Lesson One: Machine Configurations

Lesson One: Machine Configurations
Turning Center Programming And Operation Note that we provide a presentation named “Introduction” to let you introduce some important points about the course. In this presentation, we’re digging in to subject matter. Lesson one is the first of seven consecutive lessons related to key concept number one. In this lesson you will introduce students to the various types of turning centers available, and to their most common programmable features. Lesson One: Machine Configurations Copyright 2002, CNC Concepts, Inc.

Key Concept Number One You must understand the machine you’ll be working with! CYCLE START FEED HOLD EDIT AUTO MDI JOG HANDLE ZERO RETURN MODE 0% 100% 200% FEEDRATE OVERRIDE 10% 25% 50% RAPID OVERRIDE 1 12 TURRET INDEX 2 3 4 5 6 7 8 9 10 11 SLOW FAST EMERGENCY STOP FANUC 10T POWER ON OFF O N G P A X Y Z Q B I J K R C F D H L # M S T / EOB U V W Sp E ? @ , [ ] ( ) * PAGE CURSOR SHIFT - + = CAN RESET START CALC INPUT NC/PC AUX X Z X1 X10 X100 ON DRY RUN SINGLE BLOCK MACHINE LOCK OPTIONAL STOP BLOCK DELETE X+ X- Z- JOYSTICK Z+ SPINDLE ORIGIN 130% SPINDLE LOAD AXIS LOAD OD ID CLAMP DIRECTION MEMORY PROTECT CHUCK TAILSTOCK From operator’s viewpoint Key concept #7 In key concept #1 we look at the machine from a programmer’s viewpoint Key concept #1 From programmer’s viewpoint Lesson one is part of key concept number one, Know Your Machine. You must point out that it is from two distinctly different perspectives a beginner must understand the CNC turning center. Here, in key concept number one, we concentrate on having the student view the machine from a programmer’s viewpoint. Later, in key concept number seven, we’ll have them look at it from an operators standpoint. In key concept #7 we look at the machine from an operator’s viewpoint

You must understand the machine you’ll be working with!
Key Concept Number One You must understand the machine you’ll be working with! Seven Lessons Machine configurations Understanding turning center feeds and speeds General flow of CNC Usage Visualizing the execution of a CNC program Understanding program zero Determining program zero assignment values Three ways to assign program zero We begin each key concept by listing the lessons related to the key concept. Here are the seven lessons related to key concept number one.

You must understand the machine you’ll be working with!
Key Concept Number One You must understand the machine you’ll be working with! Seven Lessons Machine configurations Understanding turning center feeds and speeds General flow of CNC Usage Visualizing the execution of a CNC program Understanding program zero Determining program zero assignment values Three ways to assign program zero

Seven Lessons This is the longest of the key concepts! Key Concept
Number One You must understand the machine you’ll be working with! Seven Lessons Machine configurations Understanding turning center feeds and speeds General flow of CNC Usage Visualizing the execution of a CNC program Understanding program zero Determining program zero assignment values Three ways to assign program zero This is the longest of the key concepts!

Machine Configurations
Lesson Number One: Machine Configurations

Lesson One Lesson Plan Basic machining practice Machine configurations
Universal slant bed Chucker slant bed Twin spindle horizontal Single/twin spindle vertical Mill/turn machines Programmable functions

Lesson One Lesson Plan Basic machining practice Machine configurations
1 Basic machining practice Machine configurations Universal slant bed Chucker slant bed Twin spindle horizontal Single/twin spindle vertical Mill/turn machines Programmable functions Each lesson begins with a lesson plan to help you introduce the main topics of the lesson. Here is the lesson plan for lesson number one. Note that each lesson plan will also point out the page number at which the lesson begins in the student manual (in upper right corner).

