CNC Programming Techniques : An Insider's Guide to Effective Methods and Applications,9780831131852

CNC Programming Techniques : An Insider's Guide to Effective Methods and Applications

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Edition: 1st
ISBN13: 9780831131852
ISBN10: 0831131853
Format: Hardcover
Pub. Date: 2005-09-12
Publisher(s): INDUSTRIAL PRESS
List Price: $74.84

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Summary

Written by the author of the bestselling CNC Programming Handbook and the recent release Fanuc CNC Custom Macros, this practical and very useful resource covers dozens of special CNC programming techniques that can be applied to machining parts in an efficient way.

Table of Contents

Part Program Development
1(22)
Program Development Drawing
1(2)
Drawing Evaluation
2(1)
Material and Stock
3(1)
Part Setup
3(1)
Part Reference Point
3(1)
Part Orientation
3(1)
Selecting Part Zero
4(1)
Tooling Selection
4(6)
Identifying Machining Operations
4(1)
Face Milling
5(1)
Contour Milling
6(1)
Circular Pocket Milling
6(1)
Slot Milling
7(1)
Spot Drilling
8(1)
Drilling
9(1)
Tapping
9(1)
Summary of Tools Used
9(1)
Machining Data
10(1)
Spindle Speed
10(1)
Cutting Feedrate
11(1)
Tooling Data
11(1)
Details of Operations
11(12)
Tool 1 - Face Milling
12(1)
Tool 2 - Outside Contour
13(2)
Tool 2 - Circular Pocket
15(1)
Tool 3 - Slot Milling
16(1)
Tool 4 - Spot Drilling
17(1)
Tool 5 - Drilling
18(1)
Tool 6 - Tapping
19(1)
Complete Program
20(3)
Calculating Contour Points
23(10)
Tools and Knowledge
23(2)
Mathematical Knowledge
23(2)
Organized Approach
25(1)
Process of Calculating XY Coordinates
25(8)
Step 1 - Establish the Main Contour Points
26(1)
Step 2 - Fill-in the Coordinate Sheet
26(1)
Step 3 - Identify Calculation Zones
27(1)
Step 4 - Helpful Ideas for Calculations
27(2)
Step 5 - Calculations for Zone 1
29(2)
Step 6 - Calculations for Zone 2
31(1)
Updating Coordinate Sheet
32(1)
Writing the CNC Program
32(1)
Formulas for Contouring
33(10)
Contour Point Between Two Lines (Lathe)
33(1)
Contour Point Between Line and Arc
34(5)
Intersecting Contour Point
34(1)
Tangent Contour Point
35(4)
Calculating the Sharp Point
39(1)
Contour Point Between Two Arcs
40(3)
Intersecting Arcs
40(1)
Tangent Arcs
41(2)
Using Cutter Radius Offset
43(24)
General Concepts
43(2)
Benefits Of Cutter Radius Offset
44(1)
Controlling Cutter Radius
44(1)
Radius Offset Commands
45(1)
Commands G40-G41-G42
45(1)
Using the D-offset Number
45(1)
Basic Programming Techniques
46(1)
Cutter Radius Activation
46(1)
Cutter Radius Application
47(1)
Cutter Radius Cancellation
47(1)
D-offset Stored Amount
47(2)
Equidistant Centerline - G40 Mode
48(1)
Equidistant Centerline - G41/G42 Mode
48(1)
Drawing Dimensions - G40 Mode
48(1)
Drawing Dimensions - G41/G42 Mode
48(1)
Radius vs Diameter
48(1)
Contour Lead-In and Lead-Out
49(5)
Methods For Lead-In - Linear Motion
49(3)
Methods For Lead-In - Arc Motion
52(1)
Methods For Lead-Out - Linear Motion
53(1)
Methods For Lead-Out - Arc Motion
53(1)
Program Example
53(1)
Internal Contours
54(4)
Linear Slot Machining
54(1)
Circular Slot Machining
55(1)
Finishing Internal Contour
56(2)
Maintaining Dimensional Sizes
58(2)
Basic Rule
58(1)
Handling Dimensional Tolerances
58(2)
Handling Cutter Radius Offset Errors
60(2)
Common Errors
60(1)
Offset Programmed Too Late or Too Early
61(1)
Offset Start or End on an Arc
62(1)
Tool Nose Radius Offset
62(5)
Command Point and Radius Center
62(1)
Tool Tip Orientation
63(1)
Common Tool Nose Radius Errors
64(3)
Part Reversal in Milling
67(22)
Project Description
67(1)
