Intelitek ProMill 8000 User Manual Download Page 14

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2 Introducing the ProMill 8000

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2.1 Overview of Standard Features

Standard milling specifications

y-axis travel of 6 inches (152 mm)

X-axis travel of 10.24 inches (260mm)

Z-axis travel of 7.09 inches (180mm)

Feed rates up to 20 IPM (500mm/min) (rapid traverse up to 79 IPM
(2000mm/min))

Computer-controlled spindle speeds from 100 to 5,000 RPM

Safety features

Full enclosure with automatic safety door lock

Automatic diagnostics and power cut off protection

Safety door and limit switches

Emergency stops from the milling center and computer keyboard

Machine ready optional accessories

Coolant ready

Jog pendant ready

Robotic integration ready with 6 inputs, 6 outputs

Summary of Contents for ProMill 8000

Page 1: ...ProMill 8000 Milling Center USER S GUIDE Catalog 200066 Rev C...

Page 2: ...Program listings may be entered stored and executed in a computer system but not reproduced for publication Every effort has been made to make this book as complete and accurate as possible However n...

Page 3: ...ossible injury always observe the safety precautions described in this User s Guide The following icons indicate important information throughout this User s Guide Safety Provides essential safety ins...

Page 4: ...3 Installing the Software 20 3 4 Contacting Technical Support 33 3 5 Returning Defective Products 33 4 Maintaining the ProMill 8000 35 4 1 Cleaning the Milling Center 35 4 2 Maintaining Individual Mi...

Page 5: ...Run 93 7 12 Running the Program 94 8 Basic CNC Programming 96 8 1 Elements of an NC Part Program 96 8 2 General Programming Suggestions 97 8 3 Reviewing an NC Program 98 8 4 NC Codes 98 9 NC Programmi...

Page 6: ...ndle Speeds 161 11 3 Setting Feed Rate and Depth of Cut 162 11 4 Selecting Lubricants and Coolants 163 11 5 Tool Types 163 11 6 Sharpening the Tools 165 12 Automation lntegration 166 12 1 Integration...

Page 7: ...torial Milling a Sample Part 8 Use the remaining chapters as a reference guide for NC programming a Chapter 8 Basic CNC Programming presents guidelines for writing basic NC programs and lists and desc...

Page 8: ...y before you use the milling center and keep it readily accessible for quick reference Know the intended applications and limitations of the milling center as well as its hazards Keep untrained visito...

Page 9: ...le If a grounding adapter is used to accommodate a two prong receptacle the adapter wire must be attached to a known ground Never remove the third prong from the plug on the AC power cord Keep the saf...

Page 10: ...possible binding of components which may result in possible damage to the milling machine the workpiece or the operator Always make sure the machine is properly lubricated Do not force a tool Select...

Page 11: ...prehensive range of spindle rotation speeds Speed can be set with the Control Software or by using an S code in the NC program Always use a safe spindle speed Accessories Use recommended accessories o...

Page 12: ...e safety door Only operate the machine after being properly trained in its use Perform a dry run Make certain there is no workpiece in place Run the NC program to make sure all the moves make sense be...

Page 13: ...oMill 8000 uses EIA ISO and Fanuc compatible G M code programs to cut parts in a variety of materials This section presents the following information Section Contents Introducing the ProMill 8000 Sect...

Page 14: ...00mm min rapid traverse up to 79 IPM 2000mm min Computer controlled spindle speeds from 100 to 5 000 RPM Safety features Full enclosure with automatic safety door lock Automatic diagnostics and power...

Page 15: ...8000 COMPONENTS This section shows the location of major components of the ProMill 8000 arranged by the view from which they are visible Section Contents Components 2 2 1 External View pg 9 2 2 2 Righ...

Page 16: ...operator from flying chips A magnetic shield interlock switch prevents the machine from operating with the shield open The Emergency Stop button is used to halt machine operation When pushed machine o...

Page 17: ...roMill 8000 Components 10 2 2 2 Right Side Panel The graphic below shows the machine as viewed from the right side 1 I O ports 2 PC power supply 3 Coolant power supply 4 Jog pendant port 5 Ethernet po...

Page 18: ...ProMill 8000 Components 11 2 2 3 Enclosure The graphic below shows the contents exposed by opening the safety shield 1 Work light 2 Tool release button 3 Spindle Head 4 Automatic tool changer optional...

Page 19: ...NCMotion or CNCBase that runs on your computer Using industry standard EIA RS 274D NC codes the control software provides for two axis CNC programming and milling The control software is extremely eas...

Page 20: ...1 Tool holder wrench 30mm 6 1 5mm x 20mm Fuse 7 1 Allen wrenches set of 6 8 1 CNCBase control software 9 1 Open ended wrenches set of 3 10 1 Tool holder nut wrench 11 2 Step block 12 2 Step clamp 13 2...

Page 21: ...33 3 5 Returning Defective Products 33 3 1 PREPARING FOR INSTALLATION This section presents instructions for preparing the work space and machine for installation Procedure Outline Preparing for Insta...

Page 22: ...sonal computer running Windows 95 or Windows NT version 3 51 or higher See section 3 3 1 Verifying Computer Requirements pg 20 for a complete list of the necessary computer equipment Product Care We r...

