NC-3e-S 11-14, 14/06, 06/04/07

Chapter 7
NUMERICAL CONTROL
REVIEW QUESTIONS
7.1 What is numerical control?
Answer: As defined in the text, numerical control (NC) is a form of programmable automation in which the
mechanical actions of a machine tool or other equipment are controlled by a program containing coded
alphanumeric data.
7.2 What are the three basic components of an NC system?
Answer: The three components are (1) the part program of instructions, (2) the machine control unit, and (3)
the processing equipment (e.g., machine tool) that accomplishes the operation.
7.3 What is the right-hand rule in NC and where is it used?
Answer: The right-hand rule is used to distinguish positive and negative directions for the rotational axes in
NC. Using the right hand with the thumb pointing in the positive linear axis direction (+x, +y, or +z), the
fingers of the hand are curled in the positive rotational direction for the a, b, and c axes.
7.4 What is the difference between point-to-point and continuous path control in a motion control system?
Answer: Point-to-point systems move the worktable to a programmed location without regard for the path
taken to get to that location. By contrast, continuous path systems are capable of continuous simultaneous
control of two or more axes, thus providing control of the tool trajectory relative to the workpart.
7.5 What is linear interpolation, and why is it important in NC?
Answer: Linear interpolation is the capability to machine along a straight-line trajectory that may not be
parallel to one of the worktable axes. It is important in NC because many workpiece geometries require cuts to
be made along straight lines to form straight edges and flat surfaces, and the angles of the lines are not be
parallel to one of the axes in the coordinate system.
7.6 What is the difference between absolute positioning and incremental positioning?
Answer: In absolute positioning, the workhead locations are always defined with respect to the origin of the
NC axis system. In incremental positioning, the next workhead position is defined relative to the present
location.
7.7 How is computer numerical control (CNC) distinguished from conventional NC?
Answer: CNC is an NC system whose machine control unit is a dedicated microcomputer rather than a hard-
wired controller, as in conventional NC.
7.8 Name five of the ten features and capabilities of a modern CNC machine control unit listed in the text.
Answer: The ten features and capabilities identified in the text are (1) storage of more than one part program,
(2) various forms of program input, such as punched tape, magnetic tape, floppy diskette, RS-232
communications with external computers, and manual data input, (3) program editing at the machine tool,
(4) fixed cycles and programming subroutines (macros), (5) linear and circular interpolation, (6) workpiece
positioning features for setup, (7) cutter length and size compensation, (8) acceleration and deceleration
calculations when the cutter path changes abruptly, (9) communications interface, and (10) diagnostics to
detect malfunctions and diagnose system breakdowns.
7.9 What is distributed numerical control (DNC)?
Answer: Distributed numerical control is a distributed computer system in which a central computer
communicates with multiple CNC machine control units. It evolved from direct numerical control in which
the central computer played the role of the tape reader, downloading part programs one block at a time. In a
modern distributed NC system, entire part programs are downloaded to the MCUs. Also shop floor data is
collected by the central computer to measure shop performance.
7.10 What are some of the machine tool types to which numerical control has been applied?
Answer: NC has been applied to nearly all machine tools types, including lathes, boring mills, drill presses,
milling machines, and cylindrical grinders.

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7.11 What is a machining center?

Answer: As defined in the text, a machining center is a machine tool capable of performing multiple
machining operations on a single workpiece in one setup. The operations involve rotating cutters, such as
milling and drilling, and the feature that enables more than one operation to be performed in one setup is
automatic tool-changing.
7.12 Name four of the six part characteristics that are most suited to the application of numerical control listed in
the text.
Answer: The six part characteristics identified in the text are the following: (1) batch production, (2) repeat
orders, (3) complex part geometry, (4) much metal needs to be removed, (5) many separate machining
operations on the part, and (6) the part is expensive.
7.13 Although NC technology is most closely associated with machine tool applications, it has been applied to other
processes also. Name three of the six examples listed in the text.
Answer: The six non-machine tool applications listed in the text are (1) electrical wire-wrap machines, (2)
component insertion machines, (3) drafting machines (x-y plotters), (4) coordinate measuring machines, (5)
tape laying machines for polymer composites, and (6) filament winding machines for polymer composites.
7.14 What are four advantages of numerical control when properly applied in machine tool operations?
Answer: The text lists the following 11 advantages: (1) nonproductive time is reduced, (2) greater accuracy
and repeatability, (3) lower scrap rates, (4) inspection requirements are reduced, (5) more-complex part
geometries are possible, (6) engineering changes can be accommodated more gracefully, (7) simpler fixtures
are needed, (8) shorter manufacturing lead times, (9) reduced parts inventory, (10) less floor space required
due to fewer machines, and (11) operator skill requirements are reduced.
7.15 What are three disadvantages of implementing NC technology?
Answer: Four disadvantages are identified in the text: (1) higher investment cost because NC machines are
more expensive than conventional machine tools, (2) higher maintenance effort due to greater technological
sophistication of NC, (3) part programming is required, and (4) equipment utilization must be high to justify
the higher investment, and this might mean additional work shifts are required in the machine shop.
7.16 Briefly describe the differences between the two basic types of positioning control systems used in NC?
Answer: The two types of positioning control systems used in NC systems are open loop and closed loop.
An open-loop system operates without verifying that the actual position achieved in the move is the same as
the programmed position. A closed-loop system uses feedback measurements to confirm that the final
position of the worktable is the location specified in the program.
7.17 What is an optical encoder, and how does it work?
Answer: An optical encoder is a device for measuring rotational speed that consists of a light source and a
photodetector on either side of a disk. The disk contains slots uniformly spaced around the outside of its
face. These slots allow the light source to shine through and energize the photodetector. The disk is
connected to a rotating shaft whose angular position and velocity are to be measured. As the shaft rotates,
the slots cause the light source to be seen by the photocell as a series of flashes. The flashes are converted
into an equal number of electrical pulses.
7.18 With reference to precision in an NC positioning system, what is control resolution?
Answer: Control resolution is defined as the distance separating two adjacent addressable points in the axis
movement. Addressable points are locations along the axis to which the worktable can be specifically
directed to go. It is desirable for control resolution to be as small as possible.
7.19 What is the difference between manual part programming and computer-assisted part programming?
Answer: In manual part programming, the programmer prepares the NC code using a low-level machine
language. In computer-assisted part programming, the part program is written using English-like statements
that are subsequently converted into the low-level machine language.
7.20 What is postprocessing in computer-assisted part programming?
Answer: Postprocessing converts the cutter location data and machining commands in the CLDATA file
into low-level code that can be interpreted by the NC controller for a specific machine tool. The output of
postprocessing is a part program consisting of G-codes, x-, y-, and z-coordinates, S, F, M, and other

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functions in word address format. A unique postprocessor must be written for each machine tool system.
7.21 What are some of the advantages of CAD/CAM-based NC part programming compared to computer-assisted
part programming?
Answer: The text lists the following advantages of CAD/CAM NC part programming: (1) the part program
can be simulated off-line to verify its accuracy; (2) the time and cost of the machining operation can be
determined; (3) the most appropriate tooling can be automatically selected for the operation; (4) the
CAD/CAM system can automatically insert the optimum values for speeds and feeds; (5) in constructing the
geometry or the tool path, the programmer receives immediate visual feedback on the CAD/CAM monitor;
(6) the CAD database containing the part design can be used to construct the tool path rather than
redefining the part geometry; and (7) some of the steps in the tool path construction can be automated.
7.22 What is manual data input of the NC part program?
Answer: Manual data input is when the machine operator manually enters the part program data and motion
commands directly into the MCU prior to running the job.
PROBLEMS
NC Applications
7.1 A machinable grade of aluminum is to be milled on an NC machine with a 20 mm diameter four-tooth end
milling cutter. Cutting speed = 120 m/min and feed = 0.008 mm/tooth. Convert these values to rev/min and
mm/rev, respectively.
120m / min
Solution: N = = 1909.9 rev/min
20π(10−3 ) m / rev
Feed in mm/rev = (4 teeth/rev)(0.08 mm/tooth) = 0.32 mm/rev
7.2 A cast iron workpiece is to be face milled on an NC machine using cemented carbide inserts. The cutter has 16
teeth and is 120 mm in diameter. Cutting speed = 200 m/min and feed = 0.005 mm/tooth. Convert these
values to rev/min and mm/rev, respectively.
200m / min.
Solution: N = = 530.5 rev/min
120π(10−3 ) m / rev
Feed in mm/rev = (16 teeth/rev)(0.05 mm/tooth) = 0.80 mm/rev
7.3 An end milling operation is performed on an NC machining center. The total length of travel is 625 mm along
a straight line path to cut a particular workpiece. Cutting speed = 2.0 m/s and chip load (feed/tooth) = 0.075
mm. The end milling cutter has two teeth and its diameter = 15.0 mm. Determine the feed rate and time to
complete the cut.
2.0( 60) m / min.
Solution: N = = 2546.5 rev/min
15π(10−3 ) m / rev
fr = 2546.5 rev/min(2 teeth/rev)(0.075 mm/tooth) = 382.0 mm/min
625 + 15 *
Tm = = 1.675 min
382.0
* overtravel allowance = 1.0 tool diameter = 15 mm.
7.4 A turning operation is to be performed on an NC lathe. Cutting speed = 2.5 m/s, feed = 0.2 mm/rev, and depth
= 4.0 mm. Workpiece diameter = 100 mm and its length = 400 mm. Determine (a) rotational speed of the
workbar, (b) feed rate, (c) metal removal rate, and (d) time to travel from one end of the part to the other.
2.5( 60) m / min.
Solution: (a) N = = 477.5 rev/min
100π(10−3 ) m / rev.
(b) fr = 477.5 rev/min(0.2 mm/rev) = 95.5 mm/min
(c) RMR = vfd = 2.5 m/s(103)(.2 mm)(4.0 mm) = 2000 mm3/s
(d) Tm = 400/95.5 = 4.188 min
7.5 A numerical control drill press drills four 10.0 mm diameter holes at four locations on a flat aluminum plate in

