INTRODUCTION

Study Analysis on VMC/CNC Machines
CHAPTER 1
INTRODUCTION
1.1 Overview of Computer Numerical Control (CNC) Machines
In Industry it is not efficient or profitable to make everyday products by hand. On

a CNC machine it is possible to make hundreds or even thousands of the same items in a
day. First a design is drawn using design software, and then it is processed by the
computer and manufactured using the CNC machine. This is a small CNC machine and
can be used to machine woods, plastics and aluminum. In industry, CNC machines can be
extremely large.
Figure 1: Overview of CNC
1.2 Meaning of ‘CNC’
CNC means Computer Numerical Control. This means a computer converts the
design into numbers which the computer uses to control the cutting and shaping of the
material.
Dept. of Mechanical Engg. SCET Belagavi. Page 1

1.3 Use of Typical CNC Machine
1. The design is loaded into the computer which is attached to the CNC machine.
The computer changes the design into a special code (numerical) that controls the
way the CNC cuts and shapes the material.
2. The material to be shaped is taped on to a block with double sided tape. This must
be done carefully so that it does not come off the block during machining.
3. The block is then placed in the vice, inside the CNC. It must be tightened up
carefully. If it is not secure when the machine starts to cut the material it can come
away from the vice. When the machine starts working, the vice moves up, down,
right and left according to the design.
4. The guard is placed in position. It protects the machine operator in case the
material is pulled out of the vice by the power of the cutter. For safety reasons, if
the guard is not in position the motor will not start.
5. The CNC is turned on and the shape is cut from the material. When the cutter has
stopped the shaped material can be removed from the vice.

CHAPTER 2
CNC WORK THEORY
2.1 Work Theory
 Computer Numerical control (CNC) is used to automate the machine tools that are
operated by precisely programmed commands encoded on a storage medium, as opposed
to controlled manually via hand wheels or levers, or mechanically automated via cams
alone.
 Computers play an integral part of the control. In modern CNC system computer-aided
design (CAD) and computer-aided manufacturing (CAM) programs are used for
development and machining of the final finished product.
 The series of steps needed to produce any part is highly automated and produces a part
that closely matches the original CAD design. Modern CNC mills differ little in concept
from the original model built at MIT in 1952.
 Mills typically consist of a table that moves in the X and Y axes, and a tool spindle that
moves in the Z (depth).
 The position of the tool is driven by motors through a series of step-down gears in order
to provide highly accurate movements, or in modern designs, direct-drive stepper motor
or servo motors.
 Open-loop control works as long as the forces are kept small enough and speeds are not
too great.
 On commercial metalworking machines closed loop controls are standard and required in
order to provide the accuracy, speed, and repeatability demanded.
 As the controller hardware evolved, the mills themselves also evolved. One change has
been to enclose the entire mechanism in a large box as a safety measure, often with
additional safety interlocks to ensure the operator is far enough from the working piece
for safe operation.
 Most new CNC systems built today are completely electronically controlled. CNC-like
systems are now used for any process that can be described as a series of movements and
operations.
 These include laser cutting, welding, friction stir welding, ultrasonic welding, flame and
plasma cutting, bending, spinning, hole-punching, pinning, gluing, fabric cutting, sewing,
tape and fiber placement, routing, picking and placing (PnP), and sawing.
 Most CNC machines use Siemens or Fanuc made control systems.
 For Fanuc generally the coding is done using G codes and M codes. G codes are used for
machining operations and movement of the tools whereas M codes are used for
controlling the spindle movement like on/off, rotation in clockwise or anti-clockwise
direction and also for tool change operation.
Figure 2.1 Block Diagram of CNC Lathe

2.2 Classification of CNC Machines
CNC: - CNC is stand for “Computerized Numerical Control”. A machine which is

controlled by computer with Numerical values is known as CNC Machine.
Turning Machine
+
NC System
NC Machine
+
Computer
CNC Machine
Two Axis More than Two Axis

(x& z) (x, y, z, a, b, c, ….)
CNC Turning CNC Wire Cut CNC Milling CNC Grinding
VMC HMC
(Vertical Machining Centre) (Horizontal Machining Centre)

2.3 Coordinate System
 Coordinate system is used for getting point to point movement of tool according to
coordinates of points.
 AXIS: -Horizontal and vertical lines are known as Axis.
Horizontal Axis Vertical Axis
1. Plane: - A plane has two axes.
+Y
Center of Origin
-X +X
0
-Y
Origin or Center Point: - It is the point at a plane where value of both axes zero.
 Coordinate: - The value of axis at any point of a plane known as coordinate.
 Types of Coordinates: -
I. Absolute Coordinate: The value of any point will be taken with respect to center
point.
II. Incremental Coordinate: The value of any point will be taken with respect to
previous point.