Page 23: ...9mm wrench 9 Store the bolts and other packaging materials in case the product has to be returned or transported 10 Lift the milling center off of the pallet and place it at its designated location 11...

Page 24: ...d wrenches set of 3 10 1 Tool holder nut wrench 11 2 Step block 12 2 Step clamp 13 2 Hex head nut 14 2 Threaded shank 15 2 T nut 16 2 Electrical panel keys 17 1 Ethernet cable 5 Additional accessories...

Page 25: ...19 3 Install additional accessories purchased 3 2 3 19 3 2 1 Connecting the Milling Center to a Computer Follow the procedure below to connect the milling center to a computer You will connect the mi...

Page 26: ...ched to a known ground Never remove the third prong from the plug on the AC power cord Follow the procedure below to connect the milling center to a power supply Procedure Connecting the Power 1 Ensur...

Page 27: ...3 1 20 2 Run the installation to install the software 3 3 2 21 3 Configure the software for your machine and accessories 3 3 4 25 4 Configure the IP address of the milling center 3 3 5 29 This sectio...

Page 28: ...ion 1 Insert the installation disk into the CD DVD drive The installation program should open automatically If the installation does not open automatically navigate to the Install folder and launch th...

Page 29: ...ware 22 4 Click Yes to accept and continue The Software Selection screen is displayed 5 Select the software to install It is important that the software you select here matches the license you have pu...

Page 30: ...Configuration Options screen is displayed 9 Select whether the configuration and sample programs are to be exclusive to each user first option or common to all users second option The first option is...

Page 31: ...Installing the Hardware and Software 3 3 Installing the Software 24 11 If necessary click Browse to change the destination folder 12 Click Next The Ready to Install screen is displayed 13 Click Insta...

Page 32: ...ment by clicking the Help button during software registration Note that CNCBase does not require registration If you have purchased CNCMotion that software does require registration 3 3 4 Configuring...

Page 33: ...u try to launch the Configuration Program while the CNCBase Motion software is open you will be asked to close CNCBase Motion first Procedure Running the Configuration Program 1 Ensure that CNCBase Mo...

Page 34: ...ew all available settings Click the tabs at the top of the window Access online help Click the Help button Save changes made Click OK Clicking OK will close the configuration program Make all required...

Page 35: ...tall to install others For more information see 3 3 4 3 Adding Installed Optional Accessories pg 28 Machine Configuration Allows you to select a different machine and to save and load previously defin...

Page 36: ...Running the Configuration Program pg 26 2 Click the Options tab 3 Click Reinstall The Reinstall Options window is displayed 4 Select the option to be added 5 Click Reinstall 0 The Reinstall Options wi...

Page 37: ...e the settings of your LAN adapter Follow the procedure below to configure the IP address Procedure Configuring the IP Address 1 Run the Machine IP Configuration utility To do so locate the CNCBase Mo...

Page 38: ...splays the configuration for all active network connections 6 Click OK to close the program 0 3 3 6 Uninstalling the Software When necessary follow the procedure below to uninstall the software Proced...

Page 39: ...displays The Uninstall Wizard is displayed asking for confirmation 6 Click Yes to uninstall CNCBase Motion 7 Wait while the software is uninstalled The Uninstall Complete window is displayed 8 Select...

Page 40: ...to walk through the problem with you Technical support contact details Info Table Intelitek Technical Support Contact Details Toll free U S only 800 221 2763 Direct Dial 603 413 2600 e mail support in...

Page 41: ...its original packaging and crate as was packed originally 4 Write the RMA number and your return address on the outside of the product carton or crate Failure to do so can result in a delay in the re...

Page 42: ...components 4 2 36 Follow a maintenance schedule 4 3 38 Adjust the pneumatic systems 4 4 39 Maintaining a computer in a shop environment 4 4 39 4 1 CLEANING THE MILLING CENTER Keeping your machine clea...

Page 43: ...major component Maintaining the Milling Center Components Task Section Page Maintaining the Milling Machine Bed 4 2 1 36 Maintaining the Milling Machine Bed Linear Bearings 4 2 2 37 Maintaining the Ba...

Page 44: ...ated with oil to prevent rust 4 2 2 Maintaining the Milling Machine Bed Linear Bearings Play in the table could indicate that the milling machine bed bearings require adjustment The bearings are facto...

Page 45: ...Customer Service if the belt makes a squealing sound 4 3 MAINTENANCE SCHEDULE SUMMARY Follow the maintenance schedule outlined in the table below Guidelines Maintenance Schedule Continuously Before Ev...

Page 46: ...ly powered The pneumatic controls for both systems are located in the rear pneumatics panel as shown below 1 Drawbar regulator 2 Airblast 3 ATC regulator This section presents the following informatio...

Page 47: ...ter clockwise Open Increase air blast pressure 4 4 2 Adjusting the Air Pressure The air pressure should be set to 80 psi The air pressure is adjusted using the control unit on the regulator located on...

Page 48: ...from sources of heat and in a relatively clean environment i e not right next to the foundry room Keep liquids soda coffee cutting fluid grease away from the computer and peripherals Keep oil grease...

