Programming Manual

For all Doosan Machining Centers Using Fanuc Controls

Phil Misseldine 2007

Forward
While similar in appearance your CNC Machining Center operates somewhat differently from your conventional mill. Although they may share the same work envelope and number of axis the CNC does not have the array of knobs, levers or handles associated with the manual machine. In place of these are motors that move the X, Y, and Z-axis. The axis motors receive commands from the control, which is user programmed with a series of instructions. It is these instructions which determine the shape of the part to be machined.

Notice of Disclaimer
This manual is intended not to replace but to supplement the control manufactures original manual. The control manufactures manual will be the final say in any discrepancy that may evolve.

Introduction to Programming
Programming of your Doosan Machining Center involves the sequential study of the operations required to produce a component, using established engineering methods.

S tudy P art D raw ing

Finished P art

M ethodize the P art

P rogram the Part

S et up M achine

M achine P art

Example
S4000 M03 Set spindle speed to 4000 (S4000) and turn on spindle clockwise (M03). A number of Words can be programmed on the same line. Once the line is complete this forms a Block of information.

Example of a Block
N40 G1 X20.0 Y-8.0 F80. It contains the Words: N40, G1, X20.0, Y-8.0, F80. The Addresses used are N, G, X, Y, and F, and the values are 40, 1, 20.0, -8.0 and 80.

Most Commonly Used G-Codes

G-Code
G00 G01 G02 G03 G04 G05 G08 G09 G10 G11 G17 G18 G19 G20 G21 G28 G30 G40 G41 G42 G43 G49 G54 G55 G56 G57 G58 G59 G65 G73 G80 G81 G83 G84 G86 G90 G91 G92 G94 G95 G98 G99

Function
Rapid Positioning Feedrate Positioning Arc Clockwise Arc counter Clockwise Dwell High Speed Machining Look Ahead Control Exact Stop Data Setting Data Setting Cancel X and Y Plane Selection Z and X Plane Selection Y and Z Plane Selection Input in Inch Input in Metric Return to Reference Position Return to 2nd Reference Position Cutter Compensation Cancel Cutter Compensation Left Cutter Compensation Right Tool Length Compensation Tool Length Compensation Cancel Work piece Coordinate System 1 Work piece Coordinate System 2 Work piece Coordinate System 3 Work piece Coordinate System 4 Work piece Coordinate System 5 Work piece Coordinate System 6 Macro Call High Speed Peck Drilling Canned Cycle Cancel Drilling Cycle Peck Drilling Cycle Tapping Cycle Boring Cycle Absolute Command Incremental Command Setting Work Coordinate System Feed Per Minute Feed Per Rotation Return to Initial Point in Canned Cycle Return to R Point in Canned Cycle Standard Standard Standard Standard Standard Optional Optional Standard Optional Optional Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard

For a complete G-code list please refer to your Fanuc manual.

4

Most Commonly Used M-Codes

M Code Function M00 Program Stop M01 Optional Stop M02 Program End M03 Spindle Clockwise Rotation M04 Spindle Anti - Clockwise Rotation M05 Spindle Stop M06 Tool Change M07 Thru-Spindle Coolant On M08 Flood Coolant On M09 Coolant Off (all coolant) M10 Table (Pallet) Clamp M11 Table (Pallet) Unclamp M12 Shower Coolant On M14 Spindle Air Blow On M15 Spindle Air Blow Off M16 Air Blast for Tool Setter M18 Air Blast off M19 Spindle Orientation M29 Rigid Tapping Mode (Fanuc only) M30 Program End & Rewind M50 Auto Door Open M51 Auto Door Close M54 Parts Count M60 Pallet Change M61 Load Pallet 1 M62 Load Pallet 2 M66 ATC & APC Change with one command M76 Fixture 1 Clamp M77 Fixture 1 Unclamp M84 G01 Possible with spindle stopped M86 Fixture 2 Clamp M87 Fixture 2 Unclamp M98 Sub-Program Call M99 Sub-Program End * Not standard on all machining centers Vertical Standard Standard Standard Standard Standard Standard Standard Standard* Standard Standard N/A N/A Optional Standard Standard Optional Optional Standard Standard Standard Optional Optional Standard Standard Standard Standard Standard Optional Optional Standard Optional Optional Standard Standard Horizontal Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Standard Optional Standard Standard Optional Optional Standard Standard Standard Optional Optional Standard Standard Standard Standard Standard Optional Optional Standard Optional Optional Standard Standard

For a complete M-code list please refer to your Doosan Manual.

5

Control Panel

R E S E T

O( N X
U , # [

) V A = ]

GE P C Z
W

7 4 1 _ /

8 5 2 0
E O B

9 6 3

A L T E R

P O W E R O N
H E L P

Y J S D

IN S E R T

I M

K@ R T H
* &

D E L E T E

L B
S P

S H IF T

O F F

C A N

IN P U T

P O S P A G E P A G E

P R O G

O F F S E T S E T T IN G

C U S T O M

S Y S T E M

M E S S A G E

G R A P H

M O D E
T A P E M E M O R Y M D I R E F .R T N . JO G

F E E DO P E R A T IO N
80 60
25
R E F .P O IN T

S P IN D L E
100 120 130 140 180

W O R K L IG H T
O N O F F A L A R M
6 0 8 0

5 0 10 0

E D IT H A N D L E

F O

40 20

E M E R G E N C YS T O P

M O D ES E L E C T
X

R A P IDO V E R ID E

4T H

0 F E E D R A T EO V E R ID E

4 0 30

50

2 0 90 10

M 0 2/M 3 0 LU B . M A C H IN E

M A C H IN ER E A D Y E M E R G E N C YR E L E A S E

A X ISS E L E C T
F E E DH O L D C Y C L ES T A R T

R A P ID

S P IN D L EO V E R ID E

10 0

R E S E T

F U N C T IO N
O N O F F
P R O G R A MR E S T A R T

F L O O D

M A N U A L A U T O O F F C O O L A N T

T H R O U G H

S IN G L EB L O C K O P IO N A LB L O C KS K IP D P T IO N A LS T O P O R YR U N

C O N V E Y O R

M A C H IN EL O C K

P R O G R A MP R O T E C T

C W

S T O P

C C W

Doosan Machining Centers uses the following Fanuc Controls:

0i MB 21i MB 18i MB 16i MB

All screen pictures in this manual are from the 18i control and may differ from the control you are running.

Axis Movement

Every Vertical Machining Center has three axes: X - side to side Y - forwards and backwards Z - up and down

All Horizontal Machining Centers have four axes: X - side to side Y - up and down Z - forwards and backwards B - rotary

Manual Pulse Generator

4 T H

X 1

X 1 0

X 1 0 0

_
0 9 0 8 0 1 0

+
2 0

7 0 6 0 5 0 4 0

3 0

The Manual Pulse Generator (MPG) or Hand Wheel is used during the setup of the machine. This is separate from the machine control and gives better control of all axis during setup.

TOOL LENGTH OFFSET

When a cutting tool is inserted into its holder, the cutting edge is located at an imprecise distance from the gauge line of the holder. By specifying G43 and the corresponding offset value (H) it is possible to compensate the difference without changing the part program. This is known as the Tool Offset Value and is unique to the tool in the spindle.

Z Axis Home Position

Tool Length Offset Distance

Workpiece

Tool Length Setting Method

Using a combination of the jog buttons and MPG, bring the tool down to the predetermined "Z" point.

Work piece

Operators choice of 'Z' zero position. (This example uses the top of the work piece).

Press the function key

OFFSET SETTING

and then the [OFFSET] soft key to display the following screen.

Cursor down to Tool Number to be set. Key in value displayed in Actual Position (Relative) and press INPUT.
10

Tool Offset Memory 'C' (Optional)

Tool Offset Memory 'C' allows you to use the same number for Length (H) and Diameter (D) offsets.

Press the function key

OFFSET SETTING

and then the [OFFSET] soft key to display the following screen.

Cursor down to tool number to be set. Press 'Z' and then the 'INP.C' soft key. Position value is automatically transferred in to the offset.

If using height and cutter compensation for the same tool the program should look like this N15 G43 Z.10 H1 N20 G41 X-5.0 D1 You also have the ability to adjust the tool length and diameter in the wear column.

11

Work Coordinates
Every CNC machine has a reference or machine zero. This is a position that is constant to the machine. When a machine is turned on or powered up by the operator it must first be referenced. When the machine reaches its limit switches the control registers this location as home. Using the home position as a reference you can now tell the control where the work piece is located on the machine table.

'X' Zero point

Machine Home Position (X, Y, Z Ref. Point)

'Y' Zero point

W ork Piece

Machine Table

12

Work Coordinate System Setting Method

To set the work piece co-ordinates the user has the choice of six co-ordinate systems to choose from G54 to G59.

Press function key

OFFSET SETTING

and then the [WORK] soft key to display the following page.

Method
Using an edge finder or indicator locate the part datum position. Without moving go to the work offset screen and highlight desired offset. Press hard key X, hard key 0 soft key [measure] hard key Y, hard key 0 soft key [measure] (Position value is automatically transferred in to Offset).

13

Work Coordinate System G54 - G59 and G54.1 P1 -P300

The desired Work Coordinate number should always be called at the start of every tool. Example. N4 (.75 DIA. ENDMILL ) N5 G0 G54 G90 X-2.25 Y.625 S8000 M3 N6 G43 Z.1 H1 N7 G1 Z-1. F25

Work Coordinate System Addition

This option expands the Work Coordinate System giving the user up to 300 sets of work offsets to chose from.

Work Coordinate System Addition's are called in the following way. Example. N4 (.75 DIA. ENDMILL ) N5 G0 G54.1 P1 G90 X-2.25 Y.625 S8000 M3 N6 G43 Z.1 H1 N7 G1 Z-1. F25
14

PROGRAMMING
Linear Interpolation (G00/G01)

GOO Rapid Traverse path (Axis will take the shortest path at 45 degrees)

Y X
G00 Rapid Path

P2

G01 Feedrate Path

GO1 Feedrate path ( Axis will travel in a staight line)

P1

All axis of the machine tool will move in linear at either RAPID or FEEDRATE traverse rates. Any movement preceded by G00 will occur at RAPID traverse G00 X4.0 Y-3.0 Any movement preceded by G01 will occur at FEEDRATE. G01 X4.00 Y-3.00 F100.

These commands are MODAL and will stay in effect until changed.

15

Co-Ordinate Programming (G90/G91)

Absolute co-ordinate programming (G90)

In absolute programming all dimensioning is taken from a fixed point.

Incremental co-ordinate programming (G91)

In incremental programming dimensioning is taken from the last position programmed and NOT from a fixed point.

16

Absolute and Incremental Programming Example

Datum

Y+

X+

Find the absolute and Incremental co-ordinates of the points listed.

ABSOLUTE (G90) A X __________ _ Y__ B X __________ _ Y__ C X __________ _ Y__ D X __________ _ Y__ E X __________ _ Y__ F X __________ _ Y__

INCREMENTAL (G91) A X__________Y___________ B X__________Y___________ C X__________Y___________ D X__________Y___________ E X__________Y___________ F X__________Y___________

Answers are on page 100.

