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SYLLABUS

For the trade of

CNC PROGRAMMER CUM OPERATOR

Under

Apprenticeship Training Scheme

Government of India
Ministry of Labour & Employment
Directorate General of Employment & Training
New Delhi-110001
GENERAL INFORMATION

Name of the Trade : CNC Programmer cum Operator

N.C.O. Code No. : 3121.20

Entry Qualification : Passed 10th class examination under


10+2 system of education or its
equivalent.

Duration of the Apprenticeship Training : 02 years

Rebate allowed in Apprenticeship Training : One year and six months for trainees
completed Broad Based Basic Training in
Production and Manufacturing Sector
under Centre of Excellence Scheme and
Advanced module of Centre of
Excellence Scheme in CNC Machining.

Ratio of apprentices to workers other than : 1:3


unskilled workers

Terminal Behavior : On completion of training, the trainee is


able to program & operate CNC machine.

Course Outline :

The training shall comprise of-

a) On the job training


The actual training shall be depended on the facilities available in the
establishments with an idea to expose the trainees to as many activities as
possible. The trainee shall maintain a daily work for a job training, which shall be
periodically authenticated by the supervisor..

b) Project
Each apprentice shall under take a project in any of the areas depending on
his/her interest and facilities available in the establishment. The duration of the
project shall be two Weeks.
Syllabus for the trade of CNC Programmer cum Operator
under
Apprenticeship Training Scheme

List of the members present in trade committee meeting held on 13th January 2007 at
ITI, Aundh, Pune, Maharashtra

S.No. Name and Designation Organisation


1. Shri Rajendra Gaikwad, Specialist Engineer, R & Force Motors Ltd., Pune
D-HCV
2. Shri B.U.Bhandari, Works manager TATA Motors, Pune
3. Col. U.G.Umrani, G.M. Maruti Suzuki
Syllabus for trade of ‘CNC Programmer cum Operator’ under
Apprenticeship Training Scheme

SR.NO. SHOPFLOOR TRAINING

1 Any CNC Control – Turning


(Sinumeric – 802D-T or latest)
Study of CNC machine, keyboard & specifications, Machine starting &
operating in reference point, jog & incremental modes, coordinate system
points, assignments absolute & incremental co-ordinate.

Identification of machines over travel limits & emergency stop, machine


parts, mode practice (Jog, MDI, Edit, R.P. Auto, Single Block, MPG)
Work & Tool setting CNC m/c part program preparation
2 Linear interpolation, assignments & simulations on software on old
program. Circular interpolation, assignment & simulation on old program.
Work offset & tool offset measurement & entry in CNC control.
Part program preparation by absolute & incremental programming.
CNC m/c turning with radius/Chamfer with TNRC editing practice &
simulation.
3 Chuck removing & its assembly.
Cutting tool setting
Work setting
Program editing & simulation
4 Cycle 95-Stock removal cycle OD/ID
Drilling/boring cycles in CNC turning
5 Grooving/Threading on OD/ID in CNC turning
Offset correction practice
Size control on CNC machine
Sub program with repetition
Threading cycle OD
Sub program with repetition, sub-program with macro
Call eccentric turning etc.
6 CNC turning exercise: Mutlistart threading
Programming with variables
Project work :CAD/CAM programming & DNC operations final test &
evaluations.

7 FANUC CNC Control – Turning


Study of CNC machine, keyboard & specifications, Machine starting &
operating in reference point, jog & incremental modes, coordinate system
points, assignments absolute & incremental co-ordinate.

