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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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11
22
44
33
55
66
77
88
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).
4.1EDIToperating mode
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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.
12
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:
4.1EDIToperating mode
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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.
4.1EDIToperating mode
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Selection ofthecontour elements
Input of known dimensions Result
4.1EDIToperating mode
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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.
4.1EDIToperating mode
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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
8.Programming examples
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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.
8.Programming examples
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.
8.Programming examples
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
Press thesoft key Start
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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Press thesoft key Start
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
Press thesoft key Cycle
Press thesoft key Start
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 Insert
Endby pressingthesoft key Select
Selection of pocket roughing
Complete parameter
Pay attentiontovalues T andS
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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Endby pressingthesoft key Insert
Selection ofthe form ofthepocket tobe machined
Complete parameter
Press thesoft key Start
Toolchange
Press thesoft key Select
8.1Example 1
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Correct manually
Select Drilling
Press thesoft keySelect
Endby pressingthe
soft key Insert
Selection of operating
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
Press thesoft key Select
Endby pressingthesoft key Insert
8.1Example 1
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Endby pressingthesoft key Insert
Complete parameter
Press thesoft key Start
Toolchange
Endby pressingthe
soft key Insert
8.1Example 1
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Correct manually
Press thesoft key Cycle
1x
Press thesoft key Select
Select Drill
Selection of operating
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 pressingthesoft key Insert
Endby pressingthe
soft key Insert
Complete parameter
4x
Press thesoft key Select
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
Press thesoft key Start
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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Endthe program input
by pressingthesoft keyCreate
New program
Enter the program numberusingthealphanumerickeyboard
Select the program list
New program
Select operating modeEDIT
8.2 Example2
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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
Confirmtheselectionbypressing Select
Press thesoft key Start
Blank part definition
Select theblank part usingthearrow keys
2 x
8.2 Example2
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Enter the followingvaluesonthe keyboard:B: 160D: 90H: 30
I: 5J: 5K: 1
Confirm datainput by press-ingthesoft key Insert.
Press thesoft key Start
Press thesoft key Insert
Selection ofatemplate
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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Complete parameter
Endby pressingthesoft key
Insert
Press thesoft key Select
Complete parameter
Selection ofthe form ofthemachiningsurface
Endby pressingthesoft key Insert
8.2 Example2
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Endby pressingthesoft key Insert
Press thesoft key Start
Press thesoft key Cycle
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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Endby pressingthesoft key Select
Complete parameter
Complete parameter
Endby pressingthesoft key Insert
Selection ofPocketMilling
3 x
1x
Pay attentiontovalues T andS
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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Selection ofthe form ofthemachiningsurface
Complete parameter
Endby pressingthesoft key OK
Press thesoft key Line
3 x
Endby pressingthesoft key Select
Definition of pocket
geometry
8.2 Example2
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Press thesoft key Line
Press thesoft key Radius
Endby pressingthesoft key OK
8.2 Example2
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Endby pressingthesoft key OK
Endby pressingthesoft key OK
Press thesoft key Line
8.2 Example2
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Press thesoft key Radius
Press thesoft key Line
Press thesoft key OK
8.2 Example2
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Press thesoft key Radius
Press thesoft key OK
Endby pressingthesoft key OK
8.2 Example2
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Press thesoft key OK
Endby pressingthesoft key OK
Press thesoft key Line
8.2 Example2
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Press thesoft key Radius
Endby pressingthesoft key OK
Press thesoft key Line
8.2 Example2
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Press thesoft key Create
Endby pressingthe
soft key OK
Endby pressingthesoft 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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Press thesoft key End
Press thesoft key Insert
Selection ofthetemplate end
Programcompleted
8.2 Example2
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Press thesoft keySimulation
Simulation over
Simulation
Select the operating mode: AUTO
(MEM)
Press thesoft key Rewind
Press thesoft key Start
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:
Image of finished part
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8.3 Example3
Endthe program input
by pressingthesoft keyCreate
New program
Enter the program numberusingthealphanumerickeyboard
Select the program list
New program
Select operating modeEDIT
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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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8.3 Example3
Selection of furthersoft keys
Press 1x
Confirmtheselectionbypressing Select
Press thesoft key Start
Blank part definition
Select theblank part usingthearrow keys
2 x
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8.3 Example3
Confirm datainput bypressingthesoft keyInsert
Press thesoft key Start
Note
: The
bla
nk pa
rt dimensions enteredhere a re only used for the graphic simula-
tionand have no influence onthetool path.
