FADALManual Guide i for Milling - Training Manual

8/10/2019 FADALManual Guide i for Milling - Training Manual

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TRAINING BOOK

MILLING MADE EASY


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Technicalspecifications can be alteredwithoutprior notification.

Allrights reserved.

The editor accepts no liability for any damageto machinery or plant arising fromusageofthis training book.

Thecopying or transferring of evenindividualtext sections,images or drawingsis not permissiblewithout the prior writtenagreement ofthe publisher. This is alsotruefor photocopying or any other procedure as

wellas transferringthetext to films,tapes,discs,worktransparencies or other media.

Thetrainingbookwas compiledby:

GE Fanuc Automation CNC Europe S.A.

ZoneIndustrielle L-6468 Echternachwww.gefanuc-europe.com

CTDT Centre Technique et de Formation

Les Lovires 13 CH-2720 Tramelanwww.ctdt-cip.ch

CNC-Technologie Service

Elbinger Str.21 D-41812 Erkelenz

2005 1stedit. GE Fanuc Automation CNC EuropeS.A., Echternach, Luxemburg

This trainingbook is the property of:This trainingbook is the property of:


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Pages

Introduction 5

TheCNC controller and operating panel 6

Mainscreen ofManualGuidei 7

Basicprogram functions 8

4.1 EDIToperating mode 8

4.1.1 Creatinga new program 104.1.2 Program list 184.1.3 Changingthe program 19

4.2 MEM operating mode 20

4.2.1 Graphically simulatingthe program 204.2.2 Convertingthe program 21

4.2.3 Executingthe program 214.3 JOGoperating mode 21

General information 22

5.1 Coordinatesystem ofa milling machine 22

5.2 Zero point selection 23

ISOprogramming 24

Tools and offsets 28

Programming examples 30

8.1 Example 1 36

8.2 Example2 58

8.3 Example3 80

8.4 Example 4 104

ManualGuideiMilling


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User-friendly shop floor programming

ManualGuidei,theuser-friendly software for shop floor programming,makes it easier for you to

operatethe machine. The innovative programming enables development from a drawingto a pro-

duction part in avery short time. Thanks to Manual Guidei, G E F anuc CNCs can be programmed,

very easily and quickly, for turning, milling and compound machining. Self-explanatory menus

and graphic simulations guide the user through the programming, producing highly efficient

results even for complex machining processes.

The GE Fanuc Manual Guideisoftware is based onthe ISO code format and has an ergonomic CNC

user interface for programmingcycles.It uses a GraphicalUser Interfacewithuser-friendly icons

whichallow you to interactively create part programs in just a few steps.All oftherelevant infor-

mation is displayed on one CNCscreen.Havingtoconstantly changebetweenscreens is avoided

as is therisk of getting lost inthe numerous pop-upscreens.

This trainingbookwill giveyou an overview ofManual Guideisoftware for the programming of

millingapplications,including four practical programming examples.It was developedby specia-

lists andwill facilitateyour introductiontoManualGuideisoftware.You willbeready to program

even complicated parts with Manual Guide ionce you haveworked your way through the four

examples.

Wewishyou lots of funandsuccess when programming. Wewouldbe delightedto hear fromyou

ifyou haveany suggestions relatingtothis training document.

1.Introduction


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The programmingsoftware ManualGuide i runs onall i series CNCcontrollers from GE Fanuc andFANUC. In this way we have com-bined the highest reliability withuncomplicated shop floor pro-gramming.Thetargeted endresultis high machine availability as wellas quicker work progress.

The following CNC MDI keys areusedwhenselecting and manipulating processes in Manual Guidei

:

Entering data

Confirming entered data

Modifying existing data

Deleting entry tothe left

Deleting data,e.g.a line

Scrolling pageup/down

Movingthecursor inthe direction ofthearrow

ManualGuideiis normally startedby pressing the key.

Note:Tostart ManualGuideipleaserefer alsotothe machinebuilders operation manual.

2.TheCNC controller and operating panel

Series 0i-TC/-MC 30i/31i/32iCNC

FANUC Operating panel

Model B CNC

Series 16i/18i/21i


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The person using the CNC controller with Manual Guide i will find that all of the importantinformation is well laid out and easy tosee onthe mainscreen.Thescreen is subdivided into fourareas:

Millingsimulation in2D and3D

Machine information

Axis position

Distanceto go

Spindlespeed

Load display

Feedrate

ModalG code

Program input

High quality editor

Auxiliary function

Alarm function

Soft keys

Milling-specific

Self-explanatory

Intuitive

3.Mainscreen ofManualGuidei


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The followingthree main operating modes areavailabletotheuser: EDIT(create or changea new program)

MEM(execute or graphically simulatea program)

JOG(manual operation).

4.1EDIToperating mode

The following operations can be executed in this mode: Create, alter, copy, delete newprograms or download or upload programs from/to external data carriers.

