Professional Documents
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G Code Programming
MCAR
May 2012
Part
Table of Contents
One Programming Skills
3 Axis Programming
Programming Words
o G Codes
o M Codes
o Program Zero and Work Offsets
o Tool Offsets
Basic Program Structure
CNC Programming Exercise #1
Homework Programming Exercise #2
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32
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Part
57
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G0 X12.75 Y-6.00;
Position move
X10.25 Y-8.;
G0 G80 Z1. ;
This program example uses a Deep Hole Peck Drilling Cycle to cut
a hole 3.2 inches deep into a part in two places. The Z Axis is the
primary axis performing all the work to achieve the hole depth.
Exercise
On the next page decide what type of function is being
performed. Choose between a milling function or other function. Be
careful and do not assume that just because you may not see a canned
cycle that the cycle is automatically a milling function
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Programming Words
What are programming words?
Programming words are a letter/number combination inserted in
a program to tell the machine to perform a task. Each code entered
into a CNC program must contain a letter entered before a numeric
value. This letter/number data is called a programming word. A word
simply tells the machine what parameter data to alter in order to
perform a task. G and M codes are the most common words used in
programming.
Using words to create a program
X, Y, & Z program moves are prime examples of words that tell a
machine where to move to. Various words can be used by themselves
or group inside a canned cycle to allow for complex equations to be
performed. Every function of a program will need different words to
complete the necessary parameters in order to work.
Decimal point usage in words
Words that are used in CNC programming are grouped into two
classes. Ones that allow for a decimal point and others that do not.
The ones that allow a decimal point are:
A, B, C, F, I, J, K, Q, R, U, V, W, X, Y, & Z
The ones that do not allow decimal points are:
D, G, H, L, M, N, O, P, S, & T
Know your Codes
When writing a program, you will need to know which codes are
needed to perform a certain task. You will also need to be sure to
include any extra codes that will give the machine enough information
to perform the task you have assigned.
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G Codes
What are G Codes?
G codes are preparatory codes. This means that the codes instruct
the machine to perform a function based on a particular G codes
parameters. Sometimes, additional information must be inserted in the
form of other programming words, along with the G code so that the
function performs as expected.
For example, G00 tells the machine to move in a rapid motion
while G01 tells the machine to move in a controlled motion along a
straight line.
Most G codes must have extra programming words included on
the same line in order to perform the task requested. An example
would be calling G01 which is a linear feed move. Most often, you will
find G01 on a line with X, Y, and/or Z.
There are some G codes however, that can work all by themselves
without the extra words. G20 is the Inch Input G code is an example of
a G code that does not need any other variable to operate.
G codes control a variety of functions such as machine
positioning, offset length compensation, tool radius compensation,
hole pattern creation, canned cycles, feed rate control, to name a few.
What makes G codes so useful is that each code specializes in a
function and thus helps reduce the programming time by requiring
only specific data.
There are just about as many G Codes as there are functions to a
machine.
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G00
Rapid Traverse
G43
G01
Linear Feed
G54
Work Offset
G02
Circular Interpolation CW
G80
G03
G90
Absolute Programming
G04
Dwell
G91
Incremental Programming
G28
Reference Return
G94
G40
G98
Return to Initial Z
G41
G99
Return to R Point
G42
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example above, notice that the X and Y coordinate values were the
same but the machine responded differently based on the G code
called and the other programming words used.
The best advice for understanding what format your particular
machine uses is to consult the programming manuals for your machine,
contact your machine tool manufacturer or talk to a programmer
within your company. This manual contains only reference material
that may not be available or may not be in the same format that you
need to use. Most programming manuals for a machine tool will have
the basic list of codes like the ones listed above. It will also contain the
format for each G code as well as the various programming words
needed to make the code work most efficiently.
Complex G Codes
When programming, you will come across the need to drill, bore,
ream, and tap holes. One of the most useful functions performed by a
G code is known as a canned cycle. Along with other program words
(variables) the machine will perform a complex task using minimal data
from the programmer. Canned cycles are, in effect, custom macros built
into the machine to act like mini programs when they are called up.
You will learn more about canned cycles in a later lesson.
Other complex G codes that will be taught later are cutter radius
compensation for milling functions, and hole patterns for canned
cycles.
