3000H SERIES CNC LATHE USER’S MANUAL » DYNA MECHTRONICGS, INC. 926 W. Maude. Avenue Sunnyvale, CA, 94086 Copyright 1991UNIT CHAPTER | 10 n 44 11.2 11.3, 11.4 115 11.6 W7 11.8 CHAPTER Il TABLE OF CONTENTS SUBJECT GENERAL INFORMATION AND INSTALLATION SAFETY RULES PRECAUTIONS KNOW YOUR MACHINE INSTALLATION MACHINING PERSONNEL INSTALLATION SHIPPING CRATE UNPACKING REMOVING THE PALLET LOCATING THE MACHINE: CLEANING THE MACHINE LEVELING THE MACHINE ELECTRICAL INSTALLATION VOLTAGE SURGE REQUIREMENTS R.F. REQUIREMENTS POWER PACKAGE AIR SUPPLY POWERING UP LUBRICATION COOLANT INSPECTION REPORT OPTIONAL ACCESSORIES SAFETY CONSIDERATIONS ELECTRICAL AND MECHANICAL OVERVIEW SPINDLE SPEED RANGE ADJUSTMENT ‘SPINDLE PICKUPS SPINDLE MOTOR, THE SPINDLE THE AXES ‘THE TURRET CHUCK OR COLLET BAR FEED GETTING ACQUAINTED WITH THE DM3000H CNC LATHE AND CONTROLLER (CONSOLE) INTRODUCTION THE MACHINE PAGE OP OSBVIVLIRRODOTATDARLOOOOLLENNNNN 10 1022 224 2.2.2 23 CHAPTER IIL 3.1 3.2 33 3.3.4 3.3.2 3.3.3 3.4 3.5 3.6 CHAPTER IV 44.6 TABLE OF CONTENTS (CONT.) THE CONTROLS THE CONTROL PANEL THE CONTROLLER: THE FOUR OPERATING MODES: MACHINE MOVEMENTS (CONVENTIONS) CARTESIAN COORDINATE SYSTEM APPLICATION OF CARTESIAN COORDINATE SYSTEM TO THE LATHE NUMERICAL CONTROL DIMENSIONING SYSTEMS ABSOLUTE SYSTEM INCREMENTAL SYSTEM POLAR COORDINATE SYSTEM POINT-TO-POINT AND CONTINUOUS PATH SYSTEMS LINEAR AND CIRCULAR INTERPOLATION FLOATING ZERO (THREE TYPES OF REFERENCE POINTS) GAINING PROGRAMMING INFORMATION CONVERSATIONAL INPUTS ENTERING CYCLES PROGRAM SECTION THE START SECTION THE BODY SECTION ‘THE END SECTION PLANNING THE JOB PROPERLY BUILDING SAFETY INTO THE PROGRAM CHOOSING PROPER MOUNTING AND PART JMACHINE RELATIONSHIPS PLANNING THE PROPER SEQUENCE OF CUTS AND CUTTER PATHS SELECTING THE CORRECT CUTTING TOOLS FIGURING OUT PROPER CUTTING SPEEDS, APM'S, FEEDS, AND DEPTHS OF CUT * RPM * FEED * DEPTH OF CUT PLANNING FOR TOOL CHANGES 10 10 16 16 18 19 21 at 23 24 26 26 35 36 38 39 40CHAPTER V CHAPTER VI 6.1 TABLE OF CONTENTS (CONT.) PRACTICING SAFETY AND SAFE MACHINE OPERATION PROGRAMMING SAFETY 42 OPERATOR SAFETY 43 EMERGENCY CRASH PROCEDURE 45 SAFETY RULES AND PRECAUTIONS 45 THE MANUAL MODE AND TOOL CALIBRATION PRELIMINARY INFORMATION ON THE, MANUAL MODE 48 WHEN THE MANUAL MODE IS USED 48 ENTERING A SUB-MODE 48 MOVING THE MACHINE IN THE MANUAL MODE = 49 SELECT AXIS 49 MOVING AN AXIS (JOGGING) 4g JOGGING AND INCREMENTAL JOGGING 50 MANUAL CUTS: 50 EXAMPLE OF MANUALLY CUTTING 50 SELECT TOOL 51 FEED-RATE SETTING 51 SPINDLE CONTROLS: 51 SPINDLE OFF/ON 51 ‘SPINDLE SPEED (rpm) 51 JOGGING 52 OPERATING IN THE MANUAL MODE 52 INFORMATION ON TOOLS AND TOOL CALIBRATION 52 DIFFERENT TOOLS FOR DIFFERENT JOBS, 52 RIGHT HAND AND LEFT HAND TURNING TOOLS 53 TOOL HOLDER MOUNTING ON THE TURRET 53 TOOL CUT LENGTH 54 TOOL CALIBRATION 54 TOOL ORIENTATION CODES: 55 DOING A TOOL CALIBRATION 56 TOOL CALIBRATION USING THE LED PROBE 56 TOOL CALIBRATION PROCEDURE WITH THE PROBE 57 TOOL CALIBRATION WITHOUT A PROBE 59 EXAMPLES OF PROBE SETUPS 61 INSERT REPLACEMENT 62 SINGLE TOOL OFFSET ADJUSTMENT 62TABLE OF CONTENTS (CONT.) 69 SETTING WORKING LIMITS 62 6.9.1 PROCEDURE FOR SETTING THE WORKING LIMITS. 63 6.9.2 CHECKING THE NEW WORKING LIMITS. 64 6.10 EMERGENCY STOPPING AND RESTARTING 64 CHAPTER VII PROGRAMMING WITH PROMPTS: 7A HOW PROMPTS WORK 66 72 DESCRIPTIONS & DEFINITIONS OF PROMPTS ~—s 67. CHAPTER Vill WRITING, ENTERING, AND RUNNING A PROGRAM 8.41 MORE ABOUT THE FOUR OPERATING MODES 70 8.2 A REVIEW OF THE MANUAL MODE, 70 8.2.1 LINE NO MODE 71 8.2.2 PROGRAM ENTER MODE 73 8.2.3 PROGRAM RUN MODE 73 8.3 PROGRAM STRUCTURE 74 8.4 PREPARING TO ENTER A PROGRAM (CLEARING MEMORY) rey 8.5 ENTERING THE PRELIMINARY PORTION OF THE PROGRAM (THE START SECTION) 75 8.5.1 START. 75 8.5.2 SET UP. 76 8.5.3 FEED RATE 7 8.5.4 SPINDLE ON/OFF AND SPINDLE SPEED (RPM) 8.5.5 COOLANT ON/OFF AND OTHER CONTROL CODES 86 DEVELOPING AND ENTERING THE MAIN PORTION OF THE PROGRAM (THE MIDDLE SECTION) 78 87 ENDING THE PROGRAM (THE END SECTION) 79 88 SUMMARY OF NORMAL PROCEDURES FOR PRODUCING PARTS ON THE DYNA LATHE 79 8.9 OPERATING IN THE PROGRAM RUN MODE 80 8.9.1 PROCEDURE FOR SETTING UP 80 8.9.2 TESTING THE PROGRAM 82CHAPTER IX CHAPTER X 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.7.1 10.7.2 10.7.3 10.8 10.9 10.10 10.14 10.12 10.13, 10.14 10.15 10.16 10.17 10.18 TABLE OF CONTENTS (CON'T) PROGRAMMING EASIER (CANNED CYCLES) THE BASIC PHILOSOPHY BEHIND THE DM3000H CANNED CYCLES WORK THREAD THREADING SPINDLE SPEED DRILL RECTANGLE TRIANGLE ARC 1 ARC 2 NOTCH CHAMFER MAKING PROGRAMMING MORE POWERFUL (THE DYNA LANGUAGE) GO ABS INSTRUCTION TWO AXIS COMMANDS GO REL INSTRUCTION PROGRAM FORMATS GENERATING ARCS GO AND GR QUALIFIERS SHIFTING ZEROES "ZERO COODS* INSTRUCTION “ZERO AT" INSTRUCTION "MACH 0° INSTRUCTION “XZ > REF 0° INSTRUCTION DISPLAY INSTRUCTION CONTROL INSTRUCTION SPINDLE ON / OFF INSTRUCTION TOOL SELECT INSTRUCTION HALT INSTRUCTION SKIP TO INSTRUCTION REPEAT AND REPEAT END DWELL INSTRUCTION PROG REF INSTRUCTION TOOL NOSE RADIUS COMPENSATION 120SAMPLE PROGRAM 1'm sure that you are curious to see what a program for your machine will look like. Following is a typical program for the DM3000H. To the right is a brief ‘explanation of each command. This is only to satisfy your curiosity. Please read the manual. 000 START INS 01 Start the program, inches, file #1 001TOOL 4 Select tool #1 002 SET UP >dezx Establish the Zero point oOsTOOL 2 Select rough tuming tool 004 SPINDLE ON ‘Tum the spindle on 005 SPD SP= 1800 Set speed at 1800 RPM's 4 X axis feed-rate at .004 per rev. 6 Z axis feed-rate at .006 per rev. 008CONTROL 4 ‘Tum the coolant on 009 GOIX 1.0000 Rapid move to X coordinate of 1" 010 GOFZ 0.0000 Rapid move to Z coordinate of "0" 011 RECT Fo 03 Rough tum cycle, 3 cuts, leave finish 012 XA = 0.5000 Final diameter 013 ZB =- 1.0000 Length of cut 014 FIN= 0.0150 Amount left for finish cut 015 GOFX 0.5000 Rapid to start point of arc 016 ARC 1 F 03 Arc cycle, 3 cuts, leave finish stock 017 Xt = 0.0000 ist point of arc on X axis 018Z1 = 0.0000 1st point of arc on Z axis 019 X2 = 0.5000 2nd point of arc on X axis 020 Z2 =- 0.2500 2nd point of arc on Z axis 021 R =- 0.2500 Size and direction of radius 022 FIN= 0.0150 Amount left for a finish cut 023 X>CLR X Move to clearance to change tool 024TOOL 1 Finish profiling tool 025 GOIZ 0.0300 Position tool away from part on Z 026 GOFX 0.0000 Rapid to position for finish cut 027 GO Z- 0.0050 Feed .005 into part for facing 028ZERO Z Re-zero the Z axis at current location 029 GOIA- 0.2500 Create radius cut - .25 radius 030 X 0.5000 Ending X coordinate 031 Z- 0.2500 Ending Z coordinate 032 GO Z- 1.0000 Feed move to -1" on Z axis 033 GO X 0.8750 Feed on X axis to start of chamfer 034 GO X 1.0000 Create a 2 axis move to chamfer 035 Z- 1.0625 2nd coordinate for 2 axis move 036 X>CLR X Move the too! to X cleararice position 037 Z>CLRZ Move the tool to Z clearance position 038 SPINDLE OFF Tum the spindle off 039 END NEWPART End the programERROR CODES INDEXCHAPTER I GENERAL INFORMATION AND INSTALLATION1d 1.2. 13. 1.4, SAFETY RULES AND PRECAUTIONS KNOW YOUR MACHINE -Read the operating manual carefully. Leam the machine features, applications and limitations. Follow all recommended operating and maintenance procedures. INSTALLATION -Only use @ qualified electrician to install the power. -Make absolutely sure the power line ground is adequately grounded. -Avoid dangerous environments. Do not locate this machine in damp wet, gaseous or explosive locations. MACHINING ~Keep the area well lighted. -Secure the work adequately and properly in the chuck or collect. -Make suro the tools are firmly in place. -Select the right tool and the right speed. Do not force the tool. Keep all of your too! holders clean and maintained. PERSONNEL -Should not wear loose clothing when operating the machine. -Should not try to grasp the part before the chuck has stopped tuming, -Should vacuum chips up, not air blow them away. The chips can be ‘blown into the machine and cause serious problems.INSTALLATION STEPS FOR MECHANICAL INSTALLATION 2.1 SHIPPING CRATE The crate measures 65" x 42" x 72" and weighs 1220 Ibs. 2.2. UNPACKING ‘The machine is attached to the wooden pallot at the base. The crate sides are screw bolted to the wooden pallet. The screws should be removed around the outside base of the crate and the sides lifted straight up to clear the machine. Next remove the bolts on one side which will allow one of the sides to be removed. Then slide the remaining sides off the base. ‘The machine should be inspected for signs of damage. If there is any indication of damage, a claim shouid be filed with the carrier. For other damages refer to the warranty policy. 2.3. REMOVING THE PALLET The machine is held to the wooden pallet with four nuts. These should be removed. Then the machine can be lifted directly off the pallet by means of a fork lift truck with the times inserted at the front above the coolant tank area. 2.4 LOCATING THE MACHINE ‘The machine should be placed on an adequate surface capable of supporting approximately 1500 tbs (600kg). 