CNGMACHINE MOOUSy2) LAPS CNC MILL CUTTER COMPENSATION (DENFORD NOWAMILL HC, B706B-BA AMATROL|CNC MACHINE TOOLS 2 QNC MILL CUTTER COMPENSATION (DENFORD NOVAMILL) =ITC... TECHNOLOGY CONCEPTS Le aCNC MILL CUTTER COMPENSATION (DENFORD NOVAMILL) INTRODUCTION As you begin to program complex shapes for machining on the CNC machine, it becomes important to lea ways in which to simplify the program. In this LAP, you will learn how to use cutter compensation, a feature in many CNC machines which can greatly simplify CNC programs. In addition, you will learn another feature called mirroring which will allow you to simplify certain programs even further. You will use it in this LAP to create a playing card ITEMS NEEDED secter School or Amatrol Supplied cc) 1 Denford Novamill 1 Vise, Manual or Pneumatic 1 Denford Programming Software 2 3-1/2" x 2-1/2" x 1/4" (90 mm x 65 mm x 6 mm) Plastic 15/16" End Mill 1/8" End Mill 1 Edgefinder School Supplied Computer FIRST EDITION, LAP 3, REV. B ‘Amaivol, AMNET, CIMSOFT, MCL, MINLCIM, IST, ITC, VEST and Technovato are trademarks ot registered ‘wademarks of Arto, Inc. Al other brand and product ames are trademarks o registred trademmanks of their respective companies (Copyright © 2004 by AMATROL, INC. Al ighs Reserved. No part of his publication may be reproduced, translated, or transmited inary form or by any ‘means, electronic, optical, mechanical, or magnetic, Including Dut not lmifed to photographing. photocopying, recording or any informaton storage and retievalsysiem, without wniten permission of the copyright owner. ‘Amato, in, P. 0. Box 2687, Jeffersorvil, Indiana 47131 USA, Phone 812-288-8285, FAX 812-283-1584 B706B-BA LAP 3 CNC MILL GUTTER COMPENSATION (OENFORD NOVAMILL) Copyright © 2004 Amato, neTABLE OF CONTENTS SEGMENT 1 CUTTER COMPENSATION LEFT. ete OBJECTIVE 1 Define cutter compensation and give two advantages OBJECTIVE 2. List and describe lour imitations fo using cutter compensation OBJECTIVE 3 Explain the use of the cutter compensation left G-Code (G41) QEYECTIVE 4 Explain he us of ne foal change command (MOE) | OBJECTIVE 5 Explain the use of the cutter compensation cancel G-Code (G40) ‘Activity 1 Using cutter compensation left SEGMENT 2 CUTTER COMPENSATION RIGHT ........ tea OBJECTIVE 6 Explain the use of the cutter compensation right G-Code (G42) ‘Activity 2. Using cutter compensation right SKILL 1 Design a CNC program that uses cutter compensation SEGMENT 3 SCALING AND MIRRORING ... iia OBJECTIVE 7 Explain the use of the scaling G-Code (G-51) ‘Activity 3. Using Scaling OBJECTIVE 8 Describe the use of the scaling G-Code for mirroring Activity 4. Using the Scaling G-Code for mirroring SKILL 2 Design a CNC program that Uses mirroring B706B-BA LAPS. CNC MILL GUTTER COMPENSATION (OENFORD NOVAMILL) Copyright © 2004 Amato, ne.SEGMENT 1 CUTTER COMPENSATION LEFT fe) -S oN Tay DEFINE CUTTER COMPENSATION AND GIVE TWO ADVANTAGES “a Cutter compensation allows the user to program in the actual geometry of a part, and instruct the controller to position the edge (not eo =... ‘When programming contours that travel around the outside of a part, it has been necessary so far to determine where the center of the tool ‘must travel in order to have the edge of the tool trace the desired edge of the part. This is shown in figure 1 Gor x0.25 025 Gor x0.25 v425 Goi X400¥428 (G02 X4.00¥275 0.00 4.078 (G08 x4.0877 ¥2 2659 10.00 4.0.25, G01 xs.2453 71.1082 a2 x4.00 ¥ 0.25 1.2483 J-0,1082 Gor x028 4.0.95 NOTE: ALL DIMENSIONS ARE IN INCHES. Figure 1. Programming the Center of the Toolpath Notice that some of the coordinates are very precise. These require difficult calculations. In fact, some of the coordinates on the right side of the part cannot be determined without the use of fairly complex trigonometry (the mathematics of angles). {3700B-BA LAP 9. CNC MILL CUTTER COMPENSATION (DENFORD NOVAMILL) Copyright © 2004 Amatr, ne, 4Fortunately, almost all CNC controllers support cutter compensation as a solution to this problem. The part from figure 1 programmed with cutter compensation is shown in figure 2. Got xovo Gor xovs Gor xa Gee xa¥3 10.05 03 xé¥2 10908 Gor xs¥s G02 X40 1-1 40 Got xovO NOTE: ALL DIMENSIONS ARE IN INCHES Figure 2. Programming Using Cutter Compensation Cutter compensation has two major advantages which make it a commonly-used technique in CNC programming: ‘+ Simpler Programming - When using cutter compensation, it is no