TABLE OF CONTENTS 1 - NUMERICAL CONTROL

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DEFINITION OF NUMERICAL CONTROL NC and CNC Technology

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CONVENTIONAL AND CNC MACHINING . NUMERICAL CONTROL ADVANTAGES . Setup Time Reduction . . . . . . Lead Time Reduction . . . . . . . Accuracy and Repeatability . . . . Contouring of Complex Shapes . . . Simplified Tooling and Work Holding . Cutting Time and Productivity Increase

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TYPES OF CNC MACHINE TOOLS .

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3 3 3 3 3 4

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Mills and Machining Centers . . . . . . . . . . . . 4 Lathes and Turning Centers . . . . . . . . . . . . 5

PERSONNEL FOR CNC .

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CNC Programmer . . . . . . . . . . . . . . . . 5 CNC Machine Operator . . . . . . . . . . . . . . 6

SAFETY RELATED TO CNC WORK .

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2 - CNC MILLING

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CNC MACHINES - MILLING .

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Types of Milling Machines . . . . . . . . . . . . . 7 Machine Axes . . . . . . . . . . . . . . . . . . 8 Vertical Machining Centers. . . . . . . . . . . . . 8 Horizontal Machining Centers . . . . . . . . . . . 9 Horizontal Boring Mill . . . . . . . . . . . . . . 10 Typical Specifications . . . . . . . . . . . . . . 10

3 - CNC TURNING

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CNC MACHINES - TURNING .

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Types of CNC Lathes . . . . . . . . . . . . . . 11 Number of Axes . . . . . . . . . . . . . . . . 11

AXES DESIGNATION . Two-axis Lathe . Three-axis Lathe Four-axis Lathe . Six-axis Lathe .

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FEATURES AND SPECIFICATIONS

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12 12 13 13

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Typical Machine Specifications . . . . . . . . . . 13 Control Features . . . . . . . . . . . . . . . . 14

4 - COORDINATE GEOMETRY REAL NUMBER SYSTEM . . . . . RECTANGULAR COORDINATE SYSTEM .

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Axes and Planes . . . . . . Point of Origin . . . . . . . Quadrants . . . . . . . . . Right Hand Coordinate System

MACHINE GEOMETRY

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Axis Orientation - Milling . . . . . . . . . . . . . 17 Axis Orientation - Turning . . . . . . . . . . . . . 18 Additional Axes. . . . . . . . . . . . . . . . . 18

5 - CONTROL SYSTEM GENERAL DESCRIPTION .

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Operation Panel . . . . . . . . . . . . . . . . 20 Screen Display and Keyboard . . . . . . . . . . . 21 Handle . . . . . . . . . . . . . . . . . . . . 22

SYSTEM FEATURES .

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Parameter Settings . . . . . . . . . . . . . . . 22 System Defaults . . . . . . . . . . . . . . . . 23 Memory Capacity . . . . . . . . . . . . . . . . 24

MANUAL PROGRAM INTERRUPTION.

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Single Block Operation . . . . . . . . . . . . . . 25 Feedhold . . . . . . . . . . . . . . . . . . . 25 Emergency Stop . . . . . . . . . . . . . . . . 25

MANUAL DATA INPUT - MDI . PROGRAM DATA OVERRIDE . Rapid Motion Override . Spindle Speed Override Feedrate Override . . . Dry Run Operation . . Z Axis Neglect . . . . Manual Absolute Setting Sequence Return . . . Auxiliary Functions Lock Machine Lock . . . . Practical Applications .

SYSTEM OPTIONS

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Graphic Display. . . . . . . In-Process Gauging . . . . . Stored Stroke Limits . . . . . Drawing Dimensions Input . . Machining Cycles . . . . . . Cutting Tool Animation . . . . Connection to External Devices

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26 27 27 27 28 28 28 28 28 29

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6 - PROGRAM PLANNING STEPS IN PROGRAM PLANNING . INITIAL INFORMATION . . . MACHINE TOOLS FEATURES . .

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29 30 30 30 30 30 30

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31 31 31

Machine Type and Size . . . . . . . . . . . . . . 31

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Table of Contents Control System . . . . . . . . . . . . . . . . . 31

PART COMPLEXITY . . MANUAL PROGRAMMING

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Disadvantages . . . . . . . . . . . . . . . . . 32 Advantages . . . . . . . . . . . . . . . . . . 32

CAD/CAM AND CNC .

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Integration . . . . . . . . . . . . . . . . . . 33 Future of Manual Programming . . . . . . . . . . 33

TYPICAL PROGRAMMING PROCEDURE . PART DRAWING . . . . . . . Title Block . . . . Dimensioning . . Tolerances. . . . Surface Finish . . Drawing Revisions Special Instructions

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METHODS SHEET . . . . MATERIAL SPECIFICATIONS .

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Material Uniformity . . . . . . . . . . . . . . . 36 Machinability Rating . . . . . . . . . . . . . . . 37

MACHINING SEQUENCE . TOOLING SELECTION . . PART SETUP . . . .

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37 38 38

Setup Sheet . . . . . . . . . . . . . . . . . . 38

TECHNOLOGICAL DECISIONS

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Cutter Path . . . . . . . . . . . . . . . . . . 38 Machine Power Rating . . . . . . . . . . . . . . 39 Coolants and Lubricants . . . . . . . . . . . . . 39

WORK SKETCH AND CALCULATIONS

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Identification Methods . . . . . . . . . . . . . . 40

QUALITY IN CNC PROGRAMMING

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7 - PART PROGRAM STRUCTURE BASIC PROGRAMMING TERMS . Character Word . . Block . . Program

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PROGRAMMING FORMATS . WORD ADDRESS FORMAT .

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FORMAT NOTATION .

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Short Forms . . . . . . Milling System Format . . Turning System Format. . Multiple Word Addresses .

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SYMBOLS IN PROGRAMMING

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Plus and Minus Sign . . . . . . . . . . . . . . . 45

PROGRAM HEADER . . . . TYPICAL PROGRAM STRUCTURE

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8 - PREPARATORY COMMANDS DESCRIPTION AND PURPOSE . APPLICATIONS FOR MILLING . . APPLICATIONS FOR TURNING . G CODES IN A PROGRAM BLOCK

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Modality of G-commands . . . . . . . . . . . . . 50 Conflicting Commands in a Block . . . . . . . . . 50 Word Order in a Block . . . . . . . . . . . . . . 51

GROUPING OF COMMANDS .

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Group Numbers . . . . . . . . . . . . . . . . 51

G CODE TYPES

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G Codes and Decimal Point . . . . . . . . . . . . 52

9 - MISCELLANEOUS FUNCTIONS DESCRIPTION AND PURPOSE

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Machine Related Functions . . . . . . . . . . . . 53 Program Related Functions . . . . . . . . . . . . 53

TYPICAL APPLICATIONS . Applications for Milling. Applications for Turning Special MDI Functions . Application Groups . .

