Professional Documents
Culture Documents
Manual
For all Daewoo Machining Centers Using
Fanuc Controls
Notice of Disclaimer
2
Introduction to Programming
Programming of your Daewoo Machining Center involves the sequential
study of the operations required to produce a component, using established
engineering methods.
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.
3
Most Commonly Used G-Codes
G-Code Function
G00 Rapid Positioning Standard
G01 Feedrate Positioning Standard
G02 Arc Clockwise Standard
G03 Arc counter Clockwise Standard
G04 Dwell Standard
G05 High Speed Machining Optional
G08 Look Ahead Control Optional
G09 Exact Stop Standard
G10 Data Setting Optional
G11 Data Setting Cancel Optional
G17 X and Y Plane Selection Standard
G18 Z and X Plane Selection Standard
G19 Y and Z Plane Selection Standard
G20 Input in Inch Standard
G21 Input in Metric Standard
G28 Return to Reference Position Standard
G30 Return to 2nd Reference Position Standard
G40 Cutter Compensation Cancel Standard
G41 Cutter Compensation Left Standard
G42 Cutter Compensation Right Standard
G43 Tool Length Compensation Standard
G49 Tool Length Compensation Cancel Standard
G54 Work piece Coordinate System 1 Standard
G55 Work piece Coordinate System 2 Standard
G56 Work piece Coordinate System 3 Standard
G57 Work piece Coordinate System 4 Standard
G58 Work piece Coordinate System 5 Standard
G59 Work piece Coordinate System 6 Standard
G65 Macro Call Standard
G73 High Speed Peck Drilling Standard
G80 Canned Cycle Cancel Standard
G81 Drilling Cycle Standard
G83 Peck Drilling Cycle Standard
G84 Tapping Cycle Standard
G86 Boring Cycle Standard
G90 Absolute Command Standard
G91 Incremental Command Standard
G92 Setting Work Coordinate System Standard
G94 Feed Per Minute Standard
G95 Feed Per Rotation Standard
G98 Return to Initial Point in Canned Cycle Standard
G99 Return to R Point in Canned Cycle Standard
For a complete G-code list please refer to your Fanuc manual.
4
Most Commonly Used M-Codes
5
Control Panel
RESET O( N ) GE P 7 8 9 ALTER
C
POWER X Y Z Q 4 5 6 INSERT
U V W ?
ON HELP I , J K@ R 1 2 3 DELETE
A
M S T L _ 0
# = *
SHIFT F [ D ]
H B / EOB CAN INPUT
OFF & SP
PROG OFFSET
POS SETTING CUSTOM
PAGE
PAGE
SYSTEM MESSAGE GRAPH
SPINDLE WORK
MODE FEEDOPERATION
100 LIGHT
80
TAPE
MDI 120
REF.RTN.
60
MEMORY JOG
130 ON
25 50
REF.POINT
FO 100 40
EDIT OFF
140
HANDLE 20
RAPIDOVERIDE 180 50 ALARM
EMERGENCYSTOP MODESELECT Y Z 0 40
60
FEEDRATEOVERIDE
_
30
+
X 4TH
80
20 M02/M30 LUB. MACHINE
90
10
100
0
AXISSELECT RAPID SPINDLEOVERIDE RESET
MACHINEREADY EMERGENCYRELEASE FEEDHOLD CYCLESTART
FUNCTION
ON FLOOD THROUGH
MANUAL
AUTO
OFF OFF
SINGLEBLOCK OPTIONAL STOP OPIONAL BLOCKSKIP DRYRUN PROGRAMRESTART
CONVEYOR COOLANT MACHINELOCK PROGRAMPROTECT CW STOP CCW
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.
6
Axis Movement
7
Manual Pulse Generator
Y Z X10
X 4TH X1 X100
_
+
0
90 10
80 20
70 30
60 40
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.
8
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.
Workpiece
9
Tool Length Setting Method
Operators choice of
'Z' zero position.
Work piece (This example uses the
top of the work piece).
OFFSET
Press the function key SETTING
and then the [OFFSET] soft key to display the following screen.
10
Tool Offset Memory 'C' (Optional)
Tool Offset Memory 'C' allows you to use the same number for
Length (H) and Diameter (D) offsets.
