CNC Programming Techniques : An Insider's Guide to Effective Methods and Applications

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ISBN: 9780831131852 | 0831131853
Cover: Hardcover
Copyright: 9/12/2005

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Written by the author of the bestselling CNC Programming Handbook and the recent release Fanuc CNC Custom Macros, this practical and very useful resource covers dozens of special CNC programming techniques that can be applied to machining parts in an efficient way.

Part Program Development

(22)

Program Development Drawing

(2)

Drawing Evaluation

(1)

Material and Stock

(1)

Part Setup

(1)

Part Reference Point

(1)

Part Orientation

(1)

Selecting Part Zero

(1)

Tooling Selection

(6)

Identifying Machining Operations

(1)

Face Milling

(1)

Contour Milling

(1)

Circular Pocket Milling

(1)

Slot Milling

(1)

Spot Drilling

(1)

Drilling

(1)

Tapping

(1)

Summary of Tools Used

(1)

Machining Data

(1)

Spindle Speed

(1)

Cutting Feedrate

(1)

Tooling Data

(1)

Details of Operations

(12)

Tool 1 - Face Milling

(1)

Tool 2 - Outside Contour

(2)

Tool 2 - Circular Pocket

(1)

Tool 3 - Slot Milling

(1)

Tool 4 - Spot Drilling

(1)

Tool 5 - Drilling

(1)

Tool 6 - Tapping

(1)

Complete Program

(3)

Calculating Contour Points

(10)

Tools and Knowledge

(2)

Mathematical Knowledge

(2)

Organized Approach

(1)

Process of Calculating XY Coordinates

(8)

Step 1 - Establish the Main Contour Points

(1)

Step 2 - Fill-in the Coordinate Sheet

(1)

Step 3 - Identify Calculation Zones

(1)

Step 4 - Helpful Ideas for Calculations

(2)

Step 5 - Calculations for Zone 1

(2)

Step 6 - Calculations for Zone 2

(1)

Updating Coordinate Sheet

(1)

Writing the CNC Program

(1)

Formulas for Contouring

(10)

Contour Point Between Two Lines (Lathe)

(1)

Contour Point Between Line and Arc

(5)

Intersecting Contour Point

(1)

Tangent Contour Point

(4)

Calculating the Sharp Point

(1)

Contour Point Between Two Arcs

(3)

Intersecting Arcs

(1)

Tangent Arcs

(2)

Using Cutter Radius Offset

(24)

General Concepts

(2)

Benefits Of Cutter Radius Offset

(1)

Controlling Cutter Radius

(1)

Radius Offset Commands

(1)

Commands G40-G41-G42

(1)

Using the D-offset Number

(1)

Basic Programming Techniques

(1)

Cutter Radius Activation

(1)

Cutter Radius Application

(1)

Cutter Radius Cancellation

(1)

D-offset Stored Amount

(2)

Equidistant Centerline - G40 Mode

(1)

Equidistant Centerline - G41/G42 Mode

(1)

Drawing Dimensions - G40 Mode

(1)

Drawing Dimensions - G41/G42 Mode

(1)

Radius vs Diameter

(1)

Contour Lead-In and Lead-Out

(5)

Methods For Lead-In - Linear Motion

(3)

Methods For Lead-In - Arc Motion

(1)

Methods For Lead-Out - Linear Motion

(1)

Methods For Lead-Out - Arc Motion

(1)

Program Example

(1)

Internal Contours

(4)

Linear Slot Machining

(1)

Circular Slot Machining

(1)

Finishing Internal Contour

(2)

Maintaining Dimensional Sizes

(2)

Basic Rule

(1)

Handling Dimensional Tolerances

(2)

Handling Cutter Radius Offset Errors

(2)

Common Errors

(1)

Offset Programmed Too Late or Too Early

(1)

Offset Start or End on an Arc

(1)

Tool Nose Radius Offset

(5)

Command Point and Radius Center

(1)

Tool Tip Orientation

(1)

Common Tool Nose Radius Errors

(3)

Part Reversal in Milling

(22)

Project Description

(1)

Material and Setup Conditions

(1)

Cutting Tools

(1)

Material Removal

(1)

Machining Process

(1)

Clamping 1

(1)

Clamping 2

(1)

Program Zero Selection

(2)

First Clamping

(1)

Second Clamping

(1)

Programming Methods

(1)

Tool Length Settings

(2)

First Clamping

(1)

Second Clamping

(1)

Using the WORK OFFSET Method - G54-G55

(2)

Common Toolpath

(1)

Program Listing - Work Offsets G54-G55

(2)

Program Listing - Work Offsets G54-G55 - with Subprograms

(2)