longer necessary to perform the complex calculations required to determine the toolpath. The calculations are left to the controller, and all that needs to be done in order to program in the part is to properly interpret the part drawing. ‘+ Simpler Tool Changes - A program which has been programmed using cutter compensation can be run with any size tool. All that is required is to change the program block which sets the diameter of the tool. [B7066-BA LAP 3 CNC MILL CUTTER COMPENSATION (DENFORD NOVAMILL) Copyright © 2004 Amatral, ne.eS ei) 23 LIST AND DESCRIBE FOUR LIMITATIONS TO USING CUTTER COMPENSATION While cutter compensation is of great assistance to CNC Programmers, there are certain restrictions which are placed on the CNC programs in which cutter compensation is used. These are + The first compensated move must be a linear interpolation - Because of the way most CNC controllers read a program, the first tool movement after cutter compensation is activated must be a G01. This allows the controller to properly activate cutter compensation and arrive at the correct coordinate to begin cutting. + The first compensated move must be longer than the cutter’s radius - In order for cutter compensation to be activated correctly, the first tool movement (which must be a GO1) must also be longer than the radius of the tool. If not, the cutter will not be properly Positioned to begin cutting. + Two consecutive Z-value changes are not permitted with cutter compensation - Because of the manner in which most CNC controllers read a program, it is possible to make one Z-value change, but two in a row will confuse the controller when cutter compensation is active. + Rapid traverse does not function with cutter compensation active - This is not true for every controller, however most will have difficulty properly compensating a GOO. For that reason, it is recommended that rapid traverse never be used when cutter compensation is active. Always use GOI, even if no material is being cut. '87088-BA LAPS. CNC MILL CUTTER COMPENSATION (DENFORD NOVAMILL) Copyright © 2008 Amatrl, nc #CENSeeee © EXPLAIN THE USE OF THE CUTTER COMPENSATION LEFT G-CODE (G41) ” Cutter compensation can be set to either side of the geometry you wish to create. Whether you use left or right cutter compensation will @ depend on the part you want to make. Examine figure 3 to understand how both directions of cutter ‘compensation work. Notice that, as indicated, you can determine the ccutter compensation being used by looking in the direction in which the cutter is moving. With cutter compensation left, the tool will be to the left of the programmed path. With cutter compensation right, the tool will be to the right of the programmed path. SEs NOTE S YYou wil learn about cutter compensation right in the next toonent Lert OFF RIGHT CUTTER POSITIONED curren posimionep — TO LEFT OF TO RIGHT OF PROGRAMMED PROGRAMMED GEOMETRY GEOMETRY Figure 3. Cutter Compensation Lett, Off, and Right G41 will set the cutter compensation to the left. The G41 command requires no additional syntax. It is simply: Gat This command will determine the amount of compensation to select based on the size of the current tool. [B7068-BA LAP 3 ONG MILL CUTTER COMPENSATION (DENFORD NOVAMILL) Copyright © 2004 Amati, ne 7tS] EXPLAIN THE USE OF THE TOOL CHANGE COMMAND (M06) oe The tool change command is used for two purposes. When the CNC ‘machine is equipped with an automatic tool changer, the M06 command @ will instruct the CNC machine to retum the current tool to the tool carousel, and select the new tool indicated by the command. If, however, no tool changer is used, the M06 is used to tell the Controller the size of the tool which should be compensated for. ‘The syntax for M06 is: MO6T.. ‘The T-word indicates the number of the tool used. In order for the cutter compensation to be properly set, the diameter of the cutting tool used must be set as well. This is most often set by configuring Tool and Billet settings within the control software. OBJECTIVE 5 EXPLAIN THE USE OF THE CUTTER COMPENSATION CANCEL G-CODE (G40) @ ‘The G40 command is used to cancel cutter compensation. With the next linear interpolation (G01) move, the compensation will be gradually ramped off, restoring normal positioning. The G40 requires no additional syntax. Itis simply: G40 Just like with G41, the first movement after a G40 must be a linear interpolation. B708B-BA LAPS GNC MILL CUTTER COMPENSATION (DENFORD NOVAMILL) Copyright © 2008 Amato, re 8Activity 1. Using Cutter Compensation Left Procedure Overview In this procedure, you will program a part that requires the use of the cutter compensation left command. @ 1. Start the CNC mill and the CNC programming software. Q 2. Examine the part shown in figure 4. ‘You will create a CNC program to cut this part using cutter compensation. 