be changed.

2.

The chuck elements can be defined as

modules. The chuck position is specified
by the user.

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The milling cutter machine table with its T-slots is the basis for work part clamping. Depending on how the
work part is to be clamped, the following clamping devices can be distinguished:

mechanical clamping devices

hydraulic clamping devices
pneumatic clamping devices
electric clamping devices

Mechanical clamping devices

Mechanical clamping devices usually consist of various individual components, e.g. clamping iron, clamping
board and clamping bolts with T-nuts.

work part

clamping iron

clamping board

machine table

support element

work part

clamping iron

clamping board

machine table

4
Figure 149
Clamping iron and clamping bard
For bedding with heavy work parts, alignment and support elements are used.

1
2

5
Figure 150
Clamping iron, clamping board and support element

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3.5

CNC clamping systems

Shallow clamps are used for flat work parts whose surfaces need to be kept free for machining.

work part

shallow clamp

Figure 151
shallow clamp
A dividing apparatus with circular table enables work parts to be quickly and symmetrically machined from
both sides. It is also possible to flange a chuck to a dividing apparatus which then can be used for accurately
dividing and machining round work parts.

Figure 152
Dividing apparatus with circular table

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Machine vises
Machine vises are easy to use and reliable. They are used for clamping smaller work parts. Alignment is
achieved with a measuring gauge.

Figure 153
Machine vise Rhm UZ
The clamping force transmission of machine vises is illustrated in the following figure.

Figure 154
Power transmission
Universal machine vises can be horizontally as well as vertically turned. Furthermore, there are also vises
that pneumatically generate clamping power.

Figure 155
Precision sine vise Rhm PS-SV

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CNC clamping systems

Pneumatic and hydraulic clamping devices

High precision NC vises, that are operated by pneumatic and hydraulic clamping cylinders, are used for
CNC-machine tools. Pneumatically operated high precision NC vises allow short opening and closing times.
However, the low operating pressure impedes high clamping power. On the other hand, depending on the
pressure adjustment, hydraulic clamping elements can exert high clamping power.

Figure 156
High precision NC vice Rhm RBA
The construction of a high precision NC vises is illustrated in the following figure.

fixed clamping jaw

movable clamping jaw

hydraulic unit

movable jaw

spindle

spindle nut

basic body

pneumatic spring

Figure 157
High precision NC vice Rhm RBA
Magnetic clamping devices
Work parts made of iron can be clamped with electromagnetic devices. The work part is drawn to the clamping plate after a current is switched on. It can be easily removed after the current is switched off.

Figure 158
Electromagnetic clamping plate

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7.

Control test Technological Basics

1.

What does a tool system on a CNC-lathe consist of?

1.

Why are hard-metal indexable inserts primarily used for tools for CNC-machine tools?

1.

Roughly describe the application areas of hard-metals.

1.

Explain the significance of the clearance angle for machining tools.

1.

What are the advantages of a larger angle of rake for the machining process?

1.

What are the disadvantages of a larger angle of rake for the machining process?

1.

When are negative are negative angles of rake necessary?

1.

What is the significance of the adjustment angle for the machining process?

1.

Exercise: Calculating the number of rotations

A shaft with a diameter of d=80mm is to be roughed with vc=120m/min.
How high is the number of rotations n?

1.

Exercise: Calculating the cutting speed

A disk with a diameter of d=250mm rotates with n=100 /min. How high is the cutting speed vc during
turning at the circumference?

1.

Name the functions of a clamping system.

1.

Name the different types of chucks.

1.

What parts are clamped on a faceplate?

1.

When are steady rests used?

1.

Name the different types of clamping power generators.

1.

Name the clamping possibilities on a milling cutter.

1.

What advantages do fixtures have?

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CNC clamping systems

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Introduction into NC programming

8.

4 Introduction into NC programming

4.1

Work organization and flow of manual NC programming

Comparison of work preparation of conventional and CNC machining

CNC-manufacturing has advantages over manufacturing with conventional machine tools, e.g. shorter production times and a higher manufacturing capacity. In order to effectively use these advantages, the work
preparation must be accordingly adapted.
The objective of manufacturing is to keep the machining time on the machine tool as high as possible. However, to achieve this extensive planning must be done.
On conventional machine tools, the skilled worker can only produce or plan. However, on a CNC-machine
tool, the worker can concentrate on planning in parallel to the autonomous execution of the NC-program.
This consequently leads to much higher machining times on the CNC-machine tool.
Using conventional machine tools for production, the workshop drawing, a work plan and work order are
available to the worker. Furthermore, the worker must thoroughly plan the work steps and select the tools.
Since tool measuring is not possible on conventional machine tools, following each operation the tools must
be marked (touched) and then be measured. These steps are redundant when using a CNC-machine tool.
However, this does require the tools to be precedingly measured.
Many prepatory tasks can be transferred to the machine for CNC-work preparation. The objective is to allocate all documents, tools and clamping devices as well as the blanks so that setting-up and production can
immediately begin. The tasks of work preparation can be divided into the following categories:

creating the required documents,

tool measuring,
managing tools and clamping devices, and
allocating all documents and accessories.

The documents required for CNC-manufacturing are much more defined compared with those for manufacturing on conventional machine tools. Creating these documents takes more time, however they are then
immediately accessible for repeated orders.
In addition to the NC-program, a set-up form is created for setting-up the CNC-machine tool. All information
on the used tools and the tool parts clamping situation is documented in this form.
Tool measuring enables the autonomous operation of the CNC-machine tool and easy application of tools on
various machines.
Tool and clamping device management is more extensive in CNC-work preparation, since they are generally
more varied than those for conventional machine tools and accordingly their description is more detailed.
The data is stored in tool and clamping device indices.
A complete allocation of all documents, preset tools and accessories enables the quick set-up of the CNCmachine tool. The objective is to avoid machining delays and therefore, increase machining time

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Work organization and flow of manual NC programming

Organizing the steps of NC programming

NC-programs can be generated in different departments. Accordingly, the following forms of NCprogramming can be differentiated:
programming as part of production organization and
programming in the workshop.
The organizational classification of both these forms is illustrated in the following figure.

figure 159
Organizational classification of NC-programming
Programming as part of production organization
All planning measures for realizing a manufacturing order are carried out in the department for production
planning and precede manufacturing. Programming in this department is termed external programming since
the department is outside the workshop area.
The NC-programs are written by staffmembers who are specifically trained in NC-programming. They usually
work at a programming terminal and create the programs on a computer. Programs are not only generated
here but managed as well. The connection to the CNC-machine tool is over a DNC-system.
It is practical to generate programs in production planning when

extensive NC-programs or
NC-programs for complicated work parts are to be created, when
many NC-programs need to be managed or
when there are many CNC-machine tools.

Disadvantageous is that
the NC-programs must be optimized on the CNC-machine tools and
there is little contact with the workshop.
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Introduction into NC programming

Programming in the workshop

Generating NC-programs in the workshop is known as machine-based programming. The NC-programs can
either be directly created on a machine or at a programming terminal near the machines.
The NC-programs written in the workshop and in production planning are directly controlled and optimized
on the CNC-machine tool by the operator during set-up.
It is practical to generate programs in production planning when:

the experience of the workshop staff is to be considered,

short NC-programs or
NC-programs for simple tool parts are to be created,
there are only few CNC-machine tools, or
available NC-programs are to be quickly accessed.

Disadvantageous is that
the workshop personnel needs to specially trained and
lengthy programming time can possibly result in machining standstill.

Differences between the programming types

For manual programming, the programmer formulates the NC-program so that it can be directly understood
by the CNC-control. Every step that a CNC-machine tool is to execute must be individually programmed.
Extensive geometric calculations must be made with respect to the CNC-control efficiency and the geometric
complexity of the work part. Possible errors or collisions with e.g. clamping devices can not be automatically
detected. Simulations, which illustrate the tool movements, are integrated into most CNC-controls for testing
the NC-program.
For computer-aided (automatic) programming, the programmer is supported by a programming system. This
system takes over routine work that is susceptible to error when programming manually, such as calculating
coordinates and cutting data.
The fundamental difference to manual programming is that not the tool path is defined step-by-step, but
rather how the tool part is meant to look after machining. The geometric and technological data is herewith
strictly separated.
For automatic programming the sequence of operations for generating a NC-program is as follows:
1. First the work part must be geometrically defined. A representation of the finished part as
well as the blank is necessary.
1. Subsequently, the individual machining operations are specified. The programming system
assists the programmer in selecting the appropriate tool and automatically calculates the
necessary cutting data.
1. Finally a NC-program for a specific CNC-machine tool with a specific CNC-control is generated and can then be transferred to the machine.

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4.1

Work organization and flow of manual NC programming

CNC-programming can be done with different procedures and at different places. An overview of these possibilities is given in the following figure.

figure 160
Overview of NC-programming procedures and systems

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Introduction into NC programming

Programming procedure for manual NC programming at programming seat

Manufacturing on CNC-machine tools requires thorough planning and production preparation. All operations
that are executed by a skilled worker on a customary turning or milling machine must be well thought-out
and defined by the programmer in advance.
In manual NC-programming, the programmer formulates the machining task in an NC-program without assistance from a programming system. The subsequent steps are herewith followed:
1. definition of machining steps
1. definition of necessary tools
1. calculation of technological data
1. calculation of geometric data
1. generating NC programs for individual machining processes
1. control of NC programs
The partial tasks to be executed are illustrated in fig. 3 and are subsequently explained.

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Work organization and flow of manual NC programming

figure 161
NC Programming Phases

Definition of machining steps

Specifying the machining sequence structures the NC-program to be generated. The programmer defines
the individual operations based on the production drawing. Furthermore, the necessary clampings and the
applicable clamping devices are registered in a clamping plan. Similarly, the individual machining steps are
registered in an operation sheet.
Definition of necessary tools
The programmer specifies the tools needed for each machining step. The tools are selected from a tool index.
Calculation of technological data
The cutting data with respect to the material and the used tool must be specified for each machining step.
Calculation of geometric data
The coordinates needed for programming traverse are taken from the production drawing or are specified by
calculating known coordinates.
Generating NC programs for individual machining processes
With respect to the previously determined geometric and technological data, the programming steps are
registered on a programming sheet.
Control of NC programs
The travel movements are simulated on a CNC-machine tool in order to detect and control programming
errors.