OFFSET
Press the function key SETTING
and then the [OFFSET] soft key to display the following screen.
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.
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.
OFFSET
Press function key 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
This option expands the Work Coordinate System giving the user up to 300 sets of work
offsets to chose from.
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)
Y P2
X G00 Rapid Path
P1
15
Co-Ordinate Programming (G90/G91)
16
Absolute and Incremental Programming Example
Datum
Y+
X+
17
Plane Selection (G17, G18, G19)
Before an arc can be machined the correct plane must be selected.
Y+ G17
When generating an arc in the 'X' and 'Z'
X+ axis G17must be selected.
G03 G02
Viewfromtop of machine
G18 Z+
When generating an arc in the 'X' and 'Y'
axis G18 must be selected.
G03 G02
X+
View fromfront of machine
G19
When generating an arc in the 'Y' and 'Z' Plane selection is MODAL
axis G19 must be selected. and will stay effective until
another plane is selected.
Z+
Y+ G03 G02
18
Circular Interpolation (G02, G03)
There are two directions in which you can produce an arc -
G02 Clockwise and G03 Counter Clockwise.
Arc offset in 'X' is represented by 'I'. 'I' is the Incremental value parallel to the 'X' axis.
Arc offset in 'Y' is represented by 'J'. 'J' is the Incremental value parallel to the 'Y' axis.
Arc offset in 'Z' is represented by 'K'. 'K' is the Incremental value parallel to the 'Z' axis.
Example
G02 X1.0 Y0. I0.0 J-1.0
G02 (Clockwise movement)
Datum G02
0
X 1.0 (Tool finish position in 'X')
000
R1. Y 0.0 (Tool finish position in 'Y')
I 0.0 (Arc offset in 'X')
J-1.00
J-1.0 (Arc offset in 'Y')
G03
I-1.00 Example
G03 X1.0 Y0. I-1.0 J0.0
G03 (Counter Clockwise movement)
Datum 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')
Cutting direction N6
G02
Arc offset
parallel to N7
the Xaxis. R.75
X&YZERO
Start N3 I 1.5
Finish N10
R1.5
N8 Arc offset
parallel to
the Yaxis.
J -.75
Arc offset
parallel to
N9
the Yaxis.
J 1.5
20
Circular Interpolation G03
Arc offset
parallel to
the Yaxis. Arc offset
J- 1.5 N9 parallel to
the Yaxis.
J .75
N8
R1.5 X&YZERO
Start N3
Finish N10
Arc offset
parallel to
R.75
the Xaxis. N7
I 1.5
Cutting direction N6
G03
21
Radius Command (R)
8 1
7 2
6 3
5 4
This example machines a ½” 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 1
G2X4.25Y-.5R.75 2
G1Y-3.5 3
G2X3.5Y-4.25R.75 4
G1X.5 5
G2X-.25Y-3.5R.75 6
G1Y-.5 7
G2X.5Y.25R.75 8
22
Cutter Compensation (G41/G42)
Cutter compensation allows a program to be written without considering
the size of the cutter.
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 ap-
plied 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 90°applying
cutter comp
G41
Always apply cutter compensation at 90 degrees to the work piece. The program
for applying cutter compensation should look like this.
G1G41Y0 D1 F25.
G41 and G42 are Modal commands and will stay active until canceled by G40.
24
Cutter Compensation (G42)
Approach part
at 90°applying Endmill is on
cutter comp the right hand side
G42 of the work piece
Direction
of
travel
Always apply cutter compensation at 90 degrees to the work piece. The program for
applying cutter compensation should look like this.
G1G42Y0D1F25.
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 program-
ming quicker and also saves on program memory.
The formats for the most commonly used canned cycles are
Drilling
Peck Drilling
Tapping
Boring
Legend
For additional canned cycles please consult your Fanuc Operator’s 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
27
High Speed Peck Drilling (G73)
Example
G98 G73 X0.0 Y0.0 Z-1.25 Q.250 R.250 F20.
28
Drilling (G81)
Example
G98 G81 X0.0 Y0.0 Z-1.25 R.25 F20.
29
Peck Drilling (G83)
Example
G98 G83 X0.0 Y0.0 Z-1.25 Q.25 R.25 F20.