17

Plane Selection (G17, G18, G19)

Before an arc can be machined the correct plane must be selected.
Y +

G17
X +
When generating an arc in the 'X' and 'Z' axis G17must be selected.

G 0 3

G 0 2

V iewfro mto po fm ach in e

G18
When generating an arc in the 'X' and 'Y' axis G18 must be selected.

Z+

G03
G19
When generating an arc in the 'Y' and 'Z' axis G19 must be selected.

G02

View fromfront of machine

X+

Plane selection is MODAL and will stay effective until another plane is selected.
Z +

Y +

G 0 3

G 0 2

V ie wfro mle ft sid eo fm a c h in e

18

Circular Interpolation (G02, G03)

There are two directions in which you can produce an arc G02 Clockwise and G03 Counter Clockwise. To machine an arc the machine tool requires the following information. Tool finish position in 'X' Tool finish position in 'Y' Arc offset in 'X' Arc offset in 'Y'
Arc offset in 'X' is represented by 'I'. Arc offset in 'Y' is represented by 'J'. Arc offset in 'Z' is represented by 'K'.

'I' is the Incremental value parallel to the 'X' axis. 'J' is the Incremental value parallel to the 'Y' axis. 'K' is the Incremental value parallel to the 'Z' axis.

G02 Circular Interpolation Clockwise.

Example G02 X1.0 Y0. I0.0 J-1.0 G02 (Clockwise movement) X 1.0 (Tool finish position in 'X') Y 0.0 (Tool finish position in 'Y') I 0.0 (Arc offset in 'X') J-1.0 (Arc offset in 'Y')

Datum
0 000 R1.

G02

J-1.00

G03

I-1.00

Datum

Example G03 X1.0 Y0. I-1.0 J0.0 G03 (Counter Clockwise movement) X 1.0 (Tool finish position in 'X') Y 0.0 (Tool finish position in 'Y') I-1.0 (Arc offset in 'X') J 0.0 (Arc offset in 'Y')

G03 Circular Interpolation Counter Clockwise

19

Circular Interpolation G02

C utting direction G 02

N 6
A rc offset parallel to the Xaxis. I 1.5

N 7
X&YZ E R O

R .75

S tart N 3 F in ish N 10

R 1.5

N 8
A rc offset parallel to the Yaxis. J 1.5

N 9

A rc offset parallel to the Yaxis. J -.75

O1066 (Program number) N1G17G40G80G90 (Safe start) N2T1M6 (Calls T1 and changes tool) N3G54G90G0X-1.5Y0.S718M3 (Tool moves to start position) N4G43Z.1H1 (Picks up tool length value) N5G1Z-.1F20. (Feeds to Z-depth) N6G2X0.Y1.5I1.5F40. (Clock-wise move) N7G1X3.75Y.75 (Linear move) N8G2Y-.75J-.75 (Clock-wise move) N9G1X0.Y-1.5 (Linear move) N10G2X-1.5Y0.J1.5 (Clock-wise move) N11G0Z.1 (Lifts up in Z) N12G91G28Z0Y0. (Returns Z and Y to home position) N13G90 (Back into absolute) N14M30 (Return to beginning of program)

20

Circular Interpolation G03

A rc offset p arallel to the Yaxis. J- 1.5

N 9

N 8
R 1 .5 S ta rt N 3 F in ish N 1 0
A rc offset p arallel to the Xaxis. I1 .5 C u ttin gd irectio n G 0 3

A rc offset p arallel to the Yaxis. J .7 5

X&YZ E R O

N 7

R .7 5

N 6

O1066 (Program number) N1G17G40G80G90 (Safe start) N2T1M6 (Calls T1 and changes tool) N3G54G90G0X-1.5Y0.S718M3 (Tool moves to start position) N4G43Z.1H1 (Picks up tool length value) N5G1Z-.1F20. (Feeds to Z-depth) N6G3X0.Y-1.5I1.5F40. (Counter Clock-wise move) N7G1X3.75Y.75 (Linear move) N8G3Y-.75J.75 (Counter Clock-wise move) N9G1X0.Y-1.5 (Linear move) N10G3X-1.5Y0.J-1.5 (Counter Clock-wise move) N11G0Z.1 (Lifts up in Z) N12G91G28Z0Y0. (Returns Z and Y to home position) N13G90 (Back into absolute) N14M30 (Return to beginning of program)

21

Radius Command (R)

As an alternative to using the 'I' and 'J' commands it is possible to program an arc using the 'R' command.

8 7

1 2

6 5 4

This example machines a radius on each corner. The datum is the top left-hand corner of the part. The tool diameter is .500. Position No. G1X3.5Y.25 G2X4.25Y-.5R.75 G1Y-3.5 G2X3.5Y-4.25R.75 G1X.5 G2X-.25Y-3.5R.75 G1Y-.5 G2X.5Y.25R.75 1 2 3 4 5 6 7 8

The R+ command can only be used for arcs up to 180 degrees. The R- command can only be used for arcs greater than 180 degrees.

22

Cutter Compensation (G41/G42)

Cutter compensation allows a program to be written without considering the size of the cutter.
The three G-codes used to control cutter compensation are G41 - Cutter compensation Left G42 - Cutter compensation Right G40 - Cutter compensation Cancel

If your control has cutter compensation 'B' then different offset numbers have to applied to 'H' and 'D' values. Your program should look like this G0 G43 Z1. H1 G1 G41 Y0. D11 F50.

If your control has cutter compensation 'C' then the same offset numbers can be applied to 'H' and 'D' values. Your program should look like this G0 G43 Z1. H1 G1 G41 Y0. D1 F50.

23

Cutter Compensation (G41)

D irection of travel A pproach part at 90applying cutter com p G 41

E ndm ill is on the left hand side of the w ork piece

G41 - Cutter compensation to the Left of the work piece.

Always apply cutter compensation at 90 degrees to the work piece. The program for applying cutter compensation should look like this. G1G41Y0 D1 F25. or if using cutter compensation 'B' it should look like this G1G41Y0 D11F25. When turning of cutter compensation the program should be as follows. G1G40Y.5. G41 and G42 are Modal commands and will stay active until canceled by G40.

24

Cutter Compensation (G42)

A pproach part at 90applying cutter com p G 42

D irection of travel

E ndm ill is on the right hand side of the w ork piece

G42 - Cutter compensation to the Right of the work piece.

Always apply cutter compensation at 90 degrees to the work piece. The program for applying cutter compensation should look like this. G1G42Y0D1F25. or if using cutter compensation 'B' it should look like this G1G42Y0 D11F25. When turning of cutter compensation the program should be as follows. G1G40Y.5. G41 and G42 are Modal commands and will stay active until canceled by G40.

25

Canned (Fixed) Cycles (G73, G81, G83, G86)

Canned cycles are designed to make it easier for the programmer to create programs. With the use of a single 'G' function the canned cycle can be performed in a single block. This makes programming quicker and also saves on program memory.

The formats for the most commonly used canned cycles are High Speed Peck Drilling Cycle G73 X _____ Y_____ Z_____ Q_____ R_____ F_____ Drilling G81 X _____ Y_____ Z_____ R_____ F_____ Peck Drilling G83 X_____ Y_____ Z_____ Q_____ R_____ F_____ Tapping G84 X_____ Y_____ Z_____ R_____ F_____ Boring G86 X_____ Y_____ Z_____ R_____ F_____ Legend X = X Co-ordinate Position Z = Finale depth of Hole Q = Depth of Peck Y = Y Co-ordinate Position R = Rapid Plane Depth F = Feedrate

G80 cancels all Canned Cycles For additional canned cycles please consult your Fanuc Operators Manual
26

Initial and Rapid Planes (G98/G99)

When using canned cycles the controller provides the ability to return to one of two reference planes.

G98
Initial Point Level

G99

R Point Level

Point Z

Point Z

G98 - Returns the tool to the INITIAL plane. G99 - Returns the tool to the RAPID plane.

27

High Speed Peck Drilling (G73)

Example G98 G73 X0.0 Y0.0 Z-1.25 Q.250 R.250 F20.

Initial Point (G 43 Z1. H 01) Tool w ill stop1.0"above part.

W henG 98 is used'Z' will returnto the Initial point.

RPoint(R.25) 'Z' - Zero is topof part. 1st Peck 2ndPeck 3rdPeck 4th Peck Final H ole Depth(Z-1.25)

W henG 99 is used'Z' will returnto the Rpoint. 0.050"retractedafter eachpeck.

Unlike G83 (peck drilling) G73 does not rapid to the R plane after each peck.

28

Drilling (G81)
Example G98 G81 X0.0 Y0.0 Z-1.25 R.25 F20.

When G98 is used 'Z' will return to the Initial point. When G99 is used 'Z' will return to the R point.

Initial Point (G43 Z1. H01) Tool will stop 1.0" above part. R Point(R.25) 'Z' - Zero is top of part.

Final Hole Depth (Z-1.25)

29

Peck Drilling (G83)

Example G98 G83 X0.0 Y0.0 Z-1.25 Q.25 R.25 F20.

Initial Point (G 43 Z1. H 01) Tool w ill stop1.0"above part.

W henG 98 is used'Z' w ill return to the Initial point.

RPoint(R .25) 'Z' - Zero is topof part. 1st Peck. 2ndPeck. 3rdPeck. 4thPeck. Final H ole D epth(Z-1.25)

W henG 99 is used'Z' w ill returnto the Rpoint.

After each peck 'Z' will rapid to the 'R' plane and then back to within 0.1" of where it finished cutting.

30

Tapping (G84)
Example G98 G84 X0.0 Y0.0 Z-1.25 R.25 F10.

Initial Point (G43 Z1. H01) Tool will stop 1.0" above part.

W hen G98 is used 'Z' will return to the Initial point. W hen G99 is used 'Z' will return to the R point.

R Point(R.25) 'Z' - Zero is top of part.

Final Hole Depth (Z-1.50)

You must use a floating tap holder when using G84.

For Rigid Tapping example please see page 33.

31

Fine Boring (G76)

Example G98 G76 X0.0 Y0.0 Z-1.5 R.25 Q.005 F10.

Initial Point (G43 Z1. H01) Tool will stop 1.0" above part.

W hen G98 is used 'Z' will return to the Initial point. W hen G99 is used 'Z' will return to the R point.

R Point(R.25) 'Z' - Zero is top of part.

Final Hole Depth (Z-1.50) Spindle stops. Moves .005" away frompart. Rapids out.
Please consult your machine operation manual for correct orientation when using a single point-boring tool. 'Q' represents the amount tool will move away from machined face before lifting out of hole.

Set the direction and axis in which you want to move away in using parameter 5101 bit 4 and 5
32

Rigid Tapping (G84)

Initial Point (G43 Z1. H01) Tool will stop 1.0" above part.

W hen G98 is used 'Z' will return to the Initial point. W hen G99 is used 'Z' will return to the R point.

R Point(R.25) 'Z' - Zero is top of part.

