Programming

Manual
For all Doosan Machining Centers Using
Fanuc Controls

Phil Misseldine 2007

Forward
While similar in appearance your CNC Machining Center operates somewhat differently
from your conventional mill. Although they may share the same work envelope and number of
axis the CNC does not have the array of knobs, levers or handles associated with the manual
machine. In place of these are motors that move the X, Y, and Z-axis. The axis motors receive
commands from the control, which is user programmed with a series of instructions.
It is these instructions which determine the shape of the part to be machined.

Notice of Disclaimer
This manual is intended not to replace but to supplement the control
manufactures original manual. The control manufactures manual will be the final say in any
discrepancy that may evolve.

Introduction to Programming
Programming of your Doosan Machining Center involves the sequential
study of the operations required to produce a component, using established
engineering methods.

Finished
Part

Study Part
Drawing

Methodize
the Part

Program
the Part

Set up
Machine

Machine
Part

Example
S4000 M03
Set spindle speed to 4000 (S4000) and turn on spindle clockwise (M03).
A number of Words can be programmed on the same line. Once the line is complete this
forms a Block of information.

Example of a Block
N40 G1 X20.0 Y-8.0 F80.
It contains the Words:
N40, G1, X20.0, Y-8.0, F80.
The Addresses used are N, G, X, Y, and F,
and the values are 40, 1, 20.0, -8.0 and 80.

Most Commonly Used G-Codes

G-Code

Function

G00
G01
G02
G03
G04
G05
G08
G09
G10
G11
G17
G18
G19
G20
G21
G28
G30
G40
G41
G42
G43
G49
G54
G55
G56
G57
G58
G59
G65
G73
G80
G81
G83
G84
G86
G90
G91
G92
G94
G95
G98
G99

Rapid Positioning
Feedrate Positioning
Arc Clockwise
Arc counter Clockwise
Dwell
High Speed Machining
Look Ahead Control
Exact Stop
Data Setting
Data Setting Cancel
X and Y Plane Selection
Z and X Plane Selection
Y and Z Plane Selection
Input in Inch
Input in Metric
Return to Reference Position
Return to 2nd Reference Position
Cutter Compensation Cancel
Cutter Compensation Left
Cutter Compensation Right
Tool Length Compensation
Tool Length Compensation Cancel
Work piece Coordinate System 1
Work piece Coordinate System 2
Work piece Coordinate System 3
Work piece Coordinate System 4
Work piece Coordinate System 5
Work piece Coordinate System 6
Macro Call
High Speed Peck Drilling
Canned Cycle Cancel
Drilling Cycle
Peck Drilling Cycle
Tapping Cycle
Boring Cycle
Absolute Command
Incremental Command
Setting Work Coordinate System
Feed Per Minute
Feed Per Rotation
Return to Initial Point in Canned Cycle
Return to R Point in Canned Cycle

Standard
Standard
Standard
Standard
Standard
Optional
Optional
Standard
Optional
Optional
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard

For a complete G-code list please refer to your Fanuc manual.

4

Most Commonly Used M-Codes

M Code
Function
M00
Program Stop
M01
Optional Stop
M02
Program End
M03
Spindle Clockwise Rotation
M04
Spindle Anti - Clockwise Rotation
M05
Spindle Stop
M06
Tool Change
M07
Thru-Spindle Coolant On
M08
Flood Coolant On
M09
Coolant Off (all coolant)
M10
Table (Pallet) Clamp
M11
Table (Pallet) Unclamp
M12
Shower Coolant On
M14
Spindle Air Blow On
M15
Spindle Air Blow Off
M16
Air Blast for Tool Setter
M18
Air Blast off
M19
Spindle Orientation
M29
Rigid Tapping Mode (Fanuc only)
M30
Program End & Rewind
M50
Auto Door Open
M51
Auto Door Close
M54
Parts Count
M60
Pallet Change
M61
Load Pallet 1
M62
Load Pallet 2
M66
ATC & APC Change with one command
M76
Fixture 1 Clamp
M77
Fixture 1 Unclamp
M84
G01 Possible with spindle stopped
M86
Fixture 2 Clamp
M87
Fixture 2 Unclamp
M98
Sub-Program Call
M99
Sub-Program End
* Not standard on all machining centers

Vertical
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard*
Standard
Standard
N/A
N/A
Optional
Standard
Standard
Optional
Optional
Standard
Standard
Standard
Optional
Optional
Standard
Standard
Standard
Standard
Standard
Optional
Optional
Standard
Optional
Optional
Standard
Standard

Horizontal
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Standard
Optional
Standard
Standard
Optional
Optional
Standard
Standard
Standard
Optional
Optional
Standard
Standard
Standard
Standard
Standard
Optional
Optional
Standard
Optional
Optional
Standard
Standard

For a complete M-code list please refer to your Doosan Manual.

5

Control Panel

O( N

RESET

POWER
ON

HELP

M
F

SHIFT

OFF

,
#
[

S
D

=
]

GE P
C

ALTER

INSERT

K@ R

DELETE

EOB

CAN

INPUT

POS

PROG

OFFSET
SETTING

CUSTOM

SYSTEM

MESSAGE

GRAPH

T
H

*
&

SP

PAGE
PAGE

TAPE

MDI

80
REF.RTN.

25
REF.POINT

100

120
ON

130

50

FO

EDIT

40

OFF

140

20

HANDLE

EMERGENCYSTOP

100

60

JOG

MEMORY

WORK
LIGHT

SPINDLE

FEEDOPERATION

MODE

MODESELECT

RAPIDOVERIDE

4TH

180

0
FEEDRATEOVERIDE

40

ALARM

50
60

30
80
M02/M30 LUB. MACHINE

20
90
10

MACHINEREADY EMERGENCYRELEASE

AXISSELECT
FEEDHOLD

RAPID

CYCLESTART

100

SPINDLEOVERIDE

RESET

FUNCTION
FLOOD

ON

SINGLEBLOCK OPTIONAL STOP OPIONAL BLOCKSKIP DRYRUN

OFF
PROGRAMRESTART

CONVEYOR

MANUAL
AUTO

THROUGH

OFF
COOLANT

MACHINELOCK

PROGRAMPROTECT

CW

STOP

Doosan Machining Centers uses the following Fanuc Controls:

0i MB
21i MB
18i MB
16i MB

All screen pictures in this manual are from the 18i control
and may differ from the control you are running.

CCW

Axis Movement

Every Vertical Machining Center

has three axes:
X - side to side
Y - forwards and backwards
Z - up and down

All Horizontal Machining Centers have

four axes:
X - side to side
Y - up and down
Z - forwards and backwards
B - rotary

Manual Pulse Generator

X1

4TH

X10

X100

+
0
90

10

80

20

70

30
40

60
50

The Manual Pulse Generator (MPG) or Hand Wheel is used during the
setup of the machine.
This is separate from the machine control and gives better control of all
axis during setup.

TOOL LENGTH OFFSET

When a cutting tool is inserted into its holder, the cutting edge is located at an
imprecise distance from the gauge line of the holder. By specifying G43 and the
corresponding offset value (H) it is possible to compensate the difference
without changing the part program.
This is known as the Tool Offset Value and is unique to the tool in the spindle.

Z Axis Home Position

Tool Length Offset

Distance

Workpiece

Tool Length Setting Method

Using a combination of the jog buttons

and MPG, bring the tool down to the
predetermined "Z" point.

Work piece

Press the function key

Operators choice of
'Z' zero position.
(This example uses the
top of the work piece).

OFFSET
SETTING

and then the [OFFSET] soft key to display the following screen.

Cursor down to Tool Number to be set.

Key in value displayed in Actual Position (Relative) and press INPUT.
10

Tool Offset Memory 'C' (Optional)

Tool Offset Memory 'C' allows you to use the same number for
Length (H) and Diameter (D) offsets.

Press the function key

OFFSET
SETTING

and then the [OFFSET] soft key to display the following screen.

Cursor down to tool number to be set.

Press 'Z' and then the 'INP.C' soft key.
Position value is automatically transferred in to the offset.

If using height and cutter compensation for the same tool the program should look
like this
N15 G43 Z.10 H1
N20 G41 X-5.0 D1
You also have the ability to adjust the tool length and diameter in the wear column.

11

Work Coordinates
Every CNC machine has a reference or machine zero. This is a position that is constant to the machine.
When a machine is turned on or powered up by the operator it must first be referenced.
When the machine reaches its limit switches the control registers this location as home. Using the home
position as a reference you can now tell the control where the work piece is located on the machine table.

Machine Home Position

(X, Y, Z Ref. Point)

'X' Zero point

'Y' Zero point

W ork Piece

Machine Table

12

Work Coordinate System Setting Method

To set the work piece co-ordinates the user has the choice of six
co-ordinate systems to choose from G54 to G59.

Press function key

OFFSET
SETTING

and then the [WORK] soft key to display the following page.

Method
Using an edge finder or indicator locate the part datum position. Without moving go
to the work offset screen and highlight desired offset. Press
hard key X, hard key 0 soft key [measure]
hard key Y, hard key 0 soft key [measure]
(Position value is automatically transferred in to Offset).

13

Work Coordinate System G54 - G59 and G54.1 P1 -P300

The desired Work Coordinate number should always be called at the start of every tool.
Example.
N4 (.75 DIA. ENDMILL )
N5 G0 G54 G90 X-2.25 Y.625 S8000 M3
N6 G43 Z.1 H1
N7 G1 Z-1. F25

Work Coordinate System Addition

This option expands the Work Coordinate System giving the user up to 300 sets of work
offsets to chose from.

Work Coordinate System Addition's are called in the following way.

Example.
N4 (.75 DIA. ENDMILL )
N5 G0 G54.1 P1 G90 X-2.25 Y.625
S8000 M3
N6 G43 Z.1 H1
N7 G1 Z-1. F25
14

PROGRAMMING
Linear Interpolation (G00/G01)

GOO Rapid Traverse path (Axis will take the shortest path at 45 degrees)

P2
X

G00 Rapid Path

G01 Feedrate Path

GO1 Feedrate path ( Axis will travel in a staight line)

P1

All axis of the machine tool will move in linear at either

RAPID or FEEDRATE traverse rates.
Any movement preceded by G00 will occur at RAPID traverse
G00 X4.0 Y-3.0
Any movement preceded by G01 will occur at FEEDRATE.
G01 X4.00 Y-3.00 F100.

These commands are MODAL and will stay

in effect until changed.

15

Co-Ordinate Programming (G90/G91)

Absolute co-ordinate programming (G90)

In absolute programming all dimensioning is taken from a fixed point.

Incremental co-ordinate programming (G91)

In incremental programming dimensioning is taken from the last position

programmed and NOT from a fixed point.

16

Absolute and Incremental Programming Example

Datum

Y+

X+

Find the absolute and Incremental co-ordinates of the points listed.

ABSOLUTE (G90)

INCREMENTAL (G91)

A X __________ _ Y__

A X__________Y___________

B X __________ _ Y__

B X__________Y___________

C X __________ _ Y__

C X__________Y___________

D X __________ _ Y__

D X__________Y___________

E X __________ _ Y__

E X__________Y___________

F X __________ _ Y__

F X__________Y___________

Answers are on page 100.

17

Plane Selection (G17, G18, G19)

Before an arc can be machined the correct plane must be selected.

