CNC Lathe Beginning, Advanced, Comprehensive Levels Module Guide

Transcription

1 Tech-Design CNC Lathe Beginning, Advanced, Comprehensive Levels Module Guide Edition E0

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3 SECOND EDITION Second Printing, May 2010 Copyright 2005, 2006, 2007, 2008, 2009 Lab-Volt Systems, Inc. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form by any means, electronic, mechanical, photocopied, recorded, or otherwise, without prior written permission from Lab-Volt Systems, Inc. Information in this document is subject to change without notice and does not represent a commitment on the part of Lab-Volt Systems, Inc. The multimedia Tech-Design software and other materials described in this document are furnished under a license agreement or a nondisclosure agreement. The software may be used or copied only in accordance with the terms of the agreement. ISBN Lab-Volt and Tech-Design are registered trademarks of Lab-Volt Systems, Inc. Windows TM is a trademark of Microsoft Corp. All other trademarks belong to their respective owners.

4 Lab-Volt License Agreement By using the software in this package, you are agreeing to become bound by the terms of this License Agreement, Limited Warranty, and Disclaimer. This License Agreement constitutes the complete agreement between you and Lab-Volt. If you do not agree to the terms of this agreement, do not use the software. Promptly return the software and all other materials that are part of Lab-Volt's multimedia Tech-Design product within ten days to Lab-Volt for a full refund or credit. 1. License Grant. In consideration of payment of the license fee, which is part of the price you paid for this Lab-Volt product, Lab-Volt, as Licensor, grants to you, the Licensee, a nonexclusive, nontransferable license to use this copy of the software with the corresponding curriculum resources. Lab- Volt reserves all rights not expressly granted to the Licensee. 2. Ownership. As the Licensee, you own the physical media on which the software is originally or subsequently recorded or fixed, but Lab-Volt retains title to and ownership of the software programs recorded on the original compact disc and any subsequent copies of the software, regardless of the form or media in or on which the original and other copies may exist. This license is not a sale of the original software program of Lab-Volt's software or any portion or copy of it. 3. Copy Restrictions. The software and the accompanying materials are copyrighted and contain proprietary information and trade secrets of Lab-Volt. Unauthorized copying of the software even if modified, merged, or included with other software or with written materials is expressly forbidden. You may be held legally responsible for any infringement of Lab- Volt's intellectual property rights that is caused or encouraged by your failure to abide by the terms of this agreement. 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As a highly advanced software product, it is quite complex; thus, it is possible that if it is used in hardware configurations with characteristics other than those specified in Tech-Lab Multimedia Installation & User s Guide or in environments with non-specified, unusual, or extensive other software products, problems may be encountered by a user. In such cases, Lab-Volt will make reasonable efforts to assist the user to properly operate the software but without guaranteeing its proper performance in any hardware or software environment other than as described in the Tech-Lab Multimedia Installation & User s Guide. This software is warranted to conform to the descriptions of its functions and performance as outlined in the courseware documentation. 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LICENSOR DISCLAIMS ALL OBLIGATIONS AND LIABILITIES ON THE PART OF LICENSOR FOR DAMAGES, INCLUDING BUT NOT LIMITED TO SPECIAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF OR IN CONNECTION WITH THE USE OF THE SOFTWARE PRODUCT LICENSED UNDER THIS AGREEMENT. Questions concerning this agreement and warranty and all requests for product repairs should be directed to Lab-Volt field representative in your area. LAB-VOLT SYSTEMS, INC. P.O. Box 686 Farmingdale, NJ Attention: Program Development Phone: (732) or (800) LAB-VOLT Fax: (732) Technical Support: (800) Technical Support techsupport@labvolt.com

5 Table of Contents Introduction Beginning Level... 3 Lesson 4, Lab-Volt CNC Lathe software Instructions... 3 Lesson 4, Procedure Lesson 5, Procedure Lesson 6, Procedure Lesson 7, Procedure Advanced Level Lesson 2, Program Familiarization Lesson 3, Procedure Lesson 4, Procedure Lesson 5, Procedure Lesson 6, Procedure Lesson 7, Procedure Comprehensive Level Lesson 4, Lab-Volt CNC Lathe software Instructions Lesson 5, Procedure Lesson 6, Procedure Lesson 7, Procedure Lesson 8, Procedure Lesson 9, Procedure Independent Study Projects Project Project Project Module Guide i

6 Table of Contents ii Module Guide

7 Introduction INTRODUCTION This Module Guide contains the directions that you will use when you are completing lesson activities. The multimedia curriculum will direct you to this guide and a specific activity. The directions are titled and are organized by Lesson. The table of contents will guide you to the appropriate page. Module Guide 1

8 Introduction 2 Module Guide

9 DIRECTIONS BEGINNING LEVEL Lesson 4, Lab-Volt CNC Lathe software Instructions To open and close a part program file: Lab-Volt CNC Lathe Main Screen From the File pull-down menu, select Open. The Open window appears with a Data folder directory containing a list of folders with lathe model numbers. Select the 5300 folder to view a list of lathe files stored in the *.l5 directory. Open Window Module Guide 3

10 Click Cancel to close the Open window. Before you select a file, review another way to access the Open window. On the Main Menu toolbar of the Lab-Volt CNC Lathe main screen, click the Open button. The Open window appears again with the same listing of folders with lathe model numbers. NOTE: The Main Menu toolbar buttons on the Lab-Volt CNC Lathe screen perform the same operations as their menu equivalents. In the Open window, select the 5300 folder to view a list of lathe files stored in the *.l5 directory. Click on demo1.l5. The demo1.l5 file name becomes highlighted. Click on Open. (Another way to open the demo1.l5 Part Program Editor window is to double-click on demo1.l5 in the Open window.) The demo1 Part Program Editor window appears. Demo1 Part Program Editor Window with ISO Codes The Part Program Editor window contains a list of the steps, or lines, that make up the part program. This program was written using ISO (Industrial Standard Operation) machine codes, also called G- and M-codes. For example, G91 indicates incremental mode and M97 calls a subroutine. 4 Module Guide

11 The Part Program Editor in the Lab-Volt CNC Lathe allows you to toggle between the G- and M-codes and their equivalent Conversational Codes. Conversational Codes: From the Edit pull-down menu, select Conversational. The program listing in the Part Program Editor window changes to the Conversational Codes as shown in the following figure. demo1 Part Program Editor Window With Conversational Codes Click on any line of code. A vertical flashing cursor appears in the program. Press the F2 key in the top row of the keyboard. The program listing changes back to ISO Codes. Leave it in this mode. NOTE: You can easily switch between ISO Codes and Conversational Codes by either choosing Conversational from the Edit menu or by pressing F2 on your keyboard. Module Guide 5

12 To compile a part program: From the Lathe pull-down menu, select Emulate. The Compiling window appears. Compiling Window The Compiling window shows several fields: the Status (Compile Status) field, the Line Number (Current Line Number) field, and the Error (Error Messages) field. Compiling a program tests the program for errors and verifies it for emulation and downloading to the lathe. All part programs must be compiled with no errors before they can be emulated or downloaded. There should be no errors in the demo1.l5 file. Click Cancel in the Compiling window to close it. On the toolbar, click the Emulate Part Program button. The Compiling window appears again. Click Cancel to close it. To open the Compiling window, you can choose the Emulate Part Program button or access it from the Main Menu by selecting Lathe and then Emulate. To emulate a part program: Once a part program has been successfully compiled, it can be emulated. When you emulate a program, the computer performs a graphic simulation of the open part program. All part programs must be emulated from several views before actual production. This ensures that machining will occur without errors or tool crashes. Simulation of the cutting of the part before production saves costly damage to the lathe and wasted stock due to errors. 6 Module Guide

13 Click the Emulate Part Program button on the toolbar. The Compiling window appears. Click OK, and the Lathe 3D Emulator window appears. You can also open the Lathe 3D Emulator window by selecting Emulate from the Lathe pull-down menu and then clicking OK in the Compiling window that appears. When the 3D Emulator window appears, the stock is shown in the full view. The full-view simulation shows the full cross-section of your design on the stock. Running the full-view simulation before machining allows you to be sure that the part will fit on the stock without extending beyond any of the edges. To ensure that the cutting tool will not be damaged during the cutting of the part, perform a full-view simulation for every part to be cut on the CNC lathe. To see a full-view simulation, click on the green Start Simulation button under Control section on the Lathe 3D Emulator window. Module Guide 7

14 The following full-view graphic of the design simulation appears. In this view, the PRZ (Programmable Reference Zero) is on the centerline, where the X and Z coordinates intersect. Notice on your monitor that some of the lines indicating the tool path are red and others are yellow. The red lines represent movement of the cutting tool out of the stock at the rapid rate, and the yellow lines represent the movement of the cutting tool inside the stock at the feed rate. To reset the simulation: Click the Reset Simulation button in the Control section. This clears the simulation screen and prepares for a new simulation. The following five view buttons are available under View on the Lathe 3D Emulator window. Mouse Zoom button Mouse Light Control button Mouse Pan button Reset 3D View button Mouse Rotate button 8 Module Guide

15 The directions that follow show you how to use each view function. Mouse Zoom Click on the Mouse Zoom button. Click, hold, and drag the mouse on the Lathe 3D Emulator grid to zoom in or out on the stock piece. Mouse Pan Click on the Mouse Pan button. Click, hold, and drag the mouse on the Lathe 3D Emulator grid to move the stock piece left, right, up or down. Mouse Rotate Click on the Mouse Rotate button. Click, hold, and drag the mouse on the Lathe 3D Emulator grid to rotate the stock piece degrees in any direction. Mouse Light Control Click on the Mouse Light Control button. Click, hold, and drag the mouse on the stock piece to increase or decrease the highlights surrounding the stock. Reset 3D View Click on the Reset 3D View button to return the stock piece to its original size and gird location. Module Guide 9

16 Lesson 4, Procedure From the File menu, select Open and then select the 5300 folder. On the Open screen, select demo1.l5 (a preexisting part program file) by doubleclicking on it. The G- and M-codes for the demo1 part program appear in the Part Program Editor window. Using a micrometer or dial caliper, measure the diameter of your piece of stock. It should measure 0.75 (1.91cm) in diameter with a length of 2.5 inches (6.35). From the File menu, select Info. The Program Information window appears. Program Information Window Make sure that the X value in the Stock Size section is 0.75 and that the Z- value is Although the stock is 2.5 inches (6.35cm) long, the actual workable portion of the stock is 1.5 inches (3.81cm). This is explained in more detail in the next section, SETTING THE PRZ. Make sure that Inch is selected under Units (defaulted for this program file). Make sure that Absolute is selected under Coordinates (defaulted for this program file). Make sure that Plastic Delrin is selected under Material Type. If you are using wax, select Wax. Either way, this will have no effect on how the program will be executed. When you are done, click OK. 10 Module Guide

