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Peter Smid

CIMC Programming HandbookSecond EditionA C o m p re h e n s iv e G uide to Practical C N C Prog ram m in g

Peter Smid

Industrial Press Inc.989 Avenue of the Americas, New York, NY 10018 http://www.industrialpress.com

Library of Congress Cataloging-in-Publication Data Smid, Peter. CNC programming handbook: comprehensive guide to practical CNC programming/ Peter Smid. p. cm. ISBN 0-8311-3158-6 1. M achine-tools-Numerical control-Programm ing -H andbooks, manuals,etc..I. Title. TJ1189 .S592 2000 621.9023 dc21 00-023974

Second Edition CNC Programming Handbook

Industrial Press Inc.989 Avenue of the Americas, New York, NY 10018

C opyright 2003. Printed in the U nited States o f A m erica. All rights reserved. This book or parts thereof may not be reproduced, stored in a retrieval system , or transm itted in any form w ithout the perm ission o f the publishers.

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DedicationTo my father Frantisek and my mother Ludmila, who taught me never to give up.

AcknowledgmentsIn this second edition of the CNC Programming Handbook, I would like to express my thanks and appreciation to Peter Eigler for being the bottomless source of new ideas, knowledge and inspiration - all that in more ways than one. My thanks also go to Eugene Chishow, fo r his always quick thinking and his ability to point out the elusive detail or two that I might have missed otherwise. To Ed Janzen, I thank for the many suggestions he of fered and for always being able to see the bigger picture. To Greg Prentice, the President of GLP Technologies, Inc., - and my early mentor - you will always be my very good friend. Even after three years of improving the CNC Programming Handbook and developing the enclosed compact disc, my wife Joan will always deserve my thanks and my gratitude. To my son Michael and my daughter Michelle - you guys have contributed to this handbook in more ways than you can ever imagine.

I have also made a reference to several manufacturers and software developers in the book. It is only fair to acknowledge their names:

FANUC and CUSTOM MACRO or USER MACRO or MACRO B are registered trademarks of Fujitsu-Fanuc, Japan GE FANUC is a registered trademark of GE Fanuc Automation, Inc., Charlottesville, VA, USA

MASTERCAM is the registered trademark of CNC Software Inc., Tolland, CT, USA AUTOCAD is a registered trademark of Autodesk, Inc., San Rafael, CA, USAHP and HPGL are registered trademarks of Hewlett-Packard, Inc., Palo Alto, CA, USA IBM is a registered trademark of International Business Machines, Inc., Armonk, NY, USA WINDOWS is a registered trademarks of Microsoft, Inc., Redmond, WA, USA

About the AuthorPeter Smid is a professional consultant, educator and speaker, with many years of practi cal, hands-on experience, in the industrial and educational fields. During his career, he has gathered an extensive experience with CNC and CAD/CAM applications on all levels. He consults to manufacturing industry and educational institutions on practical use of Com puterized Numerical Control technology, part programming, CAD/CAM, advanced ma chining, tooling, setup, and many other related fields. His comprehensive industrial back ground in CNC programming, machining and company oriented training has assisted several hundred companies to benefit from his wide-ranging knowledge. Mr. Smid's long time association with advanced manufacturing companies and CNC ma chinery vendors, as well as his affiliation with a number of Community and Technical Col lege industrial technology programs and machine shop skills training, have enabled him to broaden his professional and consulting skills in the areas of CNC and CAD/CAM training, computer applications and needs analysis, software evaluation, system benchmarking, programming, hardware selection, software customization, and operations management. Over the years, Mr. Smid has developed and delivered hundreds of customized educa tional programs to thousands of instructors and students at colleges and universities across United States, Canada and Europe, as well as to a large number of manufacturing companies and private sector organizations and individuals. He has actively participated in many industrial trade shows, conferences, workshops and various seminars, including submission of papers, delivering presentations and a number of speaking engagements to professional organizations. He is also the author of articles and many in-house publications on the subject of CNC and CAD/CAM. During his many years as a professional in the CNC industrial and educational field, he has developed tens of thousands of pages of high quality training materials.

The author welcomes comments, suggestions and other input from educators, students and industrial users. You can e-mail him through the publisher of this handbook from the Main Menu of the enclosed CD. You can also e-mail him from the

CNC Program ing Handbook page at www.industrialpress.com m

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TABLE OF CONTENTS1 - NUMERICAL CONTROLDEFINITION OF NUMERICAL CONTROL . . NC and CNC Technology............................................ CONVENTIONAL AND CNC MACHINING . . . .

11 1 2

Axes and P la n e s ................................................................ 16 Point of O r ig in .................................................... 16 Quadrants............................................................................ 16 Right Hand Coordinate S y s te m ........................................17 MACHINE GEOMETRY...................................................... 17 Axis Orientation - M illin g .................................................... 17 Axis Orientation - Turning.................................................... 18 Additional Axes.................................................................... 18

NUMERICAL CONTROL ADVANTAGES . . . 2 Setup Time R e d u c tio n ....................................................... 3 Lead Time Reduction........................................................... 3 Accuracy and R e p e a ta b ility............................................... 3 Contouring of Complex Shapes........................................... 3 Simplified Tooling and Work Holding................................... 3 Cutting Time and Productivity Increase............................... 4 TYPES OF CNC MACHINE T O O L S ................................. 4 Mills and Machining Centers............................................... 4 Lathes and Turning C e n te rs ............................................... 5 PERSONNEL FOR C N C ..................................................... 5 CNC P ro g ra m m e r............................................................... 5 CNC Machine O perator....................................................... 6 SAFETY RELATED TO CNC W O R K ................................. 6

5 - CONTROL SYSTEM

19

GENERAL D E S C R IP T IO N ............................................... 20 Operation P a n e l................................................................20 Screen Display and K eyboard............................................21 H a n d le ................................................................................22 SYSTEM F E A T U R E S ......................................................22 Parameter S e ttin g s ............................................................22 System D e fa u lts ................................................................23 Memory Capacity................................................................24 M ANUAL PROGRAM INTERRUPTION. . . . 25 Single Block Operation........................................................25 F e e dhold............................................................................25 Emergency S t o p ................................................................25 M ANUAL DATA INPUT - M D I ........................................ 26 PROGRAM DATA O V E R R ID E ........................................ 26 Rapid Motion Override........................................................26 Spindle Speed O v e rrid e ....................................................27 Feedrate Override................................................................27 Dry Run O p e ra tio n ............................................................27 Z Axis N e g le c t....................................................................28 Manual Absolute S e ttin g ....................................................28 Sequence R eturn................................................................28 Auxiliary Functions L o c k ....................................................28 Machine L o c k ....................................................................28 Practical A p p lic a tio n s ........................................................29 SYSTEM O PTIO NS.............................................................29 Graphic Display....................................................................29 In-Process G auging............................................................30 . Stored Stroke Limits............................................................30 Drawing Dimensions In p u t................................................30 Machining Cycles................................................................30 Cutting Tool Animation........................................................30 Connection to External D e v ic e s ........................................30

2 - CNC MILLING

7

CNC M A C H IN E S -M IL L IN G ...............................................7 Types of Milling M achines................................................... 7 Machine Axes....................................................................... 8 Vertical Machining Centers................................................... 8 Horizontal Machining C e n te r s ........................................... 9 Horizontal Boring M i l l ........................................................10 Typical S p e cifica tio n s........................................................10

3 -CNC TURNING

11

CNC M A C H IN E S -T U R N IN G ........................................ 11 Types of CNC Lathes............................................................11 Number of A x e s ................................................................11 AXES D E S IG N A T IO N ......................................................11 Two-axis L a th e ................................................ 12 Three-axis L a th e ................................................................12 Four-axis L athe ....................................................................13 Six-axis L a t h e ....................................................................13 FEATURES AND SPECIFICATIONS . . . . 13 Typical Machine Specifications............................................13 Control F e a tu re s................................................................14

6 - PROGRAM PLANNING

31

4 - COORDINATE GEOMETRYRECTANGULAR COORDINATE SYSTEM . . .

