CNC Crashes ** Think The Unthinkable

Category : Useful Stuff

CNC Crashes ** Think The Unthinkable

Every CNC Setter, every CNC Operator, every CNC Programmer they all have a story about their worst CNC Crashes. I’ll tell you about mine in a minute. That’s not what this post is all about. Today I want to give you something to think about next time the unthinkable happens.

CNC Crashes

It all happened on a machine not unlike the one above, good old Mori Seiki work horse. I was so grateful of those bars on the door.

Centrifugal Force

An outward force on a body rotating about an axis, assumed equal and opposite to the centripetal force and postulated to account for the phenomena seen by an observer in the rotating body.

Bloody hell! Anyway what I did (like a bloody turkey) was to put a manual chuck inside a power chuck on a CNC Lathe. Worked great that was until the speed clamp stopped working.

G50 that is (oh and here is an explanation of that).

When the machine faced off the part in G96 (see explanation) the spindle accelerated up to its maximum RPM. This was about 3000 revs. Now when a power chuck gets up to that kind of speed the centrifugal force starts to force the jaws open.

https://www.youtube.com/watch?v=x14poOHTXlM

Well if you are holding a manual chuck in there you are in deep shit, and I was. The manual chuck came out ripping off the power chuck soft jaws. Oh and for good measure it took off the machine door. I have never been so scared since my hamster bit me when I was six years old.

People say to me all the time an expression I hate “human error”, mmm. Nope sorry that will not do. It actually was a catalogue of cockups.

  1. Although G50 is modal  you must have one at the beginning of every programme. Even if it’s not needed set it to the maximum RPM of the machine.
  2. Never never put a manual chuck inside a power chuck.
  3. Power chucks need regular servicing to maintain optimum pressure.
  4. Never stand right in front of the chuck, try to stay to one side of it.
  5. Never remove machine interlocks.
  6. Wear two pairs of underpants if you think you might mess yourself.

The Solution (CNC Crashes)

At the CNC Training Centre we offer to help companies make productivity improvements. When we do this I talk about ways to make things stick. That is what you need to do after a collision. Implement solutions so that this particular CNC Crash cannot be repeated.

When CNC Crashes Occur.

CNC Crashes

  1. Get everyone involved together and fully analyze what happened.
  2. Make lists of all the errors and mistakes.
  3. Make sure everyone knows it is not about apportioning blame.
  4. Make it very easy for people to be honest oh and don’t forget torture is illegal under the Geneva Convention..
  5. Look at the things you can change. If someone forgot to do something then how do you automatically remind him. Maybe you can put something in place so he does not need to remember.
  6. For everything that went wrong introduce a new rule or procedure to make sure it can never happen again.
  7. Oh by the way it’s never human error where CNC Crashes are involved.

So let’s look at my example.

  1. Put G50 in every programme on the first line. Go through all the old programmes and do this.
  2. Maintenance programme for chucks and dated sheets on the back of each machine.
  3. Training sessions to explain exactly how G50 and G96 work.
  4. Videos are excellent for training as they cannot be altered. Word of mouth is unreliable.
  5. Training sessions to explain about modal G codes.
  6. Be sure to create an environment where people can comfortably own up to making mistakes. (Not an easy one).
  7. Centrifugal force, what’s that all about?

Thanks for reading this article and don’t forget the most important thing is your personal safety and the safety of others.

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Edgecam Instruction Simulation

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Category : Edgecam

Edgecam Instruction Simulation

In Edgecam there are two ways that you can simulate your programmes:

  1. Full simulation, this includes machine and fixture as well as tool collision detection.

    Edgecam

  2. Instruction Simulation, individual or all your instructions can be simulated as you produce them.

    Edgecam

This article is about Edgecam Instruction simulation.

You can simulate the whole sequence using the simulator in Edgecam. This is really good for collision checking and being sure that your final programme will run ok.

Before the full simulation you can run a simulation from the instruction window. You can see the tool path and accurately see the shape you are machining.

It is really useful for checking your tool path as you produce it. But it does not check for collisions.

