Getting More From Your CNC Machines

Getting More From Your CNC Machines
Lesson 5: Setup Reduction Techniques Topics Setup reduction techniques (cont.) Program verification Program optimizing Other setup tasks Setup reduction techniques Introduction Evaluating how well organized you are Gathering components for a setup Workholding setup Cutting tools Program zero assignment Program development Program transfer and storage Setup tasks and improvements 1 Copyright 2011

Introduction To Setup Reduction Techniques

You should be ready to begin
With an understanding of principles: Definition of setup time Two task types Three ways to reduce setup time Four steps to setup reduction You should be ready to begin

General flow of making a setup:
We’ll be going through setup tasks in this order: Get ready Workholding setup Program zero assignment Cutting tools Program development Program transfer and storage Program verification Program optimizing Other tasks related to setup

2) To Move The Task Off Line 3) To Facilitate The Task
With every task, we’ll give suggestions… 1) To Eliminate The Task 2) To Move The Task Off Line 3) To Facilitate The Task

With every task, we’ll give suggestions… 1) To Eliminate The Task 2) To Move The Task Off Line 3) To Facilitate The Task Hardest to justify Repeated task or urgency Finite # of repeated setups

With every task, we’ll give suggestions… 1) To Eliminate The Task 2) To Move The Task Off Line 3) To Facilitate The Task Sufficient CNC staff Sufficient cycle time Sufficient lot sizes

With every task, we’ll give suggestions… 1) To Eliminate The Task 2) To Move The Task Off Line 3) To Facilitate The Task Little repeat business Setup person does all No off-line time

Study your current methods!
While we’ll show many techniques and make many suggestions… …we’re just scratching the surface of what’s possible Study your current methods! With ingenuity – and your knowledge of your company’s methods – you should be able to come up with more – and more appropriate –ideas

Your list of tasks will likely be different than ours
In each setup reduction step, we will: Develop a list of related tasks Provide general suggestions Provide specific machining center techniques Provide specific turning center techniques Your list of tasks will likely be different than ours

Evaluating How Well Organized You Are

Disorganization is pretty easy to spot…

…you must encourage and enhance the potential for organization…

…you must encourage and enhance the potential for organization… …since getting more organized improves every CNC task! Remember: The more often you repeat a task, the easier it is to justify improving it. Every task you perform is affected by how well organized you are!

Workbenches Does every hand tool have a place? How cluttered is the work surface? Is it ever used for storage? Does every operator have one?

Cleanliness can also have an impact on safety
Cleanliness of work area and machine/s Is everything put away when not in use? Are chips, coolant, oil, and debris cleaned? Cleanliness can also have an impact on safety

Storage of components Are needed components properly stored? Is every drawer/cabinet clearly labeled?

Storage of components Are needed components properly stored? Is every drawer/cabinet clearly labeled? Are work holding devices properly stored?

Storage of components Are needed components properly stored? Is every drawer/cabinet clearly labeled? Are work holding devices properly stored? What about cutting tool and insert storage?

Storage of components Are needed components properly stored? Is every drawer/cabinet clearly labeled? Are work holding devices properly stored? What about cutting tool and insert storage? Are common gauges readily available? Watch for any time that CNC people seem confused - or when they must search the shop to find a needed component

Documentation Have procedures been developed for important or complex tasks? Does everyone know what they’re expected to do? Do key people get called at home to solve problems? How often are mistakes made?

Work habits Does everyone do things in a consistent manner? Does everyone understand and adhere to safety standards? Have you set priorities for shop-related tasks? Has there been any horse-play

Consistency of programming methods
Program mean value for all dimensions No offset adjustment will be necessary Handle programming features consistently Cutter radius compensation Tool length compensation Tool nose radius compensation Do you ever see your setup people having to make adjustments from job to job due to inconsistent programming methods?

Job order planning 1 A-2346 2 A-3856 3 B-2917 Do you consecutively run similar jobs to minimize setup effort? Work holding setup Cutting tools Do your people ever have to tear down a job in the middle of a production run for a “hot job”

Non-production time Can you make use of time that the machine would normally be down? Lunch Breaks Off shifts Shutdowns Any setup – or portion of a setup – that can be made during these periods will be off line!

If you have never undertaken an improvement program…
…it’s likely that you’ll find problems with organization In this case, your first step must be to get better organized! The goal is to eliminate confusion and wasted time Fortunately, it’s pretty easy to come up with ways to improve organization… …it takes little more than common sense

An example: A machining center operator needs the vise handle to load and remove every workpiece… …stick the vise handle to the machine (with Velcro) to eliminate the need to locate it

Almost everything we do to get better organized falls into the category of facilitating tasks…
…we’re trying to make it as quick and easy to perform just about any tasks!

Is there room for improvement with organization in your own company?

Gathering Components For A Setup

Think of everything a setup person needs to complete a setup…
Hand tools Workholding devices and/or components Fasteners Cutting tool components and inserts Program Documentation Raw material Finished workpiece storage bins Gauges Coolant Documentation: Print, Production control material, Setup sheet, production run instructions, SPC material Think of all the time that could be saved if they could complete the setup without leaving the machine How often do setup people currently leave the machine to go get something? In the setup reduction planning form (provided in lesson four), list items that must be gathered

In this way, the entire task of gathering can be moved off line
With good documentation and in well organized companies, a lesser skilled person can do the gathering for upcoming jobs… …anything gathered prior to a setup moves the task of gathering off line And if everything can be gathered prior to starting the setup… …the setup person will be able to complete the setup without ever having to leave the machine! In this way, the entire task of gathering can be moved off line Also… If anything is missing, you will know it before the job hits the machine!

Who will do the gathering?
Setup person? Tool crib attendant? Operator? Lead person? CNC helper? Be sure to pick someone who truly has the time to consistently gather all components prior to a setup And be sure that all components are properly stored and labeled, and easy to find – so anyone can do the gathering This requires a high degree of organization

The gathered components are commonly referred to as a kit
If small and light, the kit can be placed in a box or bin and brought out to the machine prior to the setup If large and heavy, the kit can be placed in a cart and wheeled out to the machine prior to setup Either way, the goal is to allow the setup person to complete the setup without having to leave the machine.

Tear Down The Previous Setup

Think of what must be done to remove the previous setup from the machine
Remove workholding device Remove cutting tools not needed for next job Clear offsets for tools removed from the machine Disassemble certain components (like cutting tools) Put everything away Save changes to program and remove from the machine Empty chip pan (if machining a different material) Clean machine Here is our list, but be sure to create a list of your own Use the setup reduction planning form provided in lesson four

First, try to come up with ways to eliminate tasks…
…some may seem far-fetched Remove workholding device Remove cutting tools not needed for next job Clear offsets for tools removed from the machine Disassemble certain components (like cutting tools) Put everything away Save changes to program and remove from the machine Empty chip pan (if machining a different material) Clean machine Can you think of any way to keep from having to remove the work holding device? Can multiple workholding devices be mounted to the machine? (On the table of a vertical machining centers.) Can jobs requiring the same workholding device be run consecutively? Can workholding devices be more versatile, allowing different jobs to be run?

…some may seem far-fetched Remove workholding device Remove cutting tools not needed for next job Clear offsets for tools removed from the machine Disassemble certain components (like cutting tools) Put everything away Save changes to program and remove from the machine Empty chip pan (if machining a different material) Clean machine Can you think of any way to keep from having to remove cutting tools? Does the machine have enough tool stations to hold all tools for all jobs? Can a set of “standard” cutting tools be kept in the machine at all times? Cam jobs requiring the same cutting tools be run consecutively?

…some may seem far-fetched Remove workholding device Remove cutting tools not needed for next job Clear offsets for tools removed from the machine Disassemble certain components (like cutting tools) Put everything away Save changes to program and remove from the machine Empty chip pan (if machining a different material) Clean machine Does this task really have to be done? Setup people may feel more comfortable doing so, but having a value in an unused offset will have no adverse effect. Offsets for “standard tool stations” will not have to be cleared.

…some may seem far-fetched Remove workholding device Remove cutting tools not needed for next job Clear offsets for tools removed from the machine Disassemble certain components (like cutting tools) Put everything away Save changes to program and remove from the machine Empty chip pan (if machining a different material) Clean machine Can you think of any way to keep from having to disassemble cutting tools? If using a limited number of different tools, leave them assembled at all times. Consider the redundancy of tearing down and assembling cutting tools Again, pick a set of “standard tools” that will be left assembled at all times.

…some may seem far-fetched Remove workholding device Remove cutting tools not needed for next job Clear offsets for tools removed from the machine Disassemble certain components (like cutting tools) Put everything away Save changes to program and remove from the machine Empty chip pan (if machining a different material) Clean machine Can you think of any way to keep from having to put things away? If all the cutting tools you use can fit in the machine’s tool changing system, nothing will have to be put away

…some may seem far-fetched Remove workholding device Remove cutting tools not needed for next job Clear offsets for tools removed from the machine Disassemble certain components (like cutting tools) Put everything away Save changes to program and remove from the machine Empty chip pan (if machining a different material) Clean machine Can you think of any way to keep from having to save and delete programs? With some controls that are networked to they company’s computer system, programs can be run from the network – not from internal control memory. In essence, the machine cannot run out of memory capacity.

…some may seem far-fetched Remove workholding device Remove cutting tools not needed for next job Clear offsets for tools removed from the machine Disassemble certain components (like cutting tools) Put everything away Save changes to program and remove from the machine Empty chip pan (if machining a different material) Clean machine Can you think of any way to keep from having to empty the chip pan? Can you run jobs that are made from the same material consecutively?

…some may seem far-fetched Remove workholding device Remove cutting tools not needed for next job Clear offsets for tools removed from the machine Disassemble certain components (like cutting tools) Put everything away Save changes to program and remove from the machine Empty chip pan (if machining a different material) Clean machine Can you think of any way to keep from having to clean the machine? Some machine designs minimize the need for cleaning Slant bed versus flat bed turning centers Horizontal versus vertical machining centers

…some may seem far-fetched Remove workholding device Remove cutting tools not needed for next job Clear offsets for tools removed from the machine Disassemble certain components (like cutting tools) Put everything away Save changes to program and remove from the machine Empty chip pan (if machining a different material) Clean machine Again, some ideas to eliminate tasks will be infeasible – but try to come up with at least one way to do so for every task

If you cannot justify what it takes to eliminate the task…
…can you move it off line? Remove workholding device Remove cutting tools not needed for next job Clear offsets for tools removed from the machine Disassemble certain components (like cutting tools) Put everything away Save changes to program and remove from the machine Empty chip pan (if machining a different material) Clean machine Can you think of any way to be tearing down setups while a machine is in production? Machining centers with pallet changers If you have additional pallets, they can be set up while the machine is in production

…can you move it off line? Remove workholding device Remove cutting tools not needed for next job Clear offsets for tools removed from the machine Disassemble certain components (like cutting tools) Put everything away Save changes to program and remove from the machine Empty chip pan (if machining a different material) Clean machine Can you think of any way to be removing cutting tools while a machine is in production? Some machining centers do allow cutting tools to be removed while the machine is in cycle But of course, cutting tools needed for the job must remain in the machine until the job is completed

…can you move it off line? Remove workholding device Remove cutting tools not needed for next job Clear offsets for tools removed from the machine Disassemble certain components (like cutting tools) Put everything away Save changes to program and remove from the machine Empty chip pan (if machining a different material) Clean machine Can you think of any way to be clearing offsets while a machine is in production? Again, machines do allow offsets to be cleared while the machine is in cycle But offsets needed for cutting tools in a job cannot be cleared until the job is completed. BUT REMEMBER – this task can postponed until the machine is back in cycle, running the next job This means the task will be done off line

…can you move it off line? Remove workholding device Remove cutting tools not needed for next job Clear offsets for tools removed from the machine Disassemble certain components (like cutting tools) Put everything away Save changes to program and remove from the machine Empty chip pan (if machining a different material) Clean machine Can you think of any way to be disassembling components and putting things away during a production run? Again, needed components will be required until the production run is completed BUT REMEMBER – this task can be postponed until the next job is up and running. In this way the task is done off line. Another person – the same person who does the gathering – can do this task

…can you move it off line? Remove workholding device Remove cutting tools not needed for next job Clear offsets for tools removed from the machine Disassemble certain components (like cutting tools) Put everything away Save changes to program and remove from the machine Empty chip pan (if machining a different material) Clean machine Can you think of any way to be manipulating programs during a production run? Again, the program will be required until the production run is completed BUT REMEMBER – with background edit, you can transfer programs while the machine is in cycle. The modified version of the program can be saved during the production run. In this way, program transfer is done off line. And – background edit also allows programs to be deleted. Wait until the next production run begins to delete the program used in the previous job.

