160 Prog

Programming Manual
Boxford 160 TCL CNC Turning Machine Tool
Boxford
Boxford Ltd., Wheatley, Halifax, West Yorkshire, England, HX3 5AF. (Registered Office) Telephone: 01422 358311 Fax: 01422 355924 E-Mail: [email protected] Web: www.boxford.co.uk
Boxford 160 TCL
Contents
Contents
1 Introduction 2 Running the Demonstration Program 3 Axes and Tooling
3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 Axes and Datums Turret Quick Change Toolpost Gang Plate Spindle Rotation and Tool Orientation Tailstock Chuck Tool Libraries Setting Up
4 Main Front End Menu 5 CAD and CAM Processing

5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 Functions Information Required Creating a CAD Profile CAD Window Drawing Aids Drawing Tools Editing Tools 3D Renderer Example CAM Processing a Profile CAM Processor Error Messages
6 DXF File Imports
Boxford 160 TCL
Contents
7 Administration Mode
7.1 7.2 7.3 7.4 7.5 7.6
Access & Password Setting Tool Library Material Cutting Data Internal Machining Data Park Position and Units Language Settings
8 Manual Data Input CNC Programming

8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 Operations and Programming Sheets Absolute and Incremental Co-ordinates Speeds and Feeds Program Format Preparatory Functions (G Codes) Miscellaneous Functions (M Codes) Canned Cycles Inputting a New Program 8.8.1 Information required 8.8.2 Tabulated Format 8.8.3 Compact Format 8.9 Saving a Program 8.10 Examining an Existing Program 8.11 Editing a Program 8.11.1 New Programs 8.11.2 Existing Programs 8.11.3 MENU Editing Options 8.12 Continuing a Program 9.1 9.2 9.3 Initial Checks Manufacture Options During Machining
9 CNC and CAM Machining
10 Manual Machining 11 Robotic Interfacing
Boxford 160 TCL
Contents
CNC Tutorials and Exercises

Tutorial 1: Exercise 1: Tutorial 2: Exercise 2: Tutorial 3: Exercise 3: Tutorial 4: Exercise 4: Tutorial 5: Exercise 5: Tutorial 6: Exercise 6: Tutorial 7: Exercise 7: Tutorial 8: Exercise 8: Tutorial 9: Exercise 9: X and Y Co-ordinate Calculation Absolute and Incremental Co-ordinates Calculation of Co-ordinates Linear Interpolation Linear Interpolation - Absolute Co-ordinates Canned Cycles - Hole Drilling and Pocket Milling Canned Cycles - Programming a Tool Change Circular Interpolation - Clockwise and Counter-clockwise Circular Interpolation Combining Operations and Tool Changing Combining Operations Subroutines Subroutines Mirror Images Mirror Images Further Canned Cycles - Pitch Circle Drilling and Dish Milling Use of Canned Cycles - Pitch Circle Drilling and Dish Milling Subroutines, Mirror Images and Circular Interpolation Subroutines and Mirror Images
Tutorial 10: Datum Shift and Jump to Line Exercise 10: Datum Shift and Jump to Line Operations Sheet Programming Sheet
1 Introduction
This manual gives guidance in using the 160TCL CAD/CAM software to create ISO G&M code programs for turned components, and in component manufacture. The 160TCL CAD/CAM software includes a demonstration program (called DEMO), and a number of tutorial programs. It is suggested the manual is used as follows: 1. 2. 3. 4. 5. 6. Refer to section 2 and run the demonstration. This will provide rapid familiarisation with the operation of the software and the machining process. Study Section 3 to become proficient in setting up the tooling. Refer to sections 4 and 5 to demonstrate the ease of operation of the integrated CAD and CAM processor package. Refer to Section 6 to become familiar with the conventions for importing DXF files from third party CAD packages. Refer to Section 7 for details of the functions available to administrators (tutors) of the CAD/CAM system. Use section 8 for detailed instruction in CNC programming. Tutorial 1 is used as an example to demonstrate the stages of programming and software operation. Use the Tutorials and Exercises in the order in which they appear, to progress from basic programming skills to proficiency in the more advanced features of CNC programming. When programs have been written and verified, refer to section 10 as required, to machine components.
7.
8.
Boxford 160 TCL
2 Running the Demonstration Program

The demonstration program contains examples of parallel and radius turning, and a finished component can be machined from the billet supplied with the machine. Run the program as follows to provide a tutorial in programming and machining:
Set Up the Machine
1.
Make sure the billet is securely fitted in the chuck. Check that the first tool to be used is the LH turning tool (this is the reference tool). and the second tool is the parting tool. Set these up as follows: Fit LH turning tool in position 1, Parting tool in position 7. (Refer to Figure 3.2 in Section 3 for tool positions in the turret). Set both tools into individual toolholders, then fix toolholders into suitable locations on the gang plate to permit their use in sequence. Set both tools into individual toolholders. Fit the LH turning tool and toolholder assembly into the X-axis slot of the toolpost (refer to Figure 3.4 in Section 3 for tool fitting and axis slot). During machining, the machine will stop and it will be necessary to remove and replace the reference tool with the parting tool assembly in the same X-axis toolholder slot. Run the Simulation and Manufacture software and check that it is correctly configured by selecting CONFIG from the main menu. (Refer to Installation and User Manual Section 5 - Configuring the 160 Software, if necessary). From the main menu, select MACHINE and then Tools to display the Tool Data Library. Check the settings of the LH turning tool and the parting tool, which should be as follows:
NO. 1 2 TURRET TYPE 1 7 1 11 DESCRIPTION LH TURNING TOOL PARTING TOOL X OFF Z OFF ( - as set - ) ( - as set - )
Turret: Gang Plate: Quick Change:
2.
Check Tool Settings
3.
If the settings are incorrect, refer to Section 3 - Axes and Tooling, 3.9 Setting Up: Select and Set LH Turning Tool, and Select and Set Parting Tool.
Boxford 160 TCL
Select the Program
4.
From the main menu select PROGRAM, then Program, and view Catalogue 1 to identify the demonstration program which is called DEMO:
5.
Select the program. The screen shows the Program display, with a 2D view of the component:
Boxford 160 TCL
View the Component
6.
Select VIEW to produce a 3D view of the component. After a pause, the display will show the 3D view:
Control buttons
Manipulate the 3D view as follows: Using a Mouse

Increase size Rotate anticlockwise Decrease size Restore to original size Rotate clockwise
Boxford 160 TCL
Using the Keyboard

Increase size Rotate anticlockwise Decrease size
HOME
Rotate clockwise
Restore original view
Note: The time taken for the display to respond will depend on the speed of the PC and whether a co-processor is fitted.
Show the Program Details
7.
Select
INFO
to show the program details:
8.
Turn off the program details display. (Click off the display window or press Return).
Boxford 160 TCL
Display the Program
9.
Select
MENU
, and then Display:
10.
Turn off the program display. Using a Mouse Click on the 'off' button Using the Keyboard Press
ESC .
Boxford 160 TCL
Simulate Machining - 2D
11.
Select
MENU
, then 2D Simulate:
Repeatedly click the mouse button or press Return to move through the program lineby-line. The simulation shows the tool movement and metal removed as each line of the program is executed. To move forward through the program to a specific line, select MENU , and then Go to Line. Type the required line number when prompted, and press Return. To produce a 3D view of the workpiece, select MENU and then 3D View. To return to the 2D view, click the mouse button or press Return. To run the simulation automatically, select MENU and then Fast Mode; the program will be run in a continuous sequence. To return to line-by-line simulation, select MENU and then Step Mode. To end the simulation before the end of the program, click on the 'off' button or press ESC . At the end of the program the screen returns to the program display.
Boxford 160 TCL
Simulate Machining - 3D
12.
Select
MENU
, then 3D Simulate:
Select MENU , and demonstrate the use of the options available as for 2D simulation, until the screen again shows the program display. 13. Turn off the program display. Refer to Section 9 - CNC and CAM Machining.
Machine the Component
Boxford 160 TCL
Axes and Tooling
3 Axes and Tooling

3.1. Axes and Datum
Axes: The toolholder can move in two axes, X and Z, (see Figure 3.1). Datum Position: On new machines, all Datum positions and Tool Offsets are set at the factory when tooling and clamping is ordered with the machine. The offsets of all required tools are set in relation to the machine X and Z datum. Before any Tool Offsets can be set, the Machine X and Z Datum has to be defined. These value are provided with the machine documentation and are printed on a label located inside the machine end guard.
+X
-Z
+Z
-X
Figure 3.1 Machines with Turrets:
Axes and Datum Position From the machines Home Position, the Machine Z Datum is the measured distance from the front face of the chuck jaws to the turret disc front face as shown in the diagram 3.2. The Y Datum is the measured distance from the spindle centreline to the centreline of the internal tool bores on the turret.
Boxford 160 TCL
3.1 Axes and Tooling
Tool Offsets:
The Tool Z offset is the distance from the Turret Disc front face to the Tool Cutting tip point. The X offset is the distance from the centreline of the internal tool bores on the turret to the Tool Cutting Tip Point (therefore theoretically all drills should have an X offset of Zero). The X offset is always twice the measured distance because the Boxford software uses X values specified in Diameter (not radius).
Datum Z Value Tool Z Offset Centre Line of Internal Tool Holder Tool X Offset TURRET
Datum X Value
Centre Line of Spindle
Figure 3.2
Turret
Boxford 160 TCL
Machines with Quick Change Tool Posts: From the machines Home Position, the Machine Z Datum is the measured distance from the front face of the chuck jaws to the front face of the machine cross slide as shown in the diagram below. (figure 3.3) The Y Datum is the measured distance from the spindle centreline to the bottom face of the tool post mounting plate.
Tool X Offset
Tool Z Offset Centre Line of Spindle
Datum X Value
Datum Z Value
Figure 3.3 Tool Offsets:
Quick Change The Tool Z offset is the distance from the Cross Slide front face to the Tool Cutting tip point. The X offset is the distance from the bottom face of the tool post mounting plate to the Tool Cutting Tip Point. The X offset is always twice the measured distance because the Boxford software uses X values specified in Diameter (not radius).
Boxford 160 TCL
External tools: 1, 3, 5, 7 Internal tools: 2, 4, 6, 8
5 6
7 8 1 Machines without homing switches: 1: Reference tool 7: Second tool
Figure 3.4
Turret Tool Positions
Boxford 160 TCL
3.2 Turret (Figure 3.4)

The turret is a motor driven, disc type toolpost with positions for up to eight tools, four external and four internal; each position is numbered. Tools can be accessed by indexing the turret using the TURRET INDEX push button on the machine controls or from the software.
Fitting Tools
External tools are secured in radial slots by tapered clamp blocks held by two fixing screws. Longitudinal positioning is achieved by pushing the tool towards the turret centre so that it touches the location stop. Internal tools are secured in their predrilled holes with tubular toolholders and two sunken screws. This will normally have been set at the factory and should require no adjustment. If it is found to be incorrect it is recommended that a Boxford service engineer is called. However it is permissible to adjust it by putting a tool into the working position, then inserting packing as appropriate between the turret toolpost and cross-slide. If this does not achieve correct tool height, or other tools heights are still incorrect, contact the factory.
Setting Tool Height
Boxford 160 TCL
3.3 Quick Change Toolpost

Fitting Tools (Figures 3.5 and 3.6)
The quick change toolpost has two slots to provide for convenient and rapid manual tool changing. A toolholder with a tool already secured in it by the four securing screws is placed into the shaped slots which provide instant positive location, and is rigidly held there by tightening the single clamping screw, using the clamp screw key provided. The toolpost will only accept a single toolholder at a time. External tools are fitted to the X axis slot while internal tools use the Z axis slot. A quick change toolpost can be fitted to the lower section of the X-axis cross slide in addition to a gang plate. Fit the LH turning tool into the standard flat bottomed toolholder by tightening the four securing screws onto the tool shank. The tool should protrude approximately 20mm (0.75in) from the toolholder face. Keep this dimension consistent for all the external tools. Put the toolholder into the toolpost and lock it into position using the clamping screw.
Tool Clamping Screw
Tool
Tool Securing Screws
Figure 3.5
Quick Change Toolpost
Boxford 160 TCL
Height Setting-External Tools Refer to Section 10 Manual Machining to move the tool manually to set the tool height,
which is checked by taking a light facing cut on the end of the workpiece. If adjustment is needed to centre the tool, use the centre height adjustment screw on toolholder as follows: Visually check the height to the workpiece centre point. The actual height from the top of the cross slide to the centre of the spindle is stamped on the left face of the bed adjacent to the headstock cover. Note: Do not confuse this value with the machine serial no. which is also stamped here.
1.
2.
To adjust the height slacken the toolpost clamp screw and the centre height adjustment screw. Turn the knurled adjustment knob clockwise to raise the tool, anticlockwise to lower it. When the height is correct tighten the Allen screw then tighten the toolholder clamp screw.
3.
Check that the tool is exactly on the centre line by taking a light facing cut on the end of the workpiece, using spindle in reverse direction. Repeat adjustment above as necessary.
Tool Clamping Screw Constant
Centre Height Adjustment Screw
Tool Securing Screws
Figure 3.6
Tool Fitting and Adjustment
Boxford 160 TCL
Height Setting - Internal Tools These tools can be fitted directly into the V location toolholders intended for use with
the drills. Although not essential, it is better if they are located into a tubular holder. This can easily be made as shown in Figure 3.7. Put a toolholder with its tool on to the toolpost and set the centre height to the workpiece centre line exactly as for external tools. Repeat this procedure for all of the tools.
Drill Tube
Figure 3.7
Internal Tool Fitting Detail
Boxford 160 TCL
3.4 Gang Plate (Figure 3.8)

This is a plate with drilled holes enabling up to three simple channel shaped toolholders to be clamped on to it. Tool positions are free, limited by hole line-up between toolholder and gang plate and by ensuring that every tool mounted can reach the work over the required range without fouling anything or causing other tools to foul something.
Fitting the Tools Setting Tool Height
Select a tool position and fit the channel toolholder using the securing screws. Clamp the tool into it with the four clamping screws. There is no tool height setting adjustment provided as this is pre-set at the factory. If correction is needed, contact the factory.
Securing Screws Clamping Screws Channel Toolholder
Figure 3.8
Gang Plate
Boxford 160 TCL
3.5 Spindle Rotation and Tool Orientation