Page 49: ...C File 62 5 6 Verifying an NC Program 64 5 7 Running an NC Program 71 5 8 Accessing Help 72 5 1 LAUNCHING THE CONTROL SOFTWARE CNCBase Motion can be used with or without the milling center attached to...

Page 50: ...tware 43 4 Locate and click the CNCBase Motion for Intelitek CNC folder 5 Click CNCBase Motion for Intelitek CNC 6 Click No if the message below displays This message is only displayed the first time...

Page 51: ...ware in on line mode Simulation mode For use without the ProMill 8000 connected In simulation mode you can write edit and verify NC programs as in on line mode but you cannot control or send NC progra...

Page 52: ...Section Content Toolbars Section Name Page 5 3 1 1 Main Menu 45 5 3 1 2 Standard Toolbar 49 5 3 1 3 Tool Menu and ATC Control Toolbar 50 5 3 1 4 Outputs Toolbar 52 5 3 1 5 lnputs Toolbar 53 5 3 1 1 Ma...

Page 53: ...losing Edit Undo Undo the most recent editing command Redo Redo the most recent Undo command Cut Cut selected text to the clipboard Copy Copy selected text to the clipboard Paste Paste text from the c...

Page 54: ...timate the runtime of the current NC program Pause Pause the NC program after the current line of NC code finishes executing Spindle continues to turn Feedhold Immediately pauses the NC program Stops...

Page 55: ...used for certain NC codes Spindle Specify a spindle speed if you have not used an S code in your NC program Backlash Define the amount of play in the turning screws Soft Limits Establish and configur...

Page 56: ...rator resumes operation Feedhold Pauses the currently running program immediately even if the current block in the NC program has not been fully executed The spindle continues spinning The program wil...

Page 57: ...Reset Workpiece Returns the workpiece to its original uncut form in the 3D window 5 3 1 3 Tool Menu and ATC Control Toolbar The configuration of the tools and the optional 4 position tool changer is p...

Page 58: ...to select a different tool to be moved to milling position The Tool drop down list lists all tools defined in the Confugure ATC window If you select a tool that is Currently configured within the ATC...

Page 59: ...Switches for Robotic outputs 1 through 4 are also provided Power is ON when the buttons are depressed Info Table Outputs Toolbar Icon Name Function Spindle Output Turns the spindle on off Spindle Dire...

Page 60: ...ates when the Emergency Stop is pressed Door Indicates that the doors are open Shield Open Indicates that the shield is open Shield Closed Indicates that the shield is closed Negative Limit Indicates...

Page 61: ...as not been modified Homed The milling center is homed not homed CAP The Caps Lock key is activated not activated NUM The Num Lock key is activated not activated 16 106 The current line and total numb...

Page 62: ...Hide 5 3 2 3 Machine Info Panel The Machine Info panel provides information on the current tool tool reference point feed rate spindle speed number of passes made coordinate system in use as well as t...

Page 63: ...s have been made 5 3 3 Program Editing Window Whenever you open an NC part program file it is displayed in its own Edit window You can have multiple Edit windows open at a time A sample Edit window is...

Page 64: ...procedure to unlock an NC program for editing Procedure Unlocking an NC Program for Editing 1 Click Edit Lock in the Main Menu to remove the lock Alternatively press Ctrl L on your keyboard 0 The Edi...

Page 65: ...tool in the X Y and Z directions and to control the speed and distance of that motion The Operator panel allows you to run programs control how programs run and control the feed rate and spindle spee...

Page 66: ...l The arrow buttons will disappear 2 Click again to deactivate the handwheel and restore the arrow buttons 3 To deactivate the jog controls click anywhere in the control software window other than the...

Page 67: ...executed The spindle continues spinning The program will continue from the point at which it stopped once the operator resumes operation Sets the feed rate override The actual feed rate while milling...

Page 68: ...on The milling center uses this point as a reference for all machine coordinate movements This allows you to use the Soft Limits and Coordinate Systems commands under the Setup Menu to move the millin...

Page 69: ...f you are sure that doing so is safe The machine will move to its home position 5 5 OPENING AN NC FILE The control software allows NC files to be saved and then opened again at a later time In additio...

Page 70: ...5 Using the Control Software 5 5 Opening an NC File 63 3 Select the program and click Open 0 The NC program is displayed...

Page 71: ...actually running the part program on the milling center The Verify Window displays a 2D simulation of your part program This section presents the following information Section Contents Verify Window...

Page 72: ...Launching Verification Follow this procedure to launch verification Procedure Launching Verification 1 Either click the Verify icon on the Standard Toolbar or click Program Verify on the Main Menu or...

Page 73: ...in the Verify window Run Settings to open the Run Settings window The settings here specify how the program will run See 5 6 2 Modifying Run Settings pg 67 Verify Settings to open the Verify Settings...

Page 74: ...ode for programming arc centers in which arc centers are always incremental When this box is unchecked the default mode is EIA 274 in which arc centers follow the general programming mode absolute whe...

Page 75: ...essed by clicking Verify Settings on the Verify Program window The Verify Settings window consists of three tabs The settings available in this window are described below arranged by tab Info Table Ve...

Page 76: ...out or view the entire workpiece All All changes are reflected in the Preview window Stock Tab Specifies the length width and height of the stock to be used Spacer specifies the height of the spacer...