Using the Local Coordinates Method - G52

(2)

Program Listing - Local Coordinate System G52

(2)

Using the Datum Shift Method - G10

(1)

Program Listing - Datum Shift G10

(2)

Summary

(1)

Using Tapered End Mills

(8)

Types of Tapered End Mills

(2)

Tool Material

(1)

Range of Taper Angles

(1)

Flat Tip Tapered End Mills

(1)

Ball Tip Tapered End Mills

(1)

Effective Diameter Calculation

(5)

Flat Tip

(2)

Stock Removal

(1)

Ball Tip with Specified Radius

(1)

Flat Tip with Added Blend Radius

(2)

Tapered Holes

(1)

Special Purpose G-Codes

(26)

Single Direction Positioning - G60

(1)

Special Cutting Modes

(3)

Exact Stop Check G09 - G61

(1)

Automatic Corner Override - G62

100

(1)

Tapping Mode - G63

100

(1)

Normal Cutting Mode - G64

101

(1)

Stored Stroke Limits Definitions - G22 - G23

101

(2)

Spindle Fluctuation G25 - G26

103

(1)

Machine Zero Commands - G27 - G28 - G29 - G30

104

(4)

Primary Machine Zero Return - G28

104

(2)

Return from Machine Zero - G29

106

(1)

Machine Zero Return Position Check - G27

106

(2)

Secondary Machine Zero Return - G30

108

(1)

Position Register - G92/G50

108

(10)

G92 Position Register for Milling

109

(2)

G50 Position Register for Turning

111

(2)

Tool Change Position

113

(4)

Conversion of G50 to Geometry Offset

117

(1)

Skip Command - G31

118

(1)

Other Seldom Used G-codes

119

(4)

Tool Length Offset Negative - G44

119

(1)

Tool Length Offset Cancel - G49

119

(3)

Conclusion

122

(1)

Tool Length Offset Change

123

(8)

Tool Length Offset

123

(1)

Offset Adjustment

124

(4)

Practical Application

124

(1)

Programming Method 1 - No Offset Adjustment

125

(1)

Programming Method 2 - With Offset Adjustment

125

(1)

Programming Method 3 - Advanced Macro Method

126

(2)

Offset Adjustment - Setup for Two Parts

128

(3)

Method 1 - One Work Offset + One Length Offset

128

(1)

Method 2 - Two Work Offsets + One Length Offset

129

(1)

Method 3 - Two Work Offsets + Two Length Offsets

130

(1)

Block Skip Applications

131

(12)

General Applications

131

(1)

Similar Parts Applications

132

(2)

Programming a Trial Cut

134

(3)

Trial Cut for Milling

134

(2)

Trial Cut for Turning

136

(1)

Irregular Stock Removal

137

(3)

Variable Stock in Milling

137

(2)

Variable Stock in Turning

139

(1)

Summary of Rules

139

(1)

Block Skip Within A Block

140

(2)

Conflicting Words

140

(1)

One Program - Two Materials

140

(2)

Numbered Block Skip Functions

142

(1)

Standard and Rigid Tapping

143

(6)

Standard Tapping Method

143

(3)

Basic Principles

143

(1)

Why Underfeed?

144

(1)

Feed-In Slower - Feed-Out Faster

144

(2)

Rigid Tapping Method

146

(3)

Basic Principles

146

(1)

Benefits

146

(1)

Setup

147

(1)

Possible Problems

147

(1)

Programming Approach

147

(2)

Polar Coordinates

149

(6)

Definition and G-codes

149

(2)

Polar Coordinates and Planes

150

(1)

G15 - G16 Polar Coordinates

151

(1)

Programming Format

151

(4)

Toolpath Direction

153

(1)

Applications in Planes

154

(1)

Subprogram Development

155

(14)

Definition and Usage

155

(1)

Drawing Evaluation

156

(1)

Subprogram Planning

156

(2)

Depth Control

157

(1)

Width of Cut Control

157

(1)

Cutting Tool Selection

157

(1)

Developing the Subprogram

158

(4)

Method 1 - Full Width and Full Depth

158

(1)

Method 2 - Full Width and Divided Depth

159

(1)

Method 3 - Smaller Width and Full Depth

160

(2)

Round Pocket Subprogram

162

(3)

Single Depth Pocket with Stepovers

162

(2)

Multidepth Pocket with Stepovers

164

(1)

Rough and Finish Cuts with a Subprogram

165

(4)

One Toolpath for Two Cuts

165

(2)

Lead-in and Lead-Out

167

(1)

Common Contour Toolpath

167

(1)

Main Program

168

(1)

