Manual de CNC Torno

Programming Manual
Boxford 280 B Programming Manual
Boxford
Boxford Ltd., Wheatley, Halifax, West Yorkshire, England, HX3 5AF. (Registered Office) Telephone: 01422 358311 Fax: 01422 355924 E-mail: info@boxford.co.uk Web: www.boxford.co.uk
Boxford 280B
Contents
Contents
1 Introduction 2 Running the Demonstration Program 3 Axes and Tooling
3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 Axes and Datum Turret Quick Change Toolpost Gang Plate Driven Tool Spindle Speed, Rotation and Tool Orientation Tailstock Chuck Collet Tool Libraries Setting Up Functions Information Required Creating a CAM Program Example Drawing Straight Lines Drawing Arcs Drawing Threads Processing a Profile Editing a CAM Profile CAM Tools
4 CAM Programming
Boxford 280B
Contents
5 CNC Programming
5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8
Operations and Programming Sheets Absolute and Incremental Co-ordinates Speeds and Feeds Program Format Preparatory Functions (G Codes) Miscellaneous Functions (M Codes) Canned Cycles Inputting a New Program 5.8.1 Information Required 5.8.2 Tabulated Format 5.8.3 Compact Format 5.9 Saving a Program 5.10 Examining an Existing Program 5.11 Editing a Program 5.11.1 New Programs 5.11.2 Existing Programs 5.11.3 MENU Editing Options 5.12 Continuing a Program 6.1 6.2 6.3 Initial Checks Manufacture Options During Machining
6 CNC and CAM Machining
7 Manual Machining
Boxford 280B
Contents
Tutorials and Exercises

Tutorial 1: Exercise 1: Tutorial 2: Exercise 2: Tutorial 3: Exercise 3: Tutorial 4: Exercise 4: Tutorial 5: Exercise 5: Tutorial 6: Exercise 6: Tutorial 7: Exercise 7: Tutorial 8: Exercise 8: Tutorial 9: Exercise 9: Linear Interpolation Tabulated and Compact Program Display Simple Programming - Absolute Co-ordinates Incremental Co-ordinate Programming Simple Programming - Incremental Co-ordinates Turning and Facing a Stepped Shaft Turning and Facing a Stepped Shaft Circular Interpolation Circular Interpolation Circular Interpolation and Roughing Cuts with a Tool Change Circular Interpolation and Roughing Cuts with a Tool Change Canned Cycles - Facing and Rough Turning Canned Cycles - Facing and Rough Turning Canned Cycles - Grooving Canned Cycles - Grooving Canned Cycles - External LH Thread Canned Cycles - External RH Thread Canned Cycles - Peck Drilling Canned Cycles - Deep Hole Peck Drilling
Tutorial 10: Circular Interpolation - Partial Arcs Exercise 10: Circular Interpolation - Partial Arcs Tutorial 11: Combining G Codes to Produce a Program Exercise 11: Using a Combination of G Codes Tutorial 12: Programming Spidle Orientation and Driven Tooling. Operations Sheet Programming Sheet
1 Introduction
This manual gives guidance in using the 280 B machine for creating and editing CNC and CAM programs for turned components, and in executing programs to manufacture components. The software includes a demonstration CNC program, and a number of tutorial programs. It is suggested that the manual should be used as follows: 1. 2. 3. 4. 5. Refer to Section 2 and run the demonstration program. This will provide rapid familiarisation with the operation of the software and the machining process. Study Section 3 to become proficient in setting up the tooling. Refer to Section 4 to demonstrate the convenience and ease of operation of a typical CAM system. Use Section 5 for detailed instruction in CNC programming. Tutorial 1 is used as an example to demonstrate the stages of programming and software operation. Use the Tutorials and Exercises in the order in which they appear, to progress from basic programming skills to proficiency in the more advanced features of CNC programming. When programs have been written and verified, refer to Section 6 as required, to machine components.
Boxford 280B
2 Running the Demonstration Program

The demonstration program contains examples of parallel and radius turning, and a finished component can be machined from the billet supplied with the machine. Run the program as follows to provide a tutorial in programming and machining:
Set Up the Machine
1. Turret:
Make sure the billet is securely fitted in the chuck. Check that the first tool to be used is the LH turning tool and the second tool is the parting tool. Set these up as follows: Fit LH turning tool in position 1, Parting tool in position 7. (Refer to Figure 3.2 in Section 3 for tool positions in the turret). Set both tools into individual toolholders, then fix toolholders into suitable locations on the gang plate to permit their use in sequence. Set both tools into individual toolholders. Fit the LH turning tool and toolholder assembly into the X-axis slot of the toolpost (refer to Figure 3.4 in Section 3 for tool fitting and axis slot). During machining, the machine will stop and it will be necessary to remove and replace this tool with the parting tool assembly in the same Xaxis toolholder slot. Run the software and check that it is correctly configured by selecting CONFIG from the main menu. (Refer to Appendix A in the Installation and User Manual if necessary). Refer to Section 3 - Axes and Tooling, 3.9 Setting Up, to set up the tooling, offsets and datum position.
Gang Plate: Quick Change Toolpost:
2.
Check Tool Settings
3.
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Select the Program
4.
From the main menu select PROGRAM, then Program, and view Catalogue 1 to identify the demonstration program which is called DEMO:
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5.
Select the program. The screen shows the Program display, with a 2D view of the component:
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View the Component
6.
Select VIEW to produce a 3D view of the component. After a pause, the display will show the 3D view:
Use the cursor keys to manipulate the 3D view as follows:
Increase size Rotate anticlockwise Decrease size

HOME
Rotate clockwise
Restore original view
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Show the Program Details
7.
Select
INFO
to show the program details:
8.
Turn off the program details display. (Press ESC or EOB).
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Display the Program
9.
Select
MENU
, and then Display:
Scroll the display to examine the program: Press or to scroll one line.
10.
Turn off the program display: (Press ESC).
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Simulate Machining - 2D
11.
Select
MENU
, then 2D Simulate:
Repeatedly press EOB to move through the program line-by-line. The simulation shows the tool movement and material removed as each line of the program is executed. To move forward through the program to a specific line, select MENU , and then Go to Line. Input the required line number when prompted, and press EOB. To produce a 3D view of the workpiece, select return to the 2D view, press EOB.
MENU
and then 3D View. To
To run the simulation automatically, select MENU and then Fast Mode; the program will be run in a continuous sequence. To return to line-by-line simulation, select MENU and then Step Mode. To end the simulation before the end of the program, press
ESC .
At the end of the program the screen returns to the program display.
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Simulate Machining - 3D
12.
Select
MENU
, then 3D Simulate:
Select MENU , and demonstrate the use of the options available as for 2D simulation, until the screen again shows the program display. 13. Turn off the program display. Refer to Section 6 - CNC and CAM Machining.
Machine the Component
Boxford 280B
Axes and Tooling
3 Axes and Tooling

3.1. Axes and Datum
Axes: Datum Position: Home Position: The toolholder can move in two axes, X and Z, (see Figure 3.1). The location of the datum position is established at the factory, and details are provided with the machine. The offsets of all tools are set in relation to the datum position. The toolholder is parked in the home position by homing switches. During setting up, it is necessary to set the datum position in relation to the home postion.
+X
-Z
+Z
-X
Figure 3.1
Axes and Datum Position
Boxford 280B
3.1 Axes and Tooling
External tools: 1, 3, 5, 7 Internal tools: 2, 4, 6, 8
5 4
3 2 1
Machines without homing switches: 1: Reference tool 3: Second tool
Figure 3.2
Turret Tool Positions
Boxford 280B
3.2
Turret (Figure 3.2)

The turret is a motor driven, disc type toolpost with positions for up to eight tools, four external and four internal; each position is numbered. Tools can be accessed by indexing the turret using the TURRET INDEX key on the control panel or from the software.
Fitting Tools
External tools are secured in radial slots by tapered clamp blocks held by two fixing screws. Longitudinal positioning is achieved by pushing the tool towards the turret centre so that it touches the location stop. Internal tools are secured in their predrilled holes with tubular toolholders and two sunken screws. This will normally have been set at the factory and should require no adjustment. If it is found to be incorrect it is recommended that a Boxford service engineer is called. However it is permissible to adjust it by putting a tool into the working position, then inserting packing as appropriate between the turret toolpost and cross-slide. If this does not achieve correct tool height, or other tools heights are still incorrect, contact the factory.
Setting Tool Height
Boxford 280B
3.3 Quick Change Toolpost

Fitting Tools (Figures 3.3 and 3.4)
The quick change toolpost has two slots to provide for convenient and rapid manual tool changing. A toolholder with a tool already secured in it by the four securing screws is placed into the shaped slots which provide instant positive location, and is rigidly held there by tightening the single clamping screw, using the clamp screw key provided. The toolpost will only accept a single toolholder at a time. External tools are fitted to the X axis slot while internal tools use the Z axis slot. A quick change toolpost can be fitted to the lower section of the X-axis cross slide in addition to a gang plate. Fit a tool into the standard flat bottomed toolholder by tightening the four securing screws on to the tool shank. The tool should protrude approximately 20mm (0.75in) from the toolholder face. Keep this dimension consistent for all the external tools. Put the toolholder into the toolpost and lock it into position using the clamping screw.
Tool Clamping Screw
Tool
Tool Securing Screws
Figure 3.3
Quick Change Toolpost
Boxford 280B
Height Setting-External Tools Refer to Section 7 - Manual Machining to move the tool manually to set the tool height,
which is checked by taking a light facing cut on the end of the workpiece. If adjustment is needed to centre the tool, use the centre height adjustment screw on the toolholder as follows:
1.
Visually check the height to the workpiece centre point. The actual height from the top of the cross slide to the centre of the spindle is stamped on the right hand side of the cross slide near the bottom of the slide. Note: Do not confuse this value with the machine serial no. which is stamped on the right hand face of the Z axis slide.
2.
To adjust the height slacken the clamping screw and the centre height adjustment screw. Turn the knurled adjustment knob clockwise to raise the tool, anticlockwise to lower it. When the height is correct tighten the Allen screw then tighten the tool clamping screw. Check that the tool is exactly on the centre line by taking a light facing cut on the end of the workpiece, running the spindle in reverse. Repeat the adjustment if necessary.
3.
Tool Clamping Screw Constant
Centre Height Adjustment Screw
Tool Securing Screws
Figure 3.4
Tool Fitting and Adjustment
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Height Setting - Internal Tools These tools can be fitted directly into the V location toolholders intended for use with
the drills. Although not essential, it is better if they are located into a tubular holder. This can easily be made as shown in Figure 3.5. Put a toolholder with its tool on to the toolpost and set the centre height to the workpiece centre line exactly as for external tools. Repeat this procedure for all of the tools.
Drill Tube
Figure 3.5
Internal Tool Fitting Detail
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3.4 Gang Plate (Figure 3.6)

This is a plate with drilled holes enabling up to three simple channel shaped toolholders to be clamped on to it. Tool positions are free, limited by hole line-up between toolholder and gang plate and by ensuring that every tool mounted can reach the work over the required range without fouling anything or causing other tools to foul something.
Fitting the Tools Setting Tool Height
Select a tool position and fit the channel toolholder using the securing screws. Clamp the tool into it with the four clamping screws. There is no tool height setting adjustment provided as this is pre-set at the factory. If correction is needed, contact the factory.
Securing Screws Clamping Screws Channel Toolholder
Figure 3.6
Gang Plate
Boxford 280B
3.5 Driven Tooling