1515

STEPS IN PROGRAM P L A N N IN G ................................. 31 INITIAL I N F O R M A T I O N ............................................... 31 MACHINE TOOLS FEATUR ES ........................................ 31 Machine Type and Size........................................................31

REAL NUMBER S Y S T E M ...............................................15

ix

XControl System................................................................... 31 PART C O M P L E X I T Y ..................................................... 32 M AN UAL P R O G R A M M IN G ........................................32 Disadvantages................................................................... 32 A dvantages........................................................................32 CAD/CAM AND C N C ..................................................... 32 Integration................................................................ 33 Future of Manual P rogram m ing....................................... 33 TYPICAL PROGRAMMING PROCEDURE . . . 33 PART D R A W I N G ............................................................ 34 Title B lock............................................................................34 D im e n sio n in g ................................................................... 34 Tolerances............................................................................35 Surface F in is h ................................................................... 35 Drawing R e v is io n s ........................................................... 36 Special Instructions........................................................... 36 METHODS S H E E T ............................................................ 36 MATERIAL S P E C IF IC A TIO N S ........................................ 36 Material U n ifo rm ity ............................................................36 Machinability Rating........................................................... 37 MACHINING S E Q U E N C E ...............................................37 TOOLING S E L E C T IO N ..................................................... 38 PART S E T U P ................................................................... 38 Setup S h e e t........................................................................38 TECHNOLOGICAL D E C I S I O N S ................................. 38 Cutter P a t h ........................................................................38 Machine Power Rating....................................................... 39 Coolants and Lub rica n ts................................................... 39 WORK SKETCH AND CALCULATIONS . . . 40 Identification M ethods....................................................... 40 QUALITY IN CNC PROGRAMMING . . . . 40

Table of Contents

8 - PREPARATORY COMMANDS

47

DESCRIPTION AND PURPOSE........................................ 47 APPLICATIONS FOR M IL L IN G ........................................ 47 APPLICATIONS FOR T U R N I N G ................................. 49 G CODES IN A PROGRAM BLOCK . . . . 50 Modality of G-commands....................................................50 Conflicting Commands in a B lo c k ....................................50 Word Order in a B lo c k ........................................................51 GROUPING OF C O M M A N D S ........................................ 51 Group N u m b e rs ................................................................51 G CODE TYPES................................................................... 52 G Codes and Decimal P oint................................................52

9 MISCELLANEOUS FUNCTIONS

53

DESCRIPTION AND PURPOSE........................................ 53 Machine Related Functions................................................53 Program Related Functions................................................53 TYPICAL A P P L IC A T IO N S ............................................... 54 Applications for Milling........................................................54 Applications for T u rn in g ....................................................54 Special MDI Functions........................................................54 Application G ro u p s ............................................................54 M FUNCTIONS IN A B L O C K ........................................ 55 Startup of M Functions........................................................56 Duration of M Functions....................................................56 PROGRAM F U N C T IO N S ............................................... 56 Program S t o p ....................................................................56 Optional Program S top........................................................57 Program End........................................................................58 Subprogram E n d ................................................................58 MACHINE F U N C T I O N S ............................................... 58 Coolant F u n c tio n s ............................................................58 Spindle Functions................................................................59 Gear Range S e le c tio n ........................................................60 Machine A ccessories........................................................60

7 - PART PROGRAM STRUCTURE

41

BASIC PROGRAMMING T E R M S ................................. 41 Character............................................................................41 W ord....................................................................................41 Block....................................................................................41 Program........................................................................ . 42 PROGRAMMING F O R M A T S ................................. . 4 2 WORD ADDRESS F O R M A T ........................................42 FORMAT N O T A T IO N ..................................................... 43 Short F o rm s........................................................................43 Milling System Format....................................................... 43 Turning System Format....................................................... jZ Multiple Word Addresses.................................... 45 SYMBOLS IN P R O G R A M M IN G ................................. 45 Plus and Minus Sign........................................................... 45 PROGRAM H E A D E R ..................................................... 45 TYPICAL PROGRAM STRUCTURE................................. 46

10 - SEQUENCE BLOCK

61

BLOCK S T R U C T U R E ......................................................61 Building the Block Structure................................................61 Block Structure for M illin g ................................................61 PROGRAM ID E N T IF IC A T IO N ........................................ 62 Program N um ber................................................................62 62 Program N am e........................................ SEQUENCE N U M B E R S ............................................... 63 Sequence Number Command............................................63 Sequence Block F o rm a t....................................................63 Numbering Increm ent........................................................64 Long Programs and Block Numbers....................................64 END OF BLOCK C H A R A C TE R ........................................ 64 STARTUP BLOCK OR SAFE BLOCK . . . . 65

Table of ContentsPROGRAM C O M M E N T S ...............................................66 CONFLICTING WORDS IN A BLOCK M ODAL PROGRAMMING VALUES . . . . . . . . 66 67

xiExact Stop C om m and........................................................89 Exact Stop Mode C o m m a n d ............................................89 Automatic Corner O ve rrid e ................................................89 Tapping M o d e ....................................................................89 Cutting M o d e ....................................................................90 CONSTANT F E E D R A T E ............................................... 90 Circular Motion F e e d ra te s ................................................90 M A X IM U M FEEDRATE......................................................91 Maximum Feedrate Considerations....................................91 FEEDHOLD AND O V E R R ID E ........................................ 91 Feedhold S w itc h ................................................................91 Feedrate Override Switch....................................................91 Feedrate Override F u n c tio n s ............................................92 E ADDRESS IN T H R E A D IN G ........................................ 92

EXECUTION PRIORITY..................................................... 68

11 - INPUT OF DIMENSIONS

69

ENGLISH AND METRIC U N I T S ................................. 69 Comparable Unit V a lu e s ................................................... 70 ABSOLUTE AND INCREMENTAL MODES . . 70 Preparatory Commands G90 and G 9 1 ............................... 71 Absolute Data Input - G 9 0 ............................................... 72 Incremental Data Input - G 9 1 ........................................... 72 Combinations in a Single B lo c k ....................................... 72 DIAMETER P R O G R A M M IN G ........................................73 M INIM U M MOTION IN C R E M E N T ................................. 73 FORMAT OF DIMENSIONAL INPUT . . . . 73 Full Address Format........................................................... 74 Zero Suppression............................................................... 74 Decimal Point Programming............................................... 75 Input Comparison............................................................... 76 CALCULATOR TYPE I N P U T ........................................76

14 - TOOL FUNCTIONT FUNCTION FOR MACHINING CENTERS . .

