Getting More From Your CNC Machines
Lesson 5: Setup Reduction Techniques
Topics
Setup reduction techniques
Introduction
Evaluating how well organized you are
Gathering components for a setup
Workholding setup
Cutting tools
Program zero assignment
Program development
Program transfer and storage
Setup reduction techniques (cont.)
Program verification
Program optimizing
Other setup tasks
Setup tasks and improvements
1
Lesson topics
Copyright 2011
Lesson topics
With an understanding of principles:
Definition of setup time
Two task types
Three ways to reduce setup time
Four steps to setup reduction
You should be ready to begin
Lesson topics
General flow of making a setup:
We’ll be going through setup tasks in this order:
Get ready
Workholding setup
Program zero assignment
Cutting tools
Program development
Program transfer and storage
Program verification
Program optimizing
Other tasks related to setup
Lesson topics
With every task, we’ll give suggestions…
1) To Eliminate The Task
2) To Move The Task Off Line
3) To Facilitate The Task
Lesson topics
With every task, we’ll give suggestions…
1) To Eliminate The Task
2) To Move
The
Task
Off
Line
Hardest to justify
3) To Facilitate
Thetask
Task
Repeated
or urgency
Finite # of repeated setups
Lesson topics
With every task, we’ll give suggestions…
1) To Eliminate The Task
2) To Move The Task Off Line
3) To Facilitate
The
Task
Sufficient CNC staff
Sufficient cycle time
Sufficient lot sizes
Lesson topics
With every task, we’ll give suggestions…
1) To Eliminate The Task
2) To Move The Task Off Line
3) To Facilitate The Task
Little repeat business
Setup person does all
No off-line time
Lesson topics
While we’ll show many techniques and
make many suggestions…
…we’re just scratching the surface of
what’s possible
Study your current methods!
With ingenuity – and your knowledge of your
company’s methods – you should be able to come
up with more – and more appropriate –ideas
Lesson topics
In each setup reduction step, we will:
Develop a list of related tasks
Provide general suggestions
Provide specific machining center techniques
Provide specific turning center techniques
Your list of tasks will likely be different than ours
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Disorganization is pretty easy to spot…
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Disorganization is pretty easy to spot…
…you must encourage and enhance the potential for organization…
Lesson topics
Disorganization is pretty easy to spot…
…you must encourage and enhance the potential for organization…
…since getting more organized improves every CNC task!
Remember: The more often you repeat a task, the easier it is to
justify improving it.
Every task you perform is affected by how well
organized you are!
Lesson topics
Workbenches
 Does every hand tool have a place?
 How cluttered is the work surface?
 Is it ever used for storage?
 Does every operator have one?
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Cleanliness of work area and machine/s
 Is everything put away when not in use?
 Are chips, coolant, oil, and debris cleaned?
Cleanliness can also have
an impact on safety
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Storage of components
 Are needed components properly stored?
 Is every drawer/cabinet clearly labeled?
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Storage of components
 Are needed components properly stored?
 Is every drawer/cabinet clearly labeled?
 Are work holding devices properly stored?
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Storage of components
 Are needed components properly stored?
 Is every drawer/cabinet clearly labeled?
 Are work holding devices properly stored?
 What about cutting tool and insert storage?
Lesson topics
Storage of components
 Are needed components properly stored?
 Is every drawer/cabinet clearly labeled?
 Are work holding devices properly stored?
 What about cutting tool and insert storage?
 Are common gauges readily available?
Watch for any time that CNC people seem
confused - or when they must search the
shop to find a needed component
Lesson topics
Documentation
 Have procedures been developed for important or complex tasks?
 Does everyone know what they’re expected to do?
 Do key people get called at home to solve problems?
 How often are mistakes made?
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Work habits
 Does everyone do things in a consistent manner?
 Does everyone understand and adhere to safety standards?
 Have you set priorities for shop-related tasks?
 Has there been any horse-play
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Consistency of programming methods
 Program mean value for all dimensions
 No offset adjustment will be necessary
 Handle programming features consistently
 Cutter radius compensation
 Tool length compensation
 Tool nose radius compensation
Do you ever see your setup people having to make adjustments
from job to job due to inconsistent programming methods?
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Job order planning
 Do you consecutively run similar jobs to minimize
setup effort?
 Work holding setup
 Cutting tools
 Do your people ever have to tear down a job in the
middle of a production run for a “hot job”
Lesson topics
1 A-2346
2 A-3856
3 B-2917
Non-production time
 Can you make use of time that the machine would normally
be down?
 Lunch
 Breaks
 Off shifts
 Shutdowns
Any setup – or portion of a setup – that can be
made during these periods will be off line!
Lesson topics
If you have never undertaken an improvement program…
…it’s likely that you’ll find problems with organization
In this case, your first step must
be to get better organized!
The goal is to eliminate
confusion and wasted time
Fortunately, it’s pretty easy to come up with ways
to improve organization…
…it takes little more than common sense
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An example:
A machining center operator needs the vise
handle to load and remove every workpiece…
…stick the vise handle to the machine (with
Velcro) to eliminate the need to locate it
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Almost everything we do to get better
organized falls into the category of facilitating tasks…
…we’re trying to make it as quick and easy
to perform just about any tasks!
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Is there room for improvement with
organization in your own company?
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Think of everything a setup person
needs to complete a setup…
Hand tools
Workholding devices and/or components
Fasteners
Cutting tool components and inserts
Program
Think of all the time that could be
Documentation
saved if they could complete the
setup without leaving the machine
Raw material
Finished workpiece storage bins
Gauges
How often do setup people currently leave
the machine to go get something?
Coolant
Documentation: Print, Production control material,
Setup sheet, production run instructions, SPC material
In the setup reduction planning form (provided in
lesson four), list items that must be gathered
Lesson topics
With good documentation and in well organized companies, a lesser
skilled person can do the gathering for upcoming jobs…
…anything gathered prior to a setup moves
the task of gathering off line
And if everything can be gathered prior to starting the setup…
…the setup person will be able to complete the setup without ever
having to leave the machine!
In this way, the entire task of
gathering can be moved off line
Also…
If anything is missing, you will know
it before the job hits the machine!
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Who will do the gathering?
Setup person?
Tool crib attendant?
Operator?
Be sure to pick someone who truly has the time to
Lead person?
consistently gather all components prior to a setup
CNC helper?
And be sure that all components are
properly stored and labeled, and easy to
find – so anyone can do the gathering
This requires a high degree of organization
Lesson topics
The gathered components are
commonly referred to as a kit
If small and light, the kit can be placed in a box or bin
and brought out to the machine prior to the setup
If large and heavy, the kit can be placed in a cart
and wheeled out to the machine prior to setup
Either way, the goal is to allow the setup person to
complete the setup without having to leave the machine.
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Think of what must be done to remove
the previous setup from the machine
Remove workholding device
Remove cutting tools not needed for next job
Clear offsets for tools removed from the machine
Disassemble certain components (like cutting tools)
Put everything away
Save changes to program and remove from the machine
Empty chip pan (if machining a different material)
Clean machine
Here is our list, but be sure to create a list of your own
Use the setup reduction planning form provided in lesson four
Lesson topics
First, try to come up with ways to eliminate tasks…
…some may seem far-fetched
Remove workholding device
Remove cutting tools not needed for next job
Clear offsets for tools removed from the machine
Disassemble certain components (like cutting tools)
Put everything away
Save changes to program and remove from the machine
Empty chip pan (if machining a different material)
Clean machine Can you think of any way to keep from
having to remove the work holding device?
 Can multiple workholding devices be mounted to the machine? (On the table
of a vertical machining centers.)
 Can jobs requiring the same workholding device be run consecutively?
 Can workholding devices be more versatile, allowing different jobs to be run?
Lesson topics
First, try to come up with ways to eliminate tasks…
…some may seem far-fetched
Remove workholding device
Remove cutting tools not needed for next job
Clear offsets for tools removed from the machine
Disassemble certain components (like cutting tools)
Put everything away
Save changes to program and remove from the machine
Empty chip pan (if machining a different material)
Clean machine Can you think of any way to keep from
having to remove cutting tools?
 Does the machine have enough tool stations to hold all tools for all jobs?
 Can a set of “standard” cutting tools be kept in the machine at all times?
 Cam jobs requiring the same cutting tools be run consecutively?
Lesson topics
First, try to come up with ways to eliminate tasks…
…some may seem far-fetched
Remove workholding device
Remove cutting tools not needed for next job
Clear offsets for tools removed from the machine
Disassemble certain components (like cutting tools)
Put everything away
Save changes to program and remove from the machine
Empty chip pan (if machining a different material)
Clean machine Does this task really have to be done?
 Setup people may feel more comfortable doing so, but having a value in an
unused offset will have no adverse effect.
 Offsets for “standard tool stations” will not have to be cleared.
Lesson topics
First, try to come up with ways to eliminate tasks…
…some may seem far-fetched
Remove workholding device
Remove cutting tools not needed for next job
Clear offsets for tools removed from the machine
Disassemble certain components (like cutting tools)
Put everything away
Save changes to program and remove from the machine
Empty chip pan (if machining a different material)
Clean machine Can you think of any way to keep from
having to disassemble cutting tools?
 If using a limited number of different tools, leave them assembled at all times.
 Consider the redundancy of tearing down and assembling cutting tools
 Again, pick a set of “standard tools” that will be left assembled at all times.
Lesson topics
First, try to come up with ways to eliminate tasks…
…some may seem far-fetched
Remove workholding device
Remove cutting tools not needed for next job
Clear offsets for tools removed from the machine
Disassemble certain components (like cutting tools)
Put everything away
Save changes to program and remove from the machine
Empty chip pan (if machining a different material)
Clean machine Can you think of any way to keep from
having to put things away?
 If all the cutting tools you use can fit in the machine’s tool changing system,
nothing will have to be put away
Lesson topics
First, try to come up with ways to eliminate tasks…
…some may seem far-fetched
Remove workholding device
Remove cutting tools not needed for next job
Clear offsets for tools removed from the machine
Disassemble certain components (like cutting tools)
Put everything away
Save changes to program and remove from the machine
Empty chip pan (if machining a different material)
Clean machine Can you think of any way to keep from
having to save and delete programs?
 With some controls that are networked to they company’s computer system,
programs can be run from the network – not from internal control memory. In
essence, the machine cannot run out of memory capacity.
Lesson topics
First, try to come up with ways to eliminate tasks…
…some may seem far-fetched
Remove workholding device
Remove cutting tools not needed for next job
Clear offsets for tools removed from the machine
Disassemble certain components (like cutting tools)
Put everything away
Save changes to program and remove from the machine
Empty chip pan (if machining a different material)
Clean machine Can you think of any way to keep from
having to empty the chip pan?
 Can you run jobs that are made from the same material consecutively?
Lesson topics
First, try to come up with ways to eliminate tasks…
…some may seem far-fetched
Remove workholding device
Remove cutting tools not needed for next job
Clear offsets for tools removed from the machine
Disassemble certain components (like cutting tools)
Put everything away
Save changes to program and remove from the machine
Empty chip pan (if machining a different material)
Clean machine Can you think of any way to keep from
having to clean the machine?
 Some machine designs minimize the need for cleaning
 Slant bed versus flat bed turning centers
 Horizontal versus vertical machining centers
Lesson topics
First, try to come up with ways to eliminate tasks…
…some may seem far-fetched
Remove workholding device
Remove cutting tools not needed for next job
Clear offsets for tools removed from the machine
Disassemble certain components (like cutting tools)
Put everything away
Save changes to program and remove from the machine
Empty chip pan (if machining a different material)
Clean machine
Again, some ideas to eliminate tasks will be infeasible – but
try to come up with at least one way to do so for every task
Lesson topics
If you cannot justify what it takes to eliminate the task…
…can you move it off line?
Remove workholding device
Remove cutting tools not needed for next job
Clear offsets for tools removed from the machine
Disassemble certain components (like cutting tools)
Put everything away
Save changes to program and remove from the machine
Empty chip pan (if machining a different material)
Clean machine Can you think of any way to be tearing down
setups while a machine is in production?
 Machining centers with pallet changers
 If you have additional pallets, they can be set up while the machine is in
production
Lesson topics
If you cannot justify what it takes to eliminate the task…
…can you move it off line?
Remove workholding device
Remove cutting tools not needed for next job
Clear offsets for tools removed from the machine
Disassemble certain components (like cutting tools)
Put everything away
Save changes to program and remove from the machine
Empty chip pan (if machining a different material)
Clean machine Can you think of any way to be removing
cutting tools while a machine is in production?
 Some machining centers do allow cutting tools to be removed while the
machine is in cycle
 But of course, cutting tools needed for the job must remain in the
machine until the job is completed
Lesson topics
If you cannot justify what it takes to eliminate the task…
…can you move it off line?
Remove workholding device
Remove cutting tools not needed for next job
Clear offsets for tools removed from the machine
Disassemble certain components (like cutting tools)
Put everything away
Save changes to program and remove from the machine
Empty chip pan (if machining a different material)
Clean machine Can you think of any way to be clearing offsets
while a machine is in production?
 Again, machines do allow offsets to be cleared while the machine is in cycle
 But offsets needed for cutting tools in a job cannot be cleared until the
job is completed.
 BUT REMEMBER – this task can postponed until the machine is back in
cycle, running the next job
 This means the task will be done off line
Lesson topics
If you cannot justify what it takes to eliminate the task…
…can you move it off line?
Remove workholding device
Remove cutting tools not needed for next job
Clear offsets for tools removed from the machine
Disassemble certain components (like cutting tools)
Put everything away
Save changes to program and remove from the machine
Empty chip pan (if machining a different material)
Clean machine Can you think of any way to be disassembling
components and putting things away during a
production run?
 Again, needed components will be required until the production run is
completed
 BUT REMEMBER – this task can be postponed until the next job is up and
running. In this way the task is done off line.
 Another person – the same person who does the gathering – can do this task
Lesson topics
If you cannot justify what it takes to eliminate the task…
…can you move it off line?
Remove workholding device
Remove cutting tools not needed for next job
Clear offsets for tools removed from the machine
Disassemble certain components (like cutting tools)
Put everything away
Save changes to program and remove from the machine
Empty chip pan (if machining a different material)
Clean machine Can you think of any way to be manipulating
programs during a production run?
 Again, the program will be required until the production run is completed
 BUT REMEMBER – with background edit, you can transfer programs while
the machine is in cycle. The modified version of the program can be saved
during the production run. In this way, program transfer is done off line.
 And – background edit also allows programs to be deleted. Wait until the
next production run begins to delete the program used in the previous job.
Lesson topics
If you cannot justify what it takes to eliminate the task…
…can you move it off line?
Remove workholding device
Remove cutting tools not needed for next job
Clear offsets for tools removed from the machine
Disassemble certain components (like cutting tools)
Put everything away
Save changes to program and remove from the machine
Empty chip pan (if machining a different material)
Clean machine Can you think of any way to be emptying the
chip pan during a production run?
 The chip pan cannot be emptied until the job is finished but…
 …anything that can be prepared for this task (bringing the new chip pan
close by the machine, for example) should be done before the production
run ends.
Lesson topics
If you cannot justify what it takes to eliminate the task…
…can you move it off line?
Remove workholding device
Remove cutting tools not needed for next job
Clear offsets for tools removed from the machine
Disassemble certain components (like cutting tools)
Put everything away
Save changes to program and remove from the machine
Empty chip pan (if machining a different material)
Clean machine Can you think of any way to be cleaning the
machine during a production run?
 Probably not, but do anything you can in preparation for cleaning the machine
while the machine is still running the job (like gathering cleaning supplies,
brushers, rags, etc.)
Lesson topics
If you cannot justify what it takes to eliminate the task…
…can you move it off line?
Remove workholding device
Remove cutting tools not needed for next job
Clear offsets for tools removed from the machine
Disassemble
components
Final
suggestioncertain
for moving
tasks(like
off cutting
line: tools)
Put everything away
Watch
for tasks
that people
perform
onmachine
line
Save
changes
to program
and remove
from the
that could
be(ifperformed
line. material)
Empty
chip pan
machining aoff
different
Clean machine Can you think of any way to be cleaning the
machine during a production run?
 Probably not, but do anything you can in preparation for cleaning the machine
while the machine is still running the job (like gathering cleaning supplies,
brushers, rags, etc.)
Lesson topics
If you cannot justify what it takes to move the task off line…
…can you facilitate it?
Remove workholding device
Remove cutting tools not needed for next job
Clear offsets for tools removed from the machine
Disassemble certain components (like cutting tools)
Put everything away
Save changes to program and remove from the machine
Empty chip pan (if machining a different material)
Clean machine
Can you think of any way to simplify the
task of removing the workholding device?
 Consider fastener types
 Socket head cap screws (using ratchet wrenches) are easier to remove
and replace than hex head screws (with box end wrenches)
 Provide lifting help (cranes) for heavy workholding devices
 Consider method of clamping.
Bolts into tapped holes are usually easier than tee-nuts.
Lesson topics
If you cannot justify what it takes to move the task off line…
…can you facilitate it?
Remove workholding device
Remove cutting tools not needed for next job
Clear offsets for tools removed from the machine
Disassemble certain components (like cutting tools)
Put everything away
Save changes to program and remove from the machine
Empty chip pan (if machining a different material)
Clean machine
Can you think of any way to simplify the
task of removing cutting tools?
 Keep cutting tool storage rack/s close by the tool changer.
 If a wrench is required to remove cutting tools, dedicate one for this purpose
and keep it near by where it is needed. (Velcro it to the machine, if possible.)
Lesson topics
If you cannot justify what it takes to move the task off line…
…can you facilitate it?
Remove workholding device
Remove cutting tools not needed for next job
Clear offsets for tools removed from the machine
Disassemble certain components (like cutting tools)
Put everything away
Save changes to program and remove from the machine
Empty chip pan (if machining a different material)
Clean machine
Can you think of any way to simplify the
task of clearing offsets?
 Study control documentation – there may be a better/faster way than clearing
one offset at a time.