CHAPTER 3
MACHINERY AND EQUIPMENTS
3.1 COMPANY MACHINERY
Company mainly has following categories of CNC machines:
1. Vertical Machining Centre ( BFW VAYU BMV 51 TC 24)

2. CNC Lathe Machine ( HWACHEON Hi-Eco 31A)
3.2 Vertical Machining Center (VMC):
VMC machines were developed for higher precision and high speed over TMC
machines. It has moving table for easy access. The main difference between TMC and
VMC is tool holder (Headstock) is rotating and job which clamped on pallet (table)
moves in X-Y directions. Many operations like facing, turning, milling, profile cutting,
boring, drilling can be done easily with the help of VMC.
Mainly machine has three axis to move job and vertical column X-Y-Z. Usually pallet
can only move in X-Y direction and vertical column can move in Z- direction. In addition
to this 3 axis two more axis are available mainly for rotation and tilting action for easy
machining of even complex profiles.
VMC has ATC (Automatic Tool Changer) controlled by three servo motors to
automatically change the tool during machining process according to the requirement.
Vertical spindle can rotate up to 15000 rpm. Maximum torque that is available in any axis
is 700 Nm.
For fast work both two and six pallet VMC is also available which has APC
(automatic pallet changer) in which after completion of one operation in one job, pallet is
automatically rotated and another pallet is positioned for machining operation.
VMC can hold up to 120 tools in the tool post. All movements of pallet and vertical
column are through bolt screw. For less friction movement of saddle and pallet over

Linear Motion Guide ways (LM) either pneumatic or hydraulic system is used. The whole
VMC machine is operated by mainly Siemens and Fanuc controllers.
Job has to be cooled down while operation is being done on it due to friction between tool
and job. Cooling system of job is also installed along with vertical column. Generally,
1000 liters coolant tank is used.
Usually cooling fluid is mixture of water and cutting oil of job. Scrap cleaning system is
also installed in VMC so that accumulated scrap or chips can easily be drained by flow of
fluid.
3.2.1 Vertical Machining Center ( BFW VAYU BMV 51 TC 24)
Figure 3.1: BFW BMV VMC Machine
The BMV51 series vertical machining center Vayu is fast, powerful, stable, and
accurate. Vayu superbly integrates in a line, but also serves excellently as a standalone
machine. The machine contours ensure smooth rear chip disposal. Vayu is ideal for
machining ferrous and non-ferrous components for a variety of applications.

3.3 COMPONENTS OF VMC
 Structure
The complete structure is made out of graded casting and heat treated for consistent
accuracy for long time. Broad rigid base with heavy cross ribs dampens the effect of
vibrations. The twin layer heavy column structure helps in balancing the whole machine
while taking high cutting load. Table of the machine is made of modular casting with the
addition of special alloys for consistent accuracy over a long time of period.
 Fem proven structure
Advanced design with reinforced body structure through FEM analysis, the BMV 51
offers high cutting rigidity and low vibration to meet die and mold machining application.
 3-Point Leveling
With the 3 Point support system, the machines can be quickly installed and relocated
easily. These machines can also be moved easily and do not require any kind of leveling
maintenance
Auto Tool Changer
The auto tool changer is an Arm type with Disc

type tool magazine capable of multiple tool
capacity at a time. The tool time change is
2.4seconds. A wide variety of tool magazine is
also available
Figure 3.2: ATC

 High Performance Spindle
High quality balanced spindle on large precision

bearings eliminates vibration and offers accurate
machining under heavy load. For high speeds
spindle chiller is offered as an option.
This spindles are manufactured in dedicated dust

free, temperature controlled assembly shop where
spindles are extensively tested for various
performance criteria.
Figure 3.3 Spindle and Spindle Torque/Speed
 Flush Coolant System
High pressure coolant splash via flexible nozzles

such a system enhances reduction in machining
down time for cleaning, giving peace of mind to
operator and hence attain productivity positively.
Figure 3.4 Flush Coolant Nozzle System

