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Programming
Handbook
Second Edition
CNC
Programming
Handbook
Second Edition
A Comprehensive Guide to Practical CNC Programming
Peter Smid
Smid, Peter.
CNC programming handbook: comprehensive guide to practical CNC programming!
Peter Smid.
p.cm.
ISBN 0-8311-3158-6
I. Machine-tools--Numerical control--Programming --Handbooks, manuals,etc .. !'
Title.
Second Edition
system, or transmitted in any form without the permission of the publi shers.
5 6 7 8 9 10
Dedication
To my father Frantisek and my mother Ludmila,
who taught me never to give up.
Acknowledgments
In this second edition of the eNC Programming Handbook, I would like to express my
thanks and appreciation to Peter Eigler for being the bottomless source of new ideas,
knowledge and inspiration" all that in more ways than one. My t hanks also go to Eugene
Chishow, for his always quick th inking and his ability to point out the elusive detail or two
that I might have missed otherwise. To Ed Janzen, I thank for the many suggestions he of-
fered and for always being able to see the bigger picture. To Greg Prentice, the President of
GLP Technologies, Inc., - and my early mentor - you w ill always be my very good friend.
Even after three years of improving the eNC Programming Handbook and developing the
enclosed compact disc, my wife Joan w ill always deserve my thanks and my gratitude. To
my son Michael and my daughter Michelle - you guys have contributed to this handbook in
more ways than you can ever imagine.
I have also made a reference to several manufacturers and software developers in the
book. It is only fair to acknowledge their names:
Over the years, Mr. Sm id has developed and delivered hundreds of customized educa-
tional programs to thousands of instructors and students at colleges and universities
across United States, Canada and Europe, as we ll as to a large number of manufacturing
companies and private sector organ izations and individuals.
He has actively participated in many industrial trade shows, conf erences, workshops and
various seminars, including submission of papers, delivering presentations and a number
of speaking engagements to professional organizatio ns. He is also the author of articles
and many in-house publications on t he subject of CNC and CAD/CAM. During his many
years as a professional in the CNC industrial and educational field, he has developed tens
of thousands of pages of high quality training materials.
The author welcomes comments, suggestions and other input from educators, students and industrial users.
You can e-mail him through the publisher of this handbook from the Main Menu of the enclosed CO.
You can also e-mail him from the CNC Programming Handbook page at www.industrialpress.com
TABLE OF CONTENTS
1 - NUMERICAL CONTROL 1 Axes and Planes 16
Point of Origin 16
DEFINIT ION OF NUMERICAL CONTROL
Quad rant s. 16
Right Hand Coordinate Syst em 17
NC and CNC Technology.
MACHINE GEOMETRY. 17
CO NVENTIONAL AND CNC MACHINING 2 Axis Orientation - Milling 17
NU MERICAL CONTROL ADVANTAGES 2 Axis Orientatio n - Turning . 18
Setup Time Reduction 3 Additional Axes. 18
lead Time Reduct ion 3
Accuracy and Repeatability 3
Contouring of Complex Shapes. 3 5 - CONTROL SYSTEM 19
Simplified Tooling and Work Holding. 3
Cutting Time and Productivity Increase. 4
GENERAL DESCRIPTION 20
TY PES OF CNC MACHINE TOOLS 4 Operation Panel 20
Mills and Machin ing Centers. 4 Screen Display and Keyboard 21
Lathes and Turning Centers 5 Handle 22