Lesson topics
If you cannot justify what it takes to move the task off line…
…can you facilitate it?
Remove workholding device
Remove cutting tools not needed for next job
Clear offsets for tools removed from the machine
Disassemble certain components (like cutting tools)
Put everything away
Save changes to program and remove from the machine
Empty chip pan (if machining a different material)
Clean machine
Can you think of any way to simplify the
task of disassembling components?
 Study this process. Ensure that the person who does the disassembling has
a clean work area and all of the appropriate hand tools for this purpose.
 Consider having a dedicated work station for disassembling cutting tools.
 Again, this task should not be the responsibility of the (highly skilled) setup
person.
 The same person who gathers components can perform this task.
Lesson topics
If you cannot justify what it takes to move the task off line…
…can you facilitate it?
Remove workholding device
Remove cutting tools not needed for next job
Clear offsets for tools removed from the machine
Disassemble certain components (like cutting tools)
Put everything away
Save changes to program and remove from the machine
Empty chip pan (if machining a different material)
Clean machine
Can you think of any way to simplify the
task of putting things away?
 Again, organization is the key.
 Every component must have a storage location
 If storage locations are clearly marked, a person with lesser skill can
perform this task (not the setup person).
Lesson topics
If you cannot justify what it takes to move the task off line…
…can you facilitate it?
Remove workholding device
Remove cutting tools not needed for next job
Clear offsets for tools removed from the machine
Disassemble certain components (like cutting tools)
Put everything away
Save changes to program and remove from the machine
Empty chip pan (if machining a different material)
Clean machine
Can you think of any way to simplify the
task of saving and deleting programs?
 For saving programs, an automatic DNC system will allow the setup person to
save a program without having to leave the machine.
 Be sure setup people are using the most efficient techniques to delete
programs.
Lesson topics
If you cannot justify what it takes to move the task off line…
…can you facilitate it?
Remove workholding device
Remove cutting tools not needed for next job
Clear offsets for tools removed from the machine
Disassemble certain components (like cutting tools)
Put everything away
Save changes to program and remove from the machine
Empty chip pan (if machining a different material)
Clean machine
Can you think of any way to simplify the
task of emptying the chip pan?
 Provide gloves and shovel (or hand scoop) – and any other needed item.
Store them close by the chip pan.
Lesson topics
If you cannot justify what it takes to move the task off line…
…can you facilitate it?
Remove workholding device
Remove cutting tools not needed for next job
Clear offsets for tools removed from the machine
Disassemble certain components (like cutting tools)
Put everything away
Save changes to program and remove from the machine
Empty chip pan (if machining a different material)
Clean machine
Can you think of any way to simplify the
task of cleaning the machine?
 Provide (another set of) gloves – store them close to the machine’s work
area.
 If cleaning involves an air-blowing system, be sure to provide full-face
protection.
 Keep any needed cleaning supplies near the machine.
Lesson topics
If you cannot justify what it takes to move the task off line…
…can you facilitate it?
Remove workholding device
Remove cutting tools not needed for next job
Clear offsets for tools removed from the machine
Disassemble
components
(like cutting tools)
Final
suggestioncertain
for facilitating
tasks:
Put everything away
Lookchanges
for times
when people
struggle
with
a
Save
to program
and remove
from the
machine
task. chip
When
do, it should
be material)
taken as a
Empty
pan they
(if machining
a different
signalmachine
that you MUST
facilitate the task.
Clean
Can you think of any way to simplify the
task of cleaning the machine?
 Provide (another set of) gloves – store them close to the machine’s work
area.
 If cleaning involves an air-blowing system, be sure to provide full-face
protection.
 Keep any needed cleaning supplies near the machine.
Lesson topics
If you cannot justify what it takes to move the task off line…
…can you facilitate it?
Remove workholding device
Remove cutting tools not needed for next job
Clear offsets for tools removed from the machine
Disassemble certain components (like cutting tools)
Put everything away
Save changes to program and remove from the machine
Empty chip pan (if machining a different material)
Clean machine
One more point:
These are all physical tasks that can be
consistently done and easily measured.
Are there any non-physical tasks
occurring as setups are torn down?
Lesson topics
If you cannot justify what it takes to move the task off line…
…can you facilitate it?
Remove workholding device
Remove cutting tools not needed for next job
Clear offsets for tools removed from the machine
Disassemble certain components (like cutting tools)
Put everything away
Save changes to program and remove from the machine
Empty chip pan (if machining a different material)
Clean machine
Again, non-physical tasks are inconsistent and/or immeasurable
(possibly wasted) actions or inactions that increase the time
required to make a setup or complete a production run
Are any of these happening
 Time spent searching for needed items
while tearing down?
 Time wasted while duplicating effort after a mistake
 Time lost while waiting for an unavailable item
 Any time the machine sits idle while no-one is working on it
Lesson topics
Lesson topics
Think of what must be done to make the
workholding setup
Prepare the new workholding device
For machining centers
Clamp to machine table
Square up workholding device with table
Using dial indicator
For turning centers
Mount top tooling
Bore jaws (if necessary
Prepare work support device (if necessary)
Mount center and position tailstock
Align tailstock
Adjust clamping pressure
Here is our list, but be sure to create a list of your own
Use the setup reduction planning form provided in lesson four
Lesson topics
First, try to come up with ways to eliminate tasks…
…some may seem far-fetched
Prepare the new workholding device
For machining centers
Clamp to machine table
Square up workholding device with table
Using dial indicator
Can you think of any way to
For turning centers
keep from having make new
Mount top tooling
workholding setups?
Bore jaws (if necessary
Prepare work support device (if necessary)
Mount center and position tailstock
Align tailstock
Adjust clamping pressure
 Can multiple workholding devices be mounted to the machine? (On the table
of a vertical machining centers.)
 Can jobs requiring the same workholding device be run consecutively?
 Can workholding devices be more versatile, allowing different jobs to be run?
 Are there any parameters to change? Program them with G10.
Lesson topics
First, try to come up with ways to eliminate tasks…
…some may seem far-fetched
Prepare the new workholding device
For machining
centersworkholding devices
An example
of multiple
Clamp to machine table
Square up workholding device with table
Using dial indicator
Can you think of any way to
For turning centers
keep from having make new
Mount top tooling
workholding setups?
Bore jaws (if necessary
Prepare work support device (if necessary)
Mount center and position tailstock
Align tailstock
This devices
staysworkholding
on table
Vise
Can multiple
devices be mounted to the machine? (On the table
changes job to job
of a vertical machining centers.)
 Can jobs requiring the same workholding device be run consecutively?
 Can workholding devices be more versatile, allowing different jobs to be run?
 Are there any parameters to change? Program them with G10.
Lesson topics
First, try to come up with ways to eliminate tasks…
…some may seem far-fetched
Prepare the new workholding device
For machining centers
Clamp to machine table
Square up workholding device with table
Using dial indicator
Can you think of any way to
For turning centers
keep from having make new
Mount top tooling
workholding setups?
Bore jaws (if necessary
Prepare work support device (if necessary)
Mount center and position tailstock
Align tailstock
Adjust clamping pressure
 Can multiple workholding devices be mounted to the machine? (On the table
of a vertical machining centers.)
 Can jobs requiring the same workholding device be run consecutively?
 Can workholding devices be more versatile, allowing different jobs to be run?
 Are there any parameters to change? Program them with G10.
Lesson topics
First, try to come up with ways to eliminate tasks…
…some may seem far-fetched
Prepare the new workholding device
For machining centers
Clamp to machine table
Square up workholding device with table
Using dial indicator
Can you think of any way to
For turning centers
keep from having make new
Mount top tooling
workholding setups?
Bore jaws (if necessary
Prepare work support device (if necessary)
Mount center and position tailstock
Align tailstock
Adjust clamping pressure
 Can multiple workholding devices be mounted to the machine? (On the table
of a vertical machining centers.)
 Can jobs requiring the same workholding device be run consecutively?
 Can workholding devices be more versatile, allowing different jobs to be run?
 Are there any parameters to change? Program them with G10.
Lesson topics
Eliminate workholding setup tasks
Do you have to change any control
parameters from one setup to another?
 When removing and replacing rotary tables
 When using probing systems
 When switching between inch and metric
 Others?
Remember, most current model Fanuc
controls let you change parameters with G10
This keeps the setup person from doing so!
Lesson topics
First, try to come up with ways to eliminate tasks…
…some may seem far-fetched
Prepare the new workholding device
For machining centers
Clamp to machine table
Square up workholding device with table
Using dial indicator
Can you think of any way to
For turning centers
keep from having make new
Mount top tooling
workholding setups?
Bore jaws (if necessary
Prepare work support device (if necessary)
Mount center and position tailstock
Align tailstock
Adjust clamping pressure
 Can multiple workholding devices be mounted to the machine? (On the table
of a vertical machining centers.)
 Can jobs requiring the same workholding device be run consecutively?
 Can workholding devices be more versatile, allowing different jobs to be run?
 Are there any parameters to change? Program them with G10.
Lesson topics
First, try to come up with ways to eliminate tasks…
…some may seem far-fetched
Prepare the new workholding device
For machining centers
Clamp to machine table
Square up workholding device with table
Using dial indicator
Can you think of any way to
For turning centers
keep from having make new
Mount top tooling
workholding setups?
Bore jaws (if necessary
Prepare work support device (if necessary)
Mount center and position tailstock
Align tailstock
Adjust clamping pressure
 If the setup is qualified, the workholding device will be square with the table
when mounted
Lesson topics
A qualified setup:
Definition:
A qualified setup is one that can placed on
the machine table in exactly the same
fashion over and over again
Lesson topics
A qualified setup:
Does your machine
have a center slot?
Table slots
Top view of VMC table
Lesson topics
A qualified setup:
Keys
Bottom plate of
workholding device
Top view of VMC table
Lesson topics
First, try to come up with ways to eliminate tasks…
…some may seem far-fetched
Prepare the new workholding device
For machining centers
Clamp to machine table
Square up workholding device with table
Using dial indicator
Can you think of any way to
For turning centers
keep from having make new
Mount top tooling
workholding setups?
Bore jaws (if necessary
Prepare work support device (if necessary)
Mount center and position tailstock
Align tailstock
Adjust clamping pressure
 If the setup is qualified, the workholding device will be square with the table
when mounted
Lesson topics
First, try to come up with ways to eliminate tasks…
…some may seem far-fetched
Prepare the new workholding device
For machining centers
Clamp to machine table
Square up workholding device with table
Using dial indicator
Can you think of any way to
For turning centers
keep from having make new
Mount top tooling
workholding setups?
Bore jaws (if necessary
Prepare work support device (if necessary)
Mount center and position tailstock
Align tailstock
Adjust clamping pressure
 Some turning centers allow tailstock positioning to be programmed
 Eliminating the need for a setup person to move the tailstock
Lesson topics
First, try to come up with ways to eliminate tasks…
…some may seem far-fetched
Prepare the new workholding device
For machining centers
Clamp to machine table
Square up workholding device with table
Using dial indicator
Can you think of any way to
For turning centers
keep from having make new
Mount top tooling
workholding setups?
Bore jaws (if necessary
Prepare work support device (if necessary)
Mount center and position tailstock
Align tailstock
Adjust clamping pressure
 With some machines, the tailstock stays in alignment – even when moved
 Eliminating the need for a setup person to align the tailstock from job to
job
Lesson topics
First, try to come up with ways to eliminate tasks…
…some may seem far-fetched
Prepare the new workholding device
For machining centers
Clamp to machine table
Square up workholding device with table
Using dial indicator
Can you think of any way to
For turning centers
keep from having make new
Mount top tooling
workholding setups?
Bore jaws (if necessary
Prepare work support device (if necessary)
Mount center and position tailstock
Align tailstock
Adjust clamping pressure
 Some turning centers allow chuck pressure to be programmed
 This keeps the setup person from having to change chuck pressure
Lesson topics
If you cannot justify what it takes to eliminate the task…
…can you move it off line?
Prepare the new workholding device
For machining centers
Clamp to machine table
Square up workholding device with table
Using dial indicator Can you think of any way to be
For turning centers
making workholding setups while a
Mount top tooling
machine is in production?
Bore jaws (if necessary
Prepare work support device (if necessary)
Mount center and position tailstock
Align tailstock
Adjust clamping pressure
Same suggestions as for tearing down:
 Machining centers with pallet changers
 If you have additional pallets, they can be set up while the machine is in
production
Lesson topics
Making use of pallet changing systems
Automatic type
Manual type
As long as you have extra pallets, two tasks related
to workholding setup can be moved off line
 Remove previous workholding device
 Mount new workholding device
On-line time will be limited to
placing the pallet on the machine
Lesson topics
If you cannot justify what it takes to eliminate the task…
…can you move it off line?
Prepare the new workholding device
For machining centers
Clamp to machine table
Square up workholding device with table
Using dial indicator Can you think of any way to be
For turning centers
making workholding setups while a
Mount top tooling
machine is in production?
Bore jaws (if necessary
Prepare work support device (if necessary)
Mount center and position tailstock
Align tailstock
Adjust clamping pressure
Same suggestions as for tearing down:
 Machining centers with pallet changers
 If you have additional pallets, they can be set up while the machine is in
production
Lesson topics
If you cannot justify what it takes to move a task off line…
…can you facilitate it?
Prepare the new workholding device
For machining centers
Clamp to machine table
Square up workholding device with table
Using dial indicator Can you think of any way to make it
For turning centers
easier to make the workholding
Mount top tooling
setup?
Bore jaws (if necessary
Prepare work support device (if necessary)
Mount center and position tailstock
Align tailstock
Again, look for times when
Adjust clamping pressure people struggle
 Consider fastener types
 Socket head cap screws (using ratchet wrenches) are easier to remove
and replace than hex head screws (with box end wrenches)
 Provide lifting help (cranes) for heavy workholding devices
 Consider method of clamping.
 Bolts into tapped holes are usually easier than tee-nuts.
Lesson topics
If you cannot justify what it takes to move a task off line…
…can you facilitate it?
Prepare the new workholding device
For machining centers
Clamp to machine table
Square up workholding device with table
Using dial indicator Can you think of any way to make it
For turning centers
easier to make the workholding
Mount top tooling
setup?
Bore jaws (if necessary)
Prepare work support device (if necessary)
Mount center and position tailstock
Align tailstock
Again, look for times when
Adjust clamping pressure people struggle
 Mounting jaws can be a very tedious task
 Study this task to find improvements
 Consider quick-change chucks
 Use a pointer to specify the serration into which jaws must be placed
Lesson topics
Facilitating workholding setup tasks
3-jaw chuck
Lesson topics
Mounting top tooling
Note tiny serrations
Facilitating workholding setup tasks
Mounting top tooling
Hard jaw
Lesson topics
Soft jaw
Facilitating workholding setup tasks
Mounting top tooling
Jaw changing is a very cumbersome task
 Six socket head cap screws must be loosened
 Tee nuts must be placed on new jaws
 Jaws must be accurately placed in serrations
 Six socket head cap screws must be tightened
If placement is off, this must be repeated!
Jaw replacement can take
5-15 minutes or more
Lesson topics
Facilitating workholding setup tasks
Mounting top tooling
Jaw changing is a very cumbersome task
For your next chuck purchase…
…consider quick-jaw-change chucks
 One screw is involved per jaw
 One quarter turn of special wrench loosens jaw
 One quarter turn tightens
 Jaw changing time is about 5 seconds per jaw!
Serrations are larger (soft jaws don’t last as long)
Confirm concentricity requirements
Lesson topics
If you cannot justify what it takes to move a task off line…
…can you facilitate it?
Prepare the new workholding device
For machining centers
Clamp to machine table
Square up workholding device with table
Using dial indicator Can you think of any way to make it
For turning centers
easier to make the workholding
Mount top tooling
setup?
Bore jaws (if necessary)
Prepare work support device (if necessary)
Mount center and position tailstock
Align tailstock
Again, look for times when
Adjust clamping pressure people struggle
 Mounting jaws can be a very tedious task
 Study this task to find improvements
 Consider quick-change chucks
 Use a pointer to specify the serration into which jaws must be placed
Lesson topics
If you cannot justify what it takes to move a task off line…
…can you facilitate it?
Prepare the new workholding device
For machining centers
Clamp to machine table
Square up workholding device with table
Using dial indicator Can you think of any way to make it
For turning centers
easier to make the workholding
Mount top tooling
setup?
Bore jaws (if necessary)
Prepare work support device (if necessary)
Mount center and position tailstock
Align tailstock
Again, look for times when
Adjust clamping pressure people struggle
 Mounting jaws can be a very tedious task
 Study this task to find improvements
 Consider quick-change chucks
 Use a pointer to specify the serration into which jaws must be placed
Lesson topics
Facilitating workholding setup tasks
Mounting jaws
Align with tool
diameter
X01.3569
Z02.4236
1.3569
Select the boring bar you
use for boring jaws
Lesson topics
Facilitating workholding setup tasks
Mounting jaws
Align with tool
diameter
Determine the diameter for chucking
(with chuck unclamped):
X01.3569
Z02.4236
1.3569
Clamping diameter plus jaw stroke
If clamping on a 3.0” dia. and jaw stroke is 0.5”,
this diameter is 3.5”
Lesson topics
Facilitating workholding setup tasks
Mounting jaws
Align with tool
diameter
X03.5000
Z02.4236
3.5
Open jaws and move X axis to
clamping diameter
Lesson topics
Facilitating workholding setup tasks
Mounting jaws
Align with tool
diameter
X03.5000
Z02.4236
Use boring bar as a pointer
and mount each jaw
 Each jaw can be easily mounted in the same serration
 Jaws will clamp on workpiece at mid-stroke
Lesson topics
If you cannot justify what it takes to move a task off line…
…can you facilitate it?
Prepare the new workholding device
For machining centers
Clamp to machine table
Square up workholding device with table
Using dial indicator Can you think of any way to make it
For turning centers
easier to make the workholding
Mount top tooling
setup?
