Cim lab manual (10 mel77) by mohammed imran

GHOUSIA COLLEGE OF ENGINEERING
RAMANAGARAM-562159
CIM & AUTOMATION LABORATORY MANUAL
(10MEL77)
Mr. MOHAMMED IMRAN
ASST PROFESSOR
DEPARTMENT OF MECHANICAL ENGINEERING

GHOUSIA COLLEGE OF ENGINEERING
RAMANAGARAM-562159
CIM & AUTOMATION LABORATORY MANUAL
(10MEL77)
PREPARED BY
MOHAMMED IMRAN
ASST PROFESSOR
DEPARTMENT OF MECHANICAL ENGINEERING

CIM & AUTOMATION LAB SYLLABUS
PART - A
CNC part programming using CAM packages. Simulation of Turning, Drilling, Milling operations. 3 typical
simulations to be carried out using simulation packages like Master- CAM, or any equivalent software.
PART - B
(Only for Demo/Viva voce)
1. FMS (Flexible Manufacturing System): Programming of Automatic storage and Retrieval system (ASRS) and
linear shuttle conveyor Interfacing CNC lathe, milling with loading unloading arm and ASRS to be carried out
on simple components.
2. Robot programming: Using Teach Pendent & Offline programming to perform pick and place, stacking of
objects, 2 programs.
PART - C
(Only for Demo/Viva voce)
Pneumatics and Hydraulics, Electro-Pneumatics: 3 typical experiments on Basics of these topics to be
conducted.
Scheme of Examinations
Two questions from Part A – 40 Marks (10 Write up +30)
Viva Voce – 10 Marks
Total – 50 Marks

CONTENT PAGE NO.
PART A
I INTRODUCTION TO CIM AND AUTOMATION 1to8
1.1 Definition of CAD 1
1.2 Definition of CAM 1
1.2.1 Computer Manufacturing and Control. 1
1.2.2 Manufacturing Support Applications 2
1.3 The Product Cycle and CAD/CAM 2
1.4 COMPUTER INTEGRATED MANUFACTURING (CIM) 3
1.4.1 Production System Defined 3
1.4.2 Computer integrated manufacturing 4
1.4.3 DEFINITION OF CIM (Computer Integrated Manufacturing) 4
1.5 AUTOMATION DEFINED 4
1.6 TYPES OF AUTOMATION 5
a. Fixed automation 5
b. Programmable automation 5
c. Flexible automation 6
1.7 What is AGV? 7
1.8 Types of AGV’S 7
1.8.1 Driverless trains:- 7
1.8.2 AGV Pallet Trucks:- 7
1.8.3 Unit load carriers:- 7
1.9 Common AGV Applications 8
1.9.1 Raw Material Handling:- 8
1.9.2 Pallet Handling:- 8
1.9.3 Finished Product Handling:- 8
1.9.4 Other application of AGV’s 8
II. CNC PART PROGRAMMING 9 to 31
2.1 DEFINITION OF CNC MACHINE 9
2.1.a 2.1.a Manual Part Programming 9
2.1.b 2.1.b Computer Aided Part Programming 10
2.2 STEPS IN PART PROGRAMMING: 11
2.2.1 PROCESS PLANNING: 11
2.2.2 Axes selection: 11
2.2.3 Tool selection: 11
2.2.4 Selection of cutting parameters: 11
2.2.5 Job and tool setup Part programming: 11
2.2.6 Program verification and feed back: 12
2.2.7 Machining process: 12
2.3 PROGRAMMING FUNDAMENTALS 12
2.3.1 Reference Point 12
a) Machine Origin 12
b) Program Origin 13

c) Part Origin 13
2.3.2 Axis Designation 14
2.3.3 Setting up of Origin 14
2.3.4 Coding Systems. 14
2.4 CNC Code Syntax 14
2.5 Types of CNC codes 15
2.5.1 Preparatory codes (G-Codes) 15
2.5.2 Miscellaneous codes (M-Codes) 15
2.5.3 MILLING POSITIONING COMMAND CODS AND ITS
FUNCTIONS
17
2.5.4 TURNING POSITIONING COMMAND CODS AND ITS
FUNCTIONS.
18
2.6 CNC Part Programming II 20
2.6.1 Programming modes 20
2.6.1.1 Absolute programming (G90) 20
2.6.1.2 Relative programming (G91) 21
2.6.2 Spindle control 21
2.6.3 Tool selection 22
2.6.4 Feed rate control 22
2.7.1 Subroutines 22
2.7.2 Canned Cycles 23
2.7.3 Letter addresses 23
2.7.4 List of G-codes commonly found on MASTER-CAM and
similarly designed controls
25
2.7.5 List of M-codes commonly found on MASTER-CAM and
similarly designed controls
27
2.7.6 Machining a Rectangular pocket
Square/ rectangular pocketing, circular pocketing and lathe canned cycles
syntax and its description
28
2.8 Understanding Cutter Compensation 31
2.8.1 Turning cutter compensation on and off 31
PART B
III FLEXIBLE MANUFACTURING SYSTEM (FMS) 34 to37
3.1 DEFINITION 34
3.2 The various factors influencing the layouts of FMS are: 34
3.3 BASIC COMPONENTS OF FMS 34
3.3.1 Workstations 35
3.3.2. Automated Material Handling and Storage system: 35
3.3.3 Computer Control System: 35
3.4 DIFFERENT TYPES OF FMS 37
IV PROGRAMMING THE ROBOT 38 to50
4.1 Definition 38
4.2 Robot Physical Configuration 38
4.2.1 Cartesian configuration 38

4.2.2 Cylindrical configuration: 39
4.2.3 Polar configuration 39
4.2.4 Jointed-arm configuration: 39
4.3 Basic Robot Motions 40
4.4 Technical Features of an Industrial Robot 41
4.4.1 Degree of Freedom (D.O.F 41
4.4.2 Work Volume/Workspace 41
4.4.3 Precision Movement 41
4.4.4 Control Resolution 41
4.4.5 Accuracy 42
4.4.6 Repeatability 42
4.4.7 Speed 42
4.4.8 Weight Carrying Capacity (Payload) - 42
4.5 End Effectors: 43
4.5.1 Grippers 43
4.5.2 Tools: 44
4.5.3 Work Cell Control and Interlocks4.6 Functions of work cell
controller
44
4.6 Functions of work cell controller 44
4.7 Interlocks 45
4.8 Various methods of robots can be programmed 46
4.8.1 Manual method 46
4.8.2 Walkthrough method 46
4.8.3 Lead through method 46
4.8.4 Off- line programming 48
4.9 Robot Programming Languages 48
4.9.1 The VALTM Language 48
4.9.2 The MCL Language 48
4.10 TEXTUAL STATEMENTS 49
4.11 INTERLOCK AND SENSOR STATEMENTS 50
V PROGRAMS ON MILLING, DRILLING AND TURNING 53 to 64
VI Viva voce Questions 65

CIM & AUTOMATION LAB MANUAL 10MEL77
DEPARTMENT OF MECHANICAL ENGG Page 1
I. INTRODUCTION TO CIM AND AUTOMATION
1.1 Definition of CAD
“The creation, modification, analysis and optimization of a new component using a computer”.
 CAD involves three major elements- CAD Hardware, Software and User
 The primary functions of CAD involve design, analysis and application to manufacturing.
 In an Engineering sense CAD also incorporates Finite Element Analysis, Stress analysis,
Heat Transfer analysis, Fluid Flow analysis, etc…
1.2 Definition of CAM
“The application of computers to plan, process, manage and control various operations in a
manufacturing organization either with direct of indirect computer interface with the available
resources”.
CAM can be broadly classified into 2 categories:
i. Computer Manufacturing and Control.
ii. Manufacturing Support Applications.
1.2.1 Computer Manufacturing and Control.
 This involves a direct interface of the computer, mainly for the maintaining purpose.
 This includes equipment and process observation and data collection.
 This data is use indirectly to control the process as directed (Programmed) by the human
operators.
 Hence, the main control of any process remains in the hand of the humans supervising the
operations.
 It is also possible to achieve complete control by the use of computers.
 The control is based on the observation and then using the programmed instructions,
without the interference of Humans to suit the situation.
 Hence, monitoring is a one way process wherein the observed data is used by the
computer to send control signals to the process system.

1.2.2 Manufacturing Support Applications
 This involves the indirect use of computers to support the production operations. There is
no direct interface between the computer and the process.
 Such support applications are:-
1. NC Part Programming.
2. CAPP.
3. Production scheduling.
4. MRP (Material requirement Planning).
5. Computer Generated Work Standards.
6. Shop Floor Activity Control.
1.3 The Product Cycle and CAD/CAM
 The product cycle refers to the activities that take place starting from the product concept till
it reaches the end user i.e., the customer.
 It is realistic to take the market as a large collection of diverse industrial and consumer
markets rather than one monolithic market.
 The product life cycle gets activated depending on the particular customer group and its
needs.
 Sometimes, the design activity is performed by the customer and is manufactured by
different firms (as in sub-contracting and ancillaries), while in certain cases both design and
manufacturing are performed by the same firm.
 In either case, the product cycle starts with a concept i.e. a basic idea for a product
Product cycle

 This concept is cultivated, refined, analyzed, improved and translated into a plan for the
product through the design engineering and process planning.
 This plan is documented by drafting a set of engineering drawings, indicating the production
process and the specifications.
 After design, the next activity is to manufacture the product. A process plan, showing the
sequence of operations is prepared.
 New tools, equipments and materials are procured. Scheduling, showing the plan of material
and production targets based on the available capacity is made.
 Once all these activities are performed, the production starts, which is tested for quality to
meet the design specifications and finally deliver to the market/end user.
1.4 COMPUTER INTEGRATED MANUFACTURING (CIM)
CIM - to integrate design, production, and logistics
1.4.1 Production System Defined
A collection of people, equipment, and procedures organized to accomplish the manufacturing
operations of a company
Two categories:
 Facilities – the factory and equipment in the facility and the way the facility is organized
(plant layout)

