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 |  موضوع: كتاب CNC Control Setup for Milling and Turning الإثنين 13 سبتمبر 2021, 11:48 pm | |
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أخواني في الله
أحضرت لكم كتاب
CNC Control Setup for Milling and Turning
Mastering CNC Control Systems
Peter Smid
و المحتوى كما يلي :
TA&LE OF CONTENTS ix
Table of Contents
Chapter 1
CONCERTS OF CNC MACHINING ]
CMC PROCESS
Drawing Evaluation
Material identification
Part Holding
looting Selection
Cutting Conditions
Program Writing 2
Program Verification 2
Program Documentation
Program Transfer
WORK COMPLETION
Program Evaluation
Material Check
Tooling Preparation
Tooling Setup
Fixture Setup
Program Loading .
Setting Offsets
First Part Rim
Program Optimization
Production Pun
Part inspection
Safety Issues
33 3333344444444
Chapter 2
CNC MACHINE SPECIFFCATIONS ri
MACHINE SPECIFICATIONS
Useful information
VERTICAL MACHINING CENTER
Ty picaI Specifications VMC ft
HORIZONTAL MACHINING CENTER ft
Typical Specifications - 1 IMC ft
LATHES AND TURNING CENTERS
Typical Specifications
FANUC SYSTEM SPECIFICATIONS
Controlled Axm
Operation Functions K
Interpolation Functions ft
Feedrate Func Non j K
Spindle Functions ft
Tool f-unctions o
Program Input ft
Editing Functions
Setting and Display l unctions ftX TABLE OF CONTENTS
Data Input / Output . n\
Options . 10
Chapter 3
PROGRAM INTERPRETATION .11
PROGRAM STRUCTURE . n
Logical Structure . 1 1
Program StructureConsistency
PROGRAM INTERPRETATION
Units
Type of Operation . IS
5peeds and Feeds L ?
foo/ Number; , , , . 1 5
Dwelt Time
Other Considerations
PROGRAM ERRORS
Syntax Errors . 1 7
Logical Errors .1 7
Offset Errors . :8
Incorrect Units 18
C h a p t e r 4
CONTROL SYSTEM w
CONTROL SYSTEM OVERVIEW 19
SYSTEM MEMORY
PaperTape
Memory Capacity
CONTROL PANEL 22
ON-Qrr Buttons 22
Display Screen and Soft Keys 23
Selection Keys 22
Address Keyboard 25
Shift Key IS
Numeric Keyboard 2S
Edit Keys IF
Page and Cursor Keys 2b
EOB - CAN - INPUT Keys 2b
Beset Key . 2b
Help Key 2F
Chapter 5
OPERATION PANEL 2 7
OPERATION PANEL LAYOUT 2S
MAIN BUTTONS AND SWITCHES I*
Power ON / Ready i ight Indicat o r 28
Cycle Start / Feedhold - Auto Operation 28
STATUS INDICATOR LIGHTS 29
IndjcgtgrUghts - Three Groups 29
ON/OFF SWITCHES
Toggle and Button Switches 33TABLE OF CONTENTS xi
Program Tfsrj'rm and Setup Mode
ROTARY SWITCHES 37
Mode Selection 77
AX/J Selection r , 4 j
OVERRIDES 41
Rapid Override 41
feedrate Override 42
Spindle Override
Jog Feedrate Selection
EDIT KEY
EMERGENCY STOP SWITCH AS
OTHER FEATURES 45
TONTROI PANFI SYMROI S -1 >
Switches
Modes
Operations
Chapter 6
SETUP HANDLE 41-)
PURPOSE 49
DESIGN 49
HANDLE FEATURES .^ 50
Mode Selection SO
AXJ'3 Selection 50
ffcJrTqtr SgjgCtion 50
Dipl Wheel SD
APPLICATIONS > 2
Manual Absolute Switch ^ -i
SafetZjssutt ;
Chapter 7
MILLING TOOLS - SETUP
MILLING TOOLS $5
tool Holders 53
Cutting Tools
Tooting System
ATC - AUTOMATIC TOOL CHANGE
Monual Toot Change
Toot Magazine
Fixed Type ATC
Random Mrmoty Type ATC \
REGISTERING TOOLS
TOOL SPECIFICATIONS
MaximumTool Length
Maximum Tool Diameter
MaximumTool Weight
ATC PROCESS
TOOL REPETITION
Repeating the SomeTool
61xii TABLE OF CONTENTS
Repeating a Different Toot
Solving the Problem
ToolChange - One or Two Blocks
DUMMY TOOL
SUMMARY
Chapter 8
SETTING PART ZERO 65
SYMBOLS
WHAT IS PART ZERO ?