Page 77: ...y window provide quick access to the display settings Info Table Verify Window Controls Displays the workpiece in solid view Displays the workpiece in wireframe view Speeds up slows down the verificat...

Page 78: ...afety Guidelines pg 1 4 Be prepared to press the Emergency Stop button on the machine if anything goes wrong 0 Product Care Before running an NC program for the first time you are advised to follow th...

Page 79: ...5 6 2 Modifying Run Settings pg 67 5 Once the program has ended press the Emergency stop button open the safety door and remove the finished part 0 5 8 ACCESSING HELP The comprehensive online help ca...

Page 80: ...up tools in a tool changer are provided in the documentation supplied with that product Safety Milling tools are extremely sharp To avoid cutting yourself it is best to handle them from the shank wit...

Page 81: ...e that the safety shield is open 5 While holding the tool by the bottom of the tool holder press the green drawbar button on the spindle 6 Pull the tool holder downward removing it from the spindle 0...

Page 82: ...Follow this procedure to insert the tool holder into the spindle Procedure Inserting the Tool Holder into the Spindle 1 Ensure that Emergency Stop button is released 2 Turn on the power switch 3 Ensu...

Page 83: ...ng the Tool Holder into the Spindle 76 5 Ensure that the tool is installed correctly by holding the tool by the flange of the tool holder and turning the tool and spindle Ensure that the tool and spin...

Page 84: ...ure Outline Tutorial No Step Section Page 1 Review safety procedures 7 1 78 2 Prepare tools and materials required 7 2 78 3 Open the sample NC file 7 3 78 4 Determine the stock size required to mill t...

Page 85: ...sed enough Safety Ensure that you are familiar with all safety guidelines in 1 Safety Guidelines pg 1 before continuing 7 2 PREPARING TOOLS AND MATERIALS For this tutorial you will require the followi...

Page 86: ...g 7 4 DETERMINING THE STOCK SIZE For the Verify window to accurately simulate the NC program you will have to specify the stock size before running the verification Milling stock is defined by three v...

Page 87: ...ettings so that the verification simulation will accurately simulate the tool workpiece combination you will be using This section provides instructions for configuring the Verify Settings Outline Con...

Page 88: ...cedure to access the Verify Settings window Procedure Accessing the Verify Settings Window 1 Check to see if the Verify window shown below is currently displayed on the CNCBase Motion screen If the Ve...

Page 89: ...the view settings Procedure Adjusting the View Settings 1 Click the View tab This tab is used to specify the appearance of the Verify animation 2 Make all required settings See 5 6 3 Configuring Verif...

Page 90: ...nsions and origins Procedure Setting Stock Dimensions and Origins 1 Select the Stock tab 2 Enter the stock dimensions for the superman_imp nc part program The stock dimensions define the dimensions of...

Page 91: ...ses and your changes are applied to the workpiece in the Verify Window 7 6 DEFINING THE TOOL You will use an eighth inch end mill to mill this part You will use the parameters for this particular tool...

Page 92: ...isplayed 2 Select Tool 01 a 0 125 endmill 3 Check that the settings for Tool 01 are as shown below If they are not modify the settings to match the settings shown 4 Click OK to close the Setup Tool Li...

Page 93: ...m on the Milling Center Follow this procedure to verify the program Procedure Verifying the Program 1 Click Program Verify in the Main Menu or click the Verify icon in the Standard Toolbar 2 Ensure th...

Page 94: ...ise You will now prepare to test the program on the CNC machine itself first without the workpiece in place and later with the workpiece in place First however the machine must be turned on and homed...

Page 95: ...iece should be a block 3 0 wide 2 deep and 1 5 tall Use a spacer to ensure that the face of the stock is at least 1 8 above the top of the vise jaws 6 Close the safety door 7 Release the Emergency Sto...

Page 96: ...e paper Note the following a Click the arrow buttons or press the arrows keys on your keyboard to move the tool b To make the tool move continuously while one of the X Y or Z buttons is pressed i Clic...

Page 97: ...the Axes Zero Positions 90 d To adjust the preset Speed and Step Size values i Right click anywhere in the Jog Control panel A menu is displayed ii Click Setup The Jog Settings window is displayed ii...

Page 98: ...inch steps Carefully jog the tool down until the tool tip just pinches the paper Check this point by trying to move the paper after each step When you can no longer move the paper you have reached th...

Page 99: ...ly calculate half the diameter of the tool as 0 0625 18 Verify in the Machine Info window that the Y value reads 0 0625 inches 19 You will now touch off the left of the stock X 0 Switch to continuous...

Page 100: ...piece in place Safety The Emergency button must be pressed in before starting this procedure Follow this procedure to perform a dry run Procedure Performing a Dry Run 1 Press the Emergency Stop button...

Page 101: ...ou are satisfied that the tool motions are correct you can proceed to the next step mounting the workpiece and milling the part 7 12 RUNNING THE PROGRAM Now that the program has been checked in the Ve...

Page 102: ...gram Run Continue in the Main Menu The Run Program window is displayed 4 Ensure that Start at Line is set to line 1 5 Click Run Program to begin running your program 6 Once the program has ended press...

Page 103: ...lock contains a string of words An NC word is a code made up of an alphabetic character called an address character and a number called a parameter or value Each line can end with a comment which is i...