Final Hole Depth (Z-1.50)

Example (1/2-13 Tap) G0 G90 G54 X0 Y0 G43 H01 Z.25 M8 G95 S1000 (G95 feed per rotation) M29 (Rigid tapping mode) G98 G84 Z-1.5 R.25 F.0769 (Tapping cycle with 'F' = pitch of thread) G80 M9 G94 (Feed per minute) G91 G28 Z0 M5 G90 M30

Important thing to remember when Rigid Tapping the feedrate must be the pitch of the thread.

When rigid tapping it is possible to retract the tap up to 200% faster than the programmed feedrate. This is achieved by changing the following parameters: Parameter 5200 bit 4 (DOV) to 1 Parameter 5211 enter amount 1% - 200% The only limitation is that once the parameter is changed it will be the same for every tap.

33

Rigid Tapping Using an Alternate Axis

It is possible to rigid tap using an axis other than Z. This is often used when the use of a right angled head is necessary. Parameters. Before starting set the following parameter. 5101 bit 0 to 1 (FXY) If an axis other than Z is required to apply the 'H' value (Tool Length Offset G43) then set the following parameter. 5001.1 bit 1 to 1 (TLB)

Make sure that the program contains the correct reference plane selection. G18 X and Z G19 Y and Z

The following example will tap 4 holes using the Y axis

N10 G0 G19 G54 G90 X0. X0. N20 G43 Y.5 H01 N30 G95 S1000 N40 M29 N50 G84 G98 Y-1. R.5 F.0769 N60 X-3.25 Z-.75 N70 X-.75 N80 Z-3.25 N90 G80 N100 G94

When finished remember to return parameters back to their original settings

34

Repetition of Canned Cycles (K)

By placing an 'K' on the same line as the canned cycle command it is possible to repeat the cycle.

Example G0 G90 X0 Y0 (1st hole position) G91 G98 G81 X0.50 Y0.0 Z-1.R.25 K6 F20. G90

Example 2 G0 G90 X0 Y0 (1st hole position) G91 G98 G81 X0.50 Y0.50 Z-1.R.25 K3 F20. G90

The 'K' command should only be used with G91(incremental). If G90 (absolute) were to be used only the 1st hole would be machined.

35

Use of 'K0' in Canned Cycles

Placing a 'K0' at the end of a canned cycle will prevent the cycle from being executed at that position. This allows the operator to have all the hole positions in a subprogram and define canned cycles in the main program.

T01 M6 (SPOT DRIL) G90 G54 X0. Y0. S8000 M03 G43 H01 Z1. M8 G98 G81 Z-.25 R.1 F5. K0 - Peck cycle M98 P1000 (call sub program) G0 G80 Z1. T02 M6 (DRILL) G90 G54 X0. Y0. S6500 M03 G43 H02 Z1. M8 G98 G83 Z-1.0 R.1Q.1F10. K0 - Drill cycle M98 P1000 (call sub program) G0 G80 Z1. T03 M6 ( TAP) G90 G54 X0. Y0. G43 H03 Z1. M8 G95 S1000 M29 G98 G84 Z-1.2 R.3 F.05 K0 - Tap cycle M98 P1000 (call sub program) G94 G0 G80 Z1. G91 G28 Z0. Y0 G90 M30

O1000(HOLE SUB) X0.0Y0.0 X1.0Y0.0 X2.0Y-1.0 X2.0Y-2.0 M99

O1000(HOLE SUB) X0.0Y0.0 X1.0Y0.0 X2.0Y-1.0 X2.0Y-2.0 M99

O1000(HOLE SUB) X0.0Y0.0 X1.0Y0.0 X2.0Y-1.0 X2.0Y-2.0 M99

36

Thread Milling (Helical Interpolation)

Helical Interpolation provides a method of thread cutting without having to use a machine tap.

O n e re v o lu tio nm u s t e q u a lp itc ho f th re a d

P itch

A lw a y s fe e do n u s in gc u tte r c o m p e n s a s io n

37

Thread Milling (Helical Interpolation)

Example

N10 G 0G 90 G 54 X 0. Y 0. S1000 M 3 The m achine m oves to the part datumusing the G54 w ork coordinate and starts the spindle at 1000 r.p.m .

N20 G 43 Z.250 H 1M 8 The m achine applies Tool Length Offset and turns on the coolant. N40 G 41 X-.75 D 31 F20. The m achine m oves to the start position applying cutter com pensation at 20 i.p.m . (U sing cutter com pensation allow s for easy adjustm ent of the thread).

N30 G 01 Z-.500 F50. The m achine m oves to the required Zdepth at 50 i.p.m .

N50 G 02 I-.750 Z-.6666 The m achine m oves 360 degrees and feeds in Z to finished depth of thread (.500 +.1666)

N60 G 0G 40 X0. The m achine m oves back to center of the hole at the sam e tim e canceling cutter com pensation.

N70 G 0G 91 G 28 Z0. The m achine m oves clear of the part to the Z hom e position.

This example machines a 11/2 - 6 thread .50" deep Pitch of thread is .1666

38

Manual Data Input (MDI)

In MDI mode you can create and run a program without having to store it in the controls memory.
M O D E
T A P E M E M O R Y M D I R E F .R T N . J O G

Select MDI using the Mode Select Switch.

E D IT H A N D L E

M O D ES E L E C T

Press the PROG hard key and the following screen will be displayed.

In this example the machine will rapid to the X and Y zero location using the G54 work offset. Then the spindle will start at 2000 rpm.

Enter the program manually using the key pad, include end of block (EOB) at the end of each line. Pressing the RESET key will clear the MDI screen.
39

Starting a Program
M O D E
T A P E M D I R E F .R T N . J O G

Select EDIT using the Mode Select switch.

M E M O R Y

E D IT H A N D L E

M O D ES E L E C T

Press the PROG hard key and the following screen will be displayed.

All programs must start with the letter 'O'

Manually key in the program number and then press the insert hard key. Before any more lines can be added you must enter an end of block. Example O1234 - INSERT - EOB - INSERT

40

Program Numbers
Technically the numbers O0000 through O9999 are available for creating program numbers. However some numbers are used by other functions and are best avoided when creating a program. O9000 through O9999. These numbers are used for Macro programs and for 'Tool change' and 'Pallet change' programs. It is possible to call these programs using a 'G' or 'M' code by setting parameters.

O9000 program numbers are protected. To unprotect them change parameter 3202 bit 4 (NE9) to 0.

O8000 through O8999 O8000 program numbers can be protected by changing parameter 3202 bit 0(NE8) to 1. These numbers are also used for Macro programs and can also be protected against accidental editing and deletion by setting a parameter.

O0001 through O7999 These numbers are generally used for 'G' code programs and can not be protected by parameters.

To prevent accidental editing or deletion of programs, turn program protect key to lock and remove the key.

P R O G R A MP R O T E C T

41

Editing a Program
The following is the procedure for Inserting, Altering and Deleting a command in a program which is registered in the controls memory.
M O D E
T A P E M D I R E F .R T N . J O G

Select EDIT using the Mode Select switch.

M E M O R Y

E D IT H A N D L E

M O D ES E L E C T

Press the PROG hard key and make sure that the program requiring editing is displayed.

Using the cursor keys highlight the command to be changed.

Once the command is highlighted it is possible to change it. If the command is no longer needed simply press the Delete key to erase it. If the value needs to be changed simply key in the new value and press Alter. If a command has to be added, highlight the command before the point were the new data is to be inserted, key in the new command and press Insert. Delete Example N20 G1 X3.265 Y-2.987 F30. Pressing the Delete key will remove Y-2.987 N20 G1 X3.265 F30. Alter Example N20 G1 X3.265 Y-2.987 F30. Key in new value (Y-2.950) Pressing the Alter key will change Y-2.987 to the new value N20 G1 X3.265 Y-2.950 F30.

Insert Example N20 G1 X3.265 Y-2.987 F30. Key in new value (Z-1.250) Pressing the Insert key will insert the new value after Y-2.987 N20 G1 X3.265 Y-2.987 Z-1.250 F30.

42

Extended Part Program Edit

Extended Part Program Edit is the name given to the copy, move and merge function. This allows the programmer to duplicate whole or parts of a program without having to rewrite the whole program.
M O D E

Select EDIT using the Mode Select switch.

T A P E M E M O R Y

M D I

R E F .R T N . J O G

E D IT H A N D L E

M O D ES E L E C T

Press the PROG hard key and make sure that the program you want to copy is displayed.
After displaying the program press soft key [(OPRT)] then the continuous menu key until the [EX-EDT] soft key appears. Pressing this key will display the COPY, MOVE and MERGE keys. If you want to copy the whole program. Press soft key COPY and then soft key ALL. Enter a new program number and press INPUT. Then press the [EXEC] key. Copy Example O1234 G90 G80 G40 T1 M6 G90 G0 G54 X0.0 Y0.0 S3500 M3 G43 Z.1 H1 M8 G98 G81 Z-1. R.1 F15. G80 M9 G91 G28 Z0 Y0 M30 Press COPY key Press ALL key Enter new program number (O2468) Press INPUT key Press EXEC key

O2468 G90 G80 G40 T1 M6 G90 G0 G54 X0.0 Y0.0 S3500 M3 G43 Z.1 H1 M8 G98 G81 Z-1. R.1 F15. G80 M9 G91 G28 Z0 Y0 M30

Always make a backup copy of your program before attempting to alter it. This way should an error occur while using COPY, MOVE or MERGE you will always have the original for backup.

43

Extended Part Program Edit (Move)

If you want to move part of the program. Press soft key [MOVE]. Then move the cursor to the start of the range you wish to move and press soft key [CRSR~]. Move the cursor to end of the range to be moved and press [~CRSE] or press [~BTTM] if you want to copy everything below the 1st cursor position. Enter a new program number and press INPUT. Then press the [EXEC] key. Press MOVE key Position 1st cursor [CRSR~] Position 2nd cursor [~CRSR] Enter new program number (O2468) Press INPUT key Press EXEC key

Move Example O1234 G90 G80 G40 T1 M6 (CRSR~) G90 G0 G54 X0.0 Y0.0 S3500 M3 G43 Z.1 H1 M8 G98 G81 Z-1. R.1 F15. G80 M9(~CRSR) G91 G28 Z0 Y0 M30

O2468 T1 M6 G90 G0 G54 X0.0 Y0.0 S3500 M3 G43 Z.1 H1 M8 G98 G81 Z-1. R.1 F15. G80 M9

OR
Press MOVE key Position 1st cursor [CRSR~] Position 2nd cursor [~BTTM] Enter new program number (O2468) Press INPUT key Press EXEC key

Move Example O1234 G90 G80 G40 T1 M6 [CRSR~] G90 G0 G54 X0.0 Y0.0 S3500 M3 G43 Z.1 H1 M8 G98 G81 Z-1. R.1 F15. G80 M9 G91 G28 Z0 Y0 M30 [~BTTM]

O2468 T1 M6 G90 G0 G54 X0.0 Y0.0 S3500 M3 G43 Z.1 H1 M8 G98 G81 Z-1. R.1 F15. G80 M9 G91 G28 Z0 Y0 M30

44

Extended Part Program Edit (Merge)

If you want to insert part of a program into another program. Press soft key [MERGE]. Then move the cursor to the position at which the new information is to be inserted. And press soft key [~CRSR] or press [~BTTM] if you want the new information to be inserted at the end of the program. Enter the number of the program to be inserted and press INPUT. Then press the [EXEC] key.