17 Now you will verify that the part program is correct and view an emulation (visual simulation) of the program. From the Lathe pull-down menu, select Emulate. The Compiling window appears and should indicate that there are no errors detected. Click on OK. The Lathe 3D Emulator appears. Click on the green Start Simulation button under the Control section to begin the simulation. Try viewing the simulation in other views by clicking on the different buttons in the View section. When you are done, close the 3D Emulator window by clicking on the x in the upper right-hand corner. Leave the demo1 part program open. You are now ready to set up the lathe and download the demo1 part program. Follow the steps in the next section, SETTING THE PRZ (program reference zero). From the Options pull-down menu, select Lathe Tool Table. The Program Options window appears, displaying the Tool Table tab. Program Options Window Whenever a part program is written, you must always choose the proper tool for the part to be machined. Module Guide 11

18 The programs you will be creating will require tool number 1. This is described as a right-55 degree cutter. This tool comes pre-installed on the Lab-Volt CNC Lathe because it is the most commonly used. Scroll through the different tools by clicking on the up and down arrows to the right of the Tool Number field. A graphic representation of each tool is shown. Remember to re-select tool number 1 when you are done. Before downloading a part program, it is good practice to check this window to be sure the correct tool is selected. When you are done, click Save. Setting the PRZ Setting the PRZ designates a reference point identified as (0,0). This is important because the lathe's operation relies on the PRZ as a point of reference from which all other coordinates are measured. WARNING: Always wear eye protection! Place the stock in the chuck, a three-pronged device that centers the stock and holds it in place. Be sure the stock is as far in as possible. Now, using the tension bars, clamp the chuck closed on the stock by turning the right disk clockwise and the left disk counterclockwise. Remove the tension bars before operating the lathe. If the power light on the front panel of the lathe is not on, turn on the lathe by pressing the switch located on the left side panel of the lathe. It will take a minute or so for the lathe to initialize and the Main Menu to appear. Close the cover. 12 Module Guide

19 You need to use the control panel keypad on the front panel of the lathe to move the cutter to the end of the stock. Select Manual from the lathe control panel Main Menu. If the cursor is not next to Manual, use the X keys to move the cursor to it. Press ENTER to select Manual. Using the +Z and Z keys, position the left edge of the cutting tool along the right outside edge of the stock. Use the +X and X keys to position the tool on the very edge of the stock. Press the SPINDLE SPEED key to access the Spindle Speed menu. Press the +Z key to turn the spindle on. The exact speed is not important. Press ENTER to return to the Manual menu. Use the X key to move the tool up just enough to remove a thin thread from the edge. Press SPINDLE SPEED, then ZERO to stop the spindle. Press ENTER to return to the Manual menu. Set the X offset value by pressing ZERO, +X and enter the diameter of the stock by pressing the appropriate number keys, in this case.75, then ENTER. Although it is the diameter that is entered, the radius (which is the distance needed) is displayed in the Manual menu. Module Guide 13

20 The Z offset is the distance from the outer edge of the stock (current position of the tool) to a point on the stock just in front of the chuck. It is equal to the length of the stock indicated in the Program Setup screen for the part to be turned (the Z component of the stock size). Set the Z offset by pressing ZERO, +Z and press 0 then ENTER. The PRZ is now set. Return to the Main Menu by pressing ESC. Go to the next section, SAFETY NOTES. Safety Notes Use caution at all times. Lifting the cover or pressing the EMERGENCY STOP button while the lathe is running will shut off power to the lathe and cause complete program loss. Always wear eye protection. Before operating the lathe, be sure to remove any loose objects from inside the lathe cabinet. Complete the next section, DOWNLOADING YOUR PART PROGRAM. Downloading Your Part Program You should have your program loaded, the workpiece loaded, and the PRZ set. You are now ready to download your part program. On the lathe control panel, use the +X key to move the cursor next to Remote Serial and press Enter. The lathe s display now reads: Ready to Download <Esc> Abort From the Lathe pull-down menu on your computer desktop, select Download Program via Serial port. The Serial Download screen appears. The Remote Machine field tells you that you are downloading to a lathe. 14 Module Guide

21 The Status field tells you that you are ready to download and the Last Error field tells you that there are no errors. If an error occurs, this field displays the error message code for the problem. If this happens, ask your instructor for help. Click the Download button. Look at the display on the lathe s control panel and you will see Downloading and a rotating cursor indicating that your part program is being downloaded to the lathe. When the Download Complete screen is displayed on the lathe control panel, your part program has been downloaded. Click OK to close the Download Program via Serial Port window. Close the demo1 Part Program Editor window. Go to the next section, EXECUTING YOUR PART PROGRAM. Executing Your Part Program You are now ready to execute your part program. Remember to always wear safety glasses when operating the lathe. Once your part program has been downloaded to the CNC Lathe, the control panel s display will read: Download Complete <Enter> Machine Part <Esc> Abort Press Enter to begin machining your part program. As the program executes, the display will change to show the current x and z positions; spindle speed, feed rate, and G-code. Watch the lathe closely to make sure that you will not have a tool crash. After the program has finished, the tool will return to its home position and the lathe will stop. Go to the next section, CLEANUP. Module Guide 15

22 Cleanup Press Esc to return to the lathe Main Menu. Press the EMERGENCY STOP button. Open the safety doors and use the tension bars to remove the workpiece. Turn off the power switch located on the left side panel of the lathe. Clean up your area and return everything to its proper place. Using a brush or a shop vacuum, carefully clean out the inside of the lathe. Go to the next section in the presentation. 16 Module Guide

23 Lesson 5, Procedure From the File pull-down menu, select New and then Script Program. In the Program Information window, type Lesson 5 in the Project field and enter your name in the Author field. Make sure that Inches is selected under Units. Make sure that Absolute is selected under Coordinate Type. Make sure Plastic (Delrin) is selected under Material Type. If you are using wax, select Wax. Also check to make sure that the PRZP is X 0.75 and Z -1.5 inches. When you are done, click OK The Part Program Editor window appears. NOTE: On the left are command line numbers to the right of which the commands are entered. After you enter these commands, if there are any mistakes, the line containing the mistake will be highlighted when the program is compiled. There will be a blinking insertion point alongside line 00001, followed by the word END. Part Program Editor Window Module Guide 17

24 On line 00001, Type G20. This tells the program you will be working in inches. Press the Enter key on your keyboard. The blinking insertion point moves to line On line 00002, type V10 R.03 then press Enter. V10 tells the computer that you are asking for a rough cut, and.03" indicates the total amount of material to be removed on each rough cut pass. On line 00003, type V11 R.01 then press Enter. V11 tells the computer that you are asking for a final finishing cut of.01", which is the total amount of material to be removed on each finish cut pass. On line 00004, type M04 S1300 then press Enter. The code M04 turns on the spindle, and S1300 sets the speed at 1300 RPM. On line 00005, type F3 then press Enter. This sets the feed rate for the tool post at 3 inches per minute. NOTE: The commands up to this point are modal commands. This means that all further actions will incorporate these commands until they are changed to something else. On line 00006, type G00 X.375 Z0 and press Enter. This command moves the tool from the home position to a point 1.55" away from the material along the z-axis. From the Lathe pull-down menu select Emulate to compile your program. The Compiling window appears indicating whether or not there are errors in the program. If there are errors, the program will highlight the line(s) where the error occurs. If there are no errors, the message, No errors detected appears in the Error field. Correct any errors in the program by editing the appropriate line(s). When all errors are corrected, click Cancel. On line 00007, type G81 X.3 Z-1.1 and press Enter. This is a turning command. G81 is a turning cycle command. This means that all you need to provide is the finish (or end) position and the turning cycle will begin from the current position (X1.5 Z1.55). From the Lathe pull-down menu, select Emulate. The Compiling appears. There should be no errors. 18 Module Guide

25 Click OK. The Lathe 3D Emulator window appears. Click the green Start Simulation button to simulate the part. When the simulation is finished, it should look like the screen below. This is the first actual machining of the part. Close the Lathe 3D Emulator. On line 00008, type G00 X.3 Z0 then press Enter. This moves the tool to the start point for the next cut. On line 00009, type G81 X.2 Z-.4 then press Enter. This creates the next turn. Highlight the G81 code in your program. Press F1 and the Glossary (Help) screen appears with information on the G-code you have highlighted. You can also click the Help Topics button and select any of the G- and M-codes that appear on the Help Topics screen. If you ever have a question about a code, use the Help screen. Click on the x in the upper-right corner to close the Glossary screen. On line 00010, type G00 X.2 Z0 then press Enter. This is another positioning, or setup, command. On line 00011, type G00 X.2 Z-.2 then press Enter. This is also a setup command. Module Guide 19

26 On line 00012, type G03 X0 Z0 R0.4 and press Enter. The G03 command is a counterclockwise arc. From the Lathe pull-down menu, select Emulate. Once again, the Compiling window appears. There should be no errors. If you have an error, correct it in the line of code highlighted in the Editor window. When you are done, click OK. The Lathe 3D Emulator appears. Before pressing the green Start simulation button, press the Step simulation button several times to get a step-by-step indication of how the part will be cut. Close the Lathe 3D Emulator window. On line 00013, type G00 X.3 Z0 and press Enter. On line 00014, type G00 X.3 Z-.75 then press Enter. Lines and are setup commands. NOTE: The purpose of having more than one setup or positioning command is to prevent tool crashes from occurring. On line 00015, type G00 X.2 Z-.4 then press Enter. This line creates a taper. On line 00016, type G00 X.2 Z-1.1 then press Enter. NOTE: The next four lines in the program clean up any loose material or edges. On line 00017, type G00 X.3 Z-.4 then press Enter. On line 00018, type G00 X.3 Z-.75 then press Enter. On line 00019, type G00 X.37 Z-1.1 then press Enter. On line 00020, type G00 X.45 Z-1.1 then press Enter. On line 00021, type M05 then press Enter. This turns off the spindle. On line 00022, type M28. This sends the tool to the home position. On line 00023, type M30. This command is used to indicate the end of a program. 20 Module Guide

27 Review your part program. It should appear as shown below. Compile and emulate the part program. Correct any errors. Module Guide 21