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Introduction into NC programming

Quality assurance during CNC production

The quality of parts manufactured on conventional machine tools is especially dependent upon the machine
operators training and constancy. In contrast, identical work parts of consistent quality can be repeatedly
manufactured on CNC-machines over a long period of time.
The following factors can affect the quality of the manufactured work part:
the created NC-program,
tool abrasion (cutting-edge life of the tool edge),
the work part material (characteristics and form),
the CNC-machine (precision and non-oscillating installation),
environmental factors (temperature effects) and
the operators behavior (error recognition with respect to quality).
Possibilities for regulating quality
How can the factors influencing quality be minimized?
Test, optimize and carefully run the program for the first work part as well as make necessary corrections with respect to accurate dimensioning.
Tool wear can be monitored on a CNC-machine. This monitoring function is done by the CNC-control,
e.g. when the maximum machining duration for the tool has been reached, the tool is automatically
replaced by an identical one. Another possibility for determining abrasion is with a modern CNCmachine equipped with a cutting force gauge. Herewith a tool is automatically changed as soon as the
cutting force increases beyond a set limit.
Deviations in dimension can be detected with integrated measuring systems. For internal tool measuring, e.g. a probe is incorporated in a collision-free position in the turret of a CNC-lathe (see fig. 4). In
the cyclical sequence of part manufacturing, a measuring process is included and automatically implemented. This process is executed by a CNC-measuring program accessed by the CNC-control.

1
probe
tool

turret

2
Figure 162
Internal tool measuring
Calibrated measurement and test techniques for precise measuring and verification.
Operator training.
Air-conditioning the workshop rooms.
Observing quality when purchasing and installing a machine.

Workshop
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4.2

NC programming basics

The different programming procedures, the NC-program management as well as the clamp and tool indices
should be demonstrated.

4.2

NC programming basics

A NC-program comprises a series of commands with which the CNC-machine tool is instructed to manufacture a certain tool.
For each machining process on a CNC-machine tool, the NC-program has a command with relevant information. These commands are alphanumerically coded, i.e. they consist of letters, numbers and characters.

NC programming standards (ISO)

The ISO-Norm 6983 strives for standardizing the NC-programming of machines in the production area. This
is however limited to standardizing certain commands as well the general structure of a NC-program. CNCcontrol manufacturers have considerable liberty for incorporating their own NC-commands in their controls.
Subsequently, the general structure of an NC-program according to ISO 6983 is illustrated.

Structure of an NC program
Structure of an NC program:
A complete NC-program consists of the following elements:
% TP0147

NC-program beginning,

N10 G54 X80 Y100...

a series of NC-blocks

...

with the information for machining and

N75 G01 Z-10 F0.3 S1800 T03 M08

...
a command for ending the program.

N435 M30
figure 163
Structure of an NC-program

The program beginning consists of a character or a command (ex. %) which informs the CNC-control that
a NC-program will follow. Additionally, the first line of the NC-program also contains the program name (ex.
TP0147). Furthermore, both characteristics are also important for the NC-program manager as well as for
calling the NC-programs in the CNC-control.
NC-program names can contain alphanumerical or numerical characters. For most CNC-controls 2-6 digit
character sequences are used for identification.
An NC-program consists of a chronological sequence of blocks. They contain the relevant geometric and
technical information that the CNC-control requires for each machining step.
The program end is commanded with M30 or M02.
Everything that stands before the character % for commenting the program is ignored by the control. This
enables any explanations on the program or tool to be attached preceding the actual program. Comments
are also allowed within a program, e.g. for identifying particular blocks. These, however, must be set in
brackets.

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Introduction into NC programming

Structure of a program block

Every NC-block consists of a block number, a number of words as well as a specific control character which
informs the CNC-control that the NC-block has ended. This control character is called LF for line feed. It is
automatically generated in NC-programming when the enter-key of the CNC-control or the enter-key on the
PC-keyboard is pressed.
N75

G01

Z-10.75

F0.3

S1800

T03

M08

LF

Number of
the NC-block

Word

Word

Word

Word

Word

Word

invisible block
ending character

figure 164
Structure of a program block

Structure of a program word

A word consists of address letters and a number with a plus/minus sign. The definition and sequence are
designated in the programming instructions of the CNC-control systems. Depending on the address letter,
the number either pertains to a code or a value.
Example

Address

Number

Definition

N75

75

For the address N, 75 is the number of the NC-block.

G01

01

For the address G, 01 is a code. The NC-command G01 is "Moving

the tool along a straight line at infeed speed".

Z-10.75

-10.75

For the address Z, -10.75 is a value. Corresponding to the NCcommand G01 of the preceding NC-block example, this means that
the tool is to be moved to the position Z=-10.75 in the current tool coordinate system.

figure 165
Structure of a program word
The form of numerical entry depends on the CNC-control: Z-35.5 is equivalent to e.g. the same target coordinates as Z-035.500. For most CNC-controls the positive sign "+" can be excluded in the NC-program.
Generally, three groups of words in an NC-block can be differentiated:
G-Functions

Coordinates

Additional and Switching Functions

G00

G01

G02

T
M

G54
figure 166
Groups of program words

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NC programming basics

The sequence of the words in an NC-block is designated as follows:

Address

Definition

1.

block number

2.

G-functions

3.

X, Y, Z

coordinates

4.

I, J, K

interpolation parameter

5.

feed

6.

speed

7.

tool position

8.

additional functions

figure 167
Sequence of program words
Words that are not needed by a block can be excluded.
Block number N
The block number is the first word in a block and designates it. It can only be conferred once. The block
number has no influence on the execution of the individual blocks since they are invoked following the order
in which they were entered into the control.
G-function
Together with the words for the coordinates, this word essentially determines the geometric part of the NCprogram. It consists of the address letter G and a two-digit code.
Coordinates X, Y, Z
The coordinates X, Y, Z define the target points that are needed for travel.
Interpolation parameters I, J, K
The interpolation parameters I, J, K are e.g. used to define the center of a circle for circular movements.
They are usually entered incrementally.
Feed F
The speed at which the tool is to be moved is programmed with the function F. The infeed speed is usually
entered in mm/min. For turning, the unit mm/U pertaining to spindle rotation can also be used.
Spindle speed S
The function S is for entering the spindle speed. It can be directly programmed in rotations per minute.
Tool position T
The address T together with a numerical code designates a specific tool. The definition of this address differs according to the control and can have the following functions:
Saving the tool dimensions in the tool offset table
Loading the tool from the tool magazine.
Additional functions M
The additional functions, also known as auxiliary functions, primarily contain technical data that is not programmed in the words with address letters F, S, T. These functions are entered with the address letter M
and a two-digit code.

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Comparison of programming codes/keys of various CNC controls

The basic commands are standardized in ISO 6983. CNC-control manufacturers add their own extensions or
commands to these basic ones.
Subsequently, a comparison of commands in different controls is given

Description

MTS

OKUMA

FANUC 16M

rapid traverse

G00

G00

G00

linear interpolation in slow feed motion

G01

G01

G01

circular interpolation clockwise

G02

G02

G02

circular interpolation counter-clockwise

G03

G03

G03

Dwell Time

G04

G04

G04

cancel Cutter or tool nose compensation

G40

G40

G40

Cutter or tool nose compensation: left

G41

G41

G41

Cutter or tool nose compensation: right

G42

G42

G42

Maximum spindle speed designation

G50

Select work cordinate system one

G54

Activate absolute dimensioning

G90

G90

G90

Activate incremental dimensioning

G91

G91

G91

feedrate in mm per min

G94

G94

G94

feedrate in mm per revolution

G95

G95

G95

Constant Speed Cutting ON

G96

Constant Speed Cutting OFF

G97

X-coordinate of the target point

Y-coordinate of the target point

Z-coordinate of the target point

Distance between starting position and circle center in X

Distance between starting position and circle center in Y

Distance between starting position and circle center in Z

spindle speed

Feedrate

Tool Changing

activate the spindle in clockwise rotation

M3

M3

M3

activate the spindle in counter-clockwise rotation

M4

M4

M4

deactivate the spindle

M5

M5

M5

Mounting the tool

M6

Activate coolant

M8

M8

M8

deactivate coolant

M9

M9

M9

Program hold

M00

M00

M00

program end and backspacing

M30

M30

M30

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NC programming basics

Select the higher spindle speed Range

M42

ignoring spindle rotation M code answer

M63

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CNC Exercise
In the following NC-program, the contour of a pre-turned part is finished. For each command give the corresponding definition.
Block
No.
N05

Commands

Description

O 0300

0300 program name

T040404

select the tool from the turret position 4

M3
M42
M63
G96
S140
N10

G50
S3000

N15

spindle speed (revolution per minute)

G0
X20
Z2
M8

N20

G1
X20
Z0
G42

N25

G3
X28
Z-4
I0
K-4

N30

G1
Z-28

N35

G2
X34
Z-31
I3
K0

N40

G1
X38
Z-33

N45

G1
Z-53

N50

G1
X44

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4.2
Block
No.
N55

NC programming basics
Commands

Description

G3
X50
Z-56
I0
K-3

N60

G1
Z-64

N65

G2
X62
Z-70
I6
K0

N70

G1
X66

N75

G1
X71
Z-72

N80

G1
X76

N85

G40

N90

G0
X500
Z500
M5
M9

N95

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Introduction into NC programming

CNC Exercise
In the following NC-program, the contour of a work part is milled. For each command, give the corresponding
definition.
Block
No.

Commands
FX100

N05

G54

N10

G90

Description
program name

G49

cancel tool length compensation

G80

cancel canned cycle

G40

N20

G17

select the X-Y-plane

G21

metric input

G91
G28

reference point return

Z0.
M9
N25

G91
G28

reference point return

X0.
Y0.
N30

T01

select the tool number 1 from the magazine

M06
N35

G90
S1600
M03

N40

G0
G43

tool length compensation

Z20.
H17
N45

offset number for the tool length

X-20.
Y-20.

N50

Z-6.
M08

N55

G1
G41
X10.

N60

D1

offset number for the cutter radius

F250.

feedrate (in mm per min)

G1
Y82.

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4.2

Block
No.
N65

NC programming basics

Commands

Description

G2
X18.
Y90.
R8.

N70

radius of the circle

G1
X82.

N75

G2
X90.
Y82.
R8.

N80

G1
Y18.

N85

G2
X82.
Y10.
R8.

N90

G1
X18.

N95

G2
X10.
Y18.
R8.