The attached video shows you how to tune in to a specific part of your toolpath and analyze it by using the zoom function.

Top Slider

The top slider shows the progress of the simulation throughout the instruction list. Slide it with your mouse to fast forward or back through the simulation.

The current cycle or command is displayed (‘Finish Turning’ in this example).

Slide

Speed Control

You can control the speed of the simulation by moving the bottom slider, left to slow down and right to speed up.

Speed

Factor

The number to the right of the bottom slider acts as a multiplier to the speed set by the slider. Use the buttons to the left of the number to change it.

Numbers

Constant

Click the Constant button to activate it and set the simulation to run at a fixed rate. Click the button again to deactivate it, the tool will then move at a rate proportional to the feeds in the cycle.

ConstantButton

Using the Stop button halts the simulation for the current tool only.

https://www.youtube.com/watch?v=_K0rMtwAjLA

 

 

Watch This Video to See How:

You can narrow the selection to an individual instruction or just a small part of the cutter path.

Just drag the slider while holding down the SHIFT key, then click Zoom. Now when you play the simulation it will just be you chosen part.

Click Zoom again to return to the the full simulation of the instruction list.

Other Edgecam Stuff

Edgecam Associativity How it Works

Layers in Edgecam

Roughing Edgecam (Centre Cutting Tool)

Edgecam Version Update Now

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CNC Lathe Tool Nose Radius Compensation

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Category : Fanuc Turn Haas Turn

CNC Lathe Tool Nose Radius Compensation

This video “CNC Lathe Tool Nose Radius Compensation” is a follow up from my previous video “Tool Nose Radius Compensation on a CNC lathe”.

When you use tool nose radius compensation on a CNC Lathe (that means we are using G41 and G42) you have to tell the machine where the cutting point of the turning tool is so that the correct tool path is produced.

On a CNC Milling machine the cutting point is the centre of the tool but on a CNC lathe there are numerous choices depending on how the tool is going to cut.

This is sometimes known as the virtual nose position or the Tool Cutting Point. It is usually shown in a square diagram like this.

CNC Lathe Tool Nose Radius Compensation

It is designated by a number from 0 to 9. On a Haas control this is under the column TIP on a Fanuc control it is usually under the column T although it is different on some controls.

 

You would be forgiven for thinking that T stands for tool and that it is the tool number (sorry it aint). Mmm I dunno the jury is out on this one.

CNC Lathe Tool Nose Radius Compensation

 

On the offset page your machine will need to know the X and the Z position of the tool. If you are using a Tool Presetting arm or you want to use tool nose radius compensation (and you definitely should) then you will need to input the Tip Radius under the R column and the Virtual Nose position under the T column or the TIP column on a Haas.

 

 

CNC Lathe Tool Nose Radius Compensation

So when you use CNC Lathe Tool nose Radius Compensation the computer will allow for the radius that you specify for your tool. The cutter path will also use the cutting point that you specify.

Below is a tool measurement arm. This can automatically measure a turning tool. It will need to know the type of tool in order to measure it in the correct part of the square. This boring bar would be a type 2.

CNC Lathe Tool Nose Radius Compensation

So here it is folks and remember……..

 

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Heidenhain Programming Examples

Category : Heidenhain

Heidenhain Programming Examples

Heidenhain Programming Examples

Heidenhain Programming Examples

  • The control has been around for a long time and is fitted on many machines.
  • It has improved with age as more and more useful features get added.
  • This is a control that can be learned quickly and easily.
  • It is a control that can be used on many levels and has some very sophisticated features.

The problem with learning something quickly and easily is that lots of good features are missed.

I often say to my customers “I get paid to read the manuals you can’t be arsed to read”

Obviously I wouldn’t say “arsed” to my customers. I’d say something more sophisticated like  “the manuals you don’t give a flying fuck about”

I hate to see things underused we are The Wombles of CNC Programming. Check out this article.

You know, like when you find a piece of cheese behind the fridge. My mother taught me that so long as you cut all the mould off it’s fine to eat.

