33. CNC Part Program Verification Programs prepared for any kind of CNC machine should be cautiously verified.

Though there are exceptions to this rule, manually prepared programs are more prone to having mistakes than CAM system generated programs. However, even the best CAM system generated CNC programs could still include disastrous problems. Syntax Mistakes-These are "silly" mistakes on the programmer's part that cause the program to be unacceptable to the control. Motion Mistakes-This kind of mistake is usually harder to find and correct. Setup Mistakes-Even a perfectly prepared program will behave poorly if setup mistakes are made. Cutting Condition Mistakes-Though the program's motions may be correct, the operator must be on guard for cutting condition problems. Feeds and speeds must be properly applied. While machining the first workpiece with any program, the operator must be very cautious, watching for possible machining problems.
The basic procedures that will help insure safety during the verification of a CNC program are discussed below

1.1 Machine Dry Run Prior to letting a program cause motion, it is wise to let the control check the program for syntax mistakes. With Machine Lock and Dry Run turned on, the operator can rest assured that the axes of the machine will not move. When the program is executed, the control will scan the program for basic mistakes. If the control determines a problem, it will go into alarm state. While there could still be serious problems if the control completes the program, the operator can be rest assured that at least the program is acceptable to the control. "Free Flowing" Dry Run Once the Machine Lock Dry Run can be executed without generating alarms, the operator is ready to let the program generate motion. The Free Flowing Dry Run will allow the operator to see the motion the program will generate, and also allow the operator to control how fast motion will be. With Dry Run in the on condition, a multi position switch (usually Feed Rate Override or Jog Feed Rate) acts like a rheostat, allowing the operator to manipulate how fast axis motion will be. If the operator senses a problem, Feed Hold is pressed. With no part loaded into the setup, the operator can allow the motion generated by the program to take place and will be able to tell if the basic motions are correct. The first time the Free Flowing Dry Run is executed for a program, the operator will be most concerned with dangerous situations like interference with obstructions and spindle direction. For this reason, it may be necessary to repeat this procedure several times before the operator becomes comfortable with the cycle.

1.2 On-line program verification

Any time spent between production runs verifying CNC programs must be considered as part of setup time - and anything that can be done to reduce on-line program verification time effectively reduces setup time. Since new programs will contain more potential for mistakes than proven programs, companies that perform little repeat business should be highly interested in minimizing the time spent verifying the CNC program. One way to achieve this goal is to move the task of program verification off line. This means performing as much of the program verification procedures as is possible while the machine is still running workpieces in a previous production run. Following are several ways to verify CNC programs. The CNC machine makes a poor verification tool. If the quality of the CNC program is unknown before it is loaded into the machine, the setup person must be very careful at every step of the verification process. A series of dry runs must be performed just to confirm that the basic motions of the program will not cause interference. And since the machine is down between production runs, the entire task of program verification must be done on line. More CNC controls are coming with graphic capabilities that allow you to plot a program's movement's right on the display screen. While this is an excellent feature, and one we would recommend you purchase if it is available, keep in mind that many controls do not allow a tool path to be shown for one program while the machine is running another program. In such a case, program verification is still an on-line task. If the tool path display exposes mistakes in the program, corrections must be made during setup, meaning corrections must also be done on line. This can waste a great deal of precious machine time. Almost all current computer-aided manufacturing (CAM) systems allow some form of tool path display aimed at helping a programmer locate motion mistakes in a program. More and more software companies are developing attractively priced products aimed at helping their users verify CNC programs off line. Several companies offer PC based tool path display capabilities, similar to those found in many current CNC controls.

34. CNC Part Program generation from CAD Model Generation of part program for machining a complex shapes is very difficult without use of available CAD/CAM software packages. Use of this leads to decrease in time required for part programming and increases the accuracy of programming. Software packages like PRO/engineer, ideas, MasterCAM allows the user to create machining tool paths. Within the package you can create milling and turning (lathe) machining simulations. After creating a series of these simulations, the user can machine the 3D model created and at a later stage transfer the information to a NC lathe or miller.

Generation of part program requires some basic information like final geometry, workpiece geometry, orientation of principle axis and location of origin on the raw material geometry, machining parameters, tool geometry, machine which is to be used etc. Other than this some information like which type of operation has to be done, volume which is to be removed, etc also has to be given.