The Complete CNC Solution Providers.: Online Support Even After Completion The Training Program. Sundays Also

104/815-A First floor, MTH Road,Padi, Chennai - 600 050.
Phone: 044-45011057 , 9840999411

E-mail: info@millwright.in Web: www.millwright.in SMS: MILLWRIGHT 56070

Introduction

The Complete CNC Solution Providers.
Millwright is a budding CAD/ CAM/ CNC consulting company; kick started its operation in
Chennai in the recent past. We have a focused vision in providing Manufacturing solutions,
CAD/ CAM Training and Manpower sourcing for manufacturing industries.
The trainers in Millwright were professional with vast experience in CNC Machining. The
trainings given by Millwright are with real and complicated industrial samples which are
developed by us. We are conducting live class on CNC Machines to improve the practical
knowledge of the peoples. And also we providing job assistance for those undergo training
from us. Online support even after completion the training program. Training classes available on
Sundays also.

104/815-A First floor, MTH Road,Padi, Chennai - 600 050. Phone: 044-45011057 , 9840999411

G-CODES FOR MILLING

G codes
G-Code, or preparatory code or function, are functions in the Numerical control programming
language. The G-codes are the codes that position the tool and do the actual work. G-codes are only
a part of the NC-programming language that controls NC and CNC machine tools.

G56 Work piece coordinate system 3 selection
G60 Single Direction Position
G62 Automatic corner override
G63 Tapping mode
G64 Cutting mode
G65 Macro call
G66 Macro modal call
G67 Macro modal call cancel
G68 Work coordinate rotation
G69 Work coordinate rotation cancel
G73 High seep peck drilling
G74 Counter tapping Cycle
G80 Canned cycle cancel
G81 Spot drilling cycle
G82 Counter Drilling Cycle
G83 Peck Drilling cycle
G84 Tapping Cycle
G85 Boring Cycle
G86 Boring Cycle
G87 Back Boring Cycle
G88 Boring Cycle
G89 Boring Cycle
G90 Absolute Command
G91 Incremental Command
G92 Setting for work piece co-ordinate System
Or Maximum spindle speed
G94 Feed per Minute
G95 Feed per Rotation
G96 Constant Surface speed control
G97 Constant Surface speed control Cancel
G98 Return to initial point in canned cycle
G99 Return to R point in canned Cycle
G00 Rapid transverse
G01 Linear Interpolation
G02 Circular Interpolation cw
G03 Circular Interpolation ccw
G04 Dwell
G10 Programmable data input
G11 Programmable data input mode cancel
G15 Polar co-ordinate cancel
G16 Polar co-ordinate call
G17 Xp Yp Plane Selection
G18 Zp Xp Plane Selection
G19 Yp Zp Plane Selection
G20 Input in inch
G21 Input in mm
G28 Return to reference Position
G29 Return from reference Position
G30 2
nd
3
rd
4
th
Reference position return
G31 Skip function
G33 Thread cutting
G40 Cutter compensation cancel
G41 Cutter compensation Left
G42 Cutter compensation Right
G43 Tool length compensation +direction
G44 Tool length compensation - direction
G49 Tool length compensation cancel
G50 Scaling Cancel
G51 Scaling Call
G50.5 Programmable mirror image cancel
G51.1 Programmable mirror image
G52 Local coordinate system setting
G53 Machine coordinate system selection
G54 Work piece coordinate system 1selection
G54.1 Additional work piece coordinate system
selection


M-CODES FOR MILLING
M00 Unconditional Stop
M01 Conditional Stop
M02 Program Stop
M03 Spindle Rotation CW
M04 Spindle Rotation CCW
M05 Spindle Stop
M06 Tool Change
M07 Coolant On
M08 Coolant On

M codes
A word used to signal an action from a miscellaneous group of commands. M codes manage
the machine functions. M codes change cutting tools, turn on or turn off the coolant,
spindle, or workpiece clamps, etc.

Drill Point Depth &
Countersink Diameter Formulas
Example: To calculate for a 118-degree drill tip depth, multiply the Dia by 0.3
i.e., 0.25 drill diameter x 0.3 =0.075 drill tip depth.
If the drill angle changes the value also change accordingly as like the following table.

