OmniTurn Training Manual

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1 OmniTurn Training Manual Phone (631) Fax (631)

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3 OmniTurn Control Welcome to our world This manual will guide first time users to startup, home, enter, edit, and run programs. First we will discuss the control layout. On the upper lefthand side of the control you will see a large red button called emergency stop. (1). Twist and pull, button should snap out. Next check the other E stop located on the palm box make sure this is also disengaged. (2). Now you are ready to press the yellow control on button. (3). The first screen that comes up will ask you if you want to back up your files on a disc. Press the letter Y for yes or N for no on the keyboard. The next screen will prompt turn servos on. The blue button in figure (4) is the servo on button, press this now. This brings you to the Jog menu screen with a prompt HOME MUST BE ESTABLISHED. See page 5. There are two other buttons on the control a green button (5) which is cycle start and a small red button (6) that is motion stop. Note: The cycle start button on the control is only active on retrofits without the AC spindle drives option. Otherwise the two black palm buttons on the operator station activate cycle start fig (7). The motion stop button is used to stop slide motion while running a program in the automatic mode. Below the emergency stop button is the spindle speed pot. This will adjust the speed of the spindle. Note: This only works with the AC spindle drive option. Under the speed pot is the spindle on / off switch (8). This is used to manually stop the spindle. ( 1 ) ( 2 ) ( 3 ) ( 4 ) ( 5 ) ( 6 ) Jog Menu [Chapter 1, Page in OmniTurn Programming Manual] The jog menu allows the operator to perform several functions. 1.Establishing home. 2. Move slide manually either incrementally or continuously. 3.Set tool offsets The first three choices on the menu are continuous jog moves made in Inches per minute feed rates 1: slow 1 IPM 2: medium 10 IPM 3: 100 IPM. To activate these moves select 1, 2, and 3, on the main keypad. The joystick on the control will move the slides in one of four directions: X +, X- Z+ or Z-. Choose speed number 2:10 IPM. Then point the joystick (9) down in the X+ direction and hold. The slide will move toward you at 10 IPM until you release it. Now push the joystick to the left in the Z- direction. Try the different speeds and get comfortable with this mode. Use caution when jogging in the fast mode, and be careful not to over travel the axis s. Also if there are tools mounted on the slide be aware of their position in relationship to the spindle or work piece. ( 7 ) ( 8 ) ( 9 ) 3

4 4 Picture or graphic of slides at home position

5 Jog Menu Incremental Jog selections [Chapter 1, Page 1.5 in OmniTurn Programming Manual] There are five incremental jog selections numbered four through eight. 4. = = = = = Selecting an increment by pressing the appropriate number on the keypad, and moving the joystick in one of the four directions will move the slide one increment at a time. It does not matter how long you hold it. The slide will move only one increment each time you move the joystick. Note: Selection becomes highlighted on menu screen see Fig Establishing Home [Chapter 1, Pages ] The OmniTurn slides must be homed before a program may be entered. To home the slides you must select a continuous jog speed, usually this is the medium jog speed number 2 on the keypad. After selecting medium jog hold the joystick in the X+ direction until you have traveled at least 2 marks on the X-axis scale. Then jog back between the first mark and zero. Repeat this process for the Z axis traveling in the Z- direction then back between the first mark and zero. Your pointer should look like the pictures to the right for both X & Z-axis s. When your slides are in position press the number 9 key and the cycle start palm buttons. The slides move to the zero mark on the scale. Home has been established. S. Set Zero [Chapter 1] Pressing the S key on the control then pressing the X key and the Z key will zero the position numbers for the slide at whatever position they are at. This is useful if you are cutting a collet or soft chuck jaws. Setting zero does not effect the Home position. H. Go Home [Chapter 1] At any time when you are in the jog menu, and you want to return the slides home you may press the H key. The prompt on the screen will say DEPRESS X TO HOME X AND Z TO HOME Z. Always press Z first to clear the tools away from the spindle then X. T. Set Tool [Chapter 1] Selecting the T key from the menu will allow you to enter tool offsets in the computer for your program. This will be discussed later. EXIT To exit jog menu press the escape key on the upper left hand corner of the Keypad. 5