Bore jaws (if necessary)
Prepare work support device (if necessary)
Mount center and position tailstock
Align tailstock
Again, look for times when
Adjust clamping pressure people struggle
 Mounting jaws can be a very tedious task
 Study this task to find improvements
 Consider quick-change chucks
 Use a pointer to specify the serration into which jaws must be placed
Lesson topics
If you cannot justify what it takes to move a task off line…
…can you facilitate it?
Prepare the new workholding device
For machining centers
Clamp to machine table
Square up workholding device with table
Using dial indicator Can you think of any way to make it
For turning centers
easier to make the workholding
Mount top tooling
setup?
Bore jaws (if necessary)
Prepare work support device (if necessary)
Mount center and position tailstock
Align tailstock
Again, look for times when
Adjust clamping pressure people struggle
 For repeated jobs, save soft jaws
 Don’t re-bore them for another job
 This saves time the next time the job is run
 Make a set of chucking rings – or a special clamping tool
 Provide instructions for jaw-boring or create a jaw-boring program
Lesson topics
Facilitating workholding setup tasks
Clamp on ring
Lesson topics
Facilitating workholding setup tasks
Clamp on ring
1.0
1.875
1.125
1.25
2.0
1.375
2.125
1.5
1.625
2.375
Make a set of chucking rings!
Lesson topics
1.75
2.5
Facilitating workholding setup tasks
Clamp on ring
Hex head
screws
Hex stock
Or make an adjustable chucking tool
Lesson topics
Facilitating workholding setup tasks
Clamp on ring
Lesson topics
If you cannot justify what it takes to move a task off line…
…can you facilitate it?
Prepare the new workholding device
For machining centers
Clamp to machine table
Square up workholding device with table
Using dial indicator Can you think of any way to make it
For turning centers
easier to make the workholding
Mount top tooling
setup?
Bore jaws (if necessary)
Prepare work support device (if necessary)
Mount center and position tailstock
Align tailstock
Again, look for times when
Adjust clamping pressure people struggle
 For repeated jobs, save soft jaws
 Don’t re-bore them for another job
 This saves time the next time the job is run
 Make a set of chucking rings – or a special clamping tool
 Provide instructions for jaw boring – or create a jaw-boring program
Lesson topics
If you cannot justify what it takes to move a task off line…
…can you facilitate it?
Prepare the new workholding device
For machining centers
Clamp to machine table
Square up workholding device with table
Using dial indicator Can you think of any way to make it
For turning centers
easier to make the workholding
Mount top tooling
setup?
Bore jaws (if necessary)
Prepare work support device (if necessary)
Mount center and position tailstock
Align tailstock
Again, look for times when
Adjust clamping pressure people struggle
 For repeated jobs, save soft jaws
 Don’t re-bore them for another job
 This saves time the next time the job is run
 Make a set of chucking rings – or a special clamping tool
 Provide instructions for jaw boring - or create a jaw-boring program
Lesson topics
Facilitating workholding setup tasks
Actually boring jaws
Be sure the setup person can
align the jaw boring cutting tool
Lesson topics
Facilitating workholding setup tasks
Actually boring jaws
Be sure the setup person can
align the jaw boring cutting tool
Lesson topics
Facilitating workholding setup tasks
Actually boring jaws
Set to zero
X02.3857
Z00.0000
Be sure the setup person can
align the jaw boring cutting tool
Lesson topics
Facilitating workholding setup tasks
Actually boring jaws
Align with
tool
diameter
X01.3569
Z02.4236
1.3569
At least now the setup person can
determine diameters and depths!
Lesson topics
Facilitating workholding setup tasks
Actually boring jaws
Better yet, why not develop
programs to bore jaws?
One jaw boring program per job, or…
…one universal program (custom macro)
Lesson topics
Facilitating workholding setup tasks
Actually boring jaws
If one program per job:
N205 G00 X6.5 Z5.0
N210 M30
N999 (BEGIN JAW BORING)
N1000 T1212 (Boring bar)
.
.
.
N1105 M30
Place jaw boring commands after M30
Lesson topics
Facilitating workholding setup tasks
Actually boring jaws
If universal custom macro:
O0002 (Program number)
#101 = 3.00 (Starting diameter to bore)
#102 = 4.00 (Ending diameter to bore)
#103 = 1.0 (Z depth of jaw boring)
#104 = 0.100 (Depth of cut per pass)
#105 = 300. (Speed in SFM for boring)
T1212 (Index to boring bar)
G96 S#105 M03 (Start spindle)
G98 G01 X#101 Z0.15 F30.0 (Fast feed to approach position)
G99 G71 P1 Q2 U-0.01 W0.005 D#104 F0.10 (Rough bore jaws)
N1 G00 X#102
G01 Z-#103
N2 X#101
G70 P1 Q2 F0.005
M30
Lesson topics
Facilitating workholding setup tasks
Actually boring jaws
If universal custom macro:
O0002 (Program number)
#101 = 3.00 (Starting diameter to bore)
#102 = 4.00 (Ending diameter to bore)
Input data
#103 = 1.0 (Z depth of jaw boring)
#104 = 0.100 (Depth of cut per pass)
#105 = 300. (Speed in SFM for boring)
T1212 (Index to boring bar)
G96 S#105 M03 (Start spindle)
G98 G01 X#101 Z0.15 F30.0 (Fast feed to approach position)
G99 G71 P1 Q2 U-0.01 W0.005 D#104 F0.10 (Rough bore jaws)
N1 G00 X#102
G01 Z-#103
N2 X#101
G70 P1 Q2 F0.005
M30
Lesson topics
Facilitating workholding setup tasks
Actually boring jaws
If universal custom macro:
O0002 (Program number)
#101 = 3.00 (Starting diameter to bore)
#102 = 4.00 (Ending diameter to bore)
Will change with
#103 = 1.0 (Z depth of jaw boring)
input data
#104 = 0.100 (Depth of cut per pass)
#105 = 300. (Speed in SFM for boring)
T1212 (Index to boring bar)
G96 S#105 M03 (Start spindle)
G98 G01 X#101 Z0.15 F30.0 (Fast feed to approach position)
G99 G71 P1 Q2 U-0.01 W0.005 D#104 F0.10 (Rough bore jaws)
N1 G00 X#102
G01 Z-#103
N2 X#101
G70 P1 Q2 F0.005
M30
Lesson topics
If you cannot justify what it takes to move a task off line…
…can you facilitate it?
Prepare the new workholding device
For machining centers
Clamp to machine table
Square up workholding device with table
Using dial indicator Can you think of any way to make it
For turning centers
easier to make the workholding
Mount top tooling
setup?
Bore jaws (if necessary)
Prepare work support device (if necessary)
Mount center and position tailstock
Align tailstock
Again, look for times when
Adjust clamping pressure people struggle
 For repeated jobs, save soft jaws
 Don’t re-bore them for another job
 This saves time the next time the job is run
 Make a set of chucking rings – or a special clamping tool
 Provide instructions for jaw boring - or create a jaw-boring program
Lesson topics
Lesson topics
Think of what must be done to get cutting
tools ready to use in the machine
Machining centers
Assemble needed tools
Insert, cutting tool body,
extension, adapter, holder, pull stud
Measure
Tool length compensation value
Cutter radius compensation value
Preset
Boring bars to specified diameter
Load in specified tool stations
Enter offsets
Tool length compensation
Cutter radius compensation
Sharpen / replace dull tools
Turning centers
Assemble needed tools
Insert, cutting tool shank or body,
etc.
Load in specified turret stations
Enter offsets
Tool nose radius compensation
Sharpen / replace dull tools
Again, here is our list, but be sure to create a list of your own
Use the setup reduction planning form provided in lesson four
Lesson topics
First, try to come up with ways to eliminate tasks…
…some may seem far-fetched
Machining centers
Assemble needed tools
Insert, cutting tool body,
extension, adapter, holder, pull stud
Measure
Tool length compensation value
Cutter radius compensation value
Preset
Boring bars to specified diameter
Load in specified tool stations
Enter offsets
Tool length compensation
Cutter radius compensation
Sharpen / replace dull tools
Turning centers
Assemble needed tools
Insert, cutting tool shank or body,
etc.
Load in specified turret stations
Enter offsets
Tool nose radius compensation
Sharpen / replace dull tools
Can you think of any way to
eliminate cutting tool tasks?
 Can jobs requiring the same cutting tools be run consecutively?
 Can you consolidate the number of cutting tools needed?
 Can you come up with standard tool stations?
Lesson topics
Eliminate cutting tool tasks
Standard tool stations
You probably have some
tools that are used regularly
 Spot drill
 ¾ end mill
 3” face mill
 Drill & tap combos
Assign permanent tool stations to these tools
Lesson topics
Eliminate cutting tool tasks
Standard tool stations
By the way, how many tool
stations do your machines have?
Standard tool stations should be a major
consideration when buying machines!
Finite number of different jobs?
You may be able to store all
tools in the ATC magazine!
Lesson topics
Eliminate cutting tool tasks
Standard tool stations
Even if you can’t store all tools in the
ATC magazine…
…place a storage rack right next
to the machine!
Lesson topics
Eliminate cutting tool tasks
Having standard tool stations requires
duplicated cutting tool components
You must be able to justify the additional cost
How much on-line setup time is currently
taken to perform cutting tool tasks?
Lesson topics
First, try to come up with ways to eliminate tasks…
…some may seem far-fetched
Machining centers
Assemble needed tools
Insert, cutting tool body,
extension, adapter, holder, pull stud
Measure
Tool length compensation value
Cutter radius compensation value
Preset
Boring bars to specified diameter
Load in specified tool stations
Enter offsets
Tool length compensation
Cutter radius compensation
Sharpen / replace dull tools
Turning centers
Assemble needed tools
Insert, cutting tool shank or body,
etc.
Load in specified turret stations
Enter offsets
Tool nose radius compensation
Sharpen / replace dull tools
Can you think of any way to
eliminate cutting tool tasks?
 Can jobs requiring the same cutting tools be run consecutively?
 Can you consolidate the number of cutting tools needed?
 Can you come up with standard tool stations?
Lesson topics
First, try to come up with ways to eliminate tasks…
…some may seem far-fetched
Machining centers
Assemble needed tools
Insert, cutting tool body,
extension, adapter, holder, pull stud
Measure
Tool length compensation value
Cutter radius compensation value
Preset
Boring bars to specified diameter
Load in specified tool stations
Enter offsets
Tool length compensation
Cutter radius compensation
Sharpen / replace dull tools
Turning centers
Assemble needed tools
Insert, cutting tool shank or body,
etc.
Load in specified turret stations
Enter offsets
Tool nose radius compensation
Sharpen / replace dull tools
Can you think of any way to
eliminate cutting tool tasks?
 Can jobs requiring the same cutting tools be run consecutively?
 Can you consolidate the number of cutting tools needed?
 Can you come up with standard tool stations?
Lesson topics
Eliminate cutting tool tasks
Consolidate cutting tools
How do you designate tools on setup sheets?
DJ0500-HC1.0-E1.0-C0.5-L6.5
½ drill
Approx 6.5
Or
C0500
collet
E1000
extension
HC1000 collet holder
Lesson topics
Jobbers
length
½ drill
Eliminate cutting tool tasks
Consolidate cutting tools
If you designate all components for cutting tools…
…and if you minimize the number
of different tool assemblies…
…there will be a better chance that needed
cutting tools will already be assembled
Lesson topics
First, try to come up with ways to eliminate tasks…
…some may seem far-fetched
Machining centers
Assemble needed tools
Insert, cutting tool body,
extension, adapter, holder, pull stud
Measure
Tool length compensation value
Cutter radius compensation value
Preset
Boring bars to specified diameter
Load in specified tool stations
Enter offsets
Tool length compensation
Cutter radius compensation
Sharpen / replace dull tools
Turning centers
Assemble needed tools
Insert, cutting tool shank or body,
etc.
Load in specified turret stations
Enter offsets
Tool nose radius compensation
Sharpen / replace dull tools
Can you think of any way to
eliminate cutting tool tasks?
 Can jobs requiring the same cutting tools be run consecutively?
 Can you consolidate the number of cutting tools needed?
 Can you come up with standard tool stations?
Lesson topics
First, try to come up with ways to eliminate tasks…
…some may seem far-fetched
Machining centers
Assemble needed tools
Insert, cutting tool body,
extension, adapter, holder, pull stud
Measure
Tool length compensation value
Cutter radius compensation value
Preset
Boring bars to specified diameter
Load in specified tool stations
Enter offsets
Tool length compensation
Cutter radius compensation
Sharpen / replace dull tools
Turning centers
Assemble needed tools
Insert, cutting tool shank or body,
etc.
Load in specified turret stations
Enter offsets
Tool nose radius compensation
Sharpen / replace dull tools
Can you think of any way to
eliminate cutting tool tasks?
 Offset entries can be programmed
 For machining center tools with known lengths or diameters
 For tool nose radius compensation on turning centers
 This keeps the setup person from having to enter them
Lesson topics
Eliminate cutting tool tasks
About tool nose radius compensation:
The programmer specifies the tool nose
radius for single point turning tools
The setup person must use the specified TNR!
Why not program the TNR offset settings?
G10 P2 R0.0312 T3
G10 P6 R0.0156 T2
Lesson topics
Eliminate cutting tool tasks
About tool nose radius compensation:
By the way…
…CAM systems have the ability to output modified
tool path based upon the specified tool nose radius
There will be no G41 or G42 in the program!
(And no need for offset entry)
Lesson topics
First, try to come up with ways to eliminate tasks…
…some may seem far-fetched
Machining centers
Assemble needed tools
Insert, cutting tool body,
extension, adapter, holder, pull stud
Measure
Tool length compensation value
Cutter radius compensation value
Preset
Boring bars to specified diameter
Load in specified tool stations
Enter offsets
Tool length compensation
Cutter radius compensation
Sharpen / replace dull tools
Turning centers
Assemble needed tools
Insert, cutting tool shank or body,
etc.
Load in specified turret stations
Enter offsets
Tool nose radius compensation
Sharpen / replace dull tools
Can you think of any way to
eliminate cutting tool tasks?
 Offset entries can be programmed
 For machining center tools with known lengths or diameters
 For tool nose radius compensation on turning centers
 This keeps the setup person from having to enter them
Lesson topics
If you cannot justify what it takes to eliminate tasks…
…can you move them off line?
Machining centers
Assemble needed tools
Insert, cutting tool body,
extension, adapter, holder, pull stud
Measure
Tool length compensation value
Cutter radius compensation value
Preset
Boring bars to specified diameter
Load in specified tool stations
Enter offsets
Tool length compensation
Cutter radius compensation
Sharpen / replace dull tools
Turning centers
Assemble needed tools
Insert, cutting tool shank or body,
etc.
Load in specified turret stations
Enter offsets
Tool nose radius compensation
Sharpen / replace dull tools
What can be done while the
machine is in production for the
previous job?
 Assemble cutting tools for up-coming jobs while the machine is producing
 When the job hits the machine, cutting tools will be ready
 This can be done by a tool setter (not necessarily the setup person)
Lesson topics
If you cannot justify what it takes to eliminate tasks…
…can you move them off line?
Machining centers
Assemble needed tools
Insert, cutting tool body,
extension, adapter, holder, pull stud
Measure
Tool length compensation value
Cutter radius compensation value
Preset
Boring bars to specified diameter
Load in specified tool stations
Enter offsets
Tool length compensation
Cutter radius compensation
Sharpen / replace dull tools
Turning centers
Assemble needed tools
Insert, cutting tool shank or body,
etc.
Load in specified turret stations
Enter offsets
Tool nose radius compensation
Sharpen / replace dull tools
What can be done while the
machine is in production for the
previous job?
 For machining centers, tool length and cutter radius compensation values can
be determined off line
Lesson topics
Move cutting tool tasks off line
Measuring cutting tools
 Tool length
 Cutter radius (for milling cutters)
Remember – there are two ways to
use tool length compensation…
Lesson topics
Move cutting tool tasks off line
Measuring cutting tools
Fixture offset
Z is zero
TLC offset
Fixture
offset Z
Program Zero
TLC offset
Program
Zero
Offset value can be easily measured off line
Offset value doesn’t change from job to job
Offset value can be shared among machines
Lesson topics
Move cutting tool tasks off line
A simple height gage can be used…
#
1
2
3
4
5
6
7
Value
6.5445
5.6743
5.9876
7.5654
6.5654
4.5657
7.6544
…tool setter can write down tool lengths
Many tooling suppliers can provide a
special tool length measuring device
Lesson topics
Move cutting tool tasks off line
For cutter radius compensation, a micrometer
can be used to measure most milling cutters…
…tool setter can write down
cutter radius or diameter
Lesson topics
By the way…
Multiple identical tools
Do you keep more than one of your most
popular tools assembled and ready to go?
One company:
 Has fifteen CNC machining centers
 Picked ten most popular cutting tools
 Tool crib attendant keeps at least three of each
 Anyone who needs them has immediate access
Lesson topics
If you cannot justify what it takes to eliminate tasks…
…can you move them off line?
Machining centers
Assemble needed tools
Insert, cutting tool body,
extension, adapter, holder, pull stud
Measure
Tool length compensation value
Cutter radius compensation value
Preset
Boring bars to specified diameter
Load in specified tool stations
Enter offsets
Tool length compensation
Cutter radius compensation
Sharpen / replace dull tools
Turning centers
Assemble needed tools
Insert, cutting tool shank or body,
etc.
Load in specified turret stations
Enter offsets
Tool nose radius compensation
Sharpen / replace dull tools
What can be done while the
machine is in production for the
previous job?
 For machining centers, tool length and cutter radius compensation values can
be determined off line
Lesson topics
If you cannot justify what it takes to eliminate tasks…
…can you move them off line?
Machining centers
Assemble needed tools
Insert, cutting tool body,
extension, adapter, holder, pull stud
Measure
Tool length compensation value
Cutter radius compensation value
Preset
Boring bars to specified diameter
Load in specified tool stations
Enter offsets
Tool length compensation
Cutter radius compensation
Sharpen / replace dull tools
Turning centers
Assemble needed tools
Insert, cutting tool shank or body,
etc.