 Manufacturing support systems – the set of procedures used by a company to manage
production and to solve technical and logistics problems in ordering materials, moving work
through the factory, and ensuring that products meet quality standards
1.4.2 Computer integrated manufacturing
CIM is the integration of total manufacturing enterprise through the use of integrated system and data
communication mixed with new managerial philosophies which results in the improvement of personnel
or organizational efficiencies.
• CIM (Computer Integrated Manufacture) allows for the connection between all aspects of the
production of a product.
• CIM can be viewed as an integrated system, e.g.
– A drawing of a component/product is produced using CAD
– The CAD file is then processed using CAM to create a sequence the machine will
understand deleted full stop for consistency
– The CAM sequence is then downloaded to a CNC machine/machines which
manufacture the component/product
1.4.3 DEFINITION OF CIM (Computer Integrated Manufacturing)
Computer Integrated Manufacturing (CIM) technology concerns the developing field of
automated manufacturing and materials handling. The use of computers applied to design,
machining and manufacturing of products, as well as in quality and process control, is
emphasized.
1.5 AUTOMATION DEFINED
Automation is a technology concerned with the application of mechanical, electronic, and
computer-based systems to operate and control production. This technology includes:
 Automatic machine tools to process parts
 Automatic assembly machines
 Industrial robots
 Automatic material handling and storage systems
 Automatic inspection systems for quality control
 Feedback control and computer process control

 Computer systems for planning, data collection, and decision making to support
manufacturing activities
1.6 TYPES OF AUTOMATION
Automated production systems are classified into three basic types:
a. Fixed automation
b. Programmable automation
c. Flexible automation
a. Fixed automation
Fixed automation is a system in which the sequence of processing (or assembly) operations is
fixed by the equipment configuration. The operations in the sequence are usually simple. It is the
integration and coordination of many such operations into one piece of equipment that makes the
system complex. The typical features of fixed automation are:
(1) High initial investment for custom-engineered equipment
(2) High production rates
(3) Relatively inflexible in accommodating product changes
The economic justification for fixed automation is found in products with very high demand
rates and volumes. The high initial cost of the equipment can be spread over a very large number
of units, thus making the unit cost attractive compared to alternative methods of production.
b. Programmable automation
In programmable automation, the production equipment is designed with the capability to change
the sequence of operations to accommodate different product configurations. The operation
sequence is controlled by a program, which is a set of instructions coded so that the system can
read and interpret them. New programs can be prepared and entered into the equipment lo
produce new products. Some of the features that characterize programmable automation include:
(1) High investment in general-purpose equipment
(2) Low production rates relative to fixed automation
(3) Flexibility to deal with changes in product configuration
(4) Most suitable for batch production
Automated production systems that are programmable are used in low and medium volume
production. The parts or products are typically made in batches. To produce each new batch of a

different product, the system must be reprogrammed with the set of machine instructions that
correspond to the new product. The physical setup of the machine must also be changed over:
Tools must be loaded, fixtures must be attached to the machine table, and the required machine
settings must be entered. This changeover procedure takes time. Consequently, the typical cycle
for a given product includes a period during which the setup and reprogramming takes place,
followed by a period in which the batch is produced.
c. Flexible automation
Flexible automation is an extension of programmable automation. The concept of flexible
automation has developed only over the last 15 to 20 years, and the principles are still evolving.
A flexible automated system is one that is capable of producing a variety of products (or parts)
with virtually no time lost for changeovers from one product to the next. There is no production
time lost while reprogramming the system and altering the physical setup (tooling, fixtures and
machine settings). Consequently, the system can produce various combinations and schedules of
products, instead of requiring that they be made in separate batches.
The features of flexible automation can be summarized as follows:
(1) High investment for a custom-engineered system
(2) Continuous production of variable mixtures of products
(3) Medium production rates
(4) Flexibility to deal with product design variations
The essential features that distinguish flexible automation from programmable automation are
(1) The capacity to change part programs with no lost production time, and
(2) The capability to change over the physical setup, again with no lost production time.

1.7 What is AGV?
AGV is a material handling system that uses independently operated, self-propelled vehicles
guided along defined pathways.
AGVS stands for Automated Guided Vehicle System
An AGVS consists of one or more computer controlled wheel based load carriers (normally
battery powered) that runs on the plant floor (or if outdoors on a paved area) without the need for
an onboard operator or driver.
1.8 Types of AGV’S
 Driverless trains
 AGV’s pallet trucks
 Unit load carriers
1.8.1 Driverless trains:-
 It consists of a towing vehicle that pulls one or more trailers to form a train.
 This type is applicable in moving heavy pay loads over large distance in warehouses or
factories with or without intermediate pickup and drop off points along the route.
 It consists of 5-10 trailers and is an efficient transport system.
 The towing capacity is up to 60,000 pounds
1.8.2 AGV Pallet Trucks:-
 Pallet trucks are used to move palletized loads along predetermined routes.
 The capacity of an AGV pallet truck ranges up to several thousand kilograms and some are
capable of handling two pallets.
 It is achieved for vertical movement to reach loads on racks and shelves.
1.8.3 Unit load carriers:-
 These are used to move unit loads from one station to another.
 It is also used for automatic loading and unloading of pallets by means of rollers.

 Load capacity ranges up to 250 kg or less.
 Especially these vehicles are designed to move small loads.
1.9 Common AGV Applications
Automated Guided Vehicles can be used in a wide variety of applications to transport many
different types of material including pallets, rolls, racks, carts, and containers.
1.9.1 Raw Material Handling:-
AGVs are commonly used to transport raw materials such as paper, steel, rubber, metal,
and plastic. This includes transporting materials from receiving to the warehouse, and
delivering materials directly to production lines.
Work-in-Process Movement:-
Work-in-Process movement is one of the first applications where automated guided vehicles
were used, and includes the repetitive movement of materials throughout the manufacturing
process.
1.9.2 Pallet Handling:-
Pallet handling is an extremely popular application for AGVs as repetitive movement of pallets
is very common in manufacturing and distribution facilities.
1.9.3 Finished Product Handling:-
Moving finished goods from manufacturing to storage or shipping is the final movement of
materials before they are delivered to customers. These movements often require the gentlest
material handling because the products are complete and subject to damage from rough handling.
1.9.4 Other application of AGV’s:
Major Industries that use AGVS, Aerospace, Apparel, Automotive, Beauty Products, Books and
Library Systems, Dairy, Food and Beverage, Mail Order Fulfillment, Office and Computer
Equipment, Pharmaceuticals and Health Care, Refrigerator and Freezer Applications, Retail,
Sporting Goods, Textiles

II. CNC PART PROGRAMMING
2.1DEFINITION OF CNC MACHINE
Numerical control (NC) part programming involves the process of writing the set of instructions
to be followed to perform the sequence of operations on the machine. In this numerical control
machine the part programs were transferred to input medium like punched tape, magnetic tape
etc. the tape was then read by a machine control unit (MUC), and sent the control instruction to
the NC machine.
In above definition gives that programming of NC machine as that of same programming to
CNC machine except in addition to that the program is downloaded to a computer , from where
the machine control unit ( MCU) read the program & send suitable control commands to the NC
machine. Hence, the name called Computer Numerical Control (CNC).
There are two types of part programming:
a. Manual part programming
b. Computer Assisted part programming.
2.1.a Manual Part Programming
The programmer first prepares the program manuscript in a standard format. Manuscripts are
typed with a device known as flexo writer, which is also used to type the program instructions.
After the program is typed, the punched tape is prepared on the flexo writer. Complex shaped
components require tedious calculations. This type of programming is carried out for simple
machining parts produced on point-to-point machine tool.
To be able to create a part program manually, need the following information:
(a) Knowledge about various manufacturing processes and machines.
(b) Sequence of operations to be performed for a given component.
(c) Knowledge of the selection of cutting parameters.
(d) Editing the part program according to the design changes.
(e) Knowledge about the codes and functions used in part programs.

2.1.b Computer Aided Part Programming
If the complex-shaped component requires calculations to produce the component are done by
the programming software contained in the computer. The programmer communicates with this
system through the system language, which is based on words. There are various programming
languages developed in the recent past, such as APT (Automatically Programmed Tools),
ADAPT, AUTOSPOT, COMPAT-II, 2CL, ROMANCE, SPLIT is used for writing a computer
programme, which has English like statements. A translator known as compiler program is used
to translate it in a form acceptable to MCU.
The programmer has to do only following things:
(a) Define the work part geometry.
(b) Defining the repetition work.
(c) Specifying the operation sequence.
Over the past years, lot of effort is devoted to automate the part programme generation. With the
development of the CAD (Computer Aided Design)/CAM (Computer Aided Manufacturing)
system, interactive graphic system is integrated with the NC part programming. Graphic based
software using menu driven technique improves the user friendliness. The part programmer can
create the geometrical model in the CAM package or directly extract the geometrical model from
the CAD/CAM database. Built in tool motion commands can assist the part programmer to
calculate the tool paths automatically. The programmer can verify the tool paths through the
graphic display using the animation function of the CAM system. It greatly enhances the speed
and accuracy in tool path generation.
Figure: Interactive Graphic System in Computer Aided Part Programming

2.2STEPS IN PART PROGRAMMING:
With the help of latest CAD/CAM facilities, the coding is generated automatically from the CAD
model database. This is in turn fed to the machine control unit (MCU) and the part is machined.
The important steps involved in the development of a part program are as follows:
1. Process planning
2. Axes selection
3. Tool selection
4. Selection of cutting parameters
5. Job and tool setup
6. Part programming
7. Program verification and feed back
8. Machining process
Each of these steps is important, and this is interlinked. NC machine cannot function unless all
the above steps are followed in the sequence.
2.2.1 PROCESS PLANNING: any design transformed into engineering drawing cannot be
straight away taken to shop production. The process involved should be studied and planned in a
proper fashion. This is called process planning.
2.2.2 Axes selection: it is essential to select necessary axes for the programming and
machining. Most NC machines come with a specified datum/reference position/axis. the other
axes can be selected based on the datum position.
2.2.3 Tool selection: the selection of tools to be used in an NC machine is an essential step in
programming. The types of tools required depend mainly of the component geometry, contours,
size and the machining operation to be performed. This selection also depends on the tool
availability, machining economics, and part complexity.
2.2.4 Selection of cutting parameters: the cutting parameters like cutting speed, feed rate,
depth of cut, changing of tool, etc. need to be decided and included in the program. In fact this
step forms an important part of part program.
2.2.5 Job and tool setup: most NC machines, through automatic, require initial job setting and
tool setting for new operations. Once the setting is complete, the same can be continued until the
program is changed.