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7 The Main Menu [Chapter 5 in OmniTurn Programming Manual] The main menu screen will allow you four choices: Jog, Automatic, Single Block, and Manual Data Input. Automatic Mode The automatic mode allows you to run programs. There are ten F function keys in this mode:! F1: Quit Automatic mode return to main menu.! F2. Tool Offset screen. This is where your primary tool offsets are saved and adjusted.! F3. Editor: This function is used for creating and editing programs.! F4. Verification: Allows you to run your program graphically on screen and verify tool path.! F5. New File: Enter or remove a program.! F6. Search: This function allows the operator to run a tool without starting at the beginning of the program.! F7. Programming system.! F8. Disc operations: This mode allows you to erase programs, copy user files back and forth between hard drive and disc. Communicate to another computer via RS232 cable.! F9. Secondary Compensation: Tool nose radius comp and secondary offsets are stored here.! F10. Special Functions: Parts counter, saving and loading offsets, cycle repeat counter, preset feed rates and continuous cycle countdown. Active Keys in the Automatic mode There are many keys that remain active in the Automatic mode. When in this mode you will see on screen the letter C for Continuous operation of a program. To make it active you press C on the keypad, to deactivate it press C again. This is used primarily in bar feed applications. The letter O is an optional stop. To use this feature you must have the M01 code in your program where you want it stop. This also activates and deactivates by pressing O on the keypad. The front slash key / activates and deactivates the block delete function, any line of program that you do not choose to run must start with this /. The S key changes the automatic mode to Single Block allowing each program line to be executed one at a time, every time the cycle start is pressed. Pressing A key returns the program back to automatic. Allowing the program to run from start to finish with one press of the cycle start. 7

8 8 Picture or graphic of T1 at X 0 Z 0

9 The Main Menu [Chapter 5 in OmniTurn Programming Manual] More Hot keys " Feedrate override: While running a program in the Automatic mode. You may slow down the feed rate in ten- percent increments by pressing the F1 through F10. " Located on the right side of the keyboard you will notice several blue keys. These keys activate their printed functions. Fig 1. Pressing the key once turns the function on. Press the key again turns it off. Manual Data Input Mode Pressing the M key while in the Main Menu accesses this mode. You are now able to type in a command, enter it and execute it. Note: The term hit cycle start means press and release the palm buttons on the operator station. Examples:! Type: M03 s1000. Press the return key and hit cycle start palm buttons. The spindle will start clockwise and run 1000 rpms.! Type: M05. Press the return key and hit cycle start palm buttons. The spindle will stop. Example of moves after tool offsets are entered:! Type: T1 Press the return key and hit the cycle start palm buttons! Type: X0. Press the return key and hit the cycle start palm buttons.! Type: Z1. Press the return key and hit cycle start palm buttons. The above to examples are a typical MDI statement. If T1 was a drill it would be located 1 inch from the face of the work piece and on center X0. If using a OmniTool holder such as an 800 bar. Each of the 5/8" dia holes are located on centers. Say you already know the location of your center drill T4 and want to add a drill and a tap. You can go to MDI and type: T4 press enter, then X0 press return hit cycle start and your center drill will move to X0. Then press F1 to go to main menu press J to enter jog menu. Then press 8 key for a 1.00 inch increment move click the joystick in the direction of the next hole on the 800 bar where you want your drill. Then press 7 key for a.100 inch move click the joystick once in the same direction, now you are at the center of the next hole in the toolbar. Enter the X offset for T5 drill, then set Z offset. Repeat process for tap. 9

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11 The Main Menu [Chapter 5, Page 2 of OmniTurn Programming Manual] Single Block The single block mode will allow the operator to execute a single line of program code with each press of the palm buttons. This is very useful for dry running a program and accident prevention You may initiate the single block mode while on the automatic screen by pressing the S key. Note: Make sure all your tool offsets are entered first. After Pressing the S key press the palm buttons. Look at the screen the first line of your program will be displayed after the prompt NEXT: G90G94F300G72. Hit the palm buttons again and G90G94F300G72 jumps up to the COM- MAND line. The NEXT prompt will say T1. Hit the palm buttons again and T1jumps to the COMMAND line and X0 Z0 appears on the NEXT line. - NOTE 1: When you run the program for the first time pay CARE- FUL attention to the NEXT prompt to see were your tools are going. This will help in preventing a smash up. - NOTE 2: Use the training program included in this. Manual to practice setting up and running this procedure. 11