2.5 CLEANING THE MACHINE ‘The ways and spindle nose are coated with cosmoline, Use @ soft tissue and machine oil to clean off this anti-rust coating. Manually operate the lubrication pump several times to oil the ball screws and ways. Note: WD40 works very well for this. 2.6 LEVELING THE MACHINE Use the leveling adjust bolts and a lavel indicator to accurately level the machine. This is absolutely necessary to prevent distortion of the bed and to ensure sonsistent accuracy on part production. The level reading should be under 0.04mm/m or -0005"/ft.3. ELECTRICAL INSTALLATION 1. It is absolutely necessary to obtain the services of a qualified electrician to wire the machine up. 2. It should be wired to a 220V AC single phase outlet. Make sure the ground line (green) corresponds to the ground pin of the plug and that the ground wire in the wall socket is grounded and not floating free. DO NOT PLUG THE MACHINE IN YET, THERE ARE MORE CHECKS TO DO. 3. The maximum current is 12 Amps. The outlet if fused should be fused for 15 Amps. 4, Measure the AC voltage at the socket and check that it is nominal 20V AC. If itis higher (230, 240 VAC), the tap of the primary transformer needs to be changed (moved). Slide up the cover and move the tap on the primary side to corresponds. 5. Under no circumstances use the 115V TAP. The maximum current pulled at this voltage is 24 Amps and this exceeds normal US wiring for 110V AC, 3.1 VOLTAGE SURGE REQUIREMENTS What ever the nominal wall socket voltage is 220, 280, 240 the voltage should be within + 10% at all time, The machine should have a dedicated line. If large motors, air conditioners are also wired into this line even in another building you can easily get much higher or lower voltage fluctuations. This causes erratic behavior. if the voltage becomes too high the spindle will switch off (reset), the axes will reset if too tow. 3.2 R. F, REQUIREMENTS Do not locate the machine near any arc welding sites. This will cause erratic operation due to high frequency noise. 3.3. POWER PACKAGE ‘With the power plug removed from the wall socket open the doors of the power package. ~ Check that all connectors are firmly in place. - Check that these are no loose screws in the base of the power package.4, AIR SUPPLY Connect the air supply to the input of the filter, regulator, lubricator section at the back of the machine. It requires at least 8Olbs per square inch. This is used for tool change and chuck or collet closer activation. 5. POWERING UP 2 2 © - Unpack and plug in the controller. Do not plug in or unplug the controller with power on. Check that the emergency switch is released. Rotate clockwise to release. Make sure the front and back doors are closed. Connect the power cord to a wall lever switch. Tum on the main circuit breaker which is located on the left side of the machine. Lift up to tun on, The red light should come on. Check the control panel. If all doors are closed the green standby light should be flashing. This means that the machine is in the standby mode and is ready to be tumed on. If the back doors and front door are not closed you cannot power up. Ifthe emergency switch is not released the amber light will be on. The switch has to be out to power up. , The *POWER? key will blink. Press this and the machine will go from stand- by to power on. Prass the spindle ON/OFF key to tum the spindle on and use the local speed control to adjust to 600 rpms. It should be run for at least an hour in low belt range to break in the bearings. When finished tum the spindle off. The machine is now ready to be initialized. To initialize the machine press the "YES" key on the controller to the prompt “READY?". The axes will go to their "home* positions. The Z home is to the right and X out is towards the front. 40. Pressing the POWER again and the machine will retum the machine to the 1. stand by mode. When the machine is not in use tum off the main circuit breaker to tum off the main power.6. LUBRICATION The auto-lube system is on the left side of the machine lubricates the ways and ball screws. It comes on automatically when the main circuit breaker is on. To deactivate it turn the main circuit breaker off. It should not be allowed to run dry. 7. COOLANT The pump on the coolant tank plugs in at the left side. It is activated with the coolant key in the manual mode or by program control program in REMOTE. 8. INSPECTION REPORT A clear plastic envelope accompanies the machine containing the inspection report. The identification numbers on the report and on the machine should be verified for agreement. Each machine goes through a rigorous accuracy test for parallelism, accuracy and spindle total indicator runout (TIR). The values which were actually measured are printed beside the allowable quality control (QC) values. 9, OPTIONAL ACCESSORIES These are packaged separately. Operation and assembly instructions for the optional accessories are included in their own shipping cartons. 10. SAFETY CONSIDERATIONS ‘There are safety features built into the machine which are required legally to be on the machine. They should not be bypassed! 1. During operation under program control opening the front door will also cause the machine to power down. The user must switch to "LOCAL" in order to open the door. The spindle will tum off and the orange caution light will come on. It may be necessary to access the work area for tool calibration and insert replacement. Turing the spindle off will allow this. 2. There is a mechanical stop on the front of the slide that can be set to prevent the turret hitting the chuck. Tighten the two screws atter locating it in the desired position. 3. Depressing the emergency button will cause power down and apply the spindle brake. This should not be used to turn off the power because it will shorten the life of the brake.11. ELECTRICAL AND MECHANICAL OVERVIEW There are several adjustments and operations that the user may have to perform manually or be aware of before operating the machine. 11.1 SPINDLE SPEED RANGE ADJUSTMENT There is a 3 level V belt setting to optimize the torque transmission between the motor and the spindle, The ranges are 0-1000, 0-1800, and 0-4500 and may be programmed and operated anywhere inside of these ranges. Selection depends on diameter, material and tooling to gain the optimum cutting power. To change the setting, loosen the bolts on the idler and move the pulley to the desired position. When the desired position is attained put tension on the belt and re-tighten the screws. 11.2. SPINDLE PICKUPS Behind the spindle pulley there are 2 pickups on a disk. The disk has 1 slot on the periphery to synchronize threading and 4 slots further in to provide information to the spindle RPM display. There is an encoder with a 3 to 1 belt ratio mounted on a bearing block bolted to the right of the spindle head. This provides information to the controller on spindle revolutions per minute. 11.3. SPINDLE MOTOR This is a 3 HP DC. brush type motor with integral tach and brake. Periodic brush inspection is necessary. Inspect it every month with heavy usage or every three months with light usage. Please note that HP falls off linearly as the rpm of the motor changes. Therefore, using half of the rpm (in any pulley setting) gives half of the HP. For heavy cutting we recommend using the low gear with the maximum rpm that can be used. 11.4 THE SPINDLE ‘The spindle is supported by three sets of bearings. There are two sets in the front and one set in the rear. It has a 1.49" (39mm) hole through the center. The spindle nose is equipped with an A2-4 mount.41.5 THE AXES Each axis is identical, only the length of the ball screw is different. The piten is 2.8mm. The ball screw is reduced through a 5:1 timing belt to the stepping motor, At 200 full steps por revolution this works out at 1 step equals .0025mm. The maximum thrust generated is approximately 800Ibs. There is a precision limit switch on each axis which acts as the home position. During initialization (switch on) the axis seeks this limit switch and uses it to measure the backlash and to position itself at home. Any chips or dirt will affect this accuracy. This ara should be kept clean. The Z may require more attention as it is more exposed. 116 THE TURRET ‘There is a curvic coupling attached to the turret which is hydraulically locked in place or unlocked to allow the turret to rotate to a new position. When the position is located it is locked again. The air to hydraulic intensifier is located in the belt compartment next to the Z axis drive motor. ‘Two micro switches are used in the turret to detect locking and uniocking of the turret. When the turret is out or unlocked a stepper motor rotates it to its new position. ‘There is a 3 channel opto pickup with 3 discs absolutely encoded to monitor and check the new position. Two air-solenoids are used - one to lock the turret and the other to unlock. 11.7 CHUCK OR COLLET CLOSER Ifnot factory installed, the user can install his own power chuck or collet closer at a later date, Make sure it is will handle 4500 rpms and also check the holding power at this rpm. In general as the rpm goes up the holding power goes down. Please refer to the service manual for installation. 118 BAR FEED Refer to the bar feed manufacturers instructions.CHAPTER II GETTING ACQUAINTED WITH THE DM 3000H CNC LATHE & CONTROLLER (CONSOLE)CHAPTER IL INTRODUCTION The DYNA MYTE 3000 Series CNC Lathe is a compact floor type lathe (see Figure 2.1) and is ideal for manufacturers of small precision parts. it is important to ‘eam useful information such as how large a part can be made, how fast it travels, how much power it has, how many tools it can hoid, and how accurate it can machine. Furthermore, it is also important to understand the various controls and functions of the Machine. This knowledge will help you to be a safe and efficient operator and/or programmer. 