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Unit 1 Introduction of CNC Machine Tool1

1.1 Machining Center Configurations1

1.2 Vertical Machining Centers2

1.3 Horizontal Machining Centers5

1.4 Other Programmable Features of Machining Centers8

1.4.1 Spindle Speed8

1.4.2 Spindle Activation and Direction8

1.4.3 Spindle Range8

1.4.4 Feedrate8

1.4.5 Coolant9

1.4.6 Tool Changes9

1.4.7 What Else Might Be Programmable9

Exercises10

Unit 2 Tooling for CNC Machine12

2.1 Introduction12

2.2 Material for Cutting Tools13

2.3 The Practical Application of Cemented Carbides15

2.3.1 Solid Tools15

2.3.2 Brazed Tips15

2.3.3 Indexable Inserts16

2.4 Tooling Systems19

2.5 Automatic Tool Changer System22

2.5.1 Turret Head22

2.5.2 Carousel Storage with Spindle Direct Tool Changer23

2.5.3 Horizontal Storage Matrix Magazine with Pivot Insertion Tool Changer24

Exercises26

Unit 3 Program Zero and Coordinate System27

3.1 What is Coordinate System27

3.2 Plus and Minus30

3.3 Program Zero31

3.4 Absolute vs.Incremental33

Exercises35

Unit 4 Mathematics for NC Programming36

4.1 Introduction36

4.2 Geometry37

4.2.1 Properties of Intersecting Lines37

4.2.2　Tangency38

4.3 Trigonometry40

4.3.1 The Pythagorean Theorem40

4.3.2 Right Triangle Trigonometry41

4.3.3 Oblique Triangle Trigonometry44

Exercises48

Unit 5 Word Address Programming50

5.1 Introduction50

5.2 Programming Language Format50

5.3 Programming Language Terminology52

5.4 Program and Sequence Numbers(O,N Codes)53

5.5 Preparatory Functions(G Codes)55

5.6 Dimension Words(X,Y,Z,…Codes)56

5.7 Feedrate(F Codes)57

5.8 Spindle Speed(S Codes)57

5.9 Miscellaneous Machine Functions(M Codes)58

5.10 Why Learn Manual Programming59

Exercises62

Unit 6 Speeds and Feeds63

6.1 Cutting Speeds and Feeds63

6.2 Spindle Speeds65

6.3 Feed Rates67

6.3.1 Feed Rates for Turning68

6.3.2 Feed Rates for Milling69

6.3.3 Feed Rates for Drilling70

6.4 Feed Rate and Spindle Speed Override71

Exercises72

Unit 7 Preparation for Programming73

7.1 The Importance of Preparation73

7.2 Typical Mistakes74

7.2.1 Syntax Mistakes75

7.2.2 Motion Mistakes75

7.2.3 Mistakes of Omission76

7.2.4 Process Mistakes76

7.3 Steps for Preparing to Write a CNC Program77

7.3.1 Study and Mark Up the Print77

7.3.2 Prepare the Machining Process77

7.3.3 Develop the Needed Cutting Conditions81

7.3.4 Do the Required Math81

7.3.5 Check the Required Tooling83

7.4 Plan the Work Holding Setup84

7.5 Other Documentation85

7.5.1 Setup Sheet85

7.5.2 Program Listing86

7.6 Is It All Worth It86

Exercises87

Unit 8 Programming Techniques88

8.1 Introduction88

8.2 Programming Hole Operation88

8.3 Programming Linear Profiles90

8.4 Programming Circular Profiles91

8.4.1 Circular Interpolation Commands91

8.4.2 Circular Interpolation Via Direct Radius Specification92

8.4.3 Profiling Arcs at Constant Feed Rate94

8.5 Programming with Subprogram96

8.5.1 Subprogram Concept96

8.5.2 Commands for Calling a Subprogram and Returning to the Main Program97

8.5.3 General Rules for Subprogramming98

Exercises99

Unit 9 Three Kinds of Compensation100

9.1 Introduction100

9.2 What is Compensation101

9.3 Understanding Offsets103

9.3.1 How Many Offsets do You Have104

9.3.2 Offsets and Trial Machining104

9.3.3 Organization of Offsets105

9.3.4 Wear Offsets Versus Geometry Offsets106

9.3.5 How Offsets are Instated106

9.4 Tool Length Compensation108

9.4.1 The Reason for Tool Length Compensation108

9.4.2 How Tool Length Compensation is Used110

9.5 Cutter Radius Compensation111

9.5.1 Reasons for Using Cutter Radius Compensation112

9.5.2 How does Cutter Radius Compensation Work116

9.6 Fixture Offsets117

Exercises118

Unit 10 Machine Design120

10.1 Repeatability120

10.2 Basic Structure122

10.3 Machine Spindles123

10.4 Spindle Drives126

10.5 Machine Slides128

10.6 Slide Drives130

Exercises133

Unit 11 Setup and Maintain135

11.1 Tasks Related to Setup and Operation135

11.1.1 Setup Tasks Versus Production Maintaining Tasks136

11.1.2 Tasks Related to Setup137

11.2 Tasks Related to Maintaining Production143

11.2.1 Workpiece Unload and Load144

11.2.2 Maintaining Critical Dimensions(with Close Tolerances)during Each Tool's Life145

11.2.3 Replacing Worn Tools147

11.3 Other Possible Tasks to be Done During the Production Run149

Exercises150

Unit 12 Three Modes of Operation151

12.1 The Manual Mode152

12.2 The Manual Data Input Mode153

12.2.1 The Manual Data Input Position of the Mode Switch154

12.2.2 The Edit Position of the Mode Switch155

12.3 The Program Operation Mode157

12.3.1 The Memory(or Auto)Mode Switch Position159

12.3.2 The Tape Mode Switch Position160

Exercises162

Unit 13 Program Verification Techniques163

13.1 Introduction163

13.2 Safety Priorities165

13.2.1 Operator Safety165

13.2.2 Machine Tool Safety166

13.2.3 Workpiece Safety167

13.3 Typical Mistakes168

13.3.1 Syntax Mistakes in the Program169

13.3.2 Motion Mistakes in the Program170

13.3.3 Setup Mistakes170

13.3.4 Mistakes of Omission171

13.4 Procedures to Program Verification172

13.4.1 The Machine Lock Dry Run172

13.4.2 Free Flowing Dry Run173

13.4.3 Normal Air Cutting Cycle Execution175

13.4.4 Running the First Workpiece176

13.4.5 Making Good Parts177

13.5 Conclusion to Program Verification178

Exercises179

Unit 14 CAD/CAM180

14.1 Introduction180

14.2 Computer-Aided Anything(CAA)181

14.3 What is CAD/CAM Software182

14.4 Description of CAD/CAM Components and Functions184

14.4.1 CAD Module184

14.4.2 CAM Module187

14.4.3 Geometry vs.Toolpath189

14.4.4 Tool and Material Libraries191

14.4.5 Verification and Post-Processor192

14.4.6 Portability193

14.5 Software Issues and Trends195

Exercises198

Appendix A G＆M Code Reference199

Appendix B The Sample of CNC Machine Specification203

Appendix C Vocabulary208

References232