EMCO Compact 5 CNC Instructor Manual

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4 .17

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G01

G01 - Linear Interpolation Linear means str aight lined I nterpol ation means the finding o f intermed iate values Linear int erpolation ~eans the f i nding of intermediate values on a (stra i gh t) line. This line can also be at a certain angle .

Possibilities of G01

~ )

..

-z

1. Turning in Z·directlon (axis)

.

(Longitudi na l tur ning) with gi ven feed rate . No i nt erpo l a t ion tak i ng p lace .

+Z

(X-movement = 0 }

-X

( )

n

II II Jv ~

2. Turning in X·directlon (axis)

+X

(Z-move:cent = 0)

3. Taper turning \~i th given feed r ate. X- and Z- va l ues are being interpolat ed.

(. )

.

(Facing ) with given feed rate. No interpolation taking place .

(X- and z-n:overr.e nts)

4.19

page 4.21/ G01

()

)

1. G01 - Turning in Z-Direction - .9" ~~~~e!~.:

Tool bit shall lllOve . 95 '' in Z-di rection . Tool bit position as indicated in drawing.

I I IL __ __ _

-*'- .os

Inputs I. &nter block nuaher 2. &nt.er GO I 3. x-value = 0 4 . z-value to be put in thousandth o f inch 5 . Put in F-value in tenth inch per min\• te

11

() N

G

...__

0-1

X

0

z -950

Input form at longitudinal turning

F

25

N . . /G0 1/X

..

= 0 /Z = ±

.. ... IF =

2. G01 - Turning in X-Direction !::~~~~!~.: Tool bit shall face end pla ne (c ut e nd plane); tool bit position to start as indi cated in drawing .

()

Inputs I. &nter b l ocl< n\L'I\her 2. Enter C~l 3. X-value to be put i n in thousandth o f i nch 4 . z-value = 0 5 . Put in P-value in tenth of inch

N

G

X

z

Input form at G01 facing

e

F

N . ./GOI/X = ±

••

~

250

0

25

4. 21

.. I Z =OIF • . ..

)

G01

1. G01 - Turning in Z-Direction 22,5 ~~~~P!~~ 'fool bit shall r.:ove 23,5 r..m in Z-direction . Tool bit position as indicated in dra•<~ing .

I I

Inputs I. Enter block nurrber 2. Enter GOI 3. x-value = 0 4 . z-value to be put in in hundredth of

-+~-oo- 1

I

L ____ _

r:.m. l

5. Put in F- value in rrm/ min

)

N

G

z

X

F

longitudinal turning N . ./GOI/X

.'