…can you move it off line? Remove workholding device Remove cutting tools not needed for next job Clear offsets for tools removed from the machine Disassemble certain components (like cutting tools) Put everything away Save changes to program and remove from the machine Empty chip pan (if machining a different material) Clean machine Can you think of any way to be emptying the chip pan during a production run? The chip pan cannot be emptied until the job is finished but… …anything that can be prepared for this task (bringing the new chip pan close by the machine, for example) should be done before the production run ends.

…can you move it off line? Remove workholding device Remove cutting tools not needed for next job Clear offsets for tools removed from the machine Disassemble certain components (like cutting tools) Put everything away Save changes to program and remove from the machine Empty chip pan (if machining a different material) Clean machine Can you think of any way to be cleaning the machine during a production run? Probably not, but do anything you can in preparation for cleaning the machine while the machine is still running the job (like gathering cleaning supplies, brushers, rags, etc.)

Final suggestion for moving tasks off line:
If you cannot justify what it takes to eliminate the task… …can you move it off line? Remove workholding device Remove cutting tools not needed for next job Clear offsets for tools removed from the machine Disassemble certain components (like cutting tools) Put everything away Save changes to program and remove from the machine Empty chip pan (if machining a different material) Clean machine Final suggestion for moving tasks off line: Watch for tasks that people perform on line that could be performed off line. Can you think of any way to be cleaning the machine during a production run? Probably not, but do anything you can in preparation for cleaning the machine while the machine is still running the job (like gathering cleaning supplies, brushers, rags, etc.)

If you cannot justify what it takes to move the task off line…
…can you facilitate it? Remove workholding device Remove cutting tools not needed for next job Clear offsets for tools removed from the machine Disassemble certain components (like cutting tools) Put everything away Save changes to program and remove from the machine Empty chip pan (if machining a different material) Clean machine Can you think of any way to simplify the task of removing the workholding device? Consider fastener types Socket head cap screws (using ratchet wrenches) are easier to remove and replace than hex head screws (with box end wrenches) Provide lifting help (cranes) for heavy workholding devices Consider method of clamping. Bolts into tapped holes are usually easier than tee-nuts.

…can you facilitate it? Remove workholding device Remove cutting tools not needed for next job Clear offsets for tools removed from the machine Disassemble certain components (like cutting tools) Put everything away Save changes to program and remove from the machine Empty chip pan (if machining a different material) Clean machine Can you think of any way to simplify the task of removing cutting tools? Keep cutting tool storage rack/s close by the tool changer. If a wrench is required to remove cutting tools, dedicate one for this purpose and keep it near by where it is needed. (Velcro it to the machine, if possible.)

…can you facilitate it? Remove workholding device Remove cutting tools not needed for next job Clear offsets for tools removed from the machine Disassemble certain components (like cutting tools) Put everything away Save changes to program and remove from the machine Empty chip pan (if machining a different material) Clean machine Can you think of any way to simplify the task of clearing offsets? Study control documentation – there may be a better/faster way than clearing one offset at a time.

…can you facilitate it? Remove workholding device Remove cutting tools not needed for next job Clear offsets for tools removed from the machine Disassemble certain components (like cutting tools) Put everything away Save changes to program and remove from the machine Empty chip pan (if machining a different material) Clean machine Can you think of any way to simplify the task of disassembling components? Study this process. Ensure that the person who does the disassembling has a clean work area and all of the appropriate hand tools for this purpose. Consider having a dedicated work station for disassembling cutting tools. Again, this task should not be the responsibility of the (highly skilled) setup person. The same person who gathers components can perform this task.

…can you facilitate it? Remove workholding device Remove cutting tools not needed for next job Clear offsets for tools removed from the machine Disassemble certain components (like cutting tools) Put everything away Save changes to program and remove from the machine Empty chip pan (if machining a different material) Clean machine Can you think of any way to simplify the task of putting things away? Again, organization is the key. Every component must have a storage location If storage locations are clearly marked, a person with lesser skill can perform this task (not the setup person).

…can you facilitate it? Remove workholding device Remove cutting tools not needed for next job Clear offsets for tools removed from the machine Disassemble certain components (like cutting tools) Put everything away Save changes to program and remove from the machine Empty chip pan (if machining a different material) Clean machine Can you think of any way to simplify the task of saving and deleting programs? For saving programs, an automatic DNC system will allow the setup person to save a program without having to leave the machine. Be sure setup people are using the most efficient techniques to delete programs.

…can you facilitate it? Remove workholding device Remove cutting tools not needed for next job Clear offsets for tools removed from the machine Disassemble certain components (like cutting tools) Put everything away Save changes to program and remove from the machine Empty chip pan (if machining a different material) Clean machine Can you think of any way to simplify the task of emptying the chip pan? Provide gloves and shovel (or hand scoop) – and any other needed item. Store them close by the chip pan.

…can you facilitate it? Remove workholding device Remove cutting tools not needed for next job Clear offsets for tools removed from the machine Disassemble certain components (like cutting tools) Put everything away Save changes to program and remove from the machine Empty chip pan (if machining a different material) Clean machine Can you think of any way to simplify the task of cleaning the machine? Provide (another set of) gloves – store them close to the machine’s work area. If cleaning involves an air-blowing system, be sure to provide full-face protection. Keep any needed cleaning supplies near the machine.

Final suggestion for facilitating tasks:
If you cannot justify what it takes to move the task off line… …can you facilitate it? Remove workholding device Remove cutting tools not needed for next job Clear offsets for tools removed from the machine Disassemble certain components (like cutting tools) Put everything away Save changes to program and remove from the machine Empty chip pan (if machining a different material) Clean machine Final suggestion for facilitating tasks: Look for times when people struggle with a task. When they do, it should be taken as a signal that you MUST facilitate the task. Can you think of any way to simplify the task of cleaning the machine? Provide (another set of) gloves – store them close to the machine’s work area. If cleaning involves an air-blowing system, be sure to provide full-face protection. Keep any needed cleaning supplies near the machine.

Are there any non-physical tasks occurring as setups are torn down?
If you cannot justify what it takes to move the task off line… …can you facilitate it? Remove workholding device Remove cutting tools not needed for next job Clear offsets for tools removed from the machine Disassemble certain components (like cutting tools) Put everything away Save changes to program and remove from the machine Empty chip pan (if machining a different material) Clean machine One more point: These are all physical tasks that can be consistently done and easily measured. Are there any non-physical tasks occurring as setups are torn down?

Are any of these happening while tearing down?
If you cannot justify what it takes to move the task off line… …can you facilitate it? Remove workholding device Remove cutting tools not needed for next job Clear offsets for tools removed from the machine Disassemble certain components (like cutting tools) Put everything away Save changes to program and remove from the machine Empty chip pan (if machining a different material) Clean machine Again, non-physical tasks are inconsistent and/or immeasurable (possibly wasted) actions or inactions that increase the time required to make a setup or complete a production run Are any of these happening while tearing down? Time spent searching for needed items Time wasted while duplicating effort after a mistake Time lost while waiting for an unavailable item Any time the machine sits idle while no-one is working on it

Workholding Setup

Think of what must be done to make the workholding setup
Prepare the new workholding device For machining centers Clamp to machine table Square up workholding device with table Using dial indicator For turning centers Mount top tooling Bore jaws (if necessary Prepare work support device (if necessary) Mount center and position tailstock Align tailstock Adjust clamping pressure Here is our list, but be sure to create a list of your own Use the setup reduction planning form provided in lesson four

…some may seem far-fetched Prepare the new workholding device For machining centers Clamp to machine table Square up workholding device with table Using dial indicator For turning centers Mount top tooling Bore jaws (if necessary Prepare work support device (if necessary) Mount center and position tailstock Align tailstock Adjust clamping pressure Can you think of any way to keep from having make new workholding setups? Can multiple workholding devices be mounted to the machine? (On the table of a vertical machining centers.) Can jobs requiring the same workholding device be run consecutively? Can workholding devices be more versatile, allowing different jobs to be run? Are there any parameters to change? Program them with G10.

This devices changes job to job
First, try to come up with ways to eliminate tasks… …some may seem far-fetched Prepare the new workholding device For machining centers Clamp to machine table Square up workholding device with table Using dial indicator For turning centers Mount top tooling Bore jaws (if necessary Prepare work support device (if necessary) Mount center and position tailstock Align tailstock Vise stays on table This devices changes job to job An example of multiple workholding devices Can you think of any way to keep from having make new workholding setups? Can multiple workholding devices be mounted to the machine? (On the table of a vertical machining centers.) Can jobs requiring the same workholding device be run consecutively? Can workholding devices be more versatile, allowing different jobs to be run? Are there any parameters to change? Program them with G10.

This keeps the setup person from doing so!
Eliminate workholding setup tasks Do you have to change any control parameters from one setup to another? When removing and replacing rotary tables When using probing systems When switching between inch and metric Others? Remember, most current model Fanuc controls let you change parameters with G10 This keeps the setup person from doing so!

…some may seem far-fetched Prepare the new workholding device For machining centers Clamp to machine table Square up workholding device with table Using dial indicator For turning centers Mount top tooling Bore jaws (if necessary Prepare work support device (if necessary) Mount center and position tailstock Align tailstock Adjust clamping pressure Can you think of any way to keep from having make new workholding setups? If the setup is qualified, the workholding device will be square with the table when mounted

A qualified setup: Definition:
A qualified setup is one that can placed on the machine table in exactly the same fashion over and over again

Does your machine have a center slot?
A qualified setup: Does your machine have a center slot? Table slots Top view of VMC table

A qualified setup: Bottom plate of workholding device Keys If fixture is square with table, there will be no need to align! Top view of VMC table

…some may seem far-fetched Prepare the new workholding device For machining centers Clamp to machine table Square up workholding device with table Using dial indicator For turning centers Mount top tooling Bore jaws (if necessary Prepare work support device (if necessary) Mount center and position tailstock Align tailstock Adjust clamping pressure Can you think of any way to keep from having make new workholding setups? If the setup is qualified, the workholding device will be square with the table when mounted

…some may seem far-fetched Prepare the new workholding device For machining centers Clamp to machine table Square up workholding device with table Using dial indicator For turning centers Mount top tooling Bore jaws (if necessary Prepare work support device (if necessary) Mount center and position tailstock Align tailstock Adjust clamping pressure Can you think of any way to keep from having make new workholding setups? Some turning centers allow tailstock positioning to be programmed Eliminating the need for a setup person to move the tailstock

…some may seem far-fetched Prepare the new workholding device For machining centers Clamp to machine table Square up workholding device with table Using dial indicator For turning centers Mount top tooling Bore jaws (if necessary Prepare work support device (if necessary) Mount center and position tailstock Align tailstock Adjust clamping pressure Can you think of any way to keep from having make new workholding setups? With some machines, the tailstock stays in alignment – even when moved Eliminating the need for a setup person to align the tailstock from job to job

…some may seem far-fetched Prepare the new workholding device For machining centers Clamp to machine table Square up workholding device with table Using dial indicator For turning centers Mount top tooling Bore jaws (if necessary Prepare work support device (if necessary) Mount center and position tailstock Align tailstock Adjust clamping pressure Can you think of any way to keep from having make new workholding setups? Some turning centers allow chuck pressure to be programmed This keeps the setup person from having to change chuck pressure

…can you move it off line? Prepare the new workholding device For machining centers Clamp to machine table Square up workholding device with table Using dial indicator For turning centers Mount top tooling Bore jaws (if necessary Prepare work support device (if necessary) Mount center and position tailstock Align tailstock Adjust clamping pressure Can you think of any way to be making workholding setups while a machine is in production? Same suggestions as for tearing down: Machining centers with pallet changers If you have additional pallets, they can be set up while the machine is in production

On-line time will be limited to placing the pallet on the machine
Making use of pallet changing systems Automatic type Manual type As long as you have extra pallets, two tasks related to workholding setup can be moved off line Remove previous workholding device Mount new workholding device On-line time will be limited to placing the pallet on the machine

…can you move it off line? Prepare the new workholding device For machining centers Clamp to machine table Square up workholding device with table Using dial indicator For turning centers Mount top tooling Bore jaws (if necessary Prepare work support device (if necessary) Mount center and position tailstock Align tailstock Adjust clamping pressure Can you think of any way to be making workholding setups while a machine is in production? Same suggestions as for tearing down: Machining centers with pallet changers If you have additional pallets, they can be set up while the machine is in production

If you cannot justify what it takes to move a task off line…
…can you facilitate it? Prepare the new workholding device For machining centers Clamp to machine table Square up workholding device with table Using dial indicator For turning centers Mount top tooling Bore jaws (if necessary Prepare work support device (if necessary) Mount center and position tailstock Align tailstock Adjust clamping pressure Can you think of any way to make it easier to make the workholding setup? Again, look for times when people struggle Consider fastener types Socket head cap screws (using ratchet wrenches) are easier to remove and replace than hex head screws (with box end wrenches) Provide lifting help (cranes) for heavy workholding devices Consider method of clamping. Bolts into tapped holes are usually easier than tee-nuts.

