CNC Turning Technology

Purpose
To evaluate each contestants preparation for
employment in Computer Numeric Control
machining. To recognize outstanding students
for excellence and professionalism in the CNC
machining field
Clothing Requirement
Official SkillsUSA khaki work shirt and pants,
black or brown leather work shoes, and safety
glasses with side shields or goggles. Prescription
glasses can be used only if they are equipped
with side shields. If not, they must be covered
with goggles.) To purchase official work clothes,
contact Midwest Trophy Manufacturing Co. Inc.
by calling 1-800-324-5996 or order online at:
http://www.mwtrophy.com/vica/index.html.
Eligibility
Open to active SkillsUSA-VICA members
enrolled in programs with precision machining,
automated manufacturing or CNC as the
occupational objective.
Equipment and Materials
1. Supplied by the technical committee:
a. CNC Lathe with proper work holding
devices
b. Workbench
c. Necessary hand tools and cutting tools
d. Necessary information and furnishings
for judges and technical committee
2. Supplied by the contestants:
a. 0-1 micrometer
b. 6 inch caliper (digital or vernier)
c. Non-programmable calculator
d. Pencils and paper
e. Machinerys Handbook (optional)
f. Deburring tools (files, Emory cloth, etc.)

Page 1 of 3

Scope of the Contest

This contest is split into two sections, CNC
milling and CNC turning. Participants will
compete in one section only.
Each contestant will receive a dimensioned
drawing and material to CNC-machine a part.
Participants are expected to write a CNC
program, set up the machine and tool offsets and
machine a part without the use of CAD/CAM
software. Only the part will be evaluated, not the
CNC program. Participants are given 15 minutes
to study the task and ask questions before
beginning. The competition may run 6 to 8
hours, depending on the project design.
Competencies required are as follows:
1. Programming
a. Write and verify CNC program without
the use of CAM software (competitor has
the opportunity to correct any program
errors on the machine)
b. Display complete knowledge of DIN/ISO
programming (G and M codes)
c. Apply the correct use of cutter
compensation (G41/G42)
d. Adjust speeds and feeds as needed
2. Setup
a. Setup machine and establish a zero
reference point for machining the part
b. Select and mount necessary tools from
the provided set
c. Establish tool offsets and enter them into
the CNC machine control
d. Enter any necessary tool corrections into
the CNC machine control
3. Perform mathematical calculations
a. Calculate CNC speeds and feeds
b. Calculate programming coordinates from
the drawing
c. Calculate radius tangent points

CNC Turning Technology

4. Measuring
a. Measure test part to the nearest 0.001
5. Communication
a. Read and interpret technical blue prints
b. Understand all symbols on technical blue
prints, such as geometric tolerances,
surface-finish symbols, corner-break
symbols, etc
General Information
The CNC machines will be available for
orientation on the day before the competition.
During this time, technicians will be on hand to
help competitors and their advisors familiarize
themselves with the equipment. An actual test
part will be programmed, set up and machined
from the provided drawing and stock material.
Materials used for the competition may be
Aluminum, Brass, Cold-rolled Steel, or Delrin.
Test project scoring
The three evaluation criteria for the test part are:
1. Conformity to Print:
a. Visual conformity of part to drawing.
(Look for shape and features of part)
b. Edges broken
c. Transitions of surfaces
d. Part is burr free
e. Damage to part (clamp marks,
scratches)
2. Dimensions:
This is an objective scoring. Scores will
only be granted if dimension is in
compliance with the print. The score for

Page 2 of 3

each dimension will either be full points

or zero points.
3. Use of Material
If the competitor makes a mistake on the
test part, he/she may request a second
piece of stock material. A deduction of
points will be assessed for the use of
extra stock.
See the following sample-scoring sheet.