0.0% “NOTE: AMOUNT ‘OF MATERIAL INSIDE RECESS {S UNIMPORTANT] 2.50 3 ete 8 fa i - L100 Foon NOTE: ALL DIMENSIONS ARE IN INCHES Figure 4. Part Drawing Q 3. Create the header and begin the CNC program with the following lines. Noto G20 1Noz0 G90 1NOgo Moé Tt No4o M03 $1600, ‘These lines set the positioning system to inches, activate absolute positioning, select tool #1, and start the spindle at 1600 rpm, {B705.8A LAP CNC MILL CUTTER COMPENSATION (OENFORD NOVAMILL) ‘Copyright © 2004 Amato, ne. 8G 4, Perform the following substeps to write the toolpath blocks of the program. A. Enter the following five lines. NO50 GOO X0.5 YO.5 ‘Noo 20.5 No70 Gai Noso Got x1 NOQO X1.5 Y0.5 F7 These lines moved the cutter to a position near the plunge Point, activated cutter compensation left, and moved to the plunge point. It is necessary, when using cutter compensation, to start away from the plunge point so that cutter compensation can be enabled before finding the correct plunge point. ‘Notice that the plunge point is in the center of one of the lines to be cut. This is necessary for cutter compensation to work properly for the entire contour. Notice also that the approach to the plunge point was made in ‘two moves. Cutter compensation “ramps on”, or activates gradually over the course of the next interpolation command. Adding two moves between activating cutter compensation and plunging ensures that cutter compensation will be fully activated before cutting any material. B, Enter the following two lines. N100 2-0.025 NI10X1.75 ‘These plunge the cutter into the material and start cutting the ‘octagon. The points programmed in are those based on the part drawing, but with cutter compensation, the cutter’s edge, not its center, will be along the line from (1.5, 0.5) to (1.75, 0.5). C. Enter the following nine lines to finish the octagon and lift the ‘cutter from the surface of the part. N120 x2.25 ¥1 N30 71.5 N140 x1.75 2 N180 X1.25 N60 0.75 V1.5, Nizov1 N180 X1.25 Yo.s N190 x1.5 1N200 20.5 Q 5. Enter the following four lines to tum off cutter compensation, return to the origin, shut off the spindle, and end the program. Ne10. G40 N20 Go1 xo Yo 1N230 MoS; 240 M30 Q 6, Examine the completed program to make sure it has been entered correctly. Q 7. Configure the control software's tool settings for a 1/8" end mill 87068-8A LAPS CNC MILL CUTTER COMPENSATION (DENFORD NOVAMILL) Copytight © 2004 Amato, Ine. 10@ 8. Simulate the program. Its output should look like figure 5 Rrra x:ooise _vifacsss 22/6500 F:7omo Mis) Ss: Tih Figure 5. Simulated Output As you can see, it is difficult to notice the effects of cutter ‘compensation at this point NOTE an At the time this LAP was created, the cutter compensation &% code did not simulate correctly. You will not be able to complete objectives and skills on cutter compensation. You will be able to correctly use cutter compensation on the actual mil 9. To notice cutter compensation better, reconfigure the tool settings for a 1/2” end mill. {B7056.BA LAPS CNC WILL CUTTER COMPENSATION (DENFORD NOVAMILL) ‘Copyright © 2004 Amatrol, Inc. W10. Now simulate the program again. Its output should look like figure 6. Notice that, while a different Cutter was used, the outside edge of the octagon remained the same size. The only thing that changed when you changed tool sizes was the amount inside the octagon that was removed, ere Sar Reset Figure 6. Simulated Output OIL. Try changing to some other tool sizes and simulating the program again, Find a tool size which will remove all of the material inside the octagon, 12. Save the program as A\7010. 