DOCUMENT RESUME ED 391 901 CE 070 758 TITLE INSTITUTION .
DOCUMENT RESUMEED 391 901TITLEINSTITUTIONPUB DATENOTEPUB TYPEEDRS PRICEDESCRIPTORSCE 070 758Basic CNC Operation. Training Workbook [and]Assessment and Training Guide (and) Hands-onAssessment.Anoka-Hennepin Technical Coll., Minneapolis, MN.94401p.; For related documents, sec CE 070 760, CE 070763, and CE 070 765-768.Teaching Guides (ForClassroom UseGuidesTeacher) (052)MF01/PC17 Plus Postage.Adult Education; *Adult Vocational Education;Behavioral Objectives; *Competency Based Education;*Computer Assisted Manufacturing; *EquipmentUtilization; Learning Activities; *Machine ToolOperators; *Numerical Control; Programming;Troubleshooting; WorkbooksABSTRACTThis workbook is intended for students taking acourse in basic computer numerical control (CNC) operation that wasdeveloped during a project to retrain defense industry workers atrisk of job loss or dislocation because of conversion of the defenseindustry. The workbook contains daily training guides for each of thecourse's 13 sessions. Among the topics covered in the course sessionsare the following: CNC machine terms, machine specifications, the CNCcoordinate grid system, and absolute/incremental programming;toolholder manufacturing processes, toolholding systems, andtoolholder styles; functions and keys on CNC operator panels andwriting/editing CNC programs; alarm codes and messages; program codesand preset tool methodology; operating CNC machines; usingprogramming codes and locating errors in programs; operating ahorizontal machine center; defining and determining machinabilityfactors (speed, feed, and depth of cut); operating a CNC lathe; andtroubleshooting CNC machine tools. Each daily training guide includessome/all of the following: session objectives, diagrams andspecifications of the machine(s) introduced during the session,information sheets, and learning activities. An assessment andtraining guide and hands-on assessment for students in the course arealso provided. **************************Reproductions supplied by EDRS are the best that can be made*from the original ******************************
sMS,Op aro111114111111b.TrainingWorkbookU S. DEPARTMENT OF EDUCATIONOf I rco of Edocationa: Research and ImprovornentEDU0"PERMISSION TO REPRODUCE THISMATERIAL HAS BEEN GRANTED BYIONAL RESOURCES INFORMATIONCENTER (ERIC)his document has been reproduced asreceived from the person or organizationoriginating it.0 Minor changes have been made toimprove reproduction quality.Points of view or opinions stated in thisdocument do not necessarily representofficial OERI position or policy.TO THE EDUCATIONAL RESOURCESFORMATION CENTER (ERIC)."rr.2BEST COPY AVAILABLE
Se IticrOmeYour Notes:AlI3
Trainin Dail GuideSession OneDuring this two hour session, participants will:1.Locate, identify and explain the purpose of thebasic components of CNC machine terms.2.Explain machine specifications.3.Explain machine home and the coordinate gridsystem and how it relates to the CNC machine.4.Explain the four most common axes: X, Y, Z, andB.5.Define absolute /incremental programming andthe use of coordinates and signed numbers.
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Axes TravelAxes TravelTable (X axis)Saddle (Y axis)Head (Z axis)Additional 'Z' stroke for toolchangePositioning SpeedAuto (X & Y)AUTO (Z)Manual (X, Y, & Z)Feedrate RangeMinimum increment2
TableTableWorking SurfaceT SlotsT Slots SizeHeight above FloorMaximum Table LoadSpindleSpindle DriveSpindle Speed RangeSpindle Speed ControlSpindle DiameterSpindle Taper/3
ISpindleTool Holder ClampingTool HolderSpindle Speed RangeMinimum Distance Spindle Nose to Table TopMaximum Distance Spindle Nose to Table TopAutomatic Tool ChangerMagazine CapacityTool SelectionMaximum Tool DiameterMaximum Tool WeightMaximum Total Weight of all ToolsMaximum Tool Length48
I.,III.!Automatic Tool ChangerTool Change TimeTool Change Time Chip to ChipStandard EquipmentSpindle OrientationFlood CoolantAutomatic Centralized Lubrication SystemFull Machine GuardingSlideway ProtectionSwarf Collection TraysLow Voltage Work light5