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M FUNCTIONS IN A BLOCK

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Startup of M Functions . . . . . . . . . . . . . . 56 Duration of M Functions . . . . . . . . . . . . . 56

PROGRAM FUNCTIONS Program Stop . . . . Optional Program Stop . Program End . . . . . Subprogram End . . .

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MACHINE FUNCTIONS Coolant Functions . Spindle Functions . . Gear Range Selection Machine Accessories

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10 - SEQUENCE BLOCK BLOCK STRUCTURE

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Building the Block Structure. . . . . . . . . . . . 61 Block Structure for Milling . . . . . . . . . . . . 61

PROGRAM IDENTIFICATION .

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Program Number . . . . . . . . . . . . . . . . 62 Program Name . . . . . . . . . . . . . . . . . 62

SEQUENCE NUMBERS

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Sequence Number Command . . . Sequence Block Format . . . . . Numbering Increment . . . . . . Long Programs and Block Numbers.

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END OF BLOCK CHARACTER . . STARTUP BLOCK OR SAFE BLOCK

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Table of Contents PROGRAM COMMENTS . . . CONFLICTING WORDS IN A BLOCK MODAL PROGRAMMING VALUES EXECUTION PRIORITY. . . .

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66 66 67 68

Exact Stop Command . . . Exact Stop Mode Command Automatic Corner Override . Tapping Mode . . . . . . Cutting Mode . . . . . .

CONSTANT FEEDRATE

11 - INPUT OF DIMENSIONS ENGLISH AND METRIC UNITS

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Comparable Unit Values . . . . . . . . . . . . . 70

ABSOLUTE AND INCREMENTAL MODES Preparatory Commands G90 and G91 . Absolute Data Input - G90 . . . . . Incremental Data Input - G91 . . . . Combinations in a Single Block . . .

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DIAMETER PROGRAMMING . . . MINIMUM MOTION INCREMENT . . FORMAT OF DIMENSIONAL INPUT . Full Address Format . . . . Zero Suppression . . . . . Decimal Point Programming. Input Comparison . . . . .

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CALCULATOR TYPE INPUT

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Direction for Milling . . Direction for Turning . . Direction Specification . Spindle Startup . . . .

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SPINDLE STOP. . . . SPINDLE ORIENTATION . SPINDLE SPEED - R/MIN . SPINDLE SPEED - SURFACE

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78 78 79 79

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Material Machinability . . . . . . . . . . . . . . 81 Spindle Speed - English Units . . . . . . . . . . . 82 Spindle Speed - Metric Units . . . . . . . . . . . 82

CONSTANT SURFACE SPEED.

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MAXIMUM FEEDRATE

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Maximum Spindle Speed Setting . . . . . . . . . . 84 Part Diameter Calculation in CSS . . . . . . . . . . 85 CSS Calculation . . . . . . . . . . . . . . . . 86

FEEDRATE CONTROL . FEEDRATE FUNCTION.

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Feedrate per Minute . . . . . . . . . . . . . . . 87 Feedrate per Revolution . . . . . . . . . . . . . 88

FEEDRATE SELECTION . . . . ACCELERATION AND DECELERATION

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FEEDHOLD AND OVERRIDE .

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Feedhold Switch . . . . . . . . . . . . . . . . 91 Feedrate Override Switch . . . . . . . . . . . . . 91 Feedrate Override Functions . . . . . . . . . . . 92

E ADDRESS IN THREADING .

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T FUNCTION FOR MACHINING CENTERS . . . . . .

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TOOL CHANGE FUNCTION - M06 .

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Conditions for Tool Change . . . . . . . . . . . . 95

AUTOMATIC TOOL CHANGER - ATC . Typical ATC System . . Maximum Tool Diameter Maximum Tool Length . Maximum Tool Weight . ATC Cycle . . . . . . MDI Operation . . . .

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PROGRAMMING THE ATC

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96 97 97 97 98 98

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Single Tool Work . . . . . . . . . . . . . . . . 98 Programming Several Tools . . . . . . . . . . . . 99 Keeping Track of Tools . . . . . . . . . . . . . . 99 Any Tool in Spindle - Not the First . . . . . . . . . 99 First Tool in the Spindle . . . . . . . . . . . . . 100 No Tool in the Spindle. . . . . . . . . . . . . . 101 First Tool in the Spindle with Manual Change . . . . 101 No Tool in the Spindle with Manual Change . . . . . 102 First Tool in the Spindle and an Oversize Tool . . . . 102 No Tool in the Spindle and an Oversize Tool . . . . . 102

T FUNCTION FOR LATHES .

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Lathe Tool Station . . . . . . . . . . . . . . . 103 Tool Indexing . . . . . . . . . . . . . . . . . 103

TOOL OFFSET REGISTERS .

13 - FEEDRATE CONTROL

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Maximum Feedrate Considerations . . . . . . . . . 91

Tool Storage Magazine . . . . Fixed Tool Selection . . . . . Random Memory Tool Selection Registering Tool Numbers . . Programming Format . . . . Empty Tool or Dummy Tool . .

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Spindle Speed Input . . . . . . . . . . . . . . . 77

DIRECTION OF SPINDLE ROTATION .

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Circular Motion Feedrates

14 - TOOL FUNCTION

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12 - SPINDLE CONTROL SPINDLE FUNCTION .

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Geometry Offset. . . . Wear Offset . . . . . Wear Offset Adjustment. The R and T Settings . .

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15 - REFERENCE POINTS REFERENCE POINT GROUPS

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104 105 106 106

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Table of Contents

Reference Point Groups Relationship. . . . . . . . 108

MACHINE REFERENCE POINT

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Return to Machine Zero . . . . . . . . . . . . . 109

PART REFERENCE POINT

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Program Zero Selection . . . . . . . . . . . . . 109 Program Zero - Machining Centers . . . . . . . . 110 Program Zero - Lathes . . . . . . . . . . . . . 112

TOOL REFERENCE POINT

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16 - REGISTER COMMANDS POSITION REGISTER COMMAND

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Position Register Definition . . . . . . . . . . . 113 Programming Format . . . . . . . . . . . . . . 113 Tool Position Setting . . . . . . . . . . . . . . 114

MACHINING CENTERS APPLICATION . Tool Set at Machine Zero . . . . Tool Set Away from Machine Zero . Position Register in Z Axis . . . . Programming Example . . . . .

LATHE APPLICATION Tool Setup . . . . . . Three-Tool Setup Groups Center Line Tools Setup . External Tools Setup . . Internal Tool Setup . . . Corner Tip Detail. . . . Programming Example .

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17 - POSITION COMPENSATION DESCRIPTION

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Programming Commands . . . . . . Programming Format . . . . . . . . Incremental Mode . . . . . . . . . Motion Length Calculation . . . . . . Position Compensation Along the Z axis Using G47 and G48 . . . . . . . . Face Milling. . . . . . . . . . . .