13. Leave the CNC mill and programming software running and go on to the next objective. BT06E-BA LAP S. CNC MILL CUTTER COMPENSATION (DENFORD NOVAMILL) Copyright © 2004 Amara, Ine. 121a SELF REVIEW When using cutter compensation, the of the tool will move along the programmed geometry, not the center. ‘The same CNC program using cutter compensation can be used for roughing and finishing cuts by simply adjusting the of the tool in the software. AI sets the cutter compensation to the of the programmed geometry. ‘The correct tool is selected using the__ command. The control software has Tool and Billet allow the user to set the of a specific cutting tool, 157008-5A LAPS GNG MILL CUTTER COMPENSATION (DENFORD NOVAMILL) Copyright © 2004 Amato, no. 13ei) CUTTER COMPENSATION RIGHT OBJECTIVE 6 EXPLAIN THE USE OF THE CUTTER COMPENSATION RIGHT G-CODE (G42) ie G42 sets the cutter compensation to the right. The G42 command @ requires no additional syntax. It is simply: G42 This command works identically to G41, except that cutter compensation is set in the opposite direction. G42 will determine the amount of compensation to select based on the size of the current tool. The cutter will be to the right of the programmed path when using G42, Activity 2, Using Cutter Compensation Right Procedure Overview In this procedure, you will program a part that requires the use of the cutter compensation right command. running from the previous activity If not, start them now. G2. The program 7010 should already be in memory from the previous activity. If not, load it from your floppy disk now. Program 7010 was created using cutter compensation left. You will change the program to use cutter compensation right Q 3. Edit line NO70 to read: NO70 G42 ‘This will change the cutter compensation in the program from left to right cay G 1. The CNC machine and programming software should already be 87068-BA LAPS. CNC MILL CUTTER COMPENSATION (DENFORD NOVAMILL) Copyright © 2004 Amato, in. 14G4. Simulate the program using a 1/ like figure 7 ind mill. Its output should look Xi 21_¥: BAI 2300050 F: 7.0000 Mi 3 5; 160 1 Figure 7. Simulated Output NOTE At the time this LAP was created, the cuter compensation code didnot simulate correctly. You wil not be able 16 complete eS this actviy, but it is important that you read through the objectives and skills on cutter compensation. You will be able to correctly use cutter compensation on the actual mil B706B-BA.LAP 3. CNC MILL CUTTER COMPENSATION (OENFORD NOVAMILL) A (Copyright © 2004 Amat, Inc. 1G5. Change the cutter diameter to 0.5" and simulate the program again. ‘The output should look like figure 8, Cree Berio | ent Tuto Pate | 30 Moons) Figure 8. Simulated Output 6. Try changing to some other tool sizes and simulating the program again. Note that if the cutter size is too large, the cutter will move beyond the machine limits and produce an error message. Q 7. Retum the tool size to 0.25" and use the Save As option in the CNC files menu to save the program as A:\7020, 8. Leave the CNC mill and programming software running and go on to the next skill [870668 LAP CNC MILL CUTTER COMPENSATION (DENFOAD NOVAMILL) Copyright © 2004 Amatrl, ne. 16ms Lae DESIGN A CNC PROGRAM THAT USES CUTTER Ee COMPENSATION Procedure Overview In this procedure, you will design a CNC program which will require you to use cutter compensation left and cutter compensation right. CS Se eee | NOTE At the time this LAP was created, the cutter compensation code did not simulate correctly. You will not be able to complete this activity, but it is important that you read through the objectives and skills on cutter compensation. You will be able to correctly use cutter compensation on the actual mill, — Q 1. The CNC mill and programming software should already be running. If they are not, start them up now. Gi 2. If necessary, clear any program in memory so you have a clear work area in which to program. '87008-BA LAP CNC MILL CUTTER COMPENSATION (OENFORD NOVAMILL) Copyright © 2004 Amato, ne3. Create and enter the CNC program to cut the part shown in figure 9. The three circles are all made by entering the same set of cutter moves, only with different cutter compensations. The circle on the left was made with cutter compensation left, the circle in the middle was made without cutter compensation, and the circle on the right was made with cutter compensation right. Use a spindle speed of 2000 rpm and a feedrate of 4 inches per minute, NOTE: MATERIAL THICKNESS IS 1/4" NOTE: DEPTH OF CUT IS 1/16" 0.063") Figure 9. Part Drawing Be sure to use the appropriate directives and startup blocks to allow cutter compensation to work correctly. 