Most of the buttons will look familiar if you worked on older controls and you come to the newer models. Don’t be fooled by this there is loads of new stuff lurking under the bonnet.
It has a parametric programming function using Q defs.

“Bloody hell what are they” I hear you say.

It’s ok it’s just me trying to be posh again. It means that you can control a programme externally. The sizes, feeds and speeds, all sorts of stuff can be changed each time the programme runs.

(1) Here is an example of how to use the various arc commands on a Heidenhain control. 

Heidenhain Programming Examples       Heidenhain Programming Examples         Heidenhain Programming Examples        Heidenhain Programming Examples

You can programme circular arc moves in four different ways on this control.

“Why would I want to do that sounds complicated”

Actually it ain’t. The idea is you programme the same as your drawing.

  • The drawing gives me sharp corners. Use this button Heidenhain Programming Examples
  • The drawing gives me the centre of the radius. Use these two button.Heidenhain Programming Examples
  • My line is tangent to the circle. Use this. Heidenhain Programming Examples
  • End point and radius?  This buttons for you .Heidenhain Programming Examples

 

(2) Here is another Heidenhain Programming Examples. This is how to use cutter compensation on both Heidenhain and Fanuc.

Heidenhain Programming ExamplesHeidenhain Programming Examples

Heidenhain Programming ExamplesHeidenhain Programming Examples

 

(3) This example shows how to use sections in Heidenhain Programmes.

Heidenhain Programming Examples

Contact me if you are interested in learning Heidenhain Programming

Don’t forget to watch my Tutorial Videos on YouTube

Heidenhain Training call David 07834 858 407

We offer training on all types of CNC Machines and controls check em out.

Services offered at CNC Training Centre

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Classroom programmer training.

Onsite CNC Machine Training.

CNC Training on all controls and machines.

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Don’t forget we offer training on all types of Mazak Machines and all Fanuc Controls 6m to 31i Oi old to young.


Heidenhain Programming

Heidenhain Programming

Category : Heidenhain

Heidenhain Programming

Click for CNC Training on any Machine

(Read to the end for Heidenhain Programming tips)

The Heidenhain control is very easy to learn because it gives the operator prompts right from the outset. Follow these ten easy Heidenhain Programming steps to create your first working CNC program.

(1) Start your Heidenhain Programming. Heidenhain Programming input a Program Number when asked. On starting a new program you are asked if you want millimetres or inches.

(2) Create some stock for the graphics. You go on to create what is known as a blank form (BLK FORM). This is optional but is the blank shape for the graphics.

The first figure 0.1  is the bottom left hand corner and the second figure 0.2 is the top right. Take your datum figure into account when you dimension the blank.

Heidenhain Programming

This is a blank 110 x 110 x 10 and the datum is in the centre. If your datum was in the bottom left hand corner then it would be like this.

Heidenhain Programming

Hope this does not confuse you but I will be machining a 100mm square so this blank would leave me 5mm all round and you will see it removed when the graphics run..

Now we Need A Tool

(3) Define the tools to use. Heidenhain Programming

Heidenhain Programming

Above is the tools defined in the programme. The length has not been put in yet.

In Heidenhain programming tool offsets can be defined inside the program, which is traditionally how these controls worked. You can have them in an external file the same way as Fanuc and Mazak controls. These offsets are controlled from outside of the program.

In Heidenhain Programming work offsets (datums) again can be embedded in the program or external. If you use the external work offsets then each one has a number that you can call out to use it. It’s a bit like G54 to G59 on a Fanuc Control

It’s All So Easy On This Control.

You can just zero the display to set your datum position if you wish.

There is an advantage to everything being self-contained within a program. It means that when you recall the program everything is set and ready to go. Tools are defined in the program using the TOOL DEF button and you can either define all tools at the beginning or on the fly as you use them.

If your machine has an automatic tool changer the these will usually be in an external table.

You’re doing Well, So Far so Good

(4) Get the tool.  Heidenhain Programming

Heidenhain Programming

Call Tool 1

The tool call button will ask for a tool number and a spindle speed which you input. Once this line is read the tool is active. You may need to add an M6 if you have a tool changer. The M6 will instigate the tool change in this case Tool 1.

