1. CNC Machining
Pittsburg State University TechnologyEducation
AUTOMATED SYSTEMS
Name: VIGNESH K VELUSAMY Date: 1/30/2016
PROJECT OVERVIEW
The project is to learn about the Automated Systems in a brief context. Among different automated technologies that exist in an
industrial platform, CNC program is one of the basic and widely used Automated Programming System. In this project, programmed
numerical control codes in Absolute,Incremental and polar types,to machine a block of wood in a CNC PRO Light 1000 Milling
machine. General machining operations like facing, pocketing, holes are made using different types of programming. Practiced the
setup procedure before to starting the machining process and learned the safety measures during the operation.
ACTIVITY 1:
G-CODE PROGRAMMING
; Vignesh K Velusamy
; Tooling: 0.250
; Work piece: T 0.750 W 1.970 L 3.980
; Slot: W 0.346 L 2.212 D 0.202
; Absolute Programming
; Activity #1; Slot Milling; Pass 1
N10G90
N15M3
N20G0X0Y0
N30Z.1
N40X1.055Y.937
N60Z-.302
N70X2.93
N80Y1.03
N90X1.055
N100Y.937
N100Z.302
N110M5
N120G0X0Y0
; Vignesh K Velusamy
; Tooling: 0.250
; Work piece: T 0.750 W 1.970 L 3.980
; Slot: W 0.346 L 2.212 D 0.202
; Absolute Programming
; Activity #1; Slot Milling; Pass 2
N10G90
N15M3
N20G0X0Y0
N30Z.1
N40X1.055Y.937
N60Z-.202
N70X2.93
N80Y1.03
N90X1.055
N100Y.937
N100Z.302
N110M5
N120G0X0Y0
EQUIPMENT SET-UP
Equipment name is CNC Base for 1000 Prolight.
Setup:
 Make sure the machine works fine, check the fuses and safety switches.
 Place the Part onto the machining table and clamp the smaller part with spacers,the part should not touch the base.
 Use vice for the larger part, tighten the jaws so that the part stay put.
 Insert the Tool using the adapterand make sure it fits well onto the spindle.
 Set the Tool to the origin of the part block either using the manual jog control or using the computer program for the CNC
base for 1000 Prolight software.
MACHINING THE PART
Before machining the part, some setting needs to be adjusted and entered in the software program to get the part machined correctly.
The following procedure explain the Pre- and Post-machining process;
PerformancePerformance

2.  Start the program, and open new program to enter the codes.
 From the Settings tab, select verify setting,and enter the work piece size (Dimensions in IN).
 Move the tool bit suing the computer controller to the find the edges for the X, Y and Z axis.
 Make sure the tool is set at 90o angle to the respective sides before setting the zero position, use a thin sheet of paper to find
the tool touches the part by continuously moving the paper.
 Once the X, Y and Z set to zero, move the tool half the bit size from the X and Y positions to set the Origin Position.
 After setting the origin the Equipment is ready to run the program to machine the part, but before checking the program runs
correct is recommended.
 From Program tab,select verify option to see the simulation run each code virtually to check the program is correct or not.
 Finally Run the program and machine the part, use the emergency stop in the machine or from computer or pressing SPACE
BAR in PC keyboard to halt the process.
 Use Vacuum to remove the dust and other scrap material from the work piece and the Equipment.
 Wear Protective Glasses once entered the Machine Shop.
FINISHED PART
The completed part is a piece of stock with centered slot.
Fig. Pass 1.1
Fig. Pass 1.2
Lessons Learned:
Form this exercise, learned how to do CNC programming in Absoulte programming type. Familiarized with Numerial
Control Codes and their usage in different machining environment. Practiced to setup the Eqiupment for Pre- and Post- Machining and
the procedures to do it. Operated the equipmet, CNC Base for ProLight software program to mancine the Part.
ACTIVITY 2:

3. G-CODE PROGRAMMING
; Vignesh K Velusamy
; Tooling: 0.250
; Work piece: T 0.750 W4.00 L 6.50
; Absolute Programming
; Activity #2
N10G90
N20M3
N30G0X0Y0 Z.1
N40X.375Y.375
N60Z-.745
N70Y1.55
N80X.823Y2.00
N90X.375Y2.45
N100Y2.875
N110X1.130Y3.625
N120X2.875
N130Y3.250
N140X3.0Y3.125
N150X4.00
N160X4.125Y3.250
N170Y3.625
N180X5.302
N190X6.125Y2.802
N200Y1.750
N210X4.750Y.375
N220X3.375
N230Y.875
N240X2.125
N250Y.375
N260X.375
N265Z.1
N270M5
N280G0X0Y0
EQUIPMENT SET-UP
Equipment name is CNC Base for 1000 Prolight.
Setup:
 Make sure the machine works fine, check the fuses and safety switches.
 Place the Part onto the machining table and clamp the smaller part with spacers,the part should not touch the base.
 Use vice for the larger part, tighten the jaws so that the part stay put.
 Insert the Tool using the adapterand make sure it fits well onto the spindle.
 Set the Tool to the origin of the part block either using the manual jog control or using the computer program for the CNC
base for 1000 Prolight software.
FINISHED PART
The Computer simulation showing the part with Milling profile .
Fig. 2.1 Absolute programming of Milling profile
ACTIVITY 3:

4. G-CODE PROGRAMMING
; Vignesh K Velusamy
; Tooling: 0.250
; Work piece: T 0.750 W 4.5 L 6.50
; Incremental Programming
; Activity #3
N10G91
N20M3
N30G0X0Y0Z.1
N40X.375Y.375
N60Z-.845
N70Y3.750
N80X2.250
N90Y-.750
N100X1.570
N110X.680Y.680
N120Y1.070
N130X2.250
N140Y-3.650
N150X-.550Y-1.100
N160X-2.130
N170X-.450Y.450
N180X-.450Y-.450
N190X-3.18
N200Z.950
N210M5
N220G0X0Y0
EQUIPMENT SET-UP
Equipment name is CNC Base for 1000 Prolight.
Setup:
 Make sure the machine works fine, check the fuses and safety switches.
 Place the Part onto the machining table and clamp the smaller part with spacers,the part should not touch the base.
 Use vice for the larger part, tighten the jaws so that the part stay put.
 Insert the Tool using the adapterand make sure it fits well onto the spindle.
 Set the Tool to the origin of the part block either using the manual jog control or using the computer program for the CNC
base for 1000 Prolight software.
FINISHED PART
The Computer simulation showing the part with Milling profile .
Fig. 3.1 Incremental Programming of milling profile
POLAR G-CODE PROGRAMMING AND ABSOLUTE PROGRAMMING

5. ; Vignesh K Velusamy
; Tooling: 0.250”
; Work piece: T 0.750 W5 L 5
; Holes; Inside dia: .25” depth: .625”
; Outside dia: .25” depth: .375”
; Finished part: 4 x 4
; Holes circle radius: 1.25”
; Offset Depth: 3/16” or Depth of cut:
0.576”
; Using Polar and Absolute type
N10G90
N15M3
N20G0X0Y0Z.1
N25Z-.625
N30Z.1
N35G16
N40G99G81X1.25R.125Y0Z-.375
N50X1.25Y45
N60X1.25Y90
N70X1.25Y135
N80X1.25Y180
N90X1.25Y225
N100X1.25Y270
N120X1.25Y315
N140G15G80
N150G90
N160G0X0Y0Z.1
N170X-2.125Y-2.125
N180Z-.25
N190Y2.125
N200X2.125
N210Y-2.125
N220X-2.125
N180Z-.5
N190Y2.125
N200X2.125
N210Y-2.125
N220X-2.125
N180Z-.0625
N190Y2.125
N200X2.125
N210Y-2.125
N220X-2.125
N300Z.1
N310M5
N320G0X0Y0
EQUIPMENT SET-UP
Equipment name is CNC Base for 1000 Prolight.
Setup:
 Make sure the machine works fine, check the fuses and safety switches.
 Place the Part onto the machining table and clamp the smaller part with spacers,the part should not touch the base.
 Use vice for the larger part, tighten the jaws so that the part stay put.
 Insert the Tool using the adapterand make sure it fits well onto the spindle.
 Set the Tool to the origin of the part block either using the manual jog control or using the computer program for the CNC
base for 1000 Prolight software.
MACHINING THE PART
Before machining the part, some setting needs to be adjusted and entered in the software program to get the part machined correctly.
The following procedure explain the Pre- and Post-machining process;
 Start the program, and open new program to enter the codes.
 From the Settings tab, select verify setting,and enter the work piece size (Dimensions in IN).
 Move the tool bit suing the computer controller to the find the center for the X, Y and Z axis.
 Make sure the tool is set at 90o angle to the respective sides before setting the zero position, use a thin sheet of paper to find
whether the tool touches the part by continuously moving the paper.
 Once the X, Y and Z set to zero, move the tool half the size of the Part from the X and Y positions to set the Origin Position.
 After setting the origin the Equipment is ready to run the program to machine the part, but before checking the program runs
correct is recommended.
 From Program tab,select verify option to see the simulation run each code virtually to check the program is correct or not.
 Finally Run the program and machine the part.
 Start from center by drilling the holes first and then move on to milling, where give three passes each not more than ¼” depth
of cut.
 Use the emergency stop in the machine or from computer or pressing SPACE BAR in PC keyboard to STOP the process.
 Use Vacuum to remove the dust and other scrap material from the work piece and from the Equipment.
 Wear Protective Glasses once entered the Machine Shop.