G17

Y+

X+

When generating an arc in the 'X' and 'Z'

axis G17must be selected.

G02

G03

Viewfromtop of machine

G18

Z+

When generating an arc in the 'X' and 'Y'

axis G18 must be selected.

G03

G02

View fromfront of machine

G19

Plane selection is MODAL

and will stay effective until
another plane is selected.

When generating an arc in the 'Y' and 'Z'

axis G19 must be selected.

Z+

Y+

X+

G02

G03

Viewfromleft side of machine

18

Circular Interpolation (G02, G03)

There are two directions in which you can produce an arc G02 Clockwise and G03 Counter Clockwise.
To machine an arc the machine tool requires the following information.
Tool finish position in 'X'
Tool finish position in 'Y'
Arc offset in 'X'
Arc offset in 'Y'
'I' is the Incremental value parallel to the 'X' axis.
'J' is the Incremental value parallel to the 'Y' axis.
'K' is the Incremental value parallel to the 'Z' axis.

Arc offset in 'X' is represented by 'I'.

Arc offset in 'Y' is represented by 'J'.
Arc offset in 'Z' is represented by 'K'.

G02 Circular Interpolation Clockwise.

Datum

Example
G02 X1.0 Y0. I0.0 J-1.0
G02 (Clockwise movement)
X 1.0 (Tool finish position in 'X')
Y 0.0 (Tool finish position in 'Y')
I 0.0 (Arc offset in 'X')
J-1.0 (Arc offset in 'Y')

G02

0
000
R1.

J-1.00

G03

I-1.00

Datum

Example
G03 X1.0 Y0. I-1.0 J0.0
G03 (Counter Clockwise movement)
X 1.0 (Tool finish position in 'X')
Y 0.0 (Tool finish position in 'Y')
I-1.0 (Arc offset in 'X')
J 0.0 (Arc offset in 'Y')

G03 Circular Interpolation Counter

Clockwise
19

Circular Interpolation G02

N6

Cutting direction
G02

Start N3
Finish N10

Arc offset
parallel to
the Xaxis.
I 1.5

N7
X&YZERO

R.75

R1.5

N8
Arc offset
parallel to
the Yaxis.
J 1.5

N9

O1066 (Program number)

N1G17G40G80G90 (Safe start)
N2T1M6 (Calls T1 and changes tool)
N3G54G90G0X-1.5Y0.S718M3 (Tool moves to start position)
N4G43Z.1H1 (Picks up tool length value)
N5G1Z-.1F20. (Feeds to Z-depth)
N6G2X0.Y1.5I1.5F40. (Clock-wise move)
N7G1X3.75Y.75 (Linear move)
N8G2Y-.75J-.75 (Clock-wise move)
N9G1X0.Y-1.5 (Linear move)
N10G2X-1.5Y0.J1.5 (Clock-wise move)
N11G0Z.1 (Lifts up in Z)
N12G91G28Z0Y0. (Returns Z and Y to home position)
N13G90 (Back into absolute)
N14M30 (Return to beginning of program)

20

Arc offset
parallel to
the Yaxis.
J -.75

Circular Interpolation G03

Arc offset
parallel to
the Yaxis.
J- 1.5

Arc offset
parallel to
the Yaxis.
J .75

N9

N8
R1.5

X&YZERO

Start N3
Finish N10
Arc offset
parallel to
the Xaxis.
I 1.5
Cutting direction
G03

N7

N6

O1066 (Program number)

N1G17G40G80G90 (Safe start)
N2T1M6 (Calls T1 and changes tool)
N3G54G90G0X-1.5Y0.S718M3 (Tool moves to start position)
N4G43Z.1H1 (Picks up tool length value)
N5G1Z-.1F20. (Feeds to Z-depth)
N6G3X0.Y-1.5I1.5F40. (Counter Clock-wise move)
N7G1X3.75Y.75 (Linear move)
N8G3Y-.75J.75 (Counter Clock-wise move)
N9G1X0.Y-1.5 (Linear move)
N10G3X-1.5Y0.J-1.5 (Counter Clock-wise move)
N11G0Z.1 (Lifts up in Z)
N12G91G28Z0Y0. (Returns Z and Y to home position)
N13G90 (Back into absolute)
N14M30 (Return to beginning of program)

21

R.75

Radius Command (R)

As an alternative to using the 'I' and 'J' commands it is possible to program an
arc using the 'R' command.

8
7

3
4

This example machines a radius on each corner. The datum is the top
left-hand corner of the part. The tool diameter is .500.
Position No.
G1X3.5Y.25
G2X4.25Y-.5R.75
G1Y-3.5
G2X3.5Y-4.25R.75
G1X.5
G2X-.25Y-3.5R.75
G1Y-.5
G2X.5Y.25R.75

1
2
3
4
5
6
7
8

The R+ command can only be used for arcs up to 180 degrees.

The R- command can only be used for arcs greater than 180 degrees.

22

Cutter Compensation (G41/G42)

Cutter compensation allows a program to be written without considering
the size of the cutter.
The three G-codes used to control cutter compensation are
G41 - Cutter compensation Left
G42 - Cutter compensation Right
G40 - Cutter compensation Cancel

If your control has cutter compensation 'B' then different offset numbers have to applied to
'H' and 'D' values. Your program should look like this
G0 G43 Z1. H1
G1 G41 Y0. D11 F50.

If your control has cutter compensation 'C' then the same offset numbers can be applied to 'H' and 'D' values. Your program should look like this
G0 G43 Z1. H1
G1 G41 Y0. D1 F50.

23

Cutter Compensation (G41)

Endmill is on
the left hand side
of the work piece

Direction
of
travel
Approach part
at 90applying
cutter comp
G41

G41 - Cutter compensation to the Left of the work piece.

Always apply cutter compensation at 90 degrees to the work piece. The program
for applying cutter compensation should look like this.
G1G41Y0 D1 F25.
or if using cutter compensation 'B' it should look like this
G1G41Y0 D11F25.
When turning of cutter compensation the program should be as follows.
G1G40Y.5.
G41 and G42 are Modal commands and will stay active until canceled by G40.

24

Cutter Compensation (G42)

Approach part
at 90applying
cutter comp
G42

Endmill is on
the right hand side
of the work piece

Direction
of
travel

G42 - Cutter compensation to the Right of the work piece.

Always apply cutter compensation at 90 degrees to the work piece. The program for
applying cutter compensation should look like this.
G1G42Y0D1F25.
or if using cutter compensation 'B' it should look like this
G1G42Y0 D11F25.
When turning of cutter compensation the program should be as follows.
G1G40Y.5.
G41 and G42 are Modal commands and will stay active until canceled by G40.

25

Canned (Fixed) Cycles (G73, G81, G83, G86)

Canned cycles are designed to make it easier for the programmer to create programs. With the use
of a single 'G' function the canned cycle can be performed in a single block. This makes programming quicker and also saves on program memory.

The formats for the most commonly used canned cycles are
High Speed Peck Drilling Cycle
G73 X _____ Y_____ Z_____ Q_____ R_____ F_____
Drilling
G81 X _____ Y_____ Z_____ R_____ F_____
Peck Drilling
G83 X_____ Y_____ Z_____ Q_____ R_____ F_____
Tapping
G84 X_____ Y_____ Z_____ R_____ F_____
Boring
G86 X_____ Y_____ Z_____ R_____ F_____
Legend
X = X Co-ordinate Position
Z = Finale depth of Hole
Q = Depth of Peck

Y = Y Co-ordinate Position
R = Rapid Plane Depth
F = Feedrate

G80 cancels all Canned Cycles

For additional canned cycles please consult your Fanuc Operators Manual
26

Initial and Rapid Planes (G98/G99)

When using canned cycles the controller provides the ability to return
to one of two reference planes.

G98

G99
Initial Point
Level
R Point
Level

Point Z

Point Z

G98 - Returns the tool to the INITIAL plane.

G99 - Returns the tool to the RAPID plane.

27

High Speed Peck Drilling (G73)

Example
G98 G73 X0.0 Y0.0 Z-1.25 Q.250 R.250 F20.

Initial Point (G43 Z1. H01)

Tool will stop1.0"above part.

WhenG98 is used'Z' will

returnto the Initial point.

RPoint(R.25)

WhenG99 is used'Z' will

returnto the Rpoint.

'Z' - Zero is topof part.

0.050"retractedafter eachpeck.

1st Peck
2ndPeck
3rdPeck
4th Peck
Final Hole Depth(Z-1.25)

Unlike G83 (peck drilling) G73 does not rapid to the

R plane after each peck.

28

Drilling (G81)
Example
G98 G81 X0.0 Y0.0 Z-1.25 R.25 F20.

When G98 is used 'Z' will

return to the Initial point.

Initial Point (G43 Z1. H01)

Tool will stop 1.0" above part.

When G99 is used 'Z'

will return to the R point.

R Point(R.25)
'Z' - Zero is top of part.

Final Hole Depth (Z-1.25)

29

Peck Drilling (G83)

Example
G98 G83 X0.0 Y0.0 Z-1.25 Q.25 R.25 F20.

Initial Point (G43 Z1. H01)

Tool will stop1.0"above part.

WhenG98 is used'Z' will

return to the Initial point.

RPoint(R.25)

WhenG99 is used'Z' will

returnto the Rpoint.

'Z' - Zero is topof part.

1st Peck.
2ndPeck.
3rdPeck.
4thPeck.
Final Hole Depth(Z-1.25)

After each peck 'Z' will rapid to the 'R' plane and then back to within
0.1" of where it finished cutting.

30

Tapping (G84)
Example
G98 G84 X0.0 Y0.0 Z-1.25 R.25 F10.

Initial Point (G43 Z1. H01)

Tool will stop 1.0" above part.

When G98 is used 'Z' will

return to the Initial point.

R Point(R.25)

When G99 is used 'Z' will

return to the R point.

'Z' - Zero is top of part.

Final Hole Depth (Z-1.50)

You must use a floating tap holder when using G84.

For Rigid Tapping example please see page 33.

31

Fine Boring (G76)

Example
G98 G76 X0.0 Y0.0 Z-1.5 R.25 Q.005 F10.

Initial Point (G43 Z1. H01)

Tool will stop 1.0" above part.

When G98 is used 'Z' will

return to the Initial point.

R Point(R.25)

When G99 is used 'Z' will

return to the R point.

'Z' - Zero is top of part.

Final Hole Depth (Z-1.50)

Spindle stops. Moves .005" away
frompart. Rapids out.
Please consult your machine
operation manual for correct
orientation when using a single
point-boring tool.

'Q' represents the amount tool

will move away from machined
face before lifting out of hole.

Set the direction and axis in which you want to

move away in using parameter 5101 bit 4 and 5
32

Rigid Tapping (G84)

Initial Point (G43 Z1. H01)

Tool will stop 1.0" above part.

When G98 is used 'Z' will

return to the Initial point.

R Point(R.25)

When G99 is used 'Z' will

return to the R point.

'Z' - Zero is top of part.