…can you facilitate it? Prepare the new workholding device For machining centers Clamp to machine table Square up workholding device with table Using dial indicator For turning centers Mount top tooling Bore jaws (if necessary) Prepare work support device (if necessary) Mount center and position tailstock Align tailstock Adjust clamping pressure Can you think of any way to make it easier to make the workholding setup? Again, look for times when people struggle Mounting jaws can be a very tedious task Study this task to find improvements Consider quick-change chucks Use a pointer to specify the serration into which jaws must be placed

Facilitating workholding setup tasks
Mounting top tooling Note tiny serrations 3-jaw chuck

Mounting top tooling Hard jaw Soft jaw

Mounting top tooling Jaw changing is a very cumbersome task Six socket head cap screws must be loosened Tee nuts must be placed on new jaws Jaws must be accurately placed in serrations Six socket head cap screws must be tightened If placement is off, this must be repeated! Jaw replacement can take 5-15 minutes or more

Mounting top tooling Jaw changing is a very cumbersome task For your next chuck purchase… …consider quick-jaw-change chucks One screw is involved per jaw One quarter turn of special wrench loosens jaw One quarter turn tightens Jaw changing time is about 5 seconds per jaw! Serrations are larger (soft jaws don’t last as long) Confirm concentricity requirements

Select the boring bar you use for boring jaws
Facilitating workholding setup tasks Mounting jaws X Z Align with tool diameter 1.3569 Select the boring bar you use for boring jaws

Mounting jaws X Z Align with tool diameter Determine the diameter for chucking (with chuck unclamped): 1.3569 Clamping diameter plus jaw stroke If clamping on a 3.0” dia. and jaw stroke is 0.5”, this diameter is 3.5”

Mounting jaws X Z Align with tool diameter 3.5 Open jaws and move X axis to clamping diameter

Mounting jaws X Z Align with tool diameter Use boring bar as a pointer and mount each jaw Each jaw can be easily mounted in the same serration Jaws will clamp on workpiece at mid-stroke

…can you facilitate it? Prepare the new workholding device For machining centers Clamp to machine table Square up workholding device with table Using dial indicator For turning centers Mount top tooling Bore jaws (if necessary) Prepare work support device (if necessary) Mount center and position tailstock Align tailstock Adjust clamping pressure Can you think of any way to make it easier to make the workholding setup? Again, look for times when people struggle For repeated jobs, save soft jaws Don’t re-bore them for another job This saves time the next time the job is run Make a set of chucking rings – or a special clamping tool Provide instructions for jaw-boring or create a jaw-boring program

Clamp on ring

Make a set of chucking rings!
Facilitating workholding setup tasks Clamp on ring 1.0 1.125 1.25 1.375 1.5 1.625 1.75 1.875 2.0 2.125 2.375 2.5 Make a set of chucking rings!

Or make an adjustable chucking tool
Facilitating workholding setup tasks Clamp on ring Hex stock Hex head screws Or make an adjustable chucking tool

Clamp on ring

…can you facilitate it? Prepare the new workholding device For machining centers Clamp to machine table Square up workholding device with table Using dial indicator For turning centers Mount top tooling Bore jaws (if necessary) Prepare work support device (if necessary) Mount center and position tailstock Align tailstock Adjust clamping pressure Can you think of any way to make it easier to make the workholding setup? Again, look for times when people struggle For repeated jobs, save soft jaws Don’t re-bore them for another job This saves time the next time the job is run Make a set of chucking rings – or a special clamping tool Provide instructions for jaw boring – or create a jaw-boring program

…can you facilitate it? Prepare the new workholding device For machining centers Clamp to machine table Square up workholding device with table Using dial indicator For turning centers Mount top tooling Bore jaws (if necessary) Prepare work support device (if necessary) Mount center and position tailstock Align tailstock Adjust clamping pressure Can you think of any way to make it easier to make the workholding setup? Again, look for times when people struggle For repeated jobs, save soft jaws Don’t re-bore them for another job This saves time the next time the job is run Make a set of chucking rings – or a special clamping tool Provide instructions for jaw boring - or create a jaw-boring program

Actually boring jaws Be sure the setup person can align the jaw boring cutting tool

Actually boring jaws X Z Set to zero Be sure the setup person can align the jaw boring cutting tool

At least now the setup person can determine diameters and depths!
Facilitating workholding setup tasks Actually boring jaws X Z Align with tool diameter 1.3569 At least now the setup person can determine diameters and depths!

Better yet, why not develop programs to bore jaws?
Facilitating workholding setup tasks Actually boring jaws Better yet, why not develop programs to bore jaws? One jaw boring program per job, or… …one universal program (custom macro)

Place jaw boring commands after M30
Facilitating workholding setup tasks Actually boring jaws If one program per job: N205 G00 X6.5 Z5.0 N210 M30 N999 (BEGIN JAW BORING) N1000 T1212 (Boring bar) . N1105 M30 Place jaw boring commands after M30

Actually boring jaws If universal custom macro: O0002 (Program number) #101 = 3.00 (Starting diameter to bore) #102 = 4.00 (Ending diameter to bore) #103 = 1.0 (Z depth of jaw boring) #104 = (Depth of cut per pass) #105 = 300. (Speed in SFM for boring) T1212 (Index to boring bar) G96 S#105 M03 (Start spindle) G98 G01 X#101 Z0.15 F30.0 (Fast feed to approach position) G99 G71 P1 Q2 U-0.01 W0.005 D#104 F0.10 (Rough bore jaws) N1 G00 X#102 G01 Z-#103 N2 X#101 G70 P1 Q2 F0.005 M30

Actually boring jaws If universal custom macro: O0002 (Program number) #101 = 3.00 (Starting diameter to bore) #102 = 4.00 (Ending diameter to bore) #103 = 1.0 (Z depth of jaw boring) #104 = (Depth of cut per pass) #105 = 300. (Speed in SFM for boring) T1212 (Index to boring bar) G96 S#105 M03 (Start spindle) G98 G01 X#101 Z0.15 F30.0 (Fast feed to approach position) G99 G71 P1 Q2 U-0.01 W0.005 D#104 F0.10 (Rough bore jaws) N1 G00 X#102 G01 Z-#103 N2 X#101 G70 P1 Q2 F0.005 M30 Input data

Actually boring jaws If universal custom macro: O0002 (Program number) #101 = 3.00 (Starting diameter to bore) #102 = 4.00 (Ending diameter to bore) #103 = 1.0 (Z depth of jaw boring) #104 = (Depth of cut per pass) #105 = 300. (Speed in SFM for boring) T1212 (Index to boring bar) G96 S#105 M03 (Start spindle) G98 G01 X#101 Z0.15 F30.0 (Fast feed to approach position) G99 G71 P1 Q2 U-0.01 W0.005 D#104 F0.10 (Rough bore jaws) N1 G00 X#102 G01 Z-#103 N2 X#101 G70 P1 Q2 F0.005 M30 Will change with input data

…can you facilitate it? Prepare the new workholding device For machining centers Clamp to machine table Square up workholding device with table Using dial indicator For turning centers Mount top tooling Bore jaws (if necessary) Prepare work support device (if necessary) Mount center and position tailstock Align tailstock Adjust clamping pressure Can you think of any way to make it easier to make the workholding setup? Again, look for times when people struggle For repeated jobs, save soft jaws Don’t re-bore them for another job This saves time the next time the job is run Make a set of chucking rings – or a special clamping tool Provide instructions for jaw boring - or create a jaw-boring program

Cutting Tools

Again, here is our list, but be sure to create a list of your own
Think of what must be done to get cutting tools ready to use in the machine Machining centers Turning centers Assemble needed tools Insert, cutting tool body, extension, adapter, holder, pull stud Measure Tool length compensation value Cutter radius compensation value Preset Boring bars to specified diameter Load in specified tool stations Enter offsets Tool length compensation Cutter radius compensation Sharpen / replace dull tools Insert, cutting tool shank or body, etc. Load in specified turret stations Tool nose radius compensation Again, here is our list, but be sure to create a list of your own Use the setup reduction planning form provided in lesson four

…some may seem far-fetched Machining centers Turning centers Assemble needed tools Insert, cutting tool body, extension, adapter, holder, pull stud Measure Tool length compensation value Cutter radius compensation value Preset Boring bars to specified diameter Load in specified tool stations Enter offsets Tool length compensation Cutter radius compensation Sharpen / replace dull tools Insert, cutting tool shank or body, etc. Load in specified turret stations Tool nose radius compensation Can you think of any way to eliminate cutting tool tasks? Can jobs requiring the same cutting tools be run consecutively? Can you consolidate the number of cutting tools needed? Can you come up with standard tool stations?

Eliminate cutting tool tasks
Standard tool stations You probably have some tools that are used regularly Spot drill ¾ end mill 3” face mill Drill & tap combos Assign permanent tool stations to these tools

Standard tool stations By the way, how many tool stations do your machines have? Standard tool stations should be a major consideration when buying machines! Finite number of different jobs? You may be able to store all tools in the ATC magazine!

Standard tool stations
Eliminate cutting tool tasks Standard tool stations Even if you can’t store all tools in the ATC magazine… …place a storage rack right next to the machine!

You must be able to justify the additional cost
Eliminate cutting tool tasks Having standard tool stations requires duplicated cutting tool components You must be able to justify the additional cost How much on-line setup time is currently taken to perform cutting tool tasks?

Consolidate cutting tools
Eliminate cutting tool tasks Consolidate cutting tools How do you designate tools on setup sheets? DJ0500-HC1.0-E1.0-C0.5-L6.5 HC1000 collet holder E1000 extension C0500 collet Jobbers length ½ drill Approx 6.5 ½ drill Or

Consolidate cutting tools If you designate all components for cutting tools… …and if you minimize the number of different tool assemblies… …there will be a better chance that needed cutting tools will already be assembled

…some may seem far-fetched Machining centers Turning centers Assemble needed tools Insert, cutting tool body, extension, adapter, holder, pull stud Measure Tool length compensation value Cutter radius compensation value Preset Boring bars to specified diameter Load in specified tool stations Enter offsets Tool length compensation Cutter radius compensation Sharpen / replace dull tools Insert, cutting tool shank or body, etc. Load in specified turret stations Tool nose radius compensation Can you think of any way to eliminate cutting tool tasks? Offset entries can be programmed For machining center tools with known lengths or diameters For tool nose radius compensation on turning centers This keeps the setup person from having to enter them

Why not program the TNR offset settings?
Eliminate cutting tool tasks About tool nose radius compensation: The programmer specifies the tool nose radius for single point turning tools The setup person must use the specified TNR! Why not program the TNR offset settings? G10 P2 R T3 G10 P6 R T2

(And no need for offset entry)
Eliminate cutting tool tasks About tool nose radius compensation: By the way… …CAM systems have the ability to output modified tool path based upon the specified tool nose radius There will be no G41 or G42 in the program! (And no need for offset entry)

…some may seem far-fetched Machining centers Turning centers Assemble needed tools Insert, cutting tool body, extension, adapter, holder, pull stud Measure Tool length compensation value Cutter radius compensation value Preset Boring bars to specified diameter Load in specified tool stations Enter offsets Tool length compensation Cutter radius compensation Sharpen / replace dull tools Insert, cutting tool shank or body, etc. Load in specified turret stations Tool nose radius compensation Can you think of any way to eliminate cutting tool tasks? Offset entries can be programmed For machining center tools with known lengths or diameters For tool nose radius compensation on turning centers This keeps the setup person from having to enter them