Part Zero Location .
VISES FOR CNC WORK
CNC Vise - Basic Design bl
CNC Vise - Setup 67
APPLICATION EXAMPLE 68
PanOrientation M
ViseOrientation
FINDING A CENTER
PART ZERO ON CNC LATHES
X-axis Zero
Z-axisZero
Work Shift
Chapter 9
WORK OFFSET SETTINGS 73
REFERENCE POINTS
MachineZero
Part Zero
MachineZero fo Part Zero Connection
PART SETUP EVALUATION
USING WORK OFFSETS
Preparatory Commands G54-G59 .
Establishing the Conn^cffofl
USING EDGE FINDERS
Magnetic Single Edge Finder
Magnetic Center Finder
DISTANCE-TO-GO
SHAFT TYPE EDGE FINDERS
Prerequisites
Individual Steps
Work Offset Calculations
Original Example Revisited
WORK OFFSET Z-SETTING
Where is theZ-setting?
Serrrng theZ-axis
MULTIPLE WORK OFFSETS
Program Entry
WORK OFFSET ADJUSTMENTS
Mixing Units of Measurement
83TABLE OF CONTENTS xiii
Heightof Part
EXT WORK OFFSET
EXT or COM ?
Offset AdjustmentOptions
WORK OFFSETS - DATA INPUT
DataChange Example
Chapter ^0
TOOL LENGTH OFFSET 87
TOOL LENGTH
Tool iength Offset Register
TOOL LENGTH OFFSET COMMANDS
Limitations of Work Offsets
G43 and 044 Commands
Applying Tool Length Offset
G49 Command
OFFSET MEMORY TYPE
Offset Memory - Type A
Offset Memory - Type B
Offset Memory - TypeC
INPUT and +INPUT Key Selection
Adjustment Examples
MACHINE GEOMETRY
SETTING THE TOOL LENGTH
Tool /Issembly Fixture
Preset Tool Method
Touch'Off Method
Reference Tool Method
EXT OFFSET AND WORK OFFSET
WORK AND TOOL LENGTH OFFSET
Chapter 11
MACHfNfNG A PART LOl
MACHINING OBJECTIVES
PROCESS OF MACHINING
DRAWING EVALUATION
Tolerances
Radius from I and J
Surface Finish
Allowance „ r .
MATERIAL INSPECTION
PROGRAM EVALUATION
Programs Generated Manually
Programs Generated by Software
Part Sefwp and Tooling
PROGRAM INPUT
Memory Mode
DNCMode
PROGRAM VERIFICATION
106xiv TABLE OF CONTENTS
Manual Verification
Software Verification
PRODUCTION MACHINING
Responsibilities
PART INSPECTION
PROGRAM SOURCES
CAM Programs and Machining
Conversational and Macro Programruing
PREVENTING A SCRAP
Causes ofScrap
Steps to 6fiminate Scrap
Let Offsets Work for You
Offset Adjustment - Example
PROGRAM MODIFICATION
MAINTAINING SURFACE FINISH
SurfaceFinish in a Drawing
Effect of Cutting Tools
Selection of Cutting Data
Machining Direction
Chatter / Vibration
COOLANTS
BenefitsofCoolants
Working with Coolant
Chapter 12
MACHINING HOLES ! 15
FIXED CYCLES - OVERVIEW
DRILLING HOLES
Drilling Example
Terminobgy
Initial Levd and R-Level
Depth
SpotDrilling + Counterbore + Countersink
Peck Drilling
Changing Q-depth
TAPPING OPERATIONS 120
Tap Drill 120
Feedrate Calculation . 120
Troubleshooting 121
Rigid Tapping 122
BORING OPERATIONS . 123
Cycle 123
G86 Cycle 1 2 3
G87 Cycle [ 23
G8S Cycle 123
G89 Cycle . 1 2 4
G76 Cycle . 1 2 4
DRILLING FORMULAS . 123
Center Drills . 1 2 5
Spot Drills . 12^TABLE OF CONTENTS XV
Twist Drills 1 26
Chapter 1 3
MULTIPART SETUP [ 27
MULTIPLE PARTS 127