Identification of machines over travel limits & emergency stop, machine


parts, mode practice (Jog, MDI, Edit, R.P. Auto, Single Block, MPG)
Work & Tool setting CNC m/c part program preparation
8. Linear interpolation, assignments & simulations on software on old
program. Circular interpolation, assignment & simulation on old program.
Work offset & tool offset measurement & entry in CNC control.
Part program preparation by absolute & incremental programming.
CNC m/c turning with radius/Chamfer with TNRC editing practice &
simulation.
9. Linear & Circular interpolation simulation & assignment
Chuck removal & mounting on CNC Lathe
Tool changes in CNC turning & MPG Mode operation. Linear interpolation
& circular interpolation.
Manual Data Input(MDI) mode operations & zero offsets & tool offsets,
measurement on tool presenter Automatic Mode Execution.
Blue print programming contours with TNRC etc.
10. Part program preparation, simulation & auto mode execution of CNC m/c
exercises-stock removal cycle OD drilling/boring cycles stock removal
cycle ID etc.
Review, assignment/practice/test
11 Geometry & wear offset correction
Part program preparation, simulation & auto mode execution of CNC m/c
exercises-stock removal cycle OD drilling/boring cycles stock removal
cycle ID etc.
Review, assignment/practice/test
12. Threading cycle OD
Sub program with repetition, sub-program with macro Call eccentric turning
etc. CNC turning exercises: Multistart threading, programming with
variables.
Project work: CAD/CAM programming & DNC operations final test &
evaluations
13. FANUC CNC Control –Milling
Study of CNC machine, keyboard & specifications, Machine starting &
operating in reference point, jog & incremental modes, coordinate system
points, assignments absolute & incremental co-ordinate.

Identification of machines over travel limits & emergency stop, machine


parts, mode practice (Jog, MDI, Edit, R.P. Auto, Single Block, MPG)
Work & Tool setting CNC m/c part program preparation
14. Linear interpolation, assignments & simulations on software on old
program. Circular interpolation, assignment & simulation on software on old
program.
Work offset & tool offset measurement & entry in CNC control.
Part program preparation by absolute & incremental programming.
CNC m/c practical milling examples, chamfering & end milling with CRC
etc. Editing practice & simulation. Review, assignment, practice,test.
15. Linear & Circular interpolation simulation & assignment milling
Tool changes in CNC milling with ATC & Tool Magazine & MPG mode
operation. Manual Data Input (MDI) mode operations & zero offsets & tool
offsets, measurement on tool presenter Automatic Mode Execution.
CNC machine exercise end milling with polar co-ordinates. Drilling-G81 etc.
16. Geometry & wear offset correction
Part program preparation, simulation on CNC milling & auto mode
execution of CNC m/c exercises. Chamfer & counter-sink drilling.
Deep hole drilling G83
Threading & tapping G84
Boring cycles G85-G89
Review, assignment/practice/test
17. Preparation of part programme for thread cutting, thread milling for CNC
milling center simulation on CNC mill computers. Auto mode execution of
CNC machine exercises sub program/repetition & macro call. Circular &
rectangular pockets. Drilling, Milling patterns thread milling etc.
18. CNC Machining of Custom Macro Program G65
Project Work: CAD/CAM programming & DNC operations
Final test & evaluations
19. SIEMENS CNC Control – Milling
(Sinumeric 802D-M or latest)
Study of CNC machine, keyboard & specifications, Machine starting &
operating in reference point, jog & incremental modes, coordinate system
points, assignments absolute & incremental co-ordinate.

Identification of machines over travel limits & emergency stop, machine


parts, mode practice (Jog, MDI, Edit, R.P. Auto, Single Block, MPG)
Work & Tool setting CNC m/c part program preparation
20. Linear interpolation & circular interpolation, assignments & simulations on
software on old program Milling.
Work offset & tool offset measurement & entry in CNC control.
Part program preparation by absolute & incremental programming.
CNC m/c practical milling examples chamfering & end milling with CRC
etc. Editing practice & simulation. Review, assignment/practice test.
21 Linear & Circular interpolation simulation & assignment milling
Tool changes in CNC milling with ATC & Tool Magazine & MPG mode
operation.
Manual Data Input(MDI) mode operations & zero offsets & tool offsets,
measurement on tool presenter Automatic Mode Execution.
CNC machine exercise end milling with polar co-ordinates. Drilling-Cycle
81 etc. Chamfer & counter-sink drilling.
Deep hole drilling Cycle 83
Threading & tapping Cycle 84
Boring cycles 85-89

22 Geometry & wear offset correction


Part program preparation, simulation on CNC milling & auto mode
execution of CNC m/c exercises.
Boring cycles G85-G89
Review, assignment/practice/test
23. Preparation of part programme for thread cutting, thread milling for CNC
milling center. Simulation on CNC mill computers. Auto mode execution of
CNC machine exercises sub program/repetition & macro call. Circular &
rectangular pockets. Drilling, Milling patterns thread milling etc.
24. Row of holes (Drilling pattern cycle)
HOLES 1
Circle of poles (Drilling pattern cycle)
HOLES 2