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Tool Storage Magazine........................................................93 Fixed Tool Selection............................................................94 Random Memory Tool S election........................................94 Registering Tool N u m b e rs ................................................94 Programming F o rm a t........................................................95 Empty Tool or Dummy T o o l................................................95 TOOL CHANGE FUNCTION - M 0 6 ................................. 95 Conditions for Tool C hange................................................95 AUTOMATIC TOOL CHANGER - ATC . . . . 96 Typical ATC S y s te m ............................................................96 Maximum Tool D iam eter....................................................97 Maximum Tool L ength ........................................................97 Maximum Tool W e ig h t........................................................97 ATC C ycle............................................................................98 MDI Operation....................................................................98PROGRAMMING THE A T C ............................................... 98 Single Tool W o r k ................................................................98 Programming Several T ools................................................99 Keeping Track of Tools........................................................99 Any Tool in Spindle -Not the First.........................................99 ....................................100 First Tool in the Spindle No Tool in the Spindle........................................................ 101 First Tool in the Spindle with Manual Change . . . . 101 ' No Tool in the Spindle with Manual C hange................... 102 First Tool in the Spindle and an Oversize Tool . . . . 102 No Tool in the Spindle and an Oversize T o o l....................102 T FUNCTION FOR L A T H E S ........................................ 103 Lathe Tool S ta tio n ............................................................ 103 Tool In d e xin g ........................................ 103 TOOL OFFSET R E G IS T E R S ........................................ 104 Geometry Offset............................................................ 104 Wear Offset........................................................................ 105 Wear Offset Adjustment................................................ 106 The R and T S e ttin g s........................................................ 106

12 - SPINDLE CONTROL

77

SPINDLE F U N C T IO N ......................................................77 Spindle Speed Input........................................................... 77 DIRECTION OF SPINDLE ROTATION . . . . 77 Direction for M illin g ........................................................... 78 Direction for Turning........................................................... 78 Direction Specification....................................................... 79 Spindle Startup................................................................... 79 SPINDLE S T O P ................................................................... 80 SPINDLE O R IE N T A T IO N ...............................................80 SPINDLE SPEED - R / M I N ...............................................81 SPINDLE S P E E D -S U R F A C E ........................................81 Material M achinability....................................................... 81 Spindle Speed - English U n its ........................................... 82 Spindle Speed - Metric U n it s ........................................... 82 CONSTANT SURFACE SPEED........................................82 Maximum Spindle Speed Setting....................................... 84 Part Diameter Calculation in CSS....................................... 85

13 - FEEDRATE CONTROL

87

FEEDRATE C O N T R O L ..................................................... 87 FEEDRATE FUN CTIO N ..................................................... 87 Feedrate per M inute........................................................... 87 Feedrate per R vo lu tio n ................................................... 88 FEEDRATE S E L E C T I O N ...............................................88 ACCELERATION AND DECELERATION . . . 88

15 - REFERENCE POINTS

107

REFERENCE POINT G R O U P S ..................................107

XMReference Point Groups Relationship................................108 MACHINE REFERENCE P O I N T ..................................108 Return to Machine Z e ro ....................................................109 PART REFERENCE P O I N T ........................................ 109 Program Zero S election....................................................109 Program Zero - Machining Centers....................................110 Program Zero - L a th e s ....................................................112 TOOL REFERENCE P O I N T ........................................ 112

Table of ContentsTOOL S E T U P ....................................................................129 Center Line T o o ls ............................................................ 129 Turning T o o ls .................................................................... 130 Boring T o o ls .................................................................... 130 Command Point and Tool Work O ffs e t............................130

19 - TOOL LENGTH OFFSET

131

GENERAL PRINCIPLES........................................ 131

1 6 - REGISTER COMMANDS

113

Actual Tool Le n g th ............................................................ 131 Gauge L in e ........................................................................ 131 Table Top Face.................................................................... 132 TOOL LENGTH OFFSET COM M ANDS . . . 132 Distance-To-Go in Z Axis................................................ 132 TOOL LENGTH S E T U P .................................... 133 On-Machine Tool Length S e tt in g .................................... 133 Off-Machine Tool Length S e ttin g .................................... 134 Tool Length Offset Value Register.................................... 134 Z AXIS R ELATIO NSHIPS ............................................... 134 Preset Tool Length............................................................ 135 Tool Length by Touch O f f ................................................ 135 Using a Master Tool L e n g th ............................................136 G43-G44 D iffe re n c e ........................................................ 136 PROGRAMMING F O R M A T S ........................................ 137 Tool Length Offset not Available........................................ 137 Tool Length Offset and G 9 2 ............................................138 Tool Length Offset and G 5 4 -G 5 9 .................................... 139 Tool Length Offset and Multiple T o o ls ............................ 139 CHANGING TOOL LENGTH OFFSET. . . . . . . . 140 141 141 HORIZONTAL MACHINE APPLICATION . TOOL LENGTH OFFSET CANCEL . .

POSITION REGISTER C OM M AND . . . . 113 Position Register D e fin itio n ............................................113 Programming Form at........................................................113 Tool Position S e ttin g ........................................................114 MACHINING CENTERS APPLICATION . . . 114 Tool Set at Machine Z e r o ................................................114 Tool Set Away from Machine Zero....................................114 Position Register in Z A x is ................................................115 Programming E x a m p le ....................................................115 LATHE APPLICATIO N ......................................................115 Tool S e tu p ........................................................................ 116 Three-Tool Setup G r o u p s ................................................116 Center Line Tools S etup....................................................116 External Tools S e tu p ........................................................117 Internal Tool S e tu p ............................................................ 117 Corner Tip Detail................................................................117 Programming E x a m p le ....................................................117

17 - POSITION COMPENSATION

119

DESCRIPTION....................................................................119 Programming C om m ands................................................119 Programming Form at........................................................119 Incremental M o d e ............................................................120 Motion Length Calculation................................................120 Position Compensation Along the Z a x i s ........................122 Using G47 and G48............................................................122 Face Milling................................................................ . 122

20 - RAPID POSITIONING

143

RAPID TRAVERSE M O T IO N ........................................ 143 GOO C o m m a n d ................................................................ 143 RAPID MOTION TOOL P A T H .........................................144 Single Axis M o tio n ............................................................ 144 Multiaxis M otion................................................................ 144 Straight Angular M otion.................................................... 146 Reverse Rapid M o t io n .................................................... 146 TYPE OF MOTION & TIME COMPARISON REDUCTION OF RAPID MOTION RATE . . . . . 146 147

1 8 - WORK OFFSETS

123

W ORK AREAS A V A I L A B L E ........................................ 123 Additional Work O ffsets....................................................124 WORK OFFSET DEFAULT AND STARTUP . . 124 Work Offset C h a n g e ........................................................125 126 Z Axis A p p lic a tio n ................................................ HORIZONTAL MACHINE APPLICATION . . . 127 EXTERNAL WORK OFFSETS........................................ 128 LATHE A P P L IC A T IO N S ............................................... 128 Types of O ffse ts ................................................................128 Geometry O ffset................................................................128 Wear Offset........................................................................ 129 Tool and Offset N u m b e rs ................................................129

RAPID MOTION F O R M U LA S ........................................ 147 APPROACH TO THE P A R T ........................................ 148

21 - MACHINE ZERO RETURN

149

MACHINE REFERENCE POSITION . . . . 149 Machining Centers............................................................ 149 Lathes................................................................................ 150 Setting the Machine A x e s ................................................ 150 Program C om m ands........................................................ 151 Command G r o u p ............................................................ 151