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116 116 116 117 117 117 117

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18 - WORK OFFSETS

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WORK AREAS AVAILABLE .

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Additional Work Offsets . . . . . . . . . . . . . 124

WORK OFFSET DEFAULT AND STARTUP .

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Work Offset Change . . . . . . . . . . . . . . 125 Z Axis Application . . . . . . . . . . . . . . . 126

HORIZONTAL MACHINE APPLICATION . EXTERNAL WORK OFFSETS. . . . LATHE APPLICATIONS . . . . . Types of Offsets . . . . Geometry Offset. . . . Wear Offset . . . . . Tool and Offset Numbers

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127 128 128 . . . .

128 128 129 129

TOOL SETUP .

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Center Line Tools . . . . . . . . Turning Tools . . . . . . . . . . Boring Tools . . . . . . . . . . Command Point and Tool Work Offset

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19 - TOOL LENGTH OFFSET GENERAL PRINCIPLES

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129 130 130 130

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Actual Tool Length . . . . . . . . . . . . . . . 131 Gauge Line . . . . . . . . . . . . . . . . . . 131 Table Top Face . . . . . . . . . . . . . . . . 132

TOOL LENGTH OFFSET COMMANDS

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Distance-To-Go in Z Axis . . . . . . . . . . . . . 132

TOOL LENGTH SETUP

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On-Machine Tool Length Setting . . . . . . . . . 133 Off-Machine Tool Length Setting . . . . . . . . . 134 Tool Length Offset Value Register . . . . . . . . . 134

Z AXIS RELATIONSHIPS . Preset Tool Length . . . . Tool Length by Touch Off . Using a Master Tool Length G43-G44 Difference . . .

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Tool Length Offset not Available . . Tool Length Offset and G92 . . . . Tool Length Offset and G54-G59 . . Tool Length Offset and Multiple Tools

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PROGRAMMING FORMATS .

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CHANGING TOOL LENGTH OFFSET. . HORIZONTAL MACHINE APPLICATION . TOOL LENGTH OFFSET CANCEL . .

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20 - RAPID POSITIONING RAPID TRAVERSE MOTION .

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G00 Command . . . . . . . . . . . . . . . . 143

RAPID MOTION TOOL PATH. Single Axis Motion . . . Multiaxis Motion . . . . Straight Angular Motion . Reverse Rapid Motion .

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TYPE OF MOTION & TIME COMPARISON REDUCTION OF RAPID MOTION RATE . RAPID MOTION FORMULAS . . . . APPROACH TO THE PART . . . .

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Machining Centers . . . Lathes . . . . . . . . Setting the Machine Axes Program Commands . . Command Group . . .

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21 - MACHINE ZERO RETURN MACHINE REFERENCE POSITION

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149 150 150 151 151

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Table of Contents RETURN TO PRIMARY MACHINE ZERO . Intermediate Point . . . . . . Absolute and Incremental Mode Return from the Z Depth Position Axes Return Required for the ATC Zero Return for CNC Lathes . .

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RETURN POSITION CHECK COMMAND. . RETURN FROM MACHINE ZERO POINT. . RETURN TO SECONDARY MACHINE ZERO.

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22 - LINEAR INTERPOLATION LINEAR COMMAND .

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Start and End of the Linear Motion Single Axis Linear Interpolation . . Two Axes Linear Interpolation . . Three Axis Linear Interpolation . .

PROGRAMMING FORMAT LINEAR FEEDRATE . .

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151 152 153 155 155

156 157 158

159

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159 . . . .

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159 159 160 160

160 161

Feedrate Range . . . . . . . . . . . . . . . . 161 Individual Axis Feedrate . . . . . . . . . . . . . 161

PROGRAMMING EXAMPLE .

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23 - BLOCK SKIP FUNCTION

163

TYPICAL APPLICATIONS . . . . . BLOCK SKIP SYMBOL . . . . . CONTROL UNIT SETTING . . . . BLOCK SKIP AND MODAL COMMANDS PROGRAMMING EXAMPLES . . . Variable Stock Removal . . Machining Pattern Change . Trial Cut for Measuring . . Program Proving . . . . . Barfeeder Application . . . Numbered Block Skip . . .

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24 - DWELL COMMAND PROGRAMMING APPLICATIONS

162

163 163 163 164 165 . . . . . .

165 166 168 169 170 170

171 .

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171

Applications for Cutting . . . . . . . . . . . . . 171 Applications for Accessories . . . . . . . . . . . 171

DWELL COMMAND .

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171

Dwell Command Structure . . . . . . . . . . . . 172

DWELL TIME SELECTION . SETTING MODE AND DWELL

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172 173

Time Setting . . . . . . . . . . . . . . . . . 173 Number of Revolutions Setting . . . . . . . . . . 173

MINIMUM DWELL . . . NUMBER OF REVOLUTIONS

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173 174

System Setting . . . . . . . . . . . . . . . . 174 Time Equivalent . . . . . . . . . . . . . . . . 174

LONG DWELL TIME .

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175

Machine Warm-Up . . . . . . . . . . . . . . . 175 X Axis is the Dwelling Axis . . . . . . . . . . . . 176 Safety and Dwell. . . . . . . . . . . . . . . . 176

FIXED CYCLES AND DWELL .

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176

25 - FIXED CYCLES

177

POINT-TO-POINT MACHINING .

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177

Single Tool Motions vs. Fixed Cycles . . . . . . . . 178

FIXED CYCLE SELECTION . . . . PROGRAMMING FORMAT . . . . GENERAL RULES . . . . . . . ABSOLUTE AND INCREMENTAL VALUES INITIAL LEVEL SELECTION . . . . R LEVEL SELECTION . . . . . . Z DEPTH CALCULATIONS . . . . DESCRIPTION OF FIXED CYCLES . . G81 - Drilling Cycle . . . . . . . . . . . G82 - Spot-Drilling Cycle. . . . . . . . . G83 - Deep Hole Drilling Cycle - Standard . . G73 - Deep Hole Drilling Cycle - High Speed . G84 - Tapping Cycle - Standard . . . . . . G74 - Tapping Cycle - Reverse . . . . . . G85 - Boring Cycle . . . . . . . . . . . G86 - Boring Cycle . . . . . . . . . . . G87 - Backboring Cycle . . . . . . . . . G88 - Boring Cycle . . . . . . . . . . . G89 - Boring Cycle . . . . . . . . . . . G76 - Precision Boring Cycle . . . . . . .

FIXED CYCLE CANCELLATION . FIXED CYCLE REPETITION . .

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178 179 180 180 181 181 182 183 . . . . . . . . . . . .

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183 183 184 184 186 186 187 187 187 188 188 189

189 189

The L or K Address . . . . . . . . . . . . . . . 190 L0 or K0 in a Cycle . . . . . . . . . . . . . . . 190

26 - MACHINING HOLES SINGLE HOLE EVALUATION .