01

0

2 35"0

= 0/Z = ± .. .. .IF =

80

2. G01 - Turning in X-Direction

\

~~~IE~!~ ~ Tool bit shall face end p l ane (cut e nd plane) ; tool bit position to start as indicated in dra·.dng .

)

Inputs I. Enter blo~k,.·:number 2 . Enter GOI 3. x-value to be put i n in hundredth of rr...rn

4. z - value = 0 5 . Put in F- value in rrm/ min

N

G

z

X

Input format G01 facing

F

N . ./G01/X

..

•

01

- soo

0

80

4.21

=±

.. .IZ = 0/F=

t-t

).

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Example: Finishing o f the s houlder workpiece in one c ut. The depth of c ut to be .01" The tool bit' s starting posit i on as indicated in t he drawing .

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G

X

00

00

- 240 0

.QL 01_ 0.2. Of 01 0:!>

•

()t

- ·- ~ - a

$.

OS (X,

Ol

( )

1-- - -- 1.6"

z

N

01 00 00 22

AOO 0 ~~~0

F

-560

.20

0

2.0 20

- 200 0

20

250

0

160

()

------~

•-: ___ _ - - ·- -

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u 4. 23

..

G01

)

Exampie: -

t-· -

<'4 ('4 -&

·

Fini shing o f the shoulder >:orkpie ce in one cut. The depth of cut to be o , 2o "-"· The tool bit ' s starting position as indiea ted in the drawi ng .

)

N

G

X

00

-soo

01

0 2oo

01 () -I

01 00

oo , 121

0 3oo

z

F

- 1320 0 - 600 ()

r;oo

0

1flo

)

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4. 23

so

so

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so

;-

Page 4. 25/ GOt

( ) Programming exerclce 5 (GOt)

Unfinished /"J

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~ $

~or~piccc

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1-'-

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( )

A chip of .012" depth has to be turned off the unfin ished ~orkpiece (exercise 3, page 4.15)in one cut.

Star ting position of turning t ool see d ra~ing .

1

·1.6

Finished

~orkpiecc

Hake a drawing i n scale of the transparent scale using the dra~ing paper and put in block numbers . Note that the tousa ndth o f inch cannot be measured f rom the drawing in thi s scale, so you must ca lculate the paths .

...

z

G

N

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TJI)

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f\ J

t-- - --

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o l.

ol

.812"=-:J

{)~

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1.6"

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nl

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z

X

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100

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u 4. 25

G01

)

(

Programming exercise 5 (G01)

Un f ini shed workpiece /"V

T ...

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-· -

N

$

$

-- r-

r

A c h i p o f o, 3 ~~ depth h as t o b e tur ne d o ff t h e unf ini s h ed •,·; o r kpiece (exerci se 3 ) i n o ne c u t .

('(

$·

1

-f.-- 15 20 40

( )

Pin i shed workp iece

('( ('( $

S tar ting p osi tion o f tu r ni ng too l se e d rawi ng . Naxe a drawing i n scale 10 : I using t he dra·.· ing p aper a nd p ut in b lock nu.• .bcrs .

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4. 25

( )

LINEAR Il.'l'ERPOIJ\TION I ndus trial machines are quipped with De- motors and position measuring systems . Toe slides are not moving step by step but in the prograu~ed speed to each other. This type of control/drive was not used on the COHPACT 5 cr.~ for cost reasons . The calculation capacity of the pe rs: X:Z = (1-39) : (1-39).

E~~co

COl'J>JICT 5 Cl\C for ta-

With industrial machines you can program both taper angles as we ll as taper end points.

(

I

Taper denomination see 4 . 35

( )

1 4.26

J

Page 4. 27/ G01

( l

,___

J.:zlt

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Example2 The ratio X: Z • 0.4:1. 2" • 1:3 This means 3 steps in Z-&xis and I step in x-axis .

( 4.27

G01

3. G01 - Linear Interpolation Taper Turning

)

Hand operated machine On a c:echanical I coJwentional la t he the top s l ide is clac:ped a t the desired tape r angle. I t is the top slide ..·hich e ffects t he feed ~~vec:ent and not long itudina l or cross slides.

) Exarr.p le

CNC·machine On the CNC- l athe •..:e do not f ind a t op s lide. Tnc feed movements must be e xecuted by longitudinal and cress s lidcs. Tnat means: longitudinal a nd c ~oss s lides have t o c:ove in a certai n relation to each other , according to the taper angle .

---,___

30

on the cO~!PACT 5 CIIC both slides are no-c covi ng at the sac:e tiree , but one after another . 'Th e microprocessor calculates the ratio X:Z and gives the instruc tions to traverse to the step mo tors. 'fi1 is ca l cu lation o f the X:Z ratios is called ll neat· in t erpolation.

Example 1 lingle = 45° The r atio X:Z at 45° is 1:1. LOngitudinal and c ress slides move at s aJT~ intervals.

Ex ample 2 The ratio X: Z • 10: 30 = 1:3 Th i s c:eans ?. steps in Z-axis and I step in x-axis.

4.27

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Page 4. 29 / G01

()

Taper 45° (X-value and Z-value are t he same) Inputs GOI I . Block nwr.ber

2 . GO I

3. X- va lue

cs 2

value) of taper end po int

in thousandth of inch

4. Z-value

cs 2

value ) of taper end point

in thousandth of inch 5 . F-value in tenth inch per minute

(

.

N

1-

••

G

01

z

X

- 250

250

F

a.

Input format G01

(

N . ./G01/X ± ... .IZ ± ..... /F ...

...

Example: 0

A chamfer of 45 x .25" has to be turned. Starting point of t ool bit as indicated .

( )

~ - -

1-

)

N

G

X

z

00

00

-250 0

-200 -215

25

-,iQO

- HS

-AS() -7oo -215

-A2S - lS

25 25

215

-215 21S

.J2L 00 '-

02. glj~ 8lt Oii 81t

05

8ft

06

00 01

_Q!_ 08 09 _1Q__

00 00

-so

0

F

25

--25

-:!;:x)

01 1-- ?;::f;J 00 H 250 42 00 0 ~ __21_ - -

_::.3oo_

2.L

.

500

-

-

u

(J 4. 29

G01

\

Taper45 ° (X-value and Z·va lue are the same)

I . Block number 2. GO \ 3. x-value (S 2 value ) of taper end point in h undredth of rr.~ 4 . Z-value (52 value) of taper e nd point in hundred t h of r-m 5 . F-value in em/min

N

-. .

G

0 -1

X

z

Input format G01

F

N . ./GO\ /X ± ... .IZ ± .... .I F

- - --- -... --.. 500 _:_500

Exa mple: ..-1---lf- 5 x4S•

A chanfer of 45° x S ~, has to be turned • Starting point of t ool bit as i ndicated . N

( )

00

.P1

G

z

X

~ -=..£0 0 8~

- 400

03

K~

- ZOo

_Q1

g~

OS

8~

- 3 00 - ~00

,_QQ_ 0 0

go - qso co _ - 3SO - 2.£Q__ _jp_ - 1SO 8o

-sse_

--· ---

_ -J"SO +SSo

,..2.l _Qj_ _±_S!>o_ 08

00

0

_oj_ ~ - -600 ~ jQ_

-

--·

_QL - ~+ 602 ~-

11 00 12 00 1-j-!._ Z.L

-

- ~ 00

00

Ol

F

~

~-

- €00

soo 0

+ 10()1)

--

I

4. 29 J

Page 4 . 31 /G01

n

(

Programming exercise 6 (G01)

. I

Tap er45°

Program the tape r out of prograoming exercise page 4.17,G84 . Choose the ·x starting position of the tool bit on your own .

(

( )

)

1---

( )

N

G

..f)_Q .

Ql

- 1.611 - - - - . l

z

X

F

::.}:IJQ _oJ_ ..oL -·~QL_ "':;:,tl" n O:.l f){) .< /\fl ~...300 ___ _O_l ..Q.Q_ -_Q_ _

4()

L __ o___ ··,_o4_.-·

JJ.::i _Q

nl ,?.oo - ~00 _j) (J __ Q __ _ ,' ]5_ _Q]_ J_~ -· . -- - - ----·

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_oi.

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-

-

-

.

..

----- - 1..

.

.

--- ·- ---- --

.

.

u 4.31

( )

.

---

G01

)

Programming exercise 6 (G01) Taper45°

Progr am the taper out of progracoi nq exerci se 4, G84. Choose the starti ng p osi t ion of the tool bit on your ~~n .

... 0

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l )

1--- -40- ---1

tl

G

1.>0 . o l kL. 11 1 (,~

)

z

X

r-0 t on

-

- I , C:O

oo

t~o G

01

ob ou_ -~ ,, ) ' ' ~'---'- - · -

-

,jt;

- <;n

.H

.- [.t.U

)5

-----·

--· - ..

s

11CV

-

- --- 1-

~-

~f.,()

_li_ f-L -'-60 [) Di_ ,_ol_ L5

I I) S O

F

-

·----··---

---- --

( )

4.31

J

Inputs

Page 4.3 3 I . Block nur.ber 2. GO! 3. X-coor dinate of taper end point 4 . z-coordinat e o f taper end point 5. F-value in t ent h o f i nch

u

N

G

X

z

F

01

250

-250

2S

Input format G01 taper N . ./GO I IX± ... .ll ± ..... IF .. .J

AlarQ signa l A07

u

\\'hen you put in other data t ha n X:Z (1-39):(1 - 39) the alarQ signal A07 appears . The C03puter does not kno~ these other X:Z ratios .

4.33

~

(

G01

Tapers in General . ) Possible angles on COMPACT 5 CNC The

follo~ing

t aper angles are possible :

Ratio X:Z X:Z

(I to 39) :

to 39)

(I

Tne number o f possible angles is l imited because o f computer capacities. On the Compact 5 CKC the slides do not move at the same tir.e , but one a f ter another . l~hen t ur ning at an angle rat io o f 39:35 ·.~e •..:ou ld produce a some·, ;hat r ough sur face on the \,~orkpiece, so ~. .·e limi t ourselves i n the tu r ning e xercises · to the ratio .

( )

X:Z =

(I

to lo)

(I to lo)

Inputs Program the end poi nt of t he taper. I . Block nurrber 2. GOI

3. x-coo rdinate of t aper end point 4. z-coo r dinate of t aper end point 5 . F-va lue in rouo/mi n

(

)

N

G

--1..0.1

z

X

+.>oo

-

Soo

F

80

Input format GOt tap er

-

N . .IG01/X± , . . . IZ± .... ./F .. . I

-

Alarm signal A07 you put in othe r data than X:Z ( 1- 39): ( 1-39) the a l a rm s ignal A07 appears . The computer does not kn~,; these other X: Z ratios . ~llien

)

=

4.33 j

- II

4.34

I

Page 4.35/

()

( )

z

N

G

X

00

00

01

02

00 Sit-

-250 0 - 50

ro

00

0

Olf

00

-So

05

01

06

01 08 01

(

G01

I

Taper 1:2

-200

A taper 1:2 is to be turned.

-850 -250

2o

-so

- 200

Oi

0

0!

:JJ 0

__o_

20 20 _2Q_

00

00 01

~0

Example: F

-

-so -So

- 400

1-

-

400

__-2oo_

2o

--

2o 2o_ 1--

01

0

0-1

50

- 2oo 0

0

2oo

AIf

()()

-5)

~5

01

~6

01

-2oo-·- 20 - 50 -2oo __ _ o ·- J.Q_ 250

·-

.-foSO

-

~()()

4l ·111 00

22

-{'!

0

-- --

(

--

11 42

__&. 00

Right hand side tool .

--

()

() Taper denomination ·

Taper I :K = 0

=

~

Di f ference of Taper le ngth 0-d 1

is the prograrumlng an9le

«- is called taper an9le

'•

) 4.35

dia~ ter

\

G01

z

F

N

G

X

oo

- soo

0~

00 00

oz

l~

t>J

00

nil

00

-100

OS

-100

- 400

80

0 100 0 - 100

- Roo

Ko

10

01 01 0-1 00 00 01

-ion

- i{oo

·U

0{

112

•H

01 00

0 101l

- /tOO 0 ~00

1~

on

-15"

01 01

J)_6 01

08 09

....iL

..11_ 00

I <1f I -1 9

nfl

0 - 100 0

0 - 100 -100

Example: Taeer 1:2

- ~~ - 1 100

go

- '00

0

A taper 1: 2 is to be turned . Right hand side tool.

iO

Roo

- Itno

!too S'Oo

0

0

11no

Ko

So

-4-·- ~ -- :! -1- · -- · --1---t-

1

~

flO

-'--+-~

go flo

2'J_

Taper denomination

( ) Taper I : K = Difference of diaceter Taper length 0

=

I

D-d 1

is the prcgrarr~i ng ang l e

oe. is called taper angle

4. 35

·-

Page 4 . 37/G01

()

( Programming exercise 7 (G01)

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---

~-

_ o.j

00

.~ 5 0

ICj

Ol)

:},_'l

. dtl- {

0

-

1.15()

---

-

() 4.37

G01

) Programming exercis e 7 (G01)

~

-- ~ ---~ & &

0

.

('t

&

\

....

..

1x45° 1---10-

20 '

N

G

(

!-U2ro

(

~

(

. ?:.J

'

- Q(.J

- \cf u

.-U1

J

I .~ n l -". fl

nl

_2_

'

- •on D

'

l}

. - I.,

...!LL -~

<,

.. c' ,r-

L

,:

J.. '

I

I

r

·-

~,c.._

- I·~

~:'

r

I )j )J

JO )

~~

\)')

-

•::.0 '

'

' '"

~,_,

·'.....

- -,~ \"j

~· u

0

,.,_

As ~ ':'

.·) J - ·'>ct.

:i ;l~ - ·- ,. ( . '·1 i

o'

•D~

I } CD

:"..._;__ ")

0

t

.

l

.

t.l

. ~

·-:'

-,Jj D

-~0 I l" :)

0

'j .~

.)

oO

~

F

~

0

..1..-

)

,.,.....

O)

(j_'

z

X

1 ~1... r· r

,. u -

)

4.37

~ l

G01

) Angle a/2 and X : Z ratios

X: Z

Angl e

X: Z

Angle

X:Z

5 , 7 1°

I : Io

35 , 54°

5: 7

6o , 26u

7: 4

6 , 34°

I:

9

36 , 87°

3: II

6o, 9 5°

9: 5

8 ,1 3°

I:

7

38 , 66°

·I :

5

63 , 43°

2:

9 , 64°

I :

6

39 , 8o0

5: 6

66 , o4°

9: 3

6: 7

, 8o 0

7: 3

0

Angle

( )

I I,

3°

4o , 6o0

GG

12, 52°

2: 9

i'Jo , 19°

7: 8

66 , 2o

5: 2

111, o 0

l: 4

•l\ , 63°

8: 9

G9 , tl4°

8: 3

15, 9•1°

2: 7

4 1' 99°

9 : lo

71. 56°

3:

0

-.iS , o 0

I :

73 , 3o

lo : 3

3

,18 , 8 1°

8: 7

74, o5°

7: 2

2o, 56°

3: B

49, ~o0

7: 6

75 , 96°

4:

2 1, 8°

2: 5

So, 19°

6: 5

77 , 47°

9: 2

16 , 69°

3: lo

18 , 43°

I:

23 , 2o

3: 7

5 1, 3<1°

5: 4

76 , 69°

5:

23 , 96°

4:

9

52 . 13°

9: 7

Bo, S4°

6:

26 . 56°

I:

2

53 , 13°

4: 3

81. 87°

7:

29, 74° 3o, 96

4: 7

5•1' 64°

7: 5

82 , 87°

8:

3: 5

56 ,61°

83 , 66°

9:

32 , o 0

5: 8

58, o0

3: 2 8: 5

84 , 29°

lo: I

33 , 69°

2: 3

59 , o4°

5: 3

0

( )

l: 5

I

Th e chart sha•s only the a ngles for t he r atios X:Z • (1 - l o) :(1-lo). Alarm s i gn will appea r ha•evcr onl y if a ngle ra tios othe r than X: Z • (1 - 39):(1 - 3)) are prograrrr.:ed . For the turning exercises we limite ourselve s to ratios X:Z • (1 - lo): (1 - lo).

l )

4.39

----------------------------·--

G01

Data on angles

Z• 5 x 1,67 • 8,35

Example k'e t ake for ~ 3o0 the ratio X: Z = 3: 5 ( ""~ with 3 : 5 • 3o, 96°.

The z-val ue is 5 tir.es as large, thu s 1,67 x 5 • 8 , 35 rr~

( ) 0 • -

('I - - .

-s.

-1-- - - --1--

The block for t he traverse path S 1 S2 is: N

G

X

z

F

~ne

tool bit has to t raverse from points S1 to S2.

.~O~~S~0~1--~~~-I~· · --

Z= ?

(

)

By ra ising t he value fro~ 5 to 5 , ol, t he t ool bi t juts out o , ol r"' i n xd irection and o ,o3 ~ i n Z-direct i o n over the i deal point. Please ta~e this into consi doration when prograocmi ng the fol l~~ing blocks.

Sl 0/1

"

)(

52

~ne

path X is 5

~~ -

~ne

ratio X:Z

~

3: 5

5 :3 • 1, 66666 ... , thus not divisible . l'/c t ake the ne xt greate r nurr.ber which i s divisible by a : 5 . o l 5,ol : 3 a 1, 67

( )

4. 41

Page 4 . 4 3 G02/G03

(

G02 - . Circular Interpolation Clockwise G03 - Circular Interpolation Counterclockwise With the circular i nterpolati on t he circular arc is divi ded into single s t eps . It is substituted by many straight l ines . Oi fferent fron the linea r interpolation the r atio X:Z changes h ere perma nently.

(

)

(

Possible radii on the COMPACT 5 CNC .OS"/ .1"/

.15"/ . 2"/.25"/ . .. up to 1.95"

Program input I . Block nwr.ber 2. G02 or G03 3 . X-value in thousandth of inch . As X- value we put in the X- coordinate of the 4th part of ci rcumference. Tne longitudinal s l ide moves aut onat ically in minus- direction (d i~.

rection chuck). No Z- Input F-value in tenth of inch

Alarm sign A01 ~:hen input of radius is undefined (for e xample r= J.13 inch) the alarm sign AOI appears .

u 4. 43

(

G02/G03

(

)

G02

Circular Interpolation Clockwise

G03

Circular Interpolation Counterclockwise l~ith the circu l ar interpolation the circ ular arc is d.ivided into singl e steps. It is substituted by many stra i ght line s. Di f ferent from the linea r interpolation the ratio X:Z changes here permanentl y .

( ) !'.

1

--;zr "'.

~-

·-~·

z:x )

·'-....__./ Possible radii on the COMPACT 5 CNC o ,25/o, 5o/l/2/3/4/5 ... up to 59 rum

Program input 1. Block numb er 2. G02 or G03

)

3. X-value in hundredth o f rr~ . As x- value ~e put in the x- coordinate of the 4th part of circum fere!lce . 4. z = 0. The longitudinal s lide moves au t omatically in minus-direction (direction chuck) . 5. F-value

Alarm sign A01 When input of radius is undefined (for e xamp l e r = 4,5 run) the alarm sign Aol appears.

)

4.43

(

DIN and ISO describe G02 and G03 as

foll~NS:

"Circular interpolation in which the curvature of the path o f the tool with respect to the workpiece i s clockwise (counter-clockwise) when the plane of motion is viewed in the negative direction of the axis perpendicular to it."

Translation for COMPACT 5 CNC The rr~vement of the tool bit has to be looked at f rom belo•.<. In the drawings tool and workpiece are depicted in their working position from above, therefore the inversion o f directions.

(

Have the student draw on transparent paper the circle directions and looked at the paper from belo'" and above . So he will realize the inversion of d i rection quite easily. The

sy~Jbols

on the headstock correspond to ISO and DIN.

A simple rule G02

G03

G02 sense of rotation = short way from +X to +Z

G03 sense of rotation = long way from +X to +Z

=G03

(

=G 02

+X

+X

(

14.44

1

G02/G03

)

Radii when outside turning

Radii clockwise G02

)

N

--

G

02,

X

+

z

F

N

--

G

X

z

F

Ol

-

Rad ii counter clockwi se G03

( )

N

G

03

\ )

4. 45

X

z

F

oage 4 . 47 / G02/G03

)

(

G02 - Radii clockwise

of turning t ool as seen f r c m above

:~ovez:ent

2

.

--~·J_·-·. ()

Program for fourth part of ci r cumference I

·~ ! ·-

.. ,

,®.

-

Fourth pa rt of c ircumference 2

(

Fourth parts of circu~ ference 3 and 4 arP not proqra"nablc since Z-direction i s po sitive .

Input format G02 N . .IG02JX ± .. . .I F ...

G03 - Radii counterclockwise I·!Ovemen t of tu r ning tcol

Prog r am for four th par t o f circumfere nce 3

as seen from above

()

·-t-·" c;J · ~

·- · ~ ~~I ·- ·· ~ I

( Pr ogram for fourth part o f circuc ference

Fourth parts of c ircu:nf ere nce I and 2 are not programmab le since Z-direction is po sitive.

Input format G03 N . ./G03/ X:!: . .. .IF= ...

·U 4.47

~

G02/G03

------------------------------------------------------------------------G02 - Radii clockwise

:·loveP".e nt of turning tool as seen fro~ above

Program for fourth part of circumference 1

Fourth part of

circlli~ference

2

I~ I ~2 I ~~ I ~ I~~ I Fourth parts of circumference 3 and 4 are not prograr-~able since Z-direction is positive .

Input form at G02 N . ./G02/X± ... .IF ...

G03 - Radii counterclockwise r·!ovecent of turning tool as seen fro~ abnve

.-,---" I

)

~-4 3

~I

G<

Pr ogram for fourth part of c i rcumference 3

I ~ Io~ 1-~~ I ~ I~~ I Program for fourth part of circ umference 4

I~ Io~ 1,~ I ~ I,~ I Fourth parts of circumference 1 and 2 are not prograr.mable since Z-direction is positive.

Input form at G03 N . ./G03/X± .... IF= ...

4. 47

-~

Page 4 • 4 9 G02/G03

()

)

pepth of cut when

tu~ning

radii

You turn a radi\•s with the right hand side 0 tool. Of? = 9 3 You have seen that with outside' turning (as with facing) the max. depth of cut is .012". h'hen turning a radius you find a similar situation , eitl1er at the beginning or at the end o f the f ourth part of ci~­ cwnference .

Exercise :

( )

FolleY.; ·.dth the transparent paper (r ight hand side tool) I.Uo :1 the indicated radius. You will recognize the changing situation i r:rrned iately .

(

G02

Hax . depth of cut o f .012" onl y at the begin at 93° .

()

Line of possible depth of cut

( )

' G03

l·lax. depth of cut .012" only at the 0 end of radius at 93 •

u 4. 49

G021G03

f

)

Dep th of cut when turning radii ¥ou tur n a radius with the r i ght hand side tool . ~ = 93° ¥ou have see n that with outside tur ning (as with facing) the max. depth of cut is o, 3 rr""'· lfuen t urning a radius you fi nd a similar situation , either at t he b eginning or at the end of the fourth part of circumference . Exercise: Follu" with t he transparent paper (r i ght

( )

ha nd s ide tool ) Hlo:l the indicated rad ius . You will recognize the changi ng situation irr:..ediately .

' ~lax .

depth of cut o f o , 3 m:!l only at t he begin ·at 93°.

Line o f possible depth of cut

( )

' G03 Hax. depth of cu t of o ,o3 mm only at the end of radius at 93° .

()

4.49

I

-1-

:.

i-

-1-i

I

_..

L ....;-,_,._,-r-- .... ...

-

•

•

4-

.._

j_

.

·f-

- ·-

-I·

·-

·-

f-.

~'-

11-

•

..

...

L

i

1'-. j.

I 4.50

·- -Lh-+-

I I -+ I

I

l

--

Page 4 . 5 1/ G02/G03

Example G02 ~laterial: Alu::>iniun St.a rting p osition of turning tool as in drawing .

..

•

--.\--

- -- f--

: t - .1.. ~

- .-

-9 (

1...

)

)

_/

/

'

()

()

N

G

00 00

z

X

-250 0

_.QL

00

02

81t

-50

03 tl't _QL

-400

OS 06

01 08 09

JO 11

1 -1~00 01

02

00 00 22

- -1:0 - 200 -250 0 250 2£;0

0 4. 51

F

-200 -185 - 160

25 25

-I~S

2S

- 615

25

-550

25

-

25

40QQ__ - -

-

()

G02/G03

)

Example G02 Material: Alum1niuo Sta~tin9 position of turning t ool as in dra·.. ing. t--- 1 5 -~

.

)

__../ J

s { ) N

G

X

00

00

- Soo

z

F

0 - 100

-200

-1100 0 __j}_j_ _oo

)

10 _g_p_ 11 n

Ko soo C1

2000

4.51

- --

Page •l . 53 G02/G03

()

Programming exercise G02/G03 Hateria l: 1\luoiniu~:~ Progra~ this exercise such that you finis h it with one final cut. Starti ng pos ition of tool bit as in drawing. Posi tion of tool bit at end of program to be identi cal with starting position . Hal
(

( )

),

(>

N

G

X

z

F

...

}

Start position

(

-. ~00

s -~ ~

JS ••311.2__ -~s

A -' 1q

--~., ~5'

-

J.~ • _ =._,').()\,)

u

J~

.. nso l 4.53

G02/G03

)

Programming exercise G02/G03 Natcrial: 1\lur:U nium Program this e xercise such that you fi nish it with one final cut . Starting position of tool bit as in dra~ing. Posi t ion of t ool bit at end of prograo t o be identical •.-ith starting posi t ion. Mal
)

~

~

- - - ·-

6

~ .....

- - ·--1--

10

)

z

N

G

X

.~o

Ov

-5ou

JllL

.D. . \:>v

w.

C.1

)"' {,:"

' '> J I.

'>'i

~" ~~~

73-

l

..L

I

~

l'

-/I!)~

.. II'\'

I)

l ( '--

_.u_ l)l.

00

-

-· ,, ( 0

-

0

'

-

- I ":C:t;

l>

A ~.J.L

[r)i>

'" < ·'" ~ '•) u - CJCq.) -.·I '.J r.t -

., ~: -

-·~-

- Li ~:)

F

LOt)

I 0 •)

' ------ fr__t___ •I

)

-· - '

·~ao

;n ' ·o ...

\QU

'-s::

0

-

-

' I o o-

'. ---

------

)

4.53

4.54

J

( )

) Example G02/G03 Turning of intersected a nd combined radii. Re;,ark: The tool bit always e xecutes the move cent of a fou rth part of ci rcumference . A/

1\.

..

. - •... - - ·

" ~

-&

()

.

"'~

-

'&

(

·Is,

~

""K-,. I

~ N

l

•

----1-

)

-

i-- .6" -

()

() star t posi t ion

z

X

N

G

00 01 02.

00

-250

00

0

-2oo

-50

-·Hs

0~

Slt g4

-AOO

-155

04 _

00

-4-350

00

0

OS

06 ~. 01 02

og

oq AO

~) 4.55

C()

0

22

25 25

-

25

25

+450

00

-

-150

-500 +250

F

+AOOO

---

( )

G02/G03

)

(

Example G02/G03 Turning of intersected and radl1 .

co~~ined

Remark : ------The tool bit always executes

the covemont of a fourth part of circumference.

-+-· - ~

...

co

--II- ~ - -1--

-e.

'&

'&

( l

12

t>~ 12 -

(

) N

s

G

oo

X

z

F

- S(X)

0 -100

- J,Oo '100 0 -1000

- JOO

300 SOD

0

1() ~

0

0

ooo

22.

)

4.55

J

Page 4 . 57/ G33/G78

Thread Cutting on the COMPACT 5 CNC On the C6tr.pact 5 CNC you cut l e f t hand and riqht ha nd th reads , insi de a nd outside .

Possible pitches .001"- .199"in steps of . 001"

Main spindle speeds when thread cutting

( )

(

These are limited . If t he ma in spi ndl e speed is t oo fas t , tile f eed :ill be i nac t ive and <:iHHlC t be s ync hroni z ed ·..:i t h t he mai n s pi ndle s peed any not:c .

Tnere fo re better pr ogram G20 be fo r e th r e ad- c ut ting s o you can slo-" de<.m t he main spindle speed , i f necessa r y . If the speed i s t oo high, the re will be alar m indi ca tion. Hax

Pitch in inch

Hax .

25

.001 - . 040

300

16

.041 - .060

200

16 - 12

.00 1 - .080

180 130

TPI

1ooo 25

()

spindle speed in relation to pitch (approximate values)

12

8

-

-

8

.OBI

- . 120

6

. 121

-

spindle speed

(I /

min)

(

70

.199

;\larm sign A06 1-lhen you su rpass t he spind l e s peed by rr~re than 5 t , the al a rm sign appears.

u

\ 4.57

G33/G78

~

)

Thread Cutting on the COMPACT 5 CNC On the Co~pact 5 CNC you cut l eft hand a nd right hand th reads , inside and out side .

Possible pilches o , ol - 4,99 i n steps of o , ol rom

Main spindle speeds when thread cutting

( )

These are limited . If t he main spindle speed is t oo fast, tile feed drives ;:ill be inactive and cannot be synchronize d •,:ith the

~a in

spind l e speed arw rr.ore .

Tnerefore better p r ogram G20 before thread- cutting so you can s lzy~ d~~n t he main spindle s peed, if necessary. If the speed i s too high, there ~ill be a l arm indication .

. . spindle speed in relation to pitch

!·'ax .

(l

Pi tch in mm

!·lax . spindle speed (1/mi n)

o , ol - I

3oo

I ,ol - I, 5

2oo

I, 51

- 2

IOo

2,ol

-

13o

3

3, ol - 4, 99

7o

Alarm sign A06 1-lhe n you s urpass the spi nd le speed by rr.ore than 5 %, the alarm sign appears .

4.57 j

!'age 4. 59/ G33/G78

()

( UNR Bolt Threads

X 0

w

()

( )

As a n e xample for inch threads we have a lool< to the UNR threads. Tne pitch is specified by the nucber of threads per i nch .

~~!~~!~~!~~-~~-e!~~~: Thread UNRC size 12 ha s 24 threads per i nch: 1 Pitch • ~~ch = .o4167" ( J

The geometr ical s hapes and dimensions are sta ndardized and ca n be found i n t echnica l handbooks . Example: Desi9nations and dimension of an URR bolt thread. D• E • K5• r = H• P • h3•

u

Basic major diameter Basic pitch diame ter Minor d i ar.eter for e xterna l thread Root radius llei9ht o f sharp U- thread Pitch Depth of ex terna l thread

The Va lues I Cal cula tion D and correspondin9 pitch are given for the relat i ve threads . h3 is

Dts

= .1 4434 H= .866o3

r

or

. 6 1343 x Pitch

x Pitch x Pitch

As the root radius r is dependent on the pi t ch (r = .14434 x pitch), for every pi tch a certain root radius has to be considered.

( )

G33/G78

)

Determination of a Thread Scre~s,

nuts , machine parts can be ex-

changed . Thi s is poss ible zation

~~ye

of standardi-

of q uality standards of speciul i nspection procedures of sta ndard s o n the denomination o f thread types As example ,..e usc in the foll
( )

. -- p

( )

P d D

o o o

d2 = d3 Dl

o

H

= =

h3

=

r

= =

HI H

= =

113 HI 3 =

(

----1

I

i

~ "'o 0 0

Pitch of thread Outs i de dia~e ter of bolt ds No~ina l diaceter f or bolt and nu t D2a •r hread pitch diar..e t er for bolt and nut Hi nor thread diaa:e t er o f bolt Hinor t hread diar..e t er of nut Height of profile = height of fictitions profi le triangle (with rounding and lcve li ng) Depth of thread of bolt = l /2 (d-d3) Roundi ng radius = H/6 = o , l4434 P Bearing depth o,8G6o3 P o , GI 343 P 0 , 54127 p H/6 ,. o , 14434

)

4. 59

Calculated va lues

Pag e 4. 61/G33/G78

(

() UNRF

Thread

0

w

()

)fin or oi aoe!!!:_ Sizes

I - -·

()

4(.11 2 ) 5(.1?.1) ) 6 (. 138) ' 8(. 16 4) 10(,190 ) 12 ( . 216}1/4 5/16 3/8 7/16 1/2 9/1 C 5/8 3/ 4 7/8

Bas ic Hajor Dlam.

On sic P itch

Thd s . per Inch .

Diam.,

In c hes

Inches O, I 120 O, t ?.fiO o. 1380 o. 16 40 o. 1900 0. 2 160

o. 2500 0 . 3125 0 . 3750 0 .4375 0 . 5000 0. 5625 0 . 6250 0 , 7500 0 . 8750

F.xt. Thds.

Int . Thds .

I nches

Inches

Roo t Radius

Pi t ch

In ch es

I nch es

44 40 36 32 28

(l.

0 . 0085 1102 o. 12 18 o. 1460 o. 1697 o. 1928

0 ,0864 0 ,0!)71 o. 1073 o. 1299 0.1517 o. 1722

0,0894 0 .1004 o. 1 109 0.1339 o. 1562 0 . 1773

0 . 0030 0 , 0033 0.0036 0.0040 0 .0045 0 . 0051

0 .0208 0 . 0227 0.0250 0 . 0278 0 .031 2 0 . 0357

28 24 24 20 20 18

0 . 2268 o. 2854 0.3479 0. 4050 0 .4675 0.5264

0 . 2062 0.2614 o.3239 0.3762 0 . 4387 0 .4943

o. 2 113

16 14

' · ''~'0 .6733 · '''' 0.7094 0 . 8286 0 . 7874

0 . 006i 0.0060 0 . 0060 0.0072 0 .0072 0.0010 0 . 0080 0.0090 0.0103

0 .0357 0 .0417 0 . 0 41 7 0 . 0500 0 . 0500 0 .0556 0 . 0556 0 . 0625 0 . 0714

48

,,

0.2 671

o. 3299 0 . 3834 0 . 44 59 0 . 5024 0 . 5649 0.6823 0 . 7977

-

(

-- You see th at t o e ach pitch there be l ongs a round i ng radi us r . ~hat ~ean s: for each pitch you need a th ~ead-cu tting t ool.

(

0 4.61

G33/G78

)

Metric ISO - Standard threads according to DIN 13

,I ,I N

'0

I

I

<'>

Q~a

I Thread Nominal dia. d• D

Pitch

p

'Ill read pitch Minor thread

dia. d2• D2

dJ dia.

o,5

2, 675

2 , 387

•I

0, 7

3 , 545

5

0,8

~

I ,o

8

I , 25

lo

I. 5

12

3

Dl

DePth of hJ thread HI

Rounding t·adius r

2 , .J59

o ,. lo7

o , 27 1

o , oi2

3, 141

3' 242

0 ,4 29

0 , )79

o , l ol

t. , 48o

tl , o l9

..;,.1)4

o , t.91

0 ,4 ))

o , 11 5

5 , 35o

4 , 773

4 , 9 17

o , 613

o , S-11

o , 144

7 ' 188

6 , .;66

6 , 647

0 , 767

0 , 677

o , I So

9 , o26

8 , 16o

8 ,376

o,9 2o

o , 8 12

0 , 217

I , 75

o , e&J

9 , 853 b, !o6

l, o74

o , 9~7

o , 253

16

2,o

W, 7o l

13 , 546 13,835

I , 227

l. o83

o , 209

2o

2, 5

Ja, 376

:6,933 17' 294

1' 534

I, 353

0 , 361

J .

.

. .

You see that to each pitch there belongs a rounding radius r. That means: for each pi t ch you need a thread-cutting tool.

,)

4. 61

G33/G78

)

lndexable tips for threading

2. Partial profile tips

I. Full profile tips

(

'

IH th the full profile tips you cut the correct thread profile . You need for each t hread profile and for each pitch a scperate tip .

Advant age: using partial profile tips , you can use on tips for various pitches ~ithin a certai n range of pitches.

h~en

Disadvantage : The roundi ng radius is not accord ing to standa rd.

The outside diaroote r will also be calibrated.

( )

On the CO~IPACT 5 cr:c ~
( )

4.63

Page 4. 6SIG33/G78

)

.J

The tool holder for external threading (order no. 260 620)

The lndexable tips for right h and threading (order no. 260 621) Ca l c ulation of In feed

hj wi th partial profile tips:

h3 with full profi le tips : B

=

l

.61343

Basic

X

~Ialor

• . 75777 x Pitch - r ·

Pitch

r

Dia - Minor Oia 2

• D - Ks

)

Threads per I nch

Pitch (inch)

1) 8

o. o 2o8

of tool bit nose

The indexable tip i s a pa r tial profile tip. It can be used for pitches froD o , S to 1 . 5~ and for 16- 48 threads per inch (TPI). 0 ~nread angle = 6o Rounding radius r • .ool 6 (o , o4mml That means : t he minor thread diame ter Ks l
2

I

= Radius

Infeed h) with profile tool (inch)

Infeed with o.oo16" r ad i us

t ool ( i nch) o.o l 28 ..

Suggested ~l i nimum No . of rough passes

o.ol42

4

o :ol 56

4

114

o . o22 7

o.o l 39

4o

o.o25o

o.ol 53

o.o1'P

5

36

o.o278

o.o17o

o.o195

s

32

o.o312

0.0192

o.o22o

5

28

o . o357

0 . 0219

o.o255

5

24

o.o417

o.o2 56

o.o3oo

6

2o

o .oSoo

0 . 0)07

o.o363 ,

7

18

o .o556

o.o341

o .o4o5

7

16

o . o625

o.o383

o .o458

8

.

(

\)' \." -=-t'' c:.''\ 'l .,

• \>,...,""\ - S> I)\~ , 01>\\o,"'(

4.65

(I

G33/G78

) The tool holder for external threading (order no. 260 620)

The lndexable tips for right hand threading (order no. 260 621)

(

The indexable tip is a partia l profile tip . It can be used for pitches fro~ o , 5 to 1 , 5 ~~ and for 16- 48 threads per inch (TPI) . 0 Thread angle a 6o Rounding radius r = o,o4 - o,o4S rr"" Tnat u.eans: the minor thread diamet er d3 wil l change for the relative pitch, when compared to !SO- standard. d - d3 The depth of thread = h3 is 2 bigger.

)

) Pitch P (mml

h3 ace. ISO , OINI3 (top radius changes with every pitch)

h3 •.;he n using tip ,_.; th t op radius o,o4 rrm

o, 5

o, 3o7

o , 337

o,G

o, 368

0,415

o, 7

o,429

o , 490

o , 75

o , 46o

o , 5 28

o,8

0, 491

0, 551

I ,o

o,613

o . 717

1, 25

o,767

o,9o7

1, 5

o,92o

I, 1oo

)

4. 65

-----

G33/G78

)

Synchronisation Hain spi nd lo speed - Feed when thread cu t ting Conve ntiona l lathe l~ith

)

a conventiona l l athe , the dr i ve of the l eadscrew co~s via a gear wheel on the ma in spindle, via change gears , via the feed gearbox ont o t he leadscre~ . Tnere is a closed ~echanical ci r cuit of force . If the ca in spindle ruaves sla~er (e .g . because of heavier load), t hen the leadscrow ·..:ill turn slO'.
. ----(

_......-·- ·-.

---

· '-...

....__

...............

{ )

4. 67

~

- - -J.J.i!([{(T11l7 'l.\1~\l

·-·~~

G33/G78

Synchronisation Ha~n

spindle drive - Feed size when thread- cutting on the CO)lPAcr 5 C!;C.

spi ndle and feed drive are not frictionally connected. The synchroni sation is effected via the compu ter.

~!ain

Pri nciple

( )

I. The impulse sender I gets the revolutions of the main spindle from the perforated disc and transmits it to the corr.p uter . Here it is processed , and from that information it determines the f e ed required to obtain the prograrra.ed thread pitch. Tne result is transformed into an instruction i
S l ots for synchroni sation

I mpulse sender f or start- feed

I r.-opul se sender (I) l r.opulse froo per fora ted disc to regulate feed.

2 . A thread is ·ah do I get back to the same position? CNC-Hachine The start instruction f or the feed has to be always at same angle position of the main spindle . The perforation on the disc t r ansoi t s via the i~pulse sender the angle position to the compute!: . The latter one gives the start instruction to the stepping u.otor of the longitudinal slide.

4.69

J

G33/G78

(

)

Su:~ ry

Synchroni sati on

I. The feed rate is controlled via the pe r forated disc on the main spindle.

( )

2. Tne perforation of the discs transmits the angle position of the main spindle and initiat es the start instruction to the stepping cQtor of the longitudinal slide , thus the t ool bit always returns to correct posi tion f or next cut.

Tr ansmission of revolution Trans oission angle position

I mpulse for feed rate • speed

\

4. 71 )

Pa 9e 4 . 73/ G33/G78

()

G33 - Threading with Constant Pitch

Inputs G33 I . Block nuu.ber

Example: Ri9ht thread 2o tpi Pitc h ~ .!. 2o

(

2 . G33

.. -05 06

G

3. X ~ 0 4. Lenqth o f thread in column Z in thousandth of i nc h +Z a Ri9ht h a nd threa d

.0 50"

Len9 t h of thread N

u

X

-z ~ Left hand thread 5 . In c ol umn F, thread pi t c h i n thousand th o f i nch

. S"

z

F

Input format G33

.

N . ./G33/ Z:t .... .IF . . .

.

20 :33

tiOO

50

Technique of threading The tool bit has to be fed i n steps by rr.easurernent h 3 .

(

(

)

I. Fe e d in only in x-axis :

-------------------------Firs t cut with de pth o f .008" Furthe r cuts at Las t cut at

.004 "

.002"

2 . Feed in x- and z-ax is :

---------7--------------(

) 4. 73

G33/G78

)

G33 - Threading with Constant Pitch

Example :

I nput s C33

Length of th read 12, 5 Pitch o,75 rr.11

I . Block

IUD

na~er

N

2. C33 3. X = 0

N

. .

G

X

z

0

)

-

OS 20 H

33

4 . Length of th read i n column Z in hundredth of ru n

F

12SO

JL -

+Z ~ Right hand thread -z a Le ft hand thr e ad S . In column F, thread pitch in hundr edth of r.m .

Input format G33 N . ./G33/Z± .... .IF .. .

Technique of threading The tool bi t has to be fed in steps by meas urement h 3.

)

!; _~~~~-!~-~~!~ - ~~ - ~=~ ~!~~ Firs t cut wi th depth o f o , 2 Further cuts at o,l rrm Last c ut at o,oS ~~

2 . Foed in x- a nd z-axis: )

4.73

~m

-

Page 4 . 75 / G331G78

()

l '

Threading with G33

.. ~. 8' -

•

.

-~

.

.

Example:

•

....0ii:"

.... t

UNF thread Si:ze 3/4" 16 threads per inch Pitch ~ I = .0625"

i6

infeed with partia l profile tool r ~o .04rro = .0016'' : h;= .0458"

(

We assume that clearance cut and chamfer are al r eady done, threading too l is at a distance of .o5" to the facing side and .ool" to outside of workpiece. Since turning tool will have to be changed as well as main spindle speed , the block before the threading itself mus t be H.• /G=20 (dwe ll). l~e assume this block carries the number 11 . N=l2 N=13 N=14 N=15 N=l 6

u

N

Positioning .010 with rapid traverse First c ut (Depth of cut .009") Repositioning wi th rapid traverse Repositioning with rapid traverse Positioning .014" with rapid traverse; ( (Prograrrtned cutting depth .oo5") G

X

z

F

I

:

Nl3

:

.AL 20 Nl4

N12

-12 00 ,(?J 33

- .{O

AIt 00 As oo

10

N!5

-'too 0

62

9oo

For one cut 4 blocks have to be proA very time consuming programming. There fore you use cycle G78 for threading. grarr~ed.

u

( 4. 75

G33/G78

)

Threading with G33

Examole :

l - - 22 -

-- -

.

.

! )(

0

('4

f

Fine threading accord i ng to ISO H2o x I, 5 d cG

= 2o

= 6o0

p

h3

=

rr"-:1

1, 5 1,1

ILI1l

~~

(depth of thread)

( ) We assume th at clearance cut a nd chamfer are already done , threading tool i s at a distance of l ~" to the facing s i de and o , l ~" to outside o f workpiece. Since turning tool will have to be changed a s well as main spindle speed, the block before the threading itsel f must be N. ./G:2o (d-.-e ll) . 1\e a ssutce this b l ock carries the nurrber II . Nl2 = Positioning o,3 ~" with rapid traverse N!3 = First cut Nl4 = Repos i tioning with rapid t raverse Nl5 c Repositioning with rapid t raverse Nl6 = Positioning o,3 mm with rapid traverse, etc. N

G

z

F

- 2~00

1fiO

X

(

N13

N14

N12

N)5

-11

lO

12 13 1lf 1S

00

-30

33 00 00

.,. 30 0

-t-

21foo

For one cut 4 blocks have to be pro gr~ed. A very time consuming programming. Therefore you use cycle G78 for thread i ng.

(, )

4. 75

G33/G78

( 1

Threading Cycle G78 As with the cycles f or long itudinal turning a l so with the threading cyc le 4 single steps are put t ogether i n ona block.

Programming : ~~~~-!~ Enter t he feed in value in the x-column.

--H--p=1,25

( )

z

I.. ~

~E!!t?-~~ - Enter the thread l ength in the Z-column. - Enter the p i tch in hundredth of rr~ i n the F-column. ~E!!E~ -~-:!:-~.:. Tne repositioning of the t ool bit to the s t arting point is done automatically .

Input format G78 N . ./G78/X± ... .IZ± . ... ./F .. ./

( )

The speeds for the 4 steps Step I : Programr...ed th r ead p itch Step 2 : Progr arr.-ced t h read pitch Step 3 : Prog rammed thread p i tch Step 4: Rap id traverse

)

4. 77

Page 4. 79/G33/G78 I

(

J

Possible cycles

( J

( l

A

Right hand thread, e xternal

811

B

Left hand thread , externa l

No12- 24UNC ~ht

(. \ J

~

EJ

C?J Pro~~am

r.l.

78

Program for one cycle

for one cycle

I I 1-;0 1-9~ I G

cs:J

I I 1-;0 I +~00! 50 I II

F

G

F

78

42

Input format G78

Input fo rmat G78 N . .IG781X = - .. . .I Z = + .. .. .IF = .. .

N . . IG781X = - .. . .I

Z = - .... .IF= .. .

u 4. 79

G33/G78

)

Possible cycles

A ~--~4r---~----~4~--~

c ( ) A Right hand thread, external

B Left hand thread , external

20

()

Program for one cycle

Program for one cycle

Input format G78

lonput format G78 N ./G78/X = .I Z = + .... o/F = .. o

N .. IG781X = - .. .I o

Z = - .... .IF = ..

0

o

( ) •

4o79

o ..

Page 4. 81 /G33/G78

()

..:

lnt<> L"nal thread, ri')ht hand 1/2-28.UNEF

v

.4"

()

t::D

CiNVJ 1/16 = .0625" Pr09 ram for the first cycle.

1/28 - .03571" Program f or one cycle

I~~. I I G

X

70

10

1-:oo I

r 36

I I I I I I

I

II

~

G

X

z

F

70

10

GOO

62

Input format G78

Input format G78 N . ./G78/X

t)

+ ... .I

N . ./G78/X

=

+ ... .I

( )

u TECHNIQUE OF THREADING

Tool bit position at start of cycle G78 1. Choose zero-poi nt of cyc l e such that you keep a little distance to the end o f the ~orkpicce.

()

2. The zero- point of cycle should nei ther be to close to the surface of the workpiece. It could scratch on the surface when ~oving back to the starting position (step 4). So choose the zero-point of cycle at o, l rr~ distance to the surface.

4.81

(

G33/G78

(

)

C

D Internal thread , l ef t hand

Inte r nal th read, right hand

( )

Program for the first cycle.

Program for one cycle

Input format G78

Input format G78 N . ./G78/X =

+ ... ./

N . .IG781X

=+

.. . ./

)

TECHNIQUE OF

THRE~D ING

Tool bi t position at start of cycle G78 I . Cnoose zero-poin t of cycle such that you keep a little distance to the end of the ,;orkpiece . 2 . rne zero-point of cycle should neither be to close to the surface of the 1-10rkpiece. It could scratch on the surface when rr.¢ving back to t he starting position (step 4). So choose the zero- point of cycle at o , l rrm distance to the surface .

( )

4.81 J

Page 4.6 3

)

Programming exercise 9 (G78) Look in the ch arts for the details of the thread.

l

- :ZO.UNEF

..J

ru

. ,_

r - . _ ... - - · '
-&

~

q

-- -

-

1- ·-

€'

~~ f-.3'!.-

~ T

(

.OS~ 450

f.-.4'

~

.9"

,.,

N

G

00

'H

01 01 03 1- 0.i.-

n!'>

~~~

' I

".. ,.

z

X

- 0"30 - o?>ll

- .1\'l , - ot.J? - 0~ 1

F

- !?DO


- .7 0 {\

'' '' ''

-.'/ oo

- .700 ~700

,,- 1'1 '-4 • - .o.Sb

.?o o - .?b"<> ~

"

I

'I

- - - - f-- - - - - - - -

( )

--

----

-----r-

----

---

(J 4.83

·- I··

--·-

--

(

)

Programming exercise 9 (G78)

LOOk in the charts for the detQils of the thread. ..}il

..

