FASCINATION OF

SHEET METAL

A material of limitless possibilities

ABOUT THIS PUBLICATION

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in part or total, except where prohibited by law.

Editor Dr. Nicola Leibinger-Kammüller, TRUMPF GmbH + Co. KG, Ditzingen, Germany

Author Gabriela Buchfink

Translation Matthew R. Coleman

Project coordinators Frank Neidhart, Gabriela Buchfink

Project associates Dr. Nicola Leibinger-Kammüller, Dr. Klaus Parey, Ingo Schnaitmann

Layout and design Felix Schramm, Karen Neumeister (SANSHINE GmbH, Stuttgart)

Text consultant Gurmeet Röcker

Translation coordination euroscript Deutschland GmbH, Berlin

Production coordination Jeanette Blaum (SANSHINE GmbH, Stuttgart)

Printing Rösler Druck GmbH, Schorndorf

Finishing Oskar Imberger & Söhne GmbH, Stuttgart

Binding Josef Spinner Großbuchbinderei GmbH, Ottersweier

Image editing Reprotechnik Herzog GmbH, Stuttgart

Publisher Vogel Buchverlag, Würzburg

ISBN-13 978-3-8343-3071-0

ISBN-10 3-8343-3071-X

1st edition 2006

PROGRAMMING
PROGRAMMING

T O TA C K L E A J O B, Y O U N E E D A P L A N. 50 | NO PROGRAM, NO WORK
From punch cards to data files
The informative function of programming

T H E S A M E I S T R U E F O R M A C H I N E S. 52 | WORKING INSTRUCTIONS FOR MAN AND MACHINE

NC programs
T H E Y R E LY O N T H E I N S T R U C T I O N S Setup plans
How the programmers fit in

C O N TA I N E D I N T H E I R P R O G R A M S. 58 | THE JOB OF A PROGRAMMER

Design and programming software

T O D AY, T H E P R O G R A M C O D E I S N O The drawing

Choosing the right strategy
The knowledge base of the system
L O N G E R W R I T T E N B Y H A N D. I T I S Like pieces in a puzzle
Performing test runs at the office

W R I T T E N B Y T H E P R O G R A M M I N G S O F T-
Leave the rest to the system

64 | THE FUTURE OF PROGRAMMING

WA R E, W H I C H A L S O H E L P S W I T H Intelligent systems
Keeping software up -to -date
NC programs and beyond

D ATA E X C H A N G E A N D M A N A G E M E N T
IN THE PROCESS CHAIN.

48 49
No program, no work
A program describes a sequence. The sequence is a lot like
the script of a play describing what actors are supposed to
do and say. In manufacturing, programs describe the move-
ments and processes that a machine has to perform in order
to produce a part. The machine control then reads, interprets,
and implements the program.
50 | Programming
FROM PUNCH CARDS TO DATA FILES
The first industrially used machine that worked with a program
was a weaving machine developed in 1805. The machine’s
motions were controlled using metal cards with holes punched
in them. The arrangement of the holes told the machine which
actions it had to perform.
1 where there is little or no human involvement.
1
2
Industrial textile production in the 19th century
Songs are “programmed” into the revolving cylinder to make the music.
Mechanical programming Mechanically coded and evaluated programs
can be found in devices such as musical clocks. Small protuberances,
or bumps, are arranged in various patterns on a revolving cylinder. A row
3 Automated production requires reliable and well functioning programs.
of tuned steel teeth are located next to the cylinder. When the cylinder
turns, the small bumps pluck the steel teeth and produce a sound. The
song you hear is created by the pattern of bumps on the cylinder.
In sheet metal processing today, NC programs specify the
sequence of steps that are carried out in production. NC
stands for “numerical control.” The control commands in the
program are expressed using a combination of numbers and
letters. At the machine itself, the NC control reads the pro-
gram, evaluates it, calculates the required tool path, and ini-
tiates the machine movements.
The 1950s saw the emergence of programmable sheet
metal working machines. These machines made it possible to
produce parts more quickly and accurately than ever before.
Until the advent of computer technology, information had to
be evaluated using electromechanical components.
Since the 1970s, NC programs have relied on computer
technology. NC programs today are created exclusively using
computers. This is done with the help of efficient programming 2
software, which automatically generates the program code.
The NC programs are transferred to the machine via a network
connection. After being sent to the machine, the programs are
evaluated and processed by an industrial computer running
compatible control software.
THE INFORMATIVE FUNCTION OF PROGRAMMING
The programming stage is a part of the process chain that
involves laying down all the information required by man and
machine to produce the part.
Today, programmers are playing an ever-growing role in
ensuring that the entire process works smoothly and efficiently.
They serve as the link between design and production. If pro-
grammers discover a design error in the part, they must fix the
problem before generating the program and releasing it for
production. Creating reliable programs and ensuring trouble-
free production is especially crucial in untended production,
3
51
Working instructions for man and machine Using numeric codes to control machines The development of
NC technology goes back to 1952, when the first numerically controlled
initiating machine movements; instead, the NC program did the job.
The program was read, interpreted, and processed by the machine
machine tool was developed at the Massachusetts Institute of Technology. control. A decisive breakthrough in NC technology was achieved with
The tool worked according to instructions condensed into a single control the advance of computer technology in the 1970s.
program – the NC program. Humans were no longer responsible for

