lesson topics 1 getting more from your cnc machines copyright 2011 topics lesson 5: setup reduction...
Post on 11-Jan-2016
217 Views
Preview:
TRANSCRIPT
Lesson topics
1
Getting More From Your CNC Machines
Copyright 2011
Topics
Lesson 5: Setup Reduction Techniques
Setup reduction techniques (cont.)Program verificationProgram optimizingOther setup tasks
Setup tasks and improvements
Setup reduction techniques Introduction Evaluating how well organized you are Gathering components for a setup Workholding setup
Cutting toolsProgram zero assignmentProgram developmentProgram transfer and storage
Lesson topics
Lesson topics
With an understanding of principles:
Definition of setup timeTwo task typesThree ways to reduce setup timeFour steps to setup reduction
You should be ready to begin
Lesson topics
General flow of making a setup:
Get readyWorkholding setupProgram zero assignmentCutting toolsProgram developmentProgram transfer and storageProgram verificationProgram optimizingOther tasks related to setup
We’ll be going through setup tasks in this order:
Lesson topics
1) To Eliminate The Task
2) To Move The Task Off Line
3) To Facilitate The Task
With every task, we’ll give suggestions…
Lesson topics
1) To Eliminate The Task
2) To Move The Task Off Line
3) To Facilitate The TaskHardest to justifyRepeated task or urgencyFinite # of repeated setups
With every task, we’ll give suggestions…
Lesson topics
1) To Eliminate The Task
2) To Move The Task Off Line
3) To Facilitate The TaskSufficient CNC staffSufficient cycle timeSufficient lot sizes
With every task, we’ll give suggestions…
Lesson topics
1) To Eliminate The Task
2) To Move The Task Off Line
3) To Facilitate The Task
Little repeat businessSetup person does allNo off-line time
With every task, we’ll give suggestions…
Lesson topics
While we’ll show many techniques and make many suggestions…
…we’re just scratching the surface of what’s possible
Study your current methods!
With ingenuity – and your knowledge of your company’s methods – you should be able to come
up with more – and more appropriate –ideas
Lesson topics
In each setup reduction step, we will:
Develop a list of related tasksProvide general suggestionsProvide specific machining center techniquesProvide specific turning center techniques
Your list of tasks will likely be different than ours
Lesson topics
Lesson topics
Disorganization is pretty easy to spot…
Lesson topics
Disorganization is pretty easy to spot…
…you must encourage and enhance the potential for organization…
Lesson topics
Disorganization is pretty easy to spot…
…you must encourage and enhance the potential for organization…
…since getting more organized improves every CNC task!
Remember: The more often you repeat a task, the easier it is to justify improving it.
Every task you perform is affected by how well organized you are!
Lesson topics
Workbenches Does every hand tool have a place? How cluttered is the work surface? Is it ever used for storage? Does every operator have one?
Lesson topics
Cleanliness of work area and machine/s Is everything put away when not in use? Are chips, coolant, oil, and debris cleaned?
Cleanliness can also have an impact on safety
Lesson topics
Storage of components Are needed components properly stored? Is every drawer/cabinet clearly labeled?
Lesson topics
Storage of components Are needed components properly stored? Is every drawer/cabinet clearly labeled? Are work holding devices properly stored?
Lesson topics
Storage of components Are needed components properly stored? Is every drawer/cabinet clearly labeled? Are work holding devices properly stored? What about cutting tool and insert storage?
Lesson topics
Storage of components Are needed components properly stored? Is every drawer/cabinet clearly labeled? Are work holding devices properly stored? What about cutting tool and insert storage? Are common gauges readily available?
Watch for any time that CNC people seem confused - or when they must search the
shop to find a needed component
Lesson topics
Documentation Have procedures been developed for important or complex tasks? Does everyone know what they’re expected to do? Do key people get called at home to solve problems? How often are mistakes made?
Lesson topics
Work habits Does everyone do things in a consistent manner? Does everyone understand and adhere to safety standards? Have you set priorities for shop-related tasks? Has there been any horse-play
Lesson topics
Consistency of programming methods
Program mean value for all dimensions No offset adjustment will be necessary
Handle programming features consistently Cutter radius compensation Tool length compensation Tool nose radius compensation
Do you ever see your setup people having to make adjustments from job to job due to inconsistent programming methods?
Lesson topics
Job order planning
1 A-23462 A-38563 B-2917
Do you consecutively run similar jobs to minimize setup effort?
Work holding setup Cutting tools
Do your people ever have to tear down a job in the middle of a production run for a “hot job”
Lesson topics
Any setup – or portion of a setup – that can be made during these periods will be off line!
Non-production time Can you make use of time that the machine would normally be down?
Lunch Breaks Off shifts Shutdowns
Lesson topics
If you have never undertaken an improvement program…
…it’s likely that you’ll find problems with organization
In this case, your first step must be to get better organized!
The goal is to eliminate confusion and wasted time
Fortunately, it’s pretty easy to come up with ways to improve organization…
…it takes little more than common sense
Lesson topics
An example:
A machining center operator needs the vise handle to load and remove every workpiece…
…stick the vise handle to the machine (with Velcro) to eliminate the need to locate it
Lesson topics
Almost everything we do to get better organized falls into the category of facilitating tasks…
…we’re trying to make it as quick and easy to perform just about any tasks!
Lesson topics
Is there room for improvement with organization in your own company?
Lesson topics
Lesson topics
Think of everything a setup person needs to complete a setup…
Hand toolsWorkholding devices and/or componentsFastenersCutting tool components and insertsProgramDocumentationRaw materialFinished workpiece storage binsGaugesCoolantDocumentation: Print, Production control material, Setup sheet, production run instructions, SPC material
How often do setup people currently leave the machine to go get something?
Think of all the time that could be saved if they could complete the
setup without leaving the machine
In the setup reduction planning form (provided in lesson four), list items that must be gathered
Lesson topics
With good documentation and in well organized companies, a lesser skilled person can do the gathering for upcoming jobs…
…anything gathered prior to a setup moves the task of gathering off line
And if everything can be gathered prior to starting the setup…
…the setup person will be able to complete the setup without ever having to leave the machine!
In this way, the entire task of gathering can be moved off line
Also…If anything is missing, you will know it before the job hits the machine!
Lesson topics
Who will do the gathering?
Be sure to pick someone who truly has the time to consistently gather all components prior to a setup
This requires a high degree of organization
Setup person?
Tool crib attendant?
Operator?
Lead person?
CNC helper?And be sure that all components are properly stored and labeled, and easy to find – so anyone can do the gathering
Lesson topics
The gathered components are commonly referred to as a kit
If small and light, the kit can be placed in a box or bin and brought out to the machine prior to the setup
Either way, the goal is to allow the setup person to complete the setup without having to leave the machine.
If large and heavy, the kit can be placed in a cart and wheeled out to the machine prior to setup
Lesson topics
Lesson topics
Think of what must be done to remove the previous setup from the machine
Remove workholding deviceRemove cutting tools not needed for next jobClear offsets for tools removed from the machineDisassemble certain components (like cutting tools) Put everything awaySave changes to program and remove from the machineEmpty chip pan (if machining a different material)Clean machine
Here is our list, but be sure to create a list of your own
Use the setup reduction planning form provided in lesson four
Lesson topics
First, try to come up with ways to eliminate tasks…
Remove workholding deviceRemove cutting tools not needed for next jobClear offsets for tools removed from the machineDisassemble certain components (like cutting tools) Put everything awaySave changes to program and remove from the machineEmpty chip pan (if machining a different material)Clean machine Can you think of any way to keep from
having to remove the work holding device?
Can multiple workholding devices be mounted to the machine? (On the table of a vertical machining centers.) Can jobs requiring the same workholding device be run consecutively? Can workholding devices be more versatile, allowing different jobs to be run?
…some may seem far-fetched
Lesson topics
First, try to come up with ways to eliminate tasks…
Remove workholding deviceRemove cutting tools not needed for next jobClear offsets for tools removed from the machineDisassemble certain components (like cutting tools) Put everything awaySave changes to program and remove from the machineEmpty chip pan (if machining a different material)Clean machine Can you think of any way to keep from
having to remove cutting tools?
Does the machine have enough tool stations to hold all tools for all jobs? Can a set of “standard” cutting tools be kept in the machine at all times? Cam jobs requiring the same cutting tools be run consecutively?
…some may seem far-fetched
Lesson topics
First, try to come up with ways to eliminate tasks…
Remove workholding deviceRemove cutting tools not needed for next jobClear offsets for tools removed from the machineDisassemble certain components (like cutting tools) Put everything awaySave changes to program and remove from the machineEmpty chip pan (if machining a different material)Clean machine Does this task really have to be done?
Setup people may feel more comfortable doing so, but having a value in an unused offset will have no adverse effect. Offsets for “standard tool stations” will not have to be cleared.
…some may seem far-fetched
Lesson topics
First, try to come up with ways to eliminate tasks…
Remove workholding deviceRemove cutting tools not needed for next jobClear offsets for tools removed from the machineDisassemble certain components (like cutting tools) Put everything awaySave changes to program and remove from the machineEmpty chip pan (if machining a different material)Clean machine Can you think of any way to keep from
having to disassemble cutting tools?
If using a limited number of different tools, leave them assembled at all times. Consider the redundancy of tearing down and assembling cutting tools
Again, pick a set of “standard tools” that will be left assembled at all times.
…some may seem far-fetched
Lesson topics
First, try to come up with ways to eliminate tasks…
Remove workholding deviceRemove cutting tools not needed for next jobClear offsets for tools removed from the machineDisassemble certain components (like cutting tools) Put everything awaySave changes to program and remove from the machineEmpty chip pan (if machining a different material)Clean machine Can you think of any way to keep from
having to put things away?
If all the cutting tools you use can fit in the machine’s tool changing system, nothing will have to be put away
…some may seem far-fetched
Lesson topics
First, try to come up with ways to eliminate tasks…
Remove workholding deviceRemove cutting tools not needed for next jobClear offsets for tools removed from the machineDisassemble certain components (like cutting tools) Put everything awaySave changes to program and remove from the machineEmpty chip pan (if machining a different material)Clean machine Can you think of any way to keep from
having to save and delete programs?
With some controls that are networked to they company’s computer system, programs can be run from the network – not from internal control memory. In essence, the machine cannot run out of memory capacity.
…some may seem far-fetched
Lesson topics
First, try to come up with ways to eliminate tasks…
Remove workholding deviceRemove cutting tools not needed for next jobClear offsets for tools removed from the machineDisassemble certain components (like cutting tools) Put everything awaySave changes to program and remove from the machineEmpty chip pan (if machining a different material)Clean machine Can you think of any way to keep from
having to empty the chip pan?
Can you run jobs that are made from the same material consecutively?
…some may seem far-fetched
Lesson topics
First, try to come up with ways to eliminate tasks…
Remove workholding deviceRemove cutting tools not needed for next jobClear offsets for tools removed from the machineDisassemble certain components (like cutting tools) Put everything awaySave changes to program and remove from the machineEmpty chip pan (if machining a different material)Clean machine Can you think of any way to keep from
having to clean the machine?
Some machine designs minimize the need for cleaning Slant bed versus flat bed turning centers Horizontal versus vertical machining centers
…some may seem far-fetched
Lesson topics
First, try to come up with ways to eliminate tasks…
Remove workholding deviceRemove cutting tools not needed for next jobClear offsets for tools removed from the machineDisassemble certain components (like cutting tools) Put everything awaySave changes to program and remove from the machineEmpty chip pan (if machining a different material)Clean machine
Again, some ideas to eliminate tasks will be infeasible – but try to come up with at least one way to do so for every task
…some may seem far-fetched
Lesson topics
If you cannot justify what it takes to eliminate the task…
Remove workholding deviceRemove cutting tools not needed for next jobClear offsets for tools removed from the machineDisassemble certain components (like cutting tools) Put everything awaySave changes to program and remove from the machineEmpty chip pan (if machining a different material)Clean machine Can you think of any way to be tearing down
setups while a machine is in production?
Machining centers with pallet changers If you have additional pallets, they can be set up while the machine is in production
…can you move it off line?
Lesson topics
If you cannot justify what it takes to eliminate the task…
Remove workholding deviceRemove cutting tools not needed for next jobClear offsets for tools removed from the machineDisassemble certain components (like cutting tools) Put everything awaySave changes to program and remove from the machineEmpty chip pan (if machining a different material)Clean machine Can you think of any way to be removing
cutting tools while a machine is in production?
Some machining centers do allow cutting tools to be removed while the machine is in cycle
But of course, cutting tools needed for the job must remain in the machine until the job is completed
…can you move it off line?
Lesson topics
If you cannot justify what it takes to eliminate the task…
Remove workholding deviceRemove cutting tools not needed for next jobClear offsets for tools removed from the machineDisassemble certain components (like cutting tools) Put everything awaySave changes to program and remove from the machineEmpty chip pan (if machining a different material)Clean machine Can you think of any way to be clearing offsets
while a machine is in production?
Again, machines do allow offsets to be cleared while the machine is in cycle But offsets needed for cutting tools in a job cannot be cleared until the job is completed.
BUT REMEMBER – this task can postponed until the machine is back in cycle, running the next job
This means the task will be done off line
…can you move it off line?
Lesson topics
If you cannot justify what it takes to eliminate the task…
Remove workholding deviceRemove cutting tools not needed for next jobClear offsets for tools removed from the machineDisassemble certain components (like cutting tools) Put everything awaySave changes to program and remove from the machineEmpty chip pan (if machining a different material)Clean machine Can you think of any way to be disassembling
components and putting things away during a production run?
Again, needed components will be required until the production run is completed BUT REMEMBER – this task can be postponed until the next job is up and running. In this way the task is done off line. Another person – the same person who does the gathering – can do this task
…can you move it off line?
Lesson topics
If you cannot justify what it takes to eliminate the task…
Remove workholding deviceRemove cutting tools not needed for next jobClear offsets for tools removed from the machineDisassemble certain components (like cutting tools) Put everything awaySave changes to program and remove from the machineEmpty chip pan (if machining a different material)Clean machine Can you think of any way to be manipulating
programs during a production run?
Again, the program will be required until the production run is completed BUT REMEMBER – with background edit, you can transfer programs while the machine is in cycle. The modified version of the program can be saved during the production run. In this way, program transfer is done off line. And – background edit also allows programs to be deleted. Wait until the next production run begins to delete the program used in the previous job.
…can you move it off line?
Lesson topics
If you cannot justify what it takes to eliminate the task…
Remove workholding deviceRemove cutting tools not needed for next jobClear offsets for tools removed from the machineDisassemble certain components (like cutting tools) Put everything awaySave changes to program and remove from the machineEmpty chip pan (if machining a different material)Clean machine Can you think of any way to be emptying the
chip pan during a production run?
The chip pan cannot be emptied until the job is finished but… …anything that can be prepared for this task (bringing the new chip pan close by the machine, for example) should be done before the production run ends.
…can you move it off line?