Merge Example. O1234 G90 G80 G40 T1 M6 G90 G0 G54 X0.0 Y0.0 S3500 M3 G43 Z.1 H1 M8 G98 G81 Z-1. R.1 F15. G80 M9(~CRSR) G91 G28 Z0 Y0 M30

Press MERGE key Position cursor [~CRSR] Enter program number to be inserted (O2468) Press INPUT key Press EXEC key

O2468 T2 M6 G90 G0 G54 X0.0 Y0.0 S3500 M3 G43 Z.1 H21 M8 G98 G81 Z-1. R.1 F15. G80 M9

O1234 G90 G80 G40 T1 M6 G90 G0 G54 X0.0 Y0.0 S3500 M3 G43 Z.1 H1 M8 G98 G81 Z-1. R.1 F15. G80 M9 T2 M6 G90 G0 G54 X0.0 Y0.0 S3500 M3 G43 Z.1 H21 M8 G98 G81 Z-1. R.1 F15. G80 M9 G91 G28 Z0 Y0 M30

It is not possible to move information within a program. You must first copy the range of information to a new program and then it is possible to insert it back into the original program at a different location.

45

Extended Part Program Edit (Change)

The change feature gives the operator the ability to 'Mass Edit' a program.

Press the 'Change' soft key and the above screen appears. Enter the data that you want to change. e.g. F100. Then press the 'Before' soft key the screen below will be displayed.

Enter the new data and then press the 'After' soft key. e.g.. F50. The screen below will be displayed.

Pressing the 'EXES' soft key will change all F100. in the program to F50. Pressing the 'EX-SGL' soft key will change one line at a time. If you not want to change a particular block press the 'SKIP' soft key.
46

Background Edit
Background Edit gives the programmer the ability to create a new program or edit an existing program while a program is being executed. While the machine is running press the hard key PROG then press soft key [(OPRT)] and then soft key [BG-EDT].

When you have finished using Background Edit press soft key BG-END to return to normal operation.

47

Program Stop, Optional Stop and Block Delete

M0

Program Stop. A program stop is used whenever the operator requires the program cycle to stop and allow the operator to perform some manual function such as inspection, manual tool change, coolant adjustment, etc.

M1

Optional Program Stop. This M-code stops the machine in the same manner as program stop (M0) except the operator must turn on the Optional stop switch anytime prior to the M1 being read. If the Optional stop switch is not turned on then the M1 command is ig-

To turn ON the switch must be in the UP position.

To continue operation after an M0 or M1 press cycle start.

/
Optional Block Delete. It is possible to skip a line or lines of information without having to delete them from the program. By placing a forward slash (/) at the beginning of a line and by turning on the block delete switch the control will ignore these lines. Example. N10 G0 G90 G54 X2.00 Y2.00 / N20 S4000 M3 N30 G1X-4.00 F20. With block delete turned ON the program will move from line N10 to N30 ignoring N20. With block delete turned OFF all lines of information are read.

48

Program Restart
This function gives you the option of restarting a tool anywhere in a program
Before starting you must set parameter 7310 X=1 Y=2 Z=3

P R O G R A MR E S T A R T

1) Retract the spindle, send all the axis to reference point. 2) Reset Tool. 3) Go to Edit Mode. 4) Hit Reset Button. 5) Go To MDI, type in the original RPM, press cycle start 6) Go to Auto Mode. 7) Flip Toggle Switch to PROGRAM RESTART. 8) Hit (Oprt) button on Soft Keys. 9) Hit Right Arrow Key (Soft Key). 10) You will see (Ptype)(Qtype) soft keys. 11) Type in the sequence # you want to start. 12) Press (Ptype) Soft Key. 13) Turn OFF the Rstart/Prgm Toggle switch. 14) HIT (CYCLE START).

If the program has been run through completely press Ptype. If the program has not been partially run press Qtype.

49

Tool Registry
To access the machines tool registry

SYSTEM

PMC

PMCPRM

DATA

G.DATA

450 Tool in spindle 452 Waiting tool Use the Page down key to display the complete Tool Registry on one page.

Tool Registry only applies to machines with random select tool magazines.

ADDRESS D0300 D0301 D0302 D0303 D0304 etc

POCKET No Pocket 1 Pocket 2 Pocket 3 Pocket 4 etc To change settings parameter write must be turned on. (see page 51)

50

Changing Parameters
Before changing parameters you must first enable parameter write
M O D E

Select MDI using the Mode Select switch.

T A P E M E M O R Y

M D I

R E F .R T N . J O G

E D IT H A N D L E

M O D ES E L E C T

Press the function key

Offset Setting

and then the [setting] soft key to display the Setting screen.

Change parameter write to 1

Once this is done you are now able to change machine parameters.

Always make a back up copy of the machines parameters before making changes.

To display machine parameters press function key [PARAM].

SYSTEM

and then soft key

Input parameter number to be changed and then press the No. Search key.

51

Sample Program
In this sample program the following operations are performed. Tool 1 - 3/4" end mill, machines part profile & roughs 2" hole. Tool 2 - 5/8" Spot drill, spots all holes. Tool 3 - 27/64" drill, drills 4 holes. Tool 4 - 1/2-13 tap, taps 4 holes. Tool 5 - 1/2" end mill, finish 2.0" thru hole.

52

Sample Program
O1066 (DEMO) - - - - - - - - - -- Program Number with comment N1G0G90G80G40G17- - - - - G80 & G40 Cancels any offsets stored in memory, G17 sets plane selection N2G91G28Y0Z0- - - - - - - - - - Sends Z & Y to the G28 reference position N3T1M6- - - - - - - - - - --- - - - - Calls tool 1 and places tool in spindle

Program Start

Tool 1

Blank Material

N4 (.75 DIA. ENDMILL )- - - - - - - - - Tool description N5G0G54G90X-2.25Y.625S8000M3- - Moves to 1st position using G54 work offset starts spindle at 8000 rpm N6G43Z.1H1T2 - - - - - - - - - - - - - - - - -Picks up the tool length offset, turns on the coolant and calls next tool N7G1Z-1.F25.- - - - - - - - - - - - - - - - - - Feeds to finale Z depth at 25 ipm. N8G3X-2.Y.375I.25- - - - - - - - - - - - N8 through N18 machines profile N9G1X-.5 N10G2X.375Y-.5J-.875 N11G1Y-3.5

After machining profile

N12G2X-.5Y-4.375I-.875 N13G1X-3.5 N14G2X-4.375Y-3.5J.875 N15G1Y-.5 N16G2X-3.5Y.375I.875 N17G1X-2. N18G3X-1.75Y.625J.25 N19G0Z.1- - - - -- - - -- - - - - - - - Rapid move to 0.1 above the part N20X-2.Y-2.- - - - - - - - - - - - - - Rapid move to hole center N21G1Z-1.F25.- - - - - - - - - - - - Feeds to finale Z depth at 25 ipm N22G1Y-1.75F15. - - - - - - - - - - N22 through N27 machines 2" hole N23G3J-.25 N24G1X-1.75Y-1.625 N25G3X-2.Y-1.375I-.25 N26J-.625 N27X-2.25Y-1.625J-.25 N28G0Z.1- - - - -- - - -- - - - - - -Rapid move to 0.1 above the part

After machining center hole

Part after tool 1 has finished

53

Sample Program
Tool 2
N29M01- - - - -- - - - - - - - - - - - Optional stop N30T2- - - - - - - - - - - - - - - - - -Verifies tool 2 is in waiting pocket N31M6- - - - - - - - - - - - - - - - - Change to tool 2 ( .625 DIA. SPOT DRILL )- - - - -Tool description N32G0G54G90X-2.Y-2.S6000M3- Moves to 1st position using G54 work offset starts spindle at 6000 rpm N33G43Z.1H2M8T3- - - - - - - - - Picks up the tool length offset, turns on the coolant and calls next tool
After spot drilling holes

N34G81G98X-2.Y-2.Z-.275R.1F10.- - - G81drilling cycle N35X-3.25Y-.75- - - - - - - - - - - -N35 through N38 next hole positions N36X-.75 N37Y-3.25 N38X-3.25 N39G80Z.1- - - - - - - - - - - - - - - G80 cancels pecking cycle

Tool 3

N40M1- - - - -- - - - - - - - - - - - - Optional stop N41T3- - - - - - - - - - - - - - - - - - Verifies tool 3 is in waiting pocket N42M6- - - - - - - - - - - - - - - - - Change to tool 3 ( .4375 DIA. DRILL )- - - - -- - - - Tool description N43G0G54G90X-2.Y-2S8000M3- - Moves to 1st position using G54 work offset starts spindle at 8000 rpm N44G43Z.1H3M8T4- - - - - - - - - Picks up the tool length offset, turns on the coolant and calls next tool
After drilling holes

N45G83G98X-2.Y-2.Z-1.25R.1Q.2188F10.- - - G83 peck drilling cycle N46X-3.25Y-.75- - - - - - - - - - - - -N46 through N49 next hole positions N47X-.75 N48Y-3.25 N49X-3.25 N50G80Z.1- - - - - - - - - - - - - - - G80 cancels pecking cycle

54

Sample Program
Tool 4
N51M1- - - - -- - - - - - - - - - - - - Optional stop N52T4- - - - - - - - - - - - - - - - - - Verifies tool 4 is in waiting pocket N53M6- - - - - - - - - - - - - - - - - Change to tool 4 ( 1/2-13 UNC TAP )- - - - -- - - - - Tool description N54G0G54G90X-2.Y-2.- - - - - - - -Moves to 1st position using G54 work offset N55G43Z.1H4M8T5- - - - - - - - - Picks up the tool length offset, turns on the coolant and calls next tool N56G95S1000- - - - - - - - - - - - - -G95 feed per rotation
After tapping holes

N57M29- - - - - - - - - - - - - - - - Rigid tapping mode N58G84G98X-2.Y-2.Z-1.5R.5F.0769- - - G84 tapping cycle with F = pitch of thread N59X-3.25Y-.75- - - - - - - - - - - - N59 through N62 next hole positions N60X-.75 N61Y-3.25 N62X-3.25 N63G80Z.5- - - - - - - - - - - - - - - G80 cancels pecking cycle N64G94 - - - - - - - - - - - - - - - - Change back to feed per minute

Tool 5

N65M1- - - - -- - - - - - - - - - - - - Optional stop N66T4- - - - - - - - - - - - - - - - - - Verifies tool 5 is in waiting pocket N67M6- - - - - - - - - - - - - - - - - Change to tool 5 (.5 FINISHING ENDMILL )- - - - Tool description N68G90G54G0X-1.75Y-1.75S8000M3- Moves to 1st position using G54 work offset starts spindle at 8000 rpm N69G43Z.1H5T1- - - - - - - - - - - - - - Picks up the tool length offset, turns on the coolant and calls next tool N70G1Z-1.F25.- - - - - - - - - - - - - - - Feeds to final Z depth at 25 ipm
After finishing 2" hole