Usingthesoft keys,you canselect all other menus fromthe main menu.

Simpleselectionthanks tothesoft keys:

Examples

4.Basicprogram functions


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Menu selection for the machiningcycles.Cycleselection for all operating modes:

Drilling

Externaland internal

contour milling

Slot milling

End face milling

Self-explanatory,easy-to-use datainput menu for amillingcycle:

Pocketing


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4.1.1Creatinganew programTocreatea new program,press thesoft key New Programme(NEWPRG).

Then enter aprogram number between 1and 9999,e.g.:4712 and press thesoft key CREATE.

The program no. 4712 is opened.

Ifa program number has already beenallocated,it is indicatedby a corresponding message.

The new program is enteredas follows:

START

CYCLE

END

Eachcycleconsists ofthe followingtwo parts:

Cuttingconditions

Geometricdata(workpiececontour).



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Programstart: START

To aid comprehension, the following explana-tions refer tothis part drawing:

A personal template can be predefined forthe program start and be simply called up bypressing thesoft key START in the Selectionmenu.

The required data for workpiecemachining is entered step by step.The diagram of the program start

withthe description oftheblank partfor graphicalsimulation as well as toolfunction or replacement arerepeated

with minor modifications.

Thecontroller allows you tostorerecurring program parts as atemplate intheStart menu andto easily callthemupas required.Typicalapplication examples are:programstart,tool functionor toolreplacement and program end.

Theblank part definition has its ownselectionand input menu.


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Machining: CYCLE

There are a wide variety of machining cycles available formilling.Toselect therequiredcycle press thesoft key CYCLE.

Selection is simpleas canbeseen inthe illustrationbelow.Inthe following example, a cubicwork-piece is tobecut inseveral operations.

1.Face milling2.Side milling3.Pocketing4.Drill four holes

End face milling

Using the cursor, select the menu for end face milling and confirm your entry by pressing theSELECTsoftkey.Then,theMachiningConditions menu appears onthescreen.

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When you have entered the machiningconditions, the next screen appears auto-matically.

GeometricdataTo enter the dimensions of thesurface tobe milled.

MachiningconditionsEnter the machining conditions inthe fol-lowingscreen:



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Side milling

Usingthecursor,select thecycle for Outer wall contouringandconfirmyour entry by pressingthe SELECTsoftkey.

ThentheMachiningConditions menu appears onthescreen.

MachiningconditionsEnter the machiningconditions inthe followingscreen:

Geometricdata

Whenyou have enteredthe machiningconditions,thescreenappears automatically inwhichyouenter the dimensions for the exterior contour tobe milled.


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Pocketing

Using the cursor, select the menu for Pocketing and confirm your entry by pressing theSELECTsoftkey.

ThentheMachiningConditions menu appears onthescreen.

MachiningconditionsEnter the machining conditions inthe followingscreen:

GeometricdataWhenyou have enteredthe machin-

ing conditions, the screen appearsautomatically in which you enterthe dimensions for the pocket to bemilled.



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Selection ofthecontour elements

Input of known dimensions Result



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4.1.2 Program listAllthe programs inthe program list are displayedwhenthesoft key O LIST is pressed.

NEW New program

COPY Copy program

DELETE Delete program

EDTCOM Edit comment

SEARCH Search program

M-CARD Memory card

ALL DEL Deleteall

SRTORD Sort programs

OPEN Open program

The following information isdisplayed: program number,comment, date of creation oralteration, time and size of theprogram.

Program list options:

Program input and display

The CNC controller conveniently allows you, by means ofastandard memory card,torapidly readin/out programs and all other datasuch as tool offset, as well as machine and controller data. Thereading in/out of datais fully controlledby the menu usingthesoft keys.

Thecontent ofthe memory cardcanalsobe displayed ontheCNC controller screen.This guar-antees anunrestricted,uncomplicatedandabovealla quick dataexchange.



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4.1.3 Changingthe program

Press thesoft key OPENto display andsubsequently makechanges tothe program.

You can edit cycles usingthe graphical aid by pressingthe ALTERsoft key onthe originalscreen.

Inthe following example,the cycle G1020: FACHIN (ROUGH) is selected. The precise meaning oftherespective function is displayed inthe marked field.

Thechanges are made inthe input menu andareacceptedby pressingthesoft key ALTER.


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The machining is realistically displayed insolidbody animation.You seethe materialremoval bythecorresponding machiningtool.The movement ofthetooltip is displayedas aline inthetoolpath-line graphics.

ZoomFunction

4.2 MEMoperating mode

Programs can be graphically simulated, executed and converted to DIN/ISO in this operatingmode.

4.2.1Graphically simulatingthe program

Aprogram is graphically simulated inthis operating mode. There aretwo different types of dis-play:

a)Solidbody graphicalanimation b)Tool path-line graphics

It is as easy to operateas a DVDplayer.