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a production work cycle. Although the plate is only 12 mm thick, the drill must travel a full 20 mm vertically
at each hole location to allow for clearance above the plate and breakthrough of the drill on the underside of
the plate. Cutting conditions: speed = 0.4 m/s and feed = 0.10 mm/rev. Hole locations are indicated in the
following table:
Hole number x-coordinate (mm) y-coordinate (mm)
1 25.0 25.0
2 25.0 100.0
3 100.0 100.0
4 100.0 25.0
The drill starts out at point (0,0) and returns to the same position after the work cycle is completed. Travel rate
of the table in moving from one coordinate position to another is 500 mm/min. Owing to effects of
acceleration and deceleration, and time required for the control system to achieve final positioning, a time loss
of 3 s is experienced at each stopping position of the table. Assume that all moves are made so as to minimize
the total cycle time. If loading and unloading the plate take 20 s (total handling time), determine the time
required for the work cycle.
0.4( 60)
Solution: Drilling operations: N = = 763.9 rev/min
10π(10−3 )
fr = Nf = 763.9(0.10) = 76.39 mm/min
For each hole, Tm = 20/76.39 = 0.262 min
Assume retraction of dril at each hole takes an equal time. Total time/hole = 0.524 min
For four holes, Tm = 4(0.524) = 2.096 min
Workpart and axis system with assumed tool path shown in accompanying drawing:
y (25,100)
(100,100)

(25,25) (100,25)

x
(0,0) (100,0)
Total distance traveled between positions = 252 + 252 + 75 + 75 + 75 + 252 + 1002 = 363.43 mm

363.43 5( 3)
Time to move between positions = + = 0.977 min
500 60
Cycle time = Th + Tm + move time = 20/60 + 2.096 + 0.977 = 3.406 min
Analysis of Open Loop Positioning Systems
7.6 Two stepping motors are used in an open loop system to drive the lead screws for x-y positioning. The range of
each axis is 250 mm. The shaft of the motors are connected directly to the lead screws. The pitch of each lead
screw is 3.0 mm, and the number of step angles on the stepping motor is 125. (a) How closely can the position
of the table be controlled, assuming there are no mechanical errors in the positioning system? (b) What are the
required pulse train frequencies and corresponding rotational speeds of each stepping motor in order to drive
the table at 275 mm/min in a straight line from point (x = 0, y = 0) to point (x = 130 mm, y = 220 mm)?
3mm
Solution: (a) table position can be controlled to = 0.024 mm.
125
(b) Travel rate of the table vt = 275 mm/min from (x = 0, y = 0) to (x = 130 mm, y = 220 mm).
Angle = tan -1(220/130) = 59.42°
Travel rate for x-axis = 275 cos 59.42 = 139.9 mm/min

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139.9mm / min.
x-axis motor speed N = = 46.63 rev/min
3mm / rev.
125pulse / rev( 46.63rev / min)
Pulse rate fp = = 97.15 Hz
60s / min.
Travel rate for y-axis = 275 sin 59.42 = 236.7 mm/min
236.7mm / min.
y-axis motor speed N = = 78.92 rev/min
3mm / rev.
125pulse / rev( 78.92rev / min)
Pulse rate fp = = 164.41 Hz
60s / min.
7.7 One axis of an NC positioning system is driven by a stepping motor. The motor is connected to a lead screw
whose pitch is 4.0 mm, and the lead screw drives the table. Control resolution for the table is specified as
0.015 mm. Determine (a) the number of step angles required to achieve the specified control resolution, (b)
size of each step angle in the motor, and (c) linear travel rate of the motor at a pulse frequency of 200 pulses
per second.
4.0mm / rev
Solution: (a) Number of step angles n s = = 266.67 → 267 pulses/rev
0.015mm / pulse

360°
(b) Step angle α = = 1.348°
267
60s / min( 200pulses / s)
(c) Motor speed N = = 44.94 rev/min
267pulses / rev.
Linear travel rate of machine table = 44.94 rev/min(4.0 mm/rev) = 179.8 mm/min
7.8 The worktable in an NC positioning system is driven by a lead screw with a 4 mm pitch. The lead screw is
powered by a stepping motor which has 250 step angles. The worktable is programmed to move a distance of
100 mm from its present position at a travel speed of 300 mm/min. (a) How many pulses are required to move
the table the specified distance? (b) What is the required motor speed and (c) pulse rate to achieve the desired
table speed?
pA
Solution: (a) Eq. (6.14): x = . Rearranging, A = 360x/p = 360(100 mm)/(4.0 mm/rev.) = 9000°
360
α = 360/250 = 1.44°
Since rg = 1.0, A = Am = npα. Rearranging, np = Am/α = 9000°/1.44° = 6250 pulses.
300mm / min.
(b) Nm = = 75 rev/min
4.0mm / rev.
60 f p
(c) Since rg = 1.0, N = Nm. Eq. (6.16): N = = 75 rev/min
ns rg
Rearranging, fp = = 312.5 Hz
7.9 A stepping motor with 200 step angles is coupled to a lead screw through a gear reduction of 5:1 (5 rotations
of the motor for each rotation of the lead screw). The lead screw has 2.4 threads/cm. The worktable driven by
the lead screw must move a distance = 25.0 cm at a feed rate = 75 cm/min. Determine (a) the number of pulses
required to move the table, (b) required motor speed, and (c) pulse rate to achieve the desired table speed.
1
Solution: (a) Pitch p = = 4.1667 mm/rev. and α = 360/200 = 1.8°
2.4thrds / cm
360 xrg
np = = = 60,000 pulses
pα

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750mm / min.
(b) Leadscrew N = = 180 rev/min
4.1667 mm / rev.
Motor speed Nm = 5(180) = 900 rev/min
ns N m 200( 900)
(c) fp = = = 3000 pulses/s
60 60
7.10 A component insertion machine takes 2.0 sec to put a component into a printed circuit (PC) board, once the
board has been positioned under the insertion head. The x-y table that positions the PC board uses a stepper
motor directly linked to a lead screw for each axis. The lead screw has a pitch = 5.0 mm. The motor step angle
= 7.2 degrees and the pulse train frequency = 400 Hz. Two components are placed on the PC board, one each
at positions (25, 25) and (50, 150), where coordinates = mm. The sequence of positions is (0,0), (25, 25), (50,
150), (0,0). Time required to unload the completed board and load the next blank onto the machine table = 5.0
sec. Assume that 0.25 sec. is lost due to acceleration and deceleration on each move. What is the hourly
production rate for this PC board?
360
Solution: ns = = 50 steps/rev
7.2
vt ns rg fp p ( 400 puls / s)(5.0mm / rev)
fp = . Given rg = 1.0 and rearranging the equation, vt = = = 40
60 p ns 50 puls / rev.
mm/s
25mm
Time for move from (0, 0) to (25, 25) = = 0.625 s
40mm / s
150 − 25
Time for move from (25, 25) to (50, 150) = = 3.125 s
40
150
Time for move from (50, 150) to (0, 0) = = 3.75 s
40
Cycle time Tc = 5.0 + (0.625 + 0.25 + 2.0) + (3.125 + 0.25 + 2.0) + (3.75 + 0.25) = 17.25 s
60x60
Cycle rate (assumed equal to production rate) Rc = = 208.7 units/hr.
17.25
7.11 The two axes of an x-y positioning table are each driven by a stepping motor connected to a leadscrew with a
4:1 gear reduction. The number of step angles on each stepping motor is 200. Each leadscrew has a pitch = 5.0
mm and provides an axis range = 400.0 mm. There are 16 bits in each binary register used by the controller to
store position data for the two axes. (a) What is the control resolution of each axis? (b) What are the required
the rotational speeds and corresponding pulse train frequencies of each stepping motor in order to drive the
table at 600 mm/min in a straight line from point (25,25) to point (300,150)? Ignore acceleration.
Solution: (a) CR1 = p/rgns = 5.0/(4 x 200) = 0.00625 mm
CR2 = L/(2B – 1)= 400/(216 – 1) = 400/65,535 = 0.00610 mm
CR = Max{0.00625, 0.00610} = 0.00625 mm
(b) vt = 600 mm/min from (25, 25) to (300, 150)
∆x = 300 - 25 = 275 mm, ∆y = 150 - 25 = 125 mm
Angle A = tan -1(125/275) = 24.44°
vtx = 600 cos 24.44 = 546.22 mm/min
Nx = rgvtx/p = 4(546.22)/5.0 = 436.98 rev/min
fpx = Nxns/60 = 436.98(200)/60 = 1456.6.8 Hz
vty = 600 sin 24.44 = 248.28 mm/min
Ny = rgvty/p = 4(248.28)/5.0 = 198.63 rev/min
fpx = Nyns/60 = 198.63(200)/60 = 662.1 Hz
Analysis of Closed Loop Positioning Systems
7.12 A dc servomotor is used to drive one of the table axes of an NC milling machine. The motor is coupled directly
to the lead screw for the axis, and the lead screw pitch = 5 mm. The optical encoder attached to the lead screw
emits 500 pulses per revolution of the lead screw. The motor rotates at a normal speed of 300 rev/min.
Determine (a) control resolution of the system, expressed in linear travel distance of the table axis, (b)