If you cannot justify what it takes to eliminate tasks…
…can you move them off line? Machining centers Turning centers Assemble needed tools Insert, cutting tool body, extension, adapter, holder, pull stud Measure Tool length compensation value Cutter radius compensation value Preset Boring bars to specified diameter Load in specified tool stations Enter offsets Tool length compensation Cutter radius compensation Sharpen / replace dull tools Insert, cutting tool shank or body, etc. Load in specified turret stations Tool nose radius compensation What can be done while the machine is in production for the previous job? Assemble cutting tools for up-coming jobs while the machine is producing When the job hits the machine, cutting tools will be ready This can be done by a tool setter (not necessarily the setup person)

…can you move them off line? Machining centers Turning centers Assemble needed tools Insert, cutting tool body, extension, adapter, holder, pull stud Measure Tool length compensation value Cutter radius compensation value Preset Boring bars to specified diameter Load in specified tool stations Enter offsets Tool length compensation Cutter radius compensation Sharpen / replace dull tools Insert, cutting tool shank or body, etc. Load in specified turret stations Tool nose radius compensation What can be done while the machine is in production for the previous job? For machining centers, tool length and cutter radius compensation values can be determined off line

Move cutting tool tasks off line
Measuring cutting tools Tool length Cutter radius (for milling cutters) Remember – there are two ways to use tool length compensation…

Measuring cutting tools Program Zero TLC offset Fixture offset Z Program Zero TLC offset Fixture offset Z is zero Offset value can be easily measured off line Offset value doesn’t change from job to job Offset value can be shared among machines

A simple height gage can be used… 1 Value 2 3 4 5 7 # 6 6.5445 5.6743 5.9876 7.5654 6.5654 4.5657 7.6544 …tool setter can write down tool lengths Many tooling suppliers can provide a special tool length measuring device

For cutter radius compensation, a micrometer can be used to measure most milling cutters… …tool setter can write down cutter radius or diameter

Multiple identical tools
By the way… Multiple identical tools Do you keep more than one of your most popular tools assembled and ready to go? One company: Has fifteen CNC machining centers Picked ten most popular cutting tools Tool crib attendant keeps at least three of each Anyone who needs them has immediate access

…can you move them off line? Machining centers Turning centers Assemble needed tools Insert, cutting tool body, extension, adapter, holder, pull stud Measure Tool length compensation value Cutter radius compensation value Preset Boring bars to specified diameter Load in specified tool stations Enter offsets Tool length compensation Cutter radius compensation Sharpen / replace dull tools Insert, cutting tool shank or body, etc. Load in specified turret stations Tool nose radius compensation What can be done while the machine is in production for the previous job? For machining centers, tool length and cutter radius compensation values can be determined off line

…can you move them off line? Machining centers Turning centers Assemble needed tools Insert, cutting tool body, extension, adapter, holder, pull stud Measure Tool length compensation value Cutter radius compensation value Preset Boring bars to specified diameter Load in specified tool stations Enter offsets Tool length compensation Cutter radius compensation Sharpen / replace dull tools Insert, cutting tool shank or body, etc. Load in specified turret stations Tool nose radius compensation What can be done while the machine is in production for the previous job? If boring bars must be preset, do so before the job comes to the machine

Setup person must trial machine to fine-tune
Move cutting tool tasks off line Most companies don’t try to perfectly set boring bars… …instead, they set them or so undersize Setup person must trial machine to fine-tune

…if you can come up with a way to perfectly set boring bars off line…
Move cutting tool tasks off line Trial boring takes time… …if you can come up with a way to perfectly set boring bars off line… …you can minimize down time between production runs!

…can you move them off line? Machining centers Turning centers Assemble needed tools Insert, cutting tool body, extension, adapter, holder, pull stud Measure Tool length compensation value Cutter radius compensation value Preset Boring bars to specified diameter Load in specified tool stations Enter offsets Tool length compensation Cutter radius compensation Sharpen / replace dull tools Insert, cutting tool shank or body, etc. Load in specified turret stations Tool nose radius compensation What can be done while the machine is in production for the previous job? If boring bars must be preset, do so before the job comes to the machine

…can you move them off line? Machining centers Turning centers Assemble needed tools Insert, cutting tool body, extension, adapter, holder, pull stud Measure Tool length compensation value Cutter radius compensation value Preset Boring bars to specified diameter Load in specified tool stations Enter offsets Tool length compensation Cutter radius compensation Sharpen / replace dull tools Insert, cutting tool shank or body, etc. Load in specified turret stations Tool nose radius compensation What can be done while the machine is in production for the previous job? Can you be loading cutting tools for the next job while the machine is running the current job? Some machines allow cutting tools to be loaded and removed while the machine is in cycle.

Tool Magazine Loading Station Rotate CW Rotate CCW Magazine Manual Auto If you have enough tool stations… …during production, load tools for the next job!

…can you move them off line? Machining centers Turning centers Assemble needed tools Insert, cutting tool body, extension, adapter, holder, pull stud Measure Tool length compensation value Cutter radius compensation value Preset Boring bars to specified diameter Load in specified tool stations Enter offsets Tool length compensation Cutter radius compensation Sharpen / replace dull tools Insert, cutting tool shank or body, etc. Load in specified turret stations Tool nose radius compensation What can be done while the machine is in production for the previous job? Can you be loading cutting tools for the next job while the machine is running the current job? Some machines allow cutting tools to be loaded and removed while the machine is in cycle. Can you be loading cutting tools for the next job while the machine is running the current job?

…can you move them off line? Machining centers Turning centers Assemble needed tools Insert, cutting tool body, extension, adapter, holder, pull stud Measure Tool length compensation value Cutter radius compensation value Preset Boring bars to specified diameter Load in specified tool stations Enter offsets Tool length compensation Cutter radius compensation Sharpen / replace dull tools Insert, cutting tool shank or body, etc. Load in specified turret stations Tool nose radius compensation What can be done while the machine is in production for the previous job? If you assemble and measure cutting tools off line, you can program the tool length and cutter radius compensation offset entries This keeps the setup person from having to do so.

Earlier we said tool setters can measure tool lengths 1 Value 2 3 4 5 7 # 6 6.5445 5.6743 5.9876 7.5654 6.5654 4.5657 7.6544 …and write down tool length values But the setup person must still enter offsets while the machine is down!

The tool setter can create a program to set offset values!
Move cutting tool tasks off line The tool setter can create a program to set offset values! Template program O8001 (Offset program) G90 G10 P1 R G10 P2 R G10 P3 R G10 P4 R G10 P5 R G10 P6 R G10 P7 R G10 P8 R G10 P9 R G10 P10 R . M30 Tool setter calls up this template program and modifies the R word for each tool

The tool setter can create a program to set offset values!
Move cutting tool tasks off line The tool setter can create a program to set offset values! Template program O8001 (Offset program) G90 G10 P1 R6.5893 G10 P2 R6.3321 G10 P3 R5.4678 G10 P4 R7.5746 G10 P5 R3.4858 G10 P6 R4.3433 G10 P7 R8.4872 M30 Tool setter calls up this template program and modifies the R word for each tool This program is stored in the DNC system – called up and executed by the setup person

Some tool measuring devices can output measured values! 6.5643 Offset setting program is automatically created!

Either way, the on-line time required for entering offsets will be the time it takes to download this program and execute it!

…can you move them off line? Machining centers Turning centers Assemble needed tools Insert, cutting tool body, extension, adapter, holder, pull stud Measure Tool length compensation value Cutter radius compensation value Preset Boring bars to specified diameter Load in specified tool stations Enter offsets Tool length compensation Cutter radius compensation Sharpen / replace dull tools Insert, cutting tool shank or body, etc. Load in specified turret stations Tool nose radius compensation What can be done while the machine is in production for the previous job? If you assemble and measure cutting tools off line, you can program the tool length and cutter radius compensation offset entries This keeps the setup person from having to do so.

If you cannot move tasks off line…
…can you facilitate any tasks? Machining centers Turning centers Assemble needed tools Insert, cutting tool body, extension, adapter, holder, pull stud Measure Tool length compensation value Cutter radius compensation value Preset Boring bars to specified diameter Load in specified tool stations Enter offsets Tool length compensation Cutter radius compensation Sharpen / replace dull tools Insert, cutting tool shank or body, etc. Load in specified turret stations Tool nose radius compensation What can you do to make it simpler to get cutting tools ready? Again, study your setup people – Is there anything you can do to help them?

…can you facilitate any tasks? Machining centers Turning centers Assemble needed tools Insert, cutting tool body, extension, adapter, holder, pull stud Measure Tool length compensation value Cutter radius compensation value Preset Boring bars to specified diameter Load in specified tool stations Enter offsets Tool length compensation Cutter radius compensation Sharpen / replace dull tools Insert, cutting tool shank or body, etc. Load in specified turret stations Tool nose radius compensation What can you do to make it simpler to get cutting tools ready? Being well organized is the key to efficiently assembling cutting tools

…can you facilitate any tasks? Machining centers Turning centers Assemble needed tools Insert, cutting tool body, extension, adapter, holder, pull stud Measure Tool length compensation value Cutter radius compensation value Preset Boring bars to specified diameter Load in specified tool stations Enter offsets Tool length compensation Cutter radius compensation Sharpen / replace dull tools Insert, cutting tool shank or body, etc. Load in specified turret stations Tool nose radius compensation What can you do to make it simpler to get cutting tools ready? Do any of your machining centers have a tool probe?

Most can also measure diameter/radius
Facilitate cutting tool tasks If you must measure tool lengths on line… …use a tool length measuring probe! Most can also measure diameter/radius

This program helps with measurement and enters offset values!
Facilitate cutting tool tasks If your machine doesn’t have a probe… O9500 (Program to touch off tool lengths) N1 #100 = 1 (First tool station number to measure) #101 = 15 (Last tool station to measure) N2 #3006 = 100 (TOUCH SPINDLE TO BLOCK) N3 #5003 = 0 (Set current Z position as program zero point) N4 G91 G01 Z1.5 F30.0 (Move away from block in Z) N5 G91 G28 Z0 M19 (Move to tool change position, orient spindle) N7 T#100 M06 (Place current tool in spindle) N8 #3006 = 101 (TOUCH TOOL TIP TO BLOCK) N9 #[ #100] = #5003 (Set tool length compensation offset) N10 G91 G01 Z1.5 F30. (Move away from block in Z) N11 G91 G28 Z0 M19 (Move to tool change position, orient spindle) N12 #100 = # N13 #3006 = 102 (PRESS CYCLE START TO CONT) N14 GOTO 7 This program helps with measurement and enters offset values!

…can you facilitate any tasks? Machining centers Turning centers Assemble needed tools Insert, cutting tool body, extension, adapter, holder, pull stud Measure Tool length compensation value Cutter radius compensation value Preset Boring bars to specified diameter Load in specified tool stations Enter offsets Tool length compensation Cutter radius compensation Sharpen / replace dull tools Insert, cutting tool shank or body, etc. Load in specified turret stations Tool nose radius compensation What can you do to make it simpler to get cutting tools ready? Do any of your machining centers have a tool probe?