Final Hole Depth (Z-1.50)

Example (1/2-13 Tap)

G0 G90 G54 X0 Y0
G43 H01 Z.25 M8
G95 S1000 (G95 feed per rotation)
M29 (Rigid tapping mode)
G98 G84 Z-1.5 R.25 F.0769 (Tapping cycle
with 'F' = pitch of thread)
G80 M9
G94 (Feed per minute)
G91 G28 Z0 M5
G90
M30

Important thing to
remember when Rigid
Tapping
the feedrate must be
the pitch of the thread.

When rigid tapping it is possible to retract the tap up to 200% faster than the programmed
feedrate. This is achieved by changing the following parameters:
Parameter 5200 bit 4 (DOV) to 1
Parameter 5211 enter amount 1% - 200%
The only limitation is that once the parameter is changed it will be the same for every tap.

33

Rigid Tapping Using an Alternate Axis

It is possible to rigid tap using an axis other than Z.
This is often used when the use of a right angled head is necessary.
Parameters. Before starting set the following parameter.
5101 bit 0 to 1 (FXY)
If an axis other than Z is required to apply the 'H' value (Tool Length
Offset G43) then set the following parameter.
5001.1 bit 1 to 1 (TLB)

Make sure that the program contains the correct reference plane selection.
G18 X and Z
G19 Y and Z

The following example will tap 4 holes using the Y axis

N10 G0 G19 G54 G90 X0. X0.

N20 G43 Y.5 H01
N30 G95 S1000
N40 M29
N50 G84 G98 Y-1. R.5 F.0769
N60 X-3.25 Z-.75
N70 X-.75
N80 Z-3.25
N90 G80
N100 G94

When finished remember to return parameters back to their original settings

34

Repetition of Canned Cycles (K)

By placing an 'K' on the same line as the canned cycle command it is possible
to repeat the cycle.

Example
G0 G90 X0 Y0 (1st hole position)
G91 G98 G81 X0.50 Y0.0 Z-1.R.25 K6 F20.
G90

Example 2
G0 G90 X0 Y0 (1st hole position)
G91 G98 G81 X0.50 Y0.50 Z-1.R.25 K3 F20.
G90

The 'K' command should only be used with G91(incremental). If G90 (absolute)
were to be used only the 1st hole would be machined.

35

Use of 'K0' in Canned Cycles

Placing a 'K0' at the end of a canned cycle will prevent the
cycle from being executed at that position.
This allows the operator to have all the hole positions in a subprogram and
define canned cycles in the main program.

T01 M6 (SPOT DRIL)

G90 G54 X0. Y0. S8000 M03
G43 H01 Z1. M8
G98 G81 Z-.25 R.1 F5. K0 - Peck cycle
M98 P1000 (call sub program)
G0 G80 Z1.
T02 M6 (DRILL)
G90 G54 X0. Y0. S6500 M03
G43 H02 Z1. M8
G98 G83 Z-1.0 R.1Q.1F10. K0 - Drill cycle
M98 P1000 (call sub program)
G0 G80 Z1.
T03 M6 ( TAP)
G90 G54 X0. Y0.
G43 H03 Z1. M8
G95 S1000
M29
G98 G84 Z-1.2 R.3 F.05 K0 - Tap cycle
M98 P1000 (call sub program)
G94
G0 G80 Z1.
G91 G28 Z0. Y0
G90
M30

36

O1000(HOLE SUB)
X0.0Y0.0
X1.0Y0.0
X2.0Y-1.0
X2.0Y-2.0
M99

O1000(HOLE SUB)
X0.0Y0.0
X1.0Y0.0
X2.0Y-1.0
X2.0Y-2.0
M99

O1000(HOLE SUB)
X0.0Y0.0
X1.0Y0.0
X2.0Y-1.0
X2.0Y-2.0
M99

Thread Milling (Helical Interpolation)

Helical Interpolation provides a method of thread cutting without
having to use a machine tap.

One revolution must

equal pitch of thread

Pitch

Always feedon
using cutter
compensasion

37

Thread Milling (Helical Interpolation)

Example

N10 G0 G90 G54 X0. Y0. S1000 M3

The machine moves to the part datumusing the
G54 work coordinate and starts the spindle at
1000 r.p.m.

N20 G43 Z.250 H1 M8

The machine applies Tool Length Offset and
turns on the coolant.

N30 G01 Z-.500 F50.

The machine moves to the required Zdepth at
50 i.p.m.

N40 G41 X-.75 D31 F20.

The machine moves to the start position
applying cutter compensation at 20 i.p.m.
(Using cutter compensation allows for easy
adjustment of the thread).

N50 G02 I-.750 Z-.6666

The machine moves 360 degrees and feeds in Z
to finished depth of thread (.500 +.1666)

N60 G0 G40 X0.

The machine moves back to center of the hole at
the same time canceling cutter compensation.

N70 G0 G91 G28 Z0.

The machine moves clear of the part to the Z
home position.

This example machines a 11/2 - 6 thread .50" deep

Pitch of thread is .1666

38

Manual Data Input (MDI)

In MDI mode you can create and run a program without having to store it in
the controls memory.
MODE
TAPE

MDI

REF.RTN.
JOG

MEMORY

Select MDI using the

Mode Select Switch.

EDIT
HANDLE

MODESELECT

Press the PROG hard key and the following screen will be displayed.

In this example the machine will rapid to the X

and Y zero location using
the G54 work offset.
Then the spindle will
start at 2000 rpm.

Enter the program manually using the key pad, include end of
block (EOB) at the end of each line.
Pressing the RESET key
will clear the MDI screen.
39

Starting a Program
MODE
TAPE

Select EDIT using the

Mode Select switch.

MDI

REF.RTN.
JOG

MEMORY

EDIT
HANDLE

MODESELECT

Press the PROG hard key and the following screen will be displayed.

All programs
must start
with the letter
'O'

Manually key in the program number and then press the insert hard key.
Before any more lines can be added you must enter an end of block.
Example
O1234 - INSERT - EOB - INSERT

40

Program Numbers
Technically the numbers O0000 through O9999 are available for creating
program numbers. However some numbers are used by other functions and
are best avoided when creating a program.
O9000 through O9999.
These numbers are used for Macro programs and
for 'Tool change' and 'Pallet change' programs.
It is possible to call these programs using a 'G' or
'M' code by setting parameters.

O9000 program numbers are

protected. To unprotect them
change parameter 3202 bit 4
(NE9) to 0.

O8000 through O8999

O8000 program numbers
can be protected by
changing parameter
3202 bit 0(NE8) to 1.

These numbers are also used for Macro programs

and can also be protected against accidental editing
and deletion by setting a parameter.

O0001 through O7999

These numbers are generally used for 'G' code programs and can not
be protected by parameters.

To prevent accidental editing

or deletion of programs, turn
program protect key to lock
and remove the key.

PROGRAMPROTECT

41

Editing a Program
The following is the procedure for Inserting, Altering and Deleting a command
in a program which is registered in the controls memory.
MODE
TAPE

Select EDIT using the

Mode Select switch.

MDI

REF.RTN.
JOG

MEMORY

EDIT
HANDLE

MODESELECT

Press the PROG hard key and make sure that the program
requiring editing is displayed.

Using the cursor keys

highlight the command to
be changed.

Once the command is highlighted it is possible to change it.

If the command is no longer needed simply press the Delete key to erase it.
If the value needs to be changed simply key in the new value and press Alter.
If a command has to be added, highlight the command before the point were the
new data is to be inserted, key in the new command and press Insert.
Delete Example
N20 G1 X3.265 Y-2.987 F30.
Pressing the Delete key will remove Y-2.987
N20 G1 X3.265 F30.

Alter Example
N20 G1 X3.265 Y-2.987 F30.
Key in new value (Y-2.950)
Pressing the Alter key will change Y-2.987
to the new value
N20 G1 X3.265 Y-2.950 F30.

Insert Example
N20 G1 X3.265 Y-2.987 F30.
Key in new value (Z-1.250)
Pressing the Insert key will insert the new value after Y-2.987
N20 G1 X3.265 Y-2.987 Z-1.250 F30.

42

Extended Part Program Edit

Extended Part Program Edit is the name given to the copy, move and merge function. This
allows the programmer to duplicate whole or parts of a program without having to rewrite the
whole program.
MODE

Select EDIT using the

Mode Select switch.

TAPE

MDI

REF.RTN.
JOG

MEMORY

EDIT
HANDLE

MODESELECT

Press the PROG hard key and make sure that the program you want to
copy is displayed.
After displaying the program press soft key [(OPRT)] then the continuous menu key until the
[EX-EDT] soft key appears. Pressing this key will display the COPY, MOVE and MERGE keys.
If you want to copy the whole program. Press soft key COPY and then soft key
ALL. Enter a new program number and press INPUT. Then press the [EXEC] key.
Copy Example
O1234
G90 G80 G40
T1 M6
G90 G0 G54 X0.0 Y0.0
S3500 M3
G43 Z.1 H1 M8
G98 G81 Z-1. R.1 F15.
G80 M9
G91 G28 Z0 Y0
M30

Press COPY key

Press ALL key
Enter new program
number (O2468)
Press INPUT key
Press EXEC key

O2468
G90 G80 G40
T1 M6
G90 G0 G54 X0.0 Y0.0
S3500 M3
G43 Z.1 H1 M8
G98 G81 Z-1. R.1 F15.
G80 M9
G91 G28 Z0 Y0
M30

Always make a backup copy of your program before attempting to alter it.
This way should an error occur while using COPY, MOVE or MERGE
you will always have the original for backup.

43

Extended Part Program Edit (Move)

If you want to move part of the program. Press soft key [MOVE]. Then move the cursor to the start
of the range you wish to move and press soft key [CRSR~]. Move the cursor to end of the range to
be moved and press [~CRSE] or press [~BTTM] if you want to copy everything below the 1st cursor
position. Enter a new program number and press INPUT. Then press the [EXEC] key.

Move Example
O1234
G90 G80 G40
T1 M6 (CRSR~)
G90 G0 G54 X0.0 Y0.0 S3500 M3
G43 Z.1 H1 M8
G98 G81 Z-1. R.1 F15.
G80 M9(~CRSR)
G91 G28 Z0 Y0
M30

Press MOVE key

Position 1st cursor
[CRSR~]
Position 2nd cursor
[~CRSR]
Enter new program
number (O2468)
Press INPUT key
Press EXEC key

O2468
T1 M6
G90 G0 G54 X0.0 Y0.0
S3500 M3
G43 Z.1 H1 M8
G98 G81 Z-1. R.1 F15.
G80 M9

OR

Move Example
O1234
G90 G80 G40
T1 M6 [CRSR~]
G90 G0 G54 X0.0 Y0.0 S3500 M3
G43 Z.1 H1 M8
G98 G81 Z-1. R.1 F15.
G80 M9
G91 G28 Z0 Y0
M30 [~BTTM]

Press MOVE key

Position 1st cursor
[CRSR~]
Position 2nd cursor [~BTTM]
Enter new program
number (O2468)
Press INPUT key
Press EXEC key

44

O2468
T1 M6
G90 G0 G54 X0.0 Y0.0
S3500 M3
G43 Z.1 H1 M8
G98 G81 Z-1. R.1 F15.
G80 M9
G91 G28 Z0 Y0
M30

Extended Part Program Edit (Merge)

If you want to insert part of a program into another program. Press soft key [MERGE]. Then move
the cursor to the position at which the new information is to be inserted. And press soft key [~CRSR]
or press [~BTTM] if you want the new information to be inserted at the end of the program. Enter
the number of the program to be inserted and press INPUT. Then press the [EXEC] key.