Press thesoft key Insert
Enter the followingvaluesonthe keyboard:B: 120
D: 110H: 20
I: 15J: 15K: 0
Selection ofatemplate
Selection ofasuitabletemplate
T1 = ToolselectionM6 = ToolchangecommandS1200 = 1200 rpm.Rotational
speed ofspindleH1 = Correction oftool
lengthD1 = Correction oftool radiusG43 = Activatetool length
correction
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8.3 Example3
Complete parameter
Press thesoft key Select
Note: At the end of a manual data input,
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).
Press thesoft key Cycle
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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8.3 Example3
Selection ofthe form ofthepocket tobe machined
Complete parameter
Press thesoft key Insert
Press thesoft key OK
Selection ofthe pocket
typeand geometry
definition
Blank part definition
3 x
Endby pressingthesoft key Select
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8.3 Example3
Press thesoft key Line
Press thesoft keyBlankPart
Endby pressingthesoft key OK
1x
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8.3 Example3
Press thesoft key Line
Endby pressingthesoft key OK
Note: The linetype Blank Partremainsautomatically selected.
Press thesoft key Line
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8.3 Example3
Endby pressingthesoft key OK
Press thesoft key Line
Endby pressingthesoft key OK
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8.3 Example3
Endby pressingthesoft key OK
Press thesoft key Create
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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8.3 Example3
Press thesoft key Create
Press thesoft key Island
Note: The island must show thetype Part.In this example the manual guide i hasautomatically selected Part.
Endby pressingthesoft key OK
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8.3 Example3
Press thesoft key Line
Endby pressingthesoft key OK
Press thesoft key Line
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8.3 Example3
Press thesoft key Tangent
Press thesoft key OK
Endby pressingthesoft key OK
Press thesoft key Arc
Press thesoft key Short
Do not forget toselectTangent
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8.3 Example3
Press thesoft key Line
Press thesoft key OK
Press thesoft key Line
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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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8.3 Example3
Press thesoft key Chamfer
Endby pressingthesoft key OK
Press thesoft key Line
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8.3 Example3
Endby pressingthesoft key OK
Endby pressingthesoft key OK
Press thesoft key Chamfer
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100
8.3 Example3
Endby pressingthesoft key OK
Press thesoft key Create
Press thesoft key Line
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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8.3 Example3
Press thesoft key OK
Press thesoft key End
Press thesoft key Insert
Selection ofthe
template end
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8.3 Example3
Press thesoft keySimulation
Press thesoft key Rewind
Programcompleted
Simulation
Select the operating mode:
AUTO(MEM)
Press thesoft key Start
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8.3 Example3
Simulation over
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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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8.4Example 4
Image of finished part
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Endcreation ofthe programby pressingthesoft keyCreate
New program
Enter the program numberusingthealphanumerickeyboard
Select the program list
New program
Select operating modeEDIT
8.4Example 4
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8.4Example 4
Selection of furthersoft keys
Press 1x
Confirmtheselectionbypressing Select
Press thesoft key Start
Blank part definition
Select theblank part usingthearrow keys
2 x
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8.4Example 4
Confirm datainput bypressingthesoft key Alter
Press thesoft key Start
Note
: The
bla
nk pa
rt dimensions enteredhere are only used for the graphicsimula-
tion and have no influence onthetool path.
Press thesoft key Insert
Enter the followingvaluesonthe keyboard:B: 100D: 60
H: 20
I: 50
J: 0
K: 0
Selection ofatemplate
Selection ofasuitabletemplateT1 = ToolselectionM6 = Tool changecommandS1200 = 1200 rpm.Rotational
speed ofspindleH= Correction oftool lengthD= Correction oftoolradiusG43 = Activatetool length
correction
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8.4Example 4
Complete parameter
Press thesoft key Select
Note: At the end of a manual data input,
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).