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frequency of the pulse train emitted by the optical encoder when the servomotor operates at full speed, and (c)
travel rate of the table at normal rpm of the motor.
5mm / rev
Solution: (a) CR = = 0.01 mm
500pulse / rev

500pulse / rev ( 300rev / min)

(b) fp = nsNm = = 2500 pulse/s = 2500 Hz
60s / min.
5mm / rev ( 2500pulse / s)(60s / min)
(c) vt = 60pfp/ns = = 1500 mm/min
500pulse / rev
7.13 In Problem 7.3, the axis corresponding to the feed rate uses a dc servomotor as the drive unit and an optical
encoder as the feedback sensing device. The motor is geared to the lead screw with a 10:1 reduction (10 turns
of the motor for each turn of the lead screw). If the lead screw pitch = 5 mm, and the optical encoder emits 400
pulses per revolution, determine the rotational speed of the motor and the pulse rate of the encoder in order to
achieve the feed rate indicated.
Solution: From Problem 7.3, fr = 382 mm/min
10(382mm / min)
Nm = rgfr/p = = 764 rev/min
5mm / rev.
f r ns (382mm / min)(400pulse / rev )
fp = = = 509.33 Hz
60 p (60s / min)(5mm / rev )
7.14 The worktable of an NC machine is driven by a closed-loop positioning system which consists of a servomotor,
leadscrew, and optical encoder. The lead screw pitch = 4 mm and is coupled directly to the motor shaft (gear
ratio = 1:1). The optical encoder generates 225 pulses per leadscrew revolution. The table has been
programmed to move a distance of 200 mm at a feed rate = 450 mm/min. (a) How many pulses are received by
the control system to verify that the table has moved the programmed distance? What are (b) the pulse rate and
(c) motor speed that correspond to the specified feed rate?
pn p xns 200mm(225pulse / rev )
Solution: (a) x = . Rearranging, np = = = 11,250 pulses
ns rge p 4 mm / rev
(450mm / min)( 225pulse / rev )
(b) fr = = 421.875 pulse/s = 421.875 Hz
(60s / min)(4 mm / rev )
450mm / min
(c) N = fr/p = = 112.5 rev/min
4 mm / rev
7.15 A NC machine tool table is powered by a servomotor, lead screw, and optical encoder. The lead screw has a
pitch = 5.0 mm and is connected to the motor shaft with a gear ratio of 16:1 (16 turns of the motor for each
turn of the lead screw). The optical encoder is connected directly to the lead screw and generates 200
pulses/rev of the lead screw. The table must move a distance = 100 mm at a feed rate = 500 mm/min.
Determine (a) the pulse count received by the control system to verify that the table has moved exactly 100
mm; and (b) the pulse rate and (c) motor speed that correspond to the feed rate of 500 mm/min.
Solution: (a) x = p np/ns Rearranging, np = xns/p = 100(200)/5 = 4000 pulses.
(b) fp = fr ns /60p = 500(200)/60(5) = 333.3 Hz
(c) N = rg fr /p = 16 x 500/5 = 1600 rev/min
7.16 Solve the previous problem assuming the optical encoder is directly coupled to the motor shaft rather than to
the lead screw.
Solution:(a) x = p np/rg ns Rearranging, np = rg x ns/p = 16(100)(200)/5 = 64,000 pulses.
(b) fp = rg fr ns /60p = 16(500)(200)/60(5) = 5333.3 Hz
(c) N = rg fr /p = 16 x 500/5 = 1600 rev/min
7.17 A lead screw coupled directly to a dc servomotor is used to drive one of the table axes of an NC milling

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machine. The lead screw has 2.5 threads/cm. The optical encoder attached to the lead screw emits 100
pulses/rev of the lead screw. The motor rotates at a maximum speed of 800 rev/min. Determine (a) the control
resolution of the system, expressed in linear travel distance of the table axis, (b) frequency of the pulse train
emitted by the optical encoder when the servomotor operates at maximum speed; and (c) travel speed of the
table at maximum motor speed.
1
Solution: (a) p = = 0.4 cm = 4.0 mm, CR = p/ns = 4.0/100 = 0.04 mm
2.5threads / cm
(b) fp = Nns/60 = 800 rev/min(100 pulse/rev))/(60 s/min) = 1333.3 Hz
(c) vt = Np = 800 rev/min(4.0 mm/rev.) = 3200 mm/min
7.18 Solve the previous problem only the servomotor is connected to the lead screw through a gear box whose
reduction ratio = 10:1 (10 revolutions of the motor for each revolution of the lead screw).
1
Solution: (a) p = = 0.4 cm = 4.0 mm, CR = p/ns = 4.0/100 = 0.04 mm
2.5threads / cm
(b) fp = Nns/60rg = 800 rev/min(100 pulse/rev))/(10(60 s/min)) = 133.33 Hz
(c) vt = Np/rg = 800 rev/min(4.0 mm/rev.)/10 = 320 mm/min
7.19 A milling operation is performed on a NC machining center. Total travel distance = 300 mm in a direction
parallel to one of the axes of the worktable. Cutting speed = 1.25 m/s and chip load = 0.05 mm. The end
milling cutter has four teeth and its diameter = 20.0 mm. The axis uses a dc servomotor whose output shaft is
coupled to a lead screw with pitch = 6.0 mm. The feedback sensing device is an optical encoder which emits
250 pulses per revolution. Determine (a) feed rate and time to complete the cut, (b) rotational speed of the
motor and (c) pulse rate of the encoder at the feed rate indicated.
Solution: (a) N = (1.25 x 103 mm/s)/(20π mm/rev) = 19.89 rev/s.
fr = N f nt = 19.89(0.05)(4) = 3.978 mm/s. Tm = 300/3.978 = 75.4 s = 1.26 min
(b) N = fr /p = (3.978 mm/s)/(6 mm/rev) = 0.663 rev/s. fp = ns N = 250(0.663) = 165.75 Hz
7.20 A dc servomotor drives the x-axis of a NC milling machine table. The motor is coupled directly to the table
lead screw, whose pitch = 6.25 mm. An optical encoder is connected to the lead screw. The optical encoder
emits 125 pulses per revolution. To execute a certain programmed instruction, the table must move from point
(x = 87.5 mm, y = 35.0) to point (x = 25.0 mm, y = 180.0 mm) in a straight-line trajectory at a feed rate = 200
mm/min. Determine (a) the control resolution of the system for the x-axis, (b) rotational speed of the motor,
and (c) frequency of the pulse train emitted by the optical encoder at the desired feed rate.
Solution: (a) CR = p/ns = (6.25 mm/rev)/(125 pulse/rev) = 0.05 mm
(b) Move from (87.5, 35.0) to (25.0, 180.0) at fr = 200 mm/min
∆x = 25.0 - 87.5 = -62.5, ∆y = 180.0 - 35.0 = 145.0, Angle A = tan -1(145/-62.5) = 113.32°
fr = 200 cos 113.32 = 200(-0.3958) = -79.19 mm/min
N = frx/p = (-79.17 mm/min)/(6.25 mm/rev) = -12.67 rev/min

(c) fp = nsN/60 =
(12.67 )(125) = 26.4 Hz
60
Resolution and Accuracy of Positioning Systems
7.21 A two-axis NC system used to control a machine tool table uses a bit storage capacity of 16 bits in its control
memory for each axis. The range of the x-axis is 600 mm and the range of the y-axis is 500 mm. The
mechanical accuracy of the machine table can be represented by a Normal distribution with standard deviation
= 0.002 mm for both axes. For each axis of the NC system, determine (a) the control resolution, (b) accuracy,
and (c) repeatability.
600 600
Solution: (a) x-axis: CR2 = 16 = = 0.0091 mm
2 −1 65,536 −1
y-axis: CR2 = = 0.0076 mm

30
NC-3e-S 11-14, 14/06, 06/04/07

CR 0.0091
(b) x-axis: Accuracy = + 3σ = + 3(0.002) = 0.0106 mm
2 2
0.0076
y-axis: Accuracy = + 3(0.002) = 0.0098 mm
2
(c) Repeatability = ± 3σ = ± 3(0.002) = ± 0.006 mm
7.22 Stepping motors are used to drive the two axes of an insertion machine used for electronic assembly. A printed
circuit board is mounted on the table which must be positioned accurately for reliable insertion of components
into the board. Range of each axis = 700 mm. The lead screw used to drive each of the two axes has a pitch of
3.0 mm. The inherent mechanical errors in the table positioning can be characterized by a Normal distribution
with standard deviation = 0.005 mm. If the required accuracy for the table is 0.04 mm, determine (a) the
number of step angles that the stepping motor must have, and (b) how many bits are required in the control
memory for each axis to uniquely identify each control position.
CR
Solution: (a) Accuracy = + 3σ = 0.5CR + 3(0.005) = 0.04 (as specified)
2
Assume CR = CR1. 0.5CR1 = 0.04 - 0.015 = 0.025 mm, CR1 = 0.05 mm
p p
CR1 = . Rearranging, ns = , since rg = 1.
ns rg CR1
ns = = 60 steps/rev.

