Machining Level III

Based on October, 2023 Curriculum Version II

Module Title: Advanced CAD/CAM Applications

Module code: IND MAC3 M01 1023

Nominal duration: 100 Hours

Prepared by Ministry of Labor and Skills

October, 2023
Addis Ababa, Ethiopia
Acknowledgment

Ministry of Labor and Skills and Ministry of Health wish to extend thanks and
appreciation to the many representatives of TVET instructors and respective industry experts
who donated their time and expertise to the development of this Teaching, Training and
Learning Materials (TTLM).

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Acronyms

2D Two Dimension
3D Three Dimension
CAD Computer-Aided Design
CAM Computer- Aided Manufacturing
H.S.S. High Speed Steel
in. Inch /Inches
M Metre/s
Mm Millimetre/s
Rpm Revolution per minute

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Table of Contents
Acknowledgment ....................................................................................................................... I
Acronyms .................................................................................................................................. II
Table of Contents .................................................................................................................... III
Introduction to the module ........................................................................................................ 1
Module Unit .............................................................................................................................. 2
Learning objectives of the Module ........................................................................................... 2
Module Learning Instructions: .................................................................................................. 2
Unit one: Design working drawing ........................................................................................... 3
1.1. Requirements and purpose of part drawing ............................................................... 4
1.2. CAD/CAM system and its application ....................................................................... 6
1.3. Producing the working drawing ............................................................................... 10
1.4. Engineering drawing symbols, references and terminology .................................... 13
1.5. Reviewing 2D Automated CAD blueprint of the part.............................................. 20
Self-check - 1 ...................................................................................................................... 21
Unit Two: Translate CAD in to CNC machine program ........................................................ 23
2.1. Coordinate system and calculation ........................................................................... 23
2.2. Coding using CAD software .................................................................................... 27
2.3. Program writing into a Computer Aided Manufacturing (CAM) code /process...... 51
2.4. Tool path creation using MastercamX5 user interface - Metric ............................... 55
2.5. Uploading and storing the Program ......................................................................... 86
2.6. Simulation, verifying and editing ............................................................................. 93
2.7. Self-check - 2 ........................................................................................................... 99
2.8. Operation sheet – 2.1 .............................................................................................. 101
2.9. LAP Test ................................................................................................................ 102
Unit Three: CAM/CNC operations ....................................................................................... 103
3.1. Occupational health and safety .............................................................................. 103
3.2. Mounting the parts ................................................................................................. 106
3.3. Tools and materials selection for the job ............................................................... 106
3.4. Machine setting and operating procedures ............................................................. 108

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 3.5. Dry run ................................................................................................................... 112
3.6. CAM/CNC operations ............................................................................................ 114
3.7. Self-check - 3 ......................................................................................................... 119
3.8. Operation sheet – 3.1 .............................................................................................. 121
3.9. LAP Test ................................................................................................................ 122
Unit Four: Quality assurance ................................................................................................ 123
4. Standard product specifications .................................................................................... 123
4.1. Measuring devices and methods for product inspection ........................................ 123
4.2. Error & risk identification and control measures in computer controlled machines
127
4.3. Self-check - 4 ......................................................................................................... 132
Reference .............................................................................................................................. 133
Developer profile .................................................................................................................. 134

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Introduction to the module

CAD/CAM is a term which means computer-aided design and computer- aided

manufacturing. It is the technology concerned with the use of digital computers to perform
certain functions in design and production. This technology is moving in the direction of
greater integration of design and manufacturing, two activities which have traditionally been
treated as distinct and separate functions in a production firm. Ultimately, CAD/CAM will
provide the technology base for the computer-integrated factory of the future. Computer-
aided design (CAD) can be defined as the use of computer systems to assist in the creation,
modification, analysis, or optimization of a design. The computer systems consist of the
hardware and software to perform the specialized design functions required by the particular
user firm. The CAD software consists of the computer programs to implement computer
graphics on the system plus application programs to facilitate the engineering functions of
the user company. The collection of application programs will vary from one user firm to the
next because their product lines, manufacturing processes, and customer markets are
different. Computer-aided manufacturing (CAM) can be defined as the use of computer
systems to plan, manage, and control the operations of a manufacturing plant through either
direct or indirect computer interface with the plant's production resources.

CAD-CAM systems are probably the most significant development in the field of new
technology related to engineering, design and drafting in all technical spheres. These systems
find application in all branches of modern design – from machine engineering to
microelectronics and others. This module describes in detail via review, selection, application
and implementation of such systems. The past decade has additionally witnessed the
emergence of new manufacturing technologies that build parts on a layer-by-layer basis.
Using these technologies, manufacturing time for parts of virtually any complexity is
measured in hours instead of days, weeks, or months. In other words, it is rapid. A host of
related technologies that are used to fabricate physical objects directly from Computer-Aided
Design data sources are reviewed in the module. These methods are generally similar to each
other in that they add and bond materials in layerwise-fashion to form objects.

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Module Unit
This module covers the units:

• Design working drawing

• Translate CAD in to CNC machine program
• CAM/CNC operations
• Quality assurance

Learning objectives of the Module

At the end of this session, the students will able to:

• Design detailed part drawing

• Translate CAD in CNC machine program
• Perform appropriate CAM / CNC operations
• Comply with quality assurance

Module Learning Instructions:

For effective use this modules trainees are expected to follow the following instruction:

1. Read the information written in each unit

2. Accomplish the Self-checks at the end of each unit
3. Perform Operation Sheets which were provided at the end of units
4. Do the “LAP test” giver at the end of each unit and
5. Read the identified reference book for Examples and exercise

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Unit one: Design working drawing
This learning unit is developed to provide the trainees the necessary information regarding
the following content coverage and topics:

• Requirements and purpose of part drawing.

• CAD/CAM system and its application
• Producing the working drawing
➢ Lay-outdrawing
➢ Detail drawing
➢ Component drawing
➢ Auxiliary views
➢ Sections
➢ Assemblies
• Standard engineering drawing symbols, references and terminology
➢ Limits and fits
➢ Geometric tolerances
➢ Datum references
➢ Surface texture and
• Reviewing 2D Computer Aided/Automated Design (CAD) blueprint of the part

This unit will also assist you to attain the learning outcomes stated in the cover page.
Specifically, upon completion of this learning guide, you will be able to:

• Check requirements and purpose of part and interpret drawing

• Determine and insert all drawing details and specifications
• Produce auxiliary views, sections and assemblies in ISO 1st and 3rd angle projection
• Review 2D Automated CAD blueprint of the part is for CAM application

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 1.1. Requirements and purpose of part drawing
The geometric model of the part is the input for the process planning system. The system
outputs the process plan (Figure 1.1). The input to the process planning system may be
engineering drawing or CAD model. The other prerequisites for process planning are given
below:
• Parts list
• Annual demand/batch size
• Accuracy and surface finish requirement (CAD Database)
• Equipment details (Work centre Database)
• Data on cutting fluids, tools, jigs & fixtures, gauges
• Standard stock sizes
• Machining data, data on handling and setup

Figure 1.1: Activities in Process Planning

In a computerized process planning system a formal structure and a knowledge database are
required in order to transform the engineering design information into the process definition.
A brief description of the operation of a computer aided process planning software is given in
the following section.

Factors Determining Job Requirements

1. Materials to be used
2. Surface finished required
3. Tolerance to be allowed
4. Quantity of units
5. Types and Scale of drawings
6. Name of the object and how it is used

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Working drawings Interpretation

The term working drawing is used to describe the complete set of drawing information
needed for the machining and assembly of a product based on its design. An essential
element of a working drawing is the parts list, or bill of materials (abbreviated BOM). A
working drawing is a drawing or set of drawings produced by the designer, manufacturer, or
fabricator. Shop drawings are typically required for prefabricated components. The working
drawing normally shows more detail. Working drawings will develop in detail from block
and massing drawings and sketches to very detailed technical drawings describing every
component in a way that will enable them to be constructed and operated. The primary role
or function of working drawings is to convert design data into finished part information and
to clearly communicate that information to industry, code officials, product manufacturers,
suppliers and fabricators. Drawings show the machinist what to make and identify the
standards that must be followed so the various parts will fit together properly. The resulting
parts will also be interchangeable with similar components on equipment already in service.

A very important skill needed for success in the machining field is the ability to interpret
engineering drawings, or prints. Engineering drawings show the sizes and shapes of
components and their specific features, such as holes, slots, or surfaces. No matter how
skilled you are at performing machining operations, if you are unable to properly interpret
these drawings, you will not be able to produce machined components independently or
efficiently within required specifications.

Sequence of operation

It is a sequence of operation plan. Which is prepared based on the information provided on

the job sheet or verbal instructions of the component to be machined has to ready for
producing expected parts / components / with required specification. Sequencing refers to the
order in which activities occur in the operations process. But there are a lot of operations are
performed by different machines. A work instruction is a tool provided to help someone to do
a job correctly. A Work Instruction is the most detailed description of a task. Its purpose is to
explain step by step how to do a specific task or work. Work instructions are key to reducing
variation, allowing manufacturers to improve quality and meet demand.

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 1.2. CAD/CAM system and its application
1.2.1. CAD/CAM System
• CAD/CAM: Computer Aided Design and Computer Aided Manufacturing. It is the
technology concerned with the use of computers to perform design and manufacturing
functions.
• A CAD/CAM system integrates the design and manufacturing function by translating
final design specifications into detailed machine instructions for manufacturing an item.
• CAD/CAM is quicker, less error prone than humans, and eliminates duplication between
engineering and manufacturing.
• CAD/CAM systems allow engineers to see how the various parts of a design interact with
each other without having to build a prototype.
• The CAD process is a subset of the design process. Similarly, the CAM process is a
subset of the manufacturing process.

Figure 1.2: The structure of CAD/CAM Systems

1.2.2. Components of CAD/CAM/CAE Systems

• Major component is hardware and software allowing shape manipulation
• Hardware includes graphic devices and their peripherals for input and output operations
• Software includes packages that manipulate or analyze shapes according to user interaction

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 Figure 1.3: Components of CAD/CAM/CAE Systems

Hardware Components
• Graphic device is composed of a display processing unit, a display device, and one or
more input devices
• Input devices:
➢ Mouse
➢ Space ball
➢ Data tablet with a puck or stylus
➢ Keyboard
• Output Devices:
➢ Plotters
➢ Color laser printers
Software Components
• CAD software allows the designer to create and manipulate a shape interactively and
store it
• CAM software plans, manages and controls the operations of a manufacturing site
• CAE software analyzes design geometry, allowing designer to study product behavior

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 1.2.3. Advantages and Disadvantages of CAD/CAM
CAD/CAM (Computer-Aided Design/Computer-Aided Manufacturing) is a general term for
a variety of technologies, including computer numerical control, rapid prototyping,
component modeling and design software. CAD.CAM technologies were developed during
the 1980s and are now widespread in industry and academia. CAD/CAM refers to the use of
computers and computer-controlled manufacturing in the design of products.

Advantages of CAD/CAM systems

• Greater flexibility. • Greater manufacturing control.

• Reduced lead times and inventories. • Supported integration.
• Increased Productivity. • Reduced costs.
• Improved customer service and quality. • Increased utilization.
• Improved communications with suppliers. • Reduction of machine tools.
• Better product design. • Less floor space.

Advantage: Software Flexibility

Using CAD software enables design changes to be made rapidly. Before CAD, a particular
design change would have required a draftsperson to completely redraw the design to the
new specification. CAD software allows designers to thinker with designs and makes small
changes on the fly. It can also be used to simulate the behavior of the design in software. For
example, CAD software can be used to simulate the airflow around an engine. This allows
for greater flexibility in the software design process.

Advantage: Design Flexibility

Another term for CAM is rapid prototyping. Rapid prototyping allows designers to construct
physical prototypes during the design process. These physical prototypes can be used to test
various aspects of the design. For example, if the goal is to design a steel object, then a
prototype can be made out of transparent acrylic. The transparency of the acrylic prototype
allows designers to view the pattern of stresses and strains within the object. This allows for
greater flexibility in the physical design and prototyping process.

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Advantage: Automatic Specification Checking

Using CAD software enables the designer to automatically check if the design is within
specification. CAD software also enables clients to view designs at an earlier stage in the
design process than is usually the case. CAM also enables clients to check the progress of
functional and semi-functional prototypes at a much earlier stage than is possible in the
traditional design process.

Disadvantage: Processing Power Limitations and Cost

CAD software often consumes large amounts of computer processing power. This requires
high-quality computer hardware that can be costly. CAM requires advanced manufacturing
devices that are also very expensive. The cost of hardware is a significant disadvantage of
CAD.CAM and a major barrier to the wider uptake of CAD.CAM technologies.

Disadvantage: Software Complexity

As CAD software advances, it becomes more flexible and adaptable. However, this comes at
the cost of making the software more complex. This complexity makes it more difficult for
first-time users to learn the software. Combined with the cost of training personnel in
CAD.CAM technologies, this complexity represents another disadvantage of CAD.CAM.

1.2.4. Application of CAD/CAM

Solid Modelling
This process is used to create solid components of desired shape by joining and cutting
different solid volumes. The final solid model is a virtual replica of an actual product but it
can be seen and rotated like a real product. There are two main types:
• Direct where the model can be edited by undoing or modifying the model directly on 3D.
• Parametric where the model is constructed using parameters (variable quantities such as
measurements) and the model can be edited at any point in its history.

Surface Modelling
This process is used to create surfaces of desired shape by trimming, stitching and joining
different surfaces to create a final shape model.

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Assembly

This process is used to assemble the models created in solid or surface modelling to create a
final assembly. This is used to see the actual fitment of all models and see the actual working
of assembly.

Drafting Detailing

This process is used to create the 2D drawings of components or assemblies; usually directly
from a 3D model, although 2D CAD can create 2D drawings directly.

Reverse Engineering

This process is used to convert the real component into 3D CAD Model. Different types of
instruments such as laser scanner, white light scanner, CMM (coordinate measuring
machine) etc. are used to measure or decode the shape of real model. The virtual model
obtained can then be modified in a CAD program.

1.3. Producing the working drawing

Introduction to drawing

Engineering drawing is a two dimensional representation of three dimensional objects. In

general, it provides necessary information about the shape, size, surface quality, material,
manufacturing process, etc., of the object. It is the graphic language from which a trained
person can visualize objects. Drawings prepared in one country may be utilized in any other
country irrespective of the language spoken. Hence, engineering drawing is called the
universal language of engineers. Any language to be communicative, should follow certain
rules so that it conveys the same meaning to everyone. Similarly, drawing practice must
follow certain rules, if it is to serve as a means of communication.

Classification of drawing
1. Assembly drawing
2. Lay-outdrawing
3. Detail drawing
4. Component drawing

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 1.3.1. Lay-outdrawing
Lay-outdrawing - Most original designs are planned in the drawing office where existing or
known information is collected and used to prepare a provisional layout drawing before
further detailed design work can proceed. This type of drawing is of a preliminary nature and
subject to much modification so that the designer can collect his thoughts together. The
drawing can be true to scale or possibly enlargements or reductions in scale depending on the
size of the finished product or scheme, and is essentially a planning exercise. They are useful
in order to discuss proposals with prospective customers or design teams at a time when the
final product is by no means certain, and should be regarded as part of the design process.
Provisional layout drawings may be prepared for use with tenders for proposed work where
the detailed design will be performed at a later date when a contract has been negotiated, the
company being confident that it can ultimately design and manufacture the end product. This
confidence will be due to experience gained in similar schemes undertaken previously.