CNC Turning Technology

CNC Machining Technology Rating Sheet

Test Project

Possible
Points (max)

Conformity
Visual conformity
All edges broken
Part is burr free
Surface finish

10
3
3
3

Dimensions
Dimension 1
Dimension 2
Dimension 3
Dimension 4
Dimension 5
Dimension 6
Dimension 7
Dimension 8
Dimension 9
Dimension 10

Use of Material (subtract 3 pts. for each extra stock)

Professional Assessment
Written Test

10
10
8
8
5
5
5
5
5
5
0
5
10

Clothing Penalty (minus 0 to 5 percent of total points)

Total

Page 3 of 3

100

Points
Gained

CNC Machining Demonstration Contest

Demonstration Contest CNC Machining

The WorldSkills Competition for World Class Standards

International Vocational Training Organization

SeoulKorea 2001

Page 1 of 10

CNC Machining Demonstration Contest

This contest is designed to

simulate the International skills
championships. The difference to
the international competition is the
duration of the contest, the
difficulty level, the size of
machines and projects as well as
the metric vs. standard system.
However, the principles of the
contest are the same as at the
international competition.
The contest is split into two
sections, CNC turning and CNC
milling. Participants will compete in
one section only.
Each contestant will receive a
blueprint and material to CNCmachine a part according to a
drawing. Participants are asked to
write the CNC program, set up the
machine and machine the part
without the use of CAD/CAM. Only
the final result ( the part ) is
evaluated, not the CNC program.
Participants are given 15 minutes
to study the task and ask
questions, which is not competition
time. The competition may run 6 to
8 hours, depending on the project
design.

Solve shop/laboratory problems

requiring the use of formulas,
handbooks, charts and tables
Communication competencies
Read and interpret technical blue
prints
Understand all symbols on
technical blue prints, such as
geometric tolerances, surfacefinish symbols, corner-break
symbols, etc.

Scope of Work
The test project consists only of
practical work comprised of
programming and actual
machining work. The jury will
determine the ratio between
programming and machining time
on the basis of the competition
projects.
The time allowed for the test
project(s) will not exceed 8 hours
Practical Work

Perform CNC Machining

Complete knowledge of DIN/ISO
programming ( G- and M-codes )
Write and verify CNC program ( on
machine control, not on CAM
system )

The competitor has to carry out,

independently, the following tasks:
Programming
The CNC competitor must create
(based on the manufacturing
drawings) usable CNC-programs.

Setup machine
Select, mount and set tools and
offsets
Apply the correct use of cutter
compensation ( G40/ G41/ G42 )

Machine set-up
The competitor must select,
measure and adjust the
appropriate cutting tools. He/she
must also enter any tool
corrections into the CNC unit and
mount/fix the tools in the holders.

Perform tool changes

Participants are given up to one
full day of orientation on the
equipment to familiarize
him/herself with the machines and
setup.

Adjust speeds and feeds as

needed

Name and description

Performing mathematical
calculations and measurements
Measure work piece to the nearest
0.001 inch
Calculate speeds and feeds
Apply functional algebra, geometry
and trigonometry to solve
workplace problems

Page 2 of 10

The Name of the trade is CNC

MACHINING and is divided into
two sections, CNC MILLING and
CNC TURNING.
Students compete in either CNC
MILLING or CNC TURNING; they
cannot compete in both.
Both Trades cover the
processing of work pieces on
CNC Machines.

CNC program optimization

The adaptation and optimization of
the CNC programs prepared by
the competitor may be done on the
CNC machine. If there are errors in
the program, the candidate has the
opportunity to correct his/her
program on the machine.
Machining conditions
The competitor must comply with
the safety instructions of the
machine manufacturer and with
the safety regulations of SkillsUSA.

CNC Machining Demonstration Contest

Preparation work
The CNC programming software
as well as the specifications of the
machines used will be made
available to all competitors.
External specialists
The machine manufacturers must
supply specialists and service staff
for the software and the CNC
machines in adequate numbers to
ensure that the competition runs
smoothly. These specialists will be
available at all times before and
during the competition, as well as
during scoring of test projects.
Orientation
The competitors and the advisors
will get an orientation on site from
the specialists so they can
familiarize themselves with the
equipment. During this orientation
an actual test part will be
programmed, set up and executed.
Theoretical Knowledge
Interpretation and execution of
detail and assembly prints to ISOA and ISO-E standards.
Knowledge of materials used and
the correct machining process.