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Name
Motion
2
3
5
6
7
8
10
12
Plane
Distance
Feed
Units
Cutter Comp.
Tool Length
Return Mode
Coord. System
Group
Name
0 or 00
Non-Modal
Modal G Codes
Codes in the Group
G00,G01,G02,G03,G73,G74,G76,G77,
G80,G81,G82,G84,G85,G86,G87,G88,G89
G17,G18,G19
G90,G91
G93,G94
G20,G21
G40,G41,G42
G43,G49
G98,G99
G54,G55,G56,G57,G58,G59 (work offsets)
Non-Modal G Codes
Codes in the Group
G04,G10,G12,G13,G70,G71,G72,G28,G52,G53,G92
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M-Codes
Miscellaneous Codes
M codes are known as Miscellaneous codes. This means that they
perform various tasks on the equipment, such as turn the coolant on
and off, turn the conveyor on and off, start and stop the spindle, and
many more functions. An easy way to remember what an M code does
is to think of the code as a machine code. They are simply a code that
activates and deactivates a series of switches and relays within the
electrical control panel on the machine.
Below are some of the most common M codes used in
programming. Although these are not all of the codes you may use,
they are the most common ones and most machine tool builders do not
alter these common M codes.
M00
Program Stop
M08
Coolant On
M01
Optional Stop
M09
Coolant off
M02
Program End
M19
Orient Spindle
M03
Spindle Start CW
M30
M04
M97
M05
Spindle Stop
M98
M06
Tool Change
M99
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Start of a Program
Start of a Program
O1234(Part #### for XYZ Company);
(COMMENT);
(T1 TOOL DESCRIPTION);
T1 M06;
G0 G54 G90 X#.# Y#.# S1500 M03;
G43 H01 Z.5 M08;
The code on above is an example of a typical program start up.
Each line of a program ends with a semi colon ( ; ) known as an end of
block ( EOB ). The machine will attempt to execute all the code before
each end of block in a program. If you do not insert an end of block
when you want to end a line of code, errors or erratic machine
movement can occur. For every CNC program on a Fanuc style control,
a program number must be designated for the machines memory. The
letter O is used before a 4 or 5 number program designation for most
Fanuc based controls. It is important to remember to use the letter O
and not a zero here otherwise the machine will generate an alarm and
will not load the program. Any words in parenthesis are called
comments. Comments can be seen by the operator but are ignored by
the machine. The first tool is called as well as the tool change M Code.
Once the machine completes the tool change, it will proceed to the
next line and not before!
The machine now activates a work offset, moves in Absolute and
Rapid mode to the first position and starts the spindle at a set RPM.
Once this has been done, the machine inserts the Tool length offset
value, moves to the initial Z movement and turns the coolant pump on.
You are now ready to cut some chips!
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Tool Call
(T1 TOOL DESCRIPTION);
T1 M06;
G0 G54 G90 X#.# Y#.# S1500 M03;
G43 H01 Z.5 M08;
The tool call is very similar to the program start up except the lack
of extra comments and the program number. The rest of the code stays
the same. Even though you may not change your work offset while
running the part, always make a habit of inserting it when calling a
tool. The reason for this is in case you need to power down your
machine while in a cycle. This happens a lot if you have a long cycle
time and it is the end of the work day. For example, you write a
program using G57 and it is a 40 minute total run time. The operator
starts the run 20 minutes before quitting time. Since he knows he will
not finish the entire program, he will activate the optional stop button
and stop the program before the next tool change. The next morning
when he starts the machine back up, the machine automatically
defaults to G54. See where you would run into a problem? If he
advances the program to the next tool and the work offset was not in
there to be picked up, the machine will not be performing the work in
the correct location. The part will be scrap or worse, the machine will
crash.
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Ending of a Program
;
G0 G80 Z.5 M09;
G28 G91 Y0 Z0;
M30;
When ending a program, you will most likely want to position the
machine so the operator can get to the work piece without reaching
too far into the machine. Moving the Y Axis out and the Z Axis to their
home positions will allow the operator to gain easy access to the vise
or fixture, making work piece change out less cumbersome. If only one
tool is used throughout the program, the Z Axis does not need to be
taken to the home position, this is only done to assure that the tool
does not interfere with the operator as he/she changes parts.