Turning and Boring in Depth

169

(30)

Program Zero Selection

169

(1)

Corner Radius and Back Angle Selection

170

(1)

Cutter Radius Offset

171

(1)

Imaginary Tool Point

172

(1)

Stock Allowance

172

(4)

Contour Shape

173

(1)

Cutting Tool Used

173

(1)

Stock Allowance in X and Z axes

173

(1)

Grinding Allowance

174

(2)

Tool Approach Techniques - Lead-In

176

(3)

Approaching the Front Face

176

(1)

Approaching a Diameter

176

(1)

Approaching a Chamfer

177

(1)

Approaching a Radius

177

(2)

Approaches to Avoid

179

(1)

Tool Retract Techniques - Lead-Out

179

(3)

Retract from a Face

179

(1)

Retract from a Diameter

180

(1)

Retract from a Chamfer

180

(1)

Retract from a Radius

181

(1)

Retracts to Avoid

181

(1)

One Job - Two Operations

182

(2)

About Jaws

182

(1)

Single Setup - Two Chuckings

183

(1)

Two Setups - Two Operations

184

(1)

Multi Cut Facing

184

(1)

Width of Cut Distribution

184

(1)

Breaking Corners

185

(1)

Direction Specification

186

(1)

Using Tailstock

186

(3)

Types of Tailstock

187

(1)

Programming a Tailstock with a Bar Stopper

187

(2)

Using 45-degree Tool

189

(3)

Machining Thin Stock

192

(1)

Adjusting Chuck Pressure

192

(1)

Using an Inner Plug / Outer Ring

192

(1)

Using Special Split Jaws

192

(1)

G70/G71/G72 Cycle Methods

193

(5)

Programming Formats - G71

193

(1)

Programming Formats - G72

194

(2)

G70 - Finishing Cycle

196

(1)

G71 and G72 Compared

196

(2)

Programming Undercuts

198

(1)

Hard Turning

198

(1)

Programming Tapers

199

(16)

What is a Taper?

199

(1)

Taper Definitions

199

(1)

Taper per Foot

200

(3)

Taper Ratios

203

(2)

Taper Defined as Percentage

205

(1)

Taper Angle Defined in D-M-S

206

(1)

Taper Length and Angle

206

(5)

Chamfers

206

(1)

45° Chamfer

207

(2)

Start Chamfer with a Clearance

209

(1)

End Chamfer with a Clearance

209

(1)

Other Chamfers

210

(1)

Tapers with Leads

211

(4)

Taper with a Lead Chamfer

212

(1)

Taper with a Lead Fillet

213

(2)

Techniques for Grooving

215

(12)

Tooling for Grooves

215

(2)

Cutting Width

215

(1)

Cutting Depth

215

(1)

Groove Location

216

(1)

Setting the Command Point

216

(1)

Plunge and Retract Method

217

(1)

G75 Cycle

217

(1)

Grooving for Precision

218

(3)

Machining Procedure

219

(1)

Programming Procedure

220

(1)

Deep Grooving

221

(1)

Grooves with Tapers - O-Ring Grooves

222

(3)

Grooves with Tapers - V-Pulley Grooves

225

(2)

Insert Selection

225

(1)

Depth Calculation

226

(1)

Tool Setup and Program

226

(1)

Techniques for Threading

227

(16)

Types of Thread Forms

227

(2)

UN - Unified National and Metric

227

(1)

Other Thread Forms

228

(1)

Thread Depth Calculation

229

(1)

Infeed Methods

230

(1)

Tool Motions

231

(1)

Cutting Conditions

231

(1)

Acceleration and Deceleration

231

(1)

Cutting Depth

232

(1)

Hand of Thread

232

(2)

External Threading - Right Hand Thread

232

(1)

External Threading - Left Hand Thread

233

(1)

Internal Threading - Right Hand Thread

233

(1)

Internal Threading - Left Hand Thread

233

(1)

Sample Thread Evaluation

234

(2)

Initial Data

234

(1)

Cutting Conditions

234

(1)

Number of Threading Passes

235

(1)

Distribution of Depth Cuts

236

(1)

G32 Threading Method

236

(4)

Radial Infeed Example

237

(1)

Flank Infeed Example

237

(1)

Tapping with G32

238

(2)

G92 Threading Method

240

(1)

G76 Threading Method

241

(2)

Programming Format

241

(2)

Restrictions in Threading

243

(8)

Thread Programming Basics

243

(1)

Threading Feedrate

244

(1)

Standard Example

244

(1)

Final Threading Program - Single Start

245

(1)

Special Example

245

(2)

Final Threading Program - Multi Start

246

(1)

Slow Spindle Speed

247

(1)

Metric Applications

247

(1)

Long Thread Programming

248

(3)

Defining a Long Thread

248

(1)

Lead Error

249

(1)

Number of Decimal Places

250

(1)

Practical Thread Milling

251

(22)

Thread Milling - General

251

(1)

Helical Interpolation

251

(1)

Is Helical Interpolation Available?