Rotation (Figure 3.9)
The spindle can run forward (anticlockwise when viewed on chuck jaws) and in reverse (clockwise when viewed on chuck jaws). Direction and speed of rotation are controlled either by the SPIND FWD/SPIND REV buttons on the machine control panel (refer to Installation and User Manual Section 6 Machine Controls) or by means of M codes (M03 = Forward and M04 = Reverse) selected from software. For machining a workpiece held in the chuck with the tool fitted in the normal way, i.e. with the cutting edge uppermost, the direction of rotation is as follows: Direction External turning, toolholder at back External turning, toolholder at front Internal turning Reverse Forward Forward M Code M04 M03 M03
If tools are fitted upside down, take care to select the appropriate direction of spindle rotation.
Tool Orientation
Once the initial tool is specified, which then sets the direction of rotation, ensure that all subsequent tools are fitted in the same orientation to avoid the need to reverse the direction of rotation at tool changes while running a program.
Boxford 160 TCL
WORKPIECE IN CHUCK
REVERSE
+X
Tool holder at back
-Z
+Z
FORWARD
-X
Tool holder at front EXTERNAL TURNING INTERNAL TURNING
USING TAILSTOCK
REVERSE
+X
POSITIVE X VALUES ONLY
-Z
+Z
FORWARD
-X
NEGATIVE X VALUES ONLY
Figure 3.9
Spindle Rotation and Tool Orientation
Boxford 160 TCL
3.6 Tailstock (Figure 3.10)

The tailstock is bolted to the main slide. The upper part can be rotated about a longitudinal axis to its working or parked positions. When not required, the upper part is swung down and locked into its parked position to allow the toolholder its full travel along the Z axis. The tailstock contains a quill to hold a centre, and is adjusted manually in the Z axis.
Position Changing and Securing
Two fixing screws secure the two halves of the tailstock rigidly into the working position. Removing these screws allows the top half of the tailstock to be swung down to rest against the machine frame. This exposes a sunken Allen screw for securing the parked tailstock section in place.
Fixing Screws
Locking Screw
Flat on Handwheel
Figure 3.10
Tailstock
Boxford 160 TCL
3.7 Chuck
A manual or pneumatic chuck may be fitted. Pneumatic chucks are operated either by using the CHUCK OPEN/CHUCK CLOSE pushbuttons on the machine control panel (refer to Installation and User Manual Section 6 Machine Controls) or from within software by use of appropriate M code (M40 = Open, M39 = Close). Unless specified otherwise, pneumatic chuck jaws are prebored at the factory to 20mm diameter. Should work with larger diameter workpieces be undertaken, the pneumatic chuck jaws can be bored out to avoid the need to purchase another pneumatic chuck, as follows: 1. Press the CHUCK CLOSE button and set the jaws to position to provide sufficient material for boring. To move the jaws unfasten the two screws in the jaws, raise the jaws from the serration plates and position them accordingly, then refasten the screws ensuring that the jaws are equi-distant from the centre line of the chuck. Make a washer 1mm thick with bore the same diameter that the chuck is to be bored. The outside diameter of washer can be 30mm. Press the CHUCK OPEN button. Bore out the face of the jaws 1mm deep, 30.12mm diameter (0.12mm bigger than the outside diameter of the washer). Place the washer on to the machined jaw face and press the CHUCK CLOSE button to clamp the outside diameter of the washer. Revolve the chuck forward at approximately 2000 rev/min. Bore out the jaws using the washer bore as a gauge. Use the axis control buttons to provide tool movement with the FEED knob set to 75%. When boring is complete stop the spindle and press the CHUCK OPEN button to release the washer.
2. 3. 4. 5. 6. 7. 8.
Boxford 160 TCL
3.8 Tool Libraries

The 160 software provides a Tool Data Library which enables details of tooling and offsets to be entered and a Tool Library from which tools can be selected for inclusion in the Tool Data Library. The library is set up by means of a tooling menu. Before attempting to set up the tooling for the first time, view the libraries and the tooling menu to become familiar with the details, as follows: 1. Switch on the PC, run the 160 software. From the Simulation and Manufacture software main menu, select MACHINE and then Tools. The screen shows the Tool Data Library, (Figure 3.11). Practice selecting tools using the mouse and keyboard.
Tool Data Library
2.
1. Tool number used by CNC program to select required tool 2. Tool position on Turret (not used with Gang plate or Quick change tool holder) 3. Tool type and description (selected from tool catalogue) 4. Tool offsets 5. Scroll buttons
To select a tool: Using a mouse Click on the scroll buttons (5) to highlight the required tool, point to required tool and click mouse button. Using the keyboard Press Figure 3.11 or to highlight the required tool.

Tool Data Library
Boxford 160 TCL
Tooling Menu
3.
Select MENU to display the tooling menu:
The use of these options for setting and editing the Tool Data Library is detailed later in this section. Note: After setting up or editing the library, always select Save Tool data.
Tool Library
4.
From the tooling menu, select Tool Library. The screen shows the Tool Library, (Figure 3.12). Turn off the Tool Library display to reveal the Tool Data Library.
Figure 3.12
Tool Library
Boxford 160 TCL
3.9Axes and Tooling
3.9 Setting Up
Note: A billet of the appropriate size will be required for this procedure. In order to run the demonstration program, a LH turning tool and a parting tool are required. To run the program, set up the LH turning tool as the first tool and the parting tool as the second tool in the following procedure.
Fit Tooling
1.
Fit the required tools into the toolholding system supplied. With the quick change toolpost, fit the first tool required. After setting the offset of the first tool, it will be necessary to substitute the next tool before setting its offset. If the toolholder is too close to the chuck to allow the tools to be fitted, move the toolholder away from the chuck under manual control, (see Section 10 - Manual Machining).
2.
Check that the POWER RESET button on the machine control panel has been pressed to initialise the machine. Run the Simulation and Manufacture software. From the main menu select CONFIG and then Program. On the PROGRAM display, set UNITS MODE to the units required for tool offsets and programming. If a turret is fitted, select CONFIG and then Hardware, and check that TURRET is set to FITTED. Note: It is only necessary to set the datum position when the machine is first installed, or if the original setting is lost. In order to set the datum position, the information supplied with the machine will be required; this information consists of an X and a Z axis measurement. From the main menu, select MACHINE and then Datum Position. The screen shows:
Configure Software
3. 4. 5.
Set Datum Position

6.
Boxford 160 TCL
Enter the X and Z axis measurements supplied with the machine, and select SAVE . The screen returns to the main menu. 7. From the main menu, select MACHINE and then Tools to display the Tool Data Library. Defaults of the first tool will be highlighted, for example:
Check the settings. If they are correct, continue at step 15 to set the second tool. For the demonstration program, the settings should be as shown. 8. 9. Select the tool to be edited by clicking on it with the mouse, or on the keyboard use the keys to highlight the required tool and press Return. The screen shows the tool editing display, with the first item (Tool type) highlighted, (refer to Figure 3.13). Edit the display to show the required Tool type (and Turret position if applicable). Do not edit the offsets. 10. 11. Select
MENU
The screen shows:
, and then Set Tool Offsets.
Boxford 160 TCL
3.9Axes and Tooling
Follow the instructions, selecting AUTO mode on the machine control panel and pressing both X axis buttons simultaneously, then both Z axis buttons, to home the axes. 12. When the axes are homed, the screen shows:
Fit a billet into the chuck. Enter its diameter and length, and select Return. 13. The screen shows the tool offsets setting display, (Figure 3.14).
OK or press
On the machine control panel, select MANUAL mode. Using the X and Z axis buttons, follow the instructions appropriate to a drill or other type of tool to position the point of the tool on the reference diameter (the periphery of the billet).
Boxford 160 TCL
1 2 3
CANCEL To check tool type, press Escape or select MENU and Tool library to view tool library.
To check tool position, for Turret only, refer to Figure 3.2 Offsets for reference tool are zero.
, then select
To edit tool details: Type required number in highlighted box Press Return to accept last entry and highlight next box When last box is highlighted, press Return: highlight will disappear Press Return or click on OK to turn off display Figure 3.13 Tool Editing Display
Boxford 160 TCL
3.9Axes and Tooling
TOOLS OTHER THAN DRILLS
Tool position on axes
DRILLS
Tool position on axes
Figure 3.14
Tool Offsets Setting Display
Boxford 160 TCL
14.
When the tool is in the correct position, select ACCEPT . The screen shows:
Use the X and Z axis buttons to touch the point of the tool on the end of the billet, and select ACCEPT .
Set Additional Tool Offsets
15.
The screen again shows the Tool Data Library. To set the offset of the next tool, fit or index the tool and repeat the procedure from step 7. Note: For setting the offsets of the second and any subsequent tools, it will not be necessary to home the axes or enter the billet dimensions (steps 11 and 12). When the offsets of all the required tools have been set, either select MENU `and then Save Tool Data, or click the 'off' button of the Tool Data Library display. If the 'off' button is clicked, the screen shows the message:
Click on
YES
or press Return to save the offsets.
4 Main Front End Menu

When the Boxford CADCAM package is started, the Main Front End Menu screen below is shown. This menu is the central manager of the CADCAM tools within the Boxford TCL package.
File Import & Administration Functions Program Simulate, Manufacture and Machine Tool Driver
CAD and CAM Processor
Exit to Windows Desktop
Boxford 160 TCL
4 Main Front End Menu
In Standard User mode this menu accesses the File import filter. In Administration mode (See section 7) additional CAM processor data settings can be accessed and modified. Accesses the Integrated Computer Aided Design package and CAM processor. (See section 5)
Accesses the G&M program Simulator, Editor, Writer and Machine Tool driver. All the configurations for connecting the TCL machine to the PC are set in this section of the package (See Installation & User Manual).
Exits to the Windows desktop.
Boxford 160 TCL
CAD and CAM Processing
5 CAD and CAM Processing

5.1 Functions
The CADCAM programming features of the software provide the following functions:
New Programs
A new component is created by producing a profile on screen using the integrated CAD system. When the profile is complete, it is processed by the CAM system which converts it into a CNC program and saves it. The appropriate G and M codes are included, and speeds, feeds, roughing cuts and tool changes are incorporated into the program automatically. Profiles stored in a CAD format can be edited. Programs created by the CAM processor are presented in CNC format using absolute co-ordinates. Programs created by the CAM processor and stored in a CNC catalogue can only be viewed and edited in CNC format.
Existing Programs
Boxford 160 TCL
5.2 CAD and CAM Processing
5.2 Information Required

To create a new CAM program you will need the following information: 1. Drawing: The work datum is the centre of the right hand end of the bar. Since the profile is symmetrical about the centreline of the bar, only positive X coordinates need be dimensioned. All Z co-ordinates are negative, measured from the end of the bar:
dimensions required
+X
-Z
datum
The drawing should make allowance for completing the chuck end of the workpiece. If threads are incorporated, make allowance for undercutting between the end of the thread and any shoulder. For ease of programming, mark the co-ordinates of the start and end points of each element of the profile as shown in the example in 5.4. 2. Tools Used: Choose the appropriate tools for each machining operation, and set up the tooling as for CNC machining. Details of the billet: Outside diameter Inside diameter (if the billet is hollow or a tube) Length Hole Depth Material (aluminium, brass, mild steel or plastic).
3.
Boxford 160 TCL
4.
Program Name: A name for your program (This must be a valid filename, without a file extension. Configuration Settings: The STANDOFF option automatically adds the depth of cut to a 2mm standoff (clearance between tool and workpiece) when using canned cycles. This option, and other configuration settings, can be activated by selecting CONFIG - Program from the main menu of the Simulation and Manufacture software and making the required settings.
5.
Boxford 160 TCL
5.3 Creating a CAD Profile

Check Configuration Input Program Details
1. From the main simualtion and manufacture menu, select CONFIG Program, and select STANDOFF if required. From the main Front End Menu, select the CAD icon. To start a new profile, select File - New or select the icon Note:- If you want to open an existing file, select File - Open, or the icon, and locate the required file. The window below is displayed.
2.
Input the details as follows:DIMENSIONS:- As required. UNITS:- Metric of Imperial. COMPONENT INFORMATION:- This is a field which allows more detailed information about the profile to be entred alowing easier identification. It is NOT the program file name. CREATED BY:- Allows the user to name stamp their work. When the information is correct, OK is selected. This brings up the CAD Window.
Boxford 160 TCL
5.4 CAD Window

The CAD program window provides a clear view of the current drawing, various information areas, and a selection of icons with tools to cover the most common drawing, editing and display functions.
Grid Snap Menu bar Grid Spacing
Tool bar Absolute coordinates shows the position of the cursor relative to the workpiece datum (thecentre of the component front face)
Status Bar
Billet area
Help message bar
Billet Information
Menu Selection
Menu items are normally chosen from the menu bar or the tool bar, using the mouse (although keyboard alternatives are available). To choose a menu item from the tool bar, position the pointer over the appropriate icon and click the LH mouse button. Many items will cause the icon to stay depressed until an alternative mode is selected from another icon. Holding the mouse over an icon will bring up an icon Tool Tip.
Boxford 160 TCL
Initial Set-up
1. 2.
Before starting to use the CAD system, a number of Initial Set-up steps must be completed. Complete the following from the relevant menu:DRAWING TOOLS - SHOW GRID - Tick to show a drawing grid or untick to clear. CONFIGURATION - DEFAULTS - When in Administrator Mode (see section 7 of this manual), the current Billet Information, Colours and Grid Snap can be saved as the default setting for all New profiles. See below for details. UNITS - Check the units. Specify Millimetres or Inches. GRID SPACING - Specify the spacing for the Grid. The default value is 1.00mm as shown. Along the Z axis the pitch of the grid is equal to the value set. Along the X axis the pitch is half the set value, since each element of the profile is mirrored below the centreline of the workpiece. For example, setting the grid snap to 5.00mm produces the following grid:
+X
From the Tool Bar:-
1. 2.
-Z
centreline 5mm
2.5mm
Note: The setting can be edited later during the creation of a profile if required. 3. 4. BILLET DIMENSIONS - Check and modify the billet dimensions. COLOUR SELECTION - Modify the screen display colours. Prints the currently displayed view of the complete billet and any displayed dimensions.
Printing
Boxford 160 TCL
5.5 Drawing Aids

Drawing Aids
The tool bar contains a number of drawing aids which are active when selected (icon is highlighted). Undo - Undoes the last drawn or edited entity. Delete - Deletes the currently selected entity. Redo - Redoes the last drawn or edited entity. Zoom Window - Zooms in on a user defined window. Zoom In - Performs a quick and simple zoom in facility on the billet area currently being worked on. Zoom Out - Performs a quick and simple zoom out facility on the billet area currently being worked on. Grid Snap - Toggles locking the cursor movement to the grid on and off. Profile View - Toggles the billet view between half and full.
Advanced Zooms
A number of zooms to a specified percentage value can be selected from the drop down menu. Alternatively, FIT can be selected to fit the drawn entities and billet to the current screen area.
Status Bar
When defining points with the mouse, the status bar provides dynamic coordinate readouts for the X axis (diameter reading), Z axis and Radius when applicable. The currently active Zoom, Snap and Drawing Tool are displayed.
Node Position
Hovering the mouse cursor over a node (point) will display the node number and absolute co-ordinates.
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5.6 Drawing Tools