2.2.6 Part programming: once the sequence of operation is planned, these are programmed as
a set of instructions. This operation is called as part programming. The programming for NC
machine can be either (a) manual or (b) computer-assisted part programming
2.2.7 Program verification and feed back: program verification after part programming is
essential to ensure that the program produces the part the described shaped and size by
performing the proper sequence of operations. The information like deviation/errors, etc., is fed-
back so as to modify the program or the selection of axis, tools and parameters like the speed,
feed and depth of cut.
2.2.8 Machining process: the final step in NC system is to use verified NC part program for
actual machining process this involves raw material loading, tool setting and other fixturing
work.
2.3 PROGRAMMING FUNDAMENTALS
Machining involves an important aspect of relative movement between cutting tool and
workpiece. In machine tools this is accomplished by either moving the tool with respect to
workpiece or vice versa. In order to define relative motion of two objects, reference directions
are required to be defined. These reference directions depend on type of machine tool and are
defined by considering an imaginary coordinate system on the machine tool. A program defining
motion of tool / workpiece in this coordinate system is known as a part program. Lathe and
Milling machines are taken for case study but other machine tools like CNC grinding, CNC
hobbing, CNC filament winding machine, etc. can also be dealt with in the same manner.
2.3.1 Reference Point
Part programming requires establishment of some reference points. Three reference points are
either set by manufacturer or user.
a) Machine Origin
The machine origin is a fixed point set by the machine tool builder. Usually it cannot be
changed. Any tool movement is measured from this point. The controller always remembers tool
distance from the machine origin.

b) Program Origin
It is also called home position of the tool. Program origin is point from where the tool starts for
its motion while executing a program and returns back at the end of the cycle. This can be any
point within the workspace of the tool which is sufficiently away from the part. In case of CNC
lathe it is a point where tool change is carried out.
c) Part Origin
The part origin can be set at any point inside the machine's electronic grid system. Establishing
the part origin are also known as zero shifts, work shift, floating zero or datum. Usually part
origin needs to be defined for each new setup. Zero shifting allows the relocation of the part.
Sometimes the part accuracy is affected by the location of the part origin. Figure 1 and 2 shows
the reference points on a lathe and milling machine.
Figure 1 - Reference points and axis on a lathe
Figure 2 - Reference points and axis on a Milling Machine

2.3.2 Axis Designation
An object in space can have six degrees of freedom with respect to an imaginary Cartesian
coordinate system. Three of them are liner movements and other three are rotary. Machining of
simple part does not require all degrees of freedom. With the increase in degrees of freedom,
complexity of hardware and programming increases. Number of degree of freedom defines axis
of machine. Axes interpolation means simultaneous movement of two or more different axes
generate required contour.
For typical lathe machine degree of freedom is 2 and so it called 2 axis machines. For typical
milling machine degree of freedom is , which means that two axes can be interpolated at a time
and third remains independent. Typical direction for the lathe and milling machine is as shown in
figure 1 and figure 2.
2.3.3 Setting up of Origin
In case of CNC machine tool rotation of the reference axis is not possible. Origin can set by
selecting three reference planes X, Y and Z. Planes can be set by touching tool on the surfaces of
the workpiece and setting that surfaces as X=x, Y=y and Z=z.
2.3.4 Coding Systems
The programmer and the operator must use a coding system to represent information, which the
controller can interpret and execute. A frequently used coding system is the Binary-Coded
Decimal or BCD system. This system is also known as the EIA Code set because it was
developed by Electronics Industries Association. The newer coding system is ASCII and it has
become the ISO code set because of its wide acceptance.
2.4 CNC Code Syntax
The CNC machine uses a set of rules to enter, edit, receive and output data. These rules are
known as CNC Syntax, Programming format, or tape format. The format specifies the order and
arrangement of information entered. This is an area where controls differ widely. There are rules
for the maximum and minimum numerical values and word lengths and can be entered, and the
arrangement of the characters and word is important. The most common CNC format is the word
address format and the other two formats are fixed sequential block address format and tab

sequential format, which are obsolete. The instruction block consists of one or more words. A
word consists of an address followed by numerals. For the address, one of the letters from A to Z
is used. The address defines the meaning of the number that follows. In other words, the address
determines what the number stands for. For example it may be an instruction to move the tool
along the X axis, or to select a particular tool.
Most controllers allow suppressing the leading zeros when entering data. This is known as
leading zero suppression. When this method is used, the machine control reads the numbers from
right to left, allowing the zeros to the left of the significant digit to be omitted. Some controls
allow entering data without using the trailing zeros. Consequently it is called trailing zero
suppression. The machine control reads from left to right, and zeros to the right of the significant
digit may be omitted.
2.5 Types of CNC codes
2.5.1 Preparatory codes (G-Codes)
The term "preparatory" in NC means that it "prepares" the control system to be ready for
implementing the information that follows in the next block of instructions. A preparatory
function is designated in a program by the word address G followed by two digits. Preparatory
functions are also called G-codes and they specify the control mode of the operation.
2.5.2 Miscellaneous codes (M-Codes)
Miscellaneous functions use the address letter M followed by two digits. They perform a group
of instructions such as coolant on/off, spindle on/off, tool change, program stop, or program end.
They are often referred to as machine functions or M-functions. Some of the M codes are given
below.

M00 Unconditional stop
M02 End of program
M03 Spindle clockwise
M04 Spindle counterclockwise
M05 Spindle stop
M06 Tool change (see Note below)
M30 End of program
In principle, all codes are either modal or non-modal. Modal code stays in effect until cancelled
by another code in the same group. The control remembers modal codes. This gives the
programmer an opportunity to save programming time. Non-modal code stays in effect only for
the block in which it is programmed. Afterwards, its function is turned off automatically. For
instance G04 is a non-modal code to program a dwell. After one second, which is say, the
programmed dwell time in one particular case, this function is cancelled. To perform dwell in the
next blocks, this code has to be reprogrammed. The control does not memorize the non-modal
code, so it is called as one shot codes. One-shot commands are non-modal. Commands known
as "canned cycles" (a controller's internal set of preprogrammed subroutines for generating
commonly machined features such as internal pockets and drilled holes) are non-modal and only
function during the call.
On some older controllers, cutter positioning (axis) commands (e.g., G00, G01, G02, G03, &
G04) are non-modal requiring a new positioning command to be entered each time the cutter (or
axis) is moved to another location.

MILLING POSITIONING COMMAND CODS AND ITS FUNCTIONS

TURNING POSITIONING COMMAND CODS AND ITS FUNCTIONS
Illustration

Illustrative Example Program
A contour illustrated in figure 3 is to be machined using a CNC milling machine. The details of
the codes and programs used are given below.
Example:
G21 G98 Metric programming
M03 S1000 Spindle start clockwise with 1000rpm
G00 X0 Y0 Rapid motion towards (0, 0)
G00 Z-10.0 Rapid motion towards Z=-10 plane
G01 X50.0 Linear interpolation
G01 Y20.0 Linear interpolation
G02 X25.0 Y45.0 R25.0 Circular interpolation clockwise (c.w)
G03 X-25.0 Y45.0 R25.0 Circular interpolations counter clockwise (c.c.w)
G02 X-50.0 Y20.0 R25.0 Circular interpolation clockwise (cw)
G01 Y0.0 Linear interpolation
G01 X0.0 Linear interpolation
G00 Z10.0 Rapid motion towards Z=10 plane
M05 Spindle stops
M09 and program end

2.6. CNC Part Programming II
In the previous section, fundamentals of programming as well basic motion commands for
milling and turning have been discussed. This section gives an overview of G codes used for
changing the programming mode, applying transformations etc.
2.6.1 Programming modes
Programming mode should be specified when it needs to be changed from absolute to
incremental and vice versa. There are two programming modes, absolute and incremental and is
discussed below.
2.6.1.1 Absolute programming (G90)
In absolute programming, all measurements are made from the part origin established by the
programmer and set up by the operator. Any programmed coordinate has the absolute value in
respect to the absolute coordinate system zero point. The machine control uses the part origin as
the reference point in order to position the tool during program execution (Figure 4).

2.6.1.2 Relative programming (G91)
In incremental programming, the tool movement is measured from the last tool position. The
programmed movement is based on the change in position between two successive points. The
coordinate value is always incremented according to the preceding tool location. The
programmer enters the relative distance between current location and the next point (Figure 5).
2.6.2 Spindle control
The spindle speed is programmed by the letter 'S' followed by four digit number, such as S1000.
There are two ways to define speed:
1. Revolutions per minute (RPM
2. Constant surface speed
The spindle speed in revolutions per minute is also known as constant rpm or direct rpm. The
change in tool position does not affect the rpm commanded. It means that the spindle RPM will
remain constant until another RPM is programmed. Constant surface speed is almost exclusively
used on lathes. The RPM changes according to diameter being cut. The smaller the diameter, the
more RPM is achieved; the bigger the diameter, the less RPM is commanded. This is changed
automatically by the machine speed control unit while the tool is changing positions. This is the
reason that, this spindle speed mode is known as diameter speed.

2.6.3 Tool selection
Tool selection is accomplished using 'T' function followed by a four digit number where, first
two digits are used to call the particular tool and last two digits are used to represent tool offset
in the program. The tool offset is used to correct the values entered in the coordinate system
preset block. This can be done quickly on the machine without actually changing the values in
the program.
Using the tool offsets, it is easy to set up the tools and to make adjustments
2.6.4 Feed rate control
Cutting operations may be programmed using two basic feed rate modes:
1. Feed rate per spindle revolution
2. Feed rate per time
The feed rate per spindle revolution depends on the RPM programmed.
2.7.1 Subroutines
Any frequently programmed order of instruction or unchanging sequences can benefit by
becoming a subprogram. Typical applications for subprogram applications in CNC programming
are:
• Repetitive machining motions
• Functions relating to tool change
• Hole patterns
• Grooves and threads
• Machine warm-up routines
• Pallet changing
• Special functions and others
Structurally, subprograms are similar to standard programs. They use the same syntax rules. The
benefits of subroutines involve the reduction in length of program, and reduction in program
errors.