2.1. THE MACHINE A photo of the 3000 Series Lathe is shown in Figure 2.1 and the major parts of the lathe are labelled in Figure 2.2. The DM3000H Lathe can tum parts as large as 4 inches in diameter and up to 7 inches long. The 2 horsepower motor can turn the spindle up to a maximum of 4500 APM. The tool can be moved in feed mode up to 63 inches per minute (1600 mm/min.). The tool turret has 6 tool positions which can be automatically selected. The machine can move to a programmed position with an accuracy of + 0.0003 inch and repeat that same move within + 0.0001 inch. 2.2 THE CONTROLS The 3000H is controlled from the Control! Panel and the Main Controller which are shown in Figures 1.1, 1.2, 1.3, and 1.4. 2.2.1 THE CONTROL PANEL The switches mounted on the Controi Panel control the primary functions of the machine. These switches include the Power On/Off switch, the Emergency Stop button, and the Spindle On/Off switch, Spindle Local/program, Door disable/enable, Coolant On/O#,, Collet open/close, and work light off/on switch.FIGURE 2.1 THE DYNA MYTE 3000H SERIES CNC LATHEController Main, Control Emergency Savor i Cid switch a Spinde Headstock Tailstock Weys Bed ™Lsuasorew Crosslide Turret Saddle FIGURE 2.2 THE DYNA MYTE 3000H SERIES CNC LATHETAT Ler [sa 3] YE 1 oe SPINOLE ON/OFF. TOOL ABS => WACK 0 a xt -> er O Feast REPEAT REPEAT ND 5 _comeBACK, Cc FIGURE 2.3 DYNA MYTE DM3000H CONTROLLER: a =CONTROL PANEL continued FIGURE 2.4 THE DM3000H CONTROL PANEL PANEL EXPLANATION PLEASE LOCATE AND LEARN THE FOLLOWING ON THE ABOVE DRAWING. SYSTEM POWER LIGHT There is a small LED located above the door open light. When this is lit it means that there is power in the system. (VOLTAGE TO THE POWER SUPPLIES) DOOR OPEN LIGHT When the door is open this light will be on. If the door is open and the spindle is on this light will flash. OPENING THE DOOR WHEN THE SPINDLE IS ON IN THE PROGRAM RUN MODE WILL KILL ALL POWER TO THE MACHINE! EMERGENCY STOP SWITCH This will kill all power to the system. Press to activate. Rotate clock-wise to release. POWER ON/OFF When power is to the system and the system is ready to be started this light will blink meaning that it is in the stand-by mode. Press this button to turn on the main power. The light will stay on, COOLANT ON/OFF The light on this switch should be on after turning the power on. This means that the cl coolant is ready to be tumed on by program control (CONTROL 4) or will come on when the spindle is switched from program to local. 4. CHUCK OPEN/CLOSE This light will be lit when the chuck or collet is in the open position. LOCAL/PROGRAM This switch is for the spindle. When the light is lit the spindle is in the program mode and may be tumed on by program control. The default for this mode after powering up the machine is the program mode. SPINDLE ON/OFF This is an over-ride to tum tho spindle off during a program or can be used to tum the spindle on when the LOCAL/PROGRAM key is in the LOCAL position. NOTES: 1. WHEN switching from the program to the local mode the spindle on/off will change to off. 2. If you are running a job which required part changing between cycles switch the PROGRAM/LOCAL switch to LOCAL to open the door. DOOR DISABLE (not available on all models) This allows the door to be opened when the spindle is tuming. This is only allowed when the spindle is in the local mode. BAR FEEDER ON/OFF This light will come on when this mode is active. LIGHT ON/OFF This is for the work light. t will come on automatically when the machine goes from the standby to the run mode. SPINDLE RPM This displays the current spindle speed. It is normal to be relatively slow responding due to the fact that is is doing a sampling cycle for accuracy. REMOTE SPEED OVER-RIDE ‘The spindle speed may be increased or decreased by 10 per-cent using this knob when the spindle speed is set in the program. LOCAL SPEED CONTROL ‘This knob if for adjusting the spindle speed when the spindle is in the local mode.POWER METER This meter monitors the power that the spindle motor is drawing. Please monitor this during heavy cuts, If the spindle is drawing more than 15 amps for an extended period it will open the circuit breaker and stop the main power to the machine. 2.2.2. THE CONTROLLER The microprocessor in the Controller enables the DIV3000H Series Lathe to have many advanced features. The buttons on the controller are used to program, edit, and control the functions of the 3000 Series Lathe which are not controlled by the Control Panel. The purpose or use of each button of the Controller is explained in Table 1.1. 2.3 THE FOUR OPERATING MODES ‘The machine has four operating modes. The desired MODE is selected by pressing any of these four keys on the Controller: PROGRAM PROGRAM TINE nee RUN ENTER No - The MANUAL MODE is used for tool calibration, manual operation of the machine and diagnostics. - The LINE NO. is used for reviewing programs stored in the controller and for selecting the desired program. - The PROGRAM ENTER MODE is used for entering a program into the controller. - The PROGRAM RUN MODE is used for operating the machine under program control. (Running a program) The capabilities of all four modes will be explained further in later sections.CHAPTER Ill LEARNING MACHINE MOVEMENTS (CONVENTIONS)CHAPTER If MACHINE MOVEMENTS Be YY FIGURE 3.1 THE CARTESIAN COORDINATE SYSTEM IN TWO DIMENSIONS. (BASIC TO NUMERICAL CONTROL AND THE AUTOMATED FACTORY) 3.1 CARTESIAN COORDINATE SYSTEM The Cartesian Coordinate System is the basis of the axis identification system which is used for programming machine tools and other forms of flexible automation. ‘As you can see from Figure 3.1, the Cartesian Coordinate System is simply the X and Y graphing system used in algebra in other common applications. This system is ideally Suited for describing the motions of maciine tools as it is simple and easy to use and yet provides a positive identification of any point, or series of points, in space. Figure 3.2 shows how the Cartesian Coordinate System is applied to three dimensional space which is required to describe most parts other than ones which are made out of thin material such as sheet metal.FIGURE 3.2. THE CARTESIAN COORDINATE SYSTEM IN THREE DIMENSIONS 3.2 APPLICATION OF THE CARTESIAN COORDINATE SYSTEM TO THE LATHE For many CNC machine tools three axes of motion are described based upon the Cartesian Coordinate System as shown in Figure 3.2. For example, for the vertical milling machine *X’ is assigned to movements of the long direction on the table, "Y* is assigned to movements in the short direction of the table, and *Z" is assigned to vertical movements of the spindle. However, the lathe has only two principal axes of motion to describe (see Figure 3.3). Tool movements parallel to the spindle centerline ( "2" axis) which were vertical for the milling machine are horizontal for the lathe but are still called "2" moves, and *X" is assigned to movements of the tool perpendicular to the center- line of the spindle, When the tool is moved toward or into the work on either the X or Z axis, it is considered to be moving in a *negative" direction, When the tool is moved away from she work on either axis itis considered to be moving in a "positive" direction (see Figure 23). fiENGINE LATHE FIGURE 3.3 THE CARTESIAN COORDINATE SYSTEM AS. APPLIED TO THE LATHE 203.3 NUMERICAL CONTROL DIMENSIONING SYSTEMS in Numerical Control there are three ways or systems for describing points or locations on a part or machine. These systems are called absolute, incremental (Telative), and polar. The first two (absolute and incremental) are based on the Cartesian Coordinate System which we have just been discussing while the third system (polar) is based upon a radius and an angle. 