28 This is what the final simulation should look like. If it doesn t look like this, go back and check your program. Close the Lathe 3D Emulator window. From the File pull-down menu, select Save. Your Lesson 5 part program is now saved in the.l5 directory. You can access it at any time by simply choosing Open and then 5300 folder from the File pull-down menu. Close the Lesson 5 Part Program Editor window. NOTE: You have entered and saved a new part program. You are now going to download and machine the part. WARNING: Wear eye protection! Set the PRZ as you did in the previous lesson. If necessary, refer to SETTING THE PRZ. Next, execute the part program as you did in the previous lesson. If necessary, refer to SAFETY NOTES, DOWNLOADING YOUR PART PROGRAM, EXECUTING YOUR PART PROGRAM, and CLEANUP. Go to the next section in the presentation. 22 Module Guide

29 Lesson 6, Procedure From the File pull-down menu, select New and then CADCAM. In the Program Information window, type Lesson 6 in the Project field and your name in the Author field. This will be the name of your drawing. Check the other settings as you did in the previous lessons. Click OK. The Lathe CADCAM screen appears. Lathe CADCAM Screen Observe the important features of this screen. The long rectangle visible on your monitor is a graphic picture of your stock. You also have a graphic picture of the x- and z-axes. Because the stock is spinning, one side is the same as the other, so it is symmetrical (the same on both sides). Locate the PRZ (the point where the X and Z coordinates intersect) by using your mouse pointer and the graphic of your stock. Notice that the bottom left portion of the Lathe CADCAM screen indicates that the PRZ is designated X: 0.000, Z: Module Guide 23

30 Locate the Split Tool, Turn Cycle, Taper Cycle, and CW & CCW Cycle buttons on the left of your screen. You will use these to select the proper cutting function. See below. Remember, the area outlined in light green is the area you are working in. NOTE: Before you perform the steps in the activity, make sure the light green outlined area changes to red when you click on the desired coordinates. You are going to set the grid and the snap settings to make it easier for you to locate points on the screen. From the Control section of the toolbar click on the button Show Grid and Snap Settings and the CADCAM Spacing window will open and defaulted to the Snap tab, from spacing values select in. This measurement represents the nearest of an inch the lines will snap to when you are designing your part program. 24 Module Guide

31 Click on the Grid tab and from the Grid spacing values select in., these are the increments that will show on the Lathe CADCAM screen. It is measured in percentages of an inch. Close the CADCAM Spacing window by clicking on the red X in the upper right-hand corner of the window. Click on the Split Tool, move the mouse pointer until the Z coordinate reads and click. If you click your mouse at the wrong coordinate(s) when inserting your line, click the Join to Right button. Your screen should look like this: Click on the line and drag it to where the Z coordinate reads , and then release the mouse button. Release the mouse button after each line is dragged to the desired coordinate. Module Guide 25

32 Using the same procedure, drag the new line in the drawing to where the Z coordinate reads Drag this line in the drawing to where the Z coordinate reads Your screen should now look like this: Click on Select Tool. Move the mouse pointer to X and Z to highlight the coordinate(s). Click on Taper Cycle and go back to the same position. Click and drag the line toward the top of the screen until the X coordinate reads Your screen should now appear as shown below. 26 Module Guide

33 With the Taper Cycle still selected, click on the Z coordinate of and drag the line upward until the X coordinate reads Your screen should appear as shown below. (Make sure the Triangle is still selected.) Click the Clockwise Arc Cycle, and click on the diagonal line. Your screen should appear as shown below. Module Guide 27

34 Click on Select Tool. Move the mouse pointer to X and Z to highlight the coordinates. Click on Turn Cycle and go back to the same position. Click and drag the line until X coordinate reads Click on Select Tool. Move the mouse pointer to X and Z to highlight the coordinates. Click on Taper Cycle and go back to the same position. Click and drag the line until X coordinate reads Module Guide

35 With the Taper Cycle selected, move the mouse pointer to X and Z Drag the line up to X Click on Select Tool. Move the mouse pointer to X and Z to highlight the coordinates. Click on Turn Cycle and go back to the same position. Click and drag the line until X coordinate reads Your final drawing should look like this: You will now export your CAD drawing to the Lesson 6 Part Program Editor window. Click the CAD Export to G&M Code button [the top left button in the Control section]. The Save As window appears. Select the 5300 folder. Module Guide 29

36 Enter Lesson 6" in the File name field and then click Save. Your part program is now saved in the.l5 directory. A lesson 6 part program is generated from your CADCAM drawing and displayed in the Part Program Editor window. Close the Lathe CAD window. When the Save Application window appears, click on Yes. The Save AS window appears. In the File name field type, Lesson 6 and click on Save. Now you will verify that the part program is correct and view an emulation (visual simulation) of the part program. From the Lathe pull-down menu, select Emulate. The Compiling window appears and should indicate that there are no errors detected. Click OK. Click on the green Start Simulation button on the top left corner of the screen (in the Control section). Try viewing the simulation in different views by selecting the buttons in the View section. When you are done, close the Lathe 3D Emulator window. Close the Lesson 6 Part Program Editor window. Go to the next section in the presentation. 30 Module Guide

37 Lesson 7, Procedure From the File pull-down menu, select New and then CADCAM. In the Program Information window, type Lesson 7 in the Project field and your name in the Author field. Always check the defaults to make sure they conform with the your program requirements. The defaults should remain the same as those selected in previous lessons. Click OK. The Lathe CADCAM screen appears. From the Control section of the toolbar click on the button Show Grid and Snap Settings and the CADCAM Spacing window will open and defaulted to the Snap tab, from spacing values select in. This measurement represents the nearest of an inch the lines will snap to when you are designing your part program. Click on the Grid tab and from the Grid spacing values select in., these are the increments that will show on the Lathe CADCAM screen. It is measured in percentages of an inch. Close the CADCAM Spacing window by clicking on the red X in the upper righthand corner of the window. You are now going to create separations, or Splits, in order to manipulate different slopes and designs in your part profile. After that you will use the Taper and Arc Cycles to shape it. NOTE: You can use the Split Tool to create separations and the Join Tools to connect them. As you create your part profile, remember that if you make a mistake, there are a few ways to correct it, such as using the Join tools or by using any of the other tool buttons. Remember that the Clear CAD Part button will completely wipe out your program. Click the Split Tool, then move the mouse pointer to Z and click. Drag the line to Z and release the mouse button. Release the mouse button after each line is dragged to the desired coordinate Drag the line to Z Drag the line to Z Module Guide 31

38 Drag the line to Z Drag the line to Z Drag the line to Z Drag the line to Z Your screen should appear as shown below. Click on Select Tool. Move the mouse pointer to X and Z to highlight the coordinate(s). Click on Taper Cycle and go back to the same position. Click and drag the line toward the top of the screen until the X coordinate reads forming a taper as shown below. 32 Module Guide

39 With the Taper Cycle still selected, move the mouse pointer to Z and X and drag the line to X See below. Click the Clockwise Arc Cycle. Click on Select Tool. Move the mouse pointer to X and Z to highlight the coordinates. Click on Turn Cycle and go back to the same position. Click and drag the line until X coordinate reads Your screen should appear as below. Click on Select Tool. Move the mouse pointer to Z to highlight the coordinate(s). Click on Turn Cycle and go back to the same position. Drag the line up to X Click the Counterclockwise Arc Cycle and drag the line down to X Click on Select Tool. Move the mouse pointer to Z to highlight the coordinate(s). Click on Turn Cycle and go back to the same position. Drag the line up to X Module Guide 33

40 Click on Select Tool. Move the mouse pointer to Z to highlight the coordinate(s). Click on Turn Cycle and go back to the same position. Drag the line up to X Click the Taper Cycle, move the mouse pointer to , and drag the line to X Your screen should appear as shown below. Click on Select Tool. Move the mouse pointer to Z to highlight the coordinate(s). Click on Turn Cycle and go back to the same position. Drag the line up to X Click on Select Tool. Move the mouse pointer to Z to highlight the coordinate(s). Click on Turn Cycle and go back to the same position. Drag the line up to X Click the Taper Cycle, move the mouse pointer to Z , and then drag the line to X Click the Join to Right on the bottom left of the Section tools area. The section selected joins with the section to the left. 34 Module Guide

41 Click the Taper Cycle, move the mouse pointer to X and Z , and then drag the line up to X Your screen should appear as shown below. Click on Select Tool. Move the mouse pointer to Z and X to highlight the coordinate(s). Click on Turn Cycle and go back to the same position. Drag the line to X The completed part profile appears as shown below. Module Guide 35

42 NOTE: You have just completed the CAD portion of the exercise: the design of a part. You are now going to use CAM so that the part can be machined on the lathe. Click the CAD Export to G&M Code button to export the CAD drawing to the Part Program Editor window. The Save As window appears, select the 5300 folder. Enter "Lesson 7" in the File name field and then click Save. Your part program is now saved in the.l5 directory with the other part programs. A lesson 7 part program is generated from your CADCAM drawing and displayed in the Part Program Editor window. Highlight to activate the CAD window. Click File, Save As, and then open the 5300 folder. Enter "Lesson 7" in the Filename field. Your CAD drawing is now saved in the *.l5c directory. Close the Lathe CAD window. Now you will verify that the part program is correct and view an emulation (visual simulation) of the program. From the Lathe pull-down menu, select Emulate. The Compiling window appears and should indicate that no errors detected. Click OK. Click the green Start Simulation button. Your part should appear as shown below. Lathe 3D Emulator 36 Module Guide

43 Try viewing the simulation in different views. When you are done, close the Lathe 3D Emulator. If the simulation was successful, you have created, compiled, and emulated a part program. WARNING: Wear eye protection! Set the PRZ as you did in Lesson 4. If necessary, refer to SETTING THE PRZ. Next, download and execute the part program. If necessary, refer to SAFETY NOTES, DOWNLOADING YOUR PART PROGRAM, and EXECUTING YOUR PART PROGRAM. When you have completed executing your part program, clean up your area. If necessary, refer to CLEANUP. Go to the next section, SAVING TO A FLOPPY DISK. Module Guide 37

44 Saving to a Floppy Disk When all lesson activities have been completed, your part programs should be saved to a floppy disk, CD-ROM, or to a personal on-line file and then removed from the 5300 folder, DATA directory. Your part programs can be downloaded to Lab-Volt CNC Lathe at any time in the future if necessary. Follow the steps below. Go to the next section in the presentation. 38 Module Guide

45 ADVANCED LEVEL Lesson 2, Program Familiarization To open and close a part program file: Lab-Volt CNC Lathe Main Screen From the File pull-down menu, select Open. The Open window appears with a Data folder directory containing a list of folders with lathe model numbers. Select the 5300 folder to view a list of lathe files stored in the *.l5 directory. Open Window Click Cancel to close the Open window. Module Guide 39