Presentation links Key concept #1 Basic machining practice
Machine configurations Universal slant bed Chucker Twin spindle horizontal Sub-spindle Single spindle vertical Twin spindle vertical Mill / turn Gang style Sliding headstock Programmable features Turret Spindle Feedrate Coolant This slide (with underlined topics) provides hypertext links to each of the topics. Notice the return button at the lower left hand corner of each slide. Clicking on it at any time will return you to this slide. This will provide you with several ways to make presentations. 1) Make the entire presentation You can simply skip this slide (advance to the next slide) if you want to make the entire presentation. Just remember that if you get into an area that you’d not like to cover at the present time, you can always click the return button to come back to this slide. 2) Skipping topics To skip topics all together, simply click on the topic at which you’d like to start. When finished, click the return button to come back to this page. This makes a great way to get around if you ended the last session at the end of one of the topics. 3) Use the elevator bar to get to a specific slide. Remember that in the full version of PowerPoint (not just the viewer), you can click on the elevator bar and move it to bring the presentation to a specific slide. The slide numbers at the top of each of these pages (instructor notes) match slide numbers in the actual presentation. 4) Bullet points for reviews Having this slide available when you review will allow you remember to recap all important topics. If students are confused during your review, you can quickly jump to the topic in question and re-present the material.

Basic Machining Practice
The Key To Proper CNC Machine Usage! We assume that students entering this course already know basic machining practice as it relates to turning centers. Here we simply list those things the student should already know. Depending upon the level of your own students, you may have to dive deeper, explaining more about basic machining practice. However, if students know little in this area, it should be taken as a signal that they should take a course specifically for basic machining practice. We do provide a lengthy presentation in the student manual about the kinds of machining operations turning centers can perform. While this will acquaint students with many important points about those things a student must know to complete this course, it is not intended to replace a full course on basic machining practices. You must understand basic machining practice as it relates to turning centers

Though basic machining practice is beyond the scope of this course…
…you must understand: Machining operations Like: Rough turning/finish turning Rough boring/finish boring Drilling Tapping Threading Grooving/necking Knurling

Development of the machining order by which the workpiece is produced
Though basic machining practice is beyond the scope of this course… …you must understand: Machining operations Processing Development of the machining order by which the workpiece is produced Processing:

…you must understand: Machining operations Processing Cutting conditions You must be able to determine spindle speed, feedrate, and depth of cut based upon cutting tool material workpiece material, and rigidity of setup

You must be able to design safe work-holding setups
Though basic machining practice is beyond the scope of this course… …you must understand: Machining operations Processing Cutting conditions Work-holding setups You must be able to design safe work-holding setups

…you must understand: Machining operations Processing Cutting conditions Work-holding setups Blueprint reading, dimensioning, etc. You must understand all aspects of basic machining practice in order to write safe, workable CNC programs

If you feel weak in your basic machining practice skills…
Though basic machining practice is beyond the scope of this course… …you must understand: If you feel weak in your basic machining practice skills… Machining operations Processing Cutting conditions See pages 1-1 through 1-37 in the student manual! Work-holding setups Blueprint reading, dimensioning, etc. You must understand all aspects of basic machining practice in order to write safe, workable CNC programs

Machine Configurations
This series of slides helps you explain the various types of turning centers available. However, you may wish to minimize how much you present to avoid confusing newcomers with too many machine types. We recommend showing just those machine types that you know your students will be working with in class (and in the near future). Generally speaking, this means two axis universal slant bed turning centers. Turning centers are available in several styles

There are many forms of CNC turning centers…
Universal slant bed Chucker slant bed Twin spindle horizontal Single spindle vertical Twin spindle vertical Mill/turn machines Gang type Sliding headstock Here is a list of machine types that we provide introductions to. Again, (using the presentation links slide) you may want to show only the style of machine that you know students will be working with. In all cases… X will be the diameter controlling axis Z will be the length controlling axis

Universal slant bed Chucker slant bed Twin spindle horizontal Single spindle vertical Twin spindle vertical Mill/turn machines Gang type Sliding headstock In all cases… X will be the diameter controlling axis Z will be the length controlling axis

Universal style slant bed turning center
Front view of machine Universal style slant bed turning center

Headstock & Spindle Universal style slant bed turning center
We show the components of each machine type. Universal style slant bed turning center

Work-holding Device Universal style slant bed turning center

Body Quill Center Tailstock Universal style slant bed turning center

Turret Universal style slant bed turning center
This is the last slide in a series that helps you introduce the most basic components (headstock, chuck, tailstock, and turret). Universal style slant bed turning center

That’s why it’s called a “universal” style
A universal slant bed turning center can perform all types of turning applications: Chucker work Shaft work Bar work This slide helps you explain why this machine type is called a universal style. Universal style slant bed turning center