~

,

. -~F==Jii:---T -.---1--......-

-

1- -

~

"

0

N

~

j (

-+t-oo-1 )( 45°

)

6

f- -~10t--- -20----1

N

OD •70 _CL!.... •• ol

6 .1

...iLL ..1d__

( )

II

nS J.i.L ll1

I

A

f

- 3Q - 4)

- -I!J - '!!l - 00

.

I'

- 110

·' I'

•

( )

4.83

" ••

-;;oI oI

- 1::.(.)

~--1---

ol

•• •'

;{):

I SO

I ,

,

j~ll

-II C::, I

F

-=..1~ 0( •'

- SD - (,0

-

D~

z

X

G

,.

Control of Dimensions- Corrections of Dimensions

)

Hand-operated machine

NC-Machine

'.·a th hand- operated I!'.achines the turni ng operation often ·.< ill be interrupted for

To rr.easure is also necessary

rr.easu r ernents .

You posi t ion by rr~ans o f the graduated scale on t h e hand>:hee L hO'.:i 11 have to t ake.

( )

,~·hen

using

particularly nhen manufact.tn' in
\\ny a r e rne asuren:ents necessary?

- Setting of tool bit not acc urate - \·lear of bit e d ge - Pre ssure o f the chip can often not be calculated (de f ormation of machine and workpiece possible )

Corrections of dimensions You have certainl y realized hO!I the corrections can be made. I . Correc t ion without a

progra~

2 . Correction by prog ram change during

change

or after the manu facture He>:< d i d 1·:e posit i on the tool bit for the program start?

Compare page 5 . 31

- Scratching the face side - Scra t chi ng the outside - Positioning of tool bit into s t at· t po si t ion Nhich mistakes can be made? - Diame ter of um·: orked piece \..·as not

c hecked - Scratching •,;as no t accura te

(

)

~nis rr~ans

that the given position for the program start ·..:as not correct .

Correction after the first l
~:easure

- Correct start pos ition of t ool bit for follo>~ing l
l!&J + !mol

Attention :

- l·:easure

l )

\·;hat do you have to consider with a correction dut'ing manufactu re?

- Switch to hand- operation and correct tool bit.

4.85

I

Outline programming

Programming the outline of a workpiece

~ -- -

--- .-

-

This me thod is used when preforrr~d pieces (cast-iron part, forging , co lded p iece) are turned.

_..,

::::-

-

The workpi ece can also be manufactured by outline/contour cuts to be execu t ed step by step .

f

I. Roughing cut 2. Fi nishing cut

Method used on Compact 5 CNC: Example: Working out of the full

1'\ -

-

-

-

Fro~ the example you see that the tool bit executes with prograumed feed cany

v Bre~~-d~~n

I

)

"cuts in the air". That r.eans longer ~
of cuts:

ng time .

The nurr.be r of blocks in the program is ho·~ever less. And this means on the other hand l ess programming ti me a nd input t i me .

First cut

Second cut

-I

Third c ut

-I

l I

I

-,

/r,.----l --t

L__ ___r_===-:-:._J:::::

4. 87 J

~

-+

-~

.--

r-1 - -

1-

.

-~

l I

.t.

1- 1-

'

1-

. 1- -1-

. .

.

1-- l -

-

-

- - ..-- -, ~

i

+-

'

t-1-'-

--

_,.

f-

--

I

1- '--

t

l

I

-

-

j··

- 1-

1 I

--

1-

-- -

r-- 1- '-I

. ._ 1-

l

-·-

1-- +1•-

.

: ;- . I !

I l- I-(

1- 1-

jI !

4.88

Page 4.89/0utllne programming

Programming example:

)

Depth of cut per run

~

.05"

.....+r--:osx45°

R.25 1

--~ - -+ -G

)

R-15

,

-1-~H---G

--~-+... Osx45°

L

IJ5'

(

.5"-*"">--- .8" --~

)

( )

1-- -- - - - 2.2:~"- -- - ----i

I

a

Proqrarr.oing the outline o f the workpiece

'rool blt position - Program start (fi rst run)

Bloc ks NOO to NI O '

2G Tool bit position - Program end (after f i rst run)

X

z

00 00

0

-so

01 ' ()1

50

-50 - 250

N

= Start position for second run

G

02

J

-250 0

42

-400

~

NOO N01 N02

__\_ __

()

01 0~ 02 Ott 01 05 01 06 01 - 01 01 og (J!> 011 ().{ · .- ' ..{0 0~ . 11 00

-

N12

13

N11

~----

00 .2~

450

F

:)o

30 ~0

so

- 50

.30

0

-~00

30

250 0 ..{00

0

-soo

-

-

)

~0

-3<>0

'.00'

-350 0

3o

~

.3o

....

-

2250

Tool bit position at program end Nil Move back in +Z -axis Nl2 Hove back in - x -ax is The tool bit is positioned .05" (wh e n depth of ~ut~is .OS" over the program start point .

4.89

)

1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -0.:..:. ulline program~ )

Programming example: Dept h of c ut per run = I

0 -&

•. N

~n

-

0

N

-&.

$

--+·- +-- - --11-N#-- -9

)

12

1-- - -- - -

10 -

- 1 - - 16 -

44- --

-

(first run)

Blocks

= Tool bi t pos ition - Pt·oqt·am e nd (fi rst r un)

= Start

- -.-1

Progra:-_'Jling the outline of the l
= Tool bit position - Program start

2

--1

posit i on f or s econd run

1>00

N

G

Jl D_

_QQ_

to

111 0

z

X

F

_o___ _-=..iQP ___ _

O_i _ _0-1_ 100 _-: .iQL_ 10!)_ _ ..Q2 - S/Jo .IOiOy.. ., _Ql 02 300 _ ___ .1PIL _Q!L _Qj_ __1Qq_ _ - 100 10()_,_ -

)

o.r _Qj_ QL o-.1_ - =-soo_

- {,OQ

-"-'Y - -"0 -'1-1__0

01

_ Q_

_1Q_ -ti

oo 1.:.: oo'-+- 1ooo oo _ _ -

0

01__ o _ -7oo _ 01 __z.9.Q_ _ __ 0 00 0 oo

QQ_ ~

"-" 00~-

oo ·__

O.L _

- -

N11

~----

Tool bi t position at program e nd bacl< i n +Z - a xi s back i n - X- a xi s The t ool bi t is pos ition ed I ~~ (when depth of cut is I ~n) over the progr aJ start poi nt . N il Nl 2

)

4. 89

~:ov e ~:ove

J

Page 4. 91/0utllne programming

,

()

I

Manufacture:

Tool bit position - first run We have determined the maximum depth of cut with . 05": thus the tool bit has to be positioned for the first run o f f the ,·orkpiece outs i de l ine. X=- . OS"

()

(

~~ _ ,-----

Execution o f further outl ine/contour cuts

~

..._ _} ~-- --- - --------- ~~~

By pressing the key S!'1\RT, the follo•,.,ing cuts ••ill be executed .

(.)

(

)

u

(

I

4.91

Outline programming

Manu facture:

Tool bit position - first r un l·:e have determined the ll'.aximum depth of cut ,.;ith 1 c.:n : thus the tool bit has to be positi oned fo~ the first r un X= -1 mn off t he "'orkpiece outside li ne .

(

)

___ ~ ,

../

'.....__-

/~

-- --- - ---- - ---- -- ~'

(

l

Execution of further outline/ contour cuts By pressing the key S'i'ART, t he follo:
)

)

4.91

Exercises

)

Exercises TECHt:OLOGICAL DA'I'A Max. Cutting Speed:

1-~ax .

Turning: Aluoiniuo 2So m/oin Brass: !So o/min

Turning: Alumi nium o , o5 em/rev. Brass: o , o3 •~/ rev .

Parting off: Aluminium ! So o/min Brass: 12o m/ o i n

Part i ng off : Alumlniun o , o2 r.~/rev . Brass: o , o2 rr~/rev.

Feed :

lo!ax . depth of c ut: approx . I

run

Workpiece time and produclion tim e

)

I.

l~orkpiece

t i rr.e = Portion of setting tirr.e +

~:ounting

and d i s-

counting ti r::c + Production time + ~easure me nt tice 2. Production period = Ti me passing from pressing key ls r ARTi to fin i sh of ma nufacture (i.e. slides have rr~ved back to starting posi t i on for next workpiece) .

The production time {1 0 ) is divided Into

( J

Secondary Ti rr.c ( t nl

:tain ti rt.e (chip remova l time t 11 )

• Time during operation, when t.l>ere is no chip rel!:oval. (= t i l!:e for too l change or t i ce in which s l ide moves without any chip rer.~val)

• Total of tir-.e during which chip i s rec:oved .

The total of tices (workpiece ti~e ) and the rat i o of secondary and main tic:e depends on the progr am whi ch you are doing.

( J

4.93

Exercises

( ) The ratio between input- and programming time

(lp) to production tim e (10 ) Technological data such as - F.ax . cutting speed - max . depth of cut - ~~ x . feed rate are mainly given . The chip rem~val expert 1dll influence production tiiLe , surface quality and precision achieved by variations o f the technological data .

Tne most i mportant factor in f luenc ing the production time will h
Example

()

Tne workpiece has to be oanufactured. 1: Contour file programming)

Prograrr~ing

prograrr~i ng

(pro-

Prograrr.-oing 2 : Target is to achieve a very short •,·,·ark-

I-Ii th

contour prograu.ming the programming time and input time >:i ll be ver-1 short. Tne production ti ue ha..:ever quite long, since there are secondary times . Progra~Lming

(

)

piece time , that rreans very short secondary ti~Les too . So in most cases the program::>ing and input time .-ill be larger.

and input tirr.e (tpl

Programming and input t i l".>e (tpl

l'orkpiece time ( tel

l~orkpiece

time (tel

Secondary tirre (t 11 )

Secondaty time Ctnl

1-!ain time ( th )

Conclusion: The prograrute r •,;ill decide ·,;hich way to go depending on the nu~ber of workpie ces. He has to optinize bet...;ee n tir..e

necessary f or progra!Lroing and workpiece

l )

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4.95

( )

Exercises The exercises serve to deepen what has been theoretically learned. - Deteroine the

necessat~

tool bit

- Tool pre-setting - Determ ine a possible progra mm ing whereby the wo rkpiece n~T~er as well as the relation prograrrming time t o workpiece time has to be considered. - Drawings to sca l e - Turning true to size Progranming of equidistant (if i ncl uded in course)

( )

The si~plest and fastest way to program a workpiece is via contour prograr~ing. Progra~~ing with the aim to reach shortest possible "orkpiecc times needs a lot of experience in the set up of the drawing. Wi th figure 1 (pawn) the student should calcu l ate , from which workpiece number on a prograrrning economic (with the aim of the shortest possible workpiece ti~e) . Smooth cut (finishi ng) The prograo should be such that the final run should be a smooth cut taking off o , S IUD . h'hen contour programming, there i s a correction of the infeed depth in handoperatlon code necessary . Figure I: Pawn

( I

Ncccss at~ tool bits: neutral side tool , parting- off tool 'l'his exercise i s ideally sui ted to demonstrate the relation of prograrr~ ing time to workpiece ti~e .

Possibility I: Contour programm i ng (parting-off in handoperation mode ) Uumber of bloc ks : 13 Programm ing time : approx. S minutes Workpiece time: approx. 2,7 clnutes , whereby 4o% is auxiliary t in:e Possi bili t y 2 : Program for shortest possible workpiece t i me (parting-off program::led) uurr~er of blocl
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14.95/1

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Figure 2: Bishop An exercise for contour progra~ming . Necessary tool bits: right ha nd side tool, parting-off tool The student should repeat the possibilities of corrections in measurements. Parting-off in handoperation mode. Figure 3: Castle Necessary tool b its: right hand side tool, parting- off tool If the width of the parting - off tool is sma ller than 4 rrm , choose width of groove equal to width of parting-off tool edge to facilitate the progra~ming. Figure 4: Knight tool bits: right hand side tool , left hand side tool , parting - off tool If you want to mill the head, mount the chuck with workpiece onto cross slide (details in i nstruction manua l). Necessat~

( \

Figure 5 : Queen Necessary t ool bits: right hand side tool, left hand side tool, parting-off tool Figure 6 : King Contour prograu.ming possible. Necessary tool bits: right hand side tool, parting- off tool

( )

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5. 1 . 5. 3 5. 4. 5. 5 5. 7 · 5. 9 5. 11

Operating elements Figure keys, word display, memory key, delete key

5.13-q.27

Double keys Program hold Program interruption Delete program

5. 29· 5. 35

Program Input

Program Input

The knobs, digital read-outs and symbols may confuse you at t he begi nning a l i ttle bi t. It is bet ter to start with putting in a si~ple program and go through the key-functions step by step . I n half-an-hour you will certainly be famil iar with it .

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PROGRAH I!IPUT

Summary: IINP}

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de l e t e key

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(REV}

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5.1

Tnis drawing should make it c l ear t o the student, th at the logics of a cooputer are la id out such that only the very necessa ry d ata have to be put in . Additional inputs are not necessary and supe rf l uous. However , if there are importa nt data not being entered, the computer gives alarm. The princ iple of the industrial machines, which of course have more addresses (N/G/X/Z/U/ W/F/P1/P2/P3/P4/PS/S/T/M), is the sane .

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15.2

Program Input

Input format The input forma t proscribes which i n format ion ha s to be pu t in and whic h not . T"ne 1 nput format depends on t he G- function. The computer asks certain i nputs fo r t h e r e l at i ve G-func tion.

Input format N •• // X • ••• I

Let ' s take the fi r st block again.

I ~ ~ ~- ~~

z

F

) !·:ode of operation: ct:C-operation

•••••••• GD ••••••••

•••••••• GD •••••••• I

~

Oh, o.k .

ready for the first

Yo~

want GOO, the

rapid traverae .

blo-c::t :;oo.

'l1H~ t

1 have

under stood a nd reqlstered . I c= vaitln9 for the x -val~e !

l~c put in 1000 - and press ll NP~

)

•••••••• QV ••••••••

We press key IIN P~

•••••••• GP ••••••••

ftoll , o:ell. y o'J inu:!nd to COV
lo ~ in X• =Unus•diroc t i on. I havo e nO'J9h in for::attcn for b loc~ ~;oo

blocit 1:0 1 .

We put in 00 and p ress

-

-

luzpl 5.3

a r.d 1

a=J

r o&dy for

What happens when data Is put in? We put in G84.

I. Secretary (interface element) reports to di rector: "So::nebody \\•ants G84 ! "

4. The director instructs the ~emory operating program (RAY.sRandoo access c:emory): "Re=..ember G84"

2 . Director (CPU=Ce ntral Processi ng Unit ~Nicroprocessor ) asks his s pec i a lists:

5 . The memor y reports to the director: "0. k. , I have noteci 1 t dO'.-In I "

"Can v-.·e execute G94?"

3 . The specialists (EPRO~:·Programmable read-only ~emory) think and inform the d lrcctor:

6. Di r ector inst ruc t s his press-speaker (out put ele~ent): "ShO'.,. them out there , that we are clear wi th GB4. We have everything understood a nd ready for f ur ther in-

"'ies \
puts !"

5.4

Data Input

What happens when Data is put in? (

)

Data Input

(

)

Interface element (secretary)

(

Digital read-out

Central processing unit ~ Microprocessor (Director)

Output eleme nt (press speaker)

)

l )

Operating program ~ EPROMS (Specie,lists)

Memory = RAM

5.5

L-- - - -- - - --'

Have the student put in the first program by himself using this instructio.n . . He ' has to

leer~

to work with

this kind of instructions. He should learn:

- to exactly read a drawing or t e xt - not to sk ip cer tain instruc tions.

Measurements with alarm sign Switch off cain switch and start from beginning. Tnese inputs according t o given i nstr uctions usually produce quite a feeling o f success and satisfaction with the studen t, i .e . being after such short time a l ready in position to put in a program. The uncertainty when operating keys disappea rs . If the student presses a wrong key: switch off main switch and star t f rom the beginning.

15.6

Program Input

~------------------------------------------------------------~ )

Program Input

~

KOI

N

G

00 0 -1

0 00

Ol

22

- Hoo

z

X

- f 000 0

F

B<

-lioo

) Sh·itch on main swit ch : The control l arr.p "current supply" and t he lamp indicating th e mode o f operation 'hand oper ation" light up .

2. Press key

[H7CI

'The light j w:ps fro:'~ " h and-operation" to Cl~C-operation ". 11

On digital read-out the light of address "II" lights up and you can read 00,

( ) 3 . P ress key (UiP} a instruction to regis ter :;oo) Th e block nurr~ er NOD is registered. At the same time the light jumps t o the word indication G. The computer i s waiting for the input of G.

G X 2 F A

0 0000

9 0

)

4. Put inOO: 00 appears on the digi tal read- out.

5. 7

Program input

)

~

N G X Z F A

0 00 0 0 0

9 0

5 . Press key (l!i"P} GOO is registered . The light of t h e ...-or d indication j un:ps to X.

N G X Z F A

( )

0© .. :B I·

00 0 0 0 0

""'~

Ou

Q

... rro/M

10001

6. Put in l ooo- :

9 0

The value put in appears on the digital read-out. The "'im•s sign "-" i s put in after t he figures . I t is shown on the di gital r ead-out as point. I f there is no roinus-si gn put in , th en the value is automa t i ca lly "+" .

000§3 B El , ,.--, 000§1 Ot9 ,.--, ~ N G X

Z

F

A

0000 0 0 7. Press key

,.--, (. )

,

,.--,

[iNP}

X-looo is regis tered . The co:nputer 11 kOO"AS" that the block NOO is finished . The light

j ur.ps toN . On tho digital read-out the value 0 1 = NOl appears.

8. Put in second block in the way.

sa~e

9. G22 • Program end has to be put i n. lo. Press key !sTART} 'roe program r_uns. No-.< you have ~
5. 9

Take over of registered values

' Take over of registered values from previous blocks

By pressing the key iiNPI the c:e:::ory t a kes over the value of the relative ~ord colu mn G,X,Z,F "'hich has been registered last.

Example 1 Exampll: 1Cl1H.f2

(

\

N

G

z

X

00

1000 0

00

Bloci< l·; oo is prograrr.med .

-

In bloci< 1;01 the addre ss letter G lights up.

-

Press key lwP I The value 00 lights up shortly and is registered in block 1101 .

>oo

01

soo zoo

00 01

F

-

100

00

200

100

~ Example2 In block N02 ;.·e prograrr;ned F 100. This is t he value for F which was put in last. I f you press I IIIP~ nO'" FIOO will be taken over into block N04.

E xample 3 N

G

X

_QQ_

00

-500

0-1

00

0

02

8~

03

Sit

-100 -200

Oil

s~

- 300

z

-- -soo

- 'JitM:
Example3

F

-100

-

You have regi stered block N03. You see by chance that t he z-value o f block NOI is wrong. You correct it i~~diately, e .g. to z c - Soo and continue with putting in block N04. I f you press I111PI wi th the z-value input also will r egister the value which was put in last, e .g. z • -soo.

l )

5. 11

Operating elements

Operating Elements CNC-Operatlon

1. Option key: Hand operation CNC-operatlon (H/C - pos. 1.)

( )

. 1©1 Itt

©

D

H

~·

G A

lF

A

2

@'o 0 § ~ ·@=B I 1~ o,.-. o .•. •) rca;~ 0 00li H3 Bjl- 1--{ 1 8 :~· ro t.=_j 000 §I ~~!>

I~-----~-I ·.~; lblJ

1)

00 0000

EI¢-B CDITJ0 0 •r. El GGEJB El

~

Cl

:i!i!H!!!:: !!!i!i!!!fi: 1! niiijh

.... ··--.... '"' 'I ..... i·h ! COMPUTER NUMERICALLY CONTROLLEO •:!;!!iii!i' i!l! !!!! I 1111111 m: .... ::iiji• ii=i

1

l )

By p ressing the key lH/CI yo u ch ange

fro:~

h and operati on to CNC-ope r a tio n. The mode in ope rati o n i s i nd icated by lamp (!> o) (position 2 ) oq~o ) (posit ion 3) • To pu t in a prog r a n yo u h a ve to chango o ver t o c ue- ope r a tio n . Afte r tha t you cannot move tho s l i des by hand- ope ration anymore .

5. 13

; - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - . . . . . ;O;.:P;.;e;.:.:ratlng elements )

The Figure Keys

D

NO.llF

A

000000

l~ith

the f igure l
9 0

E]o t ·..1.1, .I

-

G-functions (GOO, GO!, G2l etc .)

-

X- and Y-values

-

Feed sizes

-

Tnread pitches

The values wh ich are entered appear on the digital read-out (4).

( )

The Minus-Sign KeyE] (5) D

x- o r z-va l ues can have a minus or a plus sign. Plus sign input for X,Z:

( )

t , ·'·' . I

Put in f igures on ly.

D

_ .._

(I

0H 0G 0A 0l 0I 0A

·Ao r:o I• ..1400I 9o

o-~:L:J

'8

0 00 8 El EIIIIGB ~'3

B-#B EJ0ITI~ •I• El GGEJB B E ' ·' ·' • I

Hlnus sign input for X,Z: lift er i nput of figures pr ess 8 l
Input : []ffi[2J[Q)E]

l )

5. 15

Operating elements

( )

The Word Display (6)

( )

.... .. ...

iiiHiiHih Ji :.•i iliiiil:: ' ii i Hi! !!!! !! , ,~.

H !....:::: Hl! ONTROLLEO ·: iHiHi'' illi

!!!! H !!!! ' t

'f·he larr.ps fo~ the word display light up and inforo you l
~

blcck number

= path f unction x,z ; value s

G

F ; f eed I thread pitch

@ ~

) Example: La~p X ligh t s . 'fhe digital read- out (4) is dark. Value X can be put in and appears on the digital read- out.