N100

G3
X-10.
Y38.
R20.

N105

G0
G40.
X-20.
Y-20.

N110

G0
Z40.
M5

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Introduction into NC programming

Block
No.
N115

Commands

Description

G91

activate incremental dimensioning

G28

reference point return

Z0.
M9
N120

G90
G80

cancel canned cycle

G49

cancel tool length compensation

G40
N125

M30

Workshop
On the CNC-machine tools, available NC-programs are to be loaded and be executed step-by-step.
Special attention should be paid to the respective control panels with the manufacturer-specific pictograms.

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4.3

Introduction to manual NC programming

4.3

Introduction to manual NC programming

Procedure for manual NC programming

The procedure for manual programming can be divided into four steps:
1.
1.
1.
1.

analysis of workshop drawings

definition of work plans
choice of clamping devices and necessary tools (set-up sheet)
generating the NC program (program sheet)

Various documents must be analyzed and plans for production execution must be created. (see fig. 168).
study
work order

tools

study
workshop drawing

clamping
devices

programmer

work plan

set-up form

program sheet

figure 168
Procedure for manual programming
Analysis of workshop drawings
The workshop drawing (see fig. 169) contains the geometric and technical information for the finished part.
The dimensions, the surface specifications as well as information on the machining procedure to be used
(e.g. cutting, threading, hardening) are taken from the drawing. Information on the work to be executed as
well as on the number of work parts and the deadlines is specified in the work order.

figure 169
Workshop drawing turning

156

figure 170
Workshop drawing milling

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Introduction into NC programming

Definition of work plans
The workshop drawing and the work order determine the machining operation sequence.
Basic type No..: 4711

Standard work plan No.: 007

Sketch for basic type: Gear wheel

Maximum ratings:

Work piece material:

90 <= Da < 150

35 <= Di < 80
10 <= NB < 20
2 <= Z < 20

Round bar
Dr = 1.05 x Da
Lr = L + 5
Material: C45

Da: = External diameter

Di: = Internal diameter

N.

Machining description

Production
aids

Machining alternatives
Decision criteria

01

saw LR mm long and

deburr

02

turning and main drilling

03

sketching

axial drillings available

04

auxiliary drillings

axial drillings available and

drilling- <= 10 mm
axial drillings available and
drilling- > 10 mm

sketch

Date 13.03.91

120 <= Da < 240 and

30 <= L < 80

Z: = Counter value
NB: = Slot width

Machine
group

Cost
center

Dr: = Work piece diameter

Lr: = Work piece length

tr [min]

Calculation formula for time per piece te

[min/piece]

55/1

1101

te = 0,5 x Dr

66/1

1212

12

te = 1,5 x (Dr - Da) + 0,1 x Lr

1300

te = 0,5 x number of drillings

71/1

1217

te = 0,5 x number of drillings

72/2

1217

te = 0,05 x number of drillings x

drilling depth

figure 171
Work order
This sequence is then registered in a work plan. The clamping situation must already be considered at this
time. Clamping must be sketched for complicated situations or reclamping.

figure 172
Work plan

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Choice of clamping devices and necessary tools

In this phase, all data needed for executing the individual machining operations, i.e. for high-quality production, is entered into the work plan (see fig. 14). After selecting the required clamping elements, the necessary tools are chosen and the pertinent cutting data for each operation is calculated.

figure 173
Set-up form
All data that is needed for setting up the CNC-machine tool is listed in the set-up form (see fig. 15). Especially the information on the program number and drawing number as well as the work part name identifies
all documents required for the order. For repeated orders, information on the position of the work part enables an easier set-up of the clamping situation.
Generating the NC program
The programmer creates the NC-program based on the workshop drawing and work plan, and enters the
individual program blocks into a program sheet (see fig. 16). This program sheet supplements the documents at hand. For a repeated order, the machine can then immediately be set-up.
Program Sheet

Programming

M T

figure 174
Program Sheet

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Manual NC programming Turning

CNC exercise
Instructed generation of NC-programs for CNC-turning operations
Task:
An NC-program is to be generated for manufacturing the following part.

figure 175
Follow the subsequent steps for generating the NC-program:
1.
1.
1.
1.

definition of the work plan

choice of clamping devices and necessary tools
generating the NC program
simulating the NC program

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Definition of the work plan

Work plan for machining the first side:
Machining Sequence

Tool

Turret Position

Cutting
Values

Outline

1 check blank

dimensions
2 clamp work part
1.side
3 define work part zero
point

3
2

4 Face Turning

Left Corner Tool

T04

G96
F0.15

CL-SCLCL-2020/R/1208

S140

5 Centering

Center Drill

T09

G97
F0.16

CD-03.15/050/R/HSS

S1800

6 Drilling

Twist Drill 14mm

T07

G97
F0.22

DR-18.00/130/R/HSS

S1000

7 Outside contour
roughing

Left Corner Tool

T04

G96
F0.1

CL-SCLCL-2020/R/1208

S140

8 Outside contour finish- Left Corner Tool

ing

CL-SVJCL-2020/R/1604

T02

G96
F0.1
S280

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Work plan for machining the second side:
Machining Sequence

Tool

Turret Position

Cutting
Values

Outline

1 check work part

2 clamp work part

2.side

1
3

3 define work part zero

point

4 Face Turning with

offset 0.2mm

Left Corner Tool

T04

G96
F0.28

CL-SCLCL-2020/R/1208

S140

5 Outside contour
roughing

Left Corner Tool

T04

G96
F0.28

CL-SCLCL-2020/R/1208

S140

6 Predrilling

Reversible Tip Drill

22mm
DI-22.00/051/R/HMT

T12

G97
F0.2
S850

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Machining Sequence

7 Inside contour roughing with offset

Tool
Inside Turning Tool
Post

Turret Position

Cutting
Values

T05

G96
F0.2

BI-SDQCL-1616/R1104

8 Inside contour finishing

Inside Turning Tool

Post

S120

T10

9 Outside contour finish- Left Corner Tool

ing

CL-SVJCL-2020/R/1604

S220

T02

G96
F0.1
S280

162

G96
F0.1

BI-SVQJCL-2020/R/1604

Outline

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Setting-up the CNC machine (set-up sheet)
After start, the MTS-simulator is automatically set-up with blank, clamping and turret allocation. If the following set-up data does not conform with the current set-up data, then it must be changed in the set-up operation.

figure 176
Setup Dialog

figure 177
Interactivmod

Set-up sheet for machining the first side:

CONFIGURATION
MACHINE MTS01 TM-016_-R1_-060x0646x0920
CONTROL MTS TM01
PART
CYLINDER D075.000 L100.000
MATERIAL AlMg 1::Aluminium
DENSITY 002.70
MAIN SPINDLE WITH WORKPART
CHUCK "Chuck Turning\Jaw chuck\KFD-HS 160"
STEP JAW "Jaw\Step jaw\HM-160_200-02.001"
TYPE OF CHUCK EXTERNAL CHUCK OUTSIDE STEP JAW
CHUCKING DEPTH E18.000
TAILSTOCK
TAILSTOCK POSITION Z+1095.000
CURRENT TOOL
T01
TOOLS
T02 "DIN69880 V 30\
T04 "DIN69880 V 30\
T05 "DIN69880 V 30\
T07 "DIN69880 V 30\
T09 "DIN69880 V 30\
T12 "DIN69880 V 30\
T14 "DIN69880 V 30\

Left corner tool\CL-SVACL-2020 L 1604 ISO30"

Left corner tool\CL-SCLCL-2020 L 1208 ISO30"
Inside turning tool postaxial\BI-SDQCL-1212 L 0704 ISO30"
Twist drill\DR-14.00 108 R HSS ISO30"
Center drill\CD-04.00 056 R HSS ISO30"
Reversible tip drill\DI-22.00 051 R HMT ISO30"
Inside turning tool postaxial\BI-SDQCL-1212 L 0704 ISO30"

TOOL COMPENSATION
D02 T02 Q3
D04 T04 Q3
D05 T05 Q2
D07 T07 Q7
D09 T09 Q7
D12 T12 Q7
D14 T14 Q2

R0.4 X+70.0 Z+45.0

R0.8 X+70.0 Z+45.0
R0.4 X-8.364 Z+160.0
R0.0 X+0.0 Z+180.0
R0. 0 X+0. 0 Z+70.0
R0.0 X+0.0 Z+180.0
R0.4 X-8.364 Z+160.0

G0.0 E52.393 I-0.4 K-0.4

G0.0 E05.005 I-0.8 K-0.8
G0.0 E18.027 I+0.4 K-0.4
G14.0 E59.0
I+0.0 K+0.0
G04.0 E0.0
I+0.0 K+0.0
G22.0 E0.0
I+0.0 K+0.0
G0.0 E18.027 I+0.4 K-0.4

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A+2.372 L16.178 N01

A+4.375 L11.855 N01
A+16.744 L7.029 N01
A+0.0 L0.0 N01
A+0.0 L0.0 N01
A+0.0 L0.0 N01
A+16.744 L7.029 N01

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Set-up sheet for machining the second side:

For machining the second side, the work part is reclamped, i.e. no blank is clamped!
The work part is clamped after the first side is machined. The current form is defined in part GEOMETRY.

File Selection Window

figure 178
Diagram of the menu sequence for the Work part
Manager.

figure 179
File information for loading a preproduced work
part.

CONFIGURATION
MACHINE MTS01 TM-016_-R1_-060x0646x0920
CONTROL MTS TM01
PART
GEOMETRY X+071.331 Z+0165.500
G01 X+075.000 Z+0165.500
G01 X+075.000 Z+0191.000
G01 X+014.000 Z+0191.000
G01 X+014.000 Z+0093.000
G01 X+020.000 Z+0093.000
G02 X+028.000 Z+0097.000 I+000.000 K+004.000
G01 X+028.000 Z+0121.000
G03 X+034.000 Z+0124.000 I+003.000 K+000.000
G01 X+034.000 Z+0145.600
G03 X+034.800 Z+0146.000 I+000.400 K+000.000
G01 X+044.000 Z+0146.000
G02 X+050.000 Z+0149.000 I+000.000 K+003.000
G01 X+050.000 Z+0157.000
G03 X+062.000 Z+0163.000 I+006.000 K+000.000
G01 X+066.000 Z+0163.000
G01 X+070.766 Z+0165.383
G03 X+071.331 Z+0165.500 I+000.283 K-000.283
M30
MAIN SPINDLE WITH CHUCK "Chuck Turning\Jaw chuck\KFD-HS 160"
WORKPART
STEP JAW "Jaw\Step jaw\HM-160_200-02.001"
CHUCKING DEPTH E53.000
Right side of the part: Z+0191.000
CHUCK "Chuck Turning\Jaw chuck\KFD-HS 160"

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NC programming
NC program for the first side
Block Commands
No.