NC PROGRAMS
An NC program consists of a long list of commands, with
each line containing a set of instructions. Each line begins
with a line number followed by a series of coded instructions.
NC programs contain the following information:
• Instructions on positioning and activating all movable
elements of the machine such as the punch press
coordinate guide, which moves the sheet, or the laser
head on a laser cutting machine.
• Instructions on the manufacturing techniques to be
performed by the machine such as punching or nibbling
on a punch press.
Programming language | Each set of machine instruc-
tions is expressed in coded form, or functions. Basic func-
tions required for all types of manufacturing techniques are
defined in international guidelines. These include information
on movement to a defined position, geometric information
describing the contour of the part, and technology informa-
tion on how the contour is to be produced, for example by
punching or laser cutting.
Each program is organized according to the same principle.
First there is the starting portion of the program, followed by
the list of instructions. The end of the program is also indicated
by a code.
piercing methods are required for different sheet thicknesses
when a sheet is cut with a laser. Each piercing method can
be activated with an NC function. Functions such as these
are not internationally defined. Mechanical engineers now
have to do two things. First, they have to tell the programmer
about the NC function, so that he or she can use the function.
Second, the machine control has to be adapted so that it is
able to implement the NC function properly. In the past, the
Task NC block
machine control could only be modified by the control manu-
facturer. This made making adjustments very difficult. Today,
things are easier. Machine manufacturers can now use the
control software to perform this task.
To assist programmers in their work, NC functions are
documented and stored in the programming system. This
means that the programmers can find the functions they
need, without having to memorize the code.
Description

• Notes that tell the programmer which detail is currently

Specific functions | In addition to basic functions, me- Positioning G01 X35.221 Y64.779 F50 The laser cutting head takes the shortest route from its current position to the
being processed on the part. chanical engineers develop special NC functions for their programmed target point (X,Y), moving at a speed of 50 meters per minute.
machines and the processes involved. For example, different

Activate laser TC_LASER_ON (1,“1778”,10,100) The laser beam is activated according to method 1: it pierces the workpiece
and begins cutting from a specified distance. Cutting parameters are given
in technology table no. 1778. The piercing operation is specified as piercing
type 10 (normal piercing). The cutting operation is specified as cutting type
100 (a large contour is cut with normal acceleration).

Cut circle X32.393 Y67.607 G02 I17.607 Starting from position X,Y, the laser beam begins cutting a circle in clockwise
J-17.607 direction. The radius of the circle is 17.607 millimeters.

Switch off laser TC_LASER_OFF (1) The laser beam is switched off according to method 1 (laser is switched off,
Z-axis moves to overshoot height).

Program end M 30 The main program ends and is then reset to program start.

Manual programming: the tasks of a programmer, from completion of the drawing to creation of the NC program How do you tell the laser cutting machine to cut a circle? Lines from an NC program.