Load in specified turret stations
Enter offsets
Tool nose radius compensation
Sharpen / replace dull tools
What can be done while the
machine is in production for the
previous job?
 If boring bars must be preset, do so before the job comes to the machine
Lesson topics
Move cutting tool tasks off line
Most companies don’t try to perfectly set boring bars…
…instead, they set them 0.005 or so undersize
Setup person must trial
machine to fine-tune
Lesson topics
Move cutting tool tasks off line
Trial boring takes time…
…if you can come up with a way to
perfectly set boring bars off line…
…you can minimize down time between
production runs!
Lesson topics
If you cannot justify what it takes to eliminate tasks…
…can you move them off line?
Machining centers
Assemble needed tools
Insert, cutting tool body,
extension, adapter, holder, pull stud
Measure
Tool length compensation value
Cutter radius compensation value
Preset
Boring bars to specified diameter
Load in specified tool stations
Enter offsets
Tool length compensation
Cutter radius compensation
Sharpen / replace dull tools
Turning centers
Assemble needed tools
Insert, cutting tool shank or body,
etc.
Load in specified turret stations
Enter offsets
Tool nose radius compensation
Sharpen / replace dull tools
What can be done while the
machine is in production for the
previous job?
 If boring bars must be preset, do so before the job comes to the machine
Lesson topics
If you cannot justify what it takes to eliminate tasks…
…can you move them off line?
Machining centers
Assemble needed tools
Insert, cutting tool body,
extension, adapter, holder, pull stud
Measure
Tool length compensation value
Cutter radius compensation value
Preset
Boring bars to specified diameter
Load in specified tool stations
Enter offsets
Tool length compensation
Cutter radius compensation
Sharpen / replace dull tools
Turning centers
Assemble needed tools
Insert, cutting tool shank or body,
etc.
Load in specified turret stations
Enter offsets
Tool nose radius compensation
Sharpen / replace dull tools
What can be done while the
machine is in production for the
previous job?
 Can you be loading cutting tools for the next job while the machine is running
the current job?
 Some machines allow cutting tools to be loaded and removed while the
machine is in cycle.
Lesson topics
Move cutting tool tasks off line
Magazine
Manual
Tool Magazine
Auto
Rotate CW
Rotate CCW
Loading
Station
If you have enough tool stations…
…during production, load tools for the next job!
Lesson topics
If you cannot justify what it takes to eliminate tasks…
…can you move them off line?
Machining centers
Assemble needed tools
Insert, cutting tool body,
extension, adapter, holder, pull stud
Measure
Tool length compensation value
Cutter radius compensation value
Preset
Boring bars to specified diameter
Load in specified tool stations
Enter offsets
Tool length compensation
Cutter radius compensation
Sharpen / replace dull tools
Turning centers
Assemble needed tools
Insert, cutting tool shank or body,
etc.
Load in specified turret stations
Enter offsets
Tool nose radius compensation
Sharpen / replace dull tools
What can be done while the
machine is in production for the
previous job?
 Can you be loading cutting tools for the next job while the machine is running
the current job?
 Some machines allow cutting tools to be loaded and removed while the
machine is in cycle.
Lesson topics
If you cannot justify what it takes to eliminate tasks…
…can you move them off line?
Machining centers
Assemble needed tools
Insert, cutting tool body,
extension, adapter, holder, pull stud
Measure
Tool length compensation value
Cutter radius compensation value
Preset
Boring bars to specified diameter
Load in specified tool stations
Enter offsets
Tool length compensation
Cutter radius compensation
Sharpen / replace dull tools
Turning centers
Assemble needed tools
Insert, cutting tool shank or body,
etc.
Load in specified turret stations
Enter offsets
Tool nose radius compensation
Sharpen / replace dull tools
What can be done while the
machine is in production for the
previous job?
 If you assemble and measure cutting tools off line, you can program the tool
length and cutter radius compensation offset entries
 This keeps the setup person from having to do so.
Lesson topics
Move cutting tool tasks off line
Earlier we said tool setters can measure tool lengths
#
1
2
3
4
5
6
7
Value
6.5445
5.6743
5.9876
7.5654
6.5654
4.5657
7.6544
…and write down tool length values
But the setup person must still enter
offsets while the machine is down!
Lesson topics
Move cutting tool tasks off line
The tool setter can create a program to set offset values!
Template program
Tool setter calls up
this template program
and modifies the R
word for each tool
Lesson topics
O8001 (Offset program)
G90 G10 P1 R20.0000
G10 P2 R20.0000
G10 P3 R20.0000
G10 P4 R20.0000
G10 P5 R20.0000
G10 P6 R20.0000
G10 P7 R20.0000
G10 P8 R20.0000
G10 P9 R20.0000
G10 P10 R20.0000
.
.
M30
Move cutting tool tasks off line
The tool setter can create a program to set offset values!
Template program
Tool setter calls up
this template program
and modifies the R
word for each tool
O8001 (Offset program)
G90 G10 P1 R6.5893
G10 P2 R6.3321
G10 P3 R5.4678
G10 P4 R7.5746
G10 P5 R3.4858
G10 P6 R4.3433
G10 P7 R8.4872
M30
This program is stored in the DNC system –
called up and executed by the setup person
Lesson topics
Move cutting tool tasks off line
Some tool measuring devices
can output measured values!
6.5643
Offset setting program is
automatically created!
Lesson topics
Move cutting tool tasks off line
Either way, the on-line time required for
entering offsets will be the time it takes to
download this program and execute it!
Lesson topics
If you cannot justify what it takes to eliminate tasks…
…can you move them off line?
Machining centers
Assemble needed tools
Insert, cutting tool body,
extension, adapter, holder, pull stud
Measure
Tool length compensation value
Cutter radius compensation value
Preset
Boring bars to specified diameter
Load in specified tool stations
Enter offsets
Tool length compensation
Cutter radius compensation
Sharpen / replace dull tools
Turning centers
Assemble needed tools
Insert, cutting tool shank or body,
etc.
Load in specified turret stations
Enter offsets
Tool nose radius compensation
Sharpen / replace dull tools
What can be done while the
machine is in production for the
previous job?
 If you assemble and measure cutting tools off line, you can program the tool
length and cutter radius compensation offset entries
 This keeps the setup person from having to do so.
Lesson topics
If you cannot move tasks off line…
…can you facilitate any tasks?
Machining centers
Assemble needed tools
Insert, cutting tool body,
extension, adapter, holder, pull stud
Measure
Tool length compensation value
Cutter radius compensation value
Preset
Boring bars to specified diameter
Load in specified tool stations
Enter offsets
Tool length compensation
Cutter radius compensation
Sharpen / replace dull tools
Turning centers
Assemble needed tools
Insert, cutting tool shank or body,
etc.
Load in specified turret stations
Enter offsets
Tool nose radius compensation
Sharpen / replace dull tools
What can you do to make it
simpler to get cutting tools ready?
 Again, study your setup people – Is there anything you can do to help them?
Lesson topics
If you cannot move tasks off line…
…can you facilitate any tasks?
Machining centers
Assemble needed tools
Insert, cutting tool body,
extension, adapter, holder, pull stud
Measure
Tool length compensation value
Cutter radius compensation value
Preset
Boring bars to specified diameter
Load in specified tool stations
Enter offsets
Tool length compensation
Cutter radius compensation
Sharpen / replace dull tools
Turning centers
Assemble needed tools
Insert, cutting tool shank or body,
etc.
Load in specified turret stations
Enter offsets
Tool nose radius compensation
Sharpen / replace dull tools
What can you do to make it
simpler to get cutting tools ready?
 Being well organized is the key to efficiently assembling cutting tools
Lesson topics
If you cannot move tasks off line…
…can you facilitate any tasks?
Machining centers
Assemble needed tools
Insert, cutting tool body,
extension, adapter, holder, pull stud
Measure
Tool length compensation value
Cutter radius compensation value
Preset
Boring bars to specified diameter
Load in specified tool stations
Enter offsets
Tool length compensation
Cutter radius compensation
Sharpen / replace dull tools
Turning centers
Assemble needed tools
Insert, cutting tool shank or body,
etc.
Load in specified turret stations
Enter offsets
Tool nose radius compensation
Sharpen / replace dull tools
What can you do to make it
simpler to get cutting tools ready?
 Do any of your machining centers have a tool probe?
Lesson topics
Facilitate cutting tool tasks
If you must measure tool lengths on line…
…use a tool length measuring probe!
Most can also measure
diameter/radius
Lesson topics
Facilitate cutting tool tasks
If your machine doesn’t have a probe…
O9500 (Program to touch off tool lengths)
N1 #100 = 1 (First tool station number to measure)
#101 = 15 (Last tool station to measure)
N2 #3006 = 100 (TOUCH SPINDLE TO BLOCK)
N3 #5003 = 0 (Set current Z position as program zero point)
N4 G91 G01 Z1.5 F30.0 (Move away from block in Z)
N5 G91 G28 Z0 M19 (Move to tool change position, orient spindle)
N7 T#100 M06 (Place current tool in spindle)
N8 #3006 = 101 (TOUCH TOOL TIP TO BLOCK)
N9 #[2000 + #100] = #5003 (Set tool length compensation offset)
N10 G91 G01 Z1.5 F30. (Move away from block in Z)
N11 G91 G28 Z0 M19 (Move to tool change position, orient spindle)
N12 #100 = #100 + 1
N13 #3006 = 102 (PRESS CYCLE START TO CONT)
N14 GOTO 7
Lesson topics
If you cannot move tasks off line…
…can you facilitate any tasks?
Machining centers
Assemble needed tools
Insert, cutting tool body,
extension, adapter, holder, pull stud
Measure
Tool length compensation value
Cutter radius compensation value
Preset
Boring bars to specified diameter
Load in specified tool stations
Enter offsets
Tool length compensation
Cutter radius compensation
Sharpen / replace dull tools
Turning centers
Assemble needed tools
Insert, cutting tool shank or body,
etc.
Load in specified turret stations
Enter offsets
Tool nose radius compensation
Sharpen / replace dull tools
What can you do to make it
simpler to get cutting tools ready?
 Do any of your machining centers have a tool probe?
Lesson topics
If you cannot move tasks off line…
…can you facilitate any tasks?
Machining centers
Assemble needed tools
Insert, cutting tool body,
extension, adapter, holder, pull stud
Measure
Tool length compensation value
Cutter radius compensation value
Preset
Boring bars to specified diameter
Load in specified tool stations
Enter offsets
Tool length compensation
Cutter radius compensation
Sharpen / replace dull tools
 Help for setting a taper reamer
Lesson topics
Turning centers
Assemble needed tools
Insert, cutting tool shank or body,
etc.
Load in specified turret stations
Enter offsets
Tool nose radius compensation
Sharpen / replace dull tools
What can you do to make it
simpler to get cutting tools ready?
Facilitate cutting tool tasks
Taper reaming
Setup people may be struggling:
 Guessing at initial offset
 Several tries required
 Same process for sharpened reamer
Lesson topics
Facilitate cutting tool tasks
Taper reaming
N040 G43 H05 Z2.0
N045 G81 R-0.7 Z-1.0 F5.0 G98
Lesson topics
If you cannot move tasks off line…
…can you facilitate any tasks?
Machining centers
Assemble needed tools
Insert, cutting tool body,
extension, adapter, holder, pull stud
Measure
Tool length compensation value
Cutter radius compensation value
Preset
Boring bars to specified diameter
Load in specified tool stations
Enter offsets
Tool length compensation
Cutter radius compensation
Sharpen / replace dull tools
 Help for setting a taper reamer
Lesson topics
Turning centers
Assemble needed tools
Insert, cutting tool shank or body,
etc.
Load in specified turret stations
Enter offsets
Tool nose radius compensation
Sharpen / replace dull tools
What can you do to make it
simpler to get cutting tools ready?
If you cannot move tasks off line…
…can you facilitate any tasks?
Machining centers
Assemble needed tools
Insert, cutting tool body,
extension, adapter, holder, pull stud
Measure
Tool length compensation value
Cutter radius compensation value
Preset
Boring bars to specified diameter
Load in specified tool stations
Enter offsets
Tool length compensation
Cutter radius compensation
Sharpen / replace dull tools
Turning centers
Assemble needed tools
Insert, cutting tool shank or body,
etc.
Load in specified turret stations
Enter offsets
Tool nose radius compensation
Sharpen / replace dull tools
What can you do to make it
simpler to get cutting tools ready?
 Loading tools into a turning center’s turret can be cumbersome
 Ensure that needed hand tools are readily available
 Some turning centers have quick-change tooling, which makes loading and
removing tools very easy
Lesson topics
Lesson topics
Think of what must be done to assign
program zero
Machining centers
Turning centers
Determine program zero assignment
Determine program zero assignment
values
values
For each tool
Measure with edge finder or dial
Measure distance between tool tip
indicator
and program zero
Calculate
Calculate
Enter program zero assignment values
Enter program zero assignment values
Into fixture offsets (preferred)
Into geometry offsets (preferred)
Edit G92 command
Edit G50 commands
Again, here is our list, but be sure to create a list of your own
Use the setup reduction planning form provided in lesson four
Lesson topics
Program zero assignment aligns the
workholding setup position with the program
FANUC
X value
Program
zero
10M
X00.0000
Y00.0000
Z00.0000
+
Machine Position
Y value
Top view of vertical machining center
Lesson topics
Program zero assignment aligns the
workholding setup position with the program
FANUC
10M
X-10.2837
Y-6.9837
Z00.0000
Spindle nose
+
Program
zero
Lesson topics
Z value
Machine Position
Program zero assignment aligns the
workholding setup position with the program
One way:
FANUC
POWER
ON
10T
O
X
I
F
M
X00.0000
Z00.0000
U
E
OFF
[
N
Y
J
D
S]
V
?
PAGE
G
Z
K
H
T
@
P
Q
R
L
(
EOB)
W
@
A
B
C
#
/
7
4
1
+
Sp
,
*
8 9
5 6
2 3
0
=
RESET
START
CALC
CAN
INPUT
CURSOR
NC/PC
SHIFT
AUX
CYCLE
START
FEED
HOLD
MDI
JOG
AUTO
ON
HANDLE
OFF
DRY
RUN
ZERO
EDIT
MODE RETURN
100%
0%
X-
MEMORY
PROTECT
EMERGENCY
STOP
200%
ON
6
7
8
1
FAST
TURRET INDEX
100%
130%
0%
130%
OD
ID
AXIS LOAD
SPINDLE LOAD
X
Z
CLAMP
DIRECTION
Program zero
X axis geometry offset value value
CHUCK
TAILSTOCK
Lesson topics
X
0
2
SLOW
BLOCK
DELETE
ORIGIN
9 10 11
12
5
4
3
OFF
SPINDLE
100%
0%
RAPID
OVERRIDE
FEEDRATE
OVERRIDE
JOYSTICK
OPTIONAL
STOP
ON
X
100%
10%
Z+
Z-
MACHINE
LOCK
OFF
50%
25%
X+
SINGLE
BLOCK
X1
Z
X10
X100
Z
Program zero assignment aligns the
workholding setup position with the program
Another way:
Z axis geometry offset value
FANUC
Work shift value
POWER
ON
10T
O
X
I
F
M
X00.0000
Z00.0000
U
E
OFF
[
N
Y
J
D
S]
V
?
PAGE
G
Z
K
H
T
@
P
Q
R
L
(
EOB)
W
@
A
B
C
#
/
7
4
1
+
Sp
,
*
8 9
5 6
2 3
0
=
RESET
START
CALC
CAN
INPUT
CURSOR
NC/PC
SHIFT
AUX
CYCLE
START
FEED
HOLD
MDI
JOG
AUTO
ON
HANDLE
OFF
DRY
RUN
ZERO
EDIT
MODE RETURN
100%
0%
X-
MEMORY
PROTECT
EMERGENCY
STOP
200%
ON
6
7
8
1
FAST
TURRET INDEX
100%
130%
0%
130%
OD
ID
AXIS LOAD
SPINDLE LOAD
X
Z
CLAMP
DIRECTION
Program zero
X axis geometry offset value value
CHUCK
TAILSTOCK
Lesson topics
X
0
2
SLOW
BLOCK
DELETE
ORIGIN
9 10 11
12
5
4
3
OFF
SPINDLE
100%
0%
RAPID
OVERRIDE
FEEDRATE
OVERRIDE
JOYSTICK
OPTIONAL
STOP
ON
X
100%
10%
Z+
Z-
MACHINE
LOCK
OFF
50%
25%
X+
SINGLE
BLOCK
X1
Z
X10
X100
Z
Think of what must be done to assign
program zero
Machining centers
Turning centers
Determine program zero assignment
Determine program zero assignment
values
values
For each tool
Measure with edge finder or dial
Measure distance between tool tip
indicator
and program zero
Calculate
Calculate
Enter program zero assignment values
Enter program zero assignment values
Into fixture offsets (preferred)
Into geometry offsets (preferred)
Edit G92 command
Edit G50 commands
Again, here is our list, but be sure to create a list of your own
Use the setup reduction planning form provided in lesson four
Lesson topics
First, try to come up with ways to eliminate tasks…
…some may seem far-fetched
Machining centers
Turning centers
Determine program zero assignment
Determine program zero assignment
values
values
For each tool
Measure with edge finder or dial
Measure distance between tool tip
indicator
and program zero
Calculate
Calculate
Enter program zero assignment values
Enter program zero assignment values
Into fixture offsets (preferred)
Into geometry offsets (preferred)
Edit G92 command
Edit G50 commands
Can you think of any way to eliminate
program zero assigning tasks?
 If machining center setups are qualified, you can eliminate the entire task of
program zero assignment
 Program zero assignment values will be included in the program
 Setup person will not have to measure or enter program zero assignment
values
Lesson topics
A qualified setup:
Definition:
A qualified setup is one that can placed on
the machine table in exactly the same
fashion over and over again
For repeated setups, program zero
will be in the same location
Lesson topics
A qualified setup:
Does your machine
have a center slot?