Description

%200

Program name

4) Plandrehen
N010 G54 Z+226.000

G54 set absolute zero

Z+226.000 Z- coodinate of the current workpart zero

N015 G96 S0140 T0404 M03

G96 Constant speed cutting ON

S140 Spindle speed
T0404 Selection of the tool from turret position 4
M3 activate the spindle in clockwise rotation

N020 G92 S3000

G92 Speed limit

S3000 Spindle speed

N025 G00 X+078.000 Z+000.200

G00 Rapid traverse

X+078.000 X- Coordinate of the target point
Z+000.200 Z- Coordinate of the target point

N030 G01 X-001.000 F000.150 M08

G01 Linear interpolation in slow speed motion

X-001.000 X- Coordinate of the target point
F000.150 feedrate in mm per revolution
M8 activate coolant

N035 G00 Z+002.000

G00 Rapid traverse

Z+002.000Z- Coordinate of the target point

N040 X+200.000 Y+200.000 M5 M9

X200.000 X- Coordinate of the target point

Z200.000 Z- Coordinate of the target point
M5 deactivate spindle
M9 deactivate coolant

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Block Commands
No.

Description

5) Centering
5) Zentrieren
N045 G97 S1800 T0909 M03

G97 Constant Speed Cutting OFF

S1800 Spindle speed
T0909 Selection of the tool from turret position 9
M3 activate the spindle in clockwise rotation

N050 G00 Z+002.000

G00 Rapid traverse

Z2 Z- Coordinate of the target point

N055 X+000.000

X+000.000 X- Coordinate of the target point

N060 G01 Z-005.800 F000.160 M08

G01 Linear interpolation of slow feed motion

Z-005.800 Z- Coordinate of the target point
F000.160 feedrate in mm per revolution
M08 activate coolant

N065 G00 Z+002.000

G00 Rapid traverse

Z002.000 Z- Coordinate of the target point

N070 X+200.000 Z+200.000 M5 M9

X200.000 X- Coordinate of the target point

Z200.000 Z- Coordinate of the target point
M5 deactivate spindle
M9 deactivate coolant

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Block Commands
No.

Description

6) Drilling
N075 F000.220 T0707 M03

F000.220 feedrate in mm per revolution

T0707 Selection of the tool from turret position 7
M3 activate the spindle in clockwise rotation

N080 G97 S1000

G97 Constant Speed Cutting OFF

S1000 Spindle speed

N085 G00 Z+002.000

G00 Rapid traverse

Z+002.000Z-Coordinate of the targer point

N090 X+000.000 M08

X000.000 X- Coordinate of the target point

M08 activate coolant

N095 G84 Z-105.000 A+001.000

B+001.000 D+005.000
K+025.000

G84 Drilling cycle

Z-105.000 Z-coordinae of the target point
A+001.000 Dwell time after retraction
B+001.000 Dwell time when target point is reached
for chip breaking
D+005.000 Digression (reduction of drilling depth)
K+025.000 first depth of cut

N100 G00 X+200.000

G00 Rapid traverse

X200.000 X- Coordinate of the target point

N105 Z+070.000 M5 M9

Z070 Z- Coordinate of the target point

M5 deactivate spindle
M9 deactivate coolant

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Block Commands
No.

Description

7) Outside contour roughing

N110 G96 S0140 T0404 M03

G96 Constant speed cutting ON

S0140 Spindle speed
T0404 Selection of the tool from turret position 4
M3 activate the spindle in clockwise rotation

N115 G92 S3000

G92 Maximum spindle speed

S3000 Spindle speed

N120 G00 X+075.000 Z+002.000

G00 Rapid traverse

X+075.000 X- Coordinate of the target point
Z+002.000 Z- Coordinate of the target point

N125 G57 X+000.600 Z+000.200

G57 finishing allowance activation

X+000.600 finishing allowance activation in X-Richtung (durchmesserbezogen)
Z+000.200 finishing allowance activation in Z-Richtung

N130 G81 X+018.000 Z+002.000

I+004.000

G81 straight roughing cycle

X+018.000 X- Coordinate of contour start point
Z+002.000 Z- Coordinate of contour start point
I+004.000 Infeed

N135 G42

G42 tool nose compensation: right of the contour

N140 G01 X+018.000 Z+000.000

G01 Linear interpolation of slow feed motion

X+018.000 X- Coordinate of the target point
Z+000.000 Z- Coordinate of the target point

N145 X+020.000

X+018.000 X- Coordinate of the target point

N150 G03 X+028.000 Z-004.000

I+000.000 K-004.000

G03 circular interpolation counter-clockwise

X+028.000 X- Coordinate of the target point
Z-004.000 Z- Coordinate of the target point
I+000.000 Distance between starting position and circle center in
X
K-004.000 Distance between starting position and circle center in
Z

N155 G01 Z-028.000

G01 Linear interpolation of slow feed motion

Z-028.000 Z- Coordinate of the target point

N160 G01 X+018.000 Z+000.000

G01 Linear interpolation of slow feed motion

X+018.000 X- Coordinate of the target point
Z+000.000 Z- Coordinate of the target point

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N165 G02 X+034.000 Z-031.000
I+003.000 K+000.000

G02 Circular interpolation counter-clockwise

X+034.000 X- Coordinate of the target point
Z-031.000 Z- Coordinate of the target point
I+003.000 Distance between starting position and circle center in
X
K-000.000 Distance between starting position and circle center in
Z

Block Commands
No.

Description

N170 G01 Z-053.000

G01 Linear interpolation of slow feed motion

Z-053.000 Z- Coordinate of the target point

N175 G01 X+044.000

G01 Linear interpolation of slow feed motion

X+044.000 X- Coordinate of the target point

N180 G03 X+050.000 Z-056.000

I+000.000 K-003.000

G03 Circular interpolation counter-clockwise

X+050.000 X- Coordinate of the target point
Z-056.000 Z- Coordinate of the target point
I+000.000 Distance between starting position and circle center in
X
K-003.000 Distance between starting position and circle center in
Z

N185 G01 Z-064.000

G01 Linear interpolation of slow feed motion

Z-064.000 Z-Coordinate of the target point

N190 G02 X+062.000 Z-070.000

I+006.000 K+000.000

G02 Circular interpolation counter-clockwise

X+062.000 X-Coordinate of the target point
Z-070.000 Z-Coordinate of the target point
I+006.000 Distance between starting position and circle center in
X
K-000.000 Distance between starting position and circle center in
Z

N195 G01 X+066.000

G01 Linear interpolation of slow feed motion

X+066.000 X- Coordinate of the target point

N200 G01 X+071.000 Z-072.500

G01 Linear interpolation of slow feed motion

X+071.000 X- Coordinate of the target point
Z-072.500 Z- Coordinate of the target point

N205 G01 X+076.000

G01 Linear interpolation of slow feed motion

X+076.000 X-Coordinate of the target point

N210 G40

G40 cancel tool nose compensation

N215 G80

G80 End of contour definition for straight roughing cycle

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N220 G00 X+200.000 Z+200.000 M5 G0 Rapid traverse

M9
X200.000 X-Coordinate of the target point
Z200.000 Z-Coordinate of the target point
M5 deactivate spindle
M9 deactivate coolant

8) Outside contour finishing

N225 G96 F000.100 S0280 T0202
M03

G96 Constant speed cutting ON

F000.100 feedrate in mm per revolution
S0280 Spindle speed
T0202 Selection of the tool from turret position 2
M03 activate the spindle in clockwise rotation

N230 G92 S4000

G92 Speed limit

S4000 Spindle speed

N235 G00 X+010.000 Z+002.000

G00 Rapid traverse

X+010.000 X- Coordinate of the target point
Z+002.000 Z- Coordinate of the target point

N240 G42

G42 tool nose compensation: right of the contour

N245 G01 X+013.000 Z+000.000

G01 Linear interpolation of slow feed motion

X+013.000 X- Coordinate of the target point
Z+000.000 Z- Coordinate of the target point

N250 G23 O135 Q210

G23 Programmteilwiderholung
O135 Start block number
Q210 End block number

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N255 G00 X+200.000 Z+200.000 M5 G00 Rapid traverse

M0
X200.000 X-Coordinate of the target point
Z200.000 Z-Coordinate of the target point
M5 deactivate spindle
M9 deactivate coolant
N260 M30

M30 End of program

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NC program for the second side

Block Commands
No.

Description

%201

Program name

4) Face Turning
N005 G54 Z+188.000

G54 set absolute zero

Z+188.000 Z-Coordinate of the current workpart zero

N010 G96 S0140 T0404 M03

G96 Constant Speed Cutting ON

S140 Cutting Speed
T0404 Selection of the tool from turret position 4
M3 activate the spindle in clockwise rotation
M42 Select the higher spindle speed range

N015 G92 S3000

G92 Spindle speed limitation

S3000 Maximum spindle speed

N020 G00 X+078.000 Z+001.5 0

G00 Rapid traverse

X+078.000 X-Coordinate of the target point
Z+001.500 Z-Coordinae of the target point

N025 G01 X-001.000 F000.280 M08

G01 linear interpolation in slow feed motion

X-001.000 X-Coordinate of the target point
F000.280 feedrate in mm per revolution
M8 activate coolant

N030 G00 Z+002.000

G00 Rapid traverse

Z+002.000 Z-Coordinate of the target point

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Block Commands
No.

Description

5) Outside contour roughing

N035 G00 X+078.000

G00 Rapid traverse

X+078.000 X-Coordinate of the target point

N040 G00 Z+000.200

G00 Rapid traverse

Z+000.2000 Z-Coordinate of the target point

N045 G01 X+012.000

G01 Linear interpolation of slow feed motion

X+012.000 X-Coordinate of the target point

N050 G88 X+070.400 Z+000.200

R+004.000

G88 Cycle radius

X+070.400 X-Coordinate of the target point
Z+000.200 Z-Coordinate of the target point
R+004.000 Rounding radius

N055 G01 Z-025.000

G01 Linear interpolation of slow feed motion

Z-025.000 Z-Coordinate of the target point

N060 G00 X+200.000 Z+200.000 M5 G00 Rapid traverse

M9
X200.000 X-Coordinate of the target point
Z200.000 Z-Coordinate of the target point
M5 deactivate spindle
M9 deactivate coolant

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Block Commands
No.

