Professional Documents
Culture Documents
CNC-Basics
MTS TeachWare Students Book
MTS Mathematisch Technische Software-Entwicklung GmbH
Kaiserin-Augusta-Allee 101 D-10553 Berlin
Phone: +49 / 30 / 349 960 - 0
Fax: +49 / 30 / 349 960 - 25
eMail: mts@mts-cnc.com
World Wide Web: http://www.mts-cnc.com
Created by BK & BM, 2005.
All rights reserved, including photomechanical reproduction and storage on electric media
Contents
Introduction into CNC Technology .................................................................................. 9
1.1
1.2
1.3
CNC-Exercise ...........................................................................................................................................28
Feed and Turning Axes on CNC Machines....................................................................................31
CNC-Demo........................................................................................................................ 34
CNC milling ...............................................................................................................................................34
CNC turning ..............................................................................................................................................35
2.2
NC Mathematics .............................................................................................................................36
Basics of coordinate point calculations ..........................................................................................36
Calculation of NC coordinates........................................................................................................39
2.3
CNC exercise............................................................................................................................................47
2.4
2.5
Inhalt
Using tool compensation values.................................................................................................... 62
Tool length compensation for milling and turning.......................................................................... 62
Tool radius compensations............................................................................................................ 63
Tool measuring and adjusting with an adjusting device ................................................................ 69
Tool measuring and setup using the CNC machine...................................................................... 71
2.6
3.2
3.3
3.4
3.5
Contents
4.2
NC programming basics...............................................................................................................146
NC programming standards (ISO)................................................................................................146
Structure of an NC program .........................................................................................................146
Structure of a program block ........................................................................................................147
Structure of a program word.........................................................................................................147
Comparison of programming codes/keys of various CNC controls .............................................149
4.3
2.
2.
1.1
CIM
CAD / CAM
CAD
FFS
CNC
NC
NC
1950
1960
Numerical control
1970
1980
1990
Figure 1
Development into CIM technology
The technical realization of this idea required a control which interprets binary and digital entries for travel
paths and switching operations in such a way that they could be understood and processed by the milling
machine. Herewith the basic principle was formulated for the application of numerical controls. The rapid
development of electronic data processing then enabled the practical realization.
First a corresponding NC control was developed for a vertical milling machine. The machining path and
switching information necessary for manufacturing was given on punch card. The idea was to control the
infeed axis of the milling machine so that separately working motors control the axis movements of the tool
carrier. The sequence of the travel path and switching information in form of code letters and numbers was
called a NC program.
This first NC machine tool already showed all the characteristics of the NC machines to be developed later
on:
Entry unit with numerical starting value for the travel path and switch information on a punch card.
Computer control to process the travel path and switch information.
Separate power supply for each infeed axis and spindle to control the movements of the tool and tool
carrier.
Measuring and control systems returning feedback to the controlling computer regarding the tool positions.
In the mid 50s almost all machine tool manufacturers began developing and manufacturing numerically controlled milling machines which were soon followed by NC lathes. The rapid development of new microeletronic components, such us micro processors and micro computers, enhanced the development of NC controls to CNC (computerized numerical control) controls in the mid 70s.
With the increased contribution of high-performance microprocessors it was possible to extend the operations of the computer controlled machine tools. The current microcomputers and CNC controls as well as the
PLC (programmable logic controller) of the machine tools have improved NC programming efficiency. Contour precision and machining speed of the tools as well as cutting power have continuously improved. Modern CNC controls additionally offer a multitude of further characteristics. This has made it possible, for instance, to program complex tool geometries without using mathematical calculations.
The continuous further development of CNC machine tools takes place in a reciprocal innovation exchange
between the manufacturers of microelectronic components, CNC controls, tools and machine tools. Users
also facilitate this increasingly rapid development by continuously demanding new and improved solutions.
CNC machining centers, flexible production systems (FFS) and fully automated manufacturing (CIM) mark
significant stages of this development which started in the 50s.
The following list shows some of the current user requirements:
interfaces with high performance for more rapid transfer of constantly increasing data
complete machining centers with high precision, e.g. CNC lathes with 7-32 NC axis, several spindles and
live milling tools for turning
high speed machining for turning, milling and boring with maximum dynamic travel path accuracy
development of servo motors whose scanning rate for defining the manufacturing dimensions becomes
smaller and smaller (presently the scanning speed is already less than 1ms)
minimizing the programming effort for the individual manufacturing tasks
simple, high-performance NC programming systems with dynamic-interactive simulation of the machining
processes
graphic control error diagnosis of the CNC machine tool or of the complete machining system
10
1.2
Machine Structure
The CNC machine tools are basically built in the same way as conventional machine tools. The difference
lies in the fact that the machine components relevant for turning and milling processes are controlled by
computers.
The movement directions of the components of a CNC controlled machine tool are specified by a coordinate
system, which refers to the work part to be machined and shows axes located parallel to the main linear
movement. The movements necessary for machining the individual machine tool assemblies (table, turret
and others) are calculated, controlled and tested by a computer. For this purpose each machining direction
has a separate measuring system to calculate the corresponding positions of the machine tool assemblies
and to return this information to the control.
Function
In the following overview conventional, NC and CNC machine tools are compared in their basic functionality:
Conventional
Machine Tools
NC Machine Tools
Entry:
Entry:
The qualified worker manually The NC program is transmitted to
adjusts the machine tool according the NC control using a punch card.
to the drawing, clamps the raw part
as well as the tools and aligns
them.
Entry:
NC programs can be entered into
the CNC control either using a
keyboard, disks or data interface
(serial, Bus). Several NC programs
are stored in an internal storage,
whereby modern controls also use
hard disks.
Manual control:
The qualified worker manually sets
the machining values (number of
rotations, infeed) and controls the
machining using hand wheels.
NC control:
The NC control processes the path
and feed information of the NC
program and passes the corresponding control signals to the
components of the NC machine.
CNC control:
The micro computer integrated in
the CNC control and the corresponding software take over all
control functions of the CNC machine. Hereby internal storage are
used for programs and subprograms, machine data, tool and
compensation values and fixed
and free cycles. Frequently, error
monitoring software is integrated in
the CNC control.
Dimension control:
The qualified worker manually
measures and verifies the dimensions of the work part and, if necessary, must repeat the machining
process.
NC machine:
The NC machine ensures the dimensional stability of the work part
already during the machining
process with the continuous feedback from the measuring system
and the servo motors.
CNC machine:
The CNC machine ensures the
dimensional stability of the work
part already during the machining
process with the continuous feedback from the measuring system
and the servo motor, which is controlled by the number of rotations.
Integrated measuring sensors
make it possible to control the
dimensions during the machining.
In parallel to active machining it is
possible to continue work on the
CNC control, e.g. to test and optimize new NC programs.
11
Productivity
Advantages of the CNC machine tool
1. The higher machining speed of the CNC machine tool as well as decreased basic, auxiliary, preparation
and finishing times on the machine increases productivity. The following factors are especially influential:
programming directly on the machine tool with manual entries
shared responsibility in a department responsible for work preparation for programming, materials and
tools and due entry of the data at the CNC work seat
storing recurrent machining processes of a tool specific program in form of subprograms
optimizing NC programs on the control
description of the work part shapes to be machined with simple geometry entries
automatic infeed of the tool until the required dimension has been reached
automatic initiation of all functions of the machine and direct intervention when identifying errors or
disturbances
automatic monitoring of the production through the CNC control (automatic measuring and testing)
universal application of tools in tool clamping systems
possibility to preset the tools outside of the machine tool without influencing machine run-time
2. Constant quality of the work part and less scrap.
3. Increased dimension precision of the work part through high basic precision of the machine tool
(1/1000 mm)
4. Short run-through-times through product organization and combination of split machining processes
5. Improved machine utilization and rentability
6. Improved production flexibility through machining systems and correspondingly rational production of
small lots or single work parts with high complexity
Due to the advantages mentioned above the CNC machine tools are prevalent in cutting production. The
wide application field (see figure 2) is a typical characteristic of the CNC machine tools.
Figure 2
Application field of CNC machine tools
Requirements for using CNC machine tools
To operate and program CNC machine tools the machine operator needs a higher qualification. Experience
from conventional machining can not necessarily be transferred.
12
1.3
Figure 3
Controllable NC axes on an automatic lathe
CNC- milling machines (see figure 4) on the other hand have at least 3 controllable or adjustable feed axes
marked as X, Y, Z.
Figure 4
Controllable NC axes on a milling machine
MTS TeachWare CNC-Grundlagen Students Book
13
+B
+A
+X
+C
+Z
Figure 5
Feed and rotation axes
in Cartesian coordinate system
Often further controllable feed axes are needed. These are then marked as U, V, W. Additionally there are
the adjustable rotation axes around which the machining table, head stock and tool holder can rotate independent of the feed axes. They are marked as A, B and C.
The required tool and work part carriers are moved by feed drives. The feed drives meet the highest requirements due to high machining and iteration precision. The individual axis movements must be carried
out with maximum feed speed and minimum positioning time. To meet these requirements a modern feed
drive (see figure 6) consists of the following components:
motor, mechanical gears against overload as well as electronic control
ball screw drive for power transfer free from play
sensor as path measuring system, mostly located at the free end of the axis
power amplifier with analog or digital interfaces for CNC control
For exact positioning the feed drives are connected with the measuring facilities. Each controllable axis of a
CNC machine needs a path measuring system with automatic interpretation of the measuring signal. The
most frequently used resolution for length measuring is 0.001 mm, however for the X axis of the lathe (diameter dimension) 0.0005 and for the precision grinding machine up to 0.0001 are customary.
2
1
feed drive
work table
measuring system
ball screw
Figure 6
Feed drive for carrier with ball screw drive
14
2
ball screw nut
Clamping ring
balls
Drive spindle
3
4
Figure 7
ball screw drive with play-free double nut
The manufacturing tolerances resulting from the manufacturing process of the ball screw drive can be rectified by modern CNC controls using the spindle pitch error adjustment. For this purpose the tolerances are
measured by laser measuring systems and stored in the CNC control.
pick-up
1
2
Figure 8
Direct position measuring
15
carrier
Figure 9
Indirect position measuring
In absolute position measuring (see figure 10) a coded measuring scale immediately shows the position
of the carrier with reference to one fixed orientation point on the machine. This point is the machine zero
point, which is specified by the machine manufacturer. This method presupposes that the reading-in area of
the measuring scale is as large as the machining area and that the coding of the measuring scale is binary.
This is to enable the control to allocate a numerical value to each read-in position.
012345678
2
binary-coded measuring scale
current tool carrier position
Figure 10
Absolute position measuring
In incremental position measuring (see figure 11) a measuring scale with a simple grating consisting of
light and dark fields is used. For a feed movement passing the sensor the sensor counts the number of light
and dark fields and calculates the current carrier position based on the difference from the last carrier position.
4
ruled grating
previous carrier position
current carrier position
carrier on reference point
Figure 11
Incremental position measuring
16
The control has once to be given one absolute position, which it then uses as a reference point when calculating the current carrier position using incremental position measuring. Therefore, it is necessary to go to
this absolute point once the control is started. This absolute point is called the reference point on the machine. Each axes movement, even when traveled manually using the hand wheel or buttons, needs to be
registered by the control.
Since the control loses the control/information on mechanical movements when switched off the reference
point has to be returned to each time the control is switched on.
17
Figure 12
Example of a turret
Depending on the type and size, the turrets of the CNC machines have 8 to 16 tool places. In large milling
centers up to 3 turrets can be used simultaneously. If more than 48 tools are used tool magazines of different types are used in such machining centers allowing a charge of up to 100 and even more tools. There are
longitudinal magazines, ring magazines, plate magazines and chain magazines (see figure 13) as well as
cassette magazines.
18
milling tools
3
4
Figure 14
Automatic tool change facility
In the tool magazine the tool change takes place using a gripping system also called tool changer (see figure
14). The change takes place with a double arm gripping device after a new tool has been called in the NC
program as follows:
The tool change procedure takes between 6 to 15 seconds, whereby the quickest tool changers are able to
make the tool change in merely one second.
19
Workshop
Clarification of machine parts of CNC machines in the workshop.
The parts of machine tools should be shown and explained on the available machine tools. Similarities and
differences between conventional machine tools and CNC machine tools are to be emphasized.
20
Discuss relevant differences between CNC machine tools and conventional machine tools.
1.
1.
What are the advantages of CNC machine tools compared with conventional machine tools?
1.
1.
1.
1.
1.
How many feed axes at minimum should be available on a CNC milling machine?
1.
1.
1.
1.
Which operations can be achieved by controllable rotation axes on CNC milling machines?
1.
1.
1.
1.
What are the advantages of main drive motors with controllable number of rotations?
1.
1.
21
22
3.
2.1
Example:
P2
P1
X
P1
X= 80
Y= 40
P2
X= -80
Y= 70
P3
X= -50
Y= -40
P4
X= 40
Y= -70
P3
P4
Figure 15
Cartesian coordinate system with 2 axis (X;Y)
If a work part drawing is placed in this coordinate system all important work points can be determined. Depending on where the zero point of the work part is placed, it is possible to exactly define the points either
with positive or also with negative coordinates.
MTS TeachWare CNC-Grundlagen Students Book
23
P1
Example:
P1
X= 30
Y= 20
Z=
P2
X= 30
Y=
Z= -10
X
P2
Figure 16
Cartesian coordinate system with 3 axes (X,Y,Z)
The specifications of the three axes as well as the three coordinates is done as a so-called clockwiserotating system and follows the right-hand-rule (see figure 17). The fingers of the right hand always show to
the positive direction of each axis.