Material
Materials used for the Competition
may be :
Cold rolled Steel
Brass
Aluminum
Delrin
Each competitor will be supplied
with one piece of stock per project.
For a point-penalty the participant
may request a second piece of
material.

Workshop installation
The following machines and
equipment will be made
available for each competitor :

Workbench or worktable,
cutting tools, a basic set of cutters
for internal and external machining
and suitable holders.

The competitor has to bring :

Outside Micrometer (up to 1 )
6 inch Caliper
Depth gage and / or micrometers
Needle files and/or other deburring
tools
Calculator and writing utensils
Test project scoring
The setup of tools in the machine
(touch-up and set tool offsets, part
zero settings etc )

Page 3 of 10

Conformity to Print
20 points
Main dimensions
50 points
Secondary dimensions 25 points
Use of material
5 points
TOTAL :

100 points

Conformity to Print :
Visual conformity of part to
drawing. ( Look for shape and
features of part )
Edges broken
Transitions of surfaces

CNC Lathe with proper work

holding devices
OR
CNC Mill with proper work holding
devices, as well as vise-parallels

Knowledge of applied trigonometry

to calculate project coordinates.
CNC programming without the use
of CAD-CAM software. Entering
the program with G- and M- codes
into the control is a necessity for
this competition. Understanding
the correct use of cuttercompensation will be very helpful
for the success of the competitor.

zero points ( dimension either in

tolerance or out ).
On subjective markings
(conformity) the score may be
partial points. The four evaluation
criteria for the test part are:

The scoring of the projects is

conforming to the international
skills championships. On objective
markings ( measurements ) the
score can only be full points or

Part is burr free

Damage to part ( clamp marks,
scratches, etc )
Main Dimensions :
This is an objective scoring.
Scores will only be granted if
dimension is in compliance with
the print. It will be either full points
or zero points.
Secondary Dimensions :
This is also an objective scoring.
Scores will only be granted if
dimension is in compliance with
the print. It will be either full points
or zero points.
Use of Material
Point deduction if participant
requests a second piece of stock.
See the following sample-scoring
sheet.

CNC Machining Demonstration Contest

Page 4 of 10

CNC Machining Demonstration Contest

General Information
Provided CNC machines will be
set-up prior to the competition and
will be available for an orientation.
During the orientation the
participants are given one piece of
stock material to practice.
During the competition each
contestant is given one piece of
stock per project. For a pointpenalty the contestant may request
a second piece of stock.
Due to the size and capability of
the turning equipment, competitors
in the CNC turning competition
may be asked to finish two
different projects in the time given,
where each test will count for 50%
of the total score.
Contestants are encouraged to
bring calculators and Machinery
Handbooks.

We will show some examples of

cutter compensation later in this
document.
Also familiarize yourself with
applying trigonometry. The
dimensions on the print will require
you to calculate certain tangentand intersection points. Many
controls will not allow you to fill a
radius or an angle in, therefore you
will need to calculate the locations,
without any use of CAD or CAM
software.

Example for CNC Lathe

As you might know, in order to use
cutter-compensation, you need to
program the tool offsets correctly.
Usually on a Lathe the Tool-Data
screen looks similar to this :
T01
T02

X.
X.

Z.
Z.

R.
R.

P.
P.

T.. :
X.
Z..
R.
P

Tool Number
X-offset of the tool
Z-offset of the tool
Tool-nose radius
Tool Tip orientation code

On most CNC Lathes, your tool-tip

codes are like shown in Fig. 1.
However, the codes might change
from machine to machine. You will
be shown the codes you need on
site, during the orientation.