Lesson topics
If you cannot justify what it takes to eliminate the task…
Remove workholding deviceRemove cutting tools not needed for next jobClear offsets for tools removed from the machineDisassemble certain components (like cutting tools) Put everything awaySave changes to program and remove from the machineEmpty chip pan (if machining a different material)Clean machine Can you think of any way to be cleaning the
machine during a production run?
Probably not, but do anything you can in preparation for cleaning the machine while the machine is still running the job (like gathering cleaning supplies, brushers, rags, etc.)
…can you move it off line?
Lesson topics
If you cannot justify what it takes to eliminate the task…
Remove workholding deviceRemove cutting tools not needed for next jobClear offsets for tools removed from the machineDisassemble certain components (like cutting tools) Put everything awaySave changes to program and remove from the machineEmpty chip pan (if machining a different material)Clean machine Can you think of any way to be cleaning the
machine during a production run?
Probably not, but do anything you can in preparation for cleaning the machine while the machine is still running the job (like gathering cleaning supplies, brushers, rags, etc.)
…can you move it off line?
Final suggestion for moving tasks off line:
Watch for tasks that people perform on line that could be performed off line.
Lesson topics
If you cannot justify what it takes to move the task off line…
Remove workholding deviceRemove cutting tools not needed for next jobClear offsets for tools removed from the machineDisassemble certain components (like cutting tools) Put everything awaySave changes to program and remove from the machineEmpty chip pan (if machining a different material)Clean machine Can you think of any way to simplify the
task of removing the workholding device? Consider fastener types
Socket head cap screws (using ratchet wrenches) are easier to remove and replace than hex head screws (with box end wrenches)
Provide lifting help (cranes) for heavy workholding devices Consider method of clamping.Bolts into tapped holes are usually easier than tee-nuts.
…can you facilitate it?
Lesson topics
If you cannot justify what it takes to move the task off line…
Remove workholding deviceRemove cutting tools not needed for next jobClear offsets for tools removed from the machineDisassemble certain components (like cutting tools) Put everything awaySave changes to program and remove from the machineEmpty chip pan (if machining a different material)Clean machine Can you think of any way to simplify the
task of removing cutting tools?
Keep cutting tool storage rack/s close by the tool changer. If a wrench is required to remove cutting tools, dedicate one for this purpose and keep it near by where it is needed. (Velcro it to the machine, if possible.)
…can you facilitate it?
Lesson topics
If you cannot justify what it takes to move the task off line…
Remove workholding deviceRemove cutting tools not needed for next jobClear offsets for tools removed from the machineDisassemble certain components (like cutting tools) Put everything awaySave changes to program and remove from the machineEmpty chip pan (if machining a different material)Clean machine Can you think of any way to simplify the
task of clearing offsets?
Study control documentation – there may be a better/faster way than clearing one offset at a time.
…can you facilitate it?
Lesson topics
If you cannot justify what it takes to move the task off line…
Remove workholding deviceRemove cutting tools not needed for next jobClear offsets for tools removed from the machineDisassemble certain components (like cutting tools) Put everything awaySave changes to program and remove from the machineEmpty chip pan (if machining a different material)Clean machine Can you think of any way to simplify the
task of disassembling components?
Study this process. Ensure that the person who does the disassembling has a clean work area and all of the appropriate hand tools for this purpose. Consider having a dedicated work station for disassembling cutting tools. Again, this task should not be the responsibility of the (highly skilled) setup person.
The same person who gathers components can perform this task.
…can you facilitate it?
Lesson topics
If you cannot justify what it takes to move the task off line…
Remove workholding deviceRemove cutting tools not needed for next jobClear offsets for tools removed from the machineDisassemble certain components (like cutting tools) Put everything awaySave changes to program and remove from the machineEmpty chip pan (if machining a different material)Clean machine Can you think of any way to simplify the
task of putting things away?
Again, organization is the key. Every component must have a storage location If storage locations are clearly marked, a person with lesser skill can perform this task (not the setup person).
…can you facilitate it?
Lesson topics
If you cannot justify what it takes to move the task off line…
Remove workholding deviceRemove cutting tools not needed for next jobClear offsets for tools removed from the machineDisassemble certain components (like cutting tools) Put everything awaySave changes to program and remove from the machineEmpty chip pan (if machining a different material)Clean machine Can you think of any way to simplify the
task of saving and deleting programs?
For saving programs, an automatic DNC system will allow the setup person to save a program without having to leave the machine. Be sure setup people are using the most efficient techniques to delete programs.
…can you facilitate it?
Lesson topics
If you cannot justify what it takes to move the task off line…
Remove workholding deviceRemove cutting tools not needed for next jobClear offsets for tools removed from the machineDisassemble certain components (like cutting tools) Put everything awaySave changes to program and remove from the machineEmpty chip pan (if machining a different material)Clean machine Can you think of any way to simplify the
task of emptying the chip pan?
Provide gloves and shovel (or hand scoop) – and any other needed item. Store them close by the chip pan.
…can you facilitate it?
Lesson topics
If you cannot justify what it takes to move the task off line…
Remove workholding deviceRemove cutting tools not needed for next jobClear offsets for tools removed from the machineDisassemble certain components (like cutting tools) Put everything awaySave changes to program and remove from the machineEmpty chip pan (if machining a different material)Clean machine Can you think of any way to simplify the
task of cleaning the machine?
Provide (another set of) gloves – store them close to the machine’s work area. If cleaning involves an air-blowing system, be sure to provide full-face protection. Keep any needed cleaning supplies near the machine.
…can you facilitate it?
Lesson topics
If you cannot justify what it takes to move the task off line…
Remove workholding deviceRemove cutting tools not needed for next jobClear offsets for tools removed from the machineDisassemble certain components (like cutting tools) Put everything awaySave changes to program and remove from the machineEmpty chip pan (if machining a different material)Clean machine Can you think of any way to simplify the
task of cleaning the machine?
Provide (another set of) gloves – store them close to the machine’s work area. If cleaning involves an air-blowing system, be sure to provide full-face protection. Keep any needed cleaning supplies near the machine.
…can you facilitate it?
Final suggestion for facilitating tasks:
Look for times when people struggle with a task. When they do, it should be taken as a signal that you MUST facilitate the task.
Lesson topics
If you cannot justify what it takes to move the task off line…
Remove workholding deviceRemove cutting tools not needed for next jobClear offsets for tools removed from the machineDisassemble certain components (like cutting tools) Put everything awaySave changes to program and remove from the machineEmpty chip pan (if machining a different material)Clean machine
…can you facilitate it?
One more point:
These are all physical tasks that can be consistently done and easily measured.
Are there any non-physical tasks occurring as setups are torn down?
Lesson topics
If you cannot justify what it takes to move the task off line…
Remove workholding deviceRemove cutting tools not needed for next jobClear offsets for tools removed from the machineDisassemble certain components (like cutting tools) Put everything awaySave changes to program and remove from the machineEmpty chip pan (if machining a different material)Clean machine
…can you facilitate it?
Again, non-physical tasks are inconsistent and/or immeasurable (possibly wasted) actions or inactions that increase the time
required to make a setup or complete a production run
Time spent searching for needed items Time wasted while duplicating effort after a mistake Time lost while waiting for an unavailable item Any time the machine sits idle while no-one is working on it
Are any of these happening while tearing down?
Lesson topics
Lesson topics
Prepare the new workholding device For machining centers
Clamp to machine tableSquare up workholding device with table
Using dial indicatorFor turning centers
Mount top toolingBore jaws (if necessaryPrepare work support device (if necessary)
Mount center and position tailstockAlign tailstock
Adjust clamping pressure
Think of what must be done to make the workholding setup
Here is our list, but be sure to create a list of your own
Use the setup reduction planning form provided in lesson four
Lesson topics
Prepare the new workholding device For machining centers
Clamp to machine tableSquare up workholding device with table
Using dial indicatorFor turning centers
Mount top toolingBore jaws (if necessaryPrepare work support device (if necessary)
Mount center and position tailstockAlign tailstock
Adjust clamping pressure
First, try to come up with ways to eliminate tasks…
Can you think of any way to keep from having make new workholding setups?
Can multiple workholding devices be mounted to the machine? (On the table of a vertical machining centers.) Can jobs requiring the same workholding device be run consecutively? Can workholding devices be more versatile, allowing different jobs to be run? Are there any parameters to change? Program them with G10.
…some may seem far-fetched
Lesson topics
Can multiple workholding devices be mounted to the machine? (On the table of a vertical machining centers.) Can jobs requiring the same workholding device be run consecutively? Can workholding devices be more versatile, allowing different jobs to be run? Are there any parameters to change? Program them with G10.
Prepare the new workholding device For machining centers
Clamp to machine tableSquare up workholding device with table
Using dial indicatorFor turning centers
Mount top toolingBore jaws (if necessaryPrepare work support device (if necessary)
Mount center and position tailstockAlign tailstock
First, try to come up with ways to eliminate tasks…
Can you think of any way to keep from having make new workholding setups?
…some may seem far-fetched
Vise stays on tableThis devices
changes job to job
An example of multiple workholding devices
Lesson topics
Prepare the new workholding device For machining centers
Clamp to machine tableSquare up workholding device with table
Using dial indicatorFor turning centers
Mount top toolingBore jaws (if necessaryPrepare work support device (if necessary)
Mount center and position tailstockAlign tailstock
Adjust clamping pressure
First, try to come up with ways to eliminate tasks…
Can you think of any way to keep from having make new workholding setups?
Can multiple workholding devices be mounted to the machine? (On the table of a vertical machining centers.) Can jobs requiring the same workholding device be run consecutively? Can workholding devices be more versatile, allowing different jobs to be run? Are there any parameters to change? Program them with G10.
…some may seem far-fetched
Lesson topics
Prepare the new workholding device For machining centers
Clamp to machine tableSquare up workholding device with table
Using dial indicatorFor turning centers
Mount top toolingBore jaws (if necessaryPrepare work support device (if necessary)
Mount center and position tailstockAlign tailstockAdjust clamping pressure
First, try to come up with ways to eliminate tasks…
Can you think of any way to keep from having make new workholding setups?
Can multiple workholding devices be mounted to the machine? (On the table of a vertical machining centers.) Can jobs requiring the same workholding device be run consecutively? Can workholding devices be more versatile, allowing different jobs to be run? Are there any parameters to change? Program them with G10.
…some may seem far-fetched
Lesson topics
Eliminate workholding setup tasks
Do you have to change any control parameters from one setup to another?
When removing and replacing rotary tables When using probing systems When switching between inch and metric Others?
Remember, most current model Fanuc controls let you change parameters with G10
This keeps the setup person from doing so!
Lesson topics
Prepare the new workholding device For machining centers
Clamp to machine tableSquare up workholding device with table
Using dial indicatorFor turning centers
Mount top toolingBore jaws (if necessaryPrepare work support device (if necessary)
Mount center and position tailstockAlign tailstock
Adjust clamping pressure
First, try to come up with ways to eliminate tasks…
Can you think of any way to keep from having make new workholding setups?
Can multiple workholding devices be mounted to the machine? (On the table of a vertical machining centers.) Can jobs requiring the same workholding device be run consecutively? Can workholding devices be more versatile, allowing different jobs to be run? Are there any parameters to change? Program them with G10.
…some may seem far-fetched
Lesson topics
Prepare the new workholding device For machining centers
Clamp to machine tableSquare up workholding device with table
Using dial indicatorFor turning centers
Mount top toolingBore jaws (if necessaryPrepare work support device (if necessary)
Mount center and position tailstockAlign tailstockAdjust clamping pressure
First, try to come up with ways to eliminate tasks…
Can you think of any way to keep from having make new workholding setups?
If the setup is qualified, the workholding device will be square with the table when mounted
…some may seem far-fetched
Lesson topics
A qualified setup:
Definition:A qualified setup is one that can placed on the machine table in exactly the same fashion over and over again
Lesson topics
A qualified setup:
Top view of VMC table
Table slots
Does your machine have a center slot?
Lesson topics
A qualified setup:
Top view of VMC table
Bottom plate of workholding device
Keys
If fixture is square with table,
there will be no need to align!
Lesson topics
Prepare the new workholding device For machining centers
Clamp to machine tableSquare up workholding device with table
Using dial indicatorFor turning centers
Mount top toolingBore jaws (if necessaryPrepare work support device (if necessary)
Mount center and position tailstockAlign tailstockAdjust clamping pressure
First, try to come up with ways to eliminate tasks…
Can you think of any way to keep from having make new workholding setups?
If the setup is qualified, the workholding device will be square with the table when mounted
…some may seem far-fetched
Lesson topics
Prepare the new workholding device For machining centers
Clamp to machine tableSquare up workholding device with table
Using dial indicatorFor turning centers
Mount top toolingBore jaws (if necessaryPrepare work support device (if necessary)
Mount center and position tailstockAlign tailstockAdjust clamping pressure
First, try to come up with ways to eliminate tasks…
Can you think of any way to keep from having make new workholding setups?
Some turning centers allow tailstock positioning to be programmed Eliminating the need for a setup person to move the tailstock
…some may seem far-fetched
Lesson topics
Prepare the new workholding device For machining centers
Clamp to machine tableSquare up workholding device with table
Using dial indicatorFor turning centers
Mount top toolingBore jaws (if necessaryPrepare work support device (if necessary)
Mount center and position tailstockAlign tailstockAdjust clamping pressure
First, try to come up with ways to eliminate tasks…
Can you think of any way to keep from having make new workholding setups?
With some machines, the tailstock stays in alignment – even when moved Eliminating the need for a setup person to align the tailstock from job to job
…some may seem far-fetched
Lesson topics
Prepare the new workholding device For machining centers
Clamp to machine tableSquare up workholding device with table
Using dial indicatorFor turning centers
Mount top toolingBore jaws (if necessaryPrepare work support device (if necessary)
Mount center and position tailstockAlign tailstockAdjust clamping pressure
First, try to come up with ways to eliminate tasks…
Can you think of any way to keep from having make new workholding setups?
Some turning centers allow chuck pressure to be programmed This keeps the setup person from having to change chuck pressure
…some may seem far-fetched
Lesson topics
Prepare the new workholding device For machining centers
Clamp to machine tableSquare up workholding device with table
Using dial indicatorFor turning centers
Mount top toolingBore jaws (if necessaryPrepare work support device (if necessary)
Mount center and position tailstockAlign tailstockAdjust clamping pressure
Same suggestions as for tearing down:
If you cannot justify what it takes to eliminate the task…
Can you think of any way to be making workholding setups while a machine is in production?
Machining centers with pallet changers If you have additional pallets, they can be set up while the machine is in production
…can you move it off line?
Lesson topics
Making use of pallet changing systems
Automatic typeManual type
As long as you have extra pallets, two tasks related to workholding setup can be moved off line
Remove previous workholding device Mount new workholding device
On-line time will be limited to placing the pallet on the machine
Lesson topics
Prepare the new workholding device For machining centers
Clamp to machine tableSquare up workholding device with table
Using dial indicatorFor turning centers
Mount top toolingBore jaws (if necessaryPrepare work support device (if necessary)
Mount center and position tailstockAlign tailstockAdjust clamping pressure
Same suggestions as for tearing down:
If you cannot justify what it takes to eliminate the task…
Can you think of any way to be making workholding setups while a machine is in production?