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13 In the following exercise we will type the training program into the computer and enter it.! 1. Start up computer and Home the slides. {See page 3: Number 9. Establish home - see page 5}! 2. Press escape key to main menu.! 3. Press A for Automatic mode.! 4. Type: TRAIN1 press return key.! 5. If this is a new file screen prompts: Train1 not found.! 6. Press the F3 (editor) 2 times.! 7. Press F1 to create. Now the cursor drops down to the screen and you are ready to type in the program. Type program in then proceed to page 19. NOTE: When writing programs the following rules for formatting must apply:! 1.The first G code of any program must be either G90 absolute or G91 incremental.! 2.The Omniturn control when powered up and homed automatically defaults to G73 radius mode.! 3. To program in the diameter mode you must also include G72 on the first line of your progam.! 4. The first line of most programs will be G90G94F300G72! 5. Blank lines are not allowed however spaces are ok.! 6. After a tool call on the very next line you must have a X Z move. Example: T1 X.525 Z1! 7. Number lines are not allowed.! 8. Text may be put in Parentheses (left hand turning tool) Do not use periods or commas or any of these symbols!@#$%^&*?><: {},.! 9. Trailing zeros are not necessary whole numbers are permitted.! 10. Must include G95 before running canned cycles with F value. Example: G95 G75 I.05 U.01 f.005 Entering a Program G95 G83Z-1 K.25 F.003 L 200 R.05 C.03. Train1 G90G94F300G72 T1 (WORKSTOP) X0 Z.02 M00 Z1 M08 M03S2500 T2 (LEFTHAND TURN TOOL) X.525 Z1 Z0 G95F.0035 X-.01 S2800 G00 Z.03 X.525 G95 G75 I.05 U.008 F.005 X0 Z0 X.125 R.0625 Z-.250 X.187C.025 Z-.6R.02 X.227 Z-.75X.312 Z-.875 X.485 C.025 Z-1 X.525 RF G00 X-.01 G95F.002 Z0 X.125 R.0625 Z-.250 X.187 C.025 Z-.6 R.02 X.227 Z-.750X.312 Z-.875 X.485 C.025 Z-1 X.525 G00 Z1 T3 (THREADING TOOL) X-.187Z1 Z-.15 G33 X Z-.55 I.015 K C G00 T0 M30 13

14 Line Program Name Train1 Explanation 1 G90 G94F300 G72 2 T1 (work stop) 3 X0 Z.02 4 M00 G90 absolute mode/rapid 300 ipm/diameter mode Tool call/work stop in text parenthese s Position tool 1 will move to and stop. Note: must have an X & Z move on the same line After a tool call, Motion stop/slides come to a halt/open collet pull stock collet you to stop close Press Cycle Start to continue 5 Z1 6 M08 7 M03 S T2 (left handed turning tool) 9 X.525 Z1 10 Z0 Work stop backs up 1" from work in rapid Starts coolant pump M03 starts spindle clockwise at 2500 rpms Tool call/text in parenthese s Tool moves to x.525 and Z1 in rapid Tool moves to Z0 in rapid to position for face cut 11 G95 F.0035 X-.01 G95 F.0035 ipr feed rate to X S2800 Rpms to 2800 spindle still clockwise 13 G00 Z.050 G00 rapid at 300 ipm to Z X.525 Rapid X to.525/tool 2 will start roughing from X.525 Z G95 16 G75 I.05 U.008 F.005 G95 return to inches per revolution feed rate G75 box rough contour cycle/i.05 increment of cut/u.008 is amount of material left for the finish pass/f.005 inches per revolution feed rate for roughing. This cycle will start from X.525 Z.050. The program from this point on will be written to the exact geometry of this part starting with X0 Z0 and ending in RF. When the cycle initiates it looks to RF and starts roughing back to X0 Z0. This cycle when complete will return to the point of X.525 Z.05. From here we will rapid to X-.01 (line 28) 17 X0 Z0 18 X.125 R Z X.187 C Z-.6 R X Z-.75 X Z