3.4 VMC Machine Dimensions
Figure 3.5: BFW BMV51 TC24 machine dimensions

3.5 Machine Specifications:
Technical Specifications Unit BFW BMV 51

TC 24
Table
Table Size mm x mm 510 x 1,000
No./ Width/ CD of T-slots no./ mm/ mm 5/ 18/ 100
Max. safe load on table kg 800
Distance from table to spindle face mm 150 - 660
(with height block) (350 - 860)
Traverse
X-axis mm 800
Y-axis mm 510
Z-axis mm 510
Feed Rate
Cutting feed rate mm/ min 1-10,000
Rapid feed rate X/ Y/ Z axes m/ min 30
Spindle
Speed rpm 8,000(10,000)
Maximum Power kW 7.5/ 11 (11/15)
Taper Figure 3: BFW BMV 51 TC 24 Machine Dimension BT 40
Auto Tool Changer
Number of tools nos. 24
Max. tool diameter with adj. pocket full/ empty mm 80/ 125
Max. tool length mm 250
Max. tool weight kg 8
Tool Change time (tool to tool) sec 2.5
Auto Pallet Changer (Optional)
Number of pallets nos. 2
Pallet size mm x mm 410 x 800
Maximum safe load per pallet kg 400
Accuracy
Positioning mm ± 0.005
Repeatability mm ± 0.003
CNC System Fanuc 0iMD/ Siemens 810D/ 840D
(optional)
Installation Data
Machine weight kg 6,500
Pneumatic supply bar 6
Total connected load kVa 30
Power supply 415 ± 5% V, 50 ± 2% Hz, 3 phase
Table 3.1: Machine Specifications
3.6 Machine Features
FEATURES FANUC-OiMO SIEMENS-810D SIEMENS-802D

PCU20/ PCU 50 (OPTION)
Display 8.4” color LCD 10.4” color TFT 10.4” color TFT
LCD
Simultaneously 3 axes (max. 4 3 axes (max. 4 axes) 3 axes (max. 4 axes)
controllable axes axes)
Minimum input 0.001 mm, 0.001 0.001 mm, 0.001 mm, 0.001
increment deg 0.001 deg deg
Spindle speed 5-digit S code 5-digit S code 5-digit S code
command
Spindle speed 50% ~ 120% 50% ~ 120% 50% ~ 120%
override (in steps of 10%) (in steps of 10%) (in steps of 10%)
Feed override 200% 150% 150%
(in steps of 10%) (in steps of 10%) (in steps of 10%)
Feed rate command 4-digit F code 4-digit F code 4-digit F code
Inch/ mm conversion Yes Yes Yes
Part program storage 512kB 1.5MB 256kB
length
Number of part 400 Unlimited 200
programs
Sub program nesting 4 levels 7 levels 7 levels
Number of tool 400 100 100
offsets
Program number/ Yes Yes Yes
Sequence number
search
Single block Yes Yes Yes
Optional stop Yes Yes Yes
Dry run Yes Yes Yes
DNC operations Through RS232C/ Through Through RS232C/
PCMCIA RS232C/PCMCIA / PCMCIA /
Ethernet Ethernet
Run hour and part Yes Yes Yes
count
Help function Yes Yes Yes
Graphic function Yes Yes Yes
Graphics simulation Yes Yes Yes

Nurbs - Yes -
Spline interpolation - Yes (option) -
Ethernet facility Yes Yes Yes
Data server Optional - -
Remote diagnosis Standard Yes (option) -
Table 3.2: Machine Features

CHAPTER 4
INSTALLATION AND PREPARATION
4.1 Installation Precautions & Procedure
1. Only trained, qualified, qualified workers should operate forklift trucks, cranes or
similar equipment and apply slings.
2. Use only wires of dimensions specified in the manual. They must be strong enough to
support machine weights.
3. Before hoisting the machine, fixed each unit securely
4. Maintain a clean and orderly surrounding around the machine.
5. "POWER ON" on the control panel can be pressed only after the complete installation.
6. Be sure electrical cables and wires are not damaged during installation.
7. After installation, proper capacity should be checked before connection the wire to the
power source.
4.2 SERVICE REQUIREMENTS

 Electricity
The machine runs on three-phase, 200-240V, 50 or 60-Hz supply. Power supplied to the
machine should not fluctuate more than ±5 %. The power required is 20 KVA. Using a
minimum section of 8m2, the input power cable should be within 5 meters between
electrical cabinet and power supply end. A separate earth ground is required
 Air
The air requirement for the machining center is a continuous clean, dry air at 85-100 psi
(6-8 kg/cm2).
Figure 4.1: Components of Air Filter

