manual centro mecanizado doosan

Programming Manual

For all Doosan Machining Centers Using

Fanuc Controls

Phil Misseldine 2007

Forward

While similar in appearance your CNC Machining Center operates somewhat differently

from your conventional mill. Although they may share the same work envelope and number of axis the CNC does not have the array of knobs, levers or handles associated with the manual

machine. In place of these are motors that move the X, Y, and Z-axis. The axis motors receive commands from the control, which is user programmed with a series of instructions.

It is these instructions which determine the shape of the part to be machined.

Notice of Disclaimer

This manual is intended not to replace but to supplement the control manufactures original manual. The control manufactures manual will be the final say in any

discrepancy that may evolve.

2

Introduction to Programming

Programming of your Doosan Machining Center involves the sequential study of the operations required to produce a component, using established

engineering methods.

Study Part Drawing

Methodize the Part

Programthe Part

Set upMachine

Machine Part

Finished Part

Example

S4000 M03 Set spindle speed to 4000 (S4000) and turn on spindle clockwise (M03).

A number of Words can be programmed on the same line. Once the line is complete this

forms a Block of information.

Example of a Block

N40 G1 X20.0 Y-8.0 F80.

It contains the Words: N40, G1, X20.0, Y-8.0, F80.

The Addresses used are N, G, X, Y, and F, and the values are 40, 1, 20.0, -8.0 and 80.

3

Most Commonly Used G-Codes G-Code Function

G00 Rapid Positioning Standard G01 Feedrate Positioning Standard G02 Arc Clockwise Standard G03 Arc counter Clockwise Standard G04 Dwell Standard G05 High Speed Machining Optional G08 Look Ahead Control Optional G09 Exact Stop Standard G10 Data Setting Optional G11 Data Setting Cancel Optional G17 X and Y Plane Selection Standard G18 Z and X Plane Selection Standard G19 Y and Z Plane Selection Standard G20 Input in Inch Standard G21 Input in Metric Standard G28 Return to Reference Position Standard G30 Return to 2nd Reference Position Standard G40 Cutter Compensation Cancel Standard G41 Cutter Compensation Left Standard G42 Cutter Compensation Right Standard G43 Tool Length Compensation Standard G49 Tool Length Compensation Cancel Standard G54 Work piece Coordinate System 1 Standard G55 Work piece Coordinate System 2 Standard G56 Work piece Coordinate System 3 Standard G57 Work piece Coordinate System 4 Standard G58 Work piece Coordinate System 5 Standard G59 Work piece Coordinate System 6 Standard G65 Macro Call Standard G73 High Speed Peck Drilling Standard G80 Canned Cycle Cancel Standard G81 Drilling Cycle Standard G83 Peck Drilling Cycle Standard G84 Tapping Cycle Standard G86 Boring Cycle Standard G90 Absolute Command Standard G91 Incremental Command Standard G92 Setting Work Coordinate System Standard G94 Feed Per Minute Standard G95 Feed Per Rotation Standard G98 Return to Initial Point in Canned Cycle Standard G99 Return to R Point in Canned Cycle Standard

For a complete G-code list please refer to your Fanuc manual.

4

Most Commonly Used M-Codes

For a complete M-code list please refer to your Doosan Manual.

M Code Function Vertical Horizontal M00 Program Stop Standard Standard M01 Optional Stop Standard Standard M02 Program End Standard Standard M03 Spindle Clockwise Rotation Standard Standard M04 Spindle Anti - Clockwise Rotation Standard Standard M05 Spindle Stop Standard Standard M06 Tool Change Standard Standard M07 Thru-Spindle Coolant On Standard* Standard M08 Flood Coolant On Standard Standard M09 Coolant Off (all coolant) Standard Standard M10 Table (Pallet) Clamp N/A Standard M11 Table (Pallet) Unclamp N/A Standard M12 Shower Coolant On Optional Optional M14 Spindle Air Blow On Standard Standard M15 Spindle Air Blow Off Standard Standard M16 Air Blast for Tool Setter Optional Optional M18 Air Blast off Optional Optional M19 Spindle Orientation Standard Standard M29 Rigid Tapping Mode (Fanuc only) Standard Standard M30 Program End & Rewind Standard Standard M50 Auto Door Open Optional Optional M51 Auto Door Close Optional Optional M54 Parts Count Standard Standard M60 Pallet Change Standard Standard M61 Load Pallet 1 Standard Standard M62 Load Pallet 2 Standard Standard M66 ATC & APC Change with one command Standard Standard M76 Fixture 1 Clamp Optional Optional M77 Fixture 1 Unclamp Optional Optional M84 G01 Possible with spindle stopped Standard Standard M86 Fixture 2 Clamp Optional Optional M87 Fixture 2 Unclamp Optional Optional M98 Sub-Program Call Standard Standard M99 Sub-Program End Standard Standard

* Not standard on all machining centers

5

Control Panel

EMERGENCY STOP

MODE

MODE SELECT

MDITAPE

MEMORY

EDIT

REF.RTN.

JOG

HANDLE

MACHINE READY EMERGENCY RELEASE FEED HOLD CYCLE START

FEED OPERATION

REF.POINT

RAPID OVERIDE

FEEDRATE OVERIDE

AXIS SELECT RAPID

0

20

40

60

80 100 120

130

140

180

SPINDLE

SPINDLE OVERIDE0

10

20

30

40 5060

80

90

100

ALARM

RESET

M02/M30 LUB. MACHINE

WORK LIGHT

ON

OFF

CW STOP CCW

+_

MACHINE LOCK PROGRAM PROTECT

THROUGHFLOOD

COOLANTOFF

AUTOMANUAL

4TH

ZY

X

ON

OFFCONVEYORPROGRAM RESTARTDRY RUNOPIONAL BLOCK SKIPOPTIONAL STOPSINGLE BLOCK

FUNCTION

POWER

ON

OFF

RESET

HELP

SHIFT

PAGE

PAGE

POS

SYSTEM

PROG

MESSAGE

OFFSETSETTING

GRAPH

CUSTOM

INPUT

DELETE

INSERT

ALTER

CANEOB

7 8 9

654

1 2 3

0_

/

O N G P

X Y Z Q

I J K R

M S T L

BHDF

( ) E C

U V W ?

@A,

# = *

SP&][

FO

25 50

100

Doosan Machining Centers uses the following Fanuc Controls:

0i MB

21i MB 18i MB

16i MB

All screen pictures in this manual are from the 18i control

and may differ from the control you are running.

6

Axis Movement

Every Vertical Machining Center has three axes: X - side to side Y - forwards and backwards Z - up and down

All Horizontal Machining Centers have four axes: X - side to side Y - up and down Z - forwards and backwards B - rotary

7

Manual Pulse Generator

XY Z

4TH X1X10

X100

090

80

70

6050

40

30

20

10

_ +

The Manual Pulse Generator (MPG) or Hand Wheel is used during the setup of the machine.

This is separate from the machine control and gives better control of all axis during setup.

8

TOOL LENGTH OFFSET

When a cutting tool is inserted into its holder, the cutting edge is located at an imprecise distance from the gauge line of the holder. By specifying G43 and the corresponding offset value (H) it is possible to compensate the difference without changing the part program. This is known as the Tool Offset Value and is unique to the tool in the spindle.

Workpiece

Tool Length Offset Distance

Z Axis Home Position

9

Tool Length Setting Method

Using a combination of the jog buttons and MPG, bring the tool down to the predetermined "Z" point.

Operators choice of 'Z' zero position.(This example uses the top of the work piece).

Work piece

Press the function key and then the [OFFSET] soft key to display the following screen.

Cursor down to Tool Number to be set. Key in value displayed in Actual Position (Relative) and press INPUT.

OFFSET SETTING

10

Tool Offset Memory 'C' (Optional)

Tool Offset Memory 'C' allows you to use the same number for Length (H) and Diameter (D) offsets.

Press the function key and then the [OFFSET] soft key to display the following screen.

Cursor down to tool number to be set. Press 'Z' and then the 'INP.C' soft key. Position value is automatically transferred in to the offset.

If using height and cutter compensation for the same tool the program should look like this

N15 G43 Z.10 H1 N20 G41 X-5.0 D1 You also have the ability to adjust the tool length and diameter in the wear column.

OFFSET SETTING

11

Work Coordinates

Every CNC machine has a reference or machine zero. This is a position that is constant to the machine. When a machine is turned on or powered up by the operator it must first be referenced. When the machine reaches its limit switches the control registers this location as home. Using the home position as a reference you can now tell the control where the work piece is located on the machine table.

Machine Table

'X' Zero point

'Y' Zero point

Work Piece

Machine Home Position (X, Y, Z Ref. Point)

12

Work Coordinate System Setting Method

To set the work piece co-ordinates the user has the choice of six co-ordinate systems to choose from G54 to G59.

Press function key and then the [WORK] soft key to display the following page.

Method Using an edge finder or indicator locate the part datum position. Without moving go

to the work offset screen and highlight desired offset. Press hard key X, hard key 0 soft key [measure] hard key Y, hard key 0 soft key [measure]

(Position value is automatically transferred in to Offset).

OFFSET SETTING

13

Work Coordinate System G54 - G59 and G54.1 P1 -P300

The desired Work Coordinate number should always be called at the start of every tool.

Example. N4 (.75 DIA. ENDMILL )

N5 G0 G54 G90 X-2.25 Y.625 S8000 M3 N6 G43 Z.1 H1 N7 G1 Z-1. F25

This option expands the Work Coordinate System giving the user up to 300 sets of work offsets to chose from.

Work Coordinate System Addition's are called in the following way.

Work Coordinate System Addition

Example. N4 (.75 DIA. ENDMILL )

N5 G0 G54.1 P1 G90 X-2.25 Y.625 S8000 M3

N6 G43 Z.1 H1 N7 G1 Z-1. F25

14

Linear Interpolation (G00/G01)

PROGRAMMING

All axis of the machine tool will move in linear at either RAPID or FEEDRATE traverse rates.

Any movement preceded by G00 will occur at RAPID traverse

G00 X4.0 Y-3.0

Any movement preceded by G01 will occur at FEEDRATE. G01 X4.00 Y-3.00 F100.

These commands are MODAL and will stay in effect until changed.

Y

X

P2

P1

GOO Rapid Traverse path (Axis will take the shortest path at 45 degrees)

GO1 Feedrate path ( Axis will travel in a staight line)

G00 Rapid Path

G01 Feedrate Path

15

Co-Ordinate Programming (G90/G91)

Absolute co-ordinate programming (G90)

In absolute programming all dimensioning is taken from a fixed point.