Page 104: ...xt block line The system assumes no change in codes unless a new code appears This does not apply to the following codes N words I and K G04 G05 G25 G26 G92 F used for dwell M02 M20 M25 M26 M30 M47 M9...

Page 105: ...rs 5 Run the part program without mounting stock in the milling center to see if the tool movements are logical 0 8 4 NC CODES NC codes are divided according to category Some categories consist of one...

Page 106: ...ingle 8 4 21 127 Z Z axis motion coordinate Single 8 4 22 127 Comment Single 8 4 23 127 8 4 1 Code Incremental Arc Center The incremental arc center code selects the Fanuc mode of programming arc coor...

Page 107: ...ed only when the Optional Skip parameter from the Run Settings window is checked see 5 6 2 Modifying Run Settings pg 67 To use the Optional Skip code place the code at the beginning of the line you wi...

Page 108: ...6 1 101 The Units Group G70 G71 G20 G21 8 4 6 2 102 The Wait Group G04 G05 G25 26 8 4 6 3 102 The Canned Cycle Group G32 G72 G73 G77 G79 G80 G81 G83 8 4 6 4 103 The Programming Mode Group G90 G91 8 4...

Page 109: ...and metric modes throughout the program The Fanuc equivalents G20 inch and G21 metric can also be used Info Table Units Group Code Function G70 Inch Units G71 Metric Units G20 Fanuc inch units G21 Fan...

Page 110: ...ill stop if the input state changes from High to Low Otherwise the motion will stop if the input state changes from Low to High The P word specifies the line number to jump to see 8 4 15 P Code Subpro...

Page 111: ...the milling center G91 Incremental programming mode Each motion to a new coordinate is specified relative to the previous coordinate 8 4 6 6 The Preset Position Group The Preset Position G codes move...

Page 112: ...re axes the machine first rapids from the current position to the intermediate point then continues to the specified destination If you command a G29 code in incremental mode your specified XYZ point...

Page 113: ...ar Programming Group Code Function G15 Polar programming OFF G16 Polar programming ON Using polar coordinates allows you to specify a radius and an angle by specifying a G16 code polar programming on...

Page 114: ...rees M98 P1 Call subprogram 1 L12 Sets the number of repeats to 12 M2 End program O1Z30 G81Z 1R0 G80 01 Subprogram label 1 Z30 Move to position 30 degrees from current position G81 Start canned drilli...

Page 115: ...an angle of 0 degrees Z 1 Move 0 1 inches in the negative Z direction M98 P1 Call subprogram 1 L90 Sets the angle of the arc to 90 degrees G15 Turn Polar programming OFF M2 O1Y1 M99 M2 End program O1...

Page 116: ...path The G39 instructs the cutter compensation function to complete the current segment by moving to its default endpoint the endpoint of the Offset Vector It then creates an arc with a radius equal t...

Page 117: ...xample 1 G40 The G40 code cancels cutter compensation The cutter moves from the offset path to the programmed end point G91G41D1 X 25 Y 25 Z 2 RETRACT G40 X 5Y 25 M2 2 G40XYZ The G40 cancels the cutte...

Page 118: ...ion but a subsequent motion X 5Y 25 is included in the program The tool moves towards the programmed path in the direction of X 5Y 25 Setting the offset number to zero has the same effect as cancellin...

Page 119: ...mand left and right cutter compensation as illustrated below Info Table Left and Right Cutter Compensation Code Explanation Explanation G41 Left compensation when you need to move the tool to the left...

Page 120: ...es show the specified tool path The purple dashed lines show the compensated tool path that the tool will follow Note that the distance between the two paths is always as specified by D1 8 4 6 9 4 D S...

Page 121: ...shape then multiplies those values by the P value The code I is used to specify the X axis center of scaling see 8 4 8 I Code X Axis Coordinate of Center Point pg 116 The J code is used to specify the...

Page 122: ...supported Rotation codes are listed below Info Table Rotation Group Code Function G68 Invokes rotation G69 Cancels rotation R When used with G68 specifies the angle of rotation in degrees This exampl...

Page 123: ...ut number The H code and input must be specified H codes specify inputs and outputs as defined in the table below Info Table H Code H Code H11 H12 H13 H14 Input specified for Wait Codes G25 and G26 1...

Page 124: ...nters are specified in incremental mode Incremental G91 The distance along the Y direction from the starting point of motion to the arc circle center The J code is also used with the G51 code to speci...

Page 125: ...e segments to approximate the circle The L code specifies the resolution in terms of the angle in degrees across which a line segment approximates a portion of the arc Setting a low value of L increas...

Page 126: ...equation as 360 2 360 001 2 5 0 1146 Negative L Values A negative value for L will generate a normalized L factor calculated as Angle degrees L Radius inches For example with the default L factor of 1...

Page 127: ...e spindle execute at the beginning of the tool motion for that block of NC code All M codes used to turn off a device execute after the tool motion for that block is completed The supported M codes ar...

Page 128: ...on pg 166 M26 Sets the output specified by the H command to Off Used for robot synchronization Use the H code to specify an output see 8 4 7 H Code lnput Selection Number pg 116 See 12 Automation lnte...