2.7.2 Canned Cycles
A canned cycle is a preprogrammed sequence of events / motions of tool / spindle stored in
memory of controller. Every canned cycle has a format. Canned cycle is modal in nature and
remains activated until cancelled. Canned cycles are a great resource to make manual
programming easier. Often underutilized, canned cycles save time and effort.
2. 7.3. LETTER ADDRESSES
Some letter addresses are used only in milling or only in turning; most are used in
both. Bold below are the letters seen most frequently throughout a program.
Variable Description
A Absolute or incremental position of A axis (rotational axis around X axis)
B Absolute or incremental position of B axis (rotational axis around Y axis)
C Absolute or incremental position of C axis (rotational axis around Z axis)
D Defines diameter or radial offset used for cutter compensation. D is used for
depth of cut on lathes.
E Precision feed rate for threading on lathes
F Defines feed rate
G Address for preparatory commands
H Defines tool length offset;
Incremental axis corresponding to C axis (e.g., on a turn-mill)
I Defines arc center in X axis for G02or G03 arc commands.
Also used as a parameter within some fixed cycles.
J Defines arc center in Y axis for G02or G03 arc commands.

Also used as a parameter within some fixed cycles.
K Defines arc center in Z axis for G02or G03 arc commands.
Also used as a parameter within some fixed cycles, equal to Lad Adress.
L Fixed cycle loop count;
Specification of what register to edit using G10
M Miscellaneous function
N Line (block) number in program;
System parameter number to be changed using G10
O Program name
P Serves as parameter address for various G and M codes
Q Peck increment in canned cycles
R Defines size of arc radius or defines retract height in milling canned cycles
S Defines speed, either spindle speed or surface speed depending on mode
T Tool selection
U Incremental axis corresponding to X axis (typically only lathe group A
controls)
Also defines dwell time on some machines (instead of "P" or "X").
V Incremental axis corresponding to Y axis
W Incremental axis corresponding to Z axis (typically only lathe group A
controls)
X Absolute or incremental position of X axis.
Also defines dwell time on some machines (instead of "P" or "U").
Y Absolute or incremental position of Y axis
Z Absolute or incremental position of Z axis

2.7.4. List of G-codes commonly found on MASTER-CAM and similarly designed controls
Milling Turning
G00 Positioning in Rapid G00 Positioning in Rapid
G01 Linear Interpolation G01 Linear Interpolation
G02 Circular Interpolation (CW) G02 Circular Interpolation (CW)
G03 Circular Interpolation (CCW) G03 Circular Interpolation (CCW)
G04 Dwell G04 Dwell
G07 Imaginary axis designation G07 Feed rate sine curve control
G09 Exact stop check . .
G10 Program parameter input G10 Data setting
G11 Program parameter input cancel G11 Data setting cancel
G12 Circle Cutting CW . .
G13 Circle Cutting CCW . .
G17 XY Plane G17 XY Plane
G18 XZ Plane G18 XZ Plane
G19 YZ Plane G19 YZ Plane
G20 Inch Units G20 Inch Units
G21 Metric Units G21 Metric Units
G22 Stored stroke limit ON G22 Stored stroke check function ON
G23 Stored stroke limit OFF G23 Stored stroke check function OFF
. G25 Spindle speed fluctuation detection OFF
. . G26 Spindle speed fluctuation detection ON
G27 Reference point return check G27 Reference point return check
G28 Automatic return to reference
point
G28 Automatic Zero Return
G29 Automatic return from reference
point
G29 Return from Zero Return Position
G30 Return to 2nd, 3rd, 4th reference
point
G30 2nd reference point return
G31 Skip function G31 Skip function
. . G32 Thread cutting
G33 Thread cutting . .
G34 Bolt hole circle (Canned Cycle) G34 Variable lead thread cutting
G35 Line at angle (Canned Cycle) . .
G36 Arc (Canned Cycle) G36 Automatic tool compensation
G40 Cutter compensation Cancel G40 Tool Nose Radius Compensation Cancel
G41 Cutter compensation Left G41 Tool Nose Radius Compensation Left
G42 Cutter compensation Right G42 Tool Nose Radius Compensation Right
G43 Tool Length Compensation (Plus) . .
G44 Tool Length Compensation
(Minus)
. .
G45 Tool offset increase . .
G46 Tool offset decrease G46 Automatic Tool Nose Radius
Compensation

G47 Tool offset double increase . .
G48 Tool offset double decrease . .
G49 Tool Length Compensation Cancel . .
G50 Scaling OFF G50 Coordinate system setting and
maximum rpm
G51 Scaling ON . .
G52 Local coordinate system setting G52 Local coordinate system setting
G53 Machine coordinate system
selection
G53 Machine coordinate system setting
G54 Workpiece Coordinate System G54 Workpiece Coordinate System
G55 Workpiece Coordinate System 2 G55 Workpiece Coordinate System 2
G60 Single direction positioning . .
G61 Exact stop check mode G61 Exact stop check mode
G62 Automatic corner override G62 Automatic corner override
G63 Tapping mode G63 Tapping mode
G64 Cutting mode G64 Cutting mode
G65 Custom macro simple call G65 User macro simple call
G66 Custom macro modal call G66 User macro modal call
G67 Custom macro modal call cancel G67 User macro modal call cancel
G68 Coordinate system rotation ON G68 Mirror image for double turrets ON
G69 Coordinate system rotation OFF G69 Mirror image for double turrets OFF
G70 Inch Units G70 Finishing Cycle
G71 Metric Units G71 Turning Cycle
G72 User canned cycle G72 Facing Cycle
G73 High-Speed Peck Drilling Cycle G73 Pattern repeating
G74 Counter tapping cycle G74 Peck Drilling Cycle
G75 User canned cycle G75 Grooving Cycle
G76 Fine boring cycle G76 Threading Cycle
G77 User canned cycle . .
G80 Cancel Canned Cycles G80 Canned cycle for drilling cancel
G81 Drilling Cycle . .
G82 Counter Boring Cycle . .
G83 Deep Hole Drilling Cycle G83 Face Drilling Cycle
G84 Tapping cycle G84 Face Tapping Cycle
G85 Boring Cycle . .
G86 Boring Cycle G86 Face Boring Cycle
G87 Back Boring Cycle G87 Side Drilling Cycle
G88 Boring Cycle G88 Side Tapping Cycle
G89 Boring Cycle G89 Side Boring Cycle

G90 Absolute Positioning G90 Absolute Programming
G91 Incremental Positioning G91 Incremental Programming
G92 Reposition Origin Point G92 Thread Cutting Cycle
G93 Inverse time feed . .
G94 Per minute feed G94 End face Turning Cycle
G95 Per revolution feed . .
G96 Constant surface speed control G96 Constant surface speed control
G97 Constant surface speed control
cancel
G97 Constant surface speed control cancel
G98 Set Initial Plane default G98 Linear Feed rate Per Time
G99 Return to Retract (Rapid) Plane G99 Feed rate Per Revolution
. . G107 Cylindrical Interpolation
. . G112 Polar coordinate interpolation mode
. . G113 Polar coordinate interpolation mode
cancel
. . G250 Polygonal turning mode cancel
. . G251 Polygonal turning mode
Milling Turning
2.7.5. List of M-codes commonly found on MASTER-CAM and similarly designed controls
Milling Turning
M00 Program Stop M00 Program Stop
M01 Optional Program Stop M01 Optional Program Stop
M02 Program End M02 Program End
M03 Spindle On Clockwise M03 Spindle On Clockwise
M04 Spindle On Counterclockwise M04 Spindle On Counterclockwise
M05 Spindle Stop M05 Spindle Stop
M06 Tool Change . .
. . M07 Coolant 1 On
M08 Coolant On M08 Coolant 2 On
M09 Coolant Off M09 Coolant Off
M10 Clamps On . .
M11 Clamps Off . .
M30 End of Program, Reset to Start M30 End of Program, Reset to Start
M98 Call subroutine command M98 Subprogram call
M99 Return from subroutine command M99 Return from subprogram
Note: On some machines and controls, some may be differ.

2.7.6 Machining a Rectangular pocket
This cycle assumes the cutter is initially placed over the center of the pocket and at some
clearance distance (typically 0.100 inch) above the top of the pocket. Then the cycle will take
over from that point, plunging the cutter down to the "peck depth" and feeding the cutter around
the pocket in ever increasing increments until the final size is attained. The process is repeated
until the desired total depth is attained. Then the cutter is returned to the center of the pocket at
the clearance height as shown in figure 14
Figure14. Pocket machining
The overall length and width of the pocket, rather than the distance of cutter motion, are
programmed into this cycle.
The syntax is:
G172 I J K P Q R X Y Z
G173 I K P T S R F B J Z
DESCRIPTION: SQUARE/ RECTANGULAR POCKETING
G172
I-pocket total x-length
J-pocket total y-length
K-radius of corner roundness
P-zero for rough cycle allowance (smooth <0.5)
Q-cut increment along z-axis (5pecks 5mm)
R-absolute reference point for z
X-absolute datum or reference position x-axis
Y- Absolute datum or reference position y-axis
Z-depth of cut
G173
I-pocket side finishing allowance (0-0.5)
K-pocket base finish allowance (0-0.5)
P-cut with % in roughing cycle
T-pocket tool
S-roughing spindle speed
R-roughing feed in z-axis
F- Roughing feed in x-y-axis
B- Finishing spindle speed,
J- Finishing feed
Z-safety z-axis (above or out taking tool 5mm)

