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MANUFACTURING PROCESS
ARTICLE
2018
By: Rino Andias Anugraha and Assistant Team
Telkom University
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Manufacturing Process Laboratory Assistants 2018/2019
Audrey Rahmanti Unadi Aldyan Nurfaizi B. Tau
Aufa Rinaldo Alia Agistina
Dimas Fathurrahman Anak Agung Sri Nandini
Evita Rengganis Anggit Pratama
Fahreza Fadhil Hakeki Bagas Arganto P
Fildzah Fajrina Bela Pitria Hakim
FM Anggra Mandala Putra Damario Haznam
Husein Bimantoro Farras Burhanuddin
Lailatul Fitri Gitanjali Widayu Diatri
Nurul Farhana Mario Adiprana Muki
Maulidan Khoir Nafisha Herma Hanifha
Muhammad Ichsan Nurliyan Pangestu Rizky Purnama
Patricia Amelia Sabrina Diana Pratiwi
Putu Ayu Anggrasari Wirawardani Satria Rahmadani Putra
Raihan Muhammad Faizal Sri Yuzarnimar
Sarah Wahyuni Tri Maisyah Nugrah Samudro
Silmi Aprilia Andari Zakaria Gunada
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MANUFACTURING PROCESS Document
LABORATORY Number
Form
MODULE 3
Number
Valid 2018
Module Machining Process
Labwork NC Code Turning
Student Outcomes SO2. Able to apply mathematics, science and engineering
principles to solve complex engineering problems in
integrated systems (including human, material, equipment,
energy, and information)
Learning Outcomes LO14. Students are able to make a process plan for a given
product
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A. Tools and Requirements
Tools & Software Requirements
1. HAAS Control Simulator 1. Labwork of Module 2.2
2. Guideline of Module 2.2
3. Stationary
B. References
Haas Automation Inc. (2015). Lathe Series Training Manual: HAAS CNC Lathe
Programming. USA: [Link].
No Name. (2016). Retrieved from CNC Programming Basics, Tutorials and Example Code:
[Link] Accessed May 5th 2017
Manufacturing Process Laboratory. (2016). Modul Praktikum Proses Manufaktur. Bandung:
Universitas Telkom
Manufacturing Process Laboratory. (2017). Modul Pelatihan NC Code Milling dan Turning
Novice 1.0. Bandung: Universitas Telkom
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C. Labwork Steps
Flow Process Charts Process Description
1. Read the study case well. Because the study
START case contained information that will be
carried out.
2. Pay attention to specifications for each
Read The Study process.
Case 3. Create NC Code and input it on HAAS
Control Simulator.
4. Simulate NC Code that has been created on
Pay Attention To HAAS Control Simulator according to the
The
tutorial on labwork.
Specifications Of
Each Process
Create NC Code
Simulate NC
Code
END
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MODULE 2.2
MACHINING PROCESS : NC CODE LATHE
1. OBJECTIVES
1.1 Students are able to understand about Lathe/Turning Machining Processes.
1.2 Students are able to understand about NC Code Lathe.
1.3 Students are able to create and simulate NC Code of Lathe Processes.
2. OUTLINES
2.1 2-Axis Lathe CNC Machine
2.2 Program Structure
2.3 O.D./I.D. Explanation
2.4 G71 O.D./I.D. Stock Removal Cycle
2.5 G70 O.D./I.D. Finishing Cycle
2.6 G75 O.D./I.D. Grooving Cycle
2.7 G81 Drill Canned Cycle
2.8 G83 Normal Peck Drilling Canned Cycle
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3. BASIC THEORY
3.1 2-Axis Lathe CNC Machine
Figure 2.2 1 Lathe Operation ([Link])
The definition of lathe is a machine that shapes objects by rotating them while a shaping
tool such as a chisel is applied to its surface or in other reference it called turning process. A
lathe is a machine tool which turn cylindrical material, touches a cutting tool to it, and cuts the
material. The lathe is one of the machine tools most well used by machining. A lathe machine
can be used to create symmetrical shapes into a piece of wood, metal or other material.
Figure 2.2 2 CNC Turning Construction ([Link])
For more understanding about CNC Lathe Machine you can access it
using this barcode or simply click this link
[Link]
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3.2 Program Structure of NC
Code Lathe
The table below is the structure of NC Code Lathe:
Table 2.2 1 Program Structure of NC Code Lathe
No Structure Explanation
Contains the number of the program that will be or have
Program Number been made. Consists of 5 digits. Examples of writing is
1.
‘O00123’.
Tool is located in machine home, where initial tool is
2. Homing Tool
located.