Incremental co-ordinate programming (G91)

In incremental programming dimensioning is taken from the last position programmed and NOT from a fixed point.

16

Absolute and Incremental Programming Example

X+

Y+

Datum

Find the absolute and Incremental co-ordinates of the points listed.

Answers are on page 100.

ABSOLUTE (G90) INCREMENTAL (G91) A X __________ _ Y__ A X__________Y___________ B X __________ _ Y__ B X__________Y___________ C X __________ _ Y__ C X__________Y___________ D X __________ _ Y__ D X__________Y___________ E X __________ _ Y__ E X__________Y___________ F X __________ _ Y__ F X__________Y___________

17

Plane Selection (G17, G18, G19)

Before an arc can be machined the correct plane must be selected.

When generating an arc in the 'X' and 'Y' axis G18 must be selected.

G17

G18

When generating an arc in the 'X' and 'Z' axis G17must be selected.

G19

G02G03X+

Z+

View from front of machine

View from top of machine

Y+

X+

G02G03

View from left side of machine

Z+

G02Y+ G03

When generating an arc in the 'Y' and 'Z' axis G19 must be selected.

Plane selection is MODAL and will stay effective until another plane is selected.

18

Circular Interpolation (G02, G03)

There are two directions in which you can produce an arc - G02 Clockwise and G03 Counter Clockwise.

To machine an arc the machine tool requires the following information. Tool finish position in 'X' Tool finish position in 'Y'

Arc offset in 'X' Arc offset in 'Y'

Arc offset in 'X' is represented by 'I'. Arc offset in 'Y' is represented by 'J'. Arc offset in 'Z' is represented by 'K'.

'I' is the Incremental value parallel to the 'X' axis. 'J' is the Incremental value parallel to the 'Y' axis. 'K' is the Incremental value parallel to the 'Z' axis.

Datum G02

J-1.00

G02 Circular Interpolation Clockwise.

R1.0000

Example G02 X1.0 Y0. I0.0 J-1.0 G02 (Clockwise movement) X 1.0 (Tool finish position in 'X') Y 0.0 (Tool finish position in 'Y') I 0.0 (Arc offset in 'X') J-1.0 (Arc offset in 'Y')

Datum

G03

I-1.00

G03 Circular Interpolation Counter Clockwise

Example G03 X1.0 Y0. I-1.0 J0.0 G03 (Counter Clockwise movement) X 1.0 (Tool finish position in 'X') Y 0.0 (Tool finish position in 'Y') I-1.0 (Arc offset in 'X') J 0.0 (Arc offset in 'Y')

19

Circular Interpolation G02

O1066 (Program number) N1G17G40G80G90 (Safe start) N2T1M6 (Calls T1 and changes tool) N3G54G90G0X-1.5Y0.S718M3 (Tool moves to start position) N4G43Z.1H1 (Picks up tool length value) N5G1Z-.1F20. (Feeds to Z-depth) N6G2X0.Y1.5I1.5F40. (Clock-wise move) N7G1X3.75Y.75 (Linear move) N8G2Y-.75J-.75 (Clock-wise move) N9G1X0.Y-1.5 (Linear move) N10G2X-1.5Y0.J1.5 (Clock-wise move) N11G0Z.1 (Lifts up in Z) N12G91G28Z0Y0. (Returns Z and Y to home position) N13G90 (Back into absolute) N14M30 (Return to beginning of program)

Start N3 Finish N10

N6

N7

N8

N9

X & Y ZERO

Arc offsetparallel tothe X axis. I 1.5

Arc offsetparallel tothe Y axis. J -.75 Arc offset

parallel tothe Y axis. J 1.5

Cutting direction G02

R1.5

R.75

20

Circular Interpolation G03

O1066 (Program number) N1G17G40G80G90 (Safe start) N2T1M6 (Calls T1 and changes tool) N3G54G90G0X-1.5Y0.S718M3 (Tool moves to start position) N4G43Z.1H1 (Picks up tool length value) N5G1Z-.1F20. (Feeds to Z-depth) N6G3X0.Y-1.5I1.5F40. (Counter Clock-wise move) N7G1X3.75Y.75 (Linear move) N8G3Y-.75J.75 (Counter Clock-wise move) N9G1X0.Y-1.5 (Linear move) N10G3X-1.5Y0.J-1.5 (Counter Clock-wise move) N11G0Z.1 (Lifts up in Z) N12G91G28Z0Y0. (Returns Z and Y to home position) N13G90 (Back into absolute) N14M30 (Return to beginning of program)

Start N3 Finish N10

N6

N7

N8

N9

X & Y ZERO

Arc offsetparallel tothe X axis. I 1.5

Arc offsetparallel tothe Y axis. J .75

Arc offsetparallel tothe Y axis. J- 1.5

Cutting direction G03

R1.5

R.75

21

Radius Command (R)

As an alternative to using the 'I' and 'J' commands it is possible to program an arc using the 'R' command.

8 12

345

6

7

This example machines a radius on each corner. The datum is the top left-hand corner of the part. The tool diameter is .500.

Position No. G1X3.5Y.25 1 G2X4.25Y-.5R.75 2 G1Y-3.5 3 G2X3.5Y-4.25R.75 4 G1X.5 5 G2X-.25Y-3.5R.75 6 G1Y-.5 7 G2X.5Y.25R.75 8

The R+ command can only be used for arcs up to 180 degrees. The R- command can only be used for arcs greater than 180 degrees.

22

Cutter Compensation (G41/G42)

Cutter compensation allows a program to be written without considering the size of the cutter.

The three G-codes used to control cutter compensation are G41 - Cutter compensation Left G42 - Cutter compensation Right G40 - Cutter compensation Cancel

If your control has cutter compensation 'B' then different offset numbers have to applied to 'H' and 'D' values. Your program should look like this

G0 G43 Z1. H1 G1 G41 Y0. D11 F50.

If your control has cutter compensation 'C' then the same offset numbers can be ap-plied to 'H' and 'D' values. Your program should look like this

G0 G43 Z1. H1 G1 G41 Y0. D1 F50.

23

Cutter Compensation (G41)

G41 - Cutter compensation to the Left of the work piece.

Always apply cutter compensation at 90 degrees to the work piece. The program for applying cutter compensation should look like this.

G1G41Y0 D1 F25.

or if using cutter compensation 'B' it should look like this G1G41Y0 D11F25.

When turning of cutter compensation the program should be as follows.

G1G40Y.5.

G41 and G42 are Modal commands and will stay active until canceled by G40.

Endmill is on the left hand sideof the work piece

Approach part at 90applyingcutter comp G41

Direction of travel

24

Cutter Compensation (G42)

G42 - Cutter compensation to the Right of the work piece.

Always apply cutter compensation at 90 degrees to the work piece. The program for applying cutter compensation should look like this.

G1G42Y0D1F25.

or if using cutter compensation 'B' it should look like this G1G42Y0 D11F25.

When turning of cutter compensation the program should be as follows.

G1G40Y.5.

G41 and G42 are Modal commands and will stay active until canceled by G40.

Endmill is on the right hand sideof the work piece

Approach part at 90applyingcutter comp G42

Direction of travel

25

Canned (Fixed) Cycles (G73, G81, G83, G86)

Canned cycles are designed to make it easier for the programmer to create programs. With the use of a single 'G' function the canned cycle can be performed in a single block. This makes program-

ming quicker and also saves on program memory.

The formats for the most commonly used canned cycles are

High Speed Peck Drilling Cycle

G73 X _____ Y_____ Z_____ Q_____ R_____ F_____

Drilling

G81 X _____ Y_____ Z_____ R_____ F_____

Peck Drilling

G83 X_____ Y_____ Z_____ Q_____ R_____ F_____

Tapping

G84 X_____ Y_____ Z_____ R_____ F_____

Boring

G86 X_____ Y_____ Z_____ R_____ F_____

Legend

X = X Co-ordinate Position Y = Y Co-ordinate Position Z = Finale depth of Hole R = Rapid Plane Depth Q = Depth of Peck F = Feedrate

G80 cancels all Canned Cycles

For additional canned cycles please consult your Fanuc Operators Manual

26

Initial and Rapid Planes (G98/G99)

When using canned cycles the controller provides the ability to return to one of two reference planes.

G98 G99

Point Z Point Z

Initial Point Level

R Point Level

G98 - Returns the tool to the INITIAL plane. G99 - Returns the tool to the RAPID plane.

27

High Speed Peck Drilling (G73)

Example G98 G73 X0.0 Y0.0 Z-1.25 Q.250 R.250 F20.

Unlike G83 (peck drilling) G73 does not rapid to the R plane after each peck.

When G98 is used 'Z' will return to the Initial point.

When G99 is used 'Z' will return to the R point.

Initial Point (G43 Z1. H01)Tool will stop 1.0" above part.

R Point(R.25)'Z' - Zero is top of part.

Final Hole Depth (Z-1.25)

1st Peck

2nd Peck

3rd Peck4th Peck

0.050" retracted after each peck.

28

Drilling (G81)

Example G98 G81 X0.0 Y0.0 Z-1.25 R.25 F20.


R Point(R.25)




'Z' - Zero is top of part.

29

Peck Drilling (G83)

Example G98 G83 X0.0 Y0.0 Z-1.25 Q.25 R.25 F20.

After each peck 'Z' will rapid to the 'R' plane and then back to within 0.1" of where it finished cutting.




R Point(R.25)



1st Peck.2nd Peck.3rd Peck.

4th Peck.

30

Tapping (G84)

Example G98 G84 X0.0 Y0.0 Z-1.25 R.25 F10.

You must use a floating tap holder when using G84.

For Rigid Tapping example please see page 33.




R Point(R.25) When G99 is used 'Z' will return to the R point.


31

Fine Boring (G76)

Example G98 G76 X0.0 Y0.0 Z-1.5 R.25 Q.005 F10.

Please consult your machine operation manual for correct

orientation when using a single point-boring tool.

'Q' represents the amount tool will move away from machined face before lifting out of hole.

Set the direction and axis in which you want to move away in using parameter 5101 bit 4 and 5

Initial Point (G43 Z1. H01)Tool will stop 1.0" above part. When G98 is used 'Z' will

return to the Initial point.


R Point(R.25)'Z' - Zero is top of part.


Spindle stops. Moves .005" away from part. Rapids out.

32

Rigid Tapping (G84)

Example (1/2-13 Tap) G0 G90 G54 X0 Y0 G43 H01 Z.25 M8 G95 S1000 (G95 feed per rotation) M29 (Rigid tapping mode) G98 G84 Z-1.5 R.25 F.0769 (Tapping cycle with 'F' = pitch of thread) G80 M9 G94 (Feed per minute) G91 G28 Z0 M5 G90 M30

Important thing to remember when Rigid

Tapping the feedrate must be

the pitch of the thread.