…can you facilitate any tasks? Machining centers Turning centers Assemble needed tools Insert, cutting tool body, extension, adapter, holder, pull stud Measure Tool length compensation value Cutter radius compensation value Preset Boring bars to specified diameter Load in specified tool stations Enter offsets Tool length compensation Cutter radius compensation Sharpen / replace dull tools Insert, cutting tool shank or body, etc. Load in specified turret stations Tool nose radius compensation What can you do to make it simpler to get cutting tools ready? Help for setting a taper reamer

Facilitate cutting tool tasks
Taper reaming Setup people may be struggling: Guessing at initial offset Several tries required Same process for sharpened reamer

Facilitate cutting tool tasks
Taper reaming N040 G43 H05 Z2.0 N045 G81 R-0.7 Z-1.0 F5.0 G98

…can you facilitate any tasks? Machining centers Turning centers Assemble needed tools Insert, cutting tool body, extension, adapter, holder, pull stud Measure Tool length compensation value Cutter radius compensation value Preset Boring bars to specified diameter Load in specified tool stations Enter offsets Tool length compensation Cutter radius compensation Sharpen / replace dull tools Insert, cutting tool shank or body, etc. Load in specified turret stations Tool nose radius compensation What can you do to make it simpler to get cutting tools ready? Help for setting a taper reamer

…can you facilitate any tasks? Machining centers Turning centers Assemble needed tools Insert, cutting tool body, extension, adapter, holder, pull stud Measure Tool length compensation value Cutter radius compensation value Preset Boring bars to specified diameter Load in specified tool stations Enter offsets Tool length compensation Cutter radius compensation Sharpen / replace dull tools Insert, cutting tool shank or body, etc. Load in specified turret stations Tool nose radius compensation What can you do to make it simpler to get cutting tools ready? Loading tools into a turning center’s turret can be cumbersome Ensure that needed hand tools are readily available Some turning centers have quick-change tooling, which makes loading and removing tools very easy

Program Zero Assignment

Think of what must be done to assign program zero
Machining centers Turning centers Determine program zero assignment values Measure with edge finder or dial indicator Calculate Enter program zero assignment values Into fixture offsets (preferred) Edit G92 command Determine program zero assignment values For each tool Measure distance between tool tip and program zero Calculate Enter program zero assignment values Into geometry offsets (preferred) Edit G50 commands Again, here is our list, but be sure to create a list of your own Use the setup reduction planning form provided in lesson four

Program zero assignment aligns the workholding setup position with the program
Top view of vertical machining center Machine Position Program zero FANUC 10M + X Y Z X value Y value

Spindle nose Machine Position FANUC 10M + X Y Z Z value

One way: CYCLE START FEED HOLD EDIT AUTO MDI JOG HANDLE ZERO RETURN MODE 0% 100% 200% FEEDRATE OVERRIDE 10% 25% 50% RAPID OVERRIDE 1 12 TURRET INDEX 2 3 4 5 6 7 8 9 10 11 SLOW FAST EMERGENCY STOP FANUC 10T POWER ON OFF O N G P A X Y Z Q B I J K R C F D H L # M S T / EOB U V W Sp E ? @ , [ ] ( ) * PAGE CURSOR SHIFT - + = CAN RESET START CALC INPUT NC/PC AUX X Z X1 X10 X100 ON DRY RUN SINGLE BLOCK MACHINE LOCK OPTIONAL STOP BLOCK DELETE X+ X- Z- JOYSTICK Z+ SPINDLE ORIGIN 130% SPINDLE LOAD AXIS LOAD OD ID CLAMP DIRECTION MEMORY PROTECT CHUCK TAILSTOCK X axis geometry offset value value Program zero

Another way: Z axis geometry offset value CYCLE START FEED HOLD EDIT AUTO MDI JOG HANDLE ZERO RETURN MODE 0% 100% 200% FEEDRATE OVERRIDE 10% 25% 50% RAPID OVERRIDE 1 12 TURRET INDEX 2 3 4 5 6 7 8 9 10 11 SLOW FAST EMERGENCY STOP FANUC 10T POWER ON OFF O N G P A X Y Z Q B I J K R C F D H L # M S T / EOB U V W Sp E ? @ , [ ] ( ) * PAGE CURSOR SHIFT - + = CAN RESET START CALC INPUT NC/PC AUX X Z X1 X10 X100 ON DRY RUN SINGLE BLOCK MACHINE LOCK OPTIONAL STOP BLOCK DELETE X+ X- Z- JOYSTICK Z+ SPINDLE ORIGIN 130% SPINDLE LOAD AXIS LOAD OD ID CLAMP DIRECTION MEMORY PROTECT CHUCK TAILSTOCK Work shift value X axis geometry offset value value Program zero

Think of what must be done to assign program zero
Machining centers Turning centers Determine program zero assignment values Measure with edge finder or dial indicator Calculate Enter program zero assignment values Into fixture offsets (preferred) Edit G92 command Determine program zero assignment values For each tool Measure distance between tool tip and program zero Calculate Enter program zero assignment values Into geometry offsets (preferred) Edit G50 commands Again, here is our list, but be sure to create a list of your own Use the setup reduction planning form provided in lesson four

…some may seem far-fetched Machining centers Turning centers Determine program zero assignment values Measure with edge finder or dial indicator Calculate Enter program zero assignment values Into fixture offsets (preferred) Edit G92 command Determine program zero assignment values For each tool Measure distance between tool tip and program zero Calculate Enter program zero assignment values Into geometry offsets (preferred) Edit G50 commands Can you think of any way to eliminate program zero assigning tasks? If machining center setups are qualified, you can eliminate the entire task of program zero assignment Program zero assignment values will be included in the program Setup person will not have to measure or enter program zero assignment values

For repeated setups, program zero will be in the same location
A qualified setup: Definition: A qualified setup is one that can placed on the machine table in exactly the same fashion over and over again For repeated setups, program zero will be in the same location

Does your machine have a center slot?
A qualified setup: Does your machine have a center slot? Table slots Top view of VMC table

Bottom plate of workholding device
A qualified setup: Bottom plate of workholding device Keys Top view of VMC table

A qualified setup: Program zero Top view of VMC table

A qualified setup: Top view of VMC table

A qualified setup: Program zero will be in the same position every time the setup is made! Don’t believe it? Top view of VMC table

A qualified setup: Program zero will be in the same position every time the setup is made! Machine a tooling hole Don’t believe it? This command sends the spindle directly above the tooling hole Using a dial indicator, check that the fixture is properly placed After doing this a few times to confirm the setup is qualified, stop doing this procedure O0001 . M30 N999 G53 X Y Top view of VMC table

A qualified setup: Program zero will be in the same position every time the setup is made! If program zero is in the same location every time a setup is made… Program zero assignment values will be the same every time the setup is made! But how do you determine program zero assignment values the first time a setup is made?

If workholding device is accurately made:
Determining program zero assignment values If workholding device is accurately made: Known values

Determining program zero assignment values If workholding device is accurately made: Easy to calculate

Determining program zero assignment values If workholding device is accurately made: By the way… …this is one reason why sub-plates are so helpful! A B C D E F G H I J K L M N O P Q R S 1 2 3 4 5 6

Determining program zero assignment values
If workholding device is not accurately made: These values must be measured once

Include G10 commands to enter fixture offset values
Programming fixture offset entries Include G10 commands to enter fixture offset values O0001 . M30 N999 G90 G10 L2 P1 X Y Z

More on sub-plates Top view of VMC table Plug 2.0000 typ
0.7500” location hole typ A B C D E F G H I J K L M N O P Q R S 1 2 3 4 5 6 ½-13 clamping hole Top view of VMC table

More on sub-plates FANUC 16M #0: COMMON X 00.0000 Y 00.0000 Z 00.0000
+ #0: COMMON X Y Z WORK COORDINATE SYSTEM SETTING #1: G54 X Y Z #2: G55 #3: G56 Z – Normal use of fixture offsets

More on sub-plates FANUC 16M #0: COMMON X 00.0000 Y 00.0000 Z 00.0000
Use common offset to shift the point of reference for fixture offset entries WORK COORDINATE SYSTEM SETTING #0: COMMON X Y Z #2: G55 X Y Z #1: G54 X Y Z #3: G56 X Y Z Z +

More on sub-plates Top view of VMC table
Determine distances to lower-left hole A B C D E F G H I J K L M N O P Q R S 1 2 3 4 5 6 Top view of VMC table

More on sub-plates FANUC 16M #0: COMMON X -32.2223 Y -15.4734
+ #0: COMMON X Y Z WORK COORDINATE SYSTEM SETTING #1: G54 X Y Z #2: G55 Z #3: G56 Enter them into common offset

Place corner stop in hole F5
Distances from lower-left hole to program zero surfaces are easy to determine More on sub-plates Corner stop Place corner stop in hole F5 1 2 3 4 5 6 8.0 10.0 A B C D E F G H I J K L M N O P Q R S Top view of VMC table

More on sub-plates O0001 . M30 N999 G90 G10 L2 P1 X10.0 Y8.0 Z2.25
FANUC 16M Program them with a G10 command WORK COORDINATE SYSTEM SETTING #0: COMMON X Y Z #2: G55 X Y Z #1: G54 X Y Z #3: G56 X Y Z +

More on sub-plates If you have a mishap (crash)…
…only the common offset values must be re-measured

…some may seem far-fetched Machining centers Turning centers Determine program zero assignment values Measure with edge finder or dial indicator Calculate Enter program zero assignment values Into fixture offsets (preferred) Edit G92 command Determine program zero assignment values For each tool Measure distance between tool tip and program zero Calculate Enter program zero assignment values Into geometry offsets (preferred) Edit G50 commands Can you think of any way to eliminate program zero assigning tasks? If machining center setups are qualified, you can eliminate the entire task of program zero assignment Program zero assignment values will be included in the program Setup person will not have to measure or enter program zero assignment values

…some may seem far-fetched Machining centers Turning centers Determine program zero assignment values Measure with edge finder or dial indicator Calculate Enter program zero assignment values Into fixture offsets (preferred) Edit G92 command Determine program zero assignment values For each tool Measure distance between tool tip and program zero Calculate Enter program zero assignment values Into geometry offsets (preferred) Edit G50 commands Can you think of any way to eliminate program zero assigning tasks? For cutting tools that remain in the turret from one job to the next, there is no need to re-assign program zero As long as you use geometry offsets with work shift

…can you move them off line? Machining centers Turning centers Determine program zero assignment values Measure with edge finder or dial indicator Calculate Enter program zero assignment values Into fixture offsets (preferred) Edit G92 command Determine program zero assignment values For each tool Measure distance between tool tip and program zero Calculate Enter program zero assignment values Into geometry offsets (preferred) Edit G50 commands What can be done while the machine is in production for the previous job? If you can calculate program zero assignment values up-front, they will not have to be determined while the machine is down for setup

If you cannot move a task off line…
…can it be facilitated? Machining centers Turning centers Determine program zero assignment values Measure with edge finder or dial indicator Calculate Enter program zero assignment values Into fixture offsets (preferred) Edit G92 command Determine program zero assignment values For each tool Measure distance between tool tip and program zero Calculate Enter program zero assignment values Into geometry offsets (preferred) Edit G50 commands What can you do to make it easier to assign program zero? Use a spindle probe to determine and enter fixture offset values Or use an edge finder (more manual intervention, but still very effective)

Facilitate program zero assignment tasks
If you don’t make qualified setups… …and you don’t have a spindle probe… …setup people must measure program zero assignment values Edge finder or dial indicator is used Machine position displays must be manipulated Calculations may have to be made Fixture offsets must be manually entered Time consuming – cumbersome – error prone Do what ever you can to help!

Anything a touch probe can do can be done with an edge finder… …except that touching must be done manually

A corner pickup custom macro: O9051 (Corner pickup routine for lower left corner) N1 G91 G01 Y0.75 Z-0.75 F30. (Move to first touch position) N2 #3006 = 101 (TOUCH LEFT SIDE IN X) N3 G90 G10 L2 P1 X[# #500] (Set fixture offset X) N4 G91 G01 X-0.2 (Move away in X) N5 Y-0.75 (Move down in Y) N6 X0.55 (Move to second touch position) N7 #3006 = 101 (TOUCH BOTTOM SURFACE IN Y) N8 G90 G10 L2 P1 Y[# #500] Set fixture offset Y) N9 G91 G01 Y-0.2 (Move away in Y) N10 Z0.75 (Move up in Z) N11 Y0.55 (Move to third touch position) N12 #3006 = 101 (TOUCH TOP SURFACE IN Z) N13 G90 G10 L2 P1 Z[# #501] (Set fixture offset Z) N14 G91 G01 Z.5 (Move away in Z) N15 X-0.75 Y-0.75 (Move away in X and Y) N16 M30 (End of program)

…can it be facilitated? Machining centers Turning centers Determine program zero assignment values Measure with edge finder or dial indicator Calculate Enter program zero assignment values Into fixture offsets (preferred) Edit G92 command Determine program zero assignment values For each tool Measure distance between tool tip and program zero Calculate Enter program zero assignment values Into geometry offsets (preferred) Edit G50 commands What can you do to make it easier to assign program zero? Use a spindle probe to determine and enter fixture offset values Or use an edge finder (more manual intervention, but still very effective)

…can it be facilitated? Machining centers Turning centers Determine program zero assignment values Measure with edge finder or dial indicator Calculate Enter program zero assignment values Into fixture offsets (preferred) Edit G92 command Determine program zero assignment values For each tool Measure distance between tool tip and program zero Calculate Enter program zero assignment values Into geometry offsets (preferred) Edit G50 commands What can you do to make it easier to assign program zero? Use a tool-touch-off probe Use the measure function with geometry offsets

Program Development This task is only related to setup if:
Programs must be created while the machine is down between production runs Small lots, short cycle times (short production runs) Lots of new jobs No lead time

Think of what must be done to create programs…
Manual programming Develop machining process Choose cutting tools and assign tool stations Design setup Calculate coordinates needed in program Write manual program Computer aided manufacturing (CAM) system programming Import CAD drawing (or create workpiece geometry) Specify machining operations to be performed Check tool path Conversational (shop floor) programming Choose cutting tools Define workpiece geometry Specify machining operations

Finite number of different jobs
Eliminate tasks related to programming Finite number of different jobs Once all programs are created, there is no need for more programming But in reality… …there will likely be new products, revisions, and process improvements

CAM systems facilitate programming
Move programming tasks off line Assumes: Manageable number of new jobs Sufficient number of programmers Adequate lead time Large enough lot sizes Long enough cycle times Even if programming is done off line… …it may still be necessary to facilitate the related tasks CAM systems facilitate programming

How often are machines down waiting for programs?
Facilitate on line task of programming But maybe: Every job is a new one There is no lead time You run very small lots… …with very short cycle times Programming must be done while the machine is down… …do everything you can to facilitate the task! How often are machines down waiting for programs?