Exercise
For the exercise on the next page you will need to write the code for a
program start up, tool call, end of tool, and end of program. The code
provided next to each exercise number will give you all the required
information. Simply rearrange all of the information in order. Some or
all of the code may not be positioned on the line where it is needed.
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The Rules
These simple rules must be followed when using Cutter Radius
Compensation. They do not need to be followed in exact order, only
that they ALL need to be followed.
Rule #1: Figure which mode of Cutter Radius Compensation is
to be used.
Figure G41 or G42 based on what you want the cutter to do and
how the cutter will be interacting with the part.
More programming mistakes are made from making the wrong
compensation selection than other compensation errors
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Rule #4: Do not try to cut an ID radius that is smaller than the
radius of the tool.
One of two things will happen.
1: the machine gives a compensation error alarm. (This is the better of
the two)
2: the machine plunges the tool into the part in an attempt to make
the compensation. This results in an imperfection.
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Programming Methods
Types of Programming Methods
There are two types of programming methods used in profile
milling operations on modern machining centers, Machine
Compensated and User Compensated.
For all other non milling operations such as drilling, tapping, etc.
The tool centerline is ALWAYS programmed.
Machine Compensated Programming Method
Machine Compensated programming is the most widely used
method of programming side milling functions. Common examples of
side milling functions are Pockets, Profile, and Slots. This type of
programming involves positioning the cutter in reference to the actual
dimensions of the work piece shape. The programmer then uses Cutter
Radius Compensation to allow the machine to perform complex
calculations that produces an offset tool path based on the required
data entered. If the operator needs to change the tool size, all he/she
would have to do is make sure the proper diameter is inserted into the
tools Diameter Offset location in the offset page. The machine will
then recalculate the new path using this new diameter.
Example of Machine Compensated Programming
The following Code is an example of Machine Compensated
Programming using the picture to the right of the code.
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T1 M06;
G0 G54 G90 X5. Y5. S1500 M03;
G43 H01 Z.5 M08;
G01 Z-.5 F50.;
G41 X4. D01;
Y0. F15.;
X0.;
Y4.;
X4.5.;
G40 X5.5 F50.;
G0 Z.5 M09;
G28 G91 Y0 Z0;
M30;
What you are seeing in the above example is a machine
compensated method of programming. The part is a 4 Square. Using
Cutter Comp, you simply insert the cutter compensation and program
the actual size of the profile you wish to machine. Using the offset
values you assign while setting up the tools, the machine will adjust
the tool path then compensate for the tool size as it moves to each
coordinate.
Key factors for this type of programming are the correct Cutter
Compensation Mode, Inserting the D# value when using Cutter Comp,
and Using Cutter Compensation Correctly(lead in /out)
User Compensated Programming Method
User Compensated programming is mostly used in older
equipment that does not have Cutter Radius Compensation.
All the programmed moves must be calculated out manually to
compensate the cutters size in reference to the geometry being
machined.
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In this example, can you see how much more work a programmer
will need to do in order to calculate all the end points for each
manually compensated moves while the machine compensated method
will allow the programmer to just insert cutter compensation and
program to exact points as they are referenced on a part print?
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Functions
Below are the functions that canned cycles can perform.
Spot drilling
Drilling, straight and peck
Reaming
Boring
Tapping
Structure
Position machine
Call cycle
Perform cycle
Parameters
A typical canned cycle requires the machine to be in position
before the canned cycle is called. Once the canned cycle is called, it will
perform the operation at that location. The programmer will also
need to know what parameters to alter or insert in order for the cycle
to work correctly.
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Example
G81Z-1.0F15.0R.100
G81 Canned cycle
Z Final depth
F Feed rate
R Reference (rapid) plane
Modal or Non Modal?
If a machine is moved to a new position without cancelling the
canned cycle, the machine will perform the same operation at the new
location as soon as the machine stops moving. Canned cycles are
considered modal, meaning they stay active until cancelled.
When programming a canned cycle, you will first need to decide
what function you want to perform and if a cycle is available to do so.