'B7068-8A LAPS. CNC MILL CUTTER COMPENSATION (DENFORD NOVAMILL) CCopytight © 2004 Amatrol, Inc. 18Q 4, When the program is finished, simulate it to make sure itis correct. ‘The output should look like figure 10. Milling 3 Sieulation Rewer wy | Reset Tuto Pate | 3D Mesnae| Figure 10. Program Output G 5. If the output is correct, save the program as A:\7030. G 6. Run the program using a 1/4" end mill and a piece of 3-1/2" x 2-1/2" x 1/4" plastic. Be sure to observe all safety precautions before cutting material Q 7. When the program is finished, remove the part from the CNC mill, shut down the CNC mill and the programming software. [B706B-BA LAP S_ CNC MILL GUTTER COMPENSATION (OENFORD NOVAMILL) Copyright © 2004 Amato, Ine 19G8. Measure the two distances shown in figure 11 using a dial caliper. ‘These distances should both be 1.000” Figure 11. Distances to Measure [87068-BA LAP CNG MILL CUTTER COMPENSATION (DENFORD NOVAMILL) Copyright © 2004 Amato, Inc. 20SELF REVIEW The first tool movement after activating cutting ‘compensation must be a movement, Cutter compensation is canceled using the ‘command, G42 is the G-code for When using cutter compensation, extremely utter sizes can make the cutter move beyond the machine limits, 1B7068-BA LAP CNC MILL CUTTER COMPENSATION (DENFORD NOVAMILL) Copyright © 2008 Amato, Ine. 21e111} SCALING AND MIRRORING fel -8] ea) ae EXPLAIN THE USE OF THE SCALING G-CODE (G51) of similar features which are sized differently, like those shown in figure 12. On many CNC machines, the three features shown would each need to be programmed separately. , Occasionally, large or complex CNC programs will have a number Figure 12. Similar Features However, the proLIGHT CNC machine (and others) allow the Programmer to change the scale of the coordinate system. This means that the features on the could all be made using a single set of tool moves. that was run three times (in a subprogram, for example). ‘The scaling commands are as follows: 650 - Cancel Sealing G51 - Invoke Sealing B7068-8A LAP. CNC MILL CUTTER COMPENSATION (DENFORD NOVAMILL) Copyright © 2004 Amato, ne 2GSI, Invoke Scaling, G-code is used to change the scale of the coordinate system's axes. This G-code uses the following syntax: GSIL.I.K.. ‘The values specified for I and J indicates the values by which the X- and Y-axes are scaled. For example, 12 32 Kiwould double all of the values on the X- and Y-axes but leave the Z. values the same. This would double the length of all tool moves thereafter and create an object twice its original size. Saran opie ama : : ; ‘| Figure 13. The Scaling G-Code with 12 J2 Kt ‘The command G51 10.5 J0.5 K1 would cut all of the X- and Y-axis values in half, as shown in figure 15. aa : Faerie ‘ : ’ 3 i : : : : ‘| BS : — Figure 14. The Scaling G-Code with 10.5 J0.5 K1 G50, Cancel Scaling, turns off any scaling and returns the coordinate system to normal. It is important to keep in mind that careless use of the scaling command can cause the tool to move in unexpected directions, All programs should be simulated and dry runs should be performed before attempting to cut material, B706B-BALAP 3. CNC MILL CUTTER COMPENSATION (DENFORD NOVAMILL) ‘Copyright © 2004 Amat, ne. 23Activity 3. Using Scaling Procedure Overview In this procedure, you will enter a CNC program which will use the mirror commands to simplify and shorten the program. You will create the CNC program to create the part shown in the previous objective in figure 12. 2. Enter the following subprogram and save it as A:\2331. 02831 a Q 1. Start up the CNC mill and the programming software. No10 Goo 20.5 NO20 X1.75 Y1.5 NO30 GO} 2-0.05 Noo x2.3995 ¥1.875 NOSO G03 X1.0101 ¥1.6229 R75 NO60 GOI X0.4243 ¥2.1875 NO70 YO.75 ‘Nogo x1.0101 1.3771, No90 Gos X2.3995 ¥1.125 .75 N100 Got X1.75 ¥1.5 N1140 G00 20.5 N120 M99 ‘The program 2331 will be used as a subprogram which will cut the fish shape. If you wish to see the subprogram execute, remove line N120 and run the program. NOTE If you do not remove the M99 (subprogram end) command, the program will loop continuously until you press the [ESC] key. When there is no main program to which to return, M89 simply restarts the current program. Be sure to put the M99 command back into the subprogram before continuing. © 3, Start a new program. You will now create the master program which subprogram three times. call the 1B7068-8A LAP3_ CNC MILL CUTTER COMPENSATION (DENFORD NOVAMILL) Copyright © 2008 mato, Inc. 24G 4, Create a header that contains the following workpiece information as Bilet Length 4.5" Bilet Width =" Billet Thickness 25° Enter the following program blocks to begin the program, 02332, No10 G20 'No20 G90 'No30 Mos T1 No40 Mos $1600 'NO50 Goo Z0.5 'No6o Xo YO These blocks set the positioning system and the stock size, the tool size, the positioning system, start the spindle, and position the cutter at X=0, Y=0, 20.5. . Enter the following program block. 