1.3.2. Detail drawing

Detail drawing - is a multi-view representation of a single part with dimensions and notes.
Detail drawing conveys the information and instructions for manufacturing the part.
Information in Detail Drawing
• General information (name of company, drawing sheet number, name of drafter and
checker, relevant date of action, scale, unit etc.)
• Parts information
➢ Shape description (orthographic drawing, pictorial drawing)
➢ Size description (dimension and tolerances)
➢ Specifications (part number, name, quantity, type of material used and general notes)

1.3.3. Component drawing

Component drawing- Component or part drawing is a detailed drawing of a component to
facilitate its manufacture. All the principles of orthographic projection and the technique of
graphic representation must be followed to communicate the details in a part drawing. A part
drawing with production details are rightly called as a production drawing or working
drawing.

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 1.3.4. Auxiliary views
Auxiliary views shall be connected to the adjacent view from which they are developed by a
single center line or an extension line connecting identical external edges of the part. The
centerline shall go through the same feature in both views. The extension line shall have a
gap between the visible edge of the part and the extension line equal to ͘0.09" or 2 mm.
• The break line on all partial auxiliary views shall be smooth curve.
• Hidden lines shall be omitted on features when they appear foreshortened in
orthographic views.

Figure 1.4: Auxiliary Views.

1.3.5. Sections
• The break line on all broken-out section views shall be created with a smooth curve.
• The plotted arrowhead size on the cutting-plane line shall be ͘25"_(6 mm), two times
(2x) the size of the dimension arrow.
• Cutting-plane lines shall be drawn with thick phantom lines (lineweight = 0.6 mm).
(see Figure 1.4).

1.3.6. Assemblies
Assembly drawing- Is a drawing of various parts of a machine or structure assembled in their
relative working positions. Assembly drawings can be used to represent items that consist of
more than one component. Assembly drawings may include instructions, lists of the
component parts, reference numbers, and references to detail drawings or shop drawings, and
specification information. It helps streamline the manufacturing process. The precise details
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of the technical drawing helps builders create objects without errors, delays or other costly
issues. This alone is the most important duty of the drawings.

Assembly drawing conveys

• Completed shape of the product
• Overall dimensions
• Relative position of each part
• Functional relationship among various components

1.4. Engineering drawing symbols, references and terminology

1.4.1. Limits, fits and Geometric tolerances
• Due to the inevitable inaccuracy of manufacturing methods, a part cannot be made
precisely to a given dimension. The permissible variation on the size is called tolerance.
• The two extreme permissible sizes on the actual size are called limits.
• When two parts are to be assembled, the relation resulting from the difference between
their sizes before assembly is called a fit.
➢ FIT is condition of looseness or tightness between two mating parts being assembled.

Figure 1.5: Limits, Fits and Tolerances

Hole basis system and shaft basis system

Hole basis system: Size of hole is kept constant, shaft size is varied to get different fits.
Hole Max Hole size – Basic Size = Upper Deviation
Min Hole size – Basic Size = Lower Deviation
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 Figure 1.6: Hole basis system

Shaft basis system: - Size of shaft is kept constant, hole size is varied to get different fits.

Shaft Max shaft size – Basic Size = Upper Deviation

Min shaft size – Basic Size = Lower Deviation

Figure 1.7: Shaft basis system

Clearance Fit: Maximum shaft dimension < Minimum hole dimension

Figure 1.8: Clearance Fit

Interference Fit: Maximum hole size < Minimum shaft size

Figure 1.9: Interference Fit

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Transition Fit: Obtained by overlapping of tolerance zones of shaft and hole. It does not
guarantee neither clearance nor interference fit.

Figure 1.10: Transition Fit

Figure 1.11: Well-designed, fully-dimensioned technical drawing

1.4.2. Datum references

Programming System

There are two types of programming modes or positioning reference system which is called
the incremental and the absolute system, are used for CNC. Both systems have applications
in CNC programming, and no system is either right or wrong all the time. Most controls on
machine tools today are capable of handling either incremental or absolute programming.
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Incremental program locations are always given as the distance and direction from the
immediately preceding point (Figure 1.12). Command codes which tell the machine to move
the table, spindle and knee are explained here using vertical milling machine as an example.

• A “X plus” (X+) command will cause the cutting tool to be located to the right of the last
point.
• A “X minus” (X-) command will cause the cutting tool to be located to the left of the last
point.
• A “Y plus” (Y+) command will cause the cutting tool to be located toward the column.
• A “Y minus” (Y-) will cause the cutting tool to be located away from the column.
• A “Z plus” (Z+) command will cause the cutting tool or spindle to move up or away from
the work piece.
• A “Z minus” (Z-) moves the cutting tool down or into the work piece.

Figure 1.12: A work piece dimensioned in the incremental system mode.

In incremental programming, the G91 command indicates to the computer and Machine
Control Unit (MCU) that programming is in the incremental mode.

Absolute program locations are always given from a single fixed zero or origin point
(Figure 1.13). The zero or origin point may be a position on the machine table, such as the
corner of the worktable or at any specific point on the work piece. In absolute dimensioning
and programming, each point or location on the work piece is given as a certain distance
from the zero or reference point.

• A “X plus” (X+) command will cause the cutting tool to be located to the right of the zero
or origin point.

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• A “X minus” (X-) command will cause the cutting tool to be located to the left of the zero
or origin point.
• A “Y plus” (Y+) command will cause the cutting tool to be located toward the column.
• “Y minus” (Y-) command will cause the cutting tool to be located away from the column.

Figure 1.13: A work piece dimensioned in the absolute system mode.

In absolute programming, the G90 command indicates to the computer and MCU that the
programming is in the absolute mode.

Absolute and Incremental Co-ordinates

The addresses X and Z, within a program, relate to a co-ordinate position from the workpiece
datum (the zero position). The addresses U and W, within a program, relate to the individual
axis movements required to reach the new position, from the last position reached by the
tool. The address U refers to the X axis and the address W refers to the Z axis.

Figure 1.14

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The taper turning shown can be written in four different ways.

1. Absolute: GØ1 X3Ø Z-5Ø FØ.15;

2. Incremental: GØ1 U1Ø W-52 FØ.15;
3. Absolute/Incremental: GØ1 X3Ø W-52 FØ.15;
4. Incremental/Absolute: GØ1 U1Ø Z-5Ø FØ.15;

When programming arcs and radii, the programmer needs to describe the destination point
(X, Y, Z axis coordinates), the direction of the arc (G02 or G03) and the location of the
center of the arc. After choosing destination point, and direction of the arc, describe the
center of the arc using an I, J, and/or K code(s).

Where,
• I refers to an incremental distance and direction (+/-) from the start point of the arc to
the arc center along the X axis.
• K refers to an incremental distance and direction (+/-) from the start point of the arc
to the arc center along the Z axis.
• J, refers to an incremental distance and direction (+/-) from the start point of the arc to
the arc center along the Y axis. (see diagram shown).

Example: The plate shown can be programmed as follows:

Absolute:
G01X40; (P1-P2)
G03X60Y60J20; (P2-P3)
G01X80; (P3-P4)
G02X100Y40J-20; (P4-P5)

Incremental:
G01U40; (P1-P2)
G03U20W20J20; (P2-P3)
G01U20; (P3-P4)
Go2U20U-20J-20; (P4-P5)

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 Figure 1.15

1.4.3. Surface texture /Finish

Surface finish refers to the texture of the surface of a machined part. Roughness and
waviness are the two factors generally considered when discussing surface finish. Roughness
is the peaks and valleys created by the cutting action of a machining process. Waviness is the
variation of those peaks and valleys over a larger distance. Figure below shows the difference
between roughness and waviness.

Figure 1.16: Surface characteristics

Figure 1.17: The basic concept of Ra surface finish measurement

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There are several systems for measuring surface finish, but the most widely used system
measures roughness and is called Ra, or arithmetical average. It is a measure of the average
height of a surface above a line that is midway between the highest peak and lowest valley of
a surface within a given waviness length.

1.5. Reviewing 2D Automated CAD blueprint of the part

Design Review is a program used for creating and reviewing DWF files. DWF enables
secure file format to combine and publish rich 2D and 3D design data and share it with
others. Design Review enables the entire project team to view, print, measure and markup
DWF, DWG, DXF, PDF and raster files containing 2D and 3D content. Fully integrated with
CAD, Design Review helps to easily share drawings, models and design data with team
members, suppliers and other reviewers by email, websites and physical media, such as
DVDs. A DWF file can be used to organize sheet sets, models, animations and other project-
related files, into a single, highly compressed file. Together with Design Review, DWF files
help to enhance collaboration by clearly communicating information, such as design changes
or corrections, all while reducing the printing and distributing costs. Unlike PDF files,
however, DWF files retain detailed design information and scale.
• Most DWF files begin as a drawing or model created in CAD programs, Inventor and
Revit. Before a DWF file is published, the DWF file determines which features (model,
layouts, layers, blocks, named views, and so on) are included in the DWF file. Once the
content has been determined, the designer publishes the file from its original format to a
DWF file and sends to the review team to begin the digital design review process.
• Receive- Reviewers get the DWF file from the publisher and open it in Design Review to
verify the content (a 2D drawing, 3D model, or image).
• Review Reviewers add digital comments and markup to the DWF file using callouts,
text, shapes, dimensions, stamps, and custom symbols, saving changes to the DWF file
• Return- Reviewers send the marked‐up DWF file back to the original publisher
• Revise- The designer uses the publishing software to import the marked‐up DWF file,
referring to comments in context to revise the original design quickly.
• Republish- After revising the original content in the software, the designer republishes
an updated DWF file, a new sheet set /model to begin the digital design workflow again.
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 Self-check - 1
Directions: Attempt to answer all the questions listed below. Illustrations may be necessary
to aid some explanations/answers. Note: Be precise and scientific in writing.

Part I - Instructions: For the following questions say True or False.

1. DWF enables you to combine and publish only 2D design data.
2. Design Review helps you easily share drawings, models, maps, and design data with
team members.
3. DWF file can be used to organize sheet sets, models, animations, finite element
analyses (FEA), and map information.

Part II: Multiple Choice - Instructions: For each of the following question choose the best
correct answer and circle the letter of your choice from the given alternatives.

1. ______ is used to create surfaces of desired shape by trimming, stitching and joining
different surfaces to create a final shape model.
a. Solid modeling b. Surface Modelling
c. Drafting Detailing d. Reverse Engineering
2. Which one of the following is not a benefit of CAD/CAM
(a) Ease of modification (c) Quality of output
(b) Repeatability of output (d) Reduction of wastage (e) None
3. _____ is locations are always given from a single fixed zero or origin point.
a. 3D printing b. Surface modeling
c. Absolut program d. Incremental program
4. The main application of CAM is __________.
a. Plotter b. Laser cutting c. Turning d. All
5. The permissible variation on the size is called__________.
a. Fit b. limits c. tolerance d. none
6. Specification includes
A. Part number B. Number required
C. Type of material E. All

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 7. Assembly drawing conveys
A. Completed shape of the product
B. Overall dimensions
C. Relative position of each part
D. Functional relationship among various components
E. All
8. Reviewers send the marked‐up DWF file back to the original publisher
a. Receive b. Review c. Return d. Revise

Part III: Marching - Instructions: For the following questions match from “B” to “A”
column

No. “A” Column “B” Column

Size of hole is kept constant, shaft size is varied to
______ 1. A. Hole basis system
get different
A two dimensional representation of three
______ 2. B. Engineering drawing
dimensional objects
C. Name of drafter, checker
______ 3. The general information contains n detail drawing
and company

Part IV: Short answer – Instructions answer all the questions listed below.

1. List advantages of CAM and CIM.

2. List purpose of CAM and CIM.
3. CAD/CAM Systems
4. Write purpose of engineering drawing.

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Unit Two: Translate CAD in to CNC machine program
This learning unit is developed to provide the trainees the necessary information regarding
the following content coverage and topics:
• Coordinate system and calculation
• Coding using CAD software
➢ Auto CAD
➢ Solid works
➢ CATIA
➢ Master CAM
• Program writing into a Computer Aided Manufacturing (CAM) code /process.
• Uploading, verifying and storing the Program
• Simulation and editing

This unit will also assist you to attain the learning outcomes stated in the cover page.
Specifically, upon completion of this learning guide, you will be able to:
• Calculate coordinates for simple tool path machining functions
• Code the program using CAD software
• Write a program into an Automated CAM code/process
• Simulate and edit a program according
• Download, verify and store a program according to standard operating procedures

2.1. Coordinate system and calculation

2.1.1. Coordinate systems
Unless they are sketches; in production of any drawing, objects should be drawn in their
desired size. The Coordinate system is a powerful tool for making objects in their actual size.
Mainly there are three coordinate systems; absolute, relative and polar. The names for the
coordinate systems may vary in different articles but all imply the same system. All the
coordinates systems only produce one point at a step so according to the command in
progress, locating a point or successive points using one of the three coordinate systems
helps to draw an object.
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In Auto CAD, all objects are produced in 1:1 scale then during a plotting process a proper
scale will be chosen.

Three types of coordinate systems are needed in order to input, store, and display model
geometry and graphics.
• The working coordinate system (WCS),
• The model coordinate system (MCS), and
• The screen coordinate system (SCS).

In AutoCAD, you can use either relative polar or Relative Cartesian coordinates.

A. Absolute coordinate system

The other name for this system is Cartesian coordinate system. In this system all coordinated
points are measured or referenced from the origin, absolute point. This coordinate system is
less applied since it consumes time. It can be used for some specific applications like data
obtained from surveying instrument.

The form of the coordinate system is x,y. The first value is always for X and then Y, they are
separated by comma “,”. X and Y can be positive or negative. Both x and y are positive if
they are in the first quadrant. (See figure 2.1 for detail) By default objects are mostly drawn
in the first quadrant, it is not a rule.

Figure 2.1
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 B. Relative coordinate system
Relative coordinate system is also called rectangular coordinate system. Even some times it
is also called relative Cartesian coordinate system. That’s OK, let’s worry about its use.

A point or a coordinate is obtained by taking a previous point as a reference. A step forward

is taken relative to a previous point. That is why it is called relative coordinate.

The form is @X,Y. A space is not needed while entering coordinate. X becomes negative if
the next coordinate is to the left side of a previous point and Y becomes negative if a
coordinate moves down from the last point.

Specifying Relative Cartesian Coordinates

For the next line segment, let’s try another method for specifying exact distances:

1. Enter @0, 0.15 . Metric users should enter @0, 0.5 . A short line appears above the
endpoint of the last line. Once again, @ tells AutoCAD that the coordinate you specify
is from the last point picked. But in this example, you give the distance in X and Y
values. The X distance, 0, is given first, followed by a comma, and then the Y
distance, 0.15. This is how to specify distances in relative Cartesian coordinates.
2. Enter @-3,0. Metric users should enter @-9,0. This distance is also in X,Y values,
but here you use a negative value to specify the X distance. The result is a drawing
that looks like Figure 2.2. Positive values in the Cartesian coordinate system are from
left to right and from bottom to top. (You may remember this from your high school
geometry class!) If you want to draw a line from right to left, you must designate a
negative value. It’s also helpful to know where the origin of the drawing lies. In a new
drawing, the origin, or coordinate 0,0, is in the lower-left corner of the drawing.
3. Type C. This C stands for the Close command. It closes a sequence of line segments.
A line connecting the first and last points of a sequence of lines is drawn and the Line
command terminates. The rubber-banding line also disappears, telling you that
AutoCAD has finished drawing line segments. You can also use the rubber-banding
line to indicate direction while simultaneously entering the distance through the
keyboard. See the upcoming sidebar “A Fast Way to Enter Distances.”

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 Figure 2.2

C. Polar coordinate system

Polar coordinate uses true length and angle to specify a point unlike absolute and relative
coordinates which use X and Y. The form of the system is @L<A for relative polar
coordinate system and for absolute polar coordinate system L < A. Where:
• L is true length and a length is non negative and non-zero.
• < is angle sign
• A is angle value. It can be positive or negative. Unless it is changed intentionally, the
reference for angle measurement is east, 00. The angle value will be positive if the
angle is measured in counter clockwise direction from east. If the measurement is
taken to the clockwise direction, it becomes negative.