Table of ContentsRETURN TO PRIMARY MACHINE ZERO. . . 151 Intermediate P o in t............................................................151 Absolute and Incremental M o d e ....................................152 Return from the Z Depth P o sitio n ....................................153 Axes Return Required for the ATC....................................155 Zero Return for CNC L a th e s ............................................155 RETURN POSITION CHECK C O M M AN D . RETURN FROM MACHINE ZERO POINT. RETURN TO SECONDARY MACHINE ZERO. . . . . . 156 157 158

XIIILONG DWELL T I M E ...................................................... 175 Machine Warm-Up............................................................ 175 X Axis is the Dwelling A xis................................................ 176 Safety and Dwell................................................................ 176 FIXED CYCLES AND D W E L L ........................................ 176

25 - FIXED CYCLES

177

POINT-TO-POINT MACHINING............................ 177Single Tool Motions vs. Fixed Cycles................................178 FIXED CYCLE S E L E C T I O N .................................. 178 PROGRAMMING F O R M A T ........................................ 179 GENERAL R U LE S ............................................................. 180 ABSOLUTE AND INCREMENTAL VALUES . . 180 INITIAL LEVEL S E L E C T IO N ........................................ 181 R LEVEL S E LE C TIO N ...................................................... 181 Z DEPTH C A L C U L A T IO N S ........................................ 182 DESCRIPTION OF FIXED CYCLES . . . . 183 G81 - Drilling Cycle............................................................ 183 G82 - Spot-Drilling Cycle................................................ 183 G83 - Deep Hole Drilling Cycle - Standard...................... 184 G73 - Deep Hole Drilling Cycle - High Speed.................. 184 G84 - Tapping Cycle - S tandard........................................186 G74 - Tapping Cycle - R e v e rs e ........................................186 G85 - Boring C ycle ............................................................ 187 G86 - Boring C ycle ............................................................ 187 G87 - Backboring C y c le .................................................... 187 G88 - Boring C ycle ............................................................ 188 G89 - Boring C ycle ............................................................ 188 G76 - Precision Boring C y c le ............................................ 189 FIXED CYCLE C A N C E L L A T IO N ..................................189 FIXED CYCLE R E P E T IT IO N ........................................ 189 The L or K Address............................................................ 190 L0 or K0 in a C ycle ............................................................ 190

22 - LINEAR INTERPOLATION

159

LINEAR C O M M A N D ......................................................159 Start and End of the Linear M o t io n ................................159 Single Axis Linear Interpolation........................................159 Two Axes Linear In te rp o la tio n ........................................160 Three Axis Linear Interpolation........................................160 PROGRAMMING F O R M A T ........................................ 160 LINEAR F E E D R A T E ......................................................161 Feedrate R a n g e ................................................................161 Individual Axis Feedrate....................................................161 PROGRAMMING E X A M P L E ........................................ 162

23 - BLOCK SKIP FUNCTION

163

TYPICAL APP LIC A TIO N S ............................................... 163 BLOCK SKIP S Y M B O L ............................................... 163 CONTROL UNIT S E T T I N G ........................................ 163 BLOCK SKIP AND M ODAL COMM ANDS . . 164 PROGRAMMING EXAMPLES........................................ 165 Variable Stock Removal....................................................165 Machining Pattern Change................................................166 Trial Cut for M e a s u rin g ....................................................168 Program Proving................................................................169 Barfeeder Application.................................................... 170 Numbered Block Skip........................................................170

26 - MACHINING HOLES

191

24 - DWELL COMMAND

171

SINGLE HOLE E V A LU A T IO N ........................................ 191 Tooling Selection and Applications................................ 191 Program D a ta .................................................................... 194 DRILLING O P E R A T IO N S ............................................... 194 Types of Drilling O p e ra tio n s............................................ 194 Types of D rills.................................................................... 194 Programming Considerations........................................ 195 Nominal Drill D ia m e te r.................................................... 195 Effective Drill D iam eter.................................................... 195 Drill Point Length............................................................ 195 Center Drilling................................................................ 196 Through Hole D rilling.................................................... 196 Blind Hole D rillin g ........................................................ 197 Flat Bottom Drilling........................................................ 197 Indexable Insert D rilling................................................ 198 PECK D R I L L IN G .............................................................199 Typical Peck Drilling Application.................................... 199 Calculating the Number of P e c k s ................................ 199

PROGRAMMING APPLICATIONS . . . . 171 Applications for C u ttin g ....................................................171 Applications for Accessories............................................171 DWELL C O M M A N D ......................................................171 Dwell Command Structure................................................172 DWELL TIME S E L E C T I O N ........................................ 172 SETTING MODE AND D W E L L ..................................173 Time S e tt in g ....................................................................173 Number of Revolutions S e ttin g ........................................173 M IN IM U M D W E L L ......................................................173 NUMBER OF R E V O L U T I O N S ................................. 174 System S e ttin g ................................................................174 Time Equivalent................................................................174

xivSelecting the Number of Pecks....................................... 200 Controlling Breakthrough Depth....................................... 200 R E A M IN G .......................................................................... 201 Reamer D e s ig n ............................................................... 201 Spindle Speeds for Reaming........................................... 201 Feedrates for R e a m in g ................................................... 201 Stock Allowance............................................................... 202 Other Reaming Considerations....................................... 202 SINGLE POINT B O R IN G ...............................................202 Single Point Boring T o o l................................................... 202 Spindle Orientation........................................................... 203 Block T ools........................................................................203 BORING WITH A TOOL S H I F T ................................. 203 Precision Boring Cycle G76 203 Backboring Cycle 87.................................................... 204 Programming E x a m p le ................................................... 204 Precautions in Programming and Setup........................... 205 ENLARGING H O L E S ......................................................205 C ountersinking ............................................................... 205 Counterboring....................................................................206 S potfacing........................................................................207 MULTILEVEL D R IL L IN G ...............................................207 WEB D R I L L I N G ............................................................ 208 T A P P IN G .......................................................................... 209 Tap Geometry................................................................... 210 Tapping Speed and Feedrate........................................... 210 Pipe Taps............................................................................211 Tapping Check L is t............................................................212 HOLE OPERATIONS ON A LATHE . . . . 212 Tool Approach M o t io n ................................................... 213 Tool Return M otion........................................................... 213 Drilling and Reaming on Lathes....................................... 214 Peck Drilling Cycle - G74................................................... 214 Tapping on L a th e s ............................................................215 Other O p e ra tio n s ........................................................... 216

Table of Contents

28 - FACE MILLING

227

CUTTER S E LE C TIO N ......................................................227 Basic Selection C rite ria ....................................................227 Face Mill Diameter............................................................227 Insert Geometry................................................................228 CUTTING C O N S ID E R A T IO N S ................................. 228 Angle of Entry....................................................................229 Milling M o d e ....................................................................229 Number of Cutting Inserts................................................230 PROGRAMMING T E C H N IQ U E S ................................. 230 Single Face Mill C u t ........................................................231 Multiple Face Mill C u t s ....................................................232 USING POSITION COMPENSATION . . . . 233

29 - CIRCULAR INTERPOLATION

235

ELEMENTS OF A CIRCLE........................................235Radius and Diam eter........................................................235 Circle Area and Circum ference........................................236 Q U A D R A N T S ................................................................... 236 Quadrant P oints................................................................236 PROGRAMMING F O R M A T ........................................ 237 Arc Cutting D irection........................................................237 Circular Interpolation Block................................................237 Arc Start and End Points....................................................238 Arc Center and R a d iu s ....................................................238 Arc Center Vectors............................................................238 Arc in P la n e s ....................................................................239 RADIUS P R O G R A M M IN G ........................................ 240 Blend R a d iu s....................................................................240 Partial R adius....................................................................240 FULL CIRCLE P R O G R A M M IN G ................................. 240 Boss M i llin g ....................................................................242 Internal Circle Cutting - Linear S t a r t ............................... 243 Internal Circle Cutting - Circular Start................................243 Circle Cutting C y c le ........................................................244 ARC PROGRAMMING......................................................245 FEEDRATE FOR CIRCULAR MOTION . . . 245 Feedrate for Outside A r c s ................................................246 Feedrate for Inside A rcs....................................................246

27 - PATTERN OF HOLESTYPICAL HOLE P A T T E R N S .............................. 217 RANDOM HOLE P A T T E R N .............................. 217 STRAIGHT ROW HOLE PATTERN . . . .