191

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191

Tooling Selection and Applications. . . . . . . . . 191 Program Data . . . . . . . . . . . . . . . . . 194

DRILLING OPERATIONS . Types of Drilling Operations . Types of Drills . . . . . . . Programming Considerations. Nominal Drill Diameter . . . Effective Drill Diameter . . . Drill Point Length . . . . . Center Drilling . . . . . . . Through Hole Drilling . . . . Blind Hole Drilling . . . . . Flat Bottom Drilling. . . . . Indexable Insert Drilling . . .

PECK DRILLING .

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194 . . . . . . . . . . .

194 194 195 195 195 195 196 196 197 197 198

199

Typical Peck Drilling Application . . . . . . . . . . 199 Calculating the Number of Pecks . . . . . . . . . 199

xiv

Table of Contents

Selecting the Number of Pecks . . . . . . . . . . 200 Controlling Breakthrough Depth. . . . . . . . . . 200

REAMING .

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Reamer Design . . . . . . Spindle Speeds for Reaming . Feedrates for Reaming . . . Stock Allowance . . . . . . Other Reaming Considerations

SINGLE POINT BORING .

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201 . . . . .

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201 201 201 202 202

202

Single Point Boring Tool . . . . . . . . . . . . . 202 Spindle Orientation . . . . . . . . . . . . . . . 203 Block Tools . . . . . . . . . . . . . . . . . . 203

BORING WITH A TOOL SHIFT

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Precision Boring Cycle G76 . . . . . Backboring Cycle G87 . . . . . . . Programming Example . . . . . . . Precautions in Programming and Setup.

ENLARGING HOLES .

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203 . . . .

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Tap Geometry . . . . . . Tapping Speed and Feedrate Pipe Taps . . . . . . . Tapping Check List . . . .

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HOLE OPERATIONS ON A LATHE Tool Approach Motion . . . . Tool Return Motion . . . . . . Drilling and Reaming on Lathes . Peck Drilling Cycle - G74. . . . Tapping on Lathes . . . . . . Other Operations . . . . . .

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27 - PATTERN OF HOLES

210 210 211 212 213 213 214 214 215 216

217 . . .

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217 217 218

ANGULAR ROW HOLE PATTERN

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218

Pattern Defined by Coordinates . . . . . . . . . . 218 Pattern Defined by Angle . . . . . . . . . . . . 219

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220 220

Angular Grid Pattern . . . . . . . . . . . . . . 221

ARC HOLE PATTERN . . . . BOLT HOLE CIRCLE PATTERN .

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222 223

Bolt Circle Formula . . . . . . . . . . . . . . . 224 Pattern Orientation . . . . . . . . . . . . . . . 224

POLAR COORDINATE SYSTEM .

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CUTTING CONSIDERATIONS

225

Plane Selection . . . . . . . . . . . . . . . . 226 Order of Machining . . . . . . . . . . . . . . 226

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227

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228

Angle of Entry . . . . . . . . . . . . . . . . . 229 Milling Mode . . . . . . . . . . . . . . . . . 229 Number of Cutting Inserts . . . . . . . . . . . . 230

PROGRAMMING TECHNIQUES .

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230

Single Face Mill Cut . . . . . . . . . . . . . . 231 Multiple Face Mill Cuts . . . . . . . . . . . . . 232

29 - CIRCULAR INTERPOLATION

TYPICAL HOLE PATTERNS . . RANDOM HOLE PATTERN . . STRAIGHT ROW HOLE PATTERN

CORNER PATTERN . GRID PATTERN . .

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205

212 . . . . . .

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Basic Selection Criteria . . . . . . . . . . . . . 227 Face Mill Diameter . . . . . . . . . . . . . . . 227 Insert Geometry . . . . . . . . . . . . . . . . 228

USING POSITION COMPENSATION .

207 208 209 . . . .

CUTTER SELECTION .

227

203 204 204 205

Countersinking . . . . . . . . . . . . . . . . 205 Counterboring. . . . . . . . . . . . . . . . . 206 Spotfacing . . . . . . . . . . . . . . . . . . 207

MULTILEVEL DRILLING . WEB DRILLING . . . TAPPING . . . . .

28 - FACE MILLING

ELEMENTS OF A CIRCLE.

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233

235

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235

Radius and Diameter . . . . . . . . . . . . . . 235 Circle Area and Circumference . . . . . . . . . . 236

QUADRANTS .

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236

Quadrant Points . . . . . . . . . . . . . . . . 236

PROGRAMMING FORMAT Arc Cutting Direction . . . Circular Interpolation Block Arc Start and End Points. . Arc Center and Radius . . Arc Center Vectors . . . . Arc in Planes . . . . . .

RADIUS PROGRAMMING

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237 . . . . . .

237 237 238 238 238 239

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240

Blend Radius . . . . . . . . . . . . . . . . . 240 Partial Radius . . . . . . . . . . . . . . . . . 240

FULL CIRCLE PROGRAMMING . Boss Milling . . . . . . . . . . Internal Circle Cutting - Linear Start . Internal Circle Cutting - Circular Start . Circle Cutting Cycle . . . . . . .

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ARC PROGRAMMING . . . . FEEDRATE FOR CIRCULAR MOTION

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240 . . . .

242 243 243 244

245 245

Feedrate for Outside Arcs . . . . . . . . . . . . 246 Feedrate for Inside Arcs . . . . . . . . . . . . . 246

30 - CUTTER RADIUS OFFSET MANUAL CALCULATIONS

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247 .

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247

Tool Path Center Points . . . . . . . . . . . . . 248 Cutter Radius . . . . . . . . . . . . . . . . . 249 Center Points Calculation . . . . . . . . . . . . 249

COMPENSATED CUTTER PATH .

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250

Types of Cutter Radius Offset . . . . . . . . . . 250 Definition and Applications . . . . . . . . . . . 250

PROGRAMMING TECHNIQUES .

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250

Direction of Cutting Motion . . . . . . . . . . . 251

xv

Table of Contents Left or Right - not CW or CCW Offset Commands . . . . . Radius of the Cutter . . . . History of Offset Types . . . Programming Format . . . . Address H or D ? . . . . . Geometry and Wear Offsets .

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APPLYING CUTTER RADIUS OFFSET

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251 251 252 252 253 253 254

254

Startup Methods. . . . . . . . . . . . . . . . 254 Offset Cancellation . . . . . . . . . . . . . . . 256 Cutter Direction Change . . . . . . . . . . . . . 256

HOW THE RADIUS OFFSET WORKS

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Look-Ahead Offset Type . . . . . . . . Rules for Look-Ahead Cutter Radius Offset Radius of the Cutter . . . . . . . . . Radius Offset Interference . . . . . . . Single vs. Multiaxis Startup . . . . . .