L L 700mm
(b) Let CR2 ≤ CR1 .CR2 = . Rearranging, 2B - 1 = = = 14,000 positions
2 −1
B
CR2 0.05mm / step
2B = 14,001
B ln2 = ln 14001
0.6931 B = 9.5469, B = 13.77 → 14 bits
7.23 Referring back to Problem 7.8, the mechanical inaccuracies in the open loop positioning system can be
described by a normal distribution whose standard deviation = 0.005 mm. The range of the worktable axis is
500 mm, and there are 12 bits in the binary register used by the digital controller to store the programmed
position. For the positioning system, determine (a) control resolution, (b) accuracy, and (c) repeatability. (d)
What is the minimum number of bits that the binary register should have so that the mechanical drive system
becomes the limiting component on control resolution?
Solution: (a) CR1 = p/ns = 4 mm/250 = 0.016 mm.
L 500 500
CR2 = B = 12 = = 0.122 mm.
2 −1 2 −1 4095
CR = Max{CR1, CR2} = Max{0.016, 0.122} = 0.122 mm.
(b) Accuracy = 0.5 CR + 3 σ = 0.5(0.122) + 3(0.005) = 0.076 mm.
(c) Repeatability = ± 3 σ = ± 3(0.005) = ± 0.015 mm.
(d) For mechanical errors to be the limiting factor in control resolution in this problem, CR1 must = CR2.
500
Thus, 0.016 = B . Rearranging, 2B -1 = 500/0.016 = 31,250
2 −1
B ln 2 = ln 31,251
0.69315 B = 10.3498 B = 14.93 Use B = 15 bits
7.24 The positioning table for a component insertion machine uses a stepping motor and lead screw mechanism.
The design specifications require a table speed of 0.4 m/s and an accuracy = 0.02 mm. The pitch of the lead
screw = 5.0 mm, and the gear ratio = 2:1 (2 turns of the motor for each turn of the lead screw). The
mechanical errors in the motor, gear box, lead screw, and table connection are characterized by a normal
distribution with standard deviation = 0.0025 mm. Determine (a) the minimum number of step angles in the
stepping motor and (b) frequency of the pulse train required to drive the table at the desired maximum speed.
Solution: (a) Accuracy = 0.5 CR + 3 σ: 0.02 = 0.5 CR + 3(0.0025) = 0.5 CR + 0.075
0.02 - 0.0075 = 0.0125 = 0.5 CR, CR = 0.025 mm
Assume CR = CR1

31
NC-3e-S 11-14, 14/06, 06/04/07

CR1 = 0.025 = p/(rg ns) = 5.0/2ns. Rearranging, ns = 5/(2 x 0.025) = 100 step angles
rg vt ns 2 (0.4m / s)(100pulse / rev)
(b) fp = = 2(0.4)(100)/(5.0) = 16,000 Hz
p 5(10−3 ) m / rev
7.25 The two axes of an x-y positioning table are each driven by a stepping motor connected to a lead screw with a
10:1 gear reduction. The number of step angles on each stepping motor is 20. Each lead screw has a pitch =
4.5 mm and provides an axis range = 300 mm. There are 16 bits in each binary register used by the controller
to store position data for the two axes. (a) What is the control resolution of each axis? (b) What are the
required rotational speeds and corresponding pulse train frequencies of each stepping motor in order to drive
the table at 500 mm/min in a straight line from point (30,30) to point (100,200)? Ignore acceleration and
deceleration.
Solution: (a) CR1 = p/rgns = 4.5/(10 x 20) = 0.0225 mm
L 300 300
CR2 = B = 16 = = 0.00458 mm
2 −1 2 −1 65,535
CR = Max{0.0225, 0.00458} = 0.0225 mm
(b) vt = 500 mm/min from (30, 30) to (100, 200)
∆x = 100 - 30 = 70 mm, ∆y = 200 - 30 = 170 mm, Angle A = tan -1(170/70) = 67.62°
vtx = 500 cos 67.62 = 190.38 mm/min, Nx = rgvtx/p = 10(190.38)/4.5 = 423.06 rev/min
fpx = Nx ns/60 = 423.06(20)/60 = 141.02 Hz
vty = 500 sin 67.62 = 462.34 mm/min, Ny = rgvty/p = 10(462.34)/4.5 = 1027.42 rev/min
fpx = Ny ns /60 = 1027.42(20)/60 = 342.47 Hz
NC Manual Part Programming
Note: Appendix A7 will be required to solve the problems in this group.
7.26 Write the part program to drill the holes in the part shown in Figure P7.26. The part is 12.0 mm thick. Cutting
speed = 100 m/min and feed = 0.06 mm/rev. Use the lower left corner of the part as the origin in the x-y axis
system. Write the part program in the word address format using absolute positioning. The program style
should be similar to Example A7.1.
Solution: At the beginning of the job, the drill point will be positioned at a target point located at x = 0, y = 0,
and z = + 10. The program begins with the tool positioned at this target point. Feed is given as 0.06 mm/rev.
Rotational speed of drill is calculated as follows:
100
N= = 3183 rev/min
10π(10−3 )
NC part program code Comments
N001 G21 G90 G92 X0 Y0 Z010.0; Define origin of axes.
N002 G00 X040.0 Y025.0; Rapid move to first hole location.
N003 G01 G95 Z-20.0 F0.06 S3183 M03; Drill first hole.
N004 G01 Z010.0; Retract drill from hole.
N005 G00 Y100.0; Rapid move to second hole location.
N006 G01 G95 Z-20.0 F0.06; Drill second hole.
N007 G01 Z010.0; Retract drill from hole.
N008 G00 X100.0; Rapid move to third hole location.
N009 G01 G95 Z-20.0 F0.06; Drill third hole.
N010 G01 Z010.0; Retract drill from hole.
N011 G00 X160.0; Rapid move to fourth hole location.
N012 G01 G95 Z-20.0 F0.06; Drill fourth hole.
N013 G01 Z010.0; Retract drill from hole.
N014 G00 X125.0 Y060.0; Rapid move to fifth hole location.
N015 G01 G95 Z-20.0 F0.06; Drill fifth hole.
N016 G01 Z010.0; Retract drill from hole.
N017 G00 X200.0 Y040.0; Rapid move to sixth hole location.
N018 G01 G95 Z-20.0 F0.06; Drill sixth hole.
N019 G01 Z010.0; Retract drill from hole.
N020 G00 X0 Y0 M05; Rapid move to target point, stop spindle rotation.

32
NC-3e-S 11-14, 14/06, 06/04/07

N021 M30; End of program, stop machine.

7.27 The part in Figure P7.27 is to be drilled on a turret-type drill press. The part is 15.0 mm thick. There are three
drill sizes to be used: 8 mm, 10 mm, and 12 mm. These drills are to be specified in the part program by tool
turret positions T01, T02, and T03. All tooling is high speed steel. Cutting speed = 75 mm/min and feed =
0.08 mm/rev. Use the lower left corner of the part as the origin in the x-y axis system. Write the part program
in the word address format using absolute positioning. The program style should be similar to Example A7.1.
Solution: At the beginning of the job, the drill point will be positioned at a target point located at x = 0, y = 0,
and z = + 10. The program begins with the tool positioned at this target point. Feed is given as 0.08 mm/rev.
Rotational speeds for the three drill diameters are calculated as follows:
For the 8 mm drill, N = 75/(8π x 10-3) = 2984 rev/min
For the 10 mm drill, N = 75/(10π x 10-3) = 2387 rev/min
For the12 mm drill, N = 75/(12π x 10-3) = 1989 rev/min
NC part program code Comments
N001 G21 G90 G92 X0 Y0 Z010.0; Define origin of axes.
N002 G00 X025.0 Y025.0 T01; Rapid move to first hole location, select 8 mm drill.
N003 G01 G95 Z-20.0 F0.08 S2984 M03; Drill first hole.
N004 G01 Z010.0; Retract drill from hole.
N005 G00 X150.0; Rapid move to second hole location.
N006 G01 G95 Z-20.0 F0.08; Drill second hole.
N007 G01 Z010.0; Retract drill from hole.
N008 G00 X175.0; Rapid move to third hole location.
N009 G01 G95 Z-20.0 F0.08; Drill third hole.
N010 G01 Z010.0; Retract drill from hole.
N011 G00 X100.0 Y075.0 T02; Rapid move to fourth hole location, select 10 mm drill.
N012 G01 G95 Z-20.0 F0.08; Drill fourth hole.
N013 G01 Z010.0; Retract drill from hole.
N014 G00 X050.0; Rapid move to fifth hole location.
N015 G01 G95 Z-20.0 F0.08; Drill fifth hole.
N016 G01 Z010.0; Retract drill from hole.
N017 G00 X050.0 Y075.0 T03; Rapid move to sixth hole location, select 12 mm drill.
N018 G01 G95 Z-22.0 F0.08; Drill sixth hole.
N019 G01 Z010.0; Retract drill from hole.
N020 G00 X0 Y0 M05; Rapid move to target point, stop spindle rotation.
N021 M30; End of program, stop machine.