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.
31
Fine Boring (G76)
Example
G98 G76 X0.0 Y0.0 Z-1.5 R.25 Q.005 F10.
32
Rigid Tapping (G84)
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
Make sure that the program contains the correct reference plane selection.
G18 X and Z
G19 Y and Z
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
36
Thread Milling (Helical Interpolation)
Helical Interpolation provides a method of thread cutting without
having to use a machine tap.
Pitch
Always feedon
using cutter
compensasion
37
Thread Milling (Helical Interpolation)
Example
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
MDI
TAPE REF.RTN.
MEMORY JOG
MODESELECT
Press the PROG hard key and the following screen will be displayed.
Enter the program manually using the key pad, include end of
block (EOB) at the end of each line.
39
Starting a Program
MODE
MDI
TAPE REF.RTN.
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.
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
MDI
TAPE REF.RTN.
JOG
Select EDIT using the MEMORY
HANDLE
MODESELECT
Press the PROG hard key and make sure that the program
requiring editing is displayed.
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
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.
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.
OR
44
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 O2468
Press MERGE key T2 M6
Position cursor G90 G0 G54 X0.0 Y0.0
[~CRSR] S3500 M3
Enter program number G43 Z.1 H21 M8
to be inserted (O2468) G98 G81 Z-1. R.1 F15.
Press INPUT key G80 M9
Press EXEC key
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 It is not possible to move information
G43 Z.1 H21 M8 within a program. You must first copy the
G98 G81 Z-1. R.1 F15. range of information to a new program and
G80 M9 then it is possible to insert it back into the
G91 G28 Z0 Y0 original program at a different location.
M30
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
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
M0 inspection, manual tool change, coolant adjustment, etc.
Optional Program Stop. This M-code stops the machine in the same manner as program
M1 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-
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
PROGRAMRESTART
49
Tool Registry
Use the Page down key to display the complete Tool Registry on one page.
ADDRESS POCKET No
D0300
Tool Registry only D0301 Pocket 1 To change settings parameter
applies to machines D0302 Pocket 2 write must be turned on.
with random select D0303 Pocket 3 (see page 51)
tool magazines. D0304 Pocket 4
etc etc
50
Changing Parameters
Before changing parameters you must first enable parameter write
MODE
MDI
TAPE REF.RTN.
Select MDI using the Mode Select switch. MEMORY JOG
EDIT
HANDLE
MODESELECT
Press the function key Offset and then the [setting] soft key to display the Setting screen.
Setting
Once this is done you are now able to change machine parameters.
To display machine parameters press function key Offset and then soft key
[PARAM]. Setting
Input parameter number to be changed and then press the No. Search key.
51
Sample Program
52
Sample Program
Tool 1
After machining
N19G0Z.1- - - - -- - - -- - - - - - - - Rapid move to 0.1 above the part
center hole
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
53
Sample Program
Tool 2
Tool 3
54
Sample Program
Tool 4
Tool 5
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 let-
ter P replacing the O. e.g. N20 M98 P1066
56
Searching Programs
MODE
MDI
TAPE REF.RTN.
JOG
Select EDIT using the MEMORY
HANDLE
MODESELECT
Press the PROG hard key and the following screen will be displayed.
Enter the Line number, Tool number, G-code or Feedrate to search for then press the
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
MDI
TAPE REF.RTN.
HANDLE
MODESELECT
Press the PROG hard key and the following screen will be displayed.
58
Deleting a Program
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
MDI
TAPE REF.RTN.
HANDLE
MODESELECT
Key in 'O' followed by the desired program number then press the 'Delete' hard key.
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)
Daewoo 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.
60
Uploading and Downloading Programs
Using the PCMCIA Card
MODE
MDI
Insert PCMCIA card TAPE REF.RTN.
MEMORY JOG
Select EDIT using the
Mode Select switch. EDIT
HANDLE
MODESELECT
Press the PROG hard key then the + soft key and CARD soft key to display the
following screen.
61
DNC Operation using the PCMCIA Card
MODE
MDI
TAPE REF.RTN.