217

218

ANGULAR ROW HOLE PATTERN . . . . 218 Pattern Defined by Coordinates....................................... 218 Pattern Defined by A n g le ............................................... 219 CORNER P A T T E R N ............................................220 GRID P A T T E R N .................................................. 220 Angular Grid P a tte rn ....................................................... 221 ARC HOLE P A T T E R N ............................................222 BOLT HOLE CIRCLE PATTERN . . . . , 223 Bolt Circle Formula............................................................224 Pattern Orientation............................................................224 POLAR COORDINATE S Y S T E M ....................... 225 Plane S e le c tio n ............................................................... 226 Order of Machining............................................................226

30 - CUTTER RADIUS OFFSET

247

M AN UAL C A L C U L A T IO N S ........................................ 247 Tool Path Center P o in ts ....................................................248 Cutter Radius....................................................................249 Center Points C a lcu la tio n ................................................249 COMPENSATED CUTTER P A T H ................................. 250 Types of Cutter Radius Offset............................................250 Definition and Applications................................................250 PROGRAMMING T E C H N IQ U E S ................................. 250 Direction of Cutting M o t io n ............................................251

Table of ContentsLeft or Right - not CW or C C W ....................................... 251 Offset Com m ands........................................................... 251 Radius of the C u tte r ....................................................... 252 History of Offset T y p e s ................................................... 252 Programming Form at....................................................... 253 Address H or D ?............................................................... 253 Geometry and Wear O ffs e ts ............................... 254 APPLYING CUTTER RADIUS OFFSET . . . 254 Startup Methods............................................................... 254 Offset Cancellation........................................................... 256 Cutter Direction Change................................................... 256 HOW THE RADIUS OFFSET WORKS . . . 256 Look-Ahead Offset Type................................................... 257 Rules for Look-Ahead Cutter Radius O f f s e t................... 257 Radius of the C u tte r ....................................................... 258 Radius Offset Interference............................................... 259 Single vs. Multiaxis S ta r t u p ........................................... 260 OVERVIEW OF GENERAL RULES . . . . 261 PRACTICAL EXAMPLE - MILLING . . . . 262 Part T o le ra n ces............................................................... 262 Measured Part Size........................................................... 262 Programmed O ffs e ts ....................................................... 263 D Offset Amount - General Setting................................... 263 Offset A djustm ent........................................................... 264 Offset for External C utting............................................... 264 Offset for Internal C u ttin g ............................................... 265 One Offset or Multiple Offsets?....................................... 265 Preventing a S crap........................................................... 265 Program Data - Nominal or M id d le ? ............................... 266 TOOL NOSE RADIUS O F F S E T ................................. 266 Tool Nose T ip ................................................................... 266 Radius Offset Com m ands............................................... 266 Tool Tip Orientation........................................................... 266 Effect of Tool Nose Radius O ffs e t................................... 267 Sample Program............................................................... 267 Minimum Clearance R e q u ire d ....................................... 268 Change of Motion D ire c tio n ........................................... 268 High Speed Steel End Mills Solid Carbide End Mills . . Indexable Insert End Mills . Relief A n g le s .................... End Mill S iz e .................... Number of Flutes . . . . SPEEDS AND FEEDS. . Coolants and Lubricants . . Tool Chatter........................ STOCK REMOVAL . . Plunge Infeed.................... In and Out Ramping . . . Direction of C u t ................ Width and Depth of Cut . .

XV

276 , 276 276 , 276 276 277 277 , 278 278 . . . . 279 279 279 279 280

33 - SLOTS AND POCKETSOPEN AND CLOSED BOUNDARYOpen Boundary.................................... Closed Boundary.................................... PROGRAMMING SLOTS . . . . Open Slot Example................................ Closed Slot E xam ple............................ POCKET M ILLIN G .................................. General P rinciples................................ Pocket T y p e s ........................................ RECTANGULAR POCKETS . . . Stock Amount........................................ Stepover A m o u n t................................ Length of C u t........................................ Semifinishing M o tio n s ........................ Finishing Tool P a th ................................ Rectangular Pocket Program Example . CIRCULAR PO C KETS........................... Minimum Cutter Diameter.................... Method of E ntry.................................... Linear Approach.................................... Linear and Circular Approach................ Roughing a Circular Pocket.................... CIRCULAR POCKET CYCLES . . .

281281 . 281 . 281 281 . 281 . 283 284 . 284 . 285 . . . . . . . . . . . 285 286 286 287 287 287 288 289 289 289 289 290 291 292

.

31 - PLANE SELECTION

269

W H AT IS A P L A N E ? ..................................................... 269 MACHINING IN P L A N E S ...............................................269 Mathematical P lanes....................................................... 269 Machine Tool P la n e s....................................................... 270 Program Commands for Planes Definition....................... 270 Default Control S t a t u s ................................................... 271 STRAIGHT MOTION IN P L A N E S ................................. 271 CIRCULAR INTERPOLATION IN PLANES . . 271 G17-G18-G19 as Modal C om m ands............................... 272 Absence of Axis Data in a Block....................................... 272 Cutter Radius Offset in P la n e s ....................................... 273 PRACTICAL E X A M P L E ...............................................273 FIXED CYCLES IN P L A N E S ........................................274

34 - TURNING AND BORINGTOOL FU N CTIO N -TUR NING . . T A d d re s s ................................................ LATHE O F F S E T S .................................. Offset Entry................................................ Independent Tool Offset............................ Tool Offset with M o tio n ............................ Offset Change............................................ MULTIPLE O F F S E T S ........................... General A p p ro a ch .................................... Diameter Tolerances................................ Shoulder Tolerances................................ Diameter and Shoulder Tolerances. . . .

293293 . 293 . . . . . . . . 294 294 294 295 295 295 296 296 297 297 298

32 - PERIPHERAL MILLINGEND MILLS

275275

OFFSET SETTING................................

