M a th e m a tis c h Te c h n is c h e
Software-Entwicklung GmbH
Introduction to TopMill
CNC simulator milling
Version 7.1
Introduction to TopMill
CNC simulator milling Version V 7.1
© MTS Mathematisch Technische Software-Entwicklung GmbH
Kaiserin-Augusta-Allee 101 • D - 10553 Berlin • Tel.: (++49 30) 349 960 0 • Fax: 349 960 25 • http//www.mts-cnc.com Berlin, 2005.
1.0. INTRODUCTION... 5
1.1. HOW OPERATING ELEMENTS ARE REPRESENTED IN TOPMILL ... 5
1.2. STARTING OF TOPMILL ... 6
1.3. NOTES ON SETTING UP A CONFIGURATION TYPE ... 7
2.0. TOPMILL - THE CNC SIMULATOR MILLING ... 8
2.1. AUTOMATIC MODE ... 9
2.2. INTERACTIVE MODE... 10
2.3. SINGLE BLOCK MODE ... 11
2.4. TOOL TRACING ... 12
2.5. 3D-DISPLAY ... 13
2.6. 2D-DISPLAY ... 14
3.0. THE NC-EDITOR ... 15
3.1. SETUP SHEET ... 16
3.2. KEYBOARD LAYOUT FOR NC EDITOR FUNCTIONS ... 17
3.3. NC DIALOG PROGRAMMING ... 18
3.4. ADDITIONAL INFORMATION TO MTS NC EDITOR ... 19
4.0. THE “MILLING” SET-UP DIALOG... 20
4.1. OPEN THE DIALOG WINDOW AND ASSIGN A PROGRAM NAME ... 20
4.2. SELECT THE CLAMPING DEVICE AND CLAMPING CONFIGURATION... 20
4.3. DEFINE THE WORKPART DIMENSIONS AND WOKRPART ORIGIN... 21
4.4. SELECT THE MACHINING TOOL SET ... 22
5.0. SETUP MODE... 24
5.1. CLAMPING DEVICES, CLAMPING METHODS AND BLANK MATERIAL SHAPES... 24
5.2. TOOL MAGAZINES, TOOL MOUNTINGS AND TOOLS ... 24
5.3. TOOL LIBRARY ... 25
5.4. AXIS MOTIONS IN SETUP MODE... 25
6.0. PREPARATIONS FOR PROGRAMMING... 26
6.1. PRODUCTION PLANNING AND TECHNOLOGY ... 27
6.2. SETUP FORM FOR “MILLING WORKPART” ... 30
7.0. SETTING UP THE MACHINE... 32
7.1. ASSIGNING TOOLS TO TOOL STATIONS IN THE MAGAZINE ... 35
8.0. NC PROGRAMMING (MTS PROGRAMMING KEY) ... 41
8.1. MILLING A PIN ... 42
8.2. GRAPHICAL CONTOUR EDITOR (WOP) ... 45
8.3. MILLING CIRCULAR POCKETS ... 58
8.4. CONTOUR AND GUIDE-WAY MILLING ... 58
8.5. RECTANGULAR AND CIRCULAR POCKETS ... 59
8.6. LINEAR DRILL PATTERN ... 59
8.7. INTERNAL AND EXTERNAL T SLOT MILLING IN ISO CODE... 60
8.8. INTERNAL AND EXTERNAL CHAMFERING THE PINS IN ISO CODE ... 61
8.9. SLOT MILLING IN ISO CODE... 61
8.10. REAMING... 62
8.11. RECLAMPING THE WORKPART ... 63
9.0. QUALITY CONTROL AND MEASURING OF THE WORKPART ... 64
10.0. APENDICES... 66
10.1. NC-PROGRAM %30 ... 67
10.2. NC-PROGRAMM %31 ... 71
10.3. WORKPART DRAWING ... 72
10.4. WORKING TEMPLATES ... 73
10.5. NOTICE FOR ADMINISTRATING AND ORGANISING OF SETUP DIALOG MILLING ... 76
1.0. Introduction
The individual chapters of this manual explain the essential functions involved in operating and handling the system. The functions described here are also intended to give you a general idea of the system’s capabilities (as well as the possibilities offered for implementing dedicated training courses).
These not only include the creation of NC programs and simulating and checking their quality, but also many other realistic ways of teaching the trainees basic CNC machine tool functions using computer support.
The examples used in the simulation are available in the programming keys of all CNC control systems supplied by our company.
Trainees are guided through system operation step-by-step, enabling them to learn the underlying principles and the operation of the CNC simulator in a very short time.
After some introductory explanations, we will first show you how to set up the simulator according to a work plan and how to create a setup sheet.
1.1. How operating elements are represented in TopMill
The operating elements and the meaning of their functions are shown by the simulator as 10 function buttons in a menu bar at the bottom of the screen corresponding to the function keys of a PC or control keyboard
Main menu:
To activate the desired function, either move the mouse pointer to the respective function button and click on the leftt-hand mouse button , or press the appropriate function key … of the PC keyboard. This enables you to adapt system operation to your preferences.
To help you follow the explanations more easily, the functions which you have to select from the menu structures are shown in the explanatory and instruction texts with a coloured or darker background, or are indicated by symbols representing PC keys.
To begin with, you only need to carry out the individual steps as instructed.
If the desired result is be achieved due to an input error, please observe the following notes:
• You can return to the main menu or the start-up status of the simulator at any time by pressing the or key. Depending on how far down the menu tree you are, you may have to press the key several times. • To select or de-select functions, use the keys … . This may pull up a new menu.
• Generally, a function is concluded or accepted by pressing . If you have navigated through several menus in order to select a specific function, you will have to exit each menu, one at a time by pressing or the appropriate number of times. This, too, will return you to the main menu.
1.2. Starting of TopMill
Click on the Windows START button in the task bar, select the Programs folder and then (provided you have not changed the folder name when installing the software) the MTS-CNC English folder to access the MTS programs TopTurn, TopMill or TopCAM.
The respective documentation / training manuals are stored in PDF format in the Help subfolder.
If you start TopCAM, the start-up menu will offer you the following software modules for selection, which can be activated only if the corresponding software licence is available.
TopCAM
A CAD system with integrated NC programming for turning/lathe work with up to five axes and milling work with three axes.
TopTurn
NC programming module, either control-system-specific or of neutral ISO control system type, with simulation and collision detection; optionally available with opposite spindle and up to 7 axes.
TopMill
NC programming module, either control-system-specific or of neutral ISO control system type, with simulation and collision detection in three axes
To start the CNC simulator turning, either click on the Start TopMill button in theTopCAM start menu, or double-click directly on the TopMill program name in the MTS-CNC English folder.
When you start up the TURNING software for the first time, an MTS configurationtype with the MTS programming key will always be active:
MTS VMC-0550x0550x0500-ISO30 - MTS VMC30 CONTROL
If you have not purchased the MTS programming key, which is independent of the type of control system, but have a turning/lathe work control system using e. g. PAL94 command codes or SINUMERIK 820DM, the Start
Milling button is not active after you have installed the software. In this case, you first have to select a
corresponding configurationtype. This activates the Start Milling button. This configuration type selection is memorized for subsequent program starts.