52 | Programming 53
Faster programming A programmer used to have to work two to three “Creating NC programs today is as easy as using Word or Excel. However, 1 The setup plan contains all the information the machine operator
days to create a complex NC program by hand. Today, the same program automatically created programs are always subject to certain limitations. needs to know.
can be generated in 30 minutes with the help of programming software. But with their background knowledge, programmers are able to optimize
the many factors involved to ensure creation of the best possible NC
program – even for jobs that push the limits of the possible.”
Ralf Dlapal, Programming Software Sales

SETUP PLANS
Black
SETUP PLAN
The machine isn’t the only thing that has to know what it GENERAL DATA
05/04/2005

MACHINE: TYPE: 1 (2535.0 x 1280.0 mm)

needs to do. The people operating the machine also require CONTROL: Sin 840D VARIANT: 1
COMPANY: TRUMPF
information in order to carry out a production job. JOB NAME:
NC PROGRAM NAME:
How should the machine be tooled? How long will the PROGRAM NAME:
MATERIAL ID:
machine be running? How heavy is the sheet? Which NC STOCK DESIGNATION:
BLANK:
program do I need to use? What settings still need to be WEIGHT:
MACHINE TIME:
made on the machine? The answers to all of these questions REQUIRED MEMORY: 30830 CHARACTERS
TOTAL LASER CUTTING LENGTH:
are contained in the setup plan. NUMBER OF PROGRAM RUNS:
WASTE:
Setup plans can have different names, depending on the
PRODUCTION INSTRUCTIONS
manufacturing technology involved: a “tooling plan” may be CLAMP POSITIONS:
INDEX PIN: 1 FROM THE LEFT

used for a punching job, while a “bending plan” may be used START POINT:
REMARKS:

for a bending job. In both cases, the goal is the same: to TOOLING LIST
provide all the information that the machine operator will ID NO. TYPE DIM. 1 DIM. 2 DIM. 3 ANGLE REMARKS
Circular 3.5 mm
WT MT LT STROKES

Circular 4.5 mm
Software for creating NC programs: programming software automates the programming process. require to prepare the machine and initiate production. Circular 5.5 mm
Circular 6 mm
Circular 6 mm

Contents of the setup plan | To start off, the setup

Laser
NUMBER OF STEEL/RTC CARTRIDGES: 5 / 0

Writing NC programs manually | In the early days of Automated programming | To reduce the workload of plan contains general specifications referring to the job in
LASER TECHNOLOGY TABLES
NC technology, the programmers who worked at sheet metal the programmers, the NC code had to be generated automa- question: the machine type, current date, program name, TABLE NO. KERF LENS FOCAL NOZZLE MAX. LASER SET GAS
WIDTH LENGTH DIAMETER POWER DIMENSION
processing companies had the same job that software pro- tically. In the early 1990s, software companies and machine operator name, material, and the sheet size. The production
Gas type: 1 = oxygen, 2 = nitrogen, 4 = compressed air
grammers do today: they wrote programs line by line. tool manufacturers began developing programming software time is also specified. The production instructions include the
INFORMATION FOR SINGLE PART
Back then, programmers had to know both the NC func- to generate the code, so that programmers no longer had machine settings that the operator will have to make manu- PART NUMBER:
DRAWING NUMBER:
tions and the technology that was going to be used. They to write it. The software contained all necessary information ally. Using the tool list, the operator can set up the required DRAWING NAME:
CUSTOMER NAME:
were also the ones who determined the processing sequence. about the NC functions, technology data, and processing tools. The setup plan also provides information on the parts QUANTITY:
DIMENSIONS:
Doing things manually had a number of disadvantages: it took rules. Using this information, the software was able to define that will be produced. AREA:
WEIGHT:
a long time to create the program; the programmers some- the machining operations automatically and generate the NC LASER CUTTING LENGTH:
GEO FILE NAME:
times made typos; or invalid command sequences would program to run on the machine. Creating setup plans automatically | The setup plan 1

cause the program to stop. The only way to see if the pro-
gram worked properly was to perform a test run. In addition,
programmers had to take into account special NC functions
for each individual machine and manufacturing technique. All
of this made NC programming very complicated, and only
specialists had the skills and ability to do it properly.
Programmers are still the experts when it comes to tech-
nology and manufacturing techniques. It is their job to optimize
the processing parameters and strategies. The NC program,
on the other hand, is now created by simply pressing a button.
The programming software has become so sophisticated that
it makes revising the code unnecessary.
is generated automatically, just like the NC program itself.
The handwritten instructions that operators used to receive
have now been replaced with easy -to -read tables, which are
printed out on paper or displayed at the screen of the machine
control. Instructions in paper form, however, are still a very
practical means of conveying information. A piece of paper
can be taken anywhere, filed, or attached to an order. In
everyday work, using a piece of paper is often the most
convenient and direct way of supplying information with the
processed parts.