15 Line Program Name Train1 Explanation 25 X.485 C Z X RF 29 G00 X-.01 Rapid move to X.01 from X.525 Z G95F.002 Z0 Finish pass feed rate of.002 to Z0 31 X.125 R.0625 X to.125 with a full radius of Z-.25 Turn to X.187 C Z-.6 R Z-.75 X.312 Turn to X.187 with degree chamfe r Turn to Z-.600 with a.02 inside radius Turn to Z-.75 and X.312 at the same time 36 Z-.875 Turn to Z X.485 C.025 Turn to X.485 with a degree chamfe r 38 Z -1. Turn to Z X.525 Clear tool to X G00 Z1 Rapid 300 inches per minute to Z1 41 T3 (threading tool) Tool call with text in parenthese s 42 X-.187 Z1 Tool moves rapid to X-.187 Z1 43 Z-.15 Tool rapids to Z G33 X-.1517Z-.55 I.015 K C 45 G00X-2 46 Z2 47 M30 G33 Threading cycle X-.1517=minor diameter of thread. Z=depth of thread. I=increment of cut. K=pitch or lead C in feed angle 29degrees. This thread will be cut on the X minus side of the part. Note: To cut on the X plus side of the part, remove minus sign all X moves on lines 41, 43, and 44. This cycle will automatically end at its starting point. The next two lines of this program will clear the tool Rapid back to X-2 inche s Rapid back to Z2 inches from face of finished part M30 cancels Line 1 all active M codes and recycles program to the start. 15

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17 Program Name Train1.025 chamfer by.550 long.020 radius Full Radius In this exercise I would like you to use the following tools and procedure T1: workstop T2: Left hand turning tool T3: Threading X value = Face off G75 roughing cycle Threading: note threading to be don negative side K value =

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19 Saving the program [Chapter 5 in OmniTurn Programming Manual] After the program is typed on the screen. The following steps must be taken to save it to either the hard drive or user disc in drive B. 1. Press F1 for help. 2. Press F3 to save. Now the program has been saved. 3. Press F1 for help. 4. Press F2 to exit. Note: If there are errors in your program they will be posted on screen now. These errors, if any are easily corrected by returning to the editor. To return to the editor the procedure is as follows. 1.Press the escape key to return to the Automatic mode sometimes this key has to be pressed twice. 2. Press the editor key F3. 3. Press the escape key for no back up. Using the arrow keys cursor down to the line to be corrected. Make your corrections then press F1 then F2 to exit. Verify [Chapter 5, Page 11 in OmniTurn Programming Manual] Be sure to verify your program before setting up tools and running. 1. Press the F4 key now. 2. Now you are looking at an estimated cycle time press any key to continue. 3. Select tool for verification you may use the arrow keys up or down to highlight your choice then press enter. 4. Select speed for plotting tools. Use arrow keys up or down to select and press enter. a. Single block will show one move each time a key is pressed. b. Slow motion will plot each tool one at a time. c. Full speed will create an instant graphic. Note: Pressing the Z key will pop up a window on screen. Move window around by pressing arrow keys. Position window over area of part you wish to Zoom in on then press enter. Repeat this process to enlarge further. 19

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21 Entering Tool Offsets [Chapter 3 in OmniTurn Programming Manual] The tools you will need to make the part TRAIN1are as follows. The tool holders you will use will be determined by the center height of your machine either 3/8" or 1/2". 1. One: Omni-300PF tool holder or 800 bar. 2. Work stop: 1/2" diameter piece of stock three inches long, and 5/8" to 1/2" reducing bushing. 3. OmniTurn multibar with VFTR-6M152 left handed front turning insert and a VNVR-6M wide threading insert. See fig 3. 1.Mount tool holder on table and tighten mounting bolts. Insert work stop in first hole and tighten set screws down. Stop should stick out approximately 1.1/4 inches from face of tool holder. 2.Insert multibar in hole three and tighten set screws. Align multibar with face of work stop. Threading insert is mounted upside down in forward position on multibar. Left hand turning tool is mounted in rear position on multibar. 3. Mount 1/2" diameter collet in spindle and adjust to clamp tightly on stock. Insert stock into collet and leave it out about 1.1/4". Press F1 to enter main menu, now press the J key to go to jog screen. Choose continuos jog speed No.3 rapid. Jog work stop over to about 1. away from stock then choose medium jog speed No.2. Now jog up to within 1/8" of stock and choose No. 1.speed slow. Continue up to within.010 to.020 of face of stock. Then open collet pull part out to stop and hold in place while locking collet closer. Now the work stop is in position to enter the offsets for T1. To do this press the T key, this will bring up the prompt on screen OFFSET NUMBER. Press key No. 1 then press enter or return. Now screen prompts press X to enter X offset or Z to enter Z offset. In this case you may press either because the work stop is positioned to set X or Z. Press X now screen prompts what is the TURNED DIAMETER. Press 0 then enter or return key. Entering 0 is the absolute position the work stop comes to and stops. 21

