CNC Applications Engineer

Category : Useful Stuff

CNC Applications Engineer

When I was younger the job I really aspired to  was a CNC Applications Engineer.

Actually it’s not really true because being a part time rock singer I obviously wanted success from that but let me describe that as more of a dream. Oh and I don’t think you can describe being permanently pissed, incredibly wealthy and shagging all day as a job.

Anyway I will not digress.

I didn’t actually have a CNC application engineer job description but whenever I got to work with these guys I was in awe of them.

(I just realised I didn’t know the difference between ore and awe)

I remember being trained by a guy from Hitachi Seiki

They were a top class company with some amazing machines that are still around today.

They were taken over  by Mori Seiki in 2002 after going into bankruptcy.

Company Car Wow

The guy training me was Clive and he was and still is a very talented engineer. We got on great and I still talk to him sometimes to this day.

I thought how great it must be to travel all over the country staying in nice hotels. Oh and he had a company car.

Ford Sierra Estate car from the 1980's
Thanks to Simon Classic Car Auctions

 

I could have sworn Clive had a Sierra but in fact I just messaged him and he said it was a red Ford Escort. Just like this, I don’t know if he had his name across the top of the windscreen.

Red Ford Escort
Red Ford Escort

Now you might be thinking that I must have been easily impressed but these cars really were the dog’s bollocks in those days.

Dog’s bollocks what does he mean?

The job we were doing was a turned part for a fork lift truck and we had one of the very early robot loading arms.

This was around 1985 so they’ve been around longer than you think.

CNC application engineer job description

 

I remember he had a really methodical and systematic way of doing things and the final part was perfect.

By the way if you ever work with robots you need to be really precise in the way you do things.

His approach has stuck with me to this day and I still try to work that way. I mean it’s easier when you are old like me to not rush. But this is not bullshit because I can’t sprint round the block like I used to.

It’s a bit like driving fast I drive slow because, although it took several years to realise this, no one tends to die.

It’s not because I can’t drive fast.

I mean if I had one of these I might be tempted

CNC Applications Engineer

What do they actually do?

Here is a kind of CNC application engineer job description

Shit loads

So it’s any or all of what is listed below.

  • Commission Machine.
  • Write CNC code long hand.
  • Design and manufacture fixtures and tooling.
  • Setup machine.
  • Prove-out programs.
  • Check the parts and get final approval from quality department.
  • Train the operators.
  • Train programmers.
  • Make tea.
  • Program using a CAD/CAM system.

Interested?

A lot of what a CNC applications engineer does could be described as Production Engineering.

I did have to google Production Engineering to see if I had it right. It seems I might not have but to be honest who gives a flying fuck.

Production Engineering to me is controlling or doing the whole process of getting a new part produced. From design of work holding right through to final inspection.

That’s why being a CNC Applications Engineer was always so appealing to me because it’s never boring.

So How do You Get There?

Well the answer is it takes time, years in fact.

Oh and did I mention you have to be good.

Now this article is not meant to be a plug, but we do offer courses to help you keep moving up to the next level in your engineering career.

“Come on Dave you lying bastard what are all these links to courses for if you’re not plugging?” you may say.

I’m not answering that because I keep telling you not to call me Dave, it’s David.

CNC Operator (Step 1)

(One up from making the tea)

  • Pressing the button.

Production Engineering

  • Cleaning the parts.
  • Removing sharpe edges from the parts.
  • Checking the parts.

You could end up doing a lot more than just pushing buttons. Rather depends on the company you work for and your attitude.

Show your interest and gently push to do and learn more.

CNC Machine Setter Operator (Step 2)

  • Setting tools.
  • Setting datums.
  • Prove out programs.
  • Altering wear offsets.
  • Changing worn or broken tools.
  • Maybe minor program alterations.

Try to learn as much programming as you can in this role. Watch the machine and the program and try and link the two together.

Programmer Setter Operator (Step 3)

Write your own program on the machine as well as all of the above.

Don’t forget the real engineering is knowing how the tools perform and really understanding the work holding.

Programmer (Step 4)

Programming on or off the machine progressing to learning a CAD/CAM system like Edgecam

This is where you get to create potential havoc and break loads of tools.

CNC application engineer job description

Production Engineering (Step 5)

  • All of the above
  • Finding suitable tools and buying where necessary
  • Designing and managing work holding

In this role it’s difficult to know exactly what your company will ask of you. It varies massively from one company to another.

CNC Applications Engineer (Step 6)

Come on concentrate I already told you this earlier in the article. Go and watch some fast cars on YouTube you obviously are not concentrating.

Normally as a CNC applications Engineer you would d be working for one of the big machine tool companies or one of their dealers.

I think if I had my time again I would have tried to work for them all. I have worked independently now for much longer than I would care to mention.

OK I’ll care to mention, nearly 30 years.