Description

6) Predrilling
N065 G97 S0850 T1212 M03

G97 Constant Speed Cutting OFF

S0850 Spindle speed
T1212 Selection of the tool from turret positiion 12
M3 activate the spindle in clockwise rotation

N070 G92 S1500

G92 Speed limit

S1500 Spindle speed

N075 G00 Z+002.000

G00 Rapid traverse

Z+002.000 Z-Coordinate of the target point
M8 activate coolant

N080 X+000.000 F000.200 M08

X+000.000 X-Coordinate of the target point

F000.200 feedrate in mm per revolution
M08 activate coolant

N085 G84 Z-034.800 A+001.000

B+001.000 D+004.000
K+020.000

G84 Drilling cycle

Z-034.800 Z Coordinate of the target point
A+001.000 Dwell time after retraction
B+001.000 Dwell time when target point is reached for
chip breaking
D+004.000 Digression (reduction of drilling depth)
K+020.000 first depth of cut

N090 G00 X+200.000

G00 Rapid traverse

X200.000 X-Coordinate of the target point

N095 Z+070.000 M5 M9

Z70 Z-Coordinate of the target point

M5 deactivate spindle
M9 deactivate coolant

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Block Commands
No.

Description

7) Inside contour roughing

N100 G96 F000.200 S0120 T0505
M04

G96 Constant speed cutting ON

F000.200 feedrate in mm per revolution
S0120 Spindle speed
T0505 Selection of the tool form turret positin 5
M4 activate the spindle counter clockwise

N105 G92 S3000

G92 Speed limit

S3000 Spindle speed

N110 G00 X+021.000 Z+002.000

G00 Rapid traverse

X+021.000 X-Coordinate of the target point
Z+002.000 Z-Coordinate of the target point

N115 G57 X-000.600 Z+000.200

G57 finishing allowance activation

X+000.600 Finshingin X allowance
Z+000.200 Finishing in Z allowance

N120 G81 X+040.000 Z+002.000

I+002.500

G81 straight roughing cycle

X+040.000 X-Coordinate of contour start point
Z+002.000 Z-Coordinate of contour start point
I+002.500 Infeed

N125 G41

G41 Tool nose compensation: left of the contour

N130 G01 X+038.000 Z+000.000

M08

G01 Linear interpolation of slow feed motion

X+038.000 X-Coordinate of the target point
Z+000.000 Z-Coordinate of the target point
M8 activate coolant

N135 X+034.000 Z-002.000

X+034.000 X-Coordinate of the target point

Z-002.000 Z-Coordinate of the target point

N140 G88 X+034.000 Z-015.000

R+002.000

G88 Cycle radius

X+034.000 X-Coordinate of the target point
Z-015.000 Z-Coordinate of the target point
R+002.000 Rounding radius

N145 G01 X+026.000

G1 Linear interpolation of slow feed motion

X+026.000 X-Coordinate of the target point

N150 Z-035.000

Z-035.000 Z-Coordinate of the target point

N155 X+013.000

X+013.000 X-Coordinate of the target point

N160 G40

G40 cancel tool nose compensation

N165 G80

G80 End of contour definition

N170 G00 X+200.000

G00 Rapid traverse

X200.000 X-Coordinate of the target point

N175 Z+070.000 M5 M9

Z+070.000 Z-Coordinate of the target point

M5 deactivate spindle
M9 deactivate coolant

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Block Commands
No.

Description

8) Inside contour finishing

N180 G96 F000.100 S0220 T1010
M04

G96 Constant speed cutting ON

F000.1000 feedrate in mm per revolution
S0220 Spindle speed
T1010 Selection of the tool from turret position 10
M4 activate the spindle counter-clockwise

N185 G92 S4000

G92 Speed limit

S4000 Spindle speed

N190 G00 X+040.000 Z+002.000

G00 Rapid traverse

X+040.000 X-Coordinate of the target point
Z+002.000 Z-Coordinate of the target point

N195 G23 O125 Q160

G23 program part repetition

O125 Start block number
Q160 End block number

N200 G00 Z+002.000

G00 Rapid traverse

X+002.000 Z-Coordinate of the target point

N205 X+200.000

X+200.000 X-Coordinate of the target point

N210 Z+070.000 M5 M9

Z+070.000 Z-Coordinate of the target point

M5 deactivate spindle
M9 deactivate coolant

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Block Commands
No.

Description

9) Outside contour finishing

N215 G96 F000.100 S0280 T0202
M03

G96 Constant speed cutting ON

F000.100 feedrate in mm per revolution
S0280 Spindle speed
T0202 Selection of the tool from turret position 2
M3 activate the spindle in clockwise rotation

N220 G92 S4000

G92 Speed limit

S4000 Spindle speed

N225 G00 X+034.000 Z+001.000

G00 Rapid traverse

X+034.000 X-Coordinate of the target point
Z+001.000 Z-Coordinate of the target point

N230 G42

G42 tool nose compensation: right of the contour

N235 G01 Z+000.000 M8

G01 Linear interpolation of slow feed motion

Z+000.000 Z-Coordinate of the target point
M8 activate coolant

N240 G88 X+070.000 Z+000.000

R+004.000

G88 Cycle radius

X+070.000 X-Coordinate of the target point
Z+000.000 Z-Coordinate of the target point
R+004.000 Rounding radius

N245 G01 Z-026.000

G01 Linear interpolation of slow feed motion

Z-026.000 Z-Coordinate of the target point

N250 X+072.000

X+072.000 X-Coordinate of the target point

N255 G40

G40 cancel tool nose compensation

N260 X+200.000 Z+200.000 M5 M9

X+200.000 X-Coordinate of the target point

Z+200.000Z-Coordinate of the target point
M5 deactivate spindle
M9 deactivate coolant

N240 M30

M30 End of program

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Simulation of the NC program and Quality control by measuring work results

In automatic mode, the generated NC-programs are simulated in real-time and with respect to possible collisions.

figure 180
Automatic Mode menu diagram.

figure 181
Automatic Mode menu.

To start an NC program in Automatic Mode, two procedural steps are required:

1. As a first step after starting Automatic Mode, the main menu is loaded, allowing you to enter the
name of the NC program (par example: %200) to be simulated.
Accept program: Use F1 or
to confirm the program name appearing in the information line. If
the program is available, it is subsequently loaded into program memory; if not, an appropriate error message is displayed.
1. Continue by selecting the desired simulation mode for program execution
Automatic: Select F1 to execute the program specified in the dialogue line under continuous automatic control.
Single NC block: Use F2 to activate single block operation.

figure 182
Menu during continuous automatic run.

178

figure 183
CNC Turning, 3D Display, Optional section.

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Quality control by measuring work results
A work part can be measured after machining (automatic mode) or during machining after every operation
(single block) and can be compared with the values in the drawing.
Procedure:
Description

Entry

1. Call CNC turning in the main menu.

F1 (turning)

2. Select menu automatic mode.

F2 (automatic mode)

3. Call a present NC program,

par example %200.
4. Select the simulation type automatic mode.

Using the keyboard type in%200 and

confirm.

F1 (Automatic mode)
On the screen the simulation of the machining starts.

5. Select menu measurement.

F6 (Dimension 3D)

6. Select menu point dimension.

F6 (Point dimension)

7. Select the point for measurement.

F1 (next point) or
F2 (previous point)
For the selected point the data are shown
on the screen

8. Quit the menu measurement.

F8 (Abort)
F8 (Quit)

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Manual NC programming Milling

CNC Exercise
Instructed generation of NC-programs for CNC-milling
Task:
An NC-program is to be generated for manufacturing the following part:

figure 184
Follow the subsequent steps for generating the NC-program:
1.
1.
1.
1.

180

definition of the work plan

choice of clamping devices and necessary tools
generating the NC program
simulating the NC program

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Work plan
Machining Sequence

Tool

Magazine
Position

Cutting
Values

1 check blank

Outline
Y

dimensions
2 clamp work part
3 define work part zero
point

4 Contour left side

SLOT MILLING TOOL

T01

mill 8mm deep

5 Contour right side

S1600

SLOT MILLING TOOL

T01

mill 8mm deep

6 Contour octagon

F250

F250
S1600

SLOT MILLING TOOL

T01

mill 4mm deep

F250
S1600

6
7 Contour with arcs
mill 6mm deep

SLOT MILLING TOOL

T01

F250
S1600

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8 Contour Circle
r=25mm

SLOT MILLING TOOL

T01

F250
S1600

mill 2mm deep

9 Circular Pocket
r=15mm

SLOT MILLING TOOL

T02

F50
S1800

mill 4mm deep

10 4 x Centering

CORE DRILL

T03

F80
S2000

11 Drill 4 x core hole

DRILL

T04

M6

12 4 x tapping
M6

182

F50
S1500

TAP

T05

10

F150
S150

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Introduction into NC programming

Setting-up the CNC machine (set-up sheet)
After start, the MTS-simulator is automatically set-up with blank, clamping and turret allocation. If the following set-up data does not conform with the current set-up data, then it must be changed in the set-up operation

figure 185
SetupDialog

figure 186
Set-up Mode; Work part and clamping fixture definition" menu.

CONFIGURATION
MACHINE MTS VMC-024_ISO30_-0500-0400x0450
CONTROL FANUC SERIE 16M
BLANK DIMENSIONS
X+100.000 Y+100.000 Z+025.000
VISE "Chuck Milling\Vise\RS 110"
CHUCKING DEPTH E+010.000
SHIFT V+000.000
ORIENTATION A0
PART POSITION X+150.000 Y+150.000
left corner of the part: X+150.000 Y+150.000 Z+105.000
CURRENT TOOL
T01
TOOLS
T01
T02
T03
T04
T05

"ISO SK 30\
"ISO SK 30\
"ISO SK 30\
"ISO SK 30\
"ISO SK 30\

Slot Milling tool\MS-20.0 038K HSS ISO 1641"

Slot Milling tool\MS-20.0 038K HSS ISO 1641"
Core drill\DC-08.0 090 HSS ISO 3294"
Drill\DR-05.00 052 HSS ISO 235
Tap\TA-M06.0 1.00 HSS ISO 2857"

TOOL COMPENSATION
D01
D02
D03
D04
D05

T01 R010.000 Z+119.000 N01

T02 R010.000 Z+119.000 N01
T03 R000.000 Z+065.000 N01
T04 R002.500 Z+097.900 N01
T01 R010.000 Z+119.000 N01

WORKPART ZEROPOINTS
G54 X150.000 Y+150.000 Z+105.000

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NC programming
Block Commands
No.