Machining centers with pallet changers If you have additional pallets, they can be set up while the machine is in production
…can you move it off line?
Lesson topics
Prepare the new workholding device For machining centers
Clamp to machine tableSquare up workholding device with table
Using dial indicatorFor turning centers
Mount top toolingBore jaws (if necessaryPrepare work support device (if necessary)
Mount center and position tailstockAlign tailstockAdjust clamping pressure
If you cannot justify what it takes to move a task off line…
…can you facilitate it?
Can you think of any way to make it easier to make the workholding setup?
Consider fastener types Socket head cap screws (using ratchet wrenches) are easier to remove and replace than hex head screws (with box end wrenches)
Provide lifting help (cranes) for heavy workholding devices Consider method of clamping. Bolts into tapped holes are usually easier than tee-nuts.
Again, look for times when people struggle
Lesson topics
Prepare the new workholding device For machining centers
Clamp to machine tableSquare up workholding device with table
Using dial indicatorFor turning centers
Mount top toolingBore jaws (if necessary)Prepare work support device (if necessary)
Mount center and position tailstockAlign tailstockAdjust clamping pressure
If you cannot justify what it takes to move a task off line…
…can you facilitate it?
Can you think of any way to make it easier to make the workholding setup?
Mounting jaws can be a very tedious task Study this task to find improvements Consider quick-change chucks
Use a pointer to specify the serration into which jaws must be placed
Again, look for times when people struggle
Lesson topics
Facilitating workholding setup tasks
Note tiny serrations3-jaw chuck Mounting top tooling
Lesson topics
Facilitating workholding setup tasks
Hard jaw Soft jaw
Mounting top tooling
Lesson topics
Facilitating workholding setup tasks
Jaw changing is a very cumbersome task
Six socket head cap screws must be loosened Tee nuts must be placed on new jaws Jaws must be accurately placed in serrations Six socket head cap screws must be tightened
If placement is off, this must be repeated!
Jaw replacement can take 5-15 minutes or more
Mounting top tooling
Lesson topics
Facilitating workholding setup tasks
Jaw changing is a very cumbersome task
For your next chuck purchase…
…consider quick-jaw-change chucks One screw is involved per jaw One quarter turn of special wrench loosens jaw One quarter turn tightens Jaw changing time is about 5 seconds per jaw!
Serrations are larger (soft jaws don’t last as long)
Confirm concentricity requirements
Mounting top tooling
Lesson topics
Prepare the new workholding device For machining centers
Clamp to machine tableSquare up workholding device with table
Using dial indicatorFor turning centers
Mount top toolingBore jaws (if necessary)Prepare work support device (if necessary)
Mount center and position tailstockAlign tailstockAdjust clamping pressure
If you cannot justify what it takes to move a task off line…
…can you facilitate it?
Can you think of any way to make it easier to make the workholding setup?
Mounting jaws can be a very tedious task Study this task to find improvements Consider quick-change chucks
Use a pointer to specify the serration into which jaws must be placed
Again, look for times when people struggle
Lesson topics
Prepare the new workholding device For machining centers
Clamp to machine tableSquare up workholding device with table
Using dial indicatorFor turning centers
Mount top toolingBore jaws (if necessary)Prepare work support device (if necessary)
Mount center and position tailstockAlign tailstockAdjust clamping pressure
If you cannot justify what it takes to move a task off line…
…can you facilitate it?
Can you think of any way to make it easier to make the workholding setup?
Mounting jaws can be a very tedious task Study this task to find improvements Consider quick-change chucks
Use a pointer to specify the serration into which jaws must be placed
Again, look for times when people struggle
Lesson topics
Facilitating workholding setup tasks
Mounting jaws
X01.3569Z02.4236
1.3569
Select the boring bar you use for boring jaws
Align with tool diameter
Lesson topics
Facilitating workholding setup tasks
Mounting jaws
X01.3569Z02.4236
1.3569
Determine the diameter for chucking (with chuck unclamped):
Align with tool diameter
Clamping diameter plus jaw stroke
If clamping on a 3.0” dia. and jaw stroke is 0.5”, this diameter is 3.5”
Lesson topics
Facilitating workholding setup tasks
Mounting jaws
X03.5000Z02.4236
3.5
Open jaws and move X axis to clamping diameter
Align with tool diameter
Lesson topics
Facilitating workholding setup tasks
Mounting jaws
X03.5000Z02.4236
Use boring bar as a pointer and mount each jaw
Align with tool diameter
Each jaw can be easily mounted in the same serration Jaws will clamp on workpiece at mid-stroke
Lesson topics
Prepare the new workholding device For machining centers
Clamp to machine tableSquare up workholding device with table
Using dial indicatorFor turning centers
Mount top toolingBore jaws (if necessary)Prepare work support device (if necessary)
Mount center and position tailstockAlign tailstockAdjust clamping pressure
If you cannot justify what it takes to move a task off line…
…can you facilitate it?
Can you think of any way to make it easier to make the workholding setup?
Mounting jaws can be a very tedious task Study this task to find improvements Consider quick-change chucks
Use a pointer to specify the serration into which jaws must be placed
Again, look for times when people struggle
Lesson topics
Prepare the new workholding device For machining centers
Clamp to machine tableSquare up workholding device with table
Using dial indicatorFor turning centers
Mount top toolingBore jaws (if necessary)Prepare work support device (if necessary)
Mount center and position tailstockAlign tailstockAdjust clamping pressure
If you cannot justify what it takes to move a task off line…
…can you facilitate it?
Can you think of any way to make it easier to make the workholding setup?
For repeated jobs, save soft jaws Don’t re-bore them for another job
This saves time the next time the job is run Make a set of chucking rings – or a special clamping tool Provide instructions for jaw-boring or create a jaw-boring program
Again, look for times when people struggle
Lesson topics
Facilitating workholding setup tasks
Clamp on ring
Lesson topics
Facilitating workholding setup tasks
1.0 1.125 1.25 1.375 1.5 1.625 1.75
1.875 2.0 2.125 2.375 2.5
Make a set of chucking rings!
Clamp on ring
Lesson topics
Facilitating workholding setup tasks
Or make an adjustable chucking tool
Hex stock
Hex head screws
Clamp on ring
Lesson topics
Facilitating workholding setup tasks
Clamp on ring
Lesson topics
Prepare the new workholding device For machining centers
Clamp to machine tableSquare up workholding device with table
Using dial indicatorFor turning centers
Mount top toolingBore jaws (if necessary)Prepare work support device (if necessary)
Mount center and position tailstockAlign tailstockAdjust clamping pressure
If you cannot justify what it takes to move a task off line…
…can you facilitate it?
Can you think of any way to make it easier to make the workholding setup?
For repeated jobs, save soft jaws Don’t re-bore them for another job
This saves time the next time the job is run Make a set of chucking rings – or a special clamping tool Provide instructions for jaw boring – or create a jaw-boring program
Again, look for times when people struggle
Lesson topics
Prepare the new workholding device For machining centers
Clamp to machine tableSquare up workholding device with table
Using dial indicatorFor turning centers
Mount top toolingBore jaws (if necessary)Prepare work support device (if necessary)
Mount center and position tailstockAlign tailstockAdjust clamping pressure
If you cannot justify what it takes to move a task off line…
…can you facilitate it?
Can you think of any way to make it easier to make the workholding setup?
For repeated jobs, save soft jaws Don’t re-bore them for another job
This saves time the next time the job is run Make a set of chucking rings – or a special clamping tool Provide instructions for jaw boring - or create a jaw-boring program
Again, look for times when people struggle
Lesson topics
Facilitating workholding setup tasks
Actually boring jaws
Be sure the setup person can align the jaw boring cutting tool
Lesson topics
Facilitating workholding setup tasks
Actually boring jaws
Be sure the setup person can align the jaw boring cutting tool
Lesson topics
Facilitating workholding setup tasks
Actually boring jaws
X02.3857Z00.0000
Be sure the setup person can align the jaw boring cutting tool
Set to zero
Lesson topics
Facilitating workholding setup tasks
Actually boring jaws
X01.3569Z02.4236
1.3569
At least now the setup person can determine diameters and depths!
Align with tool diameter
Lesson topics
Facilitating workholding setup tasks
Actually boring jaws
Better yet, why not develop programs to bore jaws?
One jaw boring program per job, or…
…one universal program (custom macro)
Lesson topics
Facilitating workholding setup tasks
Actually boring jaws
If one program per job:
N205 G00 X6.5 Z5.0N210 M30N999 (BEGIN JAW BORING)N1000 T1212 (Boring bar)...N1105 M30
Place jaw boring commands after M30
Lesson topics
Facilitating workholding setup tasks
Actually boring jaws
If universal custom macro:O0002 (Program number)#101 = 3.00 (Starting diameter to bore)#102 = 4.00 (Ending diameter to bore)#103 = 1.0 (Z depth of jaw boring)#104 = 0.100 (Depth of cut per pass)#105 = 300. (Speed in SFM for boring)T1212 (Index to boring bar)G96 S#105 M03 (Start spindle)G98 G01 X#101 Z0.15 F30.0 (Fast feed to approach position)G99 G71 P1 Q2 U-0.01 W0.005 D#104 F0.10 (Rough bore jaws)N1 G00 X#102G01 Z-#103N2 X#101G70 P1 Q2 F0.005M30
Lesson topics
Facilitating workholding setup tasks
Actually boring jaws
If universal custom macro:O0002 (Program number)#101 = 3.00 (Starting diameter to bore)#102 = 4.00 (Ending diameter to bore)#103 = 1.0 (Z depth of jaw boring)#104 = 0.100 (Depth of cut per pass)#105 = 300. (Speed in SFM for boring)T1212 (Index to boring bar)G96 S#105 M03 (Start spindle)G98 G01 X#101 Z0.15 F30.0 (Fast feed to approach position)G99 G71 P1 Q2 U-0.01 W0.005 D#104 F0.10 (Rough bore jaws)N1 G00 X#102G01 Z-#103N2 X#101G70 P1 Q2 F0.005M30
Input data
Lesson topics
Facilitating workholding setup tasks
Actually boring jaws
If universal custom macro:O0002 (Program number)#101 = 3.00 (Starting diameter to bore)#102 = 4.00 (Ending diameter to bore)#103 = 1.0 (Z depth of jaw boring)#104 = 0.100 (Depth of cut per pass)#105 = 300. (Speed in SFM for boring)T1212 (Index to boring bar)G96 S#105 M03 (Start spindle)G98 G01 X#101 Z0.15 F30.0 (Fast feed to approach position)G99 G71 P1 Q2 U-0.01 W0.005 D#104 F0.10 (Rough bore jaws)N1 G00 X#102G01 Z-#103N2 X#101G70 P1 Q2 F0.005M30
Will change with input data
Lesson topics
Prepare the new workholding device For machining centers
Clamp to machine tableSquare up workholding device with table
Using dial indicatorFor turning centers
Mount top toolingBore jaws (if necessary)Prepare work support device (if necessary)
Mount center and position tailstockAlign tailstockAdjust clamping pressure
If you cannot justify what it takes to move a task off line…
…can you facilitate it?
Can you think of any way to make it easier to make the workholding setup?
For repeated jobs, save soft jaws Don’t re-bore them for another job
This saves time the next time the job is run Make a set of chucking rings – or a special clamping tool Provide instructions for jaw boring - or create a jaw-boring program
Again, look for times when people struggle
Lesson topics
Lesson topics
Think of what must be done to get cutting tools ready to use in the machine
Again, here is our list, but be sure to create a list of your own
Use the setup reduction planning form provided in lesson four
Machining centers Turning centersAssemble needed tools
Insert, cutting tool body, extension, adapter, holder, pull stud
MeasureTool length compensation valueCutter radius compensation value
PresetBoring bars to specified diameter
Load in specified tool stationsEnter offsets
Tool length compensationCutter radius compensation
Sharpen / replace dull tools
Assemble needed toolsInsert, cutting tool shank or body, etc.
Load in specified turret stationsEnter offsets
Tool nose radius compensationSharpen / replace dull tools
Lesson topics
First, try to come up with ways to eliminate tasks…
Can you think of any way to eliminate cutting tool tasks?
…some may seem far-fetchedMachining centers Turning centersAssemble needed tools
Insert, cutting tool body, extension, adapter, holder, pull stud
MeasureTool length compensation valueCutter radius compensation value
PresetBoring bars to specified diameter
Load in specified tool stationsEnter offsets
Tool length compensationCutter radius compensation
Sharpen / replace dull tools
Assemble needed toolsInsert, cutting tool shank or body, etc.
Load in specified turret stationsEnter offsets
Tool nose radius compensationSharpen / replace dull tools
Can jobs requiring the same cutting tools be run consecutively? Can you consolidate the number of cutting tools needed? Can you come up with standard tool stations?
Lesson topics
Eliminate cutting tool tasks
Standard tool stations
You probably have some tools that are used regularly
Spot drill ¾ end mill 3” face mill Drill & tap combos
Assign permanent tool stations to these tools
Lesson topics
Eliminate cutting tool tasks
Standard tool stations
By the way, how many tool stations do your machines have?
Standard tool stations should be a major consideration when buying machines!
Finite number of different jobs?
You may be able to store all tools in the ATC magazine!
Lesson topics
Eliminate cutting tool tasks
Standard tool stations
Even if you can’t store all tools in the ATC magazine…
…place a storage rack right next to the machine!
Lesson topics
Eliminate cutting tool tasks
Having standard tool stations requires duplicated cutting tool components
You must be able to justify the additional cost
How much on-line setup time is currently taken to perform cutting tool tasks?
Lesson topics
First, try to come up with ways to eliminate tasks…
Can you think of any way to eliminate cutting tool tasks?
…some may seem far-fetchedMachining centers Turning centersAssemble needed tools
Insert, cutting tool body, extension, adapter, holder, pull stud
MeasureTool length compensation valueCutter radius compensation value
PresetBoring bars to specified diameter
Load in specified tool stationsEnter offsets
Tool length compensationCutter radius compensation
Sharpen / replace dull tools
Assemble needed toolsInsert, cutting tool shank or body, etc.
Load in specified turret stationsEnter offsets
Tool nose radius compensationSharpen / replace dull tools
Can jobs requiring the same cutting tools be run consecutively? Can you consolidate the number of cutting tools needed? Can you come up with standard tool stations?
Lesson topics
First, try to come up with ways to eliminate tasks…
Can you think of any way to eliminate cutting tool tasks?
…some may seem far-fetchedMachining centers Turning centersAssemble needed tools
Insert, cutting tool body, extension, adapter, holder, pull stud
MeasureTool length compensation valueCutter radius compensation value
PresetBoring bars to specified diameter
Load in specified tool stationsEnter offsets
Tool length compensationCutter radius compensation
Sharpen / replace dull tools
Assemble needed toolsInsert, cutting tool shank or body, etc.