- + Z Axis Universal style slant bed turning center
The next series of slides is an animation that helps you illustrate the Z axis. After that, we show the X axis. Universal style slant bed turning center

Z Axis - + Universal style slant bed turning center

- + Z Axis Universal style slant bed turning center
Z is the length controlling axis Z Axis - + Universal style slant bed turning center

X Axis - + Universal style slant bed turning center

- + X Axis Universal style slant bed turning center
X is the diameter controlling axis Universal style slant bed turning center

- + X is DIAMETER X3.0 X Axis Universal style slant bed turning center
If you want to turn a 3.0 inch diameter… X Axis 3.000 - X3.0 Also be sure to point out that, for most turning centers, the X axis specifies the diameter of the workpiece being machined. X3.0 will be the commanding word Universal style slant bed turning center

- + X is DIAMETER X3.0 Once again:
X Axis Once again: X is always the diameter-controlling axis Z is always the length controlling axis 3.000 - Also: X+: always gets bigger in diameter Z+: always away from the spindle Upcoming slides help you illustrate all other popular forms of CNC turning centers. Point out that they all share two things in common. X always controls diameter – Z always control workpiece length. And X plus is always getting bigger in diameter – Z plus is the direction away from the spindle face. X3.0 Though some machine tool builders reverse the polarity of the X axis Universal style slant bed turning center

Universal slant bed Chucker slant bed Twin spindle horizontal Single spindle vertical Twin spindle vertical Mill/turn machines Gang type Sliding headstock Because it is the most popular turning center style, examples in this course stress this machine type In all cases… X will be the diameter controlling axis Z will be the length controlling axis

Headstock Chuck Turret NO Tailstock!
Same basic components, but… Headstock Chuck Turret NO Tailstock! We do the same things for chucker style, twin spindle horizontal style, single spindle vertical style, and all other styles of CNC turning centers. First we introduce the main components - and then we introduce the axes (including polarity). Chucker style slant bed turning center

A chucker-style turning center cannot perform shaft work!
X Axis - + X is still the diameter controlling axis… …Z is still the length controlling axis Z Axis - + Z travel is usually quite short A chucker-style turning center cannot perform shaft work! Graphic for chucker style slant bed turning center. Chucker style slant bed turning center

Separator Spindle 1 Spindle 2 Turret 1 Turret 2
View of machine from above Separator Spindle 1 Spindle 2 Turret 1 Turret 2 Twin spindle horizontal bed style

Separator This machine is like having two independent chucker-style machines in one! Spindle 1 Spindle 2 Turret 1 Turret 2 Twin spindle horizontal bed style

- - - - + + + + Once again: X is always the diameter-controlling axis
Z Axis - + Z Axis - + Once again: X is always the diameter-controlling axis Z is always the length controlling axis - + X Axis - + X Axis And also: X+: always gets bigger in diameter (regardless of which spindle) Z+: always away from the spindle

Z Axis - + Z Axis - + When it comes to axis movements, a program can be run in either spindle! - + X Axis - + X Axis

Universal slant bed Chucker slant bed Twin spindle horizontal Single spindle vertical Twin spindle vertical Mill/turn machines Gang type Sliding headstock Some two-spindle turning centers have opposing spindles – commonly called “sub-spindle” turning centers… In all cases… X will be the diameter controlling axis Z will be the length controlling axis

Main spindle Sub-spindle Main spindle turret Sub-spindle turret
Sub-spindle turning center Main spindle Sub-spindle Main spindle turret Sub-spindle turret

- - - - + + + + X Axis Z Axis X Axis Z Axis Sub-spindle turning center
Again, X controls diameter, Z controls length Z Axis - + X Axis + - Z Axis + -

Sub-spindle turning center
This kind of machine can machine both ends of the same workpiece in one cycle Half-way through the cycle, the workpiece is transferred from the main spindle to the sub-spindle…

1) Machine first half

2) Sub-spindle extends

3) Sub-spindle retracts
Sub-spindle turning center 3) Sub-spindle retracts

4) Machine second half in sub-spindle
Sub-spindle turning center 4) Machine second half in sub-spindle

Universal slant bed Chucker slant bed Twin spindle horizontal Single spindle vertical Twin spindle vertical Mill/turn machines Gang type Sliding headstock Some two-spindle turning centers have opposing spindles – commonly called “sub-spindle” turning centers In all cases… X will be the diameter controlling axis Z will be the length controlling axis