By selectingtheareausingsoft keys,detailed magnifi-cations canbe easily achieved.

4.2 MEMoperating mode


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4.2.2 Convertingthe program intoISOformat

AManualGuideiprogramcanbe fully convertedtoastandardISO program.Sucha programis hence not dependent on the make of the CNC controller. As aresult you have the option ofuniversally usingthe ManualGuideiprogram inthe entire productionarea.

4.2.3 Executingthe program

Aprogram createdusingthe Manual Guideican be executed directly inthe original format.Youdo not havetoconvert the programto execute it.

4.3 JOGoperating mode

The machine can be manually operated in this operating mode. Using the JOG keys or a handwheel, the feed of the axes being processed can be either manually selected or set at rapid.Amongst other things, theworkpiecezero point and offset are determined ifthe machine doesnot haveanautomaticmeasuring device or has no externaltool pre-setting.

4.3 JOGoperating mode


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5.2 Zero point selection

Each moving axis ofa CNC machine has a measuringsystem. Oncethe machine has beenswitchedon,these measuringsystems must besynchronisedwiththeCNC controller.Therearereferencepoints for this purpose inthe measuringsystems,whichare foundat the positive end oftheaxisstraverse pathandareusually started manually.Thereare also machines withabsolute measuringsystems whereby the measuringsystem is permanently defined.

Theworkpiecezero point canbe freely selected fromthe entire positioningrange.Theuser logi-cally sets thezero point tobe programmedat the place it is easiest to program.

Symbol for thereference point

Symbol for theworkpiecezero point


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Minimal knowledge of ISO programming is required for program generation with ManualGuidei. Machiningcycles arecalledupvia 4-digit G functions. TheG-code itself is irrelevant totheuser as the data is entered by graphic input displays. There are a few G-functions whichtheuser must know in order tobeabletoworkwith ManualGuidei.Theseare explainedbelow.

G0 =RapidTraverse

With the command G0, one or several machineaxes cansimultaneously be moved.Theaxes in ques-tion move at highspeed fromthestart to the targetpoint without interpolating,

e.g.G0 X110 Y50

G1 =Feed

With the command G1 one or several machineaxes cansimultaneously be movedat aprogrammedfeed rate. In this case, the axes in question move

alongastraight interpolating line fromthestart tothetarget point.

For milling machines the feed is normally pro-grammed in mm/minute,

e.g.: G1 X110 Y50 F100(F= feedrate).

G90 =Absolute programming

Inthecase ofabsolute programming, all ofthe pro-grammed positions refer to the selected workpiece

zero point.Example: G90 G0 X50

X70

X110

X140

X170X200

6.ISOprogramming


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G91 =Incremental programmingIn the case of incremental program-ming,each dimensionrefers tothe pre-

vious position.

Example: G91 G0 X50

X20

X40X30

X30

X30

G97 =Speed programming

Thetoolspeed is programmed directly under the S address. Select thespeedyourself ifyou areexperienced enough,or calculate it accordingtothe following formula:

n =Speed inRPMVc= Cuttingspeed in m/min (255)d =Diameter in mm (18.0)

Example: S4509s [RPM]

G94 =Feedrate in mm/min

With drilling and milling tools, the feedrate is generally programmed in mm/min. G94 isthebasic controller settingandtherefore does not needtobe programmedspecifically.The fee-drate is always programmed without a decimal point for drilling and milling applications. Thefollowing formulais usedtocalculatethe feedrate in mm/min:

Vf =Feedrate in mm/minn =Speed inRPM (4509)Z =Number ofteeth (for drill 1)

Sz =Feedrate per tooth mm/tooth or mm/rev (0.25)

Example: F1127 F [mm/min]

The functions G90/G91 and G0/G1 are self-maintaining (modal),which means that theyremainactiveuntilthey are overwrittenby thecorresponding complimentary function.


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M codes (auxiliary functions)M codes are characterised as auxiliary functions,withwhose help the greatest range of machineactions can betriggered. M functions arestandardisedtosome extent and are hencethesame in allCNCmachinetools.Thereare also freeM functions,whichareused differently by each machinemanufacturer. Please pay particular attention here to the operating instructions of the machinemanufacturer.The most important Mfunctions are listedbelow:

M00 =Programstopunconditional

M01 =Programstop optional

M03 =WorkspindleON, clockwise

M04 =WorkspindleON, anticlockwise

M05 =WorkspindleSTOPM06 =Tool exchange

M07 =Coolant 1ON

M08 =Coolant 2 ON

M09 =Coolant OFF

M30 =Program endwithresettingto programstart

M98 = Subprogramcall-up

ManualGuideiProgramandG codes

The following diagrams show parts ofa program generatedusing ManualGuidei:

Alongside there is a part of the programfor the previous example, in which themachining conditions for pocketing arehighlighted inyellow. Inthe next programline a contour is defined in subprogramno. 801.