AccuracyPositioning AccuracyRepeatabilityMains Services RequirementsElectrical SupplyStandard Electrical SupplyLow Volt Option Electrical SupplyCompressed Air610I
4111ImmommirmSTANDARD SPMFICAT1ONa) System Features.4 axis control with automatic acceleration and deceleration.- 3 axis simultaneous linear interpolation (XYZ)- Mutti Quadrant circular interpolation (XY.YZ. XZ)Input range- 0.001 to 9994.99mm (XYZ)- or 0.CCO1 to 999.9999 inch (XYZ)Part programme storage length 120mRegistered programs 63Te.ol offset memory 99ISO/EIA Automatic recognitionr CRT Mono chrome screen with MDI keyboardFeedrate command Direct programming of mm/min or inch/minFeedrate override 0 to 150%Rapid traverse override 0.25.50.1C0%Spindle speed override 50% to 120% in 10% stepsOverride cancelAutomatic co-ordinate system settingAbsolute/incremental commandProgram number display/search 4 digitsSequence number display/search 4 digitsMain program/subprogram (Subprogram: 2 levels)Optional block skipStored pitch error compensationBacklash compensationServo offCycle start/feed holdBuffer registerResetManucl pulse generator muttiplier Xl. X10, X100Machine lock (all axes)Dry runSingle blockPart program storage and editingData protect switchSett diagnosic functionEmergency stopStored-stroke check 1Interlock error displayStatus output: CNC ready, servo ready, alarm, distribution end, automatic operationAutomatic operation start-lamp, feed holdDigital Servo Controlb) Programming FeaturesPocket calculator type decimal point inputBackground editInch/metric operation (G20/G21)Exact stop/dwell G04/G09/G61Reference point return Manual automatic (G27. G28. G29)Second reference point return G30Co-ordinate system setting G92Feedrate F5 digit direct commandSpindle speed S4/35 digit command711
1AlbdrTool selection T4 digitsMiscellaneous function M3 digitsSkip function G31Tool length compensation G43. G44. G49/program end MCO/M01/M02/M30ProgrammeCanned cyclk.i for drilling boring G73. G74. G76, G80 to G89Cutter compensation C (G40-G59)Mirror image (M21 to M24)Woric co-ordincte system (G54-G59)Programme input of offset date (G 10)Absolute/incremental (G90/G91)812
ocopsng UUUIJbModelRNCS2 RNCX22513125RNC800-20004 RNC,5NC RotaryTables320RNCV160-15006RNCM250RNCB8 RNCK9 RNCBK101112NC DividingHeadsWaftFHeutomatic Dividing50057NC TiltingRotary Tables320TRNC,BTTNCTHNC250-1250320-1250250-1250160 320450-1000250 320With controller3 RDH14 I RD630IAir 0200450TPC2Numerical Control(For NC Rotary Tables)IAuto Connector System[OthersITPC-JrAuto connectorBuitt-In and Special Rotary Tables(Many deliveries have been made. Consult a Tsudakomasales person.)
N10:ofRNCS8 RNCKSuoer High SO,ad. 500r o.m.*NC Rotary Table/continuOus rOtation and variousincleixtrig function2 I RNCXStandard typeonlyLow priceRear motor maunted type.V.-Ni.- ,-.%With 8 parsrotary joint.--.13,11111pt.'.-Excellent water11ITTNC.r,t.rmesiistanncena nte a ce-!.free12iStandard typeEasy applicationIfor multi-rotaryRotation and til(Rotation)ting are lination)machinings areTHNC.All. --tables.NC tilting rotarytable withmanual tiltLow price / highquality136 RNCMRDHCompact designA4without spldshguard intorfer.tl.4?.i.iL .IHigh precisionEasy cable connectionence1illl.L.pp-141 RD*machines long.1(16)Large allowable workpiece inertia;Table center hasa large thru-hole:Z j RNCBtii'CompactHeavy-duty le5 RNCV-.rIncIinafionilik 6irea 11411.kV").tttADInclination#t%ia4 RNC705 SERIESINV360'Retaecn--pieces1Ih#Wide inclinationUnmovable motor location 110*110TRNCTurn table.-1milt(251.30i)Machines largeand heavy work-.4.1 Horizontalpositioning only.-,I.a large thru-hole10IIRNChorizontalmachining cantersTable center hasFor1.301)(25 i9 RNCBKf-1-horizontalmachining centersFor,(7;kP3\\.L)with High soemed0m,ILow priceQuick deliveryHigh speedHigh accuracy cross roller bearing andcOupling attached4 1workplacesApplications:Perfect for instaffingof an automaticpower chuck. dunAPIWe ;:mIstud device. ratan,p.nt device andothersBEST COPY AVAILABLEWorkpiece Examplescs:.--.,,. !:".,., e,",'r. 4. .-Index platePalletSerrationCylinder10.,.;.:.0c."4P-1 ::-r---Index plate11.02100"Elir"161011:10.1213174:5Bevel gear11/010Barrel camLitt camft.,.isNozrJe14" fiili i.15.Cam,,,.Irkinail.GearBarrel camIMPCam191880 )Lead cam