54 | Programming 55
Programming: the link between design and production If the design
contains flaws, the programmer is the person who is responsible for
finding and correcting them before the part goes into production. To do
this, the programmer must possess good knowledge of the processes
involved in both production and design. Programming is a challenging
job, requiring extensive interaction and communication with coworkers
in many different departments.
HOW THE PROGRAMMERS FIT IN
After the drawing of the design is ready, it goes to the pro-
grammer. Before the NC program can be created, however,
the programmer has to perform the following:
• Load and check the drawing, or create a new one
• Define the processing operations
• Generate the NC program and setup plan
All of these steps are performed using programming software
or a combined design / programming system. If processing
of a part involves multiple production steps, the programmer
creates the NC programs and setup plans for all machines.
Loading / unloading units and transportation systems are
also programmed if automated production cells or production
lines are used.
The right touch | Programmers today do not need tradi-
tional programming skills. Instead, they have to be experts
at determining the optimum processing parameters. Expe-
rienced programmers often know intuitively which setting or
machining strategy will work best.
Providers of information | Programming software is only
able to use the information it has. This is why maintaining
and updating the tables containing technology data, process
rules, and tool data is so important. Programmers are usually
the people who assume the role of data administrator. They
install newer software versions or enter values based on the
latest production results.
Administrative tasks | Data management is nearly as
important as programming itself. This applies in particular to
companies that manufacture a wide variety of parts in small
56 | Programming
1 Working together with the colleagues to find the right solution
quantities for many different clients. Such companies have
always been faced with the challenge of managing large
amounts of data for each individual job in a practical way.
Today’s “just -in -time” production means that even suppliers
of a single part often find themselves creating products in
small quantities. Here as well, the amount of administrative
work involved in managing the data is constantly growing.
Programmers have to know how to retrieve specific NC
programs and determine which processing definitions can be
reused for a particular part. Programmers are assisted by the
programming software, which contains special modules for
data management.
1
CUSTOM KITCHEN EQUIPMENT AT A MOUSE CLICK
Virginio Celetta has just received the next production order.
This time, the customer wants model 1304 to be a little higher,
deeper, and narrower than in the catalog. Model 1304 is the
cabinet module of an industrial stainless steel kitchen, and
Virginio Celetta is a programmer at Werheit Einrichtungen
GmbH, a company in Bergisch Gladbach, Germany, that
manufactures this type of kitchen equipment. Virginio Celetta
reads the order, finds model 1304 in the programming sys-
tem, and enters the dimensions. One click and the system
starts calculating. A short time later, the program displays
the layout of 44 single parts – all sized according to the
specifications. A few more steps and the NC programs are
ready to be sent to the combination punching and laser cut-
ting machine.
“It wasn’t always this easy,” says general manager Levent
Demirel. Before, the design engineer had to change all com-
ponent drawings by hand, and the parts had to go through
four production stations. The great number of steps and the
complex information channels were a constant source of
error. Demirel explains: “Often, no one would notice that the
engineer had failed to resize a part until it was being assem-
bled. Refabricating the part at this stage was very costly.”
Today the programming software contains all possible
variations of model 1304 and other kitchen modules offered
by Werheit. Variable dimensions are defined in the drawings
alongside the respective rules and dependencies. For example,
when 20 centimeters is added to the cabinet height and an
additional shelf is included, the program knows that it has
to maintain equal spacing between the shelves. One mouse
One mouse click is all it takes to resize a standard cabinet.
click is all it takes. “Our system is designed so that all we
have to do is enter the customer’s dimensions in a table.
Everything else is done automatically,” explains Demirel. The
company adopted this approach after acquiring a combina-
tion punching and laser cutting machine, which is now used
for 80 to 90 percent of the company’s sheet metal work.
Programming the product variants and providing additional
employee training means more work, but it’s an investment
that pays off. Demirel: “We now rely on programmed variants
to process all of our jobs. Instead of designing for 30 minutes,
we only have to wait 30 seconds.” The new approach reduces
machining times by 50 percent and streamlines communica-
tion channels. Employees were skeptical at first. Now they are
amazed what the new system can do. Levent Demirel adds:
“We were able to move two persons from flat processing
over to final assembly. This has increased our capacity, and
the payoff has been growing sales.”
57
The job of a programmer
DESIGN AND PROGRAMMING SOFTWARE
Software systems are used to perform design and program-
ming tasks. Such systems are offered by a host of machine
manufacturers and independent software companies.
CAD / CAM plays a vital role in the world of computer-aided
