CNC Control Setup for Milling and Turning Other books by Peter Smid: CNC PROGRAMMING HANDBOOK Comprehensive Guide to Practical CNC Programming Third Edition ‐ ISBN 9780831133474 CNC PROGRAMMING TECHNIQUES An Insider's Guide to Effective Methods and Applications ISBN 9780831131852 FANUC CNC CUSTOM MACROS Practical Resources for Fanuc Custom Macro B Users ISBN 9780831131579 CNC Control Setup for Milling and Turning Mastering CNC Control Systems Peter Smid Industrial Press, Inc. 989 Avenue of the Americas New York, NY 10018, USA http://www.industrialpress.com Library of Congress Cataloging-in-Publication Data Smid, Peter. CNC control setup for milling and turning : mastering CNC control systems / Peter Smid. p. cm. Includes index ISBN 978-0-8311-3350-4 (hard cover) 1. Milling-machines--Numerical control. 2. Turning (Lathe work)--Numerical control. 3. Machining-- Automation. I. Title. TJ1225.S557 2010 671.3'5--dc22 2010007023 Industrial Press, Inc. 989 Avenue of the Americas New York, NY 10018, USA Copyright © 2010 Printed in the United States of America All Rights Reserved. This book or parts thereof may not be reproduced, stored in a retrieval system, or transmitted in any form without the permission of the publishers. Cover Design: Janet Romano Editorial Director: John Carleo Marketing & Sales Director: Patrick V. Hansard 1 2 3 4 5 6 7 8 9 10 About the Author Peter Smid is a professional consultant, educator and speaker, with many years of practical, hands-on experience, in the industrial and educational fields. During his career, he has gathered an extensive experience with CNC and CAD/CAM applications on all levels. He consults to manufacturing industry and educational institutions on practical use of Computerized Numerical Control technology, part programming, Autocad®, Mastercam® and other CAD/CAM software, as well as advanced machining, tooling, setup, and many other related fields. His comprehen- sive industrial background in CNC programming, machining and company-oriented training has assisted several hundred companies to benefit from his wide-ranging knowledge. Mr. Smid’s long time association with advanced manufacturing companies and CNC machinery vendors, as well as his affiliation with a number of Community and Technical College industrial technology programs and machine shop skills training, have enabled him to broaden his professional and consulting skills in the areas of CNC and CAD/CAM training, computer applications and needs analysis, software evaluation, system benchmarking, pro- gramming, hardware selection, software customizing, and operations management. Over the years, Mr. Smid has developed and delivered hundreds of customized educational programs to thousands of instructors and students at colleges and universities across United States, Canada and Europe, as well as to a large number of manufacturing companies and private sector organizations and individuals. He has actively participated in many industrial trade shows, conferences, workshops and various seminars, includ- ing submission of papers, delivering presentations and a number of speaking engagements to professional organiza- tions. He is also the author of articles and many in-house publications on the subject of CNC and CAD/CAM. For six years he had a monthly column in the ShopTalk Magazine related to CNC programming. During his many years as a highly respected professional in the CNC industrial and educational field, he has developed tens of thousands of pages of high quality training materials. Peter Smid is also the author of three other best selling CNC books published by Industrial Press, Inc.: CNC PROGRAMMING HANDBOOK Comprehensive Guide to Practical CNC Programming Third Edition ‐ ISBN 9780831133474 CNC PROGRAMMING TECHNIQUES An Insider's Guide to Effective Methods and Applications ISBN 9780831131852 FANUC CNC CUSTOM MACROS Practical Resources for Fanuc Custom Macro B Users ISBN 9780831131579 All books are also available as e‐books The author welcomes comments, suggestions and other input from educators, students and industrial users. You can contact him at [email protected] Acknowledgments I have made a number of references to several manufacturers and software developers in the book. It is only fair to acknowledge their names: 2 FANUC and CUSTOM MACRO or USER MACRO or MACRO B are registered trademarks of Fanuc Ltd, Japan 2 Mastercam is a registered trademark of CNC Software Inc., Tolland, CT, USA 2 Edgecam is a registered trademark of Pathtrace, Inc., UK 2 NCPlot is a registered trademark of NCPlot LLC, Muskegon, MI, USA 2 AutoCad is a registered trademark of Autodesk, Inc., San Rafael, CA, USA 2 Kennametal is a registered trademark of Kennametal, Inc., Latrobe, PA, USA 2 WINDOWS is a registered trademarks of Microsoft, Inc., Redmond, WA, USA There are other companies mentioned in this handbook ... 2 Caterpillar 2 Fadal, Fagor 2 Haas, Heidenhain 2 Iscar 2 Kitamura 2 Makino, Matsuura, Mazak, Mitsubishi, Mori‐Seiki 2 Okuma, Osaka KiKo (OKK) 2 Sandvik, Seco, Siemens, Sumitomo 2 Valenite 2 Widia 2 Yasnac, Yamazaki 2 ... and some others that may have escaped me TABLE OF CONTENTS ix Table of Contents Chapter 1 CONCEPTS OF CNC MACHINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 CNC PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Drawing Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Material Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Part Holding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tooling Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Cutting Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Program Writing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Program Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Program Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Program Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 WORK COMPLETION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Program Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Material Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tooling Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tooling Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fixture Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Program Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Setting Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 First Part Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Program Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Production Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Part Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Chapter 2 CNC MACHINE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 MACHINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Useful Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 VERTICAL MACHINING CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Typical Specifications - VMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 HORIZONTAL MACHINING CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Typical Specifications - HMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 LATHES AND TURNING CENTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Typical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 FANUC SYSTEM SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Controlled Axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Operation Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Interpolation Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Feedrate Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Spindle Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Tool Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Program Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Editing Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Setting and Display Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9