NOTE: Excessive oil and water in the air supply will cause the machine to malfunction.
The air filter regulator has an automatic drain function that should be empty in the bowl
before starting the machine. This must be checked daily for proper operation daily. Also,
excessive contaminants in the air line may clog the dump valve and cause air or water to
pass into the machine.
The air pressure-detecting switch installed in the system is factory-set to assure the proper
"signal". The drop of air supply to the solenoid control valves will cause improper
functioning of the pneumatic actuators. Do not tamper with this switch.
4.3 Environmental Requirements
1. Avoid expose the machines to direct sunlight and/or near to a heat source, etc. Ambient
temperature during operation should be 0 through 40°C
2. Avoid installing machines in a location where the humidity fluctuates considerably and/or
highly humid.
3. Avoid installing machines in a dusty, misty location.
4. Install machines where no vibration source in surroundings is.
5. Install machines in a flat and smooth ground without or other particles. The minimum
bearing pressure of the floor is 5000 kg/m2.
6. The machine must be protected from electrical noise sources, such as electric welders and
an electric discharge machine.
7. Always ground machine independently. The ground resistance is should be 100 ohms or
less and the length of ground cable should be as short as possible.
8. The noise level at the operator's position should be under 85 dbA.
9. Foundation should be constructed of either reinforced or non-reinforced concrete with
thickness and consistency and should also be compatible to industry standard for its
machine weight.

CHAPTER 5
CNC PROGRAMMING
5.1 Programming with Codes

The definition of a part program for any CNC consists of movements of the tool, and
speed changes to the spindle RPM. It also contains auxiliary command functions such as
tool changes, coolant on or off commands, or external M code commands.
Tool movements consist of rapid positioning commands, straight line moves or

movement along an arc of the tool at a controlled feed rate.
This milling machine has three (3) linear axes defined as X axis, Y axis, and Z axis. The
X and Y axis will move the machine table below and around the spindles centerline,
while the Z axis moves the tool spindle down toward or up and away from the machine
table. The machine zero position is where the spindle is pointing down at the upper right
corner, with the machine table all the way to the left in X axis and all the way toward you
in the Y axis and Z axis is up at the tool change position. Motion in the X axis will move
the machine table to the left with negative values and to the right with positive values.
Motion in the Z axis will move the tool toward the machine table with negative values
and away from the machine table with positive values.
A program is written as a set of instructions given in the order they are to be

performed. The instructions, if given in English, might look like this:
LINE #1 = SELECT CUTTING TOOL

LINE #2 = RAPID TO STARTING POSITION OF PART, TURN COOLANT ON
LINE #3 = TURN SPINDLE ON AND SELECT THE RPM
LINE #4 = CHOOSE THE PROPER FEED RATE AND MAKE THE CUT(S)
LINE #5 = TURN OFF THE SPINDLE AND THE COOLANT
LINE #6 = RETURN TOOL TO HOLDING POSITION AND SELECT NEXT TOOL
and so on. But our machine control understands only these messages when given
in machine code, or G and M code programming.

5.2 Program Structure

A CNC part program consists of one or more blocks of commands. When viewing the
program, a block is the same as a line of text. Blocks shown on the CRT are always
terminated by the “ ; “ symbol which is called an EOB. Blocks are made up of
alphabetical address codes. Address codes are always an alphabetical character followed
by a numeric value. For instance, the specification of the position to move the X-axis
would be a number preceded by the X symbol.
Programs must begin and end with a % sign. The % signs are automatically entered in for
you, if you enter the program in on a HAAS control. A program may also contain a “ / “
symbol. The “ / “ symbol, sometimes called a slash, is used to define an optional block. If
a block contains this symbol, any information that follows the slash in a program block,
will be ignored when the BLOCK DELETE button is selected when running a program.
There is no positional requirement for the address codes. They may be placed in any order
within the block. The following page is a sample program as it would appear on the
control screen. The words following the “:” are not part of the actual program but are put
there as further explanation.
This program will drill four holes and mill a two-inch hole in a four-inch square plate
with X and Y zero at the center. The program with comment statements would appear like
this.
% Program must begin and end with %
O01010 Program number, letter "o" with four digit number
(MILL PART PROGRAM (Comments in parenthesis are ignored by control)

EXAMPLE)
N1 (DRILL 4 PLACES) (Comments in parenthesis are ignored by control)
T1 M06 (½ IN. DIA. STUB Tool change to tool #1, (notes to operator)
DRILL)
G90 G54 G00 X-1.5 Y1.5 S1400 Abs posit, work offset#, rapid x y, spindle on cw