Drawing Tools
The Tool Bar contains a variety of drawing tools. The following drawing tools require points to be defined with the mouse (using the grid).
Help and Prompts
Help for each icon is displayed on the Help Message Bar to aid the user. Straight Line - Defines a single straight line - The Start and End point are specified. The start point MUST be the end point of the last drawn entity. The system prevents any point other than this from being defined as the start point. Arcs - Draws a single arc - The Start and End point are specified. The start point MUST be the end point of the last drawn entity. The arc direction and radius is set with the mouse amd fixed with the LH button. After drawing a single arc, the system reverts to Straight Line mode. Continuous Path - Draws a series of connected straight lines and/or arcs. The End point of each entity is defined with the LH button. Line and Arc mode are toggled between using the RH button. This mode is the default drawing mode for all new drawings and will be familiar to users who have worked with previous versions of Boxford software. Press ESC to exit. Thread- Draws external and internal threads along the Z axis - The Start and End point are specified follwed by the Pitch and Hand in the dialogue box shown below.
Note:
If the Thread tool is greyed out, the system has detected that due to lathe machining conventions, the next entity can not be a thread. If a right hand thread is selected, the two dotted lines represent the minimum undercut required for the specified thread. There must NOT be any entities drawn in this area. Fillet - Draws a fillet between two perpendicular lines - The fillet radius is entered and the required corner intersection selected. Chamfer - Draws a 45 chamfer between two perpendicular lines - The chamfer distance is entered and the required corner intersection selected.
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Co-ordinate Entry
As an alternative to defining an entity using the mouse, a coordinate entry sytem is available. Note:- Co-ordinates not on the current grid can be defined. Co-ordinate Entry - Defines Lines and Arcs using a coordinate entry system. The following dialogue box of options is available. (Note:- the Absolute point displayed is the end position of the last defined entity. If an arc is required, define the arc direction CW(clockwise) or CCW (counter clockwise) and the Arc radius. Ensure a valid arc radius that can pass through the start and end point is defined. To enter a number of entities,tick the 'Enter more points' check box.
Absolute Point (x,z): - Define the end point of the entity as an absolute coordinate from the billet datum (centre of front face). Length and Angle: - Define the cord length of an entity and the angle as shown in the diagram below. See next page for angle conventions.
Co rd L en
g th
End Point
L in
Angle
90
eo
rA
rc
Start Point
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Angle Conventions
For all co-ordinate entries requiring an angle, the conventions shown in the diagram below should be used.
0 270 270 90 0 180 90 270 90 0 180 0 90 0 90
Absolute Point (x,z): - Define the end point of the entity as an incremental move from the end of the last entity co-ordinate. Displace X and Angle: - Define an incremental move in X and the angle as shown in the diagram below. Note angles should be to the conventions shown above.
End Point X in
L in
90
eo rA rc
An gle
Start Point
Displace Z and Angle: - Define an incremental move in Z and the angle as shown in the diagram below. Note angles should be to the conventions shown above.
Z
Angle
End Point
Li n
eo
rA
90
rc
Start Point
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Auto Dimensioning
The Auto Dimensioning function toggles between three modes. Please note:- auto dimensioning is an extremely difficult operation for the system to complete on the large variety of profiles that can be defined on the CAD system. In some cases the position of the dimension will be a compromise to allow all dimensions to be displayed. 1. 2. Standard Mode - Dimensions the billet only (default start up mode). Incremental Mode - Dimensions all points on the profile with the Z dimension relative to the previous and next point as shown below.
2.
Absolute Mode - Dimensions all points from the billet datum.
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5.7 Editing Tools

Editing Node Positions
Moving the mouse cursor over a node (point), pressing and holding the Right Hand mouse button, allows the node to be dragged to a new position. Releasing the RH mouse button fixes the node to the new position. A node can also be moved using the co-ordinate entry system. See the section 'Editing Entities' - Properties below.
Editing Entities
Moving a mouse cursor over an entity and clicking the RH mouse button will highlight the entity and display the dialogue box shown below.
Depending on the type of entity selected, some of the options will be greyed out as they are not applicable to to the specified entity. Insert Node - Inserts a node at the midpoint of the entity which adds an additional straight line entity. Note if this option is used on an ARC, the arc will be converted into two diagonal lines as shown below.
Insert Fillet - Inserts a fillet between the selected entity and following entity. Thr radius is specified as shown below.
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Delete Object - Deletes the selected object, connecting the end point of the previous object to the start point of the next object as shown in the diagram below.
Convert to Line - Converts an arc into a diagonal straight line. Convert to Arc - Converts a diagonal straight line into an arc. Convert to Thread - Converts a horizontal straight line into a thread. The pitch and hand of thread are entred as shown below.
Note:- If a horizontal straight line does not have this edit option available, it is because it is not in a suitable position, in relation to other entities within the profile, to be threaded. Modify the Arc Radius - Unlocks the arc radius allowing it to be re-specified with the mouse position and fixed with the LH button. Properties - Displays the properties of the entity. The co-ordinates diplayed are the end point of the entity. Co-ordinates can be modidifed to move the end point to a new (valid) position. Arc radii and/or direction can be modified. See section 5.6 - Drawing Tool - Co-ordinate Entry for specific details on co-ordinate conventions. When an entity has been highlighted with the RH mouse button, the properties field is also accessible through the icon on the tool bar.
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5.8 3D Renderer
At any point during the design of a profile, a 3D rendred image can be viewed and manipulated. 'Launch 3D Render' is selected from the 'View' menu. If the profile has not being named and saved, the user is prompted to do so at this point. If the profile has been modified and not re-saved, the box below is shown.
Select YES to overwrite the old profile. Select NO to abort and use the File - Save As option to rename the file before launching the 3D Renderer. The 3D Renderer window, as shown below, is launched.
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The 3D Renderer defaults to an automatic animation mode which continually spins the model around the vertical axis. The user can overide the animation and manipulate the model with the tools provided from the window menus. These are as follows.
Model Control
Solid Render - Solid Renders the image as shown on the previous page. Wire Frame Render - Diplays a wire frame image as shown below.. This can be useful for speeding up the animation on computers which are close the the required minimum specification.
Animate - Initiates the default automatic animation mode. Freeze Animation - Stops the automatic animation allowing manual manipulation of the model. Print - Prints an image of the model in its current position. Textual model data is also produced. Copy Image to Clipboard - Copies an image of the model in its current position to the clipboard for pasting into 3rd party packages. Note the black background is converted to white.
Rendering Material Rotate Model
Allows the shading of the model to be changed to represent Steel, Plastic, or Wax. Wax is the default material. Jogg Left, Jogg Right, Jogg Up, Jog Down - Joggs the model in the required direction by one increment. Alternatively, use the keyboard hot key. Home - Re-sets the model position to its home position. Spin Left, Spin Right - Rotates the model around the Z axis (centre line). This is a useful for viewing a screw thread.
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Using the Mouse
In addition to the mouse menu and keyboard controls, the model can be manipulated using the mouse. Move the cursor over the model. Press and HOLD DOWN the LH mouse button. The model can now be dragged to any position. To fix in the required position, release the mouse button. Examples of the positional possibilities are shown below.
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5.9 Example (Figure 5.1)

Figure 5.1 shows a drawing of a component whose profile consists of straight lines, arcs and a thread. The co-ordinates of the start and end points of each element have been marked in the top half of the billet outline. The straight lines and arcs can be machined with the LH turning tool (1) and parting tool (11). To cut the thread it will be necessary to fit an external threading tool and to add this to the Tool Data Library. Start a new CAD Profile as detailed in 5.3 and use the File - Save option to name it EXAMPLE. Refer to 5.4, 5.5, 5.6 and 5.7 for guidance in producing the profile shown in Figure 5.1.
Co-ordinates shown in the format: X, Z

10mm x 0.75mm pitch RH
X +25
21,-39 17,-45 16,-29 21,-29 15,-9 10,-14 10,-16 0,-45 8R 8R 8,-4 8,-1 0,0
Z -50
Figure 5.1
Example of Drawing for CAM Program
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1. 2.
Place the cursor in the top half of the billet outline. A cross is displayed which is connected to the datum by a straight line:
3.
Watch the co-ordinate display and drag the cross-hairs to set the end point of the line in the correct position. The line will behave like a rubber band, and X and Z co-ordinates of the display will change as the cross is moved; when they read X = 8.00, Z = 1.00, select the LH mouse button. Ensure that grid snap is set to 1.00mm or less. The first line of the profile will remain on the display, and will be mirrored by a symmetrical line in the bottom half of the billet outline if displayed.
4.
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5.
Repeat this procedure to draw the next straight line of the profile, dragging the cross to the end point of each line and checking the co-ordinate display before selecting the LH mouse button:
If you make a mistake, select procedure.
to erase the last line and repeat the
Using the RH mouse button, select each object and selecte 'Delete Object'.
Manual Input
1.
Select
; the screen will show the co-ordinate entry window:
The absolute co-ordinates of the end point of the last element to be drawn are shown. Since no element has yet been drawn the co-ordinates are those of the datum. 2. Enter the absolute co-ordinates of the end point of the first line: X = 8, Z = -1, and select OK. The first line of the profile will appear, mirrored by a symmetrical line in the bottom half of the billet outline. 3. Repeat this procedure to set the end point of the next line of the profile: X = 8, Z = -4 to erase the last line, and repeat the
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Drawing Arcs
In Continuous Path Mode If the Arc Tool
,arcs are selected with the RH mouse button.
is selected from the tool bar, in addition to the procedure
detailed below, the start point must first be defined with a LH mouse click over the end point of the last drawn entitiy. An arc is drawn in three stages as follows: 1. Set End Points Drag the cross to the end point of the arc. Check the co-ordinates on the display. Adjust the position of the cross until the co-ordinates are correct, and fix the position with the RH mouse button.
Drag to end point of arc (15,-9) then release button
'rubber band' Start of arc (8,-4) end point of last straight line
2.
Select Direction and Radius Move the cross away from the end point (1); the cross will be joined to the end point by a straight line which is the tangent to the arc at the end point. Swing the cross around the end point (2); the arc will switch from counterclockwise to clockwise, and the radius will vary as the cross is moved:
1 Counter clockwise arc 2
Clockwise arc
For the example, select a counter-clockwise arc and set the radius at 8.00mm. Check the co-ordinate display for the correct setting: X = 15.00 Z = -9.00 ARC RADIUS = 8.00mm
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3.
Enter Setting When the setting is correct, click the LH mouse button. If you make a mistake, select to erase the arc, and repeat the procedure.
Draw the second arc, setting the end point at X = 10, Z = -14. Select a counterclockwise arc, and set the radius at 8.00mm. Using the RH mouse button, select each object and select 'Delete Object'.
Manual Input
1. 2.
Select The screen shows the co-ordinate entry window: The X and Z co-ordinates shown are those of the end point of the last element in the profile (A). Enter the co-ordinates of the end point of the arc (B): In the 'Arc Properties' section, shown below, select CCW (counter-clockwise) and enter the radius of the arc. (For the example, enter 8.00mm).
8.00
3.
Select OK: the arc will appear on the display, and will be mirrored by a symmetrical arc in the bottom half of the billet outline.
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4.
For the example, repeat the procedure to draw the second arc. Set the radius to 12.00mm and the co-ordinates of the end points to X = 10, Z = -14:
10,-14
to erase the last arc, and repeat the
Drawing Threads
1.
For the example, draw the next three straight lines of the profile in preparation for adding the threaded section:
2.
Select
and then the start point of the thread, last point:
The cursor is locked to the horizontal plane. Move the cross to the Z coordinate of the end-point of the thread (B) and fix with the LH mouse button.
B A
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3.
The window below is shown.
Select left hand or right hand thread as required. For the example, select right hand thread. Change the THREAD PITCH value if required, entering either a pitch (metric units) or threads per inch (Imperial units). For the example, set the pitch to 0.75mm 4. Select OK ; the specified thread will appear on the profile.
5.
For the example, draw the remaining straight lines to complete the profile:
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3D Renderer
Select 'Launch 3D Render' from the 'View' menu. If required, name and save, the profile at this point. The Renderer window below is shown.
Select Model Control - Freeze Animation. Using the controls described in section 5.8, try manipulating the model. In paricular, try rotating the model using the keyboard + and - keys to animate the screw thread.
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5.10 CAM Processing a Profile

When the CAD profile is complete and ready to be processed into a G&M code CNC programme, select File - Process Billet. If the profile has not being named and saved, the user is prompted to do so at this point. If the profile has been modified and not re-saved, the box below is shown.
Select YES to overwrite the old profile. Select NO to abort and use the File - Save As option to rename the file before re-processing. The CAM Processor Dialogue box shown below is displayed.
The various settings are as follows:-
Material
Selecting the drop down provides a list of the available material types. (See section 7 - 'Administrator Mode' for more details on adding user defined materials and cut data). The required material is selected from the list.
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Material Dimensions
The material dimensions shown are those specified in the CAD system, unless the profile was drawn up to the left hand end of the billet, in which case a suitable parting off allowance is automatically added. The material dimensions can be modified prior to processing. This can be useful if the billet size, the component was designed for, is not available. If a larger one is specified, the CAM processor will automatically add the extra roughing cycles to remove the additional material.
Tools
Selecting the Tools Tab displays the tools currently available to the CAM processor for creating a G&M programme from a drawn profile. The window below is shown.
When logged on to the sytem as a 'standard user', this window is for information only. When logged on as an administrator (see section 7 for details), the user can define which tools are available to the CAM processor by heighlighting them. Depending on the type of component to be processed, a minimum number of tools are required. e.g. To process external profiles, the minimum tooling requirements are:1. LH Turning Tool (55 tip angle) 2. Parting Tool 3. External Threading Tool (If threads are to be cut).
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Rough and Finish Turning When in Administrator mode, if two LH Turning Tools are available, one can be set to perform the Rough Turning Process and the other se to perform the Finish Turning Process. If a second LH Turning Tool is highlighted, window below is shown.
Roughing or Finishing is selected. The second LH Turning Tool is automatically set to the alternative option.
Machine Info.
Selecting the Machine Info. Tab displays the current machine parameter which effect the CAM processor. The window is shown below.
When logged on to the sytem as a 'standard user', this window is for information only. When logged on as an administrator (see section 7 for details), the user can modify the settings. FMS Connected - When checked the CAM inserts the appropriate M81 codes to communicate with the Robot port (see section 11 - Robot interfacing). Tailstock Fitted - When checked the CAM will not face-off the billet end or specifiy operations using internal tooling.
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Processing
To process the profile and create a G&M CNC programme, is selected. The processor analyses the Drawing and produces a G&M code CNC programme specifying Cutter Paths, Speeds, Feeds and Cut Depths appropriate to the material type selected and the tooling available.
Tool Path Simulation
When the profile has been processed the following dialogue box will be displayed (Please note if processing reveals any errors this dialogue box will be proceeded by an error message dialogue box - see section 5.11 for details).
The user is prompted to select a Catalogue number to place the file into. Catalogues - All manufacture programs (G&M programs) are filed in Catalogues. There are 9 catalogues available to the user. A catalogue is selected. If a file of the same name already exists in the selected catalogue, the following dialogue box appears.
1 2 6 7 8 9
The file can be overwritten by selecting YES or NO can be selected bringing up the following dialogue box.
The filename can be changed and/or the catalogue changed. OK is selected.
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A 2 Dimensional simulation of the cutter path is shown. This is the final user check of the component that will Actually Be Machined. Any areas which can not be removed because of tooling limitations will be omitted.
3 Dimensional View
For details on 3D Views, View Manipulation and Cycle Details see sections 2 and 9.
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5.11 CAM Processor Error Messages