Description

O 200

O Program number O and program name

N005 G90 G80 G40 G49 G17 G21

G90 Absolute Dimensioning

G80 Canned cycle cancel
G40 Tool radius compensation cancel
G49 Tool length compensation cancel
G17 XY plane
G21 Metric input

N010 G91 G28 Z0

G91 Incremental dimensioning

G28 Reference point return
Z0 Z-Coordinate of the Intermediate Point

N015 G91 G28 X0 Y0

G91 Incremental dimensioning

G28 Reference point return
X0 X-Coordinate of the Intermediate Point
Y0 Y-Coordinate of the Intermediate Point

N020 G54

G54 Work coordinate system 1 selection

4) Contour left side mill 8mm deep

N025 T01 M06

T01 Select the tool 1

M06 Mounting the tool 1

N030 G90 G00 X-20 Y-20

G90 Absolute dimensioning

G00 rapid traverse
X-20 X-Coordinate of the target point
Y-20 Y-Coordinate of the target point

N035 G43 Z20 H17

G43 Tool length compensation +

Z20 Z-Coordinate of the target point
H17 Select the compensation offset 1

N040 S1600 M03

S1600 spindle speed

M03 activate the spindle in clockwise rotation

N045 Z-8 M08

Z-8 Z-Coordinate of the target point

M08 activate coolant

N050 G41 G1 X5 D1 F250

G41 Tool radius compensation left

G1 linear interpolation in slow feed motion
X5 X-Coordinate of the target point
D1 Select the compensation offset 1
F250 feedrate in mm/min

N055 Y110

184

Y110 Y-Coordinate of the target point

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Block Commands
No.

Description

5) Contour right side mill 8mm deep

N060 G0 X95

G0 rapid traverse
X95 X-Coordinate of the target point

N065 G1 Y-10

G1 linear interpolation in slow feed motion

Y-10 Y-Coordinate of the target point

N070 G40 G0 X-20 Y-20

G40 Tool radius compensation cancel

G0 rapid traverse
X-20 X-Coordinate of the target point
Y-20 Y-Coordinate of the target point

6) Octagon mill 4mm deep

N075 Z-4

Z-4 Z-Coordinate of the target point

N080 G41 G0 X15 D1

G41 Tool radius compensation left

G0 rapid traverse
X15 X-Coordinate of the target point
D1 Select the compensation offset 1

N085 G1 Y65

G1 linear interpolation in slow feed motion

Y65 Y-Coordinate of the target point

N090 X35 Y85

X35 X-Coordinate of the target point

Y85 Y-Coordinate of the target point

N095 X65

X65 X-Coordinate of the target point

N100 X85 Y65

X85 X-Coordinate of the target point

Y65 Y-Coordinate of the target point

N105 Y35

Y35 Y-Coordinate of the target point

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Block Commands
No.

Description

N110 X65 Y15

X65 X-Coordinate of the target point

Y15 Y-Coordinate of the target point

N115 X35

X35 X-Coordinate of the target point

N120 X5 Y45

X5 X-Coordinate of the target point

Y45 Y-Coordinate of the target point

N125 G40 G0 X-20 Y-20

G40 Tool radius compensation cancel

G0 rapid traverse
X-20 X-Coordinate of the target point
Y-20 Y-Coordinate of the target point

7) Contour with arcs mill 6mm deep

N130 Z-6

Z-6 Z-Coordinate of the target point

N135 G41 G1 X10 D1

G41 Tool radius compensation left

G1 linear interpolation in slow feed motion
X10 X-Coordinate of the target point
D1 Select the compensation offset 1

N140 G1 Y82

G1 linear interpolation in slow feed motion

Y82 Y-Coordinate of the target point

N145 G2 X18 Y90 R8

G2 circular interpolation clockwise

X18 X-Coordinate of the target point
Y90 Y-Coordinate of the target point
R8 radius r=8 of the circular arc

N150 G1 X82

G1 linear interpolation in slow feed motion

X82 X-Coordinate of the target point

N155 G2 X90 Y82 R8

G2 circular interpolation clockwise

X90 X-Coordinate of the target point
Y82 Y-Coordinate of the target point
R8 radius r=8 of the circular arc

N160 G1 Y18

G1 linear interpolation in slow feed motion

Y18 Y-Coordinate of the target point

N165 G2 X82 Y10 R8

G2 circular interpolation clockwise

X82 X-Coordinate of the target point
Y10 Y-Coordinate of the target point
R8 radius r=8 of the circular arc

N170 G1 X18

G1 linear interpolation in slow feed motion

X18 X-Coordinate of the target point

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Block Commands
No.

Description

N175 G2 X10 Y18 R8

G2 circular interpolation clockwise

X10 X-Coordinate of the target point
Y18 Y-Coordinate of the target point
R8 radius r=8 of the circular arc

N180 G3 X-10 Y38 R20

G2 circular interpolation counter-clockwise

X-10 X-Coordinate of the target point
Y38 Y-Coordinate of the target point
R8 radius r=8 of the circular arc

N185 G40 G0 X-20 Y-20

G40 Tool radius compensation cancel

G0 rapid traverse
X-20 X-Coordinate of the target point
Y-20 Y-Coordinate of the target point

8) Contour circle r=25mm mill 2mm deep

N190 Z-2

Z-2 Z-Coordinate of the target point

N195 G41 X25 D1

G41 Tool radius compensation left

X25 X-Coordinate of the target point
D1 Select the compensation offset 1

N200 G1 Y50

G1 linear interpolation in slow feed motion

Y50 Y-Coordinate of the target point

N205 G2 X25 Y50 I25

G2 circular interpolation clockwise

X25 X-Coordinate of the target point
Y50 Y-Coordinate of the target point
I25 X-Coordinate of the center of circular arc

N210 G40 G1 Y65

G40 Tool radius compensation cancel

G1 linear interpolation in slow feed motion
Y65 Y-Coordinate of the target point

N215 Z5

Z5 Z-Coordinate of the target point

N220 G91 G28 Z0 M5

G91 Incremental dimensioning

G28 Reference point return
Z0 Z-Coordinate of the Intermediate Point
M5 deactivate spindle

N225 G91 G28 X0 Y0 M9

G91 Incremental dimensioning

G28 Reference point return
X0 X-Coordinate of the Intermediate Point
Y0 Y-Coordinate of the Intermediate Point
M9 deactivate coolant

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Block Commands
No.

Description

9) Circular pocket r=15mm mill 4mm deep

N230 T02 M06

T02 Select the tool 2

M06 Mounting the tool 2

N235 G90 G0 X50 Y50

G90 Absolute dimensioning

G00 rapid traverse
X50 X-Cordinate of the target point
Y50 Y-Coordinate of the target point

N240 G43 Z20 H18

G43 Tool length compensation +

Z20 Z-Coordinate of the target point
H18 Select the compensation offset 2

N245 S1800 M3

S1800 spindle speed

M03 activate the spindle in clockwise rotation

N250 Z2 M8

Z2 Z-Coordinate of the target point

M8 activate coolant

N255 G1 Z-4 F50

G1 linear interpolation in slow feed motion

Z-4 Z-Coordinate of the target point
F50 feedrate in mm/min

N260 G42 G1 X38 Y53 D2

G42 Tool radius compensation right

G1 linear interpolation in slow feed motion
X38 X-Coordinate of the target point
Y53 Y-Coordinate of the target point
(Starting point of the quarter-round starting move r=12)
D2 Select the compensation offset 2

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Block Commands
No.

Description

N265 G2 X50 Y65 R12 F200

G2 circular interpolation clockwise

X10 X-Coordinate of the target point
Y18 Y-Coordinate of the target point
(Target point of the quarter-round remove r=12)
R12 radius r=12 of the circular arc
F200 feedrate in mm/min

N270 G2 J-15

G2 circular interpolation clockwise

(full circle milling r=15)
J-15 Y-Coordinate of the center of circular arc

N275 G2 X62 Y62 R12

G2 circular interpolation clockwise

X62 X-Coordinate of the target point
Y62 Y-Coordinate of the target point
(Target point of the quarter-round remove r=12)
R12 radius r=12 of the circular arc

N280 G40 G1 X50 Y50

G40 Tool compensation cancel

G1 linear interpolation in slow feed motion
X50 X-Coordinate of the target point
Y50 Y-Coordinate of the target point

N285 G0 Z50 M9

G0 rapid traverse
Z50 Z-Coordinate of the target point
M9 deactivate coolant

N290 G91 G28 Z0 M5

G91 Incremental dimensioning

G28 Reference point return
Z0 Z-Coordinate of the Intermediate Point
M5 deactivate spindle

N295 G91 G28 X0 Y0

G91 Incremental dimensioning

G28 Reference point return
X0 X-Coordinate of the Intermediate Point
Y0 Y-Coordinate of the Intermediate Point

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Block Commands
No.

Description

10) 4x centering
N300 T03 M06

T03 Select the tool 3

M06 Mounting the tool 3

N305 G90

G90 Absolute dimensioning

N310 G43 Z20 H19

G43 Tool length compensation +

Z20 Z-Coordinate of the target point
H19 Select the compensation offset 3

N315 S2200 M03

S2200 spindle speed

M03 activate the spindle in clockwise rotation

N320 G0 Z1

G0 rapid traverse
Z1 Z-Coordinate of the target point

N325 G98 G81 Z-5 R-3 F80 L0

G98 Return to the initial point

G81 Drilling cycle, spot boring
R-3 Z-Coordinate of the safety plane
Z-5 Coordinate at the bottom of the hole
F80 feedrate in mm/min
L0 The Drilling cycle is only stored!

N330 M98 P1910

M98 P Subprogram call

1910 Subprogram number

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Block Commands
No.