7.28 The outline of the part in the previous problem is to be profile milled using a 30 mm diameter end mill with
four teeth. The part is 15 mm thick. Cutting speed = 150 mm/min and feed = 0.085 mm/tooth. Use the lower
left corner of the part as the origin in the x-y axis system. Two of the holes in the part have already been
drilled and will be used for clamping the part during profile milling. Write the part program in the word
address format with TAB separation and variable word order. Use absolute positioning. The program style
should be similar to Example A7.2.
Solution: As stated, two of the holes drilled in Problem 7.27 will be used to clamp the workpart for milling the
outside edges. The part will be fixtured so that its top surface is 40 mm above the surface of the machine tool
table, and the x-y plane of the axis system will be defined 40 mm above the table surface. As given, a 30 mm
diameter end mill with four teeth will be used. The cutter is assumed to have a side tooth engagement length of
40 mm. Throughout the machining sequence the bottom tip of the cutter will be positioned 25 mm below the
part top surface, which corresponds to z = -25 mm. Since the part is 15 mm thick, this z position will allow the
side cutting edges of the milling cutter to cut the full thickness of the part during profile milling. Cutting speed
is specified as 150 m/min. Rotational speed of the cutter is calculated as N = 150/(30π x 10-3) = 1592 rev/min.
Given a feed = 0.085 mm/tooth, feed rate is calculated as 1592(4)(0.085) = 541 mm/min. Cutter diameter data
has been manually entered into offset register 05. At the beginning of the job, the cutter will be positioned so
that its center tip is at a target point located at x = -50, y = -50, and z = + 10. The program begins with the tool
positioned at this location.
NC part program code Comments
N001 G21 G90 G92 X-050.0 Y-050.0 Z010.0; Define origin of axes.

33
NC-3e-S 11-14, 14/06, 06/04/07

N002 G00 Z-025.0 S1592 M03; Rapid to cutter depth, turn spindle on.
N003 G01 G94 G42 Y0 D05 F541; Bring tool to starting y-value, start cutter offset.
N004 G01 X200.0; Mill lower part edge.
N005 G01 Y050.0; Mill right straight edge.
N006 G01 X150.0; Mill horizontal step above two 8 mm holes
N007 G17 G02 X125.0 Y075.0 R025.0; Circular interpolation around arc.
N008 G01 X125.0 Y100.0; Mill vertical step above arc.
N009 G01 Y025.0; Mill top part edge.
N010 G01 X0 Y050.0; Mill angled edge at left of part.
N011 G01 Y0; Mill vertical edge at left of part.
N012 G40 G00 X-050.0 Y-050.0 Z010.0 M05; Rapid move to target point, cancel offset, spindle stop.
N013 M30; End of program, stop machine.

7.29 The outline of the part in Figure P7.29 is to be profile milled, using a 20 mm diameter end mill with two teeth.
The part is 10 mm thick. Cutting speed = 125 mm/min and feed = 0.10 mm/tooth. Use the lower left corner of
the part as the origin in the x-y axis system. The two holes in the part have already been drilled and will be
used for clamping the part during milling. Write the part program in the word address format with TAB
separation and variable word order. Use absolute positioning. The program style should be similar to Example
A7.2.

Solution: As stated, the two holes will be used to clamp the workpart during milling. The part will be fixtured
so that its top surface is 40 mm above the surface of the machine tool table, and the x-y plane of the axis
system will be defined 40 mm above the table surface. As given, a 20 mm diameter end mill with two teeth
will be used. The cutter is assumed to have a side tooth engagement length of 30 mm. Throughout the
machining sequence the bottom tip of the cutter will be positioned 20 mm below the part top surface, which
corresponds to z = -20 mm. Since the part is 10 mm thick, this z position will allow the side cutting edges of
the milling cutter to cut the full thickness of the part during profile milling. Cutting speed is specified as 125
m/min. Rotational speed of the cutter is calculated as N = 125/(20π x 10-3) = 1989 rev/min. Given a feed =
0.10 mm/tooth, feed rate is calculated as 1989(2)(0.10) = 398 mm/min. Cutter diameter data has been
manually entered into offset register 05. At the beginning of the job, the cutter will be positioned so that its
center tip is at a target point located at x = -50, y = -50, and z = + 10. The program begins with the tool
positioned at this location.
NC part program code Comments
N001 G21 G90 G92 X-050.0 Y-050.0 Z010.0; Define origin of axes.
N002 G00 Z-020.0 S1989 M03; Rapid to cutter depth, turn spindle on.
N003 G01 G94 G42 Y0 D05 F398; Bring tool to starting y-value, start cutter offset.
N004 G01 X075.0; Mill lower horizontal edge of part.
N005 G01 X150.0 Y043.02; Mill angled edge at 35 degrees.
N006 G01 Y070.0; Mill vertical edge at right of part.
N007 G01 X080.0; Mill horizontal edge leading to arc.
N008 G17 G02 X050.0 Y100.0 R030.0; Circular interpolation around arc.
N009 G01 Y125.0; Mill vertical step above arc.
N010 G01 X0; Mill top part edge.
N011 G01 Y0 Mill vertical edge at left of part.
N012 G40 G00 X-050.0 Y-050.0 Z010.0 M05; Rapid move to target point, cancel offset, spindle stop.
N013 M30; End of program, stop machine.

NC Part Programming in APT

Note: Appendix B7 will be required to solve the problems in this group.
7.30 Write the APT geometry statements to define the hole positions of the part in Figure P7.26. Use the lower left
corner of the part as the origin in the x-y axis system.
Solution: Points are defined 10 mm above part surface for convenience in subsequent drilling.

34
NC-3e-S 11-14, 14/06, 06/04/07

10 dia., 6 holes

P3 P4
P2

100
125 P6 P5
60 P1
40
25
P0
40
100
125
160
200
225

P0 = POINT/0, 0, 10.0
P1 = POINT/40.0, 25.0, 10.0
P2 = POINT/40.0, 100.0, 10.0
P3 = POINT/100.0, 100.0, 10.0
P4 = POINT/160.0, 100.0, 10.0
P5 = POINT/200.0, 40.0, 10.0
P6 = POINT/125.0, 60.0, 10.0
7.31 Write the complete APT part program to perform the drilling operations for the part drawing in Figure P7.26.
Cutting speed = 0.4 m/s, feed = 0.10 mm/rev., and table travel speed between holes = 500 mm/min.
Postprocessor call statement is MACHIN/DRILL, 04.
Solution: Spindle speed N = 0.4(60)/(10π x 10-3) = 764 rev/min. See drawing in previous solution.
PARTNO PART P6.6 DRILLING
MACHIN/ MACHIN/DRILL, 04
CLPRNT
UNITS/MM
REMARK Part geometry. Points are defined 10 mm above part surface.
P0 = POINT/0, 0, 10.0
P1 = POINT/40.0, 25.0, 10.0
P2 = POINT/40.0, 100.0, 10.0
P3 = POINT/100.0, 100.0, 10.0
P4 = POINT/160.0, 100.0, 10.0
P5 = POINT/200.0, 40.0, 10.0
P6 = POINT/125.0, 60.0, 10.0
REMARK Drill bit motion statements. Rapid traverse speed (RAPID) set at 500 mm/min
FROM/P0
RAPID
GOTO/P1
SPINDL/764, CLW
FEDRAT/0.10, IPR
GODLTA/0, 0, -30
GODLTA/0, 0, 30
RAPID
GOTO/P2
SPINDL/764, CLW
FEDRAT/0.10, IPR
GODLTA/0, 0, -30
GODLTA/0, 0, 30
RAPID
GOTO/P3
SPINDL/764, CLW
FEDRAT/0.10, IPR
GODLTA/0, 0, -30

35
NC-3e-S 11-14, 14/06, 06/04/07

GODLTA/0, 0, 30
RAPID
GOTO/P4
SPINDL/764, CLW
FEDRAT/0.10, IPR
GODLTA/0, 0, -30
GODLTA/0, 0, 30
RAPID
GOTO/P5
SPINDL/764, CLW
FEDRAT/0.10, IPR
GODLTA/0, 0, -30
GODLTA/0, 0, 30
RAPID
GOTO/P6
SPINDL/764, CLW
FEDRAT/0.10, IPR
GODLTA/0, 0, -30
GODLTA/0, 0, 30
RAPID
GOTO/P0
SPINDL/OFF
FINI