3.3.1 ABSOLUTE SYSTEM ‘The absolute system is the most commonly used dimensioning system for numerical control. Points or locations described as absolute values always relate to a single base position or origin. For the lathe this base position is known as the Reference Zero. All points or locations used to describe a part are related to this point. Figure 3.4 shows a part in a lathe for which several Z locations have been dimensioned using the absolute system. Note that Point *C* is dimensioned directly as 3.25 inches from the Reference Zero plane. REFERENCE ZERO CHUCK FIGURE 3.4 A PART DIMENSIONED USING THE ABSOLUTE SYSTEM a3.3.2 INCREMENTAL SYSTEM In the incremental (or relative) system the location of each point is dimensioned from the previous point. In Figure 3.4 the Z location of Point "C* is defined as being 1.25 inches from Point "B" rather than as its distance from the Reference Zero as was given in the absolute system in Figure 3.5. To obtain the distance of Point *C* from Reference Zero using the incremental system, tho distance from "B" to "C* must bo added to the distances from "A" to "B* and from Reference Zero to "A". As mentioned in Section 3.3.1 the absolute system is most commonly used for NC dimensioning. However, there are instances such as when describing radius Moves that the incremental system is used to good advantage. CHUCK FIGURE 3.5 A PART DIMENSIONED USING THE INCREMENTAL (RELATIVE) SYSTEM 23.3.3. POLAR COORDINATE SYSTEM Asystem calied the Polar Coordinate System is sometimes used to define points in space. Rather than using the Cartesian Coordinate System upon which the absolute and incremental systems are based, the Polar Coordinate System is based upon a series of circles with the zero point at the center. A given location is described as being on a particular radius from the center and located at a particular number of degrees from the positive "X" axis. Thus, the polar coordinates are given as a radius and an angle instead of the more familiar X and Y or X and Z coordinates. Figure 3.6 shows the basic Polar Coordinate grid, while Figure 3.7 gives an example of @ point located in space using the Polar Coordinate System. The Polar Coordinate System is sometimes found to be especially convenient for describing certain types of cuts on the lathe such as angles for chamfers on comers. RADIUS Point Angular Reference x FIGURE 3.6 POLAR COORDINATE GRID IGURE 3.7 DEFINITION OF A POINT USING THE POLAR COORDINATE SYSTEM 2B3.4 POINT-TO-POINT AND CONTINUOUS PATH SYSTEMS There are two basic types of moves which can be made by numerical control machines. For some types of moves, the exact path or route traveied from one location to the next is not of particular importance as feng as there is no collision. An ‘example of this type of move would be when positioning between locations when drilling holes on a milling or drilling machine, The tool is simply being moved through the air above the part. Figure 3.8 shows how for point-to-point moves many NC Machines move two axes together at the same rate (making a 45 degree angle) until ‘one axis has completed its commanded distance. Then the move is completed as a straight ling parallel to the axis which still has a remaining distance to travel. For the second type of move called continuous path or contouring, the exact path in which the cutter moves is extremely important. In this case the shape of the part is being formed during the move, usually to close tolerances. Examples of continuous path moves would be milling an angle or curved section on a flat plate, or tuming a chamfer or radius on a shaft using a lathe. Figure 3.9 shows a continuous path or controlied move used to machine an angie. This cut would normally be made as a series of very small stairsstep moves using two axes at the same time. The steps would usually be so small that the finished cut surface appears smooth. Figure 3.10 shows a curved surface with arrow lines showing what the results would be if very large steps were taken. The greater the number (and smaller the size) of steps the curve is divided into, the smoother the machined surface will be.Possible path by a point-to point B machine A FIGURE 3.8 POINT - TO - POINT MOVE NOTE: THESE STEPS ARE EXAGGERATED FIGURE 3.9 CONTINUOUS PATH MOVE IN A STRAIGHT LINE ON AN ANGLE NOTE: THESE STEPS ARE MUCH CLOSER TO THE ACTUAL CURVE THAN TO THE LEFT. HOWEVER, THEY ARE STILL EXAGGERATED. FIGURE 3.10 CONTINUOUS PATH MOVE ON A CURVE3.5 LINEAR AND CIRCULAR INTERPOLATION Since CNC machine controllers include micro-processors (small, but powerful computers) it is convenient to use their help in calculating the many minute moves or steps required to generate smooth angles and arcs. Because these calculations can be made so easily and quickly using the computers, most CNC machines make straight- line moves even for point - to - point type moves between locations. When such straight-line moves between points are made on an angle, the process is called "Linear Interpolation. " When this control feature is being used to generate an angle, the computer usually needs only to know the beginning and end points of the move. It will completely calculate (or interpolate) the move. When a machine is capable of linear interpolation, the instructions for a straight-line angular move can be programmed in a singie line or block of the program When such small stair-step moves are computer generated to form smooth circular curves or ares, the process is referred to as ‘Circular Interpolation" In such cases not only does the control need to know the beginning and ending points, as for a straight line, but also needs to know the radius and center point of the are and whether the move is to be in the clockwise or counterclockwise direction. 3.6 FLOATING ZERO (THREE TYPES OF REFERENCE POINTS) On most modem CNC lathes, the X and Z coordinate axes with their origin or zero at the intersection can be conveniently moved or floated around to make programming and/or machine operation easier. These zeroes are often referred to as "Reference Points." Often more than one reference point is used in the same program or part description. Figure 3.11 shows how three different types of reference points or zeroes are used in programming the Series 3000. @Reference art Zero) ° (2. - 9 SS z | X+ X+ @Home Position Zt Local (Machine Zero) Zero X+ FIGURE 3.11 ‘THREE TYPES OF REFERENCE POINTS USED IN PROGRAMMING THE SERIES 3000 6CHAPTER IV GAINING PROGRAMMING INFORMATIONCHAPTERIV INTRODUCTION ‘There are many factors involved in a CNC program, The more we leam and understand about these factors the better programmers we can become. There ate different systems which have been developed for communicating information to a CNC machine. But each system involves a message, or directions which are given to a CNC machine to tell it how to move the machine. These instructions to the machine are called programs. Programs are generally divided into basic sections. Programs will have a much better chanca of being successful if careful planning is done first. This unit is designed to help you leam how to plan and write good CNC programs. 4.1 CONVERSATIONAL INPUTS Programming in a conversational system is easy to leam because the new programmer does not need to memorize a list of codes. There are two ways we may enter the program in a conversational system : Fae WORDS ENTERED FROM THE KEYBOARD: 2 ANSWERS TO QUESTIONS (PROMPTS) ‘When in the conversational mode the input "words" will be in English. In certain ‘operations the controller will ask you questions and the answers will be stored to form part of the program. There are two type of responses : He YES or NO ie NUMERIC (NUMBERS) These question are called PROMPTS. Prompting is a way the controller has of communicating with the programmer. Prompts remind the programmer of the next needed word and they also help to speed up the operation. Prompts also prevent some errors and help the programmer to avoid incorrect entries. Prompts are questions such as: QUESTION AS THE DYNA PROMPT APPEARS Are the dimension for this program in inches? - 000 START INCH? How many in and out motions (pecks) do you wish the dril to execute? ~ Pecks nn? Do you wish to leave material for a finish cut? = - F? Unit Vil, Programming With Prompts, contains a complete list of the prompts used on the DYNA and the correct kinds of responses.42 ENTERING CYCLES Cycles (often called "canned cycles") are pre-programmed operations that require customizing by the user to ft the part being programmed. ‘Theso variables are called PARAMETERS. For example, for @ rough tuming cycle the parameters would be the diameter and length of the cut. When you initiate a cycle from the keyboard, you will be asked a series of prompts. Each is one of the parameters and must be answered in tum to complete the cycle entry. This will be covered further in units Vil and IX. The controller is designed to minimize the chance of a mistake. Beware that once the control is locked into a cycle, it will not let you out of it until you answer all of the prompts. Once you answer the first prompt, you must answer all of them. Only after filing in all the prompts, may you then clear the cycle and proceed. If you do not respond to the first prompt, the controller will allow you to clear the cycle immediately. Table 4.2 shows the corresponding DYNA conversational words for many commonly used EIA coded words. This list should give an idea of the relationship between the ‘two input systems, Please note that some variation occurs from one manufacturer to another and the specific codes which have been applied must be leamed for each new machine. TABLE 4.2 RELATION BETWEEN CODED WORDS AND CONVERSATIONAL INPUT MISCELLANEOUS FUNCTIONS CODE CONVERSATIONAL EXPLANATION Moo HALT PROGRAM STOP Mot HALT OPTIONAL STOP Mo3 SPINDLE ON ‘TURN ON SPINDLE M05 SPINDLE OFF TURN SPINDLE OFF Mos TOOL CHANGE TOOL CHANGE Mia SPINDLE AND TURN ON SPINDLE WITH COOLANT COOLANT ON wTABLE 4.2 (CONT.) GENERAL PREPARATORY FUNCTIONS CODE GOO Got Goa G20 G70 Gai G71 G28 Gat G40 G43 Gada G73 G83 G90 G91 G92 CONVERSATIONAL f (FAST) GO orGR DWELL INS mm XY REF ioro inside or outside tHE TOOL LENGTH? DRILL - PECK Go (GO ABSOLUTE) GR (GO RELATIVE) PROG REF EXPLANATION POSITION AT RAPID TRAVEL LINEAR CUT AT FEED RATE DWELL PROGRAM IS IN INCHES PROGRAM IN MILLIMETERS (mm) RETURN TO REFERENCE POINT CUTTER COMPENSATION - CUTTER TO LEFT OF WORK CANCEL CUTTER COMPENSATION ### (ENTRY IS NOT NEEDED IF NOT COMPENSATING) TOOL LENGTH COMPENSATION. G43 1S A PLUS COMPENSATION AND G44 IS MINUS PECK DRILL CYCLE ABSOLUTE VALUE DATA RELATIVE (INCREMENTAL) VALUE DATA SET PROGRAM REFERENCE POINT43 PROGRAM SECTION ‘The programs you will write or run on the machine will be divided into three sections as follows (See Unit Vil for more detail.): START SECTION: This part of the program contains the preparatory information to holp the machine run your commands. information such as: too! selection and whether the program is in inches or millimeters. Also the reference point. BODY SECTION: This is the main part of the program. It contains the actual machine commands and the information that produces ‘the parts. ‘These commands are very similar in either coded or prompted inputs. END SECTION: _ Inthis section you determine how the machine will end it's movement. It will do one of two things : He END - Complete the commands and stop at machine home. 2. END NEWPART - Complete the commands and retum to the Program Reference Zero, ready for a new part to be put in and to run again. 