46 Before you select a file, review another way to access the Open window. On the Main Menu toolbar of the Lab-Volt CNC Lathe software main screen, click the Open button. The Open window appears again with the same listing folders. NOTE: The Main Menu toolbar buttons on the Lab-Volt CNC Lathe screen perform the same operations as their menu equivalents. In the Open window, select the 5300 folder to view a list of lathe files stored in the *.l5 directory. Click on demo1. The demo1.l5 file name becomes highlighted. Click on Open. (Another way to open the demo1.l5 Part Program Editor window is to double-click on demo1.l5 in the Open window.) The demo1 Part Program Editor window appears. Demo1 Part Program Editor Window with ISO Codes The Part Program Editor window contains a list of the steps, or lines, that make up the part program. This program was written using ISO (Industrial Standard Operation) machine codes, also called G- and M-codes. For example, G91 indicates incremental mode and M97 calls a subroutine. The Part Program Editor in the Lab-Volt CNC Lathe software allows you to toggle between the G- and M-codes and their equivalent Conversational Codes. Conversational Codes: From the Edit pull-down menu, select Conversational. 40 Module Guide

47 The program listing in the Part Program Editor window changes to the Conversational Code, as shown in the following figure. Demo1 Part Program Editor Window with Conversational Codes Click on any line of code. A vertical flashing cursor appears in the program. Press the F2 key in the top row of the keyboard. The program listing changes back to ISO Codes. Leave it in this mode. NOTE: You can easily switch between ISO Codes and conversational codes by either choosing Conversational from the Edit menu or by pressing F2. To compile a part program: From the Lathe pull-down menu, select Emulate. The Compiling window appears. Compiling Window Module Guide 41

48 The Compiling window shows several fields: the Status (Compile Status) field, the Line Number (Current Line Number) field, and the Error (Error Messages) field. Compiling a program tests the program for errors and verifies it for emulation and downloading to the lathe. All part programs must be compiled with no errors before they can be emulated or downloaded. There should be no errors in the Demo1.l5 file. Click Cancel in the Compiling window to close it. On the toolbar, click the Emulate Part Program button. The Compiling window appears again. Click Cancel to close it. To open the Compiling window, you can choose the Emulate Part Program button on the tool bar or access it from the Main Menu by selecting Lathe and then Emulate. To emulate a part program: Once a part program has been successfully compiled, the part program can be emulated. When you emulate a program, the computer performs a graphic simulation of the open part program. All part programs must be emulated from several views before actual production. This ensures that machining will occur without errors or tool crashes. Simulation of the cutting of the part before production saves costly damage to the lathe and wasted stock due to errors. Click the green Emulate Part Program button on the toolbar. The Compiling window appears. Click OK. The Lathe 3D Emulator window appears. 42 Module Guide

49 You can also open the Lathe 3D Emulator window from the Main Menu by first selecting Lathe and then Emulate, and finally clicking on OK in the Compiling window that appears. When the 3D Emulator window appears, the stock is shown in the full view. The full-view simulation shows the full cross-section of your design on the stock. Running the full-view simulation before machining allows you to be sure that the part will fit on the stock without extending beyond any of the edges. To ensure that the cutting tool will not be damaged during the cutting of the part, perform a full-view simulation for every part to be cut on the CNC lathe. To see a full-view simulation, click on the green Start Simulator button under the Control section on the Lathe 3D Emulator window. In this view, the PRZ (Programmable Reference Zero) is on the centerline, where the X and Z coordinates intersect. Notice on your monitor that some of the lines indicating the tool path are red and others are yellow. The red lines represent movement of the cutting tool out of the stock at the rapid rate, and the yellow lines represent the movement of the cutting tool inside the stock at the feed rate. Module Guide 43

50 To reset the simulation: Click the Reset Simulation button in the Control section. This clears the simulation screen and prepares for a new simulation. The following five view buttons are available under View on the Lathe 3D Emulator window. Mouse Zoom button Mouse Light Control button Mouse Pan button Reset 3D View button Mouse Rotate button The directions that follow show you how to use each view function. Mouse Zoom Click on the Mouse Zoom button. Click, hold, and drag the mouse on the Lathe 3D Emulator grid to zoom in or out on the stock piece. Mouse Pan Click on the Mouse Pan button. Click, hold, and drag the mouse on the Lathe 3D Emulator grid to move the stock piece left, right, up or down. Mouse Rotate Click on the Mouse Rotate button. Click, hold, and drag the mouse on the Lathe 3D Emulator grid to rotate the stock piece degrees in any direction. Mouse Light Control Click on the Mouse Light Control button. Click, hold, and drag the mouse on the stock piece to increase or decrease the highlights surrounding the stock. Reset 3D View Click on the Reset 3D View button gird location. to return the stock piece to its original size and 44 Module Guide

51 Lesson 2, Procedure During this procedure, you will start a new program, design a part, and emulate it on the screen. From the File pull-down menu, select New and then select CADCAM. The Program Information window appears. On the Program Setup window, enter "Lesson 2" in the Project field and you name in the Author field Using the micrometer or dial caliper, measure the diameter of your piece of stock. Look under the Part Reference Zero Position section. Next to X-Coordinate Value, the default measurement 0.75 should already be entered. This measurement represents the diameter (x value) in terms of inches. It should be the same as the diameter you just measured. Now measure the length of your piece of stock. The default measurement -1.5 is entered. This measurement represents the length [z value] in terms of inches. It is not the same length you just measured. Although the length of your stock is actually 2.5 inches (6.35cm), the actual usable portion of the stock is 1.5 inches (3.81cm). The unusable portion can be divided into two parts: 1. Approximately ½ inch (1.27cm) of stock goes in the chuck. 2. The first ½ inch (1.27cm) outside the chuck is an unusable safety portion. To help prevent a tool crash, the lathe will automatically stop if the program tries to send the cutter closer than ½ inch (1.27cm) to the chuck. Check the other defaults to make sure they conform to your program requirements. When you are done, click OK. The Lathe CADCAM screen appears. Go to the next section, DESIGNING YOUR PART. Module Guide 45

52 Designing Your Part Locate the PRZ (the point where the X and Z coordinates intersect) by using your mouse pointer and the graphic of your stock. Notice that the bottom left portion of the CAD Editor indicates that the PRZ is designated X:0.0000,, Z: Locate the Split Tool, Turn Cycle, Taper Cycle, and CW & CCW Arc Cycle buttons on the left of your screen. You will use these to select the proper cutting function. See below. Remember, the area outlined in light blue is the area you are working in. Before you start, you are going to set the grid and the snap settings to make it easier for you to locate points on the screen. From the Control section of the toolbar click on the button Show Grid and Snap Settings and the CADCAM Spacing window will open and defaulted to the Snap tab, from spacing values select in. This measurement represents the nearest of an inch the lines will snap to when you are designing your part program. 46 Module Guide

53 Click on the Grid tab and from the Grid spacing values select in., these are the increments that will show on the Lathe CADCAM screen. It is measured in percentages of an inch. Close the CADCAM Spacing window by clicking on the red X in the upper righthand corner of the window. Click the Split Tool button and move the mouse pointer to Z and click. Your screen should appear as shown below. NOTE: Release the mouse button after each line is dragged to the specified coordinate. Using your mouse, drag the line to Z It should now appear like this: Module Guide 47

54 Now drag the line to Z Your screen should now look like the one shown here. Click on Select Tool. Move the mouse pointer to Z and X to highlight the coordinate(s). Click on Taper Cycle and go back to the same position. Drag the line up to X Module Guide

55 With the Taper Cycle still selected, drag the bottom of the line up to X Click on Select Tool. Move the mouse pointer to Z and X to highlight the coordinate(s). Click on Turn Cycle and go back to the same position. Drag the line up to X and your screen should look like this: Module Guide 49

56 Click on Select Tool. Move the mouse pointer to Z and X to highlight the coordinate(s). Click on Taper Cycle and go back to the same location. Drag the line to X and your screen should like this: You have finished designing the part. Remember, this is a CAD/CAM system. So far, you have only completed the CAD portion. Now you will complete your drawing and prepare it for the lathe in CAM. Go to the next section, CAM OPERATION. CAM Operation You will now export your CAD drawing to the Part Program Editor window. Click the CAD Export to G&M Code button to export the CAD drawing to the Part Program Editor window. The Save As window appears, select the 5300 folder. Enter "Lesson 2" in the File name field and then click Save. Your part program is now saved in the.l5 directory with the other part programs. A lesson 2 part program is generated from your CADCAM drawing and displayed in the Part Program Editor window. Highlight to activate the CAD window. Click File, Save As, and then open the 5300 folder. Enter "Lesson 2" in the Filename field. Your CAD drawing is now saved in the *.l5c directory. Close the Lathe CAD window. Now you will verify that the part program is correct and view an emulation (visual simulation) of the program. 50 Module Guide

57 From the Lathe pull-down menu, select Emulate. The Compiling window appears and should indicate that no errors detected. Click OK. From the Lathe pull-down menu, select Emulate. Click on the green Start Simulation button on the top left corner of the screen (in the Control section). Try viewing the simulation in different views by selecting the buttons in the View section. When you are done, close the Lathe 3D Emulator window. If the simulation was successful, you have created, compiled, and emulated a part program. Close the Lesson 2 Part Program Editor window. Go to the next section in the presentation. Module Guide 51

58 Lesson 3, Procedure Start by reopening the file that you created in the previous lesson. From the File pull-down menu, select Open and then select the 5300 folder. The Open dialog appears showing the contents of the.l5 directory. Double-click on the Lesson 2 part program file. The Lesson 2 Part Program Editor window appears. From the File pull-down menu, select Info. The Program Information window appears. Using the micrometer or dial caliper, measure the diameter of your piece of stock. In the Program Setup window, 0.75 should appear in the X Value field (this is the diameter of your stock). Make sure -1.5 appears in the Z- Value field. Check the other defaults as you did in previous lessons. Make sure Plastic (Delrin) is selected. If you are using wax, select Wax. When you are done, click OK. You are now ready to set up the lathe and download the Lesson 2 part program. Follow the steps in the next section, SETTING THE PRZ (program reference zero). From the Options pull-down menu, select Lathe Tool Table. The Program Options window appears displaying the Tool Table tab. 52 Module Guide