Specifying relative Polar Coordinates

To enter the exact distance of 3 (or 9 metric) units to the right of the last point you selected,
do the following:
1. Type @3<0. Metric users should type @9<0. As you type, the letters appear at the
Command prompt.
2. Press Enter. A line appears, starting from the first point you picked and ending 3 units
to the right of it (see Figure 2.3). You’ve just entered a relative polar coordinate.

Figure 2.3 Notice that the rubber banding line now starts from the last point selected. This
indicates that you can continue to add more line segments.
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The “at” sign (@) you entered tells AutoCAD that the coordinate you’re specifying is from
the last point you selected. The 3 (or 9 metric) is the distance, and the less-than symbol (<)
tells AutoCAD that you’re designating the angle at which the line is to be drawn. The last
part is the value for the angle, which in this case is 0 for 0°. This is how to use polar
coordinates to communicate distances and directions to AutoCAD.

2.2. Coding using CAD software

The CODE system is a parts classification and coding system developed and marketed by
Manufacturing Data System, Inc (MDSI), of Ann Arbor, Michigan. Its most universal
application is in design engineering for retrieval of part design data, but it also has
applications in manufacturing process planning, purchasing, tool design, and inventory
control.

The code number has eight digits. For each digit, there are 16 possible values (zero through 9
and A through F) which are used to describe the parts design and manufacturing
characteristics. The initial digit position indicates the basic geometry of the part and is called
the major division of the code system. This digit would be used to specify whether the shape
was cylinder, flat, block, or other. The interpretation of the remaining digits forms a chain-
type structure. Hence the CODE system possesses a hybrid structure.

2.2.1. Auto CAD

AutoCAD Mechanical is a 2D mechanical software design tool built on the AutoCAD
platform. It allows drafting and designing mechanical pieces, and comes with a library of
standard objects meant to increase productivity. AutoCAD Mechanical design and drafting
software is AutoCAD software for manufacturing, purpose-built to accelerate the mechanical
design process. Part of the Autodesk solution for Digital Prototyping, it includes all the
functionality of AutoCAD, one of the world’s leading 2D CAD design software, plus
comprehensive libraries of standards-based parts and tools for automating common
mechanical CAD tasks. AutoCAD Mechanical design software helps save hours of design
time. Added to this platform are strong machine design means providing faster and easier
creation, editing, detailed view and management of machine projects and drawings.
AutoCAD Mechanical with Power commands – a single command provides editing and
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copying, modifying detail and openings specifications and execution of commands for
making other items. An exceptionally convenient and intuitive user interface facilitates
operation and practically leads to using specialized software functions. Some of the most
useful and attractive capabilities are:
• An automated layer control positions items in suitable layers
• Automated output and alignment of items in drawings of assembled units and
generation of specifications
• Dimensioning, tolerances, roughness symbols, shape and size deviations according to
a user selected design
• Management of two-dimensional assemblies
• AutoDetailing creates detail drawings based on the assembly drawing
• Extended Xref Manager and Block Editor

AutoCAD Mechanical Power Pack library containing over 500,000 standard machine
elements, standard technological elements, over 20,000 standard openings, coupling
elements, shafts generator, engineering shaft calculations, bearings, selection of materials, etc

Example 2.1: Absolute coordinate system

Draw the object below on figure 2.4 Point “A” is the start point. Arbitrarily you can enter a
coordinate to determine the start point. Twelve points, labeled A to L, are necessary to draw
the object. Using absolute coordinate system, first specify point A then successively the
other points up to L and finally back to point A. See the right procedures after figure 2.4.
• First select line
• From draw click “Line” or from draw tool bar click Line button or
• Enter “L” on command line (l . )
• Line specify first point appears on command line. In our case point A.
• Enter 10,30 ., it is arbitrary but for this example you should use 10,30
• Specify next point, B.
• Enter 95, 30. . Line AB is 85 and X coordinate on point A is 10 plus the distance 85
become 95. Since delta in Y direction is zero, Y on point A and B is the same, 30.

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 • Specify next point, C. 95,80 . (X remains constant and Y becomes 80, 30+50). All
the points are measured from Absolute Coordinate System (WCS)
• Specify next point, D. 145,80 .
• Specify next point, E. 145,120 .
• Specify next point, F. 105,150 . There is delta in X and Y since the line is inclined.
X decreases by 40 since the movement is to the negative X direction.
• Specify next point, G. 80,150 .
• Specify next point, H. 80,130 .
• Specify next point, I. 20,130 .
• Specify next point, J. -20,80 . (X=20-40=-20, Y= 130-50=80, J is on the II quadrant)
• Specify next point, K. -20,50 .
• Specify next point, L. 10,50 . ( X=-20+30=10)
• Specify next point, A. 10,30 . (Y=50-20=30) or instead of entering the coordinate
(10,30) possible to activate the optional command close, c.

Close and undo are optional commands for “Line”. If you make a mistake while entering the
above points, choose undo (u .) to go one step back.

Figure 2.4.

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Example 2.2: Relative coordinate system

• Draw the object on figure 2.4, on the previous page, using relative coordinate system.
➢ Select line
✓ From draw click “Line” or

✓ From draw tool bar click Line button or

✓ Enter “L” on command line
➢ Line specify first point. Click anywhere on the model or enter coordinate to get point A.
➢ Specify next point, B. enter @85,0  . Relative to point A, point B is 85 to the
positive X and 0 to Y direction.
➢ Specify next point, C. @0,50  , now there is change only in Y.
➢ Specify next point, D. @50,0 
➢ Specify next point, E. @0,40 
➢ Specify next point, F. @ -40,30. Relative to point E, change in X is -40 while Y is 30
➢ Specify next point, G. @ -25,0 
➢ Specify next point, H. @0,-20 
➢ Specify next point, I. @-60,0 
➢ Specify next point, J. @ -40,-50 
➢ Specify next point, K. @0,-30 
➢ Specify next point, L. @ 30,0 
➢ Specify next point, A. @0,-20  and press Esc to stop line command or instead of the
last coordinate @0,-20 enter c 

Example 2.3: Polar coordinate system

For the object on figure 2.5 the angle is -300 if the angle is measured in clockwise direction.
The same angle is 3300 for counter clockwise measurement. Draw the object using relative
polar coordinate system and absolute polar coordinate system.

Using relative polar coordinate system, @L<A

• Select line
➢ From draw click “Line” or

➢ From draw tool bar click Line button or

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 ➢ Enter “L” on command line
• Line specify first point,1. Click anywhere or enter a coordinate value
• Specify next point, 2. @60<180  ( the angle is 180 degree since the direction is
towards west)
• Specify next point, 3. @100<-30  or @100<330 
• Stop line command, press Esc.

Using absolute polar coordinate system, L<A

• Select line
• Line specify first point, 1. enter a coordinate value like 100,100 
• Specify next point, 2. 60<180 
• Specify next point, 3. 100<-30  or 100<330 
• Stop the command, press Esc

Figure 2.5

Example 2.4
Draw the object below using polar coordinate system. Take “A” as first point and move to
counter clockwise direction. First try by yourself and see the procedure below, haa!
• Select line
• Click any where to specify the first point, in this case A.
• Specify next point appears on command line, enter:
➢ @100<0  or @100<360  or @100,0 . ( to the right of the reference point,
A, to the east, 0 or 360 degree)
• Specify next point. @100<60  ( 60 degree from east)
• Specify next point. @60<0 
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 • Specify next point. @100<90  ( 90 degree from east, north is 90)
• Specify next point. @60<180  ( towards west)
• Specify next point. @100<120  ( it is 30 degree from north but from east it is 120
degree, 90+30)
• Specify next point. @100<180 
• Specify next poin. @173<210 (30 degree from west, 210 degree from east, 180+30)
• Specify next point. @100<270  or @100<-90  (clockwise)
• Specify next point. @173<330  or @173<-30 
• Stop the command

Figure 2.6

2.2.2. Solid works

SolidWorks is a 3D mechanical CAD (computer-aided design) program that runs on
Microsoft Windows. This product reflects the latest achievements in the world of engineering
design, exclusively easy to understand and use and available for every machine-building
company. These are the first and major characteristics of SolidWorks 2010 - SP4.0. The
latest version of the product is the latest achievement in succession, which affirms it as a
standard among the three-dimensional design systems operating under Windows. SolidWorks
2010 accelerates the process of reflecting and conveying engineering ideas. It allows
alterations of dimensions, relations and geometry of engineering components to be made at

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any time and allows the user to return and rearrange the history of their creation. All data are
100% editable. All connections between details, assembled units and drawings are constantly
current.

SolidWorks 2010 allows fast and efficient operation adequately using all typical means of
Windows menus like indicating, selecting, copying, holding and shifting objects. It is easy to
organize and develop complicated projects using the so-called FeatureManager, which
reflects the history of creation of engineering components. The work of the user has been
additionally facilitated by Internet access provided by the so-called FeaturePalette, a
constantly updated library of standard details and engineering components.

The latest version of SolidWorks has means built-in to ease transitions between two-
dimensional and three-dimensional design, which include an AutoCAD command emulator.
This emulator allows AutoCAD users to apply their acquired habits and skills to create drafts
and drawings in SolidWorks.

Solidworks 2010 offers means for efficient generation of technical documentation at

minimum effort. Drawings are generated automatically from three-dimensional models and
include all drafting elements – views, cross-sections, dimensions and notes. The drawings
generated are completely associated with respective three-dimensional models-details and
assembled units, so each change in the drawing is reflected in the model and vice versa.

The latest version provides simpler detail means especially when making detail views and
cross-sections. Various layers could be maintained. The conditions for more complete
implementation of company standards and proprietary symbols, texts and formatting frames
have greatly been improved. Some capabilities have been added to provide copying views
from different sheets, making tabulated drawings as well as adjustment of various gauges for
material specifications.

SolidWorks 2010 allows building of assembled units by means of direct addressing to details
already created and creating new details in an existing assembly unit based on the built up
geometry. It offers impressive efficiency and convenience when using both methods also
known as bottom-to-top and top-to-bottom design. Interconnections – alignment,

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concentricity, parallelism, distance, tangential have been adopted between the elements of an
assembly unit This makes the assembly unit a kinematical mechanism, which can be moved
to test the kinematical links and interrelation of separate mechanism components.
SolidWorks 2010 has a built-in Collision Detection, which establishes any available inter-
collision between separate parts of the mechanism in real time. The design of assembly units
could be accelerated by means of the so-called SmartMates – an intelligent means or pre-
determining the possibilities for linking geometrical elements when moving them. Processing
and visualization of large assembly units is considerably facilitated by the possibility for
partial loading of participating details and sub-units into the so-called Lightweight mode. An
especially important role has been given to the freedom of the user to operate with various
alternatives called configurations both for the entire assembly unit and for all its separate
sub-units.

2.2.3. CATIA
The definition of CATIA is Computer Aided Three-dimensional Interactive Application.
CATIA is a highest-class system for automation of engineering labour. It is one of the
undisputable leaders in the world of modern CAD/CAM/CAE systems. CATIA was created
by Dassault Systems and is being distributed by IBM. In 1998, a version of CATIA V5 was
released, with support for UNIX, Windows NT and Windows XP since 2001. In 2008,
Dassault announced and released CATIA V6. While the server can run on Microsoft
Windows, Linux or AIX, client support for any operating system other than Microsoft
Windows is dropped. CATIA represents a unique integrated solution for creating and
developing engineering products and their optimization in the conditions of team design. It
improves the entire product line of the system aiming at increasing customer competitiveness
in the design, optimization, production and planning of resources. It convenient to use
module for assembling products based on the abstraction for graphic representation based on
the hierarchy tree. Customers, who consider the shape of the design of significant
importance, like consumer goods or a new product for efficient and high-quality data
exchange between CATIA and ALIAS. This increases efficiency when designing shapes
allowing easy agreement between the designer and engineer’s activities.

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 Figure 2.7

The product Generative Shape Modeling dramatically accelerates the process of detail
design. The companies where the usage of highly efficient solid-body modelling is critical
are able to take advantage of the serious improvements in efficiency compared to earlier
CATIA. The drawing generation process has also been accelerated. These improvements are
of primal importance for the design of motors, reducers and all types of machine mechanism
where large models are usually involved. The CATIA new version is a move forward to a
new quality level of automation of technological operations. The Surface Machining
Programmer product is a complete and easy to use selection of means for generating 3D
programs for 3-axes milling machines. The Multi-Axis Machining Programmer product uses
leading NCCS technologies and is addressed to the need of complicated machining in plane
building techniques. As a whole, CATIA improves flexibility when selecting between two
types of functionalities: fully interactive geometrically based ones and semi-automated
process-oriented ones. This version significantly improves the analysis and optimization
functions. The product Generative Part Optimization is intended to provide sensitive analysis
and optimization of products with the aim of ensuring the best quality design in the fastest
possible way and with minimum effort involved. The design engineer is offered intuitive
analysis of shell structures, which adds to the existing functions for three-dimensional stress
analysis. The 2D arrangement of finite elements is significantly improved and enriched with
methods allowing integration of streamlining tests in the design process. Accelerating the
design process for metal ships the CATIA Shipbuilding application has been completely

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revised to a site oriented product. It uses the unique intelligence of CATIA AEC architecture.
The product Product Manager Integration provides unique functions for integration between
CAD/CAM/CAE/PDM and company business management systems.

2.2.4. Master CAM X5 user interface

Fundamentals of 2D geometry creation functions, useful tools and parameter descriptions to:
➢ Create lines using polar positioning.
➢ Trim the construction lines using Trim 2 Entities command.
➢ Use the Create Line Perpendicular command to create lines.
➢ Trim lines using the distance option in the Trim/Break/Extend command.
➢ Creating arcs using the create circle center point command.
➢ Using the arc tangent command to create tangent arcs.
➢ Use the trim divide command to clean up the geometry.

Step 1: Setting up the Graphic User Interface

Before starting the geometry creation, customize the toolbars to see the toolbars required to
create the geometry and machine a part. Make sure that the Grid is enabled. It will show you
where the part origin is.

Figure 2.8: Toolbars

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The Operations Manager to the left of the screen can be hidden to gain more space in the
graphic area for design. From the keyboard, press Alt + O keys simultaneously to hide it.
Repeat this command to make it visible again.

NOTE: Because the part is symmetrical in the Z-Axis, you will only draw 1/2 of the total
part. The size of the grid may appear differently based on the sizes you use in the config.
Change the Cplane to +D +Z.
• See Setting the Construction and
Tool Plane to DZ on page A-12 in
Getting Started.
• Select Planes from the Status Bar.
• Select Lathe diameter +D +Z.

Step 2: Create the Outside Profile

In this step you will learn how to create a line knowing an endpoint, the angle and the length.
Use this line to create other parallel lines from.

Figure 2.9: Step Preview

2.1 Create the 31.0 mm by 90° line

• Create
➢ Line.
➢ Endpoint.

➢ Enter the Length then press tab on your keyboard and enter the Angle
as shown below (Enter).

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 ✓

➢ [Specify the first endpoint]: Select the Fast Point icon.

➢ Enter in the coordinates 0, -75 (Enter). NOTE: When working with the +D, +Z
plane, enter in the coordinates in this order (D,Z).

➢ Select the Apply button to stay within the command.

➢ Use the Fit icon to fit the drawing to the screen.

➢ Using the mouse scroll wheel, roll the wheel backwards to unzoom, to see the
Grid and the line we just created as shown in Figure: 2.10.

Figure: 2.10.
NOTE: During the geometry creation of this tutorial, if you make a mistake you can undo the

last step using the Undo icon. You can undo as many steps as needed. If you delete or

undo a step by mistake, just use the Redo icon. To delete unwanted geometry, select it
first and then press Delete from the keyboard.