Theactualcontour form ofthe pocket caneither be saved directly to the same pro-gram or as a separate subprogram. Here,thecontour is storedas asubprogramwiththe number 801 (highlighted in yellow).This has the advantage that subprogram801 can be used for roughing and finish-ing.

6.ISOprogramming


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Besides thespecial 4-figureG codes for cycles,programs createdusing ManualGuideialsocon-tain normalG codes, accordingtoDIN66025.Herearesome examples:

G90 G54G40 M9M5 Typical dataset at thebeginning ofa programto movetheCNC control-ler tothebasicposition.

G0 G91G28 Z0 Approachthereference point intheZ axis at arapidtraverse, e.g.: fortool exchange

T1 Calltool no. 1,e.g.:for tool exchange

M6 Tool exchange

G43 H1 Apply tool lengthcorrection

D1 Apply toolradius

M30 Program end

You cansave programsequences whicharerepeated often,e.g.tool exchange,yourselfas atem-plate, openthemat thetouch ofa buttonand insert them inthe program.Then,you will onlyneedtochange or adjust speeds,tool or offset numbers inthe program.


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Tool commands havetheaddress Tandare programmedwitha number.This number refers either directly tothetool or the position inthetool magazine.Individual details onthetype oftool coding can be found inthe appropriate machine operatingmanual.In each case,the command T17, for example,will maketool number 17 ready for tool exchange, andinthecase ofautomaticmachines,inserted intheworkingspindleby thechangecommand M6.

Thetool memory

Thetool memory is opened by pressingthesoft key T-OFS.

The CNC controller possesses a tool correction memory, in which the dimensions for the toollengthandradius aresaved.

In addition,this memory also contains tooldatafor thetooltype,the installation posi-tionandtheshape or thetool noseangle.

This datais required,for example,for the graphicrepresentation duringsimulation.

7.Tools and offsets


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Tool orientation

Tooltipangle

Tool length correction is usually measured fromthetip ofthespindletothetip ofthetool.With millingtools,theradius ofthe millingunit is entered as theradius correction.This means that programming is very straightfor-

ward, and does not needtotakeatool length or amillingradius intoaccount.

Tool length correction is called by the H com-mand,together withthe function G43(G43 H17)and tool radius correction by the D command,together with the function G41 (G41 D17) orG42.

Radius correction is deleted by the G40 com-mand. Length correction is deleted by the G49command.

Calling G41 or G42 offsets the milling tool by thecorrectionvalue alongthe normaltothe program-medworkpiececontour,either tothe left G41 ortotheright G42,seen inthe feed direction.Whenmillinganarbitrary contour,the millingunit alwaysremains on this offset path. In so doing, the CNCcontroller always reads program lines inadvancetodetect the programmed contour,so that the inter-sections can be calculated correctly for tangentialor non-tangentialcontour transitions.

All ManualGuide icycles must be executedwiththetoolradius correction deleted,i.e. inG40.Thetoollengthcanbecorrectedbeforethecycleby callingG43 H**.


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8.Programming examples

Creating aManual GuideiProgram

A Manual Guide iprogram is created in the following steps. You must pay particular attention to thecorrect approaching ofthe cyclestart point andreturningto a definedwithdrawal point.

1) Blank part definition (only ifa programsimulation is required)

2) Approachingthetoolchange position

3) Toolselection

4) Insertingtherequired G and F functions (e.g.spindle ON,speed, coolant,feed)

5) Approachingthe cyclestart point

6) Cycle:Cutting conditions (e.g. pocketing,drilling,slot milling)

7) Cycle: Figure information (several figures e.g. drilling figures can be programmed after a cycle)

8) Movingto a definedwithdrawal point

9) Repeatingsteps 2 to 8,to add additional machining processes

10) Program end,enter therequired M and G functions


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Example:

G1902B100.D100.H30.I0.J0.K1.; Blank part definition

G0 Z300.;X100. Y100.; Approachingthetoolchange position

T1; Toolselection

M6; Toolreplacement

S1200 M3; Entry ofspeed and direction ofrotation

G43 H1 D1; Activatingtool length offset

X-25.Y-25.;G0 Z2.; Approachingthe cyclestart point

G1020T1.L38.F200.E150.W2.P2.V0.C1.M1.A1.B4.Z2.I100.; Cycle: Cutting conditions

G1220T1.B0.H50.V50.U100.W100.; Cycle: Workpiece geometry

G0 Z300.;X-100.Y-100.; Movingto a definedwithdrawal point

T0; Cancellingtool offset

M30; Program end


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Description of facingcycle

Afacingcycleas illustratedbelow is always configuredusingthetab FACE.

