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A face milling custom macro

Suggested by Glenn J. Doutrich Sr. of Inside Development Systems, Inc.


I’ve had several requests recently for this custom macro – so, here it is! This custom macro performs a face milling operation and allows the percentage of overlap to be specified. It provides for two methods of milling, climb milling (assuming a right hand cutter is used) and zig-zag milling in both directions.


The letter address M specifies which type of milling will be done. Leaving M out of the G65 command – or setting it to M1.0 will cause the machine to climb mill. Setting M to M2.0 will cause the machine to zig-zag mill back and forth until the milling is complete. This custom macro assumes the X length of the workpiece is longer than the Y length. That is, it makes passes along the X axis only.


The illustration shows the variable meanings:


Here is an example calling program followed by the custom macro.

  • O0001 (EXAMPLE MAIN PROGRAM)

  • N005 T01 M06 (4" FACE MILL)

  • N010 G54 G90 S500 M03

  • N015 G00 X0 Y0

  • N020 G43 H01 Z2.0

  • N025 G65 P1000 X0 Y0 Z0 C0.15 M2.0 U40.0 V33.0 D4.0 Q20.0 F15.0

  • N030 G91 G28 Z0 M19

  • N035 M30

Line N025 calls the face milling custom macro. X and Y specify the lower left corner. Z specifies the surface to be milled. C specifies the amount of clearance for the cutter (approach and escape distance). U and W specify the length and width of the part to be milled. D specifies the cutter diameter. Q specifies the overlap percentage (percentage of cutter diameter for overlap). F specifies the feedrate.

  • O1000 (FACE MILLING CUSTOM MACRO)

  • #120 = #7*[[100-#17]*.01] (effective cutter size)

  • #121 = [2*[#7-#120]] + #22 (TOTAL STOCK INCLUDING OVERLAP)

  • #100 = 1 (CURRENT PASS [COUNTER])

  • #101 = FUP[#121/#120] (NUMBER OF PASSES)

  • #102 = #25+#22+[#7-#120]-#7/2 (CURRENT Y)

  • #103 = [#121-#7] / [#101-1] (Y STEP AMOUNT)

  • #104 = #102-#103 (TESTER FOR "ZAG MOTION)

  • IF[#13 EQ 2.0]GOTO 20 (TEST IF ZIG-ZAG)

  • (CLIMB MILLING)

  • N1 IF[#100 GT #101] GOTO 99

  • G00 X[#24-#3-#7/2] Y#102

  • Z#26

  • G01 X[#24+#21+#3+#7/2] F#9

  • G00 Z[#26+1.0]

  • #100 = #100 +1 (STEP COUNTER)

  • #102 = #102 -#103 (STEP CURRENT Y POSITION)

  • GOTO 1 (GO BACK TO TEST)

  • (ZIG-ZAG MILLING)

  • N20 IF[#100 GT #101] GOTO 99

  • G90 G00 X[#24-#3-#7/2] Y#102

  • Z#26

  • G01 X[#24+#21+#3+#7/2] F#9

  • IF[[#25-[#7-#120]+#7/2]-0.02 GT #104] GOTO 25 (TEST IF ZAG PASS IS NEEDED)

  • G00 G91 Y-#103

  • G90 G01 X[#24-#3-#7/2]

  • N25 #100 = #100 + 2 (STEP COUNTER)

  • #102 = #102 -#103*2 (STEP CURRENT Y POSITION)

  • #104 = #102-#103 (TESTER FOR "ZAG" MOTION)

  • GOTO 20 (GO BACK TO TEST)

  • N99 G00 Z[#26+1.0]

  • M99

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