2.2 Create the 12.5 mm by 90° line

• Enter the Length then press tab on your keyboard and enter the Angle as
shown below (Enter).

➢
• [Specify the first endpoint]: Select the Origin as shown in Figure: 2.11.

Figure: 2.11.

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 • Make sure that when selecting the origin, the visual cue of the cursor changes as
shown.

• Select the Apply button to stay within the command.

2.3 Create the 44.0 mm by 180° line

• Enter the Length then press tab on your keyboard and enter the Angle as
shown below (Enter).

➢
• [Specify the first endpoint]: Select the Endpoint as shown in Figure: 2.12.

Figure: 2.12.

• Select the Apply button to stay within the command.

2.4 Create the 135° line

NOTE: The length on this line is not important as we will trim the lines later on. For now we
will use 32.0 mm.

• Enter the Length then press tab on your keyboard and enter the Angle as
shown below (Enter).
• [Specify the first endpoint]: Select the Endpoint as shown in Figure: 2.13.

Figure: 2.13.

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 • Select the Apply button to stay within the command.

2.5 Sketch the final line

In this next step we will enable an option found in the autocursor configuration to help us
sketch a horizontal line.
• Select the Config button in the Autocursor toolbar.

➢
• Ensure that you have Horizontal/Vertical enabled as shown below.

• Select the Ok button to exit the Autocursor Settings dialog box.

• [Specify the first endpoint]: Select the Endpoint as shown in Figure: 2.14.

Figure: 2.14

• [Specify the second endpoint] Sketch the line to a point beyond 135° line as shown.

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 • Select the Ok button to exit the command.
• The part should appear as shown in Figure: 2.15.

Figure: 2.15.

Step 3: Trim the Lines

In this step, we will trim the intersecting lines left from step 2.

• Edit
➢ Trim/Break.

➢ Trim/Break/Extend.

➢ Enable the Trim 2 Entities button.

➢ Select Entity A and then select Entity B to trim the geometry as shown below.

Figure 2.16

➢ Select the Ok button to exit the command.

Step 4: Create the Groove Geometry

In this step we will use the create line perpendicular command, create line parallel command
and fillet entities to create the groove geometry.

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 Figure 2.17: Step Preview

4.1 Create a line perpendicular to the 135° line

• Create
➢ Line.

➢ Perpendicular.

➢ Enter in the length in the ribbon bar as shown.

➢ [Select line, arc or spline] Select Entity A as shown below.

➢ [Sketch a point] Select Endpoint A as shown below.

➢ [Select which line to keep] Choose the line on the left side of the line as shown
below.

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 ➢ Select the Ok button to exit the command.

4.2 Create parallel lines

In this step you will create parallel lines from the polar line we created in Step #2.

• Create
➢ Line.

➢ Parallel.
➢ [Select a line] Select the perpendicular line we just created as shown in
Figure: 2.18.
➢ [Select the point to place a parallel line through] choose a point to the left of
the line we just created as shown in Figure: 2.18.

Figure 2.18.

➢ Change the Distance.

➢ [Select a line] Select the parallel line we just created as shown in Figure: 2.19.
➢ [Select the point to place a parallel line through] Choose a point to the left of
the line we just created as shown in Figure: 2.19.
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 Figure: 2.19.

➢ Select the Apply button to stay within the command.

➢ Change the Distance.

➢ Select the Ok button to exit the command.

➢ The part should appear as shown in Figure: 2.20.

Figure: 2.20.
4.3 Trim the 11 mm line to a length of 6 mm

• Edit
➢ Trim/Break.

➢ Trim/Break/Extend.
➢ Enable the Extension Length and enter in the value as shown.
➢ [Select the entity to trim/extend] Select Entity A, on the left end of the line as shown.

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NOTE: When using the Extension Length in the Trim/Break/Extend command, the side of
the line you select is the side Mastercam will trim or extend.

➢ Select the Ok button to exit the command.

4.4 Create a line knowing the endpoints

• Create
➢ Line.
➢ Endpoint.
➢ [Specify the first endpoint] Select Endpoint A as shown in Figure: 2.21.
➢ [Specify the second endpoint] Select Endpoint B as shown in Figure: 2.21.

Figure: 2.21

➢ Select the Ok button to exit the command.

4.5 Delete the construction line

• Edit
➢ Delete.

➢ Delete Entities.
➢ [Select Entities] Select the line as shown below.

➢ Click on the End Selection button once selected.

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4.6 Fillet the groove

• Create
➢ Fillet.
➢ Entities.
➢ Enter in the Fillet Radius, set the style to Normal and ensure Trim is enabled
as shown below.

✓
➢ [Fillet: Select an entity] Select Entity A as shown in Figure: 2.22.
➢ [Fillet: Select another entity] Select Entity B as shown in Figure: 2.22.

➢ Select the Apply button to continue.

➢ Change the Fillet Radius.

➢ [Fillet: Select an entity] Select Entity B as shown in Figure: 2.22.
➢ [Fillet: Select another entity] Select Entity C as shown in Figure: 2.22.

Figure: 2.22.

➢ Select the Ok button to exit the command.

➢ The part should appear as shown in Figure: 2.23.

Figure: 2.23

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Step 5: Create the Rounded Grooves

In this final step we will use the circle center point and arc tangent command to create the
needed geometry to finish the part. We will also trim the part to clean up the leftover
geometry.

Figure 2.24: Step Preview

5.1 Create arcs

• Create
➢ Arc.

➢ Circle Center Point.

➢ Enter in the Radius as shown.

➢ [Enter the center point] Select the Fast Point command.

✓
➢ [Enter the center point] Enter in the coordinates 25, -14.

✓
➢ Select the Apply button to stay within the command.
➢ The part should appear as shown in Figure: 2.25.

Figure: 2.25.
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 ➢ Enter in the Radius as shown.

➢ [Enter the center point] Select the Fast Point command.

➢ [Enter the center point] Enter in the coordinates 25, -28.

✓
➢ Select the Ok button to exit the command.
➢ The part should appear as shown in Figure: 2.26.

Figure: 2.26.

5.2 Create arcs tangent to two entities

• Create
➢ Arc.
➢ Arc Tangent.

➢ Enable the Arc Tangent 2 Entities button.

➢ Enter in the Radius as shown.

➢ [Select the entity that the arc is to be tangent to] Select Entity A.
➢ [Select the entity that the arc is to be tangent to] Select Entity B.

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 ➢ [Select the fillet to use] Select Entity C.

➢ Select the Apply button to continue.

➢ [Select the entity that the arc is to be tangent to] Select Entity D.
➢ [Select the entity that the arc is to be tangent to] Select Entity E.

➢ [Select the fillet to use] Select Entity F.

➢ Select the Apply button to continue.

➢ Enter in the Radius as shown.

➢ [Select the entity that the arc is to be tangent to] Select Entity G.
➢ [Select the entity that the arc is to be tangent to] Select Entity H.

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 ➢ [Select the fillet to use] Select Entity I.

➢ Select the Ok button to exit the command.

➢ The part should appear as shown in Figure: 2.27.

Figure: 2.27.

5.3 Trim the geometry to finish the part

• Edit
➢ Trim/Break.

➢ Trim/Break/Extend.
➢ Enable the Divide button.
NOTE: When using the Trim Divide command, ensure you select the portion
of the line you wish to delete. The entity will trim up to an intersection point.
➢ [Select the curve to divide/delete] Click on the portions of line that are shown
as dotted lines below.

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 ➢ Select the Ok button to exit the command.
➢ The completed part should appear as shown in Figure: 2.28.

Figure: 2.28.

Step 6: Save the File

• File

➢ Save As.
➢ File name: "Your Name_3".

➢ Select the OK button.

2.3. Program writing into a Computer Aided Manufacturing (CAM)

code /process
CNC programming is a term that refers to the methods for generating the instructions that
drive the CNC machine tool. For two dimensional components with little geometric
complexity, CNC instructions can be written manually. However, as the geometrical
complexity increases more sophisticated techniques are required, particularly for 3-axis, 4-
axis and 5-axis CNC machining. There are three distinct techniques adopted for creating
CNC programs:
i. Manual CNC Programming
ii. Programming using CAM software (CAD/CAM based programming systems)

Manual programming is recommended for simple workpieces which require only a few
blocks of program. Programming of complex workpieces requires the help of a CAM

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software. CAD/CAM based systems have become popular recently and are now being widely
adopted. Detailed description of these techniques is given in the following section.

Selecting the manufacturing processes to transform the raw material into the finished part is
based on matching requirements with process capabilities. Process capability is the database
of knowledge for each process. It includes:
i. The shape and size of part a process can produce
ii. The dimensions and geometric tolerances that can be obtained
iii. The surface finish attainable
iv. The material removal rate
v. The relative cost
vi. Technological parameters

Process engineering does not necessarily imply that all process selection is based on the
information above. However, the more the information considered in selecting a process, the
more complete the result will be. A computer aided process planning system functions based
on this process capability information.

Earlier it was mentioned that planning systems could be classified into variant and generative
types. A variant planning system is a retrieval system and is analogous to planning based on
experience. In the variant planning system, standard plans are stored based on component
shape. These plans are then retrieved based on the similarity of a coded part. A generative
system, however, makes processing, tooling and other decision via software logic.

2.3.1. Programming with codes

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

The milling machine has three (3) linear axes defined as X axis, Y axis, and Z axis. The X
and Y axis will move the machine table below and around the spindles centerline, while the

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Z axis moves the tool spindle down toward or up and away from the machine table. The
machine zero position is where the spindle is pointing down at the upper right corner, with
the machine table all the way to the left in X axis and all the way toward you in the Y axis
and Z axis is up at the tool change position.

Motion in the X axis will move the machine table to the left with negative values and to the
right with positive values. Motion in the Z axis will move the tool toward the machine table
with negative values and away from the machine table with positive values.

A program is written as a set of instructions given in the order they are to be performed. The
instructions, if given in English, might look like this:
• Line #1 = select cutting tool
• Line #2 = rapid to starting position of part, turn coolant on
• Line #3 = turn spindle on and select the rpm
• Line #4 = choose the proper feed rate and make the cut(s)
• Line #5 = turn off the spindle and the coolant
• Line #6 = return tool to holding position and select next tool

How CNC Works

• Controlled by G and M codes.
• These are number values and co-ordinates.
• Each number or code is assigned to a particular operation.
• Typed in manually to CAD by machine operators.
• G&M codes are automatically generated by the computer software.
• Movement is controlled by a motors (actuators).
• Feedback is provided by sensors (transducers)
• Tool magazines are used to change tools

CNC Controllers
The NC controller is the brain of the NC system, it controls all functions of the machine.
• Motion control deals with the tool position, orientation and speed.
• Auxiliary control deals with spindle rpm, tool change, fixture clamping and coolant.

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Many different types of controllers are available in the market (GE, Fanuc, Allen-Bradley,
Okuma, Bendix …).

2.3.2. Motion characterization in CNC

Point-to-Point Tool Movements

Point-to-point control systems cause the tool to move to a point on the part and execute an
operation at that point only. The tool is not in continuous contact with the part while it is
moving. Drilling, reaming, punching, boring and tapping are examples of point-to-point
operations.

Figure 2.29: Point-to-Point Tool Movements

Continuous-Path Tool Movements

Continuous-path controllers cause the tool to maintain continuous contact with the part as
the tool cuts a contour shape. These operations include milling along any lines at any angle,
milling arcs and lathe turning.

Figure 2.30: Continuous-Path Tool Movements

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 2.3.3. Preparatory Functions (G Codes)
Each G code defined in this control is part of a group. The Group 0 codes are non-modal; that
is, they specify a function applicable to that block only and do not affect other blocks. The
other groups are modal and the specification of one code in the group cancels the previous
code applicable from that group. A modal G code applies to all subsequent blocks so those
blocks do not need to re-specify the same G code. There is also one case where the Group 01
G codes will cancel the Group 9 (canned cycles) codes. If a canned cycle is active (G73
through G89), the use of G00 or G01 will cancel the canned cycle.

M-codes are not grouped into categories, although several codes may control the same type
of operations such as M03, M04, and M05 which control the machine tool spindle.
• M03 turns the spindle on clockwise
• M04 turns the spindle on counterclockwise
• M05 turns the spindle off

2.4. Tool path creation using MastercamX5 user interface - Metric

Fundamentals of toolpath creation functions, useful tools and parameter consisting of:
➢ Facing toolpath to machine the face of the part.
➢ Canned Roughing and Finish toolpath to remove the material bulk of material.
➢ Grooving at an angle with fillets in the corners of the groove.
➢ Finishing toolpath with multiple passes using a tool with a round insert.
➢ Cutoff toolpath to cut the part off at a desired position.

2.4.1. Part Setup:

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 2.4.2. Setup Sheet:

Step 7: Select The Machine And Set Up The Stock

In Mastercam, you select a Machine Definition before creating any toolpaths. The Machine
Definition is a model of your machine tool's capabilities and features and acts like a template
for setting up machining jobs. The machine definition ties together three main components:
the schematic model of your machine tool’s components, the control definition that models
your control unit’s capabilities and the post processor that will generate the required machine
code (G-code). For a Lathe exercise (2D toolpaths) we need just a basic machine definition.

NOTE: For the purpose of this tutorial, we will be using the Default lathe machine.
• To display the Operations Manager press Alt + O.
• Use the Fit icon to fit the drawing to the screen.
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 Machine type

• Lathe.

• Default.

• Select the plus sign in front of

Properties in the Toolpaths Manager
to expand the Toolpaths Group
Properties.

• Select Tool Settings to set the tool

parameters.

• Change the parameters to match the screen shot in Figure: 2.31.

Program # is used to enter a number if your

machine tool requires a number for a program
name.
Assign tool numbers sequentially allows you to
overwrite the tool number from the library with
the next available tool number.
Warn of duplicate tool numbers allows you to
get a warning if you enter two tools with the
same number.
Write home position clearance moves writes
home position clearance moves into the toolpath.
Override defaults with modal values enables the
system to keep the values that you enter.
Feed Calculation set From tool uses feed rate,
plunge rate, retract rate and spindle speed from
the tool definition. Figure: 2.31.

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 • Select the Stock setup tab.

• Choose the Properties button to set

up the stock for the Left Spindle.

• Define the stock by setting the stock geometry to Cylinder and entering the stock
dimensions. Ensure you enable Use Margins and enter in the values as shown in
Figure: 2.32.

Figure: 2.32

NOTE: The stock model that you create can be displayed with the part geometry when
viewing the file or the toolpaths, during backplot, or while verifying toolpaths. You can
create stock on the left or right spindle.

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• Select the Ok button to exit the Stock
Setup page.

• Ensure that Left Spindle is selected and

then select the Properties button in the
chuck jaws area as shown below.

Make the necessary changes to define the chuck size, the clamping method and the stock
position. Ensure that you choose the clamping method OD#1 as shown in the graphic below.

• Select the OK button to exit the

Chuck Jaws dialogue box.

• Enable Fit screen to boundaries in

the Display Options area.

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 • Select the OK button to exit Machine
Group Properties.
• Select the Top view from the view
toolbar to see the stock.
• Use the Fit icon to fit the drawing to
the screen.

• The stock should look as shown in Figure: 2.33.

Figure: 2.33

NOTE: The stock is not geometry and can not be selected.

Step 8: Face The Part

Face toolpaths allows the user to quickly clean the stock from one end of the part, and create
an even surface for future operations. Note that we do not have to chain any geometry to
create the toolpath because of the extra material we specified on the right face in the stock
setup. You can also select points to dictate where Mastercam will create the facing operation.

Figure 2.34: Toolpath Preview:

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 • Toolpaths

➢ Face.

➢ Select the Ok Button to accept the NC name.