7.32 Write the APT geometry statements to define the hole positions of the part in Figure P7.27. Use the lower left
corner of the part as the origin in the x-y axis system.
Solution: Points are defined 10 mm above part surface for convenience in subsequent drilling. See drawing
below.
P0 = POINT/0, 0, 10.0
P1 = POINT/25.0, 25.0, 10.0
P2 = POINT/150.0, 25.0, 10.0
P3 = POINT/175.0, 25.0, 10.0
P4 = POINT/100.0, 75.0, 10.0
P5 = POINT/50.0, 75.0, 10.0
P6 = POINT/50.0, 50.0, 10.0

125 10 dia., 2 holes

25
12 dia., 1 hole
P5 P4
25 rad.
100
75 8 dia., 3 holes
P6 P3
50 P1 P2

25
P0
25
50
75
100
150
175
200

7.33 Write the APT part program to perform the drilling operations for the part drawing in Figure P7.27. Use the
TURRET command to call the different drills required. Cutting speed = 0.4 m/s, feed = 0.10 mm/rev., and
table travel speed between holes = 500 mm/min. Postprocessor call statement is MACHIN/TURDRL,02.
Solution: Spindle speed N = 0.4(60)/(10π x 10-3) = 764 rev/min. See drawing in previous solution.
PARTNO PART P6.6 DRILLING

36
NC-3e-S 11-14, 14/06, 06/04/07

MACHIN/ MACHIN/TURDRL, 02
CLPRNT
UNITS/MM
REMARK Part geometry. Points are defined 10 mm above part surface.
P0 = POINT/0, 0, 10.0
P1 = POINT/25.0, 25.0, 10.0
P2 = POINT/150.0, 25.0, 10.0
P3 = POINT/175.0, 25.0, 10.0
P4 = POINT/100.0, 75.0, 10.0
P5 = POINT/50.0, 75.0, 10.0
P6 = POINT/50.0, 50.0, 10.0
REMARK Drill bit motion statements. Rapid traverse speed (RAPID) set at 500 mm/min
FROM/P0
RAPID
TURRET/T01
GOTO/P1
SPINDL/764, CLW
FEDRAT/0.10, IPR
GODLTA/0, 0, -30
GODLTA/0, 0, 30
RAPID
GOTO/P2
SPINDL/764, CLW
FEDRAT/0.10, IPR
GODLTA/0, 0, -30
GODLTA/0, 0, 30
RAPID
GOTO/P3
SPINDL/764, CLW
FEDRAT/0.10, IPR
GODLTA/0, 0, -30
GODLTA/0, 0, 30
RAPID
TURRET/T02
GOTO/P4
SPINDL/764, CLW
FEDRAT/0.10, IPR
GODLTA/0, 0, -30
GODLTA/0, 0, 30
RAPID
GOTO/P5
SPINDL/764, CLW
FEDRAT/0.10, IPR
GODLTA/0, 0, -30
GODLTA/0, 0, 30
RAPID
TURRET/T03
GOTO/P6
SPINDL/764, CLW
FEDRAT/0.10, IPR
GODLTA/0, 0, -30
GODLTA/0, 0, 30
RAPID
GOTO/P0
SPINDL/OFF
FINI

7.34 Write the APT geometry statements to define the outline of the part in Figure P7.27. Use the lower left corner
of the part as the origin in the x-y axis system.

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NC-3e-S 11-14, 14/06, 06/04/07

Solution: . Points are defined 25 mm below part upper surface to provide full engagement of cutter.

125 10 dia., 2 holes

25 P3
L5
12 dia., 1 hole
P4 L4
L6 P9 25 rad.
P10
100 P5 C1 L3 P2
75 8 dia., 3 holes
L7 P11
50 P6 P7
L2
25 P8
P0 L1
P1
25
50
75
100
150
175
200

P0 = POINT/0, 0, -25.0
P1 = POINT/200.0, 0, -25.0
P2 = POINT/200.0, 50.0, -25.0
P3 = POINT/125.0, 100.0, -25.0
P4 = POINT/25.0, 100.0, -25.0
P5 = POINT/0, 50.0, -25.0
L1 = LINE/P0, P1
L2 = LINE/P1, P2
L3 = LINE/P2, PARLEL, L1
L4 = LINE/P3, PERPTO, L3
L5 = LINE/P3, P4
L6 = LINE/P4, P5
L7 = LINE/P0, P5
C1 = CIRCLE/XLARGE, L4, YLARGE, L3, RADIUS, 25.0
PL1 = PLANE/P0, P1, P3
7.35 Write the complete APT part program to profile mill the outside edges of the part in Figure P7.27. The part is
15 mm thick. Tooling = 30 mm diameter end mill with four teeth, cutting speed = 150 mm/min, and feed =
0.085 mm/tooth. Use the lower left corner of the part as the origin in the x-y axis system. Two of the holes in
the part have already been drilled and will be used for clamping the part during profile milling. Postprocessor
call statement is MACHIN/MILL, 06.
Solution: Spindle speed N = 150/(30π x 10-3) = 1592 rev/min. Feed rate fr = 1592(4)(0.085) = 541 mm/min.
See drawing in previous solution.
PARTNO PART P6.7 PROFILE MILLING
MACHIN/ MACHIN/MILL, 06
CLPRNT
UNITS/MM
INTOL/0.01
CUTTER/30.0
REMARK Points are defined 25 mm below part upper surface to provide full engagement of cutter.
PTARG = POINT/-20.0, -30.0, -25.0
P0 = POINT/0, 0, -25.0
P1 = POINT/200.0, 0, -25.0
P2 = POINT/200.0, 50.0, -25.0
P3 = POINT/125.0, 100.0, -25.0
P4 = POINT/25.0, 100.0, -25.0
P5 = POINT/0, 50.0, -25.0

38
NC-3e-S 11-14, 14/06, 06/04/07

L1 = LINE/P0, P1
L2 = LINE/P1, P2
L3 = LINE/P2, PARLEL, L1
L4 = LINE/P3, PERPTO, L3
L5 = LINE/P3, P4
L6 = LINE/P4, P5
L7 = LINE/P0, P5
C1 = CIRCLE/XLARGE, L4, YLARGE, L3, RADIUS, 25.0
PL1 = PLANE/P0, P1, P3
FROM/PTARG
SPINDL/1592, CLW
FEDRAT/541, IPM
GO/TO, L1, TO, PL1, TO, L7
GORGT/L1, PAST, L2
GOLFT/L2, PAST, L3
GOLFT/L3, TANTO, C1
GOFWD/C1, TO, L4
GOFWD/L4, PAST, L5
GOLFT/L5, PAST, L6
GOLFT/L6, PAST, L7
GOFWD, L7, PAST, L1
GOTO/PTARG
SPINDL/OFF
FINI
7.36 Write the APT geometry statements to define the part geometry shown in Figure P7.29. Use the lower left
corner of the part as the origin in the x-y axis system.
Solution: Points are defined 20 mm below part upper surface to provide full engagement of cutter.

50
P4 P3
L6 L5
30 rad.

125 L4 P2
C1
75 L7 L3
10 dia., 2 holes

25 35 deg.
P0 L1
25 P1
75
150

P0 = POINT/0, 0, -20.0
P1 = POINT/75.0, 0, -20.0
P2 = POINT/150.0, 70.0, -20.0
P3 = POINT/50.0, 125.0, -20.0
P4 = POINT/0, 125.0, -20.0
L1 = LINE/P0, P1
L2 = LINE/P1, ATANGL, 35
L3 = LINE/P2, PERPTO, L1
L4 = LINE/P2, PARLEL, L1
L5 = LINE/P3, PERPTO, L1
L6 = LINE/P4, P3
L7 = LINE/P0, P4
C1 = CIRCLE/XLARGE, L5, YLARGE, L4, RADIUS, 30.0