Single Spindle Vertical Style
Front view of machine Turret Spindle

Single Spindle Vertical Style
Turret This kind of turning center is popular with very large, heavy workpieces… The workpiece weight helps hold the it in place in the work-holding device! Spindle

- - + + Again, X controls diameter, Z controls length
Z Axis Single Spindle Vertical Style Again, X controls diameter, Z controls length - + X Axis

Turret 1 Turret 2 Spindle 1 Spindle 2 Separator
Twin spindle vertical style Turret 1 Turret 2 Spindle 1 Spindle 2 Separator

Twin spindle vertical style
Turret 1 Turret 2 This machine is like having two single-spindle vertical turning centers in one! Spindle 1 Spindle 2 Separator

- - - - + + + + Z Axis Z Axis X Axis X Axis
Same rules for axis directions and polarity Z Axis - + - + Z Axis - + X Axis - + X Axis

Any of the machine types shown so far could be a mill/turn machine!
Mill/Turn Machines

Could be a drill, tap, reamer, end mill, etc.
These machines can rotate cutting tools (called live tooling) We also include visuals to help you describe mill/turn machines. Mill/Turn Machines

And tool could be placed along X or Z
These machines can rotate cutting tools (called live tooling) Mill/Turn Machines

Additionally, the main spindle has two “modes”: Normal turning mode
Live tooling mode The live tooling mode engages a rotary device. It could be: Indexer Full rotary axis C axis These machines can rotate cutting tools (called live tooling) Mill/Turn Machines

This kind of machine can perform operations commonly thought of as machining center operations…
…completing many workpieces that would normally require secondary operations Mill/Turn Machines

Tooling table Spindle Tool holder Gang type

- - + + The entire tooling table moves! X- X+
X Axis X- Due to X axis, these machines tend to be a little complicated to program and operate X+ - + Z Axis Tool change time is almost nothing! Gang type

- + X Axis Gang type machines tend to be quite small and are used for higher production quantities and commonly have bar feeders - + Z Axis Gang type

- + X Axis Tool only moves in X axis These machines are also called Swiss type Workpiece moves in Z axis! + Z Axis - These machines always have bar feeders and are used for small workpieces Sliding headstock type

There are many kinds of CNC turning centers!
There are many forms of CNC turning centers… Universal slant bed Chucker slant bed Twin spindle horizontal Single spindle vertical Twin spindle vertical Mill/turn machines Gang type Sliding headstock There are many kinds of CNC turning centers! In all cases… X will be the diameter controlling axis Z will be the length controlling axis

Programmable Features
This series of slides helps you describe the most popular programmable features of turning centers. All turning centers have several important programmable features

All turning centers have certain programmable features…
Turret index Spindle activation Feedrate Coolant Some turning centers have additional programmable features… Jaw open/close Tailstock positioning Door open/close Others? Here are the most popular programmable features. With upcoming slides, you’ll be introducing them one by one.

Turret index Spindle activation Feedrate Coolant Some turning centers have additional programmable features… Jaw open/close Tailstock positioning Door open/close Others?

Turret station number & geometry offset number
Turret index: We’ll discuss wear offsets in key concept number four Four digit T word… Wear offset number T0101 Turret station number & geometry offset number We’ll discuss geometry offsets later in key concept number one

Turret station number & geometry offset number
Turret index: Four digit T word… Wear offset number T0101 Turret station number & geometry offset number In this series of slides, you explain that the turret of a turning center is programmable. A T word specifies the turret index and with most machines, it is a four digit word. The first two digits specify the station number and geometry offset number. The second two digits specify the wear offset number. With most turning centers, the turret will simply take the shortest direction to the commanded station (bi-directional turrets)

T0101 Turret index: Four digit T word… Wear offset number
Turret station number & geometry offset number M codes are Miscellaneous functions (also called Machine functions) With some machines, the turret rotation direction can be specified with two M codes Most vary from builder to builder Example: M32 – clockwise M33 – counter clockwise

Spindle is programmable in four ways:
Spindle activation: Spindle is programmable in four ways: Speed type Speed Direction Range Point out that the spindle is programmed in four ways. Upcoming slides help you illustrate each way.

