milling cnc

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*RULED SURFACE SWARF MILLINGMASTERCAM 9 for CAD Model & CL file GenerationPostProcessor MATHEMATCA5-axis - MACHINE MIMT

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*RULED SURFACE P1 (-24,-24,0)P2 (24,0,0)P3(-24,-24,-20)P4 24,-24,-20


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*Generate Multi-Axis Swarf Toolpath


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*Black Plot Tool path To ObserveOvercut/Undercut


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*Observe Large Ovecut


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*Observe CL vectors (Blue lines)


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*Define Blank48x48x20


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*Define Tool


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*Verify CL file in Solid Simulation


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*Generate NCI file (NC Intermediate file)Non ISO standard Cutter Location File


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*What is Inside the NCI fileWe only need to pick up Line with Code 11x1 y1 z1 x2 y2 y3 I j k


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*StrStrip un-neccessary information with excel


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*Record below code 11 is required CL data


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*After Stripping we have Code 11Record x y z I j k


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*5 AXIS PROGRAMMING


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*OVERVIEWHaas Control5-Axis Theory5-Axis ControlCAD-CAM ProgrammingTool Paths and GeometryTool Axis ControlFeed RatesPostingTroubleshooting G-CodeMachine Set-up


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*HAAS CONTROL


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*ConfigurationsHead-Head


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*Head-Head


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*Head-Table


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*Table-Table


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*Simultaneous Dual Axis Rotary and Linear MotionRotary Axis Brakes Unclamp - M11-4th, M13-5thClamp - M10-4th, M12-5thCalculating Rotary and Linear SpeedsPi*D/360 = Inches per degreeD= Diameter (Distance from rotation centerline to tool tip, multiplied by 2)Pi*D = Circumference3.14*4./360=0.035/deg.IPM/Inches per degree = degree per min.75/0.035.=2143 degrees per min.Maximum feed on the VF6TR is 2000deg/min Max feed on the VR series is 600 deg/min


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*Simultaneous Dual Axis Rotary Linear MotionInverse Time - G93F = Strokes per minuteF = Inches per minute / stroke lengthIf F=120., each stroke takes 60/120=.5 seconds to completeAn F value is required for each interpolated motion


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*Parameters and SettingsParameter 104/165 - In Position LimitParameter 302 - Feed AccelerationParameter 303 - Feed Time Constant


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*Parameters and Settings(cont)Parameter 314 - Feed Delta VSetting 85 - Max Corner RoundingG187 - Accuracy Control


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*5-Axis ProgrammingTool Paths and CAD GeometryTool Axis ControlFeed Rates - Inverse TimePosting the G-CodeTroubleshooting bad codeNon-uniform rotary and/or linear output


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*Machine Set-upSetting up the TrunnionFinding the Centerline of RotationSetting Machine OffsetsTrunnionVR seriesSetting Tool OffsetsTrunnionVR seriesDry Run


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*Tool Length OffsetsVR Series


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*Offsets TrunnionsUse indicator and sweep Platter to align TrunnionIndicate Parallel to the Y AxisRotate to A+90. and indicate parallel to the X Axis


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*Tool Length OffsetsTrunnions


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*Y-Distance


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*Offsets (cont) TrunnionsTouch Tools to FixtureUse indicator to find center of Bore for X and Y Offsets


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*Prepared by Haas Automation Training Department Oxnard, CA 93030


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*CL-VECTORTOOLINVERSE KINEMATICS = Move X,Y,Z,A,B untill TOOL=CL-VECTOR


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*RULED SURFACE SWARF MILLING


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*110.0 0.00.00.00.01.011-17.89099-27.55785834.6406460.1110730.0262210.99346611-21.777038-28.47523-0.1172270.1110730.0262210.99346611-24-29-200.1110730.0262210.99346611-22.222222-28.995069-19.7779970.1108780.0702380.99134911-20.444444-28.980363-19.5573010.1102990.1138140.9873611-18.666667-28.95614-19.3391810.1093470.1567130.98157211-16.888889-28.922813-19.1248330.1080410.1987170.97408411-15.111111-28.880935-18.9153480.1064070.239630.96501611-13.333333-28.831175-18.7116870.1044750.2792860.95450711-11.555556-28.774284-18.5146670.1022810.3175470.94271CL File for Ruled Surface