Description of pocketingcycle

The terms CONCAVE and CONVEX refer to pockets or islands respectively whenusingManualGuidei.

A concave free figure (pocket) can also be combinedwith one or more convex free figures (islands)to producea pocket-islandcombination.Theconcave free figure (pocket) must always bethe firstfigure.Thebeginningand end ofa pocket-islandcombinationare denotedby G1990 andG1991,

whichare insertedautomatically by ManualGuide iintothe part program.Thecontour elementsusedto definethe free figurecanbe oftype Partandtype Blank.Inthecasewhenthecontourelement is oftype Part,thetool is not allowedtocut over thecontour element; inthecasewhenthecontour element is oftype Blank,thetoolcuts over thecontour element in order to deburrtheworkpieceborder.The diagrambelow shows the principle ofa pocketingcycle.

Cuttingarea



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SideThickness and BottomThicknessspecify theamount of materialtoberemoved fromtheblank.These values can be entered to avoidany air-cutting motionwhenusinga pre-machined

workpiece,wherethecentre ofthe pocket has already beenremoved.Whenusinga blankwhich isnot pre-machined,the datafields must be left empty.

DO NOT CONFUSE SIDE THICKNESS WITH SIDE FINISH AMOUNT, AND BOTTOMTHICKNESSWITHBOTTOM FINISHAMOUNT.

The diagrams below show how thecuttingareaofa pocket is defined.

Pocket ContourElement Type

Part

Island ContourElement Type

Part

Island Contour

Element Type

Part

Pocket ContourElement Type

Blank

Cutting area Cutting area

Normal Pocket

Refer to examples 1,2

Pocket-Island Combination

Refer to example 4

Pocket-Island Combination

Refer to example3

Cutting area

Side Thickness

Base Point

Side Thickness

Bottom Thickness

Cutting area

Cutting area

Depth


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Description of outer contouringcycle

An outer contouringcyclealways has to becombinedwitha figure oftypeCONVEX. The diagrambelow shows the principle ofan outer contouringcycle.Duringcutting,thetool is moving ona pathwhich is equidistant from the programmed part contour. After each cutting pass the tool path ismovedcloser tothe part shape.

Normally a pocket-island combination generates a more efficient tool path and shorter cycle time(pocket with contour elements of type Blank and island with contour elements of type Part):comparetheanimatedsimulations of example 1and example3 inthis training handbook in ordertobecome familiar withthe differencebetweena pocketinganda contouringcycle.


Warning:

WhentheSIDE THICKNESS andBOTTOM THICKNESS fields are empty, it is assumedthat theblank is as shown inthe diagrambelow.

When the SIDE THICKNESS and BOTTOM THICKNESS fields are set to 0, the workpiece isassumedtobe pre-machinedas shown inthe diagrambelow.

Rapid Motion

Cutting area

RapidMotionRisk of Collision


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Side Thickness and Bottom Thickness specify the amount of material to be removed from theblank. Avalue larger thanzero has tobe inserted.

DO NOT CONFUSE SIDE THICKNESS WITH SIDE FINISH AMOUNT, AND BOTTOMTHICKNESS WITH BOTTOM FINISH AMOUNT. The diagrams below show how the cuttingareaduring outer contouring is defined.

Description of inner contouringcycle

An inner contouring cycle always has to be combinedwith a figure oftypeCONCAVE. Thetool path is analogous to an outer contouring cycle. Thediagrambelow shows the principle ofan inner contouringcycle.

Side Thickness, Bottom Thickness, Base Point andDepthhavethesame meaningas for apocketingcycle.

Cuttingarea

Base Point

A-A

BottomThickness SideThickness

A A

Depth

SideThickness

Cuttingarea

CuttingareaDepth

The diagrams below show the outer contouring cycle:


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Contour milling (predefinedcircular figure)

Mill40 mm

End face milling (predefinedrectangle)

Mill40 mm

8.1 Example 1

In this first example, a workpiece, for which all the geometrical elements are known or have beenmeasured, is programmedusing Manual Guide i. The geometricalshapes that areused aresimple contoursthat can be reduced to basic figures such as rectangles, circles or ellipses. Therefore in this example,only predefined figures areused.InExamples 2,3 and 4that are found later in this handbook, freelyprogrammableshapes are explained in detail.These make it possibleto enter complex workpieces.


