lesson topics 1 getting more from your cnc machines copyright 2011 topics lesson 5: setup reduction...

Lesson topics

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Getting More From Your CNC Machines

Copyright 2011

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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

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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

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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:

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1) To Eliminate The Task

2) To Move The Task Off Line

3) To Facilitate The Task

With every task, we’ll give suggestions…

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3) To Facilitate The TaskHardest to justifyRepeated task or urgencyFinite # of repeated setups


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3) To Facilitate The TaskSufficient CNC staffSufficient cycle timeSufficient lot sizes


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3) To Facilitate The Task

Little repeat businessSetup person does allNo off-line time


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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

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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

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Disorganization is pretty easy to spot…

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…you must encourage and enhance the potential for organization…

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…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!

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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?

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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

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Storage of components Are needed components properly stored? Is every drawer/cabinet clearly labeled?

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Storage of components Are needed components properly stored? Is every drawer/cabinet clearly labeled? Are work holding devices properly stored?

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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?

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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

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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?

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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

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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?

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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”

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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

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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

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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

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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!

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Is there room for improvement with organization in your own company?

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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

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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!

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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

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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

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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

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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

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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?


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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.


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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.


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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


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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.


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having to empty the chip pan?

Can you run jobs that are made from the same material consecutively?


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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


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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


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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?

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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


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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


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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


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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.


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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.


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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.)


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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.)


Final suggestion for moving tasks off line:

Watch for tasks that people perform on line that could be performed off line.

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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?

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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.)


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task of clearing offsets?

Study control documentation – there may be a better/faster way than clearing one offset at a time.


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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.


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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).


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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.


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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.


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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.


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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.


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.

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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?

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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?

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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



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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.


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Vise stays on tableThis devices

changes job to job

An example of multiple workholding devices

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Mount center and position tailstockAlign tailstockAdjust clamping pressure





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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!

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If the setup is qualified, the workholding device will be square with the table when mounted


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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

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A qualified setup:

Top view of VMC table

Table slots

Does your machine have a center slot?

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A qualified setup:


Bottom plate of workholding device

Keys

If fixture is square with table,

there will be no need to align!

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If the setup is qualified, the workholding device will be square with the table when mounted


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Some turning centers allow tailstock positioning to be programmed Eliminating the need for a setup person to move the tailstock


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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


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Some turning centers allow chuck pressure to be programmed This keeps the setup person from having to change chuck pressure


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Same suggestions as for tearing down:


Can you think of any way to be making workholding setups while a machine is in production?



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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

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Same suggestions as for tearing down:


Can you think of any way to be making workholding setups while a machine is in production?



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If you cannot justify what it takes to move a task off line…


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

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Mount top toolingBore jaws (if necessary)Prepare work support device (if necessary)





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


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Facilitating workholding setup tasks

Note tiny serrations3-jaw chuck Mounting top tooling

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Hard jaw Soft jaw

Mounting top tooling

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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


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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


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Mounting jaws

X01.3569Z02.4236

1.3569

Select the boring bar you use for boring jaws

Align with tool diameter

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Mounting jaws

X01.3569Z02.4236

1.3569

Determine the diameter for chucking (with chuck unclamped):


Clamping diameter plus jaw stroke

If clamping on a 3.0” dia. and jaw stroke is 0.5”, this diameter is 3.5”

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Mounting jaws

X03.5000Z02.4236

3.5

Open jaws and move X axis to clamping diameter


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Mounting jaws

X03.5000Z02.4236

Use boring bar as a pointer and mount each jaw


Each jaw can be easily mounted in the same serration Jaws will clamp on workpiece at mid-stroke

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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


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Clamp on ring

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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

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Or make an adjustable chucking tool

Hex stock

Hex head screws

Clamp on ring

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Clamp on ring

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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


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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


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Actually boring jaws

Be sure the setup person can align the jaw boring cutting tool

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X02.3857Z00.0000

Be sure the setup person can align the jaw boring cutting tool

Set to zero

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X01.3569Z02.4236

1.3569

At least now the setup person can determine diameters and depths!


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Better yet, why not develop programs to bore jaws?

One jaw boring program per job, or…

…one universal program (custom macro)

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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

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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

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Input data

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Will change with input data

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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


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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


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

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Can you think of any way to eliminate cutting tool tasks?

…some may seem far-fetchedMachining centers Turning centersAssemble needed 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?

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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

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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!

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Even if you can’t store all tools in the ATC magazine…

…place a storage rack right next to the machine!

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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?

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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

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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

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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

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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

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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)

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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

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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










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)

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For machining centers, tool length and cutter radius compensation values can be determined off line

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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…

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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

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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

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For cutter radius compensation, a micrometer can be used to measure most milling cutters…

…tool setter can write down cutter radius or diameter

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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

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For machining centers, tool length and cutter radius compensation values can be determined off line

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If boring bars must be preset, do so before the job comes to the machine

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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

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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!