Drill Angle Factor to Multiply
60 Degree 0.866 x Dia of the drill =Depth point

M09 Coolant Off
M19 Spindle Orientation
M21 X Axis Mirror
M22 Y Axis Mirror
M23 Mirror Off
M30 Program End
M98 Sub Program Call
M99 Sub Program End


Symbols Used in Machining Drawings
SYMBOL VERBAL DESCRIPTION

Position

Concentricity

Circular Runout

Total Runout

Perpendicularity

Parallelism

Angularity

Profile of a Surface

Profile of a Line

Flatness


Straightness

Roundness or Circularity

Cylindricity

Surce finish

Surface Finish Symbols Used in Drawings
Roughness
Values
Roughness Symbols Roughness Grade Numbers
50

N12
25

N11
12.5

N10
6.3

N9
3.2

N8
1.6

N7
0.8

N6
0.4

N5
0.2

N4
0.1

N3
0.05

N2
0.025

N1




End Mill Troubleshooting Guide
Chip packing
Rough surface finish
Burr
No dimensional accuracy
No perpendicular side
Chipping
Wear
Breakage
Chattering
Short tool life (dull teeth)
PROBLEM CAUSE SOLUTION
Chip packing

Too great a cutting amount Adjust feed or speed
Not enough chip room Use end mill fewer flutes
Not enough coolant Apply more coolant. Use air pressure

Rough surface finish

Feed too fast Slow down to correct feed
Slow speed Use higher speed
Too much wear Regrind earlier stage
Chip biting Cut less amount per pass
No end tooth concavity Add margin (touch primary with oilstone)

Burr
Too much wear on primary relief Regrind sooner
Incorrect condition Correct milling condition
Improper cutting angle Change to correct cutting angle

No dimensional accuracy

Too tough condition Change to easier condition
Lack of accuracy (machine &
holder)
Repair machine or holder
Not enough rigidity (machine &
holder)
Change machine or holder or condition
Not sufficient number of flutes Use end mill with greater number of flutes

No perpendicular side

Feed too fast Slow down to correct feed
Too great a cutting amount Reduce cutting amount
Too long a flute length or long
overall length
Use proper length tool. Hold shank deeper
Not sufficient number of flutes Use end mill with greater number of flutes

Chipping
Feed too fast Slow down to proper feed
Feed too fast on first cut Slow down on first bite


Not enough rigidity of machine
tool & holder
Change rigid machine tool or holder
Loose holder Tighten tool holder
Loose holder (workpiece) Tighten workpiece fixture
Lack of rigidity (tool)
Use shortest end mill available. Hold shank
deeper. Try down cut
Teeth too sharp Change to lower cutting angle, primary relief

Wear

Speed too fast Slow down, use more coolant
Hard material
Use higher grade, tool material, add surface
treatment
Biting chips
Change feed speed to change chip size or
clear chips with coolant or air pressure
Improper feed speed (too slow) Increase feed speed. Try down cut
Improper cutting angle Change to correct cutting angle
Too low a primary relief angle Change to larger relief angle

Breakage

Feed too fast Slow down feed
Too large cutting amount Adjust to smaller cutting amount per teeth
Too long flute length or long
overall length
Hold shank deeper, use shorter end mill
Too much wear Regrind at earlier stage

Chattering

Feed and speed too fast Correct feed and speed
Not enough rigidity (machine &
holder)
Use better machine tool or holder or change
condition
Too much relief angle
Change to smaller relief angle. Add margin
(touch primary with oil stone)
Loose holder (workpiece) Hold workpiece tighter
Cutting too deep Correct to smaller cutting depth
Too long flute length or long
overall length
Hold shank deeper, use shorter end mill or
try down cut

Short tool life
(dull teeth)
Too much cutting friction Regrind at earlier stage
Tough work material Select premium tool
Improper cutting angle Change cutting angle & primary