25 Slot on circle practice


Circumferential slot practice
26 PROJECT WORK: CAD/CAM programming & DNC operations.
Final test & evaluations
Related Instructions

1) Safety Precautions:-
Safe handling of tools, equipment & CNC Machines & Personal safety tool as per
company product requirement. Machining types of CNC Machines advantages &
Limitation of CNC computer numerical control applications.
Future of CNC technology (Advance Knowledge), up date technology or latest CNC
Systems :- CNC interpolation, open loop & close loop control systems with feed
back devices co-ordinate systems & points mode knowledge.
CNC Machines-Turning –Milling Type Axes nomenclature Review
assignment/practical/test
2) CNC Control Hardware & Operating Software :-
NC Vs CNC systems, the CNC Machine control unit organization.
CNC software organization computers & information processing of the CNC system.
CNC machine working principle.
Zero offset & tool offset in SIEMENS CNC TURNING.
Tool Nose Radius Compensation (TNRC) & Addressed Letter G& M code
knowledge.
3) Cutting tool materials for CNC turning & it’s applications component materials &
cutting oil selection.
ISO codes for Carbide indexible inserts & tool holders for Turning
Tooling systems for CNC Turning centers, need for removal of chuck/
frequency.
Cutting parameters selection & process planning.
Tools layout & process sheet preparation Using sub programs & cycles in the main
programs.
Blue print programming/direct dimension programming Review, assignment/test
4) Planning for CNC operation:- Geometry & wear offset correction knowledge
Job feature identification & process selection process sequencing tool path planning
work-piece zero points.
Stock removal cycle in CNC Turning of OD/ID operation tooling systems for CNC
turning & tooling strategies for turning machines.
Drilling/ Boring Cycle in CNC Turning
5) Grooving/Treading tools, processes & tool selection
Programming for grooving/threading of OD/ID in CNC turning
Trouble shooting in CNC turning tool wear patterns & optimization of cutting
parameters factors affecting turned part quality/productivity Tapping rigid tapping on
CNC turning
TPM knowledge productive trouble shooting CNC preventive maintenance
Sub program with repetition, sub program macro call eccentric turning etc
Patterns & optimization of cutting parameters.
Factors affecting turning part quality productivity.
TPM – Knowledge, Productive trouble
Shooting, CNC preventive maintenance

6) Programming with variable & custom macros.


Program data transfer from PC to CNC machines & DNC operations.
Program preparation with CAD/CAM
7) Safety precautions (FANUC CNC OI –T or Latest)
Safe handling of tool, equipment and CNC Machines & Personal safety tool as per
company product requirement.
Machining types of CNC Machines advantages & Limitation of CNC computer
numerical control applications.
Future of CNC technology (Advance Knowledge) up date technology or latest.
CNC Systems

CNC interpolation, co-ordinate


Systems & points mode knowledge. CNC Machines AXES nomenclature,
Review, assignment/practice/test

8) CNC Control Hardware & operating Software :-


CNC software organization computers information processing of the CNC system.
CNC Machine working principle
Zero offset & tool offset in FANUC CNC TURNING.
Tool Nose Radius Compensation (TNRC) & Addressed Letter G & M code
knowledge.

9) Cutting tool materials for CNC Turning & it’s applications component materials &
cutting oil selection. ISO codes for Carbide indexible inserts & Tools holders for
turning.
Tooling systems for CNC Turning centers need for removal of chuck/ frequency.
Cutting parameters selection & process planning.
Tools layout & process sheet preparation Using sub programs & cycles in the main
programs.

Blue print programming/direct dimension programming Review, assignment/test

10) Planning for CNC operation:-


Job feature identification & process selection process sequencing tool path planning
work-piece zero points. Stock removal cycle in CNC Turning of OD/ID operation
tooling systems for turning & tooling strategies for turning machines. Drilling/ Boring
Cycle in CNC Turning

11) Planning for CNC operation:-


Job feature identification & process selection process sequencing tool path planning
work-piece zero points. Stock removal cycle in CNC Turning of OD/ID operation
tooling systems for turning & tooling strategies for turning machines. Drilling/ Boring
Cycle in CNC Turning

12) Patterns & optimization of cutting parameters.