➢ Select the OD Rough Right -80 Degree Tool and enter in the comment.

NOTE: The Feed Rate and the Spindle Speeds are based on the Mastercam Tool Definitions.
They can be changed at any time, based on the material that you are going to machine.

➢ Select the Face Parameters tab and make all of the necessary changes as
shown in the screenshot below.
➢ Once the you have entered in all of the information select the Ok button to

exit the Face Properties.

➢ The toolpath should appear as shown below.

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Entry Amount sets the height at which the
tool rapids to or from the part.
Rough Stepover sets the roughing pass value.
Finish Stepover sets the finish pass value.
Overcut Amount determines how far past the
center of the part the tool will cut.
Retract Amount determines the distance the
tool moves away from the face of the part
before it moves to the start of the next cut.
Stock to Leave sets the remaining stock after
the tool completes all passes.
Cut away from the center line sets the tool to
start cutting closest to the center line and cut
away from the center line at each pass.

Step 9: Rough The Part Using A Canned Rough Toolpath

Canned Rough Toolpaths allow you to enter parameters that define how the toolpath is cut in
preparation of a finish operation. The dialog box displays only those parameters that are
supported by your machine’s controller’s roughing canned cycle program.

Figure 2.35: Toolpath Preview

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Toolpaths

• Canned.

• Rough.
NOTE: The chaining mode is Partial by default. You will have to select the first entity
and the last entity of the contour.

• Select Entity A.
NOTE: Make sure that the chaining direction is CCW, otherwise select the Reverse

button in the Chaining dialog box.

• Select Entity B.

• Select the Ok button to exit the Chaining dialog box.

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 • In the Toolpath Parameters tab, select the same tool that we used in the facing
operation and make all of the necessary changes as shown in the screenshot.

• Select the Rough Parameters tab and make any necessary changes as shown.

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 ✓ Depth of cut sets the amount of material to be removed during each pass.
✓ Equal Steps sets the Depth of Cut value to the maximum amount of material
that the tool can remove at each pass to ensure equal passes.
✓ Minimum cut depth sets the minimum cut that can be taken per pass.
✓ Stock to leave in X sets the remaining stock in the X axis after the tool
completes all passes.
✓ Stock to leave in Y sets the remaining stock in the Y axis after the tool
completes all passes.
✓ Entry Amount sets the height at which the tool rapids to or from the part.
• Select the Lead In/Out button and enable Extend start of contour and specify a length
of 6.0 as shown.

NOTE: We need to extend the contour for the lead in and lead out to make sure that the tool
will not crash into the part on the next finish canned operation that uses the rough settings.
We will also extend the end of the contour for a better finish.
• Select the Lead out tab and enable Extend end of contour and specify a length of 6.0
as shown.

• Select the Ok button to exit the Lead In/Out parameters.

• Select the Ok button to exit the Roughing Toolpath parameters.

• The toolpath should appear as shown below.

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 Step 10: Finish The Part Using A Canned Finish Toolpath
Finish Toolpaths cut parallel to the part geometry, making one final cut on the part and
refining the canned roughing or pattern repeat toolpath. You must have an existing canned
rough or canned pattern repeat operation in order to create a canned finish toolpath.

Figure 2.36: Toolpath Preview:

• Select the Toolpaths tab in the Operations Manager.

➢
• Click on Select all Operations.
• Select Toggle Toolpath Display on selected operations to turn toolpath display off.

➢
NOTE: You can also use ALT + T to toggle toolpath display on or off. For the remaining
tutorials, the toolpath display will be automatically disabled.

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Toolpaths

• Canned.
• Finish.
NOTE: The chaining dialog box does not appear because a Canned Finish toolpath uses the
information from the Canned rough toolpath.
• Select the OD 55 Degree Right tool from the tool list and enter in the comment.

NOTE: The Feed Rate and Spindle Speed are based on the Mastercam Tool Definition.
• Select the Finish Parameters tab and make all of the necessary changes as shown below.

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 • Select the Ok Button to exit the Finish Parameters.
• The part should appear as shown in Figure: 2.37.

Figure: 2.37.

Step 11: Rough The Angled Groove

Groove toolpaths are used for machining indented or recessed areas that can not be machined
by roughing toolpaths or tools.

Figure 2.38: Toolpath Preview

Toolpaths

• Groove.
• Choose Chain when the Grooving Options dialog box opens up.

➢ 1 Point allows the user to select points from the graphics area to identify a groove.
➢ 2 Points allows you to specify a groove by indicating the top corner of the groove
and the point in the lower opposite corner.
➢ 3 Lines allows you to select three lines from the graphics screen to define the
groove shape.
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 ➢ Chain allows you to chain a more complex shape to define a groove by chaining
on-screen geometry.
➢ Multiple Chains allows you to chain multiple grooves by chaining on screen
geometry.
➢ Manual Point Selection allows you to manually select points from the graphics
area.
➢ Window Point Selection allows you to create a window in the graphics area and
chains all of the points within the window.

• Select the Ok button to exit the Grooving Options dialog box.

• The Chaining dialog box will open, leave Partial as the chaining method.

• Select Entity A as your first chain, then select Entity B as your second chain as shown
below.

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 • Select the Ok button to exit the Chaining dialog box.
• Select the OD Groove Center Wide tool from the tool list and enter in the comment as
shown below.

NOTE: We need to specify the angle we want to groove because the groove is on a 45°
angle.
• Right click on the tool and select Edit Tool.

• Select the Setup Tool button.

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 • Select the Plunge Direction button. This will tell Mastercam at what angle the tool
should machine.

• [Select a line parallel to the plunge direction] Select Entity A as shown below.

• The Plunge Direction should read -45° as shown below.

• Select the Ok button to exit.

• Select the Ok button to exit the Define Tool Dialog box.
• Select the Groove Shape Parameters tab and notice that the tool angle changed to 45°.

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 • Select the Groove Rough Parameters and make any changes as shown below.

• Select the Groove finish parameters tab and disable the option to Finish Groove as
shown below.

• Select the Ok button to exit the Lathe Groove dialog box and generate the toolpath.

• The toolpath should appear as shown in Figure: 2.39.

Figure: 2.39.

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 Step 12: Finish The Angled Groove With A Custom Tool
In this step we will create a toolpath to finish the groove using a custom tool.

Figure 2.40: Toolpath Preview

Toolpaths

• Groove.
• Choose Chain when the Grooving Options dialog box opens up.

• Select the Ok button to exit the Grooving Options dialog box.

• Select the Last button in the chaining dialog box.

• Select the Ok button to exit the chaining dialog box.

• Enter in the comment and right click in the Tool List and select Create new tool as
shown below.

• Select the Grooving/Parting as the tool type as shown below.

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 • The Inserts tab will automatically be selected. Select the Single End (Radius) insert
and make any changes as shown in the screenshot below.

• Select the Holders tab and make the changes as shown below.

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 • Select the Parameters tab and make the changes to the tool as shown below.

• Select the Setup Tool button as shown above and change the Plunge Direction as
shown below.

• Select the Ok button to exit the Lathe Tool Setup dialog box.
• To see a preview of how the tool looks, select the Draw Tool button.

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 • A preview of the tool should appear as shown.

NOTE: To save the tool to the library you can select the Save to Library button. Otherwise,
the tool will be available only for this job.
• Press Enter once complete.

• Select the Ok button to exit the Define Tool dialog box.

• Select the Groove rough parameters tab and disable Rough the groove as shown
below.

• Select the Groove Finish Parameters tab and make any changes as shown below.

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✓ Direction for 1st Pass determines the direction that the tool will finish the groove (CCW
- Starting on the right wall or CW - starting with the left wall.) With the first pass of a
finish toolpath; the tool cuts down on one wall of the groove to the groove floor and then
retracts out of the groove. On the second pass, the tool cuts down the opposite wall of the
groove to the groove floor and moves across the groove floor to the point where the first
pass ended.
✓ Retraction Moves sets the retract moves to Rapid moves or with the Feed Rate.
✓ Finish Stepover value sets the maximum amount of material the tool will remove with
the finish pass. Allows you to get a warning if you enter two tools with the same number.
✓ Stock to leave in X sets the remaining stock in the X-axis after the tool completes all
finish passes.
✓ Stock to leave in Z sets the remaining stock in the Z-axis after the tool completes all
finish passes.
✓ Overlap Distance from 1st corner sets the amount the tool cuts across the floor before
retracting out of the groove.
✓ Overlap between passes sets the amount the tool overlaps the first pass before it retracts.
✓ Wall Backoff % sets how far the tool backs away from the wall for the groove after the
first pass before it retracts.

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 • Select the Lead In button.
• Change the First pass lead in entry vector to -135° as shown.

• Select the Second pass Lead in tab and change the entry vector to -135° as shown.

• Select the Ok button to exit the Lead In dialog box.

• Enable the Select Overlap radio button and click on the Select Overlap as shown
below.

• Mastercam will return you to the Graphics User Interface.

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 • [Select endpoint for first cut] Move your cursor to a location close to the one shown
below and left click.

• [Select endpoint for second cut] Move your cursor to a location close to the one
shown below and left click.

• Select the Ok button to exit the Lathe Groove dialog box and generate the toolpath.

• The toolpath should appear as shown in Figure: 2.41.

Figure: 2.41.

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 Step 13: Finish The Rounded Grooves On The Od
In this step, we will create a finish toolpath to machine away the rest of the material above
the rounded groove. We will use a rounded tool and tell Mastercam to machine the groove by
specifying a number of finishes passes and the spacing between them.

Figure 2.42: Toolpath Preview

Toolpaths

• Finish.
• Leave the chaining mode set to Partial.
• Select Entity A as shown below.

• Select the Ok button to exit the Chaining dialog box.

• Enter in the comment and right click in the Tool List and select Create new tool as
shown below.

• Select the General Turning as the tool type as shown below.

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 • The Inserts tab will automatically be selected. Select the R (Round) insert and make
any changes as shown in the screenshot below.

• Select the Holders tab and make the changes as shown below.

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 • Select the Parameters tab and make the changes to the tool as shown below.

• To see a preview of how the tool looks, select the Draw Tool button as outlined
above.

• A preview of the tool should appear as shown.

NOTE: To save the tool to the library you can select the Save to Library button. Otherwise,
the tool will be available only for this job.

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 • Press Enter once complete.
• Select the Ok button to exit the Define Tool dialog box.
• Select the Finish parameters tab and make any changes as shown below.

• Select the Lead In/Out button as shown above and change the Lead In as shown
below.

• Select the Ok button to exit the Lead In/Out dialog box.

• Select the Plunge Parameters button as shown below.

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 • Enable Allow plunging in relief and Start cut on tool back corner as shown below.

• Select the Ok button to exit the Plunge Cut Parameters dialog box.

• Select the Ok button to exit the Lathe Finish dialog box.

• The toolpath should appear as shown in Figure: 2.43.

Figure: 2.43.

Step 14: Cutoff The Part

Lathe Cut-off Toolpaths vertically cut off pieces of the part such as sections of bar stock.

Figure 2.44: Toolpath Preview:

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Toolpaths

• Cutoff.
• [Select cutoff boundary point] Select Point A as shown below.

• Scroll to the bottom of the tool list and choose the OD Cutoff Right tool and enter in
the comment as shown below.

• Select the Cutoff parameters tab and make any changes as shown below.

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Retract Radius sets the distance
from the stock where the tool
starts with feed rate.
X Tangent Point sets the distance
as a radius value up to which the
tool cuts to.
Cut to: determines if the center of
the Front Radius or Back Radius
is going to reach the final depth.
Corner Geometry parameters
allow you to create a chamfer or
radius on the corner of the part.

• Select the Ok button to exit the Lathe cutoff dialog box.

• Your part should appear as shown in Figure: 2.45.

Figure: 2.45.

2.5. Uploading and storing the Program

2.5.1. Procedure to Download (from PC to Haas)
• On the Haas control shown in Figure 2.46, press the List Prog button
• Use cursor keys to highlight ALL
• Press the RECV RS232 button
• On the PC open the Predator Editor software
• Click on File and Open (to open your flash drive)
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 • Select your program and click Open
• Click on the DNC menu bar and select Send to CNC option
• After the status line on the Haas machine says "Download complete" you can perform
your work on the Haas

2.5.2. Procedure to Upload (from Haas to PC)

• On the Haas use cursor to select program of interest (it should have a star by it)
• Press the List Prog button
• Use cursor key to select program and press SELECT PROG key
• Use cursor keys to highlight ALL
• Press the SEND RS232 button
• On the PC open the Predator Editor software
• Click on the DNC menu bar and select Receive from CNC option
• After the status line on the Haas machine says "Upload complete" you are done.

2.5.3. The Process CAD to NC File

• Start with graphic representation of part
➢ Direct input
➢ Import from external system
✓ Example DXF / IGES
➢ 2D or 3D scan
✓ Model or Blueprint
(At this point you have a graphics file of your geometry)

• Define cutter path by selecting geometry

➢ Contours
➢ Pockets
➢ Hole patterns
➢ Surfaces
➢ Volume to be removed
(At this point the system knows what you want to cut)

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 • Define cut parameters
➢ Tool information
✓ Type, Rpm, Feed
➢ Cut method
✓ Example - Pocket mill zig-zag, spiral, inside-out
✓ Rough and finish parameters
(At this point the system knows how you want to cut the part)

• Execute cutter simulation

➢ Visual representation of cutter motion
• Modify / delete cutter sequences
(At this point the system has a “generic” cutter location (CL) file of the cut paths)
• Post Processing
➢ CL file to machine specific NC code
• Filters CL information and formats it into NC code based on machine specific
parameters
➢ Work envelope
➢ Limits - feed rates, tool changer, rpm’s, etc.
➢ G & M function capabilities

2.5.4. Output: NC Code

• Numerical Control (NC) Language
➢ A series of commands which “direct” the cutter motion and support systems
of the machine tool.
➢ G-Codes (G00, G1, G02, G81)
➢ Coordinate data (X,Y,Z)
➢ Feed Function (F)
➢ Miscellaneous functions (M13)
➢ N - Program sequence number
➢ T - Tool call
➢ S - Spindle command

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 ➢ NC Program Example
✓ N01G90 G80
✓ N03 GO T12 M06
✓ N05 GO X0 Y0 Z.1 F10 S2500 M13
✓ N07 G1Z-.5
✓ N09 G02 X-10. I0 J0 F20
✓ N13 X0Y10
✓ N17 X10Y0
✓ N19 X0Y-10
✓ N21 X-10Y0
✓ N23 M2

Example of CNC Programming

• What Must Be Done To Drill A Hole On A CNC Vertical Milling Machine

• An example of creating a CNC program using a simple hole drilled on a computer
numerical controlled (CNC) vertical milling machine.

In this case, we are using a simple analogy to stress how a programmer must be able to
visualize a CNC program’s execution. We first look at how a machinist would machine a
hole in a work piece held in a vise on a milling machine. Then we’ll show how the same
operation will be performed with a CNC program. The machinist standing in front of the
milling machine has everything they need right in front of them. They wouldn’t forget
something as simple as turning the spindle on before trying to drill the hole. On the other
hand, a CNC programmer must typically work with nothing more than a blueprint, a pencil, a
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calculator, and a blank piece of paper. They must be able to visualize every motion and
function of the program’s execution in their minds.

Here is the same operation (drilling a hole) performed by a CNC program. Each step will be
explained.

Program Description

O0001 Number Assigned to this program

N005 G54 G90 S600 M03

N005 Sequence Number
G54 Fixture Offset
G90 Absolute Programming Mode
S600 Spindle Speed set to 600 RPM
M03 Spindle on in a Clockwise Direction

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 N010 G00 X1.0 Y1.0

G00 Rapid Motion

X1.0 X Coordinate 1.0 in. from Zero
Y1.0 Y Coordinate 1.0 in. from Zero

N015 G43 H01 Z.1 M08

G43 Tool Length Compensation

H01 Specifies Tool length compensation
Z.1 Z Coordinate .1 in. from Zero
M08 Flood Coolant On

N020 G01 Z-.75 F3.5

G01 Straight Line Cutting Motion

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 Z-.75 Z Coordinate -.75 in. from Zero
F3.5 Feed Rate set to 3.5 in./min.