(

)

5.17

______

...;...._ Operating elements

ThehNPikey (7) - Memory Key

liNPI ~

Instruction t o the compute r, to register the entered value .

liNPl ~

Abbrevia~ion

for Input

( l

Exar.:ple:

( )

-

Lamp x lights up.

-

Value 235o is entered . Digital roadout indicated value , but i s only information and not in t he computer .

-

You press JnlP~ By pres sing th is key , fig ures are registered and darken on the digital read-out . At the same t i rre the light j umps to t he next letter . The next f igures can be put in.

5. 19

Op erating elements

II

""' "

g. rQ).::B

G X Z

F

A

00 0 000

IL__

_

__J

g

rt'"lr;,.

E1

"DEL" is the abbreviation of "delete•1 ,

which r.eans to cancel , to exti nguish.

El¢-~

( )

You can delete the value of the letter (X,G , Z, F) ~hich is indicated by pushing once "D?.:L" key.

G X Z F A

0000 0

~ 0

Exacple: You want to change value X froo 52o to 25o .

(

)

.

I . Press loBL) key , the value 52o will dis appear.

2. Put in t he right value ( 25o) . 3 . Pres s IINPI ke y, va l ue X is regis t ered; light jur.p s t o t he next l et ter .

5.21

Operating elements

(

)

TheiFWD!key (Forward Key) Instruction: to jump forward block-by-block

( l

N

G

· ~ .

-..

-

N

G

X

z

-- ---X

z

F

-

---

I . If G,X,Z or Far e on di splay, then prog ram wi l l jump to next block n~nber, when you touch key 1~101 once .

F

'

(

)

:l .•>

2. If b loc)< number N is indicated : you press key fFtiDI once and program will jump to next block number.

lJ

N

G

X

z

F

... \

H·' f ..~

-

3. If you keep key Inml pressed da~n . program will jump block-bYblock to progra!:l e nd .

5. 23

Operating elements

( \

TheiREVIkey (Reverse Key) Instruction: to jump back in program block-by-block

II G 'V'- ~

ntQ). 0" 0 :::E) ~

..

r.-l:!:.r.

E1 ( )

X

Z

F

A

0 00000

I 001IJE.3 000EI

lHtcl Ot3

G0EJE1

ls:attl

EJ~§] CQ00~

E1

N

X

G

~

0

z

•!•

F

1. G,X,Z or F- va lue are i ndi cat ed on the ~igiJal r ead- out . If you p ress key REV , t hen it wi l l jump back to the b l ock number .

N

(

X

G

z

F

)

2. If block number is i ndicated on ~ta l read-out , you press key ~ , then the progra8 will jump t o the p r evious block .

N

X

G

z

F

•

\

I

I./

3. If b l ock nuwber i s ind i cated on display r ead- out and you carry on to press key iREvl (or keep it p~e!'sed dm:n) , then i t 1
5. 25

Operating elements

( )

The8 Key Instruction: to jump forward within one block

G

X

Z

f

A

00000

3 0

( )

By press i ng the :
N

G

z

X

F

{

\

)

'

["'-......

l

I

5.27

J

Double ke1

---------------------------~Hold with every Word during Program Operation:ltNP I + IFWDJ

Program hol d ; lw vl + lf"-10) Th e slides stop. The comput er knaNs the actual pos i tion o f the slides . To continue program operation ; press key lSTARTJ

~rogram

ho l d?

)

You can ta~ e

measurements ,

-

change pos i t ion of tool bi t,

-

cor rect p rogran.

t. Taking measures, changing position of tool bit without changing the program ~~~~~!~.:.

You want to check, whether diameter in block 110 2 is correct (possible reasons for nis t ake: tool bit position was incorrectly set at p rogram start) .

Measuring 1. Press ImP) +lFWD) 2. Switch off ma i n spindle 3. Take me as urem~ n ts G

X

00

-500

oo

0

ot.

g~

03

8~

- 100 -200

N

oo _g_L

.Q!L J.L 05

-300

z

F

correction Your measurement te l ls you t hat th e d ia . is by o ,lo m.""l t oo large .

- ~00

- 1100 - 1100 1100

to Ko to .

Switch on main spindle 2. Press IH/Cl Feed in tool bit by o,oS am . I .

Program continuation I. Change over to CIIC-opera tion 2. Press !START! key .

-

5. 29

Double keys

\

Delete a registered Program

Possibility 1 Switch off

~ain

switch .

Possibility 2

l )

Press G X Z F A

00000

9 0

e~erqe ncy

stop.

Possibility 3 If you see a block nUJ:lber indicated on digital read- out (NOO, NO!, N02 .•. ) you have to: Delete: First press key !DEL) t hen remains pressed d~~n).

IINPI

(DEL

The registered program is deleted. The digital read-out sh~..s NOO.

)

(

)

5.35

6. Alarm Signs

'

(

..

)

I

~

)

Causes -

Mea~;u res

Page 6.1/Aiarm signs

Alarm Signs N· G X Z F A

oooooe

J .,

041 0008

~ 0

§]

000~ Ot3 alarm.

Put in alarm signs (summary) l\07 - Undefined angle programrced

l\00 - undefined di mensions programmed

The following ratios for angles C< be put in: ratio X:Z (1-39) :(1-39) . For f urther explanations please see "Taper turning .. !

Example for wrong input: If you put in G25, lamp A ·.-i ll light up and digital read-out will indicate 00. A01 - Undefined radius programmed

( )

{

The following radii can be programmed: So , loo, !So, 2oo, 25o ... 195o. Example for wrong in put: X 121o : Lamp A wil l light up , digital read- out will indicate 01 .

ALARI-l SIGNS - TAPE OPERATIOll

A02 - x-value too big

l\09 - End of tape when tape operation SAVE

Max. value for X: ± 1999 (1.999")

l\09 - Program not found

l\03 - False F-value programrr.ed

()

I

Alo

Possible input: 1- 199 (.1-19 , 9 " per minut e ,

Writing protection active

All - LOading mistake (LOAD) l\12 - Checking mistake (CH ECK)

l\04 - z-value too big ~!ax. value for Z:

± 19999 (19. 999") AOS - No program end program:ned I f you f orget to put in G22 at the program end and you press the START key , the alarm l amp will light.

( l\Ll\R~! SIGNS - FOR HSTRIC/INCH VERSION NACHINE ONLY

A06 - Revolutlon of main spind l e too fast when threading

()

l\13 - Changeover inch/metric with f ull program register

This alarm will not be during the input of the program but only duri ng t he operation G33 o r G78 it< self.

Al4 - Wrong

6.1

di~ensions

for program load,

Alarm signs

Alarm Signs

)

ALARM

\~ ~ ~

IIGXZFA

000000

JI

o41

~

1-.'hen you put in data to be proces sed which the computer does not kn~~. it wil l indicate alarm.

o

0008 E.g

Lamp ~ will light up and a number will appear on the digita l read- out . This number encodes the type o f alarm.

.., 000~ f)!~

Put In alarm signs (summary) AOO - Undefined dimensions progra""-ned

( )

A07 - Undef·i ned angle programrr.ed.

Exrunple for wrong input: I f you put in G25, l a mp A wi ll ligh t up a nd digital read- out will indicate 00. AOI - Undefined rad i us

The follo-.d ng ratios for /angles can be put in: ratio X:Z (1 - 39) :(1- 39). For further explanations p lease see 11

progra~"ed

The foll~Ning radii can be programmed : So,1oo,l5o,2oo . . . 59oo. Example for wrong i nput: X 121o: Lamp A will light up , digita l read- out l
ALARH SIGNS - TAPE OPERATI ON

A02 - x- va l ue too big

AOB - End o f tape when tape operation SAVE

Haximum value for X: + - 5999 ( 59 , 99 1Tc11) 1

)

Taper tut·ning"!

A09 - Prog ram not found

A03 - False F- value prog rammed Possible input: 1-499

A1o - Writing protection active

r.~/nin .

All - Loading mistake (LOAD)

A04 - z - value too big

Al 2 - Checking mistake (CH ECK)

Haximum value f or Z: :!:39999 ( 399,99 IUD) AOS - No pr ogram end

proqra~~d

If you forge t to put in G22 at the program end and you press the START key , the alarm lamp will light . AO;) - Revol u t l.on o f main spindle t oo fast when threading

' )

AL1\Rl·l SIGNS - FOR HSTRIC/WCH VERSION CH INE O~iLY

~lA­

Al 3 - Changeover inch/me tric with ful l program regis ter

This alarm will not be during the input of t he p l·og r am but only during the o peration G33 or G78 i tself .

Al4 - Wrong di mensions for program loaded

6. 1

What happens when wrong data Is put In - Alarm sign We put in a X-value Bo2, 4o; i.e. for the cross slide a traverse path o f Bo2,4o mm . I. The secretary (interface e l ement) reports : :'They want X

c

Bo2, 4o I"

(

2. The direc tor (central processing uni t, microprocessor) asks his specialists: "Can 'ft·e execut e X = 8o2,4o?u

3. The specialists (ope rating program) answer: "No, l-Us ter Dit·ectort"

4. The director instructs his speaker (output e l ement) : "Te ll them out there , we cannot do t hat !"

(

(

6. 2

---

Data Input

What happens when wrong Data is put in?

Data lnpul:

Data on digital read-out

(

Interlace element (Secretary)

Central processing unit a Microprocessor (Director)

( )

l )

Operating program • EPROM (specialists)

6.3

Output element (Press. Speaker)

Alarm signs

( )

Measures for alarm signs

The alarm signs AOO/AOI/A02/A03/A04/A07 will appear as soon as you put in an undefined value (put in = press )HIP) key).

Put in the follo-.
Exa~r.ole:

( )

. 0©0 :::B ""'

o ..

u

..

r:~tr......

ro

N

G

00

oo

X

z

F

8ooo

N G X Z F A

000000

I

03jl

~

0

§I EJ ,.., 000§3 000§1 Ot3 -L

G

X

Z

f

The value X 8ooo is too big . As ;oon as you put in 8ooo and pxess t he )I NP) key, the a l arm sign will appear. On the digi tal read -out the type of a la rm, in this case A03 = x- value too big, will be indicated .

A

00000

~ 0 z.~ e asures:

I . Press )lliPJ + [RBV] at the same time . The a l arm sign disappears and the entered x-value appears .

( J

PI

""''·

~.~@;:B '

,. .-:~:(\

GXZFA

000000

I

I

~)

0

2. Press )DELl and the X-value Boca •..;ill be cancelled. N G X Z

f

A

000000

I ( )

aool ~

0001i31 §I 000§1 Ot3

3. Pu t in correct x-value (e.g. x-8oo), press JIIIPI; no-.< the correct X- value is registered , the •,;ord indication jumps to the next letter.

6.5

Alarm signs

( I AlarmA05No program end (G22) put In

If you d i d no~ prog[an a program end and press k ey STliRT the alarm sign A05 will appear .

Example:

( )

""'.

II

G X

z

0©. .0 ..:::E) I'

osl

0 ..

r l:!tr:n

El ,---, ,---, - '--

F A

000000

Put in the program a nd press k e yiSTARTj

~

0

000~~

000~ Ot3

N

G

X

00

OQ

100

01

00

0

z

F

100

A05 will appear on digital read- out .

!·!easures :

( )

I. Press

G

X

Z

F

IINPI + !REv~

1105 disappears.

A

00000

~ 0

2. Press )FWD~ The block numbers will jump back to the last block number which was put in correctly . I n this case NOl .

1-.1

3. Touch until the G- larr.p of block !l02 ligh t s up.

u

4. Put in G22, press key (INP~ Th e block nurr~er will jump to N03. The program can b e started .

6. 7

Al arm signs

Main spindle spee d too high for threading

(

)

The alarn sign A06 dces not appear du~ing the program input (or when pressing the START key), but during the progra.m operation itself. Before a block G33 or G78 is star ted , the coxputer ch ecks the ~ain spind l e s peed . If i t is too high, the alarm A06 appears . The program is interrupted.

~o:easures :

I.

spindle speed (either change pulley pos iti on or use potentiome ter) .

~her

2 . Press IINP I+IREV~ The alarm sign will disappear . The program operation can continue. ( )

( )

6.9

I

)

7. Magnetic Tape Operation

)

)

Modes of operat ion: SAVE, CHECK Mode of operation: LOAD Summary Alarm signs AlarmA08 AlarmA09 Alarm A 10/A 11 Alarm A 12 Mode of operation:EAASE Program interruption Putting in the tape

7. 1 · 7. 5 7. 7 7.9

7. 11 7. 13 7. 15 7. 17 7.19-7.21 7.23 7.23 7.25

Magnetic tape operation

Magnetic Tape Operation )

The tape enabl e s you to s t ore programs a nd t o feed them into the co ~puter rr~­ rrory .

<

1. Storing on tape

)

To transmit froo co~puter merr.o ry t o tape : We call this mode o f operati on SAVE or CHECK .

. )

'

2. From tape Into computer To transoit t he program from tape into the computer meu~ry : we call t his mode of operation LQAD.

Some data - '':eu:ory cap(lc ity p e r tape side : approx . 4oo blocks. - Operat ion tirr.e per tape side : appr ox . 9o s ec .

)

Operation advice 1. Use on ly digital casset t es 3 . 11ain drive motor must not run during LQAD, CHECK , SAVE and ERASE operation. 2. Erase ne·.· casset tes completely (see page 7 . 23 ). The test impulse from 4 . Do no t put down tape near ma in motor. the final control of t he producer can cause Alarm All or Al2 .

7. 1

Modes of operation SAVE/CHECK

------------------------------------------)

Magnetic Tape Operation Transmission of a program from machine memory to magnetic tape Mode of operation SAVE = transmit from machine memory to magnetic tape CHECK control of transmitted (loaded) program

=

I. Press :
The indicated value disappears from t he digital read-out.

( )

2. Put in G65. Press keys [ill~~- On the read- out you see magnetic cassette tape operation.

C

indicated.

lc I I I l

I

3. Press key @01

On the read-out appears

lc I

IP I

4 . Put in program nurrber.

You can put in f igures ooo - o99 oo - o9 0 - 999 The sequence of the figures can be chosen as you like. Example for input of a program with nurr.ber 76: Press keys 11J(ill.

( ) 5. Press key~ The transmission I loading starts. 5.1. First free space on the tape is sought. If there are not data on the tape, it will advance approx. 4 se conds and rewind approx . 2 seconds .

Ban d

" th ou t

\\~1.

4 sec . advance

d a ta on:

2 sec. rewind Tape begin Tape end

Transmission SAVE

( ) I

7.3

Modes of operation SAVE/CHECK

(

l

If t he re are already data/programs loaded on the tape , then the t ape will advance to the end of the program which was l oaded last. Then advance 4 seconds and r ewind 2 seconds. Tape with proqrarrs already loaded: 4 sec . advance

Transmission SAVE

( ) 5 .2. Transmission operation SAVE The digital read-out indi cates le i isl A! I I SA is the abbreviation f or SAVE. The program/data are "saved" fro:n the machine ceroory - where they could be deleted - onto the tape . 5.3. At the end of the transmission ope rat ion the tape rewinds to the t ape start. 5.4. Control operation CHECK

( )

The digit al read- out i ndicates lc I lc IHI I I Tne data in the machine memory are compared with the data loaded on the tape. If you have already programs loaded on the tape , then the digita l read-out will indicate these on the read-out whilst the tape advances . It will advance t o the program loaded last and then t he "CHECK" wi ll be carried out.

CHECK of loaded program }....

I

'

)

~

!

y

ic

I

lciHIJ

3 ~.Pr~ram 2 ~ 131 lei IPI 1 2 1

Pr o2ram I£LIPI

Program y

ic

I

IPI

1 111

~

6. After CHECK the t ap e rewinds. The program is l oaded on the t ape .

\... I Please never take out tape during operation!

7.5

Mode of operation LOAD

Transmission of program from tape to machine memory Mode of operation LOAD

1. Press key 1-.1 until word indicati on G lights up. If a figure of the G- function app ea rs, press key DEL. The n indicat i on on read-out disappea rs. 2. Put in G65 . (

Press keys [§)~!:!!ill· Read-out indicates le i

IIII

3. Press key I NP . Read- out indicates le i I P l

I.

4. Put in nurrber o f program .

E.g. for progran number 76 you press keys

0@

On read-out: lei IPI7J61

5 . Press key @Pl. 5 . I. The program nwc.ber [1)@ is l ooked for. I f you have other pr ogr ams on t he tape a l r eady, then these numbers appear on the digital r ead-out . or

leI IP l7lsl

5 . 2 . Loading : h~en

the wanted program 76 is found , the loading operation starts .

On the digita l read-out you sec @:LILio ll LO is the abbreviation for "load". 5 . 3 . Af t er the l oading i s done , t he tape rewinds . The read-out shCY.;s 1100. Prograo number 76 is stored in the machine computer . 6. If you press keylSTARTl then the program starts operati ng .

£:&1 I

'-

Progra~ffi Tape begin .,.-..1

ITIPJII!l

7.7

Summary

)

From machine to tape

From tape to machine

SAVE, CHECK

LOAD

I. Put in G 65

I J 2. Press

liN PI

I. Put in G65

G

•

I I I IG isl 2 . Press IWPl

lei I I

G

•

I I I IG[S]

lei I I I I

3 . Press IHIPl

3. Press IF\m)

4. Put in program number

4. Put in program nurrber

leI

,.... e-.1-.-1P-.1--. . 1_, .I 5 . Press l iNPl Program is sought a nd will be loaded in machine .

lP 1.1.

I

5. Press IINP)

- Free space on t ape is sought . - !·lachine program is transmitted/ l oaded on tape (SAVE)

lc I ILiol I

leI Is lAI I - Loaded program on tape is checked/ compared with machine program .

lc I lc iHI I 6. If program is loaded in machine , then read- out indicates:

6. I f operation i s through, then indication on read- out: N

N

•

• .I -r-1.., . -lo. ,. io-.1

00

Program can be started .

)

7.9

Alarm sign

)

Alarm Signs - Tape Operation (Summary)

A08 - Tape end reached during l oading of program from machine ttemory to tape (only with mode o f operation SAVE) A09 - Selected program cannot be found ( rr~e o f operation LOAD) . Tape is fu ll . G22 is not put in in selected program (rr.~e of operation LOAD) .

( )

Alo - 1-lriting protection active All - Loading mistake Al2 - Checking mistake

General

{

)

1-lhen s•,.;itching off machine (a l so when current breaks da,.;n) an inte rference pulse is put onto the tape . Tnis interference pu lse does not have any e ffect since the loading star t only after 2 seconds o f tape advance. Thus: Tape has to be rewind (automatica lly). Ne ver take tape out during re·.'lind ope ration .

--------------------~------c=~~ ~ Tape '--..--' '--y-J

/

First program starts after 2 seconds.

.

)

7.11

begin

~ Empty space , interference pu l ses ineffective .

Alarm sign A08

Alarm sign A08: Only when using mode of operation " SAVE" I

(

Reason

Measures

Tape finish during loading (SAVE) from mach ine memory to tape. (A08 only when using mode SAVE) Alarm sign A08 appears on digital readout.

- Press [rnP] and [REVl Tape rewinds to tape begin.

~g~r-am

7

~..,_,.~ (

Digita l read-out indicates NOO. - Put in new tape and repea t loading operation.

1

____e_n_g_th __.-L____________________________________________--J)Tape begin

1

Tape end

)

Attention: If you put in this tape and ~ant to load t he next finished prog rac (transmit fro~ tape to machine r:emor y) A09 appears " No p rogr am end found!

( ) 4

7. 13

Alarm sign A09

Alarm sign A09: Only when using mode of operation " LOAD" I

A09 - Reason 1

Measures

Selected program not fou nd. I f you call a non-exis t i ng program number when " loading" ( from t ape to machin e oeroory) , then alarm A09 appears .

- Press IINP) + IREv) T'ne t ap e r ew i nds. T'ne digital read - out i ndi ca t es after that 1100. - LOok for prograo on another tape (i n case you are sure you put it in) .

ExaEpl e: You look on this tape for pro gram no . 5

( l 24

22

A09 - Reason 2

( )

Pr .Nr16

17

Measures

Selected progran not ful ly on t ape (G22), s i nce tape was f inished when loading from machine cemory t o t ape (already in mode of operation SAVE you had alarm A08) .

- Press I INP) +I REV) Tape re·.·i nds, read-out ind icates 1100. - LOok for program on other tape (in case you are sure that you put it in)

Ex111tple: You ca ll on program no .19 Pr ogram 19 does not have G22, thus a laro A08 was i ndicated already during mode o f op era tion SAVE .

<;

L..__

_

-~.l__,_a__

lg __

..L_

7.15

_

l_?_ _

I_G_ _

.J.__ _ _

_J

Alarm sign A 10 Alarm sign A11

A10 - Writing protection active: Only when using mode of operation " SAVE" and " ERASE" !

o-- s

0

(ol lo)

If you remove the writ ing protection (i.e. the black caps) yo u cannot put any more data on th is t ape side.

:.~easures:

If you put in such a tape side and you want to trans oit a program from the machine mec~ry to the tape, alarm sign Alo appears. (

A

Press lmPI + IREVJ Tape re~inds, put in other tape or writing protec ti on aga in.

~ount

I

A 11 - Load mistake: Only when using mode of operation "LOAD"I

( )

A11 - Reason 1

A11 - Reason 2

Motor is switched on or is being switched on during loading (tape -machine). The prograo on the tape was not destroyed by switching on t he mot or .

~ne

Measures

Measures

- S·.dtch off motor - Press IINPJ + IREvl ~n e tape rewinds , the read-out indicates NOO . - Repeat loading ope ra tion . - If you have All indicated also with the follaN ing loading operation, please see reason 2.

Transmit program to new tape.

program on the tape is destroyed . The reasons for it could be a ~echanica l fault on the tape , a power failure - or the machine was switched off when tape

~as

not reA•ound .

Summary measures 1\IJ\RM A I I

~

Repeat l oad ing

llo a l arm All ( )

~

Alat·m All

Reason \•as interfere nce when loading

Reason was

7. 17

mis ta~e

on tape

Alarm sign A 12

(

)

A12 - Check mistake: Only when using mode of operation " CHECK/SAVE" !

Possible reasons: - Tape faulty - Interference pulse : reain mot or switched on , short

p~~e r

failure, interference

pul se f rom electrical conductor (ligh t ning , switching on o f soldering transformer ... ) The i rlter f erence pulses can happen both when using mode of operations SAVE or CHECK.

(

)

Alarm sign A12 in mode of operation "SAVE" - Remedy St ore program under anothe r

Explanation :

Heasure :

You cannot delete the fals e pr ogram j ust by its O'o'ln. Thus you have to gi ve to

- Put in l iNPl+ l REV~ tape re..,inds , r eadout shO'o'IS NOO.

th is p rogram a new

l )

nurr~er .

nua~er ,

if y o u s t ore

- Put in same program unde r a new number.

in on the same t ape. If you wou l d use the same program ntlffOber, then a l arm Al l would appear when loading (tape - machine) since only the fi r st one of two ide ntical p r ogram nurrbers can be ca l led on.

I f alarm Al2 appears again , then tape is de f ective.

I nterfe rence during SAVE L __ _ _ _ _ _ _ _

J_~~~~~~a --L-----~~~7_______

--J

Same program has to be put i n under ne.., program nurr~er. 17

l )

7.19

Alarm sign A 12

(

' Alarm sign A12 in mode of operation "CHECK"

During CHECK operation there W4Y occur an inter fere nce i mpulse and alarm sign Al 2 will be illdicated, without a defect i ve tape being the reason . Check:

(

)

- Press lwPI + !REV~ Tape re·.d nds to ))egin, on read-out NOO. - I..oad tape into machine memory . If there is no alarm All when loading, then the program is o.k. - During loading All is indicated: the follcr.
l·!easut:es -

surr~rnary

Repeat loading

/~

(

No a l arm All:

Alarm All:

Tape o.k.

Tape defective - New tape - Delete tape - Put in program under another numbe r .

( )

7.21

Mode of operation " ERASE"

{

)

Mode of operation" ERASE" (Erasing the tape)

I. Press keyl-1 un t il .:ord ind i cation

G lights up. If you see a figure of a G- functio n ind icated on the digital read-ou t, the n press @[Q. 2 . Put in G65 Press 6 5 1NP, on the display you see seelcl I I I I

( )

3. PressEl+ IQmJ at t he same titte , on the d i splay you see lc I IElrl I The tape i s erased . After that t he read- out sho;;s NOO

Program Interruption during Tape Operation

Only '' hen using mode of operation LOAD , CHECK, ERASE.