Load in specified turret stationsEnter offsets
Tool nose radius compensationSharpen / replace dull tools
Can jobs requiring the same cutting tools be run consecutively? Can you consolidate the number of cutting tools needed? Can you come up with standard tool stations?
Lesson topics
Eliminate cutting tool tasks
How do you designate tools on setup sheets?
Consolidate cutting tools
½ drill Or
DJ0500-HC1.0-E1.0-C0.5-L6.5
HC1000 collet holder
E1000extension
C0500collet
Jobbers length½ drill
Approx 6.5
Lesson topics
Eliminate cutting tool tasks
If you designate all components for cutting tools…
Consolidate cutting tools
…and if you minimize the number of different tool assemblies…
…there will be a better chance that needed cutting tools will already be assembled
Lesson topics
First, try to come up with ways to eliminate tasks…
Can you think of any way to eliminate cutting tool tasks?
…some may seem far-fetchedMachining centers Turning centersAssemble needed tools
Insert, cutting tool body, extension, adapter, holder, pull stud
MeasureTool length compensation valueCutter radius compensation value
PresetBoring bars to specified diameter
Load in specified tool stationsEnter offsets
Tool length compensationCutter radius compensation
Sharpen / replace dull tools
Assemble needed toolsInsert, cutting tool shank or body, etc.
Load in specified turret stationsEnter offsets
Tool nose radius compensationSharpen / replace dull tools
Can jobs requiring the same cutting tools be run consecutively? Can you consolidate the number of cutting tools needed? Can you come up with standard tool stations?
Lesson topics
First, try to come up with ways to eliminate tasks…
Can you think of any way to eliminate cutting tool tasks?
…some may seem far-fetchedMachining centers Turning centersAssemble needed tools
Insert, cutting tool body, extension, adapter, holder, pull stud
MeasureTool length compensation valueCutter radius compensation value
PresetBoring bars to specified diameter
Load in specified tool stationsEnter offsets
Tool length compensationCutter radius compensation
Sharpen / replace dull tools
Assemble needed toolsInsert, cutting tool shank or body, etc.
Load in specified turret stationsEnter offsets
Tool nose radius compensationSharpen / replace dull tools
Offset entries can be programmed For machining center tools with known lengths or diameters For tool nose radius compensation on turning centers
This keeps the setup person from having to enter them
Lesson topics
Eliminate cutting tool tasks
About tool nose radius compensation:
The programmer specifies the tool nose radius for single point turning tools
The setup person must use the specified TNR!
Why not program the TNR offset settings?
G10 P2 R0.0312 T3G10 P6 R0.0156 T2
Lesson topics
Eliminate cutting tool tasks
About tool nose radius compensation:
By the way…
…CAM systems have the ability to output modified tool path based upon the specified tool nose radius
There will be no G41 or G42 in the program!
(And no need for offset entry)
Lesson topics
First, try to come up with ways to eliminate tasks…
Can you think of any way to eliminate cutting tool tasks?
…some may seem far-fetchedMachining centers Turning centersAssemble needed tools
Insert, cutting tool body, extension, adapter, holder, pull stud
MeasureTool length compensation valueCutter radius compensation value
PresetBoring bars to specified diameter
Load in specified tool stationsEnter offsets
Tool length compensationCutter radius compensation
Sharpen / replace dull tools
Assemble needed toolsInsert, cutting tool shank or body, etc.
Load in specified turret stationsEnter offsets
Tool nose radius compensationSharpen / replace dull tools
Offset entries can be programmed For machining center tools with known lengths or diameters For tool nose radius compensation on turning centers
This keeps the setup person from having to enter them
Lesson topics
If you cannot justify what it takes to eliminate tasks…
What can be done while the machine is in production for the previous job?
…can you move them off line?Machining centers Turning centersAssemble needed tools
Insert, cutting tool body, extension, adapter, holder, pull stud
MeasureTool length compensation valueCutter radius compensation value
PresetBoring bars to specified diameter
Load in specified tool stationsEnter offsets
Tool length compensationCutter radius compensation
Sharpen / replace dull tools
Assemble needed toolsInsert, cutting tool shank or body, etc.
Load in specified turret stationsEnter offsets
Tool nose radius compensationSharpen / replace dull tools
Assemble cutting tools for up-coming jobs while the machine is producing When the job hits the machine, cutting tools will be ready This can be done by a tool setter (not necessarily the setup person)
Lesson topics
If you cannot justify what it takes to eliminate tasks…
What can be done while the machine is in production for the previous job?
…can you move them off line?Machining centers Turning centersAssemble needed tools
Insert, cutting tool body, extension, adapter, holder, pull stud
MeasureTool length compensation valueCutter radius compensation value
PresetBoring bars to specified diameter
Load in specified tool stationsEnter offsets
Tool length compensationCutter radius compensation
Sharpen / replace dull tools
Assemble needed toolsInsert, cutting tool shank or body, etc.
Load in specified turret stationsEnter offsets
Tool nose radius compensationSharpen / replace dull tools
For machining centers, tool length and cutter radius compensation values can be determined off line
Lesson topics
Move cutting tool tasks off line
Measuring cutting tools
Tool length Cutter radius (for milling cutters)
Remember – there are two ways to use tool length compensation…
Lesson topics
Move cutting tool tasks off line
Measuring cutting tools
Program Zero
TLC offsetFixture offset Z
Program Zero
TLC offset
Fixture offset Z is zero
Offset value can be easily measured off lineOffset value doesn’t change from job to jobOffset value can be shared among machines
Lesson topics
Move cutting tool tasks off line
1Value
2345
7
#
6
6.54455.67435.98767.56546.56544.56577.6544
A simple height gage can be used…
…tool setter can write down tool lengths
Many tooling suppliers can provide a special tool length measuring device
Lesson topics
Move cutting tool tasks off line
For cutter radius compensation, a micrometer can be used to measure most milling cutters…
…tool setter can write down cutter radius or diameter
Lesson topics
By the way…
Multiple identical tools
Do you keep more than one of your most popular tools assembled and ready to go?
One company: Has fifteen CNC machining centers Picked ten most popular cutting tools Tool crib attendant keeps at least three of each Anyone who needs them has immediate access
Lesson topics
If you cannot justify what it takes to eliminate tasks…
What can be done while the machine is in production for the previous job?
…can you move them off line?Machining centers Turning centersAssemble needed tools
Insert, cutting tool body, extension, adapter, holder, pull stud
MeasureTool length compensation valueCutter radius compensation value
PresetBoring bars to specified diameter
Load in specified tool stationsEnter offsets
Tool length compensationCutter radius compensation
Sharpen / replace dull tools
Assemble needed toolsInsert, cutting tool shank or body, etc.
Load in specified turret stationsEnter offsets
Tool nose radius compensationSharpen / replace dull tools
For machining centers, tool length and cutter radius compensation values can be determined off line
Lesson topics
If you cannot justify what it takes to eliminate tasks…
What can be done while the machine is in production for the previous job?
…can you move them off line?Machining centers Turning centersAssemble needed tools
Insert, cutting tool body, extension, adapter, holder, pull stud
MeasureTool length compensation valueCutter radius compensation value
PresetBoring bars to specified diameter
Load in specified tool stationsEnter offsets
Tool length compensationCutter radius compensation
Sharpen / replace dull tools
Assemble needed toolsInsert, cutting tool shank or body, etc.
Load in specified turret stationsEnter offsets
Tool nose radius compensationSharpen / replace dull tools
If boring bars must be preset, do so before the job comes to the machine
Lesson topics
Move cutting tool tasks off line
Most companies don’t try to perfectly set boring bars…
…instead, they set them 0.005 or so undersize
Setup person must trial machine to fine-tune
Lesson topics
Move cutting tool tasks off line
Trial boring takes time…
…if you can come up with a way to perfectly set boring bars off line…
…you can minimize down time between production runs!
Lesson topics
If you cannot justify what it takes to eliminate tasks…
What can be done while the machine is in production for the previous job?
…can you move them off line?Machining centers Turning centersAssemble needed tools
Insert, cutting tool body, extension, adapter, holder, pull stud
MeasureTool length compensation valueCutter radius compensation value
PresetBoring bars to specified diameter
Load in specified tool stationsEnter offsets
Tool length compensationCutter radius compensation
Sharpen / replace dull tools
Assemble needed toolsInsert, cutting tool shank or body, etc.
Load in specified turret stationsEnter offsets
Tool nose radius compensationSharpen / replace dull tools
If boring bars must be preset, do so before the job comes to the machine
Lesson topics
If you cannot justify what it takes to eliminate tasks…
What can be done while the machine is in production for the previous job?
…can you move them off line?Machining centers Turning centersAssemble needed tools
Insert, cutting tool body, extension, adapter, holder, pull stud
MeasureTool length compensation valueCutter radius compensation value
PresetBoring bars to specified diameter
Load in specified tool stationsEnter offsets
Tool length compensationCutter radius compensation
Sharpen / replace dull tools
Assemble needed toolsInsert, cutting tool shank or body, etc.
Load in specified turret stationsEnter offsets
Tool nose radius compensationSharpen / replace dull tools
Can you be loading cutting tools for the next job while the machine is running the current job?
Some machines allow cutting tools to be loaded and removed while the machine is in cycle.
Lesson topics
Tool Magazine
Loading Station
Move cutting tool tasks off line
Rotate CW
Rotate CCW
Magazine
Manual Auto
If you have enough tool stations…
…during production, load tools for the next job!
Lesson topics
If you cannot justify what it takes to eliminate tasks…
What can be done while the machine is in production for the previous job?
…can you move them off line?Machining centers Turning centersAssemble needed tools
Insert, cutting tool body, extension, adapter, holder, pull stud
MeasureTool length compensation valueCutter radius compensation value
PresetBoring bars to specified diameter
Load in specified tool stationsEnter offsets
Tool length compensationCutter radius compensation
Sharpen / replace dull tools
Assemble needed toolsInsert, cutting tool shank or body, etc.
Load in specified turret stationsEnter offsets
Tool nose radius compensationSharpen / replace dull tools
Can you be loading cutting tools for the next job while the machine is running the current job? Can you be loading cutting tools for the next job while the machine is running the current job?
Some machines allow cutting tools to be loaded and removed while the machine is in cycle.
Lesson topics
If you cannot justify what it takes to eliminate tasks…
What can be done while the machine is in production for the previous job?
…can you move them off line?Machining centers Turning centersAssemble needed tools
Insert, cutting tool body, extension, adapter, holder, pull stud
MeasureTool length compensation valueCutter radius compensation value
PresetBoring bars to specified diameter
Load in specified tool stationsEnter offsets
Tool length compensationCutter radius compensation
Sharpen / replace dull tools
Assemble needed toolsInsert, cutting tool shank or body, etc.
Load in specified turret stationsEnter offsets
Tool nose radius compensationSharpen / replace dull tools
If you assemble and measure cutting tools off line, you can program the tool length and cutter radius compensation offset entries
This keeps the setup person from having to do so.
Lesson topics
Move cutting tool tasks off line
1Value
2345
7
#
6
6.54455.67435.98767.56546.56544.56577.6544
Earlier we said tool setters can measure tool lengths
…and write down tool length values
But the setup person must still enter offsets while the machine is down!
Lesson topics
Move cutting tool tasks off lineThe tool setter can create a program to set offset values!
Template program O8001 (Offset program)G90 G10 P1 R20.0000G10 P2 R20.0000G10 P3 R20.0000G10 P4 R20.0000G10 P5 R20.0000G10 P6 R20.0000G10 P7 R20.0000G10 P8 R20.0000G10 P9 R20.0000G10 P10 R20.0000..M30
Tool setter calls up this template program
and modifies the R word for each tool
Lesson topics
Move cutting tool tasks off lineThe tool setter can create a program to set offset values!
Template program O8001 (Offset program)G90 G10 P1 R6.5893G10 P2 R6.3321G10 P3 R5.4678G10 P4 R7.5746G10 P5 R3.4858G10 P6 R4.3433G10 P7 R8.4872M30
Tool setter calls up this template program
and modifies the R word for each tool
This program is stored in the DNC system – called up and executed by the setup person
Lesson topics
Move cutting tool tasks off lineSome tool measuring devices can output measured values!
6.5643
Offset setting program is automatically created!
Lesson topics
Move cutting tool tasks off line
Either way, the on-line time required for entering offsets will be the time it takes to
download this program and execute it!
Lesson topics
If you cannot justify what it takes to eliminate tasks…
What can be done while the machine is in production for the previous job?
…can you move them off line?Machining centers Turning centersAssemble needed tools
Insert, cutting tool body, extension, adapter, holder, pull stud
MeasureTool length compensation valueCutter radius compensation value
PresetBoring bars to specified diameter
Load in specified tool stationsEnter offsets
Tool length compensationCutter radius compensation
Sharpen / replace dull tools
Assemble needed toolsInsert, cutting tool shank or body, etc.
Load in specified turret stationsEnter offsets
Tool nose radius compensationSharpen / replace dull tools
If you assemble and measure cutting tools off line, you can program the tool length and cutter radius compensation offset entries
This keeps the setup person from having to do so.
Lesson topics
If you cannot move tasks off line…
What can you do to make it simpler to get cutting tools ready?
…can you facilitate any tasks?Machining centers Turning centersAssemble needed tools
Insert, cutting tool body, extension, adapter, holder, pull stud
MeasureTool length compensation valueCutter radius compensation value
PresetBoring bars to specified diameter
Load in specified tool stationsEnter offsets
Tool length compensationCutter radius compensation
Sharpen / replace dull tools
Assemble needed toolsInsert, cutting tool shank or body, etc.
Load in specified turret stationsEnter offsets
Tool nose radius compensationSharpen / replace dull tools
Again, study your setup people – Is there anything you can do to help them?
Lesson topics
If you cannot move tasks off line…
What can you do to make it simpler to get cutting tools ready?
…can you facilitate any tasks?Machining centers Turning centersAssemble needed tools
Insert, cutting tool body, extension, adapter, holder, pull stud
MeasureTool length compensation valueCutter radius compensation value
PresetBoring bars to specified diameter
Load in specified tool stationsEnter offsets
Tool length compensationCutter radius compensation
Sharpen / replace dull tools
Assemble needed toolsInsert, cutting tool shank or body, etc.
Load in specified turret stationsEnter offsets
Tool nose radius compensationSharpen / replace dull tools
Being well organized is the key to efficiently assembling cutting tools
Lesson topics
If you cannot move tasks off line…
What can you do to make it simpler to get cutting tools ready?
…can you facilitate any tasks?Machining centers Turning centersAssemble needed tools
Insert, cutting tool body, extension, adapter, holder, pull stud
MeasureTool length compensation valueCutter radius compensation value
PresetBoring bars to specified diameter
Load in specified tool stationsEnter offsets
Tool length compensationCutter radius compensation
Sharpen / replace dull tools
Assemble needed toolsInsert, cutting tool shank or body, etc.