This system is also called the clockwise-rotating coordinate system.
+Y
+X
+Z
Figure 17
Right-hand-rule
24
Figure 18
Polar coordinate system (positive angle )
Figure 19
Polar coordinate system (negative angle )
Figure 20
25
Y
M
Figure 22
Work part coordinate system
26
Figure 23
Milling part in three-dimensional Cartesian coordinate
system
For an easier calculation of the points needed for programming it is advisable to use the outer edges of the
upper (see figure 24) or the lower area (see figure 25).
Z
Y
Figure 24
Work part zero point in the upper left outer edge
Figure 25
Work part zero point in the lower left outer edge
CNC lathes
In the CNC lathes the working spindle (tool carrier) is specified as Z axis. This means the Z axis is identical
to the rotation axis (see figure 26 and 27). The direction of the Z axis is specified so that the tool withdraws
from the work part when moving to the positive axis direction.
The X axis is located in a right angle to the Z axis. However, the direction of the X axis always depends on if
the tool is located in front of (see figure 26) or behind (see figure 27) the rotation center.
27
+X
+Z
+Z
W
+X
Figure 26
Milling work part in Cartesian coordinate system
with 2-axis tool in front of the rotation center
Figure 27
Milling work part in Cartesian coordinate system
with 2-axis tool behind the rotation center
CNC-Exercise
Working with different coordinate systems
X
a
X
d
c
28
b
c
d
Z
Y
a
10
20
-80
-30
40
-70
-30
50
a
b
c
d
29
a
b
d
e
f
g
h
In a drawing milling work parts are specified by their diameter. Therefore, the diameter is also included for
programming.
Enter the Cartesian coordinates of the points a to g in the table. Determine the corresponding diameter values of the X coordinates!
b
a
d
e
f
g
30
+Z
+Y
-Z
-Y
-X
+X
-X
+X
-Y
+Z
+Y
-Z
Figure 28
Axis on the vertical milling machine
Figure 29
Axis on the horizontal milling machine
In a CNC lathe the working spindle is defined as the Z axis (see figure 30). The positive Z direction runs from
the work part to the tool. The X axis is vertical to the Z axis. The positive direction of the X axis runs here to
the rear (tool behind the rotation center). One rotation axis - the C axis - is available when the working spindle is approached..
+X
+Z
Figure 30
Axes on the lathe
31
+Y
+Z
+X
Figure 31
Directions of motion on a milling machine
To be able to program regardless of machine, the following definition is introduced.
During programming it is always assumed that the tool moves. The coordinate
system always refers to the work part.
Using this definition the work part coordinates can always be applied to generate the NC program.
NC compatible dimensioning
Two different types of dimensioning are used in NC programming:
absolute dimensioning and
incremental dimensioning (incremental values).
Absolute dimensioning always refers to the work part zero point, i.e. reference dimensions are used
(see figure 32). In contrast, incremental dimensioning uses incremental values which are always measured
from the current point to the next point (see figure 33).
When turning, the X values for absolute dimensioning are diameter values, whereas for incremental dimensioning they refer to radius values.
+X
+X
-Z
-Z
Figure 32
Example for absolute dimensioning
32
Figure 33
Example for incremental dimensioning
NC compatible drawings should therefore avoid incremental values and use coordinate values referring to
one reference point.
Despite these advantages it is not always possible to avoid incremental dimensioning in programming. It is,
for example, an advantage when several identical contour parts, such as recesses, are consecutively machined.
33
CNC-Demo
CNC milling
Description
Entry
F2 (Milling)
+Z
Pos 1
-X
-Y
Ende
2
-Z
Einfg
+Y
Bild
+X
( + X - direction )
( - X - direction )
( + Y - direction )
( - Y - direction )
Bild
Ende
Bild
( + Z - direction )
( - Z - direction )
Entf
F8 (Quit)
CNC-Exercise: With the CNC simulator each student practices moving along the NC axes.
34
CNC turning
Description
Entry
F1 (Turning)
+X
Pos 1
-Z
8
5
2
-X
Einfg
6
3
+Z
( + Z - direction )
( - Z - direction )
( + X - direction )
( - X - direction )
Bild
Entf
F8 (Quit)
CNC-Exercise: With the CNC simulator each student practices moving along the NC axes.
Workshop
Using the CNC machines available the students move along the controllable NC axes. Hereby the corresponding operation instructions of the machine have to be followed.
Exercise: With the CNC simulator each student practices moving along the NC machine tool.
35
2.2
NC Mathematics
Angles
, and are the corresponding angles in
the corners of the triangle.
Sides
a, b and c mark the sides of the triangle opposite to the corners A, B and C.
Figure 34
Characteristic values of a triangle
Angles of the triangle
The angles of the triangle specify the type of the triangle. Depending on the sizes of the triangle angles the
triangle is either an acute-angled, obtuse or right-angled triangle (see figure 35 - 37)
C
b
Figure 35
Acute-angled triangle
All angles are smaller than 90.
Figure 36
Obtuse triangle
One angle is larger than 90.
Figure 37
right-angled triangle
One angle is 90.
For a triangle the relation applies: the sum of the triangle angles , and is always 180.
+ + = 180o
With this formula it is possible to calculate one unknown angle if the other two angles are known.
36
counter cathetus
adjacent cathetus
1
hypotenuse
right angle
Figure 38
Right-angled triangle
The following applies for a right-angled triangle:
In a right-angled triangle it is possible to calculate the length of an unknown side if the other two side lengths
are known. For this, the Pythagorean theorem (see figure 39) is used.
The Greek Pythagoras (approx. 580 - 496 BC) was
the first to verify the following mathematical relation
which was called after him
the Pythagorean theorem
b
b
a2 + b2 = c 2
c
a = c 2 b2
b = c 2 a2
Figure 39
The Pythagorean theorem
c = a2 + b2
37
hypotenuse
sin =
counter cathetus
hypotenuse
Figure 40
Sine function
adjacent cathetus
hypotenuse
cos =
adjacent cathetus
hypotenuse
Figure 41
Cosine function
counter cathetus
adjacent cathetus
tan =
2
counter cathetus
adjacent cathetus
Figure 42
Tangent function
When calculating the unknown side the corresponding equations need to be transformed according to the
following example:
known values:
unknown value:
equation:
tan =
38
Calculation of NC coordinates
Work part drawings are not always dimensioned NC-compatible. In addition to incremental values, angle
values are also frequently given in drawings. Consequently, when programming manually the programmer
has to calculate unknown Cartesian coordinates using the points to be programmed.
In the following drawing the coordinates of the points b, c and f need to be calculated. The other points are
known.
Y
f
e
25
g
c
15
15
15
35
85
35
85
85
85
15
65
25
X
Calculation of the point b:
known :
25
solution : x = 65 mm - dx
dx = radius of the arc
dx
dx = 25 mm
x = 65 mm - 25 mm
x = 40 mm
known :
dy
25
dx
dx = ( 25mm ) ( 20mm )
dx = 225mm 2
dx = 15mm
2
x = 65 mm + 15 mm
x = 80 mm
39
known :
dx
solution : x = 15 mm + dx
equation: counter cathetus = adjacent cathesis * tan
dx = 20 mm * tan 25
dx = 20 mm * 0.4663
dx = 9.326 mm
x = 15 mm + 9.326 mm
dy
f
25
x = 24.326 mm
CNC exercise
Enter the Cartesian coordinates from the center points of the drillings a to h in the table. Give all values
rounded to three decimal points.
Y
X
60
100
c
d
h
g
e
50
50
f
g
h
100
85
70
50
unknown : Y coordinate
40
80
30
85
35
90
80
unknown: Y coordinate
2.3
reference point
Figure 43
Location of the zero and reference points for turning
Reference point R
R
M
A machine tool with an incremental travel path measuring system needs a calibration point which also
serves for controlling the tool and work part
movements. This calibration point is called the reference point R. Its location is set exactly by a limit
switch on each travel axis. The coordinates of the
reference point, with reference to the machine zero
point, always have the same value. This value has a
set adjustment in the CNC control. After switching the
machine on the reference point has to be approached from all axes to calibrate the incremental
travel path measuring system.
Figure 44
Location of the zero and reference point for milling
41
+X
+Z
W
+Z
+X
Figure 45
Work part zero point of the turned part
Z
Y
Figure 46
Work part zero point of a milled part.
Tool reference point E
A further important point in the machine work space is the tool reference point E. The tool reference point E
of a CNC lathe is a fixed point on its tool carrier. On a CNC milling machine the tool reference point E is located on the tool spindle.
The CNC control refers first to the tool reference point for all target point coordinates. When programming
the target coordinates either the tool tip of the turning tool or the center of the milling tool is referred to. To be
able to control exactly the tool tip in turning or the tools in milling along the desired machining travel path
they have to be measured precisely. It is possible to measure the tools either outside the machine with a
preset device or directly on the machine using special optics. When using an optic, the measured values are
42
Figure 47
Tool setup point of a turning tool
Location of the tool setup point at B
of a milling tool
B
L
R
Figure 48
Tool setup point of a milling tool
Location of the toolholding point A
on a turret
A
toolholding point
Figure 49
Toolholding point of a turret
If the tool system (tool post with tool) is placed into the tool carrier (i.e. a turret), then the tool setup point B
and the toolholding point A fall together and make up the tool reference point E.
Tool change point N
The tool change point N is the point in the CNC machine work space on which the tools can be changed
without collision. In most CNC controls the tool change point can be configured.
43
zw
Figure 50
Setting the work part zero point on a CNC lathe
Procedure
Starting situation: All machining tools have been measured and are available on the turret head.
The clamping device is prepared and the work part has been correctly clamped.
1. Switch on the spindle (counterclockwise rotation).
1. Change the tool to set the work part zero point, i.e. rotate the turret head to the corresponding position,
for instance T02.
Note:
The rotation area of the turret has to be checked first to avoid collision during rotation.
44
R
M
Figure 51
Setting the work part zero point on a CNC milling
machine
Z
Figure 52
Resetting in Z
Z
Figure 53
Resetting in X
The tool is raised again and taken into the new resetting position for the X axis. With the spindle switched
on it is moved along the side surface of the work part
(Y, Z plane) in the X direction (see figure 53) until a
small marking is made on the work part surface
(touching the work part).
When touching the work part in X axis the radius of
the applied tool has to be considered when confirming the value with the IST key, since the center point
coordinates of the tool are always used in NC programming.
If the milling tool of the adjacent figure has, for instance, a radius of 15 mm, then the value X=-15 is
entered into the NC control and confirmed with IST.
.
45
3. Resetting in Y direction
Figure 54
Resetting in Y
46
CNC exercise
Setting the work part zero point W in the CNC simulator Turning
By setting the work part zero point W the relation between the machine based and work part based coordinate system is created. The work part zero point corresponds to the drawing zero point. Consequently, the
drawing dimensions can be used in programming. Using the operation steps described below the distance
between the machine zero point M and the work part zero point W can be specified. This Z value is also
called the zero shift zw.
Starting situation:
All machining tools are dimensioned and available
on the turret head.
The work part is clamped in chuck jaws.
The work part zero point is located on the front
plane surface, whereby an allowance of 1mm has
to be considered.
zw
Description
Entry
F1 (Turning)
F3 (Setup mode)
Using the numeric keyboard press the corresponding arrow key simultaneously with the
shift key:
confirm.
+X
+ 4
+ 2
+Z
Travel direction options:
+X
Pos 1
-Z
2
0
Einfg
-X
6
3
Bild
+Z
( + Z - direction )
( - Z - direction )
( + X - direction )
( - X - direction )
Entf
47
F3 (Technology)
F5 (Increment)
F2 (Increment 0.1)
4
ESC
Then press
and
F8 (Quit).
8. Set the work part zero point in Z.
F4 (Tool datum)
F4 (Set datum)
F1 (Set Z coord.)
Type z+1using the keyboard and confirm
+ 8
F8 (Quit)
F8 (Quit)
F8 (Quit)
48
Setting the work part zero point W in the CNC simulator milling
In milling, setting the work part zero point W coordinates the work part zero point with the drawing zero point.
Please note that only the tool moves in the MTS simulator!
Using the operation steps described below the distance between the machine zero point M and the work
part zero point W in the three coordinates X, Y and Z is defined.
Starting situation:
Description
Entry
F2 (Milling)
F3 (Setup mode)
Using the numeric keyboard press the corresponding arrow key together with the shift
key:
confirm.
Z
W
Pos 1
+Y
Bild
+X
Bild
-Y
+ 2
X
+Z
-X
Ex.:
Ende
Einfg
2
-Z
Bild
Ende
8
2
( + X direction )
( - X direction )
( + Y direction )
( - Y direction )
( + Z direction )
( - Z direction )
Entf
49
F3 (Technology)
F5 (Increment)
F2 (Increment 0.1)
2
ESC
Then press
and
F8 (Quit).
8. Set the work part zero point in Z.
F4 (Tool/ Datum)
F4 (Set Datum)
F3 (set Z coord.)
Type in the data on the keyboard 0 and
F8 confirm it.
Check Z by setting the zero point and using the displayed coordinate values.
1
Z
+ 4
50
2) in -Z direction
+ 2
Then press
and
F8 (return).