59 Whenever a part program is written, you must always choose the proper tool for the part to be machined. The programs you will be creating will require tool number 1. This is described as a right-55 degree cutter. This tool comes pre-installed on the Lab-Volt CNC Lathe because it is the most commonly used. Scroll through the different tools by clicking on the up and down arrows to the right of the Tool Number field. A graphic representation of each tool is shown. Remember to reselect tool number 1 when you are done. Before downloading a part program, it is good practice to check this window to be sure the correct tool is selected. When you are done, click Save. Go to the next section, SETTING THE PRZ. Setting the PRZ Setting the PRZ designates a reference point identified as (0,0). This is important because the lathe's operation relies on the PRZ as a point of reference from which all other coordinates are measured. WARNING: Always wear eye protection! Place the stock in the chuck, a three-pronged device that centers the stock and holds it in place. Be sure the stock is as far in as possible. Now, using the tension bars, clamp the chuck closed on the stock by turning the right disk clockwise and the left disk counterclockwise. Remove the tension bars before operating the lathe. Module Guide 53

60 If the power light on the front panel of the lathe is not on, turn on the lathe by pressing the switch located on the left side panel of the lathe. It will take a minute or so for the lathe to initialize and the Main Menu to appear. Close the cover. You need to use the control panel keypad on the front panel of the lathe to move the cutter to the end of the stock. Select Manual from the lathe control panel Main Menu. If the cursor is not next to Manual, use the X keys to move the cursor to it. Press ENTER to select Manual. Using the +Z and Z keys, position the left edge of the cutting tool along the right outside edge of the stock. Use the +X and X keys to position the tool on the very edge of the stock. Setting the PRZ Press the SPINDLE SPEED key to access the Spindle Speed menu. Press the +Z key to turn the spindle on. The exact speed is not important. Press ENTER to return to the Manual menu. Use the X key to move the tool up just enough to remove a thin thread from the edge. Press SPINDLE SPEED, then ZERO to stop the spindle. Press ENTER to return to the Manual menu. 54 Module Guide

61 Set the X offset value by pressing ZERO, +X and enter the diameter of the stock by pressing the appropriate number keys, in this case.75, then ENTER. Although it is the diameter that is entered, the radius (which is the distance needed) is displayed in the Manual menu. The Z offset is the distance from the outer edge of the stock (current position of the tool) to a point on the stock just in front of the chuck. It is equal to the length of the stock indicated in the Program Setup screen for the part to be turned (the Z component of the stock size). Set the Z offset by pressing ZERO, +Z and press 0 then ENTER. The PRZ is now set. Return to the Main Menu by pressing ESC. Go to the next section, SAFETY NOTES. Safety Notes Use caution at all times. Lifting the cover or pressing the EMERGENCY STOP button while the lathe is running will shut off power to the lathe and cause complete program loss. Always wear eye protection. Before operating the lathe, be sure to remove any loose objects from inside the lathe cabinet. Complete the next section, DOWNLOADING YOUR PART PROGRAM. Downloading Your Part Program You should have your program loaded, the workpiece loaded, and the PRZ set. You are now ready to download your part program. On the lathe control panel, use the +X key to move the cursor next to Remote and press Enter. The lathe s display now reads: Ready to Download <Esc> Abort From the Lathe pull-down menu on your computer desktop, select Download Program via Serial port. The Download Program via Serial port screen appears. Module Guide 55

62 The Remote Machine field tells you that you are downloading to a lathe. The Status field tells you that you are ready to download and the Last Error field tells you that there are no errors. If an error occurs, this field displays the error message code for the problem. If this happens, ask your instructor for help. Click the Download button. Look at the display on the lathe s control panel and you will see Downloading and a rotating cursor indicating that your part program is being downloaded to the lathe. When the Download Complete screen is displayed on the lathe, your part program has been downloaded. Close the Lesson 2 Editor window. Go to the next section, EXECUTING YOUR PART PROGRAM. Executing Your Part Program You are now ready to execute your part program. Remember to always wear safety glasses when operating the lathe. Once your part program has been downloaded to the CNC Lathe, the control panel s display will read: Download Complete <Enter> Machine Part <Esc> Abort Press Enter to begin machining your part program. As the program executes, the display will change to show the current x and z positions; spindle speed, feed rate, and G-code. Watch the lathe closely to make that you will not have a tool crash. After the program has finished, the tool will return to its home position and the lathe will stop. Go to the next section, CLEANUP. 56 Module Guide

63 Cleanup Press Esc to return to the lathe Main Menu. Press the EMERGENCY STOP button. Open the safety doors and carefully remove the workpiece. Turn off the power switch located on the left side panel of the lathe. Clean up your area and return everything to its proper place. Using a brush or a shop vacuum, carefully clean out the inside of the lathe. Go to the next section in the presentation. Module Guide 57

64 Lesson 4, Procedure From the File pull-down Menu, select New and then select CADCAM. In the Program Information window, type "Lesson 4"in the Project field and your name in the Author field. Check the defaults as you did in previous lessons to make sure they conform to your program requirements. When you are done, click OK. The Lathe CADCAM screen appears. Remember, the area outlined in light green is the area you are working in. Before you start you are going to set the grid and the snap settings to make it easier for you to locate points on the screen. From the Control section of the toolbar click on the button Show Grid and Snap Settings and the CADCAM Spacing window will open and defaulted to the Snap tab, from spacing values select in. This measurement represents the nearest of an inch the lines will snap to when you are designing your part program. Click on the Grid tab and from the Grid spacing values select in., these are the increments that will show on the Lathe CADCAM screen. It is measured in percentages of an inch. Close the CADCAM Spacing window by clicking on the red X in the upper righthand corner of the window. Click the Split Tool, move the mouse pointer Z , and click. NOTE: Release the mouse button after each line is dragged to the specified coordinate. You can also create partitions by clicking at each of the specified coordinates. Drag the line to Z Drag the line to Z Drag the line to Z Drag the line to Z Drag the line to Z Drag the line to Z Module Guide

65 Drag the line to Z Drag the line to Z Drag the line to Z Your screen should now appear as shown below. You will manipulate these sections to create a part profile with the tools on the left of the screen. Remember that if you make a mistake, you can use any of the tools to correct it. Click on Select Tool. Move the mouse pointer to Z and X to highlight the coordinate(s). Click on Clockwise Arc Cycle and go back to the same position. Drag the line up to X With the arc still highlight it click on X and Z and drag the line up to X Click on Select Tool. Move the mouse pointer to Z and X to highlight the coordinate(s). Click on Turn Cycle and go back to the same position. Drag the line up to X Click on Select Tool. Move the mouse pointer to Z and X to highlight the coordinate(s). Click on Turn Cycle and go back to the same position. Drag the line up to X Click on Select Tool. Move the mouse pointer to Z and X to highlight the coordinate(s). Click on Turn Cycle and go back to the same position. Drag the line up to X Click on Select Tool. Move the mouse pointer to Z and X to highlight the coordinate(s). Click on Taper Cycle and go back to the same position. Drag the line up to X Click on Select Tool. Move the mouse pointer to Z and X to highlight the coordinate(s). Click on Taper Cycle and go back to the same position. Drag the line up to X Module Guide 59

66 Click on Select Tool. Move the mouse pointer to Z and X to highlight the coordinate(s). Click on Taper Cycle and go back to the same position. Drag the taper up to X Your screen should look like this: Click on Select Tool. Move the mouse pointer to Z and X to highlight the coordinate(s). Click on Turn Cycle and go back to the same position. Drag the line up to X Click the Taper Cycle. Move the mouse pointer to X and Z , then drag the taper up to X Click on Select Tool. Move the mouse pointer to Z and X to highlight the coordinate(s). Click on Turn Cycle and go back to the same position. Drag the line up to X Click on Select Tool. Move the mouse pointer to Z and X to highlight the coordinate(s). Click on Turn Cycle and go back to the same position. Drag the line to X Click on Select Tool. Move the mouse pointer to Z and X to highlight the coordinate(s). Click on Taper Cycle and go back to the same position. Drag the taper down to X Click the Counterclockwise Arc Cycle and click on the taper you just made. The screen should look like the one shown on the next page. 60 Module Guide

67 Click on Select Tool. Move the mouse pointer to Z and X to highlight the coordinate(s). Click on Turn Cycle and go back to the same position. Drag the line up to X Click on Select Tool. Move the mouse pointer to Z and X to highlight the coordinate(s). Click on Turn Cycle and go back to the same position. Drag the line to X Click the Taper Cycle. Move the mouse pointer to X and Z , then drag a taper up to X Module Guide 61

68 Click the Clockwise Arc Cycle. The screen should look like the one shown here. Click on Select Tool. Move the mouse pointer to Z and X to highlight the coordinate(s). Click on Turn Cycle and go back to the same position. Drag the line to X Click on Select Tool. Move the mouse pointer to Z and X to highlight the coordinate(s). Click on Taper Cycle and go back to the same position. Drag the taper to X The screen should now look like the one shown here. 62 Module Guide

69 Next you will export, save, compile, and emulate the part program. Complete the next section, SAVE AND EMULATE. Save and Emulate Click the CAD Export to G&M Code button to export the CAD drawing to the Part Program Editor window. The Save As window appears, select the 5300 folder. Enter "Lesson 4" in the File name field and then click Save. Your part program is now saved in the.l5 directory with the other part programs. A lesson 4 part program is generated from your CADCAM drawing and displayed in the Part Program Editor window. Highlight to activate the CAD window. Click File, Save As, and then open the 5300 folder. Enter "Lesson 4" in the Filename field. Your CAD drawing is now saved in the *.l5c directory. Close the Lathe CAD window. Now you will verify that the part program is correct and view an emulation (visual simulation) of the program. From the Lathe pull-down menu, select Emulate. The Compiling window appears and should indicate that no errors detected. Click OK. Click on the green Start button on the top left corner of the screen (under the Control section). Module Guide 63

70 Close the Lathe 3D Emulator Close the Lesson 4 Part Program Editor window Go to the next section in the presentation. 64 Module Guide

71 Lesson 5, Procedure From the File pull-down menu, select Open and then select the 5300 folder. The Open dialog appears showing the contents of the.l5 directory. Double-click on the Lesson 4 part program file. The Lesson 4 Part Program Editor window appears. Now it is time to load the stock and prepare it for downloading and executing the program. Refer to the SETTING THE PRZ and SAFETY sections if necessary. After the workpiece is loaded and the PRZ set, you are ready to download and execute your part program. WARNING: Remember to wear safety glasses! Execute the part program. If necessary, refer to DOWNLOADING YOUR PART PROGRAM and EXECUTING YOUR PART PROGRAM. Close the Lesson 4 Part Program Editor window. Turn off the lathe. Clean up your area (refer to CLEANUP if necessary). Go to the next section in the presentation. Module Guide 65