As you know, every contour you

machine will be wrong, if you do
not use cutter compensation,
because the actual tool-path will
differ from the programmed toolpath. This is not really visible on
the Lathe, but will be found when
inspecting the parts.
See Fig. 2 for an explanation

Tips and hints for competitors

When teaching CNC, many
institutions skip, or cut the basics
of CNC short and go straight to
CAD/CAM programming.
This contest will not allow
CAD/CAM, therefore, your basic
programming and machining skills
are essential for success. For
those who are not really familiar
with the manual long hand
programming, the following pages
may be helpful in preparing.
Familiarize yourself with the use of
CUTTER COMPENSATION
( G40, G41, G42 ). In order to hold
the tolerances you will need to
offset your tool, make the first cut,
measure and then offset the tool to
get the required dimension.and
run the contour again.
( This is a standard practice )
Fig. 1
Page 5 of 10

CNC Machining Demonstration Contest

First you need to determine the

intersection point of the angle and
the 0.75. Use the hatched
triangle in Fig. 4.

Actual Cut
By not using cuttercompensation, or having a
wrong tool-tip-orientation code,
your contour will be wrong.

Angle : 30
Adjacent :
(1.24 0.75) / 2 = 0.245
Opposite ? :
Tan (30) x 0.245 = 0.1415

Programmed Cut

Therefore :
1.1415 0.1415 = 1.000
X remains on 0.75.

Fig. 2

The next step will be to find the

center of the radius. Of course, in
X it is a simple addition:
0.75 + 2x0.15 = 1.05

1.1415

120

0.750

R 0.150

1.240

Again, it is important for you to

know and understand cutter
compensation (G40, G41, and
G42) or all angles and radii on
your part will be wrong.

The Center of the radius in Z is the

same as the start point of the
radius in Z.

If you familiarize yourself with the

use of CAN cycles, roughing,
threading, grooving, and contour
turning, you will be fine.

Fig. 3

You can find a sample print of a

part drawing you might expect at
the end of the document.

Fig. 5 (next page) shows the

triangle needed to solve for the
start and center of the radius in Z.

How do you do that ?

Math example:
1.1415

R0.150

?
0.750

1.240

Using the 0.150 Radius at the

0.750 (Fig. 3). Usually you will
have to program your tool to go to
the start point of the radius and
program a G02/G03 to the
endpoint of the radius.
Those points are not given on the
print, therefore you will need to
calculate them.

Fig. 4

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CNC Machining Demonstration Contest

Note :
Some controls require the use of
the codes I, K or J when
programming a radius and do not
accept the code R.
For example :
G03 X2 Z-1 I-0.25 K0

1.1415

R0.150

1.240

0.9134

As you ( or your instructor ) might

know, I is the incremental
distance from start of arc to center
of arc in X, K is the incremental
distance from start of arc to center
of arc in Z and J is the
incremental distance from start of
arc to center of arc in Y.

0.750

Fig. 5

Angle : 30
Adjacent : 0.15 ( Radius )
Opposite ? :
Tan (30) x 0.15 = 0.0866

First you need to determine (a)

and (b) :
Angle : 30
Hypotenuse :

0.15 ( Radius )

Location of start in Z :
st
1.1415 - 0.1415 ( from 1 triangle )
0.0866 ( from 2nd triangle )
= 0.9134

a = Sin ( 30 ) x 0.15
b = Cos ( 30 ) x 0.15

O.k., now you know the radius

start-point is at:
X 0.75 and Z 0.9134.

If you subtract ( a ) from your

radius ( 0.15 ) , double it and add
that to your start-point in X, you get
0.9, which is then the of the
endpoint of the radius.

Now you need to find the endpoint

of your radius:

Fig. 6

Using the triangle shown above:

a
b

Page 7 of 10

= 0.075
= 0.1299

If you add ( b ) to the start-point in

Z, you get 1.0433, which is your
endpoint in Z. ( of course it will be
1.0433 )
Make it a habit to always use all
decimals when calculating, to
avoid rounding mistakes. Many
controls give you an ARCCALCULATION error if you are off
by 0.0001.