design and machine programming. CAD (Computer-Aided De-
sign) is a technology that involves the use of computers to
Using CAD / CAM systems for designing and programming
58 | Programming
design and model parts. CAM (Computer-Aided Manufactur-
ing) is the process of using computers to control machines in
manufacturing.
CAD and / or CAM? | Both design software (CAD systems)
and combined design / programming software (CAD / CAM
systems) are available on the market today. CAD systems are
incredibly powerful tools usually featuring a highly complex
range of functions. This is especially true of 3D CAD systems,
which have largely replaced 2D CAD systems. Systems such
as these are used in companies that design and manufacture
complex parts, modules, or machines.
The drawing functions of combined CAD / CAM systems
are rarely used today to design complicated parts. Such func-
tions, however, are important for checking and, if necessary,
altering finished drawings after they have been imported.
Subcontractors, who often receive hand -drawn sketches
from their clients, use the drawing functions to create finished
drawings that they can use to produce the part.
Whether you decide to use CAD software or the design
component of a combined system does not affect your ability
to exchange data later on. Standardized interfaces ensure
reliable data exchange between CAD and CAM systems. The
most important file formats for two -dimensional representa-
tions are DXF, DWG, IGES and MI.
Systems from machine manufacturers | The advan-
tage of using systems offered by the machine manufacturers
is that all processing parameters and rules are already includ-
ed with the machine. Technology data is obtained through
regular machine testing and, thus, is continually expanded
and optimized. According to the machine manufacturers, this
is what makes their programming software the better choice
for users who want to get the most out of the machine. An
additional benefit can be created by bundling the technology
data with the drawing for use in processing. This is possible
on the systems of some machine manufacturers.
Systems from software houses | Independent software
companies, on the other hand, argue that the systems pro-
vided by machine manufacturers can only be used on their
machines. As a result, some fabricators may end up using
two or three different systems.
The programming software from independent software
companies allows you to create programs for different ma-
chines. The technology data obtained by using such systems,
however, is not as extensive.
Choosing the right software | Deciding on which pro-
gramming software to use or whether additional CAD software
is needed all depends on the company.
The important thing is for the system to be adaptable. In
other words, the system should be flexible enough to adapt
to the requirements of the company. This can be achieved,
for example, through the addition of new technology data,
new machining rules, or new tool data.
The organization and design of the system are also crucial
for enabling fast and intuitive operation. Good programming
software is always designed with the specific tasks of the
programmer in mind to make his job easier. Standard tasks
should always be easily accessible. Such tasks include im-
porting and creating drawings, running simulations, and gen-
erating NC programs and setup plans.
An essential tool | Today, all sheet metal processing is
done with the help of programming software which is the
Choosing the right programming software Is it possible to import
and edit data from other sources? Can the data be reused later on?
Which machines can be programmed? How good is the software’s
technological performance? Questions like these help sheet metal
fabricators decide which system to use.
only system that creates error-free NC programs quickly,
while taking advantage of all the possibilities of optimizing
manufacturing techniques and machining processes without
having to rely on test runs and sample parts.
THE DRAWING
The drawing of the sheet metal part serves as the basis for
the NC program. Programmers can either create the drawing
themselves using the design module of the CAD / CAM system
or import a finished drawing. Simple, flat parts are easy
to create using the design module. Macros make it easy for
users to make typical contours that would otherwise require
complicated auxiliary constructions. Good examples of such
contours are link plates, where material has to be cut out for
the bending zones.
The programmer has to import the drawing if it was created
on a CAD system. After importing it, the system analyzes the
geometry of the part and corrects any errors:
• “Rough” contours are touched up; any unconnected
lines are joined.
• Double lines and points are deleted so that they are
not processed twice by the machine.
• Contour transitions are cleaned up.
• Contours are organized according to inner and outer
contours, so that it is easy to distinguish between the
finished part and scrap.
• Auxiliary constructions required by the design engineer
to draw the contour are automatically deleted.
If the system runs into difficulty, the drawing is corrected by
the programmer.
59
 1 3D view of the part: this is what the part will look like when finished.
2 Once the flat layout is complete, programming can begin.
3 Specifying machining strategies and parameters
Job shops The term “job shop,” or “job shopper,” refers to sub -
contractors whose business involves handling large numbers of small,
individual manufacturing jobs. Job shops often receive only a rough
sketch of the part from their clients. Programmers at such companies
often double as the design engineer, whose job it is to create a
computer model of the part for production.