72 Lesson 6, Procedure From the File pull-down menu, select New and then select CADCAM. The Program Information window appears. Enter "Lesson 6is" in the Project field and your name in the Author field. Using the micrometer or dial caliper, measure the diameter of your piece of stock. Look under the Part Reference Zero Position section. Next to X Value field. The default measurement 0.75 should already be entered. This measurement represents the diameter (x value) in terms of inches. It should be the same as the diameter you just measured. Now measure the length of your piece of stock. The default measurement -1.5 is entered in the Z- Value field. This measurement represents the length [z value] in terms of inches. It is not the same length you just measured. Although the length of your stock is actually 2.5 inches (6.35 cm), the actual usable portion of the stock is 1.5 inches (3.81 cm). The unusable portion can be divided into two parts. 1. Approximately ½ inch (1.27cm) of stock goes in the chuck. 2. The first ½ inch (1.27cm) outside the chuck is an unusable safety portion. To help prevent a tool crash, the lathe will automatically stop if the program tries to send the cutter closer than ½ inch (1.27cm) to the chuck. Check the other defaults to make sure they conform to your program requirements. When you are done, click OK. The blank Lathe CADCAM screen appears. 66 Module Guide

73 Remember that the highlighted area is the area you are working in. Using the Split Tool split your drawing into the correct lengths according to the following blueprint. First, set the snap setting like you did earlier. Make sure is selected and then close the snap window. The grid setting should remain at Using the Split Tool, create segments at the following Z coordinates: ", ", ", ", ", ", and ". The X coordinates for the lines (right to left) are ", ", ", ", ", ", ", and ". Module Guide 67

74 Now, using the blueprint as a guide, select the Taper Cycle and create the tapers on the part. When you are done, check your screen with the drawing. Click the CAD Export to G&M Code button to export the CAD drawing and generate a part program in the Lesson 6is Part Program Editor window. Save your CAD drawing and part program as you did in previous lessons. Be sure to enter Lesson 6is in the File name field, then click Save. Close the Lathe CAD window. Compile and emulate the part program. It should appear as shown below. 68 Module Guide

75 If the simulation is correct, close the Lathe 3D Emulator. Close the Lesson 6is Part Program Editor window. Go to the next section in the presentation. Module Guide 69

76 Lesson 7, Procedure From the File pull-down menu, select Open and then select the 5300 folder. Open your Lesson 6is part program and compile it as you did in the previous lesson. Now it is time to load the stock and prepare it for downloading and executing. Refer to the SETTING THE PRZ and SAFETY sections if necessary. After the workpiece is loaded and the PRZ set, you are ready to download and execute your part program. WARNING: Remember to wear safety glasses! Execute the part program. If necessary, refer to DOWNLOADING YOUR PART PROGRAM and EXECUTING YOUR PART PROGRAM. Close the Lesson 6is Editor window. When you have finished machining your part, use a micrometer or dial caliper to measure its dimensions. If any of the dimensions are incorrect, try to find what caused the problem or ask your instructor for help. After correcting the problem, re-machine or redesign, compile, and emulate the part. Turn off the lathe. Clean up your area (refer to CLEANUP if necessary). 70 Module Guide

77 Saving to a Floppy Disk When all lesson activities have been completed, your part programs should be saved to a floppy disk, CD-ROM, or to a personal on-line file and then removed from the.5300 folder Data directory. Your part programs can be downloaded to Lab-Volt CNC Lathe at any time in the future if necessary. Follow the steps below. Go to the next section in the presentation. Module Guide 71

78 72 Module Guide

79 COMPREHENSIVE LEVEL Lesson 4, Lab-Volt CNC Lathe software Instructions To open and close a part program file: Lab-Volt CNC Lathe Main Screen From the File pull-down menu, select Open. The Open window appears with a Data folder directory containing a list of folders with lathe model numbers. Select the 5300 folder to view a list of lathe files stored in the *.l5 directory. Open Window Click Cancel to close the Open window. Module Guide 73

80 Before you select a file, review another way to access the Open window. On the Main Menu toolbar of the Lab-Volt CNC Lathe main screen, click the Open button. The File, Open window appears again with the same listing of folders with lathe model numbers. NOTE: The Main Menu toolbar buttons on the Lab-Volt CNC Lathe screen perform the same operations as their menu equivalents. In the Open window, select the 5300 folder to view a list of lathe files stored in the *.l5 directory. Click on demo1.l5. The demo1.l5 file name becomes highlighted. Click on Open. (Another way to open the demo1.l5 Part Program Editor window is to double-click on demo1.l5 in the Open window.) The demo1 Part Program Editor window appears. Demo1 Part Program Editor Window with ISO Codes The Part Program Editor window contains a list of the steps, or lines, that make up the part program. This program was written using ISO (Industrial Standard Operation) machine codes, also called G- and M-codes. For example, G91 indicates incremental mode and M97 calls a subroutine. The Part Program Editor in the Lab-Volt CNC Lathe allows you to toggle between the G- and M-codes and their equivalent Conversational Codes. 74 Module Guide

81 Conversational Codes: From the Edit pull-down menu, select Conversational. The program listing in the Part Program Editor window changes to the Conversational Codes as shown in the following figure. demo1 Part Program Editor Window With Conversational Codes Click on any line of code. A vertical flashing cursor appears in the program. Press the F2 key in the top row of the keyboard. The program listing changes back to ISO Codes. Leave it in this mode. NOTE: You can easily switch between ISO Codes and Conversational Codes by either choosing Conversational from the Edit menu or by pressing F2 on your keyboard. Module Guide 75

82 To compile a part program: From the Lathe pull-down menu, select Emulate. The Compiling window appears. Compiling Window The Compiling window shows several fields: the Status (Compile Status) field, the Line Number (Current Line Number) field, and the Error (Error Messages) field. Compiling a program tests the program for errors and verifies it for emulation and downloading to the lathe. All part programs must be compiled with no errors before they can be emulated or downloaded. There should be no errors in the demo1.l5 file. Click Cancel in the Compiling window to close it. On the toolbar, click the Emulate Part Program button. The Compiling window appears again. Click Cancel to close it. To open the Compiling window, you can choose the Emulate Part Program button or access it from the Main Menu by selecting Lathe and then Emulate. To emulate a part program: Once a part program has been successfully compiled, it can be emulated. When you emulate a program, the computer performs a graphic simulation of the open part program. All part programs must be emulated from several views before actual production. This ensures that machining will occur without errors or tool crashes. Simulation of the cutting of the part before production saves costly damage to the lathe and wasted stock due to errors. 76 Module Guide

83 Click the Emulate Part Program button on the toolbar. The Compiling window appears. Click OK, and the Lathe 3D Emulator window appears. Lathe 3D Emulator Window You can also open the Lathe 3D Emulator window by selecting Emulate from the Lathe pull-down menu and then clicking OK in the Compiling window that appears. When the 3D Emulator window appears, the stock is shown in the full view. The full-view simulation shows the full cross-section of your design on the stock. Running the full-view simulation before machining allows you to be sure that the part will fit on the stock without extending beyond any of the edges. To ensure that the cutting tool will not be damaged during the cutting of the part, perform a full-view simulation for every part to be cut on the CNC lathe. To see a full-view simulation, click on the green Start Simulation button under Control section on the Lathe 3D Emulator window. Module Guide 77

84 The following full-view graphic of the design simulation appears. In this view, the PRZ (Programmable Reference Zero) is on the centerline, where the X and Z coordinates intersect. Notice on your monitor that some of the lines indicating the tool path are red and others are yellow. The red lines represent movement of the cutting tool out of the stock at the rapid rate, and the yellow lines represent the movement of the cutting tool inside the stock at the feed rate. To reset the simulation: Click the Reset Simulation button in the Control section. This clears the simulation screen and prepares for a new simulation. The following five view buttons are available under View on the Lathe 3D Emulator window. Mouse Zoom button Mouse Light Control button Mouse Pan button Reset 3D View button Mouse Rotate button 78 Module Guide

85 The directions that follow show you how to use each view function. Mouse Zoom Click on the Mouse Zoom button. Click, hold, and drag the mouse on the Lathe 3D Emulator grid to zoom in or out on the stock piece. Mouse Pan Click on the Mouse Pan button. Click, hold, and drag the mouse on the Lathe 3D Emulator grid to move the stock piece left, right, up or down. Mouse Rotate Click on the Mouse Rotate button. Click, hold, and drag the mouse on the Lathe 3D Emulator grid to rotate the stock piece degrees in any direction. Mouse Light Control Click on the Mouse Light Control button. Click, hold, and drag the mouse on the stock piece to increase or decrease the highlights surrounding the stock. Reset 3D View Click on the Reset 3D View button and gird location. to return the stock piece to its original size Module Guide 79

86 Lesson 4, Procedure From the File menu, select Open and then select the 5300 folder. On the Open screen, select demo1.l5 (a preexisting part program file) by doubleclicking on it. The G- and M-codes for the demo1 part program appear in the Part Program Editor window. Using a micrometer or dial caliper, measure the diameter of your piece of stock. It should measure 0.75 (1.91cm) in diameter with a length of 2.5 inches (6.35). From the File menu, select Info. The Program Information window appears. Program Information Window Make sure that the X value in the Stock Size section is 0.75 and that the Z- value is Although the stock is 2.5 inches (6.35cm) long, the actual workable portion of the stock is 1.5 inches (3.81cm). This is explained in more detail in the next section, SETTING THE PRZ. Make sure that Inch is selected under Units (defaulted for this program file). Make sure that Absolute is selected under Coordinates (defaulted for this program file). Make sure that Plastic Delrin is selected under Material Type. If you are using wax, select Wax. Either way, this will have no effect on how the program will be executed. When you are done, click OK. 80 Module Guide

87 Now you will verify that the part program is correct and view an emulation (visual simulation) of the program. From the Lathe pull-down menu, select Emulate. The Compiling window appears and should indicate that there are no errors detected. Click on OK. The Lathe 3D Emulator appears. Click on the green Start Simulation button under the Control section to begin the simulation. Try viewing the simulation in other views by clicking on the different buttons in the View section. When you are done, close the 3D Emulator window by clicking on the x in the upper right-hand corner. Leave the demo1 part program open. You are now ready to set up the lathe and download the demo1 part program. Follow the steps in the next section, SETTING THE PRZ (program reference zero). From the Options pull-down menu, select Lathe Tool Table. The Program Options window appears, displaying the Tool Table tab. Program Options Window Whenever a part program is written, you must always choose the proper tool for the part to be machined. Module Guide 81