Merge Example.
O1234
G90 G80 G40
T1 M6
G90 G0 G54 X0.0 Y0.0 S3500 M3
G43 Z.1 H1 M8
G98 G81 Z-1. R.1 F15.
G80 M9(~CRSR)
G91 G28 Z0 Y0
M30

O1234
G90 G80 G40
T1 M6
G90 G0 G54 X0.0 Y0.0 S3500 M3
G43 Z.1 H1 M8
G98 G81 Z-1. R.1 F15.
G80 M9
T2 M6
G90 G0 G54 X0.0 Y0.0 S3500 M3
G43 Z.1 H21 M8
G98 G81 Z-1. R.1 F15.
G80 M9
G91 G28 Z0 Y0
M30

Press MERGE key

Position cursor
[~CRSR]
Enter program number
to be inserted (O2468)
Press INPUT key
Press EXEC key

O2468
T2 M6
G90 G0 G54 X0.0 Y0.0
S3500 M3
G43 Z.1 H21 M8
G98 G81 Z-1. R.1 F15.
G80 M9

It is not possible to move information

within a program. You must first copy the
range of information to a new program and
then it is possible to insert it back into the
original program at a different location.

45

Extended Part Program Edit (Change)

The change feature gives the operator the ability to 'Mass Edit' a program.

Press the 'Change' soft key and the above screen appears. Enter the data that you want to change.
e.g. F100. Then press the 'Before' soft key the screen below will be displayed.

Enter the new data and then press the 'After' soft key.
e.g.. F50. The screen below will be displayed.

Pressing the 'EXES' soft key will change all F100. in the program to F50.
Pressing the 'EX-SGL' soft key will change one line at a time.
If you not want to change a particular block press the 'SKIP' soft key.
46

Background Edit
Background Edit gives the programmer the ability to create a new program
or edit an existing program while a program is being executed.
While the machine is running press the hard key PROG then press soft
key [(OPRT)] and then soft key [BG-EDT].

When you have finished using Background Edit press soft key
BG-END to return to normal operation.

47

Program Stop, Optional Stop and Block Delete

M0

M1

Program Stop. A program stop is used whenever the operator requires the program
cycle to stop and allow the operator to perform some manual function such as
inspection, manual tool change, coolant adjustment, etc.

Optional Program Stop. This M-code stops the machine in the same manner as program
stop (M0) except the operator must turn on the Optional stop switch anytime prior to the
M1 being read. If the Optional stop switch is not turned on then the M1 command is ig-

To turn ON the switch must

be in the UP position.

To continue operation after an

M0 or M1 press cycle start.

/
Optional Block Delete. It is possible to skip a line or lines of information without
having to delete them from the program.
By placing a forward slash (/) at the beginning of a line and by turning on the block
delete switch the control will ignore these lines.
Example.
N10 G0 G90 G54 X2.00 Y2.00
/ N20 S4000 M3
N30 G1X-4.00 F20.
With block delete turned ON the program will move from line N10 to N30 ignoring
N20.
With block delete turned OFF all lines of information are read.

48

Program Restart
This function gives you the option of restarting a tool anywhere in a program
Before starting you must
set parameter 7310
X=1
Y=2
Z=3

PROGRAMRESTART

1) Retract the spindle, send all the axis to reference point.

2) Reset Tool.
3) Go to Edit Mode.
4) Hit Reset Button.
5) Go To MDI, type in the original RPM, press cycle start
6) Go to Auto Mode.
7) Flip Toggle Switch to PROGRAM RESTART.
8) Hit (Oprt) button on Soft Keys.
9) Hit Right Arrow Key (Soft Key).
10) You will see (Ptype)(Qtype) soft keys.
11) Type in the sequence # you want to start.
12) Press (Ptype) Soft Key.
13) Turn OFF the Rstart/Prgm Toggle switch.
14) HIT (CYCLE START).

49

If the program has been run

through completely press
Ptype.
If the program has not been
partially run press
Qtype.

Tool Registry
To access the machines tool registry

SYSTEM

PMC

PMCPRM

DATA

G.DATA

450 Tool in spindle

452 Waiting tool
Use the Page down key to display the complete Tool Registry on one page.

Tool Registry only

applies to machines
with random select
tool magazines.

ADDRESS
D0300
D0301
D0302
D0303
D0304
etc

POCKET No
Pocket 1
Pocket 2
Pocket 3
Pocket 4
etc

50

To change settings parameter

write must be turned on.
(see page 51)

Changing Parameters
Before changing parameters you must first enable parameter write
MODE

Select MDI using the Mode Select switch.

TAPE

MDI

REF.RTN.
JOG

MEMORY

EDIT
HANDLE

MODESELECT

Press the function key

Offset

and then the [setting] soft key to display the Setting screen.

Setting

Change parameter write to 1

Once this is done you are now able to change machine parameters.

Always make a back up copy of

the machines parameters before
making changes.

To display machine parameters press function key

[PARAM].

SYSTEM

and then soft key

Input parameter number to be changed and then press the No. Search key.

51

Sample Program
In this sample program the following operations
are performed. Tool 1 - 3/4" end mill, machines
part profile & roughs 2" hole.
Tool 2 - 5/8" Spot drill, spots all holes.
Tool 3 - 27/64" drill, drills 4 holes.
Tool 4 - 1/2-13 tap, taps 4 holes.
Tool 5 - 1/2" end mill, finish 2.0" thru hole.

52

Sample Program

Program
Start

O1066 (DEMO) - - - - - - - - - -- Program Number with comment

N1G0G90G80G40G17- - - - - G80 & G40 Cancels any offsets stored in memory, G17 sets plane selection
N2G91G28Y0Z0- - - - - - - - - - Sends Z & Y to the G28 reference position
N3T1M6- - - - - - - - - - --- - - - - Calls tool 1 and places tool in spindle

Tool 1

Blank Material

N4 (.75 DIA. ENDMILL )- - - - - - - - - Tool description

N5G0G54G90X-2.25Y.625S8000M3- - Moves to 1st position using G54 work offset starts spindle at 8000 rpm
N6G43Z.1H1T2 - - - - - - - - - - - - - - - - -Picks up the tool length offset, turns on the coolant and calls next tool
N7G1Z-1.F25.- - - - - - - - - - - - - - - - - - Feeds to finale Z depth at 25 ipm.
N8G3X-2.Y.375I.25- - - - - - - - - - - - N8 through N18 machines profile
N9G1X-.5
N10G2X.375Y-.5J-.875
N11G1Y-3.5

After machining
profile

N12G2X-.5Y-4.375I-.875
N13G1X-3.5
N14G2X-4.375Y-3.5J.875
N15G1Y-.5
N16G2X-3.5Y.375I.875
N17G1X-2.
N18G3X-1.75Y.625J.25

After machining
center hole

N19G0Z.1- - - - -- - - -- - - - - - - - Rapid move to 0.1 above the part

N20X-2.Y-2.- - - - - - - - - - - - - - Rapid move to hole center
N21G1Z-1.F25.- - - - - - - - - - - - Feeds to finale Z depth at 25 ipm
N22G1Y-1.75F15. - - - - - - - - - - N22 through N27 machines 2" hole
N23G3J-.25
N24G1X-1.75Y-1.625
N25G3X-2.Y-1.375I-.25
N26J-.625
N27X-2.25Y-1.625J-.25
N28G0Z.1- - - - -- - - -- - - - - - -Rapid move to 0.1 above the part

Part after tool 1

has finished

53

Sample Program
Tool 2
N29M01- - - - -- - - - - - - - - - - - Optional stop
N30T2- - - - - - - - - - - - - - - - - -Verifies tool 2 is in waiting pocket
N31M6- - - - - - - - - - - - - - - - - Change to tool 2
( .625 DIA. SPOT DRILL )- - - - -Tool description
N32G0G54G90X-2.Y-2.S6000M3- Moves to 1st position using G54 work offset starts spindle at 6000 rpm
N33G43Z.1H2M8T3- - - - - - - - - Picks up the tool length offset, turns on the coolant and calls next tool
After spot
drilling holes

N34G81G98X-2.Y-2.Z-.275R.1F10.- - - G81drilling cycle

N35X-3.25Y-.75- - - - - - - - - - - -N35 through N38 next hole positions
N36X-.75
N37Y-3.25
N38X-3.25
N39G80Z.1- - - - - - - - - - - - - - - G80 cancels pecking cycle

Tool 3

N40M1- - - - -- - - - - - - - - - - - - Optional stop

N41T3- - - - - - - - - - - - - - - - - - Verifies tool 3 is in waiting pocket
N42M6- - - - - - - - - - - - - - - - - Change to tool 3
( .4375 DIA. DRILL )- - - - -- - - - Tool description
N43G0G54G90X-2.Y-2S8000M3- - Moves to 1st position using G54 work offset starts spindle at 8000 rpm
N44G43Z.1H3M8T4- - - - - - - - - Picks up the tool length offset, turns on the coolant and calls next tool
After drilling
holes

N45G83G98X-2.Y-2.Z-1.25R.1Q.2188F10.- - - G83 peck drilling cycle

N46X-3.25Y-.75- - - - - - - - - - - - -N46 through N49 next hole positions
N47X-.75
N48Y-3.25
N49X-3.25
N50G80Z.1- - - - - - - - - - - - - - - G80 cancels pecking cycle

54

Sample Program
Tool 4
N51M1- - - - -- - - - - - - - - - - - - Optional stop
N52T4- - - - - - - - - - - - - - - - - - Verifies tool 4 is in waiting pocket
N53M6- - - - - - - - - - - - - - - - - Change to tool 4
( 1/2-13 UNC TAP )- - - - -- - - - - Tool description
N54G0G54G90X-2.Y-2.- - - - - - - -Moves to 1st position using G54 work offset
N55G43Z.1H4M8T5- - - - - - - - - Picks up the tool length offset, turns on the coolant and calls next tool
N56G95S1000- - - - - - - - - - - - - -G95 feed per rotation
After tapping
holes

N57M29- - - - - - - - - - - - - - - - Rigid tapping mode

N58G84G98X-2.Y-2.Z-1.5R.5F.0769- - - G84 tapping cycle with F = pitch of thread
N59X-3.25Y-.75- - - - - - - - - - - - N59 through N62 next hole positions
N60X-.75
N61Y-3.25
N62X-3.25
N63G80Z.5- - - - - - - - - - - - - - - G80 cancels pecking cycle
N64G94 - - - - - - - - - - - - - - - - Change back to feed per minute

Tool 5

N65M1- - - - -- - - - - - - - - - - - - Optional stop

N66T4- - - - - - - - - - - - - - - - - - Verifies tool 5 is in waiting pocket
N67M6- - - - - - - - - - - - - - - - - Change to tool 5
(.5 FINISHING ENDMILL )- - - - Tool description
N68G90G54G0X-1.75Y-1.75S8000M3- Moves to 1st position using G54 work offset starts spindle at 8000 rpm
N69G43Z.1H5T1- - - - - - - - - - - - - - Picks up the tool length offset, turns on the coolant and calls next tool
N70G1Z-1.F25.- - - - - - - - - - - - - - - Feeds to final Z depth at 25 ipm
After finishing
2" hole