12. Set the work part zero point in X.
F4 (set datum)
F1 (set X coordinate)
Type -10 using the keyboard and confirm.
F8
Check the X by setting the zero point using the displayed coordinate values.
14. Take the tool in rapid speed to the new resetting position approx. 5mm off the front side.
Z
W
1
3
+ 8
Using the numeric keyboard press the corresponding arrow key together with the shift
key:
1) in +X direction
+ 6
2) in -Y direction
3) in -Z direction
+ 2
51
Bild
ESC
Then press
and
F8 (Quit).
16. Set the work part zero point in Y.
Please, note the tool radius!
So, enter for the Y coordinate the negative
value of the radius, for instance -10.
F4 (Tool/Datum)
F4 (set Datum)
F2 (set Y coord.)
Type -10 using the keyboard and confirm
F8 key.
Check the Y by setting the zero point using the displayed coordinate values.
use the numeric keyboard and press the arrow key together with the shift key:
F8 (Quit)
F8 (Quit)
52
2.4
disturbance value
control path
3
Figure 55
Function principle of a control chain
Since such a control chain generates an incorrect output value it is connected with the control. The control is
a sequence of operations which constantly recalculates and adjusts the actual value to reach the required
value.This closed sequence of operations is called a control loop (see figure 56)..
1
2
4
control path
measuring equipment
5
Figure 56
Function principle of a control loop
In a CNC machine tool the principle of a control loop is applied as a position control for the axis.
CNC Control
Structure and function
The CNC control is designed to decode a NC program and to process it as geometrical and technological
information. Using CNC control it is possible to control or check the corresponding components of the CNC
machine tool so that the desired work part is formed. The functions of the CNC control can be classified as
data entry, data processing or data output (see figure 57).
Data entry and data processing
The data entry is done using the control panel consisting of a keyboard and monitor. Here the NC programs
can be generated and managed, data can be entered or program simulations can be called . The NC programs can also be read in or stored using external data carriers, such as data cassettes. It is also possible
53
technological
processing
geometrical
processing
adjustment control
X,Y,Z
axis control
actual position
value
data entry
data processing
data output
Figure 57
Structure of a CNC control
The data needed by the CNC machine tool to operate and machine the work part is generated out of the NC
data by the data processing of the CNC control.
The technological data is used e.g. for tool selection, for adjusting the spindle rotation speed, for selecting
the spindle direction of rotation or for switching the coolant on and off. They are transmitted through the adjustment control to the corresponding component of the CNC machine tool.
The geometrical information of a NC program is translated from the CNC control into set values for the different axial drives under consideration of the infeed values. The travel movements which are so created are
continuously controlled by the position control loop of the feed axis.
Travel movement using interpolation
In technical applications by far all contour lines can be classified in straight lines and circular elements. This
is the reason why the majority of the CNC controls manufactured today are equipped only with straight line
and circular interpolation. In our CNC controls interpolations of parabolas and cubic parabolas, helical interpolations and spline interpolations are also available.
If a tool goes from the starting point to a target point which is not parallel to the axis it is a question of a
straight line interpolation. To achieve a straight tool path the relevant axes have to be correspondingly adjusted to each other. The relation of the axis feeds defines then the direction of the straight lines
(see figure 58 and 59).
Y
1
1
1
2
1
X
54
X
aimed travel movement
Figure 59
Relation of axial feeds
Figure 60
Travel path of a plotter pen
The same principle is used for the interpolator of a CNC control. It calculates the intermediate values needed
for interpolation and transmits them as set values to the position control circles.
In straight line interpolation two or three axes move simultaneously (see figure 61), whereby their travel
movements are adjusted to each other in a certain relation.
If the tool moves in a circular path from the starting point it is a question of a circular interpolation
(see figure 62). The tool moves here either in clockwise or in counterclockwise direction. To achieve a circular tool path the travel movements of both axes, also depending on the path already traveled, have to be
adjusted to each other. The axis movement corresponds to a sine or cosine curve. The overlay of the two
axis makes out the arc.
Z
Figure 61
Straight line interpolation
Figure 62
Circular interpolation
55
- 2D path control
- 2 D path control
- 3D path control
Point control
It is the simplest control type. In case of a point control a target point is approached in rapid speed and a
machining operation is carried out at the target point
(see figure 63). In the same way several target points
can be approached one after an other.
The point control can be applied to work parts for
which machining is made only at certain points, e.g.
for machining surfaces by boring, reaming, recessing, threading, spot welding, punching.
Figure 63
Point control
Line control
With the line control only tool travel paths which are
parallel to axes and which have programmed infeed
values can be controlled (see figure 64).
The generated work part contours can only be parallel to axis.
The line control can be applied in cases where machining is supposed to take place only on planes
parallel to the guideways of the machine, e.g. for
simple plane and straight turning, plane parallel milling or breakthrough milling where machining takes
place in one direction at a time.
Figure 64
Line control
Path control
In path control it is possible to control any travel
paths (straight, inclines, circular, splines) of the tool
applied on planes or in space.
It is possible to achieve any contour line
(see figure 65) through the controlled interaction of
two or more infeed motors.
Figure 65
Path control on a CNC machine
56
To be able to carry out the movements simultaneously on all machine axes all intermediate values
located on the mathematically specified curve between the starting and end point need to be first calculated by the CNC control.
57
Figure 66
2D path control
2 D path control
The 2 D path control makes it possible to carry out tool movements on several planes by switching the
interpolation in each case on one of the three main planes. All three axes are controllable in 2 D path control, however in every plane only two axes simultaneously. The third axes is the so-called infeed axis.
Depending on the selected machining plane different
axis can be controlled simultaneously so that it is
possible to travel in the following directions:
- X/Y plane (see figure 67),
- X/Z plane (see figure 68),
- Y/Z plane (see figure 69).
Figure 67
2D path control (X/Y plane)
Figure 68
2D path control (X/Z plane)
Figure 69
2D path control (Y/Z plane
3 D path control
In 3 D path controls three axes are interpolated simultaneously. Herewith it is possible to realize threedimensional tool movements.
It enables complicated contours, e.g. in tool construction, especially in molded construction, to be machined in one clamping.
58
59
DNC operation
Characteristics of DNC operation
DNC is the abbreviation of direct numerical control. It is the name of an operation mode in which several NC
and CNC machines as well as further devices are connected with each other. These devices can be for instance tool presetting machines, measuring machines, programming seats and a central material and tool
management (see figure 70).
CAD
NC-Programming
PPS
...
Local area
Network (LAN)
NC
archive
...
Figure 70
Structure of a DNC system
The connection between the components of a DNC system is realized by a data bus. This direct data transmission makes the conventional data carriers such as punch cards, magnetic stripes, discs as well as the
corresponding recording and read-in instruments unnecessary.
The significant characteristic of the DNC operation is the management and timely disposition of the information. To be able to calculate and distribute this information to the right position, interfaces are needed.
Through the interfaces all the integrated parts of the DNC net are connected with the master computer. The
master computer is able to calculate machine and production data, switch operation modes, address, read-in
and record the correct storage location as well as automatically transmit them to the machine upstream computers.
Data input and data processing in DNC operation
Through the structure of a DNC system (see figure 70) it is possible to enter data into different devices.
These devices can be located far away from each other.
Small NC programs can be written directly on the CNC machine tool. For writing extensive or complicated
NC programs it is better to use an external programming work station.
A DNC system generally includes the following basic functions.
storage and management of NC programs
correct distribution of NC programs to the machines
re-transmission of the corrected and optimized NC programs from the machine to the master data
storage medium
60
For this purpose there is a central management of the NC programs in the DNC system. The generated and
optimized NC programs are transmitted to the corresponding computers through data links. In case the CNC
machine tool is not equipped with a special DNC port a DNC terminal controls the organization of the data
transmission between the CNC control and master computer.
Depending on the model of a DNC system the following additional functions can be available:
central tool management and tool compensation data
interface for tool presetting devices
work part management
set time value and definition of working sequences
control of the material flow
central storage of the current data bases
central cooperation data and machine data acquisition (BDE, MDE) with graphical evaluation
NC programming with postprocessor conversion
graphical simulation with representation of the tool, clamping device and work part contour
Advantages of the DNC operation system
A DNC operation system has the following advantages compared with a solution with non-integrated CNC
machine tools:
improved workshop organization
immediate availability of programs and additional information
minimal standstill times of the CNC machine through the continuous provision of NC programs,
tools and material
reduced data entry errors
operating data and machine data acquisition (BDE, MDE) enable the user to control and record at
any time the production data (machine operating times, out-of-service-times, down times, etc.),
maintenance information and information on reasons for out-of-service-times
Workshop
The different CNC control types are demonstrated on the CNC machine tools available.
If no CNC machine tools are available for point or line control these CNC control types can be simulated with
the help of the corresponding work parts.
Example:
point control
milling machine: go to boreholes
line control
milling machine: travel parallel to axis
lathe: travel parallel to axis
2D path control
milling machine: travel linear on two axis
milling machine: travel in a circle
lathe: machine a cone or rounding
2 D path control
milling machine: travel on various planes
milling machine: travel in a circle on various planes
3 D path control
milling machine: travel linear on two axis
MTS TeachWare CNC-Grundlagen Students Book
61
2.5
R
Figure 71
Tool compensation values on a cutting tool
In case of lathe tools the length L is defined in Z direction (see figure 72).
cutting radius
Figure 72
Tool compensation values on a lathe tool
In the CNC control these tool compensation values are stored in the compensation value storage, whereby
in most CNC controls it is possible to describe up to 99 tools. These values have to be activated during ma-
62
Figure 73
Milling center point paths (equidisants)
One equidisant is the tool center point path running in constant distance to the programmed path (contour) of
the work part. In discontinuous path transitions, i.e. in the inner and outer corners (see figure 74 and 75),
the transitions become equidisants, for instance, through insertion of arcs, in accordance with the controlspecific rules.
2
1
programmed path
programmed path
Figure 74
Inner corner in milling
Figure 75
Outer corner in milling
The CNC control calculates the contour-parallel milling center point path necessary for machining. The calculations are based on the radius value of the current milling tool, which is stored in the tool compensation
63
2
left of the contour
right of the contour
programmed contours
Figure 76
Machining directions in milling radius correction
The following figures demonstrate the selection of the milling radius compensation which depends on the
position of the tool with reference to the contour to be machined
outside machining (see figure 77) and in
inside machining (see figure 78).
2
1
1
2
programmed contour
programmed contour
Figure 77
Milling radius compensation in outside machining
64
Figure 78
Milling radius compensation in inside machining
3
2
5
2
Figure 79
Unavoidable error in turning:
contour inside corner remains
Figure 80
Error in turning: cone is not true-to-size
according to the programmed contour
programmed contour
programmed contour
The location of the actually traveled tool paths (equidisant see figure 81) is automatically calculated by the
cutter radius compensation in modern CNC controls.The following three facts have to be considered:
1. The radius of the tool tip has to be available in the compensation value storage of the CNC control.
1. The location of the tool tip (cutter compensation value vector) has to be available for the CNC control.
1. The machining direction of the tool with reference to the contour has to be correspondingly
programmed in NC programming.
the center point path (equidisant) calculated by the CNC control on which the
tool travels during machining
65
1
R
cutting radius
Figure 82
Cutting radius compensation value vector
Different cutting radius compensation value vectors have to be entered into the control depending on the fact
in which machining quadrant the applied tools are located (see figure 83). When entering the compensation
values I and K the signs of the resulting value have to be considered.
8
4
2
6
K=R
I=R
2. quadrant:
K = -R
I=R
3. quadrant:
K = -R
I = -R
4. quadrant:
K=R
I = -R
5. quadrant:
K=R
I=0
6. quadrant:
K=0
I=R
7. quadrant:
K = -R
I=0
8. quadrant:
K=0
I = -R
Figure 83
Values for the cutting radius compensation value vector
which depend on the current machining quadrant of the
tool.
66
The following example demonstrates how to define the compensation values I and K (see figure 84).
cutting edge in machining quadrant 3
cutting edge radius R = 0,8 mm
The values I and K are as follows:
K = -0,8
= -0,8
K
Figure 84
Example: Cutting edge radius compensation value
When calling the cutting edge radius compensation in the program the location of the turning tool in travel
direction has to be entered into the CNC control by using the corresponding command:
turning tool is located left of the contour in travel direction or
turning tool is located right of the contour in travel direction
The following figures demonstrate the programming of the cutting radius compensation in dependence upon
the location of the tool with reference to the contour to be machined in case of
outside machining (see figure 85 and figure 86) and in case of
inside machining (see figure 87 and figure 88).
Figure 85
Cutting radius compensation in case of outside machining
left of the contour
machining direction of the tool
left of the contour
Figure 86
Cutting radius compensation in case of outside machining
right of the contour
machining direction of the tool
right of the contour
67
programmed contour
Figure 87
Cutting radius correction, inside machining,
left of the contour.
Figure 88
Cutting radius correction, inside machining,
right of the contour
programmed contour
programmed contour
Just like programming a milling work part it is possible to directly program the contour to be machined using
the work part drawings data without data conversion. In turning as well, the selected cutting edge radius
compensation has to be switched off with the corresponding command.
68
Figure 89
Universal tool measuring and setup device
A tool setup device consists in general of four main components:
In addition to this, an electronic measuring device for measuring the tool compensation values and a storage
medium for storing data, e.g. the milling radius R and length L, are available.