CHOOSING THE RIGHT STRATEGY
Once the drawing is ready, the programmer uses the pro-
gramming software to specify how to fabricate the workpiece.
Which tools are needed? In which order should punching,
cutting, or bending take place? Which values should be
assigned to parameters such as press force or laser power?
Procedures can vary depending on the manufacturing
technique involved. In the case of bending, the key is to find
the optimum bending sequence, the appropriate tools, and
the right bending parameter values. When laser cutting is
performed, however, only one tool has to be considered. In
this case, it is more important to find the optimum piercing
up with a machining strategy. They were responsible for
choosing the tools and processing sequence. Now, these are
suggested by the programming software. The programmers
can follow the advice of the software or use their experience
to optimize the selection.
THE KNOWLEDGE BASE OF THE SYSTEM
The NC function describes not only the operation, but also the
method to be used. It contains specifications of the process
parameters and machining strategies.
For example, a certain tonnage is required to punch a
round hole in a sheet that is two millimeters thick. Or the
Technology tables | Each manufacturing technique is
characterized by certain parameters. The values of these
parameters have to be set correctly in order for the machine
to function accurately. In bending, this is the press force. Dif-
ferent press forces are required for different angles and sheet
thicknesses. The appropriate numerical values are stated in
the technology tables. In the tables, the parameter values
are listed according to type of material and sheet thickness.
A different table is needed for each manufacturing technique.
A company providing a full range of sheet metal processing
services may easily require over one hundred such tables.
3