Info on the machine tool axes, in the selected configuration
1.3. Notes on setting up a configuration type
If you have purchased the MTS programming key, you can skip over this chapter when first learning to operate the software.
The name of a configuration type is always related to a particular combination of machine tool and control system configurations. These are saved and managed by the Configuration Administration. For instance, a milling machine will be configured according to the manufacturer’s instructions. The definitive properties will include the machining space, tool travel ranges, tool magazine type and the tool positions, number of NC axes, steep-angle tapper mounting type, etc.
The control configuration will comprise the CNC programming syntax, the allocation of the optional postprocessor and the control settings.
A postprocessor is always needed for translating an MTS or PAL program into a specific control system code. The same as with the programming key, this will be activated after the target control system has been selected.
Which of these modules are available will depend on which software level you have purchased. You can add modules whenever required.
In the following illustration, both modules, i. e. the programming key and the postprocessor are available. The
Postprocessor and Start Milling buttons are therefore enabled and activated
3 axis machining (X, Z. Y)
programming key for the control system type
Sinumerik 810D with 5-axis simulation
cycle postprocessor for translating programs into
the Sinumerik 810 D NC code for five axes
transfer of the NC data between the PC and the NC
machine tool
If you have not purchased a programming key for your postprocessor, then the button is not enabled.
Before continuing, re-check the active configurationtype. Now start the CNC simulator by clicking on the <Start Milling> button. The simulator will either use the
MTS VMC-0550x0550x0500-ISO30 - MTS VMC30 CONTROL
2.0. TopMill - the CNC simulator milling
The CNC simulator has three different operating modes:NC Editor Automatic mode Setup mode
Setup dialog
For teaching purposes, it is best to start with the <Automatic mode> . This means that the trainee will first get familiar with the various types of simulation.
Let us start by explaining some features of the initial screen display. First we select the 2D simulation.
The power-on state of the CNC simulator is determined by a setup sheet. This describes a specific simulator setup which is determined by the following components:
• a vise or modular clambing,
• the workpart blank / blank material and • tooling setup with tool positions in the tool
magazine.
The start setup sheet is stored as header in an NC program. In each control system, it is stored under the program administration and is named <DLFT_MTE.FNC>. The user can adapt this setup sheet individually or can change its name of in the respective control system configuration.
To activate the <DLFT_MTE.FNC> program and set up the system, select <Automatic setup> by mouse pointer or press the key. This returns the simulator to its original power-on state.
Header of the setup sheet as shown by the NC editor.
2.1. Automatic
mode
We want to run an NC program on a CNC machine tool. To enable this process, the program first has to be loaded into the control system’s memory. The following description illustrates the individual steps required to operate the MTS system in this mode. First select automatic mode:
Press key , or select the <Select program> button to open the NC Program Administration, which will display a list of all NC programs for this control system
Move the mouse pointer to the file name
<%022___TM08-24-VMC1> and double click left in order to load this file into
the machine tool memory for further processing.
Clicking the right-hand mouse button calls up a context menu with further Explorer function:
e.g. Copy program to diskette, delete, rename etc.
In the frame below you can scroll in the marked file
In our example, the <%022___TM08-24-VMC1> program has been selected. Press to confirm the action. The system will display a new menu. This offers you four different types of simulation. We shall start by selecting automatic mode <Automatic mode>:
Automatic mode Single block
Interactive mode Tool tracing
To start the simulation in automatic mode, press the key. The CNC program currently loaded into the machine memory, i. e. <%022___TM08-24-VMC1> in our example, is run automatically from the first to the last block.
The right-hand pane shows important system information on the operating state of the virtual CNC milling machine:
• current coordinates of the X, Y and Z axis, • cutting speed, rotation speed, tool feed,
tool number,
• direction of spindle rotation, machining time, • active G code and
• override & runtime
The lower section of the simulation window shows a section of the program with the NC block currently being processed by TopMill
2.2. Interactive
mode
Interactive mode, called up by pressing the key, enables the user to create, edit and run an NC program in dialog with the software. The CNC simulator runs the NC program block-by-block. The program can be corrected at any time. After being executed by the simulator, any block can be rejected so that you can re-edit it and then re-run on the simulator. During this process, the workpart will be continuously updated, or, if the block is rejected, the workpart will be returned to its former condition.
Let us run < %006____TN01-24-VMC1> NC program in <Interactive mode> .
Initially, the program Administration is opened.
Double-click left on the program name
< %006____TN01-24-VMC1> in order to transfer the program to the machine program memory.
This will get the program running in interactive mode. After editing and confirmation by <Execute NC block> the actual NC block will be simulated and this block will be represented for editing after simulation by the question <Accept NC block [Y/N]>.
Execute the NC block: Accept the NC block [J/N] Execute NC block:
Accept NC block [J/N]
In this operating mode, the NC code can be edited again as follows:
Reject the block by pressing the or key. Using the keyboard, edit the current block. Accept NC block [J/N]
If you wish to change the speed at which the simulation is run, use the function <Override, times> . This
function is available on all modern machine tools, both during machining work and during tooling and set-up (zero-position scratching, setting zero coordinates).
To access the various functions for altering the time taken to run the simulation, press the key or double click on the <Override, times> button. Try using the individual options offered in the menu bar. To apply your settings, press key or click on <Accept>. You may change the settings at any time.
Important: The override setting affects the calculated machining time. As opposed to this, the <Disp. speed>
(slow-motion) and <Test run on/off> functions do not affect calculated machining times.
2.3. Single
block
mode
The <Single block> function is used when running in Automatic mode and requires the operator to confirm the execution of each NC block or record individually.
The NC Program <%005S12_TM03-24-VMC1> will be started in <Single block>by pressing .
The commands in the NC block are only executed when you click on the <Run NC block> button or press the or the key.
Note:
You can switch over between the simulation modes Automatic mode, Single block and Interactive mode even after simulation of an NC program has been started.
2.4. Tool
tracing
The function (<Tool tracing>) is used to display the tool travel paths described by the selected NC program e. g. <%005S_TM03-24-VMC1>.
The program is run and the programmed 3D tool travel paths of the tool tip are displayed graphically.
Careful and precise evaluation of the programmed tool movements in rapid speed and subsequent correction of the NC program can lead to considerable reductions in manufacturing times.
Note:
The currently selected NC program can be run in any of the simulation modes:
<Automatic mode> <Single block> <Interactive mode> <Tool tracing>
If the setup sheet interpreter is activated, every time an NC program is started the CNC simulator will be set up according to the setup sheet in the header of the NC program. This has the advantage that the original workpart blank is always placed back on the machine whenever the program is restarted.
2.5. 3D-Display
2.6. 2D-Display
Press <Graphical display> to modify the graphical display in different ways: Important functions:
Sectional views Tool representation NC-block display
With <Accept> you confirm your modifications in <Graphical display> and with you return to the starting situation with the graphical display settings before.
The dynamical representation of the sectional views can be permanently stopped with .
The graphical representation of the tool components mounting, shaft, tip in the sectional views can be modified with by going through a query dialog. With
<Accept> you confirm your modifications.
Press and to alter the number of NC blocs displayed by pressing or consecutively. With
<Accept> you confirm your modifications.
For any new graphical display you must use <Accept> to confirm your modifications. The chosen display will be active.