Program inter rupt ion Pre ss JHIPJ + JREVI Tape rewinds to tape begin.

( )

Why program interruption? ~~~~-~~!~2-~~~- ~!-~€~~~~~~~-~~~~ If you fi nd out that you ca lled a nonexisting program. If you press JI NPI + lREVl the tape will not advance to the tape end but rewind i wmediately.

~~~ ~-~~~~2 -~~~-~~-~~~~~~!~~-~~~~l I f yo u do not wan t to wai t for CHECK operation.

~~~~-~~!~2-~~~~-~~-~~~~~~~~~-~~~~~ It is enough that you erase about lo seconds. Whe n loa ding anew t he tape machine will erase automatically all other remaining data.

7.23

Putting In the tape

)

When putting in the Tape, pay Attention: 1. Putting In with left spool full - I f you s~itch off the machine , the tape advances I second . lsec;J

(

'

- If you swi t ch on the machine , the rr~­ tor re~inds t he tape 2 seconds. So it is made certain that the tape is at the very b egini ng .

2. Putting In with right spool full - I f you put in the t ape and program G65 , then t he tape rewi nds to the bq g in i ng.

- If you put in the t ape and not prograo GGS, and s·.
( }

s...itch

on :

rhe t ape rewinds 2

second~.

Switch off : The t ape advances l second.

, <] If you ca.rry on like this , the tape f urther t hrough the swi t chi ng on and off and you get an interf ere nce pulse on t he tape . A stored prcgrar~ Hill b e registered .

~oves

(

)

7.25

I

8. Tools

,.

)

)

Position of toolholder Turning tools Pre-adjustment of tools Radius compensation (the equidistant)

8.1. 8.3 . 8.5. 8.15 8.17-8.21 8.23- 8.31

( )

tools

With industrial c:;c-machines the tools can also be progr~~~ed and this under address T (T = abbreviation for tool) . The charlge of tools is done automatically.

) The programme r must kno~ the various tools, their application and also their actual position to each other, when writing a program .

The tool s are being positioned by means of a tool pre-se tting gauge, the edges are drawn on a tool sheet. From this tool sheet the prograr.~er can see the position o f the edges in X- and Z-direction. ·Further- eore,technological data , such as reco~nended cutting speeds, feeds etc.

I On the Co~pact 5 C~C we do not have an auto:::atic tool change . 11e position the tools with a pre-setting gauge directly on the machine. liith this gauge we determi ne the position of the various tool bits to each other .

l'lhen •.
)

Pay attention: program hold {G 20) before tool change!

Position of toolholder

)

Positions of Tool holder The toolholder can be c l amped in front position and in b&cl< positi on.

Front position Interior dia~e ter 14 to ¢ l oo ~~

OUtside dia~ eter ~ 0 to ¢ So 1u n

~

)

Back position In ter ior diarr.e t e r

Outside dia rr.ete r ¢ 2o to ¢ I 2o

¢ So to¢ 13o

~r.m

~~

)

Please cl&~p the toolholder in the front posit ion for our programming exercises .

)

8. 3

Tool bits

The Right Hand Side Tool (T01) Dimensions - Applications 2 . Shape t urning : The e xercises rna~e i t possible to use the r i ght hand side tool fo( all pr oqr ar:.rning work , part I.-

Further tools are e xplain ed in part 2 of the prog ra~~ing exerci ses .

(

1

~-:::~~~-~:-~~gger

than 3o0

,

other,..ise

there ·, .:[11 be insuffici~nt clotu.·ance

angle .

3 . Rad ii: ------------·--.-Exa ~ples

of

aepl ica~~

Clearance a nqle ~

1.

e

93°

Longitudina l t ur ning , facing and

---~~2~~-~~~~~~2~------------------

up t o ot. = max . 9o0 'The depth of cut " a" .,..ith facing must not be bigger than o , 3 ~ . otherwise the chip fla"' is bad. )

- · -·,-·

Depth o f cut a t t he end of t he 4th part of circunference max _ o , 3 r::.1

Depth of cut at the Start of the 4th part of c i rcumference ma x. o , ) ~"J .

OPERATU:C HI l\T

__

I f you set the toolholder i n another angle position, H = l oo0 , you can ta~e bigger cuts ~hen facing .

<....,_ _ ....

- ----.-

--~

•

-~J... a

OPERATING HINl' 2

)

a

:-:ove with the transparen t sca l e drawi ng o f the t ool bi t along the shape of t he dra·.dng . You will i mmed i a t e ly see if the dep tll o f cut i s teo b i g .

--------8.5

Tool bits

The Left Hand Side Tool (T02)

)

Dimensions - Applications 2. Shape turning

t

Clearance angle

~

must be at least 2°'

n max.

3o0

•

= 930

3. Radii

I. Longitudinal turning, facing , taper

turning : The depth o f cut '''i th ~ 93° when facing must not be higher than o, 3 m:n , since the edge would not cut anymore .

__T _

__ OPERATWG fliNT

( ) c:

If you set the tcol in another ang l e pos itio n, ~ = loo0 , you can ta'
=:::'•>

OPERATING HINT 2 Hove with the t r ansparent sca l e drawing of the tool bit along the s hape of the drawing . You will i rr~ed iate ly see if the depth of cut i s t oo big.

)

8. 7

Tool bits

The Neutral Tool (T03) Dimensions - Applications

The max. depth of cut (a) when turni ng outwards must not be bi gger t han o , 3 r.m with a t~Jrning angle of 6o0 • 2. Turning o f part ia l radii

-

·- - ·

0

,--

0

Examples of application with )(' ; 9o I. LOngitudinal and a ngle turning

lt The tangent of the arc c ust not b e higher than 6o .

(

+t

Nax. ang l e 6o0 Clearance angle of 2 , 5°

( )

8.9

Tool bits

External Threading Tool , right hand (T04)

-

(

·--

For external th r eads , right hand !~C::~~~~~-~~e~; For pitches from o,5- 1,5 rum 0 Clearance angle 6o

)

Plunge Cutting Tool (T05) -~--1,2

( )

Width of tips: I, 2 rr.m Max. depth of cut: 1, 5 mm

{;- Q II

II II I I LJ

(

)

8. 11

V

Page I. 7/8.5-8 .1 51Tooling of

COMPACT 5CNC

( ) On the pages 8 . 5 to 8.15 metric sizes are shown . Calculate inch sizes yourself . o , 3 mrn ; .o12" (approximation)

Parting-off Tool HSS (TOG}

()

<.. )

HSS

l'iidth of tool: . 14o"

Internal Threading Tool, right hand (T01)

( )

From minor thread dia . • SSo" Indexal>le tips: For threads 16-48 tpi . and o,S- 1,5 ~m pitch Clearance angle: Goo

( )

u Page 1 . 7/8.5-8.15

j

Page t.7/e·. 5- 8. 1S/

Toolingof COMPACT 5CNC

External Threading Tool , right hand (T04)

--·--·

()

( For exte rna l threads , right ha nd Inde xabl e tip: For threads : 16- 48 tpi . a nd o , 5-1, 5 mm Cl e a rance angl e : 6o0

Plunge Cutting Tool (T05)

()

IHdth of tlps :,047" ~!ax . depth o f cu t :.06•

(

~). I I

I I I I II

"

(J

( Page 1.7/8 . 5-8 .1 5

-

~-

Tool bits

(

)

Parting-off Tool HSS (T06) - · --·- - · -.-....._

_J

L..-_

_,1-

HSS

Nidth of knife: 3,5 ''-'"

( )

Internal Threading Tool, right hand (T07) From minor thread dia. 14 rom on. !~~!:~~!!:. ~~e::.:. For pitches from o , 5- 1 , 5 Clearance angle 6o0 •

(

J

\

)

8. 13

rr~

Tool bits

\

Inside Turning Tool (T08)

( ) From dia . I
( )

Nax . clearance angle when turning outwards : 3o0

(

)

8. 15

Presetting of tools

Presetting of tools \ 40 30

- 1-- 1--

"l -+II

I

I

I I I

I

I

1

l

I

'-

I I

'

~_J_ f- ·

-- - -

- ··i

-o. l

1{

l

! 0"

.

-~

f-

::s

!'.'he n setting up t he program you have to knCY.< the positions of the various tool s to each other in X- and Z-direction.

J

r-3,5

For t he manufa cture of most workpieces a few tools are necessary . E.g . right hand side tool, threading tool , partingoff tool.

2X4 S?

_);5

-~

10 -

15 - -

1. Righ t hand side tool

3. Parting- off t ool

2. Threading tool

( ) -

. ---

1-

.~--~ 151 ~---

u

Procedure

I . Posi t ion all t ool bits in the toolhol der at center hoight.

)

2 . 1-!ount setting gauge in 3-ja·.. chuck. Pay attention that the plane surface o f the setting'gauge (I) touches the j aws of the chuck.

s

3. Posi t ion of toolholder ' body: - Loosen clamping screw of toolholder body . - Put te~plate horizontally onto setting ga~ge , points 2 and 3 nust touch set ting gauge. 3

-

~:ove longitudi nal and cross slide by hand until toolholder body is near poi nts 4 and 5 .

- Press toolholder body by hand agai nst the ter:.plate and c la rr.p it. N G X Z F A I

)

II

G

X

Z

F

4. Se t x- and

A

000000

000000

ol

ol

z~ value

out at zero .

8 .17

on digital read-

Presetting of tools

Positioning of turning tools 1. Right hand side tool T01 1. Right hand side tool T0 1

X = Omm Z Omm

=

Looson c lamping sere~ for turning tool and move it backwards in toolholdar. -

Clar.p toolhol der onto toolholde r body. Hove right hand side t ool into groove and position i t such that the carbide tip aligns with s urface I. clamp righ t hand side tool in thi s position and remove toolholder .

(

Attention: Press tool only slightly and then position .

In the same way as t he ri ght hand side tool all other tools are to be preset. ~~en setting the right hand, left hand or neutral side tool. the position of the toolholdar body remains the same . For a ll other too l s the position of the s l ides mus t be changed .

Starting point for the ~easures is the position which you fixed with the teltplate.

2. Traverse of l eft hand side tool (T02) X cO

z

~

.3. Traverse of neutral side tool (T03) X = 0 m::> Z=O rrc

~:r.m

0 .,..,

0

®

8.18

(

Presetting of tools

(

)

4. Traverse of t hreading tool for external threads (T04)

5. Traverse of plunge cutting tool (T05)

X = 0 Olll Z = t 21,00

X = 0 mm Z = t 2 7, 00 om 1. ,' _, )

Ol'l

. ~:1.'/

0

0

'; ) 7. Traverse of internal threading tool (T07) .,2 , 5 mm •• ~"i'' X - - .c. -- uz = t 58 ,0 mm ;t.~~' 'f

6. Traverse of parting-off tool (T06) X

=0

~:;o

Z = + 16, 00 mm .G-h''

0

I

)

8. Trave rse of i nside turning tool (T08) X= - 22,5 mm ••s-;,· z = + 52 , 0 mm :1.·0'1'1

0

)

8.19

Presetting of tools Positioning of cutting edges of tools to each other, if slide position remains unchanged The values must be consider ed when prograrrming. Refe r ence point is t he pos itio n of the right hand side tool .

Neutral Side Tool L=Omm ,.._ · a + 7,00 mm , "'fr:

=

Lell Hand Side Tool L = Omm a = + 14,00 mm .:JSI' 55 '

Parting-off Tool L = Omm a = Omm

_( _:_ __ _

(

Outside Threading Tool L = Omm a = + 2,00 mm o '/'·1 '

Pluning Cutting Tool L = - 10,00 mm ,?.11\ a = Omm

(

Inside Turning Tool L = + 10 ,00 mm .·;i~ a = - 20,00 mm :·.~ .

Inside Threading Tool ., L = +10 .00mm . Y\'1 a= - 2o,oo mm • . •Wl

8.20

I

Presetting of tools Example

.

)

(

Tur nin2 o f an annular t ee- slot a nd par ti ng-off

\

r-r-~I

I I I

.,

I I

I. .. -+ ·

:\I I

.

r I 1 I , J.

I I

_ j-

!~ -~!2~~-~~~~-~!~~-~~! _ie!~~~ ~-~~- ~~ Nl 3) :

--- 1 - -1

- --------

-e.

N

'20

10 01 _jj_ 01 12 01 13 no ...1.L 21

( )

20 (16)

-

.

~·a

7.-00 5

1oo 100 10(l

0

()O

- (,oo 0

1~

01

17

19

01 00 00

-200

_lQ_

01

Q

l1

()1

2Z 00 _2._3_ 21

.·

-

~00 - 1/.Dil

-

()

..1L 00

~

.

-loo

14,00

I!'UO,

This meas ure must be t aken into account .:hen you program the fo l l ~~i ng blocks .

41

(3, 5+25)

F

2 . Le ft hand s ide tool : -----------------------Tr a ver s e of pos ition Q = +

"'

-

( )

- ·- -

z

X

~

10-

35

- -

G

..

h45°

'

'

At the end of b l ock Nl 3 the r i gh t hand side tool is a t the indicated pos itio n.

~ ~

6oo

-roo

100 10Q

0

- .>oo

n

0

zoo

soo

100

0

400

S'OO

-

3 . Part i ng-o f f t ool (b locks N24 t o N29 ) --------------------------------------The posi tion of the par ting- o ff too l' s edge i s t h e s ame as t hat o f t h e r i gh t hand side t ool. Th e dis t a nce be tween l ef t ha nd s i de tool t o t he p arting- off too l: Q = - 14,00 mm

-14-

/

/ /'1

l'l

J

00

-:-:,~·s-o

0

. . -- -

_Q!)_ . - S'Do . - - - - -·

'i t .01

3,5

(

--

1.1

Atte nt ion : Never change tools whe n main s pi ndle i s running ! Danger!

-·

Q__ -· . 3.o..

-

1{,00

_zj_ . O L ~J_ __ . .. ~~ 8.21

.

0()

.::_iQ~ I ·

-

.4~S'o

Q__

...

.

-

---

.

Inch gange/Preselting of tools

Presetting of tools (Inch gange) 40

(\1 I I

I

I

I

I I

I

I

I

.... ....

-+1

I

l i

I

....

·- -·

1----- . . ...

I

(_j-rI

I

3,5

For the manu facture of mcst wot·i
2X

.

- 1-- --'

I

30

I" :--;R5

-~ X

0

1-

"'::;:

l-lhen setting up the program you have to k naN the positions of the various tcols t o each other in X- and Z- direction .

J -· 10 -

15 -

1. Right hand side tool

2 . Thread ing tool

3. Parting- off tool

- ,-

l )

+ · - · - r·- '--

-

-

Procedure Note :T"ne i nch gauge has a t.urned ring a t the face side of the gauge . I . Position all tool bits in the toolhol -

der a t center height. 2.

I

setting gauge in 3-j aw chuck . Pay attention that the plane sur face o f the setting gauge (I) touches the jaws of t he chuck . ~!ount

3. Posit ion of toolholder body: - · Loosen clruLping screw of toolholder body . - Put te~pl ate hor izontally onto sett i ng ga~ge, points 2 and 3 o ust touch setting gauge . - l·!ove longitud i na l and cross slide by hand until toolholder body i s near points 4 and 5 . - Press toolhol der bcdy by hand against the te~plate and o la~p it. II

( ) '

G

X

Z

F

A

II

G

X

Z

F

A

000000

000000

ol

ol

4 . Set x- and z- va lue on digital readout at zero .

8.17/lnch

Inch gange/Presettlng of tools 4. Traverse of threading tool for exter· nalthreads (T04)

)

X •

0"

z • .asou

5. Traverse of plung e culling tool (TOS) X

=

z

= +1.10011

0"

0

l ) 6. Traverse of partin g· off tool (T06)

7. Traverse of internal threading tool (T07)

X • 0"

X = -. 900 11

z • +.6so••

z=

0

0

+2 . 31\0"

( >' 8. Traverse of inside turning tool (T08) X = -

z

.900"

= +2 . 100"

0

( )

8.19/lnch

Presetting of tools/inch gange

----------------------------------~ Positioning of cutting edges of tools to each other, if slide posjtion remains unchanged The va l ues must be considet·ect ·..:hen progra rr_J ing. Re f e rence poi nt is the

po sition of t he right hand side t ool.

Neutral Side Tool L 0"

=

a = + .275"

Parting-off Tool L 0"

Left Hand Side Tool L 0"

=

=

a = + .55"

a= o"

--

Outside Threading Tool L 0"

= a = + .1oo"

0"

Pluning Cutting Tool L -.400"

=

a= o"

Inside Turning Tool L + .400"

Inside Threading Tool L + .400"

=

= a = - .8oo"

a = - .soo"

I

}

~

- ;-I~

,-- - .s.oo~ -"1

( .l

8.20/lnch

Inch ganga/Prese tt ing of tools

Example Tur ning of an a nnular tee-slo t a nd parti ng - off

(-,--r-1

I

J

1 -11

I I ,.

I I

r, - -+1I '6- I

11 II 1 I

I_ Right hand side tool (bloc)
---Ni3)7 - - -~ --- ------- -- - ------ ---- ---

,l

--

--------

..

1\t the end of block 1113 the right hand side t ool is at the indicated position .

- ~ '$

I I _)--

N

G

X

z

F

.0 Sx4S' .8'----~---~~~--

141 ' (

• --

-

)

-

,lQ

01

11

01

.JL

01

-·lOO 0 -100

00

250

~21

-200 -600 0

25

25 25

1-

.JL ..1L

The posi tion of the edge is t he sa.-:te as ha nd side tool. The left hand side tool tool : Q = - . SSO" 2~

--1--+->--.1404 1\ttention: ::ever change t ools ·..:hen ma in spindle is running! Danger!

co

_25

co

28

()()

part i ng-off too l ' s that of the right distance bot•.-een to the parting-off

-590 ~-~~--1---1-­

~2~6~01~--~~--~ 50~0~~·~ '0-+ 21 00

8.21/lnch

Radius Compensation

)

Radius Compensation (The Equidistant)

a

Definition: a

The equidistant i s a line >;hich has the s ame distance co a given l ine (c urve ).

a

( ) Programming up to now \11 t h all our prog rarr.'lling exercises up to nO'..t we ass umed t hat t he tool bi t is absolutely pointed . We ha ve progran:med the workpiece shO'..tn left hand lik e follo>
(

G

X

01 01

0

z

f'

x.

I

The radius of curvature of a corner T

In fact, each carbide tip has a certain corner radius (r). Without the corner radius the carbide tip would break or melt when working. Tha radii are standardized according to ISO: r • o,4/o,8/1,2/1,6/2,o/2,4 mm S • Center of rad ius r • Corner radius K a I oaginary cutting point (Location of reference point) T • Theoretical point

8.23

Radius Compensation

The influence of the corner Radius

1. Turning at right angle . f'ollo·,; the outline A B c D The radius of the cutting edge does not i nfluence the ••orkpiecc outline ·•hen t urning in X- o r Z- direction only ( turning at the right angle) .

I. Distance AB (length Zl )

Determining the outline is point Pl.

2. Distance N

G

BC

(leng t h XI) X

z

f'

I I I I I I 01

x.

' Determining the outline is point P2 .

3. Distance CD (length Z2)

I. I :. I : I _:.I · I Determining the outl i ne i s point Pl.

Conclusion: Tne r adius of the cut ti ng edge does not i nfluence the workpiece out line when turning in X- or Z-diroc tion, (turn ing at right angle ) .

8 .24

Radius Compensation

~----------------------------------------

2. Taperturn lng The workpiece outl ine A B C D E shall be pro9ram.-c.ed.

Up to nO'• we habe been prog r arr-'lling such a n ou tline as follO'oS:

( ) 2 . 1 . Di s t a nce AB

I " I :. 1: 1-:.I · I Dete r mining for the out line is point PI o f the carbide tip .

2 . 2 . Di stance BC

(

)

I . I :.1.:.1-:. 1•I Here •,:e see that it is no t the i magi nary point of t he cu tting edge K but the poi nt P2 ~hi ch de t e r mines the outline . I n o t he r \·:ords , "'ith this prograo t he ou tli ne B' C' •
2 . 3 . Di'stance CD

I ,. I :. 1: 1-:.I · I De ter~i ning

poi nt Pl.

8.25

for t he outl i ne i s

Rad hs Compensation

2.4. Distance DE

Determi ning for the outline is P3 •

Resul t : Because of the corner radi us " r" of the too l bit the de termiting cutting poin t p alters. As you reali ze, not ABCDE is mach ine d. I t i s AB'C'DE.

So: Zf

i s to short ( size = Az )

zl is to l ong ( size +A z ) .

Consequence : l·li th taper t ur ning X and Z- di:r.ensi ons must be calculated .

(

The two possibilities

Programming the center of the radius s

Programming the Point in imaginary cutting Point K

8.26

Radius Compensation

Example 1

Calculating the pointS

Calculating the point K

1. Distance AB

( )

Path of point K:Z'

Path of point S:Z'

c~' ~z, -~or - Lc, ... ---..

1----

/H -

Calculation of Lz and
--+-

Ill. ~ r. tgt I D.Z:. =

r -L1;

~

r-rtgt_

L.6~ ... re-t- t9~) 1 •

- - - - - - - - -1-

8.27

I

J

Radiu s Compensation

2. Distance BC

Ir - - Zi • Zt

3. Distance CD

- - - z,- ---1

-z; . . l:?> - r -+ lc ,. ~~ -( r - Le) .........--..b &.

8 .28

Radius Compensation

Example 2

( )

Distance AB

I

'l. = ;.., -+ r......._..._.. - l i! A C..

(

' 8.29

Radius Compensation

--------------------------------------~ Distance BC

1--- - z,

---+~

Pa th o f S in Z-Dl rection

Path of K in Z-Di rection

r.~ ""'

r2..- r

-tl1:

.... ~.a_-(1"-l?c) \,......

I

.6i!

Path of K in X-Diraction

Path of s in x-oirection

x~

I

:. x1 - r

-t

b.

~ .X ... ~(r -l.xl D. X ~

Calculating Lx·and ux

i Cj

!::.X

!IO~c(, ..,.

=

r

r - L.x

"' r -

8.30

Lx

r. t9 9

¥

Rlldius Compensation

Distance CD

X
• .;:,::

..'

•'

.!:1

X

•' ' ><

..

l

X

( ) Path of S in X-Direction

,

Path of Kin X-Direction

X2. -= l
\

) Conclusion:

o The size of Ax and 6 z r esp . lx and lz dep e nds on the size of the o corner radius and o angle

fro~

the

eot.

o \•lith ind ustrial machines the values Ax a n 6 z are calculated by the corr.p uter.

}

8.31

Radius Compensation

Chart for A X and D. z - value s

o, 4

o,S

o, 8

I,o

so Ax AZ

o,o3 o ,38

o,o4 o , 48

o , o7

o,o8

o,76

o , 96

Ax

o,o6

Az

o , 36

o , o8 o ,46

o , 13 o ,73

o , 16 o ,91

Ax

0,09

d Z

o, 35

o , 12 o,43

o , 19 o,69

o , 23 o,87

2o0

AX AZ

o , IS o ,41

o , 24 o , 66

o , Jo

o,33

JoO


o , 17 o , 29

o , 21 o , 37

34

o , 59

o , 42 0 , 73

4o0

AX Az

o, 21 o,25

o , 27 o , 32

o , 43 o , SI

o, SJ o,64

45°

AX Az

o , 23 o,23

o , 29 o , 29

o ,47 o,47

o, 59 o, 59

5o0

Ax li Z

o,25 o , 21

o,32 o , 27

o , SI o,43

o,SJ

6o0

Ax AZ

o,29 o , 17

o , 37 o , 21

o , 59 o ,34

o , 73 o ,4 2

7o0

Ax
o,33 o, 12

o ,41 o , IS

o,66 o ,24

o,82 o, 30

75°

AX AZ

o,JS

o , 43 o, 12

0 , 69 o , 19

o,87 o , 23

aoo

Ax AZ

o, 36

0,46 o , o8

o,73 o, 13

o, 9 1 o, 16

toO 15°

'·'

o , 12

o ,o9

o,o6

8.32

0 '

o , 82

o , G«J

..

...

Conversions pa9e l

Inch- Metric Conversions

J

+ + + +

Measure of length Feed size Fe ed speed Cutting speed

Length Heasurement

:c nch

system

Metric system Basic unit of oeasures o f l eng th i s the a .