Table slots
Top view of VMC table
Lesson topics
A qualified setup:
Keys
Bottom plate of
workholding device
Top view of VMC table
Lesson topics
A qualified setup:
Program zero
Top view of VMC table
Lesson topics
A qualified setup:
Top view of VMC table
Lesson topics
A qualified setup:
Top view of VMC table
Lesson topics
A qualified setup:
Program zero will be in the same
position every time the setup is made!
Don’t believe it?
Top view of VMC table
Lesson topics
A qualified setup:
Program zero will be in the same
position every time the setup is made!
Machine a tooling hole
 This command sends the spindle
directly above the tooling hole
 Using a dial indicator, check that the
fixture is properly placed
 After doing this a few times to
confirm the setup is qualified, stop
doing this procedure
Don’t believe it?
O0001
.
.
.
M30
N999 G53 X-17.3437 Y-9.2322
M30
Top view of VMC table
Lesson topics
A qualified setup:
Program zero will be in the same
position every time the setup is made!
If program zero is in the same location
every time a setup is made…
Program zero assignment values will be the
same every time the setup is made!
But how do you determine program zero
assignment values the first time a setup is made?
Lesson topics
Determining program zero assignment values
If workholding device is accurately made:
Known values
Lesson topics
Determining program zero assignment values
If workholding device is accurately made:
Easy to calculate
Lesson topics
Determining program zero assignment values
If workholding device is accurately made:
By the way…
…this is one reason why sub-plates are so helpful!
6
5
4
3
2
1
A
B
C
D
E
F
Lesson topics
G
H
I
J
K
L
M
N
O
P
Q
R
S
Determining program zero assignment values
If workholding device is not accurately made:
These values must be
measured once
Lesson topics
Programming fixture offset entries
Include G10 commands to
enter fixture offset values
O0001
.
.
.
M30
N999 G90 G10 L2 P1 X-23.3736 Y-10.2372 Z-12.2832
M30
Lesson topics
More on sub-plates
Plug
0.7500”
location hole
2.0000 typ
6
5
4
½-13 clamping
hole
3
2
1
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Top view of VMC table
Lesson topics
O
P
Q
R
S
More on sub-plates
FANUC
16M
Normal use of fixture offsets
WORK COORDINATE SYSTEM SETTING
#0: COMMON
X 00.0000
Y 00.0000
Z 00.0000
#2: G55
X 00.0000
Y 00.0000
Z 00.0000
#1: G54
X -23.3736
Y -10.2372
Z –12.2382
-11.3645
Z
#3: G56
X 00.0000
Y 00.0000
Z 00.0000
+
Lesson topics
More on sub-plates
FANUC
16M
Use common offset to shift the
WORK COORDINATE
SYSTEM
SETTING
point
of reference
for fixture
offset entries
#0: COMMON
X 00.0000
Y 00.0000
Z 00.0000
#2: G55
X 00.0000
Y 00.0000
Z 00.0000
#1: G54
X 00.0000
Y 00.0000
ZZ-00.0000
00.0000
#3: G56
X 00.0000
Y 00.0000
Z 00.0000
+
Lesson topics
More on sub-plates
Determine distances to lower-left hole
6
5
4
3
2
1
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Top view of VMC table
Lesson topics
O
P
Q
R
S
More on sub-plates
FANUC
16M
Enter them into common offset
WORK COORDINATE SYSTEM SETTING
#0: COMMON
X -32.2223
Y -15.4734
Z -12.2322
#2: G55
X 00.0000
Y 00.0000
Z 00.0000
#1: G54
X 00.0000
Y 00.0000
Z -11.3645
Z
00.0000
#3: G56
X 00.0000
Y 00.0000
Z 00.0000
+
Lesson topics
Distances from lower-left hole
to program zero surfaces are
easy to determine
More on sub-plates
Place corner stop
in hole F5
Corner stop
6
5
4
10.0
3
8.0
2
1
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Top view of VMC table
Lesson topics
O
P
Q
R
S
More on sub-plates
O0001
16M
.
Program SETTING
them with a G10 command
WORK COORDINATE SYSTEM
.
.
#0: COMMON
#2: G55
M30
X -32.2223 N999 G90 G10
X 00.0000
L2 P1 X10.0 Y8.0 Z2.25
Y -15.4734 M30
Y 00.0000
Z -12.2322
Z 00.0000
FANUC
#1: G54
X 10.0000
Y 08.0000
Z 02.2500
#3: G56
X 00.0000
Y 00.0000
Z 00.0000
+
Lesson topics
More on sub-plates
If you have a mishap (crash)…
…only the common offset values must
be re-measured
Lesson topics
First, try to come up with ways to eliminate tasks…
…some may seem far-fetched
Machining centers
Turning centers
Determine program zero assignment
Determine program zero assignment
values
values
For each tool
Measure with edge finder or dial
Measure distance between tool tip
indicator
and program zero
Calculate
Calculate
Enter program zero assignment values
Enter program zero assignment values
Into fixture offsets (preferred)
Into geometry offsets (preferred)
Edit G92 command
Edit G50 commands
Can you think of any way to eliminate
program zero assigning tasks?
 If machining center setups are qualified, you can eliminate the entire task of
program zero assignment
 Program zero assignment values will be included in the program
 Setup person will not have to measure or enter program zero assignment
values
Lesson topics
First, try to come up with ways to eliminate tasks…
…some may seem far-fetched
Machining centers
Turning centers
Determine program zero assignment
Determine program zero assignment
values
values
For each tool
Measure with edge finder or dial
Measure distance between tool tip
indicator
and program zero
Calculate
Calculate
Enter program zero assignment values
Enter program zero assignment values
Into fixture offsets (preferred)
Into geometry offsets (preferred)
Edit G92 command
Edit G50 commands
Can you think of any way to eliminate
program zero assigning tasks?
 For cutting tools that remain in the turret from one job to the next, there is no
need to re-assign program zero
 As long as you use geometry offsets with work shift
Lesson topics
If you cannot justify what it takes to eliminate tasks…
…can you move them off line?
Machining centers
Turning centers
Determine program zero assignment
Determine program zero assignment
values
values
For each tool
Measure with edge finder or dial
Measure distance between tool tip
indicator
and program zero
Calculate
Calculate
Enter program zero assignment values
Enter program zero assignment values
Into fixture offsets (preferred)
Into geometry offsets (preferred)
Edit G92 command
Edit G50 commands
What can be done while the machine
is in production for the previous job?
 If you can calculate program zero assignment values up-front, they will not
have to be determined while the machine is down for setup
Lesson topics
If you cannot move a task off line…
…can it be facilitated?
Machining centers
Turning centers
Determine program zero assignment
Determine program zero assignment
values
values
For each tool
Measure with edge finder or dial
Measure distance between tool tip
indicator
and program zero
Calculate
Calculate
Enter program zero assignment values
Enter program zero assignment values
Into fixture offsets (preferred)
Into geometry offsets (preferred)
Edit G92 command
Edit G50 commands
What can you do to make it easier to
assign program zero?
 Use a spindle probe to determine and enter fixture offset values
 Or use an edge finder (more manual intervention, but still very effective)
Lesson topics
Facilitate program zero assignment tasks
If you don’t make qualified setups…
…and you don’t have a spindle probe…
…setup people must measure program
zero assignment values
 Edge finder or dial indicator is used
 Machine position displays must be manipulated
 Calculations may have to be made
 Fixture offsets must be manually entered
 Time consuming – cumbersome – error prone
Do what ever you can to help!
Lesson topics
Facilitate program zero assignment tasks
Anything a touch probe can do can
be done with an edge finder…
…except that touching must be done
manually
Lesson topics
Facilitate program zero assignment tasks
A corner pickup custom macro:
O9051 (Corner pickup routine for lower left corner)
N1 G91 G01 Y0.75 Z-0.75 F30. (Move to first touch position)
N2 #3006 = 101 (TOUCH LEFT SIDE IN X)
N3 G90 G10 L2 P1 X[#5021 + #500] (Set fixture offset X)
N4 G91 G01 X-0.2 (Move away in X)
N5 Y-0.75 (Move down in Y)
N6 X0.55 (Move to second touch position)
N7 #3006 = 101 (TOUCH BOTTOM SURFACE IN Y)
N8 G90 G10 L2 P1 Y[#5022 + #500] Set fixture offset Y)
N9 G91 G01 Y-0.2 (Move away in Y)
N10 Z0.75 (Move up in Z)
N11 Y0.55 (Move to third touch position)
N12 #3006 = 101 (TOUCH TOP SURFACE IN Z)
N13 G90 G10 L2 P1 Z[#5023 - #501] (Set fixture offset Z)
N14 G91 G01 Z.5 (Move away in Z)
N15 X-0.75 Y-0.75 (Move away in X and Y)
N16 M30 (End of program)
Lesson topics
If you cannot move a task off line…
…can it be facilitated?
Machining centers
Turning centers
Determine program zero assignment
Determine program zero assignment
values
values
For each tool
Measure with edge finder or dial
Measure distance between tool tip
indicator
and program zero
Calculate
Calculate
Enter program zero assignment values
Enter program zero assignment values
Into fixture offsets (preferred)
Into geometry offsets (preferred)
Edit G92 command
Edit G50 commands
What can you do to make it easier to
assign program zero?
 Use a spindle probe to determine and enter fixture offset values
 Or use an edge finder (more manual intervention, but still very effective)
Lesson topics
If you cannot move a task off line…
…can it be facilitated?
Machining centers
Turning centers
Determine program zero assignment
Determine program zero assignment
values
values
For each tool
Measure with edge finder or dial
Measure distance between tool tip
indicator
and program zero
Calculate
Calculate
Enter program zero assignment values
Enter program zero assignment values
Into fixture offsets (preferred)
Into geometry offsets (preferred)
Edit G92 command
Edit G50 commands
What can you do to make it easier to
assign program zero?
 Use a tool-touch-off probe
 Use the measure function with geometry offsets
Lesson topics
This task is only related to setup if:
 Programs must be created while the machine is down
between production runs
 Small lots, short cycle times (short production runs)
 Lots of new jobs
 No lead time
Lesson topics
Think of what must be done to create programs…
Manual programming
Develop machining process
Choose cutting tools and assign tool stations
Design setup
Calculate coordinates needed in program
Write manual program
Computer aided manufacturing (CAM) system programming
Develop machining process
Choose cutting tools and assign tool stations
Design setup
Import CAD drawing (or create workpiece geometry)
Specify machining operations to be performed
Check tool path
Conversational (shop floor) programming
Develop machining process
Choose cutting tools
Design setup
Define workpiece geometry
Specify machining operations
Check tool path
Lesson topics
Eliminate tasks related to programming
Finite number of different jobs
Once all programs are created, there
is no need for more programming
But in reality…
…there will likely be new products, revisions, and
process improvements
Lesson topics
Move programming tasks off line
Assumes:
 Manageable number of new jobs
 Sufficient number of programmers
 Adequate lead time
 Large enough lot sizes
 Long enough cycle times
Even if programming is done off line…
…it may still be necessary to facilitate the related tasks
CAM systems facilitate programming
Lesson topics
Facilitate on line task of programming
But maybe:
 Every job is a new one
 There is no lead time
 You run very small lots…
 …with very short cycle times
Programming must be done while the machine is down…
…do everything you can to facilitate the task!
How often are machines down
waiting for programs?
Lesson topics
Facilitate on line task of programming
Use conversational controls:
 Are like single-purpose CAM systems
 Are designed for the specific machine
 Minimize other setup related tasks
 Can be programmed very quickly
Or – place a CAM system close to machine/s:
 Always available to setup person
 Wired directly to CNC machine
 Acts like conversational control
Lesson topics
Facilitate on line task of programming
Do you run parts in a family?
Parametric programming allows you to
develop one program that works for all parts!
Setup person simply modifies a few
variables to create new program
Lesson topics
Facilitate on line task of programming
Lesson topics
Facilitate on line task of programming
Lesson topics
Lesson topics
Think of what must be done to transfer programs
No DNC system
Programs entered through control panel
Programs deleted upon job completion
Manual DNC system
Locate program storage location (hard drive folder, floppy disk, etc.
Get machine and DNC device ready for transmission
Make command to transfer
Automatic DNC system
Make command to transfer right from CNC machine
For programs saved from CNC machine after job…
Check correctness of changes
Save in appropriate location
Lesson topics
Eliminate tasks related to program transfer
Finite number of different jobs
Possibly all programs can be stored
in machine control
But in reality, it’s probably not feasible…
…this may cause conflicts with ISO or Quality 9000
certifications
Lesson topics
Eliminate tasks related to program transfer
Use PC based controls
With standard networking
Program transfers are as quick as
loading from a hard drive
Lesson topics
Move program transfer tasks off line
Use controls with background edit
Program transfers can be made while
the machine is running production
Lesson topics
Facilitate program transfer tasks
Manual DNC systems
 Use RS-232c serial communications protocol
 Manual switchbox for multiple machines
 Setup person must walk between devices
 Dedicate a computer for program transfers
 Specify program file location on setup sheet
Can take five to fifteen minutes
Lesson topics
Facilitate program transfer tasks
Automatic DNC systems
 Command program transfers from machine
 No walk or wait is required
 Program transfers occur in less than 30 seconds
Lesson topics
Lesson topics
Program verification
Mistakes that cause the need for program verification
Program related
Syntax mistakes
Motion command mistakes
Offset number selection
Miscellaneous functions (spindle direction, tool selection, etc.)
Setup related
Workholding device placement
Program zero assignment
Various measurements and offset settings
Tool placement
Process related
Cutting tool choices
Feeds and speeds
Machining order
Workholding choices
Lesson topics
Program verification
We offer a two part definition
for program verification:
Any task you perform to confirm the
correctness of the program
New programs present the
greatest challenges
Lesson topics
Program verification
We offer a two part definition
for program verification:
Any task you perform to confirm the
correctness of the first workpiece
Even proven programs
present difficult challenges
Lesson topics
Think of what must be done to remove
the previous setup from the machine
To confirm the correctness of the program / setup
Single block dry run
Free flowing dry run
Single blocking each tool into position with controlled
motion rate
Cautiously running first workpiece
Any modifications you make when mistakes are found
To confirm the correctness of the first workpiece
Trial machining for surfaces with critical tolerances
Checking what each tool has done after machining
First workpiece inspection
Any modifications you make due to failed inspection
Re-machining workpiece after modifications
Here is our list, but be sure to create a list of your own
Use the setup reduction planning form provided in lesson four
Lesson topics
First, try to come up with ways to eliminate tasks…
…some may seem far-fetched
To confirm the correctness of the program / setup
Single block dry run
Can you think of any way eliminate tasks?
Free flowing dry run
Single blocking each tool into position with controlled
motion rate
Cautiously running first workpiece
Any modifications you make when mistakes are found
To confirm the correctness of the first workpiece
Trial machining for surfaces with critical tolerances
Checking what each tool has done after machining
First workpiece inspection
Any modifications you make due to failed inspection
Re-machining workpiece after modifications
 For proven jobs, some of these tasks can be eliminated
 If program zero assignment has been eliminated, so can the related program
verification concerns
 If tool length measurement is done off line and an offset entering program is
automatically created, related program verification concerns will be eliminated
Lesson topics
Eliminate program verification tasks
A program can be considered proven if:
 It has been run before, and
 Corrections made to the program are saved, and
 Nothing about the job has changed
You should be able to eliminate any tasks done
for the purpose of confirming the correctness of
the program and process for proven programs!
Lesson topics
Eliminate program verification tasks
Mistakes that cause the need for program verification
Program related
Syntax mistakes
Motion command mistakes
Offset number selection
Setup related
Workholding device placement
Program zero assignment
Various measurements and offset settings
If this task has been eliminated,
Tool placement
so can
the
related tasks for program verification!
Process
related
Cutting tool choices
Feeds and speeds
Machining order
Workholding choices
Lesson topics
Eliminate program verification tasks
Mistakes that cause the need for program verification
Program related
Syntax mistakes
Motion command mistakes
Offset number selection
Setup related
Workholding device placement
Program zero assignment
Various measurements and offset settings
Tool placement
For tool length compensation, if tool length
measuring
Cutting
tool choicesdevice creates offset setting
program,
potential for mistakes is minimized
Feeds
and speeds
Process related
Machining order
Workholding choices
Lesson topics
First, try to come up with ways to eliminate tasks…
…some may seem far-fetched
To confirm the correctness of the program / setup
Single block dry run
Can you think of any way eliminate tasks?
Free flowing dry run
Single blocking each tool into position with controlled
motion rate
Cautiously running first workpiece
Any modifications you make when mistakes are found
To confirm the correctness of the first workpiece
Trial machining for surfaces with critical tolerances
Checking what each tool has done after machining
First workpiece inspection
Any modifications you make due to failed inspection
Re-machining workpiece after modifications
 For proven jobs, some of these tasks can be eliminated
 If program zero assignment has been eliminated, so can the related program
verification concerns
 If tool length measurement is done off line and an offset entering program is
automatically created, related program verification concerns will be eliminated
Lesson topics
If you cannot justify what it takes to eliminate tasks…
…can you move them off line?
To confirm the correctness of the program / setup
Single block dry run
What can be done while the machine
Free flowing dry run
is in production for the previous job?
Single blocking each tool into position with controlled
motion rate
Cautiously running first workpiece
Any modifications you make when mistakes are found
To confirm the correctness of the first workpiece
Trial machining for surfaces with critical tolerances
Checking what each tool has done after machining
First workpiece inspection
Any modifications you make due to failed inspection
Re-machining workpiece after modifications
 An off-line program verification system can find many programming mistakes
Lesson topics
Moving program verification tasks off line
It can take a great deal of setup time to
confirm the correctness of a program!
Procedures may include:
Machine Lock Dry Run
 To Check For Syntax Mistakes
Free Flowing Dry Run
 To Check For Motion Mistakes
Normal Air Cutting Run
 To Confirm Cutting Motions
Cautiously Running First Workpiece
Lesson topics
Moving program verification tasks off line
It can take a great deal of setup time to
confirm the correctness of a program!
