Programming for Lathe

Manual Guide-0i

1st EditionNovember 2007

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DOOSAN Infracore eZ Guide i

TABLE OF CONTENTS

OVERVIEW 2-3

MAIN MENU 4

CYCLE SELECTION MENU LAYOUT 5

PROCESS MENU DESCRIPTION 6

HELP SCREEN DESCRIPTION 7

CONTOUR MENU DESCRIPTION 8STARTING A NEW PROGRAM 9

CREATE A DRILLING CYCLE 9-11

CREATE A ROUGH FACING CYCLE 13-21

CREATE A ROUGH TURNING CYCLE 22-26

CREATE A GROOVING CYCLE 27-29

CREATE A THREADING CYCLE 30-32

DETAILS OF CYCLE MENU INPUT ITEMS 34-41

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OVERVIEW

Manual Guide 0i is a basic, conversational-type NC tool path generator for shop-floor programming. “Conversational” simply means that when the programmer starts a process (by pushing a selection button), thesystem will “request” information pertaining only to that process, in the form of a dialog box. When all required information is input, the system will advance to the next logical step in the process until a tool path is created.

The programming system is integrated into the standard NC edit screen, with a “soft key” to activate the programming menus.

The output from Manual Guide 0i is similar to a standard NC program, but with special 4-digit G-codes. This allows a traditional NC program created offline to be combined with Manual Guide 0i code in the same program, and edited or executed in the same screen.

Manual Guide 0i is only intended to automate the time consuming task of calculating points along a tool path. Knowledge of NC programming is still required, since the system will not output the “incidental” codes required to safely move a lathe turret to and from the cutting area, and perform tool changes, spindle start/stop, etc.

There is no special graphic simulation function provided with Manual Guide 0i. Instead, the standard Fanuc tool path graphics are used in conjunction with Machine Lock (M17) mode.

This manual will cover, step-by-step, the method of creating a usable program. Pages 34 thru 41 contain detailed descriptions of the menu input items used in creating a program in Manual Guide 0i

Manual Guide 0i

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Programs are created through the standard NC interfacePreparatory commands and initial positioning moves are input through the

standard NC edit mode, then C.A.P. mode is entered for cutting cycle creation.

NOTE: Manual Guide 0i will not create rapid points or tool change information automatically, The programmer is responsible for all machine movement between actual cutting cycles, including rapid to/from home position, tool changes, spindle and tailstock commands, etc.

Manual Guide 0i

Press the C.A.P. soft key to access the programming functions

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Main C.A.P. menu

Manual Guide 0i

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Cycle Selection Menus

Manual Guide 0i

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The PROCESS key does nothing more than paste F,S,M, and T codes into the program. It is generally easier to add these commands

manually, so this function will be not be covered in this manual.

Manual Guide 0i

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The G CODE and M CODE buttons function as an “online help” feature.

M code help is similar to G code help shown here.

Manual Guide 0i

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The CONTUR key uses the exact same menu as the FIGURE menu (shown on page 5) to create the tool path geometry, but the output is different in that the CONTUR output is converted directly into standard NC code, while the FIGURE output is in 4-digit G-code format.

Manual Guide 0i

CONTUR and FIGURE “intermediate” format

MG0i uses this code internally to calculate

the tool path, and resulting G-codes

CONTUR program output

This is direct NC code and cannot be applied to a

roughing cycle, for example

FIGURE program output

This code must be preceded by a “cycle”

block

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The first step in creating a new program is to input the startup commands that will index the turret to the proper station, start the spindle, and move the turret to the cutting start point.

Again, it is important to note that ONLY cutting motions are handled by the cycle menus - all other machine motions must be programmed manually.

Manual Guide 0i

Check for available program numbers, and start a new program. In this case, enter”O”0003, EOB, and press INSERT. This is done

on the standard NC edit screen

The first tool will drill a 1” dia. hole x 1” deep. Enter the blocks shown here through the MDI keys…

..then press the C.A.P. soft key to access the cycle and part figure menus

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Manual Guide 0i

Select DRILL

There are (5) choices for drilling. Select #2 “G1101 DRILLING”

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Manual Guide 0i

The “W” value selects the

type of drilling.

The “Q” value specifies the peck depth. We will use drilling type 1, so

this value can be omitted.

If an unneeded value is entered, the system will ignore it. If a necessary

value is missing, an alarm will be issued

when the OK button is pressed later.

Fill in remaining values as shown

When all values are entered, press OK. The cycle will be added to the program at the last

cursor position

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The system will return to the main menu. The zero return motionsand tool change must be entered manually, so press the LEFT SHIFT

soft key to return to the NC edit screen

This is the code that was just created by the G1101

DRILLING menu. Note the highlighted EOB

Insert the blocks after the G1101 line

as shown, then press the C.A.P. soft key to create

the next cycle

Manual Guide 0i

IMPORTANT : The rough facing cycle (or any other cycle) will

consider these coordinates to be the corner of the rough stock, and

will begin cutting from here

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Next, we will rough face the part. Facing cycles are in the TURN menu

Manual Guide 0i

Press TURN

Select 3 - END FACE

ROUGHING

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Manual Guide 0i

Turning cycles are slightly different than drilling cycles. Once the cycle menu has been filled out, a part figure must be created in order to describe the cutting area

Cycle information is described on 2 screens. The

screens advance automatically when

the last value on each screen is entered, or the

PAGE hard key can be used

After entering all cutting data, press FIGURE. The cycle line will be automatically written to the program,

and the part figure menu will appear

As each item is highlighted, the

diagram changes

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Manual Guide 0i

When the FIGURE or CONTUR soft key is pressed, a message may pop up asking whether to edit the contour program or create a new one. Manual Guide 0i uses a “temporary” program number, set by parameter, as a “working program” area. This has no effect on the NC program currently being created.