Load in specified turret stationsEnter offsets
Tool nose radius compensationSharpen / replace dull tools
Do any of your machining centers have a tool probe?
Lesson topics
Facilitate cutting tool tasksIf you must measure tool lengths on line…
…use a tool length measuring probe!
Most can also measure diameter/radius
Lesson topics
Facilitate cutting tool tasksIf your machine doesn’t have a probe…
O9500 (Program to touch off tool lengths)N1 #100 = 1 (First tool station number to measure)#101 = 15 (Last tool station to measure)N2 #3006 = 100 (TOUCH SPINDLE TO BLOCK)N3 #5003 = 0 (Set current Z position as program zero point)N4 G91 G01 Z1.5 F30.0 (Move away from block in Z)N5 G91 G28 Z0 M19 (Move to tool change position, orient spindle)N7 T#100 M06 (Place current tool in spindle)N8 #3006 = 101 (TOUCH TOOL TIP TO BLOCK)N9 #[2000 + #100] = #5003 (Set tool length compensation offset)N10 G91 G01 Z1.5 F30. (Move away from block in Z)N11 G91 G28 Z0 M19 (Move to tool change position, orient spindle)N12 #100 = #100 + 1N13 #3006 = 102 (PRESS CYCLE START TO CONT)N14 GOTO 7
This program helps with measurement
and enters offset values!
Lesson topics
If you cannot move tasks off line…
What can you do to make it simpler to get cutting tools ready?
…can you facilitate any tasks?Machining centers Turning centersAssemble needed tools
Insert, cutting tool body, extension, adapter, holder, pull stud
MeasureTool length compensation valueCutter radius compensation value
PresetBoring bars to specified diameter
Load in specified tool stationsEnter offsets
Tool length compensationCutter radius compensation
Sharpen / replace dull tools
Assemble needed toolsInsert, cutting tool shank or body, etc.
Load in specified turret stationsEnter offsets
Tool nose radius compensationSharpen / replace dull tools
Do any of your machining centers have a tool probe?
Lesson topics
If you cannot move tasks off line…
What can you do to make it simpler to get cutting tools ready?
…can you facilitate any tasks?Machining centers Turning centersAssemble needed tools
Insert, cutting tool body, extension, adapter, holder, pull stud
MeasureTool length compensation valueCutter radius compensation value
PresetBoring bars to specified diameter
Load in specified tool stationsEnter offsets
Tool length compensationCutter radius compensation
Sharpen / replace dull tools
Assemble needed toolsInsert, cutting tool shank or body, etc.
Load in specified turret stationsEnter offsets
Tool nose radius compensationSharpen / replace dull tools
Help for setting a taper reamer
Lesson topics
Facilitate cutting tool tasks
Taper reaming
Guessing at initial offset Several tries required Same process for sharpened reamer
Setup people may be struggling:
Lesson topics
Facilitate cutting tool tasks
Taper reaming
N040 G43 H05 Z2.0N045 G81 R-0.7 Z-1.0 F5.0 G98
Lesson topics
If you cannot move tasks off line…
What can you do to make it simpler to get cutting tools ready?
…can you facilitate any tasks?Machining centers Turning centersAssemble needed tools
Insert, cutting tool body, extension, adapter, holder, pull stud
MeasureTool length compensation valueCutter radius compensation value
PresetBoring bars to specified diameter
Load in specified tool stationsEnter offsets
Tool length compensationCutter radius compensation
Sharpen / replace dull tools
Assemble needed toolsInsert, cutting tool shank or body, etc.
Load in specified turret stationsEnter offsets
Tool nose radius compensationSharpen / replace dull tools
Help for setting a taper reamer
Lesson topics
If you cannot move tasks off line…
What can you do to make it simpler to get cutting tools ready?
…can you facilitate any tasks?Machining centers Turning centersAssemble needed tools
Insert, cutting tool body, extension, adapter, holder, pull stud
MeasureTool length compensation valueCutter radius compensation value
PresetBoring bars to specified diameter
Load in specified tool stationsEnter offsets
Tool length compensationCutter radius compensation
Sharpen / replace dull tools
Assemble needed toolsInsert, cutting tool shank or body, etc.
Load in specified turret stationsEnter offsets
Tool nose radius compensationSharpen / replace dull tools
Loading tools into a turning center’s turret can be cumbersome Ensure that needed hand tools are readily available
Some turning centers have quick-change tooling, which makes loading and removing tools very easy
Lesson topics
Lesson topics
Determine program zero assignment values
Measure with edge finder or dial indicatorCalculate
Enter program zero assignment valuesInto fixture offsets (preferred)Edit G92 command
Think of what must be done to assign program zero
Again, here is our list, but be sure to create a list of your own
Use the setup reduction planning form provided in lesson four
Machining centers Turning centersDetermine program zero assignment values
For each toolMeasure distance between tool tip and program zeroCalculate
Enter program zero assignment valuesInto geometry offsets (preferred)Edit G50 commands
Lesson topics
Program zero assignment aligns the workholding setup position with the program
Top view of vertical machining center
Machine Position
Programzero
FANUC 10M
+
X00.0000Y00.0000Z00.0000
X value
Y value
Lesson topics
Programzero
Spindle nose
Machine Position
FANUC 10M
+
X-10.2837Y-6.9837Z00.0000
Program zero assignment aligns the workholding setup position with the program
Z value
Lesson topics
Program zero assignment aligns the workholding setup position with the program
CYCLESTART
FEEDHOLD
EDIT
AUTO
MDI JOG
HANDLE
ZERORETURNMODE
0%
100%
200%
FEEDRATEOVERRIDE
10%
25% 50%
100%
RAPIDOVERRIDE
1
12
TURRET INDEX2
3
4
56
78
9 10 11
SLOW FAST
EMERGENCYSTOP
FANUC 10T
POWERON
OFF
O N G P AX Y Z Q BI J K R C
F D H L #M S T /EOB
U V W
Sp
E ? @ @,
[ ] ( ) *
PAGE CURSOR
SHIFT
7 8 94 5 61 2 3- 0+ = CAN
RESET
START
CALC
INPUT
NC/PC
AUX
X00.0000Z00.0000
X ZX1
X10X100
0
ON
OFFDRYRUN
SINGLEBLOCK
MACHINELOCK
OPTIONALSTOP
BLOCKDELETE
X+
X-
Z-
JOYSTICK
Z+
ON OFF
SPINDLE
ORIGIN
X Z
0%100%
130%
SPINDLE LOAD
0%100%
130%
AXIS LOAD
X Z
OD ID
CLAMPDIRECTION
OFF ON
MEMORYPROTECT
CHUCK TAILSTOCK
Program zero
X axis geometry offset value value
One way:
Lesson topics
Program zero assignment aligns the workholding setup position with the program
CYCLESTART
FEEDHOLD
EDIT
AUTO
MDI JOG
HANDLE
ZERORETURNMODE
0%
100%
200%
FEEDRATEOVERRIDE
10%
25% 50%
100%
RAPIDOVERRIDE
1
12
TURRET INDEX2
3
4
56
78
9 10 11
SLOW FAST
EMERGENCYSTOP
FANUC 10T
POWERON
OFF
O N G P AX Y Z Q BI J K R C
F D H L #M S T /EOB
U V W
Sp
E ? @ @,
[ ] ( ) *
PAGE CURSOR
SHIFT
7 8 94 5 61 2 3- 0+ = CAN
RESET
START
CALC
INPUT
NC/PC
AUX
X00.0000Z00.0000
X ZX1
X10X100
0
ON
OFFDRYRUN
SINGLEBLOCK
MACHINELOCK
OPTIONALSTOP
BLOCKDELETE
X+
X-
Z-
JOYSTICK
Z+
ON OFF
SPINDLE
ORIGIN
X Z
0%100%
130%
SPINDLE LOAD
0%100%
130%
AXIS LOAD
X Z
OD ID
CLAMPDIRECTION
OFF ON
MEMORYPROTECT
CHUCK TAILSTOCK
Program zero
X axis geometry offset value value
Work shift value
Z axis geometry offset valueAnother way:
Lesson topics
Determine program zero assignment values
Measure with edge finder or dial indicatorCalculate
Enter program zero assignment valuesInto fixture offsets (preferred)Edit G92 command
Think of what must be done to assign program zero
Again, here is our list, but be sure to create a list of your own
Use the setup reduction planning form provided in lesson four
Machining centers Turning centersDetermine program zero assignment values
For each toolMeasure distance between tool tip and program zeroCalculate
Enter program zero assignment valuesInto geometry offsets (preferred)Edit G50 commands
Lesson topics
Determine program zero assignment values
Measure with edge finder or dial indicatorCalculate
Enter program zero assignment valuesInto fixture offsets (preferred)Edit G92 command
Machining centers Turning centersDetermine program zero assignment values
For each toolMeasure distance between tool tip and program zeroCalculate
Enter program zero assignment valuesInto geometry offsets (preferred)Edit G50 commands
First, try to come up with ways to eliminate tasks…
Can you think of any way to eliminate program zero assigning tasks?
…some may seem far-fetched
If machining center setups are qualified, you can eliminate the entire task of program zero assignment
Program zero assignment values will be included in the program Setup person will not have to measure or enter program zero assignment values
Lesson topics
A qualified setup:
Definition:A qualified setup is one that can placed on the machine table in exactly the same fashion over and over again
For repeated setups, program zero will be in the same location
Lesson topics
A qualified setup:
Top view of VMC table
Table slots
Does your machine have a center slot?
Lesson topics
A qualified setup:
Top view of VMC table
Bottom plate of workholding device
Keys
Lesson topics
A qualified setup:
Top view of VMC table
Program zero
Lesson topics
A qualified setup:
Top view of VMC table
Lesson topics
A qualified setup:
Top view of VMC table
Lesson topics
A qualified setup:
Top view of VMC table
Program zero will be in the same position every time the setup is made!
Don’t believe it?
Lesson topics
A qualified setup:
Top view of VMC table
Program zero will be in the same position every time the setup is made!
Don’t believe it?Machine a tooling hole
O0001...M30N999 G53 X-17.3437 Y-9.2322 M30
This command sends the spindle directly above the tooling hole
Using a dial indicator, check that the fixture is properly placed
After doing this a few times to confirm the setup is qualified, stop doing this procedure
Lesson topics
A qualified setup:Program zero will be in the same
position every time the setup is made!
If program zero is in the same location every time a setup is made…
Program zero assignment values will be the same every time the setup is made!
But how do you determine program zero assignment values the first time a setup is made?
Lesson topics
Determining program zero assignment values
If workholding device is accurately made:
Known values
Lesson topics
If workholding device is accurately made:
Easy to calculate
Determining program zero assignment values
Lesson topics
A B C D E F G H I J K L M N O P Q R S1
2
3
4
5
6
If workholding device is accurately made:
Determining program zero assignment values
By the way……this is one reason why sub-plates are so helpful!
Lesson topics
If workholding device is not accurately made:
These values must be measured once
Determining program zero assignment values
Lesson topics
Programming fixture offset entries
O0001...M30N999 G90 G10 L2 P1 X-23.3736 Y-10.2372 Z-12.2832M30
Include G10 commands to enter fixture offset values
Lesson topics
More on sub-plates
Top view of VMC table
Plug
A B C D E F G H I J K L M N O P Q R S1
2
3
4
5
6
2.0000 typ
0.7500” location hole
½-13 clamping hole
Lesson topics
More on sub-platesFANUC 16M
+
#0: COMMONX 00.0000Y 00.0000Z 00.0000
WORK COORDINATE SYSTEM SETTING
#1: G54X -23.3736Y -10.2372Z -11.3645
#2: G55X 00.0000Y 00.0000Z 00.0000
#3: G56X 00.0000Y 00.0000Z 00.0000Z –12.2382
Normal use of fixture offsets
Lesson topics
More on sub-platesFANUC 16M
+
#0: COMMONX 00.0000Y 00.0000Z 00.0000
WORK COORDINATE SYSTEM SETTING
#1: G54X 00.0000Y 00.0000Z -00.0000
#2: G55X 00.0000Y 00.0000Z 00.0000
#3: G56X 00.0000Y 00.0000Z 00.0000Z 00.0000
Use common offset to shift the point of reference for fixture offset entries
Lesson topics
More on sub-plates
Top view of VMC table
A B C D E F G H I J K L M N O P Q R S1
2
3
4
5
6
Determine distances to lower-left hole
Lesson topics
More on sub-platesFANUC 16M
+
#0: COMMONX -32.2223Y -15.4734Z -12.2322
WORK COORDINATE SYSTEM SETTING
#1: G54X 00.0000Y 00.0000Z -11.3645
#2: G55X 00.0000Y 00.0000Z 00.0000
#3: G56X 00.0000Y 00.0000Z 00.0000Z 00.0000
Enter them into common offset
Lesson topics
More on sub-plates
Top view of VMC table
A B C D E F G H I J K L M N O P Q R S1
2
3
4
5
6
Corner stop
Place corner stop in hole F5
10.0 8.0
Distances from lower-left hole to program zero surfaces are easy to determine
Lesson topics
More on sub-platesFANUC 16M
+
#0: COMMONX -32.2223Y -15.4734Z -12.2322
WORK COORDINATE SYSTEM SETTING
#1: G54X 10.0000Y 08.0000Z 02.2500
#2: G55X 00.0000Y 00.0000Z 00.0000
#3: G56X 00.0000Y 00.0000Z 00.0000
O0001...M30N999 G90 G10 L2 P1 X10.0 Y8.0 Z2.25M30
Program them with a G10 command
Lesson topics
More on sub-plates
If you have a mishap (crash)…
…only the common offset values must be re-measured
Lesson topics
Determine program zero assignment values
Measure with edge finder or dial indicatorCalculate
Enter program zero assignment valuesInto fixture offsets (preferred)Edit G92 command
Machining centers Turning centersDetermine program zero assignment values
For each toolMeasure distance between tool tip and program zeroCalculate
Enter program zero assignment valuesInto geometry offsets (preferred)Edit G50 commands
First, try to come up with ways to eliminate tasks…
Can you think of any way to eliminate program zero assigning tasks?
…some may seem far-fetched
If machining center setups are qualified, you can eliminate the entire task of program zero assignment
Program zero assignment values will be included in the program Setup person will not have to measure or enter program zero assignment values
Lesson topics
Determine program zero assignment values
Measure with edge finder or dial indicatorCalculate
Enter program zero assignment valuesInto fixture offsets (preferred)Edit G92 command
Machining centers Turning centersDetermine program zero assignment values
For each toolMeasure distance between tool tip and program zeroCalculate
Enter program zero assignment valuesInto geometry offsets (preferred)Edit G50 commands
First, try to come up with ways to eliminate tasks…
Can you think of any way to eliminate program zero assigning tasks?