3.0. The
NC-Editor
The initial menu of the NC editor provides access to the following functions: • Edit the current NC program
• not assigned
• Select an NC program from the Administration in order to edit it, or to create new program • not assigned
• Print the NC-Program
• Transfer the NC-program to the machine tool in DNC mode • Return to setup mode
• Return to automatic mode
As you already learned in the section on <Automatic mode>, you can select a program or create a new program using the file selection dialog.
This offers various ways of opening or creating a program. Press or click on <Edit program>, and enter a program name.
If a program with this name already exists, it will be opened for editing, if not, you will be shown a message: “Program does not exist! Create program [Y/N]?”. In the latter case, press the [Y] key to create a new program and [N] [to abort.
You can also select a program by clicking <Select program> or pressing . The selected name is then copied into the simulator’s status bar when the dialog window is closed. You can subsequently open it with
or by using other functions.
The <%022___TM08-24-VMC1> NC program is to be opened for viewing. It contains all required information, from the setup data for simulation right down to the NC code of the program.
After you have marked the NC program with a single left mouse click , you can click on the right-hand mouse button to call up further supplementary functions.
3.1. Setup
Sheet
A setup sheet stored as header of an NC program always has the same structure. It comprises the following groups:
• Machine tool and control system configuration names, • Workpart blank and geometry
• Clamping devices and their positioning • Active tool in the machining position
• Tools in the tool magazine, tool positions including tool correction values
In the main menu, click on <Setup form > or press in order to access the setup form menu.
After the simulator was set-up in setup mode you can save this setup in a respective setup sheet: Press and enter a program name.
Setup sheet information
• () Beginning and end marks for the setup sheet interpreter • ( Setup sheet line which is to be processed by the interpreter • (( Comments, these are not to be processed by the interpreter
When you create a new setup sheet, the command <M30> (meaning “end of program”) will be the only NC line to be added to the setup sheet. Without <M30> the error message “unanticipated end of program” will be displayed when you are working in automatic mode or when the setup sheet is being used as a startup setup sheet.
3.2. Keyboard
layout
for NC editor functions
The section of the program that can currently be edited is always shown between two horizontal rules. To select a word, use the cursor key . You can change, delete or write new code as you wish.
Confirm and conclude your entries by pressing the key.
Browse a page at a time: or Browse block-by-block: or Insert a line: + Delete a line: + Insert a word Delete a word: • Link program • Group operation
• Renumber the NC program
To insert another NC program in front of the currently selected line, call up the appropriate function by pressing the key or clicking on on <Link programs>. This is an important function that is needed for creating modification copies, for instance.
The group operation function, called up by pressing the key, enables you to mark a block of multiple complete lines, including the beginning and end marks, and then carry out operations such as shift, copy or delete block.
The Renumber functions called up by pressing enable you to renumber the NC program from a first program number up to another program number by specifying a start number and a numbering increment
3.3. NC dialog programming
To enter dialog programming mode, press the key or click on <Dialog program>. This is a universal MTS software function which can be adapted to all types of NC controls. When you press the key, the current work line is analyzed to locate commands for which a dialog screen is available. If a fitting dialog screen is found, it will be displayed and the respective input parameter values shown in the dialog screen
In the above example, this is an MTS straight roughing machining cycle call G82 with six addresses: Z, W, A, D, K. You can change the address values and also add values from the dialog screen. To enter all values into the actual NC program, click on the button.
If no key word is found, the dialog programming module will call up the list of contents showing all available commands, allowing you to select one of these by clicking on “Parameter”. The corresponding dialog screen is then opened so that you can enter the desired values. Click on to confirm your input. The corresponding new NC code line will replace the line originally selected. If you have accessed the end of the NC program, a new line will be appended to the existing NC program. (This operation also applies to multiple-line NC programming commands, provided that the selected NC control system supports these).
You can either enter a numerical value, or in the case of switch functions, select the respective function setting. In this procedure, the permissible value ranges are checked and a distinction is made between mandatory addresses and optional addresses. You also have the option of using an alternative address combination.
3.4. Additional information to MTS NC editor
The function key Dialog/Help can also be activated by pressing the key combination + , or by clicking on with the right mouse button , to get into a help box. For tool information magazine.
Enter T in the input field and confirm with , then you will get the information display of the actual tool magazine equipment of the CNC simulator.
Here you can get additional informations about the marked tool.
Note:
The modification of the tool equipment is not possible in this helpscreen.
4.0. The “milling” set-up dialog
Four simple steps to create a setup sheetThe set-up dialog assists you to create a setup sheet for a new programming task quickly. First, the clamping device – the machine vice – is selected and its position on the milling machine table is defined. Then the workpart is defined, the workpart origin is specified and the new program is completed by adding a suitable set of tools. After the procedure is finished, the controls read in the setup sheet in the form of a program header, and the user can immediately start to key in the new program.
4.1. Open the dialog window and assign a program name
To open the set-up dialog, press key . Enter a new name for the CNC program you wish to create, e. g. "Exercise 01" and then open the program
4.2. Select the clamping device and clamping configuration
Select the clamping device and define its orientation on the machine table.
RS 110 WS min 10 max.110 Et=32
Explanation:
Selection of the vice corresponds to the standard in the “Milling” clamping device library
RS110 WS min. 10 max. 110 Et=32
WS min. 10 WS max. 110 describes the jaw opening range of the movable jaw.
Specify the clamping depth of the workpart: Input: 10 mm
The workpart is not displaced. Input 0
(is centered in the jaws)
Specify the position of the workpart with reference to the machine-tool coordinate system.
Default Values
Input VX= 150 mm or Input VX=175 mm Input VY= 150 mm or Input VY=175 mm Next open the tab:
Blankl/Zero point
Explanation:
Observe the range of values in the display field. If a value cannot be evaluated, then it is shown in red in the input field and is not processed
The position of the workpart / clamping device on the machine table is specified with reference to the machine tool coordinate origin (zero coordinates). The range of values will differ for each machine configuration; in this case it is 150 mm to 250 mm for VX and from 100 mm to 200 mm for VY.
4.3. Define the workpart dimensions and wokrpart origin
Specify the workpart dimensions: Input length = 100 mm, Input width = 100 mm Input heigth = 25 mm
Next open the tab: Tool
Explanation:
The position of the workpart origin can be specified by selecting a value in the center input field of this tab. This can be moved incrementally in X ±, Y ±, and Z ± directions from the selected point by shifting the origin in X ±, Y ± and Z ± directions. A total of 10 possible workpart origins is offered for selection.
4.4. Select the machining tool set
Select a tool set e.g. VMC_ISO30_24_01.
Confirm your input by clicking on the button to create the new setup sheet. This is then read in by the CNC machine tool in Automatic mode - Interactive programming - and you can then start programming the machine.
Modifying the tool set with Edit magazine equipment
Explanation:
The tool set determines which tools are to be made available on the setup sheet.
The CNC program can be created immediately. The machine origin (zero point) specified in the dialog is entered at the bottom of the setup sheet and can then be activated with the assigned command, e. g. G54.