points or determine whether smaller parts are in danger of
becoming displaced, in which case small tabs (microjoints)
can be integrated into the design to prevent the part from
falling out of the sheet skeleton. In the past, programmers
had to rely on their experience and books of tables to come
1 2
piercing point of the laser has to be farther from the contour
of a thick sheet than it does from that of a thin sheet.
Contained in technology tables and process rules, this
information forms the knowledge base of the programming
software and machine control.
Process rules | The programming software has to make
a lot of decisions when defining the machining operation. On a
job involving laser cutting, for example, the software has to
find the best place to begin cutting. To do this, it relies on
process rules specifying the conditions under which a certain
action is to be performed.
LIKE PIECES IN A PUZZLE
The first step in the manufacture of sheet metal parts is always
flat processing, during which one or more parts are made
from a sheet. The programmer uses the programming soft-
ware to specify the location of each part on the sheet. This
process is known as “nesting.”
The programmer indicates the required quantity for each
part. The nesting program then calculates the optimum sheet
layout, taking into account manufacturing specifications such
as the distance between two parts.
Nesting strategies | Different nesting strategies, or even
combinations of such strategies, can be used to create the
sheet layout. Here are two examples. The first is rectangular
nesting, in which a virtual rectangle is placed around the
outer contour of each part. The nesting processor positions
the rectangles on the sheet. This strategy is especially well
suited for parts that are almost rectangular and is frequently
used for punching jobs. The processor positions the parts
next to each other in the same fashion, so that the parts can
be processed more quickly and are easier to remove.
In true shape nesting, the nesting processor takes into
account the actual contours of the part. This means parts can
usually be nested closer together, yielding more parts per
sheet. True shape nesting is particularly well suited for parts
with irregular contours. This strategy is adopted primarily for
operations such as laser cutting, which involve the use of a
single tool for cutting.
The right strategy and an efficient nesting program can
reduce material consumption and optimize machining. which,
in turn, lowers material costs and saves time. When choosing
the programming software, it pays to consider the quality of the
nesting module.