'No70 M98 P2331 This will cut the first fish. In this case, no scaling has been activated, so the fish will be cut using the actual coordinates listed in the subprogram. Enter the following program blocks. 'NO80 G00 x45 NO80 G51 10.5J0.5 K1 ‘N00 Mes P2331 Line NO80 moves the cutter to the position X=45. This is a point ‘on the right-hand edge of the stock. Line NO90 invokes scaling of both the X- and Y-axes. They will be scaled down to 1/2 their original size. The Z-axis will be unchanged. [8706B-BA LAP.@._ CNC MILL GUTTER COMPENSATION (DENFORD NOVAMILL) Copyright © 2004 Amato, in. 25Line N100 calls the subprogram again. This time, when the subprogram is executed, the coordinates will be scaled. When the subprogram tells the cutter to move to an X value of 1.75, the cutter will actually wind up moving half of the distance needed to get there. Additionally, when the subprogram tells the cutter to move to a Y value of 1.5, the cutter will only move until half the distance. The second fish will be half the size of the first, as shown in figure 15. THis FISH Figure 15. Creating the Second Fish Until scaling is canceled, all cutter moves will be cut in half. {B7068-BA LAP 3 CNC MILL CUTTER COMPENSATION (DENFORD NOVAMILL) ‘Copyright © 2004 Amati, ne. 26G1 8. Enter the following program blocks. NIt0 G50 N120 Goo x4.5 (N190 G51 10.25 Jo.25 Kt 140 M98 P2331 Line N110 cancels scaling. All cutter movements will reflect the XY coordinates returning to their original size. Line N120 moves the cutter back to the position X=4.5, Line N130 invokes scaling. This time the X- and Y-axes will be scaled down to 1/4 their original size. Line N140 calls the subprogram again and the third fish will be drawn. This fish will be 1/4 the size of the original. THiS FISH Figure 16. Creating the Third Fish 87066-BA LAP 3. CNC MILL CUTTER COMPENSATION (DENFORD NOVAMILL) Copyright © 2004 Amato, ne 279. Enter the following program blocks. N150 G50 N160 G00 20.5 N170 Xo Yo N180 Mos N190 Moz These are your shutdown blocks. The scaling is canceled, the cutter is returned to its starting position of X=0, Y=0, Z=0.5, the spindle is shut down, and the program is ended, 10. Configure the control software’s tool settings for a 1/16" end mill. QL. Save the program as A:\2332, 12. Simulate the program. The output should look eer [= a cio y) | Pmt tuto Pate | 3 Nean| Figure 17. Program Output 1B7008-BA LAPS. CNC MILL CUTTER COMPENSATION (DENFORD NOVAMILL) Copyright © 2004 Amatra, ine. 28bot) DESCRIBE THE USE OF THE SCALING G-CODE e FOR MIRRORING oe As you have just Teamed, complex CNC programs may have G number of similar features of different size. They can also have a number of similar features which are oriented differently, as shown in figure 18 Figure 18. Similar Features with Different Orientations Again, these four features do not need to be programmed separately Instead, the scaling G-code can be used to “mirror” a single set of tool ‘moves that are run four times (in a single subprogram for example). [8706B-BA LAP 9. GNC MILL CUTTER COMPENSATION (OENFORD NOVAMILL) Copyright © 2008 Amat, ne. 20As you have already leamed, the scaling commands are as follows: G50 - Cancel scaling G51 - Invoke scaling Invoking scaling with I-1 will multiply the X-axis values around the ‘current cutter location. This is shown in figure 19. In figure 19, you can see how the X-axis has been “mirrored”, After mirroring, the positive X direction is to the left, not the right. Notice also that the Y-axis is unaffected. ‘The cutter’s location is also unaffected. Both before and after mirroring the cutter is at the coordinate (2,3). ORIGINAL. CUTTER axis < SYSTEM Figure 19. Flipping the X-Axis Using G51 87066-8A LAP 3_CNC MILL GUTTER COMPENSATION (DENFORD NOVAMILL) Copyright © 2004 Amati, Inc.Invoking scaling with J-1 works in the same manner, except that the Y-axis is flipped, and the X-axis is unaffected. This is shown in figure 20. ORIGINAL ‘CUTTER oe Figure 20. Flipping the Y-Axis Using G50 G50 can be used to cancel scaling and return the coordinate system back to normal. It is important to note that careless use of “mirror” can cause the tool to move in unexpected directions. All programs should be simulated and dry runs should be performed before attempting to cut material. 