'B' axisrotary tablewhen fated horizontal41B axisI rotary tablewhen frtled vertical.cxistable movementfront to back.'X' axistable movementside to side.The nomenclature shown assumes viewing from the Operctors Control Panel.The Bridgeport machine has three axes that are under numerical control.Each axes con move independently, the direction being designcted as a plus or minusmovement.1015
When we programme o numericcl controlled mcchine. we ctwcys consider thct the cutting tool ismoving.FRONT OF MACHINE
Absolute (G90) Coordingte programmingIn Absolute (Gc0) all dimensioning is taken from a tmed point which is specified by the programmer(see Figure 5).Figure 5 Absolute Co-ordinate Programming75.00120.001217
Incremental (G91)Co-ordinate Programming918t's)5-71825.0050.03131815.00-4-30.00
Absolute andlthcremental ProgrammingEXAMPLE 1V IGIN(XO YO)91X-1X NCREMENTALABSOLUTE6 to 1 X5 to 2 X8 to 3 X2 to 4 X4 to 5 X6 to 1 X5 to 7. X8 to 3 X2 to 4 X4 to 5 X5to6X5to6X12 to 7 X10 to 8 X4 to 9 X12 to 7 X10 to 8 X4 to 9 XEXERCISE:3Find the absolute and incremental co-ordinates of tne points listed above.ABSOLUTE SYSTEM:A numerical control system in which all co-ordinate locations creprogrammed from a fixed or absolute zero point (origin).INCREMENTALA numerical control system in which each co-ordinate location is given interms of distance and direction along fectangulor axes from the previous1419
Linear Interpolation(GOO/Gffl)The axes ot the machine will move in linecr at either Rapid or Feedrate traverse rates.Any movement preceded by:a)GOO will occur ct RAPID TRAVERSEb)GO I will occur at FEEDRATENOTE:These commands are MODAL cnd will stay in effect until chcnged.Maximum ot 3 axes ccn be programmed in one BLOCKRgure 9 Linear Intérpolation(GC0) Rcpid Traverse PathPIx1520
Circular interpolation ccn be performed in any of three planes (G17. G18. G19).There cre two directions in which arc are produced - G02 Clockwise cnd G03 Counter Clockwise.The information required to move in an arc involves four \vorcf cddresses. Assuming G17 clone isused. the progrcm would be N14 G02 X1C0.0 YOL 10.0 J-1C0.0i.e.G02X103.0Y0.010.0J-100.0Clockwise movementTool finishing posttion in XTool finishing posttion in yArc offset in X cxisArc offset in Y axisFigure 10 Circular InterpolctionClockwise DirectionAgain using G17, the program for counter clockwise movement would be:N15 G03 X0.0 Y100.0 WOOL J0.0Counter ClockvAse Direction16
AThe Interact can perform circular interpolation irt 3 planes. Either:a)X cncl Y (G17) see figure 11b)X and Z (G18) see figure 12c)and Z (G19) see figure 13NOTE:Plane selection is MODAL and once selected will stay in effect until another plane is se-lected.Figure 11 G17 XV Plane (Plan view above spindle)I. ARC CENTRE ISTART 9 TPOINTCWGO2-Figure 12 G18 LC Plane (View from behind spindle)iz-x-r,cp.rmsr STARTy POINT0GC2Figure 13 G19 YZ Plane (View from table end)Arza CENTRE.STARTPOINTtiCWGO21722
ANLAArc offsets ore addressed using theWords'.is the sign distance parallel clong the X is from the starting position of the arc to theOM centre,is the sigr: distance parallel clong the Y axis from the stetting posttion of the art to thearc centre.is the sign distance parallel along the Z axis from the starting position of the arc to thearc Centre.The 'word' vclues describe the direction in which the centre of arc lies in relation to the startingposition. Values are automatically assumed to be (plus). V a -(minus) value is required it MUST 'Dedesignated. See Figure 14.Figure 14 Arc OffsetsSTARITNGPOSMONAX- GO2ClockwiseExplanation:In the X axis, the circle is in the X negctive direction.In the Y axis, the circle is in the Y negative direcnon.Example:block of program required to move from A to B:N15 G02 Xu.0 Y-100.0I-57.357 J-81.9151823