In Example 1,the following machining cycles willbe applied:


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Pocketing (predefinedrectangle)

Mill10 mm

Drilling (square hole pattern)

Drill10 mm

Centre drilling (square hole pattern)

Centre drill12 mm

Image of finished part


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New program

Select operating modeEDIT

New program

Enter the program numberusingthe keyboard

Endthe program inputby pressingthesoft keyCreate

8.1Example 1

Select the program list


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Editingthecomments

Press thesoft key to enter

a comment

8.1Example 1

Comment or workpiecename

Opentheselectedprogram

Finishby pressingthe key Alter

Openthe program


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8.1Example 1

Press thesoft key Start

Selection of further softkeys.Press 1x

Confirmtheselectionbypressing Select

Blank part definition

2 x

Select theblank part using

thearrow keys


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8.1Example 1

Confirm datainput bypressingthesoft keyInsert


Selection ofasuitabletemplateT1 =Toolselection

M6 =Toolchangecommand

S1200 = 1200 rpm.Rotationalspeed

ofspindle

H1 =Correction oftool length

D1 =Correction oftoolradius

G43 =Activatetool length

correction

Press thesoft key Insert

Selection ofatemplate

Note

:

The b lank part dimensions entered here are

only used for the graphicsimulation and have

no influence onthetool path.

Enter the followingvaluesonthe keyboard:B: 100D: 100H: 30

I: 0

J: 0

K: 1


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Complete parameter

Selection ofthe form ofthemachiningsurface

Press thesoft key Select

Complete parameter

Endby pressingthesoftkey Insert

Note

:1Thevalues markedwith* are not obligatory.

Note:2The feedrate is entered manually in mm/min.Possible in G 95 (mm/revolutions) if this was

programmedbeforethecycle.

1x

8.1Example 1


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Endby pressingthesoftkey Insert

Note:The tool diameter is automatically compen-

sated by the machining cycle. Thereforemerely the tool length must be activatedwithG43. Address Dis obligatory,thecycles

however must be executed inG40.

Toolchange

Complete parameter

Endby pressingthesoft

key Insert

8.1Example 1


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Pay attentiontovalues T andS

T hewallthicknesses stilltobe machined

must bespecifiedwithT andS

T hesevalues are not tobeconfusedwithK and H, which represent the finishing

dimension.

Correct manually

Complete parameter

Endby pressingthesoftkey Select

2 x

Selection of operating

modeSideMilling

Note:At the end of a manual data input, position

the cursor fully to the left in order to selectthewhole line.

Press thesoft key Cycle

1x

8.1Example 1


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Endby pressingthesoft key Insert



Note:At the end of a m anual data input, position

the cursor fully to the left in order to selectthewhole line.

Correct manually

Toolchange

8.1Example 1


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Safety distancealways >0


Endby pressingthesoft key Select

Selection of pocket roughing

Complete parameter


I f the pocket is already machined, thewallthickness stillto be machined can bedeterminedwiththeaid ofT a ndS.

I f the pocket is not yet machined, novalues may be entered for T andS.

T hesevalues are not tobeconfusedwithK and H, which represent the finishing

dimension.

Selection of operatingmodePocket Milling

3 x

1x

8.1Example 1


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Selection ofthe form ofthepocket tobe machined

Complete parameter


Toolchange


8.1Example 1


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Correct manually

Select Drilling

Press thesoft keySelect

Endby pressingthe

soft key Insert


modeDrilling

Press thesoft keyCycle

Note:

At the end of a manual data input, positionthe cursor fully tothe left in order toselect

thewhole line.

8.1Example 1


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Complete parameter

Complete parameter

1x

Select drill patternRectangular points

4x



8.1Example 1


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Complete parameter


Toolchange

Endby pressingthe

soft key Insert

8.1Example 1


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Correct manually


1x


Select Drill


modeDrilling

1x

Complete parameter

Note:

At the end of a manual data input, positionthe cursor fully tothe left in order toselect

thewhole line.

8.1Example 1


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Endby pressingthe

soft key Insert

Complete parameter

4x


Select drill patternRectangular points

8.1Example 1

Complete parameter


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Press thesoft keySimulation

Simulation

Select the operating mode:AUTO(MEM)

Press thesoft key Rewind


8.1Example 1


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Simulation over

8.1Example 1


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Pocketing (freely programmable concave contour,registeredas asubprogram)

Mill 10 mm

End face milling (predefinedrectangle)

Mill 40 mm

8.2 Example2

Inthis example, a pocket is machined out ofaworkpiecewiththe aid ofManualGuidei.The pocket geometry,which is knowncompletely or has been measured,is enteredas afreely program-mablecontour andregisteredas asubprogram.Storinga contour as asubprogram makes it possibletore-usethese for further cycles; for example for asimple cycle.Since it is apocket, a concave contour isselected.

8.2 Example2

The following machining cycles willbe applied:


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60

Endthe program input

by pressingthesoft keyCreate

New program

Enter the program numberusingthealphanumerickeyboard


New program


8.2 Example2


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61

Comment or part designation

Endthecomment inputby pressingthesoft keyAlter

Select input ofa comment

Edit thecomment

Opentheselected program

Openthe program

8.2 Example2


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Selection of furthersoft keysPress 1x




Select theblank part usingthearrow keys

2 x

8.2 Example2


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63

Enter the followingvaluesonthe keyboard:B: 160D: 90H: 30

I: 5J: 5K: 1

Confirm datainput by press-ingthesoft key Insert.