13asi c ~easures of length are inch e.Jld feet. }?arts of inch are written both as t:zactional and decimal inch in t;ech nical drawing s .

f

In technical drawings all measures of length are shown in run . l r.JD = o.oo1 m Parts of mm are wr itte n as deci mal . ,.,.. o nly.

CO
Inch

lllOl

10''

254 m:n

I"

25 ,4

• 1 II

2, 54 run

.ol n .ool

Multi ply inch dimension with 25. 4

. oool" ~

1. 63" x 25 .4

~

= Conversion

l ooo (I m)

om to inch

loo by 25.1 Exal!lple: 41. 4o2 1m1

:

V@

:

o , o254 run o,oo254 m:o

41.4o2 ll'm .

J

+ Divide

m.-.

o, 254 am 11

ExaDple: 1 .63"

()

25. 4 = 1.63"

+ Hultiply inch with .o4 (rounded fac t or ) Example: l = x .o 4 = .o4"

Inch (exactly)

Inch (rounded)

39 .37oo7

4o

3 .937oo

4

lo

. 3937o

.4

I

.o3937

.o4

o ,l

.oo393

.004

o,ol

. ooo39

. ooo4

'}

)

u Conversions page

Cpnversions page 2

()

(

Feed Size (Ftl

Inch

Hetric

Feed size is given in inch per revolution .

Feed size is given in roo per revolution .

inch Ft • rev.

Ft

G

= -

rev.

(

\

\

"\

Conversion Inch - - - - - to - - - - mm Rev . rev. Multiply with factor 25.4 0.00

(

inc~ [rev. --

X

Jl"JD

)

125.41 =

o,o254

IUD

inch

to

rev.

rl_re~I

Multiply with facI:or . o4

J EJ -

.o2sf~ rev .

X

u Conversions page 2

o.oo I., ci- nch rev .

J

Conversions paqe 3

)

)

Inch

Metric

Feed speed is qiven in inch per minute

Feed speed is given in mm per minute

Conversions with fac tor 25 .4 resp. o , o4 (

)

4 inch/mm

X

125 .41

a

loo mm/ min.

loo mm/min

X

jo ,o 4j

;

4 inch/min.

Calculation o f Feed Speed (F 2 ) (inch)

F2

ci~ch] m1n .

s [r~J

Fl

X

G~J

Example:

'

s

(

)

.ooo8'' per revolution

Fl

(

•

~

F2

;

F2

a

15oo r pm ?

s

xFJ

;

I Soo x .oooB

)

;

1,2

inc h min .

I ( )

Conversions page 3

Conversions page 4 Cutt ing Speed (Vsl

)

(Surface speed) I nch

~ etric

In inch practice the cutti ng speed i s given in feed per minute

In metric practi ce the cutting speeds arc given in ceter per oinute

In short: SFH (surface speed per minu te ) or f pm (feed per minu te) S

X

"Jr

Sx7rxD

0

X

l ooo

12

()

Vs • Cutting speed (feed per minute) S & Spindle speed (rpm) D ~ Diameter of Korkpiece (inch)

)

Ys • CUtting speed (meter per minute ) s • Spindle speed (r pm) D ~ Diancter of KOrkpiece

Conversion of Cutting Speeds

Mul t iply f~-value with o,3 So fpm

2.

!-!e tric

x

o/mi'!_____.,.

B -

24 m/ mi n

~inch

to

fpo

~------------~~

Multiply m/min-value wi t h 3.3

24 m/ min

xl3.3j -

Bo fpm .

!calculati ng the Spindle Speed

Hetric

Inc h

u

. 12

X

Vs

7(

X

D

s " Spindle speed (rpm) Ys • Cutting speed (fpm l D = Diameter ( inch) 1(

I

= 3. 14

s

looo 'J(

X

Vg

xD

s • Spindle speed (rpm) Ys a Cutting speed (m/mi n) D = Diameter (rom) J( = 3 ,14

(

INDEX =====

Preface

1

Instruction Hater i al

3

Structure according to progress in the course

4

The reanual "VISIO}J"

4

Requireoents f or the course

5,6

Remarks conce t·ning ra·..... ma terial for prcgrarr.illing exet·cises as

(

l

~,·e ll

as cot·re ct

chucking

- 7,8,9

The drive power of the main spindle

-

lo

Lock-up o f

-

lo

~:easures

co~puter

•,;hen motor is stoppe d due to overl oad

Sorr.e hin t s for instructing wi th Compact 5 Tne method - experience s

Ch~

- II - 12 - 13

A pr oposal for the time schedule of h~-inst r uction

on the C5

c~~

- 14

Sub j ects, instructional advi ses , students activities

- 15 -

h~

- machines - Producti on

- 29

h~

- machines - Types o f machiner y

-

Fields of !;(;- appl i cation

COl'.PACT 5 CNC - Introduction

- 1.5

-

1.6

Wor:
-

1.8

Transmission steps

-

1.9

Cutting values

- I. lo -

Description of machine Posi t ionsof toolholder

·--=-

Toe righ_t handside tool

CHAPTER 2

)

Jo

- 31

CHAPTER I

)

28

1.1

1.7

I. II

HAND OPERATION

Operating elercents

- 2.1

Traverse indication

- 2. 3

The Plus - Minus - Sign

- 2. 5

Inching operation

- 2. 7

Switch o ver

- 2.9

Inpu t of traverse path

-2.11-2.13

Cutting-off po·ner o f step motors

- 2. 15

Positioning the tool

- 2. 17- 2.19

CIIAPTER 3 Operati ng e lements

- 3. I

Summaries

-3. 3-3 .4

~:etric/

- 3.5 - 3.6

NC-~lach

I nch oachi ne

- 3.7

i ne

ClK: - ~:ac hine h~1a t

(

- Main elerr.ents

happe ns i n Ch'C - }:anufacture?

- 3.8 - 3,. 9

- 3. lo - 3. 13

Ch'C- }lachine - Hand operated reachinc

- 3.15- 3.17

Setting up an lK:-proqram

- 3.19- 3.3 1

Coor dinate

sys t e~

- 3.33

Desc r iption o f traverse path

- 3.35

Kind of proqram

- 3 . 37

Geometrical information

- 3 . 39 - 3 .45

Feed

- 3.47

Preparatory functions (G- func tions)

- 3 . 39

Externa l struc ture

- 3 . 51 - 3 . 53

'Fne format

- 3.55

CHAPTER 4

)

CNC-OPERATION

PROGRAI·'.mt.'G

G2o/G21/G22

- 4. I

GOO Positioning with rapid traverse

- <1. 3 - 4 . 5

G84 Fixed c yc le - longitudina l turning

- 4.7 - 4.17

GOI Li near interpolation

- 4.19 - 4.4!

- Clockwise - c ounterclockwise

- 4. 43 - 4.55

G33/G78 Threading with consta nt pitch, t ht· eading cycle

- 4.57 - 4.83

Control of Dimensions - Corrections of Dimensions - ''· 85 - 4. 91

- 4.93 - 4.91

Exercises CHAPTER 5

)

PROGRA}l INPUT

Inpu t f ormat

- 5. I

Process of putting in data

- 5.4

Program input

-

5.7

- 5.3 - s.s - 5 .9

•

\

over of regi ster ed values

Take

- 5 .11

Operating elements Figure

keys , ~ord

display, cemory key ,

delet e key

- 5 . 13 - 5 . 27

Double keys Program hold Pr ogr am int erruption De l ete prograr.>

- 5 . 29 - 5.35 CHAPTER 6

ALARH

CHAPTER 7

1-'.ACNE-I'IC TAPE OPERATION

SIC~IS

Cause s - Measu res

(

) ~~des

of oper ation: SAVE,CHECK

Mode o f operation : LOA D S =.m a r y

- 7. I - 7.7 - 7.9

Alarm Signs

7 . II

Alarm A09

-

Alarll AIO/Ail

- 7. 17

Al arm Al 2 Program interruption

-

Putt i ng in the tape

- 7.25

Alarm A08

1-'~de

7. 5

of operation: ERASE

7.13 7 .I S 7. 19 - 7 . 21

7. 23 7.23

) CHAPTER 8

-TOOLS --

Positio ns of t oolhol d er

- 8.I

Turning tools

- 8 .5 - 8.1 5

Presetting of t ools

- 8. 17 - 8.21

Radius Compensation

- 8 .23 - 8 . 32 CHAPTER 9

- 8. 3

GLANCE INTO PRODUCTI O.'l MACHWERY

)

Gl ance into production machinery

- 9 .1

Charac ter store/ Address letters

- 9 .2

The preparatory functions (Format G2 )

- 9 .3

Biscellaneous functions

- 9.4

Decimal number s I Zero suppression

- 9.5

- 9.6

Format specifi cation Progra~ming

of absolute va l ue/

Programming o f reference value

- 9.7

Programming o f diameter

- 9.8

The Control Circuits on NC-Machines

- 9.9 - 9 .1o

Important points

- 9 .11 - 9.14

A Programming Sheet of an Industrial The Addresses

G/X/Z/R/~1/

Address F (Feed) (

)

( )

(

Address I/K

~lachine

- 9.15 - 9.16 - 9.19 9. 2o

Addresses X/U, Z/W

- 9.21

Addre ss T (Tool)

- 9 . 22

-

9.27

)

PREt'ACE =;::;c:::=se======

Contents and quantity o f

Kn~ft-h~~

in

~~

are continuously

grcNing. This becomes obvious when reading the va rious special journals. Thus it was difficult for t he authors of this

~~ nua l

to cut it s hor t and break up. The very

aim o f such book s hould after al l not be overlooked.

(

)

We are convinced that we met the actual requirements o f ~~-training,

h~•ever

with given possibilities and re -

stric tions. In e ach area the basics have to be undet·st
can be achieved . This is the reason why parti-

cular emphas i s was put o n genera lly accepted NC-technology and terms. ~~-semi nars

l asting one o r more days are o£fered in the

various countries by different ins titutes or by the NC departrr~nts

of our gene ral representatives.

) Assembly-, service - and safety instructions are included in the instruc tion book of COMPACT 5 CNC.

)

1

(

)

( )

(

)

All rights reserved, especial l y those of diffusion and

dupl ication through film, rad io, television, photomechanical reproduction , sound tracks of any and every kind, transl ation in to foreign languages , reprints of, extract f r9m the text.

~1982

by

E~~o

MAIER & co., Fabrik fur Spezialma-

schinen , Friedmann Maier Stra8e 9, A- 54oo Hallein Printed i n Aus tria .

\._)

2

j

)

Instruction Material

As instruction mat eria l we offer 3 manuals:

BASIS Fo r the student

(

) INSTRUCTOR

+

+

VISION For the teacher

Structure

1. The right hand- side pages of "BASIS" and "INSTRUCTOR"

are identical .

)

2. The left hand-side pages of "BASIS" are le ft blank for noti ces, drawings , etc . by the s t udent. 3 . On the left hand-s i de o f "INSTRUCTOR" you fi nd addi-

t i onal expl anations, i nstruc tiona l advices and solutions to e xe rcises as well as transitional texts . 4 . Additional pages i n "INSTRUCTOR" are numbered Il/! 2,

et c . 5 . Programm i ng sheets and drawing paper for exercises are inc l uded in both manual s "BIISIS" and "INSTRUCTOR".

( J

3

Structure according to progress In the course

The various chapters and parts are marked orange or blue. Orange chapt ers: Tloese conta·in the basic knmiledge on r;c-technology or are specifica lly connected with the cmtPI\CT 5 Ct{C and no particular kno·dedge is necessary. Blue chapters : The b l ue chapters provi de add itiona l genera l NC-kno·. dedge . Certain necessary groundings are required (e .g . kn~~ledge of trigonorr.etric fwlctions for the calculations on equidistants ).

( l

The manual "VISION"

The noverhead-Transparencies II of VISIO!J are

the basis for your lecture. - You save extensive preparations o f drawing a nd wri ting work . - The b l ank space i s thought for your l ect ure marks and not i ces. - Tne printed text he l ps you in the training o f thought .

<. )

(

I n addition to that the transparencies are ideal ly sui t ed for tests and c hecking whether the student understood your speech .

)

4

)

Requirements for th e course Student:

- Manual Basis - Pencil and colou red pencil - Ruler - For trigonometric tasks: book of specifications , slide- rule or pocket calculator

Teache r:

- Hanua l INSTRUCTOR - Manual

(

VlSIO~I

- Overhead projector - Fl i pchart or blackboard - Blank transpare ncies and llklrking pens instead of f l ipchar t or blackboard Machine :

- Ideal situa tion: One C
Turning instruction:

- 3-jaw chuck - Live center - Tool b its - Brush and clean ing to-.
)

Hilling instruction:

- Vertical mil ling and drilling attachment with c l amping devices f or workpiece and cutt ers

Ra•"' rna terial:

- Turning: both-e nd centered and faced a utomatic aluminium

- Mi ll ing: flat a l U3inium, cut to l ength Due to the light we i ght and t he compact construction of the machine it is possible to transform each c l assroom with i n short time into a C'-'C training workshop . For c l eaning of machine and room from chips you can use a vacuuu-cl eaner.

}

5

)

Objective I. To understand 2. Transforminq

h~

~c

fundamenta ls theory into practice

3. Control of machine operations 4. Ability to transform qiven writte n instructions 5 . Ability to chanqe over to industrial machines without di ff iculty 6. Fundamentals of NC-organisation and peripherical aspects of NCmachin ing.

(

)

Method I. Instruction manuals and machine are to be considered as one unit . 2. Due to the unity of theoretical instruction in t he classroom and practical application in the s aoe classroom/workshop it is possible to keep the ti me ratio between speech o f teacher and activities of student at 1:2. 3. The s tudent works on the machine from the very beginning of the course.

4. IndiVidual pace is possible . S. Theory is t ough t step by step - it will not be demanded too much by t he student. 6 . The CQ}IPACT 5 CNC excuses mistakes which the student make. Tir.;e

\ )

consuming checks of the program by the teacher and i npu t by the teacher are no t necessary. 7.

l~ritten

tests are very limited. The

~-:orking

r es ults sho..-, >:hether

the students understood or not .

Basic knowledge the student must have - Reading of simp le techn ica l drawings - Awareness of general safety requirerr;ents >:hen >:orking on a machine (lathe I) Experience in operating a traditiona l lathe. If the student does not have this e xperi ence , then you will have to provide technological data (speed, feed, etc .).

)

6

)

Remarks

Which raw material for programming exercises Type of material:

Use automatic alumin i um. Th is material is easy to machine and the ch i p formation is quite good. Vicous type s of a luminium are often hard to machine . They "smear" and often produce l ong shavings (danger!). Chips tend to rr~lt onto t he cutting edge. DIN-definition of auto~atic a luminium: Al Cu Hg Pb F 38; Material nu.mber 3. 1645 . 51 according to DIN 1725/1 747.

( ) Di rr~nsion:

~ 22 rrm i s the diame ter o f the blank in the drawings of the prograrrming examples and exerc i ses . If you use other dimensions, this will not cause any necessary conversion ~ork with increrr.en tal prograrr~ ing . ~ -------------------With 12o rr.m length the

Advisable dimension:

22 x 12o rrm student can •oork the mate-

rial at both ends. Quantity:

For the basic exercises lo blanks ~ill do. For more exerci ses you have to plan accordingly.

Clamping of the blanks (workpieces) The c l amping devices are indicated in catalog and instruction book. The most co~~n cl ampi ng device i s the 3- jaw chuck .

()

Cl ampi ng of workpiece into 3-jaw chuck

Never chuck workpiece without u sing live center!

The feeding power is approx . looo N (loo kp). Fa l se programming or fa l se input usually happen at the beginning. I f a ~orkpiece is not proper l y clamped or a long workpiece not exactly centered i t could be forced out of the chuck by the e normous feed pressure! This means danger to the operator ! So ah·ays use the live center (of the tai l stock) as support . Preparation of b l anks

Centering and f acing of blanks at both ends. You can ask your dealer to deliver the bl anks already centered.

7

The center bore of the workpleces

\

,

The tool bit and the center are laid out for a center bore of max. D ~ 6 , 3 mm .

If the cent e r bore i s bigger and s ma ll diameter are turn ed , then the tool bit body o f the right ha nd side too l will press onto the body of the live center. ~

·-·r'--

Chucking of centered workpleces into the 3·Jaw chuck

Proper chucking is required . The bla~~s are of ten chucked eccentrically, the center being forced into the bore and thus producing a rad i a l pressure onto the qu ill of t he ta i lstock. 'l'his causes: - unnecessary radial l oad of the center bearing and t a i lst ock qu il l as wel l a s the tailstock itself. - Bending of the workpiece - Bad su r face qua li ty (vibrat ions) - Since the c en ter t e nds t o a lign the norkpicce centrically, it would get loose in the chuck . Danger !

Correct chocking of centered blanks

I.

2.

)

~:ount

I>'Orkpicce using jaws .

Do

not t i ghten

yet. tai l stock qui ll forward so t hat center s i ts in center bore. Between face side of j aws and that of workpiece there should be a sma ll distance (so~e 1/lo rr~) .

~:ove

3. Press workpiece by hand against center and tighten ja..·s firmly.

8

)

Correct chucking of centered blanks

Check: tailstock quill back; i f "orkpieces g ive "ay no., - align it by Stlart blo·..:s with a harrmer until center bore and center are contrical. Tighten ~:ove

ja..s .

The t ool bit with carbide tips The chip recoval by means of carb ide t ools requ ires approx. double the po·.·er as by rr.eans of HSS tools .

( )

The C0~1PACT 5 CIIC is at the lo•,;er limit for co::---.on carbide tools. -The toolholders as we l l as t he carbide tips specified by El·:Co l
Belt position of the drive/performance at the main spindle The per f ormance of a ootor '-'ith continuous current incr eases with the rp:::o . Ther efore "ork in the speed range o f 7o to loo ' · Bel t dr i ve perfor mance to be transmitted with belt drive increases with i ncreasing belt speed. h'hen using carbide tools t he be lt positi ons BCl/BC2/BC3 are on l y necessary with thread cutting. ~ne

l

I

9

(

)

( }

The drive power of the main spindle - A weak point The cutting perfornance is determined by mechanica l considerat ions - such as with production machines. l>'hen overloading ( false program:ning, false input) the rr.otor is stopped and no damage will occur to mach ine or tool (breakage of tool bit is approx. at I ~) . I f you consider this you will agree that t he ~¢­ tor power is a strong point. It i s not the high cutting perforcance , but saf ety and no o r low cost (with false operation) which make effective NC-training on broad bas i s possible .

Lock-up of computer

()

I t may happen that with CNC operation the unit does not reac t to further input , delete etc . The ind i cations on the v.o.u. stop. The calcu l ator i s locked up. The reason f or this lock up could be a mis take in the prog rao or an e l ectr ic i nterference (e . g. e lectric supply s ys t e n).

Tur n main s1
()

10

r

-

_....,

~

..._

'......-

---

Measur~s

r:§D -c_r_g_c_ nc....;y;_s~ to_p.,J

. .../

-----

when motor is stopped due to overload (false programming/input) - Tool bit engaged

/

!Main switch

I

~ I!~]+IREV J

....

Slidcc ctop jumps back to block

Motor s tops Slides stop Program deleted

~rlli!I

~ + J

Main cpindle

I INPI+IFwo i Slides stop Program is in,erru~ed. When pressing STAR program is continued.

drive~~

+

!Main spindle drive@!!]

I

Attention: If main spindle dri ve is switched off only, the slide will carry on moving (feed power approx. looo N) - Danger that carbide t ip brakes, unnecessary load on zlides . Switching ON-Measures

.... ....

With emergency stop

With main switch

Jswitch off main switch !switch on machine! Move tool bit away i n X-dircction, check program, adjust and put in. Start anew

I

With\ INPJ + !REVJ + main spi ndle driv

With !INPI + !Fwo J + mai n cpindlc drive

- Switch over to hand operation - Move tool bit away in x- dircction - Check program and input and .:>.dj ust (comp.:>.re p.:>.ges 5.29 to 5 .3~ Start anew (program bcginc at NOO)

With the fi rst programming exerc ises students should use emergency stop or main switch!

~

•

~

Continue progr.:>.m (tool bit to be moved into st.:>.rting pocition) or st.:>.rt from the beginning. In most c.:>.scs it h.:>.s to be started f rom the beginning, s ince the cause for the interruption o f the pr ogram w.:>.s .:>. he.:>.vy bl ock mistake.

l

)

Some hints for instructing with the COMPACT 5 CNC

Guidance of student

( l

When conducting a basic h~-course on production machines, quite a problem arises because of the possibility and probability that a mistake may cause big d amage to the machi ne. In order to avoid thls, the instructor has to check the program and the entered values. - A job which is quite time consuming and which makes it practically impossible that the student works on the machine from the very begin of the course. The CO~lPACT 5 CNC is constructed in a way to avoid big damage, i.e. with fa lse prograrr~ing or input there will be no or little damage (carbide tip brakes). This feature allo~s the stud~nt to individually work on the machine or that a group of students work on various machines under your guidance.

( )

(

)

12

'!'he method Expe riences

The ho m:s a va ilable for NC - inst r uc t ion are usua ll y ver y limi t ed. I t is the objec tive t o ach ieve the utmost in s hortest tirr.e . •rhe re fore the method: - The s tudent should operate the machi ne f rom the begin o f the course.

( l

- Classr oom for theory and pract i ca l ~ork i s iden tical s o tha t the rati o be t~een the s peech of the teacher and the activi t ies by t he studen t s hou ld be kept at 1:2. - The contents of your speech i s i rrroedia t ely put into prac tice. The control whe ther unders tood or not is sirople. - The student l ea rns fast. - The student learns step by step the f unc tions o f t he ke yboard . For the firs t prograu~ ing exer c i ses i t i s enough if he kno"'s t he f unct ion of the main S>>'itch, the e r:ergency stop but ton, the number ke ys a nd t he iwPI key . - Questions a r e a s ked such as: " Do I have to cancel the whol e progr a::t i f I r.:ake an i nput mi s t a ke?" Or "How can I s top the program?" Th i s i s a sign t ha t the students understood and actively pa rt ic ipa t e .

(

)

- The student "experiences" the l ogics of th e program se t - up , o f the input, e t c . Lo ng a nd o fte n misunde r s tood explanations are not necessary. - !-!a ny terr.~s (e.g. pro;Jram set-up, s ystem of coor d i nate a xes, preparatory func tions , etc .) a re · familiar to the student by hi s work. The theoret ical e xp l a nations are easily understood . - The many quest ions a sked provide the opportu ni ty to i nclude par ts of chapt er g in to t he course . - The proper prepa r a tion of a d r awing to scale for t he program work socr.e timcs may be difficu l t for t he stude nt . Ho;;eve r, without such dra1..-ing the wri t te n prog rao o f te!l resu l t s fau lty.

( )

13

A proposal for th e time schedule of NC-instruction on the COMPACT 5 CNC

How to use the instruction material in t he course various c ircumstAnces :

wi l l depend on

Instruction t ice available Method ("·or kshop - theory roo=>, identical or not) N~~er (

of students

Number of machines Niveau of students, etc . rne teacher will take these factors int o consideration when setting up his time schedule. In the following concept we assume some conditions as given: Student knows hand-operated cachines, h~•ever does not have any prac t ical or theoretical NC-knowlcdqe. On one machine 3-4 students are wor king Theory roo::> and workshop are identical

(

)

The theoret i cal part (teacher ) is not longer than 2o mi nutes per instr uction unit (So minutes ). The manual "SIISIS " serves as l earni ng and exercise ma nual for the student. Additiona l e xpl anations by the t eache r are wr i tten d irectly into the manua l. Programs are partly written by the student as ho:ne·.
~

J

14

Co~ntary/ I nst ruct iona l

Subject

Act ivity of Student

Advise

DEVELOPMENT Of' llC TEC IIIIOLOGY

OHS 1/2 Hand operated· machine (P .

2. )

-

2.11)

Pay attention that the c l earance angle o f tho right hand side tool is over 9o0 so that also facinq is possible .

Mounti ng of t ool holder and right hand side tool without setting gauge.

If tho student ~ves t he s lide into end position (dead end) you hear the tack-tac~ sound. Tnis will not do a ny da..,age to the oachine , h~~av cr there is a unnecessary overload . By trave rsing with x,z ke ys the student "experiences " t he coordinates syste~ and t directi o n a t this poin t without any particular explanatlon.

set rpo . speed and traverse s l ides. Regulate feed . Traverse slides in x- and Z-di£ection.

