Demonstration
Program
7.1 Demonstration Program
Overview
The following steps and key stroke sequences will guide you through creating a demonstration program based upon information from the part drawing shown.
All dimensions are in inches.
This will help introduce you to MILLPWR
G2
and familiarize you with how it operates.
Selecting Datum
Although there is no clear "zero point" identified on this print, use the center of the bolt hole pattern as datum. There are advantages to using this location:
It is the center of the bolt hole pattern
It is the center of the large arc, making it easy to calculate the arc's start and end points.
The pocket is dimensioned from this point, and nearly all of the dimensions on the print originate from this point.
This print could also be programmed using another point such as the upper left corner, for example as datum.
The datum will be ready to set just before running a program.
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7 Demonstration Program
Begin Programming
From the DRO mode, begin by pressing the DRO/PGM key to enter the PGM mode.
If a program is loaded, save the open program, it does not have to be cleared. This is example is done in INCH mode. Make sure INCH is selected.
Selecting A Tool
The first step for this program is to choose the tool that will be used to begin the machining. For this step, a 1/4” diameter FLAT END MILL will be used.
Press the TOOL key to access the SET TOOL Dialogue.
In the SET TOOL dialogue enter 0.25 in the SIZE / DIAMETER field.
Press ENTER twice or ARROW Down to highlight the TOOL TYPE field.
With the TOOL TYPE field highlighted, press either the right ARROW key, or press the Tool Types soft key to open the TOOL TYPE drop down menu.
ARROW
down to highlight the FLAT END MILL.
Press the ENTER key to select the tool type.
In most dialogues, there is a drop down menu and a soft key available for choosing a selection. This program example will refer to the use of the soft keys when available.
ARROW
down to highlight the SPINDLE field.
Select Forward by pressing the Forward soft key
ARROW
down to highlight the SPEED field and enter 1300 using the numeric keypad.
ARROW
down to highlight the TOOL POSITION field.
Enter -5.00 in the X TO field.
Enter 0.00 in the Y TO field.
Enter 1.00 in the Z TO field.
Press the USE key.
The programming of the part can now begin.
Refer to chapter 8 "Selecting A Tool" on page 127 for more information
about Tool Position.
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Programming a line
For this example, the part will begin at the upper left hand corner, and cut in a clockwise (CW) direction.
Press the LINE key. The cursor will default to the
FROM: X1 field in the MILL LINE dialogue.
Using the numerical keypad, enter the following information:
In the FROM: X1 field enter -3, and press the ARROW Down key.
In this case, pressing the ENTER key twice is required to move the cursor down to the next field because a negative number was entered. The arrow key accomplishes the same result with one press of the key.
In the FROM: Y1 field enter 1.5, and press the ARROW Down key.
In the TO: X2 field enter 0, and ARROW Down.
In the TO: Y2 field enter 1.5, and ARROW Down.
In the Z: BEGIN field enter .02, and ARROW Down.
In the Z: END field enter -.25, and ARROW Down.
ARROW
Down to the OFFSET: field and press the Left soft key.
Notice that the ANGLE and TOOL specifications were filled in automatically. The tool specifications were taken from the information entered in Step 001.
To cut around the outside of the contour in a clockwise direction, a left offset is used. MILLPWR
G2
has been factory set with a feed rate of 10 inches per minute, and is used for this operation.
Press the USE key.
The line is now displayed on the Program (PGM) screen and in the graphics area.
Next, the arc will be added to the program.
If it is preferred to see the complete material work piece size for program verification, press the VIEW key, then press the Block Form soft key. In the BLOCK FORM dialogue enter the overall blank size for the part, or cutting piece. MILLPWR
G2
will calculate the block form as the program is entered.
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7 Demonstration Program
Programming an Arc
Press the ARC key. The cursor defaults to the TO: X1 field in the MILL ARC dialogue.
MILLPWR
G2
assumes that the program is continuing from the last step, so it automatically fills in the FROM: X1, and Y1 fields, the
Z: fields, TOOL: fields, FEED: fields, and the OFFSET field.
Using the numerical keypad, enter the following information:
In the TO: X2 field enter 0, and ARROW Down.