Factors affecting turned part quality/productivity
Tapping/rigid tapping on CNC Turning.
TPM knowledge productive trouble
Shooting, CNC preventive maintenance. Programming with variables & custom
macros. Program data transfer from PC to CNC machines & DNC operations.
Program preparation with CAD/CAM.

13) Safety Precaution :- safe handling tool equipment & CNC mill with FANUC control
machines & personal safety tools as per company product requirement. Machining
types of CNC Machines, advantage & Limitations of CNC applications. Future of
CNC technology (Advantage Knowledge) up date technology or latest CNC
Systems:- CNC interpolation co-ordinate systems & points

Mode knowledge. CNC Machines Milling Types Axes nomenclature Review


assignment/practical/test

14) CNC Control Hardware & operating Software :-


CNC software organization computers information processing of the CNC system.
CNC Machine working principle
Zero offset & tool offset in FANUS CNC TURNING.
Tool Nose Radius Compensation (TRNC) & Addressed Letter G & M code
knowledge.

15) Cutting tool materials for CNC Milling & it’s applications component materials &
cutting oil selection. ISO codes for Carbide indexible inserts & Tools holders for
milling. Milling machines, tool holder, removal & pull stud knowledge.
Tooling systems for CNC Turning centers need for removal of chuck/ frequency.
Cutting parameters selection & process planning.
Tools layout & process sheet preparation Using sub programs & cycles in the main
programs.
Blue print programming/direct dimension programming Review, assignment/test

16) Planning for CNC operation:-


Job feature identification & process selection process sequencing tool path planning
work-piece zero points. Stock removal cycle in CNC Turning of OD/ID operation
tooling systems for turning & tooling strategies for turning machines. Drilling/ Boring
Cycle in CNC Milling

17) Grooving tools, processes & tool selection


Programming for grooving of OD/ID in CNC milling.
Trouble shooting in CNC turning tool wear patterns & optimization of cutting
parameters factors affecting turned part quality/productivity Tapping rigid tapping on
CNC turning
TPM knowledge productive trouble shooting CNC preventive maintenance

18) Programming with variable & custom macros.


Program data transfer from PC to CNC machines & DNC operations.

19) Safety precautions- Safe handling of tools, equipment & CNC machines & personal
safety tools as per company product requirement.
Machining types of CNC Machines advantages & Limitation of CNC & its
applications.
Future of CNC technology (Advance Knowledge) up date technology or latest.

CNC Systems-
CNC interpolation, co-ordinate systems & points made knowledge.
CNC Machines – Milling type, AXES nomenclature, Review, assignment /
practice/test

20) CNC Control Hardware & Operating Software :-


CNC software organization computers & information processing of the CNC system.
CNC machine working principle.
Zero offset & tool offset in SIEMENS CNC Milling.
Tool Nose Radius Compensation (TNRC) & Addressed Letter G & M code
knowledge.
TPM – knowledge, productive trouble.

21) Cutting tool materials for CNC milling & it’s applications component materials &
cutting oil selection. ISO codes for Carbide indexible inserts & tools holders for
Milling.
Tooling systems for CNC Milling centers, tool holder removal & pull stud knowledge
Cutting parameters selection & process planning.
Tools layout & process sheet preparation Using sub programs & cycles in the main
programs. Review, assignment/practice , test.
Blue print programming/direct dimension programming.

22) Planning for CNC operation Milling-

Job feature identification & process selection process sequencing tool path planning
work-piece zero points. Machining parameters for Milling polar co-ordinate & direct
dimension programming Drilling/ Boring Cycle in CNC Milling.

23) Grooving tools, processes tool selection programming for grooving on OD/ID in
CNC Milling. Helical interpolation milling & its advantages & limitations in CNC
Milling.Machining of rectangular/circular pockets. Drilling, Milling patterns rigid
tapping in CNC Milling.
TPM- knowledge, productive trouble shooting, CNC preventive maintenance

24) Row of holes (Drilling pattern cycle) HOLES 1


Circle of holes (Drilling pattern cycle) HOLES 2

25) Theory on slots on circle & circumferential

26) Programming with variables & custom macros on SIEMENS CNC.


Program data transfer from PC to CNC machines & DNC operations

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