Page 129: ...s code is used when digitizing to write the current X and Z machine coordinates to a file The proper format for using this code is M22 filename ext A text and macros Items in brackets are optional exc...

Page 130: ...llowing special codes can be used with M22 to generate run time reports Info Table Special Codes for Use With M22 Code Description X Current X position in current coordinate system Z Current Z positio...

Page 131: ...code can be used in the main NC program as a Goto command to jump to any line before the first subprogram as denoted by an O code Use the P code to identify the block number being jumped to Control is...

Page 132: ...t from the uses listed above N codes are ignored by the control software Their presence absence or sequential value does not affect the execution of the NC program in any way unless the target of a Go...

Page 133: ...ing codes Info Table Use of P Code Used with Code To Section Page G31 Reference a GOTO target block 8 4 6 3 102 M98 Reference a subprogram using the subprogram block number 9 7 143 M99 Specify a retur...

Page 134: ...along the X axis A U code is used in absolute programming mode G90 to specify an incremental X motion You cannot use the U code to mix incremental and absolute programming in the same block 8 4 21 Y a...

Page 135: ...ever provides a more versatile and powerful message facility see 8 4 12 3 M105 Code Operator Message pg 124 Here is an example of an NC block with a pause coded comment Example Code Comment Code Expla...

Page 136: ...am Programming 143 9 1 LINEAR INTERPOLATION PROGRAMMING Linear interpolation is the movement of the tool in a straight line from its current position to a coordinate location specified by an NC code C...

Page 137: ...pg 132 Circular interpolation moves the cutting tool along an arc from the starting point specified in one line to an end point specified in the next line The curvature of motion is determined by the...

Page 138: ...along circular path in counterclockwise direction I Specifies X axis coordinate of center point J Specifies Y axis coordinate of center point An example of circular interpolation is shown below NC Co...

Page 139: ...inches per minute Example Motion Assuming the start point is X0 Y0 Z 1 the tool path generated by the preceding lines would be as below 9 3 CIRCULAR INTERPOLATION PROGRAMMING IN OTHER PLANES Circular...

Page 140: ...available feed rate 30 ipm to the specified coordinates Rapid traverse is often used to reposition the tool before ending a program or in preparation for the next cut The tool should not be engaged in...

Page 141: ...s still active G01X4 MOVE IN A STRAIGHT LINE TO X 4 AT 2 IPM G01 Turns off rapid traverse mode and engages linear interpolation X4 Moves the tool to position X 4 9 5 HELICAL INTERPOLATION PROGRAMMING...

Page 142: ...hown Note that the arc is machined in the XY axis but that the Z vertical coordinate of the end point is higher than the Z coordinate of the start point 9 6 CANNED CYCLE PROGRAMMING Canned cycle comma...

Page 143: ...ositive value R Used for specifying a starting reference point for peck drilling The point can be at the material surface or at another reference point 9 6 1 G80 Cancelling a Canned Cycle Use the G80...

Page 144: ...ANCEL CANNED CYCLE M2 END PROGRAM Code Explanation G0X1Y1Z1 RAPID TO 1 1 1 Rapid motion to X1 Y1 Z1 G98G81Z 1R 1F2 CENTER DRILL TO DEPTH OF Z 1 FROM Z 1 FEED 2 RAPID TO INITIAL POINT G81Z 1R 1 Straigh...

Page 145: ...ow The peck drill cycle will result in motion as shown below 9 6 3 G82 Straight Drilling with Dwell A G82 code works just like a G81 code see 9 6 2 G81 G83 Straight and Peck Drilling pg 136 except tha...

Page 146: ...ecified depth and is then pulled out at a rate 1 6 times the rate of insertion 60 faster A tapping head with a reversing mechanism is required when using a G84 code The use of the G84 code is shown in...

Page 147: ...position after canned cycle complete Z 5 Drill to depth of 0 5 inches R0 Retract to Z0 after canned cycle complete F2 Feed rate of 2 inches per minute Example Motion The tool path generated by the ex...

Page 148: ...INT AFTER DWELL OF FIVE SECONDS G86 Straight drilling stop spindle rotation before retraction G98 Rapid move to initial tool position after canned cycle complete Z 5 Drill to depth of 0 5 inches R0 Re...

Page 149: ...NCEL CANNED CYCLE M2 END PROGRAM Code Explanation G89G98Z 5R0P5F2 BORE TO DEPTH OF 5 RAPID TO INITIAL POINT FROM POINT R G89 Boring cycle with dwell G98 Rapid move to initial tool position after canne...

Page 150: ...in the program Optional O The O code replaces the N code on the first line of a subprogram The general program flow when using a subprogram is illustrated in this table Subprogram Flow No Description...

Page 151: ...5 FIRST MOVE FEED 5 Y1 SECOND MOVE X 1 THIRD MOVE Y 1 FOURTH MOVE G90 G0 Z 1 RAPID ABOVE WORKPIECE G91 G00 X1 5 RAPID TO START OF NEXT SQUARE M99 RETURN FROM SUBPROGRAM Note Only selected lines are ex...

Page 152: ...code using multiple tools There are six basic steps in setting up the milling center for multiple tool operation Procedure Outline Multiple Tool Programming No Description Section Page 1 In the contr...