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*11-9.777778-28.711073-18.3249520.0998620.3543050.92978311-8-28.642383-18.1430470.0972540.3894820.91588511-6.222222-28.569058-17.9693080.0944960.4230280.90117611-4.444444-28.491922-17.8039490.0916240.4549160.88580811-2.666667-28.411765-17.6470590.0886720.4851440.86992711-0.888889-28.329325-17.4986120.0856720.5137270.853665110.888889-28.245283-17.3584910.0826510.5406980.837146112.666667-28.160251-17.2264990.0796360.5661010.82048114.444444-28.074777-17.1023810.0766470.5899910.803763116.222222-27.989337-16.9858350.0737010.612430.787082118-27.904344-16.8765250.0708150.6334830.770509


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*119.777778-27.82015-16.7740960.0680.6532220.7541061111.555556-27.737047-16.6781810.0652650.6717180.7379261113.333333-27.655276-16.5884090.0626180.6890410.7220121115.111111-27.575033-16.5044120.0600630.7052630.7063971116.888889-27.496471-16.425830.0576030.7204520.6911081118.666667-27.419706-16.3523140.055240.7346740.6761681120.444444-27.344824-16.2835290.0529740.7479920.661591122.222222-27.271884-16.2191570.0508050.7604680.6473851124-27.200922-16.1588940.0487320.7721580.633561125.522423-3.0779313.634160.0487320.7721580.633561126.68023415.26774318.6868930.0487320.7721580.63356


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*Solution B4 A3Solution B4 A3


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation* (* Geometry Transform for NIMT 5-axis machine - *)cldata = ReadList["C:\\Documents and Settings\\Tin\\My Documents\\My Webs\\AT7316\\RuledSurfaceAug2013NIMT\\RULEDSURFACESEP2011.txt", Number, {RecordLists -> True}];ncprog = OpenWrite["C:\\Documents and Settings\\Tin\\My Documents\\My Webs\\AT7316\\RuledSurfaceAug2013NIMT\\O33004.NC", FormatType -> OutputForm];(* Workpiece Offsets *)rowcol = Dimensions[cldata];Print["row col = ",rowcol[[1]]];(* o1 origin workpiece coordinate system on surface of B table so 3.307 lower then o2 *)(* o2 on B table centerline at intersection of B and A axis level *)(* o4 on the same location as o2 *)(* o3 on A table centerline but 0.003 mm further in the machine *)(* x axis positive move table to right *)(* y axis positive move table move toward operator in front of machine *)(* z axis positive tool spindle move up *)(* B rotation is around z positive following right hand rule *)(* A rotation is around x positive following right hand rule *)


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*Blank Workpiece Set UP on MIMT HAAS 5-axis MachineX+Y+


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*Blank Workpiece Set UP on MIMT HAAS 5-axis Machine


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*xo1o2 =- 4.689;yo1o2 = 28.577;zo1o2 = 123.4;(* workpiece offset for rulesuface *)xo2o3 = 0;yo2o3 = -0.003; (* actualy -0.003 micron *)zo2o3 = -3.307;xo3o4 = 0;yo3o4 = 0;zo3o4 = 3.307; (* should be 3.307 *)z4T = 137.74; (* tooltip coordinate in o4 Tool length L = 133.734 mm *)


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation* i = 1;Write[ncprog,"%"];Write[ncprog,"O33004 ( ruled surface solution B4 A3 )"];Write[ncprog,"N100 T2 M06 F300"];Write[ncprog,"N101 G90 G54 X0.0 Y0.0 Z0.0 A0.0 B0.0 (Trunnion Table startup) "];Write[ncprog,"N102 S1500 M03"];Write[ncprog,"N103 G43 H02 Z0.1"];

While[ i

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*If[ Abs[j1] o2 *)(* Rotation B around z in o2 *)x2wb = x2w Cos[BB] - y2w Sin[BB];y2wb = y2w Cos[BB] + x2w Sin[BB]; z2wb = z2w; (* rotation BB in o2 *)