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PL1 = PLANE/P0, P2, P4

7.37 Write the complete APT part program to perform the profile milling operation for the part drawing in Figure
P7.29. Tooling = 20 mm diameter end mill with two teeth, cutting speed = 125 mm/min, and feed = 0.10
mm/tooth. The part is 10 mm thick. Use the lower left corner of the part as the origin in the x-y axis system.
The two holes in the part have already been drilled and will be used for clamping the part during milling.
Postprocessor call statement is MACHIN/MILL, 01.
Solution: Spindle speed N = 125/(20π x 10-3) = 1989 rev/min. Feed rate fr = 1989(2)(0.10) = 398 mm/min.
See drawing in previous solution.
PARTNO PART P6.9 PROFILE MILLING
MACHIN/ MACHIN/MILL, 01
CLPRNT
UNITS/MM
INTOL/0.01
CUTTER/20.0
REMARK Points are defined 20 mm below part upper surface to provide full engagement of cutter.
PTARG = POINT/-20.0, -30.0, -20.0
P0 = POINT/0, 0, -20.0
P1 = POINT/75.0, 0, -20.0
P2 = POINT/150.0, 70.0, -20.0
P3 = POINT/50.0, 125.0, -20.0
P4 = POINT/0, 125.0, -20.0
L1 = LINE/P0, P1
L2 = LINE/P1, ATANGL, 35
L3 = LINE/P2, PERPTO, L1
L4 = LINE/P2, PARLEL, L1
L5 = LINE/P3, PERPTO, L1
L6 = LINE/P4, P3
L7 = LINE/P0, P4
C1 = CIRCLE/XLARGE, L5, YLARGE, L4, RADIUS, 30.0
PL1 = PLANE/P0, P2, P4
FROM/PTARG
SPINDL/1989, CLW
FEDRAT/398, IPM
GO/TO, L1, TO, PL1, TO, L7
GORGT/L1, PAST, L2
GOFWD/L2, PAST, L3
GOLFT/L3, PAST, L4
GOLFT/L4, TANTO, C1
GOFWD/C1, TO, L5
GOFWD/L5, PAST, L6
GOLFT/L6, PAST, L7
GOLFT, L7, PAST, L1
GOTO/PTARG
SPINDL/OFF
FINI
7.38 Write the APT geometry statements to define the outline of the cam shown in Figure P7.38.
Solution: . Points are defined 15 mm below part upper surface to provide full engagement of cutter. Define the
origin of the axis system at the bottom left (sharp) corner of the part.

40
NC-3e-S 11-14, 14/06, 06/04/07

C2
100 rad. P3
P2 20 rad.
L3
C1

C3 P4 150
L4 C4 L2
20 L5
P0 L1 P1
75
150

P0 = POINT/0, 0, -15.0
P1 = POINT/75.0, 0, -15.0
P2 = POINT/0.0, 150.0, -15.0
P3 = POINT/80.0, 150.0, -15.0
P4 = POINT/-57.2, 37.8, -15.0
P5 = POINT/-10.0, 10.0, -15.0
L1 = LINE/P0, P1
C1 = CIRCLE/CENTER, P2, RADIUS, 100.0
C2 = CIRCLE/CENTER, P3, RADIUS, 20.0
C3 = CIRCLE/CENTER, P4, RADIUS, 17.8
C4 = CIRCLE/CENTER, P5, RADIUS, 10.0
L2 = LINE/P1, RIGHT, TANTO, C1
L3 = LINE/RIGHT, TANTO, C2, RIGHT, TANTO, C3
L4 = LINE/RIGHT, TANTO, C3, LEFT, TANTO, C4
L5 = LINE/P0, RIGHT, TANTO, C4
PL1 = PLANE/P1, P4, P3
7.39 The outline of the cam in Figure P7.38 is to be machined in an end milling operation, using a 12.5 mm
diameter end mill with two teeth. The part is 7.5 mm thick. Write the complete APT program for this job,
using a feed rate = 80 mm/min and a spindle speed = 500 rev/min. Postprocessor call statement is
MACHIN/MILL, 03. Assume the rough outline for the part has been obtained in a band saw operation. Ignore
clamping issues in the problem.
Solution: See drawing in previous solution.
PARTNO PART P6.18 PROFILE MILLING
MACHIN/ MACHIN/MILL, 03
CLPRNT
UNITS/MM
INTOL/0.01
CUTTER/12.5
REMARK Points are defined 15 mm below part upper surface to provide full engagement of cutter.
PTARG = POINT/-20.0, -30.0, -20.0
P0 = POINT/0, 0, -15.0
P1 = POINT/75.0, 0, -15.0
P2 = POINT/0.0, 150.0, -15.0
P3 = POINT/80.0, 150.0, -15.0
P4 = POINT/-57.2, 37.8, -15.0
P5 = POINT/-10.0, 10.0, -15.0
L1 = LINE/P0, P1
C1 = CIRCLE/CENTER, P2, RADIUS, 100.0
C2 = CIRCLE/CENTER, P3, RADIUS, 20.0
C3 = CIRCLE/CENTER, P4, RADIUS, 17.8
C4 = CIRCLE/CENTER, P5, RADIUS, 10.0

41
NC-3e-S 11-14, 14/06, 06/04/07

L2 = LINE/P1, RIGHT, TANTO, C1

L3 = LINE/RIGHT, TANTO, C2, RIGHT, TANTO, C3
L4 = LINE/RIGHT, TANTO, C3, LEFT, TANTO, C4
L5 = LINE/P0, RIGHT, TANTO, C4
PL1 = PLANE/P1, P4, P3
FROM/PTARG
SPINDL/500, CLW
FEDRAT/80, IPM
GO/TO, L1, TO, PL1, TO, L5
GORGT/L1, PAST, L2
GOLFT/L2, TANTO, C1
GOFWD/C1, TANTO, C2
GOFWD/L3, TANTO, C3
GOFWD/C3, PAST, L4
GOFWD/L4, TANTO, C4
GOFWD/C4, TO, L5
GOFWD, L5, PAST, L1
GOTO/PTARG
SPINDL/OFF
FINI
7.40 The part outline in Figure P7.40 is to be profile milled in several passes from a rectangular slab (outline of slab
shown in dashed lines), using a 25 mm diameter end mill with four teeth. The initial passes are to remove no
more than 5 mm of material from the periphery of the part, and the final pass should remove no more than 2
mm to cut the outline to final shape. Write the APT geometry and motion statements for this job. The final
part thickness is to be the same as the starting slab thickness, which is 10 mm, so no machining is required on
the top and bottom of the part.
Solution: Only the geometry and motion statements are required. Part geometry will be defined with P0 as
origin at point of teardrop shaped part, circle C1 at right end of part, and two lines L1 and L2 leading to each
side of the circle, respectively. L2 will be on the upper side of the part. The starting passes will use lines
parallel to L2 that are spaced at 5 mm intervals above L2 and larger circles than C1 with radii at 5 mm
intervals. These additional lines and circles will be designated with an X to indicate that they are not elements
of the actual part surface. Considerations related to part fixturing are ignored.
APT geometry statements:
UNITS/MM
REMARK Points are defined 20 mm below part upper surface to provide full engagement of cutter.
PTARG = POINT/-20.0, -30.0, -20.0
REMARK Following geometry elements define the part outline.
P0 = POINT/0, 0, -20.0
P1 = POINT/100.0, 25.0, -20.0
C1 = CIRCLE/CENTER, P1, RADIUS, 25.0
L1 = LINE/P0, RIGHT, TANTO, C1
L2 = LINE/P0, LEFT, TANTO, C1
REMARK Following geometry elements are used to define tool path immediately prior to final pass.
P1X = POINT/0, -2.0, -20.0
L1X = LINE/P1X, PARLEL, L1
C1X = CIRCLE/CENTER, P1, RADIUS, 27
P2X = POINT/0, 2.0, -20.0
L2X = LINE/P2X, PARLEL, L2
REMARK Following elements are used to define preliminary passes in upper left of slab and around circle.
P3X = POINT/0, 7.0, -20.0
P4X = POINT/0, 12.0, -20.0
P5X = POINT/0, 17.0, -20.0
P6X = POINT/0, 22.0, -20.0
P7X = POINT/0, 27.0, -20.0
P8X = POINT/0, 32.0, -20.0
P9X = POINT/0, 37.0, -20.0
P10X = POINT/0, 42.0, -20.0
P11X = POINT/0, 47.0, -20.0

42
NC-3e-S 11-14, 14/06, 06/04/07

P12X = POINT/0, 52.0, -20.0

P13X = POINT/0, 55.0, -20.0
L3X = LINE/P0, PERPTO, L1
L4X = LINE/P2X, PARLEL, L2
L5X = LINE/P3X, PARLEL, L2
L6X = LINE/P4X, PARLEL, L2
L7X = LINE/P5X, PARLEL, L2
L8X = LINE/P6X, PARLEL, L2
L9X = LINE/P7X, PARLEL, L2
L10X = LINE/P8X, PARLEL, L2
L11X = LINE/P9X, PARLEL, L2
L12X = LINE/P10X, PARLEL, L2
L13X = LINE/P11X, PARLEL, L2
L14X = LINE/P12X, PARLEL, L2
L15X = LINE/P13X, LEFT, TANTO, C1X
C2X = CIRCLE/CENTER, P1, RADIUS, 32
C3X = CIRCLE/CENTER, P1, RADIUS, 37
C4X = CIRCLE/CENTER, P1, RADIUS, 40
PL1 = PLANE/P0, P1, P13X
APT motion statements:
FROM/PTARG
REMARK Preliminary pass around part.
GO/TO, L1X, TO, PL1, TO, L3X
GORGT/L1X, TANTO, C4X
GOFWD/C4X, PAST, L15X
GOFWD/L15X, PAST, L3X
REMARK Back and forth passes parallel to L2 to remove upper left portion of slab.
GOLFT/L3X, TO, L14X
GOLFT/L14X, PAST, L15X
GOFWD/L15X, TO, L13X
GOBACK/L13X, PAST L3X
GOLFT/L3X, TO, L12X
GOLFT/L12X, PAST, L15X
GOFWD/L15X, TO, L11X
GOBACK/L11X, PAST L3X
GOLFT/L3X, TO, L10X
GOLFT/L10X, PAST, L15X
GOFWD/L15X, TO, L9X
GOBACK/L9X, PAST L3X
GOLFT/L3X, TO, L8X
GOLFT/L8X, PAST, L15X
GOFWD/L15X, TO, L7X
GOBACK/L7X, PAST L3X
GOLFT/L3X, TO, L6X
GOLFT/L6X, PAST, L15X
GOFWD/L15X, TO, L5X
GOBACK/L5X, PAST L3X
GOLFT/L3X, TO, L4X
GOLFT/L4X, PAST, L15X
GOFWD/L15X, TANTO, C3X
REMARK Roughing passes around concentric circles.
GOFWD/C3X, PAST, L1X
GORGT/L1X, TANTO, C2X
GORGT/C2X, PAST, L15X
GOLFT/L15X, TANTO, C1X
GOBACK/C1X, PAST, L1X
REMARK Move to PTARG to execute final pass around part periphery.
GOTO/PTARG
GO/TO, L1, TO, PL1, TO L3X