22 Picture of tool about.020 away Picture of tool making contact with stock 22

23 Entering Tool Offsets [Chapter 3 in OmniTurn Programming Manual] Note: The work stop does not have to be centered on the stock to enter the X zero offset. To enter the Z offset for T1 press the Z key. The screen will now prompt What is the current Z location. The current location is.020 then press enter. To SAVE T1 offsets press the escape key. The reason for setting up the Z offset at.020 is this the location that the tool is called to in the program. Example: T1(work stop) X 0 Z.020 M00- motion stop Return to the main menu. 1. Press the M key to go to the Manual Data Input screen. 2. Type M03S Press the return or enter key. 4. Now press the both palm buttons and release. This will start the spindle at 1000rpms. See fig.1 Note: You may turn the spindle off at any time by switching the on / off knob on the control. 5. Press the F1 key now and return to the main menu. 6. Press J to enter Jog menu. Setting T2 left hand turning tool. 1. Select continuos jog speed No. 2 medium or 3 rapid. 2. Jog left hand turning tool over close to part. 3. Slow down jog speed No1. 4. Position tool so tip is inside of the diameter of the work piece and about.020 away from face. See fig Press N increment. 6. Keep bumping jog stick until you make contact with the stock. See fig Press the T key to set tool offset. 8. Press the No.2 key to enter offset for T2. 9. Press the enter or return key. 10. Press the Z key to enter the Z offset. 11. Type.020 then press enter. 12. Press the escape key to save offset. 23

24 Fig. 1 Fig. 2 24

25 Entering Tool Offsets [Chapter 3, Pages 4, 5 and 6 in OmniTurn Programming Manual] To enter the X offset for a turning tool there are several ways to do this. 1. The most precise way to do this is to take a skim cut on the diameter. This is done in jog speed No.1. Then jog the tool straight out from the work in Z without changing the X plane. 2. Another way is to touch the tool to the outside of a known diameter. 3. You may also jog the tool in a.001 increment with the spindle stopped and a piece of paper between the tool and work till you make contact. We will use the first method. 4.Choose the continuos jog speed No Take a skim on the diameter and with out moving the tool away in X choose jog Speed No.2 and back tool away in Z. See fig Press the T key to set tool. 7. Press key 2 to enter offset number Press the enter or return key. 9. Press X key to enter X offset. 10. Measure part. 11. Type diameter of part measured including the decimal point. Then press the enter or return key. 12. Press escape to save T2 X offset. Setting T3 threading tool offsets [Chapter 3, page 11] There are several ways to set up the offsets for a threading tool. 1. Jog the point of the tool over to the stock, and eyeball the point to the face of the part. 2. If you know the width of the threading tool you can touch the face of the part and add half the thickness of the insert to the Z offset. We will use method No Jog the threading tool over to the backside of the work piece and eyeball the point to the face of the work piece. See fig Press T to set tool offset. Then press enter. 3. Press 3 to enter T3 offset number. 4. Press Z to enter T3 Z offset. 5. Type.020 to enter Z offset present position. 6. Press Escape key to enter T3 Z offset. 25