If the control on the lathe requires

you to program I an K, the program
sequence for the example would
look like this:
G01 ..
G01 X0.75 Z-0.9134
G02 X0.9 Z-1.0433 I0.150 K0
G01 ..
To complicate things even more,
some controls require the
incremental distance from the start
of arc to your zero-point.
Not knowing what machines and
controls will be supplied for the
competition, participants should
practice all of the possibilities to
program an arc.

CNC Machining Demonstration Contest

Example for CNC Mill

As you might know, in order to use
cutter-compensation, you need to
program the tool offsets correctly.
Usually on a milling machine the
Tool-Data screen looks similar to
this:
T01 L
T02 L
T03 L
T.. :
L.
R..

R
R
R

The tolerances on the part in Fig.7

are very tight. Therefore, it is much
better to program the actual
contour as given on the print. Use
cutter compensation (in this case
G41) and offset the end-mill (telling
the control it is bigger e.g. the
endmill is 0.75, you enter
0.755, and therefore your endmill
stays off the final surface Fig. 8).

Tool Number
Length of the tool
radius of the tool

You should have an excellent

dimension, providing you did not
take too deep of a cut and used
the right speed and feed on the
final finishing path.
As you know, end-mills have a
certain tolerance as well and if you
have a 0.75 end-mill it may be
slightly smaller or bigger. If you
make the part with the tool-offset,
you are always sure you end up
with correct dimensions.
Now you just need to run the
chamfering tool along the contour.
Be careful; please practice this
(perhaps with a countersink as the
cutting tool). Many students
damage the part on this operation
by not applying cuttercompensation correctly.

Some machines require the

diameter of the tool, some the
radius. You will learn about your
control on site.
Fig. 8

You have two choices: You

program the actual contour, using
cutter compensation, or you
program the actual tool path, which
usually requires more math.
A usual practice is described as
follows :

When you run the program, the

milled part will end up bigger than
the finished dimension (you just
made a roughing cut). Now you
measure the part, adjust the tool
offset and run the contour again.

Remember, the customers (in this

case the judges) are not the ones
who will deburr the part. If burrs
are present, the inspection of a
dimension might take place on the
burrthis will throw the
measurement off and the
dimension will not pass inspection.

5 0.001

5 0.001

R1 0.001

Fig. 7

Page 8 of 10

Fig. 9

CNC Machining Demonstration Contest

Math example:

Adjacent = Cos ( 15 ) x 0.5 =

0.482962913

1.000

Part zero will be the upper left

corner.
To find the start and endpoint of
the radius R0.500:
As you see, the start point of the
15 angle is at X 1.000 and
Y 0.125. From there you need to
go G01 to ????

Therefore: Start point of radius in

X = 0.125 + 0.875 + 1.000 0.129409522 = 1.87059
Start point of radius in Y = -0.125 +
0.25 - 0.482962913 = -0.35796
Now the endpoint of the radius:
Use the white triangle in the sketch

We know the endpoint of the

radius in Y = -0.125. The endpoint
In X= 0.125 + 0.875 + 1.000 +
Adjacent.
Adjacent = 0.5_ - 0.25_
= 0.433012701
Therefore the endpoint in
X = 0.125 + 0.875 + 1.000 +
0.433012701 = 2.433013

Use the dark triangle in the sketch

Angle :
Hypotenuse :
Opposite :
Adjacent :

15
0.5 ( Radius )
???
???

Opposite = Sin ( 15 ) x 0.5 =

0.129409522

Page 9 of 10

The angle of the triangle is

unknown.
Hypotenuse :
Opposite :
Adjacent :

0.5 ( radius )
0.25 ( given )
???

Similar as to the note in the CNC

turning section, some controls do
not accept R for the radius code. In
that case you would have to
program G02/G03, X = endpoint, Y
= endpoint, I = incremental
distance from start of arc to center
of arc, J = incremental distance
from start of arc to center of arc.

CNC Machining Demonstration Contest

Sample contest part

for CNC Milling

Sample contest part

for CNC TURNING

Page 10 of 10