10drThis command Is used cs an alternative to replace the I and J wores used inCircular interpolation.Example:N15 G02 X0.0 Y-103.0 R103.0NOTE:The R word ccn only be used for arcs up to and include 180.The -R word can only be used for arcs greater then 180. and less than WO'.Figure 15 Rcdius CommendV To move from Pos'ition 1 to Position 2 (clockwise)N1C0 G02 X57.357 Y81.915 R100.0Y-To move from Position 1 to Position 2 (counter clockwise)Y N105 G03 X57.357 Y81.915 R-1C0.0X Y-1924
Machine References (G28/G30)The machine hcs its own 'Machine Reference co-ordinate System'. from which the maximumtravels of the X. Y and Z axes are mecsured.Figure 16.Spindle positions at Mcchine Reference in X. Y cnd Z cxes.X AXISX AX/S POSITIONREFERENCEG28PL4NEY AXIS REFMENCE PLANEY AXSPOSTIONPLAN VIEWSPINDLEZ AXIS REFERENCE PLANE0G28G30Z AXISPOSITIONMACHINE TABLEFRONT VIEW20
Z Axis 028 &030 Reference PlanesThere ore 2 reference planes ih the Z axis. to which the spindle wiil return automatically:1.G28 plcne which is at the Machine reference location.2.G30 plcne is where all toolchanges occur.Program Format for G28 and G30 reference return planes.The G28 command constitutes 2 movements:a)Move to dimensionb)Move to referenceexd.rnple N50 G28 G91 ZOThe iirst movement to take place is cn incremental move of ZO.The second movement will return directly to the reference plane.Core should be taken when progromming this move in the absolute mode, as the Z dimension mustbe clecr of the workpiece.NSO G28 G90 Z150.0The G30 command works in the same way cs the G28. but is only to be used for toolchangepurposes.Le.NO0 G30 G91 Z014 MOAfter movement to the G30 reference plcne. the machine will initiate a toolchcnge cycle.selecting tool number 4.2126
Work Co-ordinate SystemProgramming (G54-G59)The work cO-ordinate system allows for the setting of datums relative to the machine referencecoordicte system.X cnd Y cs values for use with G54-G59 co-ordinate system.Figure 17G28 REFERENCEX AND Y AXISX AXIS-WO mmM'CM'CVICEVICEWORK PIECEitY AXISCOMPONENTDATUM-275 mmWhen the position of the component datum has been determined, it can be entered into the relative work offset register.This ccn be done in 2 difference ways:a)Manually, whereby the dimensions con be entered directty through the keyboard.b)Programmed. whereby the dimensiosn can be entered into the program in thefollowing format:N10 GIO G90 L2 P01 X-275.0 Y-300.0Explanation:GIO L2P01P02 Work co-ordinate offset input Specifies offset register G54G55 - G592227
MI AsrZ AXIS VALUES FOR USE WITH G54-G59 COORDINATE SYSTEMSPgure 18G28 REFERENCE PLANE & SPINDLE GAUGE UNE-250 mmCOMPONENT DATUMWORK PIECE(7.1--I-)TABLEoverall length (Gauge line - toTo determine the Z axis value. it is necessary to use a tool of knowninthepositionaldatadisplayaddedontothe tool length, becomes thetip). The distance travelledZ axis value.This con also be entered manually into the work offset registers or withinthe program. e.g.N10 GIO G90 L2 POI X-275.0 Y-300.0 Z -250.0overall tool lengthsOnce the datum positions have been recorded. it is necessary to mecsure tnewhich are to be used as offset values.23
-I IIII.MicrometerPrecision Spacers---.rTool height to be enteredInto H otfset registerL-r---r5k-T-11t1t.The tool to be measured is placed in the measuring system, and the tool height can be measuredusing the micrometer.NOTE:This is a mechanical measuring system.2429
I IIG28 ReferenceF-A-161 mm BCOMPONENTDATUMWORKPIECEWith the Z axis positioned at the G28 Z cxis reference position, we can determine the tool offset byusing the formula:H A-BWhereH is the offset valueA is the distance from spindle gauge line to component datumB is the distance between the tool tip and component datumExampleH A-BH 250 - 161.0H 69.0NOTE:Each offset value found must be positive and entered into the appropriate offsetnumber.30
Your Notes:31
ISession TwoDuring this two hour session, participants will:I.Discuss toolholder manufacturing practices.2.Examine NC toolholding systems.3.Overview styles of toolholders.4.Discuss styles of collets, tool adapters, andextensions.5.Identify toolholders and various items.