252

(1)

Benefits of Thread Milling

252

(1)

Selecting Tools

253

(2)

Initial Factors

253

(1)

Types of Thread Milling Cutters

254

(1)

Accuracy Issues

254

(1)

Thread Mill Data

255

(1)

Cutting Direction

255

(3)

External and Internal Thread Milling

255

(1)

Climb Milling and Conventional Thread Milling

255

(1)

Right Hand and Left Hand Thread Milling

255

(1)

External Thread Milling Illustrated

256

(1)

Internal Thread Milling Illustrated

257

(1)

Helix - Helical Curve

258

(2)

Programming External Threads

260

(6)

Tooling Selection

260

(1)

Cutting Conditions

261

(1)

Lead-In and Lead-Out

261

(1)

Cutter Radius Offset

262

(1)

Program Development - External Thread

262

(4)

Programming Internal Threads

266

(5)

Tooling Selection

266

(1)

Cutting Conditions

266

(1)

Lead-In and Lead-Out

267

(1)

Cutter Radius Offset

267

(1)

Program Development - Internal Thread

268

(3)

Pipe Thread Milling

271

(1)

Thread Milling Software

272

(1)

Knurling on CNC Lathes

273

(4)

Knurling Operations

273

(2)

Tooling Selection

273

(1)

Knurling Pitch

274

(1)

Programming and Machining Techniques

275

(1)

Tool Motions

275

(1)

Depth and Feedrate

275

(1)

Troubleshooting

276

(1)

Four-Axis Lathes

277

(6)

General Setup

277

(1)

Tool Tip Numbers

278

(1)

Programming Method

278

(5)

Spindle Speed and Feedrate

278

(1)

M-Functions

279

(1)

Synchronization Functions

279

(1)

Program Structure

279

(4)

Pallet Changers

283

(6)

Types of Automatic Pallets

283

(2)

Rotary Pallets

283

(1)

Shuttle Pallets

283

(1)

Setup and Work Areas

284

(1)

Programming Methods

285

(1)

M60 Function

285

(1)

General Format

285

(1)

Programming Example

286

(3)

Initial Conditions

286

(1)

Part Program

286

(3)

Working with Planes

289

(18)

Mathematical Planes

289

(1)

Machine Planes

290

(1)

G-codes for Plane Selection

290

(1)

Effect of Planes in Programming

291

(4)

Planes and Circular Motion

291

(2)

Planes and Cutter Radius Offset

293

(2)

Working With Planes In Detail

295

(6)

G17 with G41 and G02

295

(1)

G17 with G42 and G03

296

(1)

G18 with G42 and G03

297

(1)

G18 with G41 and G02

298

(1)

G19 with G41 and G02

299

(1)

G19 with G42 and G03

300

(1)

Using Right-Angle Attachment

301

(6)

Basic Concepts

301

(1)

Side Face Drilling

302

(2)

Side Face Milling

304

(3)

Programming Cams

307

(10)

Overview of Cams

307

(1)

Cam Drawing Example

308

(2)

Cam RISE and FALL - Sections Evaluation

309

(1)

The RISE Section

310

(2)

Calculating Radius Length

311

(1)

Calculating XY Coordinates

311

(1)

The FALL Section

312

(3)

Calculating Radius Length

313

(1)

Calculating XY Coordinates

314

(1)

Summary

314

(1)

Writing the Program

315

(2)

Introduction to Macros

317

(16)

Special Introduction

317

(1)

Skills Required

317

(1)

Macro is an Option

318

(1)

Common Features and Applications

318

(1)

Macro Structure

319

(8)

Macro Definition and Call

320

(2)

Variable Declarations and Expressions

322

(1)

Macro Functions

323

(3)

Branching and Looping

326

(1)

Macro Development - Bolt Circle

327

(6)

Evaluation of Drawings

328

(1)

Bolt Hole Macro Features

329

(1)

Assignment of Variables

330

(1)

Internal Calculations

330

(1)

Other Calculations

330

(1)

Final Considerations

331

(1)

Macro Call

332

(1)

Did You Know That ... ?

333

(2)

References and Resources

335

(4)

Index

339

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CNC Programming Techniques : An Insider's Guide to Effective Methods and Applications

Summary

Table of Contents

Supplemental Materials