Loading...Fundamentals of CNC Machining
A Practical Guide for Beginners
Compliments of Autodesk, Inc.
Chapter 1:
Introduction & CNC Process
Overview
Description 1-?3
Prerequisites 1-?3
Audience 1-?3
Course Design 1-?3
SRP vs. RP 1-?4
Prototype vs. Production Machining . 1-?4
Required Tools and Equipment . 1-?4
Lessons and Appendices 1-?5
Instructional Resources . 1-?5
Recommended Use . 1-?6
Overview of CAD/CAM Process . 1-?6
Chapter 2:
Shop Safety
Overview . 2-?3
Safety Awareness 2-?3
Personal Conduct & Shop Etiquette 2-?4
Shop Clothing 2-?4
Proper Shop Attire Illustration . 2-?5
General Safety Practices 2-?6
CNC Safety Practices 2-?6
Safety Contract 2-?7
Safety Contract Form . 2-?8
Chapter 3:
CNC Tools
Overview . 3-?3
End Mills 3-?3
Face Mill 3-?4
Corner Radius Mill . 3-?5
Slot Mill/Slotting Saw 3-?5
Center-?Spot Drill 3-?5
Twist Drill . 3-?6
Tap . 3-?6
Reamer 3-?7
Counterbore 3-?8
Cutting Tool Fundamentals . 3-?8
Rotational Direction . 3-?8
Chip Formation 3-?8
Chip Load . 3-?9
Climb vs. Conventional Milling . 3-?9
Cutting Speeds and Feeds Formulas 3-?10
Speed Formula . 3-?11
Feed Formula . 3-?12
Tap Feed Formula 3-?12
Speed/Feed Examples . 3-?13
Milling Speed/Feed Example 3-?13
Drill Speed/Feed Example 3-?14
Table of ContentsFundamentals of CNC Machining Contents
ii
Tap Speed/Feed Example . 3-?15
Maximum Spindle Speed Example . 3-?16
Cutting Data . 3-?17
Best Practices Machining Parameters 3-?18
Troubleshooting Speed/Feed Problems . 3-?19
Chapter 4:
Coordinate Systems
Overview . 4-?3
Cartesian Coordinate System 4-?3
Number Line 4-?3
3D Cartesian Coordinate System . 4-?3
Quadrants 4-?4
Units 4-?5
Vertical Machining Center (VMC) Motion . 4-?5
CNC Motion Control . 4-?6
CNC Machine Coordinates . 4-?6
About Machine Home Position 4-?7
Work Coordinate System (WCS) 4-?8
WCS Example-?1 4-?9
WCS Example-?2 4-?10
WCS Example-?3 4-?11
Machine and Tool Offsets . 4-?12
Machine Offset XY 4-?12
Machine Offset Z 4-?13
Tool Lenght Offset (TLO) 4-?13
Chapter 5:
CNC Programming Language
Overview . 5-?3
CNC Language and Structure . 5-?3
Program Format . 5-?4
CNC Editor . 5-?4
Alphabetic & Special Character Address Codes . 5-?5
Alphabetic Address Code Definitions . 5-?5
G&M Codes . 5-?8
G-?Codes 5-?8
M-?Codes . 5-?8
Select G-?Code Definitions (Expanded) . 5-?9
Canned Cycles 5-?10
Chapter 6:
CNC Operation
Overview of CNC Setup and Operation . 6-?3
Machine and Tool Offsets . 6-?5
Fixture Offset XY 6-?5
Fixture Offset Z 6-?6
Tool Length Offset (TLO) 6-?7
Haas Control Face 6-?8
Haas Keyboard . 6-?9
Start/Home Machine . 6-?10
Load Tools . 6-?11
Set Tool Length Offset (TLO) . 6-?13
Set Fixture Offset XY 6-?17Contents Fundamentals of CNC Machining
iii
Set Fixture Offset Z 6-?21
Load CNC Program . 6-?24
Run CNC Program 6-?26
Adjusting Diameter (CDC) Offsets . 6-?27
Shut Down CNC . 6-?29
Chapter 7:
2D Milling Toolpaths
Overview . 7-?3
2D/3D/4X/5X Defined 7-?3
2D (Prismatic) Parts 7-?3
3D Parts 7-?4
4-?Axis Parts 7-?4
Standard CAD Views vs. CAM Views 7-?6
CAD Features vs. Machining Features . 7-?6
Toolpaths by Type and Use . 7-?7
2D Machining Features Example 7-?8
2D Toolpath Terminology 7-?9
Facing 7-?10
2D Contouring . 7-?11
Cutter Diameter Compensation . 7-?12
Pocketing . 7-?13
Slot Milling . 7-?14
Chamfer Milling . 7-?15
Radius (Corner-?Round) Milling 7-?16
Center Drill 7-?17
Drilling . 7-?18
Tapping 7-?19
Chapter 8:
CNC Turning
Overview . 8-?3
Lathe Components . 8-?4
Spindle . 8-?5
Turret . 8-?6
Lathe Coordinate System 8-?8
Driven (Live) Tools . 8-?9
Imaginary Tool Tip . 8-?10
Part Datum 8-?11
Tools and Tool Holders 8-?12
Chip Breaker . 8-?12
Relief Angle 8-?13
Tool Cutting Angles 8-?13
Rake Angle . 8-?14
Insert Designations 8-?15
Lathe Tool Types 8-?17
Face/Turn Tools . 8-?17
Groove Tool 8-?18
Bore Tool 8-?19
Thread Tool 8-?20
Cutoff Tool . 8-?21
Cutting Speeds and Feeds . 8-?22
Speed/Feed Example . 8-?23
Cutting Feed Example 8-?24
Lathe Setup and Programming Example . 8-?25
Setup 8-?26Fundamentals of CNC Machining Contents
iv
Face 8-?27
Rough . 8-?28
Finish 8-?29
Groove . 8-?30
Thread 8-?31
Drill . 8-?32
Bore 8-?33
Cutoff . 8-?34
Chapter 9:
3D Toolpaths
Overview . 9-?3
3D Cutter Compensation . 9-?3
Tolerances . 9-?4
3D Toolpath Setups . 9-?6
3D Roughing 9-?6
Parallel Finish 9-?7
Scallop Height 9-?8
3D Scallop 9-?9
REST Milling . 9-?10
Pencil Toolpaths 9-?11
Conceptualizing 3D Toolpaths . 9-?12
Chapter 10:
Milling Setups
Overview . 10-?3
Fixture Components 10-?3
Subplates and Angle Plates . 10-?3
Clamps 10-?4
Shoulder Bolts and Dowel Pins 10-?5
Vise Accessories 10-?5
Hard Jaws . 10-?6
Soft Jaws 10-?6
Appendix A:
CNC Milling Work-?Holding Examples
Project 1 : Install Vise A-?2
Project 2 : Install Vise Jaws A-?4
Project 3 : Square Block .A-?5
Project 4 : Contour Square Step A-?13
Project 5 : Base A-?16
Project 6 : Housing A-?21
Project 7 : Fan Blades A-?23
Project 8 : Clamp .A-?29
Project 9 : Fixture Plate .A-?31
Project 10 : French Curve A-?33
Project 11 : Honeycomb A-?38
Project 12 : Bracket .A-?40
Project 13 : Microwave Housing A-?49
Project 14 : Geneva Gear .A-?57Contents Fundamentals of CNC Machining
v
Appendix B:
Alternate Tool Setting Methods
List of Common Methods B-?1
Using Paper .B-?2
1-?2-?3 Block on Finished Part Face B-?3
1-?2-?3 Block and Dial Indicator .B-?4
Tool Probe .B-?4
Appendix C:
CNC Process Planning Form
CNC Process Planning Form C-?1, C-?2
Appendix D:
G-?M Code Reference
Milling G-? Codes D-?1
Milling M-?Codes D-?2
Lathe G-?Codes . D-?3, D-?4
Lathe M-?Codes D-?4
Appendix E:
Glossary
Glossary E-?1, E-?2
Appendix F:
Drill Chart
Drill Chart . F-?1, F-?2
Inch Pipe Threads F-?4
Metric Taps F-?5
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