SIMILARLY IN CIRCULAR POCKETING
Syntax is:
G170 R P Q X Y Z I J K
G171 P S R F B J
DESCRIPTION:
G170
R-position of tool to start cycle i.e. 0
(surface job)
P-when p is ‘0’ then cycle is rough
(allowance)
Q-peck or cut increment (4 pecks each of
0.5 mm)
X-pocket center in x-axis
Y- Pocket center in y-axis
Z-pocket base from job surface
J- Pocket base finish allowance (0-0.5)
K-radius of pocket
G171
P-cut width % in roughing cycle
F- Roughing feed in x-y-axis
J- Finishing feed

LATHE CANNED CYCLES SYNTAX AND ITS DESCRIPTION
DRILLING CYCLE (SYNTAX)
G74 R
G74 GO1 Z Q R F
G74: PECK DRILLING CYCLE
R fixed amount of finishing allowance (2 in mm)
G74: PECK DRILLING CYCLE
G01 linear interpulation
Z End of drilling in negative z-axis
Q Cut increment in microns (if 500 it peck 0.5mm each)
R Allowance along z-axis
F Feed rate
GROOVING CYCLE(SYNTAX)
G75 R
G75 G01 X Z P Q F
G75: PECK GROOVING CYCLE
R fixed amount of finishing allowance (0.1in mm)
G75: PECK GROOVING CYCLE
X grooving dia to be end cut in x-axis
Z End of grooving length in –ve z-axis
P Number of cut in –ve z axis
F Feed rate
THREAD CUTTING CYCLE(SYNTAX)
G76 P Q R
G76 G01 X Z R P Q F
G76: PECK THREADING CYCLE
P01 01 60
P It is a 6 numbers data entry in pairs
01- Number of finihing cuts (0-99)
15-Thread champer
60- angle of thread (0,29,30,55,60,80 only)
To find depth of thread cutting by using formula:
d=X=D-2P
d or x: smallar dia of thread
D: larger or major dia of thread which is given value
P: pitch of thread (different for different threads)
(to find P= 0.613×Pitch of given theard)
Q Min cuttuing depth (positive radial value-no decimal)
R fixed amount of finishing allowance (decimal permitted)
G76: PECK THREADING CYCLE
G01 Linear interpulation
X Last dia of thread in basolute co-ordinate.
Z End of the thread along z-axis
R Radial diffrence b/w start and end positions of thread at final pass(for taper threads)
P Hight of thread
Q Depth of first threading pass(positive radial value-no decimal)
F Pitch of the thread

2.8 Understanding Cutter Compensation
Cutter compensation is one of the most useful things to know when CNC machining. Cutter
compensation allows you to program the geometry and not worry about the toolpath. It also
allows you to adjust the size of your part, based on the tool radius used to cut your part. This is
useful when you can’t find a cutter of the proper diameter. This is best explained in the graphic
below.
The solid circle is the nominal sized tool. The dashed circle is an undersized tool, and the dash-
dot circle is the oversized tool. With a little imagination, you can see all the possibilities for
tweaking your part, or getting your part made with any size end-mill.
2.8.1 TURNING CUTTER COMPENSATION ON AND OFF
It is important to note that cutter compensation becomes active after the next line move or rapid
that is at least the length of the tool radius. Failure to account for this will give a funny part. A
good method around this is to zero your part and program a move away from the part in the X
and Y direction equal to the tool radius. Then move back to 0, 0, and then continue cutting your
profile. See the graphic below.
Note the tool center is now perpendicular and to the left of point A.

To turn cutter compensation off, you must do a ramp off move similar to the ramp on move.
Again, send the tool off in the X and Y direction a distance equal to the tool radius. For the
graphic above, after reaching 0,0 turn off cutter compensation and ramp off to A. Depending on
the shape, you may have to go beyond 0,0 to eliminate any ‘nurkies’(a nurkie is an unintentional
over or under cut left by the tool). This terminates cutter compensation, and you can go on to
something else.
There are three G-Codes involved in using cutter comp : G41 initiates cutter comp to the left of
the path; G42 initiates cutter comp to the right of the path; and G40 cancels cutter compensation.

Finish and accuracy is usually better when you climb cut.
CUTTER COMPENSATION: allows you to program the geometry not the tool path is useful
when you don’t have the right end-mill is helpful in tweaking your part size allows you to
compensate for tool wear is generally a neat and powerful thing to know about

PART-B
III. FLEXIBLE MANUFACTURING SYSTEM (FMS)
3.1 DEFINITION
A flexible manufacturing system (FMS) is an arrangement of machines ... interconnected by a
transport system. The transporter carries work to the machines on pallets or other interface units
so that work-machine registration is accurate, rapid and automatic. A central computer controls
both machines and transport system.
Or
“FMS consists of a group of processing work stations interconnected by means of an automated
material handling and storage system and controlled by integrated computer control system.”
FMS is called flexible due to the reason that it is capable of processing a variety of different part
styles simultaneously at the workstation and quantities of production can be adjusted in response
to changing demand patterns.
Factors Influencing the FMS Layouts
3.2 The various factors influencing the layouts of FMS are:
 Availability of raw material
 Proximity to market
 Transport facilities
 Availability of efficient and cheap labor
 Availability of power, water and fuel
 Atmospheric and climatic condition
 Social and recreation facilities
 Business and economic conditions
3.3 BASIC COMPONENTS OF FMS
The basic components of FMS are:
1. Workstations
2. Automated Material Handling and Storage system.
3. Computer Control System

3.3.1. Workstations:
In present day application these workstations are typically computer numerical control (CNC)
machine tools that perform machining operation on families of parts. Flexible manufacturing
systems are being designed with other type of processing equipments including inspection
stations, assembly works and sheet metal presses. The various workstations are
a) Machining centers
b) Load and unload stations
c) Assembly work stations
d) Inspection stations
e) Forging stations
f) Sheet metal processing, etc.
3.3.2. Automated Material Handling and Storage system:
The various automated material handling systems are used to transport work parts and
subassembly parts between the processing stations, sometimes incorporating storage into
function.
The various functions of automated material handling and storage system are
a) Random and independent movement of work parts between workstations
b) Handling of a variety of work part configurations
c) Temporary storage
d) Convenient access for loading and unloading of work parts
e) Compatible with computer control
3.3.3 Computer Control System:
It is used to coordinate the activities of the processing stations and the material handling system
in the FMS. The various functions of computer control system are:
a) Control of each work station
b) Distribution of control instruction to work station
c) Production control
d) (vi) Traffic control
e) Shuttle control
f) Work handling system and monitoring
g) System performance monitoring and reporting

h) The FMS is most suited for the mid variety, mid value production range.
Fig Application characteristics of FMS
Fig Flexible manufacturing system

3.4 DIFFERENT TYPES OF FMS
The different types of FMS are
a.Sequential FMS
b.Random FMS
c.Dedicated FMS
d.Engineered FMS
e.Modular FMS
 Sequential FMS: It manufactures one-piece part batch type and then planning and
preparation is carried out for the next piece part batch type to be manufactured. It operates
like a small batch flexible transfer line.
 Random FMS: It manufactures any random mix of piece part types at any one time.
 Dedicated FMS: It continually manufactures, for extended periods, the same but limited mix
of piece part batch types.
 Engineered FMS: It manufactures the same mix of part types throughout its lifetime.
 Modular FMS: A modular FMS, with a sophisticated FMS host, enables and FMS user to
expand their FMS capabilities in a stepwise fashion into any of the previous four types of
FMS.

IV. PROGRAMMING THE ROBOT
Robots are devices that are programmed to move parts, or to do work with a tool. Robotics is a
multidisciplinary engineering field dedicated to the development of autonomous devices,
including manipulators and mobile vehicles.
4.1 Definition
An industrial robot is a general purpose programmable machine that possesses certain human
like features
 The most apparent anthropomorphic or human like feature of an industrial robot is its
mechanical arm, or manipulator.
 Robots can perform a variety of tasks such as loading and unloading machine tools, spot
welding automobile bodies, and spray painting etc.
 Robots are typically used as substitutes for human workers in these tasks.
An industrial robot is a programmable, multi-functional manipulator designed to move
materials, parts, tools, or special devices through variable programmed motions for the
performance of a variety of tasks.
4.2 Robot Physical Configuration
Industrial robots come in a variety of shapes and sizes. They are capable of various arm
manipulations and they possess different motion systems.
Classification based on Physical configurations
Four basic configurations are identified with most of the commercially available industrial robots
4.2.1 Cartesian configuration: A robot which is constructed around this configuration
consists of three orthogonal slides, as shown in fig. the three slides are parallel to the x, y, and z
axes of the Cartesian coordinate system. By appropriate movements of these slides, the robot is
capable of moving its arm at any point within its three dimensional rectangularly spaced work
space.

4.2.2 Cylindrical configuration: In this configuration, the robot body is a vertical column that
swivels about a vertical axis. The arm consists of several orthogonal slides which allow the arm
to be moved up or down and in and out with respect to the body. This is illustrated schematically
in figure.
4.2.3 Polar configuration: This configuration also goes by the name “spherical coordinate”
because the workspace within which it can move its arm is a partial sphere as shown in figure.
The robot has a rotary base and a pivot that can be used to raise and lower a telescoping arm.
4.2.4 Jointed-arm configuration: Is combination of cylindrical and articulated configurations.
This is similar in appearance to the human arm, as shown in fig. the arm consists of several
straight members connected by joints which are analogous to the human shoulder, elbow, and
wrist. The robot arm is mounted to a base which can be rotated to provide the robot with the
capacity to work within a quasi-spherical space.

4.3 Basic Robot Motions
Whatever the configuration, the purpose of the robot is to perform a useful task. To accomplish the task,
an end effector, or hand, is attached to the end of the robots arm. It is the end effector which adapts the
general purpose robot to a particular task. To do the task, the robot arm must be capable of moving the
end effectors through a sequence of motions and positions.
There are six basic motions or degrees of freedom, which provide the robot with the capability to move
the end effectors through the required sequences of motions. These six degree of freedom are intended to
emulate the versatility of movement possessed by the human arm. Not all robots are equipped with the
ability to move in all sex degrees. The six basic motions consist of three arm and body motions and three
wrist motions.
Arm and body motions
 Vertical traverse: Up and down motion of the arm, caused by pivoting the entire arm about a
horizontal axis or moving the arm along a vertical slide.
 Radial traverse: extension and retraction of the arm (in and out movement)
 Rotational traverse: rotation about the vertical axis (right or left swivel of the robot arm)
Wrist Motion
 Wrist swivel: Rotation of the wrist
 Wrist bend: Up or down movement of the wrist, this also involves rotation movement.
 Wrist yaw: Right or left swivel of the wrist.