Note: The blank part dimensions enteredhere are only used for the graphic simula-tionand have no influence onthetool path.

Selection ofasuitabletemplateT1 = ToolselectionM6 = ToolchangecommandS1200 = 1200 rpm.Rotational

speed ofspindleH1 = Correction oftool

lengthD1 = Correction oftool radiusG43 = Activatetool length

correction

8.2 Example2


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65

Complete parameter

Endby pressingthesoft key

Insert


Complete parameter



8.2 Example2


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66




Correct manually

Toolchange

Note: The tool diameter is automaticallycompensated by the machining cycle.Therefore merely the tool length must beactivatedw ith G43. Address Dis obligatory.Thecycle must be executed inG40.

Note: At the end of a manual data input,

positionthecursor fully tothe left in order to

selectthewhole line.

8.2 Example2


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67


Complete parameter

Complete parameter


Selection ofPocketMilling

3 x

1x


If the pocket is already machined, the

wall thickness stillto be machined can bedeterminedwiththeaid ofT andS.

Ifthe pocket is not yet machined,novalues

may be entered for T andS. These values are not to be confused with

K and H, which represent the finishing

dimension.

8.2 Example2


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68


Complete parameter

Endby pressingthesoft key OK

Press thesoft key Line

3 x


Definition of pocket

geometry

8.2 Example2


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70


Press thesoft key Radius


8.2 Example2


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71




8.2 Example2


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72



Press thesoft key OK

8.2 Example2


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73




8.2 Example2


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75




8.2 Example2


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76




8.2 Example2


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77

Press thesoft key Create

Endby pressingthe

soft key OK


Note: The geometry of the pocket mustalways be exactly closed. The start point

must correspondwiththe finish point.

Note: The determined formcanbesavedasaprofile inasubprogram.

Enter the followingvaluesonthe keyboard:Sub-prog-no.1101Designation ofthe figure:Pocket 01

1x

8.2 Example2


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78

Press thesoft key End


Selection ofthetemplate end

Programcompleted

8.2 Example2


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79


Simulation over

Simulation

Select the operating mode: AUTO

(MEM)



8.2 Example2


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8.3 Example3

Pocketing (combination of a freely programmablepocket oftype Blanktype and a freely programmableisland of type Part; combination registered as a sub-program)

Mill 10 mm

Inthis example,the following machining cycle is applied:



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82

8.3 Example3

Endthe program input

by pressingthesoft keyCreate

New program



New program



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83

8.3 Example3

Comment or part designation

Endthecomment inputby pressingthesoftkey Alter

Select input ofa comment

Edit a comment

Opentheselected program

Openthe program


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84

8.3 Example3

Selection of furthersoft keys

Press 1x





2 x


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85

8.3 Example3

Confirm datainput bypressingthesoft keyInsert


Note

: The

bla

nk pa

rt dimensions enteredhere a re only used for the graphic simula-

tionand have no influence onthetool path.


Enter the followingvaluesonthe keyboard:B: 120

D: 110H: 20

I: 15J: 15K: 0


Selection ofasuitabletemplate

T1 = ToolselectionM6 = ToolchangecommandS1200 = 1200 rpm.Rotational

speed ofspindleH1 = Correction oftool

lengthD1 = Correction oftool radiusG43 = Activatetool length

correction


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86

8.3 Example3

Complete parameter



positionthecursor fully tothe left in order

toselect thewhole line.

Completetheaddressesmanually with?Change over the programmanually:T3,H3andD3.

If there is no suit

able templ

ate

av

ail

able

,

it will be necessary to enter the data

manually or record a fixed format (seeUser Manual).


Selection of pocket

machining

Select the operating modewiththearrow keys

3 x

Note2 : The feedrate is entered manually

in mm/min. Possible in G95 (mm/revolu-tions) if this was programmed before thecycle.

Note 1: The values marked with * are not

obligatory.

1x


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87

8.3 Example3

Selection ofthe form ofthepocket tobe machined

Complete parameter



Selection ofthe pocket

typeand geometry

definition


3 x



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88

8.3 Example3


Press thesoft keyBlankPart


1x


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89

8.3 Example3



Note: The linetype Blank Partremainsautomatically selected.



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90

8.3 Example3





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91

8.3 Example3



1x

Press thesoft key Alter

Enter values andtext.

Select the option CreateSP

Note:This concludes theblank part definition.

Note:

The part tobe machined is insertedas an

island.


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92

8.3 Example3


Press thesoft key Island

Note: The island must show thetype Part.In this example the manual guide i hasautomatically selected Part.



