ME 445 INTEGRATED MANUFACTURING TECHNOLOGIES
EXPERIMENT 2
“PROCESS PLANNING IN TURNING MACHINE”
OBJECTIVE
In this experiment, you are required to design and manufacture a sample chess part in CNC
Turning Machine. For this purpose, you will design a chess part with the given restrictions,
make its technical drawing and write G-Code listing for Turning Machine. The aim of the
experiment is not only to become familiar with the basic instructions of the ISO G-Code
programming techniques but also give an idea about the “Concurrent Engineering”, namely
the “design for manufacture”. The student should take care about the restrictions about the
machine, tooling and capacity as well as the manufacturability and aesthetic considerations of
the designed part.
Figure: Overview of the METUCIM System
RAW MATERIAL
The raw material is a bar made of aluminum with a diameter of 30 and it is continuously
fed into CNC turning machine. The chess piece you will design must be 50 mm long, so you
can consider your raw material as a 50 mm long, 30mm diameter aluminum billet.
Figure 1. Raw material part drawing
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TOOL SPECIFICATIONS
Turning Machine
Tool
ID
T1
Description
Tool Drawing
Right Hand Side Cutting Tool. L=17 mm, α=55°
Preferred for rough cutting operations. Maximum
depth of cut 3 mm in diameter.
T6
6 Drill. a=6 mm, b=37 mm.
Prior to this, Center Drill (T8) must be applied.
T8
Center Drill. a=3 mm, b=5 mm, c=5 mm, d=8 mm
Must be applied prior to any drilling operation.
T10
Slotting and Parting Tool. a=3mm, b=20mm.
Capable to cut in radial direction only.
Reference point is the left corner as indicated in
the figure.
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G CODE LISTINGS OF SIEMENS SINUMERIK 802D TURNING MACHINE
G0 Rapid traverse
G1 Linear interpolation
G2 Circular interpolation in clockwise direction
G3 Circular interpolation in counterclockwise direction
G4 Dwell time
G10 Load zero offset/tool offset
G11 End loading of zero offset/tool offset
G18 Select machining plane Z-X
G20 Input system in inches
G21 Metric input system
G28 Reference point approach
G30 Reference point 2nd, 3rd, 4th ref. point approach
G31 Measure using switching pushbutton
G32 Thread cutting with constant pitch
G40 Tool radius offset OFF
G41 Tool radius offset to the left of the contour ON
G42 Tool radius offset to the right of the contour ON
G54 Workpiece coordinate system
G90 Absolute Dimensioning
G91 Incremental Dimensioning
G94 Feed per minute [mm/min]
G95 Feed per revolution [mm/rev]
G96 Constant cutting speed ON
G97 Constant cutting speed OFF
G98 Feedrate in mm/min, inch/min
G99 Feedrate in mm/rev, inch/rev
G290 Deselect ISO Dialect programming
G291 Select ISO Dialect programming
M CODE LISTINGS OF SIEMENS SINUMERIK 802D TURNING MACHINE
M0 Programmed stop
M1 Optional stop
M2 Program end (main program)
M3 Clockwise rotating spindle
M4 Counterclockwise rotating spindle
M5 Spindle stop
M6 Tool change
M30 Program end as for M2
M17 Subroutine end
M98 Subroutine call
M99 Subroutine end
M19 Spindle positioning
M70 Reserved for Siemens
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CIRCULAR INTERPOLATION
The following commands will move a tool along a circular arc:
In order to cut along the circular path with RHS tool, first tool must be placed at X3 Z5.