Choosing the appropriate tool with the machining
3. Tool Selection
process.
Turning on the spindle, set the spindle speed and the
4. Setting Spindle
spindle direction.
Tool moves quickly to the point of initial coordinates that
5. Rapid Move To Starting Point have been determined prior to machining or before
feeding workpiece.
Machining Program Contains machining program that will be or have been
6.
(G70/G71/G75/G81/G83) made according to the shape of the workpiece to be made.
Contains a machining program according with the shape
7. Content of Program of the workpiece shape or part. Consisting of [P] the
starting block and [Q] ending block.
8. Homing Tool Tool back toward machine home, applying a rapid move.
9. Spindle Off Turning Off the spindle.
10. Ending Program Ending of running program.
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3.3 O.D / I.D. Explanation
In some operation such as G70 and G75, there are two types of way to removes the
material: from outside and inside diameter of material. O.D. is the abbreviation from Outside
Diameter it means that the process of feeding is done from outside the material. I.D. is the
abbreviation from Inside Diameter which is the process of feeding is done from the inside of
material, it will make the curves on the inside of material.
3.4 G71 O.D./I.D. Stock Removal
G71 Removal Stock is a program used for rough-material removal from a CNC lathe
component. Cutting can be done in simple straight line or a complex contour can also be
machined easily.
(G71 P… Q… U… W… D… F…)
D = Depth of cut for each pass of stock removal, positive radius
F = Feed rate to use throughout G71 PQ block (the unit is in mm/revolution)
I = X-axis size and direction of G71 rough pass allowance, radius
K = Z-axis Size and direction of G71 rough pass allowance
P = Starting Block number of path to rough
Q = Ending block number of path to rough
S = Spindle speed to use throughout G71 PQ block
T = Tool and offset to use throughout G71 PQ block
U = X-axis size and direction of G71 finish allowance, diameter
W = Z-axis size and direction of G71 finish allowance
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Figure 2.2 3 Stock Removal Cycle X-Axis ([Link])
Notes :
[1] Setting 73; This setting specifies the retraction amount after a roughing cut. It represents
the tool to material clearance as the tool returns for another pass.
[2] Start position; The point at which the process will begin.
[3] Z-Axis clearance plane,
[4] Finishing allowance,
[5] Roughing allowance,
[6] Programmed path.
[D] Depth of cut for each pass of stock removal, positive radius,
[I] X-axis size and direction of G71 rough pass allowance,
[K] Z-axis size and direction of G71 rough pass allowance,
[P] Starting Block number of path to rough,
[Q] Ending Block number of path to rough,
[U] X-axis size and direction of G71 finish allowance,
[W] Z-axis size and direction of G71 finish allowance
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Programming Example G71 (O.D. Turning)
In this case, G71 using tool number 1, with spindle speed is 1000 rpm. The finishing
allowance of X-axis and Z-axis in G71 is 0.1 mm and 0.1 mm, and the depth of cut is 0.2 mm
and while the feed rate is 0.15 mm/rev with starting point at X=40 and Z=2.
Figure 2.2 4 G71 O.D. Example
Therefore, these are the NC Code that fulfill that case:
O00001 (O.D. Turning); Program Number
G28 U0. W0.; Homing Tool
T101; Selection Tool no. 1 (T101)
G97 S1000 M03; Setting Spindle
G00 G54 X40. Z2.; Rapid Move to Start Point
G71 P1 Q2 U0.1 W0.1 D0.2 F0.15; Machining Program
N1 G01 X10.; Program Content
G01 Z-5.;
G03 X20. Z-10. R5.;
G01 Z-15.;
X25. Z-20.;
Z-25.;
G02 X35. Z-30. R5.;
N2 G01 X40.;
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G28 U0. W0.; Homing Tool
M05; Spindle Off
M30; End of Program
Notes:
[1] Black font is used as the standard form of code structure
[2] Blue font is used as the movement of tool that follows the shape of the geometry
[3] Red font is used as the tool movement in G code
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Programming Example G71 (I.D. Turning)
In this case, G71 using tool number 1, with spindle speed is 1000 rpm. The finishing
allowance of X-axis and Z-axis in G71 is 0.1 mm and 0.1 mm, and the depth of cut is 0.2 mm
and while the feed rate is 0.15 mm/rev with starting point at X=0 and Z=2.