 

(5) Make a move to where you want to drill your first hole.  Heidenhain Programming

 

Heidenhain Programming

At the end of this line 5 you will need an M3 to start your spindle. The second line 6 brings your Z axis down to the component (3mm above).

Linear moves are programmed by using the L key which then prompts the operator for and X Y and or Z input. As you enter each figure you are prompted for the next input. It doesn’t take long to get the idea of how this is done.

Later controls have help screens.

After the XYZ input you are prompted to choose for RO RL or RR which is the choice of cutter compensation cancel or compensation to the left or right. You won’t need this because you are only drilling holes. So skip it or use RO.

There is no actual rapid on these controls you just program maximum feed (F9999). On the newer controls there is a FMAX soft key which does this for you.

You can input all the values in a line or press the END key which will complete the line. I recommend you play around with different keys to get the hang of how it all works. You can then just delete the program and have a go at a real one.

Let’s Tell It what We Want To Do

(6) Define your drilling cycle use.  Heidenhain Programming

Drilling is done from the CYCL DEF button. When pressed you pick your cycle from the soft keys. Select the drilling cycle and the control will ask for all the information about a drilled hole.

  • Set up clearance.
  • Depth.
  • Peck.
  • Dwell
  • Feed rate.

Heidenhain Programming

The above cycle has:

  • Q200 clearance value of 3mm
  • Q201 a depth of -20mm (Minus sign is important)
  • Q206 the feed rate is 150mm per minute
  • Q202 a peck of 20mm (same as depth so no peck)
  • Q210 no dwell at the top of the hole
  • Q203 is the surface which in this case is Z zero.
  • Q204 is the clearance
  • Q211 no dwell at the bottom of the hole
  • Q395 set this to 0

Once these are input the cycle is ready to use.

Here We Go Now Let’s Cut Metal.

(7) Drill your hole. Heidenhain Programming

You then press the CYCL CALL button and a hole is drilled. You can then repeat this process. Move to a position and CYCL CALL. The CYCL CALL will always remember the last cycle you defined.

Heidenhain Programming

In the above you have a CYCL CALL for the position that you are already at.

Then three more positions each followed by a CYCL CALL to drill the pre-defined hole in the CYCL DEF.

(8) Move the tool away from the workpiece.

You can use an M25 to do this which will take the tool upwards to the tool change position.

(9) End your program.

(10) Test your program using the graphics test run button. 

Heidenhain Programming

Heidenhain Programming

Heidenhain Programming

Congratulations

And that’s it folks Heidenhain Programming in ten steps you have a working program.

Programming circular moves is just as easy with the CC and C buttons. See explanation.

Classroom Training

Easy what?

I recommend you play around with different keys to get the hang of how it all works. You can then just delete the program and have a go at a real one.

Some Heidenhain Programming Tips

If for example an X figure is highlighted and you press the lower cursor Heidenhain Programming you will jump to the next X figure.

 

Heidenhain Programming

This can be really useful if you wanted for example to edit all the feed rates in a program. Just move your cursor to the first one and each time you press the lower cursor Heidenhain Programmingit will jump to the next one. This can be really confusing if your not expecting it because you can jump miles ahead in your program.

Get uses to this to avoid a shit-storm of confusion.

To escape a line press the end key.end

Heidenhain Programming

 

There is More……

Use the GOTO key to quickly jump to a line number.

Heidenhain Programming

Heidenhain Programming

Oh by the way, if you use GOTO and input O for the search you will go to the head of the programme.

If you have the option put loads of comments in your programme just like this but try not to be rude to your operators like this programmer.

Heidenhain Programming

Here is another cool thing you can do on this control.

Please contact me if you require:

Don’t forget to watch my Videos

Services offered at CNC Training Centre

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Classroom programmer training.

Onsite CNC Machine Training.

CNC Training on all controls and machines.

Mazak Training Fanuc Training

Don’t forget we offer training on all types of Mazak Machines and all Fanuc Controls 6m to 31i Oi old to young.


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