When Processing a drawing, the CAM processor compares the drawn profile requirements with the Cutting Tools available and machine parameters set. If any drawing requirements can not be satisfied, then an error message (or messages) is displayed.
Billet Size
If the billet specified in the CAM processor is too small then the window below is shown.
Select Accept to revert to the minimum billet size or Retry to return to the CAM window and re-specifiy the dimensions.
Tooling
If there are insufficient tools available to machine the profile, an error message is displayed. An example is shown below.
These are explained as follows. INTERNALS CANNOT BE ACCURATELY CUT - Drills are not available to machine the specified drilled holes in the profile. NO CENTRE DRILL FOR DRILLING LARGE HOLES - Centre drill not in library and selected as available. NO EXTERNAL THREADING TOOL - External threading tool not in library and selected as available. (could also be Internal Threading Tool).
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The user can continue processing by selecting A program with the compromised settings (safe) is produced. or, The user can abort processing by selecting Reprocess.
Ignore.
Profile Shape
If areas of the profile can not be machined, an error message is displayed. An example is shown below.
These are explained as follows. INTERNALS CANNOT BE ACCURATELY CUT - Drills of the correct size are not available to machine the specified drilled holes in the profile. If this warning is ignored, the drilled holes will be machined with the nearest diameter smaller drill. INTERNALS SHAPING TOO SMALL FOR BORING BAR- The internal profile above the maximum drill diameter and below the minimum boring diameter cannot be shaped with the boring bar. See section 7 for minimum bore details. INSUFFICIENT UNDERCUT FOR RH THREAD - The drawn profile has entities crossing the minimum undercut, shown on the drawing by two dotted lines. CANNOT SHAPE CHUCK END OF BAR - The left hand end of the profile has a shape which can't be cut without the workpiece falling off. To part off the profile, the last drawn entitie must be a vertical straight line. The user can continue processing by selecting A program with the compromised settings (safe) is produced. or The user can abort processing by selecting Reprocess. Ignore.
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6 DXF File Imports
6 DXF File Imports

DXF Files DXF (Drawing Exchange Format) is a file format for transferring drawing information between CAD and CAM packages. Almost every CAD package will be able to export a DXF file. Which ever drawing package you export from, there are some guidelines which will help you to successfully export DXF files suitable for importing into the Boxford CADCAM package. The Boxford CADCAM package requires the DXF file to include half the profile together with a horizontal centre line, as shown in the following examples. 1. External Profile Only - To Parted Off
Half the Profile
File Export Rules
Horizontal Centre Line
2.
External Profile Only - NOT to be Parted Off
Half the Profile
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6 DXF File Imports
3.
Combined External and Internal Profile - To be Parted Off.

Half the Profile
4.
Combined External and Internal Profile - NOT to be Parted Off.
Half the Profile
5.
External Profile manufactured from Tube - To be Parted Off.

Tube Internal Radius
Half the Profile
Leave Gap Here
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6 DXF File Imports
6.
External Profile manufactured from Tube - NOT to be Parted Off.

Half the Profile Tube Internal Radius
7.
Combined External and Internal Profile manufactured from Tube - To be parted off.
Leave Gap Here
8.
Combined External and Internal Profile manufactured from Tube - NOT to be Parted Off.
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6 DXF File Imports
Problem - Different CAD packages have a variety of Centre Line Types some of which (or even all) do not export as a Centre Line (they export as a series of Continuous straight lines which make up the centre line). The Boxford CADCAM package looks for a centreline in the DXF file to reference the centre of the profile. If one is not found, the file Import is aborted. Solution - Try different types of Centre Line and Find one that works. Alternative Solution - If the Boxford CADCAM package does not find a centre line, it will look for a line of different colour, or a line on a drawing Layer other than the Half Profile Layer. Draw the centre line as a different colour to the profile, or/and draw the centre line on a different layer.
Half the Profile
Continuous - The half profile must consist of entities which are connected together to form a continuous path. There can be no gaps or entity overlaps or the File Import will be aborted A gap between entities could be as small as the drawing package resolution and not visible on a high resolution monitor unless a high magnification drawing zoom is active.
G ap between Entities
Overlap of Entities
Connected Entities
Incorrect
Incorrect
Correct
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6 DXF File Imports
Half Profile Errors
Profiles NOT conforming to Lathe cutting Conventions - There are a number of entities which will cause a profile processing error. The Boxford CADCAM package will abort the File Import in each case. Examples of incorrect profiles are shown below - avoid these to successfully import DXF files. Holes - These Cannot be smaller at the front face of the profile than at the bottom of the hole. Internal diameters cannot have recesses.
Holes
Incorrect
Incorrect
Correct
Internal Straight Lines - The end point nearest the centre line cannot be Z+ve (to the right) in relation to the other end point.
Internal Straight Lines
Z-ve Incorrect
Z+ve
Z-ve Correct
Z+ve
Z-ve Correct
Z+ve
External Straight Lines - On a line facing the front face of the profile, the end point nearest the centre line cannot be Z-ve (to the left) in relation to the other end point. On a line facing the rear face of the profile (e.g. the first line of a recess or the line defining the end of the profile), The end point nearest the centre line cannot be Z+ve (to the right) in relation to the other end point.
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6 DXF File Imports
External Straight Lines
Z-ve Incorrect
Z+ve
Z-ve Correct
Z+ve
Z-ve Correct
Z+ve
Arcs - These must adhere to the same rules as straight lines, however it is not just the start and end point which can cause the error, it is any point around the arc radius. Generally, if at any point around the path of a continuous arc the Z co-ordinate sign changes (-ve to +ve or vice versa), the arc will be invalid. On some arcs this may be very difficult to see unless viewed under a high magnification within the CAD package. Some examples are shown.
Internal Arcs
Z-ve Incorrect
Z+ve
Z-ve Incorrect
Z+ve
Z-ve Correct
Z+ve
External Arcs
Z-ve Incorrect
Z+ve
Z-ve Correct
Z+ve
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6 DXF File Imports
Importing DXF Files
From the CAD window, File - Import - DXF is selected. The file to be imported is located and OPEN selected. The window below is shown.
The units of the imported file are defined and OK selected. Note:- If there are any Profile Errors, a message is displayed and the file import aborted. The profile is displayed and can be edited and processed like any other profile created within the Boxford CADCAM package.
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Administration Mode
7 Administration Mode
7.1 Access & Password Setting
An administration mode is built into the Boxford CADCAM package allowing authorised personnel to access and modify important CAM processor data files. Any modifications that are defined will be applied to every future processed drawing. Network Administrators Setting a Password To be able to use the Boxford administration mode and write to the relevant data files, you must have read/write access to the Public Drive With the Front End menu screen displayed, the F10 key is pressed, to define a password, or modify and existing one. The dialogue box below is shown.
is selected. The dialogue box below is shown.
The user is prompted to Enter CURRENT Password. If an initial password is to be defined,

OK
is selected.
OK
If an existing password is to be re-defined, the existing password is input and selected.
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7.1 Administration Mode
The dialogue box below is shown.
The user is prompted to Enter NEW Password The new Password is input OK selected followed by :Accessing Admin. Mode Each time the software is started, the system defaults to Standard User mode. With the Front End menu screen displayed, Administration mode is accessed by:a. b. c. d. Pressing the F10 key Selecting Inputting the current password and selecting Selecting
OK
Selecting the Configuration Icon reveals a number of icons in addition to the Standard User Import DXF file option (see section 6 for details).
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7.2 Tool Library

Accesses the tool library shown below.
New tools can be defined and existing Tools modified or removed. Defining a New Tool Using the LH mouse button or keyboard cursor, Highlight an empty tool library line. Select
Edit Tool
The dialogue below is shown.
From the Tool Type drop down, select the Tool type to be defined. Input the Tool Diameter (if appropriate to the tool) Edit an existing Tool Remove an existing Tool Saving Highlight the tool to be edited and Select Highlight the tool and select
Remove Finish Edit Tool
To close and save the tool library data, select
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7.3 Material Cutting Data

Accesses the Material Cutting Data shown below. This data is used by the CAM processor when creating a G&M code CNC programme from a Profile.
For each Material Type, Cutting data for Roughing and Finishing operations can be specified for different Tool types. New materials can be added and existing ones Modified or Deleted. Tool Type The Tool Type is selected from the drop down menu.
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Material
The Cutting Data file supplied with the software package includes a selection of Default material types. User-defined materials can be added up to a maximum of six material types in total.
Adding a New Material Add Material is selected. The dialogue box below is shown.
The user is prompted to Enter material to add to list. The material name is input and
OK
selected.
Deleting an Existing Material The material to be deleted is selected using the Material drop down menu. Delete Material is selected. The dialogue box below is shown.
YES
is selected to confirm the material delete.
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Feed
The rate at which the axes move when cutting in mm/rev (mm per revolution). Values can be set for Roughing and Finishing operations.
Speed
The Constant Surface Speed in m/min (metres per minute) or the Constant Spindle speed in RPM (revolutions per minute). The units will automatically toggle depending on the Tool type selected. Values can be set for Roughing and Finishing operations.
Depth of Cut
The maximum depth of cut. The value is the maximum amount of material which can be removed on diameter (i.e. it is 2 x the radial depth of cut). Values can be set for Roughing and Finishing operations. Note:- Unlike Feed and Speed, Depth of Cut is Material specific and not Tool type specific. (i.e. there is only one Roughing and Finishing value per material).
Restoring Defaults
Restore Defaults is selected to return All the Cutting Data currently shown in the Cut Data dialogue box to the Factory settings
Saving
To save the modified Cutting Data, select To exit without saving changes, select
OK
Cancel
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7.4 Internal Machining Data

Accesses the Internal Machining data shown below.
Warning
The Internal Machining Data is set at the factory to match the tooling supplied with the TCL Machine and should only be modified if the internal tooling on the machine is changed. The maximum diameter Drill available on the TCL Machine. The minimum internal diameter the Boring Bar will machine. The minimum internal diameter the Internal Threading Tool can cut a thread at. is selected to return All Internal Machining Data to the Factory
Max. Drill Size Min. Bore Size Min. Thread Size Restoring Defaults
settings
Restore Defaults
Saving
To save the modified Cutting Data, select To exit without saving changes, select
OK
Cancel
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7.5 Park Position and Units

Park Position Accesses the park position settings shown below.
The Park Position is the position of the Tool in relation to the workpiece datum (front left corner) at Tool Changes and the Start/End of Cycle. X, Y and Z values are specified. Restoring Defaults Restore Defaults is selected to restore the Factory settings. Saving To save the modified Cutting Data, select To exit without saving changes, select Units
OK
Cancel
Accesses the units settings for Administration mode as shown below.
Metric or Imperial units are selected.
OK
saves the setting.
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7.6 Language Settings

Language Settings Accesses the Language options for the software. Note:- This sets the language for the CAD and CAM software but not for the G&M Code CNC Programme Simulator and machine driver which has its own configuration menu. See Installation and User manual for details. The icon is selected displaying the dialogue box below.
From the drop down menu, the required language is specified.
OK
is selected to confirm the selection.
For the new setting to take effect, the software must now be restarted by exiting to the windows desktop and re-starting the software.
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Manual Data Input CNC Programming
8 Manual Data Input CNC Programming

8.1 Operations and Programming Sheets
Before commencement of programming the following points require consideration: 1. Drawing The work datum is usually centre of the right hand end of the bar; this makes it easier to set the tools. If necessary re-dimension the drawing from this datum.
-Z +Z +X
-X
2.
Machining Decide on the sequence of the machining operations (e.g. rough turn, finish turn, screw cut, part off.)
3. 4.
Tooling Choose appropriate tools for each machining operation. Programming Decide on incremental or absolute dimensions, feed mm/min, spindle speed rev/min. Use an operations sheet and a programming sheet to record your decisions. Blank sheets are included at the back of this manual for photocopying.
Boxford 160 TCL
8.2 Manual Data Input CNC Programming
8.2 Absolute and Incremental Co-ordinates

Before programming commences points on the contour have to be defined either in: (a) absolute co-ordinates relative to the workpiece datum, or (b) incremental co-ordinates relative to the previous position Examples of the two types of co-ordinate systems are shown below:
C B A C
+X
15 25
20
20 10 POINT DATUM A B C X 0 20 20 30 Z 0 0 -10 -30 POINT DATUM A B C X 0 20 0 10 Z 0 0 -10 -20
-X
10 ABSOLUTE COORDINATES POINT DATUM A B C X 0 15 15 25 Z 0 0 -10 -10
INCREMENTAL COORDINATES POINT DATUM A B C X 0 15 0 10 Z 0 0 -10 0
G90 must be inserted at the start of the program when using absolute co-ordinates. G91 must be inserted at the start of the program when using incremental co-ordinates.
30
-Z
+Z
Boxford 160 TCL
8.3 Speeds and Feeds

When writing a program the values for spindle speeds and Feed rates have to be entered. These values will vary depending upon the workpiece material and the type of cutting tool being used.
Spindle Speeds
With experience, a programmer will use values which are known to produce the required balance between surface finish, tool wear and production time, but for the beginner the following cutting speeds are offered as a guide.
CUTTING SPEED (METRES/MINUTE) CUTTING TOOL ALUMINIUM BRASS CAST IRON MILD STEEL (FREE CUTTING) 200 50 CARBON STEEL (MEDIUM) 125 40
CARBIDE H.S.S.
300 80
250 70
125 40
To calculate spindle speeds use the following formula: Spindle speed = m/min x 1000 x dia. of workpiece or feet/min x 12 x dia. of workpiece 600 x 12 x 1=2291rev/min.
e.g. for 25.4 (1in) dia. mild steel (EN1A) using carbide copy turning tool: Spindle speed = 200 x 1000 or x 25.4=2506rev/min. program say, 2500 or 2300 rev/min.
Feed Rates
Feed rates are expressed in millimetres per minute and, as with spindle speeds, the feed rate will vary with the material being cut, the depth of cut and the type of cutting tool used. Again, with experience the programmer will quickly determine the values to use for the various cutting functions.
Boxford 160 TCL
8.4 Program Format

