Manual Part Programming Formats

Introduction
NC part programming consists of planning and documenting the sequence of processing steps to be performed on an NC machine.
The documentation portion of part programming involves the input medium used to transmit the program of instructions to the NC machine control unit.
Saturday, 06 July 2013
Manual Part Programming Formats
NC Coding System
The program of instruction is communicated to the machine tool using a coding system based on binary numbers. This NC coding system is the low-level machine language that can be understood by the MCU. When higher level languages are used, such as APT, the statements in the program are converted to this basic code.
Manual Part Programming Formats 3
Part programming can be accomplished using a variety of procedures ranging from highly manual to highly automated methods. The methods are:
(1) Manual Part Programming (2) Computer-assisted Part Programming (3) Part Programming using CAD/CAM (4) Manual Data Input
Manual Part Programming

In manual part programming the codes are manually as per requirements followed by punching them on paper tapes. Part Program is the program required to machine a specific part or component. Require intimate knowledge about the processes. NC part programmer should be a skill operator and good part programmer for maximum utilization of machine capabilities and available resources like jigs and fixtures, cutting tools, without violating the machine constraints.
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Commands are input into the controller in units called blocks or statements.
Block Format: 1. Fixed sequential format. 2. Tab sequential format. 3. Word address format.
Fixed Sequential Format

The fixed sequential format requires that specific command data items be organized together in a definite order to form a complete statement or block of information. Every block must have exactly the same number of characters. The significance of each character depends on where it is located in the block.
The N/C controller has electronic pigeonholes called registers. Program information in the form of electronic pluses, minuses, and the digits zero (0) through nine (9) are placed into these registers.
The first register, the sequence number register, accepts four data characters, all numerals. The second register, the preparatory function register, receives two numeral characters. The third, fourth, and fifth registers, for the X-axis, Y-axis, and Z-axis drives, respectively, receive seven characters each (the first of which must be a plus or a minus sign). Registers six and seven are for feedrate and miscellaneous commands. These registers receive four and two characters each, respectively.
So with this particular fixed sequential format structure, thirty-three characters must be entered into each and every block and the seventh, fourteenth, and twentyfirst characters must be a plus or minus sign to indicate axis motion direction. A decimal is assumed (but not entered) to follow the ninth, sixteenth, twenty-third, and twenty-ninth character of each block.
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Limitations :
No characters can be omitted and no extra characters can be included because doing either will place other characters in the wrong register. Blank spaces, called null characters, must be used if no command data are to be given. Fixed sequential format requires that a fixed number of data characters be entered in an exact sequence (No exceptions! ). The specific number of characters, their order, and the assumed decimal placement can vary according to the make of controller.
Tab sequential format

The tab sequential format is just like the fixed sequential format except that null characters do not need to be placed into pigeon holes for which there are no data. Instead, a single character that is produced by the TAB key on the data entry terminal is placed into all registers that aren't to receive any data characters. TAB tells the controller to "skip over" those registers.
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The nice thing about tab sequential formatting is that program printouts are "columnized", making the printout easier to read. Otherwise, the tab sequential format is the same as the fixed sequential format. Both are obsolete (but still in use.)
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Word address format

This format allowed the use of alphanumeric codes and the use of the special characters was also incorporated. In this format not only can the sequence be altered, one can also choose to skip the parameter that do not change from previous block to the current block. Eg: the value for speed, feed remain constant for all the subsequent blocks untill altered. Such functions are called MODAL FUNCTIONS.
Coding Systems :
There are two standard coding systems currently used in NC: (1) The Electronic Industry Association (EIA) (2) The International Standards Organization (ISO).
The Electronics Industry Association system is known as EIA RS-244-B. The ISO code was originally developed as the American Standard Code for Information Interchange (ASCII) and has been adopted by ISO as its NC standard.
NC words :
FEED RATE (F code):
This specifies the feed in machining operation. Units are inches per minute ipm by convention.
PREPARATORY WORD (G code):

This word is used to prepare the controller for instructions that are to follow. For example, the word g02 is used to prepare the NC controller unit for circular interpolation along an arc in the clockwise direction. The preparatory word is needed so that the controller can correctly interpret the data that follow it in the block.
MISCELLANEOUS FUNCTION (M code):

The M code is used to specify certain miscellaneous or auxiliary functions, which may be available on the machine tool. Of course, the machine must possess the function that is being called. An example would be m03 to start the spindle rotation. The miscellaneous function is the last word in the block. To identify the end of the instruction, an end-of-block EOB symbol is punched on the tape.
SEQUENCE NUMBER (N code):

This is used to identify the block within an NC program and provides a means by which NC commands may be rapidly located.
CUTTING SPEED (S code):

This specifies the cutting speed of the process, the rate at which the spindle rotates.
TOOL SELECTION (T code):

This code would be needed only for machines with a tool turret or automatic tool changer. The t-word specifies which tool is to be used in the operation.
COORDINATES (x-, y-, and z-words):

These give the coordinate positions of the tool. In a two axis system, only two of the words would be used. In a four- or five-axis machine, additional a-words and/or b-words would specify the angular positions.
The above figure shows all the codes used for NC manual part programming using word address format
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Example
Assume that a drilling operation is to be programmed as: 1. The tool is positioned at (25.4,12.5,0) by a rapid movement. 2. The tool is then advanced -10 mm in the z direction at a feed rate of 500 mm/min., with the flood coolant on. 3. The is then retracted back 10 mm at the rapid feed rate, and the coolant is turned off.
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Program according to fixed sequential format

0010 00 +0025400 +0012500 +0000000 0000 00 0020 01 +0025400 +0012500 -0010000 0500 08 0030 00 +0025400 +0012500 +0000000 0000 09
Program according to tab sequential format

0010 TAB 00 TAB +0025400 TAB +0012500 TAB +0000000 TAB TAB 0020 TAB 01 TAB TAB TAB -0010000 TAB 0500 TAB 08 0030 TAB 00 TAB TAB TAB -0000000 TAB 0000 TAB 09
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Program according to word address format

N10 G00 X25400 Y125 Z0 F0 N20 G01 Z-10000 F500 M08 N30 G00 Z0 M09
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Introduction

Saturday, 06 July 2013