OHS 8.5/3/4 Exp l anation of opera-

tin? ele::ents

t )

- Main switch - Ecergency stop button -

~witch for drive of ma in spindl e

- Knob for control of ma in spindle speed (bolt drive, acoetcr) - Rapid t raverse key

- Display shooing paths move::ent (in hundredth of =l - Tip operation - Expl ain c inus- va l uc

- Zcto positioning of lLEDl Display: Poss ibilities: I. &witch off =in switch 2. Emergency stop button 3. D&L key

SetiLEDIDiaplay to zero . Switch over display.

- SWitch over traverse path indication froa X to z ~ithou t changing of pos i tlon «@ key) -

Progra=~n9 t~averse

~i t h

(!!ill

of oove=ent key.

Discussin9 tho progr~inq of t raverse path is caybe too difficult at t hi s staqo . Can be d one later.

l )

15

Progr~

t r averse path.

)

Subje ct

Cocr.-en ta ry /Instructional Ad visa

Ac tivity o f Student

EXERCISE ( P. 2. 13) I f tho raw nat crial

Thi s exerci se shall sorvo to c a l -

(blank) ha s d i fferent di¢ onsion, tell the s t udent to correct tho m eas ur~ents in tho drawing accordingly . (Aid: transpa rencies )

c u late the tcch noloqical data or to r ead t he3 froD tho diagrans. I f tho s t udents have diffi cult ies to c alculate tho cutting Values , then pro vldo theo ~ith these values and revert to it later. :O'.ain obj ectivo here is,

- Calc ulation of c utti ng values - Cl acping tho

~~r kpiece

- Turni ng - Measu re and

~a yb~

c orr ec-

tion of dlaco ter.

t hat the student gets a fee ling for feed and cachinG per f orcance.

POSIT I ONING THE TOOL ( P. 2. 17/2 .1 9 )

( Sc r atching

OHS 2.17

- Main spindle r.tust be running (otherwise danger of brca
t he toOl ) -

feed rat e (students l acks feel i ng for infccd).

LO~

- Scratch by inching opera tion.

CNC·Operation Pages 3 .1 - 3 .11 (char t s , s t ru c tures) to be left out for the ti~e being. - Could confuse the s t udent at this stago. SIMI LAR I TIES ArlO Dlf'FER EUCES

l ) (P. 3.13/3 .1 5/3 . 17)

- Could be ~~rkea out together (gr oup d i scussion) - Explain t.ert1 "technoloqical"

J

16

Posi tion tool.

Chec~ pOSition ~it~xcy .

(

)

Co~~ntary/Instructional

Subject

Activity of

Stud~nt

Advise

SETTIIIG UP All liC - PROGRAlol (P . 3 . 19) - Program sheet - Proqra.l l input

Show little exareple

- Execution AD PAGES 3.2 1 - 3.29 Tne proqrao st~ucture - the key to prog r~,­

The studen t should t·ealize that there is no mystery behind the

ming - ~ust be c l ear to t h e student .

prog ran structure but sinple and l ogic standards for a general f ie ld of application - all orien ted to·,.·a rds practice .

(

WHAT IS PROGRIIM MlliG (P. 3 . 21)

OHS3.21

7he cartoon makes it clear that a special language has to be used when proq r~~ing. Terns: "COOing", "Code" .

A siople .. code " could be c:.entioned s uc h as letters-nUEbers code: II = I B

=2

c •

3

0 = 4

etc .

( )

WHICH lliFORMATIOll TO BE PUT

Ill?

(P. 3.25/ 3 .27/3 . 29)

Develop together with students. They have to understand tha t the instructions ~us t contain

--type o f slide (longitudinol or cross s lide)

- traverse of slide - di r ectlon and - feed rate . A hand -op~rated ~achine as DOdel cakes the analysis ~~ re attractive .

( )

17

Students give inSt[UCtions

for execution .

)

Co~ntary/Instructional

Subject

Activity of Student

Advise

THOUGHTS 011 THE PROGRAM STRUCTURE

Maybe at later stage, after GOO/ G84 since explanation of G- functions is dlff lc~ l t.

(P . 3 . 3 1)

COORDINATE SYSTEM (P. 3 . 31/3. 35)

The t ranslatiol1 o! lon\ji tudinal and cross s l ide t•A)Ve:r:e nt in the

c:x: -axis and ture X and z f icultie s if f ront o f the

OHS 3.33

r:.otion noc:enc l awill no t caus e dif the rAchlne l s in s t udent .

Explanat ions of ax l s and aotion n~encla ture,

riqht hand coor-

dinate syste:> r ule later . Many students have difficulties to understand the right h and coord i nate

s yste ~

rule .

METHODS OF PRO· GRAMM I NG (P 3.37)

OHS3.37 Under cethod of proqr~ i ng ~ c undorst.a nd absoluto or 1n-

cre=ent al progra=lng. GEO METRICAL IIIFOR· MAT!Oll ( P. ).39)

)

~ny

OHS 3.39

tAo

syste~s

of

measure~ents

Develop t ogether

(depending on production and ~easure=ent reasons)?

METHODS OF PROGRAM IH llG

( P . 3.39)

OHS 3.43/0HS 5

So=e s tudents cay havo diff i c ul-

Poll o>~

pre-given e xaoplo

ties to follgd, revert to paqe oe~n st rato

zero off-

3.37 , u se transparent paper .

set us i ng transparen-

cies St udent

Exercise (P.3 . 43)

18

~~ts

in data.

Subject

Co~ntary/Instru ction a l

Activity o f Student

Advise

Advantaqcs - Disadvan-

tages (P. 3. 45)

Student should understand that wi th lncre=ent al rr09ra=~ in; the changing of one point ••ill cause the changing of all other poi nts.

THE FEED ( F ) (P . 3.47)

- I f the understand i ng of the 2 feed types causes probl~s,

revert to i t at a later stage. By ~~rking on tho ~~ chine the

student will undorstand the

feed speed . - x c ntion that on production ttachines the feed can be pre· qr acced in ~/rov . and co/~ln.

(

- The abbreviation for feed is F, whi ch corresponds to (oJ::I

and ~ requlations. PREPARATORY FUNCTIONS / G-FUNCTION~ (P . 3 . 49)

00 not t r ea t survey on this

page at this stage . THE CUC - PROGRAM ( EXTERNAL STRUC T UR E)

(P . 3.51/3.53)

)

- Skip pages and r ever t to it aft er having qono through OOO/GB4 .

- Student has t o know terns ( p . 3.51) however a t later stage .

19

Solve tasks on convers ion o£ feed .

Subjec t

Activity of Student

Co~ ntary/lnstructiona l

Advise

Blocl< for""t

Tr eat at later staqe when

stu~

dent is facillar with input lo9ic s.

~xpl anntion

on G-!unctions: can

be c oc:pored wl th the key of a pocket c6lculator (+ ,-, : ,x). I f the studen t pr09rADs GOO/G94 di rectly at tho cach i ne , the understanding of the G-functions coaes by itself , explanations not being necessary.

( ) GOO - POSITI OHIGG IH'rfl RAPID TRAV E RSE ( P. 4 . 3)

OHS4.3

-

~he

QAChlno offer s only one rapid traverse , the refore no F-pr09ra::.':1ing necessa ry.

- By GOO tho c ach ine kn~•s alr eady that rapid trave r se i s c.eant.

- Exp l ain input for X/Z ln

=·

( )

1/100 - If/ X 1& put in, there is no Z-input ncccssa~y (unnecessary prOQramoi ng effo rt), so the cooputor docs not t~
a ny input. -

S ho~

ho w to put i n proqrao .

20

)

Co~cntary/Instructional

Subject

Activity of S tudent

Advi se

PROGRAM ItiPUT

- Student shou ld l earn to execute written instruc tions.

(P. 5 .7/5 .9)

-

V.e~surc

to take with ala~ or fa l se inpu t: s~itch off ~ in s witch and have student star t froo b eg in.

- Student to follo·• r.anua l (p. 5.7/5.9) and carry through exa:-.ple . - Attention to coll isionl Er.erqency-stop-button l Main switchl

- The mea ning o f all keys usua l ly wi ll not be ~e=or ized by t he s t udent at onco . Tncreforc concentrate on lu:P I and nu:Wcr keys .

(

PROGRAM EtiD

( G22 )

(P. 4.1)

Explain G22 (The cocputer has to be told that there >~ill be no f urther i nputs to follo·,:) . Repeat positioning, check pos iti on of' t ool b it at proqrao start.

PROGRAMMI NG EXERCI SE I GOO ( P.1. 5)

OHS 4.5

(

- Main spi nd l e not switched o n

- Set up proqrao

- Check starting posit ion of slide&.

- I nput of proqra=>

Student has to consider the position of the tool bit at start, so he wil l not traverse over stop posi tion of cross s l ide .

- Set up proqrao

- Execute

PROGRAMMING EXERCISE 2 GOO (P.4.~

OHS 4.5

Student

C~us t

k.no·,.. to \.'rite in ..

put forcat for GOO.

)

21

- I npu t of prog rao - Execu te

Co~ntary/Instructiona l

Subject

Activity of Student

Advise

EXPLI\Nl\TION OF (P. 5 .3)

FOR~!AT

OHS 5.3

Explanation of aycbolic description of input for~at (also later possible)

G84 ( P .4. 7 - 4.1 7 )

- G84 function facili tates the prog rarr> ing . - 'i'he co:.1putet.' kno·,.•s that with

G8•1 the t ool bit has to be brought back to starting position4 - speeds are adapted to practical data.

( )

Student has to rea lize that first and fourth move~cnts are traverse t:ovec:onts and that second and third ~¢ v e c e nts a r c operation cove::onts .

G84 (P. 4.9)

OHS4.9

\>1'1th stu-

cx~plo

t Ogether .

~< rite

into

dent.

OHS 4.11 G94 (P.4.13) -

for~ t

Develop input

G84 (P . 4 .11 )

Student should charts signs .

Ex L~ple

~ork

throuqh

OHS 4.13 PROG RAMMI~G EXERCISE G84 (P. 4.15)

(

OHS 4.15

l\ proper technical dra-.ing to

scale on graph paper helps to avoid wrong coaaures . If there is danger of collision (false progr~ing, fa l se input) press ~e rgency -stop-butto n. Have proq rao checked at start, inpu t fro:o begin.

- Student prepares drawing on gr aph paper, scale I : lo. - Progra;-, set up

- Pragra::> input - Execution

- Student oeasurcs and makes correc tion du~inq turnlnQ operation (i f e xplained) .

(

)

22

Subjec t

Co=centary/J ns t ructional Advise

Activity of Student

OPERATIIIG ELEMEIITS/ CIIC-OPERATIOII P.S.I3 Chanqc-ove r key P.S. IS Flqure keys Minus-siqn key

Either de~nstrate key function or let students do it by the~­ selves, us ing oanua l (exaople 4.1 3/4.1 5)

use ~anua l and learn key functions (ex~~plos 4.13/ 4. 15) •

P.S. I7 WOrd Display P.S.19II11Pikcy P.S.21 !oaLikey P. 5. 23 IP'•l>l key P. 5. 25 IREVIl
( )

P.S.27l-ll
- Ora·...· ing to scal e

4.1 7)

- Sot up of proqrao - Input of proqra:o - Check progr ~ (cake corrections if necessary)

- Manufac ture, ceasure.

DISCUSS POSSIBIL ITIES OF CORREC'i' IIIG MEASURES Possibility I

( )

- Turn first workpiece - T"nen c:.easuro

- S'o
( )

23

)

Co:=entary/Instructional Advise

Subjec~

Activity of Student

ALARM S I GNS AOO/ A02/A03/A04/AOS

' Discuss alaro si9ns and ceasures.

Put in alaro causing va lue• cake alaro disappear and correc t values.

CUC-HACHIH £ ..

OPERATING ELEMENTS (P, 3.8 - 3. 11 )

OHS 3.9

The detailed e xplanation of a CI1C u nit would 90 beyond the objective of this c ourse and is

not

( }

fores~cn

hero.

h'lla~

happens •'hen data is put in? (P. 5 . 4/5.5)

OHS 3.9

Ho~ever, tho student will hear teres such as

- microprocessor - AAH -

EPRO:{ •••

and should k:no·..· tJ o n ·...-hat • s happening inside this "black boxn. 7hc cartoons and drawings will

inforo hie about the functional units and the data processing and help hio to understand the loqics. - Presentation is oasior and can be discussed in qroup . - Since student has already put in- proqr~~ s or corrected alarm signs, he will have wore relation to tho functional process

( )

described. 1\na~ happens when wconQ data is pu~ in?

( P . 6 . 2 - 6.5)

l )

24

)

Subject

Activity of Student

Co~ntary/Instruetional

Advise

.. GO I - L IN EAR INTERPOLATIO N (P.4.1 9/4.21)

OHS 4.21/1

Develop input forcat

OHS 4.21/2 Exanp le 4.22/4.23

- Th i s exaople is a continuati o n

work through ex~ple.

of exanple 4 .13.

OHS 4.22

- Aid : Transparent paper with side tool

PROGR AMMING EXERCISE 5 COl

( )

(P. 4. 25)

(Continuation of proqramoi ng exorci se l ) Take-over of reQistered values (P. S.ll l

Due to the individua l progr ess of each s t udent In f il linq in the chartt the input can be organ ised in laps, if a fe·..: students ~ork on one c achine.

- Prepare drawi ng to scale - 'Oritc proqran

- Put i n proqrau - Check proqrao - Execu te (with interruptions)

Pr09rao forcats Repeat 000/C94/00I lin X- resp. Z-di rection)

THE IIC-PROGRAH !EXTER NAL STRUCTURE)

(P, 3 . 51/3.53/3 . 55)

Explain

progr~~

structure .

~he

teres such as block/word/address have t o be ~ernorized .

( )

LIN EAR I!;TERPOLATIO!! TAPER 'i'UR!Il!IG (P. 4 . 27)

OHS4.27

Explain the tero " interpolation". Interpolation • Flndinq of intcrcediate value botween t~o point s . Linear • straiqht .

TAPER 4 5° (P, 4.29)

- Develop input forcat

OHS4.29

-

OHS4.28

~ork

out proqrac

- Input - Execution

l )

25

Co=centary/lnstructional Advise

Subject

Activity of Student

PROGRAMMING EXERCI SE 6 ( P. 4. 31) - fi x starting point -

~ork

ou t prograo

- Input - Execut ion

TAPERS IN GENER AL (P. 4 . 33 - 1.41) Exacple: OHS 4.35

Explanation, that on the CO:{P1<.Cl' 5 C!JC the nu.:obor of tapers . is lio i ted.

( ) PROGR AMMI NG EXERCIS E 7 (P. . 4.37) - Dra•,.,ing to scale

- Proqram - J nput - Execution

CONVERS I ON OP AIIGLES (P.4. 39-4. 41) T"ne chart and tho instructions serve for th o oanu fac ture of

concfete " orkpi ocos with an9les. If neces sary discuss.

G02/G03 - RAD II CLOCKW I SE / COUIITBRCLOCKWI SB (P . 4 . 43 - 4 .49 )

OHS 4.45 OHS 4.47 OHS 4.51

- Explain input format or ftork out toqether

- Exa.ttples <>nd proqrat:.:Ding exerc i ses G02/G03 (P.4 .5 1-4.55)

OHS 4.55 'i'HREADING (P.

4 .57- 4.71)

Tne proqr~~1ng has to b e done according to char t 4.65 .

26

Execution of prograooing e xorcise G02/G03

( )

Subje ct.

Co~n tory/ In structional

Ac tivi t y of Student

Ad vi s e

G 3 3 - T HREAD IIIG IIIT II CO NSTAIIT P I TCH

Discuss f or cat and progra=oing G78 - TIIREAD J ilG CYCLE - ---

OHS 4.79

Discuss foroat and cycle .

OHS4.81 PROGR AMMING EXER-

CISE 9 Write

( l

progr~,

put i t in,

execute

REPEAT MO ST IH POR'l' ANT TERM S Test:

- Student has t o write do~ n

-

input formats

Pr og rw~ s t ruc t uce (bl ock, no rd , add ress , etc. )

CONTOUR PROGRAMI-I IllG/ PROGRAM MIIIG • EXERC I SE (P . 4 . 87 - 4 . 91/ P. 4.97 - 4 . lol J

( )

- Set up progran

Discuss e xanpl es

- I nput

OHS4 .89

- £ )(ecution to true c.ea-

sure

OHS 4.91

\

)

27

Subject

Co~ontary/ l nstructional

Activi t y ot Student

Advise

SUMMARY/RE PETITION

MAGNETIC TAPE OPERATIOII

(Chapter 7)

Stude nt s ha ll learn to put written I nstructions into prac tice

- Student follo·•s writtel> instructions . ~nort pro: graws ( proqrarminq exe rcises) to be stored . - store progrL,S of followi ng e xercises in this chapter .

( )

COIITOUR PROGRAHIIIIIG ( P . 4.87 - 4. 1ol)

Explain contour pr09ramoing using cxaopl c 4.97 bishop or 4.1o l ki ng . Expl anation of canufacture o n production cachincs .

Hanufacturo of

ft'Or~pieces,

parting-off by hand operation, watch correct feed .

TOOLS AND PRE-SETT tiiG OF TOOLS

Pre -setting of tools

(P. 8. 1 - 8.23 )

OHS 8.5/8. 7/8.9 OHS 8.1118.13/8.15 exorcises (P . 4.93- 4.1o l)

proqra~~inq related to progr~ing tlce and ~orkpiece

Discuss

tice ( 4.93- 4. 95). P ro q r ~ ing with or without consideration of the equidistant.

( ) CALC ULAT ION OF EQUIDISTMIT (P . 8.23 - 8.32)

OHS 8.23/8.25 COU'l'EliTS OF . CHAP TER 9

Parts of it arc l ikely to have been discussed at earlier stage, due to questions by students .

l J

28

~·~anu facturo

of "''orkpiece!i .

( ) NC-Machlnes-Production The increase of NC-roachines production is shc·.m in the below qraph . The forecas ts for the f urther develop:r.-ent indicate their increasinq qrowth. The reasons for this development are manifold . The econo::.y o f NC- machines is certainly one of the main r easons , otherwise nobody would invest t he h igh initial costs. That the qroHth rate in ~;c-mach inery is particularl y hiqh in Japan can be read in various technica l and economical joumals.

( ) <§

Q

~

I

~"
~~

., Q

....<: £ ~ ....0 ... Q

(

)

z~

-

_____.

.--·

---·----·

,.,/

__ . /

/

I

I

I

I

I

9:-o/

q;; •

_,/

/

1980

1970 Some of the reasons for the rapid development

- The fast development 1
29 )

()

NC-Machines - Types of machinery Approx . 65 \ o f the total NC-macn1nes in use are lathes. However, h~-milling mach ines and machining centers gained importance during the last few years. The nachining ce nters developed up to 1976 rather slowly. This was due to the complex control mechanism, rather difficult in handling.

()

rnere is a new trend to be observed: are also built in smaller machinery and in i ncreasingly different types of machines.

t.~-units

Reasons: - Lower cost for control unit and thus a favourable price-/ perfo•~ance ratio of NC-machines versus handoperated machines . -

Progr~~ing

and input

~~re

cornfortanle.

( )

\)

1970

1980

30

Fields of NC-appllcatlon The number of various types of NC-machinery is increasing and will zoom in the next few years. ~h e r efore

n e w vocations will be created around NC-mach iner yl

It started with the applicati on of NC in the fie ld o f classical machine tools .

)

Lathes of all kinds Milling machines o f all kinds Drilling mach i nes and machining center s Gri nding mach ines ~~asuring machines and -equip~ent Punching presses and nibb le machines Bending machines Rotary tabl es Pipe-bending machi nes Shaping machines Welding machines Painting machines Woodworking machines Assembling units ( robots) Drawing machines etc.

)

,

I

I

( )

1970

1980

31

I

I

I

r

I

~ .

)

9. Glance Into Production Machinery

'

..

,.

)

Glance into production machinery 9.1 The address letters 9.2- 9.4 Programming of decimal point, zero suppression 9.5 Format specification . 9.6 Programming of absolute value/ Programming of reference value 9.7- 9.8 Control circuits 9.9- 9.10 Fixed points 9.11-9.14 Programming sheeJ of an industrial machine 9.15 - 9.27

(

' Glance into Proquction Machinery

IH th

a trai ning unit the emphasis is on get ting to !
or productivity are not o f concern .

1-iith pro
tool change, SHi tching-on o f coolant attachment, etc . are time consuming and therefore t hese opera t ions are usually done via the control unit , i.e . through the program .

Automation Since production titr.e (,;orkpiece time) has to be kept as short as possibl e , - s witching on t he main spindle,

- setting of spi ndle speed , - tool change, - various switchiny f unctions (e.g. cool ant on, coolan t off)

()

are automised and

prcgra~~ed.

Programming developing a CNC unit, it is always the goal to deve l op it for simple and praxis - oriented prograrr~ing.

l~hen

Therefore the computer takes over core and more calculation and storage ~ork. various data (e.g. tool data, technological data) are stored and do not have to be prograrr~ed or e ntered any core . On the following pages a

)

9.1

surr~ry .

Ch aracter store/Address leHers

Th e ch aracter store (the address leHers)

Since there are more possibilities for progra~ming ~ith industria l/production machines , therefore the char,lcter store has to be larger. Just consider a milling machine: we have to program in 3 axes: X, Y, Z. The mean i r\g of the characters is defined according to DIN 66 o25 , page 1 .

·rne

current addresses , the ir meaning ,

t hei r characteristics .

Extract from DIU 66o25, page 1 , edition 2 . 72

Character A B

c D E

F G H

I J K

L

:·1 N

0

Character

:-:eaning

Turn in9 rr~veme nt - x-axis Turning n:<>veme nt - Y- a xis Turning r;:overnent - z - axis

p

Turning movement additional axis or t hi rd feed Turning move::cent f urther axis or second feed Feed Preparatory f unction (unassigned ) Interpolation parame t e r or thread pitch para lle l to x- axis Interpolation parameter or thread pitch para llel to Y- axis Interpolation parace ter or thread pitch paralle l to z- a xis (unass igned ) Auxiliary function Bloc:< number (not to be used)

9.2

v

Thi rd rr~vement paralle l to X- axis or parameter for tool correction ?nird ~~veroent parallel to Y- axis or pararr.eter for tool correction 1 Third move~e nt parallel to Z- axis or rapid traverse direction za xis or parar.eter for tool correct ion Spindle speed Tool Second rrDver.ent para l le l to xaxis Second rrDveroent parallel to Y-

w

Second movement pa r a lle l to z -

X

l-:ovement in direction of x- axis

y

!-!overnent in direction of Y- axis.

z

~,ovement

Q R

s T

u

axis axis

in direction of z - axis

Preparatory functions

The preparatory functions (Format G2)

(

G- functions , preparatory functions these are the mos t cc~.an ter~s used . These unassigned ones can be used by the manufacturer of a contro l unit for certain control functions .

The available nurr.bcr of preparat ory functions are more numerous •n•i th industri al machines. The meaning of such functions is defined according to Dill 66 o25 , parts of lt are unassigned.

The

of such specially assigned is explained in the instruction bocks of the relative machine. r~aning

functio~s

Codes of preparatory functions G Extract froo DHl GGo25 , page 2 , paragraph 2 . 4 , edition 72 . 5 .

(

Preparatory Function GOO

Point to Point , Positi on ing

(,() I

l..ine"r 1 nterpo lation

G02

Circular Interpolation Arc

G03

Preparatory

Ne41ning

G40

Tool Offset Cancel

G41 - G52

Tool Of fset

clcci<~
G53

Linear Shift Cancel

Circular Interpolation Arc

G54 - G59

Linear Shift

G60

Positioning Exact

(fine )

GGI

Positioning Exact 2

(r.~ d )

counterclock.~ise

G04

Jj..:ell

G06

Parabolic Interpola t ion

G62

Positioni ng Fast (coarse )

GOO

Acceleration

G63

'rapping

G09

Deceleration

ceo

Fixed Cycle Cancel

Gl7

XY Plane Selection

G81 - GB9

Fixed Cycle

GIS

xz Plane Selection

G90

Absolute Dimension

Gl 9

YZ

G9 1

Increttental Dimension

G25 - G29

Permanently unassigned

G9 2

Preload Registers

c33

Thread Cutti ng , constant lead

G9 3

Inverse Ti rr.e , Feeo Rate

G34

Thread Cutting, increasing lead

G94

Feed per 1-linute

G35

T"nread Cutting , decreasing lead

G95

Feed per Spindle

G9G

Constant Surface Speed

G97

Revolution pe r

G3G -

(

)

z-:eaning

F\Jn ction

G39

Plane Selection

Permaneoltly unassigned

1111 prepa rato~y functions not IT.entioned here are unassigned.