When rigid tapping it is possible to retract the tap up to 200% faster than the programmed feedrate. This is achieved by changing the following parameters: Parameter 5200 bit 4 (DOV) to 1 Parameter 5211 enter amount 1% - 200% The only limitation is that once the parameter is changed it will be the same for every tap.




R Point(R.25) When G99 is used 'Z' will return to the R point.


33

Rigid Tapping Using an Alternate Axis

It is possible to rigid tap using an axis other than Z. This is often used when the use of a right angled head is necessary.

Parameters. Before starting set the following parameter. 5101 bit 0 to 1 (FXY)

If an axis other than Z is required to apply the 'H' value (Tool Length Offset G43) then set the following parameter.

5001.1 bit 1 to 1 (TLB)

Make sure that the program contains the correct reference plane selection. G18 X and Z G19 Y and Z

The following example will tap 4 holes using the Y axis

N10 G0 G19 G54 G90 X0. X0. N20 G43 Y.5 H01 N30 G95 S1000 N40 M29 N50 G84 G98 Y-1. R.5 F.0769 N60 X-3.25 Z-.75 N70 X-.75 N80 Z-3.25 N90 G80 N100 G94

When finished remember to return parameters back to their original settings

34

Repetition of Canned Cycles (K)

By placing an 'K' on the same line as the canned cycle command it is possible to repeat the cycle.

The 'K' command should only be used with G91(incremental). If G90 (absolute) were to be used only the 1st hole would be machined.

Example 2 G0 G90 X0 Y0 (1st hole position) G91 G98 G81 X0.50 Y0.50 Z-1.R.25 K3 F20. G90

Example G0 G90 X0 Y0 (1st hole position) G91 G98 G81 X0.50 Y0.0 Z-1.R.25 K6 F20. G90

35

Use of 'K0' in Canned Cycles

Placing a 'K0' at the end of a canned cycle will prevent the cycle from being executed at that position.

This allows the operator to have all the hole positions in a subprogram and define canned cycles in the main program.

T01 M6 (SPOT DRIL) G90 G54 X0. Y0. S8000 M03 G43 H01 Z1. M8 G98 G81 Z-.25 R.1 F5. K0 - Peck cycle M98 P1000 (call sub program) G0 G80 Z1. T02 M6 (DRILL) G90 G54 X0. Y0. S6500 M03 G43 H02 Z1. M8 G98 G83 Z-1.0 R.1Q.1F10. K0 - Drill cycle M98 P1000 (call sub program) G0 G80 Z1. T03 M6 ( TAP) G90 G54 X0. Y0. G43 H03 Z1. M8 G95 S1000 M29 G98 G84 Z-1.2 R.3 F.05 K0 - Tap cycle M98 P1000 (call sub program) G94 G0 G80 Z1. G91 G28 Z0. Y0 G90 M30

O1000(HOLE SUB) X0.0Y0.0 X1.0Y0.0 X2.0Y-1.0 X2.0Y-2.0 M99



36

Thread Milling (Helical Interpolation)

Helical Interpolation provides a method of thread cutting without having to use a machine tap.

Pitch

One revolution must equal pitch of thread

Always feed on using cutter compensasion

37

Thread Milling (Helical Interpolation)

Example

This example machines a 11/2 - 6 thread .50" deep Pitch of thread is .1666

N10 G0 G90 G54 X0. Y0. S1000 M3The machine moves to the part datum using the G54 work coordinate and starts the spindle at 1000 r.p.m.

N20 G43 Z.250 H1 M8The machine applies Tool Length Offset and turns on the coolant.

N30 G01 Z-.500 F50.The machine moves to the required Z depth at 50 i.p.m.

N40 G41 X-.75 D31 F20.The machine moves to the start position applying cutter compensation at 20 i.p.m.(Using cutter compensation allows for easy adjustment of the thread).

N50 G02 I-.750 Z-.6666The machine moves 360 degrees and feeds in Z to finished depth of thread (.500 + .1666)

N60 G0 G40 X0.The machine moves back to center of the hole at the same time canceling cutter compensation.

N70 G0 G91 G28 Z0.The machine moves clear of the part to the Z home position.

38

Manual Data Input (MDI)

In MDI mode you can create and run a program without having to store it in the controls memory.

Select MDI using the Mode Select Switch.

Press the PROG hard key and the following screen will be displayed.

Enter the program manually using the key pad, include end of block (EOB) at the end of each line.

Pressing the RESET key will clear the MDI screen.

In this example the ma-chine will rapid to the X and Y zero location using

the G54 work offset. Then the spindle will

start at 2000 rpm.

MODE

MODE SELECT

MDITAPE

MEMORY

EDIT

REF.RTN.

JOG

HANDLE

39

Starting a Program


All programs must start

with the letter 'O'

Manually key in the program number and then press the insert hard key. Before any more lines can be added you must enter an end of block.

Example O1234 - INSERT - EOB - INSERT

Select EDIT using the Mode Select switch.

MODE

MODE SELECT

MDITAPE

MEMORY

EDIT

REF.RTN.

JOG

HANDLE

40

Program Numbers

Technically the numbers O0000 through O9999 are available for creating program numbers. However some numbers are used by other functions and

are best avoided when creating a program.

To prevent accidental editing or deletion of programs, turn program protect key to lock and remove the key.

O9000 through O9999. These numbers are used for Macro programs and for 'Tool change' and 'Pallet change' programs. It is possible to call these programs using a 'G' or 'M' code by setting parameters.

O9000 program numbers are protected. To unprotect them change parameter 3202 bit 4

(NE9) to 0.

O0001 through O7999 These numbers are generally used for 'G' code programs and can not be protected by parameters.

O8000 program numbers can be protected by changing parameter

3202 bit 0(NE8) to 1.

O8000 through O8999 These numbers are also used for Macro programs and can also be protected against accidental editing and deletion by setting a parameter.

PROGRAM PROTECT

41

Editing a Program

The following is the procedure for Inserting, Altering and Deleting a command in a program which is registered in the controls memory.

Using the cursor keys highlight the command to

be changed.

Press the PROG hard key and make sure that the program requiring editing is displayed.

Alter Example N20 G1 X3.265 Y-2.987 F30. Key in new value (Y-2.950) Pressing the Alter key will change Y-2.987 to the new value N20 G1 X3.265 Y-2.950 F30.

Delete Example N20 G1 X3.265 Y-2.987 F30. Pressing the Delete key will remove Y-2.987 N20 G1 X3.265 F30.

Insert Example N20 G1 X3.265 Y-2.987 F30. Key in new value (Z-1.250) Pressing the Insert key will insert the new value after Y-2.987 N20 G1 X3.265 Y-2.987 Z-1.250 F30.

Once the command is highlighted it is possible to change it. If the command is no longer needed simply press the Delete key to erase it. If the value needs to be changed simply key in the new value and press Alter. If a command has to be added, highlight the command before the point were the new data is to be inserted, key in the new command and press Insert.


MODE

MODE SELECT

MDITAPE

MEMORY

EDIT

REF.RTN.

JOG

HANDLE

42

Extended Part Program Edit

Extended Part Program Edit is the name given to the copy, move and merge function. This allows the programmer to duplicate whole or parts of a program without having to rewrite the

whole program.

Copy Example O1234 G90 G80 G40 T1 M6 G90 G0 G54 X0.0 Y0.0 S3500 M3 G43 Z.1 H1 M8 G98 G81 Z-1. R.1 F15. G80 M9 G91 G28 Z0 Y0 M30

If you want to copy the whole program. Press soft key COPY and then soft key ALL. Enter a new program number and press INPUT. Then press the [EXEC] key.

After displaying the program press soft key [(OPRT)] then the continuous menu key until the [EX-EDT] soft key appears. Pressing this key will display the COPY, MOVE and MERGE keys.

Press the PROG hard key and make sure that the program you want to copy is displayed.

Press COPY key Press ALL key Enter new program number (O2468) Press INPUT key Press EXEC key

O2468 G90 G80 G40 T1 M6 G90 G0 G54 X0.0 Y0.0 S3500 M3 G43 Z.1 H1 M8 G98 G81 Z-1. R.1 F15. G80 M9 G91 G28 Z0 Y0 M30


MODE

MODE SELECT

MDITAPE

MEMORY

EDIT

REF.RTN.

JOG

HANDLE

Always make a backup copy of your program before attempting to alter it. This way should an error occur while using COPY, MOVE or MERGE

you will always have the original for backup.

43

Extended Part Program Edit (Move)

Move Example O1234 G90 G80 G40 T1 M6 (CRSR~) G90 G0 G54 X0.0 Y0.0 S3500 M3 G43 Z.1 H1 M8 G98 G81 Z-1. R.1 F15. G80 M9(~CRSR) G91 G28 Z0 Y0 M30

Press MOVE key Position 1st cursor [CRSR~] Position 2nd cursor [~CRSR] Enter new program number (O2468) Press INPUT key Press EXEC key

O2468 T1 M6 G90 G0 G54 X0.0 Y0.0 S3500 M3 G43 Z.1 H1 M8 G98 G81 Z-1. R.1 F15. G80 M9

If you want to move part of the program. Press soft key [MOVE]. Then move the cursor to the start of the range you wish to move and press soft key [CRSR~]. Move the cursor to end of the range to

be moved and press [~CRSE] or press [~BTTM] if you want to copy everything below the 1st cursor position. Enter a new program number and press INPUT. Then press the [EXEC] key.

OR

Move Example O1234 G90 G80 G40 T1 M6 [CRSR~] G90 G0 G54 X0.0 Y0.0 S3500 M3 G43 Z.1 H1 M8 G98 G81 Z-1. R.1 F15. G80 M9 G91 G28 Z0 Y0 M30 [~BTTM]

Press MOVE key Position 1st cursor

[CRSR~] Position 2nd cur-

sor [~BTTM] Enter new pro-gram number (O2468) Press INPUT key Press EXEC key

O2468 T1 M6 G90 G0 G54 X0.0 Y0.0 S3500 M3 G43 Z.1 H1 M8 G98 G81 Z-1. R.1 F15. G80 M9 G91 G28 Z0 Y0 M30

44

Extended Part Program Edit (Merge)

If you want to insert part of a program into another program. Press soft key [MERGE]. Then move the cursor to the position at which the new information is to be inserted. And press soft key [~CRSR]

or press [~BTTM] if you want the new information to be inserted at the end of the program. Enter the number of the program to be inserted and press INPUT. Then press the [EXEC] key.