The Driven Tooling attachment is fitted to the front of the cross-slide. The Tool can be fitted so it is in line with any of the three axis using the two holders provided. The Tool position in the Y axis can be adjusted using the manual turnwheel on the top of the slide. In figure 3.7 below, the tool is aligned with the X axis.
Handwheel with scale
Y axis slide
+Y +X
+Z -Z Y axis slide mounting block -X -Y
Mounting Bracket Type 1
Driven Tool Attachment
Figure 3.7
Driven Tool Attachment
Boxford 280B
Mounting bracket type 1 can be bolted to the front of the Y axis slide to allign the driven tool with the Z axis. To allign the driven tool with the Y axis, Mounting bracket type 2 is used. See Fig 3.8 below.
Figure 3.8
Mounting Bracket Type 2
Driven Tooling can only be activated from program using M10 (driven tool active) and M11 (driven tool off).
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3.6 Spindle Rotation and Tool Orientation
Rotation (Figure 3.9)
The spindle can run forward (anticlockwise when viewed on chuck jaws) and in reverse (clockwise when viewed on chuck jaws). Direction and speed of rotation are controlled either by the SPINDLE CW and CCW keys on the machine control panel (refer to Installation and User Manual Section 5 Machine Controls) or by means of M codes (M03 = Forward and M04 = Reverse) selected from software. For machining a workpiece held in the chuck with the tool fitted in the normal way, i.e. with the cutting edge uppermost, the direction of rotation is as follows: External turning, toolholder at back External turning, toolholder at front Internal turning (centre drills, drills) Internal turning (boring, threading) Direction Reverse Forward Forward Reverse M Code M04 M03 M03 M04
Tool Orientation
If tools are fitted upside down, take care to select the appropriate direction of spindle rotation. Once the initial tool is specified, which then sets the direction of rotation, ensure that all subsequent tools are fitted in the same orientation to avoid the need to reverse the direction of rotation at tool changes while running a program.
Boxford 280B
WORKPIECE IN CHUCK
REVERSE
+X
Tool holder at back
-Z
+Z
FORWARD
-X
Tool holder at front EXTERNAL TURNING INTERNAL TURNING
USING TAILSTOCK
REVERSE
+X
POSITIVE X VALUES ONLY
-Z
+Z
FORWARD
-X
NEGATIVE X VALUES ONLY
Figure 3.9
Spindle Rotation and Tool Orientation
Boxford 280B
3.7 Tailstock
A conventional tailstock may be fitted. Alternatively, a pneumatically-operated tailstock may be fitted, operated by the TAILSTOCK QUILL keys on the control panel. The pneumatically-operated tailstock may be operated under software control using M41 (Extend) and M42 (Retract).
3.8 Chuck
A manual or pneumatic chuck may be fitted. Pneumatic chucks are operated either by using the CHUCK OPEN and CLOSE keys on the control panel (refer to Installation and User Manual Section 5 Machine Controls) or from within software by use of appropriate M code (M40 = Open, M39 = Close). Unless specified otherwise, pneumatic chuck jaws are prebored at the factory to suit customer requirements. Should work with larger diameter workpieces be undertaken, the pneumatic chuck jaws can be bored out to avoid the need to purchase another pneumatic chuck, as follows: 1. Press the CHUCK CLOSE key and set the jaws to position to provide s u f f i c i e n t material for boring. To move the jaws unfasten the two screws in the jaws, raise the jaws from the serration plates and position them accordingly, then refasten the screws ensuring that the jaws are equi-distant from the centre line of the chuck. Make a washer 1mm thick with bore the same diameter that the chuck is to be bored. The outside diameter of washer can be 30mm. Press the CHUCK OPEN key. Bore out the face of the jaws 1mm deep, 30.12mm diameter (0.12mm larger than the outside diameter of the washer). Place the washer on to the machined jaw face and press the CHUCK CLOSE key to clamp the outside diameter of the washer. Revolve the chuck forward at approximately 2000 rev/min. Bore out the jaws using the washer bore as a gauge. Use the axis control keys to provide tool movement with the FEED knob set to 75%. When boring is complete stop the spindle and press the CHUCK OPEN key to release the washer.
2. 3. 4. 5. 6. 7. 8.
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3.9 Collet (Figure 3.10)

A Pneumatic Collet Chuck may be fitted and is controlled in the same way as a Pneumatic chuck. To fit the Pneumatic Collet, complete the following procedures. 1. 2. 3 & 4. 5 & 6. 7. 8. 9. 8 & 10. 11. 12. 13. 14. 15. 16. Isolate the machine and disconnect the main Air supply. Remove the current chucking. Remove the backplate (secured with 3 bolts). Clean the spindle nose. Asseble nose piece and collar. Fit nose piece and collar assembly onto spindle ensuring the '0' on the collar is alligned with the '0' on the spindle. Put a Dial Test Indicator on nose piece and tighten the three bolts securing the collar to the spindle until the spindle nose piece is running true. Insert the Black Knurled headed Collar Pin into the draw bar assembly. Push draw bar assembly down the rear of the spindle. Fit yoke pin into draw bar assembly and secure with 2 grub screws (3mm Alen Key). Fit yoke bar into yoke and secure with Cap head screw and washer (5mm Alen key). Locate the Collar Pin. Fit the required Collet into the nose piece. Lift up spring loaded drive sprag. Screw the drawbar unit into the collet adusting for the bar diameter to be used. Reengage drive sprag. Re-connect the main air supply and switch on the machine. The collet system is now ready for use. Removal is the reverse of the above procedure. NOTE: If reverting to manual chucking, and maximum diameter through spindle is not required, then reversse steps 16-13 and 6-1 inclusive.
Boxford 280B
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Figure 3.10
Fitting Collet Chucking
Boxford 280B
3.10 Tool Libraries

The software provides a Tool Data Library which enables details of tooling and offsets to be entered and a Tool Library from which tools can be selected for inclusion in the Tool Data Library. The library is set up by means of a tooling menu. Before attempting to set up the tooling for the first time, view the libraries and the tooling menu to become familiar with the details, as follows:
Tool Data Library
1.
From the main menu, select MACHINE and then Tools. The screen shows the Tool Data Library, (Figure 3.11). Practice selecting tools as shown.
1. Tool number used by CNC program to select required tool 2. Tool position on Turret (not used with Gang plate or Quick change tool holder) 3. Tool type and description (selected from tool library) 4. Tool offsets
To select a tool: Press or to highlight the required tool.

Figure 3.11
Tool Data Library
Boxford 280B
Tooling Menu
2.
Select MENU to display the tooling menu:
The use of these options for setting and editing the Tool Data Library is detailed later in this section. Note: After setting up or editing the library, always select Save Tool data.
Tool Library
3.
From the tooling menu, select Tool Library. The screen displays the first page of the Tool Library, (Figure 3.12), which shows the twelve pre-defined tools. These tools can not be altered.
Figure 3.12
Tool Library
Boxford 280B
Pressing EOB will display the second page which offers an additional six tools, all of which are definable by the user.
Turn off the Tool Library display to reveal the Tool Data Library.
Tool Definitions
From the tooling menu, select Tool Definitions. The screen shows tool type 1, the left hand turning tool, with three dimensions required to draw the tool. Note: Tools 1 to 12 are pre-defined and can not be altered. Scroll through the tools until tool type 13 is displayed. Initially this tool is undefined and the display area is blank.
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To define a new tool shape, press the ALTER key and use the select the required type of tool.
and
keys to
Enter the three dimensions A, B and C; pressing EOB after each entry. Should an incorrect dimension be entered, use either the CANCEL key (if EOB has not been pressed), or the and keys to move back to the value and re-enter it.

After all three dimensions have been entered, press EOB again to accept them.
The new tool shape will be displayed, along with its dimensions.
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3.11 Setting Up
Note: A billet of the appropriate size will be required for this procedure. In order to run the demonstration program, a LH turning tool and a parting tool are required. To run the program, set up the LH turning tool as the first tool and the parting tool as the second tool in the following procedure.
Fit Tooling
1.
Fit the required tools into the toolholding system supplied. With the quick change toolpost, fit the first tool required. After setting the offset of the first tool, it will be necessary to substitute the next tool before setting its offset. If the toolholder is too close to the chuck to allow the tools to be fitted, move the toolholder away from the chuck under manual control, (see Section 7 - Manual Machining).
2. 3.
Check that the RESET button on the machine control panel has been pressed to initialise the machine. From the main menu select CONFIG and then Program. On the PROGRAM display, set UNITS MODE to the units required for tool offsets and programming. If a turret is fitted, select CONFIG and then Hardware, and check that TURRET is set to FITTED. From the main menu, select MACHINE and then Tools to display the Tool Data Library. Defaults of the first tool will be highlighted, for example:
Configure Software
4. 5. 6.
Check the settings. If they are correct, continue at step 14 to set the second tool. For the demonstration program, the settings should be as shown. 7. Select the tool to be edited by using the pressing EOB. keys to highlight the required tool and
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1 2
1 2 3
To check tool type, press ESC then select Tool library to view tool library.
MENU
and
To check tool position, for Turret only, refer to Figure 3.2 Offsets for reference tool are zero.
To edit tool details: Type required number in highlighted box Press EOB to accept last entry and highlight next box When last box is highlighted, press EOB: highlight will disappear Press EOB to turn off display Figure 3.12 Tool Editing Display
Boxford 280B
8.
The screen shows the tool editing display, with the first item (Tool type) highlighted, (Figure 3.12). Edit the display to show the required Tool type (and Turret position if applicable). Do not edit the offsets.
9.
Select , Machine and then Datum Position. Note: The datum values are set at the factory, and it should only be necessary to reset the datum values if the original setting is lost or the workholding or toolholding devices are moved or changed. In order to set the datum values, the information supplied with the machine will be required; this information consists of an X and a Z axis measurement.
Set Datum Position
10.
From the main menu, select MACHINE and then Datum Position. The screen shows:
Enter the X and Z axis measurements supplied with the machine. The workshift value is the distance from the Front Face of the Spindle Nose to the Front Face of the chucking used. See fig. 3.13. Enter the appropriate value for your chucking arrangement. Select SAVE . The screen returns to the main menu.
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1. Chuck
Workshift
2. Collet
Workshift
Figure 3.13
Workshift Measurements for different Chucking
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11. 12. 13.
Select , Machine and then Tools. Select

MENU
, and then Set Tool Offsets.
The screen shows:
Home the axes using the HOME and AXIS DIRECTION keys. 14. When the axes are homed, the screen shows:
Fit a billet into the chuck. Enter its diameter and length, and select EOB.
OK by pressing
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15.
The screen shows the tool offsets setting display, (Figure 3.14). On the control panel, select Manual mode. Using the X and Z AXIS DIRECTION keys, follow the instructions to position the point of the tool on the reference diameter (the periphery of the billet).
TOOLS OTHER THAN DRILLS
Tool position on axes
DRILLS
Tool position on axes
Figure 3.14
Tool Offsets Setting Display
Boxford 280B
16.
When the tool is in the correct position, select ACCEPT . The screen shows:
Use the X and Z AXIS DIRECTION keys to touch the point of the tool on the end of the billet, and select ACCEPT .
Set Additional Tool Offsets
17.
The screen again shows the Tool Data Library. To set the offset of the next tool, fit or index the tool and repeat the procedure from step 6. Note: For setting the offsets of the second and any subsequent tools, it will not be necessary to home the axes or enter the billet dimensions (steps 13 and 14).
Setting Driven Tool Offsets
18.
The Driven Tool can be positioned in either of the two holders provided with the machine to align the tool with any of the 3 machine axis as shown in figure 3.15 (see section 3.5).
Position 2
X
Position 3
Z
Position 1
Figure 3.15 Driven Tool Positions
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With the Tool in any of the positions the user is prompted to touch on to the reference diameter and the bar end. Use the following procedures to correctly define Driven Tool offsets. a. Driven Tool - Position 1 i. Ensure the Driven Tool centre is alligned with the billet centre by adjusting the slide (Y axis.). ii. Reference Diameter - Touch the bottom of the driven tool onto the bar diameter. Select EOB iii. Bar End - Touch the outside diameter of the driven tool onto the bar end. Without moving the Z axis, move the driven tool clear of the bar diameter using XNote the Z feedback reading on the screen. Move the Z axis 1/2 the diameter of the driven tool using Z-. When in position, select EOB Driven Tool - Position 2 i. Ensure the Driven Tool centre is below the billet centre by adjusting the slide (Y axis). ii. Reference Diameter - Touch the outside diameter of the driven tool onto the bar diameter. Select EOB iii. Bar End - Touch the outside diameter of the driven tool onto the bar end. Without moving the Z axis, move the driven tool clear of the bar diameter using X-. Note the Z feedback reading on the screen. Move the Z axis 1/2 the diameter of the driven tool using Z-. When in position, select EOB c. Driven Tool - Position 3 Ensure the Driven Tool centre is is alligned with the billet centre by adjusting the slide (Y axis.). ii. Reference Diameter - Touch the outside diameter of the driven tool onto the bar diameter. Select EOB iii. Bar End - Touch the bottom of the driven tool onto the bar end. Without moving the X axis, move the driven tool clear of the bar diameter using Z+. Note the X feedback reading on the screen. Move the X axis 1/2 the diameter of the driven tool using X+. When in position, select EOB i.
b.
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When the offsets of all the required tools have been set, either select MENU `and then Save Tool Data, or press ESC. If ESC is pressed, the screen shows the message:
With the YES window highlighted, press EOB to save the offsets.
Backlash Compensation
Note: The values which appear in the X and Z windows are set at the factory. They will only require resetting if the original settings are lost, or if the ballscrews on the machine are replaced. To view the backlash compensation settings, select Machine - Backlash Compensation. The window below is shown.
Boxford 280B
CAM Programming
4 CAM Programming
4.1 Functions
The CAM programming features of the software provide the following functions:
New Programs
A new component is created by producing a profile on screen. When the profile is complete, it is processed by the software which converts it into a CNC program and saves it. The appropriate G and M codes are included, and speeds, feeds, roughing cuts and tool changes are incorporated into the program automatically. Programs stored in a CAM catalogue can be edited in CAM or CNC format. Programs created in CAM format are presented in CNC format using absolute co-ordinates. Programs stored in a CNC catalogue can only be viewed and edited in CNC format.
Existing Programs
Boxford 280B
4.2 CAM Programming
4.2 Information Required

To create a new CAM program you will need the following information: 1. Drawing: The work datum is the centre of the right hand end of the bar. Since the profile is symmetrical about the centreline of the bar, only positive X co-ordinates need be dimensioned. All Z co-ordinates are negative, measured from the end of the bar:
dimensions required
+X
-Z
datum
The drawing should make allowance for completing the chuck end of the workpiece. If threads are incorporated, make allowance for undercutting between the end of the thread and any shoulder. For ease of programming, mark the co-ordinates of the start and end points of each element of the profile as shown in Figure 4.2. 2. Tools Used: Choose the appropriate tools for each machining operation, and set up the tooling as for CNC machining. Details of the billet: Outside diameter Inside diameter (if the billet is hollow or a tube) Length Material (aluminium, brass, mild steel or plastic).
3.
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4.2 CAM Programming
4.
Program Name: A name for your program (This must be a valid DOS filename, without a file extension, using a maximum of 7 characters and not including spaces or the following punctuation marks: , . \ or /). Configuration Settings: The STANDOFF option automatically adds the depth of cut to a 2mm standoff (clearance between tool and workpiece) when using canned cycles. This option, and other configuration settings, can be activated by selecting CONFIG - Program from the main menu and making the required settings.
5.
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4.3 CAM Programming
4.3 Creating a CAM Program