187008-BA LAP.G_CNC MILL CUTTER COMPENSATION (DENFORD NOVAMILL) Copyright © 2004 Amaro, ne 31& Activity 4. Using the Scaling G-Code for Mirroring Procedure Overview In this procedure, you will enter a CNC program which will use the mirror commands to simplify and shorten the program. © 1. Start up the CNC mill and the programming software. You will create the CNC program to create the part shown in the previous objective in figure 18. Q 2. Enter the following program and save it as A:\2340. 02340 'NO10 Goo 20.5 1NO20 X1.125 ¥1.125, 1NO30 Got Z-0.05 odo 1.625 1NO5O X1.25 1.5 NO6O X1.5 ¥1.75 NO7OX1.75 Y1.5 Nog0 X15 ¥1.25 1NO90 X1.625 71.125, N00 1.125 ¥1.125, N10 Go9 0.5 12099 ‘The program 2340 will be used as a subprogram which will cut the arrow shape. If you wish to see the subprogram execute, remove line N120 and run the program. It will create the top-right arrow on the part shown in figure 18. NOTE If you do not remove the M99 (subprogram end) command, the program will loop continuously until you press the [ESC] key. ‘When there is no main program to which to return, M99 simply restarts the current program. Be sure to put the M99. command back into the subprogram before continuing. Q 3. Start a new program. You will now create the master program which will call the subprogram. [B7066-BA LAP 3. CNC MILL CUTTER COMPENSATION (DENFORD NOVAMILL) (Copyright © 2008 Amato, Inc4. Create a header that contains the following workpiece information, Bille Length 2" Bllet Wieth 2 Billet Thickness 25° Q 5. Enter the following program blocks to begin the program. 02341 Noi0 Geo ‘No20 G90 ‘N030 Mos T1 Noo Mos S1600 NNos0 Goo 0.5 No60 xo Yo ‘These blocks set the positioning system and the stock size, the tool size, the positioning system, start the spindle, and position the ~ cutter at X=0, ¥=0, 2-0. O 6. Enter the following program block. 1No70 M8 P2340 ‘This will cut the frst of the arrows. In this case, no mirroring has been activated, so the arrow will be cut using the actual coordinates listed in the subprogram, Q 7. Enter the following program blocks. 'N0B0 Goo x1 : No90 G54 1-1 Jt Kt Ni00 Mae P2340 Line NO80 moves the cutter to the position X=1. This is the point ‘around which you wish to mirror the X axis, 50 you must first ‘move the cutter to that location before activating the mirror. Line NO90 activates mirroring in the X direction, [B70G0-GA LAP.9. CNC MILL CUTTER COMPENSATION (DENFORD NOVAMILL) Copyright © 2008 Amaro, nc. 33Line N100 caifs the subprogram again. This time, when the subprogram is executed, the X coordinates will be mirrored about the position X=1. When the subprogram tells the cutter to move to an X value of 1.5, the cutter will actually wind up at X=0.5. The arrow that will be created is shown in figure 21. Figure 21. Creating the Second Arrow B7068-GA LAP CNC MILL CUTTER COMPENSATION (DENFORD NOVAMILL) ‘Copyright © 2004 Amatral, nc. 348. Enter the following program blocks. Ni10 G50 1N120 Goo v1 N190.G51 11 Jt Kt N140 Moe P2340 Line N110 cancels scaling. The X-axis will no longer be mirrored, Line N120 moves the cutter to a position where Y= about to mirror the Y axis. Line N130 activates mirroring in the ¥ direction. Line N140 calls the subprogram again. With Y mirroring active, a third arrow will be created. This arrow is indicated in figure 22, You are Figure 22, Creating the Third Arrow 87066:BA LAP 3. CNC MILL CUTTER COMPENSATION (DENFORD NOVAMILL) Copyright © 2008 Amaro, Ine. 35O 9. Enter the following program blocks. N180 G50 N60 GOO x1 Y1 N170 G54 1-1 J-1 Kit N180 M98 P2340 Line N150 cancels scaling. It is not necessary to position the cutter in a particular location before canceling. Line N160 moves the cutter to position X=1, to mirror both axes. Line N170 activiates mirroring in both the X and Y direction. Line N180 calls the subprogram again. With both X and Y mirroring active, the fourth and final arrow will be created. This arrow is indicated in figure 23, 1. You are about Figure 23. Creating the Fourth Arrow 10. Enter the following program blocks. Ni90 G50 N20 M81 N210 G00 20.5 N20 X0 YO 1N230 MoS N2ao Moz ‘These are your shutdown blocks. All mirroring is deactivated, the cutter is retumed to its starting position of X=0, Y=0, Z=0.5, the spindle is shut down, and the program is ended. Q11. Configure the control software's tool settings for a 1/8” end mill. G12. Save the program as A\2341. 