Merge Example. O1234 G90 G80 G40 T1 M6 G90 G0 G54 X0.0 Y0.0 S3500 M3 G43 Z.1 H1 M8 G98 G81 Z-1. R.1 F15. G80 M9(~CRSR) G91 G28 Z0 Y0 M30

O1234 G90 G80 G40 T1 M6 G90 G0 G54 X0.0 Y0.0 S3500 M3 G43 Z.1 H1 M8 G98 G81 Z-1. R.1 F15. G80 M9 T2 M6 G90 G0 G54 X0.0 Y0.0 S3500 M3 G43 Z.1 H21 M8 G98 G81 Z-1. R.1 F15. G80 M9 G91 G28 Z0 Y0 M30

Press MERGE key Position cursor

[~CRSR] Enter program number to be inserted (O2468)

Press INPUT key Press EXEC key

O2468 T2 M6 G90 G0 G54 X0.0 Y0.0 S3500 M3 G43 Z.1 H21 M8 G98 G81 Z-1. R.1 F15. G80 M9

It is not possible to move information within a program. You must first copy the

range of information to a new program and then it is possible to insert it back into the original program at a different location.

45

Extended Part Program Edit (Change)

The change feature gives the operator the ability to 'Mass Edit' a program.

Press the 'Change' soft key and the above screen appears. Enter the data that you want to change. e.g. F100. Then press the 'Before' soft key the screen below will be displayed.

Enter the new data and then press the 'After' soft key. e.g.. F50. The screen below will be displayed.

Pressing the 'EXES' soft key will change all F100. in the program to F50. Pressing the 'EX-SGL' soft key will change one line at a time.

If you not want to change a particular block press the 'SKIP' soft key.

46

Background Edit

Background Edit gives the programmer the ability to create a new program or edit an existing program while a program is being executed.

While the machine is running press the hard key PROG then press soft key [(OPRT)] and then soft key [BG-EDT].

When you have finished using Background Edit press soft key BG-END to return to normal operation.

47

Program Stop, Optional Stop and Block Delete

M0 Program Stop. A program stop is used whenever the operator requires the program cycle to stop and allow the operator to perform some manual function such as inspection, manual tool change, coolant adjustment, etc.

M1

/

Optional Program Stop. This M-code stops the machine in the same manner as program stop (M0) except the operator must turn on the Optional stop switch anytime prior to the M1 being read. If the Optional stop switch is not turned on then the M1 command is ig-

To continue operation after an M0 or M1 press cycle start.

To turn ON the switch must be in the UP position.

Optional Block Delete. It is possible to skip a line or lines of information without having to delete them from the program. By placing a forward slash (/) at the beginning of a line and by turning on the block delete switch the control will ignore these lines. Example. N10 G0 G90 G54 X2.00 Y2.00 / N20 S4000 M3 N30 G1X-4.00 F20. With block delete turned ON the program will move from line N10 to N30 ignoring N20. With block delete turned OFF all lines of information are read.

48

Program Restart

This function gives you the option of restarting a tool anywhere in a program

Before starting you must set parameter 7310

X = 1 Y = 2 Z = 3

PROGRAM RESTART

1) Retract the spindle, send all the axis to reference point. 2) Reset Tool. 3) Go to Edit Mode. 4) Hit Reset Button. 5) Go To MDI, type in the original RPM, press cycle start 6) Go to Auto Mode. 7) Flip Toggle Switch to PROGRAM RESTART. 8) Hit (Oprt) button on Soft Keys. 9) Hit Right Arrow Key (Soft Key). 10) You will see (Ptype)(Qtype) soft keys. 11) Type in the sequence # you want to start. 12) Press (Ptype) Soft Key. 13) Turn OFF the Rstart/Prgm Toggle switch. 14) HIT (CYCLE START).

If the program has been run through completely press

Ptype. If the program has not been

partially run press Qtype.

49

Tool Registry

To access the machines tool registry

SYSTEM PMC PMCPRM DATA G.DATA

450 Tool in spindle 452 Waiting tool

Use the Page down key to display the complete Tool Registry on one page.

Tool Registry only applies to machines with random select

tool magazines.

ADDRESS POCKET No D0300 D0301 Pocket 1 D0302 Pocket 2 D0303 Pocket 3 D0304 Pocket 4 etc etc

To change settings parameter write must be turned on.

(see page 51)

50

Changing Parameters

Before changing parameters you must first enable parameter write

Select MDI using the Mode Select switch.

MODE

MODE SELECT

MDITAPE

MEMORY

EDIT

REF.RTN.

JOG

HANDLE

Press the function key and then the [setting] soft key to display the Setting screen. Offset Setting

Change parameter write to 1

Once this is done you are now able to change machine parameters.

Always make a back up copy of the machines parameters before

making changes.

To display machine parameters press function key and then soft key [PARAM].

Input parameter number to be changed and then press the No. Search key.

SYSTEM

51

Sample Program

In this sample program the following operations are performed. Tool 1 - 3/4" end mill, machines part profile & roughs 2" hole. Tool 2 - 5/8" Spot drill, spots all holes. Tool 3 - 27/64" drill, drills 4 holes. Tool 4 - 1/2-13 tap, taps 4 holes. Tool 5 - 1/2" end mill, finish 2.0" thru hole.

52

Sample Program

Program

Start

O1066 (DEMO) - - - - - - - - - -- Program Number with comment N1G0G90G80G40G17- - - - - G80 & G40 Cancels any offsets stored in memory, G17 sets plane selection N2G91G28Y0Z0- - - - - - - - - - Sends Z & Y to the G28 reference position N3T1M6- - - - - - - - - - --- - - - - Calls tool 1 and places tool in spindle

Tool 1

N4 (.75 DIA. ENDMILL )- - - - - - - - - Tool description N5G0G54G90X-2.25Y.625S8000M3- - Moves to 1st position using G54 work offset starts spindle at 8000 rpm N6G43Z.1H1T2 - - - - - - - - - - - - - - - - -Picks up the tool length offset, turns on the coolant and calls next tool N7G1Z-1.F25.- - - - - - - - - - - - - - - - - - Feeds to finale Z depth at 25 ipm. N8G3X-2.Y.375I.25- - - - - - - - - - - - N8 through N18 machines profile N9G1X-.5 N10G2X.375Y-.5J-.875 N11G1Y-3.5 N12G2X-.5Y-4.375I-.875 N13G1X-3.5 N14G2X-4.375Y-3.5J.875 N15G1Y-.5 N16G2X-3.5Y.375I.875 N17G1X-2. N18G3X-1.75Y.625J.25 N19G0Z.1- - - - -- - - -- - - - - - - - Rapid move to 0.1 above the part N20X-2.Y-2.- - - - - - - - - - - - - - Rapid move to hole center N21G1Z-1.F25.- - - - - - - - - - - - Feeds to finale Z depth at 25 ipm N22G1Y-1.75F15. - - - - - - - - - - N22 through N27 machines 2" hole N23G3J-.25 N24G1X-1.75Y-1.625 N25G3X-2.Y-1.375I-.25 N26J-.625 N27X-2.25Y-1.625J-.25 N28G0Z.1- - - - -- - - -- - - - - - -Rapid move to 0.1 above the part

Blank Material

After machining

profile

After machining

center hole

Part after tool 1

has finished

53

Sample Program

Tool 2

N29M01- - - - -- - - - - - - - - - - - Optional stop N30T2- - - - - - - - - - - - - - - - - -Verifies tool 2 is in waiting pocket N31M6- - - - - - - - - - - - - - - - - Change to tool 2 ( .625 DIA. SPOT DRILL )- - - - -Tool description N32G0G54G90X-2.Y-2.S6000M3- Moves to 1st position using G54 work offset starts spindle at 6000 rpm N33G43Z.1H2M8T3- - - - - - - - - Picks up the tool length offset, turns on the coolant and calls next tool N34G81G98X-2.Y-2.Z-.275R.1F10.- - - G81drilling cycle N35X-3.25Y-.75- - - - - - - - - - - -N35 through N38 next hole positions N36X-.75 N37Y-3.25 N38X-3.25 N39G80Z.1- - - - - - - - - - - - - - - G80 cancels pecking cycle

After spot

drilling holes

Tool 3

N40M1- - - - -- - - - - - - - - - - - - Optional stop N41T3- - - - - - - - - - - - - - - - - - Verifies tool 3 is in waiting pocket N42M6- - - - - - - - - - - - - - - - - Change to tool 3 ( .4375 DIA. DRILL )- - - - -- - - - Tool description N43G0G54G90X-2.Y-2S8000M3- - Moves to 1st position using G54 work offset starts spindle at 8000 rpm N44G43Z.1H3M8T4- - - - - - - - - Picks up the tool length offset, turns on the coolant and calls next tool N45G83G98X-2.Y-2.Z-1.25R.1Q.2188F10.- - - G83 peck drilling cycle N46X-3.25Y-.75- - - - - - - - - - - - -N46 through N49 next hole positions N47X-.75 N48Y-3.25 N49X-3.25 N50G80Z.1- - - - - - - - - - - - - - - G80 cancels pecking cycle

After drilling

holes

54

Sample Program

Tool 4

N51M1- - - - -- - - - - - - - - - - - - Optional stop N52T4- - - - - - - - - - - - - - - - - - Verifies tool 4 is in waiting pocket N53M6- - - - - - - - - - - - - - - - - Change to tool 4 ( 1/2-13 UNC TAP )- - - - -- - - - - Tool description N54G0G54G90X-2.Y-2.- - - - - - - -Moves to 1st position using G54 work offset N55G43Z.1H4M8T5- - - - - - - - - Picks up the tool length offset, turns on the coolant and calls next tool N56G95S1000- - - - - - - - - - - - - -G95 feed per rotation N57M29- - - - - - - - - - - - - - - - Rigid tapping mode N58G84G98X-2.Y-2.Z-1.5R.5F.0769- - - G84 tapping cycle with F = pitch of thread N59X-3.25Y-.75- - - - - - - - - - - - N59 through N62 next hole positions N60X-.75 N61Y-3.25 N62X-3.25 N63G80Z.5- - - - - - - - - - - - - - - G80 cancels pecking cycle N64G94 - - - - - - - - - - - - - - - - Change back to feed per minute