Material and Setup Conditions
67(1)
Cutting Tools
68(1)
Material Removal
68(1)
Machining Process
69(1)
Clamping 1
69(1)
Clamping 2
70(1)
Program Zero Selection
70(2)
First Clamping
70(1)
Second Clamping
71(1)
Programming Methods
72(1)
Tool Length Settings
72(2)
First Clamping
73(1)
Second Clamping
74(1)
Using the WORK OFFSET Method - G54-G55
74(2)
Common Toolpath
76(1)
Program Listing - Work Offsets G54-G55
77(2)
Program Listing - Work Offsets G54-G55 - with Subprograms
79(2)
Using the Local Coordinates Method - G52
81(2)
Program Listing - Local Coordinate System G52
83(2)
Using the Datum Shift Method - G10
85(1)
Program Listing - Datum Shift G10
86(2)
Summary
88(1)
Using Tapered End Mills
89(8)
Types of Tapered End Mills
89(2)
Tool Material
90(1)
Range of Taper Angles
90(1)
Flat Tip Tapered End Mills
90(1)
Ball Tip Tapered End Mills
91(1)
Effective Diameter Calculation
91(5)
Flat Tip
91(2)
Stock Removal
93(1)
Ball Tip with Specified Radius
94(1)
Flat Tip with Added Blend Radius
94(2)
Tapered Holes
96(1)
Special Purpose G-Codes
97(26)
Single Direction Positioning - G60
97(1)
Special Cutting Modes
98(3)
Exact Stop Check G09 - G61
99(1)
Automatic Corner Override - G62
100(1)
Tapping Mode - G63
100(1)
Normal Cutting Mode - G64
101(1)
Stored Stroke Limits Definitions - G22 - G23
101(2)
Spindle Fluctuation G25 - G26
103(1)
Machine Zero Commands - G27 - G28 - G29 - G30
104(4)
Primary Machine Zero Return - G28
104(2)
Return from Machine Zero - G29
106(1)
Machine Zero Return Position Check - G27
106(2)
Secondary Machine Zero Return - G30
108(1)
Position Register - G92/G50
108(10)
G92 Position Register for Milling
109(2)
G50 Position Register for Turning
111(2)
Tool Change Position
113(4)
Conversion of G50 to Geometry Offset
117(1)
Skip Command - G31
118(1)
Other Seldom Used G-codes
119(4)
Tool Length Offset Negative - G44
119(1)
Tool Length Offset Cancel - G49
119(3)
Conclusion
122(1)
Tool Length Offset Change
123(8)
Tool Length Offset
123(1)
Offset Adjustment
124(4)
Practical Application
124(1)
Programming Method 1 - No Offset Adjustment
125(1)
Programming Method 2 - With Offset Adjustment
125(1)
Programming Method 3 - Advanced Macro Method
126(2)
Offset Adjustment - Setup for Two Parts
128(3)
Method 1 - One Work Offset + One Length Offset
128(1)
Method 2 - Two Work Offsets + One Length Offset
129(1)
Method 3 - Two Work Offsets + Two Length Offsets
130(1)
Block Skip Applications
131(12)
General Applications
131(1)
Similar Parts Applications
132(2)
Programming a Trial Cut
134(3)
Trial Cut for Milling
134(2)
Trial Cut for Turning
136(1)
Irregular Stock Removal
137(3)
Variable Stock in Milling
137(2)
Variable Stock in Turning
139(1)
Summary of Rules
139(1)
Block Skip Within A Block
140(2)
Conflicting Words
140(1)
One Program - Two Materials
140(2)
Numbered Block Skip Functions
142(1)
Standard and Rigid Tapping
143(6)
Standard Tapping Method
143(3)
Basic Principles
143(1)
Why Underfeed?
144(1)
Feed-In Slower - Feed-Out Faster
144(2)
Rigid Tapping Method
146(3)
Basic Principles
146(1)
Benefits
146(1)
Setup
147(1)
Possible Problems
147(1)
Programming Approach
147(2)
Polar Coordinates
149(6)
Definition and G-codes
149(2)
Polar Coordinates and Planes
150(1)
G15 - G16 Polar Coordinates
151(1)
Programming Format
151(4)
Toolpath Direction
153(1)
Applications in Planes
154(1)
Subprogram Development
155(14)
Definition and Usage
155(1)
Drawing Evaluation
156(1)
Subprogram Planning
156(2)
Depth Control
157(1)
Width of Cut Control
157(1)
Cutting Tool Selection
157(1)
Developing the Subprogram
158(4)
Method 1 - Full Width and Full Depth