Indexable Drilling Troubleshooting Guide
PROBLEM CAUSES SOLUTIONS
CHIPPING OR BREAKAGE
Poor chip evacuation due to
insufficient coolant pressure and/ or
volume
Increase coolant flow
Deflection Reduce overhang
Misalignment
Check concentricity not to exceed +/ -
.005 tir
Speed too slow, feed too light Increase speed and/ or feed
Wrong chipbreaker geometry Use stronger chipbreaker (3P)
CORNER OF INSIDE INSERT
CHIPS AT CENTER
High cutting force at center of drill
Use tougher grade or uncoated grade
in inside position
LOUD, ROUGH CUTTING
Excessive thrust force Reduce feed, increase speed
Re-cutting chip Increase coolant flow
LONG UNBROKEN CHIP
Insufficient coolant pressure and
volume
Increase coolant flow
Feed rate too light Increase feed
Wrong chipbreaker geometry Use more positive geometry: (1P)
CHATTER
Vibration Check setup and part rigidity
Poor chip control Increase coolant flow
Drill not properly seated in holder Check set-up
HOLE SIZE TOO LARGE Drill misaligned Correct misalignment
FRACTURING OF DRILL
Improper seating of inserts Check insert seating
Unstable spindle Use rigid machine
Insufficient horsepower Reduce feed or change machines
Excessive thrust force Reduce feed
SHORT TOOL LIFE
Excessive insert wear Lower cutting speed or change grade
Lack of rigidity Check set-up and spindle
Improper coolant Check type of coolant and mixture

Twist Drill Troubleshooting Guide
Hole Problems:
Hole expansion
Irregular hole size
Low position accuracy
Hole perpendicularity
Bad cylindrical accuracy
Poor surface finish
Bad cylindrical shape
Drill Problems:
Drill breakage
Chipping of corner edge
Chipping of cutting edge
Abnormal wear on corner part
Large wear and chipping,
crushing of the chisel edge
Chipping of margin
Margin build-up


Tang breakage
Noise of chattering
Chip rolled around drill
One-side wear
Hole Problems
Problem Causes Solutions
Hole expansion Run out of drill when attached to the
machine
Loose hold
Check holder and/ or select another one
Check run out after fixing to the chuck
Non-symmetric point angle
Different lip height
Run out of chisel edge
Regrind correctly
Check preciseness after reground
Irregular hole size Non-symmetric point angle
Large lip height
Margin wear is large
Regrind correctly
Check precision after regrind
Large run out after attached to the
machine
Loose hold
Low work holding rigidity
Check holder and select another one
Feed rate to high Decrease feed rate
Not enough lubrication Use drill with an oil hole
Low position
accuracy

Large run out when attached to the
machine
Large spindle run out
Run out when cutting material
Select more rigid tool and machine
Increase work clamping rigidity
Select a low cutting resistance thinning
Use centering
Work piece should be horizontal
Use a drill bush


Low alignment accuracy (for lathing) Check alignment
Hole
perpendicularity

Excessive tool wear Regrind
Low position accuracy Increase position accuracy
Large lip height
Regrind correctly
Check precision after regrinding
Not enough drill rigidity Increase drill rigidity
Drilling surface is not horizontal
Poor alignment (for lathing)
Work piece must be horizontal
Make a center hole. Check alignment
Bad cylindrical
accuracy

Large lip height
Regrind correctly
Large run out after attached to machine
Loose hold
Low work holding rigidity
Check hole and/ or select another one
Relief angle is too large Regrind correctly
Low drill rigidity Use carbide drill or larger web drills
Poor surface finish Poor regrinding Take off all the wear
Not suitable coolant for the material
Not enough coolant
Change supply method; increase volume
Select higher coolant quality
Loose hold
Feed rate is too high Reduce feed rate
Excessive tool wear
Build up on margin is too large
Regrind correctly
Select a coated tool
Chip packing
Select suitable drill (wide flute, high
helix oil hole drill). Change cutting


conditions (feed rate or adopt step
drilling)
Bad cylindrical
shape

Large lip height
Large margin wear
Regrind correctly
Feed rate is too low Increase the feed rate
Drill Problems
Drill breakage