N025 G00 Z.1 M09

G00 Rapid Motion

Z.1 Z Coordinate .1 in. from Zero
M09 Coolant Off

N030 G91 G28 X0 Y0 Z0

G91 Incremental Programming Mode
G28 Zero Return Command
X0, Y0, Z0 X, Y, & Z Coordinates at Zero

N035 M30

M30 End of Program

Output: NC Code - Canned Cycles

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 2.5.5. CAD to NC Code

2.6. Simulation, verifying and editing

2.6.1. NC Program Simulation, Verification and Correction
To avoid the risk of failure, tool paths should be simulated before actual machining. As
described by JerardE, the process can be divided into three steps: simulation, verification and

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correction. In simulation, the swept volume of each tool movement in a CLDATA (cutter
location data) file is modeled and a geometric model of the work piece is modified by
subtracting the swept volume. A swept volume is the space taken by a tool moving from one
position to another. In verification, the comparison between the final work piece model and a
geometric model of the part is carried out the work piece is acceptable whenever it is within
certain error bounds. In the correction step, tool movements are modified if they cause
unacceptable errors. Here the three types of simulation approaches are briefly discussed:
simulation and verification based on solid modeling, image based surface discretization, and
object based surface discretization and polygonal approximation.

2.6.2. Simulation Based on Solid Modeling

Simulation based on solid modeling techniques is achieved by a Boolean subtraction of the
swept volume of the tool movement from the work piece model. The verification is
accomplished by performing a Boolean difference between the work piece model and the
desired part model. This scheme offers accurate simulation and verification results but is
computationally expensive. The cost of simulation with the CSG approach is reported to be
proportional to the fourth power of the number of tool movements.

2.6.3. Polygon Based Simulation

Compared with a polygonal approximation, surface discretization has some drawbacks. The
required density of points is affected by the tool shape and size. Lots of sample points are
necessary even for a very flat surface. However, simulation and verification based on a
polygonal surface approximation may require more CPU time. Ongoing research at
Dartmouth College shows that the advantages of three axis simulation and verification based
on a polygonal approximation compared to a point discretization depend on the flatness of
the surface. For relatively flat surfaces, simulation based on a polygonal approximation is
much faster than the point method, especially when flat-end tools are used.

2.6.4. Image Based Surface Discretization

In image-based simulation systems, an object surface and/or the tool is approximated by
points sampled by projecting the pixels of an image plane back to the object along a view-

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direction. An extended z-buffer is used to store entry and exit values of the line from each
pixel through the object. NC program simulation is performed by subtracting the swept
volume from the z-buffers. Verification is accomplished by performing the Boolean
difference at each pixel of the design part and the work piece.

2.6.5. Object Based Surface Discretization

The object-based point method differs from the above approaches by using surface point
sampling. Instead of using an image-plane, sample points are selected on an object surface
with a spacing which depends on surface curvature, the required accuracy, and the tool size
and shape.

In all these systems based on surface discretization, simulation and verification are achieved
through the intersections of swept volumes with straight lines (i.e., point normal vectors).
Direct pixel comparison of the work piece with the design model (Hook’s, Atherton’s and
Wang’s) can produce a good volumetric approximation of the removed material. Generally,
however, image-based verification may not be adequate since it is view dependent so that
errors invisible in the viewing direction cannot be detected. Object based point-vector
approaches do not share this limitation.

2.6.6. Debugging /Correcting Your Program

The fact that you have successfully posted your program is no guarantee that it will work
without a few snags. It is recommended that you debug your program before downloading it
to the CNC machine’s controller. Following are some tips and recommendations to help you
provide a more fool-proof program.

• Determine and note the starting block of your program. This point must be in
agreement with the portion of the part graphic where the cross hairs cross in your CAM
Works setup. This point will become your X and Y part zero location during set up
• Ensure that your program begins and ends with %.
• Every program block should end with a semicolon (;).
• Your program should have a program name that begins with the letter “O” and a four-
digit number (Onnnn).

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 • Define the unit of your program (G20 for inches)
• Define whether you are programming in absolute (G90) or incremental (G91)
• Cancel any X and Y cutter compensation with G40
• Cancel the tool length compensation with G49
• Set the plane to XY plane with G17
• Delete unnecessary axes such as “A” and “B” since the two CNC mills are not enabled
for more than three axes.
• Delete unnecessary auxiliary functions like coolant (M08) and chip pan since the two
CNC mills are not enabled for these options.
• Check all your program blocks to ensure there is no garbage in the program.
• Save your program on a flash drive and take it to the CNC lab for downloading to the
machine controller.

Figure 2.46: Haas Controller

2.6.7. Tool paths simulation using MastercamX5's Verify and Back plot
Step-by-step Fundamentals of tool paths simulation functions, useful tools and parameter
descriptions

• The Student will simulate the toolpaths using Mastercam's Verify and Backplot by:
➢ Defining a 3-dimensional cylinder the size of the workpiece.
➢ Running the Backplot to see the path the tool takes to cut the part.
➢ Running the Verify to simulate the tool cutting from the solid model.

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 Step 15: Backplot The Toolpaths
Backplotting shows the path the tools take to cut the part. This display lets you spot errors in
the program before you machine the part. As you backplot toolpaths, Mastercam displays the
current X, Y, and Z coordinates in the lower left corner of the screen.

• Make sure that you Select all operations

(signified by the green check mark on the
folder icon).

• Select the Backplot selected operations

button.

• Make sure that you have the following

buttons turned on (they will appear pushed
down) to see the tool and the rapid moves.

• Select the Isometric view from the view

toolbar to see the stock.
• Select the Fit button.
• You can adjust the speed of the backplot.

• You can step through the Backplot by using the Step forward or Step back buttons.
• Select the Play button in the VCR bar.
➢
• Select the OK button to exit Backplot.

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 Step 16: Toolpath Verification
Toolpath Verification allows you to use solid models to simulate the machining of a part. The
model created by the verification represents surface finish, and shows collisions if any exist.

• Select the Verify all operations button.

• Use the Fit icon to fit the solid to the screen.

• Set the Verify Speed by moving the slider bar in the speed control bar.

• Select the Machine button to start the simulation.

• The finished part should appear as shown in the following picture.

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 2.7. Self-check - 2
Directions: Attempt to answer all the questions listed below. Illustrations may be necessary
to aid some explanations/answers. Note: Be precise and scientific in writing.

Part I - Instructions: For the following questions say True or False.

1. Continuous-path controllers cause the tool to maintain continuous contact with the
part as the tool cuts a contour shape.
2. Movement is controlled by a motors actuators

Part II: Multiple Choice - Instructions: For each of the following question choose the best
correct answer and circle the letter of your choice from the given alternatives.

1. Tool movements consist

a. rapid positioning commands
b. straight line moves
c. movement along an arc of the tool at a controlled feed rate
d. all

2. Auxiliary control deals with

a. spindle rpm b. tool change
c. fixture clamping d. coolant e. all

3. The swept volume of each tool movement in a cutter location data file is modeled and
a geometric model of the work piece is modified by subtracting the swept volume.

a. Verification b. Simulation c. Editing d. All

4. Tool movements are modified if they cause unacceptable errors.

a. In verification b. In correction
c. In simulation d. None

5. Which of the following is not an operating mode

a. Powering on the machine b. Creating a program
c. Editing d. Setting the tool offsets

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 6. ______ to show or enter settings or to select graphics simulation mode
a. SETING / GRAPH b. PRGRM / CNVRS
c. PARAM /DGNOS d. None

Part III: Marching - Instructions: For the following questions match from “B” to “A”
column

No. “A” Column “B” Column

______ 1. The number line has a zero reference point A. Absolute zero

The number line has numbered increments

______ 2. B. Positive increments
moving away from zero to the right

The axis of travel on the machine is the up-and-

______ 3. C. Z axis
down

Part IV: Marching – Instructions: Answer all the questions listed below. Use the Answer
sheet provided in the next page:

1. Write at least five recommendation when you debug your program before
downloading it to the CNC machine’s controller?
2. Write the procedures downloading the program?
3. Write the procedures uploading the program?

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 2.8. Operation sheet – 2.1
Operation Title: Create 2D Geometry drawing

Instruction: Design a 2-dimensional drawing by creating lines using polar positioning.

Purpose: Apply fundamentals of 2D geometry creation functions, useful tools and parameter

Required tools and equipment:

1. Computer
2. Mastercam X5 software

Precautions: The created geometry will be required to create toolpaths

Procedures:

Step 1. Create the top half of the geometry.

Step 2. Create Line Endpoint
Step 3. Create Line Parallel
Step 4. Create Line Perpendicular
Step 5. Chamfer Entities
Step 6. Fillet Entities
Step 7. Delete Entities

Quality criteria: the output drawing must be identical with the given figure

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 2.9. LAP Test
Practical Demonstration

Name: _________________________ Date: ___________

Time started: ________________ Time finished: ___________

Instruction I: Given necessary templates, tools and materials you are required to perform the
following tasks within 3 hours.

Task 1: Design a 2-dimensional drawing

Task 2: Create lathe tool paths

Task 3: Simulate the tool paths using Master cam's Verify and Back plot

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Unit Three: CAM/CNC operations
This learning unit is developed to provide the trainees the necessary information regarding
the following content coverage and topics:
• Occupational health and safety
• Tools and materials selection for the job
• Mounting the parts
• Machine setting and operating procedures
• Dry run
• CAM/CNC operations

This unit will also assist you to attain the learning outcomes stated in the cover page.
Specifically, upon completion of this learning guide, you will be able to:
• Observe OHS procedures and environmental guidelines
• Select tools and materials for the job and plan sequence of operations
• Set the tools and mount or set a part
• Perform dry run in accordance with the desired tool path movement
• Perform CAM/CNC operations and produce part to CAD drawing specifications
• Perform corrective measures/adjustments based on operational procedures

3.1. Occupational health and safety

General safety rules in CNC machines
• Never operate a CNC machine without proper training or consulting the specific
operator's manual for that particular machine and control type.
• Never attempt to program a CNC machine without proper training or consulting the
specific programmer's manual for that particular machine and control type

CNC machine safety system

The built-in safety system on a CNC machine includes guards and protective devices which
should be securely fitted and always kept in position while the machine is being used. It may
include: Emergency Stop Button used to shut down the machine immediately. It is located on

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the control panel and at other points on the machine, for example the hand held unit.
Soundproof Casing Reduces noise emission generated by the operating section and protects
the operator from the risk of flying objects or tool fragments. Curtain Guards Made of PVC
and designed to protect the operator from the risk of airborne chips or tool fragments. Guard
Fence The fence marks the working area in which the machine moves. It protects the
operator from the risk of interference with moving parts. The guard may be of an open type
or made of mesh. Contact Mats When the operator stands on the mat, the machine stops
immediately, protecting the operator from moving parts of the machine. Below are some
general personal safety rules that you can use as a guide only. You might like to add any
other rules that apply to you.

DO:-
• Always wear safety glasses and hearing protection when operating CNC machines.
• Always wear safety glasses when closely observing cutting tools.
• Always wear safety boots or other suitable footwear.
• Always keep long hair covered when operating CNC machines.
• Always keep hands clear of moving parts during machining operations.
• Always stand clear of the machine while it is running and warn others of the dangers of
being too close.
• Always avoid contact with cutting edges when handling tools or changing tools by hand.
• Always turn off CNC machine completely and clean it up when finished using it.

DON'T:-
• Never wear gloves.
• Never wear loose clothing or jewellery.
• Never reach into a CNC machine while it is running.
• Never place hands near a revolving spindle.
• Never leave the machine so that someone else is able to start it by pressing the cycle start
button.
• Below are some general tooling safety rules that you can use as a starting guide. You
might like to add any other rules that apply to you.

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DO:-
• Always check that the machine is not operating when loading a tool magazine.
• Always check that tools are in good condition, for example, sharp and free of cracks.
• Always check that tools are set correctly.
• Always check that the correct tool data is entered into the CNC program.
• Always test tools before use.
• Always check that the seating surfaces are clean before installing tools.
• Always check that spindle direction is correct for right-hand or left-hand operation.
• Only use tools within the limits specified by the manufacturer.
• Only tighten tools to recommended torque values.

DON'T:-
• Never use blunt tools.
• Never use cracked or chipped tools.
• Never use tools with damaged tungsten tips.
• Below are some general machine safety rules that you can use as a guide only. You might
like to add any other rules that apply to you.

DO:-
• Always keep the area around the machine clear of obstacles.
• Always stack material where you can reach it but where it is clear of the moving parts of
the machine.
• Always check that tools are sharp and set correctly.
• Always check that the correct tool data is entered into the CNC program.
• Always make sure that all guards are in position while the machine is in operation.
• Always make sure that all work and fixtures are clamped securely before starting
machine.
• Always make sure spindle direction is correct for right-hand or left-hand operation.
• Always conduct a dry run to ensure the program is correct.
• Always follow company policy on correct procedures when handling or lifting parts or
tooling.
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DON'T:-
• Do not use the machine table as a workbench.
• Do not use compressed air to blow chips from the parts of the machine, machine surfaces,
cabinets, controls or floor around the machine.

3.2. Mounting the parts

3.2.1. Clamping your part
• Place your part in the soft jaws of vise on the machine table
• Ensure the part sits in such a way that at least 0.2” of it is above the top of the vise jaws
• Tighten with just enough pressure so that the acrylic is not marred or damaged
• Use a soft hammer to set it as needed

3.2.2. Locating zero points of the part

Locating x and y zero points of your part (part zero point) using an edge finder, indicator
or your tool’s center point

• Use the jog function keys and dial to move the tool to part zero point
• Press the OFFSET key
• PAGE UP on work coordinate page to G54 X
• Push PART ZERO SET key and the X-axis value will be stored as the offset
• The cursor will automatically move to the G54 Y location
• Push PART ZERO SET key and the Y-axis value will be stored as the offset
• Leave the Z value at zero at this point

3.3. Tools and materials selection for the job

3.3.1. Materials Used in a CNC Machine
CNC machines cut through nearly any material you can think of. While there are a wide-
range of materials you can use in a CNC machine, the most commonly employed materials
used are:
• Metals — such as aluminum, brass or steel.
• Plastics — numerous choices such as Acetal (POM), Acrylics (PMMA),

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 • Polycarbonate (PC) and Polypropylene (PP), just to name a few.
• Wood — usually less to choose from but commonly hardwood, plywood, softwood etc.
• Foam — tend to be more lightweight yet durable. The two main types are carving foam
and rigid foam.

With CNC machining, manufacturing equipment and tools are controlled by programmed
software to complete various complex factory operations. Common CNC machine types
include but are not limited to three-dimensional cutting tools, lathes, routers, mills and
grinders. CNC stands for computer numerical control.

3.3.2. Tool setting

Tool setting is the process of determining geometric information – such as the length, radius,
and/or diameter of a cutting tool – using a tool setting device and dedicated software. Tool
setting products are referred to as 'contact' or 'non-contact', depending on the technology they
employ.

A. Set up

• Ensure the machine is fully powered down. Don't leave any risk of the machine
turning on by accident.
• Securely load the part. In a CNC lathe, the stock is held in a “chuck” by tightening
screws at each end.
• Select and load your tooling.
• Correctly calibrate the tools and the part.
• Enter and execute the program

Set Up CNC Milling Machine

Factors that have to be considered

1. Is the machine a vertical or horizontal machine?
2. How many axes machine have?
3. What is the capacity of the tool turret?
4. How are you planning on holding the part (work piece)?