69
The target is to precisely define the length L and the overhang Q (see figure 90) of the turning tool to be
able to give the CNC control the corresponding compensation values in X and Z.
B
L
L
Figure 90
Measuring a turning tool
Clamp the turning tool to be measured in the tool shank corresponding to the current turret.
Switch on and adjust the tool measuring and setup device.
Measure the lathe tool.
Using the control desk of the tool setup device the compound slide rest is moved with the lathe tool to
be measured in X and Z (see figure 91).
Figure 91
Display crosslines of a tool setup device
with exact positioning of the tip of the turning tool
The aim of the infeed is to adjust the tool cutting edge exactly on the display crosslines of the measuring device.
Now the length L and the overhang Q of the lathe tool on the tool setup device display can be read-in.
These values correspond to the compensation values of the clamped lathe tool in X and Z.
Store the measured compensation values
The compensation values are now either manually listed for a later entry into the CNC machine, or
they are directly carried into the CNC machine through a data link between the tool set-up device and
the CNC control in DNC mode.
Declamp the turning tool
The turning tool can now be declamped from the tool set-up device to allow a further tool to be measured.
70
Figure 92
71
Disadvantages
increased flexibility
improved design of machine work places
reduced investment since
- tool setup devices
- complicated tool holder systems
are not needed
CNC exercise
Working with tool compensation values in the MTS simulation
The MTS software, just like a real CNC machine tool, allows the user to allocate one or several compensation switches to each tool. With these switches the tool compensation values of the tool are called.
Exercise:
The following work part is to be machined, including rough turning and final turning, using a left corner turning tool and the set compensation switches. The corner turning tool
T05
CL-SDJCL-2020/L/1204 ISO30
is applied with the setting value for overhang Q and the length L to be entered in the compensation value
register D25.
It is assumed:
Setting-up the MTS simulator according to the following set-up data:
PART
CYLINDER D060.000 L082.000
MATERIAL C 45 W-Nr: 1.0503
DENSITY 007.90
MAIN SPINDLE WITH WORKPART
CHUCK KITAGAWA B-208
STEP JAW KITAGAWA-1
CHUCKING DEPTH E32.000
RIGHT SIDE OF THE PART: Z+209.500
TOOLS
T05 LEFT CORNER TOOL
CL-SDJCL-2020/R/1204 ISO30
72
Entry
F1 (Turning)
F3 (Setup mode)
F4 (Tool data)
F2
(Turret display)
Enter on the keyboard 25 using
Z: +43.0
X: +60.5
Cutting radius:
R:
0.4
Size:
G:
0.0
Recessing angle:
E: 32.178
Compensation:
K:
I:
-0.4
-0.4
F8 (Quit)
F8 (Quit)
F8 (Quit)
73
Drawing
N010
N015
N020
N025
N030
N035
N040
N045
N050
N055
N060
N065
N070
N075
N080
N085
N090
N095
N100
N105
N110
N115
N120
N125
N130
N135
N140
N145
N150
N155
G90
G54 X+000.000 Z+207.500
F000.300 T0101 M04
G96 S0180
G92 S3000
G00 X+062.000 Z+000.000
G01 X-001.000 M08
Z+002.000
G00 X+120.000 Z+040.000 M09
F000.300 T0525 M04
G00 X+050.000 Z+002.000
G01 Z-044.800 M08
X+061.000
G00 Z+002.000
X+040.000
G01 Z-044.800
X+051.000
G00 Z+002.000
X+030.000
G01 Z-014.800
X+042.000
G00 Z+002.000
T0505 M04 F000.160
G00 X+030.000
G01 Z-015.000
X+040.000
Z-045.000
X+062.000
G00 X+120.000 Z+040.000 M05 M09
M30
Workshop
Working with tool setup devices
The students should individually define the compensation values of the tool on a real tool setup machine.
The necessary operation steps can be found in the operating manual of the applied tool setup machine.
Optical measuring of tools on the CNC machine
Direct dimension measuring using the CNC machine
The students should individually measure turning and milling tools on the CNC machine tools in workshop.
The details of this procedure are given in the chapter Tool measuring and setup using the CNC machine.
The operation steps on the CNC machine are given in the respective operation.
74
2.6
2
5
7
3
motor
ball screw
measuring equipment
Figure 93
Position feedback loop
Path measuring
To define the current position of the tool carriage (actual value of the position feedback loop) there is a path
measuring system available for each travel axis of the CNC machine tool. Depending on the travel path different path measuring methods are applied.
Absolute and incremental path measuring
For absolute path measuring (see figure 94) each pitch of the binary coded measuring scale indicates the
exact numerical value. This value corresponds to an exact position of the tool slide opposite to the machine
zero point M. This means that the current tool slide position can be directly conveyed to the CNC control at
any time. The fact that the read-in area of the measuring scale has to be as large as the machining area is a
disadvantage. In connection with the binary coding this results in large, technically complicated measuring
scales.
75
012345678
ruled grating
Figure 94
absolute path measuring
Figure 95
incremental path measuring
In general, only incremental path measuring is applied in CNC machine tools due to the fact that the reference point can be gone to at any time.
In case of welding line robots, however, collisions can occur with the work parts when going to the reference
point. Therefore, absolute path measuring is required here.
76
CNC exercise
Moving to the reference point
CNC turning
Procedure:
Description
Entry
F1 (turning)
F3 (setup mode)
F2 (reference point)
X
Z
F8 (Quit)
77
Entry
F2 (milling)
F3 (setup mode)
F2 (reference point)
78
F8 (Quit)
Entry
F1 (turning)
F3 (setup mode)
confirm.
+X
+ 4
+ 2
+Z
Further travel direction options:
+X
Pos 1
-Z
-X
Einfg
+Z
Bild
( + Z direction )
( - Z direction )
( + X direction )
( - X direction )
Entf
F3 (technology)
F5 (increment)
F2 (increment 0.1)
ESC
F8
and then
press (Quit).
F8 (Quit)
79
Entry
F2 (milling)
F3 (setup mode)
confirm.
Z
W
Pos 1
+Y
Bild
+X
Bild
-Y
+ 2
X
+Z
-X
Ex.:
Ende
2
-Z
Einfg
Bild
Ende
8
2
( + X direction )
( - X direction )
( + Y direction )
( - Y direction )
( + Z direction )
( - Z direction )
Entf
F3 (technology)
F5 (increment)
F2 (increment 0.1)
2
ESC
F8
80
F8 (Quit)
Entry
F2 (milling)
F3 (setup mode)
5. Take the tool in rapid speed to the new resetting position approx. 5mm off the side surface.
confirm.
1) in -X direction
2) in -Z direction
+ 2
X
+Z
Pos 1
-X
+Y
Bild
+X
Bild
-Y
Ende
2
-Z
Einfg
Bild
Ende
8
2
( + X direction )
( - X direction )
( + Y direction )
( - Y direction )
( + Z direction )
( - Z direction )
Entf
F3 (technology)
F5 (increment)
F2 (increment 0.1)
ESC
then press
F8
and
(return) key.
F8 (Quit)
81
Entry
F2 (milling)
F3 (Setup mode)
5. Take the tool in rapid speed to the new resetting position approx. 5mm off the front side.
1) in +X direction
+ 6
confirm.
2) in -Y direction
X
+Z
Pos 1
-X
+Y
+X
-Y
Ende
2
-Z
Einfg
Bild
Bild
+ 2
Bild
Ende
8
2
( + X direction )
( - X direction )
( + Y direction )
( - Y direction )
( + Z direction )
( - Z direction )
Entf
F3 (Technology)
F5 (Increment)
F2 (Increment 0.1)
Bild
ESC
Then press
and
F8 (Quit) key.
8. Quit the Setup mode.
82
F8 (Quit)
1.
1.
1.
For which applications is it reasonable to use the polar coordinate system in milling?
1.
1.
1.
1.
Explain the zero and reference point on numerically controlled machine tools.
1.
Where should the work part zero point, which is set by the user, be positioned?
1.
1.
1.
Incrementally dimension the sketched milling work part with absolute dimensions:
12.
What is the main difference between the principle of a control chain and a feedback loop?
12.
12.
12.
12.
12.
12.
What is the significance of the working quadrants of the turning tool edge?
12.
83
84
3.1
CNC machine tools use special NC tools. These tools meet the following criteria:
better milling performance with high stand still times
short changing and setup times to enable economical production of small production lots
standardized and rationalized tools
improved tool management and flexible production
The NC tools are either a single tool or they are put together of the cutter edge holder and tool holder. To
enable a quick tool change and to secure good exchangeability of the NC tools the tool carriers are standardized.
Tool carriers
Special forms have been stablished for tool carriers. They differ from each other in their machining method.
For turning tools a straight shank with toothing (see figure 96) is mostly used and for cutting tools a steepangle taper (see figure 97). Both tool shanks can be used with automatic and/or quick manual tool change.
Figure 96
Straight shank with toothing
Figure 97
Steep-angle taper
Tool holder
Many lathe and milling tools are a combination of several components. Indexable inserts are used which are
attached, for example with clamping devices (see figure 98).
1
Clamping finger
indexable insert
pin
Insert
Figure 98
Example of a clamping system
85
Figure 99
Forms of indexable inserts
Indexable inserts are classified according to their basic form, angles, cutting edges, tolerance class as well
as their clamping system and main dimensions. Based on a norm sheet ISO 1832 / DIN-4987 the following
example (see figure 100) shows the norm title of an indexable insert.
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
Designation
Example
DIN 4987
E = orthorhombic 75
C = 7
M
T = counterborehole
60on face
side length: 9,52 mm
s = 3,97mm
r = 0,8mm
F = sharp edged
R = right
tungsten carbide P10
Figure 100
Description of an indexable insert
86
3.2
outer
inner
cutting tool
corner cutting tool
(right cutting)
corner cutting tool (left
cutting)
copying lathe tool
outer cutting tool (round
cutting edge)
inner cutting tool (preaxial)
inner cutting tool
(postaxial)
recessing tool
outer recessing tool
boring tool
axial
centering drill
twist drill
indexable insert
reamer
Figure 101
Classification of cutting tools
87
Cutting materials
Hard metals are primarily used as the cutting material for lathe tools. For certain types of cutting high-speed
steels (HSS steels) are used. Their cutting surface is usually coated. In special cases ceramic materials
(cutting ceramics) are used as indexable inserts and in some cases industrial diamonds as well.
High-speed steels
High-speed steel is a high-alloyed tool steel (HSS = high-speed steel). It is highly durable and can therefore
easily take impact loads. The cutting speed is considerable lower compared with hard metals and cutting
ceramics.
It is used for tools whose form, for instance boring and reaming tools, do not allow the use of indexable inserts or machining of thermoplastic plastics and light alloys. HSS tools are frequently coated with a hard coat
of titanium nitrid TiN. This extremely hard, golden colored coating increases the abrasion resistance and
allows higher cutting speeds.
Hard metals
Hard metals are materials which are cintered as indexable inserts using hardening materials and a binding
agent. In most cases the hardening materials are tungsten, titanium or tantalum carbide. Cobalt is used as a
binding agent.
Hard metals are considerably harder than HSS steels. They are extremely abrasion-resistent and allow very
high working temperatures. They do, however, tolerate far less temperature fluctuation and impact exposure
than the HSS steels.
Hard metals can be classified according to the main cutting groups and cutting application groups.
Main cutting
groups
Materials
P01
P
blue
P10
P20
P30
P40
K
red
steel
cast steel
malleable cast iron short
shipping
M10
steel
M20
M30
M40
hard steel
cast iron
non-iron metals
K01
K10
K20
K30
K40
precision machining,
high cutting speed
P50
M
yellow
Applications
superfinish turning,
high surface quality
rough cutting
interrupted cutting
precision machining
high cutting speed
high hardness
high infeeds
high abrasion resistance
high cutting speed
high hardness
high infeeds
high abrasion resistance
high cutting speed
rough cutting
interrupted cutting
high hardness
high infeeds
Figure 102
Application areas of hard metals
The abrasion resistance of hard metals can be increased with a corresponding coating. As coating materials
titanium nitrid, titanium carbide and aluminium oxide are applied in several layers in vacuum in a temperature of 1000C
88
Diamond
Diamands are harder than all other materials. They are extremely sensitive to impact, however create no
built-up edges during machining.
They are used for cutting non-iron materials and their alloys as well as for composite materials (GRP), hard
metal, gas and ceramics.
Diamands cannot be applied for machining steel. Here they have very high abrasion since the carbon atoms
of diamonds are given off to the iron (diffusion abrasion).
89
clearance angle
wedge angle
angle of rake
angle of point
angle of inclination
adjustment angle
r
Figure 103
Cutting geometries in turning
Clearance angle : The clearance angle reduces friction and heating up of the tool edge and the work
part.
Wedge angle :
The size of the wedge angle depends on the hardness and toughness of the work
part. The smaller the wedge angle the lighter the cutting, however, the larger the edge
abrasion and the shorter the cutting edge life.
Angle of rake :
The angle of rake has an influence on chip building and cutting forces. The larger the
angle of rake the smaller the cutting force, however, cutting edge breach and abrasion
are increased because of total decarburization. Solid, medium hard materials require
an angle of rake of approx. 10. Hard and brittle materials require a small or even a
negative angle of rake.
Adjustment angle : In the first place the entering angle has an influence on infeed force, on the forces
against the work part clamping and work part as well as on the cutting width and
thickness. In case of solid clamping situation an entering angle of 30 to 60 is selected. Only for thin shafts or right angled offsets 90 is selected for the adjustment
angle.