N71G41Y-1.5D55 - - - - - - - - - - - - - Feeds on to part applying cutter compensation

N72G3X-2.Y-1.25I-.25- - - - - - - - - - -N72 through N74 machines hole
N73J-.75
N74X-2.25Y-1.5J-.25
N75G40G1Y-1.75 - - - - - - - - - - G40 Cancels cutter compensation
N76G0Z.1- - - - -- - - -- - - - - - -Rapid move to 0.1 above the part
N77G91G28Y0.Z0.M5- - - - - - - Returns machine to Y and Z G28 reference position

Program End

N78G90- - - - - - - - - - - - - - - - G90 absolute mode

N79M30- - - - - - - - - - - - - - - - Rewinds program

55

Sub Programs
The control has the ability to access 'sub programs' from outside the program that is running in the
control memory. This is useful when tools are using the same information when machining a part
e.g. center drill, drill and tapping a number of holes.
Sub programs are accessed by using M98 followed by the desired program number with the letter P replacing the O. e.g. N20 M98 P1066

( .625 DIA. SPOT DRILL )

N32G0G54G90X-2.Y-2.S6000M3
N33G43Z.1H2M8T3
N34G81G98X-2.Y-2.Z-.275R.1F10.
N35M98P1066- - - - -(call sub program) - - - - - N39G80Z.1
N40M1
N41T3
N42M6
( .4375 DIA. DRILL )
N43G0G54G90X-2.Y-2S8000M3
N44G43Z.1H3M8T4
N45G83G98X-2.Y-2.Z-1.25R.1Q.2188F10.
N46M98P1066- - - - -(call sub program) - - - - N50G80Z.1
N51M1
N52T4
N53M6
( 1/2-13 UNC TAP )
N54G0G54G90X-2.Y-2.
N55G43Z.1H4M8T5
N56G95S1000
N57M29
N58G84G98X-2.Y-2.Z-1.5R.5F.0769
N59M98P1066- - - - -(call sub program) - - - - - N63G80Z.5
N64G94

O1066 (hole sub program)

N10X-3.25Y-.75
N20X-.75
N30Y-3.25
N40X-3.25
N50M99 (return to main program

O1066 (hole sub program)

N10X-3.25Y-.75
N20X-.75
N30Y-3.25
N40X-3.25
N50M99 (return to main program

O1066 (hole sub program)

N10X-3.25Y-.75
N20X-.75
N30Y-3.25
N40X-3.25
N50M99 (return to main program

56

Searching Programs
It is possible to search for information contained in a program. You can search
Line numbers, Tool numbers, G-codes, Feedrate, etc.
MODE
TAPE

Select EDIT using the

Mode Select switch.

MDI

REF.RTN.
JOG

MEMORY

EDIT
HANDLE

MODESELECT

Press the PROG hard key and the following screen will be displayed.

The Curser keys can

also be used for
searching

Enter the Line number, Tool number, G-code or Feedrate to search for then press the

SRH

Soft key or the down cursor arrow.

57

Searching for a Program

When there are multiple programs in the controls memory you can search for a
particular program in several ways.
MODE
TAPE

Select EDIT using the

Mode Select switch.

MDI

REF.RTN.
JOG

MEMORY

EDIT
HANDLE

MODESELECT

Press the PROG hard key and the following screen will be displayed.
Key in the desired program number and then press the

OSHR

Soft key or the down cursor arrow.

58

Deleting a Program
When no longer needed, programs stored in the controls memory can be
deleted, either one at a time or all programs at once.
Make sure that parameter 3202 bit 5 is set to a 1. If you do not set this
parameter once you press the 'Delete' key the program is removed immediately.
MODE
TAPE

Select EDIT using the

Mode Select switch.

MDI

REF.RTN.
JOG

MEMORY

EDIT
HANDLE

MODESELECT

Press the PROG hard key to display the program screen.

Key in 'O' followed by the desired program number then press the 'Delete' hard key.

Check that you have entered the correct

program number to be deleted. Press
'EXEC' to delete the program or 'CAN' to
cancel the delete operation.

To delete all programs in the control enter O-9999 and then press the 'Delete' hard key.

Before deleting all programs check that parameter 3202 bit 4 (NE9) is set to 1. This will prevent the
user from deleting the O9000 series programs which are used for Tool change, pallet change etc.

59

PCMCIA Card (Memory Card)

Doosan Machining Centers using the i series controls (not including the 0i) now have the ability to read
from a PCMCIA card. This is a memory card and is used in the same way as you would use a 31/2
floppy. With the cards you can upload and download programs and it is also possible to DNC directly
from the card. This option makes the RS232c somewhat redundant as the PCMCIA card is much faster
than the RS232c hook up. A program run from the card takes the same run time as a program that is
stored in the controls memory. It is also possible to search through and restart anywhere in a program as
long as the program contains line numbers.
Most laptop computers already come with the PCMCIA card drive installed otherwise a suitable
drive must be purchased. The easiest way to do this is to buy a stand-alone unit, which plugs in to the
computer USB port.

The PCMCIA cards and stand alone reader/writers are available

from most computer stores (CompUSA, EGGHEAD, etc.)
And also several sites on the internet.

When using the PCMCIA

card you must first set the
I/O Channel to 4

60

Uploading and Downloading Programs

Using the PCMCIA Card
MODE

Insert PCMCIA card

Select EDIT using the
Mode Select switch.

TAPE

MDI

REF.RTN.
JOG

MEMORY

EDIT
HANDLE

MODESELECT

Press the PROG hard key then the + soft key and CARD soft key to display the
following screen.

To read a program from the memory card.

Select Edit mode. Press
PRGRN - + - CARD - OPRT - F READ.
Enter the file number you wish to load and
press F SET.
Enter a program number and press O SET
and then press the EXEC soft key.

To send a program to the card.

Select Edit mode. Press
PRGRN - OPRT - PUNCH - enter Program
No - EXEC

Remember to set the

I/O Channel to 4

61

DNC Operation using the PCMCIA Card

MODE
TAPE

Insert PCMCIA card.

Select TAPE using the
Mode Select Switch.

MDI

REF.RTN.
JOG

MEMORY

EDIT
HANDLE

MODESELECT

Press the PROG hard key then the + soft key twice and then DNC-CD soft key to display the
following screen.

Parameter 138 bit 7 must

be set to 1 to display the
DNC-CD soft key.

Enter the desired file number, the soft

keys will automatically change and
then press the DNC-ST soft key.
To run the selected program press
CYCLE START.

62

Subprogram call from PCMCIA Card

You can access a program stored on the PCMCIA card at any time and
use it as a subprogram.
Main program

Program stored on PCMCIA card

(.625 DIA. SPOT DRILL)

N32G0G54G90X-2.Y-2.S6000M3
N33G43Z.1H2M8T3
N34G81G98X-2.Y-2.Z-.275R.1F10.
N35M198P1066- -(call subprogram from
PCMCIA card)
N39G80Z.1
N40M1
N41T3

O1066 (hole sub program)

N10X-3.25Y-.75
N20X-.75
N30Y-3.25
N40X-3.25
N50M99 (return to main program

When calling a program from the PCMCIA card use M198 instead of M98.
E.g. N20 M198 P1066
Remember to set the
I/O Channel to 4

Parameter 3404 bit 2 (SBP)

and parameter 138 bit 7 must
be set to 1 for this option to
work.

63

Uploading and Downloading programs using a Laptop

computer
When using suitable communication software it is also possible to load programs into the
control through the RS232 connection from a laptop computer.

Your communication software

should match these settings.

Your control parameters

should match these settings.

Baud Rate Settings

9 = 2400
10 = 4800
11 = 9600
12 = 19200

Your I/O Channel

should be set to zero.

64

Restarting a program when using the PCMCIA Card

You can search and restart a program which is being run from the PCMCIA card
in the same manor you would if the program was
running from the controls memory.
Load the desired program
(see page 61)

Turn Single Block Switch On

Press PROG hard key to

display program screen
and press cycle start to
start the program.

Enter the line number of the tool that you wish to start at (do not enter the N).
Then press the N Search soft key. Once you have reached the correct line number turn off single block and press the start button to continue machining.
This example starts at T2, assuming T2 is already in the spindle

O1066 - - - Start program in single block

200 - - - Enter line number to search to and hit N Search
N200 G90 G0 G54 X0 Y0 S2000 M3 - - - Read work offsets, rpm and start spindle.
N210 G43 Z1. H2 M8- - -Read Z offset
500 - - - Enter line number you wish to continue from and hit N search
N500 G1 X-5. F15 - - - Turn off single block and press Cycle Start to continue machining

Your program must contain

line numbers to be able to use
the N Search function

You must remember to read all relevant information for the tool that you need to restart.
e.g.. work offsets, Z offsets, rpm,work plane
cutter comp etc

65

Uploading programs using a Laptop computer

To read a program from a laptop to the control. First connect the RS232 cable. Then prepare the
communication software to send.
MODE
TAPE

Select EDIT using the

Mode Select Switch.

MDI

REF.RTN.
JOG

MEMORY

EDIT
HANDLE

MODESELECT

Press the PROG hard key then the OPRT soft key to display the following screen.

Press the READ soft key. The screen soft keys will change, then press the EXCE soft key. Starting
your communication software now will send the program.

Doosan uses and recommends Multi-DNC

as its communication software of choice.
Available at www.multi-dnc.com.

66

DNC Operation using a Laptop Computer

To DNC from a laptop to the control. First connect the RS232 cable. Then select the program you wish to run and prepare the communication software to send.
MODE
TAPE

Select TAPE using the

Mode Select Switch.

MDI

REF.RTN.
JOG

MEMORY

EDIT
HANDLE

MODESELECT

Press the PROG hard key to display the following screen.

Turn single block switch to

ON
(without single block
switch on, the machine will
start to move as soon as you
start sending the program).

Press machine
CYCLE START

SINGLEBLOCK

Starting your communication software

now will send the program.

67

CYCLESTART

RS 232-C Communication Interface Connections

The cable from your computer to the machine should be wired in one of the following configurations.

68

Additional Options
Look Ahead Control (G08)
This option is designed for high-speed-machining applications that require precession
and accuracy. When rounding corners and curves the delay due to acceleration/
deceleration in the servo system is suppressed.
Use the following format to turn G08 on and off
G08 P1 - Turns look-ahead control ON
G08 P0 - Turns look-ahead control OFF

N4 (.75 DIA. ENDMILL )

N5G0G54G90X-2.25Y.625S8000M3
N6G43Z.1H1T2
N7G1Z-1.F25.
N8G08P1- - - - - - Turns ON Look-ahead control
N9G3X-2.Y.375I.25
N10G1X-.5
N11G2X.375Y-.5J-.875
N12G1Y-3.5
N13G2X-.5Y-4.375I-.875
N14G1X-3.5
N15G2X-4.375Y-3.5J.875
N16G1Y-.5
N17G2X-3.5Y.375I.875
N18G1X-2.
N19G3X-1.75Y.625J.25
N20G08P0- - - - - - -Turns OFF Look-ahead control
N20G0Z.1

G08 must be specified on a separate line and cannot be combined with any other information.

69

Artificial Intelligence contour control (AICC)

This option allows High-Speed, High-Precision machining without the special
need for additional hardware. AICC is mainly used for mold applications.