Check Configuration Input Program Details
1. From the main menu, select CONFIG - Program, and check the UNITS MODE setting. (The other settings do not apply to CAM programming). Select STANDOFF if required. From the main menu select PROGRAM - Cam, and from the catalogue select NEW PROGRAM. Input the program title and bar dimensions (including inside diameter if the bar is hollow), as for CNC programming. If drilling is required, enter the depth of the hole at the prompt. After inputting the program details press EOB; the screen shows the CAM display. The display enables the profile of the component to be built up from straight lines, arcs and threads, superimposed on the outline of the billet. As each element of the profile is added, details of the corresponding line of the program appear in the program display window (1), in CAM program format (refer to 4.8). For a solid billet, beginning at the workpiece datum (6) the profile is built up from right to left in the graphics area (3) formed by the top half of the billet outline. As each element is added, it is automatically mirrored in the bottom half of the billet outline to produce a symmetrical profile. Note: For hollow billets, the workpiece datum is set at the intersection of the bore and the end face. The UNDO option deletes the last element added, together with the corresponding line of the program, and can be used repetitively to delete previous elements and lines. Straight lines and arcs are created by manual input of co-ordinates, (see 4.5 and 4.6 below). Threads are created by manual input of data, (see 4.7).
2.
CAM Display (Figure 4.1)
3.
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4.3 CAM Programming
1. 2. 3. 4. 5. 6.
Program display window Billet outline (bore shown if hollow) Graphics area (top half of billet outline) Length of billet (Z co-ordinate) Diameter of billet (X co-ordinate) Workpiece datum 5 1 2 3
END LINE ARC THREAD UNDO MENU
Processes the profile For manual input of straight line co-ordinates For manual input of arc co-ordinates For input of thread details Deletes last line of program (repetitively) Save profile rename a profile 3D View Redraw Grid Snap Saves profile without processing and can also be used to Produces 3D view of workpiece Re-draws profile after changes Sets fineness of graphics grid
Figure 4.1
CAM Display
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4.3 CAM Programming
Set Grid Snap

4.
The fineness of the grid to which the co-ordinates will snap can be set as follows: Select MENU - Grid snap. The screen shows:
The default value is 1.00mm as shown. Along the Z axis the pitch of the grid is equal to the value set. Along the X axis the pitch is half the set value, since each element of the profile is mirrored below the centreline of the workpiece. For example, setting the grid snap to 5.00mm produces the following grid:
+X
-Z
centreline 5mm
2.5mm
Edit the setting if required by overtyping, and press EOB. For the example given in this Section, accept the default setting. Note: The setting can be edited later during the creation of a profile if required.
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4.4 CAM Programming
4.4 Example (Figure 4.2)

Figure 4.2 shows a drawing of a component whose profile consists of straight lines, arcs and a thread. The co-ordinates of the start and end points of each element have been marked in the top half of the billet outline. The straight lines and arcs can be machined with the LH turning tool (1) and parting tool (11). To cut the thread it will be necessary to fit an external threading tool and to add this to the Tool Data Library. Create a new program named EXAMPLE as detailed in 4.3 above, and refer to 4.5, 4.6 and 4.7 for guidance in producing the profile shown in Figure 4.2. Note: A copy of the CAM program for this component is included in a catalogue, and is named CAMPROG.
Co-ordinates shown in the format: X, Z

10mm x 0.75mm pitch RH
X +25
21,-39 17,-45 16,-29 21,-29 15,-9 10,-14 10,-16 0,-45 8R 8R 8,-4 8,-1 0,0
Z -50
Figure 4.2
Example of Drawing for CAM Program
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4.5 CAM Programming
4.5 Drawing Straight Lines

1. Select
LINE ; the screen will show:
The window shows the co-ordinates of the end point of the last element to be drawn. Since no element has yet been drawn the co-ordinates are those of the datum. 2. Enter the co-ordinates of the end point of the first line: X = 8, Z = -1, and press EOB. The first line of the profile will appear, mirrored by a symmetrical line in the bottom half of the billet outline. 3. Repeat this procedure to set the end point of the next line of the profile: X = 8, Z = -4 If you make a mistake, select UNDO to erase the last line, and repeat the procedure.
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4.6 CAM Programming
4.6 Drawing Arcs

1. Select ARC as required. , and Clockwise arc (GO2) or Counter-clockwise arc (GO3)
For the first arc in the example, select Counter-clockwise arc (GO3). 2. The screen shows:
Enter the radius of the arc. (For the example, enter 8.00mm). The X and Z co-ordinates shown are those of the end point of the last element in the profile (A). Enter the co-ordinates of the end point of the arc (B):
3.
Press EOB: the arc will appear on the display, and will be mirrored by a symmetrical arc in the bottom half of the billet outline.
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4.6 CAM Programming
4.
For the example, repeat the procedure to draw the second arc. Set the radius to 12.00mm and the co-ordinates of the end points to X = 10, Z = -14:
10,-14
If you make a mistake, select UNDO to erase the last arc, and repeat the procedure.
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4.7 CAM Programming
4.7 Drawing Threads

1. For the example, draw the next three straight lines of the profile in preparation for adding the threaded section:
2.
Select THREAD ; the screen shows:
3. 4.
Select left hand or right hand thread as required. For the example, select right hand thread. The screen shows:
Change the PITCH/TPI value if required, entering either a pitch (metric units) or threads per inch (Imperial units). For the example, set the pitch to 0.75mm.
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4.7 CAM Programming
The Z co-ordinate is that of the end-point of the last element on the profile (A). Enter the Z co-ordinate of the end-point of the thread (B) and press EOB.
B A
5.
The thread will appear on the profile, and the corresponding line will be added to the program display: 9 X = 21.00 Z = -39.00 RH THREAD, PITCH/TPI = 0.75
6.
For the example, draw the remaining straight lines to complete the profile:
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4.8CAM Programming
4.8 Processing a Profile

1. Select
END
; the screen shows:
Enter the material type; the appropriate depths of cut will automatically be incorporated into the program. 2. Press EOB. The screen shows:
Enter the billet dimensions and press EOB. If any dimension is too small to enable the profile to be machined, an appropriate message will be displayed. Repeat the procedure and amend the dimension as necessary. The length must incorporate the width of the parting tool if the item is to be parted off.
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4.8 CAM Programming
3.
The program will be scrolled in the program display area, (accompanied by the graphical display beneath it, if selected), in CNC compact format. The bottom line of the program display area will show messages which explain what the program is doing. If the program contains errors or omissions, such as undefined tools, sections of profiles which a tool cannot reach, or insufficient undercut allowance for thread cutting, the bottom line will display an appropriate error message and the display will stop to allow the message to be read. If the display stops, press EOB to resume.
4.
At the end of the program, the display will show the program WRITE display, (see Section 5, Figure 5.1). The program can then be edited in CNC format if required. From the CAM display, select - Save profile.
MENU
Saving a Profile Without Validation
The profile will be saved and can be recalled later for completion or editing. Pressing ESC or selecting not already been saved.
CLOSE
will prompt you to save the profile if it has
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4.9 CAM Programming
4.9 Editing a CAM Profile

A CAM profile can be edited in either CAM or CNC format:
CAM Format
1. 2. 3. 5.
Save the program. Select PROGRAM - Cam, and select the required program. Use UNDO to step backwards through the elements of the profile, and re-create the profile as required. To move points, delete entities and insert entities, MENU EDIT PROFILE is selected. The screen below is shown.
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4.9 CAM Programming
Moving Points
The End Point of a highlighted entity can be moved. An entity is highlighted by using the selection buttons to toggle around each entity in turn. The entity End point can be moved by selecting MOVE and inputting the new coordinates (if invalid co-ordinates are entered, an error message is displayed and the move aborted. NOTE:- Moving the end points of arcs will redefine the arc as a diagonal straight line. This can be converted back to the arc in the standard CAM.
Modifying Hole Depth
The start point of the line describing the diameter at the bottom of a hole cannot be moved using the standard Move command.
MENU HOLE DEPTH
is selected displaying the window below.
The modified depth is input and Deleting Entities
OK
selected
The required entity is highlighted and DELETE selected. The end point of the previous entity and the start point of the next entity will automatically be joined to maintain a continuous path. Inserted entities are placed After the currently highlighted entity. An Entity is highlighted and INSERT selected. The inserted entities can be moved to the required position as described earlier in this section.
Inserting Entities
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4.9 CAM Programming
In the example below, a groove has been added to the outside diameter of the profile shown on a previous page.
Modifying Bar Size
MENU
BAR SIZE
is selected to modify the bar size.
The window below is shown.
The modified bar information is input. If the bar size specified is too small for the profile, relevant values will automatically be modified to the smallest acceptable size. Saving the Changes To save the changes and return to the standard CAM window,
EXIT
is selected.
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4.10 CAM Programming
4.10 CAM Tools

The CAM Tools option allows the user to define which tools are available to the CAM processor when a G&M program is created from a drawn profile.
The CAM Tools option is accessed from the CAM window by selecting Menu - CAM Tools The Tool library window below is shown.
If all the tools in the Library are Not Selected (Black text), the CAM processor will select tools from the entire list. If some Tools are Selected (Red text), the CAM processor will only select from these tools. Depending on the type of component to be processed, a minimum number of tools are required. e.g. To process external shapes, the minimum tooling requirements are. 1. 2. 3. LH Turning Tool (Note: 32 Degrees is the clearance angle not the tip angle) Parting Tool External Threading Tool (If threads are to be cut). To Select tool, the tool is highlighted with the cursor and
ALTER
selected.
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4.10 CAM Programming
Rough & Finish Turning
If two LH Turning tools are available, one can be set to perform the Rough Turning Process and the other set to perform the Finish Turning Process. When selecting Tools (Red Text), if a second LH turning tool is selected, the window below is shown.
The User is prompted to Select Process to be Performed by Tool. Roughing or Finishing is selected. The remaining LH Turning Tools process will automatically be set to the alternative option as shown below.
Saving
To exit and save the settings, the Esc. is selected.
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CNC Programming
5 CNC Programming
5.1 Operations and Programming Sheets
Before commencement of programming the following points require consideration: 1. Drawing The work datum is usually centre of the right hand end of the bar; this makes it easier to set the tools. If necessary re-dimension the drawing from this datum.
-Z +Z +X
-X
2.
Machining Decide on the sequence of the machining operations (e.g. rough turn, finish turn, screw cut, part off.)
3. 4.
Tooling Choose appropriate tools for each machining operation. Programming Decide on incremental or absolute dimensions, feed mm/min, spindle speed rev/min. Use an operations sheet and a programming sheet to record your decisions. Blank sheets are included at the back of this manual for photocopying.
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5.2 CNC Programming
5.2 Absolute and Incremental Co-ordinates

Before programming commences points on the contour have to be defined either in: (a) absolute co-ordinates relative to the workpiece datum, or (b) incremental co-ordinates relative to the previous position Examples of the two types of co-ordinate systems are shown below:
C B A C
+X
15 25
20
20 10 POINT DATUM A B C X 0 20 20 30 Z 0 0 -10 -30 POINT DATUM A B C X 0 20 0 10 Z 0 0 -10 -20
-X
10 ABSOLUTE COORDINATES POINT DATUM A B C X 0 15 15 25 Z 0 0 -10 -10
INCREMENTAL COORDINATES POINT DATUM A B C X 0 15 0 10 Z 0 0 -10 0
G90 must be inserted at the start of the program when using absolute co-ordinates. G91 must be inserted at the start of the program when using incremental co-ordinates.
30
-Z
+Z
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5.3 CNC Programming
5.3 Speeds and Feeds

When writing a program the values for spindle speeds and feed rates have to be entered. These values will vary depending upon the workpiece material and the type of cutting tool being used.
Spindle Speeds
With experience, a programmer will use values which are known to produce the required balance between surface finish, tool wear and production time, but for the beginner the following cutting speeds are offered as a guide.
CUTTING SPEED (METRES/MINUTE) CUTTING TOOL ALUMINIUM BRASS CAST IRON MILD STEEL (FREE CUTTING) 200 50 CARBON STEEL (MEDIUM) 125 40
CARBIDE H.S.S.
300 80
250 70
125 40
To calculate spindle speeds use the following formula: Spindle speed = m/min x 1000 p x dia. of workpiece or feet/min x 12 p x dia. of workpiece 600 x 12 p x 1=2291rev/min.
e.g. for 25.4 (1in) dia. mild steel (EN1A) using carbide copy turning tool: Spindle speed = 200 x 1000 or p x 25.4=2506rev/min. program say, 2500 or 2300 rev/min.
Feed Rates
Feed rates are expressed in millimetres per minute and, as with spindle speeds, the feed rate will vary with the material being cut, the depth of cut and the type of cutting tool used. Again, with experience the programmer will quickly determine the values to use for the various cutting functions.
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5.4 CNC Programming
5.4 Program Format