Inclination angle : For finishing a positive, for roughing a negative inclination angle is frequently selected.
When negative angles of rake are used the cutting edge tip is exposed to less stress.
When positive inclination angle is used the chip flow is directed away from the work
part.
Angle of point :
90
The larger the angle of point the better the stability of the tool edge and the better the
heat removal.
Figure 104
New lathe tool
Figure 105
Built-up edge
During the cutting process material particles continuously break off from the lathe tool. Correspondingly, the
geometry of the tool cutting edge changes with the time. Depending on the choice of the tool cutting edge
angle the abrasion can take different forms (see figure 106 to 109).
Figure 106
Open cutting edge wear
Figure 107
Chip surface wear
Figure 108
Crater wear
Figure 109
Edge rounding
Due to tool wear the surface quality of the machining as well as the dimensional stability of the work part are
reduced. As soon as the required surface quality or dimensional stability are not maintained any more the
cutting-edge life of the tool has been reached.
Cutting-edge life is the time during which the cutting edge is in operation and the following requirements are
met:
Generation of required surface quality
Dimensional stability within the required tolerances
When cutting-edge life has been reached it is necessary to change the tool or to resharpen it. When using
indexable inserts the insert can be turned or changed. Prior to using the tool again tool dimensioning has to
be done.
91
Cutting value
Turning is a cutting operation with a circular cutting movement and an infeed which can be in any relation to
the cutting direction. In most cases the cutting movement is made by the rotation of the work part and the
infeed of the tool (see figure 110). The
cutting speed vc and the
infeed speed vf
overlap and result in a continuous cutting process.
Cutting speed vc
Cutting speed is the movement between the tool and the work part causing only a single chip removal during
one rotation without infeed. The symbol for cutting speed is vc and is indicated in m/min.
In general the speed indicates the traversed path s within a certain period of time t. It is calculated as follows:
v=
s
t
in path/time
The traversed path s for a work part rotation can be generated in turning using the work part diameter d on
the cutting edge tip and the constant :
s = *d
in m
The starting point for the calculation of the cutting speed is now a time unit t = 1 min. The result is herewith
cutting speed vc :
vc =
*d
t
in m/min
The number or work part rotations in one minute is indicated as a number of rotations n (in rotations per
minute):
t=
1
n
in min
As a result the following formula is achieved for the calculation of the cutting speed vc:
vc = * d * n
in m/min
vc
n
vf
number of rotations
in U/min
vf
infeed speed
in mm/
vc
cutting speed
in m/min
vc
=*d*n
Figure 110
Cutting values in turning
92
vf = n *f
in mm / min
For each cutting process a certain infeed is required. Together with the spindle number of rotations n it defines the machining time for each travel path. Its value has a decisive influence on an ideal cutting force and
on the sufrace quality of the machined surface.
Chip size
The chip diameter A describes the material diameter, which is cut in one cut (see figure 111). Its size largely
defines the cutting force created.
Without considering the cutting edge radius, the chip diameter A is the product of the cutting depth a and
infeed f. It is given in mm2. The cutting depth a, i.e. the depth of the tool cutting, is the value to be fed in step
by step.
A = a *f
in mm2
Using the entering angle it is possible to calculate the width b and the thickness h of the chip.
h = f *sin
b=
in mm
a
sin
in mm
cutting depth
adjustment angle
chipping width
chipping thickness
Figure 111
Chipping sizes
The following cutting values have to be selected always considering the specific appliction, and the lathe is
to be correspondigly set up.
cutting speed vc
infeed f
cutting depth a
This requires extensive experience. As a support standard value tables are therefore available indicating the
cutting values regarding the material to be cut and the cutting edge material.
93
vc = * d * n
in m/min
1. Example:
What is the cutting speed in plain turning if the cutting is done with a 60 mm diameter and number of rotations of 1500 1/mm.
datum:
d = 60 mm
n = 1500 1/min
unknown:
vc in m/min
valid :
vc = * d * n
vc = * 0,06 m 1500 1 min
solution:
vc = 283
m
min
2. Example:
How many number of rotations are required if the smallest diameter to be machined on the same work
part with this cutting speed is 12mm?
datum:
vc = 283 m/min
d = 12 mm
unknown:
n in 1/min
valid :
vc = *d * n
solution:
94
or
n=
vc
*d
n=
283m
* min* 0,012m
n = 7511 1 min
3.3
2
Figure 112
Milling
Milling operations are classified according to the position of the milling axis towards the work part, i.e. between face milling and peripheral milling.
In case of face milling the milling axis is located vertically to the machining area (see figure 113). The work
part surface is machined by the main cutting edges. Also, the work part surface is further finished with auxiliary cutting edges.
In case of peripheral milling the milling axis is located parallel to the machining axis (see figure 114). The
milling tool machines the work part surface with the main cutting edges (the peripheral cutting edges). Furthermore, a difference is made between synchronous and conventional milling.
Figure 113
Face milling
Figure 114
Plain-milling
MTS TeachWare CNC-Grundlagen Students Book
95
The tool cutting edge is subject to constant cutting interruptions in all milling operations. Due to the cutting
path comma-form chips are cut with a changing chip thickness (see figure 117).
cutting chip
Figure 117
Milling plan
96
drills
drill
screw tap
reamer
stepped drill
radius form cutter
special forms
T slot mill
Figure 118
Classification of milling tools
concave cutter
side mill
The above milling tools including all their data are included in the MTS CNC milling simulator and can be
called by the user. These tools can be modified or extended to meet the users demand.
End mill / Slot drill
T-slot cutter
97
98
Radius cutter
Tap drill
Drill
Step drill
Reamer
Concave cutter
High-speed steel
High-speed steel is a high-alloyed tool steel. Due to its high toughness it is able to withstand impact forces.
The cutting speed is considerably lower compared with hardmetals or cutting ceramics.
It is used for drills, small milling tools and tools with a complicated form (profile cutter). Cutting tools made of
high-speed steel are used for cutting less tough materials, for profile cutting and for cutting with low cutting
speed.
Hardmetals
Hardmetals are materials which are sintered in form of indexable inserts by using hardening materials and
a binding agent. By increasing the binding agent proportion in hardmetal production it is possible to increase
the hardness of the material as required. The abrasion resistance of hardmetals can be increased by a titanium nitrid, titanium carbide or aluminium oxide coat.
Hardmetal cutting plates are soldered on the milling tool or screwed on it in form of indexable inserts.
Cutting ceramics
Cutting ceramics are rarely used for milling because of their brittleness and sensitivity to fluctuating cutting
forces. However, because of the high hardness aluminium oxide is used for machining hardcast materials
and hardened steel as well as silicon nitrid for grey cast. Both of these materials are used for cutting without
coolant application.
Like hardmetal, cutting ceramics are manufactured to be used in form of indexable inserts.
Diamond
Cutting plates made of polycrystalline diamonds are used to cut non-iron metals and plastics. The extraordinary hardness of the diamonds enables double as high cutting speeds with ten times longer cutting edge
lifes are achieved as compared with hardmetals.
MTS TeachWare CNC-Grundlagen Students Book
99
Cutting geometry
fz
Unlike lathe tools milling tools have several cutting edges (see figure 119). Typical of milling is the discontinuous cut as each cutting edge works only for a time.
z:
number of teeth
fz:
ae:
entering point
S:
entering angle
0:
clearance angle
0:
wedge angle
0:
angle of rake
S:
ap:
cutting width
ae
d:
ap
0
s
Figure 119
Cutting geometry milling
Clearance angle : The clearance angle is to reduce the friction and consequently the heating of the cutting edge and of the work part.
100
The size of the wedge angle depends on the hardness of the work part. The smaller
the wedge angle the lighter the cutting, however the greater the cutting abrasion and
the shorter the cutting edge life.
Angle of rake :
The angle of rake influences cutting chip formation and cutting forces. The larger the
angle of rake of the chip the smaller the cutting force, however the risk to breach as
well as abrasion of the cutting edge are increased due to erosion.
Entering angle S:
The entering angle indicates the machining path of the tool with reference to the circumference. It depend on the size of the entering point.
Inclination angle : The size of the inclination angle influences the process of chamfering and cutting-out.
Since the inclined cutting edges are consecutively engaged the milling tool runs with
increased quietness.
The configuration of the adjustment angle (see figure 120) is very important in milling. The adjustment angle
is the angle between the main cutting edge and the surface to be cut.
:
adjustment angle
Figure 120
Adjustment angle of milling tools
If the adjustment angle is 90, the highest radial forces are exposed. This angle value is therefore only recommended for right-angled contours. For most milling works an adjustment angle of 75 or 60 is ideal. For
long cutting materials the adjustment angle of = 45 is ideal.
If hardmetal indexable inserts are mostly used, then two cutting angles are available. They can be measured
using the reference lines:
radial cutting angle (reference line through the centerof the milling tool)
axial cutting angle (reference line parallel to milling axis)
In case of plain milling with a plain milling cutter the following combinations are mostly used (see figure 121):
double positive geometry
double negative geometry
positive-negative geometry
1
double positive geometry
1
positive-negative geometry
101
In case of double positive geometry only light driving power is required due to small cutting forces. It is therefore possible to machine thin-walled work parts as well. The spiral-form chips drop off from the tool easily. In
case of materials which tend to form built-up edge, for instance aluminium, this geometry is recommended.
Double negative geometry is used for machining hard steels and grey cast as well as for roughing. The high
cutting forces created hereby require strong driving power and high stability of the machine. Due to the geometry the chips curl on the tool. In case of long-chipping materials this can lead to a chip jam.
Positive-negative geometry makes large feeds and big cutting depths possible since the negative radial angle of rake contributes to high breaking strength of the indexable insert. Here the chipping is ideal since the
chips flow off from the tool. Tools with a positive-negative geometry are therefore applied for various situations.
Cutting values
Milling is a cutting operation with a rotating tool, whereby the cutting edges are not in operation all the time.
The cutting movement is caused by the rotation of the tool. Feed direction and cutting direction do not depend on each other. It is realized either by the tool or by the work part or by both of them (see figure 122).
The
cutting speed vc and the
feed speed vf
overlap each other and results in a continuous cutting operation.
Cutting speed vc
The cutting movement is the movement between the tool and the work part, generating only one nonrecurrent chip cut during one rotation without a feed movement. Cutting speed corresponds to circumferential speed of the milling tool on the current cutting edge. It is expressed as vc and m/min. Under consideration of the number of rotations of the spindle n the following formula is received
vc = * d * n
in m/min
The cutting speed of a cutting tool depends on the number of the rotations. The direction constantly changes
however during cutting operation (see figure 122
vc
vf
vc
vc
vc
number of rotation
vf
feed speed
vc
cutting speed
vc
Figure 122
Cutting values for milling
Feed speed vf
102
in mm / min
in mm
in mm
The calculation of the feed speed vf is based on the feed fz , i.e. the feed path per milling tooth. Under consideration ot the number of rotations n and the number or teeth z the formula is as follows:
v f = fz * n * z
in mm / min
The feed speed can be expressed with the following formula as well with reference to the feed per milling
rotation.
vf = f *n
in mm / min
v f = f * n = fz * n * z
in mm / min
Cutting width
Unlike in turning, a nonuniform chip is cut in milling (see figure 123). The average cutting thickness hm is
used as reference.
fz
1
actual chip
fz:
h m:
hm
Figure 123
Cutting thickness
In plain milling, the cutting width ap is the penetration width of the tool into the work part. The working engagement ae is measured on an imagined plane of the working plane. The cutting and feed direction are
located on the working plane (see figure 124).
103
ap
ae
ae
ap
working plane
Figure 124
Operating variables in milling
In face milling, ap is the cutting depth measured vertically to the working plane. The working engagement ap
is identical with the width of the milled surface.
The following cutting values must be selected case by case depending on the application and then entered
into the milling machine:
number of rotations n
feed f
working engagement ae
cutting depth or cutting width ap
This requires extensive experience. As a support standard value tables are therefore available containing
cutting values regarding the material to be cut and to the cutting edge material.
vc = * d * n
in m/min
Feed speed vf
v f = f * n = fz * n * z
in mm / min
1. Example:
Calculate the cutting speed for milling if the milling tool diameter d = 50 mm and the
number of rotations n = 520 1/min.
known:
d = 50 mm
n = 520 1/min
104
vc in m/min
it applies :
vc = *d * n
vc = * 0,05 m 520 1 min
solution:
vc 82
m
min
2. Example:
Calculate the number of rotations n of an end mill with a diameter of = 12 mm and cutting
speed of vc = 120m/min.
known:
d = 12 mm
vc = 120 m/min
unknown:
n in 1/min
it applies :
vc = *d * n
solution:
, or
n=
vc
*d
n=
120m
* min* 0,012m
n = 3183 1 min
105
n = 400 1/min
vc = 180 m/min
unknown:
d in mm
it applies :
vc = *d * n
Solution:
106
, or
d=
vc
*n
d=
180000mm * min
* min* 400
d = 143mm
3.4
25
45
70
Calculating the number of rotations for roughing (Cut 1-4) and for finishing (Cut 5-6)
datum:
unknown:
n in 1/min
valid :
n=
vc
*d
1. Cut
= 58mm
2. Cut
vcv = 280 m/min
280m
* min* 0,058m
n1 = 1537 1 min
n1 =
3. Cut
= 36mm
280m
* min* 0,036m
n 3 = 2476 1 min
5. Cut
280m
* min* 0,046m
n2 = 1938 1min
n2 =
= 26mm
280m
* min* 0,026m
n4 = 3428 1min
n4 =
6. Cut
vcf = 400 m/min
400m
* min* 0,025m
n5 = 5393 1 min
n5 =
4. Cut
n3 =
= 25 mm
= 46mm
= 45 mm
400m
* min* 0,045m
n6 = 2830 1min
n6 =
107
25
45
70
The machining time for roughing thuv and for finishing thuf
as well as well as the entire machining time thu are to be
calculated.