OVERVIEW OF GENERAL RULES PRACTICAL EXAMPLE - MILLING Part Tolerances . . . . . . . . Measured Part Size. . . . . . . Programmed Offsets . . . . . . D Offset Amount - General Setting Offset Adjustment . . . . . . . Offset for External Cutting . . . . Offset for Internal Cutting . . . . One Offset or Multiple Offsets?. . Preventing a Scrap . . . . . . . Program Data - Nominal or Middle?

TOOL NOSE RADIUS OFFSET Tool Nose Tip . . . . . . . . Radius Offset Commands . . . Tool Tip Orientation . . . . . Effect of Tool Nose Radius Offset Sample Program . . . . . . . Minimum Clearance Required . Change of Motion Direction . .

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257 257 258 259 260

261 262 . . . . . . . . . .

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31 - PLANE SELECTION WHAT IS A PLANE? . . MACHINING IN PLANES .

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256

262 262 263 263 264 264 265 265 265 266

266 . . . . . . .

266 266 266 267 267 268 268

269 . .

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Mathematical Planes . . . . . . . . . Machine Tool Planes . . . . . . . . . Program Commands for Planes Definition. Default Control Status . . . . . . . .

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STRAIGHT MOTION IN PLANES . . . CIRCULAR INTERPOLATION IN PLANES

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269 269 . . . .

269 270 270 271

271 271

G17-G18-G19 as Modal Commands . . . . . . . . 272 Absence of Axis Data in a Block. . . . . . . . . . 272 Cutter Radius Offset in Planes . . . . . . . . . . 273

PRACTICAL EXAMPLE . . FIXED CYCLES IN PLANES .

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32 - PERIPHERAL MILLING END MILLS

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273 274

275 .

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275

High Speed Steel End Mills Solid Carbide End Mills . . Indexable Insert End Mills . Relief Angles . . . . . . End Mill Size . . . . . . Number of Flutes . . . .

SPEEDS AND FEEDS .

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276 276 276 276 276 277

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277

Coolants and Lubricants. . . . . . . . . . . . . 278 Tool Chatter . . . . . . . . . . . . . . . . . 278

STOCK REMOVAL

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Plunge Infeed . . . . . In and Out Ramping . . Direction of Cut . . . . Width and Depth of Cut .

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279 . . . .

33 - SLOTS AND POCKETS OPEN AND CLOSED BOUNDARY

279 279 279 280

281

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281

Open Boundary . . . . . . . . . . . . . . . . 281 Closed Boundary . . . . . . . . . . . . . . . 281

PROGRAMMING SLOTS .

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281

Open Slot Example . . . . . . . . . . . . . . . 281 Closed Slot Example . . . . . . . . . . . . . . 283

POCKET MILLING.

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284

General Principles . . . . . . . . . . . . . . . 284 Pocket Types . . . . . . . . . . . . . . . . . 285

RECTANGULAR POCKETS

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Stock Amount . . . . . . . . . . Stepover Amount . . . . . . . . Length of Cut . . . . . . . . . . Semifinishing Motions . . . . . . Finishing Tool Path . . . . . . . . Rectangular Pocket Program Example

CIRCULAR POCKETS .

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Minimum Cutter Diameter . . Method of Entry . . . . . . Linear Approach . . . . . . Linear and Circular Approach . Roughing a Circular Pocket .

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CIRCULAR POCKET CYCLES .

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289 289 289 290 291

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292

34 - TURNING AND BORING TOOL FUNCTION - TURNING

286 286 287 287 287 288

293 .

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293

T Address . . . . . . . . . . . . . . . . . . 293

LATHE OFFSETS .

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Offset Entry . . . . . Independent Tool Offset. Tool Offset with Motion . Offset Change . . . .

MULTIPLE OFFSETS . General Approach . . Diameter Tolerances . Shoulder Tolerances . Diameter and Shoulder

OFFSET SETTING

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294 . . . .

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294 294 295 295

295 . . . .

296 296 297 297

298

xvi

Table of Contents

FUNCTIONS FOR GEAR RANGES AUTOMATIC CORNER BREAK . Chamfering at 45 Degrees . Blend Radius at 90 Degrees Programming Conditions . Programming Example . .

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ROUGH AND FINISHED SHAPE .

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298 299 . . . .

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299 301 301 301

302

Rough Operations . . . . . . . . . . . . . . . 302 Finish Operations . . . . . . . . . . . . . . . 303 Stock and Stock Allowance . . . . . . . . . . . 303

PROGRAMMING A RECESS . . SPINDLE SPEED IN CSS MODE . LATHE PROGRAM FORMAT . .

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304 305 306

Program Format - Templates . . . . . . . . . . . 306 General Program Format . . . . . . . . . . . . 306 Approach to the Part . . . . . . . . . . . . . . 306

35 - LATHE CYCLES

307

STOCK REMOVAL ON LATHES .

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307

Simple Cycles . . . . . . . . . . . . . . . . . 307 Complex Cycles . . . . . . . . . . . . . . . . 307

PRINCIPLES OF LATHE CYCLES . . G90 - STRAIGHT CUTTING CYCLE . Cycle Format . . . . . . . . . Straight Turning Example . . . . Taper Cutting Example . . . . . Straight and Taper Cutting Example

G94 - FACE CUTTING CYCLE

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307 308 . . . .

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308 309 309 311

312

Cycle Format . . . . . . . . . . . . . . . . . 312

MULTIPLE REPETITIVE CYCLES . General Description . . . . . Cycle Format Types . . . . . Cutting Cycles and Part Contour Chipbreaking Cycles . . . . .

CONTOUR CUTTING CYCLES

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313 . . . .

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313 313 313 313

314

Boundary Definition . . . . . . . . . . . . . . 314 Start Point and the Points P and Q . . . . . . . . . 314

TYPE I AND TYPE II CYCLES .

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315

Programming Type I and Type II Cycles . . . . . . . 315 Cycle Formatting. . . . . . . . . . . . . . . . 315

G71 - STOCK REMOVAL IN TURNING G71 Cycle Format - 10T/11T/15T . . . G71 Cycle Format - 0T/16T/18T/20T/21T G71 for External Roughing . . . . . . G71 for Internal Roughing . . . . . . Direction of Cutting in G71. . . . . .

G72 - STOCK REMOVAL IN FACING .

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315 . . . . .

316 316 316 317 317

317

G72 Cycle Format - 10T/11T/15T . . . . . . . . . 317 G72 Cycle Format - 0T/16T/18T/20T/21T . . . . . . 318

G73 - PATTERN REPEATING CYCLE .

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318

G73 Cycle Format - 10T/11T/15T . . . . . . . . . 318 G73 Cycle Format - 0T/16T/18T/20T/21T . . . . . . 319 G73 Example of Pattern Repeating . . . . . . . . 319

G70 - CONTOUR FINISHING CYCLE .