Use the following format to turn AICC on and off

G05.1 Q1 - Turns AICC ON
G05.1 Q0 - Turns AICC OFF

N2G40G80G49
N3G05.1 Q1- - - - - - Turns ON AICC
N4G0G17G54G90X-2.Y-.985S8000M3
N5G43Z.1H1T1
N7G1Z-1.005F238.
N8X-.1969Z-.9647
N9X-.1733Z-.9415
N10X-.156Z-.9393
N11X-.1346Z-.955
N12X-.095Z-1.005
N13G05.1 Q0- - - - - -Turns OFF AICC
N14G0 Z1.
G05.1 must be specified on a separate line and cannot
be combined with any other information.

AI NANO - Artificial Intelligence contour control (180 Block look-ahead) 16i,18i and 21i.
AICC - Artificial Intelligence contour control (40 Block look-ahead) available on all controls.
AI APC - Artificial Intelligence Advanced Preview Control (15 Block look-ahead) standard on all controls.

All these functions are called by G5.1 Q1

70

Programmable Data Input (G10)

It is possible to write directly to the work offsets using the G10 option. This is useful
when setting up a previously run part where the work coordinates are already know.
To write to the G54 offset the line of information would be
G10L2P1X16.234Y-3.435Z-1.0

P1 = G54
P2 = G55
P3 = G56
P4 = G57
P5 = G58
P6 = G59

To update all work coordinates, the beginning of the program should

look like this.
O1066
G10L2P1X16.234Y-3.435Z-1.0
G10L2P2X15.234Y-4.435Z-1.0
G10L2P3X14.234Y-5.435Z-1.0
G10L2P4X13.234Y-6.435Z-1.0
G10L2P5X12.234Y-7.435Z-1.0
G10L2P6X11.234Y-8.435Z-1.0

To write to the G54.1 P1P48 extended offsets the line of

information would be

G10L20P1X16.234Y-3.435Z-1.0

71

Mirror Image
There are two types of Mirror Image available for the machine. One is to set the desired axis manually
in the Offset Setting screen. The second is using programmable mirror image in the program (G51.1).

Manual Setting
Machine your 1st part and then at the end of the program move to your next X and Y
home position (e.g G55 X0 Y0) and stop the program (M00).
MODE
TAPE

Select MDI using the Mode

Select switch.

MDI

REF.RTN.
JOG

MEMORY

EDIT
HANDLE

MODESELECT

Press the function key OFFSET SETTING and then the [setting] soft key to display the Setting
screen.
Press the down page key to display the following page.

Enter 1 to activate the desired axis. Return the Mode Switch to Auto and press cycle start to
continue machining the 2nd part.
G55
X

The program format should look like this

P1066 M98 - - - Main program containing all information to machine part.
G55 X0 Y0 - - -Move to next part datum
M00 - -- - - - - -Program stop (change to MDI and set X Mirror Image on).
P1066 M98- - - -Call main program and machine mirrored part.

Part Mirrored in X - axis

72

Mirror Image
Programmable Mirror Image
There are two ways of including Mirror Image in the program.
1. Using G51.1
2. Using M-code
G51.1 (Turns Mirror Image On)
G50.1 (Turns Mirror Image Off)
The program format should look like this:
P1066 M98 - - - Main program containing all information to machine part.
G55 X0 Y0 - - - Move to next part datum
G51.1 X0- - - - Mirror Image in X -axis
P1066 M98- - - -Call main program and machine mirrored part.
G50.1 X0 - - - - Cancel Mirror Image

M81 (Turns Mirror Image On in X-Axis)

M82 (Turns Mirror Image On in Y-Axis)
M80 (Turns Mirror Image Off)

The program format should look like this:

P1066 M98 - - - Main program containing all information to machine part.
G55 X0 Y0 - - - Move to next part datum
M81- - - - Mirror Image in X -axis
P1066 M98- - - -Call main program and machine mirrored part.
M80 - - - - - -- Cancel Mirror Image

73

Coordinate System Rotation

By using this option it is possible to rotate a programmed shape.
G68 is used to turn on Coordinate System Rotation, along with 'X' & 'Y' position
which is the center of rotation and 'R' which is the angle of rotation.

To use Coordinate System Rotation the program format should look like this:
P1066 M98 - - -- - - Main program containing all information to machine part.
G68 X0 Y0 R45. - - Rotates part 45 degrees with X & Y zero being center of rotation.
P1066 M98- - - - - - -Call main program and machine rotated part.
G69 - - - - - --- - - - Cancel Coordinate System Rotation

If no R value is specified the value in parameter

5410 is used as the angle of rotation.

74

Scaling
Using the Scaling option it is possible to enlarge or reduce the size of a part without
having to change the program.

If part A is the original part size, to produce part B which is 1.5 times original. The
program should look like this.
G90 G0 G54 X0 Y0 (Move to center of part)
G51 X0 Y0 P1500 (Turn on Scaling, magnification = 1.5)
M98 P1066 (Main program containing all information to machine part)
G50(Cancel Scaling mode)
To produce part C which is half original size. The program should look like this.
G90 G0 G54 X0 Y0 (Move to center of part)
G51 X0 Y0 P500 (Turn on Scaling, magnification =0.5)
M98 P1066 (Main program containing all information to machine part)
G50(Cancel Scaling mode)

75

Tool Life Management

Tool Life Management gives the operator the ability to change a worn tool to another
tool during program run without stopping the machine. Tools are classified into
groups and a tool life is set for each group in either number of times used or length of
time. When a tool exceeds the preset number of times used or time set, then the next
tool in that group is selected. Once all tools are used then an alarm is generated to let
the operator know that the tools must be changed.

6800 .2
6810

Parameters.
(LMT) 0 (for number of times)
200 Tool Ignored Number

76

Tool Life Management

O0001
G10L3 (Sets Tool Life Management)
P1L15 (Sets group 1 with a tool life of 15 uses)
T1H1
(Tool # and tool length offset #)
T2H2
(Tool # and tool length offset #)
P2L15 (Sets group 2 with a tool life of 15 uses)
T3H3 (Tool # and tool length offset #)
T4H4 (Tool # and tool length offset #)
G11
M30

Before using TLM you must first set the tool groups using the format in the
above program
O1000
T201M6 (Selects 1st tool from group 1)
G0G90G54X0Y0S2000M3
G43H99Z5. ( H99 must be assigned when using TLM)
G98G81Z3. R.1F50.
G0G80Z5.
G0G91G28Z0
T202M6 (Selects 1st tool from group 2)
G0G90G54X0Y0S2000M3
G43H99Z1.( H99 must be assigned when using TLM)
G98G81Z3. R.1F50.
G0G80Z5.
G0G91Z0Y0
M30

Once both tools have been used 15 times the next tool assigned in the group is selected.

The format of the main program should look like this.

77

Tool Life Management

To display the TLM screen press the Offset Setting hard key then the
key and then the TOOLLF soft key.

A @ sign is displayed next to the tool that is being used.

A * appears when the tool life has expired.

78

+ soft

Tool Path Graphics

Pressing the GRAPH hard key will bring up the Tool Path Graphic screen.

Setting parameter 6500 bit 6 to 1 will always position

the graphic in the center of the screen.
79

Horizontal Setup
The horizontal machining center gives the operator the ability to set up multiple parts. It is
also possible to machine three sides of a part in one setup.

Choose a face to set all you Tool Length Offsets from.

This is usually the face of the part at G54 B0.
A

Setting Z
Work Offset Value

Using an indicator measure the distance from the face you touched
your tools off to the face of the next part to be machined. Enter this
amount (A) in your work offset Z value you have assigned for that
part.
eg. G55
X-16.500
Y-12.290
Z-1.250
80

Horizontal Setup
All faces to be machined should be assigned there own work offset numbers.
This gives better control over each work piece.

G54 P1

G54
G58

G54 P2

G55

B90

B0

G54 P07

G54 P13

G54 P10

G54 P9

G54 P16

G54 P15

G54 P8

G54 P14

G54 P12

G54 P11

G54 P6

G54 P5

G57

G59

G54 P4

G54 P3

G56

G54 P18

G54 P17

B270

B180

The above example is for pallet 1. Each work piece on pallet 2 should also be
given individual work offset numbers.

81

Horizontal Machining Example

Typically when using a horizontal machining center you will be machining the same part in
several locations on the tombstone. The use of sub-programs will save on program size, control
memory and also make proving out the program easier.

O2000 (MAIN PROGRAM)

O1976 ( MAIN SUB PROGRAM)

M61 (Calls pallet 1)

N1G0G17G40G94G90G80

P1976 M98 (calls program

N6G91G28Z0.

O1976)

G28X0Y0

M62 (Calls pallet 2)

G90

P1976 M98 (calls program

T1M6 (T1 FACE MILL) (calls tool 1)

O1976)

G54B0 (G54 work offset at B0 part 1)

P0001M98 (calls program O001)

O0001(T1 FACE MILL)

G0Z8. (move tool away from pallet)

G0G90X-2.5Y-

G54.1P1B90 (G54.1 P1 work offset at B90 part 2)

2.S1000M3T2

P0001M98 (calls program O001)

G43Z.5H01

G0Z8.

G1Z0F50.

G54.1P7B180(G54.1 P7 work offset at B180 part 3)

G1X9.F20.

P0001M98

G0Z2.

spindle to machine all

G0Z8.

M99

parts on the tombstone

G54.1P13B270(G54.1 P13 work offset at B270 part 4)

before changing to the

P0001M98

next tool. As it is quicker

G0Z8.M9

to do a B axis move than

T2M6 (T2 1/2 END MILL) (calls tool 2)

Always use the tool in the

a tool change.

G54.1P13B270(G54.1 P13 work offset at B270 part 4)

O0002( T2 .750 FINISH)

P0002M98 (calls program O002)

G90G0X-.8751Y-

G0Z8. (move tool away from pallet)

2.4995S1600M3T1

G54.1P7B180(G54.1 P7 work offset at B180 part 3)

G43Z.1H01M8

P0002M98 (calls program O002)

G1Z-1.F15.

G0Z8.

X-.3751F50.

G54.1P1B90 (G54.1 P1 work offset at B90 part 2)

G3X.1249Y-1.9995J.5

P0002M98

G1Y-.9995

G0Z8.

G2X.9999Y-.1245I.875

G54B0(G54 work offset at B part 1)

G1X3.9999

GP0002M98

G2Y-3.8745J-1.875

G0Z8.M9

G1X.9999

G91G28X0Y0Z0M5

G2X.1249Y-2.9995J.875

G90

G1Y0.

M99

G0Z.2
M99

82

Bore Mill Machining Example

Set up and use of the horizontal boring mill is very similar to a standard horizontal
machining center. The major difference is that the boring mill has a 'W' axis.

When the 'W' axis is at its home position (G91G28 W0), enter this position into the
work offset number you will be using.
E.g. G54 W 27.890
Then when you call your work offset all moves will be read as zero from this position.
The following is an example of a peck drilling cycle.
G80G49G40G0
G91G28Z0W0
T1 M6 (Calls Tool 1)
G90G54X9.0Y25.0W-5.0S700M03 (Moves to X, Y and 'W' position)
G43 Z2. H1 M8 (Picks up tool offset)
G83G99Z-3.0R1.0Q1.0F8.0 (Peck drilling cycle)
Y19.0
Y-19.0
G80 Z2. (Cancel pecking cycle)
G91 G28 Y0. Z0. W0. (Sends Y, Z and W axis to home position)
G90
M30

Always clamp the 'W' axis before

machining.
M68 - Clamp
M69 - Unclamp

83

Macro Programming
Fanuc controls have an option feature known as custom Macro. This is powerful
program language that allows programs to be written using variables instead of
fixed numbers.