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation* (* Coordinate transform from o2 to o2 *)x3w = x2wb + xo2o3;y3w = y2wb + yo2o3;z3w = z2wb + zo2o3;AA = A3;(* rotation AA in o3 *)x3wa = x3w;y3wa = y3w Cos[AA] - z3w Sin[AA];z3wa = z3w Cos[AA] + y3w Sin[AA];

(* coordinate transform o3 to o4*)x4w = x3wa + xo3o4 + delX;y4w = y3wa + yo3o4 + delY;z4w = z3wa + zo3o4-z4t;

(* coodinates of tooltip in o4 and translation delZ *)x4t = 0;y4t = 0;z4t = z4T+delZ;


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation* (* machine slide motions from handshake *)delX = -x3wa - xo3o4;delY = -y3wa - yo3o4;delZ = z3wa + zo3o4 - z4T;

If[Abs[N[delX]]

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*%O33004 ( ruled surface solution B4 A3 )N100 T2 M06 F300N101 G90 G54 X0.0 Y0.0 Z0.0 A0.0 B0.0 (Trunnion Table startup) N102 S1500 M03N103 G43 H02 Z0.1N110 G01 X -4.689 Y 28.580 Z -14.340 B-180.000 A 0.000 F300N120 G01 X -6.180 Y -39.256 Z 16.809 B-256.717 A 6.553 F300N130 G01 X -6.180 Y -39.256 Z -18.178 B-256.717 A 6.553 F300N140 G01 X -6.180 Y -39.256 Z -38.191 B-256.717 A 6.553 F300N150 G01 X -14.048 Y -35.922 Z -37.999 B-237.647 A 7.542 F300N160 G01 X -17.768 Y -33.487 Z -37.986 B-224.101 A 9.119 F300N170 G01 X -18.937 Y -32.674 Z -38.149 B-214.906 A 11.017 F300N180 G01 X -18.792 Y -33.170 Z -38.481 B-208.533 A 13.073 F300N190 G01 X -17.973 Y -34.548 Z -38.974 B-203.943 A 15.200 F300N200 G01 X -16.791 Y -36.482 Z -39.617 B-200.510 A 17.349 F300N210 G01 X -15.402 Y -38.757 Z -40.397 B-197.854 A 19.488 F300N220 G01 X -13.888 Y -41.228 Z -41.302 B-195.741 A 21.599 F300N230 G01 X -12.295 Y -43.798 Z -42.317 B-194.020 A 23.668 F300N240 G01 X -10.651 Y -46.400 Z -43.428 B-192.592 A 25.687 F300N250 G01 X -8.970 Y -48.988 Z -44.621 B-191.388 A 27.649 F300


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*N260 G01 X -7.266 Y -51.531 Z -45.883 B-190.358 A 29.550 F300N270 G01 X -5.543 Y -54.006 Z -47.201 B-189.468 A 31.387 F300N280 G01 X -3.807 Y -56.397 Z -48.562 B-188.691 A 33.160 F300N290 G01 X -2.061 Y -58.696 Z -49.957 B-188.008 A 34.867 F300N300 G01 X -0.307 Y -60.897 Z -51.374 B-187.402 A 36.509 F300N310 G01 X 1.452 Y -62.996 Z -52.804 B-186.862 A 38.086 F300N320 G01 X 3.216 Y -64.992 Z -54.241 B-186.378 A 39.600 F300N330 G01 X 4.983 Y -66.888 Z -55.677 B-185.943 A 41.053 F300N340 G01 X 6.753 Y -68.684 Z -57.106 B-185.550 A 42.445 F300N350 G01 X 8.525 Y -70.383 Z -58.523 B-185.193 A 43.779 F300N360 G01 X 10.299 Y -71.990 Z -59.924 B-184.868 A 45.057 F300N370 G01 X 12.075 Y -73.507 Z -61.304 B-184.571 A 46.282 F300N380 G01 X 13.852 Y -74.940 Z -62.662 B-184.300 A 47.455 F300N390 G01 X 15.629 Y -76.292 Z -63.995 B-184.051 A 48.579 F300N400 G01 X 17.407 Y -77.567 Z -65.301 B-183.822 A 49.655 F300N410 G01 X 19.186 Y -78.771 Z -66.579 B-183.611 A 50.687 F300N420 G01 X 19.186 Y -78.771 Z -35.338 B-183.611 A 50.687 F300N430 G01 X 19.186 Y -78.771 Z -11.579 B-183.611 A 50.687 F300N800 G00 Z50.0N900 M30%


NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation*Solution B3 A3




****With rotary (C-axis) at 0 degrees, the tilt (A-axis) rotates about the X-axis. In this case, A rotates on C.

*With rotary (C-axis) at 0 degrees, the tilt (B-axis) rotates about the Y-axis. In this case, B rotates on C.

**On the VR-11, A-axis rotates about the X-axis, and the B-axis rotates about the Y-axis. In this case, A rotates on B.

*On this machine, B- axis rotates about the Y-axis and C-axis rotates about the Z-axis.

*Your guess is as good (or better) as mine!!!

*Ive never seen one of these before, but the rotating spindle head should be the B-axis because it rotates about Y and the tilting table should be A-axis because it rotates about the X-axis.

*Again, I havent worked on one of these either.

*This unit is similar to the Haas Trunnion unit with a few differences. The advantage is this unit is small and is designed be placed with the tilting axis rotating about the Y-axis. This makes the tilting axis a B. Because the unit is small, it can be moved all the way to one side of the table, leaving room for vises or other set-ups. The disadvantage is the large distance from centerline of rotation to the surface of the rotary platter (L2).

*The Haas Trunnion series. Notice that the surface of the rotary platter is actually below (.125 +/- .010) the centerline of rotation.But wait, shouldnt the rotary axis be a C-axis because it rotates about the Z-axis? Technically, no. The actual machine home position for the Trunnion unit is + 120 degrees from the horizontal position shown here. Parameter #212 TOOL CHANGE OFFSET sets the number of encoder counts from machine home position to the horizontal position and sets the second home position. Because the actual A-axis machine home position is closer to rotating about the Y-axis as opposed to the Z-axis, it is deemed to be a B-axis and not a C-axis.*The Haas TRT series is similar to the Trunnion. Ive never actually used on of these either, but the one clear drawback is the platter being 1 or 2 above centerline of rotation, depending on the unit.**When rotary motion is commanded, the axes will unclamp themselves, execute the rotary move, and re-clamp. There is no need to command the actions with the M-codes. If you are doing 4 or 5 axis interpolation and you dont release the brakes, they will release themselves until the control encounters a block of code that doesnt command that axis. In this case, the machine motion will stop while the control clamps that axis. Then, when another block of motion for that axis is encountered, the machine motion will stop again while the control releases the brake. Anytime simultaneous 4 or 5 axis motion is commanded, ALWAYS unclamp the rotary axes before motion begins and clamp again at the end of the operation.When doing 4 or 5-axis machining and programming the feed rates in IPM, the actual rotational speed of the rotary unit will vary depending on the value of settings 34 and 79 (4TH AND 5TH AXIS DIAMETER). The degrees per minute speed of a rotary can be calculated by using this formula. Typically, we find that the setting 34 and 79 are set to 1 and the customer is trying to machine at 100 IPM. Using this formula, calculate the rotary speed. 3.14159/360 = .0087. 100IPM / .0087 IPD = 11,494 degrees per minute. The HRT210SHS is capable of 16,200 deg/min feeds (or over 500IPM in the example above)*G93 Inverse Time Mode On This code specifies that all F values (feedrates) be interpreted as strokes per minute. This is equivalent to saying that 60 (number of seconds per minute) divided by the F value, is the number of seconds the motion should take to complete. It is a way of translating linear feedrates (inches per minute), say F100., into a value that takes rotary motion into account. In G93 mode, the F value will tell you how many times per minute the stroke (tool move) can be repeated in one minute based on the linear value.When G93 is active, the feedrate specification is MANDATORY for all interpolated motion blocks; i.e. each non-rapid motion block MUST have its own feedrate specification. If it doesnt, a NO FEEDRATE alarm is generated. Alarm 309, EXCEEDED MAX FEEDRATE, will not be generated by G93 because the machine will automatically be limited by the slowest axis.All Group 9 motion commands, as well as any G12, G13, G70, or G150 command, will generate a syntax alarm when in G93 mode. *104/165 - How close the motor must be to the endpoint before any move is considered complete when not in exact stop (G09 or G61). Parameter 104 is A-axis and Parameter 165 is B-axis.A higher number will make motion smoother(and faster) but a lower number will give better accuracy.302 - The acceleration that applies to feed motion in encoder steps per second squared. Determines how aggressively the machine will accelerate when changing velocity. Larger values will result in shorter cycle times at the expense of machine vibration. 303 - The base 2 exponent of the feed time constant in milliseconds. Specified as the power of two for the time interval, in milliseconds, over which the acceleration is spread (a value of 2 equals 4 milliseconds, a value of 3 equals 8 milliseconds, etc.). *314 - Supports motion control. It is the maximum change in velocity in encoder steps per millisecond. The maximum change in velocity (delta V), specified in encoder counts per millisecond, which is allowed at a feed transition without a reduction in feed rate. It is related to acceleration (302) and feed time constant (303) by the following relationship: Delta V = acceleration * time constant (milliseconds) / 1000000 A lower number here will make motion smother.85 - A lower number will increase accuracy, but also slow down speed. Limited by Parameter 134. When deceleration begins, the next programmed motion block is fetched and begins accelerating when the first motion is within a zone specified by setting 85. The zone which allows motion blocks to overlap is a cylindrical volume around the backwards extension of the second motion vector with a radius equal to setting 85. G187 can be used instead of Setting 85 to temporarily change accuracy. *Demonstrate on Computer.**It is necessary to determine the machines pivot length and gauge length, and input them into the CAD/CAM programs. Each machine has a specific pivot length. This is the distance from the spindle heads center of rotation to the bottom surface of the master tool holder (see figure 1 above). The pivot length can be found in Setting 116, PIVOT LENGTH, and is also engraved into the master tool holder that is shipped with the machine.