A . MATERIALB . HEATSTEEL- 8620- ALLOYTREAT- CARBURI ZEANDHARDENED( Rc 35 INNER COREC . FINISH - BLACKD . BLACKOXIDEOXIDE- HELPS( NO BUILDUPRELEASESPINDLE33(Rc 58 EXTERIOR)ON OUTERTOOLHOLDERSURFACEFROMTHE
1. TOOL HOLDER TYPESFLANGE TOOLINGA. V1.2.3.4.VVVV30404550( ALSO KNOWN AS CAT)POPULAR )(POPULAR )(MrT Thd750.1,soci-:740:441413.500 T PFENGINEERING DATAtaperV30V401 872 693 25V.45V.504001251752 252 75GFED251 752 2581112 752 503 253 88TI, 13 x 1 00ss n . i 1234 10 s 1 501" 8 x 1 75i11IB. BT TOOLING351. BT402. BT453. BT504. BTJAPAN ORIGIN )((POPULAR)(POPULAR)ENGINEERING DATAta34h4r61358140814581502 152 573 254 001501 752 252.752 082 483 343 94M12 7, 1 75mmMI6 2 OommM20 z 2 50mmM2 4 3 00mm871 061 3C1 50
II00d'hj!,1117i:A. SHELL MILL ADAPTER - SHELL MILLB. END MILL ADAPTER - END MILL, BORING CHUCK - BAR354
St les of Too !holders2936
E. FLEX COLLET CHUCKS - GRIP & FLEX COLLETS.4-.IF. BORING RING ADAPTER.3037
St les of Too !holdersCOLLET REQUIREDG. LENGTH COMPENSATING TAP CHUCK - TAP NUT /.88 TENSION ( EXPAND()& .38 COMPRESSION )JTAP ADAPTERH. TAP COMPENSATING TAP ADAPTER - USE UNIVERSAL(.88 TENSION ( EXPAND )( SIZE 1SIZE 2(SIZE 3(& .38 COMPRESSION )0 - 9/19 TAP & 1/8 PIPE5/16 - 7/8 TAP & 1/4 ,1/2 PIPE ]1-3/8 TAP & 3/4, 1" PIPE )13/16)3138
TOOLHOLDER2.5IDENTIFICATIONE4SYSTEM14000\\SHANK STYLEC V-FLANGEB BT FLANGEM MILACRONHOLDERTAPER23456 3035404550TAPERTAPERTAPERTAPERTAPERACEFHJMPSTWX LENGTHSIZE (DEC)AUTOMATIVE 2 EXTRA SHORT3 STUBCOLLET4 STANDARDEND MILLSTUB ARBOR 5 EXTENDEDBORING HEAD 6 EXTRA EXTENDEDJACOBS TAPERMORSE TAPERRIGID.TAP HOLDERSHELL MILLTAPTEST BARBLANK BARrJl
ItVI i 3/4REF--a-REF.114t 34 REF. -v.REF.2)4100, AND 150100 SERIESC. SERIES AVAILABLE 075,B. EACH SIZE HAS A GRIPPING RANGE OF 1/64A. FITS ERICKSON STYLE COLLET CHUCKSE " COLLET ( SINGLE ANGLE )075 SERIESkr---A.150 SERIES1 'h. I 1/12 REF.3REF.41
GMANLFour different series to fit many needsCommandDouble AngleColletDifferent nose diameters to solve clearance problemsCollets collapse 1/64'Black oxide finish to protect precision ground surfacesThe last four digits of our collet part numbers are the ID sizeNOTE For best grip and precision we recommend the Micro Precisionni Collet series as found onpreceding pagesDACE-0030DACE-0020DACE-0010DACE-0018CI GEPART NO.AExtensions6.887.237.50.56.831,061.447.41DOUBLE ANGLE COLLETgDA20PART NO.PART DA20-0359SET:DA30-1400;DA18DA10DA30.PART NO.PART NO.DA10-0125DM 0-0140DA10-0156DA10-0171DA10-0187 ;DA10-0203DA10-03 n-0406 cREPLACEMENT NUT77-1DANDA10DA180 A20-2100DPART A18-05310A18-0546
ocopsng. UUUIJb. Waft. NC Rotary Tables. NC Tilting. Rotary Tables. Model. 1 RNCS 225 2 RNCX 125 320 3 RNC 800-2000 4 RNC,5 320 500 5 RNCV 160-1500 6 RNCM 250 630 7 RNCB 250-1250 8 RNCK 320-1250 9 RNCBK 250-1250 10 TRNC,B 160 320 11 TTNC 450-1000 12 THNC 250 320 Heads 3. NC Dividing. RDH. FHeutomatic Dividing. 14 I RD. ads. Multi-Spindle. With controller
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