A program is a series of "blocks" or lines each showing a set of functions and/or coordinates. Input of the program is usually in tabular form (although the CONFIG menu allows a change to compact format). A typical format for turning is: LINE G M X Z I K F S These are the headings used on the programming sheet, where: LINE is the block or sequence number, and G M X Z I K F S the preparatory function the miscellaneous function the X co-ordinate (diameter value) the Z co-ordinate (length value) interpolation parameter or additional information as needed interpolation parameter or additional information as needed feed rate (mm/min) spindle speed (rev/min)
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5.5 CNC Programming
5.5 Preparatory Functions (G Codes)

Note: The G codes can be displayed on the screen from the HELP menu. The address letter G is followed by two digits, and the following codes can be used: G00 G01 G02 G03 G04 G50 G70 G71 G81 G82 G83 G84 G90 G91 G94 G95 G96 G97 Rapid movement Linear interpolation F = Feed rate Circular interpolation (clockwise) I & K are co-ordinates of centre or I = radius from the start point Circular interpolation (counter clockwise) I & K are co-ordinates of centre or I = radius from the start point Time dwell F = delay (secs) Maximum Spindle Speed Limit S=Speed Imperial programming units Metric programming units O.D. Turning cycle X = Total Depth Z = Total Length I = No. of Cuts F = Feed rate Face/ Grooving Cycle X = Total Depth Z = Total Cut Length I = No. of Cuts F = Feed rate Peck Drilling Cycle Z = Total Depth I = Drill Dia K = Reduction F = Feed rate Threading Cycle Z = Total Length I = Dia Depth K = No. of Cuts F = Pitch Absolute Programming Incremental Programming Feed/min Feed/rev Constant Surface Speed Constant RPM
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5.6 CNC Programming
5.6 Miscellaneous Functions (M Codes)

Note: The M codes can be displayed on the screen from the HELP menu. The address letter M is followed by two digits, the following can be used:M01 M02 M03 M04 M05 M06 M08 M09 M10 M11 M16 M26 M27 M30 M39 M40 M41 M42 M48 M49 M51 M52 M81 M97 M99 Optional stop End of program (Single Quantity) Spindle start forward. Enter spindle speed S Spindle start reverse. Enter spindle speed S Spindle stop Tool change I = Tool Type K = Drill Diameter Coolant On Coolant Off Driven Tool 1 Active Driven Tool 1 Off Orientate Spindle I=Angle (30 Deg Increments) Parts Catcher In Parts Catcher Retract End of program (Repeat) Close Automatic Chuck Open Automatic Chuck Extend Air Quill Retract Air Quill Open Air Guard Close Air Guard Shot Bolt Engage Shot Bolt Disengage Turn output on/off I=on/off (1/0) Continuous manufacture Continuation code.
Entering M99 into a partially written program causes the program to be saved to disk. Recall of the program is simulated on the screen up to the break off point and then the prompt to "continue writing" is made.
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5.7 CNC Programming
5.7 Canned Cycles

Codes G81 - G84 are referred to as 'canned cycles'. These codes are built in to the control system of the lathe; their use simplifies the programming of repetitive operations. In each case the tool must be positioned at the start point of the cycle on the previous line of code at a point 2mm (0.1in) from the work. This point is called the stand-off point. All information within the canned cycle is incremental. On completion of the cycle the tool will return to its start point.
G81 Outside Diameter
Using this code enables several cuts to be taken automatically provided that the Z axis movements are the same. The start point in the X axis is at the 2mm stand-off point and the tool is programmed to this location on the previous line. After entering G81 the following additional information is needed. X value = Z value = I value = total cut depth, ie. the difference between the original diameter and the final diameter (excluding the stand-off). total length of travel in the Z axis, i.e. cut length plus any stand-off in the Z direction. number of cuts required. feed rate.
F value =
Cancel G81 with G80.
G82 Facing or Grooving
Facing: The start point (programmed on the previous line) is from a stand-off position in the Z axis. After entering G82 the following additional information is needed: X value = total cut depth - it is usual to go past the centre line by 0.5mm to clear the end, i.e. enter a value of the stand-off diameter plus 1mm. total cut width (excluding the stand off). number of cuts. feed rate.
Z value = I value = F value =
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5.7 CNC Programming
Grooving: This canned cycle is used to cut a rectangular section groove of width exceeding 4mm. Before entering the canned cycle routine it is necessary to create a slot of width 2mm plus the width of the tool to the required depth. This is accomplished using the parting off tool and programming using codes G00 and G01. Remember that the parting off tool is 2mm wide and that during the offset routine the reference face was set as the side nearer the chuck. After cutting this narrow groove take the tool to its stand off position. Enter G82 and then add the following values: X value = Z value = I value = the difference between the stand-off diameter and the diameter of the bottom of the groove. the additional width of the groove, e.g. 10mm-4mm = 6mm. number of cuts required. feed rate.
F value =
G83 Peck Drilling
This code is used to drill holes deeper than twice the drill diameter. From the stand-off point (X = 0, Z = 2) the first movement takes the drill in the -Z direction a distance equal to twice the drill diameter. After withdrawing from the hole (to remove swarf) the drill returns and cuts further in the -Z direction by an amount which is determined by: K multiplied by the first depth This 'pecking' is repeated until the total depth Z is reached. After entering G83 follow with: Z value = I value = K value = total depth of hole (exclude the stand-off). drill diameter. reduction: a decimal value. This is the percentage by which the second and subsequent pecks are reduced, until the required depth is reached, e.g. 0.9 or 0.99. feed rate.
F value =
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5.7 CNC Programming
G84 External or Internal Thread Cutting
External Thread: The start point for the threading cycle in the X axis is 2mm greater than the outside diameter of the point on the diameter of the material to be cut (the stand-off point). This position is programmed on the line previous to the G84 being called. After entering G84, follow with: Z value = I value = total length from stand-off (negative for left hand thread, positive for right hand thread). depth of thread (measured on diameter, e.g. 1.23 for 1mm pitch). number of cuts. The minimum is 10 cuts and this is suitable for up to 1mm pitch. For larger values of pitch increase the value of K pitch.
K value =
F value =
Cutting tool is tool no. 4, speed (S) value is 500/600 rev/min. Internal Thread: This is programmed in the same way as the external thread except that the tool is tool no.10. Note that the I value (depth) must be negative. Cancel G84 with G80.
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5.8 CNC Programming
5.8 Inputting a New Program

5.8.1 Information Required To input a new program, you will need the following information: 1. A completed programming sheet containing Program details Type of co-ordinates used (absolute or incremental) Tools used Speeds and feeds Details of the billet Outside diameter Inside diameter (if the billet is hollow) Length A name for your program (7 characters maximum - do not use spaces, . \ or / in the name.) The type of format for the program display. The options are tabulated format and compact format. Tabulated format is easier to read and therefore more suitable for the earlier stages of programming. The programming sheets used in the Tutorials and Exercises use tabulated format. Compact format is more typical of the type of display used in industry, and is suitable for the more advanced programmer. The type of format can be changed by selecting CONFIG - Program from the main menu, and setting the DISPLAY TYPE to TABULATED or COMPACT as required. A program can be input and saved in either format, and can be displayed in either format by changing the DISPLAY TYPE. The main procedure (5.8.2 on the following page) deals with the use of tabulated format, and the example used is taken from Tutorial 1 (TUT 1). Instructions for using compact format are given in 5.8.3. Other configuration settings required. The STANDOFF option automatically adds the depth of cut to a 2mm standoff (clearance between tool and workpiece) when using canned cycles. In MODAL PROGRAMMING, each of the following codes need only be typed once. Each code is then repeated automatically in subsequent lines until a different code is typed:
2.
3. 4.
5.
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5.8 CNC Programming
G01 G02 G03 F
: : : :
Linear interpolation Circular interpolation (clockwise) Circular interpolation (counter-clockwise) Feed rate
These options can be activated by selecting CONFIG - Program from the main menu, and making the required settings. 5.8.2 Tabulated Format Check Configuration 1. From the main menu, select CONFIG - Program, and check the following settings: UNITS MODE PROGRAMMING MODE DISPLAY TYPE GRID SNAP STANDOFF MODAL PROGRAMMING = Input Program Details 2. From the main menu, select PROGRAM - Program, and from the catalogue select NEW PROGRAM. The following display will appear: = as required (METRIC for TUT 1) = as required (ABSOLUTE for TUT 1) = TABULATED = as required = as required as required
Type the name of the program and press EOB.
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5.8 CNC Programming
3.
Select OK by pressing EOB. The next display will appear:
The display shows the dimensions of the last billet used, with the value of outside diameter highlighted. If required, change the diameter by overtyping. When the correct value is shown, press EOB; the next item (I-Dia) will be highlighted. Set the remaining two values in the same way. If the billet is not hollow, set the internal diameter to zero. Note: The values can be edited by using the and keys to highlight the required values, and overtyping.

Press EOB, and set the depth of hole when prompted. Input Program 4. Press EOB. The screen shows the Program WRITE display, (Figure 5.1). The first line number (block number) N10 appears automatically at the left of the display, and the text cursor is in the G column.
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5.8 CNC Programming
*! ! *
1. 2. 3.
Text cursor Simulation display * indicates that program has changed since it was last saved - save again if required. ! indicates that program has changed since simulation was last drawn select VIEW - Redraw to update display. Deletes last line entered. Redraw - updates simulation display to include latest program changes. 3D view - changes simulation display to 3D view. Displays information for reference during programming (see text). Options for saving and editing programs (see text).
UNDO VIEW HELP MENU
Figure 5.1
Program WRITE Display
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5.8 CNC Programming
When typing in the program, precede each item with the letter at the top of the corresponding column; at the end of each item press INPUT. The cursor will move automatically to the appropriate column when the letter is typed in. It is not necessary to use the / key; the keypad automatically toggles between letters and numbers at the appropriate points. Type in the first line of the program. For example, the first line of the program for TUT 1 is: N 10 Type: G90 As the code number is typed, a message appears giving the meaning of the code. (Other messages give indications of errors such as incorrect feed speeds). When the line is complete, press EOB. The next line number appears automatically and the cursor moves to the G column in the next line. Type the second line of the program. For TUT 1 the second line is: N 20 G 71 G 90
Type: G71 (EOB). Type the third line. The third line of TUT 2 is: N 30 X 30 Z 10
Type X30 (INPUT) Z10 (EOB). The cursor moves automatically to the X and Z columns. When EOB is pressed the next line number appears and the cursor moves to the G column. Continue to input the whole of the TUT2 program CAUTION REMEMBER TO SAVE YOUR PROGRAM BEFORE SWITCHING OFF THE MACHINE, EVEN IF IT IS NOT COMPLETE. (SEE 5.9 SAVING A PROGRAM).
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5.8 CNC Programming
Correcting Errors You can place the cursor anywhere in the program, and correct errors by overtyping or by deleting characters with the ALT key and re-typing.
Although the display shows only three lines of the program, you can scroll the program to show any line by using the and keys.
For more extensive changes, use the editing facilities available from the MENU option, (see 5.11 Editing a Program).
Use the and keys to move the text cursor vertically, and the to move from column to column.
and keys
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5.8 CNC Programming
HELP HELP provides the following information which you may need to refer to when creating a program: G Codes M Codes Tool Library Program Data meanings meanings graphical display of tools with tool numbers and descriptions Title Workpiece dimensions Program length (no. of lines) Estimated manufacture time Tools used Maximum bar size Minimum and maximum feedrates and speeds
Machine Data
MENU The features available from the MENU option are used for saving a program (see 5.9) and editing a program (see 5.11). 5.8.3 Compact Format To input a program in compact format, first check the software configuration as for tabulated format but set the DISPLAY TYPE to COMPACT. Input the program information in the same way as for tabulated format. When the Program WRITE display appears, the panel where the program is input looks like this:
Compare this with Figure 5.1. The line number and the text cursor appear, but there are no columns with identifying letters.
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5.8 CNC Programming
When typing in the program, precede each item with the letter at the top of the corresponding column on the programming sheet; at the end of each item press INPUT. There is no need to leave spaces between items in the line; spaces will be inserted automatically. When each line is complete, press EOB. The next line number appears automatically and the cursor moves to the first (G) column in the same way as for tabulated format. In addition, spaces are automatically inserted between items, and numerical values standardised to show two decimal places. For example, in lines 30, 40 and 50 of Tutorial 1 (TUT 1): Line 30 type: X30 (INPUT) Z10 (EOB) 40 type: M04 (INPUT) X20 (INPUT) Z2 (INPUT) S2000 (EOB) 50 type: G01 (INPUT) X20 (INPUT) Z-15 (INPUT) F70 (EOB) N30 N40 N50 X30.00 Z10.00 M04 X20.00 Z2.00 S2000 G01 X20.00 Z-15.00 F70
The display shows:
Error correction, and the other features of the Program WRITE display are the same as for tabulated format.
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5.9 CNC Programming
5.9 Saving a Program

The last line of a program must consist of one of the following codes: M99 - if the program is unfinished M02 - for single part manufacture M30 - for multiple part manufacture Note: If you try to save a program which does not end with one of these codes, the software adds the code M99 to the end of the program. There are three ways to save a program: a) b) At the last line of the program type M99, M02 or M30 as required and press EOB; the program will automatically be saved. (This is the recommended method). from the MENU option, select Save program. The display will show the message: automatically
Press EOB; the program will be saved with code M99 added at the last line.
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5.9 CNC Programming
c)
Press
ESC
The display will show the message:
Select YES last line.
by pressing EOB; the program will be saved with code M99 added at the
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5.10 CNC Programming
5.10 Examining an Existing Program