After tapping

holes

Tool 5

N65M1- - - - -- - - - - - - - - - - - - Optional stop N66T4- - - - - - - - - - - - - - - - - - Verifies tool 5 is in waiting pocket N67M6- - - - - - - - - - - - - - - - - Change to tool 5 (.5 FINISHING ENDMILL )- - - - Tool description N68G90G54G0X-1.75Y-1.75S8000M3- Moves to 1st position using G54 work offset starts spindle at 8000 rpm N69G43Z.1H5T1- - - - - - - - - - - - - - Picks up the tool length offset, turns on the coolant and calls next tool N70G1Z-1.F25.- - - - - - - - - - - - - - - Feeds to final Z depth at 25 ipm N71G41Y-1.5D55 - - - - - - - - - - - - - Feeds on to part applying cutter compensation N72G3X-2.Y-1.25I-.25- - - - - - - - - - -N72 through N74 machines hole N73J-.75 N74X-2.25Y-1.5J-.25 N75G40G1Y-1.75 - - - - - - - - - - G40 Cancels cutter compensation N76G0Z.1- - - - -- - - -- - - - - - -Rapid move to 0.1 above the part N77G91G28Y0.Z0.M5- - - - - - - Returns machine to Y and Z G28 reference position N78G90- - - - - - - - - - - - - - - - G90 absolute mode N79M30- - - - - - - - - - - - - - - - Rewinds program

After finishing

2" hole

Program End

55

Sub Programs

The control has the ability to access 'sub programs' from outside the program that is running in the control memory. This is useful when tools are using the same information when machining a part

e.g. center drill, drill and tapping a number of holes. Sub programs are accessed by using M98 followed by the desired program number with the let-

ter P replacing the O. e.g. N20 M98 P1066

( .625 DIA. SPOT DRILL ) N32G0G54G90X-2.Y-2.S6000M3 N33G43Z.1H2M8T3 N34G81G98X-2.Y-2.Z-.275R.1F10. N35M98P1066- - - - -(call sub program) - - - - - - N39G80Z.1 N40M1 N41T3 N42M6 ( .4375 DIA. DRILL ) N43G0G54G90X-2.Y-2S8000M3 N44G43Z.1H3M8T4 N45G83G98X-2.Y-2.Z-1.25R.1Q.2188F10. N46M98P1066- - - - -(call sub program) - - - - - N50G80Z.1 N51M1 N52T4 N53M6 ( 1/2-13 UNC TAP ) N54G0G54G90X-2.Y-2. N55G43Z.1H4M8T5 N56G95S1000 N57M29 N58G84G98X-2.Y-2.Z-1.5R.5F.0769 N59M98P1066- - - - -(call sub program) - - - - - - N63G80Z.5 N64G94

O1066 (hole sub program) N10X-3.25Y-.75 N20X-.75 N30Y-3.25 N40X-3.25 N50M99 (return to main program



56

Searching Programs

It is possible to search for information contained in a program. You can search Line numbers, Tool numbers, G-codes, Feedrate, etc.


MODE

MODE SELECT

MDITAPE

MEMORY

EDIT

REF.RTN.

JOG

HANDLE


The Curser keys can also be used for

searching

Enter the Line number, Tool number, G-code or Feedrate to search for then press the

Soft key or the down cursor arrow. SRH

57

Searching for a Program

When there are multiple programs in the controls memory you can search for a particular program in several ways.


MODE

MODE SELECT

MDITAPE

MEMORY

EDIT

REF.RTN.

JOG

HANDLE


Key in the desired program number and then press the

Soft key or the down cursor arrow. O SHR

58

Deleting a Program

When no longer needed, programs stored in the controls memory can be deleted, either one at a time or all programs at once.

Make sure that parameter 3202 bit 5 is set to a 1. If you do not set this parameter once you press the 'Delete' key the program is removed immediately.


MODE

MODE SELECT

MDITAPE

MEMORY

EDIT

REF.RTN.

JOG

HANDLE

Press the PROG hard key to display the program screen.

Key in 'O' followed by the desired program number then press the 'Delete' hard key.

Check that you have entered the correct program number to be deleted. Press

'EXEC' to delete the program or 'CAN' to cancel the delete operation.

To delete all programs in the control enter O-9999 and then press the 'Delete' hard key.

Before deleting all programs check that parameter 3202 bit 4 (NE9) is set to 1. This will prevent the user from deleting the O9000 series programs which are used for Tool change, pallet change etc.

59

PCMCIA Card (Memory Card)

Doosan Machining Centers using the i series controls (not including the 0i) now have the ability to read from a PCMCIA card. This is a memory card and is used in the same way as you would use a 31/2

floppy. With the cards you can upload and download programs and it is also possible to DNC directly from the card. This option makes the RS232c somewhat redundant as the PCMCIA card is much faster

than the RS232c hook up. A program run from the card takes the same run time as a program that is stored in the controls memory. It is also possible to search through and restart anywhere in a program as

long as the program contains line numbers. Most laptop computers already come with the PCMCIA card drive installed otherwise a suitable drive must be purchased. The easiest way to do this is to buy a stand-alone unit, which plugs in to the computer USB port.

The PCMCIA cards and stand alone reader/writers are available from most computer stores (CompUSA, EGGHEAD, etc.)

And also several sites on the internet.

When using the PCMCIA card you must first set the

I/O Channel to 4

60

Uploading and Downloading Programs Using the PCMCIA Card

Insert PCMCIA card Select EDIT using the Mode Select switch.

Press the PROG hard key then the + soft key and CARD soft key to display the following screen.

To send a program to the card. Select Edit mode. Press PRGRN - OPRT - PUNCH - enter Program No - EXEC

To read a program from the memory card. Select Edit mode. Press PRGRN - + - CARD - OPRT - F READ. Enter the file number you wish to load and press F SET. Enter a program number and press O SET and then press the EXEC soft key.

Remember to set the I/O Channel to 4

MODE

MODE SELECT

MDITAPE

MEMORY

EDIT

REF.RTN.

JOG

HANDLE

61

DNC Operation using the PCMCIA Card

Insert PCMCIA card. Select TAPE using the Mode Select Switch.

MODE

MODE SELECT

MDITAPE

MEMORY

EDIT

REF.RTN.

JOG

HANDLE

Press the PROG hard key then the + soft key twice and then DNC-CD soft key to display the following screen.

Parameter 138 bit 7 must be set to 1 to display the

DNC-CD soft key.

Enter the desired file number, the soft keys will automatically change and

then press the DNC-ST soft key. To run the selected program press

CYCLE START.

62

Subprogram call from PCMCIA Card

You can access a program stored on the PCMCIA card at any time and use it as a subprogram.

Main program Program stored on PCMCIA card

(.625 DIA. SPOT DRILL) N32G0G54G90X-2.Y-2.S6000M3 N33G43Z.1H2M8T3 N34G81G98X-2.Y-2.Z-.275R.1F10. N35M198P1066- -(call subprogram from PCMCIA card) N39G80Z.1 N40M1 N41T3


When calling a program from the PCMCIA card use M198 instead of M98. E.g. N20 M198 P1066

Remember to set the I/O Channel to 4

Parameter 3404 bit 2 (SBP) and parameter 138 bit 7 must be set to 1 for this option to

work.

63

Uploading and Downloading programs using a Laptop computer

When using suitable communication software it is also possible to load programs into the control through the RS232 connection from a laptop computer.

Your communication software should match these settings.

Your control parameters should match these settings.

Your I/O Channel should be set to zero.

64

Baud Rate Settings 9 = 2400 10 = 4800 11 = 9600

12 = 19200

Restarting a program when using the PCMCIA Card

You can search and restart a program which is being run from the PCMCIA card in the same manor you would if the program was

running from the controls memory.

Load the desired program (see page 61)

Turn Single Block Switch On

Press PROG hard key to display program screen and press cycle start to start the program.

Enter the line number of the tool that you wish to start at (do not enter the N). Then press the N Search soft key. Once you have reached the correct line num-ber turn off single block and press the start button to continue machining.

This example starts at T2, assuming T2 is already in the spindle

O1066 - - - Start program in single block 200 - - - Enter line number to search to and hit N Search N200 G90 G0 G54 X0 Y0 S2000 M3 - - - Read work offsets, rpm and start spindle. N210 G43 Z1. H2 M8- - -Read Z offset 500 - - - Enter line number you wish to continue from and hit N search N500 G1 X-5. F15 - - - Turn off single block and press Cycle Start to continue machining

Your program must contain line numbers to be able to use the N Search function

You must remember to read all relevant infor-mation for the tool that you need to restart. e.g.. work offsets, Z offsets, rpm,work plane cutter comp etc

65

Uploading programs using a Laptop computer

To read a program from a laptop to the control. First connect the RS232 cable. Then prepare the communication software to send.

Select EDIT using the Mode Select Switch.

MODE

MODE SELECT

MDITAPE

MEMORY

EDIT

REF.RTN.

JOG

HANDLE

Press the PROG hard key then the OPRT soft key to display the following screen.

Press the READ soft key. The screen soft keys will change, then press the EXCE soft key. Starting your communication software now will send the program.

Doosan uses and recommends Multi-DNC as its communication software of choice.

Available at www.multi-dnc.com.

66

DNC Operation using a Laptop Computer

To DNC from a laptop to the control. First connect the RS232 cable. Then select the pro-gram you wish to run and prepare the communication software to send.

Select TAPE using the Mode Select Switch.

MODE

MODE SELECT

MDITAPE

MEMORY

EDIT

REF.RTN.

JOG

HANDLE

Press the PROG hard key to display the following screen.

Turn single block switch to ON

(without single block switch on, the machine will start to move as soon as you start sending the program). SINGLE BLOCK

Press machine CYCLE START

CYCLE START

Starting your communication software now will send the program.

67

RS 232-C Communication Interface Connections

The cable from your computer to the machine should be wired in one of the fol-lowing configurations.

68

Additional Options

Look Ahead Control (G08)

This option is designed for high-speed-machining applications that require precession and accuracy. When rounding corners and curves the delay due to acceleration/

deceleration in the servo system is suppressed.

Use the following format to turn G08 on and off

G08 P1 - Turns look-ahead control ON G08 P0 - Turns look-ahead control OFF

N4 (.75 DIA. ENDMILL ) N5G0G54G90X-2.25Y.625S8000M3 N6G43Z.1H1T2 N7G1Z-1.F25. N8G08P1- - - - - - Turns ON Look-ahead control N9G3X-2.Y.375I.25 N10G1X-.5 N11G2X.375Y-.5J-.875 N12G1Y-3.5 N13G2X-.5Y-4.375I-.875 N14G1X-3.5 N15G2X-4.375Y-3.5J.875 N16G1Y-.5 N17G2X-3.5Y.375I.875 N18G1X-2. N19G3X-1.75Y.625J.25 N20G08P0- - - - - - -Turns OFF Look-ahead control N20G0Z.1

G08 must be specified on a separate line and can-not be combined with any other information.