88 The programs you will be creating will require tool number 1. This is described as a right-55 degree cutter. This tool comes pre-installed on the Lab-Volt CNC Lathe because it is the most commonly used. Scroll through the different tools by clicking on the up and down arrows to the right of the Tool Number field. A graphic representation of each tool is shown. Remember to re-select tool number 1 when you are done. Before downloading a part program, it is good practice to check this window to be sure the correct tool is selected. When you are done, click Save. Setting the PRZ Setting the PRZ designates a reference point identified as (0,0). This is important because the lathe's operation relies on the PRZ as a point of reference from which all other coordinates are measured. WARNING: Always wear eye protection! Place the stock in the chuck, a three-pronged device that centers the stock and holds it in place. Be sure the stock is as far in as possible. Now, using the tension bars, clamp the chuck closed on the stock by turning the right disk clockwise and the left disk counterclockwise. Remove the tension bars before operating the lathe. If the power light on the front panel of the lathe is not on, turn on the lathe by pressing the switch located on the left side panel of the lathe. It will take a minute or so for the lathe to initialize and the Main Menu to appear. Close the cover. 82 Module Guide

89 You need to use the control panel keypad on the front panel of the lathe to move the cutter to the end of the stock. Select Manual from the lathe control panel Main Menu. If the cursor is not next to Manual, use the X keys to move the cursor to it. Press ENTER to select Manual. Using the +Z and Z keys, position the left edge of the cutting tool along the right outside edge of the stock. Use the +X and X keys to position the tool on the very edge of the stock. Press the SPINDLE SPEED key to access the Spindle Speed menu. Press the +Z key to turn the spindle on. The exact speed is not important. Press ENTER to return to the Manual menu. Use the X key to move the tool up just enough to remove a thin thread from the edge. Press SPINDLE SPEED, then ZERO to stop the spindle. Press ENTER to return to the Manual menu. Set the X offset value by pressing ZERO, +X and enter the diameter of the stock by pressing the appropriate number keys, in this case.75, then ENTER. Although it is the diameter that is entered, the radius (which is the distance needed) is displayed in the Manual menu. Module Guide 83

90 The Z offset is the distance from the outer edge of the stock (current position of the tool) to a point on the stock just in front of the chuck. It is equal to the length of the stock indicated in the Program Setup screen for the part to be turned (the Z component of the stock size). Set the Z offset by pressing ZERO, +Z and press 0 then ENTER. The PRZ is now set. Return to the Main Menu by pressing ESC. Go to the next section, SAFETY NOTES. Safety Notes Use caution at all times. Lifting the cover or pressing the EMERGENCY STOP button while the lathe is running will shut off power to the lathe and cause complete program loss. Always wear eye protection. Before operating the lathe, be sure to remove any loose objects from inside the lathe cabinet. Complete the next section, DOWNLOADING YOUR PART PROGRAM. Downloading Your Part Program You should have your program loaded, the workpiece loaded, and the PRZ set. You are now ready to download your part program. On the lathe control panel, use the +X key to move the cursor next to Remote Serial and press Enter. The lathe s display now reads: Ready to Download <Esc> Abort From the Lathe pull-down menu on your computer desktop, select Download Program via Serial port. The Serial Download screen appears. The Remote Machine field tells you that you are downloading to a lathe. 84 Module Guide

91 The Status field tells you that you are ready to download and the Last Error field tells you that there are no errors. If an error occurs, this field displays the error message code for the problem. If this happens, ask your instructor for help. Click the Download button. Look at the display on the lathe s control panel and you will see Downloading and a rotating cursor indicating that your part program is being downloaded to the lathe. When the Download Complete screen is displayed on the lathe control panel, your part program has been downloaded. Click OK to close the Download Program via Serial Port window. Close the demo1 Part Program Editor window. Go to the next section, EXECUTING YOUR PART PROGRAM. Executing Your Part Program You are now ready to execute your part program. Remember to always wear safety glasses when operating the lathe. Once your part program has been downloaded to the CNC Lathe, the control panel s display will read: Download Complete <Enter> Machine Part <Esc> Abort Press Enter to begin machining your part program. As the program executes, the display will change to show the current x and z positions; spindle speed, feed rate, and G-code. Watch the lathe closely to make sure that you will not have a tool crash. After the program has finished, the tool will return to its home position and the lathe will stop. Go to the next section, CLEANUP. Module Guide 85

92 Cleanup Press Esc to return to the lathe Main Menu. Press the EMERGENCY STOP button. Open the safety doors and use the tension bars to remove the workpiece. Turn off the power switch located on the left side panel of the lathe. Clean up your area and return everything to its proper place. Using a brush or a shop vacuum, carefully clean out the inside of the lathe. Go to the next section in the presentation. 86 Module Guide

93 Lesson 5, Procedure From the File pull-down menu, select New and then Script Program. In the Program Information window, type Lesson 5 in the Project field and enter your name in the Author field. Make sure that Inches is selected under Units. Make sure that Absolute is selected under Coordinate Type. Make sure Plastic (Delrin) is selected under Material Type. If you are using wax, select Wax. Also check to make sure that the PRZP is X 0.75 and Z -1.5 inches. When you are done, click OK The Part Program Editor window appears. NOTE: On the left are command line numbers to the right of which the commands are entered. After you enter these commands, if there are any mistakes, the line containing the mistake will be highlighted when the program is compiled. There will be a blinking insertion point alongside line 00001, followed by the word END. Part Program Editor Window Module Guide 87

94 On line 00001, Type G20. This tells the program you will be working in inches. Press the Enter key on your keyboard. The blinking insertion point moves to line On line 00002, type V10 R.03 then press Enter. V10 tells the computer that you are asking for a rough cut, and.03" indicates the total amount of material to be removed on each rough cut pass. On line 00003, type V11 R.01 then press Enter. V11 tells the computer that you are asking for a final finishing cut of.01", which is the total amount of material to be removed on each finish cut pass. On line 00004, type M04 S1300 then press Enter. The code M04 turns on the spindle, and S1300 sets the speed at 1300 RPM. On line 00005, type F3 then press Enter. This sets the feed rate for the tool post at 3 inches per minute. NOTE: The commands up to this point are modal commands. This means that all further actions will incorporate these commands until they are changed to something else. On line 00006, type G00 X.375 Z0 and press Enter. This command moves the tool from the home position to a point 1.55" away from the material along the z-axis. From the Lathe pull-down menu select Emulate to compile your program. The Compiling window appears indicating whether or not there are errors in the program. If there are errors, the program will highlight the line(s) where the error occurs. If there are no errors, the message, No errors detected appears in the Error field. Correct any errors in the program by editing the appropriate line(s). When all errors are corrected, click Cancel. On line 00007, type G81 X.3 Z -1.1 and press Enter. This is a turning command. G81 is a turning cycle command. This means that all you need to provide is the finish (or end) position and the turning cycle will begin from the current position (X1.5 Z1.55). From the Lathe pull-down menu, select Emulate. The Compiling appears. There should be no errors. 88 Module Guide

95 Click OK. The Lathe 3D Emulator window appears. Click the green Start Simulation button to simulate the part. When the simulation is finished, it should look like the screen below. This is the first actual machining of the part. Close the Lathe 3D Emulator. On line 00008, type G00 X.3 Z0 then press Enter. This moves the tool to the start point for the next cut. On line 00009, type G81 X.2 Z-.4 then press Enter. This creates the next turn. Highlight the G81 code in your program. Press F1 and the Glossary (Help) screen appears with information on the G-code you have highlighted. You can also click the Help Topics button and select any of the G- and M-codes that appear on the Help Topics screen. If you ever have a question about a code, use the Help screen. Click on the x in the upper-right corner to close the Glossary screen. On line 00010, type G00 X.2 Z0 then press Enter. This is another positioning, or setup, command. Module Guide 89

96 On line 00011, type G00 X.2 Z-.2 then press Enter. This is also a setup command. On line 00012, type G03 X0 Z0 R0.4 and press Enter. The G03 command is a counterclockwise arc. From the Lathe pull-down menu, select Emulate. Once again, the Compiling window appears. There should be no errors. If you have an error, correct it in the line of code highlighted in the Editor window. When you are done, click OK. The Lathe 3D Emulator appears. Before pressing the green Start simulation button, press the Step simulation button several times to get a step-by-step indication of how the part will be cut. Close the Lathe 3D Emulator window. On line 00013, type G00 X.3 Z0 and press Enter. On line 00014, type G00 X.3 Z-.75 then press Enter. Lines and are setup commands. NOTE: The purpose of having more than one setup or positioning command is to prevent tool crashes from occurring. On line 00015, type G00 X.2 Z-.4 then press Enter. This line creates a taper. On line 00016, type G00 X.2 Z-1.1 then press Enter. NOTE: The next four lines in the program clean up any loose material or edges. On line 00017, type G00 X.3 Z-.4 then press Enter. On line 00018, type G00 X.3 Z-.75 then press Enter. On line 00019, type G00 X.37 Z-1.1 then press Enter. On line 00020, type G00 X.45 Z-1.1 then press Enter. On line 00021, type M05 then press Enter. This turns off the spindle. On line 00022, type M28. This sends the tool to the home position. 90 Module Guide

97 On line 00023, type M30. This command is used to indicate the end of a program. Review your part program. It should appear as shown below. Compile and emulate the part program. Correct any errors. Module Guide 91

98 This is what the final simulation should look like. If it doesn t look like this, go back and check your program. Close the Lathe 3D Emulator window. From the File pull-down menu, select Save. Your Lesson 5 part program is now saved in the.l5 directory. You can access it at any time by simply choosing Open and then 5300 folder from the File pull-down menu. Close the Lesson 5 Part Program Editor window. NOTE: You have entered and saved a new part program. You are now going to download and machine the part. WARNING: Wear eye protection! Set the PRZ as you did in the previous lesson. If necessary, refer to SETTING THE PRZ. Next, execute the part program as you did in the previous lesson. If necessary, refer to SAFETY NOTES, DOWNLOADING YOUR PART PROGRAM, EXECUTING YOUR PART PROGRAM, and CLEANUP. Go to the next section in the presentation. 92 Module Guide

99 Lesson 6, Procedure From the File pull-down menu, select New and then CADCAM. In the Program Information window, type Lesson 6 in the Project field and your name in the Author field. This will be the name of your drawing. Check the other settings as you did in the previous lessons. Click OK. The Lathe CADCAM screen appears. Lathe CADCAM Screen Observe the important features of this screen. The long rectangle visible on your monitor is a graphic picture of your stock. You also have a graphic picture of the x- and z-axes. Because the stock is spinning, one side is the same as the other, so it is symmetrical (the same on both sides). Locate the PRZ (the point where the X and Z coordinates intersect) by using your mouse pointer and the graphic of your stock. Notice that the bottom left portion of the Lathe CADCAM screen indicates that the PRZ is designated X: 0.000, Z: Module Guide 93