There are several ways to call a Macro program.

1. Using G65 followed by the Macro program number. e.g. G65 P9010
2. Using a custom G-code. G100 variables are set in parameters 6050 - 6059
3. Using an M code. M-code variables are set in parameters 6071 - 6079.

6050 G Code to call Macro program 9010

6051 G Code to call Macro program 9011
6052 G Code to call Macro program 9012
6053 G Code to call Macro program 9013
6054 G Code to call Macro program 9014
6055 G Code to call Macro program 9015
6056 G Code to call Macro program 9016
6057 G Code to call Macro program 9017
6058 G Code to call Macro program 9018
6059 G Code to call Macro program 9019

By putting 100 in parameter

6050 every time G100 is
placed in the program Macro
9010 will be called.

6071
6072
6073
6074
6075
6076
6077
6078
6079

M Code to call Macro program

M Code to call Macro program
M Code to call Macro program
M Code to call Macro program
M Code to call Macro program
M Code to call Macro program
M Code to call Macro program
M Code to call Macro program
M Code to call Macro program

9001
9002
9003
9004
9005
9006
9007
9008
9009

84

By putting 100 in parameter 6071

every time M100 is placed in the
program Macro 9001 will be called.

Macro Programming
This Bolt Hole Macro allows for quick and easy programming of a bolt hole circle
without the operator having to calculate the position of each hole.
The line of information in the program to call this macro should look like this:
G100 X0.0 Y0.0 Z-.750 D2.0 R.1 C83. A45. H4. F20. Q.15
X
Y
Z
R
D
C
H
A
F
T
Q

This is the Macro to run

this program.

X axis center
Y axis center
Depth to drill
Reference point above part
Diameter of bolt circle
G code to be used
Number of holes in pattern
Starting angle of 1st hole
Feedrate
Dwell value
Peck depth (G73 & G83 only)

O9010(BOLT HOLE MACRO)

IF[#7EQ#0]THEN #3000=1(NO DIAMETER GIVEN)
IF[#11EQ#0]THEN #3000=2(NO HOLES GIVEN)
IF[#9LT#0]THEN #3000=3(NO FEEDRATE "F" GIVEN)
IF[#3EQ#0]THEN #3000=4(NO DRILL CYCLE GIVEN)
IF[#18EQ#0]THEN #3000=20(NO REFERENCE POINT
GIVEN)
#100=1
#27=#7/2.0
G0X[[COS[#1]*#27]+#24]Y[[SIN[#1]*#27]+#25]
G98G#3Z#26R#18F#9Q#17P#20
#101=360/#11
N1WHILE[#100LTABS[#11]]DO1
X[[[COS[[#101*#100]+#1]*#27]+#24]]Y[[[SIN
[[#101*#100]+#1]*#27]+#25]]
#100=#100+1
END1
M99

85

Macro Programming (Circular Pocket)

The line of information in the program to call this macro should look like this,
G102 X0. Y0. Z-750 R1. A.05 I.02 J.02 K.25 W.8 C5.0 D3 F20.
X
Y
Z
R
D
C
I
J
A
F
K
W

X axis center
Y axis center
Depth of pocket
Radius of pocket
Direction of cut. D2 CW / D3 CCW
Feedrate for plunging
Finish cut
Finnish allowance on bottom of pocket
Reference point above the part
Feedrate
Depth of cut for roughing
Width of cut. % of endmill diameter

Circle-Pocket Macro

O9012(CIRCULAR POCKET)
IF[#3EQ#0]THEN#3000=8(NO PLUNGE FEEDRATE
GIVEN)
IF[#9EQ#0]THEN#3000=3(NO FEEDRATE GIVEN)
IF[#23EQ#0]THEN#3000=5(NO WIDTH OF CUT GIVEN)
IF[#1EQ#0]THEN#3000=21(NO REFERENCE POINT)
N1G0X#24Y#25Z#1
#100=0
#106=0
#140=#5003
#141=#5001
#142=#5002
#32=#4107+12000
#32=#[#32]
#33=#4107+13000
#33=#[#33]
#144=#32+#33(D+2000)
#10=#18-#144(POCKETRAD-EMRAD)
#143=#142-[#10-#4]
#145=[#10-#4]
#146=2*#145
#12=#23*[#144*2](WIDTH-OF-CUT)
#104=[#12*.01]
#27=#26+#5(ZDEPTH-FINISH)
IF[#7EQ2]THEN#104=[#104*[-1]]
IF[#6EQ#0]GOTO3000
#100=ABS[FIX[[#26-#1+#5]/#6]]
#101=#100
N2G90G0Z#1
N3G0G90X#141Y#142
N500IF[#106GE#100]GOTO3000
86

#14=0
G91G1Z-#6F#3
WHILE[[#12+#14]LT[#145]]DO2
N4G1G91Y-#12F#3
#14=#14+#12
N5G#7X0Y[2*#14]R#14F#9
N6G#7X0Y-[2*#14]R#14
N31G0Y0.0
N32END2
N2000#106=#106+1
N19G90G1Y[#143]
G#7G91X0.0Y#146R145F#9
G#7X0.0Y-#146R145
G0Y0
N8G90G0X#141Y#142
N201GOTO500
N3000IF[#5EQ#0]GOTO4000
N9G90G0X#141Y#142
#14=0
N10G1Z#27F#3
N40WHILE[[#12+#14]LT[#145]]DO3
N11G1G91Y-#12F#3
#14=#14+#12
N12G#7X0Y[2*#14]R#14F#9
N13G#7X0Y-[2*#14]R#14
N14G0Y0
END3
N19G90G1Y#143
G#7G91X0.0Y#146R#145F#9
G#7X0.0Y-#146R#145
G0Y0
N4000G0G90X#141Y#142
N14G1Z#26F#3
#14=0
WHILE[[#12+#14]LT[#145]]DO1
G1G91Y-#12F#3
#14=#12+#14
G#7X0Y[2*#14]R#14F#9
G#7X0Y-[2*#14]R#14
G0Y0
END1
N1000IF[#4EQ#0]GOTO23(IF NO FIN ALLOW)
N19G90G1Y#143
G#7G91X0.0Y#146R#145F#9
G#7X0.0Y-#146R#145
G0Y0
IF[#5003NE#26]GOTO4000
N23G90G1Y[#142-#10]
N24G#7G91X0Y[2*#10]R#10F#9
N25G#7X0Y-[2*#10]R#10
N26G#7X#104Y[ABS[#104]]R[ABS[#104]]
N67G0G90Z#140
G0X#141Y#142
M99

Milling Formulas
The following formulas are used to calculate speed and feeds, metal
removal rate, surface feet per minute and horse power used.

Symbols and Measurement Units

'K' Factors
Hardness
BHN
Work Material

D = diameter of milling cutter (inches)

d = depth of cut (inches)
F = feed rate (inches per minute)
f = feed (inches per tooth)
K = power constant of work material
E = spindle efficiency (varies from 75% to 90%)
W = width cut (inches)
Z = number of teofeth in the cutter
mrr = metal removal rate ( cubic in/min)
HPc = horse power at the cutter
sfm = surface feet per minute

steels, wrought
and cast (plain
carbon, alloy
steels, tool
steels)

85-200
201-253
254- 286
287-327
328-371
372-481
482-560
561-615

Precipitation
hardening
stainless steels

150-450 1.27-0.42

150-175
110-190
Cast Irons
176-200
(grey, ductile and 201-250
malleable)
251-300
301-320

To calculate Surface Feet per Minute (SFM)

sfm = .262 x D x rpm
To calculate Feed rate (inches per minute)
F = f x Z x rpm
To calculate Feed (inches per tooth)
f = F/Z x rpm
To calculate Metal Removal rate (mrr)
mrr = W x d x F
To calculate Horse Power at the cutter (HPc)
HPc = mrr/K

'K'
Factor
1.64
1.56
1.28
1.10
0.88
0.69
0.59
0.54

2.27
2.00
1.89
1.52
1.27
1.19

Stainless steels,
wrought and cast 135-275 1.54-0.76
(ferritic, austenitic 286-421 0.74-0.50
& martensitic)
Titanium

250-375 1.33-0.87

High-temperature
alloys, nickel,
200-360 0.83-0.48
colalt base
Iron Base

Example:
To find the Surface Feet per Minute (smf) of a 3/4" 4
flute end mill running at 2500 r.p.m
sfm = .262 x D x rpm
sfm = .262 x .750 x 2500 = 49

smf = 491

87

180-320 0.91-0.53

Nickel alloys

80-360

0.91-0.53

Aluminum alloys

30-150

6.25-3.33

40-90

10.0-6.67

150
100-150
151-243

3.33
3.33
2.00

Magnesium alloys
Copper
Copper alloys

Trouble Shooting

88

Side Mounted Tool Changer Recover

This is the procedure for recovering a side mounted tool changer should the machine loose power
or if the tool is inadvertently load wrong.

1. Restore Power (It is not necessary to Zero return the machine)

2. On the Automatic Tool Changer (ATC) box at the back of machine, set switch to
manual.
3. In MDI key in M39; and press the start button. (This starts maintenance mode and
allows you to use the 2 keys for rotating the tool magazine as jog keys for the tool
changing arm.)
4. Turn mode switch to JOG
If you have a tool in the spindle make sure that the tool is unclamped (Green light on).
If not, manually press tool unclamp button.
5. Using the jog keys (on the ATC box) move the tool changer arm to home position (you
will have to press the key several times). Carefully watch the tool that is being placed in the
spindle. Once it is in position in the spindle manually press tool clamp before proceeding otherwise
the tool will drop. Finish pressing the jog key until the arm is at home position.
6. Turn mode switch to MDI
7. In MDI key in M19; and press the start button (spindle orientation)
8. Key in M41 (will complete 1 complete tool change)
9. Set APC box back to Auto.
10. Check to make sure that you have the correct tool number in spindle before
continuing.
To display tool register
Press SYSTEM ? PMC ? PMCPRM ? DATA ? G.DATA
Page to show parameters D450 & D452
D450 Head Tool (shows tool number in spindle)
D452 Next Tool (shows tool number in waiting pot)

Pot must be in the down position

to run this procedure

M32 Pot UP
M33 Pot Down

89

Horizontal Machining Center

Tool Changer Recover
(DHP and DHC 400)
During a normal tool change
(1) Next tool is placed in spindle.
(2) Tool from spindle is returned to waiting pot.
(3) Tool is returned to correct pocket in magazine.
After this the next tool called is brought to the waiting pot position, then the magazine
rotates back so that the pocket number and the tool in the spindle are the same.
At all times the magazine should have (2) empty spaces.