26 Picture of paper between the work & tool Fig. 1 Fig. 2 Fig. 3 26

27 Entering Tool Offsets To enter the X offset for the treading tool T3 there are several ways to do this. A. Jog the threading tool over to the backside of the work piece. Locate the tool close to the part and choose number 5,.001 increment. Take a piece of paper and hold it between the point of the tool and the work. Bump the jog stick in until it makes contact with the part and grabs the paper. At this point press the T key set tool. Enter the diameter of the part where you made contact. See fig.1 [Chapter 3, page 11] Note: When touching a tool off on the negative side of zero you must enter the minus sign before the decimal number. Example: B. The preferred way of setting up the X offset is to start the spindle and take a skim cut on the diameter. Then back the tool out of the way in Z without moving it away in X. See fig Press the T key set tool. 2. Press the 3 key to enter offset number for T3. 3. Press the X key to enter the X offset. 4. Measure the diameter. 5. Enter the diameter as a negative number including the decimal point. 6. Press the enter or return key. 7. Press escape to save the X offset. That completes the tool offset setup for TRAIN1. Return to the jog menu 1. Press the H key to go home. 2. Then press the Z key to clear the tools away from the spindle. 3. Now press the X key and the slides will be at the home position Before we run this part in the automatic mode, we will single block the program to check for errors. 4. Press the escape key to exit the jog menu. 5. Press the A key to enter the automatic mode. If you look art the automatic screen you will see in the lower left hand corner a prompt: Press S For Single Block. Press the S key now. Every time you press the palm buttons together the control will execute one line of program command. See fig 3. 27

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29 Single Block TRAIN1 When single blocking your program, this will give you the opportunity to see each line of code before and after it is initiated. Allowing the operator to stop the program if there is a mistake. 1. We will begin by removing the stock from the collet, and closing the collet 2. Press the F10 key to preset the feed rate over ride. 3. Press the F5 key to set the feed rate at 50%. 4. Press escape to return to the automatic screen. Make sure the single block mode is activated. The SINGLE BLOCK prompt on the main menu title bar must be Highlighted. If it is not press the S key again. See fig Press the palm buttons then look at the screen. In the upper right hand corner there will be a COMMAND line. On this line you should see the command: G90G94F300G72 See fig Below this line you will see the NEXT command line. On this line you will see T1. Note: The text comment will appear in the lower left-hand corner of the screen (WORKSTOP). Note: By holding in one of the palm buttons you can stop the slide. By releasing it the slide will continue to move. 3.Press the palm buttons again, and on the Command line will be T1. The NEXT line will read X0 Z.02. See fig 3. Pressing the palm buttons again will make the slide move to the position of X0 Z.02 at 50% of the rapid feed rate. Note: There are some cycles that cannot be single blocked. 1. Do not single block a tap. 2. G33 threading cycle will run complete from its starting point to its finish point. 3. G 81 and G 83 will also run the complete cycle. Continue to single block the program through to the end. Making sure before you activate the next command that it is correct. Use the Explanation of Train1 program page 7 & 8 to double-check each line command. Note: If at any time you wish to abort from the single block mode press F1 to quit. This will return you to the main menu. 29

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31 Running the Program in Automatic [Chapter 5, Page 1] To run this program in the Automatic Mode press F1 to go to the main menu. Then press the A key. Note: Press the F10 key to preset the feed rate over ride. Choose what percent of the full speed feed rate by selecting F1Being 10% through F9 being 90%of the programmed feed rate. Pressing F5 for 50% is a good choice for a first time set up. 1. Open collet closer and insert 1/2" diameter blank that is about 3"to 4" long. Leave about 1/2" of the material sticking out of the collet. Do not lock the collet closer at this time. 2. Press the palm buttons together and release. 3. Work stop is now in position. 4. Pull work piece out and hold against stop while closing collet. 5. Press palm buttons again and program will run continuously. Adjusting Offsets F2 [Chapter 5, Page 5] When the cycle has been completed if it is necessary to make adjustments to the dimensions of the part press the F2 key. 1. The screen will prompt OFFSET NUMBER, press the number key for tool you would like to adjust. 2. The second prompt will say enter X offset. If you want to adjust the diameter in X type in the correct amount and press enter. Example 1: If the first diameter of.125 measures.1265 then you would enter X Then press the enter key. If you want to adjust the Z dimension, then do not enter a value in X. Press the enter key and the prompt will say enter Z offset. Example 2: If the first diameter of.125 measures.122 then you would enter X.003 then press enter. Note: After you enter the offset you must push the escape key to save them. This will return you to the automatic mode. 31

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34 AUTOMATIC C&R SOLUTION G90G94F300G72 M03S3000 M08 T1 (LEFT HAND TURNING TOOL) X.525Z1. Z0 G95F.003 X-.01 X.25C.015 Z-.2 X.3Z-.275 Z-.375 X.350R.025 Z-.7R.07 X.5 Z-.85 X.525 G00 Z2 M30 34