…some may seem far-fetched
For cutting tools that remain in the turret from one job to the next, there is no need to re-assign program zero
As long as you use geometry offsets with work shift
Lesson topics
Determine program zero assignment values
Measure with edge finder or dial indicatorCalculate
Enter program zero assignment valuesInto fixture offsets (preferred)Edit G92 command
Machining centers Turning centersDetermine program zero assignment values
For each toolMeasure distance between tool tip and program zeroCalculate
Enter program zero assignment valuesInto geometry offsets (preferred)Edit G50 commands
If you can calculate program zero assignment values up-front, they will not have to be determined while the machine is down for setup
If you cannot justify what it takes to eliminate tasks…
What can be done while the machine is in production for the previous job?
…can you move them off line?
Lesson topics
Determine program zero assignment values
Measure with edge finder or dial indicatorCalculate
Enter program zero assignment valuesInto fixture offsets (preferred)Edit G92 command
Machining centers Turning centersDetermine program zero assignment values
For each toolMeasure distance between tool tip and program zeroCalculate
Enter program zero assignment valuesInto geometry offsets (preferred)Edit G50 commands
Use a spindle probe to determine and enter fixture offset values Or use an edge finder (more manual intervention, but still very effective)
If you cannot move a task off line…
What can you do to make it easier to assign program zero?
…can it be facilitated?
Lesson topics
If you don’t make qualified setups…
Facilitate program zero assignment tasks
…setup people must measure program zero assignment values
Edge finder or dial indicator is used Machine position displays must be manipulated Calculations may have to be made Fixture offsets must be manually entered Time consuming – cumbersome – error prone
Do what ever you can to help!
…and you don’t have a spindle probe…
Lesson topics
Anything a touch probe can do can be done with an edge finder…
Facilitate program zero assignment tasks
…except that touching must be done manually
Lesson topics
A corner pickup custom macro:Facilitate program zero assignment tasks
O9051 (Corner pickup routine for lower left corner)N1 G91 G01 Y0.75 Z-0.75 F30. (Move to first touch position)N2 #3006 = 101 (TOUCH LEFT SIDE IN X)N3 G90 G10 L2 P1 X[#5021 + #500] (Set fixture offset X)N4 G91 G01 X-0.2 (Move away in X)N5 Y-0.75 (Move down in Y)N6 X0.55 (Move to second touch position)N7 #3006 = 101 (TOUCH BOTTOM SURFACE IN Y)N8 G90 G10 L2 P1 Y[#5022 + #500] Set fixture offset Y)N9 G91 G01 Y-0.2 (Move away in Y)N10 Z0.75 (Move up in Z)N11 Y0.55 (Move to third touch position)N12 #3006 = 101 (TOUCH TOP SURFACE IN Z)N13 G90 G10 L2 P1 Z[#5023 - #501] (Set fixture offset Z)N14 G91 G01 Z.5 (Move away in Z)N15 X-0.75 Y-0.75 (Move away in X and Y)N16 M30 (End of program)
Lesson topics
Determine program zero assignment values
Measure with edge finder or dial indicatorCalculate
Enter program zero assignment valuesInto fixture offsets (preferred)Edit G92 command
Machining centers Turning centersDetermine program zero assignment values
For each toolMeasure distance between tool tip and program zeroCalculate
Enter program zero assignment valuesInto geometry offsets (preferred)Edit G50 commands
Use a spindle probe to determine and enter fixture offset values Or use an edge finder (more manual intervention, but still very effective)
If you cannot move a task off line…
What can you do to make it easier to assign program zero?
…can it be facilitated?
Lesson topics
Determine program zero assignment values
Measure with edge finder or dial indicatorCalculate
Enter program zero assignment valuesInto fixture offsets (preferred)Edit G92 command
Machining centers Turning centersDetermine program zero assignment values
For each toolMeasure distance between tool tip and program zeroCalculate
Enter program zero assignment valuesInto geometry offsets (preferred)Edit G50 commands
Use a tool-touch-off probe Use the measure function with geometry offsets
If you cannot move a task off line…
What can you do to make it easier to assign program zero?
…can it be facilitated?
Lesson topics
This task is only related to setup if: Programs must be created while the machine is down between production runs
Small lots, short cycle times (short production runs) Lots of new jobs No lead time
Lesson topics
Manual programmingDevelop machining processChoose cutting tools and assign tool stationsDesign setupCalculate coordinates needed in programWrite manual program
Computer aided manufacturing (CAM) system programmingDevelop machining processChoose cutting tools and assign tool stationsDesign setupImport CAD drawing (or create workpiece geometry)Specify machining operations to be performedCheck tool path
Conversational (shop floor) programmingDevelop machining processChoose cutting toolsDesign setupDefine workpiece geometrySpecify machining operationsCheck tool path
Think of what must be done to create programs…
Lesson topics
Eliminate tasks related to programming
Finite number of different jobs
Once all programs are created, there is no need for more programming
But in reality……there will likely be new products, revisions, and
process improvements
Lesson topics
Move programming tasks off line
Assumes: Manageable number of new jobs Sufficient number of programmers Adequate lead time Large enough lot sizes Long enough cycle times
Even if programming is done off line…
…it may still be necessary to facilitate the related tasks
CAM systems facilitate programming
Lesson topics
Facilitate on line task of programming
But maybe: Every job is a new one There is no lead time You run very small lots… …with very short cycle times
Programming must be done while the machine is down…
…do everything you can to facilitate the task!
How often are machines down waiting for programs?
Lesson topics
Facilitate on line task of programming
Use conversational controls: Are like single-purpose CAM systems Are designed for the specific machine Minimize other setup related tasks Can be programmed very quickly
Or – place a CAM system close to machine/s: Always available to setup person Wired directly to CNC machine Acts like conversational control
Lesson topics
Facilitate on line task of programming
Do you run parts in a family?
Parametric programming allows you to develop one program that works for all parts!
Setup person simply modifies a few variables to create new program
Lesson topics
Facilitate on line task of programming
Lesson topics
Facilitate on line task of programming
Lesson topics
Lesson topics
No DNC systemPrograms entered through control panelPrograms deleted upon job completion
Manual DNC systemLocate program storage location (hard drive folder, floppy disk, etc.Get machine and DNC device ready for transmissionMake command to transfer
Automatic DNC systemMake command to transfer right from CNC machine
For programs saved from CNC machine after job…Check correctness of changesSave in appropriate location
Think of what must be done to transfer programs
Lesson topics
Eliminate tasks related to program transfer
Finite number of different jobs
Possibly all programs can be stored in machine control
But in reality, it’s probably not feasible……this may cause conflicts with ISO or Quality 9000
certifications
Lesson topics
Eliminate tasks related to program transfer
Use PC based controls
With standard networking
Program transfers are as quick as loading from a hard drive
Lesson topics
Move program transfer tasks off line
Use controls with background edit
Program transfers can be made while the machine is running production
Lesson topics
Facilitate program transfer tasks
Manual DNC systems
Use RS-232c serial communications protocol Manual switchbox for multiple machines Setup person must walk between devices Dedicate a computer for program transfers Specify program file location on setup sheet
Can take five to fifteen minutes
Lesson topics
Facilitate program transfer tasks
Automatic DNC systems
Command program transfers from machine No walk or wait is required Program transfers occur in less than 30 seconds
Lesson topics
Lesson topics
Mistakes that cause the need for program verificationProgram related
Syntax mistakesMotion command mistakesOffset number selectionMiscellaneous functions (spindle direction, tool selection, etc.)
Setup relatedWorkholding device placementProgram zero assignmentVarious measurements and offset settingsTool placement
Process relatedCutting tool choicesFeeds and speedsMachining orderWorkholding choices
Program verification
Lesson topics
We offer a two part definition for program verification:
Any task you perform to confirm the correctness of the program
New programs present the greatest challenges
Program verification
Lesson topics
We offer a two part definition for program verification:
Any task you perform to confirm the correctness of the first workpiece
Even proven programs present difficult challenges
Program verification
Lesson topics
Think of what must be done to remove the previous setup from the machine
Here is our list, but be sure to create a list of your own
Use the setup reduction planning form provided in lesson four
To confirm the correctness of the program / setupSingle block dry runFree flowing dry runSingle blocking each tool into position with controlled motion rateCautiously running first workpieceAny modifications you make when mistakes are found
To confirm the correctness of the first workpieceTrial machining for surfaces with critical tolerancesChecking what each tool has done after machiningFirst workpiece inspectionAny modifications you make due to failed inspectionRe-machining workpiece after modifications
Lesson topics
To confirm the correctness of the program / setupSingle block dry runFree flowing dry runSingle blocking each tool into position with controlled motion rateCautiously running first workpieceAny modifications you make when mistakes are found
To confirm the correctness of the first workpieceTrial machining for surfaces with critical tolerancesChecking what each tool has done after machiningFirst workpiece inspectionAny modifications you make due to failed inspectionRe-machining workpiece after modifications
First, try to come up with ways to eliminate tasks…
Can you think of any way eliminate tasks?
For proven jobs, some of these tasks can be eliminated If program zero assignment has been eliminated, so can the related program verification concerns If tool length measurement is done off line and an offset entering program is automatically created, related program verification concerns will be eliminated
…some may seem far-fetched
Lesson topics
Eliminate program verification tasks
A program can be considered proven if:
It has been run before, and Corrections made to the program are saved, and Nothing about the job has changed
You should be able to eliminate any tasks done for the purpose of confirming the correctness of the program and process for proven programs!
Lesson topics
Eliminate program verification tasksMistakes that cause the need for program verification
Program relatedSyntax mistakesMotion command mistakesOffset number selection
Setup relatedWorkholding device placementProgram zero assignmentVarious measurements and offset settingsTool placement
Process relatedCutting tool choicesFeeds and speedsMachining orderWorkholding choices
If this task has been eliminated, so can the related tasks for program verification!
Lesson topics
Eliminate program verification tasksMistakes that cause the need for program verification
Program relatedSyntax mistakesMotion command mistakesOffset number selection
Setup relatedWorkholding device placementProgram zero assignmentVarious measurements and offset settingsTool placement
Process relatedCutting tool choicesFeeds and speedsMachining orderWorkholding choices
For tool length compensation, if tool length measuring device creates offset setting
program, potential for mistakes is minimized
Lesson topics
To confirm the correctness of the program / setupSingle block dry runFree flowing dry runSingle blocking each tool into position with controlled motion rateCautiously running first workpieceAny modifications you make when mistakes are found
To confirm the correctness of the first workpieceTrial machining for surfaces with critical tolerancesChecking what each tool has done after machiningFirst workpiece inspectionAny modifications you make due to failed inspectionRe-machining workpiece after modifications
First, try to come up with ways to eliminate tasks…
Can you think of any way eliminate tasks?
…some may seem far-fetched
For proven jobs, some of these tasks can be eliminated If program zero assignment has been eliminated, so can the related program verification concerns If tool length measurement is done off line and an offset entering program is automatically created, related program verification concerns will be eliminated
Lesson topics
To confirm the correctness of the program / setupSingle block dry runFree flowing dry runSingle blocking each tool into position with controlled motion rateCautiously running first workpieceAny modifications you make when mistakes are found
To confirm the correctness of the first workpieceTrial machining for surfaces with critical tolerancesChecking what each tool has done after machiningFirst workpiece inspectionAny modifications you make due to failed inspectionRe-machining workpiece after modifications
An off-line program verification system can find many programming mistakes
If you cannot justify what it takes to eliminate tasks…
What can be done while the machine is in production for the previous job?
…can you move them off line?
Lesson topics
Moving program verification tasks off line
It can take a great deal of setup time to confirm the correctness of a program!
Machine Lock Dry RunTo Check For Syntax Mistakes
Free Flowing Dry RunTo Check For Motion Mistakes
Normal Air Cutting RunTo Confirm Cutting Motions
Cautiously Running First Workpiece
Procedures may include:
Lesson topics
Moving program verification tasks off line
It can take a great deal of setup time to confirm the correctness of a program!
Many current model controls allow setup people to display tool path
Lesson topics
FANUC 10M
POSITION PROGRAM OFFSET PRG_CHK +MDI HND HOLD **** *** *** *** ****
SETTING SERVICE GRAPHIC
Lesson topics
Moving program verification tasks off line
It can take a great deal of setup time to confirm the correctness of a program!
Many current model controls allow setup people to display tool path
But not all allow this while the machine is running production!
Program verification is still on line!
Lesson topics
Moving program verification tasks off line
Many program verification software programs are available that help
move this task off line!
Lesson topics
CAM Systems Show Tool Path Based On Source Program
Tool Path Plotters Show Tool Path Based On G Code Level Program
Simulation Systems Show More Than Just Tool Path Approaching Virtual Reality For CNC Machines
Moving program verification tasks off line
Many program verification software programs are available that help
move this task off line!
Lesson topics
Moving program verification tasks off line
There are four things off-line program verification software cannot show:
Tiny Motion MistakesMistakes Made Measuring Program Zero Off-Line Software Assumes Correct Entry
Mistakes Made With Offsets Tool Length, Cutter Radius, Etc.
Mistakes With Cutting Conditions Feeds, Speeds, Depth-Of-Cut, Tool Rigidity, Etc.
For this reason, some verification must be done on line
Lesson topics
To confirm the correctness of the program / setupSingle block dry runFree flowing dry runSingle blocking each tool into position with controlled motion rateCautiously running first workpieceAny modifications you make when mistakes are found
To confirm the correctness of the first workpieceTrial machining for surfaces with critical tolerancesChecking what each tool has done after machiningFirst workpiece inspectionAny modifications you make due to failed inspectionRe-machining workpiece after modifications
An off-line program verification system can find many programming mistakes
If you cannot justify what it takes to eliminate tasks…
What can be done while the machine is in production for the previous job?
…can you move them off line?
Lesson topics
To confirm the correctness of the program / setupSingle block dry runFree flowing dry runSingle blocking each tool into position with controlled motion rateCautiously running first workpieceAny modifications you make when mistakes are found
To confirm the correctness of the first workpieceTrial machining for surfaces with critical tolerancesChecking what each tool has done after machiningFirst workpiece inspectionAny modifications you make due to failed inspectionRe-machining workpiece after modifications
We’re assuming it is important that your first workpiece is a good one
If you cannot move tasks off line…
What can be done to make program verification easier?
…can you facilitate them?
Lesson topics
To confirm the correctness of the program / setupSingle block dry runFree flowing dry runSingle blocking each tool into position with controlled motion rateCautiously running first workpieceAny modifications you make when mistakes are found
To confirm the correctness of the first workpieceTrial machining for surfaces with critical tolerancesChecking what each tool has done after machiningFirst workpiece inspectionAny modifications you make due to failed inspectionRe-machining workpiece after modifications
Program trial machining operations
If you cannot move tasks off line…
What can be done to make program verification easier?
…can you facilitate them?
Lesson topics
Facilitating program verification tasks
Steps to trial machining:
recognizes a critical tolerance makes an adjustment to force excess stock to be left lets the tool machine the workpiece stops the machine and measures the surface changes the initial adjustment based on measurement reruns the tool stop and measure again to confirm
Setup person…
Trial machining takes time!
Lesson topics
Facilitating program verification tasks
How can you eliminate the need for trial machining?
Only by perfectly presetting the cutting tool!
