Lesson 1Basic CNC programme structure and common G-code/M-code elements relevant for verificationThis section introduces basic CNC programme structure, essential G and M codes, and reading blocks, comments, and tool calls, enabling operators to verify programmes for safety, accurate movements, and compatibility with setups.
Program header, safety lines, and commentsTool call, spindle speed, and coolant commandsLinear and circular motion G-code essentialsWork coordinate systems and tool length offsetsCommon M codes for spindle, coolant, and program endLesson 2Actions for abnormal conditions found during pre-start (tagging, notifying, isolating, initiating maintenance)This section outlines proper responses to abnormal pre-start findings, covering tagging, isolating, notifying supervisors, and starting maintenance, whilst avoiding unsafe shortcuts or unauthorised fixes.
Recognizing critical versus minor abnormalitiesApplying tags and documenting out-of-service statusIsolating energy sources when hazards are presentNotifying supervisors and maintenance promptlyRecording issues in logs or digital systemsLesson 3Mandatory PPE for CNC work and rationale (eye protection, hearing protection, cut-resistant gloves, aprons, safety shoes)This section details compulsory PPE for CNC milling, reasons for each item, and correct selection, inspection, and usage, connecting hazards like flying chips, noise, and sharp edges to specific gear.
Eye and face protection for chips and coolant splashHearing protection selection for shop noise levelsCut-resistant gloves for handling tools and stockProtective clothing, aprons, and sleeves near rotating partsSafety footwear for impact and slip protectionLesson 4Common lockout/tagout procedure steps applied to CNC machines (isolation, verification, documentation)This section describes standard lockout/tagout steps for CNC machines, including energy isolation, dissipation checks, verification, and records, emphasising teamwork with maintenance and adherence to factory protocols.
Identifying all CNC energy sources and pointsShutting down machine using normal stop sequenceApplying locks, tags, and group lockout devicesVerifying zero energy and tryout of controlsRestoring energy and removing locks safelyLesson 5CNC milling machine components and control interface (spindle, axis drives, tool changer, coolant, PLC/HMI)This section explains primary CNC milling parts and control panels, illustrating interactions of spindle, axes, tool changer, coolant, PLC, and HMI, plus safe use of screens, buttons, and modes.
Spindle assembly, drive, and speed controlLinear axes, ball screws, and feedback systemsAutomatic tool changer and tool magazine basicsCoolant delivery, chip evacuation, and guardingHMI screens, soft keys, and mode selectionPLC safety logic, interlocks, and status lightsLesson 6Machine-specific safety hazards (entanglement, flying chips, tool breakage, coolant exposure, electrical risks)This section examines CNC-specific hazards like entanglement, flying chips, tool breakage, coolant splashes, and electrical dangers, linking each to prevention steps and safe working practices.
Entanglement risks from rotating tools and partsFlying chips and high-velocity particle hazardsTool breakage causes and containment methodsCoolant mist, skin contact, and ventilation needsElectrical shock and arc risks around CNC cabinetsLesson 7Daily and shift inspection items for CNC (tool wear, spindle runout, coolant level, chip evacuation)This section lists daily and shift checks like tool wear, spindle runout, coolant levels, and chip removal, demonstrating how regular inspections avert breakdowns, enhance finishes, and ensure steady output.
Visual inspection of guards, doors, and panelsChecking tool wear, chipping, and pull stud conditionMonitoring spindle noise, heat, and basic runoutCoolant level, concentration, and contamination checksChip conveyor, augers, and filter cleanlinessLesson 8Verifying guards, interlocks, and emergency stops on CNC machinesThis section covers testing guards, interlocks, and emergency stops, with methods, pass criteria, and logging to confirm safety systems work before and during machine operation.
Types of fixed, movable, and interlocked guardsTesting door interlocks and safety switchesVerifying emergency stop buttons and circuitsConfirming light curtains or area scannersDocumenting safety device tests and findingsLesson 9CNC pre-start checklist: mechanical, electrical, tooling, workholding and coolant system checksThis section provides a systematic CNC pre-start checklist for mechanical, electrical, tooling, workholding, and coolant systems, stressing documentation, consistency, and spotting unsafe conditions early.
Visual walkaround and housekeeping verificationMechanical axis travel and limit stop checksElectrical panels, indicators, and cable conditionTooling integrity, clamping, and offset confirmationWorkholding security and part location verificationCoolant level, concentration, and flow path checks