In the TO: Y2 field enter -1.5, and ARROW Down.
In the RADIUS: MINOR field enter 1.5 and ARROW Down.
In the DIRECTION: field, press the CW soft key.
Since this arc will be starting at the top and moving out, and around to the bottom, the arc will be machined in a clockwise direction.
Press the USE key.
Saving the program:
At this point, enough information has been entered that the program can be saved and given a name.
Press the Save / Discard soft key.
Select Save from the popup menu.
Enter the program name in the popup keyboard using the ARROW
keys. Name the program DemonstrationProgram.MPT. See
"Saving a Program" on page 91 in the previous chapter for more
information.
Press the Save / Create soft key.
Next, the lower horizontal line will be programmed.
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Programming the connecting Line
Step 001 is now highlighted. ARROW Down to the last blank step number (004) to highlight that step.
The next step to program is the line that starts at the bottom of the arc.
Press the LINE key.
Again, MILLPWR
G2
assumes that the program is continuing from the last step. So it has automatically filled in the FROM: X1, and Y1 fields, the Z: fields, TOOL: fields, FEED: fields, and the OFFSET field.
Using the numerical keypad, enter the following information:
In the TO: X2 field enter -3.0, and ARROW Down.
In the TO: Y2 field enter -1.5, and ARROW Down.
Press the USE key.
Now that the upper edge, arc, and lower line have been created, the following steps will close the contour.
First the lower vertical line will be added.
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7 Demonstration Program
Programming the lower vertical Line
Next, the line that starts vertical from the bottom line at the end of the arc will be entered.
Press the LINE key.
Again, MILLPWR
G2
assumes that the program is continuing from the last step. So it has automatically filled in the FROM: X1, and Y1 fields, the Z: fields, TOOL: fields, FEED: fields, and the OFFSET field.
Using the numerical keypad, enter the following information:
In the TO: X2 field enter -3.0, and ARROW Down.
In the TO: Y2 field enter -.838, and ARROW Down.
Press the USE key.
Next, the lower angled line will be added.
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Programming the lower angle Line
Next, the line that angles in to the part from the lower vertical line will be added.
Press the LINE key.
MILLPWR
G2
has again assumed that it will continue from where it left off, and all fields are filled in except for the TO: fields. The cursor is also located here, in the first field.
Using the numerical keypad, enter the following information:
In the TO: X2 field enter .75.
Now press the ABS/INCR key.
The INC field next to the X2 field has opened. Press the X1 soft key.
X1 is displayed in this field next to the X2 field.
ARROW
Down once to the Y2 field.
In the TO: Y2 field enter 0.00.
If the X1 soft key had not been pressed, then INCR would not have been used, and MILLPWR
G2
would assume that
ABS is to be continued.
Press the USE key.
Next, the upper angle line will be added to the program.
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7 Demonstration Program
Programming the upper angle Line
The upper line that angles away from the part will now be added.
Press the LINE key.
With MILLPWR
G2
assuming that it is continuing from where it was left off, all fields are filled in except for the TO: fields. Which is also where the cursor is located in the first TO: field.
Using the numerical keypad, enter the following information:
In the TO: X2 field enter -3.0, and ARROW Down.
In the TO: Y2 field enter .838.
Press the USE key.
Although changes are not lost if a power cycle occurs, you may wish to save your program periodically while creating it, or you may want to discard the most recent changes made since the last save.
Press the Save / Discard soft key.
Select Save from the popup menu to save the program, or select discard to delete the most recent changes since the last save.
Next, a blend will be added to the two angled lines.
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Programming a Blend
In this step, a BLEND will be inserted between program steps 6 and 7.
ARROW
up one step to highlight program step 7.
Press the BLEND key.
In the TYPE field be sure that Blend is selected.
Program Step 7 has now moved to program Step 8, and the BLEND program step is now Step 7.
Also notice that the continuous line in the program steps between steps 6 and 8 is now broken. This indicates that these steps will be blended.
ARROW
down to the RADIUS: field, and enter .25.
Leave the CONTOUR field set at the default setting of OPEN.
Press the USE key.
The two angled lines are now blended with a .25 radius, and the line in the programming steps is now continuous from Step 2 through
Step 8.