Most cutting tool measurements are “static”
It can be difficult to allow for tool pressure with critical tolerances
Don’t be too quick to give up on eliminating this time-consuming task
If you can perfectly preset a boring bar, there will be no
need to trial machine!
Lesson topics
Facilitating program verification tasks
How can you eliminate the need for trial machining?
Only by perfectly presetting the cutting tool!
For turning centers applications…
…tool touch off probes can take take tool pressure into consideration when assigning program zero…
…and eliminate the need to trial machine!
Lesson topics
Facilitating program verification tasks
If you cannot eliminate the need to trial machine, make it as easy as possible to do so
recognizes a critical tolerance makes an adjustment to force excess stock to be left lets the tool machine the workpiece stops the machine and measures the surface changes the initial adjustment based on measurement reruns the tool stop and measure again to confirm
Setup person…
Why force the setup person to determine if trial machining is necessary?
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial boring on a machining center:
1) Intentionally set boring bar undersize
0.005 small
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial boring on a machining center:
2) Allow boring bar to partially machine hole
.N255 T04 M06 (2.3750 boring bar)N260 G54 G90 S450 M03 T05N265 G00 X4.0 Y4.0N270 G43 H04 Z0.1 M08 N275 F2.5/N280 M98 P1000/N285 M98 P1000/N290 M98 P1000 /N295 M98 P1000 N300 G86 R0.1 Z-1.0 F2.5.
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial boring on a machining center:
2) Allow boring bar to partially machine hole
.N255 T04 M06 (2.3750 boring bar)N260 G54 G90 S450 M03 T05N265 G00 X4.0 Y4.0N270 G43 H04 Z0.1 M08 N275 F2.5/N280 M98 P1000/N285 M98 P1000/N290 M98 P1000 /N295 M98 P1000 N300 G86 R0.1 Z-1.0 F2.5.
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial boring on a machining center:
2) Allow boring bar to partially machine hole
.N255 T04 M06 (2.3750 boring bar)N260 G54 G90 S450 M03 T05N265 G00 X4.0 Y4.0N270 G43 H04 Z0.1 M08 N275 F2.5/N280 M98 P1000/N285 M98 P1000/N290 M98 P1000 /N295 M98 P1000 N300 G86 R0.1 Z-1.0 F2.5.
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial boring on a machining center:
2) Allow boring bar to partially machine hole
.N255 T04 M06 (2.3750 boring bar)N260 G54 G90 S450 M03 T05N265 G00 X4.0 Y4.0N270 G43 H04 Z0.1 M08 N275 F2.5/N280 M98 P1000/N285 M98 P1000/N290 M98 P1000 /N295 M98 P1000 N300 G86 R0.1 Z-1.0 F2.5.
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial boring on a machining center:
2) Allow boring bar to partially machine hole
.N255 T04 M06 (2.3750 boring bar)N260 G54 G90 S450 M03 T05N265 G00 X4.0 Y4.0N270 G43 H04 Z0.1 M08 N275 F2.5/N280 M98 P1000/N285 M98 P1000/N290 M98 P1000 /N295 M98 P1000 N300 G86 R0.1 Z-1.0 F2.5.
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial boring on a machining center:
2) Allow boring bar to partially machine hole
.N255 T04 M06 (2.3750 boring bar)N260 G54 G90 S450 M03 T05N265 G00 X4.0 Y4.0N270 G43 H04 Z0.1 M08 N275 F2.5/N280 M98 P1000/N285 M98 P1000/N290 M98 P1000 /N295 M98 P1000 N300 G86 R0.1 Z-1.0 F2.5.
The subprogram must work for any
hole size
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial boring on a machining center:
2) Allow boring bar to partially machine hole
.N255 T04 M06 (2.3750 boring bar)N260 G54 G90 S450 M03 T05N265 G00 X4.0 Y4.0N270 G43 H04 Z0.1 M08 N275 F2.5/N280 M98 P1000/N285 M98 P1000/N290 M98 P1000 /N295 M98 P1000 N300 G86 R0.1 Z-1.0 F2.5.
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial boring on a machining center:
2) Allow boring bar to partially machine hole
O1000N1 G91 G86 R0 Z-0.3N2 G80 M09 N3 G00 Z3.0N4 X4.0 Y4.0N5 M00N6 G00 X-4.0 Y4.0 M03N7 Z-3.0 M08N8 G90N9 M99
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial boring on a machining center:
2) Allow boring bar to partially machine hole
O1000N1 G91 G86 R0 Z-0.3N2 G80 M09 N3 G00 Z3.0N4 X4.0 Y4.0N5 M00N6 G00 X-4.0 Y4.0 M03N7 Z-3.0 M08N8 G90N9 M99
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial boring on a machining center:
2) Allow boring bar to partially machine hole
O1000N1 G91 G86 R0 Z-0.3N2 G80 M09 N3 G00 Z3.0N4 X4.0 Y4.0N5 M00N6 G00 X-4.0 Y4.0 M03N7 Z-3.0 M08N8 G90N9 M99
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial boring on a machining center:
O1000N1 G91 G86 R0 Z-0.3N2 G80 M09 N3 G00 Z3.0N4 X4.0 Y4.0N5 M00N6 G00 X-4.0 Y4.0 M03N7 Z-3.0 M08N8 G90N9 M99
3) Move to convenient measuring position
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial boring on a machining center:
O1000N1 G91 G86 R0 Z-0.3N2 G80 M09 N3 G00 Z3.0N4 X4.0 Y4.0N5 M00N6 G00 X-4.0 Y4.0 M03N7 Z-3.0 M08N8 G90N9 M99
3) Move to convenient measuring position
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial boring on a machining center:
O1000N1 G91 G86 R0 Z-0.3N2 G80 M09 N3 G00 Z3.0N4 X4.0 Y4.0N5 M00N6 G00 X-4.0 Y4.0 M03N7 Z-3.0 M08N8 G90N9 M99
3) Move to convenient measuring position
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial boring on a machining center:
O1000N1 G91 G86 R0 Z-0.3N2 G80 M09 N3 G00 Z3.0N4 X4.0 Y4.0N5 M00N6 G00 X-4.0 Y4.0 M03N7 Z-3.0 M08N8 G90N9 M99
4) Stop, measure hole, & adjust boring bar
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial boring on a machining center:
O1000N1 G91 G86 R0 Z-0.3N2 G80 M09 N3 G00 Z3.0N4 X4.0 Y4.0N5 M00N6 G00 X-4.0 Y4.0 M03N7 Z-3.0 M08N8 G90N9 M99
5) Move back to hole location
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial boring on a machining center:
O1000N1 G91 G86 R0 Z-0.3N2 G80 M09 N3 G00 Z3.0N4 X4.0 Y4.0N5 M00N6 G00 X-4.0 Y4.0 M03N7 Z-3.0 M08N8 G90N9 M99
5) Move back to hole location
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial boring on a machining center:
O1000N1 G91 G86 R0 Z-0.3N2 G80 M09 N3 G00 Z3.0N4 X4.0 Y4.0N5 M00N6 G00 X-4.0 Y4.0 M03N7 Z-3.0 M08N8 G90N9 M99
5) Move back to hole location
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial boring on a machining center:
O1000N1 G91 G86 R0 Z-0.3N2 G80 M09 N3 G00 Z3.0N4 X4.0 Y4.0N5 M00N6 G00 X-4.0 Y4.0 M03N7 Z-3.0 M08N8 G90N9 M99
5) Move back to hole location
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial boring on a machining center:
6) Repeat until hole is on size
.N255 T04 M06 (2.3750 boring bar)N260 G54 G90 S450 M03 T05N265 G00 X4.0 Y4.0N270 G43 H04 Z0.1 M08 N275 F2.5/N280 M98 P1000/N285 M98 P1000/N290 M98 P1000 /N295 M98 P1000 N300 G86 R0.1 Z-1.0 F2.5.
Turn on block delete when hole is sized
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial boring on a machining center:
6) Repeat until hole is on size
.N255 T04 M06 (2.3750 boring bar)N260 G54 G90 S450 M03 T05N265 G00 X4.0 Y4.0N270 G43 H04 Z0.1 M08 N275 F2.5/N280 M98 P1000/N285 M98 P1000/N290 M98 P1000 /N295 M98 P1000 N300 G86 R0.1 Z-1.0 F2.5.
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial boring on a machining center:
6) Repeat until hole is on size
.N255 T04 M06 (2.3750 boring bar)N260 G54 G90 S450 M03 T05N265 G00 X4.0 Y4.0N270 G43 H04 Z0.1 M08 N275 F2.5/N280 M98 P1000/N285 M98 P1000/N290 M98 P1000 /N295 M98 P1000 N300 G86 R0.1 Z-1.0 F2.5.
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial boring on a machining center:
6) Repeat until hole is on size
.N255 T04 M06 (2.3750 boring bar)N260 G54 G90 S450 M03 T05N265 G00 X4.0 Y4.0N270 G43 H04 Z0.1 M08 N275 F2.5/N280 M98 P1000/N285 M98 P1000/N290 M98 P1000 /N295 M98 P1000 N300 G86 R0.1 Z-1.0 F2.5.
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial rough turning (minimize trial machining time):
Rough turning time: 18 minutes
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial rough turning (minimize trial machining time):
Rough turning time: 18 minutes
O0003N005 T0101 M41N010 G96 S400 M03N015 G00 X6.0 Z.1/N020 X5.5/N025 G01 Z-.3 F0.020/N030 X6.0/N035 G00 X8.0 Z3./N040 M00 (DIAMETER 5.50 IN)/N045 T0101 M03/N050 G00 X6. Z.1N055 G71 P060 Q160 D2500 …N060 . . .
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial rough turning (minimize trial machining time):
Rough turning time: 18 minutes
O0003N005 T0101 M41N010 G96 S400 M03N015 G00 X6.0 Z.1/N020 X5.5/N025 G01 Z-.3 F0.020/N030 X6.0/N035 G00 X8.0 Z3./N040 M00 (DIAMETER 5.50 IN)/N045 T0101 M03/N050 G00 X6. Z.1N055 G71 P060 Q160 D2500 …N060 . . .
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial rough turning (minimize trial machining time):
Rough turning time: 18 minutes
O0003N005 T0101 M41N010 G96 S400 M03N015 G00 X6.0 Z.1/N020 X5.5/N025 G01 Z-.3 F0.020/N030 X6.0/N035 G00 X8.0 Z3./N040 M00 (DIAMETER 5.50 IN)/N045 T0101 M03/N050 G00 X6. Z.1N055 G71 P060 Q160 D2500 …N060 . . .
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial rough turning (minimize trial machining time):
Rough turning time: 18 minutes
O0003N005 T0101 M41N010 G96 S400 M03N015 G00 X6.0 Z.1/N020 X5.5/N025 G01 Z-.3 F0.020/N030 X6.0/N035 G00 X8.0 Z3./N040 M00 (DIAMETER 5.50 IN)/N045 T0101 M03/N050 G00 X6. Z.1N055 G71 P060 Q160 D2500 …N060 . . .
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial rough turning (minimize trial machining time):
Rough turning time: 18 minutes
O0003N005 T0101 M41N010 G96 S400 M03N015 G00 X6.0 Z.1/N020 X5.5/N025 G01 Z-.3 F0.020/N030 X6.0/N035 G00 X8.0 Z3./N040 M00 (DIAMETER 5.50 IN)/N045 T0101 M03/N050 G00 X6. Z.1N055 G71 P060 Q160 D2500 …N060 . . .
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial rough turning (minimize trial machining time):
Rough turning time: 18 minutes
O0003N005 T0101 M41N010 G96 S400 M03N015 G00 X6.0 Z.1/N020 X5.5/N025 G01 Z-.3 F0.020/N030 X6.0/N035 G00 X8.0 Z3./N040 M00 (DIAMETER 5.50 IN)/N045 T0101 M03/N050 G00 X6. Z.1N055 G71 P060 Q160 D2500 …N060 . . .
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial rough turning (minimize trial machining time):
Rough turning time: 18 minutes
O0003N005 T0101 M41N010 G96 S400 M03N015 G00 X6.0 Z.1/N020 X5.5/N025 G01 Z-.3 F0.020/N030 X6.0/N035 G00 X8.0 Z3./N040 M00 (DIAMETER 5.50 IN)/N045 T0101 M03/N050 G00 X6. Z.1N055 G71 P060 Q160 D2500 …N060 . . .
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial rough turning (minimize trial machining time):
Rough turning time: 18 minutes
O0003N005 T0101 M41N010 G96 S400 M03N015 G00 X6.0 Z.1/N020 X5.5/N025 G01 Z-.3 F0.020/N030 X6.0/N035 G00 X8.0 Z3./N040 M00 (DIAMETER 5.50 IN)/N045 T0101 M03/N050 G00 X6. Z.1N055 G71 P060 Q160 D2500 …N060 . . .
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial rough turning (minimize trial machining time):
Rough turning time: 18 minutes
O0003N005 T0101 M41N010 G96 S400 M03N015 G00 X6.0 Z.1/N020 X5.5/N025 G01 Z-.3 F0.020/N030 X6.0/N035 G00 X8.0 Z3./N040 M00 (DIAMETER 5.50 IN)/N045 T0101 M03/N050 G00 X6. Z.1N055 G71 P060 Q160 D2500 …N060 . . .
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial rough turning (minimize trial machining time):
Rough turning time: 18 minutes
O0003N005 T0101 M41N010 G96 S400 M03N015 G00 X6.0 Z.1/N020 X5.5/N025 G01 Z-.3 F0.020/N030 X6.0/N035 G00 X8.0 Z3./N040 M00 (DIAMETER 5.50 IN)/N045 T0101 M03/N050 G00 X6. Z.1N055 G71 P060 Q160 D2500 …N060 . . .
Setup person measures and adjusts now
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial rough turning (minimize trial machining time):
Rough turning time: 18 minutes
O0003N005 T0101 M41N010 G96 S400 M03N015 G00 X6.0 Z.1/N020 X5.5/N025 G01 Z-.3 F0.020/N030 X6.0/N035 G00 X8.0 Z3./N040 M00 (DIAMETER 5.50 IN)/N045 T0101 M03/N050 G00 X6. Z.1N055 G71 P060 Q160 D2500 …N060 . . .
Offset must be invoked again
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial rough turning (minimize trial machining time):
Rough turning time: 18 minutes
O0003N005 T0101 M41N010 G96 S400 M03N015 G00 X6.0 Z.1/N020 X5.5/N025 G01 Z-.3 F0.020/N030 X6.0/N035 G00 X8.0 Z3./N040 M00 (DIAMETER 5.50 IN)/N045 T0101 M03/N050 G00 X6. Z.1N055 G71 P060 Q160 D2500 …N060 . . .
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Trial rough turning (minimize trial machining time):
Rough turning time: 18 minutes
O0003N005 T0101 M41N010 G96 S400 M03N015 G00 X6.0 Z.1/N020 X5.5/N025 G01 Z-.3 F0.020/N030 X6.0/N035 G00 X8.0 Z3./N040 M00 (DIAMETER 5.50 IN)/N045 T0101 M03/N050 G00 X6. Z.1N055 G71 P060 Q160 D2500 …N060 . . .