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If boring bars must be preset, do so before the job comes to the machine

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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.

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Tool Magazine

Loading Station


Rotate CW

Rotate CCW

Magazine

Manual Auto

If you have enough tool stations…

…during production, load tools for the next job!

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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.

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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.

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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


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 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










Again, study your setup people – Is there anything you can do to help them?

Lesson topics













Being well organized is the key to efficiently assembling cutting tools

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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!

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Do any of your machining centers have a tool probe?

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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

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Help for setting a taper reamer

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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



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


Z value

Lesson topics


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


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




Think of what must be done to assign program zero






Lesson topics








Can you think of any way to eliminate program zero assigning tasks?


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:


Table slots

Does your machine have a center slot?

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A qualified setup:


Bottom plate of workholding device

Keys

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A qualified setup:


Program zero

Lesson topics

A qualified setup:


Lesson topics

A qualified setup:


Program zero will be in the same position every time the setup is made!

Don’t believe it?

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A qualified setup:


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

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Easy to calculate


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A B C D E F G H I J K L M N O P Q R S1

2

3

4

5

6



By the way……this is one reason why sub-plates are so helpful!

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If workholding device is not accurately made:

These values must be measured once


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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


Plug


2

3

4

5

6

2.0000 typ

0.7500” location hole

½-13 clamping hole

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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


+

#0: COMMONX 00.0000Y 00.0000Z 00.0000


#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



2

3

4

5

6

Determine distances to lower-left hole

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+

#0: COMMONX -32.2223Y -15.4734Z -12.2322


#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



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

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+

#0: COMMONX -32.2223Y -15.4734Z -12.2322


#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

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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










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







If you can calculate program zero assignment values up-front, they will not have to be determined while the machine is down for setup



…can you move them off line?

Lesson topics







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







Use a spindle probe to determine and enter fixture offset values Or use an edge finder (more manual intervention, but still very effective)




Lesson topics







Use a tool-touch-off probe Use the measure function with geometry offsets




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


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


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


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


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


Lesson topics

Think of what must be done to remove the previous setup from the machine



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




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


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



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



For tool length compensation, if tool length measuring device creates offset setting

program, potential for mistakes is minimized

Lesson topics




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

Lesson topics



An off-line program verification system can find many programming mistakes




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



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



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


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


Many program verification software programs are available that help

move this task off line!

Lesson topics


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



An off-line program verification system can find many programming mistakes




Lesson topics



We’re assuming it is important that your first workpiece is a good one


What can be done to make program verification easier?

…can you facilitate them?

Lesson topics



Program trial machining operations




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


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


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


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











Trial boring on a machining center:

1) Intentionally set boring bar undersize

0.005 small

Lesson topics












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














The subprogram must work for any

hole size

Lesson topics














Lesson topics













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













3) Move to convenient measuring position

Lesson topics













4) Stop, measure hole, & adjust boring bar

Lesson topics













5) Move back to hole location

Lesson topics












6) Repeat until hole is on size


Turn on block delete when hole is sized

Lesson topics












6) Repeat until hole is on size


Lesson topics











Trial rough turning (minimize trial machining time):

Rough turning time: 18 minutes

Lesson topics













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














Setup person measures and adjusts now

Lesson topics














Offset must be invoked again

Lesson topics














Lesson topics














Normal rough turning begins

Lesson topics











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



Program trial machining operations




Lesson topics



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.




Lesson topics



Processing mistakes can lead to failed inspections There is an easy way to change machining order at the machine during setup




Lesson topics


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


Fanuc controls allow unconditional branching

M99 P040Go to sequence number N040

Lesson topics


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







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







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

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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

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Processing mistakes can lead to failed inspections There is an easy way to change machining order at the machine during setup




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Cutting conditionsFeeds and speedsDepths of cut

ProcessCutting tool materials

ProgramWasted movementsProgram format

Workpiece load and unloadTool maintenance

Program optimizing: Make changes related to

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Though optimizing can reduce cycle time…

Program optimizing

…it adds to setup time!

Be sure it’s feasible to optimize!

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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

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Program optimizing

But for large lot sizes…

…optimizing can really reduce overall production time!

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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!

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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…

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Eliminate program optimizing tasks

Again, eliminate these tasks with small lots

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Move program optimizing tasks off line

Some CAM systems can generate very efficient CNC programs!

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Move program optimizing tasks off line

If you use a tool path verification program, watch for unnecessary motions!

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Facilitate program optimizing tasks

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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?

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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)

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What else can you do to help setup people optimize?

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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

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308

Getting More From Your CNC Machines

Copyright 2011

End of presentation

Lesson 5: Setup Reduction Techniques

Setup tasks and improvements

lesson topics 1 getting more from your cnc machines copyright 2011 topics lesson 5: setup reduction...

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