Table of ContentsLeft or Right - not CW or C C W ....................................... 251 Offset Com m ands........................................................... 251 Radius of the C u tte r ....................................................... 252 History of Offset T y p e s ................................................... 252 Programming Form at....................................................... 253 Address H or D ?............................................................... 253 Geometry and Wear O ffs e ts ........................................... 254 APPLYING CUTTER RADIUS OFFSET . . . 254 Startup Methods.................................................... . 254 Offset Cancellation........................................................... 256 Cutter Direction Change................................................... 256 HOW THE RADIUS OFFSET WORKS . . . 256 Look-Ahead Offset Type................................................... 257 Rules for Look-Ahead Cutter Radius O f f s e t ................... 257 Radius of the C u t t e r ....................................................... 258 Radius Offset Interference............................................... 259 Single vs. Multiaxis S ta r t u p ........................................... 260 OVERVIEW OF GENERAL RULES . . . . 261 PRACTICAL EXAMPLE - MILLING . . . . 262 Part T o le ra n ces............................................................... 262 Measured Part Size........................................................... 262 Programmed O ffs e ts ....................................................... 263 D Offset Amount - General Setting................................... 263 Offset A djustm ent........................................................... 264 Offset for External C utting............................................... 264 Offset for Internal C u ttin g ............................................... 265 One Offset or Multiple Offsets?....................................... 265 Preventing a S crap........................................................... 265 Program Data - Nominal or M id d le ? ............................... 266 TOOL NOSE RADIUS O F F S E T ................................. 266 Tool Nose T ip ................................................................... 266 Radius Offset Com m ands............................................... 266 Tool Tip Orientation........................................................... 266 Effect of Tool Nose Radius O ffs e t................................... 267 Sample Program............................................................... 267 Minimum Clearance R e q u ire d ....................................... 268 Change of Motion D ire c tio n ........................................... 268

XVHigh Speed Steel End M i l l s ............................................276 Solid Carbide End M ills ....................................................276 Indexable Insert End M ills ................................................276 Relief A n g le s ....................................................................276 End Mill S iz e ....................................................................276 Number of F lu t e s ............................................................277 SPEEDS AND FEE D S ......................................................277 Coolants and Lubricants....................................................278 Tool Chatter........................................................ 278 STOCK R E M O V A L ......................................................279 Plunge Infeed....................................................................279 In and Out R a m p in g ........................................................279 Direction of C u t ................................................................279 Width and Depth of C u t....................................................280

!27227 227 227 228 228 229 229 230 230 231 232 233

33 - SLOTS AND POCKETSOPEN AND CLOSED BOUNDARY . . . .

281281

!35235 235 236 236 236 237 237 237 238 238 238 239 240 240 240 240 242 243 243 244 245 245 246 246

Open Boundary ................................................281 Closed Boundary................................................................281 PROGRAMMING S L O T S ............................................... 281 Open Slot Example............................................................281 Closed Slot E xam ple........................................................283 POCKET M ILLIN G ............................................................ 284 General P rinciples............................................................284 Pocket T y p e s ....................................................................285 RECTANGULAR P O C K E T S ........................................ 285 Stock Amount....................................................................286 Stepover A m o u n t............................................................286 Length of C u t....................................................................287 Semifinishing M o tio n s ....................................................287 Finishing Tool P a th ............................................................287 Rectangular Pocket Program E x a m p le ........................... 288 CIRCULAR PO C KETS......................................................289 Minimum Cutter Diameter................................................289 Method of E ntry................................................................289 Linear Approach................................................................289 Linear and Circular Approach............................................290 Roughing a Circular Pocket................................................291 CIRCULAR POCKET C YCLES........................................ 292

31 - PLANE SELECTION

269

W H AT IS A P L A N E ? ..................................................... 269 MACHINING IN P L A N E S ...............................................269 Mathematical P lanes....................................................... 269 Machine Tool P la n e s ....................................................... 270 Program Commands for Planes Definition....................... 270 Default Control S t a t u s ................................................... 271 STRAIGHT MOTION IN P L A N E S ................................. 271 CIRCULAR INTERPOLATION IN PLANES . . 271 G17-G18-G19 as Modal Com m ands............................... 272 Absence of Axis Data in a Block............................... . 272 Cutter Radius Offset in P la n e s ....................................... 273 PRACTICAL E X A M P L E ...............................................273 FIXED CYCLES IN P L A N E S ........................................274

34 - TURNING AND BORING

293

>47247 248 249 249 250 250 250 250 251

TOOL F U N C T IO N - T U R N IN G ................................. 293 T A d d re s s ........................................................................293 LATHE O F F S E T S ............................................................ 294 Offset Entry........................................................................294 Independent Tool Offset....................................................294 Tool Offset with M o tio n ....................................................295 Offset Change....................................................................295 MULTIPLE O F F S E T S ......................................................295 General A p p ro a ch ............................................................296 Diameter Tolerances........................................................296 Shoulder T olerances........................................................297 Diameter and Shoulder Tolerances....................................297

32 - PERIPHERAL MILLING

275

END M I L L S ...............................................................275

OFFSET SETTING.........................................................298

XViFUNCTIONS FOR GEAR RANGES . . . . 298

Table of ContentsG70 Cycle Format - All Controls........................................320 BASIC RULES FOR G70-G73 CYCLES . . . 321 G 74-P E C K DRILLING C Y C L E .......................... 321 G74 Cycle Format - 10T/11T/15T....................................321 G74 Cycle Format - 0T/16T/18T/20T/21T .................... 321 G75 - GROOVE CUTTING CYCLE..................................322 G75 Cycle Format - 10 T /1 1 T /1 5 T ....................................322 G75 Cycle Format - 0T/16T/18T/20T/21T ........................322 BASIC RULES FOR G74 AND G75 CYCLES . . 322

AUTOM ATIC CORNER B R E A K ................................. 299 Chamfering at 45 Degrees............................................... 299 Blend Radius at 90 D e g re e s........................................... 301 Programming C o n d itio n s ............................................... 301 Programming E x a m p le ................................................... 301 ROUGH AND FINISHED S H A P E ................................. 302 Rough O perations.................................................... . 302 Finish O p e ra tio n s ............................................................303 Stock and Stock A llo w a n c e ........................................... 303 PROGRAMMING A R E C E S S ........................................ 304 SPINDLE SPEED IN CSS M O D E ................................. 305 LATHE PROGRAM F O R M A T ........................................ 306 Program Format - Tem plates........................................... 306 General Program Format................................................... 306 Approach to the P a rt....................................................... 306

36 - GROOVING ON LATHES

323

GROOVING O P E R A T IO N S ........................................ 323 Main Grooving A p p lica tio n s............................................323 Grooving Criteria................................................................323 GROOVE S H A P E .............................................................323 Nominal Insert Size............................................................324 Insert Modification............................................................324 GROOVE L O C A T IO N ......................................................324 GROOVE D IM E N S IO N S ............................................... 324 Groove P osition ................................................................325 Groove D epth....................................................................325 SIMPLE GROOVE PROGRAMMING . . . . 325 PRECISION GROOVING TECHNIQUES . . . 326 Groove Width Selection....................................................327 Machining M ethod............................................................327 Finishing Allowances........................................................328 Groove Tolerances............................................................329 Groove Surface Finish........................................................330 MULTIPLE GROOVES......................................................330 FACE G R O O V E S .............................................................330 Radial Clearance................................................................331 Face Grooving Program E x a m p le ....................................331 CORNER G R O O VES/N EC K GROOVES . . . 332 GROOVING C Y C L E S ......................................................332 G75 Cycle Applications....................................................332 Single Groove with G75 ................................................ 333 Multiple Grooves with G75............................................ 333 SPECIAL G R O O V E S ...................................................... 333 GROOVES AND SUBPROGRAMS . . . . 334