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It is also assumed that you know some basic machine practices, like
1. How to use an edge finder.
2. How to navigate through your machine’s control.
3. Knowledge of basic CNC control commands.

Setting the tool offsets

• Use the jog handle to accurately position tool tip to Z0 on top of your part
• Press the OFSET key
• PAGE DOWN to the Tool Offset page and cursor to Tool #1
• Press the TOOL OFSET MESUR key and the Z value will be stored in tool offset #1
• Repeat 1-4 for other tools if using multiple tools
• Press Power Up button to return tool to its home position

3.4. Machine setting and operating procedures

3.4.1. Machine Setup Data (MSD)
MSD or machine tool parameters indicate the machine tool characteristics, specifications and
functions. The contents of each parameter should be set according to the parameter list
annexed to the machine. The end user must not change the contents on the parameters. The
OEM can use one standard control on several machine sizes and/or types.

Entering machine parameters: These are three methods of entering machine parameters.

i. Setting through parameter CD-ROM-each block contains a machine set up data code
to identify the machine parameter followed by data for that parameter.
ii. Setting data through MDI - the machine data can be input through the operator’s
control panel by following the procedure for the control system.
iii. Setting data in EPROM’s - machine parameters can be entered in the erasable
programmable read only memories. The data is permanently stored in specific
locations in the memory chip. To enter the set up data in EPROM, an EPROM
programmer is necessary.

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Now come to the setting up machine, although every CNC Milling machine set-up procedure
is slightly different, but here are explained these generic steps which CNC machinists
practice on a daily basis for a 3 axis vertical CNC Milling machine.

• Clean Surface: Clean all surfaces like table, vise jaws and part (work piece) with cloth, so
that no oil drops, material chips remain there.
• Load Tool: it required to complete part (including edge finder, vise leveling at 0).
• Load Part: Load part (work piece) in vise or hold your part (work piece) with your
machine holding arrangements.
• X, Y axis’s Offsetting: Set the part (work piece) offset. Use edge this purpose finder or
do it with End Mill Cutter (if you are using end mill cutter for tool offset, then read Tool
Offset Article). First do the zero offset for the X axis. Pick up the X0 position by using
edge finder. Go to the zero offset page and add the machine absolute X value to the value
currently in the zero offset page’s registry. Do the same for the Y axis.
• Z axis Offsetting: After X,Y axis’s offsetting set the tool length offset for each tool by
loading first tool in spindle. Manually move the Z axis down until the tool’s tip is near
the Z0 position. Get a piece of 1.00 mm shim stock (always use any fix size of shim like
1, 2 or 5 mm ) and hold it between the part (work piece) and the tip of the tool. Carefully
lower the Z axis in 0.001 mm increments until the shim stock can be pulled with a slight
drag. Go to your tool length offset page and enter the machine’s absolute Z value plus -
1.00 mm in the tools registry. Repeat procedure to additional tools. Note: -1.00 mm is
added for the shim stock’s thickness.
• Cutter Radius Compensation: Enter each tool diameter in tool length offset page. That
will be helpful when you are using Cutter Radius Compensation in your program.
• Coolant or Cutting Oil: Adjust coolant lines because coolant can properly cool tools and
wash chips away, and most important coolant will increase the cutter life.
• Cycle start: Put the machine in low feed, activate single block and then press cycle start.
Be careful and read every block programmed and watch each movement the machine
makes ready to stop the machine in case there are any programming errors. (You could
also run the program 10 mm or whatever above the part (work piece) to make sure
everything is good and use Dry Run if you feel it necessary.
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 3.4.2. Adjustment of machines
When using any machine tool, accuracy is everything. That’s why getting your tools set up
and maintained to specific tolerances from the off is vital.

Every machine tool works by holding the cutting tool against the work piece in a controlled
manner. To resist the cutting forces put on it, the machine is designed to take these forces and
be strongest where maximum force exists. Therefore the slide ways on each tool must be
adjusted precisely so they can slide smoothly, without showing slackness under stress.

On the milling machine there are, like the lathe, three main slide way movements to
maintain. These run on the three axis;
• The X axis (side to side)
• The Y Axis (back and forward)
• The Z axis (up and down)

Additionally there is the main rotary movement, which is the spindle

A. Adjusting the Mill

Similarly to the lathe, all the slide ways on the mill are adjusted using jib strips. These are
parts of the slide way that can be moved to reduce clearance. This is all done using screws,
which are tightened until the axis is stiff and then backed off slightly, to achieve the correct
clearance.

B. X and Y Axis

Both of these slide ways are adjusted in similar ways. The X axis slide way will have a row
of screws and locknuts underneath the main table on the front of the machine. It’s best to
start with the outer screws on here as they give better control of the slide way alignment.
Loosen the locknut and then whilst winding the hand wheel tighten the screw until you feel
resistance. Back off 5 degrees at most before tightening the locknut.

The Y axis requires a similar adjustment but this time the screws are to the side and
underneath the main table. Once again wind the hand wheel whilst tightening the screw until
resistance is felt. Back off again very minimally and then retighten the locknut.

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 C. Z Axis

Perhaps the hardest of the slide ways to adjust, the Z axis is also the most important. It is the
most important due to its direct effect on the alignment of the spindle.

On the Z axis you have a screw on the underside and topside of the machine head, close to
the column. These are attached to a tapered strip that increases/decreases the slide way
clearance. Firstly you will have to loosen the bottom screw. Then whilst winding the hand
wheel, tighten the top screw until resistance is felt and back off approximately 1/2 a turn.
Now re-tighten the bottom screw to push the jib strip up to the top screw.

D. The Machine Spindle

There are two things that you can do to check the accuracy of your spindle;
• Check the spindles slackness – This is done with a dial gauge pressed against the side
of the spindle. You then proceed to try and move the spindle side to side – checking
the amount of movement. Unfortunately if there is any amount of movement there is
little you can do except send the machine back to the company’s servicing
department.
• Establish if the spindle is square to the other axis (only required on tilt head
machines). To do this the dial gauge needs to be fixed on to the spindle itself with the
needle touching the main table and set to zero. The spindle then needs to be turned
180 degrees, and the figure on the gauge noted.

If the reading is slightly out, this can be rectified. Just slacken the clamping bolts and then
lightly tap the machine head, noting the dial gauge as you go. Once it’s back to zero, clamp
again and retest, just in case the reclamping has moved the head slightly.

Alongside regular adjustments, periodic lubrication is very important. Slide ways and lead
screws require lubrication to prevent premature wear and excess friction. These adjustments
to the slide ways and spindle will help you get the very best from your milling machine. It
should be noted that continued checking of the slide ways should be done on a regular basis
(depending on how much the machine is used). This is due to them being worn away by the
constant movement.

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 3.5. Dry run
3.5.1. Definition
The Dry Run function is used to check a program quickly without actually cutting parts. To
select Dry Run:
• While in MEM or MDI mode, press DRY RUN.
• When in Dry Run, all rapids and feeds are run at the speed selected with the jog speed
buttons.
• Dry Run can only be turned on or off when a program has finished or RESET is
pressed. Dry Run makes all of the commanded X Y Z moves and requested tool
changes. The override keys can be used to adjust the Spindle speeds.

3.5.2. Running your program

• Press the LIST PROG key
• Cursor to your program
• Press SELECT PROG key
• Press MEM
• Hold the safety switch and press the CYCLE START button to begin execution

3.5.3. Runing the Post Processor to Obtain the G-Code File

Step 17: Run The Post Processor To Obtain The G-Code File
Post Processing refers to the process by which the toolpaths in your Mastercam part files are
converted to a format that can be understood by your machine tool’s control. A special
program reads your Mastercam file and writes the appropriate NC code.
• Make sure that all operations are selected, otherwise.

• Select all operations.

• Select the Post Selected operations button from the Toolpath Manager.

• In the Post Processing window, make all of the necessary changes as shown to the
below.

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 ➢ NC File enabled, allows you to keep the NC file and to assign the same name
as the MCX file.
• Edit enabled allows you to automatically launch the default editor.
• Select the Ok button to continue.
• Enter the same name as the Mastercam file name in the NC file name field.

• Select the Ok button.

• Select the Red "X" Box in the upper right corner to exit the editor.

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 Step 18: Save The Updated Mcx File

Select the Save icon.

3.6. CAM/CNC operations

3.6.1. Steps to execute a part
A. Read/interpret the technical drawings

• Choice of the most adequate machine tool for the several stages of machining
• Relevant features:
➢ The workspace of a machine versus the part to be produced
➢ The options available on each machine
➢ The tools available
➢ The mounting and the part handling
➢ The operations that each machine can perform

B. Choice of adequate tools

• Relevant features the most:

➢ The material to be machined and its characteristics
➢ Standard tools cost less
➢ The quality of the mounting part is function of the number of parts to produce
➢ Use the right tool for the job
➢ Verify if there are backup tools and/or stored available
➢ Take into account tool aging

C. Cutting data

• Spindle Speed – speed of rotation of the cutting tool (rpm)

• Feed rate – linear velocity of advance to machine the part (mm/minute)
• Depth of Cut –depth of machining in z (mm)
➢ Choice of the interpolation plane
➢ Unit system - imperial –inches (G70) or international millimeters (G71).
➢ Command mode
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 ✓ Absolut – relative to world coordinate system (G90)
✓ Relative– movement relative to the actual position (G91)
➢ There are other command modes, e.g. helicoidal.

• Manual data input

N Sequence Number
G Preparatory Functions
X X Axis Command
Y Y Axis Command
Z Z Axis Command
R Radius from specified center
A Angle ccw from +X vector
I X axis arc center offset
J Y axis arc center offset
K Z axis arc center offset
F Feed rate
S Spindle speed
T Tool number
M Miscellaneous function

3.6.2. Planning sequence of cutting and finishing operation

A. Turning Programming

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Programming Sequence

% (rewind stop code/parity check)

2001 (program number)

N05 G20 G90 G40

G20 inch data input.
G90 absolute positioning mode
G40 cancels tool radius compensation.

N10 G95 G96 S2000 M03

G95 feed rate per revolution.
G96 constant feed rate.
S2000 spindle speed set at 2000 r/min.
M03 spindle ON clockwise.

N15 T0202 tool number and offsets

N20 G00 X1.200 Z.100

G00 rapid traverse mode
X&Z tool reference or change point
X1.200 tool point .100 away from the outside diameter.
Z.100 tool point .100 to the right of end of work.

Rough Turning Cycle

N25 G73 U.05 R.05

G73 rough turning cycle
U.05 0.050 allowance on diameter for finish cut
R.05 tool nose radius
N30 G73 P35 Q95 U.025 W.005 F.008
P35 start block of rough contour cycle.
Q95 end block of rough contour cycle.
W.005 shoulder allowance for finish cut.
F.008 feed rate at .008 per revolution.
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N35 G00 X.300 Z.050
G00 rapid traverse mode
X.300 tool point at .300 diameter for start of .100 radius
Z.050 tool point .050 away from end of the part

N40 G01 Z0
G01 linear interpolation (feed)
Z0 tool point touching end of the work

N45 G03 X.500 Z-.100 R.100

G03 circular interpolation (counterclockwise)
X.500 largest diameter of radius
Z-100 end of radius on .500 diameter
R.100 size of the radius

N50 G01 Z-.650

G01 linear interpolation
Z-.650 machines .500 diameter to .650 length

N55 X.580
X.580 tool moves out to the small diameter of .060 x 450 bevel

N60 X.700 Z-.710

X.700 large diameter of bevel
Z-.710 end distance of bevel

N65 Z-1.150
Z-1.150 the .700 diameter cut to 1.150 length

N70 X.750
X.750 cutting tool feeds out to .750 (small end of taper)

N75 X.875 Z-1.800 (cutting taper)

X.875 large end of taper
Z-1.800 length that taper is cut.

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N80 X.925
X.925 tool feeds out (faces) to .925 diameter

N85 Z-2.050
Z-2.050 the .925 diameter is cut to 2.050 length

N90 X1.050
X1.050 the tool is fed out to .050 past the diameter of the part

N95 G00 X1.200 Z.100 (tool back to tool reference point)

G00 rapid traverse mode
X1.200 & Z.100 (reference point positions)

Finish Turning

N100 G72 P35 Q95 F.005

G72 finish turn cycle
F.005 feed rate .005 per revolution

N105 G00 X2.000 Z.500

G00 rapid traverse mode
X2.000 & Z.500 machine home position

N110 M30
M30 end of program

% Rewind code

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 3.7. Self-check - 3
Directions: Attempt to answer all the questions listed below. Illustrations may be necessary
to aid some explanations/answers. Note: Be precise and scientific in writing. Use the Answer
sheet provided in the next page.

Part I - Instructions: For the following questions say True or False.

1. Make sure everything is good and use Dry Run if you feel it necessary.
2. It is possible to use a soft hammer to set work pieces
3. It is possible to operate a CNC machine without proper training or consulting the
specific operator's manual.
4. Guards and protective devices which should not be securely fitted and always kept in
position while the machine is being used.

Part II: Multiple Choice - Instructions: For each of the following question choose the best
correct answer and circle the letter of your choice from the given alternatives.

1. Why we adjust coolant lines properly?

a. Cool down work pieces b. Cool down cutting tool
c. Washing of chips d. Increase life time of cutter
2. Which of the following tasks doing in Setting the tool offsets
a. Press the OFFSET key
b. Press Power Up button to return tool to its home position
c. Press SELECT PROG key
d. a & b
3. ______ is the process of determining geometric information such as the length,
radius, and/or diameter of a cutting tool.
(a) Tool setting (c) Cutter Radius Compensation
(b) Cycle start (d) None

Part III: Marching - Instructions: For the following questions match from “B” to “A”
column

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 No. “A” Column “B” Column
______ 1. Used to hold in the stock in a CNC lathe A. Chuck

______ 2. Spindle Speed, Feed rate and Depth of Cut B. Cutting data

______ 3. Included in checking of spindle direction C. Tooling safety

Part IV: Short answer – Instructions answer all the questions listed below.

1. Please write the procedures locating x and y zero points

2. Define dry run
3. What are the basic adjustments in CNC machines?
4. Write at least for each of safety rules (personal safety, tooling safety and machine
safety) do and do not
5. Why would you use a canned rough cycle?
6. What type of toolpath must precede a canned finish cycle?

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 3.8. Operation sheet – 3.1
Operation Title: Create the Tool paths
Instruction: Create and simulate the Tool paths using CAD/CAM
Purpose: Apply fundamentals useful tools and parameter to create and simulate the Tool
paths using CAD/CAM

Required tools and equipment:

1. Computer
2. CAD/CAM software
Precautions: Use fundamentals tools and parameter to create and simulate the Tool paths

Procedures:

Step 1. Set the machine properties including the stock

Step 2. Rough, Face and Finish the OD.
2.1. Use the stock setup to define the face operation.
2.2. Use the OD Rough and Finish Right Tool for roughing, facing and finish operation.
2.3. Extend the ends of the contour with Lead In/Out to machines past the end of the part.
Step 3. Machine the rounded grooves on an angle.
3.1. Select the Multiple Chains option.
3.2. Chain the rounded grooves CCW.
3.3. Create a custom round tool with the tool radius equal to the fillet size.
3.4. Setup the tool so that it machines the groove on the right angle.
3.5. Use stock for outer boundary.
3.6. Rough and Finish the grooves in the same toolpath.

Quality criteria: The output of the simulation must be identical with the given figure

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 3.9. LAP Test
Practical Demonstration

Name: _________________________ Date: ___________

Time started: ________________ Time finished: ___________

Instruction I: Given necessary templates, tools and materials you are required to perform the
following tasks within 10 hours.

Task 1: Set the machine properties including the stock

Task 2: Rough, Face and Finish the OD

Task 3: Machine the rounded grooves on an angle.