Insert PCMCIA card. MEMORY JOG
Select TAPE using the
Mode Select Switch. EDIT
HANDLE
MODESELECT
Press the PROG hard key then the + soft key twice and then DNC-CD soft key to display the
following screen.
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.
When calling a program from the PCMCIA card use M198 instead of M98.
E.g. N20 M198 P1066
63
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.
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 num-
ber turn off single block and press the start button to continue machining.
Your program must contain You must remember to read all relevant infor-
line numbers to be able to use mation for the tool that you need to restart.
the N Search function e.g.. work offsets, Z offsets, rpm,work plane
cutter comp etc
64
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.
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
MDI
TAPE REF.RTN.
Select EDIT using the MEMORY JOG
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.
66
DNC Operation using a Laptop Computer
To DNC from a laptop to the control. First connect the RS232 cable. Then select the pro-
gram you wish to run and prepare the communication software to send.
MODE
MDI
TAPE REF.RTN.
Select TAPE using the MEMORY JOG
HANDLE
MODESELECT
67
RS 232-C Communication Interface Connections
The cable from your computer to the machine should be wired in one of the fol-
lowing configurations.
68
Additional Options
Look Ahead Control (G08)
69
Artificial Intelligence contour control (AICC)
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.
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.
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.
P1 = G54
P2 = G55
P3 = G56
P4 = G57
P5 = G58
P6 = G59
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
MDI
TAPE REF.RTN.
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
72
Mirror Image
73
Coordinate System Rotation
To use Coordinate System Rotation the program format should look like this:
74
Scaling
Using the Scaling option it is possible to enlarge or reduce the size of a part without
having to change the program.
B
A
C
If part A is the original part size, to produce part B which is 1.5 times original. The
program should look like this.
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.
Parameters.
6800 .2 (LMT) 0 (for number of times)
6810 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.
77
Tool Life Management
To display the TLM screen press the Offset Setting hard key then the + soft
key and then the TOOLLF soft key.
78
Tool Path Graphics
Pressing the GRAPH hard key will bring up the Tool Path Graphic 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.
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 G54 P1
G54 P2
G55
G54 P5 G54 P6
G59 G57
B90
B0
G54 P07
G54 P13
G54 P9 G54 P10
G54 P15 G54 P16
B180 B270
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.
to do a B axis move than T2M6 (T2 1/2 END MILL) (calls tool 2)
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.
The 'W' axis is a quill and can only be used for positioning.
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.
G80G49G40G0
G91G28Z0W0
T1 M6 (Calls Tool 1)
G90G54X9.0Y25.0W-5.0S700M03 (Moves to X, Y and 'W' position)
M68 (Clamps W axis)
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)
M69 (Unclamp W axis)
G91 G28 Y0. Z0. W0. (Sends Y, Z and W axis to home position)
G90
M30
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.
84
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 X axis center
Y Y axis center
Z Depth to drill
R Reference point above part
D Diameter of bolt circle
C G code to be used
H Number of holes in pattern
A Starting angle of 1st hole