T5

T1

90

Horizontal Machining Center

Tool Changer Recover
(DHP and DHC 400)
Occasionally due to tool changing errors (2) pots will be in the waiting pot position.
For this example we have T5 in the spindle and T10 as the waiting tool.
The Pot position's were the spindle tool and waiting tool came from should
be empty (e.g. P5/P10). Look in the magazine to see were the third pot is missing from (e.g. P20).
Manually rotate the magazine so that the third empty pocket and the misplaced pot are in line.
On the CRT press Hard Key - SYSTEM, (soft keys) - PMC - PMCPRM - DATA - G.DATA.
This will display the following.
N0
ADDRESS
DATA
0000
0001

D0450
DO452

5 (This is the tool in the spindle)

10 (This is the tool in the waiting pot)
Change D0452 to matched the third empty pocket number (e.g. 20).
In manual bring pot over to magazine side.
Change D0452 back to waiting pot number (e.g. 10).
Return magazine back to auto mode.
The magazine should now be back in sequence.
P10

P5

Misplaced
Pot
I
- Spindle

T10

P20

91

T5

DHP-500 and 630 Tool Change Recovery

This is the procedure to recover the Tool Changer should the machine loose
power during a tool change or if a tool is inadvertently loaded wrong.
1. Restore power.
2. Set Mode switch to Jog.

MODE
TAPE

MDI

REF.RTN.
JOG

MEMORY

EDIT
HANDLE

MODESELECT

3. Make sure that the ATC box is connected to the tool changer and set to Manual.
4. On the ATC box set switch to Tool Change Step Reverse.
5. Keep pressing Start key (green button). Carefully watch the tool being placed in the
spindle. Once the tool is in the spindle manually press the tool clamp button before
preceding otherwise the tool will drop. Finish pressing the start button until the arm is
in the home position.
6. Set switch to Close Door and press start switch.
8. Check to make sure that you have the correct tool in the spindle before continuing.

ATC
CONDITION

SPINDLE
ORIENTATION

APC
CONDITION

Maintenance box
for
DHP-500 and DHP-630

EMERGENCYSTOP
SPINDLE
ORIENTATION

DOORCLOSE
DOOROPEN

TOOLCHANGE
1 CYCLE

W-POTUNCLAMP

TOOLCHANGE
STEP FORWARD

W-POTCLAMP

TOOLCHANGE
STEP REVERSE

W-POTSPDLSIDE

MOTORBRAKE
RELEASE

PALLETCLAMP

PALLETCHANGE
STEP FORWARD

PALLETCHANGE

PALLETCHANGE
STEPREVERSE

PALLET
UNCLAMP

MOTORBRAKE
RELEASE

W-POTMAGSIDE

ATC

APC
STOP

START

92

DHP-500 and 630 Pallet Change Recovery

This is the procedure to recover the pallet changer should the
machine lose power during a pallet change.

MODE

1. Restore Power.
2. Set Mode switch to Jog.

TAPE

MDI

REF.RTN.
JOG

MEMORY

EDIT
HANDLE

MODESELECT

3. Make sure that the APC box is connected to the pallet changer, and set to Manual.
4. On APC box set switch to Pallet Change Reverse.
5. Press Start Key (Green Start Button , wait for pallet to finish rotating before continuing).
6. Set switch to Clamp Pallet and press Start.
7. Set APC switch back to Auto.
8. Check to make sure that you have the correct pallet in the machine before continuing.

When doing a pallet change all doors must be closed at all times.

93

CAT 50 PULL STUD

This pull stud will fit all 50 taper Doosan Machining Centers.

Dimensions are for reference only.

Part No

316-45
311-18

(With through hole)

(No through hole)

To Order Call:
Retention Knob Supply Company
Tel: 937-686-6405
Fax: 937-686-4125

94

CAT 40 PULL STUD

This pull stud will fit all 40 taper Doosan Machining Centers.

Dimensions are for reference only.

Part No

711-23
711-25

(With through hole)

(No through hole)

To Order Call:
Retention Knob Supply Company
Tel: 937-686-6405
Fax: 937-686-4125

95

BT 30 PULL STUD
This pull stud will fit all 30 taper Doosan Machining Centers.

18 mm

M12 x 1.75

11mm

7mm

25mm

Dimensions are for reference only.

Part No 311-09H

(With through hole)

To Order Call:
Retention Knob Supply Company
Tel: 937-686-6405
Fax: 937-686-4125

96

Heavy Tool Limitations

Before using a heavy tool you must first calculate the tools 'Moment' before
attempting a tool change. This should not exceed the machines maximum tool weight.

Weight Center

Taper Gage Line

Calculate the tools 'Moment' as follows

1. Find the tools center of gravity
2. Measure the distance from the tools center of gravity to taper gage line.
3. Weight x length = Moment

The easiest way to find the tools center

of gravity is to tie a piece of string
around the tool, and then find the point
at which the tool is balanced. Measure
from the string to the taper gage line.
Measure fromcenter point
to taper gage line

97

Uses of Large Tool

The following method is recommended when using a large diameter tool.

Empty
Pockets

Tool's with numbers 70 and higher are considered 'large Tools'.

Before you start to use a large tool you must first set the 'Tool Registry'.

To access the Tool Registry

see page 50

When loading a large tool make sure that the pots on either side are empty.
In the 'Tool Registry' set the empty pots to "00".

In this example 'Pot 8' has the large tool with Pots
7 and 9 empty.
When T70 is called in the program it will always
be placed back in Pot 8.

98

Lubrication Requirements
The following is a list of oils used on Doosan machining Centers.
Way Lube 'G' Oil
Hydraulic 'B' Oil
Spindle Cooler 'A' Oil
Grease 'Y' Oil
Air Service Unit 'B2' Oil
Table 'E' Oil

Comparative Oils

Mobil Oil

Shell Oil

Esso Oil

BP Oil

Caltex Oil

Sun Oil

Tellus
C10

Spinesso
10

Energol
HP10

Spindural
10

Solnus 55

A
(FC10)

Velocite
6

B2
(FC32)

DTE Oil Light

Tellus
32

Teresso
32

Energol
HP32

Rando
32

Sunv 916

E
(HM68)

DTE
26

Tellus
68

Nuto
H68

Energol
HLP 68

Rando
HD 68

Sunvis
831 WR

G
(G68)

Vactra
No. 2

Tonna
T68

Febis
K 68

Maccurat
68

Y
(XM2)

Mobilux
2

Alavniagrease
EP2

Beacon
2

Ener-grease
LS 2

No.

Way Lubricant Sun Waylube

68
80
Multifak
EP2

Mold cut on DMV 3016LS

In 1 Hour 32 minutes.
H13 Tool Steel RC50

99

Prestige
42 Grease

Absolute and Incremental Programming Example

Datum

Y+

X+

Answers from page 17

ABSOLUTE (G90)

INCREMENTAL (G91)

A X 4.000

Y-2.000

A X4.000

Y-2.000

B X 8.000

Y-3.000

B X4.000

Y-1.000

C X 1.000

Y-6.000

C X2.000

Y-3.000

D X 2.000

Y-5.000

D X-8.000

Y1.000

E X 3.000

Y-7.000

E X1.000

Y-2.000

F X 8.000

Y-7.000

F X5.000

Y0.000

100

Index
A.
Axis Movement - 7
Absolute Coordinate Programming (G90) - 16,17
Additional Options - 69
Artificial Intelligence Contour Control (AICC) - 70
Artificial Intelligence Advanced Preview Control (AI APC) - 70
B.
Boring,
Fine Boring (G76) - 32
Back Ground Edit - 47
Block Delete - 48
Boring Mill Program Example - 83
C.
Codes,
M Codes (Most Commonly Used) - 5
G Codes (Most Commonly Used) - 4
Control Panel - 6
Coordinate Programming - 16
Circular Programming (G02,G03) - 19,21
Cutter Compensation (G40,G41,G42) - 23,25
Canned Cycles - 26,33
Control Options - 69
Coordinate Rotation - 74
D.
Drilling,
High Speed (G73) - 28
Drilling (G81) - 29
Peck Drilling (G83) - 30
DNC,
Using PCMCIA Card - 62
Using Laptop Computer - 67
Down Loading,
Using PCMCIA Card - 61
Using Laptop Computer - 65

101

E.
Extended Part Program,
Edit - 43
Move - 44
Merge - 45
Change - 46
F.
Fixed Cycles - 28,33
G.
G - Codes (Most Commonly Used) - 4
Graphics (Tool Path) - 79

H.
High Speed Peck Drilling (G73) - 28
Helical Interpolation - 37,38
Horizontal Machining Center Setup - 80,81
Horizontal Program Example - 82
I.
Incremental Coordinate Programming (G91) - 16,17
Initial Plane (G98) - 27
J.
K.
'K' In Canned Cycles - 36
L.
Linear Interpolation (G00/G01) - 15
Look-ahead Control (G8) - 69
Lubrication Requirements - 98

102

M.
M-Codes (Most Commonly Used) - 5
M.P.G (Manual Pulse Generator) - 8
M.D.I (Manual Data Input) - 39
Memory Card - 60
Milling Formulas - 87
MBL APC (Multi Block Look-a-head Advanced Preview Control) - 70
Mirror Image - 71,73
Macro Programming Example - 84,86
N.

O.
Optional Stop - 48
Options - 69
P.
Programming - 15
Plane Selection - 18
Program,
Starting - 40
Numbers - 41
Editing - 42
Sample - 52,55
Searching - 57
Searching For - 58
Deleting - 59
Program Stop - 48
Program Restart - 49
Parameters (Changing) - 51
PCMCIA Cards,
PCMCIA Cards - 60
Uploading and Downloading - 61
DNC Operation - 62
Calling Subprograms (M198) - 63

103

P. Continued,
Restarting a program - 64
Programmable Data Input (G10) - 71
Pull Studs - 93,95
Q.

R.
Radius Command - 22
Rapid Plane - (G99) -27
Rigid Tapping - 33
Rigid Tapping Using an Alternative Axis - 34
Repetition of canned cycles (L) - 35
Restart - 49
RS231C Communication - 68
S.
Starting a Program - 40
Sample Program - 52,55
Subprogram (M98) - 56
Subprogram - Calling from PCMCIA Card (M198) - 63
Scaling - 75
T.
Tool Length Offset - 9
Setting Method - 10
Tool Offset Memory 'C' - 11
Tapping,
(G84) - 31
Rigged Tapping - 33
Rigged Tapping Using an Alternative Axis - 34
Thread Milling - 37,38
Tool Registry - 50
Tool Life Management - 76,78
Tool Path Graphics - 79

104

T. Continued,
Trouble Shooting,
Side Mounted Tool Changer - 88
Horizontal Tool Changer (400 series) - 89,90
Horizontal Tool Changer (HP500/630) - 91
Pallet Recovery (HP500/630) - 92
Heavy Tool Limitations - 96
Uses of Large Tool - 97
U.
Uploading from PCMCIA Card -61
Uploading from Laptop Computer - 66
V.

W.
Work Coordinates - 12
Work Coordinate System Setting Method - 13
Work Coordinate System (G54-G59/G54.1P1-P300) - 14

Y.

Z.

105

Phil Misseldine
Applications Engineer
Machining Centers
Doosan Infracore America Corporation
8 York Avenue
West Caldwell, New Jersey 07006
Main Tel:
Direct:
Fax:
E-mail:

973-618-2500
973-618-2436
973-618-2472
phil.misseldine@dhiac.com

04202007
106