158(1)
Method 2 - Full Width and Divided Depth
159(1)
Method 3 - Smaller Width and Full Depth
160(2)
Round Pocket Subprogram
162(3)
Single Depth Pocket with Stepovers
162(2)
Multidepth Pocket with Stepovers
164(1)
Rough and Finish Cuts with a Subprogram
165(4)
One Toolpath for Two Cuts
165(2)
Lead-in and Lead-Out
167(1)
Common Contour Toolpath
167(1)
Main Program
168(1)
Turning and Boring in Depth
169(30)
Program Zero Selection
169(1)
Corner Radius and Back Angle Selection
170(1)
Cutter Radius Offset
171(1)
Imaginary Tool Point
172(1)
Stock Allowance
172(4)
Contour Shape
173(1)
Cutting Tool Used
173(1)
Stock Allowance in X and Z axes
173(1)
Grinding Allowance
174(2)
Tool Approach Techniques - Lead-In
176(3)
Approaching the Front Face
176(1)
Approaching a Diameter
176(1)
Approaching a Chamfer
177(1)
Approaching a Radius
177(2)
Approaches to Avoid
179(1)
Tool Retract Techniques - Lead-Out
179(3)
Retract from a Face
179(1)
Retract from a Diameter
180(1)
Retract from a Chamfer
180(1)
Retract from a Radius
181(1)
Retracts to Avoid
181(1)
One Job - Two Operations
182(2)
About Jaws
182(1)
Single Setup - Two Chuckings
183(1)
Two Setups - Two Operations
184(1)
Multi Cut Facing
184(1)
Width of Cut Distribution
184(1)
Breaking Corners
185(1)
Direction Specification
186(1)
Using Tailstock
186(3)
Types of Tailstock
187(1)
Programming a Tailstock with a Bar Stopper
187(2)
Using 45-degree Tool
189(3)
Machining Thin Stock
192(1)
Adjusting Chuck Pressure
192(1)
Using an Inner Plug / Outer Ring
192(1)
Using Special Split Jaws
192(1)
G70/G71/G72 Cycle Methods
193(5)
Programming Formats - G71
193(1)
Programming Formats - G72
194(2)
G70 - Finishing Cycle
196(1)
G71 and G72 Compared
196(2)
Programming Undercuts
198(1)
Hard Turning
198(1)
Programming Tapers
199(16)
What is a Taper?
199(1)
Taper Definitions
199(1)
Taper per Foot
200(3)
Taper Ratios
203(2)
Taper Defined as Percentage
205(1)
Taper Angle Defined in D-M-S
206(1)
Taper Length and Angle
206(5)
Chamfers
206(1)
45° Chamfer
207(2)
Start Chamfer with a Clearance
209(1)
End Chamfer with a Clearance
209(1)
Other Chamfers
210(1)
Tapers with Leads
211(4)
Taper with a Lead Chamfer
212(1)
Taper with a Lead Fillet
213(2)
Techniques for Grooving
215(12)
Tooling for Grooves
215(2)
Cutting Width
215(1)
Cutting Depth
215(1)
Groove Location
216(1)
Setting the Command Point
216(1)
Plunge and Retract Method
217(1)
G75 Cycle
217(1)
Grooving for Precision
218(3)
Machining Procedure
219(1)
Programming Procedure
220(1)
Deep Grooving
221(1)
Grooves with Tapers - O-Ring Grooves
222(3)
Grooves with Tapers - V-Pulley Grooves
225(2)
Insert Selection
225(1)
Depth Calculation
226(1)
Tool Setup and Program
226(1)
Techniques for Threading
227(16)
Types of Thread Forms
227(2)
UN - Unified National and Metric
227(1)
Other Thread Forms
228(1)
Thread Depth Calculation
229(1)
Infeed Methods
230(1)
Tool Motions
231(1)
Cutting Conditions
231(1)
Acceleration and Deceleration
231(1)
Cutting Depth
232(1)
Hand of Thread
232(2)
External Threading - Right Hand Thread
232(1)
External Threading - Left Hand Thread
233(1)
Internal Threading - Right Hand Thread
233(1)
Internal Threading - Left Hand Thread
233(1)
Sample Thread Evaluation
234(2)
Initial Data
234(1)
Cutting Conditions
234(1)
Number of Threading Passes
235(1)
Distribution of Depth Cuts
236(1)
G32 Threading Method
236(4)
Radial Infeed Example
237(1)
Flank Infeed Example
237(1)
Tapping with G32
238(2)
G92 Threading Method
240(1)
G76 Threading Method
241(2)
Programming Format
241(2)
Restrictions in Threading
243(8)
Thread Programming Basics
243(1)
Threading Feedrate