Page 153: ...he Tools 1 Click Tools Setup Library to access the Setup Tool Library 2 Click a tool in the left panel to select it and enter the relevant settings in the fields on the right 3 Click OK to save change...

Page 154: ...fset The T code can be located anywhere within the block of NC code but is normally placed after any of the G codes Use the M06 code with a T code for multiple tool operations If you do not use an M06...

Page 155: ...02 into the spindle and use its offset 10 4 ESTABLISHING THE REFERENCE TOOL When using multiple tools a reference tool normally Tool 01 is set to zero for the X Y and Z axes This establishes a refere...

Page 156: ...by step until it touches the reference point 8 Click Setup Set Position the Main Menu The Set Position window opens 9 Set X Y and Z to 0 10 Click OK 0 Tool 1 is now established as the reference tool...

Page 157: ...ol list and click Select Tool 4 If an ATC is fitted the ProMill will now automatically replace the current tool in the spindle and load tool 2 If working without an ATC load tool 2 into the spindle ma...

Page 158: ...Multiple Tool Programming 10 5 Setting Tool Offsets 151 8 Select Tool 02 from the list at the left 9 Click Use Current Z The offset value is automatically filled with the position value found in step...

Page 159: ...milling center in case of a tool crash Follow this procedure to perform a dry run on a mutli tool program Procedure Testing a multi tool program 1 If using an ATC ensure that all tools are in their r...

Page 160: ...offsets for the other tools 10 7 9 156 Test the program without a workpiece in place 10 7 10 157 Mount the workpiece 10 7 11 157 Run the program 10 7 12 157 10 7 1 Reviewing Safety Procedures Like any...

Page 161: ...specifying which tool is present in each of the changer s stations For instructions on configuring the tool changer see 10 2 Configuring the ATC pg 10 2 Configure the tool ATC as detailed in the table...

Page 162: ...ool Position X 0 Y 0 Z 0 Stock Dimensions X 3 0 Y 2 0 Z 1 5 Origin X 0 Y 0 Z 0 10 7 7 Verifying the Program Tool path verification allows you to check for programming errors before actually running th...

Page 163: ...e 10 4 Establishing the Reference Tool pg 148 Set the reference point on the face at the front left corner of the workpiece the end of the stock farthest from the chuck and at the edge of the stock Yo...

Page 164: ...forming a dry run see 10 6 Testing the Multi tool Program pg 152 10 7 11 Mount the Workpiece Once you have performed a successful dry run prepare for actual milling by mounting the workpiece For instr...

Page 165: ...ts must be explained Section Contents Understanding Coordinate Systems Section Name Page 11 1 1 X Y and Z Axes 158 11 1 2 Machine Home Position 159 11 1 3 The Work Coordinates 159 11 1 4 Multiple Coor...

Page 166: ...ine Home Position Location Axis Location X Near the maximum positive position Y Near the maximum positive position Z Near the maximum positive position When moving to its home position the tool first...

Page 167: ...top left corner and define the coordinates as 0 0 0 11 1 4 Multiple Coordinate Systems For more advanced operations such as milling multiple parts on the same piece of stock set up multiple coordinate...

Page 168: ...em and run the subprogram that contains the NC code for the complex shape 0 11 2 SETTING SPINDLE SPEEDS Spindle speed refers to the rotational speed at which the spindle rotates the tool around its ve...

Page 169: ...rkpiece This is accomplished by advancing the cutting tool into the workpiece by an appropriate amount depth of cut The depth of cut is the vertical distance between the surface of the workpiece and t...

Page 170: ...ter use as some petroleum based fluids may damage the electrical wiring insulation and other components Short runs of parts on Delrin or aluminium such as would be performed in a school or college lab...

Page 171: ...sic mill operations and creates a cut with 90 degree angle edges 11 5 2 Ball Mills A ball mill is an end mill with a ball tip The rounded tip leaves a smoother finish on a contoured surface than other...

Page 172: ...oved from the workpiece in chunks leaving an imperfect surface scattered with ridges This is acceptable for roughing operations as these imperfections will be removed during finishing For finishing op...

Page 173: ...e driver or other control entity This section provides instructions on how to integrate the ProMill 8000 with various other components Section Contents Integration Instructions Section Name Page 12 1...

Page 174: ...side of the machine Wiring guidelines are presented in the diagram and table below From Shield Opener Assembly To Machine I O Panel 24V A 24 V 24V B 24 V OPEN OUT CLOSE COM 12 1 2 Integrating with an...

Page 175: ...is mounted on the spindle motor access door on the right side of the machine as shown This system regulates the air sent to the pneumatic vise forcing it to clamp onto the work piece The dual axis vi...

Page 176: ...ol device is wired via a relay to separate the electrical circuits of the CNC machine and the external controller Follow the procedure below to set up the wiring for output activation Procedure Wiring...

Page 177: ...in the specified direction is registered at the specified input This is summarized in the table below Info Table G Code Programming for Input Signals Code Function If the signal is initially Program...

Page 178: ...and the CNC as the slave The machine is waiting in standby by running a program that monitors the communication channel either a RS232 port or a file The robot uses program code and script to send com...

Page 179: ...leName fs deletefile TempFileName End Sub Sub PLACE WriteFile PLACE NC End Sub Sub OVICE WriteFile OVICE NC End Sub Sub CVICE WriteFile CVICE NC End Sub Sub ODOOR WriteFile ODOOR NC End Sub Sub CDOOR...