100 Locate the Split Tool, Turn Cycle, Taper Cycle, and CW & CCW Cycle buttons on the left of your screen. You will use these to select the proper cutting function. See below. Remember, the area outlined in light green is the area you are working in. NOTE: Before you perform the steps in the activity, make sure the light green outlined area changes to red when you click on the desired coordinates. You are going to set the grid and the snap settings to make it easier for you to locate points on the screen. From the Control section of the toolbar click on the button Show Grid and Snap Settings and the CADCAM Spacing window will open and defaulted to the Snap tab, from spacing values select in. This measurement represents the nearest of an inch the lines will snap to when you are designing your part program. 94 Module Guide

101 Click on the Grid tab and from the Grid spacing values select in., these are the increments that will show on the Lathe CADCAM screen. It is measured in percentages of an inch. Close the CADCAM Spacing window by clicking on the red X in the upper right-hand corner of the window. Click on the Split Tool, move the mouse pointer until the Z coordinate reads and click. If you click your mouse at the wrong coordinate(s) when inserting your line, click the Join to Right button. Your screen should look like this: Click on the line and drag it to where the Z coordinate reads , and then release the mouse button. Release the mouse button after each line is dragged to the desired coordinate. Module Guide 95

102 Using the same procedure, drag the new line in the drawing to where the Z coordinate reads Drag this line in the drawing to where the Z coordinate reads Your screen should now look like this: Click on Select Tool. Move the mouse pointer to X and Z to highlight the coordinate(s). Click on Taper Cycle and go back to the same position. Click and drag the line toward the top of the screen until the X coordinate reads Your screen should now appear as shown below. 96 Module Guide

103 With the Taper Cycle still selected, click on the Z coordinate of and drag the line upward until the X coordinate reads Your screen should appear as shown below. (Make sure the triangle is still selected.) Click the Clockwise Arc Cycle, and click on the diagonal line. Your screen should appear as shown below. Module Guide 97

104 Click on Select Tool. Move the mouse pointer to X and Z to highlight the coordinates. Click on Turn Cycle and go back to the same position. Click and drag the line until X coordinate reads Click on Select Tool. Move the mouse pointer to X and Z to highlight the coordinates. Click on Taper Cycle and go back to the same position. Click and drag the line until X coordinate reads Module Guide

105 With the Taper Cycle selected, move the mouse pointer to X and Z Drag the line up to X Click on Select Tool. Move the mouse pointer to X and Z to highlight the coordinates. Click on Turn Cycle and go back to the same position. Click and drag the line until X coordinate reads Your final drawing should look like this: You will now export your CAD drawing to the Lesson 6 Part Program Editor window. Click the CAD Export to G&M Code button [the top left button in the Control section]. Module Guide 99

106 The Save As window appears. Select the 5300 folder. Enter Lesson 6" in the File name field and then click Save. Your part program is now saved in the.l5 directory. A lesson 6 part program is generated from your CADCAM drawing and displayed in the Part Program Editor window. Close the Lathe CAD window. When the Save Application window appears, click on Yes. The Save AS window appears. In the File name field type, Lesson 6 and click on Save. Now you will verify that the part program is correct and view an emulation (visual simulation) of the part program. From the Lathe pull-down menu, select Emulate. The Compiling window appears and should indicate that there are no errors detected. Click OK. Click on the green Start Simulation button on the top left corner of the screen (in the Control section). Lathe 3D Emulator Try viewing the simulation in different views by selecting the buttons in the View section. When you are done, close the Lathe 3D Emulator window. Close the Lesson 6 Part Program Editor window. Go to the next section in the presentation. 100 Module Guide

107 Lesson 7, Procedure From the File pull-down menu, select New and then CADCAM. In the Program Information window, type Lesson 7 in the Project field and your name in the Author field. Always check the defaults to make sure they conform with your program requirements. The defaults should remain the same as those selected in previous lessons. Click OK. The Lathe CADCAM screen appears. From the Control section of the toolbar click on the button Show Grid and Snap Settings and the CADCAM Spacing window will open and defaulted to the Snap tab, from spacing values select in. This measurement represents the nearest of an inch the lines will snap to when you are designing your part program. Click on the Grid tab and from the Grid spacing values select in., these are the increments that will show on the Lathe CADCAM screen. It is measured in percentages of an inch. Close the CADCAM Spacing window by clicking on the red X in the upper righthand corner of the window. You are now going to create separations, or Splits, in order to manipulate different slopes and designs in your part profile. After that you will use the Taper and Arc Cycles to shape it. NOTE: You can use the Split Tool to create separations and the Join Tools to connect them. As you create your part profile, remember that if you make a mistake, there are a few ways to correct it, such as using the Join tools or by using any of the other tool buttons. Remember that the Clear CAD Part button will completely wipe out your program. Click the Split Tool, then move the mouse pointer to Z and click. Drag the line to Z and release the mouse button. Release the mouse button after each line is dragged to the desired coordinate Drag the line to Z Drag the line to Z Drag the line to Z Module Guide 101

108 Drag the line to Z Drag the line to Z Drag the line to Z Your screen should appear as shown below. Click on Select Tool. Move the mouse pointer to X and Z to highlight the coordinate(s). Click on Taper Cycle and go back to the same position. Click and drag the line toward the top of the screen until the X coordinate reads forming a taper as shown below. 102 Module Guide

109 With the Taper Cycle still selected, move the mouse pointer to Z and X and drag the line to X See below. Click the Clockwise Arc Cycle. Click on Select Tool. Move the mouse pointer to X and Z to highlight the coordinates. Click on Turn Cycle and go back to the same position. Click and drag the line until X coordinate reads Your screen should appear as below. Click on Select Tool. Move the mouse pointer to Z to highlight the coordinate(s). Click on Turn Cycle and go back to the same position. Drag the line up to X Click the Counterclockwise Arc Cycle and drag the line down to X Click on Select Tool. Move the mouse pointer to Z to highlight the coordinate(s). Click on Turn Cycle and go back to the same position. Drag the line up to X Module Guide 103

110 Click on Select Tool. Move the mouse pointer to Z to highlight the coordinate(s). Click on Turn Cycle and go back to the same position. Drag the line up to X Click the Taper Cycle, move the mouse pointer to , and drag the line to X Your screen should appear as shown below. Click on Select Tool. Move the mouse pointer to Z to highlight the coordinate(s). Click on Turn Cycle and go back to the same position. Drag the line up to X Click on Select Tool. Move the mouse pointer to Z to highlight the coordinate(s). Click on Turn Cycle and go back to the same position. Drag the line up to X Click the Taper Cycle, move the mouse pointer to Z , and then drag the line to X Click the Join to Right on the bottom left of the Section tools area. The section selected joins with the section to the left. 104 Module Guide

111 Click the Taper Cycle, move the mouse pointer to X and Z , and then drag the line up to X Your screen should appear as shown below. Click on Select Tool. Move the mouse pointer to Z and X to highlight the coordinate(s). Click on Turn Cycle and go back to the same position. Drag the line to X The completed part profile appears as shown below. NOTE: You have just completed the CAD portion of the exercise: the design of a part. You are now going to use CAM so that the part can be machined on the lathe. Module Guide 105

112 Click the CAD Export to G&M Code button to export the CAD drawing to the Part Program Editor window. The Save As window appears, select the 5300 folder. Enter "Lesson 7" in the File name field and then click Save. Your part program is now saved in the.l5 directory with the other part programs. A lesson 7 part program is generated from your CADCAM drawing and displayed in the Part Program Editor window. Highlight to activate the CAD window. Click File, Save As, and then open the 5300 folder. Enter "Lesson 7" in the Filename field. Your CAD drawing is now saved in the *.l5c directory. Close the Lathe CAD window. Now you will verify that the part program is correct and view an emulation (visual simulation) of the program. From the Lathe pull-down menu, select Emulate. The Compiling window appears and should indicate that no errors detected. Click OK. Click the green Start Simulation button. Your part should appear as shown below. Lathe 3D Emulator Try viewing the simulation in different views. When you are done, close the Lathe 3D Emulator. 106 Module Guide

113 If the simulation was successful, you have created, compiled, and emulated a part program. WARNING: Wear eye protection! Set the PRZ as you did in Lesson 4. If necessary, refer to SETTING THE PRZ. Next, download and execute the part program. If necessary, refer to SAFETY NOTES, DOWNLOADING YOUR PART PROGRAM, and EXECUTING YOUR PART PROGRAM. When you have completed executing your part program, clean up your area. If necessary, refer to CLEANUP. Go to the next section in the presentation. Module Guide 107

114 Lesson 8, Procedure From the File pull-down menu, select New and then select CADCAM. The Program Information window appears. Enter "Lesson 8is" in the Project field and your name in the Author field. Using the micrometer or dial caliper, measure the diameter of your piece of stock. Look under the Part Reference Zero Position section. Next to X Value field. The default measurement 0.75 should already be entered. This measurement represents the diameter (x value) in terms of inches. It should be the same as the diameter you just measured. Now measure the length of your piece of stock. The default measurement -1.5 is entered in the Z- Value field. This measurement represents the length [z value] in terms of inches. It is not the same length you just measured. Although the length of your stock is actually 2.5 inches (6.35 cm), the actual usable portion of the stock is 1.5 inches (3.81 cm). The unusable portion can be divided into two parts. 1. Approximately ½ inch (1.27cm) of stock goes in the chuck. 2. The first ½ inch (1.27cm) outside the chuck is an unusable safety portion. To help prevent a tool crash, the lathe will automatically stop if the program tries to send the cutter closer than ½ inch (1.27cm) to the chuck. Check the other defaults to make sure they conform to your program requirements. When you are done, click OK. The blank Lathe CADCAM screen appears. 108 Module Guide

115 Remember that the highlighted area is the area you are working in. Using the Split Tool split your drawing into the correct lengths according to the following blueprint. First, set the snap setting like you did earlier. Make sure is selected and then close the snap window. The grid setting should remain at Using the Split Tool, create segments at the following Z coordinates: ", ", ", ", ", ", and ". The X coordinates for the lines (right to left) are ", ", ", ", ", ", ", and ". Module Guide 109

116 Now, using the blueprint as a guide, select the Taper Cycle and create the tapers on the part. When you are done, check your screen with the drawing. Click the CAD Export to G&M Code button to export the CAD drawing and generate a part program in the Lesson 6is Part Program Editor window. Save your CAD drawing and part program as you did in previous lessons. Be sure to enter Lesson 8is in the File name field, then click Save. Close the Lathe CAD window. Compile and emulate the part program. It should appear as shown below. 110 Module Guide