You Might Not Settle

Even if it’s not the job that you think you’d like to stay in forever it would be a massive stepping stone for other things.

Every step of the way:

  • Be confident.
  • Tell the truth about your achievements.
  • Learn as much as you can.
  • Ask loads of questions.
  • Treat everyone with loads of respect even when they don’t deserve it.
  • Never ever bullshit your way into a job, it usually ends in tears (probably yours)
Never bullshit your way into a job.

Why on Earth would you want to Become a CNC Machinist??

Category : Beginners New Stuff

If someone asked me why I wanted to be an engineer I’d have to be honest and say I don’t know why?

In actual fact it was because I knew I didn’t want to stay at school. They were still a little cross about me putting bromide in the flapjacks and shitting in the glove compartment of the headmasters Reliant Robin.

Anyway my dad was an engineer (Capstan Setter Operator)

Oh and I’d done metalwork at school. So I thought “fuck it” let’s have a go.

I applied for a few jobs in Coventry which was the manufacturing capital of the universe in those days.

I ended up at Rolls Royce. Anyway I’ll cut this short because I hated it with a screaming passion.

Bearing in mind this was in the days when kids obeyed their parents, so I could not leave before I completed my apprenticeship.

A little footnote here, my parents were real nice people but as was the practice in those days, they tended to beat the livin’ shit out of their offspring for the tiniest of misdemeanours.

What I mean is I’m sure that had a bearing on things.

Anyway I’d discovered rock music and I wanted to be a Rock star. What attracted me to this was the fact that they seemed to be shagging all the time and spending loads of cash.

I hadn’t done much of either of these things yet but relished the idea of trying.

My mate happened to mention that I was a good singer cos he heard me singing along to the radio so he gave me a job in his band as lead singer and front-man.

From this point onwards I was hooked. My first band was called RIP and we were shit.

We didn’t know we were crap so we forced our music onto our poor innocent unsuspecting audience’s night after night.

 

 

At one such gig I was spotted by a professional band who offered me a full time singing job for more money than I could spend.

It transpired that it was my band that were shit and that I was a half decent singer.

The old man went fuckin’ bonkers and said I couldn’t leave Rolls Royce.

As I was very close to the end of my apprenticeship and after many arguments he let me leave once my apprenticeship was over.

I managed to stay professional as a singer working in nightclubs all over England for the next five years.

I loved it and made good money but couldn’t help thinking their was more.

Soon, there was more, I got offered a job as a backing singer for a 70’s pop star.

This job turned out to have it’s perks but I soon found myself constantly on tour without a pot to piss in.

I left and went back to the nightclub scene.

Soon potential bullshit fame came knocking again when I was offered a job in an established rock-band. They had already had a few mildly successful records under their belt.

They had toured the world supporting the likes of AC/DC and Black Sabbath to name a few.

Completely sucked in by all this I joined, convinced I’d be living the rock n roll life style as soon as the next album was released.

It’s a long story but I ended up skint and never finished the record.

Fanuc Yellow Manuals Saved My Life

I knew I had to work because by now I had a wife and a son who needed a place to live and food.

My only option was to go back to Engineering. I think at the time I would rather perform my own appendectomy than return to that environment.

I removed my appendix and once I recovered started applying for jobs. Surprise Surprise I got them all.

This was because I had done my apprenticeship at Rolls Royce. I always went on to explain to my future employers that I was basically a fuckin idiot but they were so impressed by the Rolls Royce pedigree they still wanted me.

Two Hundred Quid a Week

They stuck me on a Horizontal milling machine and although I say it myself I was good. Soon I got on Bridgeport BRJ’s and stuff and I was doing well. I was working probably 70 plus hours a week and couldn’t believe how much cash I was making sometimes as much as £200.

Soon I started working as a singer in my spare time but it didn’t help being torn between two cultures.

It resulted in my often not turning up for work after a late night with my band.

Happy Birthday

I was my birthday just after Christmas.

I’m not telling you the date because I will probably be inundated with birthday cards and someone will steel my identity only to find they are worse off than if they had kept their own.

The boss called me into his office “David” he said “the other two directors have advised me so sack you”.

It was like the good news bad news thing.

“Anyway I have decided not to”.

(Sorry I cant keep doing the speech marks thing so I’m going to tell you what he said.)

What he told me was that he wanted to try me on the CNC Machines because he thought I’d be good at it. He did add that it was definitely my last chance. That’s where it all began.

Fanuc Yellow Manuals Saved My Life

I know I’ve used that title twice (I’ll have the S.E.O. police on my back), that’s an in joke if you know about search engine optimisation.

Anyway these manuals really did save me.

The machine they started me on was a Matsuura 710 with a Fanuc Control.

I was hooked. I just loved it so I took the big thick yellow manuals home and studied them.