43.1 THE START SECTION All controllers must have a certain amount of information before they can direct the machine. You must provide the DYNA controller with three categories of preparatory information. The controller will need the answers to these three questions before it can execute a program. They are: START Is the program in inches? What is the file number of the program? TOOL, What is the number to be assigned to the first tool? NUMBER SET UP Where will the PART ZERO (PROGRAM RIEFERENCE ZERO) be? ‘These are the preparation part of your program. They condition the control to accept the body of what you wish to do. 34Following is a typical start of a program. LINE NUMBER RESPONSE EXPLANATION 00 STARTINS 01 — - Program in inches. File #01 001 TOOL # = Tool number of first tool. 002 GO f X 0.0 - Rapid move to Machine Zero of x axis. 003 SETUP > dezx —_- Setup location block - will be used later as we actually run the part. Must be put in now for future use. This block will be used to locate the cutter physically at the location you select as your program reference zero. 004 SPINDLEON ——_- Tums spindle on. 005 SPD SP = 1000 —_- Spindle speed = 1000 rpm. 008 TOOL 1 = (Needed for NEW PART endings.) You may select any program file number you wish. Files should be arranged in a sequential order to allow file maintenance on offline equipment. You may select any feed rate from 0.1 in. / min. to 63 in. / min. or specify feed -rate in thousands of an inch per revolution. These feed rates may also be specified in millimeters. An individual axis may have different feed rates on the DYNA by pushing the FEED RATE button for each axis. Example: FRX = 14. FRZ=10. Thus X will feed faster than Z. The screen will not ask anything until you push the first prep button on the control. This is the START button. The control will then ask you the information about inches or millimeters, and the file number. Once you have keyed in your response, you must store this in memory. To do this, push the NEXT button on the lower right of the console, NEXT KEY This stores that block and moves the sequence up one block for the next entry. Then you will proceed through the four preparatory questions . Once you have completed the four prep questions you are ready to enter your program. The NEXT button is also used to advance the display one block at a time in other modes and functions. 324.3.2. THE BODY SECTION This the main part of the program in which all the commands are given to do the actual machining. This is where we get down to business and make chips. In both coded and prompted input programming, the body of the program is very similar, The body will be a series of axis commands and miscellaneous commands such as tum on the spindle or move to a clearance point for a tool change. We will study in detail the body of the program for most of the rest of this book. 4.3.3 THE END SECTION There are two ways in which you might wish to end a program. Which way you choose depends on what you intend to do after the program is complete. 4. Will you want to run another part in the same location? 2. Will you want to run a new program? ‘When you touch the END button on the DYNA, it asks you which of the two choices you wish to make. There will be two prompts. To move on to the next prompt answer "NO" The two prompts are: ” if you respond "YES" to this prompt, the machine will return to the location you selected in your setup as the program reference zero and the controller will be ready for a new part to be loaded and run again. 2) END....? This prompt will cause the machine to go back to the machine home position. Machine home position is the location where the machine stops when it completes its initialization. This means that the original program zero is lost. This command would be used only if we were sure that part was acceptable and that we would not_be using the same setup again. The most frequently used program end is the END....NEW PART command. Even if we do not plan to run it again, we sometimes want to take another pass at the part, or maybe we want to test the program with the cutter off the part for safety. The END....NEW PART command allows this without having to relocate the part zero (program zero) each time. NOTE: AFTER SELECTING "END NEWPART" OR "END" THE "NEXT" KEY MUST BE PRESSED TO STORE THE COMMAND INTO THE MEMORY. 3344 PLANNING THE JOB PROPERLY For a CNG part program to be safe and efficient, and to produce acceptable parts, the programmer must carefully plan ahead. The whole operation must be thought out in advance. Usually the best way to make a series of cuts and operations is not only the least expensive but, at the same time, the safest. Following is a list of steps which, if properly followed, will help to ensure a sate, efficient program. 1. Build safety into the program. 2. Choose proper part mounting methods, part-to-machine relationships, and tool change positions. 3. Plan the proper sequence of cuts and cutter paths. 4. Select correct cutting tools. 5. Calculate proper cutting speeds, feeds, and depths of cut. Each of these steps will now be further explained. 4.4.1 BUILDING SAFETY INTO THE PROGRAM The programmer has the responsibility for building safety into the program. A key to doing this is to plan the entire operation before writing the program. Thus, proper thought can be given to guarding against potential collisions or other problems either during regular tool moves or during tool changes. Unit V, PRACTICING SAFETY AND SAFE MACHINE OPERATION, should be studied before attempting to write a part program and should be periodically reviewed as a reminder of safe programming practice. 4.4.2, CHOOSING PROPER MOUNTING AND PART / MACHINE RELATIONSHIPS Acritical part of the planning process is to consider the work holding method and pari-to-machine relationships. One of the first considerations is the capacity of the machine. Is the machine large enough in terms of swing (diameter) and length for the part to be machined (see Section 2.2). Another consideration is the diameter-to-length ratio of the part. Is the part short enough in relationship to its diameter to be simply clamped in the lathe chuck, or must it also be supported by the lathe center in the tail-stock? Still another question is in regard to the design of the part itself.Can the part be completely machined from a single clamping in the lathe chuck, or must it be tumed around and clamped by the other end in order to finish the job? If the part must be tumed around, the situation becomes much more compiex and there are more chances for errors. The answers to these last two questions are sometimes rather obvious. Other times they may require considerable experience. Part zero in the X axis is usually chosen as the center line of the part. Part zero in the Z axis is usually chosen as the end of the part further from the chuck (see Figure 43.11). The relationship between the part zero and the machine zero (Home Position) is normally established during the too! calibration phase of the set up process (See Section VI). ‘A tool change (Clear Point) location must be established where there is ample room for the longest tool to swing around in the turret and still clear the work-piece and where there will not be any other interference with the tool change movement. 4.4.3 PLANNING THE PROPER SEQUENCE OF CUTS AND CUTTER PATHS The path the cutter takes is critical. When writing a program, you must have already planned how the part is to be held on the machine, what kinds of cutters will be used, and what the machine size and horse power limits are. The most spectacular *crashes* on computer driven machinery occur when a programmer forgets to plan the cutter path properly. ‘There are off-line computer graphics programs available which display the actual movements of the tools in sequence on the computer screen as they are programmed to machine the part. This capability is ideal for checking your program if it is available to you. However, the following factors will stil need to be considered whether or not your program is checked by computer. Look into getting the DYNA WORKSTATION. aH Work from sketches or drawings on both the part and the machine set-up. Do not guess at the layout of the machine. Consider the chuck, tools, turret, and tail-stock when planning the tool path. 2. Think through the sequence, especially any rapid traverse moves. Make sure that the machine has the capacity and is programmed to clear the chuck, the tailsstock, and all part features. 