From the main menu select PROGRAM - Program, and from the catalogue select the required program. The screen shows the following display with a drawing of the component beneath it:
The options available enable the program to be examined as follows: VIEW INFO MENU Produces a 3-D view of the component. Displays program details. Display Edit Continue 2D Simulate 3D Simulate lists the program see 5.11 Editing a Program see 5.12 Continuing a Program simulates machining in 2D simulates machining in 3D
To use these options (except for Edit and Continue), refer to Section 2 - Running the Demonstration Program.
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5.11 Editing a Program

A new program which has been partly written can be edited, and an existing program can be edited, by using the MENU editing options described in 5.11.3 below. To access the options, refer to 5.11.1 New Programs or 5.11.2 Existing Programs as appropriate. 5.11.1 New Programs From the program WRITE display (Figure 5.1), select
MENU
5.11.2 Existing Programs Refer to 5.10 Examining an Existing Program, and select MENU - Edit. The screen shows the Program EDIT display:
Scrolling:

Line down - press Line up - press
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Amendments to the program can be made in the same way as detailed in 5.8.2 Tabulated Format - Input Program. To access the editing options, select 5.11.3 MENU Editing Options
MENU
Insert Line Inserts an additional line, and renumbers subsequent lines. Place the text cursor on the line above the required new line and press EOB. Clear Line Deletes program data from a line, but leaves the line number intact. Place the text cursor on the required line and press EOB. The prompt: "ARE YOU SURE? YES/NO' provides a safeguard against accidental deletion. Go to Line Places the text cursor on a specified line:
Type in the required line number and press EOB.
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Delete Line Delete a program line data and number from the program. Place the text cursor on the line to be deleted, and press EOB. The prompt "ARE YOU SURE? YES/NO" provides a safeguard against accidental deletion. Find and Replace Searches for a specific program item and enables it to be replaced by another specific item:
For example, to find all occurrences of code M03 (spindle start - forward) and replace them with code M04 (spindle start - reverse), starting the search from line 90 of the program, type in the following: Find Replace with Start line no. M03 MO4 90 (EOB) (EOB) (EOB)
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SELECTIVE Search A selective search will stop at each occurrence of the code, with the message:
To change the code to the replacement code and search for the next occurrence, select REPLACE. To leave the code unchanged and search for the next occurrence, select CONTINUE. At the end of the search a report will be displayed; for example:
Press EOB. GLOBAL Search A global search will find each occurrence of the code and replace it with the replacement code. At the end of the search a report will be displayed as for a selective search. Header Edit Enables the name (title) of the program, and the dimensions of the billet (bar) to be changed. (Refer to 5.8.2 Tabulated Format - Input Program Information).
Boxford 280B
Block Delete Enables highlighted blocks of the program to be omited during the manufacture cycle when the 'Block Delete' key on the Machine Control Panel is pressed (see section 5.1 of the Installation and User manual).
Note:-
Blocks containing Rapid Moves (G00), Linear (G01) and Circular Interpolations (G02 & G03) CAN NOT be block deleted. To highlight a block, the cursor is moved onto the relevent block and MENU - Block Delete selected.
Boxford 280B
5.12 Continuing a Program

An incomplete program which has been saved can be continued at the point where inputting was interrupted. Refer to 5.10 Examining an Existing Program, and select MENU - Continue. The display will simulate the completed part of the program in 2D, stopping when the last line is reached. The M99 code will be deleted from the last line of the program, enabling inputting to be continued.
Boxford 280B
6.2 CNC and CAM Machining
6 CNC and CAM Machining

The procedures for machining a component produced by a CNC program and a CAM program are the same. The software executes a CNC program to manufacture the component; CAM programs are converted to CNC format when they are saved, (see Section 4 - CAM Programming, 4.9 - Processing a Profile).
6.1 Initial Checks

Before attempting to machine a component, check: Reference 1. 2. 3. 4. Machine switched on and software running. Software correctly configured. Tooling and offsets for required program set and checked. Program verified: CNC program - verified by simulation. CAM program - automatic validation. Machine initialised. (Press RESET if necessary) Billet of correct material and dimensions fitted in chuck. Select PROGRAM - Program, then to check dimensions. INFO Guard closed. Machine in Automatic mode. (Press AUTO key on machine control panel). Installation and User Manual Section 5 Installation and User Manual Appendix A Section 3 Section 5, 5.10 Section 4, 4.9
5.
6.
7. 8.
Boxford 280B
6.2 Manufacture
1. 2. From the main menu, select MACHINE, then Manufacture. The screen shows the MANUFACTURE CATALOGUE display. Select the required program. The software will read the machine file for the component, and the screen will then list the tooling with the tools required by the selected program highlighted, for example:
Boxford 280B
3.
Provided that the offsets have already been checked as detailed in 6.1, select OFFSETS CORRECT . The screen shows:
Follow the instructions. The display shows the dimensions of the billet required by the selected program. Fit the billet in the chuck, enter the length of the billet, and check that the appropriate tool is fitted or indexed. 4. Press EOB. The screen shows:
Home the axes, using the HOME and AXIS DIRECTION keys.
Boxford 280B
5.
When the axes reach the home position, the screen shows a message indicating that the machine is being initialised. When the machine has been initialised, the screen displays the MANUFACTURE display with prompt:
6.
Press CYCLE START on the control panel. The machine performs the machining cycle which is simulated simultaneously on the screen display together with the program line currently being executed. When the machining cycle is complete, the screen shows a message giving the option of manufacturing a further component if the program ends with the code M30. Select Yes or No as required. If Yes is selected, the screen will prompt for another billet to be fitted. If No is selected, the screen returns to the main menu.
7.
Boxford 280B
6.3 6.2 CNC and CAM Machining
6.3 Options During Machining

Pressing ESC on the keypad during a machining cycle causes a status message to be displayed:
Continue: Abort:
Programmed machining continues. Stops machining and cancels program.
Select the required option ising the keyboard.
7 Manual Machining
The manual machining feature enables the machine to be controlled directly using the control panel while the screen simultaneously displays axis displacement and spindle speed. 1. 2. Selecting Manual Mode On the control panel, ensure that Manual mode is selected. From the main menu, select MACHINE - Feedback. The screen shows the Manual Mode Display, (Figure 7.1). Using the Control Panel As the tool is moved with the X and Z AXIS DIRECTION keys, the X and Z axis coordinates in the display alter correspondingly, giving a continuous and precise location of the tool tip position. The tool can be moved rapidly in either axis when away from the workpiece using the RAPID key in conjunction with the X and Z AXIS DIRECTION keys.
1 2
1. 2. 3. 4.
Tool position on axes Spindle speed indication X ZERO button Z ZERO button
Figure 7.1
Manual Mode Display
Boxford 280B
7 Manual Machining
The tool feed rate can be increased or decreased with the FEED RATE control. Direction of spindle rotation and spindle speed are controlled using the SPINDLE CW, CCW and STOP keys. Spindle speed is displayed on the screen in revs per minute. A pneumatic chuck (when fitted) is opened and closed with the CHUCK OPEN and CLOSE keys. When a tailstock is fitted, the quill is operated manually by its handwheel. On the air powered version, the quill is operated from the control panel using the TAILSTOCK QUILL keys. Zeroing Tool Displacement Set the X-axis reference point with the first or reference tool using the AXIS DIRECTION keys so that tool tip just touches the workpiece diameter. Select X ZERO on the screen with the appropriate Softkey. Set the Z-axis reference with the AXIS DIRECTION keys, touching the tool on the workpiece. The reference point is registered and displayed as zero in both X and Z axis displays. Turret Gang Plate Quick Change Toolpost Tool Changing The turret is indexed round one position at a time to any of the eight tool positions with each press of the TURRET INDEX button. Either stop the machine and manually fit another tool, or use the X and Z AXIS DIRECTION keys to access another tool already fitted to the plate. Whenever a tool change is required, use the STOP button to stop the spindle, lift the guard and change the tool assembly. Returning to Automatic Mode To return to Automatic mode, use the MODE SELECT keys; press AUTO, then RESET.
Boxford 280 B
CNC Tutorials and Exercises
Boxford 280 B
Tutorial 1 - CNC Tutorials and Exercises
Tutorial 1: Linear Interpolation Tabulated and Compact Program Display

This tutorial introduces the student to simple part programming using the G01 preparatory code (linear interpolation) and also the G00 code (rapid movement) which is the default value if G01 is not selected. The program is for the profile from A to E and does not include any roughing cuts. Do not use this program to machine a component.
E D
A T/C X30 Z10
25
24
15
15
The absolute co-ordinates of the points on the profile are tabulated below:
POINT X Z DATUM 0 0 A 20 0 B 20 -15 C 24 -30 D 24 -35 E 25 -35
Tool used: 1 (LH Turning Tool)
20
Boxford 280 B
The program is written as follows:-
DRAWING NUMBER SEQUENCE DESCRIPTION

ABSOLUTE PROGRAMMING METRIC UNITS TOOL CHANGE POSITION MOVE TO START - START SPINDLE A TO B B TO C C TO D D TO E SPINDLE STOP - TOOL CHANGE END PROGRAM
PROGRAMMING SHEET DUET PROGRAMMING SHEET-TURNING

TITLE.
TUT 1
MATERIAL:
STEEL EN1A ALUMN
WRITTEN BY AXIS COORDINATES X Z I
SHEET No. 1 OF 1 FEED RATE K F SPINDLE SPEED S
SEQUENCE PREP MISC No. FUNCTION FUNCTION N

10 20 30 40 50 60 70 80 90 100 01 01 01 01 05 02 04
G
90 71
30 20 20 24 24 25 30
10 2 -15 -30 -35 -35 10 70 70 70 70 2000 2500
Boxford 280 B
Note: The first tool is selected when setting up the machine. G00 is the default value if G01 is not selected. Using a compact display (CONFIG menu - Program - DISPLAY TYPE-COMPACT) the program will be:
N10 G90 N20 G71 N30 X30 Z10 N40 M04 X20 Z2 S2500 N50 G01 X20 Z-15 F70 N60 G01 X24 Z-30 F70 N70 G01 X24 Z-35 F70 N80 G01 X25 Z-35 F70 N90 M05 X30 Z10 N100 M02
Boxford 280 B
Exercise 1:
Simple Programming - Absolute Co-ordinates
1. 2. 3.
Tabulate the absolute co-ordinates of points A to E on the profile. Using a programming sheet write a program to machine the profile. Enter the program and simulate the tool movements. (Do not attempt to machine the component)
E D C B A T/C X15 Z15

25 20 15
10
18
10
Boxford 280 B
Tutorial 2: Incremental Co-ordinate Programming

The incremental co-ordinates of the points on the profile are tabulated below.
POINT X Z DATUM 0 0 A 20 0 B 0 -15 C 4 -15 D 0 -5 E 1 0
The program is written as follows: DUET PROGRAMMING SHEET-TURNING PROGRAMMING SHEET

TITLE.
TUT 2

ABSOLUTE PROGRAMMING METRIC UNITS TOOL CHANGE POSITION START POINT - SPINDLE START MOVE TO A INCREMENTAL PROGRAMMING A TO B B TO C C TO D D TO E ABSOLUTE PROGRAMMING SPINDLE STOP - TOOL CHANGE END OF PROGRAM
MATERIAL:
STEEL EN1A

10 20 30 40 50 60 70 80 90 100 110 120 130 01 91 01 01 01 01 90 05 30 04
G
90 71
30.0 20.0
10.0 2.0 0 70 2000 2500
0 4.0 0 1.0
-15.0 -15.0 -5.0 0
70 70 70 70
30.0
10.0
Boxford 280 B
Exercise 2:
Simple Programming - Incremental Co-ordinates
Using the component shown in Tutorial 1: 1. 2. 3. Tabulate the incremental co-ordinates of points A to E on the profile. Using a programming sheet write a program to machine the profile. Enter the program and simulate the tool movements. (Do not attempt to machine the component)
Boxford 280 B
Tutorial 3: Turning and Facing a Stepped Shaft

This tutorial introduces the student to the completion of operation and programming sheets and the writing of a program for a component requiring roughing and finishing cuts. The operations sheet lists the sequence of machining operations, feed, spindle speed and the tool required. It also gives details of the material and its position in the chuck. A roughing and a finishing cut have been asked for on each diameter. The programming sheet lists the program to machine the component; an explanation of each line has been given in the left hand column. The datum is at the right hand end of the component.
Boxford 280 B
DRAWING NUMBER BILLET
DUET OPERATIONS SHEET - TURNING

MATERIAL 25
STEEL EN1A ALUMINIUM
TYPE NO. 1 0 I/DIA. 40 STICKOUT SPINDLE SPEED 2500
TITLE TUT 3 TOOL FEED 70 TOOL NO. 1
O/DIA.
OPERATION NUMBER 1 2 3 4 5 6 7 8 9 10 FACE TURN
OPERATION DESCRIPTION
23.5 x 35 22 x 35 20.5 x 31 19 x 30 CHAMFER 1.5 x 45 O TO 23 TURN 17 x 10 15 x 10 TOOL PARK POSITION END PROGRAM
RAPID
40 35 30 45O 10
25
19
22
15
Boxford 280 B