Many current model controls allow
setup people to display tool path
Lesson topics
10M
FANUC
MDI HND
POSITION
SETTING
Lesson topics
HOLD
**** *** *** *** ****
PROGRAM
SERVICE GRAPHIC
OFFSET
PRG_CHK
+
Moving program verification tasks off line
It can take a great deal of setup time to
confirm the correctness of a program!
Many current model controls allow
setup people to display tool path
But not all allow this while the
machine is running production!
Program verification is still on line!
Lesson topics
Moving program verification tasks off line
Many program verification software
programs are available that help
move this task off line!
Lesson topics
Moving program verification tasks off line
Many program verification software
programs are available that help
move this task off line!
CAM Systems
 Show Tool Path Based On Source Program
Tool Path Plotters
 Show Tool Path Based On G Code Level Program
Simulation Systems
 Show More Than Just Tool Path
 Approaching Virtual Reality For CNC Machines
Lesson topics
Moving program verification tasks off line
There are four things off-line program
verification software cannot show:
Tiny Motion Mistakes
Mistakes Made Measuring Program Zero
 Off-Line Software Assumes Correct Entry
Mistakes Made With Offsets
 Tool Length, Cutter Radius, Etc.
Mistakes With Cutting Conditions
 Feeds, Speeds, Depth-Of-Cut, Tool Rigidity, Etc.
For this reason, some verification
must be done on line
Lesson topics
If you cannot justify what it takes to eliminate tasks…
…can you move them off line?
To confirm the correctness of the program / setup
Single block dry run
What can be done while the machine
Free flowing dry run
is in production for the previous job?
Single blocking each tool into position with controlled
motion rate
Cautiously running first workpiece
Any modifications you make when mistakes are found
To confirm the correctness of the first workpiece
Trial machining for surfaces with critical tolerances
Checking what each tool has done after machining
First workpiece inspection
Any modifications you make due to failed inspection
Re-machining workpiece after modifications
 An off-line program verification system can find many programming mistakes
Lesson topics
If you cannot move tasks off line…
…can you facilitate them?
To confirm the correctness of the program / setup
Single block dry run
What can be done to make
Free flowing dry run
program verification easier?
Single blocking each tool into position with controlled
motion rate
Cautiously running first workpiece
Any modifications you make when mistakes are found
To confirm the correctness of the first workpiece
Trial machining for surfaces with critical tolerances
Checking what each tool has done after machining
First workpiece inspection
Any modifications you make due to failed inspection
Re-machining workpiece after modifications
 We’re assuming it is important that your first workpiece is a good one
Lesson topics
If you cannot move tasks off line…
…can you facilitate them?
To confirm the correctness of the program / setup
Single block dry run
What can be done to make
Free flowing dry run
program verification easier?
Single blocking each tool into position with controlled
motion rate
Cautiously running first workpiece
Any modifications you make when mistakes are found
To confirm the correctness of the first workpiece
Trial machining for surfaces with critical tolerances
Checking what each tool has done after machining
First workpiece inspection
Any modifications you make due to failed inspection
Re-machining workpiece after modifications
 Program trial machining operations
Lesson topics
Facilitating program verification tasks
Steps to trial machining:
Setup person…
 recognizes a critical tolerance
 makes an adjustment to force excess stock to be left
 lets the tool machine the workpiece
 stops the machine and measures the surface
 changes the initial adjustment based on measurement
 reruns the tool
 stop and measure again to confirm
Trial machining takes time!
Lesson topics
Facilitating program verification tasks
How can you eliminate the need for trial machining?
Only by perfectly presetting the cutting tool!
Most cutting tool measurements are “static”
It can be difficult to allow for tool
pressure with critical tolerances
Don’t be too quick to give up on
eliminating this time-consuming task
If you can perfectly preset a
boring bar, there will be no
need to trial machine!
Lesson topics
Facilitating program verification tasks
How can you eliminate the need for trial machining?
Only by perfectly presetting the cutting tool!
For turning centers applications…
…tool touch off probes can take take tool pressure
into consideration when assigning program zero…
…and eliminate the need to trial machine!
Lesson topics
Facilitating program verification tasks
If you cannot eliminate the need to trial
machine, make it as easy as possible to do so
Setup person…
 recognizes a critical tolerance
 makes an
adjustment
to force
excess
stock to be left
Why
force the setup
person
to determine
 lets the tool machine
the workpiece
if trial machining
is necessary?
 stops the machine and measures the surface
 changes the initial adjustment based on measurement
 reruns the tool
 stop and measure again to confirm
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Commonly
taughtto
in help
basicwith
CNC
courses:
Use
block delete
trial
machining
Slash code in program (/)
If off,with
trialblock
machining
take place
Works
deletewill
switch
If on,
trialskipped..if
machining off,
will block
be skipped
If on,
block
executed
a little
ingenuity,
can streamline
NotWith
always
taught
in basic you
courses:
any trial machining
Midalmost
command
Anotheroperation!
optional stop
Conflicting words with Multiple block deletes
Trial machining
With unexpected stock
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial boring on a machining center:
Commonly
taughtto
in help
basicwith
CNC
courses:
Use
block delete
trial
machining
Slash code in program (/)
If off,with
trialblock
machining
take place
Works
deletewill
switch
If on,
trialskipped..if
machining off,
will block
be skipped
0.005 small
If on,
block
executed
a little
ingenuity,
can streamline
NotWith
always
taught
in basic you
courses:
any trial machining
Midalmost
command
Anotheroperation!
optional stop
Conflicting words with Multiple block deletes
Trial machining
Intentionally
set boring bar undersize
With1)unexpected
stock
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial boring on a machining center:
Commonly
taughtto
in help
basicwith
CNC
courses:
Use
block delete
trial
machining
.
Slash code in program
(/)
N255 T04 M06 (2.3750 boring bar)
If off,with
trialblock
machining
will
take
Works
delete
switch
N260 G54
G90
S450 place
M03 T05
N265 G00
X4.0
Y4.0
If
on,
trial
machining
will
be
skipped
If on, block skipped..if
off,
block
executed
N270 G43 H04 Z0.1 M08
N275 F2.5
/N280 M98 P1000
basic
courses:
/N285 M98 P1000
/N290
M98 P1000 optional
Another
/N295 M98 P1000
N300 G86 R0.1 Z-1.0 F2.5
.
a little
ingenuity,
you can streamline
NotWith
always
taught
in
any trial machining operation!stop
Midalmost
command
Conflicting words with Multiple block deletes
Trial machining
2) Allow
boringstock
bar to partially machine hole
With
unexpected
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial boring on a machining center:
Commonly
taughtto
in help
basicwith
CNC
courses:
Use
block delete
trial
machining
.
Slash code in program
(/)
N255 T04 M06 (2.3750 boring bar)
If off,with
trialblock
machining
will
take
Works
delete
switch
N260 G54
G90
S450 place
M03 T05
N265 G00
X4.0
Y4.0
If
on,
trial
machining
will
be
skipped
If on, block skipped..if
off,
block
executed
N270 G43 H04 Z0.1 M08
N275 F2.5
/N280 M98 P1000
basic
courses:
/N285 M98 P1000
/N290
M98 P1000 optional
Another
/N295 M98 P1000
N300 G86 R0.1 Z-1.0 F2.5
.
a little
ingenuity,
you can streamline
NotWith
always
taught
in
any trial machining operation!stop
Midalmost
command
Conflicting words with Multiple block deletes
Trial machining
2) Allow
boringstock
bar to partially machine hole
With
unexpected
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial boring on a machining center:
Commonly
taughtto
in help
basicwith
CNC
courses:
Use
block delete
trial
machining
.
Slash code in program
(/)
N255 T04 M06 (2.3750 boring bar)
If off,with
trialblock
machining
will
take
Works
delete
switch
N260 G54
G90
S450 place
M03 T05
N265 G00
X4.0
Y4.0
If
on,
trial
machining
will
be
skipped
If on, block skipped..if
off,
block
executed
N270 G43 H04 Z0.1 M08
N275 F2.5
/N280 M98 P1000
basic
courses:
/N285 M98 P1000
/N290
M98 P1000 optional
Another
/N295 M98 P1000
N300 G86 R0.1 Z-1.0 F2.5
.
a little
ingenuity,
you can streamline
NotWith
always
taught
in
any trial machining operation!stop
Midalmost
command
Conflicting words with Multiple block deletes
Trial machining
2) Allow
boringstock
bar to partially machine hole
With
unexpected
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial boring on a machining center:
Commonly
taughtto
in help
basicwith
CNC
courses:
Use
block delete
trial
machining
.
Slash code in program
(/)
N255 T04 M06 (2.3750 boring bar)
If off,with
trialblock
machining
will
take
Works
delete
switch
N260 G54
G90
S450 place
M03 T05
N265 G00
X4.0
Y4.0
If
on,
trial
machining
will
be
skipped
If on, block skipped..if
off,
block
executed
N270 G43 H04 Z0.1 M08
N275 F2.5
/N280 M98 P1000
basic
courses:
/N285 M98 P1000
/N290
M98 P1000 optional
Another
/N295 M98 P1000
N300 G86 R0.1 Z-1.0 F2.5
.
a little
ingenuity,
you can streamline
NotWith
always
taught
in
any trial machining operation!stop
Midalmost
command
Conflicting words with Multiple block deletes
Trial machining
2) Allow
boringstock
bar to partially machine hole
With
unexpected
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial boring on a machining center:
Commonly
taughtto
in help
basicwith
CNC
courses:
Use
block delete
trial
machining
.
Slash code in program
(/)
N255 T04 M06 (2.3750 boring bar)
If off,with
trialblock
machining
will
take
Works
delete
switch
N260 G54
G90
S450 place
M03 T05
N265 G00
X4.0
Y4.0
If
on,
trial
machining
will
be
skipped
If on, block skipped..if
off,
block
executed
N270 G43 H04 Z0.1 M08
N275 F2.5
/N280 M98 P1000
basic
courses:
/N285 M98 P1000
/N290
M98 P1000 optional
Another
/N295 M98 P1000
N300 G86 R0.1 Z-1.0 F2.5
.
a little
ingenuity,
you can streamline
NotWith
always
taught
in
any trial machining operation!stop
Midalmost
command
Conflicting words with Multiple block deletes
Trial machining
2) Allow
boringstock
bar to partially machine hole
With
unexpected
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial boring on a machining center:
Commonly
taughtto
in help
basicwith
CNC
courses:
Use
block delete
trial
machining
The subprogram
.
Slash
code
in
program
(/)
must work for any
N255 T04 M06 (2.3750 boring bar)
If off,
trial
machining
will
take
Works
with
block
delete
switch
N260 G54
G90
S450 place
M03 T05
hole
size
N265 G00
X4.0
Y4.0
If
on,
trial
machining
will
be
skipped
If on, block skipped..if
off,
block
executed
N270 G43 H04 Z0.1 M08
N275 F2.5
/N280 M98 P1000
basic
courses:
/N285 M98 P1000
/N290
M98 P1000 optional
Another
/N295 M98 P1000
N300 G86 R0.1 Z-1.0 F2.5
.
a little
ingenuity,
you can streamline
NotWith
always
taught
in
any trial machining operation!stop
Midalmost
command
Conflicting words with Multiple block deletes
Trial machining
2) Allow
boringstock
bar to partially machine hole
With
unexpected
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial boring on a machining center:
Commonly
taughtto
in help
basicwith
CNC
courses:
Use
block delete
trial
machining
.
Slash code in program
(/)
N255 T04 M06 (2.3750 boring bar)
If off,with
trialblock
machining
will
take
Works
delete
switch
N260 G54
G90
S450 place
M03 T05
N265 G00
X4.0
Y4.0
If
on,
trial
machining
will
be
skipped
If on, block skipped..if
off,
block
executed
N270 G43 H04 Z0.1 M08
N275 F2.5
/N280 M98 P1000
basic
courses:
/N285 M98 P1000
/N290
M98 P1000 optional
Another
/N295 M98 P1000
N300 G86 R0.1 Z-1.0 F2.5
.
a little
ingenuity,
you can streamline
NotWith
always
taught
in
any trial machining operation!stop
Midalmost
command
Conflicting words with Multiple block deletes
Trial machining
2) Allow
boringstock
bar to partially machine hole
With
unexpected
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial boring on a machining center:
Commonly
taughtto
in help
basicwith
CNC
courses:
Use
block delete
trial
machining
Slash code in program
(/)
O1000
If off,with
trialblock
machining
take
place
N1will
G91
G86 R0
Z-0.3
Works
delete
switch
N2will
G80be
M09
If
on,
trial
machining
skipped
If on, block skipped..ifN3off,
block
G00 Z3.0 executed
N4 X4.0 Y4.0
a little
ingenuity,
you
can streamline
M00
NotWith
always
taught
in basicN5
courses:
N6 G00 X-4.0
Y4.0 M03
almost
any
trial
machining
operation!
Mid command
Another
optional stop
N7 Z-3.0 M08
Conflicting words with Multiple
block deletes
N8 G90
N9 M99
Trial machining
2) Allow
boringstock
bar to partially machine hole
With
unexpected
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial boring on a machining center:
Commonly
taughtto
in help
basicwith
CNC
courses:
Use
block delete
trial
machining
Slash code in program
(/)
O1000
If off,with
trialblock
machining
take
place
N1will
G91
G86 R0
Z-0.3
Works
delete
switch
N2will
G80be
M09
If
on,
trial
machining
skipped
If on, block skipped..ifN3off,
block
G00 Z3.0 executed
N4 X4.0 Y4.0
a little
ingenuity,
you
can streamline
M00
NotWith
always
taught
in basicN5
courses:
N6 G00 X-4.0
Y4.0 M03
almost
any
trial
machining
operation!
Mid command
Another
optional stop
N7 Z-3.0 M08
Conflicting words with Multiple
block deletes
N8 G90
N9 M99
Trial machining
2) Allow
boringstock
bar to partially machine hole
With
unexpected
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial boring on a machining center:
Commonly
taughtto
in help
basicwith
CNC
courses:
Use
block delete
trial
machining
Slash code in program
(/)
O1000
If off,with
trialblock
machining
take
place
N1will
G91
G86 R0
Z-0.3
Works
delete
switch
N2will
G80be
M09
If
on,
trial
machining
skipped
If on, block skipped..ifN3off,
block
G00 Z3.0 executed
N4 X4.0 Y4.0
a little
ingenuity,
you
can streamline
M00
NotWith
always
taught
in basicN5
courses:
N6 G00 X-4.0
Y4.0 M03
almost
any
trial
machining
operation!
Mid command
Another
optional stop
N7 Z-3.0 M08
Conflicting words with Multiple
block deletes
N8 G90
N9 M99
Trial machining
2) Allow
boringstock
bar to partially machine hole
With
unexpected
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial boring on a machining center:
Commonly
taughtto
in help
basicwith
CNC
courses:
Use
block delete
trial
machining
Slash code in program
(/)
O1000
If off,with
trialblock
machining
take
place
N1will
G91
G86 R0
Z-0.3
Works
delete
switch
N2will
G80be
M09
If
on,
trial
machining
skipped
If on, block skipped..ifN3off,
block
G00 Z3.0 executed
N4 X4.0 Y4.0
a little
ingenuity,
you
can streamline
M00
NotWith
always
taught
in basicN5
courses:
N6 G00 X-4.0
Y4.0 M03
almost
any
trial
machining
operation!
Mid command
Another
optional stop
N7 Z-3.0 M08
Conflicting words with Multiple
block deletes
N8 G90
N9 M99
Trial machining
3) Move
to convenient
measuring position
With
unexpected
stock
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial boring on a machining center:
Commonly
taughtto
in help
basicwith
CNC
courses:
Use
block delete
trial
machining
Slash code in program
(/)
O1000
If off,with
trialblock
machining
take
place
N1will
G91
G86 R0
Z-0.3
Works
delete
switch
N2will
G80be
M09
If
on,
trial
machining
skipped
If on, block skipped..ifN3off,
block
G00 Z3.0 executed
N4 X4.0 Y4.0
a little
ingenuity,
you
can streamline
M00
NotWith
always
taught
in basicN5
courses:
N6 G00 X-4.0
Y4.0 M03
almost
any
trial
machining
operation!
Mid command
Another
optional stop
N7 Z-3.0 M08
Conflicting words with Multiple
block deletes
N8 G90
N9 M99
Trial machining
3) Move
to convenient
measuring position
With
unexpected
stock
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial boring on a machining center:
Commonly
taughtto
in help
basicwith
CNC
courses:
Use
block delete
trial
machining
Slash code in program
(/)
O1000
If off,with
trialblock
machining
take
place
N1will
G91
G86 R0
Z-0.3
Works
delete
switch
N2will
G80be
M09
If
on,
trial
machining
skipped
If on, block skipped..ifN3off,
block
G00 Z3.0 executed
N4 X4.0 Y4.0
a little
ingenuity,
you
can streamline
M00
NotWith
always
taught
in basicN5
courses:
N6 G00 X-4.0
Y4.0 M03
almost
any
trial
machining
operation!
Mid command
Another
optional stop
N7 Z-3.0 M08
Conflicting words with Multiple
block deletes
N8 G90
N9 M99
Trial machining
3) Move
to convenient
measuring position
With
unexpected
stock
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial boring on a machining center:
Commonly
taughtto
in help
basicwith
CNC
courses:
Use
block delete
trial
machining
Slash code in program
(/)
O1000
If off,with
trialblock
machining
take
place
N1will
G91
G86 R0
Z-0.3
Works
delete
switch
N2will
G80be
M09
If
on,
trial
machining
skipped
If on, block skipped..ifN3off,
block
G00 Z3.0 executed
N4 X4.0 Y4.0
a little
ingenuity,
you
can streamline
M00
NotWith
always
taught
in basicN5
courses:
N6 G00 X-4.0
Y4.0 M03
almost
any
trial
machining
operation!