50
60
Calculating the machining time for roughing thuv and for finishing thuf
The machining time for turning is calculated with the following formula:
th =
L *i
n *f
in min
L
i
n
f
Feed Path
Number of Cuts
Number of Rotations
Feed per Rotation
The feed path L is calculated from the path in which the cutting edge is operating (length l = feed motion in Z and X !) and possible approach / withdrawal paths (length la or lu) that are traveled in the feed.
The following feed paths result for each cut with consideration to 2mm for the approach / withdrawal
paths:
1.
1.
1.
1.
1.
1.
Cut
Cut
Cut
Cut
Cut
Cut
datum:
108
unknown:
th in min
valid :
th =
L *i
n *f
1. Cut
L = 60mm
fv= 0.2 mm
n= 1537 1/min
L = 66mm
L *i
n *f
60mm * 1 min
th =
1537 * 0,2mm
t h = 0,195 min
n= 1938 1/min
L *i
n *f
66mm * 1 min
th =
1938 * 0,2mm
t h = 0,172 min
th =
th =
4. Cut
3. Cut
L = 29mm
fv= 0.2 mm
fv= 0.2 mm
n= 2476 1/min
L = 34mm
L *i
n *f
29mm * 1 min
th =
2476 * 0,2mm
t h = 0,059 min
fv= 0.2 mm
n= 3428 1/min
L *i
n *f
34mm * 1 min
th =
3428 * 0,2mm
t h = 0,050 min
th =
th =
5. Cut
L = 25mm
fv= 0.12 mm
n= 5393 1/min
L = 46mm
L *i
n *f
25mm *1 min
th =
5393 * 0,12mm
t h = 0,039 min
th =
fv= 0.07 mm
n= 2830 1/min
L *i
n *f
46mm * 1 min
th =
2830 * 0,07mm
t h = 0,232 min
th =
109
25
45
70
50
60
Rt =
f2
8* r
in mm
datum:
f = 0.07 mm
r = 0.4 mm
datum:
f = 0.12 mm
r = 0.8 mm
unknown:
Rt in mm
unknown:
Rt in mm
1. Calculating the roughness height Rt1.6 for 2. Calculating the roughness height Rt 6.3 for
the other surfaces
the surface 45
f 2 mm2
= mm
8 r 1 mm
2
0. 07
=
8 0. 4
0. 0049
=
3. 2
Rt1.6 =
Rt 6.3 =
Rt1.6
Rt 6.3 =
Rt1.6
Rt1.6 = 0,00153 mm
110
f2
8r
mm2
1 mm = mm
0.12 2
8 0.8
0. 0144
Rt 6.3 =
8 0. 8
0. 0144
Rt 6.3 =
mm
6. 4
Rt 6.3 = 0,00225 mm
Datum:
turning length l = 50 mm
cutting depth ap = 4.5 mm
feed f v = 0.20 mm
cutting speed vcv=200m/min
adjustment angle r=90
output =0,8
MTS TeachWare CNC-Grundlagen Students Book
111
Fc = b h k c = a p f v k c , (with r=90)
if r is smaller than 90, then b is calculated with
b=
ap
sin r
h aus h = f sin r und
k N
kc = cm11c
,
h mm2
where kcl-1 is the kc-value based on the test conditions and mc
is a chip thickness index; kcl-1 and mc can be taken from the
following table.
Materials
However, the formula mentioned above is not sufficient for calculating the cutting force. Various compensation factors must first be taken into account. After these compensation factors are considered, the applicable
formula is as follows:
Fc = a p f v k c K o K v K sch K ver
[N ]
K o = 1
o ok
66. 7
, whereby 0 is the given angle of rake and ok is the angle of rake used for de-
Kv
Kv- vc - diagram:
v c in m/min
Example:
Ksch is the cutting edge variation factor for hard-metal to cutting ceramic, whereby hard-metal is 1 and cutting
ceramic is set between 0.9....0.95.
Kver is the cutting edge abrasion factor. It has to be estimated since the kc-values from the table only apply to
working sharp tools. For this reason a Kver-value of 1.3...1.5 is used.
Solution:
The compensation value Ksch conform with the table provisions and can be set with 1. aP and f v are given.
All other values must be determined:
kc11 N
h mc mm2
2220
kc =
0.20.14
N
kc = 2781
mm2
kc =
K o = 1
o ok
66.7
10 6
K o == 1
66.7
K o = 0,94
Fc = a p f k c K 0 Kv Ksch Kver
Fcv = 4.5mm 0. 2 mm 2781 N / mm 2 0. 96 0. 94 1 1. 3
Fcv = 2936 N
113
m 1 min Nm
Pc = Fc v c N
=
, using the values from the examples yields
min 60s 60s
m
Pcv = 2936 N 200
min
Nm
Pcv = 9786, 7
, da 1Nm/s = 1W (Watt) ist, sind 9786,7 Nm/s = 9,787 KW
s
Pcv = 9. 787 KW
3. The power output of the drive motor Pab
With known cutting performacne the power output of the drive motor Pab is calculated with the formula:
Pcv KW
= KW
9.787
Pab =
0.8
Pab = 12.23KW
Pab =
114
vf in mm / min
fz in mm
f in mm
v f = fz * n * z
in mm / min
vf = f *n
in mm / min
v f = f * n = fz * n * z
in mm / min
1. Example:
A plate made from C15 is to be milled in one cut using an end-face mill with indexable inserts.
The step is 10 mm high. The cutting speed vc is 160 m/min and the feed per cutter edge fz is
0,18 mm. The end-face mill with = 63 mm has four cutting edges.
How high is the infeed speed vf?
datum:
vc = 160 m/min
d = 63 mm
fz = 0,18 mm
z =4
unknown:
vf in mm/min
valid :
v f = fz * n * z
vc = * d * n
or
vc
, it follows:
*d
v
v f = c * fz * z
*d
160000mm
vf =
* 0,18mm * 4
* min* 63mm
v f = 582mm / min
n=
solution:
115
n = 1800
1
min
f z = 0.12 mm
z=2
unknown:
vf in mm/min
valid :
v f = fz * n * z
v f = 0,12mm * 1800
solution:
1
*2
min
v f = 432mm / min
3. Example
Calculating the number of rotations n
How high must the number of rotations be when the slot is machined with a boring feed of 0.1 mm per edge
and a longitudinal feed of 0.15 mm and with an infeed speed of 200 mm/min ?
datum:
unknown:
valid :
f b = 0.10mm
f z = 0.15mm
mm
v f = 200
min
nb in
1
min
z=2
unknown:
v
mm
nb = f
fb z min mm
200
0.1 2
nb = 1000
n = 1800
f z = 0.12 mm
1
min
nb =
116
datum:
1
min
valid :
nl in
1
min
vf
mm
fzl z min mm
200 1
nf =
. 2 min
015
1
nf = 667
min
nl =
hm
fz
z
ze
D
kc
kc1-1
mc
cutting depth
entering point
chip width
cutting force per edge (mean)
entering angle
middle chip thickness
feed per edge
number of cutter edges
number of edges in operation
diameter of milling cutter
angle of twist of edges
adjustment angle of edges
specific cutting force
specific cutting force related to chip diameter b hm =1 mm
chip thickness index
These are either taken from a book of specifications or, as in the case of the angle of rake variation factor,
calculated with the formula K o = 1
o ok
66. 7
ze =
b=
ae
mm and
cos
hm = f z sin
360ae
mm .
d s
Fc = ze b h m kc K o K v K ver mm mm
= N and with ze , b , hm yields the formula
2
mm
Fc =
z s ae 360a p
f z sin k c K o Kv Kver
360 cos s d
117
3.4
Example:
As shown in the figure, a guide recess should be milled with a 4-edged end-face mill =40 mm into a guide
plate made of C35.
data :
Fc =
z s a e 360a p
N
mm mm
f z sin k c K o K v K ver 1
mm
1 = N
2
mm
360 cos s d
1 mm
Fc =
4 1
40
3606
the kc-value can not be taken directly from the table. It is calculated as follows:
kc =
k c11
,
h mc
kc11 with 1860 can be taken from the table as well as mc with 0.2. The hm-value is calculated as follows:
hm =
360a p
s d
f z sin
Consequently,
360 6
= 3. 87 mm and
44. 4 40
1860
N
kc =
= 1420
.
0.2
mm 2
3. 87
10 6
ok
K o = 1 o
= 1
= 0. 94
66. 7
66. 7
hm =
Kv with 0.97 is taken from the diagram. 1.3 is selected for the edge abrasion compensation value Kver. All
values for the cutting force are therefore established and can be calculated:
4 40 6 0.12 1
1420 0. 94 0. 97 1. 3
0. 866 40
Fc = 1782 N
Fc =
Pc = Fc *v c
m
min
Nm
Pc = 1782 *140
60s
Pc = 415W
Pc = 1782N *140
118
Pab =
Pc
M c
0,45KW
0,82
Pab = 055KW
Pab =
material: ST50
miller diameter d =32 mm
feed per edge f z = 0.12 mm
cutting speed
v c = 120
m
min
t nu =
t nu =
Lges i
f vc
(2L + 2L
l
f v= fz z
c
mm 1 mm min
=
=
= min
mm
mm
min
b
f vc
+ 2 A )
;; with
012
. 3 140
vc
mm
= f vc =
= f v = 501
yields:
c
0.032
d
min
2 110 + 2 70 + 2 22
501
t nu = 0.81 min
t nu =
3.5
119
3.5
The clamping elements constrain the work part and the required force for this is called clamping power.
In order to keep the costs for the clamping system as well as for production low, further requirements are
made on the clamping system:
Mechanical clamping power generators are usually in the form of wedge lever-type or bellcrank lever-type
power chucks. These types of force chucks are usually used for turning machines.
3
2
chuck
drawbar
wedge lever
jaws
Figure 125
wedge lever-type power chuck (mechanical)
chuck
drawbar
bellcrank lever
jaws
figure 126
Bellcrank lever-type power chuck (mechanical)
Hydraulic clamping fixtures generate the movement and power needed for clamping with hydraulically
powered pistons. These are usually manually controlled by the operator with valves. The clamping power
can be accurately controlled and is monitored on a display. Although hydraulic systems require high technical effort, they are quite reliable.
120
Figure 127
Hydraulic actuating cylinders with through-hole Rhm SZ
Pneumatic clamping fixtures are operated with air pressure and function similiarly to hydraulic clamps.
Compressors are used for generating air pressure (compression).
Figure 128
Air actuating cylinders with through hole Rhm LHS
121
3.5
Electric clamps which rotate are used for force chucks with geared scroll systems. They enable a quick
adjustment to various work part diameters.
An electromagnetic clutch in the clamp blocks the spindle during the clamping and declamping process, so
that the full clamp torque is transmitted to the chuck.
Furthermore, there are electric clamps with stroke movements for operating clamping devices and force
chucks.
thread nut
thread spindle
tie bar
clutch
epicyclic gears
motor
Figure 129
Electric clamp with stroke movement
122
Figure 130
Self-centering three-jaw chuck Rhm ZG-ZS
Figure 131
Self-centering four-jaw chuck Rhm ZG-ZS
The jaws are usually hardened and have increments. The jaws can be adjusted so that they can clamp parts
with various diameters. By exchanging jaws the turned parts can be either clamped from the inside or outside.
Clamping power transmission is usually based on the principal of geared scrolls or key bars.
123
3.5
Figure 132
Geared scroll chuck Rhm EG-ES
Figure 133
Jaw operating mechanism
The disadvantage of chucks with geared scrolls is that changing requires the chucks to be fully dismounted.
:
adjusting screw
spindle
base jaw
pinion
scroll
operating screw
adjusting key
Figure 134
Geared scroll chuck Rhm EG-ES
Operation:
The rotation of the pinion (4) causes the scroll (5) to turn. The base jaw (3) consequently moves towards the
turning axis and clamps the work part.
124
Components:
22
cover
33
indicator pin
51
body
23
drive ring
34
bearing
56
24GB
base jaw
35
thrust ring
57
press pin
24EB
one-piece jaw
36
pressure spring
58
locking slide
25
37
pressure spring
76
chip guard
27
operating screw
38
taper key
90
28
slide
39-42
29
44
straight pin
Figure 135
Chuck with thrust ring and key bars Rhm Duro
Operation
The tangentially arranged operating screw (27) engages the internal thread of the actuating key bar (56) to
move a slide (28) which in turn moves the drive ring (23). Two further slides in the drive ring (23) transmit the
force to the other key bars. The key bars are provided witch helical teeth which engages the teeth of the
base jaws (24GB) so that the work part is gripped accurately and concentrically.