35 G90G94F300G72 M03S3000 M08 T1 (LEFT HAND TURNING TOOL) X.525Z.1 G95 G75I.05 U.01 F.005 X0 Z0 X.25C.015 Z-.2 X.3Z-.275 Z-.375 X.350R.025 Z-.7R.070 X.5 Z-.85 X.525 RF G00 X-.01 Z.03 G95F.003 Z0 X.25C.015 Z-.2 X.3Z-.275 Z-.375 X.350R.025 Z-.7R.070 X.5 Z-.85 X.525 G00 Z2 M30 G75 SOLUTION 35

36 G33 Threading Solution The following threading program; is designed to be run on the minus side of zero. G90G94F300G72 M03S3000 M08 T1(LEFT HAND TURNIG TOOL) X.525Z.1 G95 G75I.05U.01F.005 XOZO X.250C.045 Z-.250 X.375Z-.3 Z-.750R.04 X.5 Z-.875 X.525 RF G00X-.01 Z.05 G95F.003 Z0 X.250C.045 Z-.250 X.375Z-.3 Z-.750R.04 X.5 Z-.875 X.525 G00 Z2 T2(THREADING TOOL) X-.250 Z.2 G33X-.1887Z-.250I.018 K.050 C G00 Z2 M30 36

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38 Step by Step Procedure For CALCAID 1.To enter thecalcaid-programming mode from the automatic mode press F7. 2.From the Calcaid programming system menu press # 4; File Handling. 3 Type file name, up to eight digits, press enter or return. 4 Press # 6; return to main menu. 5.Press # 1; Define part geometry. From this menu you will have nine numbered choices, and two lettered choices. Select the appropriate one. It is EXTREMLY IMPORTANT to enter the EXACT GEOMETRY of the part to five decimal points. 6.After answering all of the questions, the screen will prompt you to save geometry; press Y or N, now assign the feature a number. GRAPHIC DISPLAY A graphic display of the written geometry is available by pressing the G key on the control. You have to size your screen according to the part size, this may take some playing around with. If the geometry looks correct procede to step #7. 7. Press R two return to main menu. Saving part geometry 8. Press control key #4 for file handling, now press key #1 to save part geometry. 9. Press # 6 for menu. 10. Press #2 to define tools. Enter correct tool number, tip radius, right-handed or left-handed, and starting position for X & Z. 11.Press F10 to return to tool menu. 12. Press # 3 on control to return to main menu. 13. Press # 3 to describe machining operation. 14. Press # 1: to select tool. 15. Screen prompts tool to run, enter tool number. Press enter or return. 16. Press # 7: move to a point. Press #1 move to coordinates. At this time you will want to position your tool in X & Z to where you want to start your contouring Stay away at least.050 thousanths on your Z axis, go to X 0. You may Press F5 for rapid to make this move. 38

39 17. Press # 4 : to contour part geometry. Now enter feature numbers, which you would like to contour. Press enter or return. NOTE: a semicolon must separate each number entered. Example: 1;2;3;4;5 Now it asks stock to leave type 0 press enter or return, enter feedrate.the computer has just written your program. Now your tool is at the end of the cut you have clear it out of the way. 18. Press # 7 : move to point, press #1 coordinates. Type in a coordinate in X that is about.030 to.050 thousanths of an inch larger than your last X move in your program. Press enter or return. Skip Z by pressing enter. Press F5 for rapid. 19. Press # 7 : move to point,press # 1 coordinates. Press enter to skip X. type in a pullout move in Z of 1 to 2 inches positive press enter. 20. Press R : to return to main menu. 21. Press # 4 : file handling. 22. Press # 3 : to SAVE NC FILE. 23. Press # 6 : to return to main menu. 24. Press # 5 : to exit, press Y to exit. 25. Now you should be back at the automatic screen. Press F5 type in program name, press enter. Press F3, then escape to view program. Enter spindle speed, coolant, any other codes of information as nessasary. Press F4 to verify program moves. CAUTION Verification does not pick up wrong feed rates. Be sure to dry run program first by using G10 work shift code or single block. 39

40 40

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