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93

8.3 Example3





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94

8.3 Example3

Press thesoft key Tangent



Press thesoft key Arc

Press thesoft key Short

Do not forget toselectTangent


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95

8.3 Example3





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96

8.3 Example3

Press this soft key,whichrecords thecurrent position,and enter 15 mm dependingonrequirements.

Enter 10 mm,depending ontheversion

Press this soft key,whichrecords thecurrent position


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98

8.3 Example3

Press thesoft key Chamfer




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99

8.3 Example3



Press thesoft key Chamfer


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100

8.3 Example3




Note: The geometry of the pocket or the

island must always be exactly closed. The

start point must correspond with the finishpoint.


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101

8.3 Example3




Selection ofthe

template end


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102

8.3 Example3



Programcompleted

Simulation

Select the operating mode:

AUTO(MEM)



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103

8.3 Example3

Simulation over


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104

8.4Example 4

Pocketing (combination of freely programmable pocket of

Blanktypeand freely programmable island ofParttype;combinationstored/filedas asubprogram)

Mill 10 mm

8.4 Example 4

Inthis example, a pocket is machined out ofaworkpiecewiththe aid ofManual Guideileaving an islandinthe centre.

Thesymmetrical pocket geometry includes severalunknown geometrical elements and is generatedbyreflection/mirroring.For machiningthe pocket withthe island, a combination oftwo freely program-mable figures is selected. One is a freely programmable pocket (concave) oftype Part andthe other is afreely programmable island contour (convex), also oftype Part,since inthis case, in contrast to Example3,thetool may not infringe on either ofthetwo figures.

Inthis example,the following machining cycle is applied:


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105

8.4Example 4



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106

Endcreation ofthe programby pressingthesoft keyCreate

New program



New program


8.4Example 4


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108

8.4Example 4

Selection of furthersoft keys

Press 1x





2 x


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109

8.4Example 4

Confirm datainput bypressingthesoft key Alter


Note

: The

bla

nk pa

rt dimensions enteredhere are only used for the graphicsimula-

tion and have no influence onthetool path.


Enter the followingvaluesonthe keyboard:B: 100D: 60

H: 20

I: 50

J: 0

K: 0


Selection ofasuitabletemplateT1 = ToolselectionM6 = Tool changecommandS1200 = 1200 rpm.Rotational

speed ofspindleH= Correction oftool lengthD= Correction oftoolradiusG43 = Activatetool length

correction


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110

8.4Example 4

Complete parameter



positionthe cursor fully tothe left in order toselect thewhole line.

Completetheaddressesmanually with?Change over the programmanually:T3,H3andD3.

Ifthere is no suit

able templ

ate

av

ail

able

,itwill be necessary to enter the data manually

or recorda fixed format (seeUser Manual).


Selection of pocket

machining

Select the operating modewiththearrow keys

3 x

Note2: Pay attentiontovalues T and S

If the pocket is already machined, thewall thickness still to b e machinedcanbe determinedwiththe aid of T and S.

If the pocket is NOT pre-machined,DONT enter any value for data fields T

and S. Do not mistake the data fields T and S

withthe finishing dimensions K and H.

Note 1: The values marked with * are not

obligatory. Leave the boxes blank in the

case of premachined parts.

1x

Note3: The feedrate is entered manually in

mm/min. Possible in G95 (mm/revolutions) ifthis was programmed beforethe cycle.


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112

8.4Example 4



Note: Option Part is automatically selected.

1x


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113

8.4Example 4





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114

8.4Example 4


Select this point




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115

8.4Example 4

Enter the different valuesfor machining


Press thesoft key Next


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116

8.4Example 4

Select this point

Press thesoft key

Sele

ct

Selection of further soft keys

Press thesoft key Mirror


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117

8.4Example 4



3 x

Select elements for reflection/

mirroring


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118

8.4Example 4


Press thesoft key Yes

Selection of previoussoft keys

Note: The geometry of the pocket or the

island must always be exactly closed. The

start point must correspond with the finishpoint.


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119

8.4Example 4

Press thesoft key Alter



Note

: If the gr

aphi

c blo

cks

are entereddirectly in the main program, it is possible

to proceed straight away with the soft key

Island.

1x


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120

8.4Example 4

Press thesoft key Island


Enter the different values formachining


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121

8.4Example 4


Note: The geometry ofthe pocket or the island

must always be exactly closed. Thestart point

must correspondwiththe finish point.




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122

8.4Example 4




Selection ofthe

template end


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8.4Example 4



Simulation

Select the operating mode:

AUTO(MEM)

Programcompleted



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8.4Example 4

Simulation over


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POLAND

GE Fanuc AutomationCNC Polska Sp.z o.o.ul.Chorzowska50 PL-40-121KatowiceTel.:(+48)32 731 5261 Fax:(+48)32 731 5260e-mail:[email protected]

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SWITZERLAND

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FADALManual Guide i for Milling - Training Manual

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