3. Be sure that the part is stiff enough and is clamped solidly enough to allow the feeds and depths of cut the program calls for. 4 Make sure that the rpm's, feed rates, and depths of cut are correct. This is not something you should guess at. There are speed and feed slide rule calculators and computer programs available to help with these calculations. However, even though you may have these means available it is good to know how to make these basic calculations yourself. The formulas and procedures you will need are given and explained in Section 4.4.5.4.4.4 SELECTING THE CORRECT CUTTING TOOLS Selecting the correct tool for CNC lathe work is no different from manual iathe work, Tool selection will be critical to safety, quality, and efficiency. The wrong tool can damage the machine as weil as the pari. This is an area that you should already be famitiar with. Some general rules to keep in mind are: 1. Be sure to select the proper type and orientation of the tool for the intended cut (see section 6.3). 2. Always use as strong and as short a tool as possible and still be able to reach the part safely. This will provide stifiness, or rigidity, to your set-up and thus help reduce vibration, chatter, and rapid tool wear or even breakage. Good surface finish of the part will be promoted. 3. Use a finishing tool with a nose radius equal to or smaller than any inside comer radius of the part. If the tool radius is less than the part radius you will need to program arcs at the comers. This is a good technique to use for reducing chatter. 4.4.5 FIGURING OUT PROPER CUTTING SPEEDS, RPM'S, FEEDS, AND DEPTHS OF CUT Cutting Speed One of the most basic ways of describing the rate at which metal is being cut is called "Cutting Speed." Cutting speed for a lathe can be described as the length of Chip that is being removed in one minute from along the surface of a cylindrical work- piece tuming at a constant rpm. Another way of saying the same thing is: Cutting speed equals the length of chip per minute produced at a constant diameter and rpm. Figure 4.1 shows a view of the end of a cylinder which is being machined on a lathe. ‘Length of chip per minute Figure 4.1 Illustration of Cutting SpeedThe cutting speed is expressed as feet per minute (fpm) or surface feet per minute (sfpm). The cutting speed at which we can cut on a lathe depends on what kind of metal or other material we are machining. Generally, the harder the material, the slower we have to go. Another ruie that usually holds true is that the faster we cut, the faster the tool gets dull. However, normally the faster we remove metal the less time it takes to get the job done. Acceptable cutting speeds which represent a balance of both factors have been worked out by experience and testing for different materials and different too! bit materials and are available in charts and tables in handbooks or from slide rule calculators which are available from cutter manufacturers. (See Appendix for tepresentative cutting speed values.) ‘The basic formula for calculating cutting speed (CS) is given as: CS= pixDxmpm divided by 12 This formula for the length of chip cut per minute can be explained rather easily as the distance around the work-piece (pi D = circumference, or distance around the part once) multiplied times the number of revolutions the part makes per minute (rpm). Since the diameter of the revolving work-piece (or a revolving cutter such as a drill) is given in inches, the answer from this muttiplication is divided by 12 to provide an answer in feet per minute (fpm). A typical example for caiculating cutting speed for the Dynamyte 3000H Series Lathe might be a 3/4 inch diameter aluminum work-piece tuming at 3000 rpm. If we substitute these values in the cutting speed formula we find that: CS= _Dxtpm = 3.1416 x.75 x 3000 = 589 fom. 12 12 This calculated value for cutting speed at which we might be planning to operate the latho can be compared with the recommended value (or range of values) that we look up in a handbook. If our calculated value is higher than the book value we probably would want to decrease our rpm so that we would not wear out our tool too fast or have other problems. If our calculated cutting speed is extremely low we may want to increase our rpm to be able to complete our job more quickly.RPM Since we normally know what material we will be cutting, we can fook up the recommended cutting speed for a particular type of machining in a table as our first step. It is then the rpm at which we need to tum the part or cutter to achieve this cutting speed that we need to calculate. This mpm can then be used in our program. When the basic cutting speed formula is rearranged for solving for rpm it ist rpm = 12.xC.S, Db ‘A typical question for a programmer of the 3000 Series Lathe might be "At what rpm should a 1.25 inch diameter 1020 mild steel part bo tured ifa cutting speed of 150 fom is used?" If these value are substituted in the rpm formula it is found that: mpm = 12xCS = 12 x 150 = 458.4 pm pixD pix 1.25 ‘The calculated rpm is 458.4; however, it would be close enough to round off to 460 pm. FEED Feed for a lathe is defined as the distance the tool advances along the work for each revolution of the spindle. For example, if a feed of .020 inch is used, the tool travels .020 inch along the work during each revolution. Therefore, it takes 50 revolutions of the spindle for the tool to travel 1 inch (50 x .020) along the work. Usually it is advisable to use as few cuts (or passes) as possible to save time and tool wear. One roughing cut and one finishing cut will commonly be enough. Since the reason for the roughing cut is to remove material as quickly as possible, and surface finish is not important, a coarse feed should be used. For finish cuts a fine feed should be used sinco a better surface and higher accuracy are produced. Tables of recommendod feed-rates for tuming various materials are availabie in handbooks. A few ropresontative feod-rates are given in the Appendix. 38DEPTH OF CUT When reducing the diameter of a cylindrical workpiece the depth of cut is related to the distance that the too! is fed in toward the center of the pari. Care must be. taken when programming the depth of cut on a lathe because the amount of material removed in each cut is always twice the actual distance the tool is fed in, However, programming of the Dyna Mechtronics 3000 Sories Lathe is very simple when using the absolute mode because the diameter ‘which is desired after the cut is the value which is programmed directly. Therefore, if a 1/2 inch diameter piace is to be machined down to 60.400 inch diameter, the "X® value which is programmed is X 0.4000. Following are some points to keep in mind when deciding the rpm's, feed-rates, and depths of cuts to use. 4. The rough stock to use for a job should be approximately 1/6 inch larger than the largest finished diameter of the work-pieco. 2, Spindle rpm's calculated from cutting speed tables are only approximate and may need to be adjusted for efficient turning operations. 3, Roughing cuts should be es deep and with as coarse a feed-rate as possible, but are limited by the horse power and rigidity of the machine and the size and shape of the part. Approximately .030 inch should be left on the diameter for the finish cut. 4, Feod-rate from tables are only approximate and should be adjusted to ft the condition of the machine, the type of tool and cut, and the rigidity of the work-piece. A Word of Caution Values for cutting speeds and calculated machining rates are intended only to be starting points. Sometimes, if cutters and workpieces are rigid and well held, the speeds, feeds, or depths of cut can be increased. At other times, the speeds or feeds must ba decreased. Spacial eare should be taken the firet time a new program is tried, ‘When testing @ program it is common practice for the machine operator to slow down the machining process purposely by using the override knobs on the control. This is done first while “dry running® the program ( with the tool moved back away from the ‘world and then especially while actually machining the first part 9446 PLANNING FOR TOOL CHANGES Tho turret of the Dyna Myte 8000 Series Lathe slows the machine to be programmed to change its own tools automatically. Obviously this feature saves a lot of time, especially when more than one tool Is required to machine the part and when many paris are to be machined from the same program. For the machine and turret to work properly and safaly, each tool must be set up properly and enough space must be allowed for the tools to clear the work-piece and all parts of the machine when the turret rotates. If enough space is not provided and a collision occurs, severe damage to the machine and cutter and possibly serious injury to the operator may ocour. A good rule of thumb is to move the turret away from the workpiece at laast one half inch further than the longth of the longest tool. In the Dyna system this toot change position is called CLEARANCE POINT and is further explained in Section 6.6, Manual tool changes are described in Section 6.4 OPERATING IN THE MANUAL MODE, and Section 6.4.1 SELECT TOOL. When programming using PROMPTS the operator or programmer simply responds to the question, Tool N 2, shown on the display sorsen by entering the desired number from 1 to 6 (see Section 7.3). Example when 3 is given as a response: TOOL 3 — -Causes the turret to rotate to Tool 3.CHAPTER V PRACTICING SAFETY AND SAFE MACHINE OPERATIONCHAPTER Y PRACTICING SAFETY ANID SAiia MACHINE OPERATION PROGRAMMING SAFE ‘The programmer has the responsibility for building safety into the program. The whole operation musi be planned belore the program cen de aritten. Usually the safest way 's aiso ihe least expensive way whwn ali things are considered, One of the best ways the programtner can help to onsure safety during the machining operation Is to provide good Socumentation cf the program. This allows ail wio might use the program an opportunity iO know what to expect. Good documentation clearly tells: 1. The Program Reference zero (Part Zero) ‘This is the place on the part or tooling to which the operator should coordinate the setup for the program. This is usually the point on the part from which the various details of the part are dimensioned (datum point). 