69

Artificial Intelligence contour control (AICC)

This option allows High-Speed, High-Precision machining without the special need for additional hardware. AICC is mainly used for mold applications.

Use the following format to turn AICC on and off

G05.1 Q1 - Turns AICC ON G05.1 Q0 - Turns AICC OFF

N2G40G80G49 N3G05.1 Q1- - - - - - Turns ON AICC N4G0G17G54G90X-2.Y-.985S8000M3 N5G43Z.1H1T1 N7G1Z-1.005F238. N8X-.1969Z-.9647 N9X-.1733Z-.9415 N10X-.156Z-.9393 N11X-.1346Z-.955 N12X-.095Z-1.005 N13G05.1 Q0- - - - - -Turns OFF AICC N14G0 Z1.

G05.1 must be specified on a separate line and cannot be combined with any other information.

AI NANO - Artificial Intelligence contour control (180 Block look-ahead) 16i,18i and 21i. AICC - Artificial Intelligence contour control (40 Block look-ahead) available on all controls. AI APC - Artificial Intelligence Advanced Preview Control (15 Block look-ahead) standard on all controls.

All these functions are called by G5.1 Q1

70

Programmable Data Input (G10)

It is possible to write directly to the work offsets using the G10 option. This is useful when setting up a previously run part where the work coordinates are already know.

To write to the G54 offset the line of information would be G10L2P1X16.234Y-3.435Z-1.0

P1 = G54 P2 = G55 P3 = G56 P4 = G57 P5 = G58 P6 = G59

To update all work coordinates, the beginning of the program should look like this.

O1066 G10L2P1X16.234Y-3.435Z-1.0 G10L2P2X15.234Y-4.435Z-1.0 G10L2P3X14.234Y-5.435Z-1.0 G10L2P4X13.234Y-6.435Z-1.0 G10L2P5X12.234Y-7.435Z-1.0 G10L2P6X11.234Y-8.435Z-1.0

71

To write to the G54.1 P1P48 extended offsets the line of information would be

G10L20P1X16.234Y-3.435Z-1.0

Mirror Image

There are two types of Mirror Image available for the machine. One is to set the desired axis manually in the Offset Setting screen. The second is using programmable mirror image in the program (G51.1).

Manual Setting

Machine your 1st part and then at the end of the program move to your next X and Y home position (e.g G55 X0 Y0) and stop the program (M00).

Select MDI using the Mode Select switch.

MODE

MODE SELECT

MDITAPE

MEMORY

EDIT

REF.RTN.

JOG

HANDLE

Press the function key OFFSET SETTING and then the [setting] soft key to display the Setting screen.

Press the down page key to display the following page.

Enter 1 to activate the desired axis. Return the Mode Switch to Auto and press cycle start to continue machining the 2nd part.

G55X

Part Mirrored in X - axis

The program format should look like this P1066 M98 - - - Main program containing all information to machine part. G55 X0 Y0 - - -Move to next part datum M00 - -- - - - - -Program stop (change to MDI and set X Mirror Image on). P1066 M98- - - -Call main program and machine mirrored part.

72

Mirror Image

Programmable Mirror Image

There are two ways of including Mirror Image in the program. 1. Using G51.1

2. Using M-code

G51.1 (Turns Mirror Image On) G50.1 (Turns Mirror Image Off)

The program format should look like this: P1066 M98 - - - Main program containing all information to machine part. G55 X0 Y0 - - - Move to next part datum G51.1 X0- - - - Mirror Image in X -axis P1066 M98- - - -Call main program and machine mirrored part. G50.1 X0 - - - - Cancel Mirror Image

M81 (Turns Mirror Image On in X-Axis) M82 (Turns Mirror Image On in Y-Axis) M80 (Turns Mirror Image Off)

The program format should look like this: P1066 M98 - - - Main program containing all information to ma-chine part. G55 X0 Y0 - - - Move to next part datum M81- - - - Mirror Image in X -axis P1066 M98- - - -Call main program and machine mirrored part. M80 - - - - - -- Cancel Mirror Image

73

Coordinate System Rotation

By using this option it is possible to rotate a programmed shape. G68 is used to turn on Coordinate System Rotation, along with 'X' & 'Y' position

which is the center of rotation and 'R' which is the angle of rotation.

To use Coordinate System Rotation the program format should look like this: P1066 M98 - - -- - - Main program containing all information to machine part. G68 X0 Y0 R45. - - Rotates part 45 degrees with X & Y zero being center of rotation. P1066 M98- - - - - - -Call main program and machine rotated part. G69 - - - - - --- - - - Cancel Coordinate System Rotation

If no R value is specified the value in parameter 5410 is used as the angle of rotation.

74

Scaling

Using the Scaling option it is possible to enlarge or reduce the size of a part without having to change the program.

AB

C

If part A is the original part size, to produce part B which is 1.5 times original. The program should look like this. G90 G0 G54 X0 Y0 (Move to center of part) G51 X0 Y0 P1500 (Turn on Scaling, magnification = 1.5) M98 P1066 (Main program containing all information to machine part) G50(Cancel Scaling mode) To produce part C which is half original size. The program should look like this. G90 G0 G54 X0 Y0 (Move to center of part) G51 X0 Y0 P500 (Turn on Scaling, magnification =0.5) M98 P1066 (Main program containing all information to machine part) G50(Cancel Scaling mode)

75

Tool Life Management

Tool Life Management gives the operator the ability to change a worn tool to another tool during program run without stopping the machine. Tools are classified into

groups and a tool life is set for each group in either number of times used or length of time. When a tool exceeds the preset number of times used or time set, then the next tool in that group is selected. Once all tools are used then an alarm is generated to let

the operator know that the tools must be changed.

Parameters. 6800 .2 (LMT) 0 (for number of times) 6810 200 Tool Ignored Number

76


O0001 G10L3 (Sets Tool Life Management) P1L15 (Sets group 1 with a tool life of 15 uses) T1H1 (Tool # and tool length offset #) T2H2 (Tool # and tool length offset #) P2L15 (Sets group 2 with a tool life of 15 uses) T3H3 (Tool # and tool length offset #) T4H4 (Tool # and tool length offset #) G11 M30

Before using TLM you must first set the tool groups using the format in the above program

O1000 T201M6 (Selects 1st tool from group 1) G0G90G54X0Y0S2000M3 G43H99Z5. ( H99 must be assigned when using TLM) G98G81Z3. R.1F50. G0G80Z5. G0G91G28Z0 T202M6 (Selects 1st tool from group 2) G0G90G54X0Y0S2000M3 G43H99Z1.( H99 must be assigned when using TLM) G98G81Z3. R.1F50. G0G80Z5. G0G91Z0Y0 M30

The format of the main program should look like this.

Once both tools have been used 15 times the next tool assigned in the group is selected.

77


To display the TLM screen press the Offset Setting hard key then the + soft key and then the TOOLLF soft key.

A @ sign is displayed next to the tool that is being used. A * appears when the tool life has expired.

78

Tool Path Graphics

Pressing the GRAPH hard key will bring up the Tool Path Graphic screen.

Setting parameter 6500 bit 6 to 1 will always position the graphic in the center of the screen.

79

Horizontal Setup

The horizontal machining center gives the operator the ability to set up multiple parts. It is also possible to machine three sides of a part in one setup.

Choose a face to set all you Tool Length Offsets from. This is usually the face of the part at G54 B0.

A

Setting Z

Work Offset Value

Using an indicator measure the distance from the face you touched your tools off to the face of the next part to be machined. Enter this amount (A) in your work offset Z value you have assigned for that

part. eg. G55

X-16.500 Y-12.290 Z-1.250

80

Horizontal Setup

All faces to be machined should be assigned there own work offset numbers. This gives better control over each work piece.

G54

G55

G56

G57G59

G58

B0

G54 P1

G54 P2

G54 P4

G54 P6G54 P5

G54 P3

B90

G54 P07

G54 P8

G54 P10

G54 P12G54 P11

G54 P9

B180

G54 P13

G54 P14

G54 P16

G54 P18G54 P17

G54 P15

B270

The above example is for pallet 1. Each work piece on pallet 2 should also be given individual work offset numbers.

81

Horizontal Machining Example

Typically when using a horizontal machining center you will be machining the same part in several locations on the tombstone. The use of sub-programs will save on program size, control

memory and also make proving out the program easier.

O2000 (MAIN PROGRAM)

M61 (Calls pallet 1)

P1976 M98 (calls program

O1976)

M62 (Calls pallet 2)

P1976 M98 (calls program

O1976)

O1976 ( MAIN SUB PROGRAM)

N1G0G17G40G94G90G80

N6G91G28Z0.

G28X0Y0

G90 T1M6 (T1 FACE MILL) (calls tool 1)

G54B0 (G54 work offset at B0 part 1)

P0001M98 (calls program O001)

G0Z8. (move tool away from pallet)

G54.1P1B90 (G54.1 P1 work offset at B90 part 2)


G0Z8. G54.1P7B180(G54.1 P7 work offset at B180 part 3)

P0001M98

G0Z8. G54.1P13B270(G54.1 P13 work offset at B270 part 4)

P0001M98

G0Z8.M9 T2M6 (T2 1/2 END MILL) (calls tool 2)

G54.1P13B270(G54.1 P13 work offset at B270 part 4)


G0Z8. (move tool away from pallet)

G54.1P7B180(G54.1 P7 work offset at B180 part 3)


G0Z8. G54.1P1B90 (G54.1 P1 work offset at B90 part 2)

P0002M98

G0Z8. G54B0(G54 work offset at B part 1)

GP0002M98

G0Z8.M9

G91G28X0Y0Z0M5

G90

M99

O0001(T1 FACE MILL)

G0G90X-2.5Y-

2.S1000M3T2

G43Z.5H01

G1Z0F50.

G1X9.F20.

G0Z2.

M99

O0002( T2 .750 FINISH)

G90G0X-.8751Y-

2.4995S1600M3T1

G43Z.1H01M8

G1Z-1.F15.

X-.3751F50.

G3X.1249Y-1.9995J.5

G1Y-.9995

G2X.9999Y-.1245I.875

G1X3.9999

G2Y-3.8745J-1.875

G1X.9999

G2X.1249Y-2.9995J.875

G1Y0.

G0Z.2

M99

Always use the tool in the spindle to machine all parts on the tombstone before changing to the

next tool. As it is quicker to do a B axis move than

a tool change.

82

Bore Mill Machining Example

Set up and use of the horizontal boring mill is very similar to a standard horizontal machining center. The major difference is that the boring mill has a 'W' axis.