ABSOLUTE PROGRAMMING METRIC UNITS TOOL PARK POSITION START SPINDLE RAPID TO START POSITION FACE END OF MATERIAL RAPID CLEAR OF FACE RAPID TO FIRST CUT DIAMETER CUT 23.5 X 35mm LONG RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT DIAMETER X 35mm LONG RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT DIAMETER X 21mm LONG RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT DIAMETER X 20mm LONG CUT CHAMFER X 45 O RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT DIAMETER X 10mm LONG RAPID CLEAR OF WORK POSITION FOR NEXT CUT ( 15) CUT DIAMETER X 10mm LONG TOOL PARK POSITION/STOP SPINDLE END PROGRAM
DUET PROGRAMMING SHEET-TURNING PROGRAMMING SHEET

TITLE.
TUT 3
25 X STEEL EN1A MATERIAL: 25X4040 ALUMN.
WRITTEN BY AXIS COORDINATES X Z
A.N, OTHER
SHEET No. 1 OF 1 FEED RATE SPINDLE SPEED S
MISC SEQUENCE PREP No. FUNCTION FUNCTION N

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 01 05 30 01 01 01 01 01 01 01 04
G
90 71
30.0
10 2000 2500
26.0 -1.0
0 70 1
23.5 -35 24.5 22.0 -35 23.0 20.5 -31 21.5 19.0 -30 23.0 -32 1 17.0 -10 18.0 15.0 -10 30.0 10 70 1 70 70 70 1 70 1 70 1 70
TUT3 T2
Boxford 280 B
Exercise 3:
Turning and Facing a Stepped Shaft
The component for this exercise is similar to that in Tutorial 3. 1. 2. 3. Write an operations sheet for this component Write a program to machine the component Give your program a test run and edit it if necessary.
25
20
15
15 25 35 40
10
Boxford 280 B
Tutorial 4: Circular Interpolation

This gives an explanation of the G02 and G03 codes for clockwise and anticlockwise circulated interpolation respectively. The programs are for the profile only and do not include any roughing cuts. Do not use these programs to machine a component. Circular Interpolation (G02 and G03) To program an arc it is necessary to define a FINISH point by an X and Z dimension and, in addition either (a) I and K values which give the co-ordinate of the arc centre from the start point in the X and Z directions respectively; (these are unsigned) or (b) the radius of the arc as an I value. The start and finish point of an arc must be in the same quadrant. A semi-circle requires two blocks to be programmed. G02 Clockwise Circular Interpolation
C R3 A B T/C X30 Z10
25
25
POINT X Z DATUM 0 0 A 17 0 B 17 -22 C 25 -25
Tool used: 1 (LH Turning Tool)
19
Boxford 280 B
The program is written as follows:DRAWING NUMBER SEQUENCE DESCRIPTION

ABSOLUTE PROGRAMMING METRIC UNITS TOOL CHANGE POSITION START POINT-SPINDLE START A TO B B TO C SPINDLE STOP-TOOL CHANGE END PROGRAM

TITLE.
TUT 4/1
MATERIAL:
ALUMN STEEL EN1A

10 20 30 40 50 60 70 80 01 02 05 30 04
G
90 71
30 19 19 25 30
10 2 -22 -25 10 3 0 70 70 2000 2500
Note: In block N70 I and K are the co-ordinates of the arc centre measured from the start of the arc. This program is for the profile only and does not include any roughing cuts.
Boxford 280 B
Tutorial 4 - CNC Tutorials and Tutorial 4 Exercises
G03 Counter Clockwise Circular Interpolation

D C R3 B A E T/C X30 Z10
25
20
POINT X Z DATUM 0 0 A 17 0 B 23 -3 C 23 -20 D 25 -20 E 17 -3
Tool used : 1 LH Turning Tool
17
23
Boxford 280 B
The program is written as follows:PROGRAMMING SHEET DUET PROGRAMMING SHEET-TURNING

TITLE.
TUT 4/2

ABSOLUTE PROGRAMMING METRIC UNITS TOOL CHANGE POSITION START POINT - SPINDLE START POINT A A TO B B TO C C TO D SPINDLE STOP - TOOL CHANGE END PROGRAM
MATERIAL:
STEEL ALUMN EN1A

10 20 30 40 50 60 70 80 90 100 01 03 01 01 05 30 04
G
90 71
30 17 17 23 23 25 30
10 2 -0 -3 -20 -20 10 3 70 70 70 2000 2500
70
Note: 3 in block N60 is the radius of the arc. This program is for the profile only and does not include any roughing cuts.
Boxford 280 B
Exercise 4:
Circular Interpolation
This exercise uses both the G02 and G03 codes. 1. 2. 3. Tabulate the absolute co-ordinates of points A to D on the profile. Using a programming sheet write a program to machine the profile. Give your program a test run and edit it if necessary.
D R3 B C E A
R3
25
25
19
Boxford 280 B
Tutorial 5: Circular Interpolation and Roughing Cuts with a Tool Change

This tutorial gives a further example of circular interpolation and also illustrates how to rough surplus material from the billet so that the maximum depth of cut of 3mm on the diameter is not exceeded. Suppose that it is required to take roughing cuts before turning an arc of 4mm radius on a steel component. A scale drawing of the arc section will reveal the variations between the lengths of roughing cut. In the drawing below, the horizontal lines represent the depths of cut and the vertical lines the lengths of roughing cuts.
An alternative method is to take chamfering cuts on the surplus material. This is generally more difficult to program because the X co-ordinates are measured on the diameter and so are double the corresponding Z co-ordinates to give a 45 degree chamfer. The drawing on the next page is used to determine the length of the roughing cuts; 2mm is left on the diameter before the final finishing cut is taken. The operations sheet shows the details of the roughing cuts and a program for the component is given. Test run the program and examine its operation.
Boxford 280 B
19 X19, Z-35
25 23 21 X19, Z-27
19 17 15 13 X11, Z-23 X11, Z-4
X11, Z-27
11 8 X3, Z0
X3, Z-4
Programming a Tool Change The first tool to be used enters the program as part of the initial programming information. The second and subsequent tools are entered on the program with two lines of information. The first line stops the spindle and moves the tool away from the work, and the second line selects the next tool. A typical example of this is:
LINE N70 N80
M 05 06
X 30.00
Z 10.00
I 5
I5 denotes a centre drill
Boxford 280 B
DUET OPERATIONS SHEET - TURNING OPERATIONS SHEET

MATERIAL 25

O/DIA. 0 I/DIA. 40
TYPE NO. 1 STICKOUT SPINDLE SPEED
OPERATION NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 FACE TURN
2500 2000
23 x 35 21 x 35 19 x 24 17 x 23 15 x 22 13 x 22 11 x 2 8x1 TAKE CONTINUOUS FINISHING CUT TOOL PARK POSITION CHANGE TOOLS PART OFF TO LENGTH TOOL PARK POSITION END PROGRAM
2500 3000
90 RAPID 50 RAPID 11
2000 2500
37 35 23 R4
25
19
11
R4
Boxford 280 B
DRAWING NUMBER

TITLE.
TUT 5
MATERIAL:
STEELALUMN EN1A
SEQUENCE DESCRIPTION
ABSOLUTE PROGRAMMING METRIC DIMENSIONS TOOL CHANGE POSITION
START SPINDLE RAPID TO START POSITION

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 01 01 01 01 01 01 01 01 04
G
90 71
30.0 26.0 -1.0
10.0 0 70 1.0 2000 2500
FACE END OF MATERIAL RAPID CLEAR OF FACE RAPID TO FIRST CUT DIAMETER CUT 23 X 35mm LONG RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT DIAMETER X 35mm LONG RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT DIAMETER X 24mm LONG RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT DIAMETER X 23mm LONG RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT DIAMETER X 22mm LONG RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT DIAMETER X 22mm LONG RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT DIAMETER X 2mm LONG RAPID CLEAR OF FACE
23.0 -35.0 24.0 21.0 -35.0 22.0 19.0 -24.0 20.0 17.0 -23.0 18.0 15.0 -22.0 16.0 13.0 -22.0 14.0 11.0 -2.0 13.0 1.0 70 1.0 70 1.0 70 1.0 70 1.0 70 1.0 70 1.0 70
Boxford 280 B

POSITION FOR NEXT CUT CUT DIAMETER X 1mm LONG RAPID CLEAR OF WORK
POSITION FOR NEXT CUT (FINISHING CUT)

TITLE.
TUT 5
MATERIAL:
STEEL EN1A
WRITTEN BY AXIS COORDINATES X

8.0
SHEET No. 2 OF 2 FEED RATE I K F

70

280 290 300 310 320 330 340 350 360 370 380 390 400 410 420 05 30 01 03 01 03 01 05 06 04 01
SPINDLE SPEED S
Z
--1.0
9.0 3.0 11.0 11.0 19.0 19.0 30.0
1.0 0 -4.0 -23.0 -27.0 -35.0 10.0 11 4 4 90 90 90 90 2500 3000
FINISH CUT 4mm RADIUS FINISH TURN 11 FINISH 4mm RADIUS FINISH TURN 19 TOOL CHANGE POSITION I11 IS A PARTING TOOL
MOVE TO PARTING POSITION - SPINDLE ON (TOOL 1.6mm WIDE)
27.0 -1.0 30.0 30.0
-38.6 70
2500 2000
PART OFF RAPID CLEAR OF WORK SPINDLE STOP - TOOL CHANGE END PROGRAM
10.0
Boxford 280 B
Exercise 5: Circular Interpolation and Roughing Cuts with a Tool Change

This exercise uses clockwise circular interpolation, tool changing and parting off. 1. 2. 3. Complete an operations sheet for roughing and finishing the component below. Using a programming sheet write a program to machine the component. Give your program a test run and edit it if necessary.
R4 R3
25
17
16 32.4 40
11
Boxford 280 B
Tutorial 6: Canned Cycles - Facing and Rough Turning

This tutorial serves as an introduction to Canned Cycles which simplify the programming of respective operations. The tutorial is in two parts. In the first part the G82 canned cycle for facing is considered, and in the second part the G81 canned cycle for roughing outside diameters is used. G82 Facing Cycle Examine the operations sheet and drawing for TUT 6/1. It is required to reduce the length of the billet from 40mm to 30mm in 25 cuts. In all outside diameter canned cycle operations, at the commencement of the cycle, the tip of the tool must be positioned at a stand-off point on the previous line of the program code. This point is always 2mm greater (on diameter) measured from the work. In this cycle it is also necessary to have a stand-off along the Z axis. This position is 2mm clear of the end of the work. On completion of the cycle the tool will return to its start point. Tool used: 1 (LH turning tool) Stand-off point: at X27 Z2 X (total cut depth): it is usual to go past the centre line by 0.5 to clear the end, i.e. standoff dia + 1mm = 28 Z (total cut width, excludes the stand-off) = 10 I (no of cuts) = 25 F (feed rate) = 70mm/min The program is shown on the programming sheet. Test run the program and examine how the cycle operates.
Boxford 280 B

MATERIAL 25
TYPE NO. 0 I/DIA. 40 STICKOUT SPINDLE SPEED
TITLE TUT 6/1 TOOL FEED RAPID 70 RAPID TOOL NO. 1
O/DIA.
OPERATION NUMBER 1 2 3 4 5
OPERATION DESCRIPTION TOOL PARK POSITION STAND OFF POSITION FACE OFF TO 30mm LONG USING G82 CYCLE WITH 25 CUTS TOOL PARK POSITION END PROGRAM
2500 2000
30
2mm ON DIA.
2mm
25
Boxford 280 B

ABSOLUTE PROGRAMMING METRIC UNITS TOOL CHANGE POSITION SPINDLE START STAND OFF POINT FACING CYCLE SPINDLE STOP - TOOL CHANGE END OF PROGRAM

TITLE.
TUT 6/1
MATERIAL:
ALUMN STEEL EN1A

10 20 30 40 50 60 70 82 05 30 04
G
90 71
30.0 27.0 28.0 30.0
10.0 2.0 -10.0 10.0 25 70 2000 2500
Boxford 280 B
G81
Rough Turning. The component previously machined is now required to have its outside diameter reduced from 25mm to 15mm for a length 25mm. This is shown on the drawing and operations sheet for TUT 6/2. The program for TUT 6/1 can be edited and extended by using the G81 canned cycle. Because it is the same component it retains work datum X0,Y0 and so the stand-off point for G81 will be X27, Z-9.5 i.e. 2mm greater in diameter and 0.5 clear of the work in the Z axis. Tool used: 1 (LH turning tool) Stand-off point: X27, Z-9. X (total cut depth ,i.e. the difference between the original dia and the final dia excluding the stand-off) =10 Z (total length of travel in the Z axis i.e. cut length plus any stand-off in the Z direction) =-25.5 I (no. of cuts required) =5 F (feed rate) =70 The program for TUT 6/2 is shown on the programming sheet. This can be used to extend TUT 6/1 at the appropriate block no. Extend TUT 6/1, test it and examine its operation.
Boxford 280 B
OPERATIONS SHEET DUET OPERATIONS SHEET - TURNING