Below is an excerpt from the setup sheet: (
( WORKPART ZERO POINTS
( G54 X150.000 Y+150.000 Z+105.000
() (( 06.03.2006 15:40 ( ( CONFIGURATION ( MACHINE MTS VMC-024_ISO30_-0500-0400x0450 ( CONTROL MTS VMC01 (
( BLANK DIMENSIONS X+100.000 Y+100.000 Z+025.000 (
( VISE "Chuck Milling\Vise\RS 110" ( CHUCKING DEPTH E+010.000 ( SHIFT V+000.000
( ORIENTATION A180° (
( PART POSITION X+150.000 Y+150.000
(( Top front left corner of the part: X+150.000 Y+150.000 Z+105.000 (
( TOOLS
( T01 "ISO SK 30\Shell end mill\MW-040 032 HSS ISO 2586" ( T02 "ISO SK 30\Shell end mill\MW-050 036 HSS ISO 2586" ( T03 "ISO SK 30\Slot Milling tool\MS-08.0 019K HSS ISO 1641" ( T04 "ISO SK 30\Slot Milling tool\MS-10.0 053L HSS ISO 1641" ( T05 "ISO SK 30\Slot Milling tool\MS-20.0 075L HSS ISO 1641" ( T06 "ISO SK 30\Radius cutter\RC-10 05.0 50 HSS ISO 1641" ( T07 "ISO SK 30\Radius cutter\RC-18 09.0 16 HSS ISO 1641" ( T08 "ISO SK 30\Drill\DR-04.80 047 HSS ISO 235"
( T09 "ISO SK 30\Drill\DR-06.50 063 HSS ISO 235" ( T10 "ISO SK 30\Drill\DR-08.50 075 HSS ISO 235"
( T11 "ISO SK 30\Step drill\DS-06.0 03.2-090 HSS ISO 3439" ( T12 "ISO SK 30\Step drill\DS-08.0 04.3-090 HSS ISO 3439" ( T13 "ISO SK 30\Step drill\DS-11.8 06.4-090 HSS ISO 3439" ( T14 "ISO SK 30\Tap\TA-M06.0 1.00 HSS ISO 2857"
( T15 "ISO SK 30\Tap\TA-M08.0 1.25 HSS ISO 2857" ( T16 "ISO SK 30\Tap\TA-M10.0 1.50 HSS ISO 2857" ( T17 "ISO SK 30\Core drill\DC-12.0 090 HSS ISO 3294" ( T18 "ISO SK 30\Core drill\DC-16.0 060 HSS ISO 3294" ( ( TOOL COMPENSATION ( D01 T01 R020.000 Z+115.500 N01 ( D02 T02 R025.000 Z+125.000 N01 ( D03 T03 R004.000 Z+084.000 N01 ( D04 T04 R005.000 Z+125.000 N01 ( D05 T05 R010.000 Z+140.000 N01 ( D06 T06 R005.000 Z+084.000 N01 ( D07 T07 R009.000 Z+115.000 N01 ( D08 T08 R002.400 Z+092.900 N01 ( D09 T09 R003.250 Z+108.900 N01 ( D10 T10 R004.250 Z+120.900 N01 ( D11 T11 R000.000 Z+110.000 N01 ( D12 T12 R000.000 Z+115.000 N01 ( D13 T13 R000.000 Z+135.000 N01 ( D14 T14 R000.000 Z+090.000 N01 ( D15 T15 R000.000 Z+100.000 N01 ( D16 T16 R000.000 Z+110.000 N01 ( D17 T17 R000.000 Z+075.000 N01 ( D18 T18 R000.000 Z+080.000 N01 ( ( WORKPART ZEROPOINTS
(( Top front left corner of the part: X+150.000 Y+150.000 Z+105.000 ( G54 X150.000 Y+150.000 Z+105.000
( ()
5.0. Setup
mode
The set-up mode integrated into the CNC simulator has a very wide function range. The following chapters provide a brief synopsis of the various options offered.
5.1. Clamping
devices,
clamping methods and blank material shapes
The machine vice can be rotated by 90 ° on the machine table and moved in X and Y directions. The workpart can be freely positioned in all three axes, but the range depends on the type of clamping selected.
Workparts already machined can be re-clamped horizontally or vertically. The makes it possible to machine two faces of the workpart. In addition, a workpart management function is available. This can be used to store data of finished parts to be re-loaded as workpart geometry data for future use. This function thus also makes other workpart shapes available for exercises.
5.2. Tool magazines, tool mountings and tools
A continuous collision detection check is kept on the tool’s cutting edge and the tool shank and mounting when execution of the NC code is being simulated. If the cutting edge contacts the machine table or a clamping device, if the tool shaft turns in the wrong direction or if the spindle is not engaged, the system will report a collision and/or an appropriate error message is given.
The size of the tool magazine can be configured from 2 to 98 tools.
There are 99 compensation value registers available. The tool length correction and the tool diameter are activated by the tool call combining the tool position number and the compensation register number e.g T0303
5.3. Tool
library
Currently, the software handles about 700 milling tools in 20 tool types (extendable by the user).
A complete tool is consisting of mounting and tool (shaft and cutting part)
5.4. Axis motions in setup mode
or move along X axis in feedrate or move along Y axis in feedrate or move along Z axis in feedrate
+ or move along X axis in rapid speed + or move along Y axis in rapid speed + or move along Z axis in rapid speed To move the tool around in the machining space, press the respective motion control keys just as on a real machine tool. The workpart coordinate origin can be determined by zero-point scratching.
With the technology menu, or the direct hot-keys: switch spindle 3, 4 or 5
rotation speed 1000
feed rate 200
tool magazine position 0202
6.0. Preparations for programming
Before starting to write an NC program, you must study the drawings and production specifications carefully. As soon as all the information required for creating a program is available, you can start planning the individual machining steps. It is important to take into consideration which machine tool the respective workpart is to be produced on and which tools and clamping devices are available on that machine tool.