M03
G43 H01 Z1. M08 Tool length comp #1, z position, coolant on
G73 G99 Z-0.625 Q0.2R0.1 F5. High speed peck drilling, drill z-.625 deep, .2
peck
Y-1.5 Drill another hole rapid plane is at r.1
X1.5 Drill third hole with an optional block delete :drill
Y1.5 Fourth hole with an optional block delete
G80 G00 Z1. M09 Cancel canned cycle, rapid z1. Coolant Off
G28 G91 Z0 M05 return z to machine zero, spindle off
N2 (COUNTERSINK 4 PLACES) (Comments in parenthesis are ignored by control)
T2 M06 (5/8 DIA. 90 DEG. Tool change to tool #2, (notes to operator)
C'SINK)
G90 G54 G00 X-1.5 Y1.5 S900 Abs posit, work offset#, rapid to posit, spindle on cw
M03
G43 H02 Z1. M08 Tool length comp #2, z position, coolant on
G82 G99 Z-0.27 P0.5 R0.1 F12. Spot drill cycle to z-.27 deep, dwell .5 second
Y-1.5 Second hole , rapid plane is at r.1
X1.5 Third hole with an optional block delete
Y1.5 Fourth hole with an optional block delete
G80 G00 Z1. M09 Cancel canned cycle, rapid z1., coolant off
G28 G91 Z0 M05 Return z to machine zero, spindle off
N3 (SET D3 DIA. OFFSET (Comments in parenthesis are ignored by control)

VALUE TO .500)
T3 M06 (½ DIA. END MILL) Tool change to tool #3 (notes to operator)

G90 G54 G00 X-2.3 Y2.3 S1100 Abs posit, work offset#, rapid to posit, spindle on cw
M03
G43 H03 Z0.1 M08 Tool length comp #3, z position, coolant on
G01 Z-0.625 F30. Feed to depth
G41 Y2. D03 F11. Compensate cutter left of line
X2.0 Cut a 2.0 in. Square cw with tool dia. Comp d03
Y-2.0
X-2.0
Y2.25
G40 X-2.3 Y2.3 G40 cancels comp while positioning away from part
G00 Z1. M09 Rapid z1., coolant off
G28 G91 Y0 Z0 M05 Return y and z to machine zero
T1 M06 Tool change back to tool #1
M30 Program stop and rewind to beginning
Table 5.1:Program structure
To change tools, all that is needed is an M06 even without a G28 in the previous line. A
G28 can be specified to send all axes to machine home, or it can be defined to send a
specific axis home with G28 G91 Z0 and/or Y0 and/or X0 to send just these axis
specified to home position.

5.3 Miscellaneous Function (M- CODES)
All M codes are activated or cause an action to occur at the end of a block, and only one
M code is allowed per block in a program.
M00 Stop Program

M01 Optional Program Stop
M02 Program End
M03 Spindle Forward
M04 Spindle Reverse
M05 Spindle Stop
M06 Tool Change
M08 Coolant On
M09 Coolant Off
M10 Engage 4th Axis Brake
M11 Release 4th Axis Brake
M12 Engage 5th Axis Brake
M13 Release 5th Axis Brake
M16 Tool Change (same as M06)
M19 Orient Spindle
M21- M24 Optional Pulsed User M Function
M30 Program End and Rewind
M31 Chip Conveyor Forward
M32 Chip Conveyor Reverse
M33 Chip Conveyor Stop
M34 Increment Coolant Spigot Position
M35 Decrement Coolant Spigot Position
M36 Pallet Rotate
M39 Rotate Tool Turret
M41 Low Gear Override
M42 High Gear Override
M51- M58 Optional User M Activate
M61- M68 Optional User M Deactivate
M75 Set Measure Point

M76 Disable Displays

M77 Enable Displays
M78 Alarm if Skip Signal Found
M79 Alarm if Skip Signal Not Found
M82 Tool Unclamp
M86 Tool Clamp
M88 Through the Spindle Coolant ON
M89 Through the Spindle Coolant OFF
M95 Sleep Mode
M96 Jump if No Input
M97 Local Sub - Program Call
M98 Sub Program Call
M99 Sub Program Return or Loop
Table 5.2: M – Codes (Miscellaneous Functions)
5.4 Preparatory Functions (G- CODES)
1. G Codes come in groups. Each group will have a specific group number.
2. A G code from the same group can be replaced by another code in the same group. By
doing this the programmer establishes modes of operation. The universal rule here is,
codes from the same group cannot be used more than once on the same line.
3. There are modal G codes which, once established, remain effective until replaced with
another code from the same group.
4. There are non-modal G codes (Group 00) which, once called, are effective only in that
block they are in, and then, do not affect any other blocks.
The rules above govern the use of all codes for programming the Haas (and other)
controls. The concept of grouping codes and rules that apply will have to be remembered
if we are to effectively program the machine tool.
The following is a summary of the G codes. A “ * “ indicates the default within each
group, if there is one:

 Preparatory Functions (G CODES):
Code: Group: Function:

G00 * 01 Rapid Motion
G01 01 Linear Interpolation Motion
G02 01 CW Interpolation Motion
G03 01 CCW Interpolation Motion
G04 00 Dwell
G09 00 Exact Stop
G10 00 Set Offsets
G12 00 CW Circular Pocket Milling (Yasnac)
G13 00 CCW Circular Pocket Milling (Yasnac)
G17 * 02 XY Circular Plane Selection
G18 02 ZX Circular Plane Selection
G19 02 YZ Circular Plane Selection
G20 06 Verify Inch (Setting 9 will need to be on INCH)
G21 06 Verify Metric (Setting 9 will need to be on METRIC)
G28 00 Return to Reference Point
G29 00 Set Return Through Reference Point
G31 00 Feed Until Skip (optional)
G35 00 Automatic Tool Diameter Measurement (optional)
G36 00 Automatic Work Offset Measurement (optional)
G37 00 Automatic Tool Offset Measurement (optional)
G40 * 07 Cutter Comp Cancel
G41 07 2D Cutter Compensation Left
G42 07 2D Cutter Compensation Right
G43 08 Tool Length Compensation +
G44 08 Tool Length Compensation -
G47 00 Text Engraving
G49 * 08 G43/G44/G143 Cancel
G50 11 G51 Cancel
G51 11 Scaling (optional)
G52 12 Select Work Coordinate System (Yasnac)
G52 00 Set Local Shift Coordinate System (Fanuc)
G52 00 Set Local Shift Coordinate System (HAAS)
G53 00 Non-Modal Machine Coordinate Selection
G54 * 12 Select Work Coordinate System 1
G55 12 Select Work Coordinate System 2
G60 00 Unidirectional Positioning
G61 13 Exact Stop Modal
G64 * 13 G61 Cancel
G65 00 Macro Subroutine Call (optional)
G68 16 Rotation (optional)
G69 16 G68 Cancel (optional)
G70 00 Bolt Hole Circle (Yasnac)
G71 00 Bolt Hole Arc (Yasnac)

G72 00 Bolt Holes Along an Angle (Yasnac)
G73 09 High Speed Peck Drill Canned Cycle
G74 09 Reverse Tap Canned Cycle
G76 09 Fine Boring Canned Cycle
G77 09 Back Bore Canned Cycle
G80 * 09 Canned Cycle Cancel
G81 09 Drill Canned Cycle
G82 09 Spot Drill Canned Cycle
G83 09 Regular Peck Drill Canned Cycle
G84 09 Tapping Canned Cycle
G85 09 Bore in/Bore out Canned Cycle
G86 09 Bore in/Stop/Rapid out Canned Cycle
G87 09 Bore in/Manual Retract Canned Cycle
G88 09 Bore/Dwell/Manual Retract Canned Cycle
G89 09 Bore/Dwell/Bore out Canned Cycle
G90 * 03 Absolute
G91 03 Incremental
G92 00 Set Work Coordinates
G93 05 Inverse Time Feed Mode
G94 * 05 Feed Per Minute Mode
G98 * 10 Initial Point Return
G99 10 R Plane Return
G100 00 Cancle Mirror Image
G101 00 Enable Mirror Image
G102 00 Programmable Output to RS-232
G103 00 Limit Block Buffering (Block Lookahead)
G107 00 Cylindrical Mapping
G136 00 Automatic Work Offset Center Measurement

G141 07 3D+ Cutter Compensation

G143 08 5 Axis Tool Length Compensation (optional)
G150 00 General Purpose Pocket Milling
G174 00 Special Purpose Rigid Tapping CCW
G184 00 Special Purpose Rigid Tapping CW
G187 00 Accuracy Control for High Speed Machining
Table 5.3: G – Codes (Preparatory Functions)
Each G code defined in this control is part of a group of G codes. The Group 0 codes are
non-modal; that is, they specify a function applicable to that block only and do not affect
other blocks. The other groups are modal and the specification of one code in the group
cancels the previous code applicable from that group. A modal G code applies to all
subsequent blocks so those blocks do not need to re-specify the same G code.
There is also one case where the Group 01 G codes will cancel the Group 9 (canned
cycles) codes. If a canned cycle is active (G73 through G89), the use of G00 or G01 will
cancel the canned cycle.