Conrifoons . 127
ORIGIN DISTANCES UNKNOWN I 27
Program Data
5efgp Process . I>>
ORIGIN DISTANCES KNOWN 129
Program Data 130
[75ragWork Offsets 130
Usir,q local CoordinateSystem 130
Using GW Setting L 30
Using Custom Macro [ .il
EXTENDED WORK OFFSETS IP
Available Range 132
Standard vs.Extended Work Offset Range 132
Z-AXIS AND MULTIPART SETUP 132
Variable Height 3 .P
Tool Length Offsets [ 32
PROGRESSIVE SETUP
SUMMARY
Chapter 14
CUTTER RADIUS OFFSET 135
BENEFITS
PROGRAM DATA
Address D
Offset Memory Types
Equidistant Toofpath
Cutting Direction
WORKING WITH RADIUS OFFSET
D-offset Number
Look-Ahead Type Offset
INITIAL CONSIDERATIONS
Cutter Diameter
Effects of Machining
ScrapPrevention
ACTUAL OFFSET SETTING
Programmed ToolSize
External Offset Settings
Intergal Offset Settings
Conclusion
USING OFFSET MEMORY TYPES
Geometry and Wear Offsets
Offset Memory - Type A
Offset Memory - Type 5
OffsetMemory - Type C
144xvi TABLE OF CONTENTS
PROGRAMS FROM COMPUTER
Ma$tercam Example
SOLVING PROBLEMS
Afarm Number 041
Insufficient Clearance
Cutter Radius Too Large
Contour Start / End Error
CHANGE Of TOOL DIAMETER
Units Conversion
Chapter 1 5
TOOLS FOR CNC LATHES . 131
PROGRAMMMING LATHE TOOLS
Zero Wear Offset
Feedrate Error
Prevention
TOOL NUMBERS
TOOL TURRET
TOOL HOLDERS
Standards
identification
iSO and ANSI
Cage Insert
Other Tool Holders
CUTTING INSERTS
insert Shape Identification
SSQ Unique Identification
ANSI UntQue identification . J 58
Grades, Coating and Chip Breakers . 158
CHANGING AN INSERT
Corner Radius Change . 15 K
TOOL CHANGING
LATHE CHUCK
Chuck Clamp and Undamp
Chuck Pressure
5ELECTION OF JAWS
Hard Jaws
SoftJam
Chapter 16
LATHE OFFSETS 161
Lathe Geometry
Machine Zero
L 6 L
161
Pari Zero 162
Topi Reference Point 162
WORK SETUP 163
Definitions 16,3
Geometry Offset . , 1 6 3
The R and T Columns I 64TABLE OF CONTENTS xvii
Wear Offset
DRAWING AND PROGRAM 165
Changing Toot Number *, . , . tf ?6
Bar Extension 166
MANAGING TOLERANCES l f -.d
Tolerances and Program Data
Tolerances on Diameters - Part A
Tolerances on Shoulders - Part 8
Tolerances on Diameters and Shoulders 170
WQRKING WITH WEAR OFFSETS Hi
Common Offset Change Example 171
WEAR OFFSET PARAMETERS 172
Chapter 17
TURNING AND BORING 171
LATHE CYCLES G7Q - G71 - G72 IT}
Concepts of Turning and Raring Cycles 174
Program Listing
Contour'shape - External
G? I Cycle Format for Two Blocks , ,
ContourShape - internal
PROGRAM FEATURES TO WATCH
SfortPoint Location
Clearances
Tool Change Clearance .
Program after Changes
PROGRAM DATA TO WATCH
Start Point Too High or Too low . IN:
Positive and Negative Stack Allowance
N Stock Amount Too Heavy . ! K2
Retorn to 5tort Poipt in the Cycle ,
P and/or Q Reference Defined Incorrectly
feedrates for Roughing and finishing
Coffer flacflus Offset
Small inside Radius
G72 AND G73 TURNING CYCLES IS?
G72 Lathe Cycle is?