Facilitate on line task of programming
Use conversational controls: Are like single-purpose CAM systems Are designed for the specific machine Minimize other setup related tasks Can be programmed very quickly Or – place a CAM system close to machine/s: Always available to setup person Wired directly to CNC machine Acts like conversational control

Setup person simply modifies a few variables to create new program
Facilitate on line task of programming Do you run parts in a family? Parametric programming allows you to develop one program that works for all parts! Setup person simply modifies a few variables to create new program

Facilitate on line task of programming

Program Transfer And Storage

Think of what must be done to transfer programs
No DNC system Programs entered through control panel Programs deleted upon job completion Manual DNC system Locate program storage location (hard drive folder, floppy disk, etc. Get machine and DNC device ready for transmission Make command to transfer Automatic DNC system Make command to transfer right from CNC machine For programs saved from CNC machine after job… Check correctness of changes Save in appropriate location

Finite number of different jobs
Eliminate tasks related to program transfer Finite number of different jobs Possibly all programs can be stored in machine control But in reality, it’s probably not feasible… …this may cause conflicts with ISO or Quality 9000 certifications

Use PC based controls Eliminate tasks related to program transfer
With standard networking Program transfers are as quick as loading from a hard drive

Use controls with background edit
Move program transfer tasks off line Use controls with background edit Program transfers can be made while the machine is running production

Can take five to fifteen minutes
Facilitate program transfer tasks Manual DNC systems Use RS-232c serial communications protocol Manual switchbox for multiple machines Setup person must walk between devices Dedicate a computer for program transfers Specify program file location on setup sheet Can take five to fifteen minutes

Automatic DNC systems Facilitate program transfer tasks
Command program transfers from machine No walk or wait is required Program transfers occur in less than 30 seconds

Program Verification

Program verification Mistakes that cause the need for program verification Program related Syntax mistakes Motion command mistakes Offset number selection Miscellaneous functions (spindle direction, tool selection, etc.) Setup related Workholding device placement Program zero assignment Various measurements and offset settings Tool placement Process related Cutting tool choices Feeds and speeds Machining order Workholding choices

We offer a two part definition for program verification:
Any task you perform to confirm the correctness of the program New programs present the greatest challenges

We offer a two part definition for program verification:
Any task you perform to confirm the correctness of the first workpiece Even proven programs present difficult challenges

Think of what must be done to remove the previous setup from the machine
To confirm the correctness of the program / setup Single block dry run Free flowing dry run Single blocking each tool into position with controlled motion rate Cautiously running first workpiece Any modifications you make when mistakes are found To confirm the correctness of the first workpiece Trial machining for surfaces with critical tolerances Checking what each tool has done after machining First workpiece inspection Any modifications you make due to failed inspection Re-machining workpiece after modifications Here is our list, but be sure to create a list of your own Use the setup reduction planning form provided in lesson four

…some may seem far-fetched To confirm the correctness of the program / setup Single block dry run Free flowing dry run Single blocking each tool into position with controlled motion rate Cautiously running first workpiece Any modifications you make when mistakes are found To confirm the correctness of the first workpiece Trial machining for surfaces with critical tolerances Checking what each tool has done after machining First workpiece inspection Any modifications you make due to failed inspection Re-machining workpiece after modifications Can you think of any way eliminate tasks? For proven jobs, some of these tasks can be eliminated If program zero assignment has been eliminated, so can the related program verification concerns If tool length measurement is done off line and an offset entering program is automatically created, related program verification concerns will be eliminated

Eliminate program verification tasks
A program can be considered proven if: It has been run before, and Corrections made to the program are saved, and Nothing about the job has changed You should be able to eliminate any tasks done for the purpose of confirming the correctness of the program and process for proven programs!

Mistakes that cause the need for program verification Program related Syntax mistakes Motion command mistakes Offset number selection Setup related Workholding device placement Program zero assignment Various measurements and offset settings Tool placement Process related Cutting tool choices Feeds and speeds Machining order Workholding choices If this task has been eliminated, so can the related tasks for program verification!

Mistakes that cause the need for program verification Program related Syntax mistakes Motion command mistakes Offset number selection Setup related Workholding device placement Program zero assignment Various measurements and offset settings Tool placement Process related Cutting tool choices Feeds and speeds Machining order Workholding choices For tool length compensation, if tool length measuring device creates offset setting program, potential for mistakes is minimized

…some may seem far-fetched To confirm the correctness of the program / setup Single block dry run Free flowing dry run Single blocking each tool into position with controlled motion rate Cautiously running first workpiece Any modifications you make when mistakes are found To confirm the correctness of the first workpiece Trial machining for surfaces with critical tolerances Checking what each tool has done after machining First workpiece inspection Any modifications you make due to failed inspection Re-machining workpiece after modifications Can you think of any way eliminate tasks? For proven jobs, some of these tasks can be eliminated If program zero assignment has been eliminated, so can the related program verification concerns If tool length measurement is done off line and an offset entering program is automatically created, related program verification concerns will be eliminated

…can you move them off line? To confirm the correctness of the program / setup Single block dry run Free flowing dry run Single blocking each tool into position with controlled motion rate Cautiously running first workpiece Any modifications you make when mistakes are found To confirm the correctness of the first workpiece Trial machining for surfaces with critical tolerances Checking what each tool has done after machining First workpiece inspection Any modifications you make due to failed inspection Re-machining workpiece after modifications What can be done while the machine is in production for the previous job? An off-line program verification system can find many programming mistakes

Moving program verification tasks off line
It can take a great deal of setup time to confirm the correctness of a program! Procedures may include: Machine Lock Dry Run To Check For Syntax Mistakes Free Flowing Dry Run To Check For Motion Mistakes Normal Air Cutting Run To Confirm Cutting Motions Cautiously Running First Workpiece

It can take a great deal of setup time to confirm the correctness of a program! Many current model controls allow setup people to display tool path

MDI HND HOLD **** *** *** *** ****
FANUC 10M POSITION PROGRAM OFFSET PRG_CHK + MDI HND HOLD **** *** *** *** **** SETTING SERVICE GRAPHIC

It can take a great deal of setup time to confirm the correctness of a program! Many current model controls allow setup people to display tool path But not all allow this while the machine is running production! Program verification is still on line!

Many program verification software programs are available that help move this task off line!

Many program verification software programs are available that help move this task off line! CAM Systems Show Tool Path Based On Source Program Tool Path Plotters Show Tool Path Based On G Code Level Program Simulation Systems Show More Than Just Tool Path Approaching Virtual Reality For CNC Machines

There are four things off-line program verification software cannot show: Tiny Motion Mistakes Mistakes Made Measuring Program Zero Off-Line Software Assumes Correct Entry Mistakes Made With Offsets Tool Length, Cutter Radius, Etc. Mistakes With Cutting Conditions Feeds, Speeds, Depth-Of-Cut, Tool Rigidity, Etc. For this reason, some verification must be done on line

…can you move them off line? To confirm the correctness of the program / setup Single block dry run Free flowing dry run Single blocking each tool into position with controlled motion rate Cautiously running first workpiece Any modifications you make when mistakes are found To confirm the correctness of the first workpiece Trial machining for surfaces with critical tolerances Checking what each tool has done after machining First workpiece inspection Any modifications you make due to failed inspection Re-machining workpiece after modifications What can be done while the machine is in production for the previous job? An off-line program verification system can find many programming mistakes

…can you facilitate them? To confirm the correctness of the program / setup Single block dry run Free flowing dry run Single blocking each tool into position with controlled motion rate Cautiously running first workpiece Any modifications you make when mistakes are found To confirm the correctness of the first workpiece Trial machining for surfaces with critical tolerances Checking what each tool has done after machining First workpiece inspection Any modifications you make due to failed inspection Re-machining workpiece after modifications What can be done to make program verification easier? We’re assuming it is important that your first workpiece is a good one

…can you facilitate them? To confirm the correctness of the program / setup Single block dry run Free flowing dry run Single blocking each tool into position with controlled motion rate Cautiously running first workpiece Any modifications you make when mistakes are found To confirm the correctness of the first workpiece Trial machining for surfaces with critical tolerances Checking what each tool has done after machining First workpiece inspection Any modifications you make due to failed inspection Re-machining workpiece after modifications What can be done to make program verification easier? Program trial machining operations

Facilitating program verification tasks
Steps to trial machining: Setup person… recognizes a critical tolerance makes an adjustment to force excess stock to be left lets the tool machine the workpiece stops the machine and measures the surface changes the initial adjustment based on measurement reruns the tool stop and measure again to confirm Trial machining takes time!

How can you eliminate the need for trial machining? Only by perfectly presetting the cutting tool! Most cutting tool measurements are “static” It can be difficult to allow for tool pressure with critical tolerances Don’t be too quick to give up on eliminating this time-consuming task If you can perfectly preset a boring bar, there will be no need to trial machine!

How can you eliminate the need for trial machining? Only by perfectly presetting the cutting tool! For turning centers applications… …tool touch off probes can take take tool pressure into consideration when assigning program zero… …and eliminate the need to trial machine!

If you cannot eliminate the need to trial machine, make it as easy as possible to do so Setup person… recognizes a critical tolerance makes an adjustment to force excess stock to be left lets the tool machine the workpiece stops the machine and measures the surface changes the initial adjustment based on measurement reruns the tool stop and measure again to confirm Why force the setup person to determine if trial machining is necessary?

Slash code in program (/) Works with block delete switch
Techniques with block delete Saving time and effort: Commonly taught in basic CNC courses: Use block delete to help with trial machining Slash code in program (/) Works with block delete switch If on, block skipped..if off, block executed If off, trial machining will take place If on, trial machining will be skipped With a little ingenuity, you can streamline almost any trial machining operation! Not always taught in basic courses: Mid command Conflicting words with Trial machining With unexpected stock Another optional stop Multiple block deletes

Techniques with block delete Saving time and effort: Trial boring on a machining center: Commonly taught in basic CNC courses: Use block delete to help with trial machining Slash code in program (/) Works with block delete switch If on, block skipped..if off, block executed 0.005 small If off, trial machining will take place If on, trial machining will be skipped With a little ingenuity, you can streamline almost any trial machining operation! Not always taught in basic courses: Mid command Conflicting words with Trial machining With unexpected stock Another optional stop Multiple block deletes 1) Intentionally set boring bar undersize

Techniques with block delete Saving time and effort: Trial boring on a machining center: Commonly taught in basic CNC courses: Use block delete to help with trial machining Slash code in program (/) Works with block delete switch If on, block skipped..if off, block executed . N255 T04 M06 ( boring bar) N260 G54 G90 S450 M03 T05 N265 G00 X4.0 Y4.0 N270 G43 H04 Z0.1 M08 N275 F2.5 /N280 M98 P1000 /N285 M98 P1000 /N290 M98 P1000 /N295 M98 P1000 N300 G86 R0.1 Z-1.0 F2.5 If off, trial machining will take place If on, trial machining will be skipped With a little ingenuity, you can streamline almost any trial machining operation! Not always taught in basic courses: Mid command Conflicting words with Trial machining With unexpected stock Another optional stop Multiple block deletes 2) Allow boring bar to partially machine hole

Techniques with block delete Saving time and effort: Trial boring on a machining center: Commonly taught in basic CNC courses: Use block delete to help with trial machining The subprogram must work for any hole size Slash code in program (/) Works with block delete switch If on, block skipped..if off, block executed . N255 T04 M06 ( boring bar) N260 G54 G90 S450 M03 T05 N265 G00 X4.0 Y4.0 N270 G43 H04 Z0.1 M08 N275 F2.5 /N280 M98 P1000 /N285 M98 P1000 /N290 M98 P1000 /N295 M98 P1000 N300 G86 R0.1 Z-1.0 F2.5 If off, trial machining will take place If on, trial machining will be skipped With a little ingenuity, you can streamline almost any trial machining operation! Not always taught in basic courses: Mid command Conflicting words with Trial machining With unexpected stock Another optional stop Multiple block deletes 2) Allow boring bar to partially machine hole