4.4 Technical Features of an Industrial Robot
The technical features of an industrial robot determine its efficiency and effectiveness at
performing a given task. The following are some of the most important among these technical
features.
4.4.1 Degree of Freedom (D.O.F) - Each joint on the robot introduces a degree of freedom.
Each DOF can be a slider, rotary, or other type of actuator. Robots typically have 5 or 6 degrees
of freedom. 3 of the degrees of freedom allow positioning in 3D space, while the other 2or 3 are
used for orientation of the end effector. 6 degrees of freedom are enough to allow the robot to
reach all positions and orientations in 3D space. 5 D.O.F requires a restriction to 2D space, or
else it limits orientations. 5 D.O.F robots are commonly used for handling tools such as arc
welders.
4.4.2 Work Volume/Workspace - The robot tends to have a fixed and limited geometry. The
work envelope is the boundary of positions in space that the robot can reach. For a Cartesian
robot (like an overhead crane) the workspace might be a square, for more sophisticated robots
the workspace might be a shape that looks like a ‘clump of intersecting bubbles’.
4.4.3 Precision Movement
The precision with which the robot can move the end of its wrist is a critical consideration in
most applications. In robotics, precision of movement is a complex issue, and we will describe it
as consisting of three attributes:
1. Control resolution
2. Accuracy
3. Repeatability
4.4.4 Control Resolution - This is the smallest change that can be measured by the feedback
sensors, or caused by the actuators, whichever is larger. If a rotary joint has an encoder that
measures every 0.01 degree of rotation, and a direct drive servo motor is used to drive the joint,
with a resolution of 0.5 degrees, then the control resolution is about 0.5 degrees (the worst case
can be 0.5+0.01).

4.4.5 Accuracy - This is determined by the resolution of the workspace. If the robot is commanded to
travel to a point in space, it will often be off by some amount, the maximum distance should be
considered the accuracy.
4.4.6 Repeatability - The robot mechanism will have some natural variance in it. This means that when
the robot is repeatedly instructed to return to the same point, it will not always stop at the same position.
A portion of a linear positioning system axis, with showing control resolution, accuracy, and repeatability
4.4.7 Speed - refers either to the maximum velocity that is achievable by the TCP, or by individual joints.
This number is not accurate in most robots, and will vary over the workspace as the geometry of the robot
changes.
4.4.8 Weight Carrying Capacity (Payload) - The payload indicates the maximum mass the robot can lift
before either failure of the robots, or dramatic loss of accuracy. It is possible to exceed the maximum
payload, and still have the robot operate, but this is not advised. When the robot is accelerating fast, the
payload should be less than the maximum mass. This is affected by the ability to firmly grip the part, as

well as the robot structure, and the actuators. The end of arm tooling should be considered part of the
payload.
4.5 End Effectors:
In the terminology of robotics, end effectors can be defined as a device which is attached to the
robots wrist to perform a specific task. The task might be work part handling, spot welding,
spray painting, or any of a great variety of other functions. The possibilities are limited only by
the imagination and ingenuity of the application engineers who design robot systems. The end
effectors are the special purpose tooling which enables the robot to perform a particular job. It is
usually custom engineered for that job, either by the company that owns the robot or company
that sold the robots. Most robot manufacturer has engineered groups which design and fabricate
end effectors or provide advice to their customers on end effectors design.
For purpose organization, we will divide the various types of end effectors into two categories:
1. Grippers &
2. Tools
4.5.1. Grippers: are generally used to grasp and hold an object and place it at a desired location.
Grippers can be classified as
 Mechanical grippers
 Vacuum or suction cups
 Magnetic grippers
 Adhesive grippers
 Hooks,
 Scoops, and so forth.

4.5.2. Tools: a robot is required to manipulate a tool to perform an operation on a work part.
Here the tool acts as end-effectors. Spot-welding tools, arc-welding tools, spray painting nozzles,
and rotating spindles for drilling and grinding are typical examples of tools used as end-effectors.
4.5.3 Work Cell Control and Interlocks
Work cell control: industrial robots usually work with other things: processing equipment, work
parts, conveyors, tools and perhaps human operators. A means must be provided for coordinating
all of the activities which are going on within the robot workstations. Some of the activities
occur sequentially, while others take place simultaneously to make certain that the various
activities are coordinated and occur in the proper sequence, a device called the work cell
controller is used. The work cell controller usually resides within the robots and has overall
responsibility for regulating the activities of the work cell components.
4.6 Functions of work cell controller
1. Controlling the sequence of activities in the work cycles
2. Controlling simultaneous activities
3. Making decisions to proceed based on incoming signals
4. Making logical decisions
5. Performing computations
6. Dealing with exceptional events
7. Performing irregular cycles, such as periodically changing tools

4.7 Interlocks
An interlock is the feature of work cell control which prevents the work cycle sequence from
continuing until a certain conditions or set of conditions has been satisfied. In a robotic work
cell, there are two types: outgoing and incoming. The outer going interlock is a signal sent from
the workstation controller to some external machine or device that will cause it to operate or not
to operate for example this would be used to prevent a machine from initiating its process until it
was commanded to process by the work cell controller, an incoming interlock is a single from
some external machine or device to the work controller which determines whether or not the
programmed work cycle sequence will proceed. For example, this would be used to prevent the
work cycle program from continuing until the machine signaled that it had completed its
processing of the work piece.
The use of interlocks provides an important benefit in the control of the work cycle because it
prevents actions from happening when they should not, and it causes actions occur when they
should. Interlocks are needed to help coordinate the activities of the various independent
components in the work cell and to help avert damage of one component by another. In the
planning of interlocks in the robotic work cell, the application engineer must consider both the
normal sequences of the activities that will occur during the work cycle, and the potential
malfunction that might occur. Then these normal activities are linked together by means of limit
switches, pressure switches, photo electric devices, and other system components. Malfunction
that can be anticipated are prevented by means of similar devices.

4.8 There are various methods which robots can be programmed to perform a given work
cycle. We divide this programming method into four categories.
1.1. Manual method
1.2. Walkthrough method
1.3. Lead through method
1.4. Off-line programming
4.8.1. Manual method:
This method is not really programming in the conventional sense of the world. It is more like
setting up a machine rather than programming. It is the procedure used for the simpler robots and
involves setting mechanical stops, cams, switches or relays in the robots control unit. For these
low technology robots used for short work cycles (e.g., pick and place operations), the manual
programming method is adequate.
4.8.2. Walkthrough method:
In this method the programmer manually moves the robots arm and hand through the motion
sequence of the work cycle. Each movement is recorded into memory for subsequent playback
during production. The speed with which the movements are performed can usually be controlled
independently so that the programmer does not have to worry about the cycle time during the
walk through. The main concern is getting the position sequence correct. The walk through
method would be appropriate for spray painting and arc welding.
4.8.3. Lead through method:
The lead through method makes use of a teach pendant to power drive the robot through its
motion sequence. The teach pendant is usually a small hand held device with switches and dials
to control the robots physical movements. Each motion is recorded into memory for future
playback during work cycle. The lead through method is very popular among robot programming
methods because of its ease and convenience.

On-Line/Lead -Through programming
Advantage:
 Easy
 No special programming skills or training
Disadvantages:
 Not practical for large or heavy robots
 High accuracy and straight-line movements are difficult to achieve, as are any other kind
of geometrically defined trajectory, such as circular arcs, etc.
 Difficult to edit out unwanted operator moves
 Difficult to incorporate external sensor data
 Synchronization with other machines or equipment in the work cell is difficult
 A large amount of memory is required

4.8.4. Off- line programming:
This method involves the preparation of the robot program off-line, in a manner similar to NC
part programming. Off-line robot programming is typically accomplished on a computer
terminal. After the program has been prepared, it is entered in to the robot memory for use
during the work cycle. The advantaged of off-line robot programming is that the production time
of the robot is not lost to delay in teaching the robot a new task. Programming off-line can be
done while the robot is still in production on the preceding job. This means higher utilization of
the robot and the equipment with which it operates. Another benefit associated with off-line
programming is the prospect of integrating the robot into the factory CAD/CAM data base and
information system.
4.9. Robot Programming Languages
Non computer controlled robots do not require programming language. They are programmed by
the walkthrough or lead through methods while the simpler robots are programmed by manual
methods. With the introduction of computer control for robots came the opportunity and the need
to develop a computer oriented robot programming language.
4.9.1. The VALTM Language
 The VAL language was developed for PUMA robot
 VAL stands for Victors Assembly Language It is basically off-line language in which
program defining the motion sequence is can be developed off-line but various point location
used in the work cycle are defined by lead through.
 VAL statements are divided into two categories
 Monitoring command
 Programming instructions.
 Monitor command is set of administrative instructions that direct the operation of the robot
system. Some of the functions of Monitor commands are
Preparing the system for the user to write programs for PUMA
Defining points in space
Commanding the PUMA to execute a program
Listing program on the CRT

 Examples for monitor commands are: EDIT, EXECUTE, SPEED, HERE etc.
 Program instructions are a set of statements used to write robot programs. One statement
usually corresponds to one movement of the robots arm or wrist.
 Example for program instructions are Move to point, move to a point in a straight line
motion, open gripper, close gripper. (MOVE, MOVES, APPRO, APPROS, DEPART,
OPENI, CLOSEI, AND EXIT)
4.9.2. The MCL Language
 MCL stands for Machine Control Language developed by Douglas.
 The language is based on the APT and NC language. Designed control complete
manufacturing cell.
 MCL is enhancement of APT which possesses additional options and features needed to do
off-line programming of robotic work cell.
 Additional vocabulary words were developed to provide the supplementary capabilities
intended to be covered by the MCL. These capability include Vision, Inspection and Control
of signals
 MCL also permits the user to define MACROS like statement that would be convenient to
use for specialized applications.
 MCL program is needed to compile to produce CLFILE.
 Some commands of MCL programming languages are DEVICE, SEND, RECEIV,
WORKPT, ABORT, TASK, REGION, LOCATE etc.