Description

11) 4x Core hole drilling

N335 T04 M06

T04 Select the tool 4

M06 Mounting the tool 4

N340 G90 G0 X0 Y0

G90 Absolute dimensioning

G0 rapid traverse
X0 X-Coordinate of the target point
Y0 Y-Coordinate of the target point

N345 G43 Z20 H20

G43 Tool length compensation +

Z20 Z-Coordinate of the target point
H20 Select the compensation offset 4

N350 S1500 M03

S1500 spindle speed

M03 activate the spindle in clockwise rotation

N355 G0 Z1

G0 rapid traverse
Z1 Z-Coordinate of the target point

N360 G98 G83 Z-10 Q6 R-3 F50 L0

G98 Return to the initial point

G83 Peck drilling cycle
Z-10 Coordinate at the bottom of the hole
Q6 Digression
R-3 Z-Coordinate of the safety plane
F50 feedrate in mm/min
L0 The Peck drilling cycle is only stored!

N365 M98 P1910

M98 P Subprogram call

1910 Subprogram number

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Block Commands
No.

Description

12) 4x Tapping
N370 T05 M06

T05 Select the tool 5

M06 Mounting the tool 5

N375 G90 G0 X0 Y0

G90 Absolute dimensioning

G0 rapid traverse
X0 X-Coordinate of the target point
Y0 Y-Coordinate of the target point

N380 G43 Z20 H21

G43 Tool length compensation +

Z20 Z-Coordinate of the target point
H21 Select the compensation offset 5

N385 S150 M3

S150 spindle speed

M03 activate the spindle in clockwise rotation

N390 G00 Z1

G00 rapid traverse

Z1 Z-Coordinate of the target point

N395 G98 G84 Z-8 R-3 F150 L0

G98 Return to the initial point

G84 Tapping cycle
Z-8 Coordinate at the bottom of the hole
R-3 Z-Coordinate of the safety plane
F150 feedrate in mm/min
L0 The Tapping cycle is only stored!!

N400 M98 P1910

M98 P Subprogram call

1910 Subprogram number

N405 G90 G49 G80 G40 M30

192

M30 program end and backspacing

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Introduction into NC programming

NC subprogram
Block Commands
No.
N10

Description

O 1910

O Program name

G90 X18 Y18 M8

First drilling position:

G90 Absolute dimensioning
X18 X-Coordinate of the drilling position
Y18 Y-Coordinate of the drilling position
M8 activate coolant

N15

Y82

Second drilling position:

Y82 Y-Coordinate of the drilling position

N20

X82

Third drilling position:

X82 X-Coordinate of the drilling position

N25

G98 Y18

Fourth drilling position:

G98 Return to the initial point
Y18 Y-Coordinate of the drilling position

N30

G00 G90 G80 Z50. M9

G00 Rapid Traverse

G90 Absolute dimensioning
G80 Canned cycle cancel
Z50 Z-Coordinate
M9 deactivate coolant

N35

G91 G28 Z0 M5

G91 Incremental dimensioning

G28 Reference point return
Z0 Z-Coordinate of the Intermediate Point
M5 deactivate spindle

N40

G91 G28 X0 Y0

G91 Incremental dimensioning

G28 Reference point return
X0 X-Coordinate of the Intermediate Point
Y0 Y-Coordinate of the Intermediate Point

N45

M99

M99 subprogram end

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Simulation of the NC program

In automatic mode, the generated NC-programs are simulated in real-time and with respect to possible collisions.

figure 187
Automatic Mode menu Diagram.

figure 188
Automatic Mode menu.

To start an NC program in Automatic Mode, two procedural steps are required:

1. As a first step after starting Automatic Mode, the main menu is loaded, allowing you to enter the
name of the NC program (par example: 1909) to be simulated.
Accept program: Use F1 or
to confirm the program name appearing in the information Line. If
the program is available, it is subsequently loaded into program memory; if not, an appropriate error message is displayed.
1. Continue by selecting the desired simulation mode for program execution
Automatic: Select F1 to execute the program specified in the dialogue line under continuous
automatic control.
Single NC block: Use F2 to activate single block operation.

figure 189
Menu during continuous automatic run.

figure 190
CNC Milling, 3D Display, Optional section.

Workshop
The students are to manufacture the programmed part on the CNC-milling machine.

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9.

Control test Introduction into NC programming

1.

List the steps for manual programming.

2.

What is the difference between a work plan and a programming sheet?

3.

Explain the meaning of "switching information".

4.

Name and explain five commands for a CNC-machine.

5.

Explain the structure of an NC-program.

6.

Explain the structure of a program block.

7.

Explain the structure of a program word.

8.

Explain the address letters F, S, T, M, X, Y, Z.

9.

Explain the following program words for

a)
absolute programming (G90)
b)
incremental programming (G91)!
X 53, Z 184.005

10.

What do the address letters I, J, K express?

11.

Define the following functions with the corresponding program words

(G-command or M-command)
clockwise circular interpolation
activate coolant
activate spindle in clockwise rotation

12.

For which cases are constant cutting speeds required? Explain why.

13.

With which G-function is constant cutting speed programmed?

14.

Read and explain the following program block.

Illustrate the sequence of motions.
G01 G95 X100 Z-5 F0.25 S600 T0101

15.

Read and explain the following program block.

Illustrate the sequence of motions.
G02 G96 X30 Z-30 I30 K-15 F0.2 S180

16.

Read and explain the following program section!

N5
N10
N20
N30
N40
N50
N60
N70

G90
G0
G1
G0
G1
G2
G0

G96
X133
Z-395
X135
X123
Z-269.8
X133
Z2

T0101
Z2
F0.3
Z2

S100

M3

M8

Z-274.8

I133

K-269.8

O70

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Solution of the CNC exercise on page 151

In the following NC-program, the contour of a pre-turned part is finished. For each command give the corresponding definition.
Block
No.
N05

N10

N15

N20

N25

N30

N35

N40

N45

196

Commands

Description

O 0300

0300 program name

T040404

select the tool from the turret position 4

M3

activate the spindle in clockwise rotation

M42

select the higher spindle speed range

M63

ignoring spindle rotation M code answer

G96

Constant speed cutting ON

S140

spindle speed

G50

maximum spindle speed designation of

S3000

revolution per minute

G0

rapid traverse

X20

X-Coordinate of the target point

Z2

Z-Coordinate of the target point

M8

activate coolant

G1

linear interpolation in slow feed motion

X20

X-Coordinate of the Target Point

Z0

Z-Coordinate of the Target Point

G42

tool nose compensation: right

G3

circular interpolation counter-clockwise

X28

X-Coordinate of the target point

Z-4

Z-Coordinate of the target point

I0

Distance between starting position and circle center in X

K-4

Distance between starting position and circle center in Z

G1

linear interpolation in slow feed motion

Z-28

Z-Coordinate of the target point

G2

circular interpolation clockwise

X34

X-Coordinate of the target point

Z-31

Z-Coordinate of the target point

I3

Distance between starting position and circle center in X

K0

Distance between starting position and circle center in Z

G1

linear interpolation in slow feed motion

X38

X-Coordinate of the target point

Z-33

Z-Coordinate of the target point

G1

linear interpolation in slow feed motion

Z-53

Z-Coordinate of the target point

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Solution of the CNC exercise on page 162

Block
No.
N50

Commands

Description

G1

linear interpolation in slow feed motion

X44

X-Coordinate of the target point

G3

circular interpolation counter-clockwise

X50

X-Coordinate of the target point

Z-56

Z-Coordinate of the target point

I0

distance between starting position and circle center in X

K-3

distance between starting position and circle center in Z

G1

linear interpolation in slow feed motion

Z-64

Z-Coordinate of the target point

G2

circular interpolation clockwise

X62

X-Coordinate of the target point

Z-70

Z-Coordinate of the target point

I6

distance between starting position and circle center in X

K0

distance between starting position and circle center in Z

G1

linear interpolation in slow feed motion

X66

X-Coordinate of the target point

G1

linear interpolation in slow feed motion

X71

X-Coordinate of the target point

Z-72

Z-Coordinate of the target point

G1

linear interpolation in slow feed motion

X76

X-Coordinate of the target point

N85

G40

cancel tool nose compensation

N90

G0

rapid traverse

X500

X-Coordinate of the target point

Z500

Z-Coordinate of the target point

M5

deactivate the spindle

M9

deactivate coolant

M30

program end and backspacing

N55

N60

N65

N70

N75

N80

N95

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Solution for the CNC exercise on page 164

Solution for the CNC exercise on page 153
In the following NC-program, the contour of a work part is milled. For each command, give the corresponding
definition.
Block
No.

Commands

Description

FX100

program name

N05

G54

select work cordinate system one

N10

G90

activate absolute dimensioning

G49

cancel tool length compensation

G80

cancel canned cycle

G40

cancel tool radius compensation

G17

select the X-Y-plane

G21

metric input

G91

activate incremental dimensioning

G28

reference point return

Z0.

Z-Coordinate of the target point

M9

deactivate coolant

G91

activate incremental dimensioning

G28

reference point return

X0.

X-Coordinate of the target point

Y0.

Y-Coordinate of the target point

T01

select the tool number 1 from the magazine

M06

mounting the tool

G90

activate absolute dimensioning

S1600

spindle speed

M03

activate the spindle in clockwise rotation

G0

rapid traverse

G43

tool length compensation

Z20.

Z-Coordinate of the target point

H17

offset number for the tool length

X-20.

Z-Coordinate of the target point

Y-20.

Z-Coordinate of the target point

Z-6.

Z-Coordinate of the target poin

M08

activate coolant

G1

linear interpolation in slow feed motion

G41

cutter compensation: left

X10.

X-Coordinate of the target point

D1

offset number for the cutter radius

F250.

feedrate in mm per min

N20

N25

N30

N35

N40

N45

N50

N55

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4.3
Block
No.
N60

N65

N70

N75

N80

N85

N90

N95

N100

N105

N110

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Introduction to manual NC programming

Commands

Description

G1

linear interpolation in slow feed motion

Y82.

Y-Coordinate of the target point

G2

circular interpolation clockwise

X18.

X-Coordinate of the target point

Y90.

Y-Coordinate of the target point

R8.

radius of the circle

G1

linear interpolation in slow feed motion

X82.

X-Coordinate of the target point

G2

circular interpolation clockwise

X90.

X-Coordinate of the target point

Y82.

Y-Coordinate of the target point

R8.

radius of the circle

G1

linear interpolation in slow feed motion

Y18.

Y-Coordinate of the target point

G2

circular interpolation clockwise

X82.

X-Coordinate of the target point

Y10.

Y-Coordinate of the target point

R8.

radius of the circle

G1

linear interpolation in slow feed motion

X18.