G codes are called preparatory functions
Spindle activation: G codes are called preparatory functions Spindle is programmable in four ways: Speed can be specified in revolutions per minute (rpm mode) Speed type Speed Direction Range G97 or Speed can be specified in surface feet per minute or meters per minute (depending upon measurement system) G96 This is called constant surface speed mode

G codes are called preparatory functions
Spindle activation: G codes are called preparatory functions Spindle is programmable in four ways: Speed can be specified in revolutions per minute (rpm mode) Speed type Speed Direction Range G97 We devote lesson number two to constant surface speed! or Speed can be specified in surface feet per minute or meters per minute (depending upon measurement system) G96 This is called constant surface speed mode

Spindle activation: Spindle is programmable in four ways: Speed type Speed Direction Range

S word Spindle activation: Spindle is programmable in four ways:
Speed type Speed Direction Range S word Again, more on constant surface speed in lesson two Specifies speed in rpm or sfm G96 S600 (600 sfm) G97 S600 (600 rpm)

Three M codes are related to spindle activation
Spindle is programmable in four ways: Speed type Speed Direction Range Three M codes are related to spindle activation M03: On in fwd direction M04: On in rev direction M05: Off Use fwd (M03) for right hand tools Use rev (M04 for left hand tools

Spindle is programmable in four ways: G96 S400 M03
Spindle activation: Examples: Spindle is programmable in four ways: G96 S400 M03 (turn spindle on fwd at 400 sfm) G97 S400 M04 (turn spindle on rev at 400 rpm) M05 (turn spindle off) Speed type Speed Direction Range Three M codes are related to spindle activation M03: On in fwd direction M04: On in rev direction M05: Off Use fwd (M03) for right hand tools Use rev (M04 for left hand tools

Most turning centers have more than one spindle range
Spindle activation: Most turning centers have more than one spindle range Just like the transmission in a car… … lower ranges offer power, higher ranges offer speed You must understand your machine’s power characteristics!

Spindle activation: An example (machines vary!) Power (hp) Speed (rpm)
2,000 5,000 30 Low range High range

A general rule of thumb:
Spindle activation: An example (machines vary!) Speed (rpm) Power (hp) 2,000 5,000 30 Low range High range A general rule of thumb: Rough in the low range Finish in the high range

Spindle is programmable in four ways:
Spindle activation: Spindle is programmable in four ways: Speed type Speed Direction Range M codes select spindle range M41: Low range M42: High range Again, M codes vary – You must check in your machine manual to find the related M codes

You can specify the feedrate for cutting motions in one of two ways…
Inches or millimeters per minute In “per minute” fashion or In “per revolution” fashion G99 Inches or millimeters per revolution An F word specifies the feedrate Explain that feedrate is also programmable – and it can be handled in two ways – feed per revolution and feed per minute. Upcoming slides help you illustrate how. In inch mode: G99 F0.005 (0.005 inches per revolution) G98 F15.0 (15.0 inches per minute)

You can specify the feedrate for cutting motions in one of two ways…
Use “per revolution” (G99) for almost all cutting operations G98 Inches or millimeters per minute In “per minute” fashion or In “per revolution” fashion Use “per minute” (G98) whenever you want to make a feedrate movement with the spindle stopped G99 Inches or millimeters per revolution An F word specifies the feedrate In inch mode: G99 F0.005 (0.005 inches per revolution) G98 F15.0 (15.0 inches per minute)

Two more M codes control flood coolant:
M08: Turn flood coolant on M09: Turn flood coolant off Coolant is, of course, used to cool and lubricate the cutting operation Next point out that flood coolant is also programmable.

Turret index Spindle activation Feedrate Coolant Some turning centers have additional programmable features… These functions are almost always handled with M codes Jaw open/close Tailstock positioning Door open/close Others? Be sure students understand that turning centers vary when it comes to how many programmable features they have.

Turret index Spindle activation Feedrate Coolant Some turning centers have additional programmable features… Jaw open/close Tailstock positioning Door open/close Others? Check in your machine’s programming manual to see if you have any other programmable features!

Lesson One Lesson Summary
Basic machining practice Machine configurations Universal slant bed Chucker slant bed Twin spindle horizontal Single/twin spindle vertical Mill/turn machines Programmable functions

Do practice exercise number one!

Lesson One: Machine Configurations

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