Mid command
Another
optional stop
N7 Z-3.0 M08
Conflicting words with Multiple
block deletes
N8 G90
N9 M99
Trial machining
4) Stop,
measure
With
unexpected
stockhole, & adjust boring bar
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial boring on a machining center:
Commonly
taughtto
in help
basicwith
CNC
courses:
Use
block delete
trial
machining
Slash code in program
(/)
O1000
If off,with
trialblock
machining
take
place
N1will
G91
G86 R0
Z-0.3
Works
delete
switch
N2will
G80be
M09
If
on,
trial
machining
skipped
If on, block skipped..ifN3off,
block
G00 Z3.0 executed
N4 X4.0 Y4.0
a little
ingenuity,
you
can streamline
M00
NotWith
always
taught
in basicN5
courses:
N6 G00 X-4.0
Y4.0 M03
almost
any
trial
machining
operation!
Mid command
Another
optional stop
N7 Z-3.0 M08
Conflicting words with Multiple
block deletes
N8 G90
N9 M99
Trial machining
5) Move
back stock
to hole location
With
unexpected
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial boring on a machining center:
Commonly
taughtto
in help
basicwith
CNC
courses:
Use
block delete
trial
machining
Slash code in program
(/)
O1000
If off,with
trialblock
machining
take
place
N1will
G91
G86 R0
Z-0.3
Works
delete
switch
N2will
G80be
M09
If
on,
trial
machining
skipped
If on, block skipped..ifN3off,
block
G00 Z3.0 executed
N4 X4.0 Y4.0
a little
ingenuity,
you
can streamline
M00
NotWith
always
taught
in basicN5
courses:
N6 G00 X-4.0
Y4.0 M03
almost
any
trial
machining
operation!
Mid command
Another
optional stop
N7 Z-3.0 M08
Conflicting words with Multiple
block deletes
N8 G90
N9 M99
Trial machining
5) Move
back stock
to hole location
With
unexpected
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial boring on a machining center:
Commonly
taughtto
in help
basicwith
CNC
courses:
Use
block delete
trial
machining
Slash code in program
(/)
O1000
If off,with
trialblock
machining
take
place
N1will
G91
G86 R0
Z-0.3
Works
delete
switch
N2will
G80be
M09
If
on,
trial
machining
skipped
If on, block skipped..ifN3off,
block
G00 Z3.0 executed
N4 X4.0 Y4.0
a little
ingenuity,
you
can streamline
M00
NotWith
always
taught
in basicN5
courses:
N6 G00 X-4.0
Y4.0 M03
almost
any
trial
machining
operation!
Mid command
Another
optional stop
N7 Z-3.0 M08
Conflicting words with Multiple
block deletes
N8 G90
N9 M99
Trial machining
5) Move
back stock
to hole location
With
unexpected
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial boring on a machining center:
Commonly
taughtto
in help
basicwith
CNC
courses:
Use
block delete
trial
machining
Slash code in program
(/)
O1000
If off,with
trialblock
machining
take
place
N1will
G91
G86 R0
Z-0.3
Works
delete
switch
N2will
G80be
M09
If
on,
trial
machining
skipped
If on, block skipped..ifN3off,
block
G00 Z3.0 executed
N4 X4.0 Y4.0
a little
ingenuity,
you
can streamline
M00
NotWith
always
taught
in basicN5
courses:
N6 G00 X-4.0
Y4.0 M03
almost
any
trial
machining
operation!
Mid command
Another
optional stop
N7 Z-3.0 M08
Conflicting words with Multiple
block deletes
N8 G90
N9 M99
Trial machining
5) Move
back stock
to hole location
With
unexpected
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial boring on a machining center:
Commonly
taughtto
in help
basicwith
CNC
courses:
Use
block delete
trial
machining
.
Slash code in program
(/)
N255 T04 M06 (2.3750 boring bar)
If off,with
trialblock
machining
will
take
Works
delete
switch
N260 G54
G90
S450 place
M03 T05
N265 G00
X4.0
Y4.0
If
on,
trial
machining
will
be
skipped
If on, block skipped..if
off,
block
executed
N270 G43 H04 Z0.1 M08
N275 F2.5
/N280 M98 P1000
basic
courses:
/N285 M98 P1000
/N290
M98 P1000 optional
Another
/N295 M98 P1000
N300 G86 R0.1 Z-1.0 F2.5
.
a little
ingenuity,
you can streamline
NotWith
always
taught
in
Turn onany
block
trial machining operation!stop
Midalmost
command
delete when
Conflicting
words with Multiple block deletes
hole is sized
Trial machining
6) Repeat
untilstock
hole is on size
With
unexpected
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial boring on a machining center:
Commonly
taughtto
in help
basicwith
CNC
courses:
Use
block delete
trial
machining
.
Slash code in program
(/)
N255 T04 M06 (2.3750 boring bar)
If off,with
trialblock
machining
will
take
Works
delete
switch
N260 G54
G90
S450 place
M03 T05
N265 G00
X4.0
Y4.0
If
on,
trial
machining
will
be
skipped
If on, block skipped..if
off,
block
executed
N270 G43 H04 Z0.1 M08
N275 F2.5
/N280 M98 P1000
basic
courses:
/N285 M98 P1000
/N290
M98 P1000 optional
Another
/N295 M98 P1000
N300 G86 R0.1 Z-1.0 F2.5
.
a little
ingenuity,
you can streamline
NotWith
always
taught
in
any trial machining operation!stop
Midalmost
command
Conflicting words with Multiple block deletes
Trial machining
6) Repeat
untilstock
hole is on size
With
unexpected
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial boring on a machining center:
Commonly
taughtto
in help
basicwith
CNC
courses:
Use
block delete
trial
machining
.
Slash code in program
(/)
N255 T04 M06 (2.3750 boring bar)
If off,with
trialblock
machining
will
take
Works
delete
switch
N260 G54
G90
S450 place
M03 T05
N265 G00
X4.0
Y4.0
If
on,
trial
machining
will
be
skipped
If on, block skipped..if
off,
block
executed
N270 G43 H04 Z0.1 M08
N275 F2.5
/N280 M98 P1000
basic
courses:
/N285 M98 P1000
/N290
M98 P1000 optional
Another
/N295 M98 P1000
N300 G86 R0.1 Z-1.0 F2.5
.
a little
ingenuity,
you can streamline
NotWith
always
taught
in
any trial machining operation!stop
Midalmost
command
Conflicting words with Multiple block deletes
Trial machining
6) Repeat
untilstock
hole is on size
With
unexpected
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial boring on a machining center:
Commonly
taughtto
in help
basicwith
CNC
courses:
Use
block delete
trial
machining
.
Slash code in program
(/)
N255 T04 M06 (2.3750 boring bar)
If off,with
trialblock
machining
will
take
Works
delete
switch
N260 G54
G90
S450 place
M03 T05
N265 G00
X4.0
Y4.0
If
on,
trial
machining
will
be
skipped
If on, block skipped..if
off,
block
executed
N270 G43 H04 Z0.1 M08
N275 F2.5
/N280 M98 P1000
basic
courses:
/N285 M98 P1000
/N290
M98 P1000 optional
Another
/N295 M98 P1000
N300 G86 R0.1 Z-1.0 F2.5
.
a little
ingenuity,
you can streamline
NotWith
always
taught
in
any trial machining operation!stop
Midalmost
command
Conflicting words with Multiple block deletes
Trial machining
6) Repeat
untilstock
hole is on size
With
unexpected
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial rough turning (minimize trial machining time):
Commonly
taughtto
in help
basicwith
CNC
courses:
Use
block delete
trial
machining
Slash code in program (/)
If off,with
trialblock
machining
take place
Works
deletewill
switch
If on,
trialskipped..if
machining off,
will block
be skipped
If on,
block
executed
a little
ingenuity,
can streamline
NotWith
always
taught
in basic you
courses:
any trial machining
Midalmost
command
Anotheroperation!
optional stop
Conflicting words with Multiple block deletes
Trial
machining
Rough turning time: 18 minutes
With unexpected stock
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial rough turning (minimize trial machining time):
Commonly
taughtto
in help
basicwith
CNC
courses:
O0003
Use
block delete
trial
machining
N005 T0101 M41
G96 S400 M03
Slash code in program N010
(/)
N015 G00 X6.0 Z.1
If off,with
trialblock
machining
will
take
place
X5.5
Works
delete/N020
switch
/N025 G01 Z-.3 F0.020
If
on,
trial
machining
will
be
skipped
If on, block skipped..if off,
executed
/N030block
X6.0
/N035 G00 X8.0 Z3.
/N040 M00 (DIAMETER 5.50 IN)
Not always taught in basic courses:
/N045 T0101 M03
/N050 G00 X6. Z.1
Mid command
Another
optional stop
N055 G71 P060 Q160 D2500 …
N060 . . . block deletes
Conflicting words with Multiple
With a little ingenuity, you can streamline
almost any trial machining operation!
Trial
machining
Rough turning time: 18 minutes
With unexpected stock
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial rough turning (minimize trial machining time):
Commonly
taughtto
in help
basicwith
CNC
courses:
O0003
Use
block delete
trial
machining
N005 T0101 M41
G96 S400 M03
Slash code in program N010
(/)
N015 G00 X6.0 Z.1
If off,with
trialblock
machining
will
take
place
X5.5
Works
delete/N020
switch
/N025 G01 Z-.3 F0.020
If
on,
trial
machining
will
be
skipped
If on, block skipped..if off,
executed
/N030block
X6.0
/N035 G00 X8.0 Z3.
/N040 M00 (DIAMETER 5.50 IN)
Not always taught in basic courses:
/N045 T0101 M03
/N050 G00 X6. Z.1
Mid command
Another
optional stop
N055 G71 P060 Q160 D2500 …
N060 . . . block deletes
Conflicting words with Multiple
With a little ingenuity, you can streamline
almost any trial machining operation!
Trial
machining
Rough turning time: 18 minutes
With unexpected stock
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial rough turning (minimize trial machining time):
Commonly
taughtto
in help
basicwith
CNC
courses:
O0003
Use
block delete
trial
machining
N005 T0101 M41
G96 S400 M03
Slash code in program N010
(/)
N015 G00 X6.0 Z.1
If off,with
trialblock
machining
will
take
place
X5.5
Works
delete/N020
switch
/N025 G01 Z-.3 F0.020
If
on,
trial
machining
will
be
skipped
If on, block skipped..if off,
executed
/N030block
X6.0
/N035 G00 X8.0 Z3.
/N040 M00 (DIAMETER 5.50 IN)
Not always taught in basic courses:
/N045 T0101 M03
/N050 G00 X6. Z.1
Mid command
Another
optional stop
N055 G71 P060 Q160 D2500 …
N060 . . . block deletes
Conflicting words with Multiple
With a little ingenuity, you can streamline
almost any trial machining operation!
Trial
machining
Rough turning time: 18 minutes
With unexpected stock
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial rough turning (minimize trial machining time):
Commonly
taughtto
in help
basicwith
CNC
courses:
O0003
Use
block delete
trial
machining
N005 T0101 M41
G96 S400 M03
Slash code in program N010
(/)
N015 G00 X6.0 Z.1
If off,with
trialblock
machining
will
take
place
X5.5
Works
delete/N020
switch
/N025 G01 Z-.3 F0.020
If
on,
trial
machining
will
be
skipped
If on, block skipped..if off,
executed
/N030block
X6.0
/N035 G00 X8.0 Z3.
/N040 M00 (DIAMETER 5.50 IN)
Not always taught in basic courses:
/N045 T0101 M03
/N050 G00 X6. Z.1
Mid command
Another
optional stop
N055 G71 P060 Q160 D2500 …
N060 . . . block deletes
Conflicting words with Multiple
With a little ingenuity, you can streamline
almost any trial machining operation!
Trial
machining
Rough turning time: 18 minutes
With unexpected stock
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial rough turning (minimize trial machining time):
Commonly
taughtto
in help
basicwith
CNC
courses:
O0003
Use
block delete
trial
machining
N005 T0101 M41
G96 S400 M03
Slash code in program N010
(/)
N015 G00 X6.0 Z.1
If off,with
trialblock
machining
will
take
place
X5.5
Works
delete/N020
switch
/N025 G01 Z-.3 F0.020
If
on,
trial
machining
will
be
skipped
If on, block skipped..if off,
executed
/N030block
X6.0
/N035 G00 X8.0 Z3.
/N040 M00 (DIAMETER 5.50 IN)
Not always taught in basic courses:
/N045 T0101 M03
/N050 G00 X6. Z.1
Mid command
Another
optional stop
N055 G71 P060 Q160 D2500 …
N060 . . . block deletes
Conflicting words with Multiple
With a little ingenuity, you can streamline
almost any trial machining operation!
Trial
machining
Rough turning time: 18 minutes
With unexpected stock
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial rough turning (minimize trial machining time):
Commonly
taughtto
in help
basicwith
CNC
courses:
O0003
Use
block delete
trial
machining
N005 T0101 M41
G96 S400 M03
Slash code in program N010
(/)
N015 G00 X6.0 Z.1
If off,with
trialblock
machining
will
take
place
X5.5
Works
delete/N020
switch
/N025 G01 Z-.3 F0.020
If
on,
trial
machining
will
be
skipped
If on, block skipped..if off,
executed
/N030block
X6.0
/N035 G00 X8.0 Z3.
/N040 M00 (DIAMETER 5.50 IN)
Not always taught in basic courses:
/N045 T0101 M03
/N050 G00 X6. Z.1
Mid command
Another
optional stop
N055 G71 P060 Q160 D2500 …
N060 . . . block deletes
Conflicting words with Multiple
With a little ingenuity, you can streamline
almost any trial machining operation!
Trial
machining
Rough turning time: 18 minutes
With unexpected stock
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial rough turning (minimize trial machining time):
Commonly
taughtto
in help
basicwith
CNC
courses:
O0003
Use
block delete
trial
machining
N005 T0101 M41
G96 S400 M03
Slash code in program N010
(/)
N015 G00 X6.0 Z.1
If off,with
trialblock
machining
will
take
place
X5.5
Works
delete/N020
switch
/N025 G01 Z-.3 F0.020
If
on,
trial
machining
will
be
skipped
If on, block skipped..if off,
executed
/N030block
X6.0
/N035 G00 X8.0 Z3.
/N040 M00 (DIAMETER 5.50 IN)
Not always taught in basic courses:
/N045 T0101 M03
/N050 G00 X6. Z.1
Mid command
Another
optional stop
N055 G71 P060 Q160 D2500 …
N060 . . . block deletes
Conflicting words with Multiple
With a little ingenuity, you can streamline
almost any trial machining operation!
Trial
machining
Rough turning time: 18 minutes
With unexpected stock
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial rough turning (minimize trial machining time):
Commonly
taughtto
in help
basicwith
CNC
courses:
O0003
Use
block delete
trial
machining
N005 T0101 M41
G96 S400 M03
Slash code in program N010
(/)
N015 G00 X6.0 Z.1
If off,with
trialblock
machining
will
take
place
X5.5
Works
delete/N020
switch
/N025 G01 Z-.3 F0.020
If
on,
trial
machining
will
be
skipped
If on, block skipped..if off,
executed
/N030block
X6.0
/N035 G00 X8.0 Z3.
/N040 M00 (DIAMETER 5.50 IN)
Not always taught in basic courses:
/N045 T0101 M03
/N050 G00 X6. Z.1
Mid command
Another
optional stop
N055 G71 P060 Q160 D2500 …
N060 . . . block deletes
Conflicting words with Multiple
With a little ingenuity, you can streamline
almost any trial machining operation!
Trial
machining
Rough turning time: 18 minutes
With unexpected stock
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial rough turning (minimize trial machining time):
Commonly
taughtto
in help
basicwith
CNC
courses:
O0003
Use
block delete
trial
machining
N005 T0101 M41
G96 S400 M03
Slash code in program N010
(/)
N015 G00 X6.0 Z.1
If off,with
trialblock
machining
will
take
place
X5.5
Works
delete/N020
switch
/N025 G01 Z-.3 F0.020
If
on,
trial
machining
will
be
skipped
If on, block skipped..if off,
executed
/N030block
X6.0
/N035 G00 X8.0 Z3.
/N040 M00 (DIAMETER 5.50 IN)
Not always taught in basic courses:
/N045 T0101 M03
/N050 G00 X6. Z.1
Mid command
Another
optional stop
N055 G71 P060 Q160 D2500 …
N060 . . . block deletes
Conflicting words with Multiple
With a little ingenuity, you can streamline
almost any trial machining operation!
Trial
machining
Rough turning time: 18 minutes
With unexpected stock
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial rough turning (minimize trial machining time):
Commonly
taughtto
in help
basicwith
CNC
courses:
O0003
Use
block
delete
trial
machining
Setup person measures N005 T0101 M41
G96 S400 M03
adjusts
Slashand
code
in now
program N010
(/)
N015 G00 X6.0 Z.1
If off,with
trialblock
machining
will
take
place
X5.5
Works
delete/N020
switch
/N025 G01 Z-.3 F0.020
If
on,
trial
machining
will
be
skipped
If on, block skipped..if off,
executed
/N030block
X6.0
/N035 G00 X8.0 Z3.
/N040 M00 (DIAMETER 5.50 IN)
Not always taught in basic courses:
/N045 T0101 M03
/N050 G00 X6. Z.1
Mid command
Another
optional stop
N055 G71 P060 Q160 D2500 …
N060 . . . block deletes
Conflicting words with Multiple
With a little ingenuity, you can streamline
almost any trial machining operation!
Trial
machining
Rough turning time: 18 minutes
With unexpected stock
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial rough turning (minimize trial machining time):
Commonly
taughtto
in help
basicwith
CNC
courses:
O0003
Use
block
delete
trial
machining
Offset must be
N005 T0101 M41
G96 S400 M03
Slash code
inagain
program N010
(/)
invoked
N015 G00 X6.0 Z.1
If off,with
trialblock
machining
will
take
place
X5.5
Works
delete/N020
switch
/N025 G01 Z-.3 F0.020
If
on,
trial
machining
will
be
skipped
If on, block skipped..if off,
executed
/N030block
X6.0
/N035 G00 X8.0 Z3.