125
3.5
work part
clamping bocy
spindle
clamping tube
Figure 136
Collet
Figure 137
Clamping between centers
The following possibilities for clamping between centers can be distinguished based on the maching specifications:
face drivers with revolving or fixed centers
driver with a vise chuck with clamping ring revolving or fixed centers
126
Figure 138
Face driver Rhm 681
The revolving tailstock center is inserted into the tail spindle of the tailstock. Since the center can revolve on
its own, higher cutting speeds during turning operation are possible.
Figure 139
Revolving tailstock center Rhm 601
127
3.5
The application area of dead centers is very limited. They only enable minor cutting depths because they
warm up and wear too quickly.
Figure 140
Dead center Rhm 667
Figure 141
Dead center with half point Rhm 670
A vise chuck with clamping ring centers the work part and additionally radially clamps it with a clamping bolt.
Consequently, larger torques can be transmitted and a higher machining performance is reached.
driving disk
work part
Figure 142
vise chuck with clamping ring
128
Figure 143
Cartridge mandrels Rhm
clamping ring
clamping sleeve
Figure 144
Cartridge mandrel Rhm MZB
Expanding mandrels are clamped between centers and only have a minor clamping area. They operate by
expanding a thin-walled, non-slotted sleeve made from a plastic for elastic deformation.
129
3.5
Figure 145
Hydraulically operated 6-jaw pull-down finger chuck Rhm
work part
clamping body
clamping bridge
Figure 146
Turning fixture
130
Figure 147
Self-centering steady rests Rhm SLZ
The work part is clamped between centers and additionally supported by steady rests.
Figure 148
Fixed steady rest
131
3.5
2.
3.
Magnetic Chucking
1.
Modular Chucking
1.
2.
132
The milling cutter machine table with its T-slots is the basis for work part clamping. Depending on how the
work part is to be clamped, the following clamping devices can be distinguished:
work part
clamping iron
clamping board
machine table
support element
work part
clamping iron
clamping board
machine table
4
Figure 149
Clamping iron and clamping bard
For bedding with heavy work parts, alignment and support elements are used.
1
2
5
Figure 150
Clamping iron, clamping board and support element
133
3.5
Shallow clamps are used for flat work parts whose surfaces need to be kept free for machining.
work part
shallow clamp
Figure 151
shallow clamp
A dividing apparatus with circular table enables work parts to be quickly and symmetrically machined from
both sides. It is also possible to flange a chuck to a dividing apparatus which then can be used for accurately
dividing and machining round work parts.
Figure 152
Dividing apparatus with circular table
134
Figure 153
Machine vise Rhm UZ
The clamping force transmission of machine vises is illustrated in the following figure.
Figure 154
Power transmission
Universal machine vises can be horizontally as well as vertically turned. Furthermore, there are also vises
that pneumatically generate clamping power.
Figure 155
Precision sine vise Rhm PS-SV
135
3.5
Figure 156
High precision NC vice Rhm RBA
The construction of a high precision NC vises is illustrated in the following figure.
hydraulic unit
movable jaw
spindle
spindle nut
basic body
pneumatic spring
Figure 157
High precision NC vice Rhm RBA
Magnetic clamping devices
Work parts made of iron can be clamped with electromagnetic devices. The work part is drawn to the clamping plate after a current is switched on. It can be easily removed after the current is switched off.
Figure 158
Electromagnetic clamping plate
136
7.
1.
1.
Why are hard-metal indexable inserts primarily used for tools for CNC-machine tools?
1.
1.
1.
What are the advantages of a larger angle of rake for the machining process?
1.
What are the disadvantages of a larger angle of rake for the machining process?
1.
1.
What is the significance of the adjustment angle for the machining process?
1.
1.
1.
1.
1.
1.
1.
1.
1.
137
3.5
138
8.
4.1
The documents required for CNC-manufacturing are much more defined compared with those for manufacturing on conventional machine tools. Creating these documents takes more time, however they are then
immediately accessible for repeated orders.
In addition to the NC-program, a set-up form is created for setting-up the CNC-machine tool. All information
on the used tools and the tool parts clamping situation is documented in this form.
Tool measuring enables the autonomous operation of the CNC-machine tool and easy application of tools on
various machines.
Tool and clamping device management is more extensive in CNC-work preparation, since they are generally
more varied than those for conventional machine tools and accordingly their description is more detailed.
The data is stored in tool and clamping device indices.
A complete allocation of all documents, preset tools and accessories enables the quick set-up of the CNCmachine tool. The objective is to avoid machining delays and therefore, increase machining time
139
4.1
figure 159
Organizational classification of NC-programming
Programming as part of production organization
All planning measures for realizing a manufacturing order are carried out in the department for production
planning and precede manufacturing. Programming in this department is termed external programming since
the department is outside the workshop area.
The NC-programs are written by staffmembers who are specifically trained in NC-programming. They usually
work at a programming terminal and create the programs on a computer. Programs are not only generated
here but managed as well. The connection to the CNC-machine tool is over a DNC-system.
It is practical to generate programs in production planning when
extensive NC-programs or
NC-programs for complicated work parts are to be created, when
many NC-programs need to be managed or
when there are many CNC-machine tools.
Disadvantageous is that
the NC-programs must be optimized on the CNC-machine tools and
there is little contact with the workshop.
140
Disadvantageous is that
the workshop personnel needs to specially trained and
lengthy programming time can possibly result in machining standstill.
141
4.1
CNC-programming can be done with different procedures and at different places. An overview of these possibilities is given in the following figure.
figure 160
Overview of NC-programming procedures and systems
142
143
4.1
figure 161
NC Programming Phases
144
1
probe
tool
turret
2
Figure 162
Internal tool measuring
Calibrated measurement and test techniques for precise measuring and verification.
Operator training.
Air-conditioning the workshop rooms.
Observing quality when purchasing and installing a machine.
Workshop
MTS TeachWare CNC-Grundlagen Students Book
145
4.2
NC programming basics
The different programming procedures, the NC-program management as well as the clamp and tool indices
should be demonstrated.
4.2
NC programming basics
A NC-program comprises a series of commands with which the CNC-machine tool is instructed to manufacture a certain tool.
For each machining process on a CNC-machine tool, the NC-program has a command with relevant information. These commands are alphanumerically coded, i.e. they consist of letters, numbers and characters.
Structure of an NC program
Structure of an NC program:
A complete NC-program consists of the following elements:
% TP0147
NC-program beginning,
a series of NC-blocks
...
N435 M30
figure 163
Structure of an NC-program
The program beginning consists of a character or a command (ex. %) which informs the CNC-control that
a NC-program will follow. Additionally, the first line of the NC-program also contains the program name (ex.
TP0147). Furthermore, both characteristics are also important for the NC-program manager as well as for
calling the NC-programs in the CNC-control.
NC-program names can contain alphanumerical or numerical characters. For most CNC-controls 2-6 digit
character sequences are used for identification.
An NC-program consists of a chronological sequence of blocks. They contain the relevant geometric and
technical information that the CNC-control requires for each machining step.
The program end is commanded with M30 or M02.
Everything that stands before the character % for commenting the program is ignored by the control. This
enables any explanations on the program or tool to be attached preceding the actual program. Comments
are also allowed within a program, e.g. for identifying particular blocks. These, however, must be set in
brackets.
146
G01
Z-10.75
F0.3
S1800
T03
M08
LF
Number of
the NC-block
Word
Word
Word
Word
Word
Word
invisible block
ending character
figure 164
Structure of a program block
Address
Number
Definition
N75
75
G01
01
Z-10.75
-10.75
For the address Z, -10.75 is a value. Corresponding to the NCcommand G01 of the preceding NC-block example, this means that
the tool is to be moved to the position Z=-10.75 in the current tool coordinate system.
figure 165
Structure of a program word
The form of numerical entry depends on the CNC-control: Z-35.5 is equivalent to e.g. the same target coordinates as Z-035.500. For most CNC-controls the positive sign "+" can be excluded in the NC-program.
Generally, three groups of words in an NC-block can be differentiated:
G-Functions
Coordinates
G00
G01
G02
T
M
G54
figure 166
Groups of program words
147
4.2
NC programming basics
Definition
1.
block number
2.
G-functions
3.
X, Y, Z
coordinates
4.
I, J, K
interpolation parameter
5.
feed
6.
speed
7.
tool position
8.
additional functions
figure 167
Sequence of program words
Words that are not needed by a block can be excluded.
Block number N
The block number is the first word in a block and designates it. It can only be conferred once. The block
number has no influence on the execution of the individual blocks since they are invoked following the order
in which they were entered into the control.
G-function
Together with the words for the coordinates, this word essentially determines the geometric part of the NCprogram. It consists of the address letter G and a two-digit code.
Coordinates X, Y, Z
The coordinates X, Y, Z define the target points that are needed for travel.
Interpolation parameters I, J, K
The interpolation parameters I, J, K are e.g. used to define the center of a circle for circular movements.
They are usually entered incrementally.
Feed F
The speed at which the tool is to be moved is programmed with the function F. The infeed speed is usually
entered in mm/min. For turning, the unit mm/U pertaining to spindle rotation can also be used.
Spindle speed S
The function S is for entering the spindle speed. It can be directly programmed in rotations per minute.
Tool position T
The address T together with a numerical code designates a specific tool. The definition of this address differs according to the control and can have the following functions:
Saving the tool dimensions in the tool offset table
Loading the tool from the tool magazine.
Additional functions M
The additional functions, also known as auxiliary functions, primarily contain technical data that is not programmed in the words with address letters F, S, T. These functions are entered with the address letter M
and a two-digit code.
148
Description
MTS
OKUMA
FANUC 16M
rapid traverse
G00
G00
G00
G01
G01
G01
G02
G02
G02
G03
G03
G03
Dwell Time
G04
G04
G04
G40
G40
G40
G41
G41
G41
G42
G42
G42
G50
G54
G90
G90
G90
G91
G91
G91
G94
G94
G94
G95
G95
G95
G96
G97
spindle speed
Feedrate
Tool Changing
M3
M3
M3
M4
M4
M4
M5
M5
M5
M6
Activate coolant
M8
M8
M8
deactivate coolant
M9
M9
M9
Program hold
M00
M00
M00
M30
M30
M30
149
4.2
NC programming basics
M42
M63
150
Commands
Description
O 0300
T040404
M3
M42
M63
G96
S140
N10
G50
S3000
N15
G0
X20
Z2
M8
N20
G1
X20
Z0
G42
N25
G3
X28
Z-4
I0
K-4
N30
G1
Z-28
N35
G2
X34
Z-31
I3
K0
N40
G1
X38
Z-33
N45
G1
Z-53
N50
G1
X44
151
4.2
Block
No.
N55
NC programming basics
Commands
Description
G3
X50
Z-56
I0
K-3
N60
G1
Z-64
N65
G2
X62
Z-70
I6
K0
N70
G1
X66
N75
G1
X71
Z-72
N80
G1
X76
N85
G40
N90
G0
X500
Z500
M5
M9
N95
152
M30
Commands
FX100
N05
G54
N10
G90
Description
program name
G49
G80
G40
N20
G17
G21
metric input
G91
G28
Z0.
M9
N25
G91
G28
X0.
Y0.
N30
T01
M06
N35
G90
S1600
M03
N40
G0
G43
Z20.
H17
N45
X-20.
Y-20.
N50
Z-6.
M08
N55
G1
G41
X10.
N60
D1
F250.
G1
Y82.
153
4.2
Block
No.
N65
NC programming basics
Commands
Description
G2
X18.
Y90.
R8.
N70
G1
X82.
N75
G2
X90.
Y82.
R8.
N80
G1
Y18.
N85
G2
X82.
Y10.
R8.
N90
G1
X18.
N95
G2
X10.
Y18.
R8.
N100
G3
X-10.
Y38.
R20.
N105
G0
G40.
X-20.
Y-20.
N110
G0
Z40.
M5
154
Block
No.
N115
Commands
Description
G91
G28
Z0.
M9
N120
G90
G80
G49
G40
N125
M30
Workshop
On the CNC-machine tools, available NC-programs are to be loaded and be executed step-by-step.
Special attention should be paid to the respective control panels with the manufacturer-specific pictograms.
155
4.3
4.3
Various documents must be analyzed and plans for production execution must be created. (see fig. 168).
study
work order
tools
study
workshop drawing
clamping
devices
programmer
work plan
set-up form
program sheet
figure 168
Procedure for manual programming
Analysis of workshop drawings
The workshop drawing (see fig. 169) contains the geometric and technical information for the finished part.
The dimensions, the surface specifications as well as information on the machining procedure to be used
(e.g. cutting, threading, hardening) are taken from the drawing. Information on the work to be executed as
well as on the number of work parts and the deadlines is specified in the work order.
figure 169
Workshop drawing turning
156
figure 170
Workshop drawing milling
Maximum ratings:
Round bar
Dr = 1.05 x Da
Lr = L + 5
Material: C45
N.
Machining description
Production
aids
Machining alternatives
Decision criteria
01
02
03
sketching
04
auxiliary drillings
sketch
Date 13.03.91
Z: = Counter value
NB: = Slot width
Machine
group
Cost
center
tr [min]
55/1
1101
te = 0,5 x Dr
66/1
1212
12
1300
71/1
1217
72/2
1217
figure 171
Work order
This sequence is then registered in a work plan. The clamping situation must already be considered at this
time. Clamping must be sketched for complicated situations or reclamping.
figure 172
Work plan
157
4.3
figure 173
Set-up form
All data that is needed for setting up the CNC-machine tool is listed in the set-up form (see fig. 15). Especially the information on the program number and drawing number as well as the work part name identifies
all documents required for the order. For repeated orders, information on the position of the work part enables an easier set-up of the clamping situation.