60 | Programming 61
Cracking the problem What’s the best way to position ten different
parts with lot sizes of up to 500 pieces on 20 sheets? Luckily, there
are special nesting programs that do the number crunching for you.
Calculations like this can be very complicated. Sometimes it can take
even very powerful computers a while to figure out the solution.
Even so, you have to be careful: a system is only as good
as the people using it. Nesting strategies can be combined;
additional options can be configured. In situations like these,
the trained eye of a programmer is indispensable.
Single part or whole sheet? | Programming software
usually allows users to put together NC programs in different
ways. One way is first nesting all of the parts on the sheet
and then defining the machining operation for the entire
sheet. Another way is first defining the machining operation
for each individual part and then nesting the parts. Both
methods can be combined.
Depending on the number of orders a company has
and the size of the company, one method may offer more
bene fits than the other. When the same parts are always
being made, it makes sense to specify the machining opera-
tion separately for each part and then apply the parts to as
many different sheets as needed. This decision, too, is made
by the programmer.
PERFORMING TEST RUNS AT THE OFFICE
Machine time is expensive, which is why plant managers
like to see machines used for production instead of testing.
Fortunately, the production sequence can be simulated on a
computer using the programming software. During the simu-
lation, the programming software can detect malfunctions
such as collisions between the tool and the workpiece during
bending. The programmer adjusts the processing sequence
and parameters until the simulation functions smoothly. Ex-
pensive test runs on the shop floor are no longer needed to
check the production sequence or NC program. For flatbed
machining simulations, all that is needed is a two-dimensional
representation. In the simulation, you can view the sheet and
62 | Programming
see the order in which it is punched or cut. For all other
manufacturing techniques, a three -dimensional representa-
tion is required. Bending simulations, for instance, show you
all the movements of the workpiece and machine in three
dimensions. Laser welding simulations show how the laser
optics move, allowing you to see how all the weld points and
seams are created.
Even with 3D simulations, the only way to determine the
machining quality is by examining the actual part. For this
reason, the operator stops the machine after the first part
is finihsed in order to check it. If imperfections or flaws are
detected, the operator readjusts the parameters.
1
2 tained in central databases.
“A few mouse clicks is all it takes to control an entire machine, which 1, 2 Different strategies for arranging parts on a sheet:
performs an incredible array of highly complex machining operations. extended rectangular nesting (1) and true shape nesting (2)
This is what always amazes me about programming software.” 3, 4 The simulation shows whether bending operations are being
Ralf Dlapal, Programming Software Sales performed properly.
LEAVE THE REST TO THE SYSTEM
Once the parts have been nested on the sheet as required
and the machining operation has been defined, the finished
NC program is only a mouse click away. All the program-
mer has to do now iss press the appropriate button on the
screen, and the programming software automatically begins
generating the NC program.
Early programming aids still required the programmer to
revise the NC code by hand. Today this is no longer necessary.
You can be sure that the program is free of errors and will
function properly during production. If machining parameters
have to be changed, all the operator has to do is enter the
new values directly at the machine, and the NC program is
updated automatically.
Creation of the setup plan, too, is now automated. The
system always remembers which tools will be needed and 3
gathers all the required data. The data itself, however, can
vary from company to company. That is why it is important
to ensure that setup plans can be configured individually,
for example by swapping data fields or changing their order.
Often you can even integrate graphical elements such as the
company logo.
Getting to the machine | Today, NC programs are sent
to the machine as files through the company’s IT network.
The programmer puts the NC program on a network server,
allowing the operator to launch it directly from the machine.
Only a few years ago, people were still using floppy disks to
transfer data. Online data transfer and today’s control system
operating software have considerably reduced the amount of
time it takes to read in NC programs. Using networks offers
another benefit: program files can be managed and main-
4
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The future of programming
INTELLIGENT SYSTEMS
In many cases, it takes the programmer longer to create the
NC program than it does for the machine to process it. For
sheet metal fabricators, this is reason enough to find a way
to reduce programming time.
The amount of time needed to create a program depends
mainly on the functions of the programming software and
the skill of the programmer. The quality of the design data
also plays an important role. Any inconsistencies that may be
present have to be resolved, and that can take time.
Even so, optimizing human factors is not always easy.
As a result, efforts aimed at speeding up the programming
process tend to focus on the programming software.
More functions, improved ergonomics | Software
companies and machine manufacturers are constantly work-
ing to further automate machining operations and make the
software more user-friendly.
For a long time, there was no way of automatically detec-
ting which parts were in danger of becoming displaced after
being cut and might collide with the laser cutting head. If
such a risk was detected, microjoints had to be set manu-
ally at all affected parts. Today, the programming software is
able to detect such risks. It adds microjoints or ensures that
the machine automatically goes around any parts that could
cause a collision.
Another example is bending. Design engineers, program-
mers, and operators would sometime rack their brains for
hours trying to come up with the right bending sequence for
a complex part. Now the programming software calculates
the bending sequences automatically and optimizes the ma-
chining process at the same time. It chooses the bending
steps in a way that minimizes the amount of time that the
64 | Programming
operator has to spend turning or rotating the part, thereby
reducing overall production time.
Uniform design | The task -oriented, ergonomic design of
the programming software ensures that it remains straight-
forward and easy to use despite its complex functions. User-
friendliness and easy operation are often the decisive factors in
the decision to purchase a system. The programming software
and the machine’s operating software are closely connected.
Machine manufacturers give their software a uniform design
for two reasons: first, to ensure that programmers don’t have
any trouble using the machine and, second, so that operators
can modify data in the programming system if necessary.
This reduces training time considerably.
KEEPING SOFTWARE UP-TO - DATE
While special functions and software interfaces can help to
speed up the programming process, this is not the only goal.
Companies that invest in programming software also want to
make sure they can use it several years down the line.
Machining strategies, technology parameters, tools, and
materials can change. This is why investing in systems that can
be updated and adapted is so important. Obtaining regular
software updates is every bit as important as purchasing new
tools for the machines.
Machine manufacturers continue to expand their program-
ming software -related services and regularly make software
updates available to customers. Special punching tools, for
example, are supplied with the required software extension,
which makes it easy to integrate the new tool geometry to the
programming software. Services of this type are becoming
increasingly more commonplace. And it’s no wonder: they
are the key to achieving long -term optimum utilization of the
1 Programming software ensures that operations are carried out
smoothly and efficiently in parts fabrication by individual machines
and throughout the process chain.
machine and tools. In addition to installing the updates sup-
plied by the manufacturer, companies have to ensure that the
data they have obtained is integrated into the programming
software. Nowadays, it is possible not only to add data to
technology tables, but also alter the machining rules. Cus-
tomized in this way, the programming software can provide
a range of functions tailored to the needs of each individual
company. It’s a trend that is certain to continue.
NC PROGRAMS AND BEYOND
Programming is a typical interface activity forming the point at
which different processes in the chain interact. So what can
programming software do to make the sheet metal process
chain even more efficient? How can it help to provide greater
information value to businesses?
More than NC Information and knowledge management is an important
issue for many businesses, including sheet metal fabricators. The experi-
ence of machine operators and process technicians is constantly growing.
Each day, they gain more insight into which parameters and machining
strategies produce the best machining results. It is important for this
knowledge to be conserved in a form that can be processed by a machine.
Programmers can do this easily by maintaining and expanding technology
tables and process rules.
1
Programming software already does more than just generate
NC programs. For example, it can accurately predict machine
times, making it possible to estimate costs for use in drawing
up offers. Programming software can also be used to label
parts – which many suppliers are required to do. This can be
done by embossing letters or numbers using a punch press.
Adhesive labeling is another marking method that is being
used increasingly more often. Programming software that
is able to generate labels alongside the actual NC program
makes work easier.
In the future, organizational and administrative functions
will continue to gain in importance. Programming today means
more than just creating an NC program for the machine.
Programmers are also responsible for processing the data
that will accompany the part after production.
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