X-Coordinate of the target point

G2

circular interpolation clockwise

X10.

X-Coordinate of the target point

Y18.

Y-Coordinate of the target point

R8.

radius of the circle

G3

circular interpolation counter-clockwise

X-10.

X-Coordinate of the target point

Y38.

Y-Coordinate of the target point

R20.

radius of the circle

G0

rapid traverse

G40.

cancel cutter compensation

X-20.

X-Coordinate of the target point

Y-20.

Y-Coordinate of the target point

G0

rapid traverse

Z40.

Z-Coordinate of the target point

M5

deactivate spindle

MTS TeachWare CNC-Grundlagen Students Book

Solution for the CNC exercise on page 164

Block
No.
N115

N120

N125

Commands

Description

G91

activate incremental dimensioning

G28

reference point return

Z0.

Z-Coordinate of the target point

M9

deactivate coolant

G90

activate absolute dimensioning

G80

cancel canned cycle

G49

cancel tool length compensation

G40

cancel tool radius compensation

M30

program end and backspacing

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Answers for the control test CNC Basics:

1. - The CNC machine tool is not operated manually but programmed.
It then automatically processes the entered NC program.
- The CNC machine has adjustable axle drives.
- The CNC machine has a path measuring system for each travel axis.
2. - All information necessary for machining the work part is entered as commands.
-The computer, integrated in the CNC control, controls all functions and adjusts all travel movements.
3. - CNC machine tools work with higher machining speeds.
- CNC machine tools work with constant quality.
- CNC machine tools work with higher precision.
- CNC machine tools lead to shorter transit times.
4. - The feed axes must be controllable to enable the tool to be moved into the exact position desired.
5. - motor
- mechanical clutch to avoid overload as well as electronic control
- ball thread drive for play-free power transmission
- sensor as a travel path measuring system
- power amplifier with analog or digital interfaces to the CNC control
6. - two axes minimum
7. - the X axis (face rotating axis)
- the Z axis (longitudinal axis)
8. - three axes minimum
9. - the X axis
- the Y axis
- the Z axis
10. - The controllable spindle axis C on the CNC lathe.
- The rotation axis C of a rotary table on a CNC milling machine.
11. - Driven tools enable milling and boring on a CNC lathe.12. - The rotary table enables turning on a CNC milling machine.
- The work part can be machined from various sides.
13. - It enables playfree movement of the feed axes
- Both halves of the ball thread nut are clamped to each other. The power is transmitted between the
spindle and the nut without friction by the balls.
14. - In case of direct position measuring the position is measured directly on the slide.
- In case of indirect position measuring the position is defined based on the rotation of the spindle.
15. - In case of absolute position measuring the position can be directly defined on the measuring scale.
- In case of indirect position measuring only movements are added together. Therefore the position
must be constantly re-calculated.
16. - To keep the cutting speed constant.
- To control the start and the halt.
17. - Tool turret
- Tool magazine with tool change device
18. - chain magazine
- line magazine
- ring magazine
- plate magazine
- cassette magazine

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Answers for the control test Basic Geometry

Answers for the control test Basic Geometry:
1. - Turning :

+X

+Z

2. - Milling :

3. - If points are dimensioned using an angle and a distance, example: drilling hole circle.
4. - Point control
- Line control
- Path control
5. - 2 D path control on the X/Y plane
- 2 D path control on the X/Z plane
- 2 D path control on the Y/Z plane
6. - In case of a 2 D path control all three axes can be traveled to one by one, only two at one time
however. Therefore, the plane on which the travel movement is to take place has to be selected first.
7. - The machine zero point M is the origin of the machine coordinate system.
- The work part zero point W is the origin of the work part referenced coordinate system. It is set so
as to enable the drawing dimensions to be taken directly from it.
- The reference point R is required for machines with incremental path measuring system to indicate
the control first an absolute position.
- The tool reference point E is used to measure the applied tools.
8. - The work part zero point W should be positioned so that the drawing dimensions can be directly
taken over for programming.
- In turning, in the rotation axis and in most cases on the front face of the work part.
- In milling, in most cases on the left lower corner point of the work part surface.
9. - Dimension tolerances do not cumulate.
- Single incorrect dimensions do not lead to subsequent errors.
- In turning work parts the diameter values can be directly entered as X value.

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10. - When incrementally dimensioning points.

- When identical contours or boring patterns as well as recesses are to be machined repeatedly.

15

20

30

20

15

11.

15

20

30

20

15

12. - A control chain is open - a feedback loop is closed!

- In case of a control chain machines are affected without controlling the consequences. Resulting
from internal or external influences deviations from the desired set values are possible.
- In case of a feedback loop these deviations are corrected by measuring the actual values and adjusting them to the set values by the feedback loop.
13. - Example: Position feedback loop:
When the tool moves, the desired position is transferred to the position feedback loop as a set
value.The path measuring system measures the actual position and returns the value to the feedback control. If these values are not identical, also as a result of internal and external influences
(disturbance entities), the corresponding movement is initiated until the desired position (set value)
has been reached.
14. - As milling tools with various diameters are eventually used. If only the milling machine center point
path were considered deviations would appear on the work part.
15. - The length of the milling tool L.
- The radius of the milling tool R.
16. - In travel movements, which do not run parallel to the X and Z axis, dimension deviations are created.
17. - The length of the turning tool L.
- The measurement of Q.
- The tool tip radius R.
18. - To enable the control to calculate the tool tip radius in the correct direction.
19. - Measuring with a tool setup device.
- Measuring with zero tools.
- Direct measuring when machining a work part.
- Optical measuring on a CNC machine tool.

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Answers for the control test Technological Basics

Answers for the control test Technological Basics:

1.

- Tool carriers
- Tool holders
- Indexable inserts

2.

- higher cutting speeds and higher cutting-edge life compared with high-speed steels
- quick and simple exchange of indexable inserts

3.

- P (blue) fr long shipping material

- M (yellow) for materials which are difficult to be machined
- K (rot) for short shipping materials

4.

- The clearance angle influences friction on the work part and consequently, the heating-up of the
cutting edge.

5.

- A larger angle of rake improves the machining flow.

- A larger angle of rake reduces the cutting forces.

6.

- A larger angle of rake increases the cutting edge breach.

- A larger angle of rake increases the decarburization.

7.

- Negative angles of rake are necessary for machining hard and brittle material.

8.

- The adjustment angle influences the feed power, the forces against the work part, the cutting width
and the cutting depth.

9.

vc = *d * n

or

n=

vc
*d

n=

120m
* min* 0,08m

n = 477 1 min
10.

vc = * d * n
vc = * 0,25 m 100 1 min

vc = 78

m
min

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11. - It must clearly determine the position of the work part.

- It must detain all forces from the work part.
12. - keybar chucks
- jaw chucks with scrolls
possibly

two-jaw chucks
three-jaw chucks
four-jaw chucks

13. - large work parts

- irregularly formed work parts
14. - For clamping long, slim work parts
15. - mechanical power generation
- pneumatic power generation
- hydraulic power generation
- electric power generation
16. - clamping with clamping elements
- machine vises
- fixtures
17. - quick work part exchange
- accurate clamping of work part

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Instroduction into CNC technology

Answers for the control test Introduction into NC programming:
1. The programmer must determine all necessary information required for the NC-program. The steps
are:
1. defining machining steps
2. defining necessary tools
3. calculating technological data
4. calculating geometric data
5. generating the NC-program
6. controlling the NC-program
2. The work plan contains all machining operations, clamping devices and technological data that was
calculated in the production drawing.
3. Switching information relates to commands that switch machining functions on or off. Example:
spindle rotation
coolant
tool change
4. see Comparison of programming codes/keys of various CNC-controls
5. An NC-program consists of a beginning (Ex. %), an end (Ex. M30) and a chronological sequence of
NC-blocks.
6. An NC-block consists of a block number and series of words.
7. A program word consists of an address letter and a number with +/-sign.
8. F
S
T
M
X
Y
Z

feed
speed
tool position in tool storage or turret
additional or switching information
target coordinates in X-direction
target coordinates in Y-direction
target coordinates in Z-direction

9. a) Travel to a diameter of 53mm and to target coordinate Z 184.005.

b) Travel incrementally from the present tool position 53mm in +X-direction and 184.005 in +Zdirection.
10. The address letters I, J, K are interpolation parameters. For example, when programming circular
movements they incrementally define the coordinates of the circle center with respect to the starting
point of the circular movement.
11. clockwise circular interpolation: G02
activate coolant: M8
activate spindle in clockwise rotation: M3
12. A constant cutting speed is used for face and form turning. A constant surface quality is obtained
since the number of rotations adapts to the changing diameters.
13. With the command G96 and starting speed S
Ex.: G96 S2000
14. G01 G95 X100 Z-5 F0.25 S600 T0101
Travel tool Nr. 1 considering the tool compensation value in storage Nr. 1 in a linear movement with
a feed of 0,25mm per rotation towards target coordinates X100 (diameter) and Z-5.

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15. G02 G96 X30 Z-30 I15 K-15 F0.2 S180

Travel clockwise in a circular movement with constant cutting speed and a feed of 0,2mm per rotation towards the target coordinates X30 and Z-30. The circle center is incrementally located 15mm in
+X-direction and 15mm in +Z-direction from the starting point.
16. N5
G90
G96
T0101 S100 M3
M8
Absolute programming call, constant cutting speed with starting speed of 100 rotations per minute,
the tool Nr. 1 with the compensation value in storage Nr. 1. Activate the spindle in clockwise rotation
and coolant.
N10
G0
X133 Z2
The tool moves in rapid traverse to the coordinates X133 and Z2.
N20
G1
Z-395 F0.3
The tool travels with a feed of 0,3mm per rotation to the target point X133 and Z-395.
N30
G0
X135 Z2
The tool moves in rapid traverse to the coordinates X135 and Z2.
N40
X123
The tool moves in rapid traverse to the coordinates X123 and Z2.
N50
G1
Z-269.8
The tool travels with a feed of 0,3mm per rotation to the target point X123 and Z-269.8.
N60
G2
X133 Z-274.8
I5
K0
The tool travels clockwise with a feed of 0,3mm per rotation in a circular movement to the target
point X133 and Z-274.8. The circle center is incrementally located 5mm in +X-direction from the
starting point.
N70
G0
Z2
The tool moves in rapid traverse to the target point X133 and Z2.

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