9.3

~linute

-

Miscellaneous functions

.,

~

The mlscellaneous functions Address:

!-1;

Forma t: M2

The s~·itc h i ng on of the spindle, of the coolant liqu i d , too l change and other functions are progra rrmed with address 1-1 . Also « i th fun c tlons H there are preli ninary a nd pe rmancntly unassigned ones.

)

.

Codes of miseellaneous functions M

I

Extract o f DI N 66o25, page 2, paragraph 4.3, e ditio n 72/5 .

~li scellaneous

Functi o n

~

Punctlon

:-:oo

Progr ao St op

:-~01

Optional (planned ) Stop

:-:0 2

End of Progran

:-:03

Spindle Cloc k•,.;ise

l·:04

Spindle Counte rcloc kr;i so

~:o s

Spindle Off

:<06

Tool Change

~:o7

Coolan t

~:os

Cool ant No . 2 ON

:·~09

Coolant OFF

:-110

Cl a mp

:-!I I

Unc l a-.:p

Hl3

Spi ndle Cl o c k.--:ise and Coolant 0:1 Spi ndle counterclockw ise nnd Coolant 0:1

}! 1 ~~

t>liscellc:.neous

:·:eaning

~:o.

I

0~1

Meani ng

HI S

:-:o tion +

1-116

!'.o tio n -

!-119

o r i ente d Spindle Stop

rHO

End of Tape

1-131

Interlock Bypass

ro!36 - H37

Peed Range s

1·!38 - M39

Spindle Speed Range

1·14 0 -

~!4 5

Ge ar Cha nges

~150

Coo l ant Uo . 3

~~

H5 1

Cool ant llo . 4

~~

1-155 - H56

Linear Tool Shi f t

:·!60

lior kpiecc Change

N6 l - !·:62

Linear liorkp iece Shift

1-!71 - M72

Angula r Horkpiece Shift

Jill misce lla ncous f unc tions not mentioned here a re pre ll ml na ry o r perro3nently unassig ned.

9.4

Decimal numbers I Zero suppression

~-----------------------------------

Some Facts and Features Programming of decimal point Nearly a ll industrial 1\C-I!'.achines ilre equipped with decic1al point input . This feature facil i tates progracming and progran input . Example: 1/loo 1nm input (like CO~IPACT 5 cr;C):

x- va lue is 24 , 25 nm Input: 2425 (no decimal poi nt) Example: Input of decima l point:

(

x-value i s 24,25 ~ I nput: 24 , 25 (prograu~ ing of decioal point)

Zero suppression (according to ISO) I. Suppression of l eading zeros The notation XOOI2,14S is vague and co:~pllcatcd. Thus :
(

)

Notation without suppression of leading zeros

Notation with suppression of lead i ng zeros

X0012 ...... ,14 5

X12 ,1 4S

Le~ing ze r os 2. Suppression of consecut ive zeros (according to ISO) The zeros a fter the decima l point need not be wr itten. Example: Notation "•i thout suppression of consecutive zer os

of cons ecutive zeros

X12,~

X12 .

/

Consecuti ve zeros

( )

9 .5

llotation ""ith suppression

Formats

Format specification

COMPACT5CNC

In ou ~ for mat specifi cation on the CO!·IPACT 5 CllC .:e have indicated the format syrr~l ically.

N. ./G .. /X ... ./Z .... .

)

Program format specification (according to ISO) A typical

exa~p le :

U4/G2/X43/ Z43/ •..• •. etc.

What means X4 3? X 43 The first figure means the numbe~ of possible digi t s before the decima l point

The second fig ure u.eans the nur.cber of possible digits aft er the decinal point

~-,

3

4 Nhat means N 4?

If t here is only one

figu~ e afte~ the address character , t hen it rr~ans the nurrcbe~ of digits befo~ e the decinal point. Tne largest progra=able b l ock nu mbe ~ 1-:ill the n be : N~991

N

Exercise :

Indicate the program format of the CO!·IPACT 5 to ISO)

Cl:C

4

(according

N .• /G •. /X ... ./Z •.... /f' . ..

l )

9.6

Programming of absolute value I Programming of reference value

(

)

Programming of absolute value I Programming of reference value

Industrial NC-machi nes a llc·• bo t h abso· l ute and incr emental program.'lling . The cowputer mus t be ho•,:e ver informed on h O'A' t o understand the da t a \.;hi c h are p ut in: abs olu te or increme nta l. This in forma tion is given via G- functions. G90 = Abso lut e di me nsion input G9 1 = Incre rr.e nta l dic.ension input

Example: Prograrrc'lling of absolute value Poi n t s P, /Pt /P,. have to be de scribed in t he abso l ute system ; zero point o f the coordinate s y s t en as indicated .

60 30

()

i- 15•

~ -z Ze ropoint

«

""

~~

0

·- -e. "

N 00

. r- !

-

N

T

v

~.

2

X

z

G9o

p,

ol

ol

lo

6o

p,

o2

ol

lo

45

p)

o3

ol

2o

) 0

By prograrrJoing o f G90 all follo:
\p3

+X

G

Exercise: Describe poin ts P, /P, /P~ in the a.bsolute s y stem. Zero point as indica ted .

( \

-x

G

N (l ()

.

.

-z

i; t

« ~

""~eropoint

+Z

X

z ()

C!o ) I

• •1

...

1) ,

10 IU

- IS

jl"J,

Cj

I ")

_3_(2

;:\

F

+X

. l

)

9 .7

Programming of diameter

Programming of diameter 'hether the custo::.er (·"ho buys the naW c hine) wants a progra=mlnq facility for r·adius or for diar.ctcr has to h e ind i c ated when ordering the ::c- machine .

l~ori
t o be turned are c:ostl y indi cated in the technical dra·.•inq "'ith the i r dia~~ters . To convert the diazeter values into radius values is tirr~ consuming a nd can bring about misca l c ul ation. Therefore , with practically all l athes t he diameter is p r ogranr.cd .

Exampie: zero poi nt as indicilted p rogrilr:--
~-------60 ------~~

---

30 - --

G

:·~

P,

-z

P,

~ 'E).---+

Ps

.. .. .. ..

X

z

2o

6o

2o

•15

40

3o

9o

,..

+X

Example : Prog rarr~ing of

d i a~~ter

Progran point P, absolute, point Pa i ncrer.ental , po in t p3 absolute.

N

G

X

z

.-

..._,-

.()

(' I

c

)

F

- I C)

q ()

.

-

J

9.8

Control circuli

The Control Circuits on NC-Machines

1. Open control circuit (e. g. COMPACT 5 CNC)

,

... ..... , . .,. ..... .

()

NC-cont rol un i t

(

<:

... ""' ... > ".. ..."'"<: ..."' 0

)

0

0 0

f<

l~ach i ne

~·eed

G!~tor

j(}-

~~~~~~!_e~~~~!e!~~

The NC-control unit gives the instruction to traverse to t he feed motor, e.g. to traverse by 37 , 25 ~" · An answer back signal, whether the slide has actually moved, is not gi ven.

l )

9.9

Control circuli

2. Closed contro l circuli ()

g'

NC-

"~ r;::::=::::;! control

CD

unit

.,.,8 ..,

c: 0 j

u

!I.,"

...c:

I

I

I

(i:::::::::::::~d lOOmm

I 230mm

y

'!"he c:achine is equ.ipped with a positi on ccasure system. The pos itions of the slides are continuously i ndicated t o the control unit. ~~!~~!~!~ -!~~~~e!~L 'The slide is at pos i tion 23o mm . l~e give instruction to traverse Z - 13o mm . The positi on c:easure s yster.> reports to the NC-control uni t: my position is

(

230 J:llll .

NC-

~

COI'ITRot VNIT

Tne ca lculator calculates:

!

Actua l value = 23o ~~ Desired va lue = (23o - 13o)

~

~ W£HIM:

c

too mm

Thus I have to give traverse inst ruc t ion until I receive informati on frorn the position ~~ a s ur e: I have reached at l oo ~~ .

TE£0 MOTO~

l

9 .10

Important points

(

Important Points 1. The machine datum M Syn:.bol

~ ~~ '£he machine datuo is the origin of the coordi nate system. ~lith lathes it i s on the mounting base of the cain &pinole fla nge and the turning axis. It cannot be cha nged by the user of the machi ne . It >:as f ixed by the manufac ture r and prograv~ed into the computer cc ~ ry . The point has the coordinates X=O , z ~ o.

t ) 2. Th e machine reference poin t R Symbol

~

R

The mach i ne reference point serves for the calibration of the ueasure syste~. The position of poin t R is determi ned from the "'a nu fac tu rer by car.-.s . The rr.easures XHR and ZNR are fixed in the co.-:>puter and cannot be changed by the user. Calibration procedure a) Tne slides are ~oved until the cac$ indicate: "The slides are at refe rence point R". The displacc~ent measuring systeo i ndicate the measured values X and Z.

( )

b) The coAputer compares Z~9t and z . X}9tl Z}L~

~'~

and X resp .

~ fix stored values

measured va lues c ) If there is a de viation , then X- and z-values i l1 t he t:easm·e systo z:~ 'd ll be corrected .

l )

-

9. 11

Important points

Ex ample Slides are in reference point position R. Progr~ing t he offset fron R to machine reference point H as f ollo;;s .

------

N

G

..

G9o

..

ol

X

z

XNR

ZHR

3. The workpiece zero-point W The various chucking devices are rrountcd onto the ma in spindle. The distance of the face side of the workpiece to the l".ach ine datum (X, /X 1 /X~) di ffers , dependi ng on the j a,.s '"h i ch '"e use for chuci
(

tion \,·ork when p r oq t:ammi n9 .

Therefore : Of fset of the origi n of the coordinate system in t o the ·,;or kpi ece zero point I~. ~

offset of reference point

The orig in of the coordinate system is the machine reference point . This origin of the coordinate system can be offset to the ~ark­ piece zero point I~ . It is effected via G-funkti on G92 .

x,,, ,

Progra~"ed

tI

~nc ~orkpiece

zero point is described from point R when the offset i s progr~d via G92

I

~ x,,,

Coordinates of

I~

x-Axis: no offset Z-Axis: M

ZRI~

= ZHR

¢ XHR= ¢ - Z~l;~

Prograr.~ing

'

N

G

x.mi

= 200

-

s

40

120=

= 160

the offset X

z

120

160

90 92 ,,.1160)

l

,.,. •100•

9. 12

J

I

l

Important points

(

Example Prog rac.m1ng the poin ts P, /P, /P, Prog r~ing of absolute value Prog ra~ing o f diarueter

... \

N

p p p (

)

G

0

0

0

0

0

0

0

0

0

0

z

X

90

92

1 20

00

lo lo 3o

ol ol

I Go So 6o 25

0

~------~------·~

Exercise

(

Prog r am the offse t o f 1-1 (design} and prog r ae poi nts P, /P~ /P3

)

0

r

-

1,

r- ... w r-· ro ----- - -B ~ r~

J

N

G

z

X

Cl o

I ..~I

.f,..

0•

L 120 200

l )

9. 13

I () <

..

F

Important points ~:--

4. The dead stop point A (Symbol-@) The distance of the point A alt e rs depending on the clamping device. Position of point A must be cosidered when proqram:ning the offset of the coordinate syste;:~ .

5. The set value E (Symbol-$) The set point E is the zero point for the Lool pre-setting. Sta r ting fr~ this point , the neas ure~ents for the tool bit dic.ensions L and Q are set and ca l culated ( c~~pare address T ).

6. Tool post reference point T (Symbol~) Point T is exactly the point o f rotation of the t oo l post.

7. Slide reference point F (Symbol -$-) A

poin t on the tool post .

M

T

L ._

·-·¥

Tnerc ~re even r~re reference points on certain r:c-nachines (compare re lative instruction book ). \~ith

mllny machines various point s are

for reusons of s i c.plicity identical •.;ith rc fcrence poin t R.

9.14

Address N

A Programming Sh eet of an Industrial Machine Address N (Block Number)

X

z

K

F

s

I I I I I R

T

M

The n umber of bloc ks i s 9999. (1\ddress format N4) . l~e progra m in decima l jurr.ps so ~e ca n put in block s also a ft erwards wi thout having t o r ewr ite the who l e pregram.

(

Corrmo n format: N4 (to 9999 blo ck s )

)

Ex ample 1-- 29 -~

The prograr..::-. er h as fi xed a depth of cut of 5 mm . l·lhon t he operation s t ar ts , tho depth of cut turns ou t to be too l arge .

0

N

..., - · -1--

00 01

X/U

G

9-

84 84

3.000 2.ooo

Z/W

3o.ooo 3o.ooo

10 20

lnsertlng a block

(

The operator changes the prog ram by di vidi ng bloc)< llOO in t ·• o s ing le blocks (1100 1101) ..,.ith 3 c.:n resp. 2 = dept h

)

' . o f c ut N

G

00

84

X/U

s.ooo

Z/1~

3o. ooo

10

20 30 possibilities do you have for ins e rt ing a block on the CO:·!PAC'l' 5 CIIC?

\~hieh

(. )

h'hich other possibili t i es •..:ould there b e in t his axar:ple - maybe 1<1 t h out dividing the block?

NOD

In which •...•ay '-"'e re the values X and Z give n?

9.15

The Addresses G/X/Z/R/M

I

Addresses G/ X/ Z: These you kn~~ already from 110r ki ng 1d t h t h e CO:-:PACT 5 CNC .

'

(

Address r.~: :·tiscellaneous functi ons , codes to be found o n page 9 . 4.

Programming example Bl oc:< I: Spi nd l e speed i n clockwi se d i rection 24oo r e v/mi n . Block 2 : Coolant I 0:1 N

G

Ol

97

02

l

I

I

(

)

s 24oo

I

(

03

07

Address R: Tile add r ess R refers t o the control unit. I t is progra.::n:ed in con nection •,; ith t he con stant cutting speed .

9 .16

Address S

Address S (Spindle Speed)

(

X

z

I

K

F

I® I

R

M

T

Wi t h industria l KC-illaChines also t he spindle spe eds are progr~d.

( )

1. Constant spindle speed ~~!!~2!~l Turn i ng a tape r With constant spi ndle speed (e .g. looo r p::>) also the c utting speed changes fro::>

Vsl •

dl

x1!"

X S

l ooo

=

2o

x1!"

X

l ooo

l ooo

.. 62 m/min . to Vs2 "

•

(

)

d2

xr looo

124

X

S

4o

X

1J

X

l oco

l ooo

m/mit.

The maxim~ cutting speed is given (dep ending on mat eria l of the tool bit, ra·" material of l
- Hany ma terials ca n be hard ly worked with too l o·" cutting speeds .

(

)

9.17

Address S

Programming

2. Constant culling speed The ideal condi tion for the chi p removal is a n unchanged cutti ng speed . 1-:i th' tiC - machine s t he c utting speed can be regulated .

you wa nt constan t s pindle s p eed or constant cutting speed h as to be in formed to the coo:puter. 'fhis is done via G-functions .

h~e ther

1. Spindle speed in rpm ( 1/min) = G
h'hen program::>ing tho f unct ion G97 the spi ndle s peed has to be give n in rpm. N

G

97,

1000 (1/min)

l

s 2 ~ 1000 (1/ min )

s 2400

I

G 97 = S-value In 1/min (rpm)

Reg ulation: Tne pos ition changes of the cross slide in X-d i rect ion are indicated vi a the position measuring system of the cross s l ide . The conputer continuously calcul a t es the values . s • v8

d

x looo X

~

2. Constant cutti ng speed (water pe r minut e ) = G% II

and gives the results .

G ~

'rhe motor is being adjusted accord ingly .

I

Posi tion measuring s yste m___ . _

s 140

I

G 96 = S-value in m/min h'hen programaing G96 additionally to the cutt i ng speed the cax i mum permissable or possib l e spi ndle speed must be prograr.~~d

x-value

Conputer

s-value Regulation

~ 9.18

)

Feed F

)

Address F (Feed)

I~N~IG~ I x~Z ~I~K~® I

R

1

sj r Ml 1

Also the feed can be prog ramied i n two ways . The alternati ves are G94 and G95 .

( ) 1. G 94 = Programming the feed In millimeters per minute (mm/mln)

1 2~ I I

I I I c

N

94

G94

=

Address format :

(

2. G 95 = Direct notation of the feed in millimeters per revolution

N

I• I :, I

lo . : so l

mm/mln

G95

F4

Adress for r.:at : F l 3 (F., ... )

(F •••• )

)

Question: l.,..nen t aper tur n l ng, will the f eed in r..I:J/ rev. change with this progra=c'lling?

N

F

G

96

s 2000

j....:..:...._J..--::9:..: 4-I+-

--/-1-_:I=SO:::.jj.-----/)

9.19

=

mm/U

I

Addresses 1/K

Addresses IlK

z CD ®

s 'I

R

F

T

There are coumon CKC-units where 1/K are used for the description of the center point of c i rcl e . On industrial machines any type of arc can be achieved.

Progra r..mi ng Tool bit is positioned i n poi nt 1. 112

N

35

z

G

X

10

01

30

-35

20

02

60

- 47

I

K

25

IS

~

1'1

l - ·- tP,

I'

Block lo: Prograrrcni ng Of P1 to P,

:0

"

/ -L--·+-·-· / t

.

Block 2o: Turn ing of radi us Tool bit is at point

PI

P~ .

X, Z-values :

In columns X and Z we enter the coordinates of point P~ . X60 (Prograr~ing of d i ~ tcr) Z-47 (Progra~ning of abs olute value) 1/K-values I and K are the coordinates of the center poi nt of radius . Tnese values have to be put in incrcoentally. Starti ng point for the desct·iption of poin t P,_ Starting point for the arc.

9.20

Addresses X/ U , Z/W

(

Addresses X/U, Z/W

I I N

G

1(8{9j(~l

I

K

IF

s

T

M

For this case the addresses U and W arc used . If the values are entered under X,Z they will be calculated as absolute. If e ntered unde r U/1-1 , t he va lues will be increr.:e ntal.

Tne measurecents in

~os t drawings are given in a mi xed code , both absolute

and incremental . '•iith the preparatory

f unctions G90 and G91 you can choose between these two codes . In ma ny i nstances it will h~hevcr be sir.:pler to progr am in both·codes in one block.

(

R

Examp l e:

I

The points P1 /P1 /P3 are prograr:rr.ed . The poi nt ~ is always wri t t en absolute .

3. X-absolute I Z-incre~ental N.. /G90 tl . ./GOO/XIO/Z80 ~: . . / GO I/XI0/1-120 II· ./GOI/X30/I-I35

I. Prog ( a tt.:>i ng of absolute value i n X-

( I

and Z.-axis N . ./G90 N.. /GOO/X IO/Z80 N.. /GOI/X IO/Z60 N.. /GOI/X30/Z25 2. Prograttmin2 of incre~ntal value in x- and Z-axis N. ./G90 N.• /GOO/XIO/Z80 N.. /GOI/UO/W20 N.. /GOI/U IO/W3S

4. x-incremental I Z-absol ute N• ./G90 N.• /GOO/X IO/Z80 N.. /GOI/UO/Z60 N. ./GOI/UIO/Z25

Exerci se: Carry ou t al l 4 ways in progra,ming Program t he workpiece zer o point in the ind i c ated position.

(

)

9.21

Address T

Address T (Tool) Address

forr~t :

T4 (T .. .. )

T is the abbreviation for "TOOL" .

z

I

K

I

F

R

I

s

M

Industri al ~achines are qu i pped with t ool holders v;hi ch can hold 4 ,6 , 8 , 12 or more t ool s . Tne toolholder of machi ning center s can hold 5o and =ore tools .

Tne tool change is done and must be prograrr~d .

auto~atically

Fixings for programming Position number (example: 4-way toolholder) We have to in form the desired angle position to the computer . Tne instruction to th e toolholder "~:ove by 27o0 ", •
Fi xing The 4 positions of the toolholder are numbered : 01 .. /02 .. / 03 . ./Ot, .. Example :

0 04

03

Programning for posit i on 02 .. in block 120

o6 The toolholder

9.22

~ill

move to position 02 .

)

Address T

Tool pre-setting 1--

Like on the COHPACT 5 Ct:C the tools must be pre-set, so the position of the edges in x- and z-a xis to each other arc known.

14--.t

h'hy a tool pre-setting device ? The setting of tools direct at the I'Cmachine ~ould be uneconomical, because the machine would be blocked too long (cos t factor).

The tool setting pointE (Symbol

-$-)

( ) a ) Orig i n fo r the ceasurcrr~ nts and setting is a point on the toolholder . Tnis point is called the tool setting poi nt. b ) Th i s is t he reference point for posit i oning the t ool. L = distance in X-axis Q = dis tance in z-axis

·rhc setting chart

(

)

Right hand too l; Go r:-rn

C~·~,:

3o on

\. <1

Le ft hand

\.001;

L • Q •

L •

Go l!!!l

Q .. 15

rtm

'

~

,.

.

# ""'

' :c; I

'fhc me asures/dirr.ensions L/Q are ente red in the setting cha rt, so that both the tcol pro-setter and the prograur-e r kn~d the position of the tool edge .

(

)

9.23

AddressT

The tool storage and the tool number Do you rercerrher exet·cise 8 . 2 1? '.·:hen c h anging f rom t he r i ght hand t o t he l eft ha nd side tool , ''e had to t a!
Programming (

Add re ss format : T4

---

T ..

......

L

Nurr.ber of tool T03 , T04)

('TO!, T02,

Position nurr.ber (O l /02/03)

- T·he first figures stand fo r the pos i tion of the too lholder. - Th e second t>:o f i g ures indicate the nur..ber of t he tool . Under this ml~.ber the tool dat a are s t ored (L/Q/R etc .) Exarr,ole : N

T

H

00

o4o4

06

l2o

o3o l

c6

T030! Th e tool holder tur ns in block 12o to position 03.

T0 301

Tne ccrr.pu t er knm:s the L/Q/R value s and ca l culates the moverr.e nt . These va l ues mus t h c·.
9.24

l

I

Address T

Input in the tool storage lie have to put in t o the tool storage the tool data for each tool (W I, ro2 .. )

Example :

( J

T01

Tool : TOI L = 25 em I Q

,

·- --$---

=4

lTD

R = o,8 m."D

--....-a

Tool: T02 L = 25 , 8 ~ I Q R = o,S m:n

I

·$-· (

= 2o

)

I nputs I . L-value 2. Q- value 3. Cutting radius "r" for calculation of the equidistant (radius co::opensation).

l )

4 . Position of the cutting radius ( 1, 2, 3,4, 5 etc. ) so the co~puter kn~•s whether the calculated correction value has to be added or substract ed .

9.25

"~

AddressT

How comes th e too l tip K to point P with thisprogrammlng?

c 00

90

01

92

z

X

+Z

Procedure : Block :;oo:G90

Program::.ing of absolute value

Bloc)< 1101 :C92 = Offse t of the coordina te s yste m by Z!;H !Hock 1103 : Tool t raverses t o position ~

X/Z.

z r-

-

-

v.r.' '-

ZpK

.--- ~

~

w 1'\'r

0

-

0

IV

)(

-

0

"&

0

"' X 0.

.__ ~

", ..J

~

a: ::E

)(

.

... --J-

'

L.-

Zwe= ZwR

z,.1n. z,.1e

9.26

E•R

"'::E

X

Address T

Run-off in Computer

Hachine storage

Too l storage

Storage

3

5 6

Hi c roprocessor

Instructions

( )

X=XPK

Z=ZPK

Hi croprocessor - Nach i ne s torage

I.

Ho·" l arge are the distances R to ~:a chine

2.

s t orage -

CALCULATION ',\QRK Of' NICROPROCESSOR

I have to instr uct t o traverse to ¢ X and dioension Z.

N?

~li croprocessor

I.

The dis tance s a re XNR and

( )

Z lo\R

3 . Nicroprocessor -S torage I

z~!R - z~~~ - Q - z =~ So I have to traverse by .zKf.,

Is machine zer o point offset?

2. X- direction:

XI-IR- L - ¢X o ~ I have to traverse in X-di r ection by ..l!JY?...

4 . Storage I - Hic roprocessor

Yes: Instruction G92 in block NOI was given . New ze r o point i s offset by distance ZK.-.' . llicroproce s sor: I have to subs trac t with a l l z - values.

s.

~li croprocessor

Zl·:O~

- Tool storage

large are the di stances of the cutting tips K and R?

H~"

6 . Tool storage - 1-!lcroprocossor No , the d i stances R to K a r e L and Q.

)

Z-direction:

1-licropr ocessor: so I have to take i nto account L/Q.

9.27