Press thesoft key Cycle
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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8.4Example 4
Press thesoft key Line
Endby pressingthesoft key OK
Note: Option Part is automatically selected.
1x
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8.4Example 4
Endby pressingthesoft key OK
Press thesoft key Radius
Press thesoft key Arc
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8.4Example 4
Endby pressingthesoft key OK
Select this point
Press thesoft key Select
Press thesoft key Arc
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8.4Example 4
Enter the different valuesfor machining
Endby pressingthesoft key OK
Press thesoft key Next
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8.4Example 4
Select this point
Press thesoft key
Sele
ct
Selection of further soft keys
Press thesoft key Mirror
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8.4Example 4
Endby pressingthesoft key OK
Press thesoft key Select
3 x
Select elements for reflection/
mirroring
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8.4Example 4
Press thesoft key Create
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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8.4Example 4
Press thesoft key Alter
Press thesoft key Create
Press thesoft key OK
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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8.4Example 4
Press thesoft key Island
Endby pressingthesoft key OK
Enter the different values formachining
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8.4Example 4
Press thesoft key Arc
Note: The geometry ofthe pocket or the island
must always be exactly closed. Thestart point
must correspondwiththe finish point.
Press thesoft key Create
Endby pressingthesoft key OK
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8.4Example 4
Endby pressingthesoft key OK
Press thesoft key End
Endby pressingthesoft key Insert
Selection ofthe
template end
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8.4Example 4
Press thesoft keySimulation
Press thesoft key Rewind
Simulation
Select the operating mode:
AUTO(MEM)
Programcompleted
Press thesoft key Start
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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]
SCANDINAVIAGE FanucAutomationCNC Nordic A.B.Hammarbacken 4B S-19149SollentunaTel.:(+46) 8 444 5520 Fax:(+46) 8 444 5521e-mail:[email protected]
SPAIN
GE Fanuc AutomationCNC Espaa S.A.PolgonoIndustrialOlaso CalleOlaso,3E-20870 Elgoibar (Guipzcoa)Tel.:(+34) 943 748290 Fax:(+34) 943 744 421e-mail:[email protected]
SWITZERLAND
GE Fanuc AutomationCNC SwitzerlandGmbHErlenstrasse35a P.O.Box CH-2555BrggBETel.:(+41)32 366 63 63 Fax:(+41)32 366 63 64e-mail:[email protected]
TURKEY
GE Fanuc CNC OtomasyonPazarlamaveTicaretLimitedS irketi
BENELUX
GE Fanuc AutomationCNC EuropeS.A.ZoneIndustrielle L-6468EchternachTel.:(+352)72 7979 1 Fax:(+352)72 7979 510e-mail:[email protected]
CZECH REPUBLICGE Fanuc AutomationCNC CRs.r.o.V Parku 2308/8 CZ-14800 Praha4 -ChodovTel.:(+420)234072 111 Fax:(+420)234072 110e-mail:[email protected]
FRANCE
GE Fanuc AutomationCNC FranceS.A.39,rue du SauleTrapu -BP219F-91882 Massy CedexTel.:(+33) 16975 86 39 Fax:(+33) 16975 86 49e-mail:[email protected]
GERMANY
GE Fanuc AutomationCNC DeutschlandGmbHBernhuser Strae22 D-73765Neuhausena.d.F.Tel.:(+49)7158 187 400 Fax:(+49)7158 187 455e-mail:[email protected]
GREAT BRITAIN
GE Fanuc AutomationCNC UK Ltd15Basset Court LoakeClose
E u ro p e a n h e a d q u a r te r s
GE Fanuc AutomationCNC EuropeS.A.ZoneIndustrielleL-6468Echternach Grand-Duch deLuxembourgTel.:(+352)72 7979 - 1 Fax:(+352)72 7979 -214e-mail:[email protected]/cnc
E u ro p e a n b r a n c h e s
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