Canned cycles cover most drilling, boring, counter boring, spot facing,
tapping, and reaming applications. Each canned cycle is similar in
appearance but the G-Code that controls it will dictate what function it
will perform and the data required making it work.
Here is a list of the standard Fanuc style canned cycles:
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G Code
Cycle Type
Cycle Description
G73
Speed Peck
G74
Tapping Cycle
G76
Boring
G77
Boring
G81
Drilling
Straight drilling
G82
Drilling
G83
Drilling
G84
Tapping
G85
Boring/Reaming
G86
Boring
G87
Boring
G88
Boring
G89
Boring/Reaming
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P
Q
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Just the same, too little information can cause mistakes as well.
Most CNC machines have codes that are called modal which means
they remain active in the memory until altered by the user. A common
modal command is feed rate. If you do not enter a new feed rate when
you want it to change, it will stay the same and may cause issues such
as when tapping.
This is why it is important to know all the variables before you try
to enter them in and not shoot from the hip as it were when
entering data. Carefully constructed programs will allow for less
mistakes and faster set up times.
Once you have used a canned cycle several times, you will start to
memorize the variables used in that cycle. You may not remember
them all for every cycle, but the main ones will surely become familiar
to you. Now that you have the cycle picked out, the next step will be to
add the variables and write the code as needed. Most programmers
will try to use the same format from cycle to cycle so that each cycle is
easy to read. An example of this will be as follows;
G81(canned cycle) Z-3.5 (final depth) R.1(reference, rapid plane,)
F4.5(feed Rate); these codes are the minimum requirements for a
canned cycle.
G73 Z-3.5 Q.25 K.75 R.1 F4.5;
G83 Z-3.5 Q.175 R.1 F4.5;
The above three sets of cycles show the Z depth is written after
the G Code calling the cycle. Next are the variables. Notice how the R
reference (rapid) plane and the F feed rate stay in order next to one
another? This is more for ease of reading for the programmer than
anything else. It will be up to you on how the codes are entered. The
more confusing you write the program, the harder and longer it takes
for someone to set up and operate. Try to follow some sort of
repeatable pattern. In short, keep things simple.
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The three sets of cycles listed above will drill the exact same hole
to the exact same depth, the only difference is how the machine will
control chip build up and coolant penetration down inside the hole.
Each cycle allows the Z axis to be manipulated in different ways in
order to achieve the objective of a hole that is 3.5 inches deep. The G73
and G83 cycles help to force the chip to break up as it is ejected from
the emerging hole while occasionally allowing coolant to flush down
into the hole.
Potential Pitfalls
Now that you have the code structure figured out, insert your
cycle and the variables needed. This may be a little tricky if you do not
understand the process of the cycle or the tools being used. For
example, if you wanted to drill a deep hole, how often should you
want the drill to retract per pass? Should you take multiple pecks
before retracting completely to clear the chips? How much feed should
there be pushing a long drill bit versus pushing a shorter one? There
may be a lot of potential questions per cycle. This knowledge comes
from not only personal experience but asking your operators who run
the machines, work with the materials, and have experience with the
tooling on a daily basis. It has been a common theme in the industry
that the best programmers are the ones who have some machining
background, knowledge of tooling, and most importantly, understand
process of machining. Though it is not required, it is an invaluable
asset.
Using G98 & G99 Canned Cycle Return Plane
G98 & G99 are used in canned cycles to change the way the Z axis
is returned to a clearance position after each completed operation.
G98 returns the Z axis after each completed canned cycle to the initial Z
axis starting location(The last Z position before the start of the canned
cycle) before moving to the next location. This is extremely handy for
moving around clamps and other obstructions.
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G00 G80;
In Review
As you have read, canned cycles are very powerful tools that you
can use to shorten the amount of programming you will need to do in
order to complete a task. Instead of writing each line of code for each
peck of a deep hole drilling cycle, for example, the canned cycle uses
built in macros that are designed to eliminate all of the extra
programming work and potential costly errors as well. Once they are
mastered, the cycles will undoubtedly become second nature when
performing any hole making task.
There are two exercises that follow on canned cycles.