F Feedrate
T Dwell value
Q Peck depth (G73 & G83 only)
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 X axis center
Y Y axis center Circle-Pocket Macro
Z Depth of pocket
R Radius of pocket #14=0
G91G1Z-#6F#3
D Direction of cut. D2 CW / D3 CCW WHILE[[#12+#14]LT[#145]]DO2
C Feedrate for plunging N4G1G91Y-#12F#3
I Finish cut #14=#14+#12
J Finnish allowance on bottom of pocket N5G#7X0Y[2*#14]R#14F#9
N6G#7X0Y-[2*#14]R#14
A Reference point above the part N31G0Y0.0
F Feedrate N32END2
K Depth of cut for roughing N2000#106=#106+1
N19G90G1Y[#143]
W Width of cut. % of endmill diameter G#7G91X0.0Y#146R145F#9
G#7X0.0Y-#146R145
G0Y0
O9012(CIRCULAR POCKET) N8G90G0X#141Y#142
IF[#3EQ#0]THEN#3000=8(NO PLUNGE FEEDRATE N201GOTO500
GIVEN) N3000IF[#5EQ#0]GOTO4000
IF[#9EQ#0]THEN#3000=3(NO FEEDRATE GIVEN) N9G90G0X#141Y#142
#14=0
IF[#23EQ#0]THEN#3000=5(NO WIDTH OF CUT GIVEN)
N10G1Z#27F#3
IF[#1EQ#0]THEN#3000=21(NO REFERENCE POINT) N40WHILE[[#12+#14]LT[#145]]DO3
N1G0X#24Y#25Z#1 N11G1G91Y-#12F#3
#14=#14+#12
#100=0 N12G#7X0Y[2*#14]R#14F#9
#106=0 N13G#7X0Y-[2*#14]R#14
#140=#5003 N14G0Y0
END3
#141=#5001 N19G90G1Y#143
#142=#5002 G#7G91X0.0Y#146R#145F#9
G#7X0.0Y-#146R#145
#32=#4107+12000
G0Y0
#32=#[#32] N4000G0G90X#141Y#142
#33=#4107+13000 N14G1Z#26F#3
#14=0
#33=#[#33] WHILE[[#12+#14]LT[#145]]DO1
#144=#32+#33(D+2000) G1G91Y-#12F#3
#10=#18-#144(POCKETRAD-EMRAD) #14=#12+#14
G#7X0Y[2*#14]R#14F#9
#143=#142-[#10-#4] G#7X0Y-[2*#14]R#14
#145=[#10-#4] G0Y0
#146=2*#145 END1
N1000IF[#4EQ#0]GOTO23(IF NO FIN ALLOW)
#12=#23*[#144*2](WIDTH-OF-CUT) N19G90G1Y#143
#104=[#12*.01] G#7G91X0.0Y#146R#145F#9
G#7X0.0Y-#146R#145
#27=#26+#5(ZDEPTH-FINISH) G0Y0
IF[#7EQ2]THEN#104=[#104*[-1]] IF[#5003NE#26]GOTO4000
IF[#6EQ#0]GOTO3000 N23G90G1Y[#142-#10]
N24G#7G91X0Y[2*#10]R#10F#9
#100=ABS[FIX[[#26-#1+#5]/#6]] N25G#7X0Y-[2*#10]R#10
#101=#100
N26G#7X#104Y[ABS[#104]]R[ABS[#104]]
N2G90G0Z#1 N67G0G90Z#140
N3G0G90X#141Y#142 G0X#141Y#142
M99
N500IF[#106GE#100]GOTO3000
86
Milling Formulas
The following formulas are used to calculate speed and feeds, metal
removal rate, surface feet per minute and horse power used.
smf = 491
87
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.
89
Horizontal Machining Center
Tool Changer Recover
(DHP and DHC 400)
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
3
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
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
Misplaced
Pot
I
P5 - Spindle
T10
T5
P20
91
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.
MEMORY JOG
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.
Maintenance box
EMERGENCYSTOP for
DHP-500 and DHP-630
SPINDLE
ORIENTATION PALLETCHANGE
DOORCLOSE PALLETCLAMP STEP FORWARD
TOOLCHANGE
DOOROPEN 1 CYCLE PALLETCHANGE
PALLETCHANGE STEPREVERSE
TOOLCHANGE MOTORBRAKE
STEP FORWARD PALLET
W-POTUNCLAMP UNCLAMP RELEASE
TOOLCHANGE
W-POTCLAMP STEP REVERSE
MOTORBRAKE
W-POTSPDLSIDE RELEASE
W-POTMAGSIDE
ATC APC
STOP START
92
DHP-500 and 630 Pallet Change Recovery
MODE
1. Restore Power.
2. Set Mode switch to Jog. TAPE
MDI
REF.RTN.
MEMORY JOG
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 Daewoo Machining Centers.
To Order Call:
94
CAT 40 PULL STUD
This pull stud will fit all 40 taper Daewoo Machining Centers.
To Order Call:
95
BT 30 PULL STUD
This pull stud will fit all 30 taper Daewoo Machining Centers.
18 mm
M12 x 1.75
11mm
7mm
25mm
To Order Call:
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
97
Uses of Large Tool
Empty
Pockets
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
Comparative Oils
Mobil Oil Shell Oil Esso Oil BP Oil Caltex Oil Sun Oil
99
Absolute and Incremental Programming Example
Datum
Y+
X+
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
106