*The gauge length is the distance from the bottom flange of the master tool holder to the tip of the tool. This distance can be calculated by setting a magnetic base indicator on the table, indicating the bottom surface of the master tool holder (figure 1), and setting this as Z0 on the Position Page, Operators Position. Then, insert each tool, and calculate the distance from the tool tip to the Z0; This is the gauge length (figure 2). Total length is the distance from the spindle heads center of rotation to the tip of the tool. It can be calculated by adding the gauge length and pivot length. This number is entered into the CAD/CAM program, which will use the value for its calculations. Setting G54-The following procedures can be used to input G54:1. Place the master tool or reference tool into the spindle.2. Jog the Z-axis down to Part Zero position.3. Go to the Offsets page and cursor down to G54 Z position4. Press the Part Zero button.5. In the Offsets page, add the Pivot length of the machine to G54

*Set G54 A-axis zero by indicating B-axis platter until it is flat. Run your indicator parallel to the Y-axis.Rotate the A-axis to G54 A +90 degrees and indicate the B-axis platter along the X-axis. Re-align the Trunnion unit until the B-axis platter is parallel with the X-axis. Tighten the Trunnion unit and rotate back to G54 A0. Make sure the platter is still flat.

*Touch Tools off to surface of fixture.Set Z Offset to rotation centerline from fixture surface.*G54 Z-zero is centerline of A-axis rotation. To set G54 Z zero, measure the distance from face of the fixture to centerline of A-axis rotation. To do this, rotate to G54 A+90. and pick-up face of fixture with an edge finder and note the Y-axis position. Rotate to G54 A-90. and pick-up face of fixture again. The difference between the two readings, divided by two, is the distance from face of the fixture to centerline of A-axis rotation.Enter the distance from face of the fixture to centerline of A-axis rotation in G54 Z-axis offset. This value will be a negative on Trunnion units.

*Because some machine configurations are tight (i.e. VF-2 TR), make sure the machine can safely change tools without hitting the top of the Trunnion rotary unit. If necessary, jog Y-axis to machine zero and X-axis all the way to right side of machine and set X and Y zero in G59. G59 X and Y-zero is used as a safe tool change position. For the VF-2 TR you will have to limit the length of your tools.*