5.6 CNC Machine START Procedure
Figure 5.4: CNC Machine Start Procedure

CHAPTER 6
OPERATOR CONTROL PANEL
6.1 Operating Panel Keys
Figure 6.1: - Operating Panel Keys of VMC/CNC

6.2 CNC Operating

6.2.1 Operator panel keys.
6.2.2 Operating mode keys.
6.2.3 MDI keys / CRT keys
6.2.1 CNC Operating Panel Keys
Sr.no. Key Function Key type Description(use)
1 E. Stop Mushroom head Used for stopping machine in

red P.B. emergency.
2 CNC ON Green P.B. Used for making CNC M/C ON
3 CNC OFF Red P.B. Used for making CNC M/C OFF
4 Feed hold Yellow P.B. Stopping the tool feed
5 Program key Toggle(key) Program lock/unlock
6 Reset P.B. Removing the temporary alarm
7 Turret index S.P.B. Tool position change
8 Chuck clamp/D clamp Foot switch Clamp & D clamp of chuck
9 Chuck OD/ID S.P.B. OD or ID clamp selection
10 Tail stock Rev/Forw. Foot switch Reverse & forward moment of tail
stock
11 Spindle clockwise S.P.B. Rotate spindle in clockwise.
11.1 Spindle CCW S.P.B. Rotate spindle in counter C.W.
11.2 Spindle stop S.P.B. Spindle stop
12 Spindle override S.S. Spindle speed override(40-120%)
13 X-Axis (+ve& -ve) S.P.B. Moment of X-axis in jog mode in

+ve& -ve direction

14 Z-Axis (+ve& -ve) S.P.B. Moment of Z-axis in jog mode in

+ve& -ve direction
15 MPG Rotary pulse Use of moment of X&Z axis in feed

generator over ride in +ve& -ve direction
handle mode.
16 Feed over ride switch S.S. Axis feed over ride from 0 TO
120%.
17 X1 S.P.B.
X10 S.P.B. X & Z axis feed rate selection in

handle mode
X100 S.P.B.
X1000 S.P.B.
18 Dry run S.P.B. Feed will be override
19 Program stop S.P.B. By dry run rate
20 M/c lock
21 Restart Cycle stop
22 Opt. stop
23 Block delete
Table 6.1: CNC operating keys and their function

 Seven Operating Modes are
Table 6.2 Types of Operating Mode

CHAPTER 7
VMC / CNC SIMULATION SOFTWARE PROGRAMS
7.1 DELCAM
DELCAM is one of the leading software brand in CAD/CAM solution in India. It

offers various structured and tailor made training courses in its power solution range of
software.
Delcam having two software training programs as follows:
a. Delcam Feature CAM for milling machines, turning and turn/mill Centre’s, and wire
EDMs.
b. Delcam Power MILL for 2.5D to MultiAxis CAM.
7.1.1 FEATURE CAM
Feature CAM deals a complete solution for milling, turning, turn/mill and wire
EDM. All of your machine tools can be programmed within a single user interface
designed to shorten programming times and reduce the learning curve for new users.
Feature CAM is used in CNC CAD/CAM.
Figure 7.1: - FeatureCAM Software Interface

7.1.2 POWERMILL
PowerMILL will quickly create gouge free cutter paths on imported component
data. It supports Wireframe, Triangle, Surface and Solid models created by other Delcam
products or from neutral formats such as IGES.
PowerMILL is a 3D CAM (Computer-aided manufacturing) solution that runs

on Microsoft Windows for the programming of tool paths for 2 to 5 axis CNC (Computer
Numerical Control) Milling machines developed by Autodesk Inc. The software is used
in a range of different engineering industries to determine optimal tool paths to reduce
time and manufacturing costs as well as reduce tool loads and produce smooth surface
finishes. More than 15,000 organisations use PowerMILL worldwide for 2,3 and 5-axis
machining.
Figure 7.2 Powermill Software Interface
7.2 MASTERCAM
Mastercam is the most widely used CAM software worldwide* and remains the
program of choice among CNC programmers. Mastercam Mill-Turn (MT) makes
machining on today's turning center and machining centers simpler and easier than ever.

Mastercam gives your shop the best possible foundation for fast and efficient multi-
tasking. It streamlines the programming process of complex machines with intelligent job
setups that are keyed to the exact machine in your shop. Mastercam ensures that you're
ready for any job. Mastercam delivers:
 Easy 3D CAD modeling.

 Utilize Mastercam's industry-proven toolpaths.
 Powerful graphical synchronization.
 State-of-the-art interface (Mastercam Code Expert).
 Machine Simulation is a click away with accurate visual feedback .
Figure 7.3 MasterCAM Software Interface
CIMdata, Inc. has reported for the 23rd year in a row that Mastercam is the most
widely used NC software package in the world! Mastercam has been delivering cutting-
edge CAD/CAM software for over 30 years, and is backed by the kind of worldwide
support and service that only the industry leader can provide.