3 5 - LATHE CYCLES

307

STOCK REMOVAL ON LATHES............................ 307Simple Cycles....................................................................307 Complex C ycle s............................................................... 307 PRINCIPLES OF LATHE C YC LE S ................................. 307 G 9 0 -S T R A IG H T CUTTING CYCLE . . . . 308 Cycle F o rm a t....................................................................308 Straight Turning E x a m p le ............................................... 309 Taper Cutting E x a m p le ................................................... 309 Straight and Taper Cutting E xa m p le ............................... 311 G94 - FACE CUTTING CYCLE........................................ 312 Cycle F o rm a t....................................................................312 MULTIPLE REPETITIVE C Y C L E S ................................. 313 General D e s c rip tio n ....................................................... 313 Cycle Format Types............................................................313 Cutting Cycles and Part Contour....................................... 313 Chipbreaking C y c le s ....................................................... 313 CONTOUR CUTTING C Y C L E S ................................. 314 Boundary D e fin itio n ....................................................... 314 Start Point and the Points P and Q ................................. 3 1 4 TYPE I AND TYPE II C YC LE S ........................................ 315 Programming Type I and Type II Cycles........................... 315 Cycle Formatting................................................................315 G 7 1 -S T O C K REMOVAL IN TURNING . . . 315 G71 Cycle Form at-10T/11T/15T................................... 316 G71 Cycle Format - 0T/16T/18T/20T/21T....................... 316 G71 for External Roughing............................................... 316 G71 for Internal R oughing............................................... 317 Direction of Cutting in G71.................................... 317 G 7 2 -S T O C K REMOVAL IN FACING. . . . 317 G72 Cycle Format- 10 T /1 1 T /1 5 T ................................... 317 G72 Cycle Format - 0T/16T/18T/20T/21T....................... 318 G73 - PATTERN REPEATING CYCLE . . . . 318 G73 Cycle Form at-10T/11T/15T................................... 318 G73 Cycle Format - 0T/16T/18T/20T/21T....................... 319 G73 Example of Pattern Repeating................................... 319 G 70-C O N T O U R FINISHING CYCLE . . . . 320

37 - PART-OFF

335

PART-OFF P R O C E D U R E ............................................... 335 Parting Tool Description....................................................335 Tool Approach M o t io n ....................................................336 Stock Allowance................................................................337 Tool Return M otion............................................................337 Part-off with a C h a m fe r....................................................337 Preventing Damage to the P a rt........................................338

38 - SINGLE POINT THREADING

339

Table of ContentsTHREADING ON CNC L A T H E S ................................. 339 Form of a Thread............................................................... 339 Threading Operations....................................................... 340 TERMINOLOGY OF THREADING................................. 340 THREADING P R O C E S S ...............................................341 Steps in Threading........................................................ 341 Thread Start P osition....................................................... 342 Thread Cutting Diameter and D e p th ............................... 342 Thread Cutting M o t io n ................................................... 343 Retract from T h re a d ....................................................... 344 Return to Start P o sitio n ................................................... 344 THREADING FEED AND SPINDLE SPEED . . 344 Threading Feedrate Selection........................................... 345 Spindle Speed Selection................................................... 345 Maximum Threading F e e d ra te ....................................... 346 Lead E r r o r ........................................................................347 TOOL REFERENCE P O I N T ........................................348 BLOCK-BY-BLOCK T H R E A D IN G ................................. 348 BASIC THREADING C Y C LE -G 92 . . . . 349 MULTIPLE REPETITIVE CYCLE - G76 . . . . 350 G76 Cycle Format -1 0T/11T / 1 5 T ................................... 350 G76 Cycle Format-0T/16T/18T....................................351 Programming E x a m p le ................................................351 First Thread Calculation................................................... 352 THREAD INFEED M E T H O D S ........................................353 Radial In fe e d ................................................................... 353 Compound Infeed........................................................... 353 Thread Insert Angle - Parameter A ................................... 354 Thread Cutting Type - Parameter P ................................... 354 ONE-BLOCK METHOD CALCULATIONS . . . 355 Initial Considerations....................................................... 355 Z Axis Start Position Calculation....................................... 355 THREAD RETRACT M O T IO N ........................................357 Thread Pullout F u n c tio n s ............................................... 357 Single Axis P u llo u t........................................................... 357 Two-Axis Pullout............................................................... 357 HAND OF T H R E A D ......................................................358 THREADING TO A S H O U L D E R ................................. 358 Insert M odification........................................................... 358 Program Testing............................................................... 360 OTHER THREAD F O R M S ...............................................360 Thread D e p th ....................................................................360 TAPERED T H R E A D ..................................................... 361 Depth and C le a ra n c e s ................................................... 361 Taper Calculation............................................................... 361 Block by Block Taper T h re a d........................................... 362 Tapered Thread Using a Simple C y c le ........................... 363 Tapered Thread and a Multi Repetitive Cycle................... 363 MULTISTART T H R E A D ...............................................364 Threading Feedrate Calculation....................................... 364 Shift A m o u n t................................................................... 365 Application E xa m p le ....................................................... 366 THREAD RECUTTING......................................................366

XVII

39 - SUBPROGRAMSMAIN PROGRAM AND SUBPROGRAMS . .

367367

Subprogram Benefits........................................................367 Identification of S u b p ro g ra m s........................................368 SUBPROGRAM FU N C TIO N S ........................................ 368 Subprogram Call Function................................................368 Subprogram End Function................................................368 Block Number to Return to ................................................369 Number of Subprogram Repetitions................................369 L0 in a Subprogram C all....................................................370 SUBPROGRAM N U M B E R I N G ..................................371 Organized A p p ro a ch ........................................................372 Protected Subprograms....................................................373 SUBPROGRAM D EVELO PM ENT..................................373 Repeating Pattern R ecognition........................................373 Tool Motion and Subprogram s........................................374 Modal Values and Subprograms........................................375 MULTI LEVEL N E S T IN G ............................................... 376 One Level N e stin g............................................................376 Two Level N e s tin g ............................................................376 Three Level N e s tin g ........................................................377 Four Level N esting............................................................377 Nesting A pplications........................................................377 CONTOURING WITH A SUBPROGRAM . . . 378 TOOL CHANGE S U B P R O G R A M ..................................379 100 000 000 HOLE G R ID ............................................... 379

40 - DATUM SHIFT

381

DATUM SHIFT WITH G92 OR G50 . . . . 381 Program Zero S h ift............................................................381 LOCAL COORDINATE S Y S T E M ..................................383 G52 C o m m a n d ................................................................384 MACHINE COORDINATE SYSTEM . . . . 384 DATA S E T T I N G .............................................................386 Data Setting Com m and....................................................386 Coordinate M o d e ............................................................386 WORK O F F S E T S .............................................................386 Standard Work Offset I n p u t ............................................386 Additional Work Offset In p u t............................................387 External Work Offset Input................................................387 TOOL LENGTH OFFSETS............................................... 387 Valid Input R a n g e ............................................................388 CUTTER RADIUS O F F S E T S ........................................ 388 LATHE O F F S E T S .............................................................388 MDI DATA S E T T IN G ...................................................... 389 PROGRAMMABLE PARAMETER ENTRY. . . 389 Modal G10 Command........................................................389 Parameters N o ta tio n ........................................................ 390 Program Portability............................................................ 390 Bit Type Parameter............................................................391 Effect of Block N u m b e rs ................................................392

Table of ContentsBARFEEDER A T T A C H M E N T ........................................ 413 Bar Stopper........................................................................413 ADDITIONAL O P T IO N S ............................................... 414 Part Catcher or Part Unloader............................................414 Continuous Operation........................................................414 Parts C ounter....................................................................415 Pull-Out F in g e r ................................................................415 PROGRAMMING E X A M P L E ........................................ 415