PE RSONNEL FOR CNC 5 SYSTEM FEATURES 22
CNC Programmer 5 Parameter Settings 22
CNC Machine Operator. 6 Syst em Defaults 23
SAFETY RELATED TO CNC WORK. 6 Memory Capacity 24
MANUAL PROGRAM INTERRU PTION. 25
Single Block Operation. 25
2 - CNC MILLING 7 Feedhold 25
Emergency Stop 25
CNC MACHINES - MILLING. 7 MAN UAL DATA INPUT - MOl 26
Types of Mill ing Machines. 7 PROGRAM DATA OVERRIDE 26
Machine Axes . 8
Ve rtical Machining Centers. B
Rap id Motion Override. 26
Spindle Speed Overri de 27
Horizontal Machining Centers 9
Feedrate Override. 27
Horizontal Boring Mi ll 10
Typical Specifications 10
Dry Run Operation 27
Z AXIS Neglect 28
Manual Absolu t e Setting . 28
Sequence Return 28
3 - CNC TURNING 11 Auxiliary Functions Lock 28
Machine Lock 28
CNC MACHINES · TURNING 11 Practical Applications 29
Types of CNC lathes. 11 SYSTEM OPTIONS. 29
Number of Axes 11 Graph ic Display. 29
AXES DES IGNATION 11 In-Process Gaug ing 30
Two-axi s Lathe. 12 Sto red Stroke limit s. 30
Three-axis Lathe 12
Dra wing Dimensions Input 30
Four-axis Lathe. 13 Machining Cycles. 30
Six-axis lathe 13 Cutting Tool Arlimation . 30
Connection to External Devices 30
FEATURES AND SPECIFICATIONS 13
Typical Machine Specifications. 13
Control Features 14 6 - PROGRAM PLANNING 31
ix
X Table of Contents
Control System . 31
PART COMPLEXITY 32 8 - PREPARATORY COMMANDS 47
MANUAL PROGRAMMING 32
DESCRIPTION AND PURPOSE. 47
Disadvantages 32
Advantages 32 APPLICATIONS FOR MILLING. 47
CAD/CAM AND CNC 32 APPLICATIONS FOR TURNING 49
Integration . 33 G CODES IN A PROG RAM BLOCK 50
Future of Manual Programming 33 Modality of G-commands. 50
TYPICAL PROGRAMMING PROCEDURE 33 Conflicting Commands In a Block 50
Word Order In a Block 51
PART DRAWING 34
GROUPING OF COMMANDS 51
Title Block . 34
DimensIoning 34 Group Numbers 51
Tolerances. 35 G CODE TYPES. 52
Surface Finish 35 G Codes and Decimal Point. 52
Drawing Revisions 36
Speclal lnsuuctions 36
METHODS SHEET . 36 9 - MISCELLANEOUS FUNCTIONS 53
MATERIAL SPECIFICATIONS 36
Matenal Un iformity 36 DESCRIPTION AND PURPOSE. 53
Machinability Rating . 37 Machine Related Functions . 53
MACHINING SEQUENCE 37 Prog ram Rela ted Functions 53
TOOLING SELECTION . 38 TYPICAL APPLICATIONS 54
PART SETUP 38 Appl ications for M illing. 54
Appl ications for Turning 54
Setup Sheet 38 Special M Ol Functions. 54
TECHNOLOGICAL DECISIONS 38 Appl ication Groups 54
Cutter Path 38 M FUNCTIONS IN A BLOCK 55
Machme Power Rat ing. 39 Startup of M Functions. 56
Coo lants and Lubricants 39 Duration of M Functions . 56
WORK SKETCH AN D CALCULATIONS 40 PROGRAM FUNCTIONS 56
Identification Methods . 40 Program Stop 56
QUALITY IN CNC PROGRAMMING 40 OptIOnal Program Stop. 57
Program End. 58
Su bprogram En d SR
7 . PART PROGRAM STRUCTURE 41 MACHINE FUNCTIONS 58
Coolant Functions 58
BASIC PROGRAMMING TERMS 41 Spmdle Functions. 59
Charac ter 41 Gear Range SelectIOn 60
Word 41 Machine Accessories 60
Bleck. 41
Program. 42
42
10 - SEQUENCE BLOCK 61
PROG RAMMING FORMATS
WORD ADDRESS FORMAT 42 BLOCK ST RUCTURE 61
FORMAT NOTATION 43 Building the Block Structure. 61
Short Forms 43 Block Structure for Milling 61
Milling System Format 43 PROGRAM IDENTIFICATION 62
Turnm g Sys tem Format·
44
Multi ple Word Addresses'
45 Program Number. 62
Program Name. 62
SYMBOLS IN PROGRAMMING 45
SEQUENCE NUMBER S 63
Plus and Minus Sign 45
Sequence Number Command. 63
PROG RAM HEADER 45 Sequence Block Format 63
TYPICAL PROGRAM STRUCTURE. 46 Numbenng Increment 64
Long Programs and Block Numbers. 64
END OF BLOCK CHARACTER. 64
STARTUP BLOCK OR SAFE BLOCK 65
Table of Contents xi