N71G41Y-1.5D55 - - - - - - - - - - - - - Feeds on to part applying cutter compensation N72G3X-2.Y-1.25I-.25- - - - - - - - - - -N72 through N74 machines hole N73J-.75 N74X-2.25Y-1.5J-.25 N75G40G1Y-1.75 - - - - - - - - - - G40 Cancels cutter compensation N76G0Z.1- - - - -- - - -- - - - - - -Rapid move to 0.1 above the part N77G91G28Y0.Z0.M5- - - - - - - Returns machine to Y and Z G28 reference position

Program End

N78G90- - - - - - - - - - - - - - - - G90 absolute mode N79M30- - - - - - - - - - - - - - - - Rewinds program

55

Sub Programs
The control has the ability to access 'sub programs' from outside the program that is running in the control memory. This is useful when tools are using the same information when machining a part e.g. center drill, drill and tapping a number of holes. Sub programs are accessed by using M98 followed by the desired program number with the letter P replacing the O. e.g. N20 M98 P1066

( .625 DIA. SPOT DRILL ) N32G0G54G90X-2.Y-2.S6000M3 N33G43Z.1H2M8T3 N34G81G98X-2.Y-2.Z-.275R.1F10. N35M98P1066- - - - -(call sub program) - - - - - N39G80Z.1 N40M1 N41T3 N42M6 ( .4375 DIA. DRILL ) N43G0G54G90X-2.Y-2S8000M3 N44G43Z.1H3M8T4 N45G83G98X-2.Y-2.Z-1.25R.1Q.2188F10. N46M98P1066- - - - -(call sub program) - - - - N50G80Z.1 N51M1 N52T4 N53M6 ( 1/2-13 UNC TAP ) N54G0G54G90X-2.Y-2. N55G43Z.1H4M8T5 N56G95S1000 N57M29 N58G84G98X-2.Y-2.Z-1.5R.5F.0769 N59M98P1066- - - - -(call sub program) - - - - - N63G80Z.5 N64G94

O1066 (hole sub program) N10X-3.25Y-.75 N20X-.75 N30Y-3.25 N40X-3.25 N50M99 (return to main program

O1066 (hole sub program) N10X-3.25Y-.75 N20X-.75 N30Y-3.25 N40X-3.25 N50M99 (return to main program

O1066 (hole sub program) N10X-3.25Y-.75 N20X-.75 N30Y-3.25 N40X-3.25 N50M99 (return to main program

56

Searching Programs
It is possible to search for information contained in a program. You can search Line numbers, Tool numbers, G-codes, Feedrate, etc.
M O D E
T A P E M D I R E F .R T N . J O G

Select EDIT using the Mode Select switch.

M E M O R Y

E D IT H A N D L E

M O D ES E L E C T

Press the PROG hard key and the following screen will be displayed.

The Curser keys can also be used for searching

Enter the Line number, Tool number, G-code or Feedrate to search for then press the

SR H

Soft key or the down cursor arrow.

57

Searching for a Program

When there are multiple programs in the controls memory you can search for a particular program in several ways.
M O D E
T A P E M D I R E F .R T N . J O G

Select EDIT using the Mode Select switch.

M E M O R Y

E D IT H A N D L E

M O D ES E L E C T

Press the PROG hard key and the following screen will be displayed. Key in the desired program number and then press the Soft key or the down cursor arrow.

OSH R

58

Deleting a Program
When no longer needed, programs stored in the controls memory can be deleted, either one at a time or all programs at once.
Make sure that parameter 3202 bit 5 is set to a 1. If you do not set this parameter once you press the 'Delete' key the program is removed immediately.
M O D E

Select EDIT using the Mode Select switch.

T A P E M E M O R Y

M D I

R E F .R T N . J O G

E D IT H A N D L E

M O D ES E L E C T

Press the PROG hard key to display the program screen.

Key in 'O' followed by the desired program number then press the 'Delete' hard key.

Check that you have entered the correct program number to be deleted. Press 'EXEC' to delete the program or 'CAN' to cancel the delete operation.

To delete all programs in the control enter O-9999 and then press the 'Delete' hard key.

Before deleting all programs check that parameter 3202 bit 4 (NE9) is set to 1. This will prevent the user from deleting the O9000 series programs which are used for Tool change, pallet change etc.

59

PCMCIA Card (Memory Card)

Doosan Machining Centers using the i series controls (not including the 0i) now have the ability to read from a PCMCIA card. This is a memory card and is used in the same way as you would use a 31/2 floppy. With the cards you can upload and download programs and it is also possible to DNC directly from the card. This option makes the RS232c somewhat redundant as the PCMCIA card is much faster than the RS232c hook up. A program run from the card takes the same run time as a program that is stored in the controls memory. It is also possible to search through and restart anywhere in a program as long as the program contains line numbers. Most laptop computers already come with the PCMCIA card drive installed otherwise a suitable drive must be purchased. The easiest way to do this is to buy a stand-alone unit, which plugs in to the computer USB port.

The PCMCIA cards and stand alone reader/writers are available from most computer stores (CompUSA, EGGHEAD, etc.) And also several sites on the internet.

When using the PCMCIA card you must first set the I/O Channel to 4

60

Uploading and Downloading Programs Using the PCMCIA Card

M O D E

Insert PCMCIA card Select EDIT using the Mode Select switch.

T A P E M E M O R Y

M D I

R E F .R T N . J O G

E D IT H A N D L E

M O D ES E L E C T

Press the PROG hard key then the + soft key and CARD soft key to display the following screen.

To read a program from the memory card. Select Edit mode. Press PRGRN - + - CARD - OPRT - F READ. Enter the file number you wish to load and press F SET. Enter a program number and press O SET and then press the EXEC soft key.

To send a program to the card. Select Edit mode. Press PRGRN - OPRT - PUNCH - enter Program No - EXEC

Remember to set the I/O Channel to 4

61

DNC Operation using the PCMCIA Card

M O D E

Insert PCMCIA card. Select TAPE using the Mode Select Switch.

T A P E M E M O R Y

M D I

R E F .R T N . JO G

E D IT H A N D L E

M O D ES E L E C T

Press the PROG hard key then the + soft key twice and then DNC-CD soft key to display the following screen.

Parameter 138 bit 7 must be set to 1 to display the DNC-CD soft key.

Enter the desired file number, the soft keys will automatically change and then press the DNC-ST soft key. To run the selected program press CYCLE START.

62

Subprogram call from PCMCIA Card

You can access a program stored on the PCMCIA card at any time and use it as a subprogram. Main program Program stored on PCMCIA card

(.625 DIA. SPOT DRILL) N32G0G54G90X-2.Y-2.S6000M3 N33G43Z.1H2M8T3 N34G81G98X-2.Y-2.Z-.275R.1F10. N35M198P1066- -(call subprogram from PCMCIA card) N39G80Z.1 N40M1 N41T3

O1066 (hole sub program) N10X-3.25Y-.75 N20X-.75 N30Y-3.25 N40X-3.25 N50M99 (return to main program

When calling a program from the PCMCIA card use M198 instead of M98. E.g. N20 M198 P1066
Remember to set the I/O Channel to 4

Parameter 3404 bit 2 (SBP) and parameter 138 bit 7 must be set to 1 for this option to work.

63

Uploading and Downloading programs using a Laptop computer

When using suitable communication software it is also possible to load programs into the control through the RS232 connection from a laptop computer.

Your communication software should match these settings.

Your control parameters should match these settings.

Baud Rate Settings 9 = 2400 10 = 4800 11 = 9600 12 = 19200

Your I/O Channel should be set to zero.

64

Restarting a program when using the PCMCIA Card

You can search and restart a program which is being run from the PCMCIA card in the same manor you would if the program was running from the controls memory. Load the desired program (see page 61) Turn Single Block Switch On

Press PROG hard key to display program screen and press cycle start to start the program.

Enter the line number of the tool that you wish to start at (do not enter the N). Then press the N Search soft key. Once you have reached the correct line number turn off single block and press the start button to continue machining. This example starts at T2, assuming T2 is already in the spindle

O1066 - - - Start program in single block 200 - - - Enter line number to search to and hit N Search N200 G90 G0 G54 X0 Y0 S2000 M3 - - - Read work offsets, rpm and start spindle. N210 G43 Z1. H2 M8- - -Read Z offset 500 - - - Enter line number you wish to continue from and hit N search N500 G1 X-5. F15 - - - Turn off single block and press Cycle Start to continue machining

Your program must contain line numbers to be able to use the N Search function

You must remember to read all relevant information for the tool that you need to restart. e.g.. work offsets, Z offsets, rpm,work plane cutter comp etc

65

Uploading programs using a Laptop computer

To read a program from a laptop to the control. First connect the RS232 cable. Then prepare the communication software to send.
M O D E

Select EDIT using the Mode Select Switch.

T A P E M E M O R Y

M D I

R E F .R T N . J O G

E D IT H A N D L E

M O D ES E L E C T

Press the PROG hard key then the OPRT soft key to display the following screen.

Press the READ soft key. The screen soft keys will change, then press the EXCE soft key. Starting your communication software now will send the program.

Doosan uses and recommends Multi-DNC as its communication software of choice. Available at www.multi-dnc.com.

66

DNC Operation using a Laptop Computer

To DNC from a laptop to the control. First connect the RS232 cable. Then select the program you wish to run and prepare the communication software to send.
M O D E

Select TAPE using the Mode Select Switch.

T A P E M E M O R Y

M D I

R E F .R T N . J O G

E D IT H A N D L E

M O D ES E L E C T

Press the PROG hard key to display the following screen.

Turn single block switch to ON (without single block switch on, the machine will start to move as soon as you start sending the program).

Press machine CYCLE START

SIN G LEB LO C K

CYCLESTA R T

Starting your communication software now will send the program.

67

RS 232-C Communication Interface Connections

The cable from your computer to the machine should be wired in one of the following configurations.

68

Additional Options
Look Ahead Control (G08)
This option is designed for high-speed-machining applications that require precession and accuracy. When rounding corners and curves the delay due to acceleration/ deceleration in the servo system is suppressed. Use the following format to turn G08 on and off G08 P1 - Turns look-ahead control ON G08 P0 - Turns look-ahead control OFF

N4 (.75 DIA. ENDMILL ) N5G0G54G90X-2.25Y.625S8000M3 N6G43Z.1H1T2 N7G1Z-1.F25. N8G08P1- - - - - - Turns ON Look-ahead control N9G3X-2.Y.375I.25 N10G1X-.5 N11G2X.375Y-.5J-.875 N12G1Y-3.5 N13G2X-.5Y-4.375I-.875 N14G1X-3.5 N15G2X-4.375Y-3.5J.875 N16G1Y-.5 N17G2X-3.5Y.375I.875 N18G1X-2. N19G3X-1.75Y.625J.25 N20G08P0- - - - - - -Turns OFF Look-ahead control N20G0Z.1

G08 must be specified on a separate line and cannot be combined with any other information.