MATERIAL 25
TYPE NO. 40 I/DIA. 40 STICKOUT SPINDLE SPEED
TITLE TUT 6/2 TOOL FEED TOOL NO.
O/DIA.
OPERATION NUMBER
OPERATION DESCRIPTION continued from TUT 6/1
1 2 3 4 5
TOOL PARK POSITION STAND OFF POSITION TURN 15 x 25mm LONG USING G81 CYCLE WITH 5 CUTS TOOL PARK POSITION END PROGRAM
2000 2500 RAPID 70 RAPID RAPID
30 25
25
15
Boxford 280 B

ABSOLUTE PROGRAMMING METRIC UNITS TOOL CHANGE POSITION SPINDLE START STAND OFF POINT FACING CYCLE SPINDLE STOP - TOOL CHANGE SPINDLE START STAND OFF POINT ROUGH TURNING CYCLE SPINDLE STOP - TOOL CHANGE END OF PROGRAM

TITLE.
TUT 6/2
MATERIAL:
STEEL EN1A ALUMN

10 20 30 40 50 60 70 80 90 100 81 05 30 82 05 04 04
G
90 71
30.0 27.0 28.0 30.0 27.0 10.0 30.0
10.0 2.0 -10.0 10.0 -9.5 -25.5 10.0 5 70 2000 2500 25 70 2000 2500
Boxford 280 B
Exercise 6:
Canned Cycles - Facing and Rough Turning
You are required to produce a component which fulfils the following machining specification: a) b) c) d) e) Billet size 25mm x 40mm stickout from chuck. Billet material - steel EN1A. Face to 35mm length with 15 cuts. Outside diameter roughed to 19mm in cuts not exceeding 3mm on diameter. Part off to a finished length of 30mm.
Complete the following tasks: 1. 2. 3. Complete an operation sheet for the above machining operations. Using a programming sheet write a program for the component. Give your program a test run and edit it if necessary.
Boxford 280 B
Tutorial 7: Canned Cycles - Grooving

Examine the operations sheet and drawing. The G82 grooving cycle is carried out using tool no.11 - the parting off tool. This tool is 2mm wide, and when setting offsets its reference face is taken as the side nearest the chuck. The cycle is used to cut a rectangular section groove of width exceeding 4mm. Before entering the canned cycle routine it is necessary to create a slot of width 2mm + the width of the tool to the required depth. This is accomplished by using the parting off tool and programming code G01. After cutting this narrow groove take the tool to its stand-off position which is always 2mm greater (on diameter) measured from the work and 2mm stand-off along the Z axis.
2mm PARTING TOOL 2mm 2mm ON DIA.
10
Relationship of stand-off position to preparatory slot. Stand-off point: at X22 Z-12 X (the difference between the stand-off diameter at the bottom of the groove 22-15) = 7 Z I F (the additional width of the groove 10-4) = 6 (no. of cuts) = 10 (feedrate) = 70
The program is shown on the programming sheet. Test it and examine its operation.
Boxford 280 B

MATERIAL 25

O/DIA. 0 I/DIA. 40
TYPE NO. STICKOUT SPINDLE SPEED
TITLE TUT 7 TOOL FEED 70 RAPID 70 RAPID 11 TOOL NO. 1
OPERATION NUMBER 1 2 3 4 5 6 7 8 9 10
OPERATION DESCRIPTION FACE STAND OFF POSITION TURN 20 x 35 USING G81 CYCLE WITH 3 CUTS CHAMFER 1mm x 45O TO 20 TOOL PARK POSITION CHANGE TOOLS CUT SLOT 15 x 3.16 EXTEND GROOVE TO 10mm LONG USING G82 CANNED CYCLE TOOL PARK POSITION END PROGRAM
2500 2000
2000 2500
50 RAPID
40 35 20 10 1mm x 45 O
25
20
15
20
Boxford 280 B

ABSOLUTE PROGRAMMING METRIC UNITS TOOL CHANGE POSITION

TITLE.
TUT 7
MATERIAL:
STEEL EN1A ALUMN

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 82 05 30 01 01 01 01 05 06 04 81 01 04
G
90 71
30.0 26.0 -1.0
10.0 0 70 1.0 2000 2500
FACE END OF MATERIAL RAPID CLEAR OF FACE RAPID TO STAND OFF POSITION TURN 20 X 35 RAPID TO START OF CHAMFER CUT CHAMFER TOOL CHANGE POSITION CHANGE TOOL TO PARTING TOOL
START SPINDLE - RAPID TO START OF PREPARATORY SLOT
27.0 5.0 18.0 20.0 30.0
0.5 -35.5 0 -1.0 10.0 11 70 3 70
22.0 15.0 22.0
-11.6 50
2500 2000
START MACHINING PREP SLOT RAPID CLEAR OF DIAMETER RAPID TO NEXT SLOT MACHINE SLOT RAPID CLEAR OF DIAMETER RAPID TO NEXT SLOT MACHINE SLOT RAPID CLEAR OF DIAMETER RAPID TO STAND OFF POSITION GROOVING CYCLE
SPINDLE STOP - TOOL PARK POSITION
-12.6 15.0 22.0 -13.6 15.0 22.0 -11.6 7.0 30.0 -6.4 10.0 10 70 50 50
END OF PROGRAM
Boxford 280 B
Exercise 7:
Canned Cycles - Grooving.
You are required to produce a component which fulfils the following machining specification: a) b) c) d) e) Billet size 25 x 40mm stickout from chuck Billet material - steel EN1A. Face to a length of 40mm with one cut. Rough outside diameter to 18mm in cuts not exceeding 2mm on diameter. Machine a groove of depth 6mm x 12mm long starting 8mm from the free end.
Complete the following tasks: 1. 2. 3. Complete an operations sheet for the above maching operations. Using a programming sheet write a program for the component. Give your program a test run and edit it if necessary.
Boxford 280 B
Tutorial 8: Canned Cycles - External LH Thread.

Note: A threading tool is required for this tutorial. Examine the operations sheet and drawing for TUT 8. The component is the same as that for TUT 7 except that a screw thread has been added and the component has to be parted off. The program for TUT 7 can be edited and extended to include the screw thread by using the G84 canned cycle. The work datum X0 Y0 is the same as that for TUT 7. The stand off point for G84 will X22 Z1.5, i.e. 2mm greater in diameter and 1.5 clear of the work in the Z axis. Tool used: 4 (threading tool). Z (total length from stand-off, negative for left hand thread, positive for right hand thread) -10 + 1.5 = -11.5. I (depth of thread, measured on diameter) = 1.23 for 1.00mm pitch. K (no. of cuts); the minimum is 10 cuts and this is suitable for up to 1.00mm pitch. Note: After the first movement in the X axis there is a pause whilst the software looks for the spindle marker point. The program for TUT 8 is shown on the programming sheet. This can be used to extend TUT 7 at the appropriate block no. Extend TUT 7, test it and examine its operation.
Boxford 280 B

MATERIAL 25

O/DIA. 0 I/DIA. 40
TITLE TUT 8 TOOL FEED TOOL NO.
OPERATION NUMBER
OPERATION DESCRIPTION continued from TUT 7
10 11 12 13 14 15 16 17
CHANGE TOOL STAND OFF POSITION 20 x 1.00mm PITCH THREAD USING G84 CYCLE WITH 10 CUTS CUT 20 x 0.75mm PITCH THREAD USING G84 CYCLE WITH 15CUTS TOOL CHANGE POSITION CHANGE TOOL PART OFF TO LENGTH 32mm TOOL PARK POSITION END PROGRAM
4 400 RAPID RAPID 11
2500 2000
50 RAPID
40 32 20 10 M20 x 0.75mm
25
15
20
Boxford 280 B


TITLE.
TUT 8
MATERIAL:
STEEL EN1A ALUMN

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 84 82 05 06 04 01 01 01 01 05 06 04 81 01 04
G
90 71
30.0 26.0 -1.0
10.0 0 70 1.0 2000 2500
FACE END OF MATERIAL RAPID CLEAR OF FACE RAPID TO STAND OFF POSITION TURN 20 X 35 RAPID TO START OF CHAMFER CUT CHAMFER TOOL CHANGE POSITION CHANGE TOOL TO PARTING TOOL
START SPINDLE - RAPID TO START OF PREPARATORY SLOT
27.0 5.0 18.0 20.0 30.0
0.5 -35.5 0 -1.0 10.0 11 70 3 70
22.0 15.0 22.0
-11.6 50
2000 2500
START MACHINING PREP SLOT RAPID CLEAR OF DIAMETER RAPID TO NEXT SLOT MACHINE SLOT RAPID CLEAR OF DIAMETER RAPID TO NEXT SLOT MACHINE SLOT RAPID CLEAR OF DIAMETER RAPID TO STAND OFF POSITION GROOVING CYCLE
SPINDLE STOP - TOOL PARK POSITION TOOL CHANGE (THREADING)
START SPINDLE RAPID TO STAND OFF POSITION
-12.6 15.0 22.0 -13.6 15.0 22.0 -11.6 7.0 30.0 -6.4 10.0 4 22.0 1.5 -11.5 0.82 1.23 10 0.75 1.00 400 10 70 50 50
CUT THREAD
Boxford 280 B

RAPID TO TOOL CHANGE
TOOL CHANGE - PARTING (1.6mm WIDE)
START SPINDLE RAPID TO PART OFF POSITION

TITLE.
TUT 8
MATERIAL:
STEEL EN1A

30.0
SHEET No. 2 OF 2 FEED RATE I

11

280 290 300 310 320 330 340 05 30 01
SPINDLE SPEED S
M
05 06 04
Z
10.0
22.0 -1.0 25.0 30.0
-33.6 70
2500
PART OFF RAPID TO CLEAR WORK SPINDLE STOP - TOOL CHANGE END OF PROGRAM
10.0
Boxford 280 B
Exercise 8:
Canned Cycles - External RH Thread.
This exercise is a repeat of Tutorial 6 except that the 20mm diameter has a right hand thread. Note that the Z value in the G84 cycle for a right hand thread is positive. A new position for the thread stand-off point will have to be calculated. 1. 2. 3. Complete an operations sheet, based on TUT 7 for the shape and TUT 8 suitably modified for the thread. Using a programming sheet write a program for the component. Give your program a test run and edit it if necessary.
Boxford 280 B
Tutorial 9: Canned Cycles - Peck Drilling

Note: A 7mm drill is required for this tutorial. Examine the operations sheet and drawing for TUT 9. It is required to face the billet, and turn the 23mm diameter, centre drill to a depth of 5mm, peck drill the 07 hole and then part off the component. The stand-off point for G83 will be X0 Z2, i.e. 2mm clear of the face. Tool used: (7) drill. Z (total depth of hole excluding the stand-off) = -20 I (drill diameter) = 7 K (the reduction; a decimal value). This is the percentage by which the second and subsequent pecks are reduced, until the required depth is reached, e.g. 0.99, (the first peck is twice the drill diameter). F (feed rate) = 50mm/min. The program for TUT 9 is shown on the programming sheet. Test it and examine its operation.
Boxford 280 B

MATERIAL 25

O/DIA. 0 I/DIA. 40
TITLE TUT 9 TOOL FEED 70 RAPID 5 TOOL NO. 1
OPERATION NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14
OPERATION DESCRIPTION FACE TURN 23 x 35 TOOL CHANGE POSITION CHANGE TOOL CENTRE DRILL 5mm DEEP TOOL CHANGE POSITION CHANGE TOOL STAND OFF POSITION DRILL 7 HOLE x 20mm DEEP USING G83 CYCLE TOOL CHANGE POSITION CHANGE TOOL PART OFF TO LENGTH (1.6 PARTING TOOL) TOOL PARK POSITION END PROGRAM
2500 2000
2000 2500
50 RAPID 7
1750 1500
RAPID 50 RAPID 11 50 RAPID
2500 2000
40 35 32 20
25
23
Boxford 280 B

ABSOLUTE PROGRAMMING METRIC UNITS RAPID TO TOOL CHANGE

TITLE.
TUT 9
MATERIAL:
STEEL EN1A ALUMN

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 05 30 01 83 05 06 04 05 06 03 01 01 05 06 03 01 04
G
90 71
30.0 26.0 -1.0
10.0 0 70 1.0
2500 2000
FACE END OF MATERIAL RAPID CLEAR OF FACE RAPID TO START OF 23 CUT TURN 23 X 35 SPINDLE STOP - TOOL CHANGE CHANGE TO CENTRE DRILL
SPINDLE START FORWARD C/ DRILL 1mm STAND OFF
23.0 -35.0 30.0 10.0 5 0 1.0 -5.0 2.0 30.0 10.0 7 0 2.0 -20.0 30.0 10.0 11 25.0 -1.0 25.0 30.0 10.0 -33.6 70 2000 2500 7 0.9 50 7 1750 80 70
2500 2000
DRILL 5mm DEEP RETRACT DRILL SPINDLE STOP - TOOL CHANGE TOOL CHANGE - 7 DRILL
G83 PECK DRILL CYCLE SPINDLE STOP - TOOL CHANGE TOOL CHANGE - 1.6mm PARTING
SPINDLE START MOVE TO PARTING POSITION
PART OFF CLEAR WORK SPINDLE STOP - PARK POSITION END OF PROGRAM
Boxford 280 B
Exercise 9:
Canned Cycles - Deep Hole Peck Drilling
Note: A 5mm drill is required for this tutorial. You are required to produce a component which fulfils the following machining specification: a) b) c) d) e) f) g) Billet size 25 x 40mm stickout from chuck. Billet material -steel EN1A Face to a length of 40mm with one cut. Rough outside diameter to 19mm in cuts not exceeding 3mm on diameter. Centre drill. Peck drill a 5mm dia. hole 12mm deep. Part off to 30mm long.
Complete the following tasks: 1. 2. 3. Complete an operations sheet for the above machining operations. Using a programming sheet write a program for the component. Give your program a run and edit it if necessary. Use tutorials 6 and 9 to help you with this exercise.
Boxford 280 B
Tutorial 10 : Circular Interpolation - Partial Arcs