Generating the NC program
The programmer creates the NC-program based on the workshop drawing and work plan, and enters the
individual program blocks into a program sheet (see fig. 16). This program sheet supplements the documents at hand. For a repeated order, the machine can then immediately be set-up.
Program Sheet
Programming
M T
figure 174
Program Sheet
158
figure 175
Follow the subsequent steps for generating the NC-program:
1.
1.
1.
1.
159
4.3
Tool
Turret Position
Cutting
Values
Outline
1 check blank
dimensions
2 clamp work part
1.side
3 define work part zero
point
3
2
4 Face Turning
T04
G96
F0.15
CL-SCLCL-2020/R/1208
S140
5 Centering
Center Drill
T09
G97
F0.16
CD-03.15/050/R/HSS
S1800
6 Drilling
T07
G97
F0.22
DR-18.00/130/R/HSS
S1000
7 Outside contour
roughing
T04
G96
F0.1
CL-SCLCL-2020/R/1208
S140
CL-SVJCL-2020/R/1604
T02
G96
F0.1
S280
160
Tool
Turret Position
Cutting
Values
Outline
1
3
T04
G96
F0.28
CL-SCLCL-2020/R/1208
S140
5 Outside contour
roughing
T04
G96
F0.28
CL-SCLCL-2020/R/1208
S140
6 Predrilling
T12
G97
F0.2
S850
161
4.3
Tool
Inside Turning Tool
Post
Turret Position
Cutting
Values
T05
G96
F0.2
BI-SDQCL-1616/R1104
S120
T10
CL-SVJCL-2020/R/1604
S220
T02
G96
F0.1
S280
162
G96
F0.1
BI-SVQJCL-2020/R/1604
Outline
figure 176
Setup Dialog
figure 177
Interactivmod
TOOL COMPENSATION
D02 T02 Q3
D04 T04 Q3
D05 T05 Q2
D07 T07 Q7
D09 T09 Q7
D12 T12 Q7
D14 T14 Q2
163
4.3
figure 178
Diagram of the menu sequence for the Work part
Manager.
figure 179
File information for loading a preproduced work
part.
CONFIGURATION
MACHINE MTS01 TM-016_-R1_-060x0646x0920
CONTROL MTS TM01
PART
GEOMETRY X+071.331 Z+0165.500
G01 X+075.000 Z+0165.500
G01 X+075.000 Z+0191.000
G01 X+014.000 Z+0191.000
G01 X+014.000 Z+0093.000
G01 X+020.000 Z+0093.000
G02 X+028.000 Z+0097.000 I+000.000 K+004.000
G01 X+028.000 Z+0121.000
G03 X+034.000 Z+0124.000 I+003.000 K+000.000
G01 X+034.000 Z+0145.600
G03 X+034.800 Z+0146.000 I+000.400 K+000.000
G01 X+044.000 Z+0146.000
G02 X+050.000 Z+0149.000 I+000.000 K+003.000
G01 X+050.000 Z+0157.000
G03 X+062.000 Z+0163.000 I+006.000 K+000.000
G01 X+066.000 Z+0163.000
G01 X+070.766 Z+0165.383
G03 X+071.331 Z+0165.500 I+000.283 K-000.283
M30
MAIN SPINDLE WITH CHUCK "Chuck Turning\Jaw chuck\KFD-HS 160"
WORKPART
STEP JAW "Jaw\Step jaw\HM-160_200-02.001"
CHUCKING DEPTH E53.000
Right side of the part: Z+0191.000
CHUCK "Chuck Turning\Jaw chuck\KFD-HS 160"
164
Description
%200
Program name
4) Plandrehen
N010 G54 Z+226.000
165
4.3
Block Commands
No.
Description
5) Centering
5) Zentrieren
N045 G97 S1800 T0909 M03
N055 X+000.000
166
Block Commands
No.
Description
6) Drilling
N075 F000.220 T0707 M03
N105 Z+070.000 M5 M9
167
4.3
Block Commands
No.
Description
N135 G42
N145 X+020.000
168
Block Commands
No.
Description
N210 G40
N215 G80
169
4.3
N240 G42
G23 Programmteilwiderholung
O135 Start block number
Q210 End block number
170
171
4.3
Description
%201
Program name
4) Face Turning
N005 G54 Z+188.000
172
Block Commands
No.
Description
173
4.3
Block Commands
No.
Description
6) Predrilling
N065 G97 S0850 T1212 M03
N095 Z+070.000 M5 M9
174
Block Commands
No.
Description
N125 G41
N150 Z-035.000
N155 X+013.000
N160 G40
N165 G80
N175 Z+070.000 M5 M9
175
4.3
Block Commands
No.
Description
N205 X+200.000
N210 Z+070.000 M5 M9
176
Block Commands
No.
Description
N230 G42
N250 X+072.000
N255 G40
N240 M30
177
4.3
figure 180
Automatic Mode menu diagram.
figure 181
Automatic Mode menu.
figure 182
Menu during continuous automatic run.
178
figure 183
CNC Turning, 3D Display, Optional section.
Entry
F1 (turning)
F2 (automatic mode)
F1 (Automatic mode)
On the screen the simulation of the machining starts.
F6 (Dimension 3D)
F6 (Point dimension)
F1 (next point) or
F2 (previous point)
For the selected point the data are shown
on the screen
F8 (Abort)
F8 (Quit)
179
4.3
figure 184
Follow the subsequent steps for generating the NC-program:
1.
1.
1.
1.
180
Tool
Magazine
Position
Cutting
Values
1 check blank
Outline
Y
dimensions
2 clamp work part
3 define work part zero
point
T01
S1600
T01
6 Contour octagon
F250
F250
S1600
T01
F250
S1600
6
7 Contour with arcs
mill 6mm deep
T01
F250
S1600
181
4.3
8 Contour Circle
r=25mm
T01
F250
S1600
9 Circular Pocket
r=15mm
T02
F50
S1800
10 4 x Centering
CORE DRILL
T03
F80
S2000
DRILL
T04
M6
12 4 x tapping
M6
182
F50
S1500
TAP
T05
10
F150
S150
11
12
figure 185
SetupDialog
figure 186
Set-up Mode; Work part and clamping fixture definition" menu.
CONFIGURATION
MACHINE MTS VMC-024_ISO30_-0500-0400x0450
CONTROL FANUC SERIE 16M
BLANK DIMENSIONS
X+100.000 Y+100.000 Z+025.000
VISE "Chuck Milling\Vise\RS 110"
CHUCKING DEPTH E+010.000
SHIFT V+000.000
ORIENTATION A0
PART POSITION X+150.000 Y+150.000
left corner of the part: X+150.000 Y+150.000 Z+105.000
CURRENT TOOL
T01
TOOLS
T01
T02
T03
T04
T05
"ISO SK 30\
"ISO SK 30\
"ISO SK 30\
"ISO SK 30\
"ISO SK 30\
TOOL COMPENSATION
D01
D02
D03
D04
D05
WORKPART ZEROPOINTS
G54 X150.000 Y+150.000 Z+105.000
183
4.3
NC programming
Block Commands
No.
Description
O 200
N020 G54
N055 Y110
184
Block Commands
No.
Description
G0 rapid traverse
X95 X-Coordinate of the target point
N065 G1 Y-10
N085 G1 Y65
N095 X65
N105 Y35
185
4.3
Block Commands
No.
Description
N115 X35
N120 X5 Y45
N140 G1 Y82
N150 G1 X82
N160 G1 Y18
N170 G1 X18
186
Block Commands
No.
Description
N200 G1 Y50
N215 Z5
187
4.3
Block Commands
No.
Description
N245 S1800 M3
N250 Z2 M8
188
Block Commands
No.
Description
N270 G2 J-15
N285 G0 Z50 M9
G0 rapid traverse
Z50 Z-Coordinate of the target point
M9 deactivate coolant
189
4.3
Block Commands
No.
Description
10) 4x centering
N300 T03 M06
N305 G90
N320 G0 Z1
G0 rapid traverse
Z1 Z-Coordinate of the target point
190
Block Commands
No.
Description
N340 G90 G0 X0 Y0
N355 G0 Z1
G0 rapid traverse
Z1 Z-Coordinate of the target point
191
4.3
Block Commands
No.
Description
12) 4x Tapping
N370 T05 M06
N375 G90 G0 X0 Y0
N385 S150 M3
N390 G00 Z1
192
NC subprogram
Block Commands
No.
N10
Description
O 1910
O Program name
N15
Y82
N20
X82
N25
G98 Y18
N30
N35
G91 G28 Z0 M5
N40
G91 G28 X0 Y0
N45
M99
193
4.3
figure 187
Automatic Mode menu Diagram.
figure 188
Automatic Mode menu.
figure 189
Menu during continuous automatic run.
figure 190
CNC Milling, 3D Display, Optional section.
Workshop
The students are to manufacture the programmed part on the CNC-milling machine.
194
9.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
For which cases are constant cutting speeds required? Explain why.
13.
14.
15.
16.
G90
G0
G1
G0
G1
G2
G0
G96
X133
Z-395
X135
X123
Z-269.8
X133
Z2
T0101
Z2
F0.3
Z2
S100
M3
M8
Z-274.8
I133
K-269.8
O70
195
4.3
N10
N15
N20
N25
N30
N35
N40
N45
196
Commands
Description
O 0300
T040404
M3
M42
M63
G96
S140
spindle speed
G50
S3000
G0
rapid traverse
X20
Z2
M8
activate coolant
G1
X20
Z0
G42
G3
X28
Z-4
I0
K-4
G1
Z-28
G2
X34
Z-31
I3
K0
G1
X38
Z-33
G1
Z-53
Block
No.
N50
Commands
Description
G1
X44
G3
X50
Z-56
I0
K-3
G1
Z-64
G2
X62
Z-70
I6
K0
G1
X66
G1
X71
Z-72
G1
X76
N85
G40
N90
G0
rapid traverse
X500
Z500
M5
M9
deactivate coolant
M30
N55
N60
N65
N70
N75
N80
N95
197
4.3
198
Commands
Description
FX100
program name
N05
G54
N10
G90
G49
G80
G40
G17
G21
metric input
G91
G28
Z0.
M9
deactivate coolant
G91
G28
X0.
Y0.
T01
M06
G90
S1600
spindle speed
M03
G0
rapid traverse
G43
Z20.
H17
X-20.
Y-20.
Z-6.
M08
activate coolant
G1
G41
X10.
D1
F250.
N20
N25
N30
N35
N40
N45
N50
N55
199
4.3
Block
No.
N60
N65
N70
N75
N80
N85
N90
N95
N100
N105
N110
200
Description
G1
Y82.
G2
X18.
Y90.
R8.
G1
X82.
G2
X90.
Y82.
R8.
G1
Y18.
G2
X82.
Y10.
R8.
G1
X18.
G2
X10.
Y18.
R8.
G3
X-10.
Y38.
R20.
G0
rapid traverse
G40.
X-20.
Y-20.
G0
rapid traverse
Z40.
M5
deactivate spindle
Block
No.
N115
N120
N125
Commands
Description
G91
G28
Z0.
M9
deactivate coolant
G90
G80
G49
G40
M30
201
4.3
202
+X
+Z
2. - Milling :
3. - If points are dimensioned using an angle and a distance, example: drilling hole circle.
4. - Point control
- Line control
- Path control
5. - 2 D path control on the X/Y plane
- 2 D path control on the X/Z plane
- 2 D path control on the Y/Z plane
6. - In case of a 2 D path control all three axes can be traveled to one by one, only two at one time
however. Therefore, the plane on which the travel movement is to take place has to be selected first.
7. - The machine zero point M is the origin of the machine coordinate system.
- The work part zero point W is the origin of the work part referenced coordinate system. It is set so
as to enable the drawing dimensions to be taken directly from it.
- The reference point R is required for machines with incremental path measuring system to indicate
the control first an absolute position.
- The tool reference point E is used to measure the applied tools.
8. - The work part zero point W should be positioned so that the drawing dimensions can be directly
taken over for programming.
- In turning, in the rotation axis and in most cases on the front face of the work part.
- In milling, in most cases on the left lower corner point of the work part surface.
9. - Dimension tolerances do not cumulate.
- Single incorrect dimensions do not lead to subsequent errors.
- In turning work parts the diameter values can be directly entered as X value.
203
4.3
15
20
30
20
15
11.
15
20
30
20
15
204
- Tool carriers
- Tool holders
- Indexable inserts
2.
- higher cutting speeds and higher cutting-edge life compared with high-speed steels
- quick and simple exchange of indexable inserts
3.
4.
- The clearance angle influences friction on the work part and consequently, the heating-up of the
cutting edge.
5.
6.
7.
- Negative angles of rake are necessary for machining hard and brittle material.
8.
- The adjustment angle influences the feed power, the forces against the work part, the cutting width
and the cutting depth.
9.
vc = *d * n
or
n=
vc
*d
n=
120m
* min* 0,08m
n = 477 1 min
10.
vc = * d * n
vc = * 0,25 m 100 1 min
vc = 78
m
min
205
4.3
two-jaw chucks
three-jaw chucks
four-jaw chucks
206
feed
speed
tool position in tool storage or turret
additional or switching information
target coordinates in X-direction
target coordinates in Y-direction
target coordinates in Z-direction
207
4.3
208