Appendix 1 contains a complete drawing of the part (“Frästeil 1”, page ……. ) used in our example. • Analyze the workshop drawing
• Fixing the work plan
• Select the clamping devices and the required tools (setup sheet) • Write the NC program
Typical work preparation and planning form
study workshop drawing study work order programmer clamping devices tools
work plan set-up form
6.1. Production
planning and technology
Machining Step Type of tool, position in magazinecutting data Machining Step diagram
1 Determine blank dimensions Clamp blank Determine origin of workpart coordinates Cube X:174 mm Y: 80 mm Z:60 Vise: RS 110/BX065 Clamping height: 15.0 mm Material : ALMG Center of upper surface
2 Milling 2 pins; Mirroring with program part repetition
SHELL END MILL
MW-063/040 HSS ISO 2586 T11 S900 M03 G94 F860 M08 3 2 x Milling external profile with cutter radius compensation in 2 passes; with program part repetition
SLOT MILLING TOOL MS-20.0/075L HSS ISO 1641 T02 S2300 M03 G94 F480 M08 4 Milling 2 circular pockets; with program part repetition
SLOT MILLING TOOL MS-20.0/075L HSS ISO 1641 T02 S2300 M03 G94 F400 M08 5 Milling profile with cutter radius compensation
SLOT MILLING TOOL MS-12.0/053L HSS ISO 1641 T01 S3800 M03
Production planning (continued)
Machining Step Type of tool, position in magazine
cutting data Machining Step diagram
6 2 x Milling the guide way on the left and right section side
SLOT MILLING TOOL MS-12.0/053L HSS ISO 1641 T01 S3800 M03 G94 F380 M08 7 Rectangular pocket in section
SLOT MILLING TOOL MS-16.0/063L HSS ISO 1641 T03 S2900 M03
G94 F430 M08
8 Throughpassing
circular pocket SLOT MILLING TOOL MS-16.0/063L HSS ISO 1641 T03 S2900 M03 G94 F430 M08 9 2 x 5 Throughpassing boreholes with countersinking with program part repetition STEP DRILL DS-08.0/04.3-090 HSS ISO 3439 T05 S1590 M03 G94 F430 M08 10 2 x 2 Internal annular T-slots; with program part repetition T-SLOT CUTTER ST-12.5/06.0 076 ISO 3337 T09 S2500 M03 G94 F250 M08
Production planning (continued)
Machining Step Type of tool, position in magazine
cutting data Machining Step diagram
11 2 x 2 External annular T-slots; mirroring with program part repetition T-SLOT CUTTER ST-22.0/10.0 030 ISO 3337 T10 S2500 M03 G94 F250 M08 12 2 x 2 45° Chamfer; mirroring with program part repetition
CORNER TOOL TYPE B CB-25/06.3/45 HSS ISO 3859 T12 S2400 M03
G94 F350 M08
13 Slot milling SLOT MILLING TOOL MS-08.6/065L HSS ISO 1641 T01 S5800 M03
G94 F320 M08
14 Reaming for fit
diameter REAMER RE-D28.0/H7 HSS ISO 521 T08 S240 M03
G94 F120 M08
6.2. Setup form for “Milling workpart”
Setup Sheet
CNCMilling
MTS Mathematisch Technische Software-Entwicklung GmbH Datum : Program No.: %030
Programmer: MTS Drawing No.: 270423
Designation: Lock device
Material: AlMg1
Raw part/blank : 174 x 80 x 60 Other info:
Clamping mode: vise Spannmittel: RS 110/BX065 Clamping height: E: 15 mm
Translation : blank in RS: 0 mm Orientation : vise 90° on machine table
Tool data / magazine or tool magazine positions
Station Tool designation Tool file No. Compensation data Mach. step 01 SLOT MILLING TOOL MS-12.0/057L HSS ISO 1641 R 006.00
Z 148.0
05 06
02 SLOT MILLING TOOL MS-20.0/075L HSS ISO 1641 R 010,00 Z 147.0
03 04
03 SLOT MILLING TOOL R MS-16.0/063L HSS ISO 1641 R 008.00 Z 135.0
07 08
04 SLOT MILLING TOOL MS-08.6/065L HSS ISO 1641 R 004.30 Z 133.0
13 05 STEP DRILL DS-08.0/04.3-090 HSS ISO 3439 R 000.00
Z 176.0
09
06 REAMER RE-D28.0/H7 HSS ISO 521 R 000.00
Z 277.0
14
09 T-SLOT CUTTER ST-12.5/06.0 076 ISO 3337 R 006.00
Z 131.0
10
10 T-SLOT CUTTER ST-22.0/10.0 030 ISO 3337 R 011.00
Z 124.5
11
11 SHELL END MILL MW-063/040 030 ISO 2586 R 020.0
Z 098.0
02 12 CORNER TOOL TYPE B CB-25/06.3/45 HSS ISO 3859 R 006.2
Z 101.5 45° 12 R Z R Z R Z R Z R Z
6.3. Production sheet “Milling Workpart”
Production Sheet
CNCMilling
MTS Mathematisch Technische Software-Entwicklung GmbH Datum : Program No.: %030
Programmer: MTS
Drawing No.: 270423
Designation: Lock device
Material: AlMg1
Raw part/blank: 174 x 80 x 60
CNC Control:
Sequence of machining steps
Nr. Machining step NC-Programming code Tool
position Cutting data
01 Milling 1 and 2 pins G03, M84, G23 T11 n 900
vf 860
fz .120
02 External contour cutting G41-G46; WOP; G23 T02 n 2300 vf 480
fz .050
03 Circular pocket 1 & 2 G88; G79 T02 n 2300
vf 400
fz .050
04 Internal contour cutting G41-G46; G71 T01 n 3800
vf 380
fz .029
05 Internal contour cutting at section G01 T01 n 3800
vf 380 fz .029 06 Rectangular pocket G87-G79 T03 n 2900 vf 430 fz .037 07 Circular pocket G88-G79 T03 n 2900 vf 430 fz .037 08 2 x 5 Throughpassing boreholes G83-G78 T05 n 1590 vf 430 fz 0,14
09 2 x Annular internal slot at pin 1 & 2 G03; M84; G23 T09 n 2500 vf 250
fz 0,023
10 2 x Annular external slot at pin 1 & 2 G03; M84; G23 T10 n 2500 vf 250
fz 0,023
11 2 x 45° Chamfering at pin 1 & 2 G02; M84; G23 T12 n 400 vf 950 fz .0,22 12 Slot milling G01 T04 n 5800 vf 320 fz .014 13 Reaming of boreholes G85; G78 T06 n 180 vf 20 fz .0,22
7.0. Setting up the machine
This chapter explains how to set up the CNC simulator for an exercise. This involves the following steps: • Selecting a blank, blank material, the clamping device and clamping method, clamping device changes • Assigning tools to tool magazine positions and creating new tool data
• Generating the setup sheet
Exercise:
A cubic aluminium alloy (AlMg1) blank, 176 x 80x60 mm is to be clamped in a vise with clamping depth of 15 mm. op (18 mm) in a jaw chuck, For machining reasons the clamping length in X direction must not exceed 60 mm.
In the setup mode menu, click on <Part/Chuck> or press to select the workpart/clamping menu.
First select the desired material from the material table by pressing , then enter the blank geometry – a block in our example. (However, material selection is not mandatory on the CNC simulator).
Select the material group Select the material and press to confirm
Enter the dimensions of the blank in the top right-hand input fields:
• Enter the block geometry data: In Field X: Enter : 174
In Field Y: Enter : 080 In Field Z: Enter : 060
To confirm your entries for the workpart blank and register them, press .
• Material information : AlMg1
You have now defined the blank, the next Step is to clamp it on the machine tool.
Press to open the clamping menu. Three different clamping systems are available: vise, magnetic plate, modular clamping.
Press to open the vise management
We select a vise as chucking system
With the cursor key or left mouse click we select vise : RS 110/BX065
With mouse click we select: KFD-HS 130 and with we confirm and leave the vise management.
The chuck device selection was confirmed with . If you want to change the clamping re-enter into the dialog with to or .
The cubic blank is now lying on the vise body. For the troughpassing holes we select a clamping height of 15 mm.
Press F1 change the blank position inside the vise. You are now able move the blank with the cursor keys in Z and X axes directions , ,. , . From the lower position we move the blank with in 15 increments.
Press to accept the clamping depth
The vise can be moved in the center of the machine table.
Press and to move the vise with blank with the cursor keys in the X and Y axes directions. You are now able to move the blank with the cursor keys in X and Z axes directions and , and .
• Housing of the machine • Travel-range in X and Y axes • Machine table
• Machine zero point
Press to confirm the clamping and leave the clamping menu.