In accurate machine
Work material deformation
Increase the rigidity of machine, drill
and work clamping
Relief angle is too small Regrind correctly
Feed rate is too high Decrease the feed rate
Excessive tool wear Regrind
Chip packing
Select suitable drill (wide flute, high
helix oil hole drill). Change cutting
conditions (feed rate or adopt step
drilling).
Difficulty entering the material
Select high rigid tool & rigid machine
Increase work clamping rigidity
Select a low cutting resistance thinning
Use centering
Work piece should be horizontal
Use bush drill
Chipping of corner
edge
In appropriate tool material Choose suitable tool material
Uneven hardness distribution on the
work material
Iso static treatment
Change tool, material & cutting
conditions, machining method (EDM)
Cutting or feed speed is too high Reduce cutting speed or feed


Not enough coolant Change lubrication method
Chipping of cutting
edge

Loose hold
Relief angle is too small Regrind correctly
Tool material is not suitable Choose suitable tool material
Cutting speed or feed is too high Reduce cutting speed or feed
Abnormal wear on
corner part

Tool late regrinding Regrind after a shorter time of use
Bad alignment (for lathe turning) Check/ adjust the alignment
Cutting speed too high Decrease the cutting speed
Point dimensions are not suitable Select correct point dimensions
Tool materials not suitable Choose suitable tool material
Coolant is not suitable Change coolant
Large wear and
chipping, crushing
of the chisel edge
Feed rate is too large Decrease feed rate
Point dimensions are not suitable Select correct point dimensions
Tool materials is not suitable Choose suitable tool material
Relief angle is too small Increase relief angle
Chipping of margin Bush diameter is too small
Chip packing between drill & bush
Select correct bush diameter or select
drill with chip breakers


Margin built-up High heat generation due to large wear
on the cutting edge
Regrind
Lubrication is insufficient Change lubrication method
Coolant is not suitable Change coolant
Bad chip ejection
Ductile material
Change drill or the cutting conditions
Tang breakage

Shank slippage due to some kind of
defect
Take off the defect by honing the surface
Defect of the inner surface of Morse
taper holder
Change holder or correct the surface of
Morse taper holder
Low accuracy of regrinding Regrind correctly
Noise of chattering Relief angle is too big Grind a smaller relief angle
Low rigidity of the tool Use drill with high rigidity
Chip rolled around
the drill
Low extended and curly chips
Chips are stubbed in the flute
Change drill and cutting conditions
One side wear
Bad alignment (for lathe turning) Check/ adjust the alignment


Drill Tap Size Chart
METRIC COARSE SIZES METRIC FINE SIZES
TAP SIZES DRILL SIZES TAP SIES DRILL SIES
1mmx.25 0.75 4mmx.35 3.6mm
1.1x.25 0.85 4x.5 3.5
1.2x.25 0.95 5x.5 4.5
1.4x.3 1.1 6x.5 5.5
1.6x.35 1.25 6x.75 5.25
1.7x.35 1.3 7x.75 6.25
1.8x.35 1.45 8x.5 7.5
2x.4 1.6 8x.75 7.25
2.2x.45 1.75 8x1 7
2.5x.45 2.05 9x1 8
3x.5 2.5 10x.75 9.25
3.5x.6 2.9 10x1 9
4x.7 3.3 11x1 10
4.5x.75 3.7 12x.75 11.25
5x.8 4.2 12x1 11
6x1 5 14x1 13
7x1 6 14x1.25 12.8
8x1.25 6.8 14x1.5 12.5
9x1.25 7.8 16x1 15
10x1.5 8.5 16x1.5 15.5
11x1.5 9.5 18x1 17
12x1.75 10.2 18x2 16
14x2 12 20x1 19
16x2 14 20x1.5 18.5
18x2.5 15.5 22x1 21
20x2.5 17.5 22x1.5 18.5
22x2.5 19.5 22x2 20
24x3 21 24x1.5 22.5
27x3 24 24x2 22
30x3.5 26.5 26x1.5 24.5
33x3.5 29.5 27x1.5 25.5
36x4 32 27x2 25
39x4 35 28x1.5 26.5
30x1.5 28.5
30x2 28
33x2 31
36x3 33
39x3 36


Angle Of projection

The above image will clearly explain you the difference between first and third angle of projection
in Engineering Drawing.

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104/815-A First floor, MTH Road,Padi, Chennai - 600 050.

Phone: 044-45011057 , 9840999411

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