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320

G70 Cycle Format - All Controls . . . . . . . . . . 320

BASIC RULES FOR G70-G73 CYCLES G74 - PECK DRILLING CYCLE . .

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321 321

G74 Cycle Format - 10T/11T/15T . . . . . . . . . 321 G74 Cycle Format - 0T/16T/18T/20T/21T . . . . . . 321

G75 - GROOVE CUTTING CYCLE

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322

G75 Cycle Format - 10T/11T/15T . . . . . . . . . 322 G75 Cycle Format - 0T/16T/18T/20T/21T . . . . . . 322

BASIC RULES FOR G74 AND G75 CYCLES .

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322

36 - GROOVING ON LATHES GROOVING OPERATIONS

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323 .

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323

Main Grooving Applications . . . . . . . . . . . 323 Grooving Criteria. . . . . . . . . . . . . . . . 323

GROOVE SHAPE .

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323

Nominal Insert Size. . . . . . . . . . . . . . . 324 Insert Modification . . . . . . . . . . . . . . . 324

GROOVE LOCATION . . GROOVE DIMENSIONS .

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324 324

Groove Position . . . . . . . . . . . . . . . . 325 Groove Depth . . . . . . . . . . . . . . . . . 325

SIMPLE GROOVE PROGRAMMING . . PRECISION GROOVING TECHNIQUES . Groove Width Selection Machining Method . . Finishing Allowances . Groove Tolerances . . Groove Surface Finish.

MULTIPLE GROOVES FACE GROOVES . .

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325 326 . . . . .

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327 327 328 329 330

330 330

Radial Clearance . . . . . . . . . . . . . . . . 331 Face Grooving Program Example . . . . . . . . . 331

CORNER GROOVES / NECK GROOVES . GROOVING CYCLES . . . . . .

. .

. .

332 332

G75 Cycle Applications . . . . . . . . . . . . . 332 Single Groove with G75 . . . . . . . . . . . . . 333 Multiple Grooves with G75. . . . . . . . . . . . 333

SPECIAL GROOVES . . . . GROOVES AND SUBPROGRAMS

. .

. .

. .

. .

333 334

37 - PART-OFF PART-OFF PROCEDURE . Parting Tool Description . . . Tool Approach Motion . . . Stock Allowance . . . . . . Tool Return Motion . . . . . Part-off with a Chamfer . . . Preventing Damage to the Part

335 . . . . . . .

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38 - SINGLE POINT THREADING

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. . . . . . .

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335 . . . . . .

335 336 337 337 337 338

339

xvii

Table of Contents THREADING ON CNC LATHES .

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.

.

.

339

Form of a Thread . . . . . . . . . . . . . . . 339 Threading Operations . . . . . . . . . . . . . . 340

TERMINOLOGY OF THREADING. THREADING PROCESS . . . Steps in Threading . . . . . . . Thread Start Position . . . . . . Thread Cutting Diameter and Depth Thread Cutting Motion . . . . . Retract from Thread . . . . . . Return to Start Position . . . . .

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. . . . . . . .

THREADING FEED AND SPINDLE SPEED Threading Feedrate Selection. Spindle Speed Selection. . . Maximum Threading Feedrate Lead Error . . . . . . . .

. . . .

. . . .

. . . .

TOOL REFERENCE POINT . . BLOCK-BY-BLOCK THREADING . BASIC THREADING CYCLE - G92 MULTIPLE REPETITIVE CYCLE - G76 G76 Cycle Format - 10T/11T/15T G76 Cycle Format - 0T/16T/18T . Programming Example . . . . First Thread Calculation . . . .

. . . .

THREAD INFEED METHODS .

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.

Radial Infeed . . . . . . . . . Compound Infeed . . . . . . . Thread Insert Angle - Parameter A . Thread Cutting Type - Parameter P .

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. . . .

. . . .

ONE-BLOCK METHOD CALCULATIONS.

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345 345 346 347

348 348 349 350 . . . .

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.

341 342 342 343 344 344

344 . . . .

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340 341

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. . . . . . . .

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350 351 351 352

353 . . . .

.

353 353 354 354

355

Initial Considerations . . . . . . . . . . . . . . 355 Z Axis Start Position Calculation. . . . . . . . . . 355

THREAD RETRACT MOTION .

.

.

.

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357

Thread Pullout Functions . . . . . . . . . . . . 357 Single Axis Pullout . . . . . . . . . . . . . . . 357 Two-Axis Pullout . . . . . . . . . . . . . . . . 357

HAND OF THREAD . . . . THREADING TO A SHOULDER .

. .

. .

. .

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358 358

Insert Modification . . . . . . . . . . . . . . . 358 Program Testing . . . . . . . . . . . . . . . . 360

OTHER THREAD FORMS.

.

.

.

.

.

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360

Thread Depth . . . . . . . . . . . . . . . . . 360

TAPERED THREAD

.

.

.

.

.

.

Depth and Clearances . . . . . . . . . Taper Calculation . . . . . . . . . . . Block by Block Taper Thread . . . . . . . Tapered Thread Using a Simple Cycle . . . Tapered Thread and a Multi Repetitive Cycle.

MULTISTART THREAD .

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.

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.

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.

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.

361 . . . . .

361 361 362 363 363

364

Threading Feedrate Calculation . . . . . . . . . . 364 Shift Amount . . . . . . . . . . . . . . . . . 365 Application Example . . . . . . . . . . . . . . 366

THREAD RECUTTING.

.

.

.

.

.

.

.

366

39 - SUBPROGRAMS

367

MAIN PROGRAM AND SUBPROGRAMS

.

.

367

Subprogram Benefits . . . . . . . . . . . . . . 367 Identification of Subprograms . . . . . . . . . . 368

SUBPROGRAM FUNCTIONS .

.

Subprogram Call Function . . . . Subprogram End Function . . . . Block Number to Return to. . . . Number of Subprogram Repetitions L0/K0 in a Subprogram Call . . .

SUBPROGRAM NUMBERING

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.

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.

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.

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368 . . . . .

.

368 368 369 369 370

371

Organized Approach . . . . . . . . . . . . . . 372 Protected Subprograms . . . . . . . . . . . . . 373

SUBPROGRAM DEVELOPMENT .

.

.

.

.

373

Repeating Pattern Recognition . . . . . . . . . . 373 Tool Motion and Subprograms . . . . . . . . . . 374 Modal Values and Subprograms . . . . . . . . . 375

MULTI LEVEL NESTING . One Level Nesting . Two Level Nesting . Three Level Nesting Four Level Nesting . Nesting Applications

. . . . .

. . . . .

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. . . . . .

CONTOURING WITH A SUBPROGRAM . TOOL CHANGE SUBPROGRAM . . . 100 000 000 HOLE GRID . . . . .

. . . . . .

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376 . . . . .

. . .

376 376 377 377 377

378 379 379

40 - DATUM SHIFT

381

DATUM SHIFT WITH G92 OR G50

.