7.1. Assigning tools to tool stations in the magazine
The tool magazine currently installed has 24 tool positions (“stations”). (You can change this in the configuration settings). Use the mouse pointer to select the tool magazine position. The tool in this position is shown in the centre of the screen. Press for additional information on the tool. To remove a tool from the tool magazine, press or click on <Delete tool>.
You will have to mount the tools on the tool magazine to comply with your production sheet. T01 SLOT MILLING TOOL MS-12.0/0573L 030 ISO 1641
Select position T01 and then open the tool library. Use the cursor to select the tooltype <Slot milling tool> and click left (2x) on use the tools bar button .
Select the tool type selection
Select the tool type <Slot milling tool>
Use the tools bar button Use the mouse <MS-12.0/057L 030 ISO 1641 to locate the tool called >. Select it and confirm by pressing . This tool is now mounted on tool magazine position T01.
In the two preceding steps, you have replaced a tool in the tool magazine. To locate this tool, you have searched through a tool type for a tool with a specific name.
We will now show you an alternative method, using the tool set-up for position T02 as an example. We need a slot milling tool with diameter 20 mm and with a length of minimum 75 mm.
Thus, the first step is to search for all tools with a diameter of 20 mm.
Select position T02. With double click to open tool list or use the tools bar button
With we select the diameter of the tool. The tool will be then arranged after the diameter
All slot milling tools of diameter 20 mm are grouped
together in the list field. The tool length is indicated in row . We select the right tool length and confirm by pressing . This tool is now mounted on tool magazine position T02.
The selected tool <MS-20.0/075L 030 ISO 1641> on
tool magazine position T02 will be displayed. You can remove unnecessary tools from the tool magazine. Select the tool position with and open the context menu with .The context menu contains several functions like change tool, delete tool and also how to enter the tool management system.
or use the tools bar button
We have now shown you two different ways of selecting tools and mounting them on the tool magazine. You can now mount the other tools of your setup sheet on your own.
Tool table synopsis
T01 SLOT MILLING TOOL MS-12.0/053L 030 ISO 1641 T02 SLOT MILLING TOOL MS-20.0/075L 030 ISO 1641 T03 SLOT MILLING TOOL MS-16.0/067L 030 ISO 1641 T04
T05 STEP DRILL DS-08.0/04.3-090 030 ISO 3439
T06 REAMER RE-D28.0/H7 HSS ISO 521
T09 T-SLOT MILL ST-12.5/06.0 076 ISO 3337
T10 T-SLOT MILL ST-22.0/10.0 030 ISO 3337
T11 SHELL END MILL MW-063/040 030 ISO 2586
T12 CORNER TOOL TYPE B CB-25/06.3/45 HSS ISO 3859
The tool for position T04, a slot milling tool of type <MS-08.6/065L 030 ISO 1641> is currently not available in the library. By activating the tool management we create a new tool with the respective tool data.
The tool management enables you to create new tool data in the individual tooltypes as well as to edit or delete existing tool data.
Select position T04 and open the tool management
menu and select administration. Click to open the tool type list. Select with the Slot milling tool type.
Since a large amount of data is required, it is helpful to select an existing, similar tool to use as a template. With mark the selected tool
< MS-08.0 047L HSS ISO 1641>
Open with right mouse click a context menu. Select <Edit> to modify the selected tool data.
A new tool name is entered:
Write <MS-08.6 065L 030 ISO 1641 in the marked field.
The new tool records can be changed in the corresponding parameters.
Select the input field.
Give the following values:
After all records are entered you can generate the tool. Comfirm with . The new tool is registered in the tool management under tool type “slot milling tool”. You come back to the list overview of the tool type.
Leave tool management .
The new tool can now be mounted on tool magazine position 04.
Assign the tool to the tool magazine position.
After all selected tools are assigned leave the tool management with .
In the main menu, press to call up the setup form menu.
Press to generate a new setup sheet. Enter a program name, e.g. <%30>, click on windows „Save“ to quit.
Confirm the query by pressing or , then press to come back to the main menu. The setup sheet has been created as header of the program <%30>.
Call up the NC editor and open the new NC program.
Press if you wish to exit the NC editor.
The newly created setup sheet includes as comments of the NC program all setting up data entered before as header of an empty NC program consisting only of block M30.
The next chapter will outline one of the methods for creating NC programs.
8.0. NC
Programming
(MTS Programming key)
This chapter describes how the editor can be used in combination with interactive programming and dialog programming as an NC programing method.
The origin of workpart G54 was set in the center of the surface.
Using the NC editor, delete the M30 command at the end of the setup form section by positioning the cursor on [M] and pressing .
The beginning of the NC program will be written. Exit the editor with and change over to interactive programming mode, a second optional method of generating NC programs with the simulator.
Each NC command block is run individually and accepted by . Starting with block number 30 new NC blocks will be added.
N0010 G90 (WINDOW L1000 N0012 G54 X+247.000 Y+150.000 Z+135.000 N0014 G00 X+140.000 Y+000.000 N0016 Z+100.000 N0018 T1111 M06 N0020 G94 F0300.000 N0022 S0980 M03 N0024 G00 X+120.000 Y+000.000 N0026 G00 Z-012.000 N0028 G01 X+114.000 M08
8.1. Milling a pin
There are different possibilities to program a pin. We decide to mill the pin without cutter radius compensation. The pin must be programmed with one circular interpolation mill radius + pin radius. The total depth is reached in three feed passes, two of 12 mm and the last of 10 mm.
We use select command and with we enter machining and confirm with
To terminate the parameter input for the coordinate values of circular interpolation click on
The circular interpolation G03 will be done for 3 different down-feeds. N0030 G03 X+114.000 Y+000.000 I-054.000 I+000.000
F275.000 N0032 G01 X+120.000 N0034 G01 Z-024.000 N0036 G01 X+114.000 F0300.000 N0038 G03 X+114.000 Y+000.000 I-054.000 J+000.000 N0040 G01 X+120.000 N0042 G00 Z-034.000 N0044 G01 X+114.000 N0046 G03 X+114.000 Y+000.000 I-054.000 J+000.000 N0048 G01 X+120.000 N0050 G00 Z+005.000
The commands M81 to M86 serve to mirror drilling patterns, contours about an axis. The command
G23 O...<Start-NC-Block Number> Q...<End-NC–Block Number> causes a program part repetition. Both features we use to program the left pin.
M81 Mirroring the X-coordinates about the Y-axis M82 Mirroring the Y-coordinates about the X-axis M83 Inverting the signs of the Z-coordinate values
M84 Mirroring about both the X- and Y-axes (point mirroring at origin)
M85 Mirroring about the Y-axis and inverting the signs of the Z-coordinate values M86 Mirroring about the X-axis and inverting the signs of the Z-coordinate values M80 cancel mirroring
Press F6 to start dialog programming, then select program part repetition and parameter input display.
Mirroring of the contour N0052 M84
N0054 G23 O0024 Q0050
N0056 M80 Note:
If renumbering the program you have to adjust the start O... and end block numbers Q... in the program part repetition.