A program is a series of "blocks" or lines each showing a set of functions and/or coordinates. Input of the program is usually in tabular form (although the CONFIG menu allows a change to compact format). A typical format for the 160 machine set up for turning is: LINE G M X Z I K F S These are the headings used on the programming sheet, where: LINE is the block or sequence number, and G M X I K F S the preparatory function the miscellaneous function the X co-ordinate (diameter value) interpolation parameter or additional information as needed interpolation parameter or additional information as needed feed rate (mm/min) spindle speed (rev/min)
Boxford 160 TCL
8.5 Preparatory Functions (G Codes)

Note: The G codes can be displayed on the PC screen from the HELP menu. The address letter G is followed by two digits, and the following codes can be used: G00 G01 G02 G03 G04 G70 G71 G81 G82 G83 G84 G90 G91 G94 G95 G96 G97 Rapid movement Linear interpolation F = Feed rate Circular interpolation (clockwise) I & J are co-ordinates of centre or I = radius from the start point Circular interpolation (counter clockwise) I & J are co-ordinates of centre or I = radius from the start point Time dwell F = delay (secs) Imperial programming units Metric programming units O.D. Turning cycle X = Total Depth Z = Total Length I = No. of Cuts F = Feed rate Face/ Grooving Cycle X = Total Depth Z = Total Cut Length I = No. of Cuts F = Feed rate Peck Drilling Cycle Z = Total Depth I = Drill Dia K = Reduction F = Feed rate Threading Cycle Z = Total Length I = Dia Depth K = No. of Cuts F = Pitch Absolute Programming Incremental Programming Feed/min Feed/rev Constant Surface Speed Constant RPM
Boxford 160 TCL
8.6 Miscellaneous Functions (M Codes)

Note: The M codes can be displayed on the PC screen from the HELP menu. The address letter M is followed by two digits, the following codes can be used:M02 M03 M04 M05 M06 M30 M39 M40 M81 M97 M99 End of program (Single Quantity) Spindle start forward. Enter spindle speed S Spindle start reverse. Enter spindle speed S Spindle stop Tool change I = Tool Type End of program (Repeat) Close Automatic Chuck Open Automatic Chuck Turn output on/off Continuous manufacture Continuation code. K = Drill Diameter
Entering M99 into a partially written program causes the program to be saved to disk. Recall of the program is simulated on the screen up to the break off point and then the prompt to "continue writing" is made.
Boxford 160 TCL
8.7 Canned Cycles

Codes G81 - G84 are referred to as 'canned cycles'. These codes are built in to the control system of the lathe; their use simplifies the programming of repetitive operations. In each case the tool must be positioned at the start point of the cycle on the previous line of code at a point 2mm (0.1in) from the work. This point is called the stand-off point. All information within the canned cycle is incremental. On completion of the cycle the tool will return to its start point.
G81 Outside Diameter
Using this code enables several cuts to be taken automatically provided that the Z axis movements are the same. The start point in the X axis is at the 2mm stand-off point and the tool is programmed to this location on the previous line. After entering G81 the following additional information is needed. X value = Z value = I value = total cut depth, ie. the difference between the original diameter and the final diameter (excluding the stand-off). total length of travel in the Z axis, i.e. cut length plus any stand-off in the Z direction. number of cuts required. feed rate.
F value =
Cancel G81 with G80.
G82 Facing or Grooving
Facing: The start point (programmed on the previous line) is from a stand-off position in the Z axis. After entering G82 the following additional information is needed: X value = total cut depth - it is usual to go past the centre line by 0.5mm to clear the end, i.e. enter a value of the stand-off diameter plus 1mm. total cut width (excluding the stand off). number of cuts. feed rate.
Z value = I value = F value =
Boxford 160 TCL
Grooving: This canned cycle is used to cut a rectangular section groove of width exceeding 3.6mm. Before entering the canned cycle routine it is necessary to create a slot of width 2mm plus the width of the tool to the required depth. This is accomplished using the parting off tool and programming using codes G00 and G01. Remember that the parting off tool is 1.6mm wide and that during the offset routine the reference face was set as the side nearer the chuck. After cutting this narrow groove take the tool to its stand off position. Enter G82 and then add the following values: X value = Z value = I value = F value = the difference between the stand-off diameter and the diameter of the bottom of the groove. the additional width of the groove, e.g. 10mm-3.6mm = 6.4mm. number of cuts required. feed rate.
G83 Peck Drilling
This code is used to drill holes deeper than twice the drill diameter. From the standoff point (X = 0, Z = 2) the first movement takes the drill in the -Z direction a distance equal to twice the drill diameter. After withdrawing from the hole (to remove swarf) the drill returns and cuts further in the -Z direction by an amount which is determined by: K multiplied by the first depth This 'pecking' is repeated until the total depth Z is reached. After entering G83 follow with: Z value = I value = K value = total depth of hole (exclude the stand-off). drill diameter. reduction: a decimal value. This is the percentage by which the second and subsequent pecks are reduced, until the required depth is reached, e.g. 0.9 or 0.99. feed rate.
F value =
Boxford 160 TCL
G84 External or Internal Thread Cutting
External Thread: The start point for the threading cycle in the X axis is 2mm greater than the outside diameter of the point on the diameter of the material to be cut (the stand-off point). This position is programmed on the line previous to the G84 being called. After entering G84, follow with: Z value = I value = total length from stand-off (negative for left hand thread, positive for right hand thread). depth of thread (measured on diameter, e.g. 1.23 for 1mm pitch). number of cuts. The minimum is 10 cuts and this is suitable for up to 1mm pitch. For larger values of pitch increase the value of K pitch.
K value =
F value =
Cutting tool is tool no. 4, speed (S) value is 300/400 rev/min. Internal Thread: This is programmed in the same way as the external thread except that the tool is tool no.10. Note that the I value (depth) must be negative. Cancel G84 with G80.
Boxford 160 TCL
8.8 Inputting a New Program

8.8.1 Information Required To input a new program, you will need the following information: 1. A completed programming sheet containing Program details Type of co-ordinates used (absolute or incremental) Tools used Speeds and feeds Details of the billet Outside diameter Inside diameter (if the billet is hollow) Length A name for your program (7 characters maximum - do not use spaces, . \ or / in the name.) The type of format for the program display. The options are tabulated format and compact format. Tabulated format is easier to read and therefore more suitable for the earlier stages of programming. The programming sheets used in the Tutorials and Exercises use tabulated format. Compact format is more typical of the type of display used in industry, and is suitable for the more advanced programmer. The type of format can be changed by selecting CONFIG - Program from the main menu, and setting the DISPLAY TYPE to TABULATED or COMPACT as required. A program can be input and saved in either format, and can be displayed in either format by changing the DISPLAY TYPE. The main procedure (8.8.2 on the following page) deals with the use of tabulated format, and the example used is taken from Tutorial 1 (TUT 1). Instructions for using compact format are given in 8.8.3. Other configuration settings required. In MODAL PROGRAMMING, each of the following codes need only be typed once. Each code is then repeated automatically in subsequent lines until a different code is typed:
2.
3. 4.
5.
Boxford 160 TCL
Manual Data Input CNC Programming
G01 G02 G03 F
: : : :
Linear interpolation Circular interpolation (clockwise) Circular interpolation (counter-clockwise) Feed rate
This option can be activated by selecting CONFIG - Program from the main menu, and making the required settings. 8.8.2 Tabulated Format Check Configuration 1. From the main menu, select CONFIG - Program, and check the following settings: UNITS MODE PROGRAMMING MODE DISPLAY TYPE GRID SNAP STANDOFF MODAL PROGRAMMING Input Program Details 2. From the main menu, select PROGRAM - Program, and from the catalogue select NEW PROGRAM. The following display will appear: = as required (METRIC for TUT 1) = as required (ABSOLUTE for TUT 1) = TABULATED = as required = as required = as required
Type the name of the program and press Return.
Boxford 160 TCL
3.
Click on OK or press Return. The next display will appear:
The display shows the dimensions of the last billet used, with the value of outside diameter highlighted. If required, change the diameter by overtyping. When the correct value is shown, press Return; the next item (I-Dia) will be highlighted. Set the remaining two values in the same way. If the billet is not hollow, set the internal diameter to zero. Note: The values can be edited by using the mouse or the and overtyping. and keys to highlight the required values,
Click on OK or press Return, and set the depth of hole when prompted. Input Program 4. Click on OK or press Return. The screen shows the Program WRITE display, (Figure 8.1). The first line number (block number) N10 appears automatically at the left of the display, and the text cursor is in the G column.
Boxford 160 TCL
* !
1. 2. 3.
Text cursor Simulation display * indicates that program has changed since it was last saved - save again if required. ! indicates that program has changed since simulation was last drawn select VIEW - Redraw to update display. Deletes last line entered. Redraw - updates simulation display to include latest program changes. 3D view - changes simulation display to 3D view. Displays information for reference during programming (see text). Options for saving and editing programs (see text).
UNDO VIEW HELP MENU
Figure 8.1
Program WRITE Display
Boxford 160 TCL
When typing in the program, precede each item with the letter at the top of the corresponding column. The cursor will move automatically to the appropriate column when the letter is typed in. Type in the first line of the program. For example, the first line of the program for TUT 1 is: N 10 Type: G90 As the code number is typed, a message appears giving the meaning of the code. (Other messages give indications of errors such as incorrect feed speeds). When the line is complete, press Return. The next line number appears automatically and the cursor moves to the G column in the next line. Type the second line of the program. For TUT 1 the second line is: N 20 G 71 G 90
Type: G71 (Return). Type the third line. The third line of TUT 2 is: N 30 X 30 Z 10
Type X30 Z10 (Return). The cursor moves automatically to the X and Z columns. When Return is pressed the next line number appears and the cursor moves to the G column. CAUTION REMEMBER TO SAVE YOUR PROGRAM BEFORE SWITCHING OFF THE PC, EVEN IF IT IS NOT COMPLETE. (SEE 8.9 SAVING A PROGRAM).
Boxford 160 TCL
Correcting Errors You can place the cursor anywhere in the program, and correct errors by overtyping or by deleting characters with the Backspace (Delete) key and re-typing. Using a Mouse Click on the required item in the program to place the text cursor at that position. Using the Keyboard
and keys to move the text cursor vertically, and the Use the keys to move from column to column.
and
Although the display shows only three lines of the program, you can scroll the program to show any line by using the and keys.
For more extensive changes, use the editing facilities available from the MENU option, (see 8.11 Editing a Program).
Boxford 160 TCL
HELP HELP provides the following information which you may need to refer to when creating a program: G Codes M Codes Tool Library Program Data meanings meanings graphical display of tools with tool numbers and descriptions Title Workpiece dimensions Program length (no. of lines) Estimated manufacture time Tools used Maximum bar size Minimum and maximum feedrates and speeds
Machine Data
MENU The features available from the MENU option are used for saving a program (see 8.9) and editing a program (see 8.11). 8.8.3 Compact Format To input a program in compact format, first check the software configuration as for tabulated format but set the DISPLAY TYPE to COMPACT. Input the program information in the same way as for tabulated format. When the Program WRITE display appears, the panel where the program is input looks like this:
Compare this with Figure 8.1. The line number and the text cursor appear, but there are no columns with identifying letters.
Boxford 160 TCL
When typing in the program, precede each item with the letter at the top of the corresponding column on the programming sheet. There is no need to leave spaces between items in the line. When each line is complete, press Return. The next line number appears automatically and the cursor moves to the first (G) column in the same way as for tabulated format. In addition, spaces are automatically inserted between items, and numerical values standardised to show two decimal places. For example, in lines 30, 40 and 50 of Tutorial 1 (TUT 1): Line 30 type: X30Z10 Return 40 type: M04X20Z2S2000 Return 50 type: G01X20Z-15F70 Return N30 N40 N50 X30.00 Z10.00 M04 X20.00 Z2.00 S2000 G01 X20.00 Z-15.00 F70
Display shows:
Error correction, and the other features of the Program WRITE display are the same as for tabulated format.
Boxford 160 TCL
8.9 Saving a Program

The last line of a program must consist of one of the following codes: M99 - if the program is unfinished M02 - for single part manufacture M30 - for multiple part manufacture Note: If you try to save a program which does not end with one of these codes, the software adds the code M99 to the end of the program. There are three ways to save a program: a) b) At the last line of the program type M99, M02 or M30 as required and press Return; the program will automatically be saved. (This is the recommended method). from the MENU option, select Save program. The display will show the message: automatically
Click on OK or press Return; the program will be saved with code M99 added at the last line.
Boxford 160 TCL
c)
Using a Mouse Click on the 'off' button at the top left hand side of the display:
Using the Keyboard Press

ESC
The display will show the message:
Click on YES the last line.
or press Return; the program will be saved with code M99 added at
Boxford 160 TCL
8.10 Examining an Existing Program

From the main menu select PROGRAM - Program, and from the catalogue select the required program. The screen shows the following display with a drawing of the component beneath it:
The options available enable the program to be examined as follows: VIEW INFO MENU Produces a 3-D view of the component. Displays program details. Display Edit Continue 2D Simulate 3D Simulate lists the program see 8.11 Editing a Program see 8.12 Continuing a Program simulates machining in 2D simulates machining in 3D
To use these options (except for Edit and Continue), refer to Section 2 - Running the Demonstration Program.
Boxford 160 TCL
8.11 Editing a Program

A new program which has been partly written can be edited, and an existing program can be edited, by using the MENU editing options described in 8.11.3 below. To access the options, refer to 8.11.1 New Programs or 8.11.2 Existing Programs as appropriate. 8.11.1 New Programs From the program WRITE display (Figure 8.1), select
MENU
8.11.2 Existing Programs Refer to 8.10 Examining an Existing Program, and select MENU - Edit. The screen shows the Program EDIT display:
1 Scrolling Buttons* 2 3 4
Scrolling Page down Line down Line up Page up
*Mouse Operation Keyboard Operation 1 2 3 4