'B706B-BA LAP 3. CNC MILL CUTTER COMPENSATION (DENFORD NOVAMILL) Copyright © 2004 Amatro, inc. 36G13, Simulate the program. The output should look like figure 25. Cie Figure 24. Program Output 214. Leave the CNC software running and continue to the next skill. {27068-BA LAP 9 CNC MILL CUTTER COMPENSATION (DENFORD NOVAMILL) Copyright © 2004 Amati), Ine aDESIGN A CNC PROGRAM THAT USES MIRRORING Procedure Overview In this procedure, you will design a program to create a part. The program will be able to be simplified dramatically with the use of mirroring. When you have completed this program, you wil understand much better how to use mirroring, Q 1, Examine the playing card shown in figure 25. In this skill, you will create a similar part from 3-1/2" x 2-1/2" x 1/4” plastic. In order to create this program, you will use mirroring and subprograms to keep the program short. Ol Figure 25. Part Diagram B7068-BA LAPS. CNC MILL GUTTER COMPENSATION (DENFORD NOVAMILL) ‘Copyright © 2004 Amatro, Inc.Q 2, Examine the three CNC subprograms shown in figure 26, Each subprogram will create one of the suits in a deck of cards, either hearts, spades, or clubs. A subprogram for diamonds is not listed, because diamonds require no mirroring to create the suit Got X-0.216 vo.t62 G3 X.0.054 ¥-0.162 1-0.054 0.072 {G03 X-0.054 ¥-0.162 10 J-0.090 G01 X0.216 Yo. 162 Goo 262 X18 cso M99 ‘icons on the bottom half of the part, HEART ‘SPADE clus ey Got Sox15 ooze See eer 2 Gee Dea ytesti0 00 | Se Se vo aera 0 sngo Go (G03 XO ¥.0.1755 1.0.02 J-0.0878 uaa G03 X0.09 ¥0.0878 10.08 .-0,0023 G01 X0.09 Yo G02 X0.99 ¥-0.09 10 4.0.09 Got x0 v0.18 (G02 X-0.09 Y-0.09 1.0.09 40 G00 252 G00 X-0.09 G90 Moo Figure 26. CNC Subprograms G 3. Select a card to create - any value from 2 to 10 is acceptable, and any of the three suits listed above is acceptable. 887066-BA LAP 3. GNC MILL CUTTER COMPENSATION (DENFORD NOVAMILL) Copyright © 2004 Amato, ine. 39a4, Create the card using all appropriate mirroring commands. The suit icons on the cards can be created by using the table shown in figure 27. This lists the absolute positioning location to which the Cutter should be moved before starting the subprogram, Before executing the subprogram, the cutter must be positioned 0.500" above the surface of the part If mirroring is required, the cutter should be positioned according to the table in figure 27, then mirroring should be activated. Don’t forget to deactivate mirroring before moving to the next coordinate. Use a spindle speed of 2000 RPM and a feedrate of 4 inches per minute, wai 2 , )) 3:7 | Seamer TRA rT 4 | Hesssoranoesa rio) | eaaarenee 7 (0.656,0.781)(0.656,1.719) 5 | OenaTe ome (2.844,0.781)(2.844,1.719) (0.656,0.781)(0.656, 1.719) 6 {eared ieee (2.844,0.781)(2.844,1.719) aSeEn Tey aRTT 7 (1.2083, 1. eolse.o 704 (2.844,0.781)(2.844,1.719) (1.750,1.719) caporpossing | eusanaesisemy a Bee RB Use 656, 0.781)(0.656,1.719) ESTs: 115,0.781 wo | Gerempessizg | eusge risers (1.385,0.781) (2.844,1.719) Figure 27. Icon Locations as. az as. If your instructor wishes, also write a separate subprogram to create the proper number of the playing card. In your main Program, include the subprogram calls and the proper mirroring to place the numbers in the correct locations. . Simulate the program to ensure that it is correct, Remember, in order for the simulation to look correct, the control software's tool settings and billet settings need to be properly configured. If the program simulates correctly, run the program using a 3-1/2” 2-1/2” x 1/4” (90mm x 65mm x 6mm) piece of plastic and a 1/83" end mill. Be sure to observe all appropriate safety precautions. ‘When you are finished, clean up the CNC machine and shut down the computer. 87068-BA LAP 3 CNC MILL CUTTER COMPENSATION (OENFORD NOVAMILL) Copyright © 2004 Amatrol, inc.SELF REVIEW © around the When mirroring is activated, the X or ¥ axis iS mirrored Mirroring the X axis is accomplished using the command Mirroring the X axis is deactivated using the command ‘The point about which an axis is mirrored is in the current position. To mitror the X-axis, the value__is assigned tol, 87068-BA LAP 3. CNC MILL CUTTER COMPENSATION (DENFORD NOVAMILL) Copyright © 2004 Amato, Ine. 41