Techniques with block delete Saving time and effort: Trial boring on a machining center: Commonly taught in basic CNC courses: Use block delete to help with trial machining Slash code in program (/) Works with block delete switch If on, block skipped..if off, block executed . N255 T04 M06 ( boring bar) N260 G54 G90 S450 M03 T05 N265 G00 X4.0 Y4.0 N270 G43 H04 Z0.1 M08 N275 F2.5 /N280 M98 P1000 /N285 M98 P1000 /N290 M98 P1000 /N295 M98 P1000 N300 G86 R0.1 Z-1.0 F2.5 If off, trial machining will take place If on, trial machining will be skipped With a little ingenuity, you can streamline almost any trial machining operation! Not always taught in basic courses: Mid command Conflicting words with Trial machining With unexpected stock Another optional stop Multiple block deletes 2) Allow boring bar to partially machine hole

Techniques with block delete Saving time and effort: Trial boring on a machining center: Commonly taught in basic CNC courses: Use block delete to help with trial machining Slash code in program (/) Works with block delete switch If on, block skipped..if off, block executed O1000 N1 G91 G86 R0 Z-0.3 N2 G80 M09 N3 G00 Z3.0 N4 X4.0 Y4.0 N5 M00 N6 G00 X-4.0 Y4.0 M03 N7 Z-3.0 M08 N8 G90 N9 M99 If off, trial machining will take place If on, trial machining will be skipped With a little ingenuity, you can streamline almost any trial machining operation! Not always taught in basic courses: Mid command Conflicting words with Trial machining With unexpected stock Another optional stop Multiple block deletes 2) Allow boring bar to partially machine hole

Techniques with block delete Saving time and effort: Trial boring on a machining center: Commonly taught in basic CNC courses: Use block delete to help with trial machining Slash code in program (/) Works with block delete switch If on, block skipped..if off, block executed O1000 N1 G91 G86 R0 Z-0.3 N2 G80 M09 N3 G00 Z3.0 N4 X4.0 Y4.0 N5 M00 N6 G00 X-4.0 Y4.0 M03 N7 Z-3.0 M08 N8 G90 N9 M99 If off, trial machining will take place If on, trial machining will be skipped With a little ingenuity, you can streamline almost any trial machining operation! Not always taught in basic courses: Mid command Conflicting words with Trial machining With unexpected stock Another optional stop Multiple block deletes 3) Move to convenient measuring position

Techniques with block delete Saving time and effort: Trial boring on a machining center: Commonly taught in basic CNC courses: Use block delete to help with trial machining Slash code in program (/) Works with block delete switch If on, block skipped..if off, block executed O1000 N1 G91 G86 R0 Z-0.3 N2 G80 M09 N3 G00 Z3.0 N4 X4.0 Y4.0 N5 M00 N6 G00 X-4.0 Y4.0 M03 N7 Z-3.0 M08 N8 G90 N9 M99 If off, trial machining will take place If on, trial machining will be skipped With a little ingenuity, you can streamline almost any trial machining operation! Not always taught in basic courses: Mid command Conflicting words with Trial machining With unexpected stock Another optional stop Multiple block deletes 4) Stop, measure hole, & adjust boring bar

Techniques with block delete Saving time and effort: Trial boring on a machining center: Commonly taught in basic CNC courses: Use block delete to help with trial machining Slash code in program (/) Works with block delete switch If on, block skipped..if off, block executed O1000 N1 G91 G86 R0 Z-0.3 N2 G80 M09 N3 G00 Z3.0 N4 X4.0 Y4.0 N5 M00 N6 G00 X-4.0 Y4.0 M03 N7 Z-3.0 M08 N8 G90 N9 M99 If off, trial machining will take place If on, trial machining will be skipped With a little ingenuity, you can streamline almost any trial machining operation! Not always taught in basic courses: Mid command Conflicting words with Trial machining With unexpected stock Another optional stop Multiple block deletes 5) Move back to hole location

Techniques with block delete Saving time and effort: Trial boring on a machining center: Commonly taught in basic CNC courses: Use block delete to help with trial machining Slash code in program (/) Works with block delete switch If on, block skipped..if off, block executed . N255 T04 M06 ( boring bar) N260 G54 G90 S450 M03 T05 N265 G00 X4.0 Y4.0 N270 G43 H04 Z0.1 M08 N275 F2.5 /N280 M98 P1000 /N285 M98 P1000 /N290 M98 P1000 /N295 M98 P1000 N300 G86 R0.1 Z-1.0 F2.5 If off, trial machining will take place If on, trial machining will be skipped With a little ingenuity, you can streamline almost any trial machining operation! Not always taught in basic courses: Turn on block delete when hole is sized Mid command Conflicting words with Trial machining With unexpected stock Another optional stop Multiple block deletes 6) Repeat until hole is on size

Techniques with block delete Saving time and effort: Trial boring on a machining center: Commonly taught in basic CNC courses: Use block delete to help with trial machining Slash code in program (/) Works with block delete switch If on, block skipped..if off, block executed . N255 T04 M06 ( boring bar) N260 G54 G90 S450 M03 T05 N265 G00 X4.0 Y4.0 N270 G43 H04 Z0.1 M08 N275 F2.5 /N280 M98 P1000 /N285 M98 P1000 /N290 M98 P1000 /N295 M98 P1000 N300 G86 R0.1 Z-1.0 F2.5 If off, trial machining will take place If on, trial machining will be skipped With a little ingenuity, you can streamline almost any trial machining operation! Not always taught in basic courses: Mid command Conflicting words with Trial machining With unexpected stock Another optional stop Multiple block deletes 6) Repeat until hole is on size

Techniques with block delete Saving time and effort: Trial rough turning (minimize trial machining time): Commonly taught in basic CNC courses: Use block delete to help with trial machining Slash code in program (/) Works with block delete switch If on, block skipped..if off, block executed If off, trial machining will take place If on, trial machining will be skipped With a little ingenuity, you can streamline almost any trial machining operation! Not always taught in basic courses: Mid command Conflicting words with Trial machining With unexpected stock Another optional stop Multiple block deletes Rough turning time: 18 minutes

Techniques with block delete Saving time and effort: Trial rough turning (minimize trial machining time): Commonly taught in basic CNC courses: Use block delete to help with trial machining O0003 N005 T0101 M41 N010 G96 S400 M03 N015 G00 X6.0 Z.1 /N020 X5.5 /N025 G01 Z-.3 F0.020 /N030 X6.0 /N035 G00 X8.0 Z3. /N040 M00 (DIAMETER 5.50 IN) /N045 T0101 M03 /N050 G00 X6. Z.1 N055 G71 P060 Q160 D2500 … N Slash code in program (/) Works with block delete switch If on, block skipped..if off, block executed If off, trial machining will take place If on, trial machining will be skipped With a little ingenuity, you can streamline almost any trial machining operation! Not always taught in basic courses: Mid command Conflicting words with Trial machining With unexpected stock Another optional stop Multiple block deletes Rough turning time: 18 minutes

Techniques with block delete Saving time and effort: Trial rough turning (minimize trial machining time): Commonly taught in basic CNC courses: Use block delete to help with trial machining O0003 N005 T0101 M41 N010 G96 S400 M03 N015 G00 X6.0 Z.1 /N020 X5.5 /N025 G01 Z-.3 F0.020 /N030 X6.0 /N035 G00 X8.0 Z3. /N040 M00 (DIAMETER 5.50 IN) /N045 T0101 M03 /N050 G00 X6. Z.1 N055 G71 P060 Q160 D2500 … N Setup person measures and adjusts now Slash code in program (/) Works with block delete switch If on, block skipped..if off, block executed If off, trial machining will take place If on, trial machining will be skipped With a little ingenuity, you can streamline almost any trial machining operation! Not always taught in basic courses: Mid command Conflicting words with Trial machining With unexpected stock Another optional stop Multiple block deletes Rough turning time: 18 minutes

Techniques with block delete Saving time and effort: Trial rough turning (minimize trial machining time): Commonly taught in basic CNC courses: Use block delete to help with trial machining O0003 N005 T0101 M41 N010 G96 S400 M03 N015 G00 X6.0 Z.1 /N020 X5.5 /N025 G01 Z-.3 F0.020 /N030 X6.0 /N035 G00 X8.0 Z3. /N040 M00 (DIAMETER 5.50 IN) /N045 T0101 M03 /N050 G00 X6. Z.1 N055 G71 P060 Q160 D2500 … N Offset must be invoked again Slash code in program (/) Works with block delete switch If on, block skipped..if off, block executed If off, trial machining will take place If on, trial machining will be skipped With a little ingenuity, you can streamline almost any trial machining operation! Not always taught in basic courses: Mid command Conflicting words with Trial machining With unexpected stock Another optional stop Multiple block deletes Rough turning time: 18 minutes

Techniques with block delete Saving time and effort: Trial rough turning (minimize trial machining time): Commonly taught in basic CNC courses: Use block delete to help with trial machining O0003 N005 T0101 M41 N010 G96 S400 M03 N015 G00 X6.0 Z.1 /N020 X5.5 /N025 G01 Z-.3 F0.020 /N030 X6.0 /N035 G00 X8.0 Z3. /N040 M00 (DIAMETER 5.50 IN) /N045 T0101 M03 /N050 G00 X6. Z.1 N055 G71 P060 Q160 D2500 … N Slash code in program (/) Works with block delete switch If on, block skipped..if off, block executed If off, trial machining will take place If on, trial machining will be skipped With a little ingenuity, you can streamline almost any trial machining operation! Not always taught in basic courses: Mid command Conflicting words with Trial machining With unexpected stock Another optional stop Multiple block deletes Rough turning time: 18 minutes

Techniques with block delete Saving time and effort: Trial rough turning (minimize trial machining time): Commonly taught in basic CNC courses: Use block delete to help with trial machining O0003 N005 T0101 M41 N010 G96 S400 M03 N015 G00 X6.0 Z.1 /N020 X5.5 /N025 G01 Z-.3 F0.020 /N030 X6.0 /N035 G00 X8.0 Z3. /N040 M00 (DIAMETER 5.50 IN) /N045 T0101 M03 /N050 G00 X6. Z.1 N055 G71 P060 Q160 D2500 … N Normal rough turning begins Slash code in program (/) Works with block delete switch If on, block skipped..if off, block executed If off, trial machining will take place If on, trial machining will be skipped With a little ingenuity, you can streamline almost any trial machining operation! Not always taught in basic courses: Mid command Conflicting words with Trial machining With unexpected stock Another optional stop Multiple block deletes Rough turning time: 18 minutes

Techniques with block delete Saving time and effort: Consider other times when block delete can help with trial machining Commonly taught in basic CNC courses: Use block delete to help with trial machining Slash code in program (/) Works with block delete switch If on, block skipped..if off, block executed Lengthy rough milling operations Thread milling Slot milling Face milling Thread chasing (turning center) Necking multiple grooves Any time trial machining is needed! If off, trial machining will take place If on, trial machining will be skipped With a little ingenuity, you can streamline almost any trial machining operation! Not always taught in basic courses: Mid command Conflicting words with Trial machining With unexpected stock Another optional stop Multiple block deletes

…can you facilitate them? To confirm the correctness of the program / setup Single block dry run Free flowing dry run Single blocking each tool into position with controlled motion rate Cautiously running first workpiece Any modifications you make when mistakes are found To confirm the correctness of the first workpiece Trial machining for surfaces with critical tolerances Checking what each tool has done after machining First workpiece inspection Any modifications you make due to failed inspection Re-machining workpiece after modifications What can be done to make program verification easier? Program trial machining operations

…can you facilitate them? To confirm the correctness of the program / setup Single block dry run Free flowing dry run Single blocking each tool into position with controlled motion rate Cautiously running first workpiece Any modifications you make when mistakes are found To confirm the correctness of the first workpiece Trial machining for surfaces with critical tolerances Checking what each tool has done after machining First workpiece inspection Any modifications you make due to failed inspection Re-machining workpiece after modifications What can be done to make program verification easier? In most companies, the production run cannot be started until a workpiece passes inspection Inspections take time – as does any task that must be done if the first workpiece fails inspection. Be sure inspections are done efficiently.