The blend step could have been added prior to adding the next line in the program step, but it would not have been displayed until the connecting line was added.
Press the down ARROW key to Step 9 (last step in the program) to continue with the program.
The following step will close the contour of the part.
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Closing the contour
The contour of the part will now be closed, and all milling steps entered will be one continuous machining operation.
Press the LINE key.
As MILLPWR
G2
assumes that you are continuing from where it was left off, all fields are filled in except for the TO: fields. Which is also where the cursor is located in the first TO: field.
Using the numerical keypad, enter the following information:
In the TO: X2 field enter -3.0, and ARROW Down.
In the TO: Y2 field enter 1.5.
Press the USE key.
The contour of the part is now complete. You may notice that the tool path shows a double radius where the tool started, and then ended.
This is because the program is dimensioning the center of the tool.
The continuous line along the program steps has now changed to a closed rectangle. This represents that the contour is now closed. This happens when the TO point of the last step is the same as the FROM point of the first step.
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G2
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Tool Change for the Bolt hole Pattern
Begin first by changing the tool.
Press the TOOL key. The tool form will open with the cursor in the SIZE: DIAMETER field.
Enter 0.25 in the SIZE: DIAMETER field using the numeric keypad.
Press ARROW Down to highlight the TOOL TYPE field (the LENGTH field will be left blank).
In the TOOL TYPE field, press the Tool Types soft key to open the
TOOL TYPE drop down menu.
ARROW
down to highlight the DRILL.
Press the ENTER key to select the tool.
ARROW
down to highlight the SPINDLE field.
Press the Forward soft key.
ARROW
down to enter the selection, and move to the RPM field.
Enter 1300 (e.g. example) using the numeric keypad, and ARROW down to the REQUIRE CHANGE field.
Press the Yes soft key.
Press the USE key.
A new tool has now been added to the program, and the previous tool will need to be changed when running the program. The program, when running, will stop at this point, and request the tool change before continuing.
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Programming the Bolt circle
Press the HOLES key.
A popup menu will appear for selecting the type of hole pattern to be used.
Select the Bolt Circle selection. The BOLT CIRCLE input dialogue will be displayed.
In the CENTER X field enter 0.00, and Y field enter 0.00. For this program it is also the CENTER location for the Bolt Circle (which is also where datum X 0 and Y0 was set).
ARROW
down to highlight the Z: END field, and press the CLEAR key to delete the default data in the field that may be present.
Enter a value of -.40 in the Z: END field.
ARROW
down to highlight the PECK field, and enter 6 for the
NUMBER.
ARROW
down to highlight the RADIUS field. Press the CLEAR key to delete any default data in the field, then enter 0.75.
ARROW
down to highlight the DIRECTION field, and press the CW
(Clockwise) soft key.
ARROW
down to highlight the HOLES field, and enter 5.
Press the USE key.
In this example, the starting and ending angles were not changed. As a result, the first hole is placed at zero degrees. If you were to look at the face of a clock, zero degrees will be at 3 o’clock. Without a specified ending angle MILLPWR
G2
spaces the number of holes entered evenly around a full circle. If a counter-clockwise direction was applied to the hole pattern, the second hole of our five hole pattern will be between 12 o’clock and 1 o’clock. The holes continue around the circle as shown below.
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G2
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Tool Change for the Rectangular Pocket
Begin by changing the tool.
Press the TOOL key.
In the SET TOOL dialogue enter 0.125 in the SIZE: DIAMETER field.
ARROW
Down to highlight the TOOL TYPE field.
With the TOOL TYPE field highlighted, press the Tool Types soft key to open the TOOL TYPE drop down menu.
ARROW
down to highlight the FLAT END MILL.
Press the ENTER key to select the tool.
ARROW
down to highlight the SPINDLE field.
Select Forward by pressing the Forward soft key
ARROW
down to highlight the RPM field and enter 1300 using the numeric keypad.
ARROW
down to highlight the REQUIRE CHANGE field and press the Yes softkey.
Press the USE key.
A new tool has now been added to the program, and a tool change will be required when running the program.
The program, when running, will stop at this point, and request the tool change before continuing.