2. The General Tool Path ‘This does not nead to be in great detail, but should give some general idea of the paths the tools will take. This can be in the form of a copy of the program which is called a hard copy {on paper). 3. The Sequence of Cuts Again this does not need to be a long document. It should state information such as: First cut Right Hand Tool Face ond of part. Second cut 3/6" Drill Drill 1* deep hole on center line. ‘This, too, ean be in the hard copy of the prograrn. 4, ‘The Toot List ‘This is a list of the tools and corresponding too! numbers that will be assigned to them in the program. If this is not clear, a disaster may occur if the wrong tool is used. 42,5, A Hard Copy of the Program A print out on paper serves a double purpose. First, it allows tho operator to read the program moves ahead of time. This helps to clear up misunderstanding. Secondly, a printed copy of the program is a sacurity move in case the stored program is damaged. Computer disks, cassette tapes, and even mylar punched tape may be lost or damaged. Given the set-up documents listed above and the print of the part, an operator should have a working knowledge of what to expect of the program. 3.2 GPERATOR SAFETY Once the program is writen, the responsibilty for a safe operation is placed upon the shop people that set-up and run the parts. That is you! The following five suggestions for operator safety are much easier to put in print than they are to follow. Safety is easy to forget when the job gets either very rushed or very routine. The slogan "THINK SAFETY" is the only way to avoid forgetting. Develop an ‘everyday safety habit. TEST THE PROGRAM DRY RUN ... SINGLE STEP READ THE DOCUMENTATION. DRY RUN You probably realize that an error-free program is difficult to write the first time. Even the best programmer oceasionally meke errors. To test the program, DRY RUN through the whola sequence. A dry run is @ pass through the program without the tool in contact with the part. On machines such as the DYNA there is no specific dry run feature. The best thing to do is t0 move the too! back away from the work far ervough to clear all moves arficipsted beiore starting the program. SINGLE STEP THROUGH THE PROGRAM All ONC controllers have the option of running the program one step at a tims. To uso this festura safaly, bo sure to read the information on the controller screen before you push the start bution for each step. Make sure that the tool wil cloar or that there is enough travel to perform the step shown. There is a tendency to put the machine in single step, then watch only the cutter and ignere the readout of the next block to be exeouted. Chvloualy, this can lead to disaster. 431. READ THE SETUP DOCUMENTATION a. a. Know where the cutter is going - the cutter path. This may not be written out but it is available from the hard copy or by watching the dry run, Know what the setup should look like. The program will be written for specific conditions such as diameter end length of stock extending from the chuck or collet Know the tool sequence and make sure that the tool turret is loaded correctly, Be sure that the tool offsets are per the setup document. 2. CHECK THE TOOL TURRET SETUP ‘This is an itern that we all agree upon, and often forget to do. The obvious time to check the setup is on tho first part run. Check to see: a. Is each tool positioned in the proper location and orientation in the turret and extending the proper distance? Is each cutter clamped tightly? \s the part clamped in the collet or chuck properly and extending the proper length? Is each cutter sharp? 3. MAKE ROUTINE CHECKS The problem with setup checks is to remember to do them every so often once everything gets going well. Machine vibration and heat can loosen the things that were once tight. “Also, check at a shift change or a new day start up. 4, BE ACTIVE AND ALERT This too, is an area that we all agree upon but nearly always forget to do. With computer equipment it is a common feeling that once the machine has run many parts and we are sure everything is working well, we can relax and let the machine do the work ., NOT SOI! YOU MUST STAY ALERT AND MONITOR THE MACHINE AT ALL TIMES. USE YOUR EARS FIRST ‘The number one way you can tell how the machining is going is with your ears. Listen for a change in the sound of the cuts. Listen for vibration, slowing of the spindle,or any odd noise that was not there before. While we are on the subject, monitor the quality of your part too. USE YOUR EYES ‘Watch the chips and the finish on the part. Look for any signs of change. EMERGENCY CRASH PROCEDURE More than one experienced machinist has had a crash and actually made things worse bocause he didn't react fast and correctly. This is the time mest of all te be ready. As you start to run the parts, go over in your mind exactly what to do if something goes wrong. Practice this until becomes automatic, Reflex action can buy you seconds and prevent you from pushing the wrong button or switch. (See Section 6.8 for more information about emergency stopping and restarting procedures.) 5.4 SAFETY RULES AND PRECAUTIONS 1. KNOW YOUR MACHINE - Read the Operating Manual carefully. Leam the machine features, applications and limitations. Follow all recommended operating procedures. a IND. MACHINE - Follow instructions for grounding as described in the manual. 3. EEP is cs - Cluttered areas and benches invite accidents. 4A AVOID DANGEROUS ENV! RONMENT - Do not use this machine in damp, wet, gaseous or explosive locations. Keep work area well lighted. 5. Kel (ALL REN AWAY - Small visitors should be kept away from the work area, 6. BONOTFORCE THE TOOL - tt will nat do a better and faster job in removing material if forced, 7. USE THE BIGHT TOOL - it will do a batter and faster job in removing material. 6. WEAR PROPER CLOTHES - Loese clothing and ties can get caught in moving paris.12. 13. 14, 15. ALWAYS USE SAFETY GLASSES - Most cutting tools can throw: dangerous and hot chips. Wear a face and dust mask if the eutting operation creaies dust. ‘SECURE WORK - Aiways make certain that the collet or chuck is securely tightene¢, ES - Form @ habit of removing adjusting wrenches and keys before operating the machine. A safe tule is to never take your hand off the chuck curench while it fs inthe chuck. Do not leave paris cr wrenches on the cross slide or turret. MAINTAIN TOSLS ¥ ep tools sharp and olean at all iimes for best and safest performance. DISCONNECT MACHINE - When not in use. 100 NOT USE AN AIR GUN TO CLEAR GHIPS - This can biast the chips in between the slicies anc through the louvers into the electronics... VACUUM OF BRUSH ONLY,CHAPTER VI THE MANUAL MODE AND TOOL CALIBRATIONCHAPTER VI THE MANUAL MODE AND TOOL CALMBRATICN $1 PRELD TNARY INFORMATION CN MANUAL MOBS Before eny operations can be done on the DMae00H the basic set-up of the machine must ba done. This includes mounting and calibrating the cutting tools and saiting the software working limits. These are accomplished using the MANUAL MODE key. The WANUAL MODE Is one of ihe four modes of the coniroiler anc is particulary useful during set up of the machine. (Refer to UNIT VIli for more dlstails regarding the operating modes.) 6.2 WHEN THE MANUAL MODE KEY IS USED - eae After being switched on the controller will ask"MODE? The second from the top loft key is MANUAL and touching it will put the controller into this mode. While in MANUAL MODE the user can perform operations in one of the sub-modes. These sub- modes are TOOL CALIBRATION, MANUAL MOVES, SET WORKING LIMITS, and do DIAGNOSTICS on the machine. Once this key is presses the conivoller will ask a series of questions before entering any of the sub-modes. 