When the 'W' axis is at its home position (G91G28 W0), enter this position into the work offset number you will be using. E.g. G54 W 27.890 Then when you call your work offset all moves will be read as zero from this position.

The following is an example of a peck drilling cycle.

G80G49G40G0 G91G28Z0W0 T1 M6 (Calls Tool 1) G90G54X9.0Y25.0W-5.0S700M03 (Moves to X, Y and 'W' position) G43 Z2. H1 M8 (Picks up tool offset) G83G99Z-3.0R1.0Q1.0F8.0 (Peck drilling cycle) Y19.0 Y-19.0 G80 Z2. (Cancel pecking cycle) G91 G28 Y0. Z0. W0. (Sends Y, Z and W axis to home position) G90 M30

Always clamp the 'W' axis before machining.

M68 - Clamp M69 - Unclamp

83

Macro Programming

Fanuc controls have an option feature known as custom Macro. This is powerful program language that allows programs to be written using variables instead of

fixed numbers.

There are several ways to call a Macro program. 1. Using G65 followed by the Macro program number. e.g. G65 P9010 2. Using a custom G-code. G100 variables are set in parameters 6050 - 6059 3. Using an M code. M-code variables are set in parameters 6071 - 6079.

6050 G Code to call Macro program 9010 6051 G Code to call Macro program 9011 6052 G Code to call Macro program 9012 6053 G Code to call Macro program 9013 6054 G Code to call Macro program 9014 6055 G Code to call Macro program 9015 6056 G Code to call Macro program 9016 6057 G Code to call Macro program 9017 6058 G Code to call Macro program 9018 6059 G Code to call Macro program 9019

By putting 100 in parameter 6050 every time G100 is

placed in the program Macro 9010 will be called.

6071 M Code to call Macro program 9001 6072 M Code to call Macro program 9002 6073 M Code to call Macro program 9003 6074 M Code to call Macro program 9004 6075 M Code to call Macro program 9005 6076 M Code to call Macro program 9006 6077 M Code to call Macro program 9007 6078 M Code to call Macro program 9008 6079 M Code to call Macro program 9009

By putting 100 in parameter 6071 every time M100 is placed in the

program Macro 9001 will be called.

84

Macro Programming

This Bolt Hole Macro allows for quick and easy programming of a bolt hole circle without the operator having to calculate the position of each hole.

The line of information in the program to call this macro should look like this: G100 X0.0 Y0.0 Z-.750 D2.0 R.1 C83. A45. H4. F20. Q.15

X X axis center Y Y axis center Z Depth to drill R Reference point above part D Diameter of bolt circle C G code to be used H Number of holes in pattern A Starting angle of 1st hole F Feedrate T Dwell value Q Peck depth (G73 & G83 only)

This is the Macro to run this program.

O9010(BOLT HOLE MACRO) IF[#7EQ#0]THEN #3000=1(NO DIAMETER GIVEN) IF[#11EQ#0]THEN #3000=2(NO HOLES GIVEN) IF[#9LT#0]THEN #3000=3(NO FEEDRATE "F" GIVEN) IF[#3EQ#0]THEN #3000=4(NO DRILL CYCLE GIVEN) IF[#18EQ#0]THEN #3000=20(NO REFERENCE POINT GIVEN) #100=1 #27=#7/2.0 G0X[[COS[#1]*#27]+#24]Y[[SIN[#1]*#27]+#25] G98G#3Z#26R#18F#9Q#17P#20 #101=360/#11 N1WHILE[#100LTABS[#11]]DO1 X[[[COS[[#101*#100]+#1]*#27]+#24]]Y[[[SIN[[#101*#100]+#1]*#27]+#25]] #100=#100+1 END1 M99

85

Macro Programming (Circular Pocket) The line of information in the program to call this macro should look like this,

G102 X0. Y0. Z-750 R1. A.05 I.02 J.02 K.25 W.8 C5.0 D3 F20.

X X axis center Y Y axis center Z Depth of pocket R Radius of pocket D Direction of cut. D2 CW / D3 CCW C Feedrate for plunging I Finish cut J Finnish allowance on bottom of pocket A Reference point above the part F Feedrate K Depth of cut for roughing W Width of cut. % of endmill diameter

Circle-Pocket Macro

86

O9012(CIRCULAR POCKET) IF[#3EQ#0]THEN#3000=8(NO PLUNGE FEEDRATE GIVEN) IF[#9EQ#0]THEN#3000=3(NO FEEDRATE GIVEN) IF[#23EQ#0]THEN#3000=5(NO WIDTH OF CUT GIVEN) IF[#1EQ#0]THEN#3000=21(NO REFERENCE POINT) N1G0X#24Y#25Z#1 #100=0 #106=0 #140=#5003 #141=#5001 #142=#5002 #32=#4107+12000 #32=#[#32] #33=#4107+13000 #33=#[#33] #144=#32+#33(D+2000) #10=#18-#144(POCKETRAD-EMRAD) #143=#142-[#10-#4] #145=[#10-#4] #146=2*#145 #12=#23*[#144*2](WIDTH-OF-CUT) #104=[#12*.01] #27=#26+#5(ZDEPTH-FINISH) IF[#7EQ2]THEN#104=[#104*[-1]] IF[#6EQ#0]GOTO3000 #100=ABS[FIX[[#26-#1+#5]/#6]] #101=#100 N2G90G0Z#1 N3G0G90X#141Y#142 N500IF[#106GE#100]GOTO3000

#14=0 G91G1Z-#6F#3 WHILE[[#12+#14]LT[#145]]DO2 N4G1G91Y-#12F#3 #14=#14+#12 N5G#7X0Y[2*#14]R#14F#9 N6G#7X0Y-[2*#14]R#14 N31G0Y0.0 N32END2 N2000#106=#106+1 N19G90G1Y[#143] G#7G91X0.0Y#146R145F#9 G#7X0.0Y-#146R145 G0Y0 N8G90G0X#141Y#142 N201GOTO500 N3000IF[#5EQ#0]GOTO4000 N9G90G0X#141Y#142 #14=0 N10G1Z#27F#3 N40WHILE[[#12+#14]LT[#145]]DO3 N11G1G91Y-#12F#3 #14=#14+#12 N12G#7X0Y[2*#14]R#14F#9 N13G#7X0Y-[2*#14]R#14 N14G0Y0 END3 N19G90G1Y#143 G#7G91X0.0Y#146R#145F#9 G#7X0.0Y-#146R#145 G0Y0 N4000G0G90X#141Y#142 N14G1Z#26F#3 #14=0 WHILE[[#12+#14]LT[#145]]DO1 G1G91Y-#12F#3 #14=#12+#14 G#7X0Y[2*#14]R#14F#9 G#7X0Y-[2*#14]R#14 G0Y0 END1 N1000IF[#4EQ#0]GOTO23(IF NO FIN ALLOW) N19G90G1Y#143 G#7G91X0.0Y#146R#145F#9 G#7X0.0Y-#146R#145 G0Y0 IF[#5003NE#26]GOTO4000 N23G90G1Y[#142-#10] N24G#7G91X0Y[2*#10]R#10F#9 N25G#7X0Y-[2*#10]R#10 N26G#7X#104Y[ABS[#104]]R[ABS[#104]] N67G0G90Z#140 G0X#141Y#142 M99

Milling Formulas

The following formulas are used to calculate speed and feeds, metal removal rate, surface feet per minute and horse power used.

Symbols and Measurement Units D = diameter of milling cutter (inches) d = depth of cut (inches) F = feed rate (inches per minute) f = feed (inches per tooth) K = power constant of work material E = spindle efficiency (varies from 75% to 90%) W = width cut (inches) Z = number of teofeth in the cutter mrr = metal removal rate ( cubic in/min) HPc = horse power at the cutter sfm = surface feet per minute

To calculate Surface Feet per Minute (SFM) sfm = .262 x D x rpm To calculate Feed rate (inches per minute) F = f x Z x rpm To calculate Feed (inches per tooth) f = F/Z x rpm To calculate Metal Removal rate (mrr) mrr = W x d x F To calculate Horse Power at the cutter (HPc) HPc = mrr/K

Example: To find the Surface Feet per Minute (smf) of a 3/4" 4

flute end mill running at 2500 r.p.m sfm = .262 x D x rpm sfm = .262 x .750 x 2500 = 49 smf = 491

'K' Factors

Work Material Hardness

BHN 'K'

Factor

steels, wrought and cast (plain carbon, alloy steels, tool

steels)

85-200 201-253 254- 286 287-327 328-371 372-481 482-560 561-615

1.64 1.56 1.28 1.10 0.88 0.69 0.59 0.54

Precipitation hardening

stainless steels 150-450 1.27-0.42

Cast Irons (grey, ductile and

malleable)

150-175 110-190 176-200 201-250 251-300 301-320

2.27 2.00 1.89 1.52 1.27 1.19

Stainless steels, wrought and cast (ferritic, austenitic

& martensitic)

135-275 286-421

1.54-0.76 0.74-0.50

Titanium 250-375 1.33-0.87

High-temperature alloys, nickel,

colalt base 200-360 0.83-0.48

Iron Base 180-320 0.91-0.53

Nickel alloys 80-360 0.91-0.53

Aluminum alloys 30-150 6.25-3.33 Magnesium al-

loys 40-90 10.0-6.67

Copper 150 3.33

Copper alloys 100-150 151-243 3.33 2.00

87

Trouble Shooting

88

Side Mounted Tool Changer Recover

This is the procedure for recovering a side mounted tool changer should the machine loose power or if the tool is inadvertently load wrong.

1. Restore Power (It is not necessary to Zero return the machine) 2. On the Automatic Tool Changer (ATC) box at the back of machine, set switch to manual. 3. In MDI key in M39; and press the start button. (This starts maintenance mode and allows you to use the 2 keys for rotating the tool magazine as jog keys for the tool changing arm.) 4. Turn mode switch to JOG If you have a tool in the spindle make sure that the tool is unclamped (Green light on). If not, manually press tool unclamp button. 5. Using the jog keys (on the ATC box) move the tool changer arm to home position (you will have to press the key several times). Carefully watch the tool that is being placed in the spindle. Once it is in position in the spindle manually press tool clamp before proceeding otherwise the tool will drop. Finish pressing the jog key until the arm is at home position. 6. Turn mode switch to MDI 7. In MDI key in M19; and press the start button (spindle orientation) 8. Key in M41 (will complete 1 complete tool change) 9. Set APC box back to Auto. 10. Check to make sure that you have the correct tool number in spindle before continuing. To display tool register Press SYSTEM ? PMC ? PMCPRM ? DATA ? G.DATA Page to show parameters D450 & D452 D450 Head Tool (shows tool number in spindle) D452 Next Tool (shows tool number in waiting pot)

Pot must be in the down position to run this procedure

M32 Pot UP M33 Pot Down

89

Horizontal Machining Center Tool Changer Recover (DHP and DHC 400)

During a normal tool change (1) Next tool is placed in spindle. (2) Tool from spindle is returned to waiting pot. (3) Tool is returned to correct pocket in magazine. After this the next tool called is brought to the waiting pot position, then the magazine rotates back so that the pocket number and the tool in the spindle are the same. At all times the magazine should have (2) empty spaces.