CHAPTER 8
CONCLUSION
 The advantage of a CNC system are that the operation of a conventional machine
is removed and the part production is made Automatic.
 It reduces the labor work and hence highly efficient n the manufacturing process.
 MAKSONTECH generally uses CNC machines to achieve its manufacturing

targets. For manufacturing works of large or small scale, it is very difficult to
work with manual machines as they are time consuming
 CNC machines have their wide scope because they are easy to handle, the work
becomes easier and jobs are done with perfection using the NC simulation
software.

REFERENCES
1) I.C.Grover, “CAD/CAM”, published by Macmillon

2) P. S. Gill and KRAR, “ Fundamental of Numeric Control”
3) Steve and Arthur Gill, “ CNC Technology and Programming”, published by McGraw Hill
4) “Computer Numerical Control” published by Joseph Pusztai and Michael Sava.
5) http://www.automation-drive.com/
6) http://www.engineeringcadcam.com/
7) http://metalshopsolutions.com/
8) https://www.mastercam.com/en-us/Solutions/Mill-Turn-Solutions/
9) https://www.autodesk.com/solutions/manufacturing/
10) https://infinitesolutionsindia.com/delcam/

INTRODUCTION

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INTRODUCTION

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Study Analysis on VMC/CNC Machines

In Industry it is not efficient or profitable to make everyday products by hand. On

Figure 1: Overview of CNC

1.2 Meaning of ‘CNC’

Dept. of Mechanical Engg. SCET Belagavi. Page 1

1.3 Use of Typical CNC Machine

Dept. of Mechanical Engg. SCET Belagavi. Page 2

2.1 Work Theory

 Most CNC machines use Siemens or Fanuc made control systems.

Figure 2.1 Block Diagram of CNC Lathe

Dept. of Mechanical Engg. SCET Belagavi. Page 4

2.2 Classification of CNC Machines

CNC: - CNC is stand for “Computerized Numerical Control”. A machine which is

Two Axis More than Two Axis

CNC Turning CNC Wire Cut CNC Milling CNC Grinding

Dept. of Mechanical Engg. SCET Belagavi. Page 5

2.3 Coordinate System

 AXIS: -Horizontal and vertical lines are known as Axis.

Horizontal Axis Vertical Axis

1. Plane: - A plane has two axes.

 Coordinate: - The value of axis at any point of a plane known as coordinate.

Dept. of Mechanical Engg. SCET Belagavi. Page 6

3.1 COMPANY MACHINERY

Company mainly has following categories of CNC machines:

1. Vertical Machining Centre ( BFW VAYU BMV 51 TC 24)

3.2 Vertical Machining Center (VMC):

Dept. of Mechanical Engg. SCET Belagavi. Page 7

3.2.1 Vertical Machining Center ( BFW VAYU BMV 51 TC 24)

Figure 3.1: BFW BMV VMC Machine

Dept. of Mechanical Engg. SCET Belagavi. Page 8

3.3 COMPONENTS OF VMC

 Fem proven structure

Auto Tool Changer

The auto tool changer is an Arm type with Disc

Figure 3.2: ATC

Dept. of Mechanical Engg. SCET Belagavi. Page 9

 High Performance Spindle

High quality balanced spindle on large precision

This spindles are manufactured in dedicated dust

Figure 3.3 Spindle and Spindle Torque/Speed

 Flush Coolant System

High pressure coolant splash via flexible nozzles

Figure 3.4 Flush Coolant Nozzle System

3.4 VMC Machine Dimensions

Figure 3.5: BFW BMV51 TC24 machine dimensions

3.5 Machine Specifications:

Technical Specifications Unit BFW BMV 51

3.6 Machine Features

FEATURES FANUC-OiMO SIEMENS-810D SIEMENS-802D

Dept. of Mechanical Engg. SCET Belagavi. Page 13

Dept. of Mechanical Engg. SCET Belagavi. Page 14

4.2 SERVICE REQUIREMENTS

Figure 4.1: Components of Air Filter

Dept. of Mechanical Engg. SCET Belagavi. Page 15

4.3 Environmental Requirements

Dept. of Mechanical Engg. SCET Belagavi. Page 16

5.1 Programming with Codes

Tool movements consist of rapid positioning commands, straight line moves or

A program is written as a set of instructions given in the order they are to be

LINE #1 = SELECT CUTTING TOOL

Dept. of Mechanical Engg. SCET Belagavi. Page 17

5.2 Program Structure