4.10. TEXTUAL STATEMENTS
Language statements taken from commercially available robot languages
1 The basic motion statement is:
MOVE P1
Commands the robot to move from its current position to a position and orientation defined by
the variable name P1.The point p1 must be defined.
The most convenient method way to define P1 is to use either powered lead through or manual
leads through to place the robot at the desired point and record that point into the memory.
HERE P1
OR
LEARN P1
Are used in the lead through procedure to indicate the variable name for the point
What is recorded into the robot’s control memory is the set of joint positions or coordinates used
by the controller to define the point.
For ex, (236, 157, 63, 0, 0, 0)
The first values give joint positions of the body and arm and the last three values (0, 0, 0) define
the wrist joint positions.
MOVES P1
Denotes a move that is to be made using straight line interpolation. The suffix‘s’ designates a
straight line motion.
DMOVE (4,125)
Suppose the robot is presently at a point defined by joint coordinates(236,157,63,0,0,0) and it is
desired to move joint 4from 0 to 125. The above statement can be used to accomplish this move.
DMOVE represents a delta move.
Approach and depart statements are useful in material handling operations.
APPROACH P1, 40 MM
MOVE P1
(Command to actuate the gripper)
DEPART 40 MM
The destination is point p1 but the approach command moves the gripper to a safe distance
(40mm) above the point.
Move statement permits the gripper to be moved directly to the part for grasping.
A path in a robot program is a series of points connected together in a single move. A path is
given a variable name

DEFINE PATH123=PATH (P1, P2, P3)
A move statement is used to drive the robot through the path.
MOVE PATH123
SPEED 75 the manipulator should operate at 75% of the initially commanded velocity. The
initial speed is given in a command that precedes the execution of the robot program.
For example,
SPEED 0.5 MPS
EXECUTE PROGRAM1
Indicates that the program named PROGRAM1 is to be executed by the robot at a speed of
0.5m/sec.
4.11. INTERLOCK AND SENSOR STATEMENTS
The two basic interlock commands used for industrial robots are WAIT and SIGNAL. The wait
command is used to implement an input interlock.
For example,
WAIT 20, ON
Would cause program execution to stop at this statement until the input signal coming into the
robot controller at port 20 was in “ON” condition. this might be used in a situation where the
robot needed to wait for the completion of an automatic machine cycle in a loading and
unloading application.
The SIGNAL statement is used to implement an output interlock. This is used to communicate to
some external piece of equipment.
For example,
SIGNAL 20, ON
Would switch on the signal at output port 20, perhaps to actuate the start of of an automatic
machine cycle.
The above interlock commands represent situations where the execution of the statement
appears.
There are other situations where it is desirable for an external device to be continuously
monitored for any change that might occur in the device.
For example, in safety monitoring where a sensor is setup to detect the presence of humans who
might wander into the robot’s work volume. The sensor reacts to the presence of humans by
signaling the robot controller.
REACT 25, SAFESTOP
This command would be written to continuously monitor input port 25 for any changes in the
incoming signal. If and when a change in the signal occurs, regular program execution is

interrupted and the control is transferred to a subroutine called SAFESTOP. This subroutine
would stop the robot from further motion and/or cause some other safety action to be taken.
Commands for controlling the end-effectors Although end effectors are attached to the wrist of
the manipulator, they are very much like external devices. Special command is written for
controlling the end effectors. Basic commands are
OPEN (fully open) and
CLOSE (fully close)
For grippers with force sensors that can be regulated through the robot controller, a command
such as ,
CLOSE 2.0 N
Controls the closing of the gripper until a 20.N force is encountered by the grippers. A similar
command would be used to close the gripper to a given opening width is,
CLOSE 25 MM
A special set of statements is often required to control the operation of tool type end effectors
.(such as spot welding guns, arc welding tools, spray painting guns and powered spindles ).

V. PROGRAMS ON MILLING, DRILLING AND TURNING
Write a manual part program and simulate using CNC train cam software for the given
profile using G-codes and M-codes: Given depth of cut = 01 mm.
Fig: Dimensions in mm (depth of cut=1mm)
Fig: Simulation of Program
G21 G98
G90 G28 Z0.
G28 X0. Y0.
M06 T01
M03 S1200
G90 G00 X-30. Y-20. Z5.
G01 Z-1. F100.
G01 X-30. Y20.
G02 X-20. Y30. R10.
G01 X20. Y30.
G03 X30. Y20. R10.
G01 X30. Y-20.
G01 X20. Y-30.
G01 X-20. Y-30.
G01 X-30. Y-20.
G00 Z5.
G90 G28 Z0.
G28 X0. Y0.
M05
M30
G21 Metric input (mm)
G98 Feed rate per minute.
G90 Absolute programming
G28 Return to reference point
M06 Automatic Tool Change
T01 Tool selection, 01 is tool name.
M03 Spindle start/rotated (forward CW)
S spindle speed in rpm
G00 Rapid positioning (tool positioning)
G01 Linear interpolation
G02 Circular interpolation clockwise (CW)
G03 Circular interpolation counter
clockwise
X Absolute or incremental position of X
axis
Y Absolute or incremental position of Y
axis
R Defines size of arc radius or defines
retract height in milling canned cycles
F Feed rate
M05 Spindle stop
M30 End/exit program

G21 G98
G90 G28 Z0.
G28 X0. Y0.
M06 T01
M03 S1200
G90 G00 X-35. Y-25. Z5.
G01 Z0. F10.
M98 P0054455
G00 Z5.
G90 G28 Z0.
G28 X0. Y0.
M05
M30
:4455
G90 G01 Z-1. F100.
G90 G01 X-35. Y25.
G02 X-25. Y35. R10.
G01 X25. Y35.
G02 X35. Y25. R10.
G01 X35. Y-25.
G02 X25. Y-35. R10.
G01 X-25. Y-35.
G03 X-35. Y-25. R10.
M99
G21- Metric input (mm)
G98-Feed rate per minute.
G90-Absolute programming
G28-Return to reference point
M06-Automatic Tool Change
T01-Tool selection, 01 is tool name.
M03-Spindle start/rotated (forward CW)
S -spindle speed in rpm
G00-Rapid positioning (tool positioning)
G01-Linear interpolation
G02-Circular interpolation clockwise (CW)
G03-circular interpolations counter
clockwise (CCW)
M98- Subprogram call
P - used in the calling and termination of
subprograms.
005 are gives that numbers pecks or cut
increment (5pecks each 1mm depth of cut).
4455 is the sub program name to be read
program.
X -Absolute or incremental position of X
axis
Y - Absolute or incremental position of Y
axis
R - Defines size of arc radius or defines
retract height in milling canned cycles
F -Feed rate
M05-Spindle stops
M30-End/exit program
M99-sub program exit

G21 G98
G90 G28 Z0.
G28 X0. Y0.
M06 T01
M03 S1200
G90 G00 X-20. Y-20. Z5.
G01 Z-2. F100.
G02 X-20. Y20. R20.
G02 X20. Y20. R20.
G02 X20. Y-20. R20.
G02 X-20. Y-20. R20.
G00 Z5.
G28 X0. Y0.
CIRCULAR POCKETING
G170- circular pocketing canned cycle
R-position of tool to start cycle i.e. 0 (surface job)
P-when p is ‘0’ then cycle is rough (allowance)
Q-peck or cut increment (4 pecks each of 0.5 mm)
X-pocket center in x-axis
Y- pocket center in y-axis
Z-pocket base from job surface
J- pocket base finish allowance (0-0.5)
K-radius of pocket
G170 R0. P0.5 Q0.5 X0. Y0. Z-2. I0.1 J0.1 K12.
G171 P80 S3000 R75 F250 B3500 J200
G00 Z5.
G90 G28 Z0.
G28 X0. Y0.
M05
M30
G171- circular pocketing canned cycle
P-cut width % in roughing cycle
F- roughing feed in x-y-axis
J- Finishing feed

SIMPLE PROBLEM FOR RECTANGULAR POCKETING
G21 G98
G90 G28 Z0.
G28 X0. Y0.
M06 T01
M03 S1200
G90 G00 X-20. Y-20. Z5.
G01 Z0. F10.
M98 P0054455
G00 Z5.
RECTANGULAR POCKETING
G172- Square pocketing canned cycle
P-zero for rough cycle allowance (smooth <0.5)
Q-cut increment along z-axis (5pecks 5mm)
R-absolute reference point for z
X-absolute datum or reference position x-axis
Y- absolute datum or reference position y-axis
Z-depth of cut
I-pocket total x-length
G172 P0 Q5 R0 X-10 Y-10 Z-5 I20 J20 K0
G173 I0.2 K0.1 P80 T01 S3000 R75 F250 B3500 J200 Z5
G00 Z5
G90 G28 Z0.
G28 X0. Y0.
M05
M30
:4455
G90 G01 Z-2. F100.
G90 G02 X-20. Y20. R20.
G02 X20. Y20. R20.
G02 X20. Y-20. R20.
G02 X-20. Y-20. R20.
M99
J-pocket total y-length
K-radius of corner roundness
G173- pocketing canned cycle
K-pocket base finish allowance (0-0.5)
P-cut with % in roughing cycle
T-pocket tool
F- roughing feed in x-y-axis
J- Finishing feed
z-safety z-axis (above or out taking tool 5mm)