Page Down
Page Up
Boxford 160 TCL
Amendments to the program can be made in the same way as detailed in 8.8.2 Tabulated Format - Input Program. Using a mouse, the text cursor can be moved to the required line by means of the scrolling buttons as indicated. To access the editing options, select 8.11.3 MENU Editing Options
MENU
Insert Line Inserts an additional line, and renumbers subsequent lines. Place the text cursor on the line above the required new line and press Return. Clear Line Deletes program data from a line, but leaves the line number intact. Place the text cursor on the required line and press Return. The prompt: "ARE YOU SURE? YES/ NO' provides a safeguard against accidental deletion. Go to Line Places the text cursor on a specified line:
Type in the required line number and press Return.
Boxford 160 TCL
Delete Line Delete a program line data and number from the program. Place the text cursor on the line to be deleted, and press Return. The prompt "ARE YOU SURE ? YES/NO" provides a safeguard against accidental deletion. Find and Replace Searches for a specific program item and enables it to be replaced by another specific item:
For example, to find all occurrences of code M03 (spindle start - reverse) and replace them with code M04 (spindle start - forward), starting the search from line 90 of the program, type in the following: Find Replace with Start line no. M03 M04 90 Return Return Return
Boxford 160 TCL
SELECTIVE Search A selective search will stop at each occurrence of the code, with the message:
To change the code to the replacement code and search for the next occurrence, select REPLACE. To leave the code unchanged and search for the next occurrence, select CONTINUE. At the end of the search a report will be displayed; for example:
Click on OK or press Return. GLOBAL Search A global search will find each occurrence of the code and replace it with the replacement code. At the end of the search a report will be displayed as for a selective search. Header Edit Enables the name (title) of the program, and the dimensions of the billet (bar) to be changed. (Refer to 8.8.2 Tabulated Format - Input Program Information).
Boxford 160 TCL
8.12 Continuing a Program

An incomplete program which has been saved can be continued at the point where inputting was interrupted. Refer to 8.10 Examining an Existing Program, and select MENU - Continue. The display will simulate the completed part of the program in 2D, stopping when the last line is reached. The M99 code will be deleted from the last line of the program, enabling inputting to be continued.
Boxford 160 TCL
9.2 CNC and CAM Machining
9 CNC and CAM Machining

The procedure for machining a component produced by a CNC program or a CAM program is the same. The 160 software executes a CNC program to manufacture the component; CAM programs are converted to CNC format when they are saved, (see Section 5 - CAD and CAM Processing).
9.1 Initial Checks

Before attempting to machine a component, check: Reference 1. 2. 3. 4. PC connected to 160 TCL, power switched on and 160 software running. 160 software correctly configured. Tooling and offsets for required program set and checked. Program verified: CNC program - verified by simulation. CAM program - automatic validation. 160 machine initialised. (Select MACHINE - Reset Machine if necessary). Billet of correct material and dimensions fitted in chuck. Select PROGRAM - Program, then to check dimensions. INFO Guards closed. Machine in Automatic mode. (Press MAN button on machine control panel). Installation and User Manual Section 6 Installation and User Manual Section 5, 5.1 Installation and User Manual Section 5, 5.3 Section 3
Section 8, 8.10 Section 5, 5.9
5.
6.
7. 8.
Boxford 160 TCL
9.2 Manufacture
1. 2. From the main menu, select MACHINE, then Manufacture. The screen shows the MANUFACTURE CATALOGUE display. Select the required program. The software will read the machine file for the component, and the screen will then list the tooling with the tools required by the selected program highlighted, for example:
Boxford 160 TCL
3.
Provided that the offsets have already been checked as detailed in 9.1, select OFFSETS CORRECT . The screen shows:
Follow the instructions. The display shows the dimensions of the billet required by the selected program. Fit the billet in the chuck, enter the length of the billet, and check that the appropriate tool is fitted or indexed. 4. Select
OK . The screen shows:
Follow the instructions, using the buttons on the machine control panel. Press both X axis buttons simultaneously, then both Z axis buttons, to home the axes.
Boxford 160 TCL
5.
When the axes reach the home position, the screen shows a message indicating that the machine is being initialised. When the machine has been initialised, the screen displays the MANUFACTURE display with prompt:
6.
Press CYCLE START on the machine control panel. The machine performs the machining cycle which is simulated simultaneously on the screen display together with the program line currently being executed. When the machining cycle is complete, the screen shows a message giving the option of manufacturing a further component if the program ends with the code M30. Select Yes or No as required. If Yes is selected, the screen will prompt for another billet to be fitted. If No is selected, the screen returns to the main menu. Note:- If yes is selected when the system is in Administrator mode (See section 7.1) the user is given the option to modify the Datum and Tool offsets. Select Yes or No, as required
7.
Boxford 160 TCL
9.2 9.3 CNC and CAM Machining
9.3 Options During Machining

Pressing ESC on keyboard during a machining cycle causes a Status message to be displayed:
Continue: Abort:
Programmed machining continues. Stops machining and cancels program.
Select option by clicking on appropriate button using the mouse or by pressing its first letter on the keyboard.
Boxford 160 TCL
10 Manual Machining
10 Manual Machining
The manual machining feature enables the 160 machine to be controlled directly using the controls on the machine control panel (refer to Installation and User Manual Section 6 - Machine Controls). It is not possible to run the machine from the PC once Manual mode is selected; the PC simply displays tool movement and spindle speed. Selecting Manual Machining: From the main menu, select MACHINE - Feedback. The screen shows the Manual Mode Display, (Figure 10.1).
1. 2. 3. 4.
Tool position on axes Spindle speed indication X ZERO button Z ZERO button
Figure 10.1
Manual Mode Display
Boxford 160 TCL
10 Manual Machining
Set the X-axis reference point with the first tool manually using the X+, X- buttons on control panel so that tool tip just touches the workpiece diameter. Using the mouse click on X ZERO , or press X. Set the Z-axis reference manually with the Z-, Z+ jog buttons on control panel to just touch the workpiece endface. Using the mouse click on Z ZERO , or press Z. The reference point is registered and displayed as zero in both X and Z axis displays. As the tool is moved with the X and Z jog buttons, the X and Z axis co-ordinates in the display alter correspondingly, giving a continuous and precise location of the tool tip position. The tool feed rate can be increased or decreased with the 0 to 100% FEED control, while the tool can be moved rapidly in either axis when away from the workpiece using the RAPID button in conjunction with the X and Z jog buttons. Direction of spindle rotation and speed are controlled using the SPIND FWD/SPIND REV and STOP buttons. Its speed in revs per minute is displayed on the PC screen under the SPEED heading. Use the correct speed range for the operation. A pneumatic chuck when fitted is opened and closed with the CHUCK OPEN/ CHUCK CLOSE button. When a tailswitch is fitted and used, the quill is operated manually by its handwheel. If it is the air powered version, the quill is operated from the control panel using the QUILL left/QUILL right buttons. The turret is indexed round one position at a time to any of the 8 tool positions with each press of the TURRET INDEX button. Using Turret Using Gang Plate QC Toolholder Either stop machine and manually fit another tool, or use the X and Z jog buttons to access another tool already fitted to the Gang Plate. Whenever a tool change is required, use the STOP button to stop the spindle, lift the guard and manually replace the tool assembly. To return to Automatic mode, press MAN button until lit then POWER RESET button.
Boxford 160 TCL
Robotic Interfacing
11 Robotic Interfacing
11.1 Principles of Interfacing
The interface of Boxford machines into Cim Cells is quite simple although several things have to be taken into consideration. The following document outlines the way to connect, program and operate the Boxford machines within a Cim. When a robot port is fitted to a Boxford machine, a 37 way D connector is fitted to the rear of the machine. The pin out and circuitry is described later. The Robot interface provides all the inputs and outputs that would normally be required to connect to a cim, some of which will not be used in a basic system. If additional functions are required it would normally be possible to customise the port after consulting with the Boxford Design Department.
11.2 Hardware and Software Requirements

Hardware
The computer being used to run the machine must have 2 com ports and if a mouse is fitted it must be a bus mouse. In the case of the 8 machines the 2nd com port is fitted to the rear of the machine as standard. If a management system is being used to transmit programs to the machine tool then it must have an RS232 port available and assigned to Com1 or Com2.
Software
When using a machine within a Cim Cell then the configuration of the Boxford software must be set to say the FMS (Flexible Manufacturing System) is connected. The Machine Datum information must be set. The reasons for the above are as follows: When the FMS is set to Connected in the configuration. the function of the M30 command changes. At the end of manufacture the machine will no longer run through the prompts asking if you wish to make another, alter offsets or alter datums, the prompt Press Cycle Start to continue appears. This allows the Robot controller to issue a Cycle start without user intervention. In addition to this when a program is designed in cam the machine busy flag (M81) is automatically set and unset in the program.
Boxford 160 TCL
11.3 Robotic Interfacing
11.3 Modes of Operation

There are two ways to run a program within a Cim, one is with for a system with a Master Control Computer the other for a simple machine / Robot combination. 1. If the system is simple then the machine can be set up manually then started with an external cycle start signal, at the end of manufacture the prompt make another appears. The robot can then issue a cycle start signal to make another or if a different component is to be made then the user must intervene and re set-up the machine for the next part. For a more complex system the program is downloaded from a master control computer, the cycle is started using the Go in Auto signal. The whole cycle will now run through with no user set-up required. To make another the Go in Auto is resent. If a different program is to be made then the new program is sent to the machine by the RS232 link then the Go in Auto start the new program again with no user intervention. IMPORTANT! When using the go in auto command it is very important that the following things are done. If not a collision could occur. 1. 2. The machine Datum Positions and Work Shift are correctly set. The component billet details have been correctly specified when writing the program (the Billet size and material type must be exactly the same as the component to be manufactured). The Billet is exactly the size specified in the program. The billet is correctly positioned in the machine chuck. The Go in Auto command uses the program header to get the billet information, by so doing the need to make measurements at the start of manufacture is not required.
2.
3. 4.
Boxford 160 TCL
11.4 Programming Requirements

The machine busy signal is created in the G and M code program, an M81 command with I set to 1 indicates that the machine is busy or in cycle, If I is set to O then it indicates the machine is not busy. If a program is created in the Cam and the configuration is set to FMS connected, then the M81 commands will automatically be inserted. If the program is created using Manual Data Input, then the M81 will have to be inserted manually.
Notes
1.
After issuing a Cycle Start or Go in Auto there will be a delay before the busy flag is set. After the program is finished the busy flag will switch off there will again be a period of time after the program is finished, as the machine moves to its park position, when the machine is moving but the flag is off. The controller program must take account these delays when deciding when to service the machine. Typically the Cycle start signal or Go in Auto will be latched until the busy flag is set. After the Busy flag switches off there should be typically a 5 second delay prior to the robot servicing the machine.
2.
The Programmed park position in X and Z may need to be edited to give a position that the robot can easily access to load and unload the machine. Programs created off-line must use the same tools that are available in the machine tool library. The programs sent down the RS232 from the master control computer will not be received correctly if they use unavailable tools.
3.
Boxford 160 TCL
11.5 Connection Requirements

The connections to the 37 way D connector are as indicated below. PIN 1 2 3 4 5 6 7-11 12 13 14 15 16 17 18 19-21 22-25 26-37 FUNCTION M81 machine busy when on Guard Opened signal when on Guard Closed signal when on Chuck Opened signal when on Chuck Closed signal when on Machine Alarm (Air Low) when on Spare Go in Auto Cycle start request Open Guard request Close Guard request Open chuck request Close chuck request Feedhold request Spare Machine 0V Spare INPUT/OUTPUT O/P O/P O/P O/P O/P O/P I/P I/P I/P I/P I/P I/P I/P
The machine inputs are internally opto isolated using an ILQ 74 device. The anode of the internal diode is connected to the machine internal 24V rail via a pull up resistor. To activate any machine input the relevant input must be connected to the machine OV on pins 22-25 of the 37 way connector. The machine outputs for mills are pulled down to machine ground by a Darlington transistor Array type ULN 2803. These inputs will sink 500mA maximum and are internally pulled up to 24V. When a machine output is activated the pin on the 37way is pulled down to ground.
Boxford 160 TCL
11.6 RS232 File Transfer

The file transfer from one computer to another can be done in two ways, the first being with two computers running the Boxford Software the second is when one computer is running a control program and the other is running Boxford software. Cable Connection for RS232 File Transfer. 9 Way Female Pin 2 3 5 7 8 Colour RED BLU GRN YEL WH 9 Way Female Pin 3 2 5 8 7
LINK PINS 1, 4 and 6 at each connector. When using this file transfer the configuration of Hardware must first be set. The above cable must be connected to Com 1 or Com 2 of each computer. There are two types of possible file transfer which allow for Simple file transfer or Remote management of the manufactured programs.
1. Simple File Transfer
The machine tool controller should be configured so that the RS232 file transfer is set to the correct port, the machine will be connected to the other Com port. If transferring Programs from a remote computer running the Boxford software to the Machine Tool Controller, the remote computer must also have the RS232 file transfer set to the correct Com port. With both the Machine Tool Controller and remote computer displaying the opening software screen, select File, Export, RS232 from the top menu bar. Select the relevant program from the catalogue display. The program will now automatically be transferred into the current catalogue on the machine tool controller.
2. Remote Management
If transferring programs from a computer not running Boxford software to the Machine Tool Controller, the Machine Tool Controller must have the configuration set correctly and be on the opening screen awaiting a program.
Boxford 160 TCL
The remote computer will use the Transmit.exe program supplied by Boxford. From a Dos prompt type transmit then return to get help information. Type Transmit DEMO.GM1 O This will send the DEMO program out to the computer controlling the machine tool via Com port 1. Transmit is the command used to send the file. The Program name (DEMO) could be prefixed by for example C:\160H\160H\DEMO.GM1 this would transfer the program from the specified directory. The file extension GM indicates that it is a G and M code listing and the 1 indicates it is stored in catalogue 1. The final O indicates the com port used. NOTE: COM1=O, COM2=1.
Note:
Only use the transmit function when the CNC machine is not in cycle and the Machine Tool controller controlling is displaying the opening screen.
11.7 Fully Automated Manufacture

To use a system for fully automated manufacture the Cim Cell will have a master controller which is connected by RS232 to the Machine Tool Controller. The method of calling a program for manufacture is as follows: The command from the master computer is executed: 1. TRANSMIT DEMO.GM10 (program Part is transmitted automatically down Com 1 to the computer controlling the machine.) Connect pin 12 of the 37way D to ground (Go in Auto) The current program will now be manufactured. Once manufacture has started the M81output will switch on: at this time the input pin 12 should be disconnected from ground. To make another repeat 2. To make a different program repeat from 1, but transmit another program name.
2.
3. 4.
Boxford 160 TCL
CNC Tutorials and Exercises
Boxford 160 TCL
Tutorial 1 - CNC Tutorials and Exercises
Tutorial 1: Linear Interpolation Tabulated and Compact Program Display