Normal rough turning begins
Lesson topics
Commonly taught in basic CNC courses:
Slash code in program (/)Works with block delete switchIf on, block skipped..if off, block executed
Techniques with block delete
Mid commandConflicting words withTrial machiningWith unexpected stock
Another optional stopMultiple block deletes
Not always taught in basic courses:
Saving time and effort:
Use block delete to help with trial machining
If off, trial machining will take placeIf on, trial machining will be skipped
With a little ingenuity, you can streamline almost any trial machining operation!
Consider other times when block delete can help with trial machining
Lengthy rough milling operationsThread millingSlot millingFace millingThread chasing (turning center)Necking multiple groovesAny time trial machining is needed!
Lesson topics
To confirm the correctness of the program / setupSingle block dry runFree flowing dry runSingle blocking each tool into position with controlled motion rateCautiously running first workpieceAny modifications you make when mistakes are found
To confirm the correctness of the first workpieceTrial machining for surfaces with critical tolerancesChecking what each tool has done after machiningFirst workpiece inspectionAny modifications you make due to failed inspectionRe-machining workpiece after modifications
Program trial machining operations
If you cannot move tasks off line…
What can be done to make program verification easier?
…can you facilitate them?
Lesson topics
To confirm the correctness of the program / setupSingle block dry runFree flowing dry runSingle blocking each tool into position with controlled motion rateCautiously running first workpieceAny modifications you make when mistakes are found
To confirm the correctness of the first workpieceTrial machining for surfaces with critical tolerancesChecking what each tool has done after machiningFirst workpiece inspectionAny modifications you make due to failed inspectionRe-machining workpiece after modifications
In most companies, the production run cannot be started until a workpiece passes inspection
Inspections take time – as does any task that must be done if the first workpiece fails inspection. Be sure inspections are done efficiently.
If you cannot move tasks off line…
What can be done to make program verification easier?
…can you facilitate them?
Lesson topics
To confirm the correctness of the program / setupSingle block dry runFree flowing dry runSingle blocking each tool into position with controlled motion rateCautiously running first workpieceAny modifications you make when mistakes are found
To confirm the correctness of the first workpieceTrial machining for surfaces with critical tolerancesChecking what each tool has done after machiningFirst workpiece inspectionAny modifications you make due to failed inspectionRe-machining workpiece after modifications
Processing mistakes can lead to failed inspections There is an easy way to change machining order at the machine during setup
If you cannot move tasks off line…
What can be done to make program verification easier?
…can you facilitate them?
Lesson topics
Facilitating program verification tasks
Mistakes with machining order will cause even a perfectly written program to fail!
1) Rough turn2) Finish turn3) Drill 2” hole4) Rough bore5) Finish bore
1) Rough turn2) Drill 2” hole3) Rough bore4) Finish bore5) Finish turn
Not all controls have “cut and paste”
Lesson topics
Facilitating program verification tasks
Fanuc controls allow unconditional branching
M99 P040Go to sequence number N040
Lesson topics
Commonly taught in basic CNC courses:
Techniques with sequence numbers
N words are sequence numbersNot needed but beginners use themUse logical order (N5, N10, N15, etc.)
EliminatingSpecial restart blocksAs statement labels
Applications not always taught in basic courses:
A statement label marks a commandO0008 (Program with bad process)N005 T0101 M41 (Rough turn)N010 G96 S400 M03N015 G00 X3.040 Z0.1N020 G01 Z-1.995 F0.017N025 X3.25 N030 G00 X6.0 Z5.0N035 M01 N040 T0202 M42 (Finish turn)N045 G96 S600 M03N050 G00 X3. Z0.1N055 G01 Z-2.0 F0.006N060 X3.25N065 G00 X6.0 Z5.0N070 M01 N075 T0303 M41 (2” drill)N080 G97 S300 M03N085 G00 X0 Z0.1N090 G01 Z-2.6 F.009
N095 G00 Z0.1N100 G00 X6.0 Z5.0N105 M01 N110 T0404 M41 (1.5” rough boring bar)N115 G96 S400 M03N120 G00 X2.085 Z0.1N125 G01 Z-1.995 F0.010N130 X2.0N135 G00 Z0.1N140 X6.0 Z5.0N145 M01 N150 T0505 M42 (1.5” finish boring bar)N155 G96 S600 M03 N160 G00 X1.125 Z0.1N165 G01 Z-2.0 F0.006N170 X2.0N175 G00 Z0.1N180 G00 X6.0 Z5.0 N185 M30
Lesson topics
Commonly taught in basic CNC courses:
Techniques with sequence numbers
N words are sequence numbersNot needed but beginners use themUse logical order (N5, N10, N15, etc.)
EliminatingSpecial restart blocksAs statement labels
Applications not always taught in basic courses:
A statement label marks a commandO0008 (Program with bad process)N005 T0101 M41 (Rough turn)N010 G96 S400 M03N015 G00 X3.040 Z0.1N020 G01 Z-1.995 F0.017N025 X3.25 N030 G00 X6.0 Z5.0N035 M01 N040 T0202 M42 (Finish turn)N045 G96 S600 M03N050 G00 X3. Z0.1N055 G01 Z-2.0 F0.006N060 X3.25N065 G00 X6.0 Z5.0N070 M01 N075 T0303 M41 (2” drill)N080 G97 S300 M03N085 G00 X0 Z0.1N090 G01 Z-2.6 F.009
N095 G00 Z0.1N100 G00 X6.0 Z5.0N105 M01 N110 T0404 M41 (1.5” rough boring bar)N115 G96 S400 M03N120 G00 X2.085 Z0.1N125 G01 Z-1.995 F0.010N130 X2.0N135 G00 Z0.1N140 X6.0 Z5.0N145 M01 N150 T0505 M42 (1.5” finish boring bar)N155 G96 S600 M03 N160 G00 X1.125 Z0.1N165 G01 Z-2.0 F0.006N170 X2.0N175 G00 Z0.1N180 G00 X6.0 Z5.0 N185 M30
N038 M99 P075
Lesson topics
Commonly taught in basic CNC courses:
Techniques with sequence numbers
N words are sequence numbersNot needed but beginners use themUse logical order (N5, N10, N15, etc.)
EliminatingSpecial restart blocksAs statement labels
Applications not always taught in basic courses:
A statement label marks a commandO0008 (Program with bad process)N005 T0101 M41 (Rough turn)N010 G96 S400 M03N015 G00 X3.040 Z0.1N020 G01 Z-1.995 F0.017N025 X3.25 N030 G00 X6.0 Z5.0N035 M01 N040 T0202 M42 (Finish turn)N045 G96 S600 M03N050 G00 X3. Z0.1N055 G01 Z-2.0 F0.006N060 X3.25N065 G00 X6.0 Z5.0N070 M01 N075 T0303 M41 (2” drill)N080 G97 S300 M03N085 G00 X0 Z0.1N090 G01 Z-2.6 F.009
N095 G00 Z0.1N100 G00 X6.0 Z5.0N105 M01 N110 T0404 M41 (1.5” rough boring bar)N115 G96 S400 M03N120 G00 X2.085 Z0.1N125 G01 Z-1.995 F0.010N130 X2.0N135 G00 Z0.1N140 X6.0 Z5.0N145 M01 N150 T0505 M42 (1.5” finish boring bar)N155 G96 S600 M03 N160 G00 X1.125 Z0.1N165 G01 Z-2.0 F0.006N170 X2.0N175 G00 Z0.1N180 G00 X6.0 Z5.0
N185 M30
N038 M99 P075
N183 M99 P040
Lesson topics
Commonly taught in basic CNC courses:
Techniques with sequence numbers
N words are sequence numbersNot needed but beginners use themUse logical order (N5, N10, N15, etc.)
EliminatingSpecial restart blocksAs statement labels
Applications not always taught in basic courses:
A statement label marks a commandO0008 (Program with bad process)N005 T0101 M41 (Rough turn)N010 G96 S400 M03N015 G00 X3.040 Z0.1N020 G01 Z-1.995 F0.017N025 X3.25 N030 G00 X6.0 Z5.0N035 M01 N040 T0202 M42 (Finish turn)N045 G96 S600 M03N050 G00 X3. Z0.1N055 G01 Z-2.0 F0.006N060 X3.25N065 G00 X6.0 Z5.0N070 M01 N075 T0303 M41 (2” drill)N080 G97 S300 M03N085 G00 X0 Z0.1N090 G01 Z-2.6 F.009
N095 G00 Z0.1N100 G00 X6.0 Z5.0N105 M01 N110 T0404 M41 (1.5” rough boring bar)N115 G96 S400 M03N120 G00 X2.085 Z0.1N125 G01 Z-1.995 F0.010N130 X2.0N135 G00 Z0.1N140 X6.0 Z5.0N145 M01 N150 T0505 M42 (1.5” finish boring bar)N155 G96 S600 M03 N160 G00 X1.125 Z0.1N165 G01 Z-2.0 F0.006N170 X2.0N175 G00 Z0.1N180 G00 X6.0 Z5.0
N185 M30
N038 M99 P075
N183 M99 P040
N073 M99 P185
Lesson topics
To confirm the correctness of the program / setupSingle block dry runFree flowing dry runSingle blocking each tool into position with controlled motion rateCautiously running first workpieceAny modifications you make when mistakes are found
To confirm the correctness of the first workpieceTrial machining for surfaces with critical tolerancesChecking what each tool has done after machiningFirst workpiece inspectionAny modifications you make due to failed inspectionRe-machining workpiece after modifications
Processing mistakes can lead to failed inspections There is an easy way to change machining order at the machine during setup
If you cannot move tasks off line…
What can be done to make program verification easier?
…can you facilitate them?
Lesson topics
Lesson topics
Cutting conditionsFeeds and speedsDepths of cut
ProcessCutting tool materials
ProgramWasted movementsProgram format
Workpiece load and unloadTool maintenance
Program optimizing: Make changes related to
Lesson topics
Though optimizing can reduce cycle time…
Program optimizing
…it adds to setup time!
Be sure it’s feasible to optimize!
Lesson topics
Program optimizingThis task should probably be
eliminated if lot sizes are small
Time spent optimizing in setup will only add to overall production time
Exception:
If you run the same materials and cutting tools regularly, time spent
optimizing can be applied to future jobs
Lesson topics
Program optimizing
But for large lot sizes…
…optimizing can really reduce overall production time!
Lesson topics
To help you evaluate feasibility:
Program optimizing
One second rule:
One second saved per cycle will save 16.6 minutes per 1,000 cycles
If you are considering optimizing for a ten part lot, and think you can save about 10 seconds…
…you’re only going to reduce the production run by about 1.5 minutes!
Lesson topics
To help you evaluate feasibility:
Program optimizing
One second rule:
One second saved per cycle will save 16.6 minutes per 1,000 cycles
On the other hand…
…you’ll save 166 minutes (2.77 hours)
…if you can save 10 seconds in a 1,000 piece lot…
Lesson topics
Cutting conditionsFeeds and speedsDepths of cut
ProcessCutting tool materials
ProgramWasted movementsProgram format
Workpiece load and unloadTool maintenance
Program optimizing: Make changes related to
Eliminate program optimizing tasks
Again, eliminate these tasks with small lots
Lesson topics
Cutting conditionsFeeds and speedsDepths of cut
ProcessCutting tool materials
ProgramWasted movementsProgram format
Workpiece load and unloadTool maintenance
Program optimizing: Make changes related to
Move program optimizing tasks off line
Some CAM systems can generate very efficient CNC programs!
Lesson topics
Cutting conditionsFeeds and speedsDepths of cut
ProcessCutting tool materials
ProgramWasted movementsProgram format
Workpiece load and unloadTool maintenance
Program optimizing: Make changes related to
Move program optimizing tasks off line
If you use a tool path verification program, watch for unnecessary motions!
Lesson topics
Cutting conditionsFeeds and speedsDepths of cut
ProcessCutting tool materials
ProgramWasted movementsProgram format
Workpiece load and unloadTool maintenance
Program optimizing: Make changes related to
Facilitate program optimizing tasks
Lesson topics
Facilitate program optimizing tasks
If you expect your setup people to modify cutting conditions and approach distance…
…make it easy as possible!
How many feed and speed words are there per tool?
Lesson topics
Facilitate program optimizing tasks
If you expect your setup people to modify cutting conditions and approach distance…
…make it easy with variable programming!
O0001 (Program number)#100 = 400 (Rough turning speed)#101 = 0.015 (Rough turning feedrate)#102 = 0.125 (Rough turning depth of cut)#103 = 5.0 (Tool changing position in X)#104 = 4.0 (Tool changing position in Z)#105 = 500 (Finish turning speed)#106 = 0.007 (Finish turning feedrate)#107 = 0.125 (Cut off tool width)#108 = 400 (Cut off tool speed)#109 = 0.005 (Cut off tool feedrate)N005 T0101 (Rough turning tool)N010 G96 S#100 M03 (Start spindle)N015 G00 X1.5 Z.1 M08 (Rapid up to position)N020 G71 P025 Q045 U.04 W.005 D#102 F#102 (Rough turn the workpiece)N025 G00 X.875 (Rapid to starting X)N030 G01 Z0 (Feed flush with face)N035 X1.0 Z-0.0625 (Form chamfer)N040 Z-[0.75 + #107 + 0.01] (Turn 1.0 diameter)N045 X1.5 (Feed up face)N050 G00 X#103 Z#104 (Rapid to tool changing position)N055 M01 (Optional stop)N060 T0202 (Finish turning tool)N065 G96 S#105 M03 (Start spindle)N070 X1.5 Z.1 M08 (Rapid up to workpiece)N075 G70 P025 Q045 F#106 (Finish turn workpiece)N080 G00 X#103 Z#104 (Rapid to tool change position)N085 M01 (Optional stop)N090 T0303 (Cutoff tool)N095 G96 S#108 M03 (Start spindle)N100 G00 X1.5 Z-[1.0 + #107] M08 (Rapid close)N105 X1.2 (Rapid closer)N110 G01 X-.03 F#109 (Cut off)N115 G00 X1.5 (Rapid out)N120 X#103 Z#104 (Rapid to tool change position)N125 M30 (End of program)
Lesson topics
Cutting conditionsFeeds and speedsDepths of cut
ProcessCutting tool materials
ProgramWasted movementsProgram format
Workpiece load and unloadTool maintenance
Program optimizing: Make changes related to
Facilitate program optimizing tasks
What else can you do to help setup people optimize?
Lesson topics
Lesson topics
PaperworkProduction controlSPCTime reporting
Gauge setupWorking on multiple machinesOthers?
Other tasks related to setup?
Approach them as you do any other setup related tasks - eliminate, move off line, or facilitate
Lesson topics
308
Getting More From Your CNC Machines
Copyright 2011
End of presentation
Lesson 5: Setup Reduction Techniques
Setup tasks and improvements
top related