While I was at work I constantly watched what the machine was doing and compared it to the program. I then checked it all out in the Pidgin English manual and made sense of it.

Picture of a Pidgin

The manuals were really shit in those days. They were really badly written and some times just wrong.

So while the other operators were reading the Daily Mail, scratching their arses and developing right wing, racist views. I was rapidly learning how to set operate and program CNC machines.

Every time my boss got a new machine guess who got to go on it?

Two years on I was running the whole CNC department. I had my own great big yellow Fanuc computer to program on.

I have continued to be fascinated by CNC machines to this day, that’s about forty years.

For the last twenty five years I have had my own business training people on CNC Machines.

I have had the pleasure of being involved in loads of exciting projects from making moulds for Viagra Pills to cutting Weetabix to writing macros to make wedding rings.

I still do loads of music and recording and all sorts of stuff but the mic I prefer to be holding is this one

 

 


CNC Turning Using T00 to Cancel Offset

CNC Turning Using T0000 to Cancel Offset

This article is about CNC turning programs and the use of T00 or T0000 to cancel the tool offset.

My daughter is autistic, and one of the things that she has taken great delight in doing during the Covid lock down, was picking up on the stupid nonsensical phrases and expressions that neurotypicals have created in their non-binary brains.

In case you don’t already know neurotypical is an expression used by autistic people to describe non-autistic people. I still haven’t worked out if it is a term of endearment or mildly offensive but I don’t really care anyway.

Anyway, whilst I was writing an article about using multiple offsets, yet to be completed, I suddenly realised why it is a good idea to cancel the tool offset on a CNC Lathe (more about that later).

We were sat drinking tea in our summer house, me my wife and my daughter.

I know it sounds grand but really, it’s not exactly a summer-house it’s more of an old shed. It’s one I converted to compete with my neighbours when they had a fancy new summer house built.

Just a few finishing touches needed

I was talking about this article in rather abstract terms as my wife and daughter are none engineers but always pretend to be interested in my rantings.

Anyway, with reference to tool offset cancellation I said “you learn something new every day”.
My daughter immediately retorted “oh so what did you learn yesterday?”. Fortunately, I could think of something I remembered learning that there are 206 bones in the human body, so I used it.

 

I need to add a this point that my daughter is not an autistic savant and we still need google and takeaway menus. She’s not like that bloke in “Rain Man” who can remember every number in a fuckin’ phonebook.

The expression is “if you know one autistic person, you know one autistic person”

Anyway with her autistic brain I should have known this wouldn’t suffice. “The world tilts at 23.5 degrees on its axis” I quickly added.

“You already knew that” she said.

(Please ignore this if you think the world is flat as I know a lot of my readers do)

She insisted that I should go back at least three weeks in order to prove the validity of the statement.
I decided to give in and the conversation ended by me admitting that all neurotypical people are stupid.

In our household that’s a result and a common strategy we use to resolve this kind of conflict.
Such idioms as “washing your dirty laundry in public” are just banned unless you think you have a simple way of explaining it.

A friend once exclaimed that “there is more than one way to skin a cat!” and as a result required a police escort to get home (joke).

My daughter has a cat and her whole existence revolves around it. I’ll let you imagine her reaction.

Using T00 to Cancel tool Offsets

Anyway, this was going to be an article about using multiple offsets in a CNC Turning program.

They are a bit like multiple orgasms but not nearly as much fun. Anyway I had this eureka moment with regards to T00 and ditched the whole thing.

On a CNC Lathe we use a four-digit number when we do a tool change.

T0101 for example.

The first two digits make the turret index T0101 (index to tool 1)

The second two T0101 will call an offset. You will note I said an offset because it can be any.

By the way some controls like Haas omit the first zero on a tool change.

CNC Turning
Geometry offset page on a Fanuc CNC Lathe

In the above case it’s offset 1 but it could be T0112 this would index to tool 1 and use offset 12.

CNC Turning
Geometry offset page on a Fanuc CNC Lathe

Anyway thinking about these four digit numbers made me think about when you use zeros.

On older machines you used to have to cancel the offset by stating T0100 or much safer T0000. Otherwise the machine would add the new offset to the old one and a shitstorm would ensue.

I had consigned, this now inert procedure, to the CNC Turning equivalent of room 101 or at least the annals of CNC History. Anyhow, it seems there is life in the old T000 dog yet.

I love this puppy I’m going to use it in every post from now on

Now this is where that eureka moment happened in my summer house / luxury shed and I wrongly claimed to learn something new every day.

The Theory

When you write a CNC Turning program you can either return the tool back to the machine reference or return it to a tool change position.

Now the first option (reference) is OK if it is a small a machine. In other words it’s not gonna take it a week to get there.

On a big machine you would have to navigate around all sorts of shit like the tailstock or a steady or the boss’s Bentley. And it would almost definitely be a waste of time.