Figure 2.2 5 G71 I.D Example
Therefore, these are the NC Code that fulfill that case:
O00002 (I.D. Turning); Program Number
G28 U0 W0; Homing Tool
T101; Selection Tool no. 1 (T101)
G97 S1000 M03; Setting Spindle
G00 G54 X0 Z2.; Rapid Move to Start Point
G71 P3 Q4 U0.1 W0.1 D0.2 F0.15; Machining Program
N3 G01 X40.; Program Content
Z-5.;
X30. Z-10.;
Z-15.;
X18.;
G03 X10. Z-20. R5.;
G01 Z-23.;
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N4 G01 X0;
G28 W0.; Homing Tool
G28 U0.; Homing Tool
M05; Spindle Off
M30; End of Program
Notes:
[1] Black font is used as the standard form of code structure
[2] Blue font is used as the movement of tool that follows the shape of the geometry
[3] Red font is used as the tool movement in G code
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3.5 G70 O.D./I.D. Finishing Cycle
G70 finishing cycle is a phase consist of a pass along the programmed tool path to
remove excess material left by roughing phase, it makes the work piece smoother. G70 is used
after the removal cycles such as G71, G72, and G73. But it can also be used alone.
Machining Program :
(G70 P.... Q.... F.....)
P = Starting block number of routine to execute
Q = Ending block number of routine to execute
F = Feed Rate (mm/rev)
Figure 2.2 6 G70 Finishing Cycle ([Link])
Note :
[P] Starting block,
[Q] Ending Block.
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Programming Example ( G70 )
In this case, G70 using tool number 1, with 1000 rpm spindle speed, while the feed
rate is 0.15 mm/rev.
Figure 2.2 7 G70 Finishing Cycle Example
Therefore, these are the NC Code that fulfill that case:
O00005 (Finishing Cycle); Program Number
G28 U0 W0; Homing Tool
T101; Selection Tool no. 1 (T101)
G97 S1000 M03; Setting Spindle
G00 G54 X40. Z2.; Rapid Move to Start Point
G70 P1 Q2 F0.15; Machining Program
N1 G01 X10.; Program Content
G01 Z-5.;
G03 X20. Z-10. R5.;
G01 Z-15.;
X25. Z-20.;
Z-25.;
G02 X35. Z-30. R5.;
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N2 G01 X40.;
G28 U0. W0.; Homing Tool
M05; Spindle Off
M30; End of Program
Notes:
[1] Black font is used as the standard form of code structure
[2] Blue font is used as the movement of tool that follows the shape of the geometry
[3] Red font is used as the tool movement in G code
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3.6 G75 O.D./I.D. Grooving Cycle
G75 Grooving Cycle is used for external or internal grooving.
Machining Program :
(G75 X...Z...I...K...F...)
• X = Axis absolute grooving depth, diameter value (mm)
• Z = Axis absolute location to the furthest peck (mm)
• I = X-axis size of increment between pecks in a cycle (radius measure)
• K = Z-axis size of increment between peck cycles
• F = Feed rate (mm/rev)
Figure 2.2 8 G75 Grooving Cycle ([Link])
Notes :
[1] Rapid; Non-cutting movement which move from a position to a specified point as fast
as it can.
[2] Feed,
[S] Start position,
[K] Z-axis size of increment between peck cycles,
[U] X-axis incremental distance to total pecking depth,
[W] Z-axis incremental distance to furthest peck cycle,
[X] X-axis absolute location total pecking depth (diameter).
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Programming Example (G75 O.D.)
In this case, G75 O.D. using tool number 2 (tool diameter 2mm), with spindle speed is
800 rpm. The X-axis pecking depth is 0.2 mm and Z-axis pecking depth is 1.5 mm and while
the feed rate is 0.15 mm/rev with starting point at X=18 and Z= -20
Figure 2.2 9 G75 O.D. Example
Therefore, these are the NC Code that fulfill that case:
O00007 (OD Grooving); Program Number
G28 U0 W0; Homing Tool
T202; Selection Tool no. 2 (T202)
G97 S800 M03; Setting Spindle
G00 G54 X18. Z-20.; Rapid Move to Start Point
G75 X10. Z-12. I0.2 K1.5 F0.15; Program Content
G28 U0.; Homing Tool
G28 W0.; Homing Tool
M05; Spindle Off
M30; End of Program
Notes:
[1] Black font is used as the standard form of code structure
[2] Blue font is used as the movement of tool that follows the shape of the geometry
[3] Red font is used as the tool movement in G code
[4] Because the tool diameter width is 2mm, the Z-axis should be add by 2mm to prevent
crash between tool and workpiece surface.
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Programming Example (G75 I.D.)
In this case, G75 I.D. using tool number 3 (the tool diameter is 2mm) with spindle
speed is 800 rpm. The X-axis pecking depth is 0.2 mm and the Z-axis pecking depth is 1.5
mm and while the feed rate is 0.15 mm/rev with starting point at X=8 and Z= -20.