The topic of circular interpolation was introduced in Tutorial 4. These arcs were of 90 degrees and occupied a single quadrant. If the arc is less than 90 degrees, it is called a partial arc. Examples of partial arcs are shown below: 1. Two partial arcs programmed next to each other to form a groove. In this case, care has to be taken to ensure that the correct tools are chosen so that the toolholders do not rub against the edges of the groove. Four partial arcs connecting tapers. A partial arc as a fillet to a taper and a shoulder.
2. 3.
2
R
R
R
R
Boxford 280 B
Examine the operations sheet and drawing for TUT 10. The drawing shows a component turned with a taper together with two partial arcs - one clockwise and the other one counter-clockwise. The operations sheet gives details of the roughing cuts. The I and K values are determined in the same way as for 90 arcs, i.e. (a) the I value is the incremental distance measured along the X axis and the K value is the distance measured along the Z axis to the arc centre from the tool position at the commencement of the cut, or the I value is the radius.
(b)
The X and Z values are the co-ordinates of the tool at the finish of the arc. The calculations required to determine these values may involve trigonometry. The program for TUT 10 is shown on the programming sheet. Test it and examine its operation.
Boxford 280 B

MATERIAL 25

O/DIA. 0 I/DIA. 40
OPERATION NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
OPERATION DESCRIPTION FACE TURN 23 x 29 21 x 28.5 19 x 28 17 x 27 15 x 21 13 x 13 11 x 7 9 x 2 7 x 1 FACE 2 (START OF RAD) TURN 4mm RAD TO 9.93 TURN TAPER TURN 4mm RAD TO 24 TURN 24 x 36.6 (1.6mm PARTING TOOL) TOOL PARK POSITION CHANGE TOOL PART OFF TO LENGTH (35mm) TOOL PARK POSITION END PROGRAM 40 35 30 R4 16.07 25 24 2 R4 9.93
2500 2000
RAPID 11 2000 2500 50 RAPID
3.48 26.53
Boxford 280 B


TITLE.
TUT 10
MATERIAL:
STEEL EN1A ALUMN

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 01 01 01 01 01 01 01 01 04
G
90 71
30.0 26.0 -1.0
10.0 0 70 1.0 2000 2500
FACE END OF MATERIAL RAPID CLEAR OF FACE RAPID TO FIRST CUT DIAMETER CUT 23 X 29mm LONG RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT 21 X 28.5 RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT 19 X 28 RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT 17 X 27 RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT 15 X 21 RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT 13 X 13 RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT 11 X 7 RAPID CLEAR OF WORK
23.0 -29.0 24.0 21.0 -28.5 22.0 19.0 -28.0 20.0 17.0 -27.0 18.0 15.0 -21.0 16.0 13.0 -13.0 14.0 11.0 -7.0 12.0 1.0 70 1.0 70 1.0 70 1.0 70 1.0 70 1.0 70 1.0 70
Boxford 280 B

POSITION FOR NEXT CUT CUT 9 X 2 RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT 7 X 1 RAPID CLEAR OF WORK
RAPID TO FACE 2 - (START OF RADIUS)

TITLE.
TUT 10
MATERIAL:
STEEL EN1A

9.0

70

280 290 300 310 320 330 340 350 360 370 380 390 400 410 420 430 440 450 05 30 01 03 01 02 01 05 06 04 01 01
SPINDLE SPEED S
Z
-2.0
10.0 7.0
1.0
-1.0 8.0 2.0 9.93 16.07 24.0 24.0 30.0 1.0 0 -3.48 -26.53 -30.0 -36.6 10.0 11 25.0 -1.0 25.0 30.0 10.0 -36.6 4 4
70
TURN RADIUS TURN TAPER TURN RADIUS TURN 24 SPINDLE STOP - TOOL CHANGE TOOL CHANGE - PARTING TOOL
START SPINDLE RAPID TO PART OFF POSITION
70 70 70 70
2000 2500 50
PART OFF RAPID CLEAR OF WORK SPINDLE STOP - PARK POSITION END OF PROGRAM
Boxford 280 B
Exercise 10:
Circular Interpolation - Partial Arcs.
You are required to produce the component drawn below. The billet size is 25 x 40mm stickout from chuck. The billet material is steel EN1A.
R10
25
10
15
12 22 6 29
Complete the following tasks: 1. 2. 3. Complete an operations sheet for the above component. Using a programming sheet write a program for the component. Give your program a test run and edit it if necessary.
23
R5
Boxford 280 B
Tutorial 11: Combining G Codes to Produce a Program.

In this tutorial a selection of preparatory codes (G codes) is used to produce the component shown. Test run the program and examine its operation.
34 28 19.5 16.75 10.75 DRILL 7
23
18
17
R1.5 20 DRILL POINT R6.5
THREAD 0.75mm PITCH L.H.
20
Boxford 280 B

ABSOLUTE PROGRAMMING METRIC UNITS TOOL PARK POSITION

TITLE.
TUT 11
MATERIAL:
STEEL EN1A ALUMN

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 03 01 02 01 01 04 01 81 01 01 01 01 01 04
G
90 71
30.0 26.0 -1.0
10.00 0
2500 2000
70
FACE END OF MATERIAL RAPID CLEAR OF FACE RAPID TO FIRST CUT DIAMETER CUT DIAMETER X 35mm LONG RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT DIAMETER X 23.5mm LONG RAPID CLEAR OF WORK CUT TAPER - TOOL CUTTING IN CUT TAPER - TOOL CUTTING OUT RAPID TO STAND OFF FOR G81 CYCLE
REDUCE DIAMETER BY 3mm IN 2 CUTS
1.00 23.0 -35.00 23.5 21.5 -23.50 22.0 20.0 23.5 -16.00 -19.50 -27.00 0.50 3.0 14.0 18.5 -2.80 0.50 12.0 18.5 -4.40 0 4.0 17.0 -6.50 -9.25 20.0 -10.75 -16.75 1.5 0 0 6.5 50 70 50 70 40 2000 2500 50 -10.50 2 80 70 70 80 0.50 80
POSITION FOR FIRST ANGLE CUT CUT CHAMFER RAPID CLEAR OF FACE POSITION FOR NEXT CUT CUT CHAMFER
CHANGE SPINDLE SPEED RAPID TO ZERO IN Z AXIS
RAPID TO 4mm CUT 6.5 RADIUS TO 17mm CUT DIAMETER X 9.25mm LONG CUT 1.5 RADIUS TO 20mm CUT DIAMETER X 16.75mm LONG
Boxford 280 B

CUT TAPER - TOOL CUTTING IN CUT TAPER - TOOL CUTTING OUT
STOP SPINDLE - TOOL PARK POSITION

TITLE.
TUT 11
MATERIAL:
STEEL EN1A

18.0 23.0 05 06 03 0 3.00 -5.00 3.00 05 06 03 0 2.00 -20.00 05 06 04 22.0 -9.25 -10.25 05 06 04 25.0 -0.5 30.0 05 02 30.0 10.00 -34.00 30.0 10.0 11 30.0 10.00 4 7 30.0 10.00 7 30.0

70 50

280 290 300 310 320 330 340 350 360 370 380 390 400 410 420 430 440 450 460 470 480 490 01 84 83 01
SPINDLE SPEED S
G
01 01
Z
-19.50 -28.00 10.00 5
CHANGE TO TOOL 5 - C/DRILL

2000 2000
50
CUT TO DEPTH RAPID CLEAR OF FACE

STOP SPINDLE - TOOL PARK POSITION CHANGE TO TOOL 7 - 7mm DRILL
7 2000 1500 0.99 50
DRILL 20mm DEEP WITH G83 CYCLE STOP SPINDLE - TOOL PARK POSITION CHANGE TO TOOL 4
400
CUT THREAD WITH G84 CYCLE (106mm) STOP SPINDLE - TOOL PARK POSITION CHANGE TO TOOL 11 START SPINDLE - RAPID TO POSITION PART OFF TO LENGTH CLEAR WORK STOP SPINDLE - TOOL PARK POSITION END OF PROGRAM
0.92 0.82
10
0.75
2500 2000
40
Boxford 280 B
Exercise 11:
Using a Combination of G Codes
You are required to produce the component drawn below. The billet size is 25 x 40mm stickout from the chuck. The billet material is steel EN1A.
15 DRILL POINT R2
THREAD 0.75mm PITCH L.H.
DRILL 5
22
14
16
5 10 12 22 30 35
R5
Complete the following tasks: 1. 2. 3. Complete an operations sheet for the above component. Using a programming sheet write a program for the component. Give your program a test run and edit it if necessary.
20
Boxford 280 B
Tutorial 12: Programming Spindle Orientation & Driven Tool.

In this tutorial the spindle orientation, shotbolt and driven tool are programmed appropriately to drill 2 radial holes at 180 deg intervals. Note the X values are -ve as the driven tool is positioned at the opposite end of the cross slide than the Turret of Quick Change Tool Post.
Drawing Number
SEQUENCE D E S C R IP T IO N
A B S O L U T E P R O G R A M M IN G M E T R IC U N IT S P A R K P O S IT IO N T O O L C H A N G E (D R IV E N ) S P IN D L E O R IE N TA T IO N E N G A G E S H O T B O LT D R IV E N T O O L A C T IV A T E M O V E T O O U T S ID E O F B A R D R IL L R A D IA L H O L E P U L L O U T D R IV E N T O O L D IS E N G A G E S H O T B O LT S P IN D L E O R IE N TA T IO N E N G A G E S H O T B O LT D R IL L R A D IA L H O L E P U L L O U T D R IV E N T O O L D IS E N G A G E S H O T B O LT D R IV E N T O O L O F F P A R K P O S IT IO N E N D O F P R O G R A M /R P T
Programming Sheet TITLE TUT12 W ritte n B y

No.
N
M a te ria l
Steel EN1A
SHEET No. 1 O F 2
FEED R AT E
I K F
PR EP M ISC FU N C TIO N FUN CTIO N

G M
A X IS C O O R D IN A T E S
X Z
S P IN D L E SPEED
S
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190
90 71 -4 0 .0 0 06 16 51 10 -2 0 .0 0 01 52 16 51 01 52 11 -4 0 .0 0 30 2 0 .0 0 -2 0 .0 0 -4 0 .0 0 -2 0 .0 0 -4 0 .0 0 180 50 50 2 0 .0 0 8 0
OPERATIONS SHEET
OPERATIONS SHEETSHEET - TURNING DUET OPERATIONS

MATERIAL O/DIA. I/DIA. TYPE NO. STICKOUT SPINDLE SPEED TOOL FEED TOOL NO. TITLE
OPERATION NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
PROGRAMMING SHEET

TITLE. SEQUENCE PREP MISC No. FUNCTION FUNCTION N G M WRITTEN BY AXIS COORDINATES X Z I
MATERIAL: SHEET No. OF SPINDLE SPEED S
FEED RATE K F

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Programming Manual

Boxford 280 B Programming Manual

6 CNC and CAM Machining

Tutorials and Exercises

2 Running the Demonstration Program

2 Running the Demonstration Program

Set Up the Machine

Gang Plate: Quick Change Toolpost:

Check Tool Settings

2 Running the Demonstration Program

Select the Program

2 Running the Demonstration Program

2 Running the Demonstration Program

View the Component

Use the cursor keys to manipulate the 3D view as follows:

Increase size Rotate anticlockwise Decrease size

Restore original view

2 Running the Demonstration Program

Show the Program Details

to show the program details:

Turn off the program details display. (Press ESC or EOB).

2 Running the Demonstration Program

Display the Program

, and then Display:

Turn off the program display: (Press ESC).

2 Running the Demonstration Program

and then 3D View. To

2 Running the Demonstration Program

Machine the Component

Axes and Tooling

3 Axes and Tooling

Axes and Datum Position

3.1 Axes and Tooling

External tools: 1, 3, 5, 7 Internal tools: 2, 4, 6, 8

Machines without homing switches: 1: Reference tool 3: Second tool

Turret Tool Positions

3.2 Axes and Tooling

Turret (Figure 3.2)

Setting Tool Height

3.3 Axes and Tooling

3.3 Quick Change Toolpost

Tool Clamping Screw

Tool Securing Screws

Quick Change Toolpost

3.3 Axes and Tooling

Tool Clamping Screw Constant

Centre Height Adjustment Screw

Tool Securing Screws

Tool Fitting and Adjustment

3.3 Axes and Tooling

Internal Tool Fitting Detail

3.4 Axes and Tooling

3.4 Gang Plate (Figure 3.6)

Fitting the Tools Setting Tool Height

Securing Screws Clamping Screws Channel Toolholder

3.5 Axes and Tooling

3.5 Driven Tooling

Handwheel with scale

+Z -Z Y axis slide mounting block -X -Y

Mounting Bracket Type 1

Driven Tool Attachment

Driven Tool Attachment