…can you facilitate them? To confirm the correctness of the program / setup Single block dry run Free flowing dry run Single blocking each tool into position with controlled motion rate Cautiously running first workpiece Any modifications you make when mistakes are found To confirm the correctness of the first workpiece Trial machining for surfaces with critical tolerances Checking what each tool has done after machining First workpiece inspection Any modifications you make due to failed inspection Re-machining workpiece after modifications What can be done to make program verification easier? Processing mistakes can lead to failed inspections There is an easy way to change machining order at the machine during setup

Mistakes with machining order will cause even a perfectly written program to fail! Rough turn Finish turn Drill 2” hole Rough bore Finish bore Rough turn Drill 2” hole Rough bore Finish bore Finish turn Not all controls have “cut and paste”

Fanuc controls allow unconditional branching M99 P040 Go to sequence number N040

A statement label marks a command
Techniques with sequence numbers A statement label marks a command O0008 (Program with bad process) N005 T0101 M41 (Rough turn) N010 G96 S400 M03 N015 G00 X3.040 Z0.1 N020 G01 Z F0.017 N025 X3.25 N030 G00 X6.0 Z5.0 N035 M01 N040 T0202 M42 (Finish turn) N045 G96 S600 M03 N050 G00 X3. Z0.1 N055 G01 Z-2.0 F0.006 N060 X3.25 N065 G00 X6.0 Z5.0 N070 M01 N075 T0303 M41 (2” drill) N080 G97 S300 M03 N085 G00 X0 Z0.1 N090 G01 Z-2.6 F.009 N095 G00 Z0.1 N100 G00 X6.0 Z5.0 N105 M01 N110 T0404 M41 (1.5” rough boring bar) N115 G96 S400 M03 N120 G00 X2.085 Z0.1 N125 G01 Z F0.010 N130 X2.0 N135 G00 Z0.1 N140 X6.0 Z5.0 N145 M01 N150 T0505 M42 (1.5” finish boring bar) N155 G96 S600 M03 N160 G00 X1.125 Z0.1 N165 G01 Z-2.0 F0.006 N170 X2.0 N175 G00 Z0.1 N180 G00 X6.0 Z5.0 N185 M30 Commonly taught in basic CNC courses: N words are sequence numbers Not needed but beginners use them Use logical order (N5, N10, N15, etc.) Applications not always taught in basic courses: Eliminating Special restart blocks As statement labels

Techniques with sequence numbers O0008 (Program with bad process) N005 T0101 M41 (Rough turn) N010 G96 S400 M03 N015 G00 X3.040 Z0.1 N020 G01 Z F0.017 N025 X3.25 N030 G00 X6.0 Z5.0 N035 M01 N040 T0202 M42 (Finish turn) N045 G96 S600 M03 N050 G00 X3. Z0.1 N055 G01 Z-2.0 F0.006 N060 X3.25 N065 G00 X6.0 Z5.0 N070 M01 N075 T0303 M41 (2” drill) N080 G97 S300 M03 N085 G00 X0 Z0.1 N090 G01 Z-2.6 F.009 N095 G00 Z0.1 N100 G00 X6.0 Z5.0 N105 M01 N110 T0404 M41 (1.5” rough boring bar) N115 G96 S400 M03 N120 G00 X2.085 Z0.1 N125 G01 Z F0.010 N130 X2.0 N135 G00 Z0.1 N140 X6.0 Z5.0 N145 M01 N150 T0505 M42 (1.5” finish boring bar) N155 G96 S600 M03 N160 G00 X1.125 Z0.1 N165 G01 Z-2.0 F0.006 N170 X2.0 N175 G00 Z0.1 N180 G00 X6.0 Z5.0 N185 M30 A statement label marks a command Commonly taught in basic CNC courses: N words are sequence numbers Not needed but beginners use them Use logical order (N5, N10, N15, etc.) N038 M99 P075 Applications not always taught in basic courses: Eliminating Special restart blocks As statement labels

Techniques with sequence numbers A statement label marks a command O0008 (Program with bad process) N005 T0101 M41 (Rough turn) N010 G96 S400 M03 N015 G00 X3.040 Z0.1 N020 G01 Z F0.017 N025 X3.25 N030 G00 X6.0 Z5.0 N035 M01 N040 T0202 M42 (Finish turn) N045 G96 S600 M03 N050 G00 X3. Z0.1 N055 G01 Z-2.0 F0.006 N060 X3.25 N065 G00 X6.0 Z5.0 N070 M01 N075 T0303 M41 (2” drill) N080 G97 S300 M03 N085 G00 X0 Z0.1 N090 G01 Z-2.6 F.009 N095 G00 Z0.1 N100 G00 X6.0 Z5.0 N105 M01 N110 T0404 M41 (1.5” rough boring bar) N115 G96 S400 M03 N120 G00 X2.085 Z0.1 N125 G01 Z F0.010 N130 X2.0 N135 G00 Z0.1 N140 X6.0 Z5.0 N145 M01 N150 T0505 M42 (1.5” finish boring bar) N155 G96 S600 M03 N160 G00 X1.125 Z0.1 N165 G01 Z-2.0 F0.006 N170 X2.0 N175 G00 Z0.1 N180 G00 X6.0 Z5.0 N185 M30 Commonly taught in basic CNC courses: N words are sequence numbers Not needed but beginners use them Use logical order (N5, N10, N15, etc.) N038 M99 P075 Applications not always taught in basic courses: Eliminating Special restart blocks As statement labels N183 M99 P040

Techniques with sequence numbers A statement label marks a command O0008 (Program with bad process) N005 T0101 M41 (Rough turn) N010 G96 S400 M03 N015 G00 X3.040 Z0.1 N020 G01 Z F0.017 N025 X3.25 N030 G00 X6.0 Z5.0 N035 M01 N040 T0202 M42 (Finish turn) N045 G96 S600 M03 N050 G00 X3. Z0.1 N055 G01 Z-2.0 F0.006 N060 X3.25 N065 G00 X6.0 Z5.0 N070 M01 N075 T0303 M41 (2” drill) N080 G97 S300 M03 N085 G00 X0 Z0.1 N090 G01 Z-2.6 F.009 N095 G00 Z0.1 N100 G00 X6.0 Z5.0 N105 M01 N110 T0404 M41 (1.5” rough boring bar) N115 G96 S400 M03 N120 G00 X2.085 Z0.1 N125 G01 Z F0.010 N130 X2.0 N135 G00 Z0.1 N140 X6.0 Z5.0 N145 M01 N150 T0505 M42 (1.5” finish boring bar) N155 G96 S600 M03 N160 G00 X1.125 Z0.1 N165 G01 Z-2.0 F0.006 N170 X2.0 N175 G00 Z0.1 N180 G00 X6.0 Z5.0 N185 M30 Commonly taught in basic CNC courses: N words are sequence numbers Not needed but beginners use them Use logical order (N5, N10, N15, etc.) N038 M99 P075 Applications not always taught in basic courses: Eliminating Special restart blocks As statement labels N073 M99 P185 N183 M99 P040

…can you facilitate them? To confirm the correctness of the program / setup Single block dry run Free flowing dry run Single blocking each tool into position with controlled motion rate Cautiously running first workpiece Any modifications you make when mistakes are found To confirm the correctness of the first workpiece Trial machining for surfaces with critical tolerances Checking what each tool has done after machining First workpiece inspection Any modifications you make due to failed inspection Re-machining workpiece after modifications What can be done to make program verification easier? Processing mistakes can lead to failed inspections There is an easy way to change machining order at the machine during setup

Program Optimizing

Program optimizing: Make changes related to
Cutting conditions Feeds and speeds Depths of cut Process Cutting tool materials Program Wasted movements Program format Workpiece load and unload Tool maintenance

Program optimizing Be sure it’s feasible to optimize!
Though optimizing can reduce cycle time… …it adds to setup time! Be sure it’s feasible to optimize!

This task should probably be eliminated if lot sizes are small
Program optimizing This task should probably be eliminated if lot sizes are small Time spent optimizing in setup will only add to overall production time Exception: If you run the same materials and cutting tools regularly, time spent optimizing can be applied to future jobs

Program optimizing But for large lot sizes…
…optimizing can really reduce overall production time!

One second saved per cycle will save 16.6 minutes per 1,000 cycles
Program optimizing To help you evaluate feasibility: One second rule: One second saved per cycle will save 16.6 minutes per 1,000 cycles If you are considering optimizing for a ten part lot, and think you can save about 10 seconds… …you’re only going to reduce the production run by about 1.5 minutes!

Program optimizing To help you evaluate feasibility: One second rule:
One second saved per cycle will save 16.6 minutes per 1,000 cycles On the other hand… …if you can save 10 seconds in a 1,000 piece lot… …you’ll save 166 minutes (2.77 hours)

Eliminate program optimizing tasks
Cutting conditions Feeds and speeds Depths of cut Process Cutting tool materials Program Wasted movements Program format Workpiece load and unload Tool maintenance Program optimizing: Make changes related to Again, eliminate these tasks with small lots

Some CAM systems can generate very efficient CNC programs!
Move program optimizing tasks off line Cutting conditions Feeds and speeds Depths of cut Process Cutting tool materials Program Wasted movements Program format Workpiece load and unload Tool maintenance Program optimizing: Make changes related to Some CAM systems can generate very efficient CNC programs!

Move program optimizing tasks off line
Cutting conditions Feeds and speeds Depths of cut Process Cutting tool materials Program Wasted movements Program format Workpiece load and unload Tool maintenance Program optimizing: Make changes related to If you use a tool path verification program, watch for unnecessary motions!

Facilitate program optimizing tasks
Cutting conditions Feeds and speeds Depths of cut Process Cutting tool materials Program Wasted movements Program format Workpiece load and unload Tool maintenance Program optimizing: Make changes related to

How many feed and speed words are there per tool?
Facilitate program optimizing tasks If you expect your setup people to modify cutting conditions and approach distance… …make it easy as possible! How many feed and speed words are there per tool?

Facilitate program optimizing tasks
O0001 (Program number) #100 = 400 (Rough turning speed) #101 = (Rough turning feedrate) #102 = (Rough turning depth of cut) #103 = 5.0 (Tool changing position in X) #104 = 4.0 (Tool changing position in Z) #105 = 500 (Finish turning speed) #106 = (Finish turning feedrate) #107 = (Cut off tool width) #108 = 400 (Cut off tool speed) #109 = (Cut off tool feedrate) N005 T0101 (Rough turning tool) N010 G96 S#100 M03 (Start spindle) N015 G00 X1.5 Z.1 M08 (Rapid up to position) N020 G71 P025 Q045 U.04 W.005 D#102 F#102 (Rough turn the workpiece) N025 G00 X.875 (Rapid to starting X) N030 G01 Z0 (Feed flush with face) N035 X1.0 Z (Form chamfer) N040 Z-[ # ] (Turn 1.0 diameter) N045 X1.5 (Feed up face) N050 G00 X#103 Z#104 (Rapid to tool changing position) N055 M01 (Optional stop) N060 T0202 (Finish turning tool) N065 G96 S#105 M03 (Start spindle) N070 X1.5 Z.1 M08 (Rapid up to workpiece) N075 G70 P025 Q045 F#106 (Finish turn workpiece) N080 G00 X#103 Z#104 (Rapid to tool change position) N085 M01 (Optional stop) N090 T0303 (Cutoff tool) N095 G96 S#108 M03 (Start spindle) N100 G00 X1.5 Z-[1.0 + #107] M08 (Rapid close) N105 X1.2 (Rapid closer) N110 G01 X-.03 F#109 (Cut off) N115 G00 X1.5 (Rapid out) N120 X#103 Z#104 (Rapid to tool change position) N125 M30 (End of program) Facilitate program optimizing tasks If you expect your setup people to modify cutting conditions and approach distance… …make it easy with variable programming!

What else can you do to help setup people optimize?
Facilitate program optimizing tasks Cutting conditions Feeds and speeds Depths of cut Process Cutting tool materials Program Wasted movements Program format Workpiece load and unload Tool maintenance Program optimizing: Make changes related to What else can you do to help setup people optimize?

Other Setup Related Tasks

Other tasks related to setup?
Paperwork Production control SPC Time reporting Gauge setup Working on multiple machines Others? Approach them as you do any other setup related tasks - eliminate, move off line, or facilitate

Getting More From Your CNC Machines
Lesson 5: Setup Reduction Techniques End of presentation Setup tasks and improvements 308 Copyright 2011

Getting More From Your CNC Machines

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