The rectangular pocket, which is the final feature, can now be programmed.
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Programming the Rectangular Pocket
Press the RECT key.
A popup menu will appear for selecting the type of rectangle to be milled.
Highlight Pocket and press the ENTER key. The RECTANGLE
POCKET dialogue will be displayed. The cursor will default to the
first field (X1).
In the 1st CORNER: X1 field enter -2.0.
In the 1st CORNER: Y1 field enter -1.0.
ARROW
down to SIZE: X field and enter 0.5
ARROW
down to SIZE: Y field and enter 2.0.
The 2nd CORNER fields will automatically fill in based on the data from the 1st CORNER: fields, and the SIZE: fields.
The Z: begin field, and Z: End field inserts the same information that was entered for the BOLT CIRCLE dialogue information.
ARROW
down to highlight the Z: BEGIN field and enter .100.
ARROW
down to highlight the Z: END field and enter -.25.
ARROW
down to highlight the Z: PASS field, and enter 4 for the
NUMBER.
ARROW
down to the CORNER BLEND RADIUS: field, and enter 0.125.
ARROW
down to highlight the DIRECTION field, and select CW
(Clock Wise) by pressing the CW soft key.
Press the USE key.
The demonstration program is now complete.
Save the program, replacing the existing program.
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Testing the Program
Whenever a new program has been created, it should always be tested first.
Graphics only
The following steps will run the program graphically only, and there will be no table movement.
Press the Run Options soft key.
Press the Graphics Only soft key.
Use the arrow up key to highlight step 001 of the program.
Press the Exit soft key.
Press the GO soft key (there will be no table movement). The part machining steps will be shown in the display graphics.
Dry Run with table movement
The complete program will be run, and the cutting of the part will be displayed graphically as the program steps are being performed.
The following steps will run the program graphically, and the table will move.
Before you press the GO key to begin the dry run, ensure that the tool will not touch the workpiece when the quill begins to move. To avoid tool interference, do one or more of the following:
- Lower the knee
- Remove the tool or workpiece
- Reestablish datum away from the part
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Press the Run Options soft key.
Press the Graphics Only soft key to display the machining steps. Displaying the graphics is not required, but can be of assistance when executing the dry run feature.
Press the Dry Run soft key.
Use the arrow up key to highlight step 001 of the program.
Press the Exit soft key.
Press the GO soft key (the table will move).
Running the Program
The first step in running a new program is to establish datum.
Remember to chose the center of the bolt circle as datum.
Place the workpiece into a vise.
Place the first tool of the program into the spindle.
From the DRO screen, press the Move Table soft key. Using the arrows, and soft keys, position the workpiece under the tool where the center of the bolt circle’s datum is to be.
After the table has been properly positioned, press the Exit soft key to return to the DRO screen.
Touch the tool to the top surface of your workpiece.
Press the Datum soft key.
Press the X = 0, Y = 0 and Z = 0 soft keys to establish the current tool position as datum.
Press the DOWN ARROW key.
Set the Z retract position 1” above the workpiece.
Press the USE key.
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G2
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Tool Changes
Whenever you encounter a SET TOOL step, MILLPWR
G2
will display the DRO screen and let you know which tool to load. If no tool diameter was programmed in the Tool Step, a prompt will be displayed to provide one.
Use the Move Table soft key and ARROW keys to move the workpiece away from the tool.
Insert the required tool into the spindle.
Using the Move Table soft key, position the surface of a known depth on the workpiece under the tool.
Press the Datum soft key.
Position your tool so that it touches a known surface, then enter that position into the Z axis.
Press the USE key.
Raise the tool and press the GO key to continue the program.
Clearing the Program
Press the DRO/PGM key to return to the Program mode.
Press the Clear Program soft key.
Press the Yes soft key to confirm exiting the program.
The program is cleared from the screen, and at any time another program can be loaded or a new program written.
If a program is loaded, and saved, it does not have to be cleared to open a new program.
If for some reason a program can not be cleared with the
Clear Program
soft key, there is an alternate method.
Cycle the power to the console. While at the home (DRO mode) screen, prior to finding home, press and hold the
CLEAR
key for 5 seconds.
Follow the instructions to clear the current program.
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