63 ENTERING A SUB-MODE The first question asked by the controller before any of the sub-modes can be reached Is "do you want to work in inches or in the metric system." This is called a prompt and requires a YES or NO to continue. Next the controller will display the current feed-rate value for the X axis. Press the NEXT key to continue. The current Zz axis feed-rate will then be displayed. Press the NEXT key again. Tho display will then ask a question to select which of the sub-modes is desired and the user must answer YES or NO to make the selection. ‘The order is: TOOL CALIB, MANUAL MOVE, WORKING LIMITS, DIAGNOSTICS64 MOVING THE MACHINE IN THE MANUAL MODE {n this mode the user can operate the machine manually by moving the X and Z axes, one at a time, from the keyboard. To accomplish this the procedure is as follows: Press the MANUAL mode key. ‘The controller will respond with “inches? if inches are desired press the YES —_ key if metric units are desirad press the NO key. ‘The controller will respond with "FR X nn.n" This is the cutting feed rate. At this time press the NEXT key. Do the same with "FR Z nn.n’. Pross the NEXT key again. ‘The controller will now respond with TOOL CALIB’ Press the *NO" key. The controller will respond with “MANUAL MOVE?” Press the "YES" key. The controller will display “TOOL 1° 6.4.1 SELECT AXIS Pressing Z or X will show the current position of that axis. That is, if the user selects the Z axis, the display will show: Z =-2.3785 for example. This indicates the present position of the Z axis. 6.4.2 MOVING AN AXIS (JOGGING) To move the axis to a new position, the user can use the jog keys or enter the desired new position into the controller. There are three different jog selections of jogging that may be used for either axis. Following is a brief description: The will start the axis moving at a constant jog. Press the key once to start the movement and again to stop it. To move the opposite direction use the appropriate adjoining key. Note: Some users feel more comfortable pressing the key once to start the movement and pressing again and holding the key down. When it is released the axis movement will stop. Please experiment to find the most desirable way for you. Caution: These jog keys are used only to jog the tool roughly close to the desired location. As the motion is rather rapid, be sure to practice jogging in a safe location with sufficient clearance before trying tool calibration or positioning a tool.64.3 JOGGING AND INCREMENTAL JOGGING ‘The DM3000H aiso has three jo . They are as follows: ONsorP x! LONsOPF x tan |OOPP XY oma | sre constant fogs hed 7 [ac 7 cme | AX Th et | AX | soveaoseoiim 007 fan (975 ao) emer FDS inecomamis mo | ST] ae | Sb] merectesset in soorincn oat em — - Ineremmnnts Jn this mode, the user can also perform manual cutting operations al a given feed-rate from the keyboard. 6.4.4 MANUAL CUTS To move any tool from its present position to a new position press the CLEAR KEY first. Then enter the desired location for the tool to move. ‘The tool will travel to the new location at the feec-rate that was previously displayed. To enter a different feed-rate press the FEED RATE KEY. The current feed- rate in inches per minute will be displayed. To change the value press the CLEAR key and enter the desired value. Then press the NEXT key. 6.4.5 EXAMPLE OF MANUALLY CUTTING NOTE: Before this Is atiempted the toot should be salibratad!. In this example we will tum a bar down from 4° to .95 with a tun tength of 1 inch. Enter the manual move mode. Select the proper jog kays to position the too! near the end of the piece on the Z axis. Select the X axis. Press the CLEAR key and enter .95 and then press the NEXT key. The X axis will move to a position to tum a .95 diameter. Select the Z axis and use the incremental jog keys to move the Z axis to contact the end of the workpiece. Press the FEED RATE key. Press CLEAR and enter the desired cutting food: rate, @ a7 Fe N=7. Press the NEXT key. & Press the ZERO COODS key. This will change the display of the current position to zero. 9. Press the CLEAR key and enter -1 and press the NEXT key. 40, The too! will move to thet position at tho given feed-rate and then stop. HF Use the jog keys or enter a new X or Z value to move to a new position. ss 6.4.6 SELECT TOOL Touch the TOOL CHANGE key and the display will show TOOL N? Key in a number from 1-6 to select whichever tool is desired. ‘Then the turret will rotate to the right tool. Note: There will be no axis movement so make sure you have clearance to index the turret. 6.5 FEED-RATE SETTING ‘Once the inch/mm choice has been selected, the user has a choice of setting the desired cutting feed-rate in inches per minute for any cuts made in this mode. The controller will display FR X = nn.n. To accept the value press the NEXT key. To change the value press the CLEAR key and enter the desired value. Then press the next key. ‘The prompt for the Z axis will follow and operates the same way. 6.6 SPINDLE CONTROLS All of the manual spindle OFF/ON and rpm controls are located on the controller panel to the right of the main controller. Refer to chapter 2. Page 14. (Note: that these functions may also be controlled by the program.) 6.6.1 SPINDLE OFE/ON To tum the spindle on or off manually, Press the spindie LOCAL/PROGRAM key to go to the local mode. Then press the SPINDLE OFF/ON key. NOTE: THE SPINDLE WILL TURN AT THE SPEED OF THE LAST SETTING UNLESS THE LOCAL SPEED CONTROL IS TURNED BACKt 6.6.2 SPINDLE SPEED (rpm) To control the spindle rpm manually, use the local speed control nob. The speed will be displayed on the readout on the panel. Note that the rpm is also further controlled by three speed ranges which are sat by the choice of different belt and pulley positions. 516.6.3 JOGGING In TOOL CALIBRATION (TOOL CALIB) and MANUAL MODE the user can use the jog keys on the controller to move the turrat in the X or Z axis. The display is used to show the current value of the selected axis. Select the axis first. Then touching will start the axis moving and touching the key again will stop the axis, To move the axis in the opposite direction use the appropriate adjoining key. Gaution: These ON/OFF keys are used only to jog the turret or tool roughiy close to the desired location. As the motion is rather rapid, be sure to practice jogging ina safe location with sufficient clearance before attempting to calibrate or position an actual tool. 6.6.4 OPERATING IN THE MANUAL MODE ‘The purpose of this "sub mode" is to give the user a feel for the machine and accomplish simple machining operations which may not require a program. It is exactly like a hand operated lathe with a digital display on each axis, but the machine moves the handles for you. In some cases, it is much easier just to go to the manual mode, do some operations, and exit, rather than going through the program mode, especially if the user just wishes to drill a hole or tum a round bar. 6.7 INFORMATION ON TOOLS AND TOOL CALIBRATION When the user first tums on the machine the controller will ask READY?" and when the user pushes the "YES" key the controller will move the turret to the Home Position (or machine zero). The turret will rotate to the Too! 1 position, and the user can load in the tools needed for the job. At this stage the controller has no idea what tools are in the turret, how they are oriented, or where the tool tips are located in respect to the turret center or spindle center line. The user has to go through a tool calibration sequence for each tool. Once this is done for a particular set of tools the controller will remember the tool calibration the next time the machine is tuned on and tool re-calibration will not be required. If a tool has never been calibrated then the information contained in memory will be meaningless and can lead to errors and possible crashing of the machine. Ifa now too! is inserted in place of the current tool and no re-calibration is done, then the tool tip will be in a different position than the controller thinks it is and a collision may result. musi 14 to ‘th 6.7.1 DIFFERENT TOOLS FOR DIFFERENT JOBS To machine most parts on a lathe different types of cuts are required such as straight turing on the outside diameter, facing the end or a shoulder, drilling a hole on 52the centertine, boring to enlarge and finish a hole in the center of the part, cutting threacis on the outside or in the hole on the inside, or cutting (parting) off the part from the bar or end held in the chuck. Many of these operations require specially shaped or mounted cutters. Figure 6.1 shows what a number of these lathe tools look ike. Df 0b RIGHT HAND LEFT HAND THREADING PARTING FURKING TOD TURBING TOOL ‘TOOL FOOn FIGURE 6.1 DIFFERENT TYPES OF LATHE TOOLS 6.7.2 RIGHT HAND AND LEFT HAND TURNING TOOLS To tell the difference between a left hand and a right hand tool, look at the tool tip, holding the too! so that the tip is toward you. If the tip points right it is a right hand tool, if left, a left hand tool. Right hand tools cut the part from right to left. Left hand tools cut from left to right. The Right Hand tuming tool is also normally used for facing the right anc of the part. ‘The tip of the tool is part of a circular arc of & specific radius. ‘The center of this arc is tho tool *ip canter... (Peter to Section 4.4.4 for iuriher information regarding the selection of correct cutting toals.) 6973 TOOL HOLDER MOUNTING ON THE TURRET ‘The turret slots are designed for 0.5° x 0.5" too! holders. For metric tool holders (i2mm x 12mm) ihe user must inser’ a shim plate (0.027" or 0.7mm thick) undameath the holder. Thess shim plates are inclucled with the machine. ‘Tho wee of too! hollers with carbide inserts is preferred over the brazed on varisty or the ground high speed steel tools. The user may easily purchase his om teol halclers ane! eut them te tengts {0 fit the turret (see drawing below).