This tutorial introduces the student to simple part programming using the G01 preparatory code (linear interpolation) and also the G00 code (rapid movement) which is the default value if G01 is not selected. The program is for the profile from A to E and does not include any roughing cuts. Do not use this program to machine a component.
E D
A T/C X30 Z10
25
24
15
15
The absolute co-ordinates of the points on the profile are tabulated below:
POINT X Z DATUM 0 0 A 20 0 B 20 -15 C 24 -30 D 24 -35 E 25 -35
Tool used: 1 (LH Turning Tool)
20
Boxford 160 TCL
The program is written as follows:-
DRAWING NUMBER SEQUENCE DESCRIPTION

ABSOLUTE PROGRAMMING METRIC UNITS TOOL CHANGE POSITION MOVE TO START - START SPINDLE A TO B B TO C C TO D D TO E SPINDLE STOP - TOOL CHANGE END PROGRAM
PROGRAMMING SHEET DUET PROGRAMMING SHEET-TURNING

TITLE.
TUT 1
MATERIAL:
STEEL EN1A ALUMN
WRITTEN BY AXIS COORDINATES X Z I
SHEET No. 1 OF 1 FEED RATE K F SPINDLE SPEED S
SEQUENCE PREP MISC No. FUNCTION FUNCTION N

10 20 30 40 50 60 70 80 90 100 01 01 01 01 05 02 04
G
90 71
30 20 20 24 24 25 30
10 2 -15 -30 -35 -35 10 70 70 70 70 2000 2500
Boxford 160 TCL
Note: The first tool is selected when setting up the machine. G00 is the default value if G01 is not selected. Using a compact display (CONFIG menu - Program - DISPLAY TYPE-COMPACT) the program will be:
N10 G90 N20 G71 N30 X30 Z10 N40 M04 X20 Z2 S2500 N50 G01 X20 Z-15 F70 N60 G01 X24 Z-30 F70 N70 G01 X24 Z-35 F70 N80 G01 X25 Z-35 F70 N90 M05 X30 Z10 N100 M02
Boxford 160 TCL
Exercise 1:
Simple Programming - Absolute Co-ordinates
1. 2. 3.
Tabulate the absolute co-ordinates of points A to E on the profile. Using a programming sheet write a program to machine the profile. Enter the program into the computer and simulate the tool movements. (Do not attempt to machine the component)
E D C B A T/C X15 Z15

25 20 15
10
18
10
Boxford 160 TCL
Tutorial 2: Incremental Co-ordinate Programming

The incremental co-ordinates of the points on the profile are tabulated below.
POINT X Z DATUM 0 0 A 20 0 B 0 -15 C 4 -15 D 0 -5 E 1 0
The program is written as follows: DUET PROGRAMMING SHEET-TURNING PROGRAMMING SHEET

TITLE.
TUT 2

ABSOLUTE PROGRAMMING METRIC UNITS TOOL CHANGE POSITION START POINT - SPINDLE START MOVE TO A INCREMENTAL PROGRAMMING A TO B B TO C C TO D D TO E ABSOLUTE PROGRAMMING SPINDLE STOP - TOOL CHANGE END OF PROGRAM
MATERIAL:
STEEL EN1A

10 20 30 40 50 60 70 80 90 100 110 120 130 01 91 01 01 01 01 90 05 30 04
G
90 71
30.0 20.0
10.0 2.0 0 70 2000 2500
0 4.0 0 1.0
-15.0 -15.0 -5.0 0
70 70 70 70
30.0
10.0
Boxford 160 TCL
Exercise 2:
Simple Programming - Incremental Co-ordinates
Using the component shown in Tutorial 1: 1. 2. 3. Tabulate the incremental co-ordinates of points A to E on the profile. Using a programming sheet write a program to machine the profile. Enter the program into the computer and simulate the tool movements. (Do not attempt to machine the component)
Boxford 160 TCL
Tutorial 3: Turning and Facing a Stepped Shaft

This tutorial introduces the student to the completion of operation and programming sheets and the writing of a program for a component requiring roughing and finishing cuts. The operations sheet lists the sequence of machining operations, feed, spindle speed and the tool required. It also gives details of the material and its position in the chuck. A roughing and a finishing cut have been asked for on each diameter. The programming sheet lists the program to machine the component; an explanation of each line has been given in the left hand column. The datum is at the right hand end of the component.
Boxford 160 TCL
DRAWING NUMBER BILLET
DUET OPERATIONS SHEET - TURNING

MATERIAL 25
STEEL EN1A ALUMINIUM
TYPE NO. 1 0 I/DIA. 40 STICKOUT SPINDLE SPEED 2500
TITLE TUT 3 TOOL FEED 70 TOOL NO. 1
O/DIA.
OPERATION NUMBER 1 2 3 4 5 6 7 8 9 10 FACE TURN
OPERATION DESCRIPTION
23.5 x 35 22 x 35 20.5 x 31 19 x 30 CHAMFER 1.5 x 45 O TO 23 TURN 17 x 10 15 x 10 TOOL PARK POSITION END PROGRAM
RAPID
40 35 30 45O 10
25
19
22
15
Boxford 160 TCL

ABSOLUTE PROGRAMMING METRIC UNITS TOOL PARK POSITION START SPINDLE RAPID TO START POSITION FACE END OF MATERIAL RAPID CLEAR OF FACE RAPID TO FIRST CUT DIAMETER CUT 23.5 X 35mm LONG RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT DIAMETER X 35mm LONG RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT DIAMETER X 21mm LONG RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT DIAMETER X 20mm LONG CUT CHAMFER X 45 O RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT DIAMETER X 10mm LONG RAPID CLEAR OF WORK POSITION FOR NEXT CUT ( 15) CUT DIAMETER X 10mm LONG TOOL PARK POSITION/STOP SPINDLE END PROGRAM
DUET PROGRAMMING SHEET-TURNING PROGRAMMING SHEET

TITLE.
TUT 3
25 40 ALUMN. MATERIAL: 25 XX 40 STEEL EN1A
WRITTEN BY AXIS COORDINATES X Z
A.N, OTHER
SHEET No. 1 OF 1 FEED RATE SPINDLE SPEED S
MISC SEQUENCE PREP No. FUNCTION FUNCTION N

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 01 05 30 01 01 01 01 01 01 01 04
G
90 71
30.0
10 2000 2500
26.0 -1.0
0 70 1
23.5 -35 24.5 22.0 -35 23.0 20.5 -31 21.5 19.0 -30 23.0 -32 1 17.0 -10 18.0 15.0 -10 30.0 10 70 1 70 70 70 1 70 1 70 1 70
TUT3 T2
Boxford 160 TCL
Exercise 3:
Turning and Facing a Stepped Shaft
The component for this exercise is similar to that in Tutorial 3. 1. 2. 3. Write an operations sheet for this component Write a program to machine the component Give your program a test run in the computer and edit it if necessary.
25
20
15
15 25 35 40
10
Boxford 160 TCL
Tutorial 4: Circular Interpolation

This gives an explanation of the G02 and G03 codes for clockwise and anticlockwise circulated interpolation respectively. The programs are for the profile only and do not include any roughing cuts. Do not use these programs to machine a component. Circular Interpolation (G02 and G03) To program an arc it is necessary to define a FINISH point by an X and Z dimension and, in addition either (a) I and K values which give the co-ordinate of the arc centre from the start point in the X and Z directions respectively; (these are unsigned) or (b) the radius of the arc as an I value. The start and finish point of an arc must be in the same quadrant. A semi-circle requires two blocks to be programmed. G02 Clockwise Circular Interpolation
C R3 A B T/C X30 Z10
25
25
POINT X Z DATUM 0 0 A 17 0 B 17 -22 C 25 -25
Tool used: 1 (LH Turning Tool)
19
Boxford 160 TCL
The program is written as follows:DRAWING NUMBER SEQUENCE DESCRIPTION

ABSOLUTE PROGRAMMING METRIC UNITS TOOL CHANGE POSITION START POINT-SPINDLE START A TO B B TO C SPINDLE STOP-TOOL CHANGE END PROGRAM

TITLE.
TUT 4/1
MATERIAL:
ALUMN STEEL EN1A

10 20 30 40 50 60 70 80 01 02 05 30 04
G
90 71
30 19 19 25 30
10 2 -22 -25 10 3 0 70 70 2000 2500
Note: In block N70 I and K are the co-ordinates of the arc centre measured from the start of the arc. This program is for the profile only and does not include any roughing cuts.
Boxford 160 TCL
G03 Counter Clockwise Circular Interpolation

D C R3 B A E T/C X30 Z10
25
20
POINT X Z DATUM 0 0 A 17 0 B 23 -3 C 23 -20 D 25 -20 E 17 -3
Tool used : 1 LH Turning Tool
17
23
Boxford 160 TCL
The program is written as follows:PROGRAMMING SHEET DUET PROGRAMMING SHEET-TURNING

TITLE.
TUT 4/2

ABSOLUTE PROGRAMMING METRIC UNITS TOOL CHANGE POSITION START POINT - SPINDLE START POINT A A TO B B TO C C TO D SPINDLE STOP - TOOL CHANGE END PROGRAM
MATERIAL:
STEEL EN1A ALUMN

10 20 30 40 50 60 70 80 90 100 01 03 01 01 05 30 04
G
90 71
30 17 17 23 23 25 30
10 2 -0 -3 -20 -20 10 3 70 70 70 2000 2500
70
Note: I3 in a block N60 is the radius of the arc. This program is for the profile only and does not include any roughing cuts.
Boxford 160 TCL
Exercise 4:
Circular Interpolation
This exercise involves using both the G02 and G03 codes. 1. 2. 3. Tabulate the absolute co-ordinates of points A to D on the profile. Using a programming sheet write a program to machine the profile. Give your program a test run in the computer and edit it if necessary.
D R3 B C E
25 19
R3 A
25
Boxford 160 TCL
Tutorial 5: Circular Interpolation and Roughing Cuts with a Tool Change

This tutorial gives a further example of circular interpolation and also illustrates how to rough surplus material from the billet so that the maximum depth of cut of 3mm on the diameter is not exceeded. Suppose that it is required to take roughing cuts before turning an arc of 4mm radius on a steel component. A scale drawing of the arc section will reveal the variations between the lengths of roughing cut. In the drawing below, the horizontal lines represent the depths of cut and the vertical lines the lengths of roughing cuts.
An alternative method is to take chamfering cuts on the surplus material. This is generally more difficult to program because the X co-ordinates are measured on the diameter and so are double the corresponding Z co-ordinates to give a 45 degree chamfer. The drawing on the next page is used to determine the length of the roughing cuts; 2mm is left on the diameter before the final finishing cut is taken. The operations sheet shows the details of the roughing cuts and a program for the component is given. Test run the program and examine its operation.
Boxford 160 TCL
19 X19, Z-35
25 23 21 X19, Z-27
19 17 15 13 X11, Z-23 X11, Z-4
X11, Z-27
11 8 X3, Z0
X3, Z-4
Programming a Tool Change The first tool to be used enters the program as part of the initial programming information. The second and subsequent tools are entered on the program with two lines of information. The first line stops the spindle and moves the tool away from the work, and the second line selects the next tool. A typical example of this is:LINE N70 N80 G M 05 06 X 30.00 Z 10.00 I 5 K F S
I5 denotes a centre drill
Boxford 160 TCL
DUET OPERATIONS SHEET - TURNING OPERATIONS SHEET

MATERIAL 25

O/DIA. 0 I/DIA. 40
TYPE NO. 1 STICKOUT SPINDLE SPEED
OPERATION NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 FACE TURN
2500 2000
23 x 35 21 x 35 19 x 24 17 x 23 15 x 22 13 x 22 11 x 2 8x1 TAKE CONTINUOUS FINISHING CUT TOOL PARK POSITION CHANGE TOOLS PART OFF TO LENGTH TOOL PARK POSITION END PROGRAM
2500 3000
90 RAPID 50 RAPID 11
2000 2500
37 35 23 R4
25
19
11
R4
Boxford 160 TCL
DRAWING NUMBER

TITLE.
TUT 5
MATERIAL:
STEEL EN1A ALUMN
SEQUENCE DESCRIPTION
ABSOLUTE PROGRAMMING METRIC DIMENSIONS TOOL CHANGE POSITION
START SPINDLE RAPID TO START POSITION

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 01 01 01 01 01 01 01 01 04
G
90 71
30.0 26.0 -1.0
10.0 0 70 1.0 2000 2500
FACE END OF MATERIAL RAPID CLEAR OF FACE RAPID TO FIRST CUT DIAMETER CUT 23 X 35mm LONG RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT DIAMETER X 35mm LONG RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT DIAMETER X 24mm LONG RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT DIAMETER X 23mm LONG RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT DIAMETER X 22mm LONG RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT DIAMETER X 22mm LONG RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT DIAMETER X 2mm LONG RAPID CLEAR OF FACE
23.0 -35.0 24.0 21.0 -35.0 22.0 19.0 -24.0 20.0 17.0 -23.0 18.0 15.0 -22.0 16.0 13.0 -22.0 14.0 11.0 -2.0 13.0 1.0 70 1.0 70 1.0 70 1.0 70 1.0 70 1.0 70 1.0 70
Boxford 160 TCL

POSITION FOR NEXT CUT CUT DIAMETER X 1mm LONG RAPID CLEAR OF WORK
POSITION FOR NEXT CUT (FINISHING CUT)

TITLE.
TUT 5
MATERIAL:
STEEL EN1A
WRITTEN BY AXIS COORDINATES X

8.0
SHEET No. 2 OF 2 FEED RATE I K F

70

280 290 300 310 320 330 340 350 360 370 380 390 400 410 420 05 30 01 03 01 03 01 05 06 04 01
SPINDLE SPEED S
Z
--1.0
9.0 3.0 11.0 11.0 19.0 19.0 30.0
1.0 0 -4.0 -23.0 -27.0 -35.0 10.0 11 4 4 90 90 90 90 2500 3000
FINISH CUT 4mm RADIUS FINISH TURN 11 FINISH 4mm RADIUS FINISH TURN 19 TOOL CHANGE POSITION I11 IS A PARTING TOOL
MOVE TO PARTING POSITION - SPINDLE ON (TOOL 1.6mm WIDE)
27.0 -1.0 30.0 30.0
-38.6 70
2500 2000
PART OFF RAPID CLEAR OF WORK SPINDLE STOP - TOOL CHANGE END PROGRAM
10.0
Boxford 160 TCL
Exercise 5: Circular Interpolation and Roughing Cuts with a Tool Change

This exercise involves the use of clockwise circular interpolation, tool changing and parting off. 1. 2. 3. Complete an operations sheet for roughing and finishing the component below. Using a programming sheet write a program to machine the component. Give your program a test run and edit it if necessary.
R4 R3
25
17
16 32.4 40
11
Boxford 160 TCL
Tutorial 6: Canned Cycles - Facing and Rough Turning