Soooo normally we would use a tool change position. This would be making use of G53

CNC Turning

Using G53 for tool change position

CNC Turning G53

Because the G53 uses the machine coordinate system it will be the same place for each tool.

CNC Turning

You could then put this position in a sub program. That way it would be the same for every tool. If you needed to change the position you would only need to change it once in the sub-program.

I will forgive beginners for thinking you could just rapid each tool to the same position away from the work piece.

For example G0 X100. Z100. for every tool.

CNC Turning
Sending a drill to a position
CNC Turning
Sending a turning tool to a position

Just look at the turret position in the pictures above. Although the X Z position of both tools is the same there is a huge difference in the turret position.

This could work but when you pick the program up again maybe months later. The tools could be different lengths the tool-change position would have to be altered.

Your drills may not be the same length and the machine may even over-travel when you try to move it to your old tool change position..

Using a G53 you can always allow for the longest tool and know your index position is safe.

Remember G53 does not consider the tool offset or the work offset. To be honest G53 is the selfish bastard of the G codes it just does not give a flying shit what offset is active.

Eureka

Anyway, thinking about cancelling tool offsets it gave me an idea.

If at the end of each CNC Turning tool you cancel its offset. you could send it to a known position.

Because no tool offset is active this would always be the same place.

Some of you probably already do this but honestly, I never thought of it.

I intend to program this way from now on.

CNC Turning
Using T00 for your tool change position

You should be able to use T00 or T000 to cancel your tool offset.

Don’t Do This (I really shouldn’t be telling you)

You can use the tool number plus the zeros so to cancel T0101 you could put T0100. I strongly recommend that you do not do this because it introduces an index move and therefore another potential collision.

You would need to remember to change this on all tools if for some reason you moved the tools around in the turret.

Oh yea about the multiple offsets. I will be writing and article on it when I can be arsed but in the meantime here is a video.

Thanks for reading my articles (no flies were killed in the writing of this article) except for the little bastard that’s flying around my office.

I will ask it politely to leave or else.

 


CNC Turning G Code List For Beginners

Download and print this nice large print CNC Turning G Code List

Download CNC turning G Code List PDF

I always begin my training sessions by telling my students not to remember anything I say.

This sounds completely stupid and my excuse is it wasn’t my idea to say it.

About ten years ago I worked in France. After about a year it seemed obvious that I would need to speak to people to order “Fish n Chips” and stuff like that.

Anyway I got these CD’s to teach me French and the bloke (can’t remember his name) started off by telling you not to remember anything he told you.

Reverse Psychology

I think there is a bit of reverse psychology going on but the main idea is that you understand not remember. It didn’t work for me because I still managed to completely fuck up the language.

Not realising French Canadians speak differently to native Frenchmen (I was working for Bombardier) . Anyway I asked this bloke, in French, to “will you come with me”. I can’t remember what it is in French and after all the bloke on the CD had specifically told me not to remember.

Anyway turns out this had a sexual connotation and made me the complete laughing stock everywhere I went from then on. (I’ll let you do the maths on that one.)

“OK which one of you bastards bought all the fuckin toilet paper in lock-down?”

Now I know what you are thinking, “that is the gnats cock of CNC Turning G Code Lists”. Honestly size isn’t everything.

Learn these first and just by seeing them every day they will just sink into your brain.

When it comes to CNC Programming it is important to enjoy your self and not get bogged down trying to remember loads of G Codes.

The truth is you only need to remember a few and it’s all about understanding what they do.

For Example This is in your Programme.

You watch in amazement as it cuts your part.

So you look up what G71 means on your list of G Codes printed in large letters on the side of your machine.

Download CNC turning G Code List PDF

“Oh yea it’s that’s roughing shit” you say.

As You Watch it Run It All Makes Sense

From your Classroom Training you know that there is a multi repetitive cycle that can rough out a part.

You understand how the cycle works already.

CNC Turning G Code List
G71 Rough Turning Cycle

So as it runs, it all makes sense.

 

CNC Turning G Code List
Keep it Simple

Type up or print this list in nice big letters and stick it to the side of your machine

Download CNC turning G Code List PDF

CNC Turning G Code List

G00                 Move at Rapid speed
G01                 Feed in a Straight Line
G02                 Clockwise Arc
G03                 Counter Clockwise Arc

G04                 Time Dwell

G28                 Return Axis to Home

G41                 Cutter Compensation Left
G42                 Cutter Compensation Right
G40                 Cancel Cutter Compensation

G50                 Maximum Spindle Speed
G54                Work Offsets

G71                 Stock Removal Cycle
G70                 Finishing Cycle for Above
G76                 Threading Cycle

G83                 Peck Drilling Cycle

G96                 Constant Surface Speed
G97                 Speed in RPM

 



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