69

Artificial Intelligence contour control (AICC)

This option allows High-Speed, High-Precision machining without the special need for additional hardware. AICC is mainly used for mold applications.

Use the following format to turn AICC on and off G05.1 Q1 - Turns AICC ON G05.1 Q0 - Turns AICC OFF

N2G40G80G49 N3G05.1 Q1- - - - - - Turns ON AICC N4G0G17G54G90X-2.Y-.985S8000M3 N5G43Z.1H1T1 N7G1Z-1.005F238. N8X-.1969Z-.9647 N9X-.1733Z-.9415 N10X-.156Z-.9393 N11X-.1346Z-.955 N12X-.095Z-1.005 N13G05.1 Q0- - - - - -Turns OFF AICC N14G0 Z1. G05.1 must be specified on a separate line and cannot be combined with any other information.

AI NANO - Artificial Intelligence contour control (180 Block look-ahead) 16i,18i and 21i. AICC - Artificial Intelligence contour control (40 Block look-ahead) available on all controls. AI APC - Artificial Intelligence Advanced Preview Control (15 Block look-ahead) standard on all controls.

All these functions are called by G5.1 Q1

70

Programmable Data Input (G10)

It is possible to write directly to the work offsets using the G10 option. This is useful when setting up a previously run part where the work coordinates are already know. To write to the G54 offset the line of information would be G10L2P1X16.234Y-3.435Z-1.0

P1 = G54 P2 = G55 P3 = G56 P4 = G57 P5 = G58 P6 = G59

To update all work coordinates, the beginning of the program should look like this. O1066 G10L2P1X16.234Y-3.435Z-1.0 G10L2P2X15.234Y-4.435Z-1.0 G10L2P3X14.234Y-5.435Z-1.0 G10L2P4X13.234Y-6.435Z-1.0 G10L2P5X12.234Y-7.435Z-1.0 G10L2P6X11.234Y-8.435Z-1.0

To write to the G54.1 P1P48 extended offsets the line of information would be

G10L20P1X16.234Y-3.435Z-1.0

71

Mirror Image
There are two types of Mirror Image available for the machine. One is to set the desired axis manually in the Offset Setting screen. The second is using programmable mirror image in the program (G51.1).

Manual Setting
Machine your 1st part and then at the end of the program move to your next X and Y home position (e.g G55 X0 Y0) and stop the program (M00).
M O D E

Select MDI using the Mode Select switch.

T A P E M E M O R Y

M D I

R E F .R T N . J O G

E D IT H A N D L E

M O D ES E L E C T

Press the function key OFFSET SETTING and then the [setting] soft key to display the Setting screen. Press the down page key to display the following page.

Enter 1 to activate the desired axis. Return the Mode Switch to Auto and press cycle start to continue machining the 2nd part.
G 55
X

The program format should look like this P1066 M98 - - - Main program containing all information to machine part. G55 X0 Y0 - - -Move to next part datum M00 - -- - - - - -Program stop (change to MDI and set X Mirror Image on). P1066 M98- - - -Call main program and machine mirrored part.

Part Mirrored in X - axis

72

Mirror Image
Programmable Mirror Image
There are two ways of including Mirror Image in the program. 1. Using G51.1 2. Using M-code G51.1 (Turns Mirror Image On) G50.1 (Turns Mirror Image Off) The program format should look like this: P1066 M98 - - - Main program containing all information to machine part. G55 X0 Y0 - - - Move to next part datum G51.1 X0- - - - Mirror Image in X -axis P1066 M98- - - -Call main program and machine mirrored part. G50.1 X0 - - - - Cancel Mirror Image

M81 (Turns Mirror Image On in X-Axis) M82 (Turns Mirror Image On in Y-Axis) M80 (Turns Mirror Image Off)

The program format should look like this: P1066 M98 - - - Main program containing all information to machine part. G55 X0 Y0 - - - Move to next part datum M81- - - - Mirror Image in X -axis P1066 M98- - - -Call main program and machine mirrored part. M80 - - - - - -- Cancel Mirror Image

73

Coordinate System Rotation

By using this option it is possible to rotate a programmed shape. G68 is used to turn on Coordinate System Rotation, along with 'X' & 'Y' position which is the center of rotation and 'R' which is the angle of rotation.

To use Coordinate System Rotation the program format should look like this: P1066 M98 - - -- - - Main program containing all information to machine part. G68 X0 Y0 R45. - - Rotates part 45 degrees with X & Y zero being center of rotation. P1066 M98- - - - - - -Call main program and machine rotated part. G69 - - - - - --- - - - Cancel Coordinate System Rotation

If no R value is specified the value in parameter 5410 is used as the angle of rotation.

74

Scaling
Using the Scaling option it is possible to enlarge or reduce the size of a part without having to change the program.

If part A is the original part size, to produce part B which is 1.5 times original. The program should look like this. G90 G0 G54 X0 Y0 (Move to center of part) G51 X0 Y0 P1500 (Turn on Scaling, magnification = 1.5) M98 P1066 (Main program containing all information to machine part) G50(Cancel Scaling mode) To produce part C which is half original size. The program should look like this. G90 G0 G54 X0 Y0 (Move to center of part) G51 X0 Y0 P500 (Turn on Scaling, magnification =0.5) M98 P1066 (Main program containing all information to machine part) G50(Cancel Scaling mode)

75

Tool Life Management

Tool Life Management gives the operator the ability to change a worn tool to another tool during program run without stopping the machine. Tools are classified into groups and a tool life is set for each group in either number of times used or length of time. When a tool exceeds the preset number of times used or time set, then the next tool in that group is selected. Once all tools are used then an alarm is generated to let the operator know that the tools must be changed.

6800 .2 6810

Parameters. (LMT) 0 (for number of times) 200 Tool Ignored Number

76

Tool Life Management

O0001 G10L3 (Sets Tool Life Management) P1L15 (Sets group 1 with a tool life of 15 uses) T1H1 (Tool # and tool length offset #) T2H2 (Tool # and tool length offset #) P2L15 (Sets group 2 with a tool life of 15 uses) T3H3 (Tool # and tool length offset #) T4H4 (Tool # and tool length offset #) G11 M30

Before using TLM you must first set the tool groups using the format in the above program
O1000 T201M6 (Selects 1st tool from group 1) G0G90G54X0Y0S2000M3 G43H99Z5. ( H99 must be assigned when using TLM) G98G81Z3. R.1F50. G0G80Z5. G0G91G28Z0 T202M6 (Selects 1st tool from group 2) G0G90G54X0Y0S2000M3 G43H99Z1.( H99 must be assigned when using TLM) G98G81Z3. R.1F50. G0G80Z5. G0G91Z0Y0 M30

Once both tools have been used 15 times the next tool assigned in the group is selected.

The format of the main program should look like this.

77

Tool Life Management

To display the TLM screen press the Offset Setting hard key then the key and then the TOOLLF soft key.

+ soft

A @ sign is displayed next to the tool that is being used. A * appears when the tool life has expired.

78

Tool Path Graphics

Pressing the GRAPH hard key will bring up the Tool Path Graphic screen.

Setting parameter 6500 bit 6 to 1 will always position the graphic in the center of the screen.
79

Horizontal Setup
The horizontal machining center gives the operator the ability to set up multiple parts. It is also possible to machine three sides of a part in one setup.

Choose a face to set all you Tool Length Offsets from. This is usually the face of the part at G54 B0.
A

Setting Z Work Offset Value

Using an indicator measure the distance from the face you touched your tools off to the face of the next part to be machined. Enter this amount (A) in your work offset Z value you have assigned for that part. eg. G55 X-16.500 Y-12.290 Z-1.250
80

Horizontal Setup
All faces to be machined should be assigned there own work offset numbers. This gives better control over each work piece.

G 54 G 58 G 55 G 59 G 57
G 54 P5

G 54 P1

G 56

G 54 P3 G 54 P2

G 54 P4

G 54 P6

B0

B90

G54 P07 G54 P9 G54 P8 G54 P11 G54 P12

G 54 P17

G 54 P13

G54 P10

G 54 P15 G 54 P14

G 54 P16

G 54 P18

B180

B270

The above example is for pallet 1. Each work piece on pallet 2 should also be given individual work offset numbers.

81

Horizontal Machining Example

Typically when using a horizontal machining center you will be machining the same part in several locations on the tombstone. The use of sub-programs will save on program size, control memory and also make proving out the program easier.

O2000 (MAIN PROGRAM) M61 (Calls pallet 1) P1976 M98 (calls program O1976) M62 (Calls pallet 2) P1976 M98 (calls program O1976)

O1976 ( MAIN SUB PROGRAM) N1G0G17G40G94G90G80 N6G91G28Z0. G28X0Y0 G90 T1M6 (T1 FACE MILL) (calls tool 1) G54B0 (G54 work offset at B0 part 1) P0001M98 (calls program O001) G0Z8. (move tool away from pallet) G54.1P1B90 (G54.1 P1 work offset at B90 part 2) P0001M98 (calls program O001) G0Z8. G54.1P7B180(G54.1 P7 work offset at B180 part 3) P0001M98 G0Z8. G54.1P13B270(G54.1 P13 work offset at B270 part 4) P0001M98 G0Z8.M9 T2M6 (T2 1/2 END MILL) (calls tool 2) G54.1P13B270(G54.1 P13 work offset at B270 part 4) P0002M98 (calls program O002) G0Z8. (move tool away from pallet) G54.1P7B180(G54.1 P7 work offset at B180 part 3) P0002M98 (calls program O002) G0Z8. G54.1P1B90 (G54.1 P1 work offset at B90 part 2) P0002M98 G0Z8. G54B0(G54 work offset at B part 1) GP0002M98 G0Z8.M9 G91G28X0Y0Z0M5 G90 M99 O0002( T2 .750 FINISH) G90G0X-.8751Y2.4995S1600M3T1 G43Z.1H01M8 G1Z-1.F15. X-.3751F50. G3X.1249Y-1.9995J.5 G1Y-.9995 G2X.9999Y-.1245I.875 G1X3.9999 G2Y-3.8745J-1.875 G1X.9999 G2X.1249Y-2.9995J.875 G1Y0. G0Z.2 M99 O0001(T1 FACE MILL) G0G90X-2.5Y2.S1000M3T2 G43Z.5H01 G1Z0F50. G1X9.F20. G0Z2. M99

Always use the tool in the spindle to machine all parts on the tombstone before changing to the next tool. As it is quicker to do a B axis move than a tool change.

82

Bore Mill Machining Example

Set up and use of the horizontal boring mill is very similar to a standard horizontal machining center. The major difference is that the boring mill has a 'W' axis.