Circular arc can be created by G02 or G03 giving the destination point and the radius:
G01 X3 Z5 F0.2 ;go to starting point X3 Z5
G02 X5 Z3 R2.5 F0.1 ;cut clockwise until X5 Z3 with radius 2.5
SAMPLE PART PROCESS PLAN
PART DRAWING
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PART G-CODES
;NOTE THAT COMMENTS BEGIN WITH “;” CHARACTER
;THEY HAVE NO EFFECT ON THE PROGRAM
;IN YOUR PROGRAM USE COMMENTS FOR READIBILITY
; ---------- PREPARATORY COMMANDS ---------G291 ;ISO dialect
G91 G28 X0 Z0 ;Go to reference point
G90 ;Absolute dimensioning
G21 ;Input in mm
G95 ;Feed in mm/rev
G18 ;Select Z-X Plane for turning
G40 ;Tool radius offset is off
G54 ;Coordinate system is on the work piece
S1500 ;Spindle speed is 1500 rpm
; ---------- FACING OPERATION ---------T1 ;Select right hand side cutting tool
M03 ; Rotate spindle in CW direction
G00 X34 Z4 ;NOTE THAT X IS DEFINED AS POSITIVE DIAMETER
G01 Z0 F0.2
G01 X-1 F0.1
G00 X34 Z4
;ROUGH CUTTING (ONLY TWO PASSES ARE ENOUGH)
G00 X27
G01 Z-28 F0.1
G01 X34 F0.2
G00 Z4
G00 X24
G01 Z-9.5 F0.1
G01 X34 F0.2
G00 X34 Z4
;FINE CONTOUR CUTTING EXCEPT POCKET WITH 3 RADIUS
G00 X23
G01 Z-10 F0.1
G01 X26 Z-12 ;CHAMFER IS CUT
G01 Z-30 ;NO POCKET YET
G01 X30 Z-42 ;INCLINED SURFACE
G01 X34 F0.2
G00 Z2
G91 G28 X0 Z0 ;Go to reference point
G90 ;Absolute dimensioning
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;NOW CUT THE POCKET WITH PARTING TOOL
;AT EACH CUT TOOL IS ADVANCED FOR 2.5 mm AT MOST
M05 ;Stop the spindle
T10 ;Select grooving tool
M03 ;Start the spindle
G00 X27 Z-21
G01 X20 F0.1 ;1ST CUT
G01 X27 F0.2
G00 Z-23.5
G01 X20 F0.1 ;2ND CUT
G01 X27 F0.2
G00 Z-26
G01 X20 F0.1 ;3RD CUT
G01 X27 F0.2
G00 Z-27
G01 X20 F0.1 ;4TH CUT
G01 X27 F0.2
G00 X32 Z2
G91 G28 X0 Z0 ;Go to reference point
G90 ;Absolute dimensioning
;NOW CUT THE POCKET RADIUS WITH RHS TOOL AGAIN
M05 ;Stop the spindle
T1 ;Select RHS tool
M03 ;Start the spindle
G00 X27 Z-27
G01 X20 F0.2
G03 X26 Z-30 R3 F0.1 ;CCW CIRC. INTERPOLATION
G01 X27 F0.2
G00 X32 Z2
G91 G28 X0 Z0 ;Go to reference point
G90 ;Absolute dimensioning
;NOW PERFORM THE DRILLING
M05 ;Stop the spindle
T8 ;Select center drilling tool
M03 ;Start the spindle
G00 X0 Z2
G01 Z-7 F0.1
G01 Z2 F0.2
G91 G28 X0 Z0 ;Go to reference point
G90 ;Absolute dimensioning
M05 ;Stop the spindle
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T6 ;Select 6 drilling tool
M03 ;Start the spindle
G00 X0 Z2
G01 Z-10
G01 Z2 F0.2
G91 G28 X0 Z0 ;Go to reference point
G90 ;Absolute dimensioning
;CUTOFF THE PIECE WITH THE PARTING TOOL
M05 ;Stop the spindle
T10 ;Select grooving tool
M03 ;Start the spindle
G00 X34 Z53
G01 X-1 F0.1
G01 X34 F0.2
G91 G28 X0 Z0 ;Go to reference point
G90 ;Absolute dimensioning
;OPERATION IS COMPLETE
M05 ;SPINDLE STOP
M30 ;PROGRAM STOP
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INSTRUCTIONS FOR THE EXPERIMENT
Before the Experiment
1. All group members must haven taken part in Part Design Process, their individual
contribution will be observed and graded by the lab assistant.
2. At the lab hour you are required to:
 The code must be written in NotePad (not Word or anything else)
 You should press Enter key after the M30 line in your code (The CNC machines need
an empty line at the end of the code)
 It would be better if you use comments to seperate some major parts of your code.
 When you finished coding, save the file as with the name as (without using Turkish
characters) “GroupNo_ME445exp2.txt” and then, change the file type to .mpf (If you
can not see the file name extensions, open any folder, go to Tools (for Windows Vista
and 7, you may need to press Alt+F (English) or Alt+D (Turkish) to see the menu
bar), in the Tools, click Folder Options, go to View tab, uncheck the “Hide file
extensions....” option.)
 Bring 2 copies of the part drawing and 2 copies of printouts of your code. Printouts of
the part drawing and code are necessary for the debugging and grading of your code.
 Bring your code in a USB Flash Drive.
During the Experiment
 The 30 aluminum raw material will be supplied at the laboratory.
 Your programs will be loaded to the machine controller.
 Your G-Code files will be controlled and debugged by the assistant for safety
considerations.
 The part will be manufactured in Turning Machine.
 The part will be retained by the assistant for grading.
Grading
 Your individual contributions will be assessed and graded.
 You are required to submit your G-Code Listings and Part Drawing one week after the
lab date until 17:30. Your submission will be graded.
 Take care of that your design is simply manufacturable. Irrelevant design can not be
debugged and processed. Also be sure that, you have not exceeded machine limits.
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