Page 180: ...KE SURE OUTPUT IS SEEN M20 CHAIN TO PROGRAM START NC Step 5 The robot monitors the CNC s input signal The robot sends a command to the CNC to open the door if the machine signals that it is idle If In...

Page 181: ...E NC Sample M26 H11 USER OUT 1 OFF M26 H4 CLOSE VICE G04F1 MAKE SURE OUTPUT IS SEEN M20 CHAIN TO PROGRAM START NC Step 9 The robot monitors the CNC s input signal Once the machine signals that it is i...

Page 182: ...task CDOOR NC Sample M26 H11 USER OUT 1 OFF M26 H102 CLOSE DOOR G04F2 MAKE SURE OUTPUT IS SEEN G25 H131 Wait door closed M20 CHAIN TO PROGRAM START NC Step 13 Depending on the system environment the...

Page 183: ...ure If Input 1 Off Call Subroutine PM8000 NOT READY Call Subroutine PLACE VICE IN LOADING POSITION Remark Set Subroutine PLACE VICE IN LOADING POSITION Call Subroutine SCRIPT PLACE Call Subroutine SYN...

Page 184: ...r It monitors the CNC s input signal and opens the clamping device if the machine signals that it is idle Go to Position SCRIPT P3 Speed 50 Go to Position SCRIPT P2 Speed 50 Open Gripper Go Linear to...

Page 185: ...he CNC control via the script file and the machine executes the task CVICE NC Sample M26 H11 USER OUT 1 OFF M25 H4 CLOSE VICE G04F1 MAKE SURE OUTPUT IS SEEN M20 CHAIN TO PROGRAM START NC Step 22 The r...

Page 186: ...n FMS Section Contents Sample Robotic CNC Integration Programs Section Name Page 12 4 1 Sample NC Programs 179 12 4 2 Sample Device Driver Script File 181 12 4 3 Sample SCORBASE Programs 182 12 4 4 Sa...

Page 187: ...START NC OVICE NC M26 H11 USER OUT 1 OFF M26 H4 CLOSE VICE G04F1 MAKE SURE OUTPUT IS SEEN M20 CHAIN TO PROGRAM START NC CVICE NC M26 H11 USER OUT 1 OFF M25 H4 CLOSE VICE G04F1 MAKE SURE OUTPUT IS SEEN...

Page 188: ...elow is a sample device driver script file for use in OpenCIM or FMS REQUEST ACTION RETURN OPERATE0 DRAW PM8000 OPERATE sendmsg 2581 DRAW OPERATING MSWINDOWS cscript O project_name WS3 MILL CHAIN VBS...

Page 189: ...3 101 Set Variable TASK_ID 300014 Set Variable PART_ID 0 Set Variable SOURCE_DEVICE_ID 31 Set Variable SOURCE_DEVICE_INDEX 1 Set Variable TARGET_DEVICE_ID 1 Set Variable TARGET_DEVICE_INDEX 3 Set Vari...

Page 190: ...Subroutine PUT001 Print to Screen PUT TEMPLATE ON CONVEYOR CNV1 Call Subroutine SCRIPT PUT_TO_CNV1 Print to Screen P1 P2 P3 PB1 SCRIPT P1 SCRIPT P2 SCRIPT P3 SCRIPT PB1 Go to Position SCRIPT P3 Fast...

Page 191: ...rom Subroutine Remark Set Subroutine GET032 Print to Screen GET FROM MILL PM8000 Call Subroutine SCRIPT GET_FROM_MILL1 Print to Screen P1 P2 P3 P4 PB1 SCRIPT P1 SCRIPT P2 SCRIPT P3 SCRIPT P4 SCRIPT PB...

Page 192: ...CRIPT P3 Speed 50 Go to Position SCRIPT P2 Speed 50 Go Linear to Position SCRIPT P1 Speed 30 Open Gripper Go Linear to Position SCRIPT P2 Speed 30 If Input 1 Off Call Subroutine PM8000 NOT READY Call...

Page 193: ...ition SCRIPT P2 Speed 50 Open Gripper Go Linear to Position SCRIPT P1 Speed 30 Close Gripper Go Linear to Position SCRIPT P2 Speed 50 Go to Position SCRIPT P3 Speed 50 Send Message Finish to MANAGER I...

Page 194: ...Interrupt 1 Return from Subroutine Remark Set Subroutine PM8000_CYCLE_FINISHED Print to Screen PM8000 is ready Disable Input Interrupt 1 Print to Screen Send message ENDMILL to Dev 32 Send Message END...

Page 195: ...Speed 50 Close Gripper Return from Subroutine Remark 12 4 4 Sample VB Script File CHAINL VBS File CHAIN VBS Date 03 10 2013 Set objArgs WScript Arguments NameofFile objArgs 0 WScript Echo NameofFile...

Page 196: ...Name FileName fs deletefile TempFileName End Sub Sub CLEAR WriteFile CLEAR NC End Sub Sub OVICE WriteFile OVICE NC End Sub Sub CVICE WriteFile CVICE NC End Sub Sub ODOOR WriteFile ODOOR NC End Sub Sub...

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