Figure 2.2 10 G75 I.D. Example
Therefore, these are the NC Code that fulfill that case:
O00008 (ID Grooving); Program Number
G28 U0 W0; Homing Tool
T303; Selection Tool no. 3 (T303)
G97 S500 M03; Setting Spindle
G00 G54 X8. Z-20.; Rapid Move to Start Point
G75 X25. Z-12. I0.2 K1.5 F0.15; Program Content
G28 U0.; Homing Tool
G28 W0.; Homing Tool
M05; Spindle Off
M30; End of Program
Notes:
[1] Black font is used as the standard form of code structure
[2] Blue font is used as the movement of tool that follows the shape of the geometry
[3] Red font is used as the tool movement in G code
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3.7 G81 Drill Canned Cycle
G81 Drill Canned Cycle is the machining process to make prefix hole as a mark so that
the further process still on its axis.
Machining Program :
(G81 Z...R...F...)
• Z = Absolute Z-Depth (Feeding to Z-depth from R-plane) (mm)
• R = Rapid to R-Plane (Where you rapid, to start feeding) (mm)
• F = Feed rate (mm/rev)
Figure 2.2 11 G81 Drill Canned Cycle ([Link])
Notes :
[1] Rapid,
[2] Feed,
[3] Start or end of stroke,
[4] Starting plane,
[R] R plane; Defined as the safe position at which the drilling operation begins.
[Z] Position at the bottom of the hole.
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3.8 G83 Normal Peck Drilling Canned
G83 Normal Peck Drilling Canned Cycle is a program to make a hole by drilling with
pecking.
Machining Program :
(G83 Z...Q...R...F...)
• Z = Absolute Z-Depth (Feeding to Z-depth from R-plane) (mm)
• Q = Pecking Depth Amount, always incremental (If I,J,K are not used) (mm)
• R = Rapid to R-Plane (Where you rapid, to start feeding) (mm)
• F = Feed rate (mm/rev)
Figure 2.2 12 G83 Normal Peck Drilling Canned Cycle ([Link])
Notes :
[1] Rapid,
[2] Feed,
[3] Start or end of stroke,
[4] Dwell; The execution of next program block is delayed by the specified time.
[#22] Setting 22; The distance above the last peck depth that the tool rapids down to before
each peck depth.
[#52] Setting 52; Sets the distance above the R plane to which the tool retracts with each
peck.
[Q] The cut-in value, always incremental,
[R] Position of the R plane,
[Z] Position of bottom of hole.
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Programming Example (G81 & G83)
In this case, G81 using tool number 4, with spindle speed is 500 rpm. The hole depth is 3
mm and rapid to R-plane is 2 mm while the feed rate is 0.05 mm/rev with starting point at
X=40 and Z=2.
G83 using tool number 5, with spindle speed is 500 rpm. The hole depth is 15 mm and the
amount of pecking depth is 2 mm and rapid to R-plane is 5 mm while the feed rate is 0.05
mm/rev with starting point at X=0 and Z=5.
Figure 2.2 13 G81 and G83 Example
Therefore, these are the NC Code that fulfill that case:
O00010 (Drilling) ; Program Number
G28 U0 W0; Homing Tool
T404; Selection Tool no. 4 (T404)
G97 S500 M03; Setting Spindle
G00 G54 X40. Z2.; Rapid Move to Start Point
G81 Z-3. R2. F0.05; Machining Program
G28 W0.; Homing Tool
U0. ;
M05; Spindle Off
T505; Selection Tool no. 5 (T505)
G97 S500 M03; Setting Spindle
G00 G54 X0. Z5.; Rapid Move to Start Point
G83 Z-15. Q2. R2. F0.05; Machining Program
G28 W0.; Homing Tool
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U0. ;
M05; Spindle Off
M30; End of Program
Notes:
[1] Black font is used as the standard form of code structure
[2] Blue font is used as the movement of tool that follows the shape of the geometry
[3] Red font is used as the tool movement in G code
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3. REFERENCE
Haas Automation Inc. (2015). Lathe Series Training Manual: HAAS CNC Lathe Programming.
USA: [Link].
No Name. (2016). Retrieved from CNC Programming Basics, Tutorials and Example Code:
[Link] Accessed May 5th 2017
Manufacturing Process Laboratory. (2016). Modul Praktikum Proses Manufaktur. Bandung:
Universitas Telkom
Manufacturing Process Laboratory. (2017). Modul Pelatihan NC Code Milling dan Turning
Novice 1.0. Bandung: Universitas Telkom
26