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Unit Four: Quality assurance
This learning unit is developed to provide the trainees the necessary information regarding
the following content coverage and topics:

• Standard product specifications

• Measuring devices and methods for product inspection
• Error and risk identification and control measures in NC and CNC machines

This unit will also assist you to attain the learning outcomes stated in the cover page.
Specifically, upon completion of this learning guide, you will be able to:

• Change errors in the program and retest until program is effective

• Check and measure the part in conformance to specification and quality outcomes
• Utilize appropriate methods, measuring tools and equipment
• Risks and control measures associated with NC and CNC machines

4. Standard product specifications

4.1. Measuring devices and methods for product inspection
2.1. Essential Metrology Tools for Modern CNC Machine Shops

Metrology is the science of measurement. In CNC machining, principles of metrology need

to be applied throughout the production process to ensure that each part is machined to the
right size and shape, in accordance with specified tolerances.

It’s simple enough to take a ruler or a measuring tape and mark out inches or millimeters. But
measuring dimensions of CNC machined parts – many with tolerances tighter than +/- .001
inch – is a whole other ball game. When you’re dealing with measurements that small, you
need to have sophisticated measuring tools, and the knowledge to use them.

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Every CNC machine shop will use a different set of metrology tools, depending on the type,
quantity and quality of work they do. The variety of available tools go a long way in
determining the overall capabilities of the facility.

2.2. Metrology Tools

• Go/No-Go Gage

Go/No-Go gages measure parts to ensure that they are within their specified tolerances. The
“no-go” portion represents one end of the tolerance range, and the “go” portion represents the
other. For example, in a plug gage, the “go” end should fit into the hole, while the “no-go”
end should not.

• Calipers

Calipers range broadly in shape, size and sophistication. Regardless of type, calipers all
measure using the same principle: by allowing two opposing tips to rest at the beginning and
end of a distance being measured. The common protractor, used to measure degrees, is also a
type of caliper.

• Vernier calipers: first perfected in the 1600s, vernier calipers consist of a flat bar
along which two opposing tips slide. The distance between the tips is measured using
an accurately graded scale.

• Dial calipers: dial calipers function similarly to Vernier calipers, but display
measurements on a simple dial, making them easier to read.

• Digital calipers: like dial calipers, digital calipers offer an easy-to-read display–in this
case, a digital screen.

• Micrometer

Micrometers use a calibrated screw, connected to a scale that moves as the screw is turned
clockwise or counterclockwise. Many micrometers look and function similarly to calipers,
but they can come in a variety of shapes.

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 • Caliper micrometer: general description of any micrometer made up of two opposing
parts joined by a frame; often similar in appearance to Vernier calipers, but replacing
the flat bar with a screw.

• Bore micrometer: a micrometer attached to a bore gage, used to measure the size and
shape of holes.

• Depth micrometer: a micrometer used to measure the depth of any recess, hole or slot.

• Air Gage

Air gages use pressurized air to measure the dimensions of an object. They were first
introduced in the 1940s, and have undergone improvements to become one of the most
trusted precision measuring tools in machine shops. Air gages function by shooting air out of
a specifically calibrated nozzle, and recording the rate at which the air returns to multiple
sensing nozzles. Thus, they are able to read the air flow between the measuring tool and the
object being measured.

• Surface Roughness Comparator

Ra surface roughness is normally inspected by one of two different methods. A surface

roughness comparator gage shows examples of different levels of Ra. Machined surfaces are
visually compared to these samples to determine if they are within acceptable limits. This
method does not give an actual measurement in microinches or micrometers, but it is simple,
highly portable, cost effective, and adequate for many applications.

Figure 4.1: Surface roughness comparator

• Profilometer

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A more accurate measurement of Ra surface roughness can be obtained with a profilometer.
This electronic tool moves a stylus, or contact point, across a surface and actually measures
the height of the peaks and valleys. An actual value in microinches or micrometers is then
automatically calculated and shown on a display.

Figure 4.2: Profilometer

• Coordinate Measuring Machine (CMM)

Dating back to the 1950s, CMMs are mechanical devices designed to automate various
aspects of measurement. They are often shaped like an upside-down “U,” with legs that move
on either side of a surface plate. The probe also moves side-to-side along the bridge of the
“U,” as well as up and down, allowing measurement of X, Y and Z axes.

CMMs vary widely when it comes to the “probe” component, or the attachment that directly
measures an object through contact or proximity. Originally, all probes were mechanical, and
recorded coordinates through direct contact with a surface. Optical probes, more recently
developed, have a camera-like component that scans images at specified coordinates,
registering changes in contrast within the image to determine accurate measurements.

Modern probes use lasers or white light to scan objects, recording thousands of data points at
a time. This technology makes it possible to integrate with CAD software and produce virtual
3D models of parts with a high degree of accuracy.

• Laser Scanning Arms

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State-of-the-art machine shops can take metrology to the next level with laser scanning arms.
These devices, a type of portable CMM, allow metrologists to measure a broad range of
dimensions simultaneously, and are capable of making millions of calculations per second.
More basic CMMs require time-consuming calibrations and dozens of measurements, but
laser scanning arms save time by automatically taking measurements from thousands of
points on an object. Laser scanning arms are especially useful when a part needs to be
considered holistically–as in the case of reverse engineering, or pinpointing a flaw of
unknown origin

• Travers Tool

Travers Tool carries a variety of measuring equipment from standard to digital. Confirm your
part's design with Travers Tool's hand-held and simple gages such as angle gages, bore
gages, chamfer gages, depth gage calipers, gage balls and blocks, height gages and
accessories, hole gages, micrometers, and more. Blocks, calipers and accessories, coating
measurement, drafting, electrical testing, hardness testers, indicators, levels, are also included
in Travers Tool's measuring and inspection section.

4.2. Error & risk identification and control measures in computer

controlled machines
Conformance in the manufacturing

Performing machining operations is only one part of a career in the machining field.
Measurement is another core duty that is performed many times every day in the industry.
During machining, dimensions, or specified print sizes, must be measured to be sure they are
within required specifications. Every dimension shown on a print is given a certain amount
of allowable variation. That allowable variation is called a tolerance. A tolerance gives a size
range that is acceptable. Why do tolerances exist? They are an engineer’s or designer’s way
of saying “so long as this print dimension is within this range, the machined part will
function correctly.”

Conformance at the manufacturing level is a subset of the overall quality definition.

Manufacturing quality means conformance to requirements. Requirements include drawings,

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procedures, specifications, workmanship details, plus fitness of the product for the intended
use. A simple definition of manufacturing conformance says:

Conformance is obtained when manufacturing follows an unbroken sequence of operations

from beginning to end for successfully meeting the requirements. All things produced must
be in agreement and harmony with the requirements. Economics of conformance require
making products right the first time and every time. Product conformance always involves
cost and scheduled deliveries.

This definition for conformance says it is right or it is not right for shipment. In
manufacturing, when products conform, we ship them. If products don’t conform, they fail
the quality test and we must rework, repair, sort good from bad, or scrap the product. We
can’t ship nonconformances “as is”. Conformance sounds like an internal requirement, but it
is not. Customers set external standards when they buy an advertised product. Costs and
schedules are also important product conformance items. As a consumer, do you want to
spend more and receive your purchase later than meets conformance to your requirements?

Conformance by sorting good product from bad is a terminal manufacturing illness. The
sorting approach is better than nothing but not much better. Waste from the sort-and-suffer
philosophy is insidious. Sorting begins with the best of intentions, but the results are costly.
A better manufacturing method is: “Do it right the first time”.

Conformance has no conscience. Conformance doesn’t mean altering, accommodating,

adjusting, or altering principles or specifications as if they were made from rubber.
Conformance simply means making parts to the requirements. Conformance doesn’t require
“more than” or “less than” drawings specify. Conformance is black or white. Conformance is
the responsibility of the machine operator who is the only one who can produce conformance
no one else. Conformance responsibility doesn’t pass to inspectors.

Machine Tool Error Sources

The accuracy of machine tools is one of the most fundamental requirements for high
precision engineering. It is typically milling, grinding and turning operations that produce the
most tightly toleranced features within high-value machines and assemblies. An

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understanding of machine tool error sources is the first step in minimizing and compensating
for these errors and therefore achieving high-accuracy machined parts. In my previous
articles, I’ve looked at methods of measuring and correcting these errors, such as rapid
verification, multi-axis calibration and simultaneous error parameter estimation. This article
goes into more depth about what the error sources actually are. The sources of errors in
machine tools include kinematic errors that are built into the machine, thermo-mechanical
errors that cause distortions with temperature changes, load and dynamic forces that cause
further distortions, spindle errors, tool errors, motion control and software errors. The control
automatically recognizes these G codes when mill is powered up:

Kinematic Errors

Kinematic errors are those built into the machine due to manufacturing inaccuracies and
clearances in its geometry-defining components such as linear slide ways and rotary
bearings. They are always present regardless of any external factors such as temperature and
forces. Many kinematic errors only depend on position, such as the straightness of an axis or
the alignment between axes. Play in drives, slide ways and rotary bearings results in
hysteresis effects, which cause different errors depending on the direction of travel.
Examples of these effects include backlash and lateral play.

Because kinematic errors are repeatable, they are relatively easy to compensate using
calibration. Traditionally, the emphasis was on making mechanical adjustments to machines
to eliminate these errors, for example, by grinding an axis flat. Although a good standard of
mechanical alignment is still the foundation for machine tool accuracy, the use of computer
numerical control (CNC) now allows much greater use of digital correction. This means that
if there is a measured high point on the x-axis that produces an error in the z-direction.
Rather than attempting to remove the high point on the x-axis, it is easier to introduce a
corrective offset in the CNC controller. So, when the x-axis approaches the high point, the z-
axis will automatically move in the opposite direction to maintain straight line motion of the
tool along the nominal x-axis.

Machine tool errors are the difference between the actual tool path and the desired path. A
physical object has 6 degrees of freedom with regard to its motion; 3 translations and 3

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rotations. It follows from this that deviation from motion along a straight line also has six
components:
• One positional deviation, in the direction of motion.
• Two linear deviations orthogonal to the direction of motion, which may be referred to
as straightness of the axis.
• Three angular deviations, which may be identified as pitch, roll and yaw, although the
distinction between pitch and yaw is dependent on an arbitrary frame of reference.

Loads and Dynamic Forces

The weight of moving parts of the machine and of the work piece will cause a repeatable
displacement of the machine structure, which depends on the combination of axis positions.
The standard approach to kinematic calibration assumes that the errors in each axis depend
only on position along that axis. This means that each axis can be calibrated in isolation and
the resultant errors for any given position calculated by superposition. However, when
considering loads acting on the axes, this assumption is not valid since when an axis as the
end of the kinematic chain is fully extended, it will exert a larger moment on the axis to
which it is attached. For this reason, for the highest accuracy, so called volumetric
compensation must be carried out. This means that instead of taking measurements at a
number of discrete positions along each independent axis, measurements are taken at grid
positions within the volume of the machine. The result is a far lengthier calibration process.
The additional controller software required to implement volumetric compensation can also
be very expensive, meaning that this is only applied for the most demanding applications.
Luckily, the inherent stiffness of machine tools means that these errors are usually very
small, probably less than a micron for typical CNC machine tools. However, for large gantry-
based machines, operating at scales of several meters, volumetric compensation can
eliminate significantly larger errors.

Additional deformations of the machine tool structure, and resulting errors, are caused by
acceleration of the machine and work piece mass, as well as process forces. These can have a
significant effect on machine errors. Inertial forces are predictable and could, therefore, be
compensated using model-based correction, although this is not thought to be done by any

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current industrial control systems. Process forces are more difficult to predict, although these
forces may be reduced to have a negligible impact on the final form of components by
reducing the depth and feed rates for finishing cuts. This involves a compromise between
process time and accuracy.

Motion Control & Software Errors

Motion control errors include both physical effects, such as the dragging of cable looms, and
control interpolation errors, such as servo mismatch and reversal spikes. Dynamic errors are
those which are only present when the machine is in motion. Such errors include controller
errors such as reversal spikes, and servo mismatch and vibration.

Spindle and Tool Errors

A spindle is effectively an additional rotary axis with the important difference that rotational
positioning about the spindle axis does not need to be accurately controlled. In fact, the
spindle may be referred to as the rotary drive axis, however, due to the high speed of
operation, entirely different measurement techniques are required to measure spindle errors.
Errors associated with this axis are sometimes referred to as runout so that radial errors are
referred to as radial runout and axial errors as axial runout. Angular positioning is generally
not a consideration since the tool is continuously rotating within the axis rather than being
rotated accurately.

Although kinematically identical to any other rotary axis, in practice error sources and
detection are very different due to the far greater speed of rotation. Non-contact sensors that
provide very high frequency measurements are therefore required, such as proximity sensors
that make use of eddy current effects.

Additional errors are associated with the repeatability of the tool change operation (index
errors) and tool wear which affects tool length, tool diameter and tool geometry. These may
be calibrated using laser tool calibrators that are able to recalibrate the tool position and size
rapidly during operation of the machine.

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 4.3. Self-check - 4
Directions: Attempt to answer all the questions listed below. Illustrations may be necessary
to aid some explanations/answers. Note: Be precise and scientific in writing. Use the Answer
sheet provided in the next page.

Part I: Multiple Choice - Instructions: For each of the following question choose the best
correct answer and circle the letter of your choice from the given alternatives.

1. One of the following materials not included in foam

a. carving b. rigid
c. Acetal d. All
2. Which code number represent rough turning
a. G03 b. G73
c. N73 d. N03
3. In N20 G00 X1.200 Z.100, the X & Y represents
a. Rapid traverse mode b. Outside diameter
c. Tool reference or change point d. The right of end of work
4. G95 G96 S2000 M03, G96 represents
a. Feed rate per revolution b. Constant feed rate
c. Spindle speed set at 2000 r/min d. Spindle ON clockwise
5. One of the following factors to be considered set up CNC milling
a. Is the machine a vertical or horizontal machine?
b. How many axes machine have?
c. What is the capacity of the tool turret?
d. All

Part II: Short answer – Instructions answer all the questions listed below.

1. List sources of machine tool errors?

2. List essential metrology tools in modern CNC machine shop?
3. Sketch different types of measuring tools and its uses?

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Reference
1. Alan Over., (2011)., CNC Machining Handbook Building, Programming, and
Implementation., GrawHill
2. Graham T. Smith., (1993)., CNC Machining Technology: Cutting, Fluids and Work
holding Technologies., Volume II, Springer-Verlag
3. Ibrahim Zeid., CAD/CAM Theory and Practice., 2nd edition
4. Michael Fitzpatrick., (2014), Machining and CNC Technology, Pearson-Prentice Hall.
MC Graw Hill, 3rd edition
5. Michael Fitzpatrick., (2013)., Machining and CNC Technology., McGraw-Hill Higher
Education., 3rd edition
6. Peter Smid., (2007)., CNC Programming Handbook: Comprehensive Guide to Practical
CNC Programming., 3rd edition
7. Peter Smid., (2005), Fanuc CNC Custom Macros: Programming Resources for Fanuc
Custom Macro by Users., Industrial Press
8. P N RAO., CAD/CAM Principles and applications., 2nd edition
9. Richard R., Warren T., Roland O., Kelly C., Jon Stenerson., (2014)., Machine Tool
Practices., Pearson, 10th edition

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 Developer profile
Quali-
Field of Organization/ Mobile
No. Name fication E-mail
Study Institution number
(Level)
Robe Poly
Mohammed M.Sc. Manufacturing
1 Technic 0913175634
Bedri (A) Technology
College
Dire Dawa Ethio
Mohammed M.Sc. Manufacturing
2 Italy Polytechnic 0907755560 [email protected]
Abdela (A) Technology
College
3
4

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