6. FINISHED PART
The Computer simulation showing the part with Milling profile.
Fig. 4.1 Finished
Lessons Learned:
Form this exercise, learned how to do CNC Polar Programming in Absoulte programming type.Familiarized with Numerial
Control Codes and their usage in radial machining environment. Practiced to setup the Eqiupment for Pre- and Post-Machining and
the procedures to do it. Operated the equipmet, CNC Base for ProLight software program to mancine the Part.

7. CNC ROUTER PROGRAMMING:
Machine: AXYZ CNC ROUTER
Material: MDF
Game: Marble Racer
Machine Set up:
 Turn on the AXYZ CNC router, let it to heat up the cutting head.
 Place the MDF board on the table, use fixture to secure in one place.
 Turn on the suction clamp and place the cutting tool in the spindle.
 Set origin using F3 function; set surface height, bottom height and top reach height using F84 function.
 Use F8 function to set surface height alone.
 Start machining using F9 function.
Procedure: File Setting
 Use TOOLPATH Software to load the machining file onto the AXYZ machine.
 Load the marble racer file “. DFX” file format.
 Using Layout menu set the origin, size and orientation.
 Using Analysis menu to Group the color for the shapes, BLUE – outside, GREEN – Open, RED - inside.
 Setup menu is used to choose the depth of cut and for the multi-pass option
 Once file is setup press SEND button and then press Transfer button to upload the file into CNC.
 Turn off the machine and suction clamp and dust suction after machining.
Finished:
Fig. 5.1 Finished Marble Racer Game

8. GORILA GAME DESIGN PROJECT
Concepts Presented: AGGRAVATION BOARD GAME
Fig. 6.1 Proposed Concept
CAD File:
Designed the layout for CNC router using SOLIDWORKS software.
Fig. 6.2 Solid works CAD file

9. Fig. 6.3 TOOLPATH file for CNC
Fig 6.4 Prototype for the Game Board

10. Procedure: CNC router machining
 Took three pieces of Maple wood; shaped and glued together into 14” x 16” rectangular board.
 Developed the CAD file for the CNC Milling and CorelDraw file for Laser Engraving.
 Converted the CAD file into PLT Plotter format
 Imported the file into TOOLPATH software for CNC router.
 Using Analysis option selected the line to be Green and Holes to the Blue as a center marks,
 Two separate files for the center hole drilling using 0.5” round cutter head.
 And the outer – line is mill out with 1/8” milling head, with multi-pass 0.25” depth.
CNC table setup:
 Place the 13”x16” board on the CNC table, then turned on the AXYZ router machine to heat the cutter
head first.
 Uploaded the files to the CNC, then turned on the suction clamping and the dust suction while operation.
 Using F3 option to set the Origin of the board, then F84 option to set the Surface height, Bottom depth
height and the Top reach height.
 F9 to start the program uploaded from the TOOLPATH software.
 Use Emergency stop in case of trouble, release the stop to start again.
 After drilling the holes, changed the cutting tool and adjusted the surface height with F8 option, rest
options remain same.
 After milling out the line, the board is cleaned and prepared for engraving.
Fig. 6.5 Milling operation done on the wood in AXYZ CNC router
Procedure: Engraving
 Board is placed in the laser machine, set the reference and align the board using laser pointer.
 CorelDraw file is imported and placed on the sheet according to laser machine reference points.
 The design is sent to the VSNL 2.0 Pinter, properties for printing is adjusted.
 All lines are set to hairline and other shapes to 1 pt., in Black color.
 In Properties, material is Maple wood, in rast option; power is full, Speed is full and Rast percentage is
20% are chosen.
 Start the engraving by pressing start green button in the machine or on the software.
 Once finished engraving, using sand paper scrap of the burning mark and clean with vacuum.

11. CorelDraw Working setup:
Fig. 6.6 CorelDraw file for Engraving – front side
Fig. 6.7 CorelDraw file for Engraving – back side
Fig. 6.8 Laser Engraving file.

12. Finished Design:
Fig. 6.9 Finished Game design – front side Fig. 6.8 Finished Game design – back side
Fig. 6.10 Marble Board game ready to play