G?? Cycle Format for Two Blocks 1* 5
G7S Pattern Repeating Cycle Ifci
G73 Cycle format For Two Blocks ISfi
ONE-BLOCK FORMAT CYCLES [S6
G7 \ Cycle Format for One Block lfr *
G72 Cycle format for One 8lock 1 * 7
G73 Cycle Format for One Block 1 * 7
G71 TYPE i AND TYPE II CYCLES M7
Type I 1*7
Type II | * 7
SUMMARY IS8xviii TABLE OF CONTENTS
Chapter 13
TOOL NOSE RADIUS OFFSET 139
BRIEF REVIEW IRQ
TOOLPATH EVALUATION 1
Program Listing - NoOffset im
Program Listing - WithOffset
Offset Screen
191
.... 191
FACING TO CENTERLINE m
Too ) Height Error 192
incorrect Tool Position 192
C4I - Vgj or No? m
OFFSET CHANGE £93
CLEARANCE AMOUNT 194
Chapter 19
GROOVING ON LATHES i 95
GROOVE MACHINING
TheSimplest Groove
StandardGrooves
Typical Groove 1%
Grooving Tool . ]%
Grooving insert . r 1%
Control Settings 197
Program Evaluation 197
Basic Groove Dimensions . J93
TOLERANCES NOT SPECIFIED m
Dimensional Problems 199
DEPTH CONTROL 1w
External and Internal Grooves 200
POSITION CONTROL 201
Left Side Reference Point 201
Right Side Reference Point .201
Reference Point Set in the Middle 20 ]
Offset Adjustment 201
WIDTH CONTROL .. 203
Program Requirements 2fr>
POSITION AND WIDTH CONTROL
GEOMETRY OFFSET
Change of Tool Width
Program Requirements - Summary .
GROOVING CYCLES 205
G74 Cycle 205
G75 Cvde 205
Chapter 20
THREAD CUTTING . 207
THREADING PROCESS 207
THREADING TOOLS . 107
Threeding Too I Holders and laser ts . 207TABLE OF CONTENTS xix
Hand of Joel Selection . . 2riff
THREADING INFEED 310
Radial infeed 210
Flank Intend 111)
Modified Flanfr .iYifeed . 210
Alternating Flank Infeed 23 ]
THREADING INSERT .:n
Full Profile . 211
Panic! Profile 2 M
Clearances .
Muttitooth inserts
THREAD RELATED DEFINITIONS
Pitch
Lead
Other Definitions
METHODS OF PROGRAMMING
Longhand Threading - Q32
Box Threading - G92
Repetitive Cycle Threading - G76
THREADING DATA 21 -1
Depth of Thread 214
Depth of the First Pass . 21 -1
Threading Feedrate 214
Angle of Thread 214
Spring Pan 214
G76 THREAD CUTTING CYCLE 211
One-Block Format :ifj
Two Block Format 215
C76 Cycle Examples
MULTI START THREADS
216
SPINDI F SPFFD i IM1TATION - I K
Machine Specifications 21«
THREADING DEFAULTS 2 I K
Chapter 21
WORKING WITH BLOCK SKP 210
BLOCK SKIP FUNCTION
Block Skip Switch
Using Block Skip
Block Skip within a Block
Variable Stock
TRIAL CUTS
Maintaining Tolerances 2 2 1
Trial Cut Concepts 221
Trial Cut Methods 221
MILLING APPLICATIONS
Program Sample
Program Evaluation
Finishing Too } - Program Details
Conclusion 222XX TABLE OF CONTENTS
TURNING APPLICATIONS m
Test Cut Addition 214
Chapter 22
OFFSET CHANGE BY PROGRAM 225
LOCAL COORDINATE SYSTEM 225
Work Offset Change
DATUM SHIFT
CIO Format - Milling Applications
GI0 For Roughing And Finishing
G10 Format - Lathe Applicatrans
SETTING PARAMETERS BY G10
Chapter 23
SYSTEM PARAMETERS 222
WHAT ARE PARAMETERS? .
Parameters for Operators
FanocParameter Classification .
Access to Parameters
Backing Up Parameters
PARAMETER TYPES
Bit Type Description
Practical Interpretation
INPUTOF REAL NUMBERS
increment System . 23»
pf Input 239
Data Panne 2H
VAUP DATA RANGES .. 240
PRACTICAL APPLICATIONS 240
PARAMETERS OF SETTING 240
Setting (Handy) 240
PARAMETERS OF FEEDRATE .
PARAMETERS OF DISPLAY
Programs Registration and Editing 243
Password Protection 241
Program Display 244
Automatic Block Numbering 144
Other Parameters 2 44
PARAMETERS OF PROGRAMS 145
Decimal Point 141
Power -On Defaults 245
End of Program Functions 241
iN'-umterof M-Functions in o Block
Automatic Corner Rounding
PARAMETERS OF SPINDLE CONTROL .
MaximumSpindleSpeed
SpindleOrientationCode
PARAMETERS OF TOOL OFFSET
Offset Address
248TABLE OF CONTENTS xxi
Lathe Offsets
Clearing Offsets , ,
Radius vs.Diameter
Wear Offset
PARAMETERS OF CYCLES 212
Fgnoc 15 Mode Compatibility . 250
5pmdfc flnfflrjpn Direction 250
Clearances inG73 / G83 Cycles 2 5 ]
PARAMETERS OF
THREADING CYCLE
PARAMFTFHS OF MLJITIPI F RFPFTITIVF CVCl FS
Available Cycles 25?