/N040 M00 (DIAMETER 5.50 IN)
Not always taught in basic courses:
/N045 T0101 M03
/N050 G00 X6. Z.1
Mid command
Another
optional stop
N055 G71 P060 Q160 D2500 …
N060 . . . block deletes
Conflicting words with Multiple
With a little ingenuity, you can streamline
almost any trial machining operation!
Trial
machining
Rough turning time: 18 minutes
With unexpected stock
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial rough turning (minimize trial machining time):
Commonly
taughtto
in help
basicwith
CNC
courses:
O0003
Use
block delete
trial
machining
N005 T0101 M41
G96 S400 M03
Slash code in program N010
(/)
N015 G00 X6.0 Z.1
If off,with
trialblock
machining
will
take
place
X5.5
Works
delete/N020
switch
/N025 G01 Z-.3 F0.020
If
on,
trial
machining
will
be
skipped
If on, block skipped..if off,
executed
/N030block
X6.0
/N035 G00 X8.0 Z3.
/N040 M00 (DIAMETER 5.50 IN)
Not always taught in basic courses:
/N045 T0101 M03
/N050 G00 X6. Z.1
Mid command
Another
optional stop
N055 G71 P060 Q160 D2500 …
N060 . . . block deletes
Conflicting words with Multiple
With a little ingenuity, you can streamline
almost any trial machining operation!
Trial
machining
Rough turning time: 18 minutes
With unexpected stock
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Trial rough turning (minimize trial machining time):
Commonly
taughtto
in help
basicwith
CNC
courses:
O0003
Use
block
delete
trial
machining
Normal rough
N005 T0101 M41
G96 S400 M03
Slashturning
code begins
in program N010
(/)
N015 G00 X6.0 Z.1
If off,with
trialblock
machining
will
take
place
X5.5
Works
delete/N020
switch
/N025 G01 Z-.3 F0.020
If
on,
trial
machining
will
be
skipped
If on, block skipped..if off,
executed
/N030block
X6.0
/N035 G00 X8.0 Z3.
/N040 M00 (DIAMETER 5.50 IN)
Not always taught in basic courses:
/N045 T0101 M03
/N050 G00 X6. Z.1
Mid command
Another
optional stop
N055 G71 P060 Q160 D2500 …
N060 . . . block deletes
Conflicting words with Multiple
With a little ingenuity, you can streamline
almost any trial machining operation!
Trial
machining
Rough turning time: 18 minutes
With unexpected stock
Lesson topics
Techniques
Saving timewith
andblock
effort:delete
Consider other times when block
Commonly
taught
in help
basictrial
CNC
courses:
deletedelete
can
help
with
machining
Use
block
to
with
trial
machining
Slash
code
in
program
(/)
Lengthy rough milling operations
If off,with
trialblock
machining
will
take place
Works
delete
switch
Thread milling
IfSlot
on,
trial
machining
will
be
skipped
If on,
block
skipped..if
off,
block
executed
milling
Face milling
a little
ingenuity,
you
can streamline
NotWith
always
taught
in
basic
courses:
Thread chasing (turning center)
any trial machining
operation!
Midalmost
command
Another
Necking multiple grooves optional stop
Conflicting
withmachining
Multiple
block deletes
Any words
time trial
is needed!
Trial machining
With unexpected stock
Lesson topics
If you cannot move tasks off line…
…can you facilitate them?
To confirm the correctness of the program / setup
Single block dry run
What can be done to make
Free flowing dry run
program verification easier?
Single blocking each tool into position with controlled
motion rate
Cautiously running first workpiece
Any modifications you make when mistakes are found
To confirm the correctness of the first workpiece
Trial machining for surfaces with critical tolerances
Checking what each tool has done after machining
First workpiece inspection
Any modifications you make due to failed inspection
Re-machining workpiece after modifications
 Program trial machining operations
Lesson topics
If you cannot move tasks off line…
…can you facilitate them?
To confirm the correctness of the program / setup
Single block dry run
What can be done to make
Free flowing dry run
program verification easier?
Single blocking each tool into position with controlled
motion rate
Cautiously running first workpiece
Any modifications you make when mistakes are found
To confirm the correctness of the first workpiece
Trial machining for surfaces with critical tolerances
Checking what each tool has done after machining
First workpiece inspection
Any modifications you make due to failed inspection
Re-machining workpiece after modifications
 In most companies, the production run cannot be started until a workpiece
passes inspection
 Inspections take time – as does any task that must be done if the first
workpiece fails inspection. Be sure inspections are done efficiently.
Lesson topics
If you cannot move tasks off line…
…can you facilitate them?
To confirm the correctness of the program / setup
Single block dry run
What can be done to make
Free flowing dry run
program verification easier?
Single blocking each tool into position with controlled
motion rate
Cautiously running first workpiece
Any modifications you make when mistakes are found
To confirm the correctness of the first workpiece
Trial machining for surfaces with critical tolerances
Checking what each tool has done after machining
First workpiece inspection
Any modifications you make due to failed inspection
Re-machining workpiece after modifications
 Processing mistakes can lead to failed inspections
 There is an easy way to change machining order at the machine during
setup
Lesson topics
Facilitating program verification tasks
Mistakes with machining order will cause
even a perfectly written program to fail!
1)
2)
3)
4)
5)
Rough turn
Finish turn
Drill 2” hole
Rough bore
Finish bore
1)
2)
3)
4)
5)
Rough turn
Drill 2” hole
Rough bore
Finish bore
Finish turn
Not all controls have “cut and paste”
Lesson topics
Facilitating program verification tasks
Fanuc controls allow unconditional branching
M99 P040
Go to sequence number N040
Lesson topics
O0008 (Program with
bad process)
N095 numbers
G00 Z0.1
Techniques
with
sequence
A statement label marks a command
N005 T0101 M41 (Rough turn)
N010 G96 S400 M03
N015 G00 X3.040 Z0.1
N020 G01 Z-1.995 F0.017
N025 X3.25
N030 G00 X6.0 Z5.0
N035 M01
N100 G00 X6.0 Z5.0
N105 M01
Commonly taught in basic CNC courses:
N110 T0404 M41 (1.5” rough boring bar)
N115 G96 S400 M03
N120 G00 X2.085 Z0.1
N125 G01 Z-1.995 F0.010
N130 X2.0
N135 G00 Z0.1
N140 X6.0 Z5.0
N145 M01
N words are sequence numbers
Not needed but beginners use them
N040 T0202 M42 (Finish turn)
Use
order (N5, N10, N15, etc.)
N045
G96 S600logical
M03
N050 G00 X3. Z0.1
N055 G01 Z-2.0 F0.006
N060 X3.25
N065 G00 X6.0 Z5.0
N070 M01
Applications not always taught
in basic courses:
N150 T0505 M42 (1.5” finish boring bar)
N155 G96 S600 M03
N160 G00 X1.125 Z0.1
N165 G01 Z-2.0 F0.006
N170 X2.0
N175 G00 Z0.1
N180 G00 X6.0 Z5.0
N185 M30
Eliminating
N075 T0303 M41 (2”Special
drill)
restart blocks
N080 G97 S300 M03
N085 G00 X0 Z0.1 As statement labels
N090 G01 Z-2.6 F.009
Lesson topics
O0008 (Program with
bad process)
N095 numbers
G00 Z0.1
Techniques
with
sequence
A statement label marks a command
N005 T0101 M41 (Rough turn)
N010 G96 S400 M03
N015 G00 X3.040 Z0.1
N020 G01 Z-1.995 F0.017
N025 X3.25
N030 G00 X6.0 Z5.0
N035 M01
N038 M99 P075
N040 T0202 M42 (Finish turn)
N045 G96 S600 M03
N050 G00 X3. Z0.1
N055 G01 Z-2.0 F0.006
N060 X3.25
N065 G00 X6.0 Z5.0
N070 M01
N100 G00 X6.0 Z5.0
N105 M01
Commonly taught in basic CNC courses:
N110 T0404 M41 (1.5” rough boring bar)
N115 G96 S400 M03
N120 G00 X2.085 Z0.1
N125 G01 Z-1.995 F0.010
N130 X2.0
N135 G00 Z0.1
N140 X6.0 Z5.0
N145 M01
N words are sequence numbers
Not needed but beginners use them
Use logical order (N5, N10, N15, etc.)
Applications not always taught
in basic courses:
N150 T0505 M42 (1.5” finish boring bar)
N155 G96 S600 M03
N160 G00 X1.125 Z0.1
N165 G01 Z-2.0 F0.006
N170 X2.0
N175 G00 Z0.1
N180 G00 X6.0 Z5.0
N185 M30
Eliminating
N075 T0303 M41 (2”Special
drill)
restart blocks
N080 G97 S300 M03
N085 G00 X0 Z0.1 As statement labels
N090 G01 Z-2.6 F.009
Lesson topics
O0008 (Program with
bad process)
N095 numbers
G00 Z0.1
Techniques
with
sequence
A statement label marks a command
N005 T0101 M41 (Rough turn)
N010 G96 S400 M03
N015 G00 X3.040 Z0.1
N020 G01 Z-1.995 F0.017
N025 X3.25
N030 G00 X6.0 Z5.0
N035 M01
N038 M99 P075
N040 T0202 M42 (Finish turn)
N045 G96 S600 M03
N050 G00 X3. Z0.1
N055 G01 Z-2.0 F0.006
N060 X3.25
N065 G00 X6.0 Z5.0
N070 M01
N100 G00 X6.0 Z5.0
N105 M01
Commonly taught in basic CNC courses:
N110 T0404 M41 (1.5” rough boring bar)
N115 G96 S400 M03
N120 G00 X2.085 Z0.1
N125 G01 Z-1.995 F0.010
N130 X2.0
N135 G00 Z0.1
N140 X6.0 Z5.0
N145 M01
N words are sequence numbers
Not needed but beginners use them
Use logical order (N5, N10, N15, etc.)
Applications not always taught
in basic courses:
N150 T0505 M42 (1.5” finish boring bar)
N155 G96 S600 M03
N160 G00 X1.125 Z0.1
N165 G01 Z-2.0 F0.006
N170 X2.0
N175 G00 Z0.1
N180 G00 X6.0 Z5.0
N183 M99 P040
N185 M30
Eliminating
N075 T0303 M41 (2”Special
drill)
restart blocks
N080 G97 S300 M03
N085 G00 X0 Z0.1 As statement labels
N090 G01 Z-2.6 F.009
Lesson topics
O0008 (Program with
bad process)
N095 numbers
G00 Z0.1
Techniques
with
sequence
A statement label marks a command
N005 T0101 M41 (Rough turn)
N010 G96 S400 M03
N015 G00 X3.040 Z0.1
N020 G01 Z-1.995 F0.017
N025 X3.25
N030 G00 X6.0 Z5.0
N035 M01
N038 M99 P075
N040 T0202 M42 (Finish turn)
N045 G96 S600 M03
N050 G00 X3. Z0.1
N055 G01 Z-2.0 F0.006
N060 X3.25
N065 G00 X6.0 Z5.0
N070 M01
N073 M99 P185
N075 T0303 M41 (2” drill)
N080 G97 S300 M03
N085 G00 X0 Z0.1
N090 G01 Z-2.6 F.009
N100 G00 X6.0 Z5.0
N105 M01
Commonly taught in basic CNC courses:
N110 T0404 M41 (1.5” rough boring bar)
N115 G96 S400 M03
N120 G00 X2.085 Z0.1
N125 G01 Z-1.995 F0.010
N130 X2.0
N135 G00 Z0.1
N140 X6.0 Z5.0
N145 M01
N words are sequence numbers
Not needed but beginners use them
Use logical order (N5, N10, N15, etc.)
Applications not always taught
in basic courses:
N150 T0505 M42 (1.5” finish boring bar)
N155 G96 S600 M03
N160 G00 X1.125 Z0.1
N165 G01 Z-2.0 F0.006
N170 X2.0
N175 G00 Z0.1
N180 G00 X6.0 Z5.0
N183 M99 P040
N185 M30
Eliminating
Special restart blocks
As statement labels
Lesson topics
If you cannot move tasks off line…
…can you facilitate them?
To confirm the correctness of the program / setup
Single block dry run
What can be done to make
Free flowing dry run
program verification easier?
Single blocking each tool into position with controlled
motion rate
Cautiously running first workpiece
Any modifications you make when mistakes are found
To confirm the correctness of the first workpiece
Trial machining for surfaces with critical tolerances
Checking what each tool has done after machining
First workpiece inspection
Any modifications you make due to failed inspection
Re-machining workpiece after modifications
 Processing mistakes can lead to failed inspections
 There is an easy way to change machining order at the machine during
setup
Lesson topics
Lesson topics
Program optimizing: Make changes related to
Cutting conditions
Feeds and speeds
Depths of cut
Process
Cutting tool materials
Program
Wasted movements
Program format
Workpiece load and unload
Tool maintenance
Lesson topics
Program optimizing
Though optimizing can reduce cycle time…
…it adds to setup time!
Be sure it’s feasible to optimize!
Lesson topics
Program optimizing
This task should probably be
eliminated if lot sizes are small
Time spent optimizing in setup will
only add to overall production time
Exception:
If you run the same materials and
cutting tools regularly, time spent
optimizing can be applied to future jobs
Lesson topics
Program optimizing
But for large lot sizes…
…optimizing can really reduce
overall production time!
Lesson topics
Program optimizing
To help you evaluate feasibility:
One second rule:
One second saved per cycle will
save 16.6 minutes per 1,000 cycles
If you are considering optimizing for a ten
part lot, and think you can save about 10
seconds…
…you’re only going to reduce the
production run by about 1.5 minutes!
Lesson topics
Program optimizing
To help you evaluate feasibility:
One second rule:
One second saved per cycle will
save 16.6 minutes per 1,000 cycles
On the other hand…
…if you can save 10 seconds in a 1,000 piece lot…
…you’ll save 166 minutes (2.77 hours)
Lesson topics
Eliminate program optimizing tasks
Program optimizing: Make changes related to
Cutting conditions
Feeds and speeds
Depths of cut
Process
Cutting tool materials
Program
Wasted movements
Program format
Workpiece load and unload
Tool maintenance
Again, eliminate these tasks with small lots
Lesson topics
Move program optimizing tasks off line
Program optimizing: Make changes related to
Cutting conditions
Feeds and speeds
Depths of cut
Process
Cutting tool materials
Program
Wasted movements
Program format
Workpiece load and unload
Tool maintenance
Some CAM systems can generate
very efficient CNC programs!
Lesson topics
Move program optimizing tasks off line
Program optimizing: Make changes related to
Cutting conditions
Feeds and speeds
Depths of cut
Process
Cutting tool materials
Program
Wasted movements
Program format
Workpiece load and unload
Tool maintenance
If you use a tool path verification program,
watch for unnecessary motions!
Lesson topics
Facilitate program optimizing tasks
Program optimizing: Make changes related to
Cutting conditions
Feeds and speeds
Depths of cut
Process
Cutting tool materials
Program
Wasted movements
Program format
Workpiece load and unload
Tool maintenance
Lesson topics
Facilitate program optimizing tasks
If you expect your setup people to modify
cutting conditions and approach distance…
…make it easy as possible!
How many feed and speed
words are there per tool?
Lesson topics
O0001 (Program number)
#100 = 400 (Rough turning speed)
#101 = 0.015 (Rough turning feedrate)
#102 = 0.125 (Rough turning depth of cut)
#103 = 5.0 (Tool changing position in X)
#104 = 4.0 (Tool changing position in Z)
#105 = 500 (Finish turning speed)
#106 = 0.007 (Finish turning feedrate)
#107 = 0.125 (Cut off tool width)
#108 = 400 (Cut off tool speed)
#109 = 0.005 (Cut off tool feedrate)
N005 T0101 (Rough turning tool)
N010 G96 S#100 M03 (Start spindle)
N015 G00 X1.5 Z.1 M08 (Rapid up to position)
N020 G71 P025 Q045 U.04 W.005 D#102 F#102 (Rough turn the workpiece)
N025 G00 X.875 (Rapid to starting X)
N030 G01 Z0 (Feed flush with face)
N035 X1.0 Z-0.0625 (Form chamfer)
N040 Z-[0.75 + #107 + 0.01] (Turn 1.0 diameter)
N045 X1.5 (Feed up face)
N050 G00 X#103 Z#104 (Rapid to tool changing position)
N055 M01 (Optional stop)
N060 T0202 (Finish turning tool)
N065 G96 S#105 M03 (Start spindle)
N070 X1.5 Z.1 M08 (Rapid up to workpiece)
N075 G70 P025 Q045 F#106 (Finish turn workpiece)
N080 G00 X#103 Z#104 (Rapid to tool change position)
N085 M01 (Optional stop)
N090 T0303 (Cutoff tool)
N095 G96 S#108 M03 (Start spindle)
N100 G00 X1.5 Z-[1.0 + #107] M08 (Rapid close)
N105 X1.2 (Rapid closer)
N110 G01 X-.03 F#109 (Cut off)
N115 G00 X1.5 (Rapid out)
N120 X#103 Z#104 (Rapid to tool change position)
N125 M30 (End of program)
Facilitate program optimizing tasks
If you expect your setup people to modify
cutting conditions and approach distance…
…make it easy with variable programming!
Lesson topics
Facilitate program optimizing tasks
Program optimizing: Make changes related to
Cutting conditions
Feeds and speeds
Depths of cut
Process
Cutting tool materials
Program
Wasted movements
Program format
Workpiece load and unload
Tool maintenance
What else can you do to help
setup people optimize?
Lesson topics
Lesson topics
Other tasks related to setup?
Paperwork
Production control
SPC
Time reporting
Gauge setup
Working on multiple machines
Others?
Approach them as you do any other setup related
tasks - eliminate, move off line, or facilitate
Lesson topics
Getting More From Your CNC Machines
Lesson 5: Setup Reduction Techniques
End of presentation
Setup tasks and improvements
308
Lesson topics
Copyright 2011