When the 'W' axis is at its home position (G91G28 W0), enter this position into the work offset number you will be using. E.g. G54 W 27.890 Then when you call your work offset all moves will be read as zero from this position. The following is an example of a peck drilling cycle. G80G49G40G0 G91G28Z0W0 T1 M6 (Calls Tool 1) G90G54X9.0Y25.0W-5.0S700M03 (Moves to X, Y and 'W' position) G43 Z2. H1 M8 (Picks up tool offset) G83G99Z-3.0R1.0Q1.0F8.0 (Peck drilling cycle) Y19.0 Y-19.0 G80 Z2. (Cancel pecking cycle) G91 G28 Y0. Z0. W0. (Sends Y, Z and W axis to home position) G90 M30

Always clamp the 'W' axis before machining. M68 - Clamp M69 - Unclamp

83

Macro Programming
Fanuc controls have an option feature known as custom Macro. This is powerful program language that allows programs to be written using variables instead of fixed numbers.

There are several ways to call a Macro program. 1. Using G65 followed by the Macro program number. e.g. G65 P9010 2. Using a custom G-code. G100 variables are set in parameters 6050 - 6059 3. Using an M code. M-code variables are set in parameters 6071 - 6079.

By putting 100 in parameter 6050 every time G100 is placed in the program Macro 9010 will be called.

6050 G Code to call Macro program 9010 6051 G Code to call Macro program 9011 6052 G Code to call Macro program 9012 6053 G Code to call Macro program 9013 6054 G Code to call Macro program 9014 6055 G Code to call Macro program 9015 6056 G Code to call Macro program 9016 6057 G Code to call Macro program 9017 6058 G Code to call Macro program 9018 6059 G Code to call Macro program 9019

6071 6072 6073 6074 6075 6076 6077 6078 6079

M Code to call Macro program M Code to call Macro program M Code to call Macro program M Code to call Macro program M Code to call Macro program M Code to call Macro program M Code to call Macro program M Code to call Macro program M Code to call Macro program

9001 9002 9003 9004 9005 9006 9007 9008 9009

By putting 100 in parameter 6071 every time M100 is placed in the program Macro 9001 will be called.

84

Macro Programming
This Bolt Hole Macro allows for quick and easy programming of a bolt hole circle without the operator having to calculate the position of each hole. The line of information in the program to call this macro should look like this: G100 X0.0 Y0.0 Z-.750 D2.0 R.1 C83. A45. H4. F20. Q.15 X Y Z R D C H A F T Q X axis center Y axis center Depth to drill Reference point above part Diameter of bolt circle G code to be used Number of holes in pattern Starting angle of 1st hole Feedrate Dwell value Peck depth (G73 & G83 only)

This is the Macro to run this program.

O9010(BOLT HOLE MACRO) IF[#7EQ#0]THEN #3000=1(NO DIAMETER GIVEN) IF[#11EQ#0]THEN #3000=2(NO HOLES GIVEN) IF[#9LT#0]THEN #3000=3(NO FEEDRATE "F" GIVEN) IF[#3EQ#0]THEN #3000=4(NO DRILL CYCLE GIVEN) IF[#18EQ#0]THEN #3000=20(NO REFERENCE POINT GIVEN) #100=1 #27=#7/2.0 G0X[[COS[#1]*#27]+#24]Y[[SIN[#1]*#27]+#25] G98G#3Z#26R#18F#9Q#17P#20 #101=360/#11 N1WHILE[#100LTABS[#11]]DO1 X[[[COS[[#101*#100]+#1]*#27]+#24]]Y[[[SIN [[#101*#100]+#1]*#27]+#25]] #100=#100+1 END1 M99

85

Macro Programming (Circular Pocket)

The line of information in the program to call this macro should look like this, G102 X0. Y0. Z-750 R1. A.05 I.02 J.02 K.25 W.8 C5.0 D3 F20.
X Y Z R D C I J A F K W X axis center Y axis center Depth of pocket Radius of pocket Direction of cut. D2 CW / D3 CCW Feedrate for plunging Finish cut Finnish allowance on bottom of pocket Reference point above the part Feedrate Depth of cut for roughing Width of cut. % of endmill diameter

Circle-Pocket Macro
#14=0 G91G1Z-#6F#3 WHILE[[#12+#14]LT[#145]]DO2 N4G1G91Y-#12F#3 #14=#14+#12 N5G#7X0Y[2*#14]R#14F#9 N6G#7X0Y-[2*#14]R#14 N31G0Y0.0 N32END2 N2000#106=#106+1 N19G90G1Y[#143] G#7G91X0.0Y#146R145F#9 G#7X0.0Y-#146R145 G0Y0 N8G90G0X#141Y#142 N201GOTO500 N3000IF[#5EQ#0]GOTO4000 N9G90G0X#141Y#142 #14=0 N10G1Z#27F#3 N40WHILE[[#12+#14]LT[#145]]DO3 N11G1G91Y-#12F#3 #14=#14+#12 N12G#7X0Y[2*#14]R#14F#9 N13G#7X0Y-[2*#14]R#14 N14G0Y0 END3 N19G90G1Y#143 G#7G91X0.0Y#146R#145F#9 G#7X0.0Y-#146R#145 G0Y0 N4000G0G90X#141Y#142 N14G1Z#26F#3 #14=0 WHILE[[#12+#14]LT[#145]]DO1 G1G91Y-#12F#3 #14=#12+#14 G#7X0Y[2*#14]R#14F#9 G#7X0Y-[2*#14]R#14 G0Y0 END1 N1000IF[#4EQ#0]GOTO23(IF NO FIN ALLOW) N19G90G1Y#143 G#7G91X0.0Y#146R#145F#9 G#7X0.0Y-#146R#145 G0Y0 IF[#5003NE#26]GOTO4000 N23G90G1Y[#142-#10] N24G#7G91X0Y[2*#10]R#10F#9 N25G#7X0Y-[2*#10]R#10 N26G#7X#104Y[ABS[#104]]R[ABS[#104]] N67G0G90Z#140 G0X#141Y#142 M99

O9012(CIRCULAR POCKET) IF[#3EQ#0]THEN#3000=8(NO PLUNGE FEEDRATE GIVEN) IF[#9EQ#0]THEN#3000=3(NO FEEDRATE GIVEN) IF[#23EQ#0]THEN#3000=5(NO WIDTH OF CUT GIVEN) IF[#1EQ#0]THEN#3000=21(NO REFERENCE POINT) N1G0X#24Y#25Z#1 #100=0 #106=0 #140=#5003 #141=#5001 #142=#5002 #32=#4107+12000 #32=#[#32] #33=#4107+13000 #33=#[#33] #144=#32+#33(D+2000) #10=#18-#144(POCKETRAD-EMRAD) #143=#142-[#10-#4] #145=[#10-#4] #146=2*#145 #12=#23*[#144*2](WIDTH-OF-CUT) #104=[#12*.01] #27=#26+#5(ZDEPTH-FINISH) IF[#7EQ2]THEN#104=[#104*[-1]] IF[#6EQ#0]GOTO3000 #100=ABS[FIX[[#26-#1+#5]/#6]] #101=#100 N2G90G0Z#1 N3G0G90X#141Y#142 N500IF[#106GE#100]GOTO3000 86

Milling Formulas
The following formulas are used to calculate speed and feeds, metal removal rate, surface feet per minute and horse power used.

Symbols and Measurement Units D = diameter of milling cutter (inches) d = depth of cut (inches) F = feed rate (inches per minute) f = feed (inches per tooth) K = power constant of work material E = spindle efficiency (varies from 75% to 90%) W = width cut (inches) Z = number of teofeth in the cutter mrr = metal removal rate ( cubic in/min) HPc = horse power at the cutter sfm = surface feet per minute To calculate Surface Feet per Minute (SFM) sfm = .262 x D x rpm To calculate Feed rate (inches per minute) F = f x Z x rpm To calculate Feed (inches per tooth) f = F/Z x rpm To calculate Metal Removal rate (mrr) mrr = W x d x F To calculate Horse Power at the cutter (HPc) HPc = mrr/K

'K' Factors Hardness BHN Work Material steels, wrought and cast (plain carbon, alloy steels, tool steels) Precipitation hardening stainless steels 85-200 201-253 254- 286 287-327 328-371 372-481 482-560 561-615

'K' Factor 1.64 1.56 1.28 1.10 0.88 0.69 0.59 0.54

150-450 1.27-0.42 2.27 2.00 1.89 1.52 1.27 1.19

150-175 110-190 Cast Irons 176-200 (grey, ductile and 201-250 malleable) 251-300 301-320

Stainless steels, wrought and cast 135-275 1.54-0.76 (ferritic, austenitic 286-421 0.74-0.50 & martensitic) Titanium 250-375 1.33-0.87

High-temperature alloys, nickel, 200-360 0.83-0.48 colalt base Iron Base Nickel alloys 180-320 0.91-0.53 80-360 30-150 40-90 150 100-150 151-243 0.91-0.53 6.25-3.33 10.0-6.67 3.33 3.33 2.00

Example: To find the Surface Feet per Minute (smf) of a 3/4" 4 flute end mill running at 2500 r.p.m sfm = .262 x D x rpm sfm = .262 x .750 x 2500 = 49

Aluminum alloys Magnesium alloys Copper Copper alloys

smf = 491

87

Trouble Shooting

88

Side Mounted Tool Changer Recover

This is the procedure for recovering a side mounted tool changer should the machine loose power or if the tool is inadvertently load wrong.

1. Restore Power (It is not necessary to Zero return the machine) 2. On the Automatic Tool Changer (ATC) box at the back of machine, set switch to manual. 3. In MDI key in M39; and press the start button. (This starts maintenance mode and allows you to use the 2 keys for rotating the tool magazine as jog keys for the tool changing arm.) 4. Turn mode switch to JOG If you have a tool in the spindle make sure that the tool is unclamped (Green light on). If not, manually press tool unclamp button. 5. Using the jog keys (on the ATC box) move the tool changer arm to home position (you will have to press the key several times). Carefully watch the tool that is being placed in the spindle. Once it is in position in the spindle manually press tool clamp before proceeding otherwise the tool will drop. Finish pressing the jog key until the arm is at home position. 6. Turn mode switch to MDI 7. In MDI key in M19; and press the start button (spindle orientation) 8. Key in M41 (will complete 1 complete tool change) 9. Set APC box back to Auto. 10. Check to make sure that you have the correct tool number in spindle before continuing. To display tool register Press SYSTEM ? PMC ? PMCPRM ? DATA ? G.DATA Page to show parameters D450 & D452 D450 Head Tool (shows tool number in spindle) D452 Next Tool (shows tool number in waiting pot)

Pot must be in the down position to run this procedure

M32 Pot UP M33 Pot Down

89

Horizontal Machining Center Tool Changer Recover (DHP and DHC 400)
During a normal tool change (1) Next tool is placed in spindle. (2) Tool from spindle is returned to waiting pot. (3) Tool is returned to correct pocket in magazine. After this the next tool called is brought to the waiting pot position, then the magazine rotates back so that the pocket number and the tool in the spindle are the same. At all times the magazine should have (2) empty spaces.