Move to he tool change position N0058 G00 Z+100.000 N0060 G00 X+140.000 Y+000.000 N0062 T0202 M06 N0064 G94 F0480.000 N0066 S2300 M03 Note:
When changing a tool the CNC simulator in its standard configuration moves automatically to a configured Z position where the tool change is executed. Here we add an additional movement to the coordinates X140, Y0 in order to allow a manual tool change (run in Z to 100 and then on the side X140, Y0).
Attention: collision of the clamping device ! N0068 G00 X+075.000 Y+055.000 N0070 G00 Z-045.000 M08 N0072 G01 X+100.000 Y+030.000 N0074 G00 Y-030.000 N0076 G01 X+075.000 Y-055.000 N0078 G00 Z-025.000 N0080 G00 X-075.000 N0082 G00 Z-045.000 N0084 G01 X-100.000 Y-030.000 N0086 G00 Y+030.000 N0088 G01 X-075.000 Y+055.000 N0090 G00 Z-025.000 N0092 G00 X+075.000 N0094 G00 Z-062.000 N0096 G23 O0072 Q0080 N0098 Z-062.000 N0100 G23 O0084 Q0094
N0096 G23 O0072 Q0080 branch mark on NC block number N0072 process NC-Code until block number N0080.
The contours of the workpart base-plate are provided with graphical contour editor (WOP: Workshop-oriented programming).
8.2. Graphical contour editor (WOP)
The in-feed when machining contours (finishing) requires specific movements to access and leave the programmed contours. We use contour with milling tool radius compensation as well as program straight line repetition with approach and exit conditions: G41/G45 G71,G72, G73, G01, G00, G23
Remark on the programmed workpart contour:
The following must be observed when programming the external contour of the workpart:
In the vicinity of the horizontal jaw holding the workpart, the contour corresponds to that of the raw part. The contour cannot be followed in this area because the jaws are in contact with the workpart; the tool must be moved up and kept clear when passing here. The clearance motion is achieved by adding the quadrant points P1, P5, P8 and P12 as auxiliary points.
The external contour of the workpart should be followed in down cut milling with the tool radius compensation, whereby the Z-motions for approaching, in-feed and leaving the workpart are inserted within the compensated contour.
Here, the following special characteristic of milling tool radius compensation with Z-in-feed must be observed: When the compensated contour is being calculated, the compensation function inserts additional motions into the compensated contour at the external corners in order to move the tool around the respective corner. In most types of controls these additional motions comprise a circular arc centered on the external corner – as is also implemented in MTS controls. In some control models, however, an external corner is created with the tool travelling past the corner tangentially by a distance greater than or equal to the milling tool radius, followed by a linear movement to the corresponding tangential approach travel to the contour element connecting to the external corner, or, in the case of corner angles equal to or greater than 90°, the tool is moved towards the intersection along this approach path.
If a permitted in-feed motion in Z-direction which does not change the compensated contour is carried out at an external corner of this type, the following question arises:
Is the in-feed motion carried out before or after the circular arc inserted by the milling tool compensation function?
As in most CNC controls, this in-feed motion is carried out before the additional motions.
If this rule is applied to our programming example task, carrying out the Z-direction in-feed before the compensation arc motion towards point P8 would lead to a collision with the vice jaws. For this reason, the auxiliary point P7 must be added to the contour to prevent the Z-in-feed at P8 causing a collision. To make the programmed coordinates easier to understand, a point P6 located symmetrically to the Y-axis is also added. The compensation is activated at point P0 and de-activated when leaving point P12 to access P13.
After the tool change, the new tool T0202, a slot-milling tool, is moved to position P0.
Using the graphical contour editor for programming (WOP), we shall describe the following contour passing through points P0 to P13. This will introduce you to the essential functions of WOP.
Please note:
Due to the workpart clamping position, care must be taken to avoid collisions between the tool and the vice jaws during approach and leaving motions.
There are several methods of creating contours with WOP, one of these is described below.
The contour description starts at point PS (top left) on the arc of radius R1 centered on P2. However, this point is not annotated on the drawing. We therefore have to divide a circle of radius R12 centered on P2 into 4 equal quadrants. In this way, the coordinates of the auxiliary point (P1) are determined as being X=42,0 und Y=54,0 and these can then be inserted into the contour description
The approach instructions for point (P1) are entered via the dialog programming function.
N0102 G00 X+048.000 Y+055.000 (P0)
N0104 G00 Z-045.000 M08
Press to call up the graphical contour editing mode. The blue cross shows the programmed actual workpart position (P1) which has not yet been accessed due to the tool compensation calculations. Press to call up the geometry input selection menu.
The first step is to enter the center (P2) of the counterclockwise arc of radius R12. Use the “Arc counterclockwise “ function (G73) to select the corresponding menu
Command: G73 <Arc counterclockwise>
Next, the absolute coordinates of the center of the arc, (P2), must be entered:
Input I + 054.000 J + 043.200
It is not necessary to calculate the radius, since this is calculated automatically on the basis of the starting coordinates.
The arc, which has no defined end point, is initially drawn as a full circle.
Now conclude the input by pressing , because the end point of the arc is not given in the drawing.
Note that tangential transitions are now also permitted after the first contour element has been input.
Command: G71 <Tangential straight line>
In the drawing, the counter-clockwise arc connects to a tangential straight line of undefined length.
Therefore an undefined straight line with a tangential transition is selected.
It is not possible to enter any other values, as there are no corresponding dimensions in the drawing.
No input is required here.
As the position of this straight line of the contour is not yet defined, only tangential transitions can be entered for the following entries.
Command: G72 <Tangential arc clockwise>
Next, the absolute coordinates of the center (P3) of the clockwise arc of radius R26 must be entered.
Input: I + 060.000
J + 000.000
B + 026.000
Now the straight line between the arcs is uniquely identified by reference to the two circles now displayed and is shown in the graphic display. The end of the second arc is not defined in the drawing, so that its coordinates cannot be entered.
Confirm and conclude your entries by pressing the key.
Command: G71 <Tangential straight line>
Here, again, a tangential connecting straight line of undefined length must be specified.
It is not possible to enter any other values, as there are no corresponding dimensions in the drawing.
No input is required here.
Command: G73 <Tangential arc
counter-clockwise >
The absolute coordinates of the end point (P5) and the center (P4) of the counterclockwise, tangentially connected arc of radius R12 are entered.
The position of the end point (P5) is calculated by dividing the corresponding circle into quadrants Input: Xe + 042.000
Ye - 043.200
Input: I + 054.000 J - 043.200
Confirm your entries by pressing the key.
Change over to the following menu by selecting function key “DIN” : G00, G01,G02, G03
Command: G00 <Linear rapid traverse> To keep the tool free of the workpart, a rapid linear
traverse to point (P6) is carried out.
Input: Ye - 048.000
Confirm your entries by pressing the key. Press to call up the next rapid traverse set.
Command: G00 <Linear rapid traverse> To prevent a collision with the jaws when approaching
(P7), we start a rapid traverse to the return position Z-30, which is above the clamping jaw.
Input: Ze - 030.000
Confirm your entries by pressing the key. Press to call up the next rapid traverse set.
Command: G00 <Linear rapid traverse> The tool is then moved across the jaw in a rapid traverse
to point (P7).
Input: Xe - 042.000
Confirm your entries by pressing the key. Press to call up the next rapid traverse set.