T5 T1

1

2

3

90

Horizontal Machining Center Tool Changer Recover (DHP and DHC 400)

Occasionally due to tool changing errors (2) pots will be in the waiting pot position. For this example we have T5 in the spindle and T10 as the waiting tool. The Pot position's were the spindle tool and waiting tool came from should be empty (e.g. P5/P10). Look in the magazine to see were the third pot is missing from (e.g. P20). Manually rotate the magazine so that the third empty pocket and the misplaced pot are in line. On the CRT press Hard Key - SYSTEM, (soft keys) - PMC - PMCPRM - DATA - G.DATA. This will display the following. N0 ADDRESS DATA 0000 D0450 5 (This is the tool in the spindle) 0001 DO452 10 (This is the tool in the waiting pot) Change D0452 to matched the third empty pocket number (e.g. 20). In manual bring pot over to magazine side. Change D0452 back to waiting pot number (e.g. 10). Return magazine back to auto mode. The magazine should now be back in sequence.

P5

T5T10

P10

P20

Misplaced Pot I

- Spindle

91

DHP-500 and 630 Tool Change Recovery

This is the procedure to recover the Tool Changer should the machine loose power during a tool change or if a tool is inadvertently loaded wrong.

1. Restore power. 2. Set Mode switch to Jog.

3. Make sure that the ATC box is connected to the tool changer and set to Manual. 4. On the ATC box set switch to Tool Change Step Reverse. 5. Keep pressing Start key (green button). Carefully watch the tool being placed in the spindle. Once the tool is in the spindle manually press the tool clamp button before preceding otherwise the tool will drop. Finish pressing the start button until the arm is in the home position. 6. Set switch to Close Door and press start switch. 8. Check to make sure that you have the correct tool in the spindle before continuing.

MODE

MODE SELECT

MDITAPE

MEMORY

EDIT

REF.RTN.

JOG

HANDLE

EMERGENCY STOP

DOOR CLOSE

DOOR OPEN

W-POT UNCLAMP

W-POT CLAMP

W-POT SPDL SIDE

W-POT MAG SIDE

SPINDLE ORIENTATION

TOOL CHANGE 1 CYCLE

TOOL CHANGESTEP FORWARD

TOOL CHANGESTEP REVERSE

MOTOR BRAKERELEASE

PALLET CHANGE

PALLET CLAMP

PALLETUNCLAMP

PALLET CHANGESTEP FORWARD

PALLET CHANGESTEP REVERSE

MOTOR BRAKERELEASE

SPINDLE ORIENTATION

ATC CONDITION

APCCONDITION

STOP START

ATC APC

Maintenance box for

DHP-500 and DHP-630

92

DHP-500 and 630 Pallet Change Recovery

This is the procedure to recover the pallet changer should the machine lose power during a pallet change.

1. Restore Power. 2. Set Mode switch to Jog.

3. Make sure that the APC box is connected to the pallet changer, and set to Manual. 4. On APC box set switch to Pallet Change Reverse. 5. Press Start Key (Green Start Button , wait for pallet to finish rotating before continuing). 6. Set switch to Clamp Pallet and press Start. 7. Set APC switch back to Auto. 8. Check to make sure that you have the correct pallet in the machine before continuing.

MODE

MODE SELECT

MDITAPE

MEMORY

EDIT

REF.RTN.

JOG

HANDLE

When doing a pallet change all doors must be closed at all times.

93

CAT 50 PULL STUD

This pull stud will fit all 50 taper Doosan Machining Centers.

Dimensions are for reference only.

Part No 316-45 (With through hole) 311-18 (No through hole) To Order Call:

Retention Knob Supply Company Tel: 937-686-6405 Fax: 937-686-4125

94

CAT 40 PULL STUD



Part No 711-23 (With through hole) 711-25 (No through hole)

To Order Call:


95

BT 30 PULL STUD


25mm

18 mm

11mm

M12 x 1.75

7mm


Part No 311-09H (With through hole)

To Order Call:


96

Heavy Tool Limitations

Before using a heavy tool you must first calculate the tools 'Moment' before attempting a tool change. This should not exceed the machines maximum tool weight.

Weight Center

Taper Gage Line

Calculate the tools 'Moment' as follows 1. Find the tools center of gravity 2. Measure the distance from the tools center of gravity to taper gage line. 3. Weight x length = Moment

The easiest way to find the tools center of gravity is to tie a piece of string

around the tool, and then find the point at which the tool is balanced. Measure from the string to the taper gage line.

Measure from center point to taper gage line

97

Uses of Large Tool

The following method is recommended when using a large diameter tool.

Empty Pockets

Tool's with numbers 70 and higher are considered 'large Tools'. Before you start to use a large tool you must first set the 'Tool Registry'.

To access the Tool Registry see page 50

When loading a large tool make sure that the pots on either side are empty. In the 'Tool Registry' set the empty pots to "00".

In this example 'Pot 8' has the large tool with Pots 7 and 9 empty. When T70 is called in the program it will always be placed back in Pot 8.

98

Lubrication Requirements

The following is a list of oils used on Doosan machining Centers.

Way Lube 'G' Oil Hydraulic 'B' Oil

Spindle Cooler 'A' Oil Grease 'Y' Oil

Air Service Unit 'B2' Oil Table 'E' Oil

Mold cut on DMV 3016LS In 1 Hour 32 minutes. H13 Tool Steel RC50

Comparative Oils

Mobil Oil Shell Oil Esso Oil BP Oil Caltex Oil Sun Oil

A (FC10)

Velocite No. 6

Tellus C10

Spinesso 10

Energol HP10

Spindural 10 Solnus 55

B2 (FC32) DTE Oil Light

Tellus 32

Teresso 32

Energol HP32

Rando 32 Sunv 916

E (HM68)

DTE 26

Tellus 68

Nuto H68

Energol HLP 68

Rando HD 68

Sunvis 831 WR

G (G68)

Vactra No. 2

Tonna T68

Febis K 68

Maccurat 68

Way Lubricant 68

Sun Waylube 80

Y (XM2)

Mobilux 2

Alavniagrease EP2

Beacon 2

Ener-grease LS 2

Multifak EP2

Prestige 42 Grease

99

Absolute and Incremental Programming Example

X+

Y+

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Answers from page 17

ABSOLUTE (G90) INCREMENTAL (G91) A X 4.000 Y-2.000 A X4.000 Y-2.000 B X 8.000 Y-3.000 B X4.000 Y-1.000 C X 1.000 Y-6.000 C X2.000 Y-3.000 D X 2.000 Y-5.000 D X-8.000 Y1.000 E X 3.000 Y-7.000 E X1.000 Y-2.000 F X 8.000 Y-7.000 F X5.000 Y0.000

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Index

A. Axis Movement - 7 Absolute Coordinate Programming (G90) - 16,17 Additional Options - 69 Artificial Intelligence Contour Control (AICC) - 70 Artificial Intelligence Advanced Preview Control (AI APC) - 70 B. Boring, Fine Boring (G76) - 32 Back Ground Edit - 47 Block Delete - 48 Boring Mill Program Example - 83 C. Codes, M Codes (Most Commonly Used) - 5 G Codes (Most Commonly Used) - 4 Control Panel - 6 Coordinate Programming - 16 Circular Programming (G02,G03) - 19,21 Cutter Compensation (G40,G41,G42) - 23,25 Canned Cycles - 26,33 Control Options - 69 Coordinate Rotation - 74 D. Drilling, High Speed (G73) - 28 Drilling (G81) - 29 Peck Drilling (G83) - 30 DNC, Using PCMCIA Card - 62 Using Laptop Computer - 67 Down Loading, Using PCMCIA Card - 61 Using Laptop Computer - 65

101

E. Extended Part Program, Edit - 43 Move - 44 Merge - 45 Change - 46 F. Fixed Cycles - 28,33 G. G - Codes (Most Commonly Used) - 4 Graphics (Tool Path) - 79

H. High Speed Peck Drilling (G73) - 28 Helical Interpolation - 37,38 Horizontal Machining Center Setup - 80,81 Horizontal Program Example - 82 I. Incremental Coordinate Programming (G91) - 16,17 Initial Plane (G98) - 27 J.

K. 'K' In Canned Cycles - 36 L. Linear Interpolation (G00/G01) - 15 Look-ahead Control (G8) - 69 Lubrication Requirements - 98

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M. M-Codes (Most Commonly Used) - 5 M.P.G (Manual Pulse Generator) - 8 M.D.I (Manual Data Input) - 39 Memory Card - 60 Milling Formulas - 87 MBL APC (Multi Block Look-a-head Advanced Preview Control) - 70 Mirror Image - 71,73 Macro Programming Example - 84,86 N.

O. Optional Stop - 48 Options - 69 P. Programming - 15 Plane Selection - 18 Program, Starting - 40 Numbers - 41 Editing - 42 Sample - 52,55 Searching - 57 Searching For - 58 Deleting - 59 Program Stop - 48 Program Restart - 49 Parameters (Changing) - 51 PCMCIA Cards, PCMCIA Cards - 60 Uploading and Downloading - 61 DNC Operation - 62 Calling Subprograms (M198) - 63

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P. Continued, Restarting a program - 64 Programmable Data Input (G10) - 71 Pull Studs - 93,95 Q.

R. Radius Command - 22 Rapid Plane - (G99) -27 Rigid Tapping - 33 Rigid Tapping Using an Alternative Axis - 34 Repetition of canned cycles (L) - 35 Restart - 49 RS231C Communication - 68 S. Starting a Program - 40 Sample Program - 52,55 Subprogram (M98) - 56 Subprogram - Calling from PCMCIA Card (M198) - 63 Scaling - 75 T. Tool Length Offset - 9 Setting Method - 10 Tool Offset Memory 'C' - 11 Tapping, (G84) - 31 Rigged Tapping - 33 Rigged Tapping Using an Alternative Axis - 34 Thread Milling - 37,38 Tool Registry - 50 Tool Life Management - 76,78

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