Set this parameter to a program number that you will never use for regular NC programs, since MG0i will delete it the first time you create a part figure

OR

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Manual Guide 0i

Press 1This is the only choice of

figures for turning

Enter values as shown. The FEED

METHOD determines how the tool will travel to the beginning of the cycle from where it is

currently located.The optional FEED

RATE may be used to vary the cutting feed at different points along

the contour.

Press OK when finished

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Manual Guide 0i

This screen shows the temporary output for the part figure, and a line drawing of the figure so far. This is an

intermediate step before the G codes are written to the

program. Later, once we have “built” a part figure, we will go back and modify one of

the elements

The first element of this figure will be a straight line to Z0, so press

LINE

In this case, the system only needs to know the end point Z for this line,

so enter 0

TOUCH STATE defaults to “nothing”. If the element you are drawing is tangent to, or blends with, the last element, press LAST,

otherwise you can just press OK to accept

the data

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Manual Guide 0i

The next element is added to the list.

Press LINE

Enter end point as shown, and press OK

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This is all that is needed for a facing tool path. The process type determines the cutting direction. The part figure points determine the area to be cut. After the area specified by the part figure is machined, the tool will return automatically to the coordinates immediately preceding the cutting cycle command.

Manual Guide 0i

Press the right shift key, then NC CNV to add this part figure to the

program

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There are (3) options on this screen:1) Enter an unused 4-digit program number, then press YES – the part figure

codes are generated and saved as a subprogram that can be called with an M98 command. This option is normally used when a rough and finis profile are the same, to save the effort of drawing the figure twice

2) Press YES without entering a number – the part figure codes are inserted directly into the main program. Use this option if the figure will only be used with one cycle / tool.

3) Press NO to return to the part figure creation menus (touchup / edit)

Manual Guide 0i

In this case, we will simply insert the figure codes directly into the main program since there are no other processes that will use this figure.

Press YES

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Manual Guide 0i

Again, the main menu appears. Press the left shift key and check the output from the facing cycle. Note the G1122 block from the rough facing cycle menu, and the 4-digit G code format representing the part figure

Output from END FACE ROUGHING

menu

Output from FIGURE menu

All MG0i output will be in this format, with a “cycle” block (G1122 in this case) followed by “part figure” blocks (G1400 through G1406). Each 4-digit G code has a specific meaning to the system, such as G1400 for start point, G1401 for a “line” element, etc.

The blocks above the G1122 shown here MUST BE MANUALLY INPUT by the programmer (ref. page 12), since MG0i only deals with the “cutting”portion of the program.

The next process will be rough turning the OD, using the same tool. After rough face machining, the tool will return to X2.35, Z1. (see above)

ALL MG0i CYCLES ATTEMP TO START CUTTING FROM WHEREVER THE TOOL HAPPENS TO BE WHEN THE CYCLE IS COMMANDED, AND WILL RETURN THE TOOL TO THAT POINT AFTER THE CYCLE IS COMPLETED

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Manual Guide 0i

Since we are using the same tool as the rough facing cycle, no manual input is required. Press the C.A.P. key, TURN key, then select 1 G1120 OUTER BAR ROUGHING

Fill in menu items with this data

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Manual Guide 0i

Press FIGURE, select “1”, and enter X0.9, Z.050 as your start point, then press OK

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Manual Guide 0i

Insert lines, arcs, and chamfers as shown here, in order

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Manual Guide 0i

Then press NC CNV to generate the codes for this part figure

This figure may be used again for another cycle, so we will save the output as a sub program. Enter 1111, then

press YES.

A graphic representation of the contour is overlaid on the program screen

Press the right shift key to continue the menu selections…

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Manual Guide 0i

This is the output from the part figure creation. Note the 4-digit G-code format.IMPORTANT: There are two methods of creating a profile, FIGURE and

CONTUR. If a profile is created using the FIGURE menu, the output must be preceded by a cycle description, like the G1122 and G1120 blocks shown above. If the profile is created using the CONTUR menu, the output will be in standard G-code format, and the cycle command will be ignored, which will most likely result in a broken tool.

In this case, we created an OUTER BAR ROUGHING block (G1120 shown above), and created the matching profile using the FIGURE menu, saving the result as subprogram 1111.

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Manual Guide 0i

The rough turning process is complete. Now we need to add commands to bring the turret to a tool change position, then bring it back to the part, and create a grooving cycle with its associated part figure

Enter these blocks manually, after the M98 block shown above

Press C.A.P. key, then select OUTER

GROOVE ROUGHING

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Manual Guide 0i

Enter these values , then press FIGURE

Select NORMAL GROOVE

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Manual Guide 0i

Enter these values, then press OK

This is the output from the grooving cycle and part figure creation

OUTER GROOVE ROUGHING cycle

NORMAL GROOVE figure

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To create a threading process, add the following to the program:

Manually insert the positioning and tool change information

Press the C.A.P. soft key, select OUTER THREADING, and enter the

values as shown here

Then press the FIGURE soft key

Manual Guide 0i

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Enter the threading figure coordinates.

Manual Guide 0i

Select G1450 THREAD FIGURE

and enter the values shown

here

Note: contour threading can be programmed using this menu. For a standard thread, as in this example, simply fill in the “A” and “B” values,

and leave the rest blank

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This is the output from the threading cycle (G1140 and G1450 blocks) and the program end sequence.

Manual Guide 0i

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The program is now complete. As an exercise, try placing the machine into Machine Lock (M17) mode, and verifying the program using standard tool path graphics.

The remainder of this manual contains excerpts from the Fanuc operator’s manual, to be used as reference material.

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