.

.

.

381

Program Zero Shift . . . . . . . . . . . . . . . 381

LOCAL COORDINATE SYSTEM .

.

.

.

.

383

G52 Command . . . . . . . . . . . . . . . . 384

MACHINE COORDINATE SYSTEM . DATA SETTING . . . . . .

. .

. .

. .

384 386

Data Setting Command . . . . . . . . . . . . . 386 Coordinate Mode . . . . . . . . . . . . . . . 386

WORK OFFSETS .

.

.

.

.

.

.

.

.

386

Standard Work Offset Input . . . . . . . . . . . 386 Additional Work Offset Input . . . . . . . . . . . 387 External Work Offset Input . . . . . . . . . . . . 387

TOOL LENGTH OFFSETS

.

.

.

.

.

.

387

Valid Input Range . . . . . . . . . . . . . . . 388

CUTTER RADIUS OFFSETS . LATHE OFFSETS . . . .

. .

. .

. .

388 388

MDI DATA SETTING . . . . . . PROGRAMMABLE PARAMETER ENTRY

. .

. .

389 389

Modal G10 Command . Parameters Notation . . Program Portability . . . Bit Type Parameter . . . Effect of Block Numbers

. . . . .

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389 390 390 391 392

xviii

Table of Contents

41 - MIRROR IMAGE

393

BASIC RULES OF MIRROR IMAGE . Tool Path Direction . . Original Tool Path . . Mirror Axis . . . . . Sign of Coordinates . Milling Direction . . . Arc Motion Direction . Program Start and End

. . . . . . .

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MIRROR IMAGE BY SETTING

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393 . . . . . . .

.

393 394 394 394 395 395 395

395

Control Setting . . . . . . . . . . . . . . . . 395 Programming - Manual Mirror Setting . . . . . . . 396

PROGRAMMABLE MIRROR IMAGE .

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.

.

396

Mirror Image Functions . . . . . . . . . . . . . 396 Simple Mirror Image Example . . . . . . . . . . 397 Complete Mirror Image Example . . . . . . . . . 398

MIRROR IMAGE ON CNC LATHES .

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.

.

42 - COORDINATE ROTATION ROTATION COMMANDS. Center of Rotation . . . . Radius of Rotation . . . . Coordinate Rotation Cancel Common Applications . .

. . . . .

PRACTICAL APPLICATION

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.

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399

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.

.

.

399 . . . .

.

43 - SCALING FUNCTION DESCRIPTION

398

399 399 401 401

401

405 .

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.

.

405

Scaling Function Usage . . . . . . . . . . . . . 405

PROGRAMMING FORMAT

.

.

.

.

.

.

405

Scaling Center . . . . . . . . . . . . . . . . 406 Scaling Factor . . . . . . . . . . . . . . . . . 406 Rounding Errors in Scaling . . . . . . . . . . . . 407

PROGRAM EXAMPLES .

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.

.

.

.

.

44 - CNC LATHE ACCESSORIES CHUCK CONTROL

.

.

.

.

.

.

407

409 .

.

409

Chuck Functions . . . . . . . . . . . . . . . . 409 Chucking Pressure . . . . . . . . . . . . . . . 410 Chuck Jaws . . . . . . . . . . . . . . . . . 410

TAILSTOCK AND QUILL . Tailstock Body. . . . . Quill. . . . . . . . . Center . . . . . . . . Quill Functions . . . . Programmable Tailstock . Safety Concerns . . . .

. . . . . .

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. . . . . . .

. . . . . .

BI-DIRECTIONAL TURRET INDEXING

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.

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.

410 . . . . . .

410 411 411 411 411 411

412

Programming Example . . . . . . . . . . . . . 412

BARFEEDER ATTACHMENT .

.

.

.

.

.

413

Bar Stopper. . . . . . . . . . . . . . . . . . 413

ADDITIONAL OPTIONS . Part Catcher or Part Unloader. Continuous Operation . . . Parts Counter . . . . . . . Pull-Out Finger . . . . . .

. . . . .

. . . . .

PROGRAMMING EXAMPLE .

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.

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.

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414 . . . .

.

415

45 - HELICAL MILLING

417

HELICAL MILLING OPERATION .

.

Helical Interpolation . . . . . . . Programming Format . . . . . . . Arc Modifiers for Helical Interpolation Applications and Usage . . . . . .

THREAD MILLING

.

.

Applying Thread Milling . . . Conditions for Thread Milling . Thread Milling Tool . . . . . Premachining Requirements . Clearance Radius . . . . . Productivity of Thread Milling.

. . . . . . .

. . . . . . .

THE HELIX . . . . . THREAD MILLING EXAMPLE. Straight Thread . . . . . . Initial Calculations . . . . . Starting Position . . . . . . Motion Rotation and Direction Lead-In Motions . . . . . . Thread Rise Calculation . . . Milling the Thread . . . . . Lead-Out Motions . . . . . Complete Program . . . . . External Thread Milling . . . Tapered Thread Milling . . . Further Considerations . . .

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. .

Units of Increment . . . . . . . . . . . Direction of Indexing . . . . . . . . . . Table Clamp and Unclamp Functions . . . . Indexing in Absolute and Incremental Mode .

.

.

.

.

.

417 417 418 418

418 . . . . . .

418 418 419 419 419 419

. .

419 421 . . . . . . . . . . . .

421 421 422 422 423 424 424 425 425 425 425 426

. .

46 - HORIZONTAL MACHINING INDEXING AND ROTARY AXES . INDEXING TABLE (B AXIS) . .

417 . . . .

.

THREAD MILLING SIMULATION METHOD . HELICAL RAMPING . . . . . . .

B AXIS AND OFFSETS

414 414 415 415

426 427

429 . .

. . . .

. . . . . .

.

. . . .

.

429 429 . . . .

429 430 430 430

431

Work Offset and B Axis . . . . . . . . . . . . . 431 Tool Length Offset and B Axis . . . . . . . . . . 432

RETURN TO MACHINE ZERO . . INDEXING AND A SUBPROGRAM . COMPLETE PROGRAM EXAMPLE . AUTOMATIC PALLET CHANGER - APC

. . . .

. . . .

. . . .

434 434 436 437

xix

Table of Contents Working Environment . . . . . . Types of Pallets . . . . . . . . Pro gramming Commands . . . . Pallet Changing Program Structure

HORIZONTAL BORING MILL .

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.

47 - WRITING A CNC PROGRAM PROGRAM WRITING .

.

.

.

.

. . . .

438 438 439 439

439

441

.

.

.

441

Legibility of Handwriting. . . . . . . . . . . . . 442 Programming Forms . . . . . . . . . . . . . . 442 Confusing Characters . . . . . . . . . . . . . . 442

PROGRAM OUTPUT FORMATTING . LONG PROGRAMS . . . . .

. .

. .

. .