Fig: Dimensions in mm (depth of cut=1mm) Fig: Simulation of Program
G21 G98
G90 G28 Z0.
G28 X0. Y0.
M06 T01
M03 S1200
G90 G00 X-30. Y-30. Z5.
G01 Z-1. F100.
G01 X-30. Y-10.
G02 X-30. Y10. R10.
G01 X-30. Y30.
G01 X-10. Y30.
G02 X10. Y30. R10.
G01 X30. Y30.
G01 X30. Y10.
G02 X30. Y-10. R10.
G01 X30. Y-30.
G01 X10. Y-30.
G02 X-10. Y-30. R10.
G01 X-30. Y-30.
G00 Z5.
G28 X0. Y0.
G170 R0. P0.5 Q0.5 X-10. Y10. Z-1. I0.1 J0.1 K5.
G171 P80 S3000 R75 F250 B3500 J200
G170 R0. P0.5 Q0.5 X10. Y-10. Z-1. I0.1 J0.1 K5.
G171 P80 S3000 R75 F250 B3500 J200
G00 Z5.
G28 X0. Y0.
G172 I10. J10. K0. P0 Q1 R0. X7. Y7. Z-1.
G173 I0.2 K0.1 P80 T01 S3000 R75 F250 B3500 J200 Z5
G172 I10. J10. K0. P0 Q1 R0. X-17. Y-17. Z-1.
G173 I0.2 K0.1 P80 T01 S3000 R75 F250 B3500 J200 Z5
G00 Z5.
G90 G28 Z0.
G28 X0. Y0.
M05
M30

Fig: Dimensions in mm (depth of cut=5mm) Fig: Simulation of Program
G21 G98
G90 G28 Z0.
G28 X0. Y0.
M06 T01
M03 S1500
G90 G00 X25. Y25. Z5.
G68 X0 Y0 R0
M98 P2323
G68 X0 Y0 R45
M98 P2323
G68 X0 Y0 R90
M98 P2323
G68 X0 Y0 R135
M98 P2323
G68 X0 Y0 R180
M98 P2323
G68 X0 Y0 R225
M98 P2323
G68 X0 Y0 R270
M98 P2323
G68 X0 Y0 R315
M98 P2323
G69
G00 Z5.
G90 G28 Z0.
G28 X0. Y0.
M05
M30
:2323
G99 G73 X25 Y25 Z-5 Q1000 R0.1 F80
G00 Z5
G80
M99
G68 Coordinate system rotation ON
R rotation angle
M98 Subprogram call
P used in the calling and termination of
Subprograms. 2323 is the sub program
Name to be read program.
G69 Coordinate system rotation OFF
M05 Spindle stops
G99 return to reference point in canned
cycle
G73 peck drilling canned cycle
axis
axis
Z depth of cut along z-axis
Q numbers cut increment in microns
(1000micron = 1mm)
R allowance
F feed rate
G80 drilling canned cycle stop
M99 sub program end or exit

G21 G98
G90 G28 Z0.
G28 X0. Y0.
M06 T01
M03 S1500
M98 P0052323
M70
M98 P0052323
M80
M70
M71
M98 P0052323
M80
M81
M71
M98 P0052323
M81
G00 Z5.
G90 G28 Z0.
G28 X0. Y0.
M05
M30
:2323
G90 G00 X25. Y25. Z5.
G01 Z-1. F100.
G01 X25. Y50.
G01 X50. Y 25.
G01 X25. Y 25.
G00 Z5.
M99
M98 Subprogram call
P used in the calling and termination of
Subprograms. 005 are gives that numbers
pecks or cut increment (5pecks each 1mm
Depth of cut). 2323 is the sub program name
To be read program.
M70 X-ON (mirror on along x-axis)
M71 X-OFF (mirror off along x-axis)
M80 Y-ON (mirror on along y-axis)
M81 Y-OFF (mirror off along y-axis)
M05 Spindle stops
axis
axis
Z depth of cut along z-axis
M99 sub program end or exit

Fig: Dimensions in mm
G98 G21
G28 U0 W0
M06 T01
M03 S1000
G90 G00 X22 Z5
G71 U0.5 R0.1
G71 P100 Q200 U0.1 W0.1
N100 G01 X8 F40
GO1 Z-15
G01 X15 Z-30
G01 Z-50
G02 X20 Z-60 R10 F0.1
N200 G01 Z-80
G70 P100 Q200
G28 U0 W0
M05
M30
G98 Feed rate per minute
U absolute format along x-axis
W absolute format along z-axis
G71 start rough turning canned cycle
U-allowance in x-axis (roughing)
R-radius of arc allowance or relief in mm
P100 starting point cycle sequence (starting
block number)
Q200 ending point cycle sequence (ending
block number)
U0.1 finishing allowance in x-axis
W0.1 finishing allowance in z-axis
N Line (block) number in program (read program
N100 and to exit program N200)
G03 circular interpolations counter clockwise
(CCW)
X Absolute or incremental position of X axis
retract height in turning canned cycles
F feed rate
G70 finishing turning cycle
M05 Spindle stops

G98 G21
G28 U0 W0
M06 T01
M03 S1000
G90 G00 X52 Z5
G71 U0.5 R0.1
G71 P100 Q200 U0.1 W0.1
N100 G01 X0 F10
GO1 Z0
G03 X20 Z-10 R10
G01 Z-30
G01 X30 Z-60
G01 Z-70
G02 X50 Z-80 R10 F0.1
N200 G01 Z-95
G70 P100 Q200
G28 U0 W0
M05
M30
block number)
block number)
(CCW)
F feed rate
M05 Spindle stops

G98 G21
G28 U0 W0
M06 T01
M03 S1000
G90 G00 X42 Z5
G71 U0.5 R0.1
G71 P100 Q200 U0.1 W0.1
N100 G01 X10 F40
GO1 Z-15
G01 X15 Z-25
G01 Z-35
G02 X25 Z-45 R5
G01 Z-55
G03 X30 Z-62 R5 F0.1
G01 Z-72
G01 X40 Z-77
N200 G01 Z-87
G70 P100 Q200
G28 U0 W0
M05
M30
block number)
block number)
(CCW)
F feed rate
M05 Spindle stops

G98 G21
G28 U0 W0
M06 T01
M03 S1000
G90 G00 X32 Z5
G71 U0.5 R0.1
G71 P100 Q200 U0.1 W0.1
N100 G01 X20 F40
GO1 Z-20
G01 X30 Z-35
N200 G01 Z-80
G70 P100 Q200
G28 U0 W0
M06 T02
GOO X0 Z2
G74 R2
G74 G01 Z-10 Q500 R0.5 F40
G28 U0 W0
M06 T03
G00 X32 Z-50
G01 Z-52 F30
G75 R0.1
G75 G01 X15 Z-60 P100 Q1000 F30
G28 U0 W0
M05
M30
DRILLING CYCLE
G74: CANNED DRILLING CYCLE
R fixed amount of finishing allowance (2)
Q Cut increment in microns (if 500 it peck
0.5mm each)
F Feed rate
GROOVING CYCLE
G75: CANNED GROOVING CYCLE
R fixed amount of finishing allowance (0.1)
F Feed rate

G98 G21
G28 U0 W0
M06 T01
M03 S1000
G90 G00 X32 Z5
G71 U0.5 R0.1
G71 P100 Q200 U0.1 W0.1
N100 G01 X20 F40
GO1 Z-20
G01 X30 Z-35
N200 G01 Z-80
G70 P100 Q200
G28 U0 W0
M06 T02
GOO X0 Z2
G74 R2
G74 G01 Z-10 Q500 R0.5 F40
G28 U0 W0
M06 T03
G00 X32 Z-50
G01 Z-52 F30
G75 R0.1
G75 G01 X15 Z-60 P100 Q1000 F30
G28 U0 W0
M06 T04
G00 X32 Z0
G01 X20
G76 P011560 Q100 R0.5
G76 G01 X18 Z-20 RO P613 Q1000 F2
G28 U0 W0
M05
M30
DRILLING CYCLE
R fixed amount of finishing allowance (2)
Q Cut increment in microns (if 500 it peck 0.5mm each)
F Feed rate
GROOVING CYCLE
R fixed amount of finishing allowance (0.1)
F Feed rate
THREAD CUTTING CYCLE
G76: CANNED THREADING CYCLE
P01 15 60
P It is a 6 numbers data entry in pairs
01-Number of finihing cuts (0-99)
15-thread champer
60- angle of thread (0,29,30,55,60,80 only)
Q Min cuttuing depth (positive radial value-no decimal)
R fixed amount of finishing allowance (decimal permitted
only)
G76: CANNED THREADING CYCLE
G01 Linear interpulation
X Last dia of thread in basolute coor.
Z End of the thread along z-axis
To find depth of thread cutting by using formula:
d=X=D-2P (to find P= 0.613×Pitch of given theard)
d or x: smallar dia of thread
D: larger or major dia of thread which is given value
P: pitch of thread (different for different threads)
R Radial diffrence b/w start and end positions of thread at
final pass(for taper threads) (if normal 0.1mm)
P Hight of thread in microns
Q Depth of first threading pass(positive radial value-no
decimal)
F Pitch of the thread

VI. Viva voce Questions
1) Define CIM?
2) Differentiate CAD, CAM & CIM.
3) Define Automation?
4) Define relationship between automation and CIM.
5) What are the types of automations?
6) What is AGV?
7) What are the types of AVG’s?
8) What is CNC Part programming?
9) What is reference point?
10) What is linear and circular interpolation?
11) What is the Name of G-code? Or G-code is called ____________
12) What are preparatory codes? Give any example.
13) What is the Name of M-code? Or M-code is called ____________
14) What are miscellaneous codes? Give any example.
15) What are the modes of programming?
16) What is absolute programming?
17) What is relative or incremental programming?
18) What is feed rate?
19) What is a rapid traverse? And its code
20) What is sub programming?
21) What is canned cycle?
22) What is tool Cutter Compensation?
23) Expand FMS.
24) What is FMS?
25) What are basic components of FMS?
26) What are the types of FMS?
27) Definition of Robot?
28) What are the methods of robot programming?
29) What is robot programming language?
30) What is end effect-or?
31) What are types of end effectors?
32) What is gripper?
33) What are different types of grippers used in robot?
34) What are interlocks?

Cim lab manual (10 mel77) by mohammed imran

Cim lab manual (10 mel77) by mohammed imran

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Cim lab manual (10 mel77) by mohammed imran