Parameters for G7 I / G72 Cycles 25 2
Pjff?;TTpr.pr? for 073Cycle 255
Parameters (arG74 / G7S 233
Parameters for G76 Cycle 255
BATTERY BACKUP m
PARAMETERS AND G10 21A
NO DECIMAL POINT ENTRY 255
Historical Background 255
FQtsivglent Numbers 23(i
Input Withaul a Decimal Point . 23ft
SUMMARY 23ft
Chapter 2^\
PROGRAM OPTIMIZATION 257
PROGRAM REVIEW , . 25?
PROGRAM RELATED CHANGES 211
CHANGESAT THE CONTROL 25*
Spindle Speeds and Feedrates
Clearances
Optimized Program
25B
. 25*
Dwells 211
Combined Too! Mahore 211
SETUP RELATED CHANGES
SUMMARY
260
260
Chapter 25
REFERENCES . 2hl
G-CODES AND M-FUNCTIQNS 261
Milling - G -codes 261
Milling - M-FGNCTIORT? . Hi2
G-CODES ANDM-FUNCTIONS 262
Turning - C-codes 262
Turning - M' functions
DECIMAL EQUIVALENTS
PARAMFTFRS Cl AERIFICATIONS
265
261
~Vi7
COMMON ABBREVIATIONS 26'J
TAP DRILL SIZES 271
Metric Threads - Course 27 )xxii TABLE OF CONTENTS
Metric Threads - Fine 211
imperial Threads - UNC/UNF 272
Straight PipeTaps - NPS . - Z7 T
Taper Pipe Japs - NPJ 273
60-DEGREE THREAD FORMS 274
USEFUL FORMULAS 274
Speeds and feeds . 274
Mgchlning Hofei - Spot DriSiir\Q 2?s
Taoers 27b
Control Memory Capacity 277
Trigonometric Chart
Index 27 QREFERENCES
G-CODES ANDM-FUNCTIONS G45 Position compensation - single increase
G4G Position compensation - single decrease
Milling - G-codes G47 Position compensation - double increase
G4S Position compensation - double decrease
GOO Rapid positioning G49 Tool length offset cancel
G01 Linear interpolation G50 Scaling function cancel
GD2 Circular interpolation - clockwise G51 Scaling function
G03 Circular interpolation - counterclockwise G52 Local coordinate offset
G04 Dwell function {as a separate block) G53 Machine coordinate system
G07 Hypothetical axis interpolation G54 Work coordinate offset1
G09 Exact stop check - one block only G54.1 Additional work coordinate offset (with P|
G10 Programmable data Input {Data setting) G55 Work coordinate offset 2
G11 Data setting mode cancel G5G Work coordinate offset 3
G15 Polar coordinate command cancel G57 Work coordinate offset 4
G16 Polar coordinate command G58 Work coordinate offset 5
G17 XY plane designation G59 Work coordinate offset 6
G18 ZX plane designation GGO Single direction positioning
G19 V2 plane designation G61 Exact stop mode
G20 English units of input GG2 Automatic comer override mode
G21 Metric units of input G63 Tapping mode
G22 Stored stroke check- on G64 Cutting mode
G23 Stored stroke check - off G65 Custom macro call
G25 Spindle fluctuation detection - on G66 Modal custom macro call
G2G Spindle fluctuation detection - off G67 Modal custom macro call cancel
G27 Machine zero position check GG3 Coordinate system rotation - active
G2S Machine zero return (reference point L) GG9 Coordinate system rotation - cancel
G29 Return from machine zero G73 High speed peck drilling cycle
G30 Machine zero return (reference point 2 ] 074 Left hand tapping cycle
<331 Skip function G76 Fine (precision) boring cycle
G33 Threading function G30 Fixed cycle cancel
G37 Tool length automatic measurement G91 Drilling cycle
G40 Cutter radius compensation - cancel G82 Drilling cycle with dwell [Spot drilling cycle)
G41 Cutter radius compensation - left G83 Peck drilling cycle
G42 Cutter radius compensation - right G84 Right hand tapping cycle
G43 Tool length offset - positive G84.2 Rigid tap cycle - right hand
G44 Tool length offset - negative G84.3 Rigid tap cycle - left hand
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