244(1)
Standard Example
244(1)
Final Threading Program - Single Start
245(1)
Special Example
245(2)
Final Threading Program - Multi Start
246(1)
Slow Spindle Speed
247(1)
Metric Applications
247(1)
Long Thread Programming
248(3)
Defining a Long Thread
248(1)
Lead Error
249(1)
Number of Decimal Places
250(1)
Practical Thread Milling
251(22)
Thread Milling - General
251(1)
Helical Interpolation
251(1)
Is Helical Interpolation Available?
252(1)
Benefits of Thread Milling
252(1)
Selecting Tools
253(2)
Initial Factors
253(1)
Types of Thread Milling Cutters
254(1)
Accuracy Issues
254(1)
Thread Mill Data
255(1)
Cutting Direction
255(3)
External and Internal Thread Milling
255(1)
Climb Milling and Conventional Thread Milling
255(1)
Right Hand and Left Hand Thread Milling
255(1)
External Thread Milling Illustrated
256(1)
Internal Thread Milling Illustrated
257(1)
Helix - Helical Curve
258(2)
Programming External Threads
260(6)
Tooling Selection
260(1)
Cutting Conditions
261(1)
Lead-In and Lead-Out
261(1)
Cutter Radius Offset
262(1)
Program Development - External Thread
262(4)
Programming Internal Threads
266(5)
Tooling Selection
266(1)
Cutting Conditions
266(1)
Lead-In and Lead-Out
267(1)
Cutter Radius Offset
267(1)
Program Development - Internal Thread
268(3)
Pipe Thread Milling
271(1)
Thread Milling Software
272(1)
Knurling on CNC Lathes
273(4)
Knurling Operations
273(2)
Tooling Selection
273(1)
Knurling Pitch
274(1)
Programming and Machining Techniques
275(1)
Tool Motions
275(1)
Depth and Feedrate
275(1)
Troubleshooting
276(1)
Four-Axis Lathes
277(6)
General Setup
277(1)
Tool Tip Numbers
278(1)
Programming Method
278(5)
Spindle Speed and Feedrate
278(1)
M-Functions
279(1)
Synchronization Functions
279(1)
Program Structure
279(4)
Pallet Changers
283(6)
Types of Automatic Pallets
283(2)
Rotary Pallets
283(1)
Shuttle Pallets
283(1)
Setup and Work Areas
284(1)
Programming Methods
285(1)
M60 Function
285(1)
General Format
285(1)
Programming Example
286(3)
Initial Conditions
286(1)
Part Program
286(3)
Working with Planes
289(18)
Mathematical Planes
289(1)
Machine Planes
290(1)
G-codes for Plane Selection
290(1)
Effect of Planes in Programming
291(4)
Planes and Circular Motion
291(2)
Planes and Cutter Radius Offset
293(2)
Working With Planes In Detail
295(6)
G17 with G41 and G02
295(1)
G17 with G42 and G03
296(1)
G18 with G42 and G03
297(1)
G18 with G41 and G02
298(1)
G19 with G41 and G02
299(1)
G19 with G42 and G03
300(1)
Using Right-Angle Attachment
301(6)
Basic Concepts
301(1)
Side Face Drilling
302(2)
Side Face Milling
304(3)
Programming Cams
307(10)
Overview of Cams
307(1)
Cam Drawing Example
308(2)
Cam RISE and FALL - Sections Evaluation
309(1)
The RISE Section
310(2)
Calculating Radius Length
311(1)
Calculating XY Coordinates
311(1)
The FALL Section
312(3)
Calculating Radius Length
313(1)
Calculating XY Coordinates
314(1)
Summary
314(1)
Writing the Program
315(2)
Introduction to Macros
317(16)
Special Introduction
317(1)
Skills Required
317(1)
Macro is an Option
318(1)
Common Features and Applications
318(1)
Macro Structure
319(8)
Macro Definition and Call
320(2)
Variable Declarations and Expressions
322(1)
Macro Functions
323(3)
Branching and Looping
326(1)
Macro Development - Bolt Circle
327(6)
Evaluation of Drawings
328(1)
Bolt Hole Macro Features
329(1)
Assignment of Variables
330(1)
Internal Calculations
330(1)
Other Calculations
330(1)
Final Considerations
331(1)
Macro Call
332(1)
Did You Know That ... ?
333(2)
References and Resources
335(4)
Index 339

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