443 445

Program Length Reduction. . . . . . . . . . . . 445 Memory Mode and Tape Mode . . . . . . . . . . 446

48 - PROGRAM DOCUMENTS DATA FILES . . . . . . PROGRAM DOCUMENTATION .

. .

447

. .

. .

. .

447 448

External Documentation . . . . . . . . . . . . . 448 Internal Documentation . . . . . . . . . . . . . 448 Program Description . . . . . . . . . . . . . . 449

SETUP AND TOOLING SHEETS .

.

.

.

.

449

Setup Sheet . . . . . . . . . . . . . . . . . 450 Tooling Sheet . . . . . . . . . . . . . . . . . 450 Coordinate Sheet . . . . . . . . . . . . . . . 451

DOCUMENTATION FILE FOLDER

.

.

.

.

451

Identification Methods . . . . . . . . . . . . . 451 Operator’s Suggestions . . . . . . . . . . . . . 452 Filing and Storage . . . . . . . . . . . . . . . 452

49 - PROGRAM VERIFICATION DETECTION OF ERRORS.

.

.

.

453

.

.

.

453

Preventive Measures . . . . . . . . . . . . . . 453 Corrective Measures . . . . . . . . . . . . . . 453

GRAPHIC VERIFICATION . AVOIDING ERRORS . .

. .

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. .

. .

. .

. .

454 454

Syntax Errors . . . . . . . . . . . . . . . . . 455 Logical Errors . . . . . . . . . . . . . . . . . 455

COMMON PROGRAMMING ERRORS Program Input Errors Calculation Errors . Hardware Errors . . Miscellaneous Errors

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50 - CNC MACHINING MACHINING A NEW PART

.

456 . . . .

456 456 456 456

457 .

.

.

.

.

457

Setup Integrity . . . . . . . . . . . . . . . . 458 Program Integrity . . . . . . . . . . . . . . . 458

RUNNING THE FIRST PART . PROGRAM CHANGES . .

. .

. .

. .

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. .

459 460

Program Upgrading . . . . . . . . . . . . . . 460 Program Updating . . . . . . . . . . . . . . . 461 Documentation Change . . . . . . . . . . . . . 461

ALTERNATE MACHINE SELECTION . MACHINE WARM UP PROGRAM . CNC MACHINING AND SAFETY . . SHUTTING DOWN A CNC MACHINE Emergency Stop Switch . . Parking Machine Slides . . Setting the Control System Turning the Power Off . .

. . . .

. . . .

. . . .

EQUIPMENT MAINTENANCE

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461 462 462 463 . . . .

.

464

51 - INTERFACING TO DEVICES RS-232C INTERFACE . PUNCHED TAPE . .

. .

Tape Reader and Puncher Leader and Trailer . . . Tape Identification . . . Non-printable Characters Storage and Handling . .

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Baud Rate . . . . Parity . . . . . . Data Bits . . . . . Start and Stop Bits .

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. . . .

. . . .

DATA SETTING . . . CONNECTING CABLES .

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465 . .

. . . . .

DISTRIBUTED NUMERICAL CONTROL . TERMINOLOGY OF COMMUNICATIONS

. . . . . . .

. . . . . .

. .

463 464 464 464

. . . . .

465 466 . . . . .

. . . . . .

. .

. . . .

466 468 468 468 468

468 469 . . . .

. .

469 469 469 469

469 470

Null Modem . . . . . . . . . . . . . . . . . 470 Cabling for Fanuc and PC . . . . . . . . . . . . 470

52 - MATH IN CNC PROGRAMMING 471 BASIC ELEMENTS

.

.

.

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.

.

.

.

471

Arithmetic and Algebra . . . . . . . . . . . . . 471 Order of Calculations . . . . . . . . . . . . . . 471

GEOMETRY .

.

.

Circle . . . . . . . . PI Constant . . . . . . Circumference of a Circle Length of Arc . . . . . Quadrants . . . . . .

POLYGONS TAPERS . Taper Taper Taper Taper Taper

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. .

. .

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. .

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. . . . . .

. .

Definition . . . . . . . Per Foot. . . . . . . . Ratio . . . . . . . . . Calculations - English Units Calculations - Metric Units

. . . . . .

. . . . . . .

CALCULATIONS OF TRIANGLES

. . . . .

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472 . . . . .

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.

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. . . . .

.

472 473 473 473 473

474 475 . . . . .

475 476 476 476 476

477

xx Types of Angles and Triangles . Right Triangles . . . . . . . Similar Triangles . . . . . . . Sine - Cosine - Tangent . . . . Inverse Trigonometric Functions Degrees and Decimal Degrees . Pythago rean Theorem . . . . Solving Right Triangles . . . .

Table of Contents . . . . . . . .

ADVANCED CALCULATIONS CONCLUSION . . . .

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. .

53 - CNC AND CAD/CAM PROGRAMMING MANUALLY ? .

. . . . . . . .

477 478 478 479 480 480 480 481

482 482

483 .

.

.

.

483

CAM Software . . . . . . . . . . . . . . . . 483 Desktop Computer Programming . . . . . . . . . 483

TOOL PATH GEOMETRY DEVELOPMENT . TOOL PATH GENERATION . . . . . COMPLETE ENVIRONMENT . . . . . Multi Machine Support . . . . Associative Operations . . . . Job Setup . . . . . . . . . Tooling List and Job Comments. Connection Between Computers Program Text Editor . . . . . Printing Capabilities . . . . . Pen Plotting . . . . . . . . CAD Software Access . . . . Support for Solids . . . . . . Software Specifications . . . .

. . . . . . . . . . .

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. . . . . . . . . . .

484 484 484 . . . . . . . . . . .

485 485 485 485 485 486 486 486 486 486 487

Hardware Specifications. . . . . . . . . . . . . 487 Typical Hardware / Software Requirements . . . . . 488 Utilities and Special Features . . . . . . . . . . . 488

POST PROCESSORS .

.

.

.

.

.

.

.

488

Customizing Post Processor . . . . . . . . . . . 488

IMPORTANT FEATURES . Input from User . Machining Cycles User Interface . . CAD Interface . .

. . . .

. . . .

. . . .

.

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.

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. . . . .

SUPPORT AND MANAGEMENT .

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.

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.

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. . . .

.

.

489 . . . .

489 489 489 489

489

Training . . . . . . . . . . . . . . . . . . . 490 System Management . . . . . . . . . . . . . . 490 Technical Support . . . . . . . . . . . . . . . 490

THE END AND THE BEGINNING .

.

.

.

.

A - REFERENCE TABLES Decimal Equivalents . . English Threads - UNC/UNF Straight Pipe Taps NPS . Taper Pipe Taps NPT . . Metric Coarse Threads . Metric Fine Threads . .

Index

.

.

.

.

.

. . . . . .

491

. . . . . .

.

490

. . . . . .

.

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.

. . . . . .

.

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.

491 494 494 495 495 495

497