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O1500(CANNED EXERCISE
#1);
(X0 Y0 IS TOP LEFT CORNER
OF PART);
(Z0 IS TOP OF PART);
(TOOLS);
(T1 1/2 SPOTTER);
(T2 5/16 DRILL);
(T3 3/8 X 16 TAP);
(T4 7/16 DRILL);
;
T1 M06 (1/2 SPOTTER);
G00 ____ G54 X2.5 Y-1.25;
S1000 M03;
____ H01 Z1. ____;
G81 G99 Z-.13 R.1 F3.;
X5. Y-.75;
X7.5 Y-1.25;
X8.5 Y-3.;
X5.Y-3.;
X7.5 Y-4.75;
X5. Y-5.25;
X2.5 Y-4.75;
X1.5 Y-3.;
G00 ____ M09;
____ G91 Z0;
M01;
T2 ____ (5/16 DRILL)
____ G90 G54 X2.5 Y-1.25;
S1200 M03;
G43 ____ Z1. ____;
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X3. Y-8.;
____ ____ ____;
____ ____ Z0;
____;
T3 ____ (1/4 DRILL)
____ ____ ____ X8. Y-2.;
S1200 ____;
____ H03 Z1. ____;
____ G99 Z-1.6 Q.1 R.15 F5.5;
X10. Y-3.5;
____ ____ ____;
____ ____ ____;
____;
T4 ____ (1 DRILL)
____ ____ ____ X5.25 Y-7.25;
S375 ____;
____ H04 Z1. ____;
____ G99 Z-1.5 Q.075 R.1 F8.;
____ ____ ____;
____ ____ Y0 Z0;
____;
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Hole Patterns
Taking the guess work out of hole patterns
Whenever you are programming and need to make a series of
holes along a circle, arc, or angle, there is a series of codes that will
simplify this task. The of G70- G72 hole pattern G Codes are considered
a support G Code series. What this means is that they do not actually
call the function to tell the machine how to make the holes. Instead,
these codes will help position the machine after the hole making G
Code is called. With only a few required operator parameters, you can
create a series of holes for a circle, arc or along an angle.
G70 Circular Hole Pattern
G70 I#,J#,L#
I = Radius
J = Starting Angle
L = Number of Holes
Out of the three pattern types, G70 is the most used. You will
come across it most in any industry drilling flanges. This function
simplifies and eliminates the need of mathematical equations in order
to figure out the various locations of a hole pattern around a circle.
The programmer simply positions the machine to the center of the
planned pattern, inserts the starting radius of the circle, the angles for
the first hole location and the number of evenly spaced holes from the
starting location. The computer then breaks down the pattern by
figuring each set of coordinates, starting with the first one described
by the programmer. It will then move counter clockwise around the
circle to each location where a hole is calculated to be. When finished,
the machine returns to the original circle center location and cancels
the cycle.
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size of the arc. The first hole location starts the same way as the G70 as
well. The programmer will then insert the amount of spacing between
each hole and the total number of holes. These two factors will
determine how long the total arc amount will be. It is possible to
create a full circle using this method but it would be easier to just use
the G70 pattern code if a full circle was desired.
Below is an example of a G71 cycle with a G81 canned cycle called
before it.
G00 X0. Y0.;
G98 G81 Z-1. L0 R.05 F4.;
G71 I6. J45. K25. L4;
As with the G70 cycle the machine will position to the center
point of the circle, X0, Y0. From there, the canned cycle is called but
again, notice the L0 which tells the machine not to drill a hole in that
location. The hole pattern is called on the next line. Starting at a 6
radius and 45 up CCW. (imagining a clock face, 0 would be at the 3
oclock position) After completing the first hole, the machine would
continue on to add 3 more holes spaced 25apart from the first
location. The total length of the arc in this case would be 100. The
machine would then return to the center of the pattern and the cycle
would cancel.
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Study the print on the next page. Using the locations from the print fill in the blanks with
the correct Hole Pattern Cycle G Code and its variables.