T5

T1

90

Horizontal Machining Center Tool Changer Recover (DHP and DHC 400)
Occasionally due to tool changing errors (2) pots will be in the waiting pot position. For this example we have T5 in the spindle and T10 as the waiting tool. The Pot position's were the spindle tool and waiting tool came from should be empty (e.g. P5/P10). Look in the magazine to see were the third pot is missing from (e.g. P20). Manually rotate the magazine so that the third empty pocket and the misplaced pot are in line. On the CRT press Hard Key - SYSTEM, (soft keys) - PMC - PMCPRM - DATA - G.DATA. This will display the following. N0 ADDRESS DATA 0000 0001 D0450 DO452 5 (This is the tool in the spindle) 10 (This is the tool in the waiting pot) Change D0452 to matched the third empty pocket number (e.g. 20). In manual bring pot over to magazine side. Change D0452 back to waiting pot number (e.g. 10). Return magazine back to auto mode. The magazine should now be back in sequence.
P 10

P 5

M isplaced P ot I -S pindle

T10

T5

P 20

91

DHP-500 and 630 Tool Change Recovery

This is the procedure to recover the Tool Changer should the machine loose power during a tool change or if a tool is inadvertently loaded wrong.
1. Restore power. 2. Set Mode switch to Jog.
E D IT H A N D L E

M O D E
T A P E M E M O R Y M D I R E F .R T N . J O G

M O D ES E L E C T

3. Make sure that the ATC box is connected to the tool changer and set to Manual. 4. On the ATC box set switch to Tool Change Step Reverse. 5. Keep pressing Start key (green button). Carefully watch the tool being placed in the spindle. Once the tool is in the spindle manually press the tool clamp button before preceding otherwise the tool will drop. Finish pressing the start button until the arm is in the home position. 6. Set switch to Close Door and press start switch. 8. Check to make sure that you have the correct tool in the spindle before continuing.

SPIN D L E O R IEN TA TIO N

A TC C O N D IT IO N

A PC C O N D ITIO N

EM ER G EN C YSTO P
SPIN D LE O R IEN TA TIO N TO O LC H A N G E 1C Y C LE TO O LC H A N G E STEP FO R W A R D TO O LC H A N G E STEP R EV ER SE M O TO RB R A K E R ELEA SE

Maintenance box for DHP-500 and DHP-630

PA LLETC LA M P PA LLETC H A N G E STEP FO R W A R D PA LLETC H A N G E STEPR EV ER SE M O TO RB R A K E R ELEA SE

D O O RC LO SE D O O RO PEN

PA LLETC H A N G E PA LLET U N C LA M P

W -PO TU N C LA M P W -PO TC LA M P

W -PO TSPD LSID E W -PO TM A GSID E

A T C
STO P STA R T

A PC

92

DHP-500 and 630 Pallet Change Recovery

This is the procedure to recover the pallet changer should the machine lose power during a pallet change.

1. Restore Power. 2. Set Mode switch to Jog.

E D IT

M O D E
T A P E M E M O R Y M D I R E F .R T N . JO G

H A N D L E

M O D ES E L E C T

3. Make sure that the APC box is connected to the pallet changer, and set to Manual. 4. On APC box set switch to Pallet Change Reverse. 5. Press Start Key (Green Start Button , wait for pallet to finish rotating before continuing). 6. Set switch to Clamp Pallet and press Start. 7. Set APC switch back to Auto. 8. Check to make sure that you have the correct pallet in the machine before continuing.

When doing a pallet change all doors must be closed at all times.

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CAT 50 PULL STUD

This pull stud will fit all 50 taper Doosan Machining Centers.

Dimensions are for reference only.

Part No
To Order Call:

316-45 311-18

(With through hole) (No through hole)

Retention Knob Supply Company Tel: 937-686-6405 Fax: 937-686-4125

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CAT 40 PULL STUD

This pull stud will fit all 40 taper Doosan Machining Centers.

Dimensions are for reference only.

Part No
To Order Call:

711-23 711-25

(With through hole) (No through hole)

Retention Knob Supply Company Tel: 937-686-6405 Fax: 937-686-4125

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BT 30 PULL STUD
This pull stud will fit all 30 taper Doosan Machining Centers.

1 8m m

M 1 2x1 .7 5

1 1 m m

7 m m

2 5 m m

Dimensions are for reference only.

Part No 311-09H

(With through hole)

To Order Call: Retention Knob Supply Company Tel: 937-686-6405 Fax: 937-686-4125

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Heavy Tool Limitations

Before using a heavy tool you must first calculate the tools 'Moment' before attempting a tool change. This should not exceed the machines maximum tool weight.

W eight C enter

T aper G age L ine

Calculate the tools 'Moment' as follows 1. Find the tools center of gravity 2. Measure the distance from the tools center of gravity to taper gage line. 3. Weight x length = Moment

The easiest way to find the tools center of gravity is to tie a piece of string around the tool, and then find the point at which the tool is balanced. Measure from the string to the taper gage line.
M easure fromcenter point to taper gage line

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Uses of Large Tool

The following method is recommended when using a large diameter tool.

E m p ty P o ck ets

Tool's with numbers 70 and higher are considered 'large Tools'. Before you start to use a large tool you must first set the 'Tool Registry'.

To access the Tool Registry see page 50

When loading a large tool make sure that the pots on either side are empty. In the 'Tool Registry' set the empty pots to "00".

In this example 'Pot 8' has the large tool with Pots 7 and 9 empty. When T70 is called in the program it will always be placed back in Pot 8.

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Lubrication Requirements
The following is a list of oils used on Doosan machining Centers. Way Lube 'G' Oil Hydraulic 'B' Oil Spindle Cooler 'A' Oil Grease 'Y' Oil Air Service Unit 'B2' Oil Table 'E' Oil

Comparative Oils

Mobil Oil A (FC10) B2 (FC32) E (HM68) G (G68) Y (XM2) Velocite 6 No.

Shell Oil Tellus C10 Tellus 32 Tellus 68 Tonna T68 Alavniagrease EP2

Esso Oil Spinesso 10 Teresso 32 Nuto H68 Febis K 68 Beacon 2

BP Oil Energol HP10 Energol HP32 Energol HLP 68 Maccurat 68 Ener-grease LS 2

Caltex Oil Spindural 10 Rando 32 Rando HD 68

Sun Oil

Solnus 55

DTE Oil Light DTE 26 Vactra No. 2 Mobilux 2

Sunv 916 Sunvis 831 WR

Way Lubricant Sun Waylube 68 80 Multifak EP2 Prestige 42 Grease

Mold cut on DMV 3016LS In 1 Hour 32 minutes. H13 Tool Steel RC50

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Absolute and Incremental Programming Example

Datum

Y+

X+

Answers from page 17

ABSOLUTE (G90) A X 4.000 B X 8.000 C X 1.000 D X 2.000 E X 3.000 F X 8.000 Y-2.000 Y-3.000 Y-6.000 Y-5.000 Y-7.000 Y-7.000 INCREMENTAL (G91) A X4.000 B X4.000 C X2.000 D X-8.000 E X1.000 F X5.000 Y-2.000 Y-1.000 Y-3.000 Y1.000 Y-2.000 Y0.000

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Index
A. Axis Movement - 7 Absolute Coordinate Programming (G90) - 16,17 Additional Options - 69 Artificial Intelligence Contour Control (AICC) - 70 Artificial Intelligence Advanced Preview Control (AI APC) - 70 B. Boring, Fine Boring (G76) - 32 Back Ground Edit - 47 Block Delete - 48 Boring Mill Program Example - 83 C. Codes, M Codes (Most Commonly Used) - 5 G Codes (Most Commonly Used) - 4 Control Panel - 6 Coordinate Programming - 16 Circular Programming (G02,G03) - 19,21 Cutter Compensation (G40,G41,G42) - 23,25 Canned Cycles - 26,33 Control Options - 69 Coordinate Rotation - 74 D. Drilling, High Speed (G73) - 28 Drilling (G81) - 29 Peck Drilling (G83) - 30 DNC, Using PCMCIA Card - 62 Using Laptop Computer - 67 Down Loading, Using PCMCIA Card - 61 Using Laptop Computer - 65

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E. Extended Part Program, Edit - 43 Move - 44 Merge - 45 Change - 46 F. Fixed Cycles - 28,33 G. G - Codes (Most Commonly Used) - 4 Graphics (Tool Path) - 79

H. High Speed Peck Drilling (G73) - 28 Helical Interpolation - 37,38 Horizontal Machining Center Setup - 80,81 Horizontal Program Example - 82 I. Incremental Coordinate Programming (G91) - 16,17 Initial Plane (G98) - 27 J. K. 'K' In Canned Cycles - 36 L. Linear Interpolation (G00/G01) - 15 Look-ahead Control (G8) - 69 Lubrication Requirements - 98

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M. M-Codes (Most Commonly Used) - 5 M.P.G (Manual Pulse Generator) - 8 M.D.I (Manual Data Input) - 39 Memory Card - 60 Milling Formulas - 87 MBL APC (Multi Block Look-a-head Advanced Preview Control) - 70 Mirror Image - 71,73 Macro Programming Example - 84,86 N.

O. Optional Stop - 48 Options - 69 P. Programming - 15 Plane Selection - 18 Program, Starting - 40 Numbers - 41 Editing - 42 Sample - 52,55 Searching - 57 Searching For - 58 Deleting - 59 Program Stop - 48 Program Restart - 49 Parameters (Changing) - 51 PCMCIA Cards, PCMCIA Cards - 60 Uploading and Downloading - 61 DNC Operation - 62 Calling Subprograms (M198) - 63

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P. Continued, Restarting a program - 64 Programmable Data Input (G10) - 71 Pull Studs - 93,95 Q.

R. Radius Command - 22 Rapid Plane - (G99) -27 Rigid Tapping - 33 Rigid Tapping Using an Alternative Axis - 34 Repetition of canned cycles (L) - 35 Restart - 49 RS231C Communication - 68 S. Starting a Program - 40 Sample Program - 52,55 Subprogram (M98) - 56 Subprogram - Calling from PCMCIA Card (M198) - 63 Scaling - 75 T. Tool Length Offset - 9 Setting Method - 10 Tool Offset Memory 'C' - 11 Tapping, (G84) - 31 Rigged Tapping - 33 Rigged Tapping Using an Alternative Axis - 34 Thread Milling - 37,38 Tool Registry - 50 Tool Life Management - 76,78 Tool Path Graphics - 79

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T. Continued, Trouble Shooting, Side Mounted Tool Changer - 88 Horizontal Tool Changer (400 series) - 89,90 Horizontal Tool Changer (HP500/630) - 91 Pallet Recovery (HP500/630) - 92 Heavy Tool Limitations - 96 Uses of Large Tool - 97 U. Uploading from PCMCIA Card -61 Uploading from Laptop Computer - 66 V.

W. Work Coordinates - 12 Work Coordinate System Setting Method - 13 Work Coordinate System (G54-G59/G54.1P1-P300) - 14

Y.

Z.

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Phil Misseldine Applications Engineer Machining Centers Doosan Infracore America Corporation 8 York Avenue West Caldwell, New Jersey 07006 Main Tel: Direct: Fax: E-mail: 973-618-2500 973-618-2436 973-618-2472 phil.misseldine@dhiac.com

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