41 - MIRROR IMAGE

393

BASIC RULES OF MIRROR IMAGE . . . . 393 Tool Path D irection............................................................393 Original Tool P a t h ........................................................... 394 Mirror A x is ........................................................................394 Sign of C o o rd in a te s ................................................ . 394 Milling D irection............................................................... 395 Arc Motion D ire ctio n....................................................... 395 Program Start and E n d ................................................... 395 MIRROR IMAGE BY S E T T I N G ..............395 Control S e tt in g ............................................................... 395 Programming - Manual Mirror S e ttin g ........................... 396 PROGRAMMABLE MIRROR IMAGE . . . . 396 Mirror Image Functions................................................... 396 Simple Mirror Image E x a m p le ....................................... 397 Complete Mirror Image E x a m p le ................................... 398 MIRROR IMAGE ON CNC LATHES . . . . 398

45 - HELICAL MILLING

417

HELICAL MILLING O P E R A T IO N ................................. 417 Helical In te rp o la tio n ........................................................417 Programming Form at........................................................417 Arc Modifiers for Helical In te rp o la tio n ............................418 Applications and Usage....................................................418 THREAD M ILLIN G ............................................................ 418 Applying Thread M illin g ....................................................418 Conditions for Thread M illing............................................418 Thread Milling Tool............................................................419 Premachining Requirements............................................419 Clearance R a d iu s ............................................................419 Productivity of Thread Milling............................................419 THE HELIX.......................................................................... 419 THREAD MILLING EXAM PLE ........................................ 421 Straight T h re a d ................................................................421 Initial C alculations............................................................421 Starting Position................................................................422 Motion Rotation and D ire c tio n ........................................422 Lead-In M o tio n s................................................................423 Thread Rise Calculation....................................................424 Milling the T h re a d ............................................................424 Lead-Out M o tio n s ............................................................425 Complete Program............................................................425 External Thread M illin g ....................................................425 Tapered Thread M illin g ....................................................425 Further C onsiderations....................................................426 THREAD MILLING SIMULATION METHOD . . 426 HELICAL R A M P I N G ......................................................427

42 - COORDINATE ROTATION

399

ROTATION C O M M A N D S ...............................................399 Center of R otation........................................................... 399 Radius of R otation........................................................... 399 ....................................... 401 Coordinate Rotation Cancel Common A p p lic a tio n s ................................................... 401 PRACTICAL A P P L IC A T IO N ........................................401

43 - SCALING FUNCTION

405

DESCRIPTION................................................................... 405 Scaling Function U sage................................................... 405 PROGRAMMING F O R M A T ........................................405 Scaling Center................................................................... 406 Scaling Factor................................................................... 406 Rounding Errors in Scaling............................................... 407 PROGRAM E X A M P L E S ...............................................407

46 - HORIZONTAL MACHINING 44 - CNC LATHE ACCESSORIES 409CHUCK C O N T R O L ............................................. 409Chuck Functions............................................................... 409 Chucking Pressure........................................................... 410 Chuck Jaws........................................................................410

429

INDEXING AND ROTARY A X E S ................................. 429 INDEXING TABLE (B AXIS) . . . . . . 429 Units of Increment............................................................429 Direction of Indexing........................................................430 Table Clamp and Unclamp Functions............................... 430 Indexing in Absolute and Incremental M ode................... 430 B AXIS AND O F F S E T S ............................................... 431 Work Offset and B A x is ....................................................431 Tool Length Offset and B A x i s ........................................432 RETURN TO MACHINE Z E R O ................................. 434 INDEXING AND A SUBPROGRAM COMPLETE PROGRAM EXAMPLE . . . . . . . . . . 434 436 437

TAILSTOCK AND Q U ILL....................................... 410Tailstock Body................................................................... 410 Quill....................................................................................411 Center................................................................................411 Quill F u n c tio n s ............................................................... 411 Programmable Tailstock................................................... 411 Safety Concerns............................................................... 411

BI-DIRECTIONAL TURRET INDEXING

412 Programming E x a m p le ................................................... 412

. . .

AUTOM ATIC PALLET CHANGER - APC .

Table of ContentsWorking Environment....................................................... 438 Types of P a lle ts ............................................................... 438 Programming C om m ands............................................... 439 Pallet Changing Program Structure..................................439 HORIZONTAL BORING M IL L ........................................439 RUNNING THE FIRST P A R T ........................459

XX

PROGRAM C H A N G E S .............................. 460 Program Upgrading............................................................460 Program U pdating............................................................461 Documentation Change....................................................461 ALTERNATE MACHINE SELECTION . . . . . . 461 462 MACHINE W ARM UP PROGRAM . .

47 - WRITING A CNC PROGRAM

441

CNC MACHINING AND S A F E T Y ................. 462 PROGRAM W R IT IN G ..................................................... 441 Legibility of Handwriting................................................... 442 Programming F o rm s ....................................................... 442 Confusing Characters....................................................... 442 PROGRAM OUTPUT FORMATTING . . . . 443 LONG P R O G R A M S ..................................................... 445 Program Length Reduction............................................... 445 Memory Mode and Tape M o d e ....................................... 446 SHUTTING DOWN A CNC MACHINE . . . 463 Emergency Stop Switch....................................................463 Parking Machine S lid e s ...................................... .......... 464 Setting the Control System................................................464 Turning the Power O ff........................................................464 EQUIPMENT M A IN T E N A N C E ................. 464

51 - INTERFACING TO DEVICES

465

48 - PROGRAM DOCUMENTS

447

RS-232C INTER FAC E......................................................465 PUNCHED T A P E .............................................................466 Tape Reader and P uncher................................................466 Leader and T ra ile r............................................................468 Tape Identification............................................................468 Non-printable C h a ra cte rs................................................468 Storage and Handling........................................................468 DISTRIBUTED NUMERICAL CONTROL . . . 468 TERMINOLOGY OF COMMUNICATIONS . . 469 Baud R a te ........................................................................469 P a rity ................................................................................469 Data B its ............................................................................469 Start and Stop B its ............................................................469 DATA S E T T I N G .............................................................469 CONNECTING C A B L E S ............................................... 470 Null M o d e m ....................................................................470 Cabling for Fanuc and P C ................................................470

D A T A F I L E S ................................................................... 447 PROGRAM D O C U M E N T A T IO N ................................. 448 External Documentation................................................... 448 Internal Documentation................................................... 448 Program D escription ....................................................... 449 SETUP AND TOOLING S H E E T S ................................. 449 Setup S h e e t ................................................................... 450 Tooling S h e e t................................................................... 450 Coordinate S h e e t ........................................................... 451 DOCUMENTATION FILE FOLDER . . . . 451 Identification M e th o d s ................................................... 451 Operator's Suggestions................................................... 452 Filing and S to ra g e ........................................................... 452

49 - PROGRAM VERIFICATION

453

DETECTION OF ERRORS...............................................453 Preventive M easures....................................................... 453 Corrective M easures....................................................... 453 GRAPHIC V ER IFICATIO N ...............................................454 AVOIDING E R R O R S ..................................................... 454 Syntax E rro rs ................................................................... 455 Logical E rrors................................................................... 455 COMM ON PROGRAMMING ERRORS . . . 456 Program Input E rro rs ....................................................... 456 Calculation E r r o r s ........................................................... 456 Hardware Errors............................................................... 456 Miscellaneous E rrors....................................................... 456

52 - MATH IN CNC PROGRAMMING

471

BASIC E L E M E N T S ......................................................471 Arithmetic and A lg e b ra ....................................................471 Order of Calculations........................................................471 G E O M E T R Y ......


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