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;
;
;
;
;
48
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X3.0;
O1000
X4.0;
T01M06;
X5.0;
G00G90G54X1.0Y1.0M03S4900;
Y1.0;
G43H01Z.1M08;
X4.0;
G81Z-.125R.1F20.0;
X3.0;
X2.0;
X2.0;
X3.0;
X1.0;
X4.0;
G80
X5.0;
G00Z1.M09;
Y1.0;
G91G28Z0;
X4.0;
M01;
X3.0;
T01M06;
X2.0;
G00G90G55X1.0Y1.0M03S4900;
X1.0;
G43H01Z.1M08;
G80
G81Z-.125R.1F20.0;
G00Z1.M09;
X2.0;
G91G28Z0;
X3.0;
M01;
X4.0;
T02M06;
X5.0;
G00G90G54X1.0Y1.0M03S3000;
Y1.0;
G43H02Z.1M08;
X4.0;
G81Z-.80R.1F20.;
X3.0;
X2.0;
X2.0;
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X1.0;
G80
G00Z1.M09;
G91G28Z0;
M01;
T02M06;
G00G90G55X1.0Y1.0M03S3000;
G43H02Z.1M08;
G81Z-.8R.1F20.0;
X2.0;
X3.0;
X4.0;
X5.0;
Y1.0;
X4.0;
X3.0;
X2.0;
X1.0;
G80
G00Z1.M09;
G91G28Z0;
M30;
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The sample program on the previous page shows how much code it
would take to run two tools for two separate work offsets making the same
part. Imagine if there were ten tools instead of two. Below is the same
program using a Sub Routine
As you can see, the M98 calls the sub program, performs the drilling
cycle and then returns to the beginning of the next line of code. When it is
called again for a different drill cycle or even a different work offset, , it still
follows the same path as described by program O1115.
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Subroutine Exercise
Create a main program and a sub program for the above part that will
spot drill and drill the holes shown. Use a G81 for the spot and a G73 for the
drill.
5/8 Spot Drill
RPM=1000
1/2 Drill
RPM=1250
56
Vise
Chuck
Clamps
Fixture
57
Vise
58
Chuck
59
Clamps
Some parts may be clamped directly to the work table as required. This
is usually done due to size constrictions or if the work piece already has a
machined surface that will be more accurate or rigid if it is clamped directly
to the table. This method of work holding is not recommended for
production runs as it takes too much time to set each piece in place and find
the work zero.
60
Fixture
Fixtures are prefabricated devices that support and clamp the work
piece for rigidity, accuracy and repeatability. They are often used instead of
direct clamping to the table when performing large production runs. Some
fixtures utilize clamps, pins and bolts to secure and locate part features. This
is especially useful when working with castings that are of irregular shapes.
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supported but an extra operation was added to the program and not
performed in an entirely new set up.
That is something to think about when looking at a part print and
getting ready to program it. Ask yourself, What operations need to be
performed to make this part and how many can I eliminate extra set ups?
Process of Machining
Visual Optimization
Tooling Needed
Proofreading for Mistakes or Typos
Process of Machining
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of the hole will be larger from tool drilling on and angle, and the hole itself
will not be straight. Tapping a hole like this can result in the tap breaking
since the tap is made of harder, more brittle material and will not be able to
flex as much. With this knowledge of what can happen, you may want to
think twice before skipping the spotting/c-drill operation if you are trying to
save some time on a job.
Visual Optimization
Once you have your idea of what needs to happen, you will want to
make sure you optimize the process to get the most out of every tool before
it is changed for another tool. An example of optimizing is a plate has five
tapped holes, three reamed holes and two bored holes. The one thing they
all have in common? They need to be spot faced/c-drilled. You can save
unneeded tool changes by spotting all of the holes while the tool is in
operation. Next, maybe the tapped holes and the reamed holes use the same
drill for the initial hole. That can save more time. Little things add up,
especially when you have a large quantity of parts.
Tooling Needed
After you know what processes you are going to use, you will need to
select the tools to perform those tasks. There is no silver bullet to any one
operation, meaning that there is not a perfect tool to do everything. What
works on large parts may not work on small parts. What works on one
material may not work on another and so forth. There are an infinite
number of variables when machining. A good example is that a certain type
of tool that works great on a new machine may not work on a machine that
is several years old and has a lot of wear and tear. Machine alignment plays
a role, part clamping is another. This list goes on and on. The key is to start
with what you know from experience. If you are not experienced, start with
a recommendation from a lead man or tool supplier. From there, it is simply
trial and error. No one can just wave a magic wand and grant you
experience, it is something that can take a while to obtain in certain
circumstances.
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