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NC-3e-S 11-14, 14/06, 06/04/07

GORGT/L1, TANTO, C1
GOFWD/C1, PAST, L2
GOFWD/L2, PAST, L3X
GOTO/PTARG
7.41 The top surface of a large cast iron plate is to be face-milled. The area to be machined is 400 mm wide and
700 mm long. The insert-type face-milling cutter has eight teeth and is 100 mm in diameter. Define the origin
of the axis system at the lower left corner of the part with the long side parallel to the x-axis. Write the APT
geometry and motion statements for this job.
Solution: Only the geometry and motion statements are required. Since the origin is defined at the lower left
corner of the rectangular slab, at x = 0 and y = 0, we define the surface to be cut as the plane at z = 0 parallel
to the x-y plane. The target point will be established at x = -60, y = -60, and z = 0. Units are mm. Cuts will be
taken parallel to the x-axis at 85 mm intervals. With a 100 mm diameter cutter, this will provide an overlap of
15 mm for successive passes back and forth across the part surface.
APT geometry statements:
UNITS/MM
PTARG = POINT/-60.0, -60.0, 0
P0 = POINT/0, 0, 0
P00 = POINT/760.0, -60.0, 0
P1L = POINT/0, 85.0, 0
P2L = POINT/0, 170.0, 0
P3L = POINT/0, 255.0, 0
P4L = POINT/0, 340.0, 0
P5L = POINT/0, 425.0, 0
P1R = POINT/700.0, 85.0, 0
P2R = POINT/700.0, 170.0, 0
P3R = POINT/700.0, 255.0, 0
P4R = POINT/700.0, 340.0, 0
P5R = POINT/700.0, 425.0, 0
PL1 = PLANE/P0, P5L, P5R
LL = LINE/P1L, P5L
LR = LINE/P1R, P5R
L1 = LINE/P1L, P1R
L2 = LINE/P2L, P2R
L3 = LINE/P3L, P3R
L4 = LINE/P4L, P4R
L5 = LINE/P5L, P5R
APT motion statements:
FROM/PTARG
GO/TO, L1, TO PL1, TO, LL
GORGT/L1, PAST, LR
GOLFT/LR, TO, L2
GOLFT/L2, PAST, LL
GORGT/LL, TO, L3
GORGT/L3, PAST, LR
GOLFT/LR, TO, L4
GOLFT/L4, PAST, LL
GORGT/LL, TO, L5
GORGT/L5, PAST, LR
REMARK Move tool to PTARG without moving across newly cut surface.
RAPID
GOTO/P00
GOTO/PTARG
7.42 Write the APT geometry statements to define the part geometry shown in Figure P7.42.
Solution: Define origin of axis system (0, 0, 0) as indicated in Figure P7.42. See drawing below.
UNITS/MM

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NC-3e-S 11-14, 14/06, 06/04/07

P00 = POINT/0, 0, 0
P010 = POINT/0, 0, -10.0
P015 = POINT/0, 0, -15.0
P1 = POINT/37.5, -25.0, 0
P2 = POINT/-50.0, -25.0, 0
PL0 = PLANE/P00, P1, P2
PL010 = PLANE/P010, PARLEL, PL0
PL015 = PLANE/P015, PARLEL, PL0
C1 = CIRCLE/P015, RADIUS, 12.5
C2 = CIRCLE/P015, RADIUS, 50.0
C3 = CIRCLE/P015, RADIUS, 37.5
P3 = POINT/-25.0, 0, 0
C4 = CIRCLE/P3, RADIUS, 37.5
C5 = CIRCLE/P3, RADIUS, 25.0
C6 = CIRCLE/P2, RADIUS, 12.5
C7 = CIRCLE/P1, RADIUS, 12.5
P4 = POINT/-25.0, -25.0, 0
C8 = CIRCLE/P4, RADIUS, 12.5
P5 = POINT/12.5, -25.0, 0
C9 = CIRCLE/P5, RADIUS, 12.5
P6 = POINT/-25.0, -12.5, 0
P7 = POINT/12.5, -12.5, 0
L1 = LINE/ P6, P7
L2 = LINE/P2, LEFT, TANTO, C5
L3 = LINE/P1, RIGHT, TANTO, C3
C10 = CIRCLE/XSMALL, L3, TANTO, C7, RADIUS, 12.5
C11 = CIRCLE/XLARGE, L2, TANTO, C6, RADIUS, 12.5
L4 = LINE/LEFT, TANTO, C4, LEFT, TANTO, C2
L5 = LINE/LEFT, TANTO, C5, LEFT TANTO, C3
L6 = LINE/LEFT, TANTO C6, LEFT, TANTO, C4
L7 = LINE/RIGHT, TANTO, C7, RIGHT, TANTO, C2

y y PL010
PL015
12.5 dia., 3 holes
PL025
50.0 rad.

L4 C2
L5 C3
C4 37.5 rad.
37.5 rad. P010
25.0 rad.
C1 12.5 rad. P00 P015
C5
P3
L2 P00 L3 x z -z
L6 P6 L1 P7
25 C11 C8 C9 C10 L7
25 12.5

P4 P1
P2 P5
12.5 rad. 12.5 rad.
C6
C7
37.5 5
10
87.5 15

Note: P010 & P015 located at P00

7.43 The part in Figure P7.42 is to be milled, using a 20 mm diameter end mill with four teeth. Write the APT
geometry and motion statements for this job. Assume that preliminary passes have been completed so that only
the final pass (“to size”) is to be completed in this program. Cutting speed = 500 rev./min, and feed rate = 250
mm/min. The starting slab thickness is 15 mm, so no machining is required on the top or bottom surfaces of
the part. The three holes have been predrilled for fixturing in this milling sequence.
Solution: The APT geometry statements are the same as in previous Problem 7.42. We add a starting target

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NC-3e-S 11-14, 14/06, 06/04/07

point PTARG for locating the cutting tool at the beginning of machining. We assume the cutting tool is a flat-
end mill (no corner radius), and that the workpart is fixtured so that its bottom surface is 20 mm above the
machine tool table. That means that the x-y plane of the axis system is 35 mm above the table surface. To
accomplish the profile milling operation around the outside periphery of the part, we define a plane PL020
below the actual bottom surface of the part. See drawing in previous solution.
APT geometry statements:
REMARK See previous Problem 6.22 for most geometry statements.
REMARK The following geometry statements are added to facilitate tool path motions.
PTARG = POINT/0, -50.0, 0
P020 = POINT/0, 0, -20.0
PL020 = PLANE/P020, PARLEL, PL0
LX0 = LINE/P00, PERPTO, L1
APT motion statements:
REMARK The profile milling operation around the outside periphery will be accomplished first.
FROM/PTARG
GO/TO, L1, TO, PL020, ON, LX0
GORGT/L1, PAST, C9
GOFWD/C9, TANTO, C7
GOFWD/C7, PAST L7
GOFWD, L7, TANTO, C2
GOFWD/C2, PAST, L4
GOFWD/L4, TANTO, C4
GOFWD/C4, PAST, L6
GOFWD/L6, TANTO, C6
GOFWD/C6, PAST, C8
GOFWD/C8, TO, L1
GOFWD/L1, PAST, LX0
GOTO/PTARG
REMARK The following statements accomplish the pocketing of the inside surfaces.
GO/TO, L1, TO, PL010, ON, LX0
GORGT/C1, PAST, L1
GOFWD/C1, PAST LX0
GOFWD/C1, PAST, L1
GOFWD/L1, PAST, C9
GOFWD/C9, TANTO, C7
GOBACK/C7, PAST, C10
GOFWD/C10, TO, L3
GOFWD/L3, PAST, C3
GOFWD/C3, TO, L5
GOFWD/L5, PAST, C5
GOFWD/C5, TO, L2
GOFWD/L2, PAST, C11
GOFWD/C11, TANTO, C6
GOFWD/C6, ON, C8
GOLFT/C8, ON, L1
GOFWD/L1, TANTO, C1
GOTO/PTARG

46