Command: G00 <Linear rapid traverse>
The appropriate quadrant end point is used as starting point of the counter-clockwise arc of radius R12 centered on (P9).
This point (P8) is approached by a rapid traverse. Input: Xe - 042.000
Ye - 043.200
Confirm your entries by pressing the key. Press to call up the next rapid traverse set.
Command: G01 <Linear milling traverse>
Here, the tool depth is set to Z-45 while it is still outside of the workpart.
Input: Ze - 045.000
Confirm your entries by pressing the key Press to call up the next rapid traverse set.
Command: G73 <Arc counter-clockwise>
The absolute coordinates I… J… for the center (P9) of the counter-clockwise arc of radius R12 are entered. Input: I - 054.000
J - 043.200
Confirm your entries by pressing the key.
Command: G71 <Tangential straight line>
Here, again, a tangential connecting straight line of undefined length must be specified.
Command: G72 <Tangential arc clockwise>
Next, the absolute coordinates of the center (P10) of the clockwise arc of radius R26 must be entered.
The hitherto undefined straight line joining this arc tangentially with its given orientation has now been uniquely defined.
Input: I - 060.000
J + 000.000
B + 026.000
Confirm your entries by pressing the key.
Command: G71 <Tangential straight line>
Here, again, a tangential connecting straight line of undefined length must be specified.
Command: G73 <Tangential arc
counter-clockwise >
The absolute coordinates of the end point (P12) and the center (P11) of the counterclockwise, tangentially connected arc of radius R12 are entered.
Input: Xe - 042.000
Ye + 043.200
Input: I - 054.000
J + 043.200
Confirm your entries by pressing the key.
Change over to the following menu: G00, G01,G02, G03
Command: G00 <Linear rapid traverse
Specify point (P13). Input: Ye + 048.000
Command: G00 <Linear rapid traverse>
In order to prevent a collision with the jaws, a rapid traverse to (P13) is made, i. e. to position Z-30. Input: Ze - 030.000
Confirm your entries by pressing the key.
Command: G00 <Linear rapid traverse>
The tool is then moved across the jaw in a rapid traverse to point (P0).
Input: Xe + 042.000
Confirm your entries by pressing the key.
Command: G01 <Linear milling traverse> Now the starting point (P1) is approached by a rapid
traverse.
Input: Xe + 042.000
Ye + 043.200
Command: G01 <Linear milling traverse>
Now the depth Z – 62 of the second contour-milling run is entered.
Input: Ze - 062.000
Confirm your entries by pressing the key. The contour is defined by the geometry and can be saved by pressing key .
Exit the WOP by pressing the key.
You have now been shown some of the basic functions of contour programming with the graphical user interface (WOP). The contour was described in a simple geometrical manner. At the same time, an NC program was generated in background.
The next step is to program two sub-program repetitions with the second in-feed depth. After that, the contour is completed before being processed by the CNC simulator.
Note: If the tool radius compensation is activated, the control must read in a certain number of NC records before it is able to calculate the milling tool path. This means that the programmed NC records are processed out of step. Depending on the pre-read depth setting of the controls, the delay will amount to one or more NC traverse records.
It is advisable to write this part of the NC program with WOP and then to simulate it.
An alternative would be to work without tool radius compensation when interactively writing the program and then to activate the compensation function in a second program run.
Processing the contour by repeating subprograms
Press to call up the NC editor. The straight line of our NC program generated by WOP is already
inserted. The milling straight line must be
supplemented by a repetition of the subprogram and the de-activating of tool radius compensation
Individual milling work straight lines are repeated with the aid of subprogram repetition <G23> (dialog programming). Press to change back to interactive programming and then simulate the program right up to NC record N0122
N0106 G41 X+042.000 Y+043.200 G45 A+007.000 G01 N0108 G73 I+054.000 J+043.200 O0070 N0110 G71 O0000 N0112 G72 I+060.000 J+000.000 O0070 B+026.000 O0000 N0114 G71 O0000 N0116 G73 X+042.000 Y-043.200 I+054.000 J-043.200 O0070 O0000 N0118 G00 Y-048.000 N0120 G00 Z-030.000 N0122 G00 X-042.000 N0124 G00 X-042.000 Y-043.200 N0126 G01 Z-045.000 N0128 G73 I-054.000 J-043.200 O0070 N0130 G71 O0000
N0132 G72 I-060.000 J+000.000 O0070 B+026.000 O0000 N0134 G71 O0000 N0136 G73 X-042.000 Y+043.200 I-054.000 J+043.200 O0070 O0000 N0138 G00 Y+048.000 N0140 G00 Z-030.000 N0142 G00 X+042.000 N0144 G01 X+042.000 Y+043.200 N0146 G01 Z-062.000 N0148 G23 O0108 Q0124 N0150 G01 Z-062.000 N0152 G23 O0128 Q0144 N0154 G40 G46 A+002.000 N0156 G00 Z+005.000
8.3. Milling circular pockets
Command: G88 Dialog programming: circular pocket
N0158 G94 F0400.000 N0160 S2300 M03 N0162 G88 Z-066.000 B+013.920 I+050.000 K-010.000 V+002.000 H+020.000 N0164 G79 X+060.000 Y+000.000 Z+000.000 N0166 G79 X-060.000 Y+000.000 Z+000.000
By means of the command G79 X.. Y.. a cycle is called up to one milling position or here in the 2 positions X60, Y0 und X-60, Y0.
8.4. Contour and guide-way milling
Commands: G42/G46, G71, G40, G01 N0168 T0101 M06 N0170 G94 F0380.000 N0172 S3800 M03 N0174 G00 Z+050.000 N0176 G42 X-010.000 Y-046.000 Z-042.000 G46 A+010.000 G00 N0178 G01 X-010.000 Y-034.000 N0180 G01 X+020.000 Y-034.000 R+012.000 N0182 G01 X+020.000 Y+034.000 R+012.000 N0184 G01 X-020.000 Y+034.000 R+012.000 N0186 G01 X-020.000 Y-034.000 R+012.000 N0188 G71 X+010.000 Y-034.000 N0190 G40 G46 A+010.000 N0192 G01 X-029.000 N0194 G01 Y+048.000 N0196 G00 X+029.000 N0198 G01 Y-048.0008.5. Rectangular and circular pockets
Commands: G87, G79, G88, G79 N0200 T0303 M06 N0202 G94 F0430.000 N0204 S2900 M03 N0206 G00 Z+050.000 N0208 G87 X+032.000 Y+060.000 Z-020.000 I+050.000 K+005.000 V+002.000 H+020.000 B+008.000 N0210 G79 X+000.000 Y+000.000 N0212 G88 Z-014.000 B+014.000 I+060.000 K+006.000 V+002.000 H+020.000N0214 G79 Z-052.000 (Call up on the same position)
8.6. Linear drill pattern
Use the dialog programming or help functions for drill programming. Commands: G81, G78 N0216 T0505 M06 N0218 G94 F0430.000 N0220 S1590 M03 N0222 G00 Z+050.000 N0224 G81 Z-036.292 V+002.000 H+020.000 N0226 G78 X-027.000 Y-030.000 A+090.000 D+015.000 S0005 N0228 G78 X+027.000 Y+030.000 Z-032.000 A+090.000 D-015.000 S0005