This tutorial serves as an introduction to Canned Cycles which simplify the programming of respective operations. The tutorial is in two parts. In the first part the G82 canned cycle for facing is considered, and in the second part the G81 canned cycle for roughing outside diameters is used. G82 Facing Cycle Examine the operations sheet and drawing for TUT 6/1. It is required to reduce the length of the billet from 40mm to 30mm in 25 cuts. In all outside diameter canned cycle operations, at the commencement of the cycle, the tip of the tool must be positioned at a stand-off point on the previous line of the program code. This point is always 2mm greater (on diameter) measured from the work. In this cycle it is also necessary to have a stand-off along the Z axis. This position is 2mm clear of the end of the work. On completion of the cycle the tool will return to its start point. Tool used: 1 (LH turning tool) Stand-off point: at X27 Z2 X (total cut depth): it is usual to go past the centre line by 0.5 to clear the end, i.e. standoff dia + 1mm = 28 Z (total cut width, excludes the stand-off) = 10 I (no of cuts) = 25 F (feed rate) = 70mm/min The program is shown on the programming sheet. Test run the program and examine how the cycle operates.
Boxford 160 TCL

MATERIAL 25
TYPE NO. 0 I/DIA. 40 STICKOUT SPINDLE SPEED
TITLE TUT 6/1 TOOL FEED RAPID 70 RAPID TOOL NO. 1
O/DIA.
OPERATION NUMBER 1 2 3 4 5
OPERATION DESCRIPTION TOOL PARK POSITION STAND OFF POSITION FACE OFF TO 30mm LONG USING G82 CYCLE WITH 25 CUTS TOOL PARK POSITION END PROGRAM
2500 2000
30
2mm ON DIA.
2mm 25
Boxford 160 TCL

ABSOLUTE PROGRAMMING METRIC UNITS TOOL CHANGE POSITION SPINDLE START STAND OFF POINT FACING CYCLE SPINDLE STOP - TOOL CHANGE END OF PROGRAM

TITLE.
TUT 6/1
MATERIAL:
ALUMN STEEL EN1A

10 20 30 40 50 60 70 82 05 30 04
G
90 71
30.0 27.0 28.0 30.0
10.0 2.0 -10.0 10.0 25 70 2000 2500
Boxford 160 TCL
G81
Rough Turning. The component previously machined is now required to have its outside diameter reduced from 25mm to 15mm for a length 25mm. This is shown on the drawing and operations sheet for TUT 6/2. The program for TUT 6/1 can be edited and extended by using the G81 canned cycle. Because it is the same component it retains work datum X0,Y0 and so the stand-off point for G81 will be X27, Z-9.5 i.e. 2mm greater in diameter and 0.5 clear of the work in the Z axis. Tool used: 1 (LH turning tool) Stand-off point: X27, Z-9. X (total cut depth ,i.e. the difference between the original dia and the final dia excluding the stand-off) =10 Z (total length of travel in the Z axis i.e. cut length plus any stand-off in the Z direction) =-25.5 I (no. of cuts required) =5 F (feed rate) =70 The program for TUT 6/2 is shown on the programming sheet. This can be used to extend TUT 6/1 at the appropriate block no. Extend TUT 6/1, test it and examine its operation.
Boxford 160 TCL
OPERATIONS SHEET DUET OPERATIONS SHEET - TURNING

MATERIAL 25
TYPE NO. 40 I/DIA. 40 STICKOUT SPINDLE SPEED
TITLE TUT 6/2 TOOL FEED TOOL NO.
O/DIA.
OPERATION NUMBER
OPERATION DESCRIPTION continued from TUT 6/1
1 2 3 4 5
TOOL PARK POSITION STAND OFF POSITION TURN 15 x 25mm LONG USING G81 CYCLE WITH 5 CUTS TOOL PARK POSITION END PROGRAM
2000 2500 RAPID 70 RAPID RAPID
30 25
25
15
Boxford 160 TCL

ABSOLUTE PROGRAMMING METRIC UNITS TOOL CHANGE POSITION SPINDLE START STAND OFF POINT FACING CYCLE SPINDLE STOP - TOOL CHANGE SPINDLE START STAND OFF POINT ROUGH TURNING CYCLE SPINDLE STOP - TOOL CHANGE END OF PROGRAM

TITLE.
TUT 6/2
MATERIAL:
ALUMN STEEL EN1A

10 20 30 40 50 60 70 80 90 100 81 05 30 82 05 04 04
G
90 71
30.0 27.0 28.0 30.0 27.0 10.0 30.0
10.0 2.0 -10.0 10.0 -9.5 -25.5 10.0 5 70 2000 2500 25 70 2000 2500
Boxford 160 TCL
Exercise 6:
Canned Cycles - Facing and Rough Turning
You are required to produce a component which fulfils the following machining specification: a) b) c) d) e) Billet size 25mm x 40mm stickout from chuck. Billet material - steel EN1A. Face to 35mm length with 15 cuts. Outside diameter roughed to 19mm in cuts not exceeding 3mm on diameter. Part off to a finished length of 30mm.
Complete the following tasks: 1. 2. 3. Complete an operation sheet for the above machining operations. Using a programming sheet write a program for the component. Give your program a test run and edit it if necessary.
Boxford 160 TCL
Tutorial 7: Canned Cycles- Grooving

Examine the operations sheet and drawing. The G82 grooving cycle is carried out using tool no.11 - the parting off tool. This tool is 1.6mm wide and when setting offsets, its reference face is taken as the side nearest the chuck. The cycle is used to cut a rectangular section groove of width exceeding 3.6mm. Before entering the canned cycle routine it is necessary to create a slot of width 2mm + the width of the tool to the required depth. This is accomplished by using the parting off tool and programming code G01. After cutting this narrow groove take the tool to its stand-off position which is always 2mm greater (on diameter) measured from the work and 2mm stand-off along the Z axis.
1.6mm PARTING TOOL 2mm 2mm ON DIA.
3.6
10
Relationship of stand-off position to preparatory slot. Stand-off point: at X22 Z-11.6 X Z I F (the difference between the stand-off diameter at the bottom of the groove 22-15) = 7 (the additional width of the groove 10-3.6) = 6.4 (no. of cuts) = 10 (feedrate) = 70
The program is shown on the programming sheet. Test it and examine its operation.
Boxford 160 TCL

MATERIAL 25

O/DIA. 0 I/DIA. 40
TYPE NO. STICKOUT SPINDLE SPEED
TITLE TUT 7 TOOL FEED 70 RAPID 70 RAPID 11 TOOL NO. 1
OPERATION NUMBER 1 2 3 4 5 6 7 8 9 10
OPERATION DESCRIPTION FACE STAND OFF POSITION TURN 20 x 35 USING G81 CYCLE WITH 3 CUTS CHAMFER 1mm x 45O TO 20 TOOL PARK POSITION CHANGE TOOLS CUT SLOT 15 x 3.16 EXTEND GROOVE TO 10mm LONG USING G82 CANNED CYCLE TOOL PARK POSITION END PROGRAM
2500 2000
2000 2500
50 RAPID
40 35 20 10 1mm x 45 O
25
20
15
20
Boxford 160 TCL

ABSOLUTE PROGRAMMING METRIC UNITS TOOL CHANGE POSITION

TITLE.
TUT 7
MATERIAL:
STEEL EN1A ALUMN

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 82 05 30 01 01 01 01 05 06 04 81 01 04
G
90 71
30.0 26.0 -1.0
10.0 0 70 1.0 2000 2500
FACE END OF MATERIAL RAPID CLEAR OF FACE RAPID TO STAND OFF POSITION TURN 20 X 35 RAPID TO START OF CHAMFER CUT CHAMFER TOOL CHANGE POSITION CHANGE TOOL TO PARTING TOOL
START SPINDLE - RAPID TO START OF PREPARATORY SLOT
27.0 5.0 18.0 20.0 30.0
0.5 -35.5 0 -1.0 10.0 11 70 3 70
22.0 15.0 22.0
-11.6 50
2500 2000
START MACHINING PREP SLOT RAPID CLEAR OF DIAMETER RAPID TO NEXT SLOT MACHINE SLOT RAPID CLEAR OF DIAMETER RAPID TO NEXT SLOT MACHINE SLOT RAPID CLEAR OF DIAMETER RAPID TO STAND OFF POSITION GROOVING CYCLE
SPINDLE STOP - TOOL PARK POSITION
-12.6 15.0 22.0 -13.6 15.0 22.0 -11.6 7.0 30.0 -6.4 10.0 10 70 50 50
END OF PROGRAM
Boxford 160 TCL
Exercise 7:
Canned Cycles - Grooving.
You are required to produce a component which fulfils the following machining specification: a) b) c) d) e) Billet size 25 x 40mm stickout from chuck Billet material - steel EN1A. Face to a length of 40mm with one cut. Rough outside diameter to 18mm in cuts not exceeding 2mm on diameter. Machine a groove of depth 6mm x 12mm long starting 8mm from the free end.
Complete the following tasks: 1. 2. 3. Complete an operations sheet for the above maching operations. Using a programming sheet write a program for the component. Give your program a test run and edit it if necessary.
Boxford 160 TCL
Tutorial 8: Canned Cycles - External LH Thread.

Note: A threading tool is required for this tutorial. Examine the operations sheet and drawing for TUT 8. The component is the same as that for TUT 7 except that a screw thread has been added and the component has to be parted off. The program for TUT 7 can be edited and extended to include the screw thread by using the G84 canned cycle. The work datum X0 Y0 is the same as that for TUT 7. The stand off point for G84 will X22 Z1.5, i.e. 2mm greater in diameter and 1.5 clear of the work in the Z axis. Tool used: 4 (threading tool). Z (total length from stand-off, negative for left hand thread, positive for right hand thread) -10 + 1.5 = -11.5. I (depth of thread, measured on diameter) = 1.23 for 1.00mm pitch. K (no. of cuts); the minimum is 10 cuts and this is suitable for up to 1.00mm pitch. Note: After the first movement in the X axis there is a pause whilst the computer looks for the spindle marker point. The program for TUT 8 is shown on the programming sheet. This can be used to extend TUT 7 at the appropriate block no. Extend TUT 7, test it and examine its operation.
Boxford 160 TCL

MATERIAL 25

O/DIA. 0 I/DIA. 40
TITLE TUT 8 TOOL FEED TOOL NO.
OPERATION NUMBER
OPERATION DESCRIPTION continued from TUT 7
10 11 12 13 14 15 16 17
CHANGE TOOL STAND OFF POSITION 20 x 1.00mm PITCH THREAD USING G84 CYCLE WITH 1015 CUTS CUT 20 x 0.75mm PITCH THREAD USING G84 CYCLE WITH CUTS TOOL CHANGE POSITION CHANGE TOOL PART OFF TO LENGTH 32mm TOOL PARK POSITION END PROGRAM
4 400 RAPID RAPID 11
2500 2000
50 RAPID
40 32 20 10 M20 x 0.75mm
25
15
20
Boxford 160 TCL


TITLE.
TUT 8
MATERIAL:
STEEL EN1A ALUMN

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 84 82 05 06 04 01 01 01 01 05 06 04 81 01 04
G
90 71
30.0 26.0 -1.0
10.0 0 70 1.0 2000 2500
FACE END OF MATERIAL RAPID CLEAR OF FACE RAPID TO STAND OFF POSITION TURN 20 X 35 RAPID TO START OF CHAMFER CUT CHAMFER TOOL CHANGE POSITION CHANGE TOOL TO PARTING TOOL
START SPINDLE - RAPID TO START OF PREPARATORY SLOT
27.0 5.0 18.0 20.0 30.0
0.5 -35.5 0 -1.0 10.0 11 70 3 70
22.0 15.0 22.0
-11.6 50
2000 2500
START MACHINING PREP SLOT RAPID CLEAR OF DIAMETER RAPID TO NEXT SLOT MACHINE SLOT RAPID CLEAR OF DIAMETER RAPID TO NEXT SLOT MACHINE SLOT RAPID CLEAR OF DIAMETER RAPID TO STAND OFF POSITION GROOVING CYCLE
SPINDLE STOP - TOOL PARK POSITION TOOL CHANGE (THREADING)
START SPINDLE RAPID TO STAND OFF POSITION
-12.6 15.0 22.0 -13.6 15.0 22.0 -11.6 7.0 30.0 -6.4 10.0 4 22.0 1.5 -11.5 0.82 1.23 10 0.75 1.00 400 10 70 50 50
CUT THREAD
Boxford 160 TCL

RAPID TO TOOL CHANGE
TOOL CHANGE - PARTING (1.6mm WIDE)
START SPINDLE RAPID TO PART OFF POSITION

TITLE.
TUT 8
MATERIAL:
STEEL EN1A

30.0
SHEET No. 2 OF 2 FEED RATE I

11

280 290 300 310 320 330 340 05 30 01
SPINDLE SPEED S
M
05 06 04
Z
10.0
22.0 -1.0 25.0 30.0
-33.6 70
2500
PART OFF RAPID TO CLEAR WORK SPINDLE STOP - TOOL CHANGE END OF PROGRAM
10.0
Boxford 160 TCL
Exercise 8:
Canned Cycles - External RH Thread.
Note: This exercise uses a tool which is not supplied with the machine. This exercise is a repeat of Tutorial 6 except that the 20mm diameter has a right hand thread. Note that the Z value in the G84 cycle for a right hand thread is positive. A new position for the thread stand-off point will have to be calculated. 1. 2. 3. Complete an operations sheet, based on TUT 7 for the shape and TUT 8 suitably modified for the thread. Using a programming sheet write a program for the component. Give your program a test run and edit it if necessary.
Boxford 160 TCL
Tutorial 9: Canned Cycles - Peck Drilling

Note: A 7mm drill is required for this tutorial. Examine the operations sheet and drawing for TUT 9. It is required to face the billet, and turn the 23mm diameter, centre drill to a depth of 5mm, peck drill the 07 hole and then part off the component. The stand-off point for G83 will be X0 Z2, i.e. 2mm clear of the face. Tool used: (7) drill. Z (total depth of hole excluding the stand-off) = -20 I (drill diameter) = 7 K (the reduction; a decimal value). This is the percentage by which the second and subsequent pecks are reduced, until the required depth is reached, e.g. 0.99, (the first peck is twice the drill diameter). F (feed rate) = 50mm/min. The program for TUT 9 is shown on the programming sheet. Test it and examine its operation.
Boxford 160 TCL

MATERIAL 25

O/DIA. 0 I/DIA. 40
TITLE TUT 9 TOOL FEED 70 RAPID 5 TOOL NO. 1
OPERATION NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14
OPERATION DESCRIPTION FACE TURN 23 x 35 TOOL CHANGE POSITION CHANGE TOOL CENTRE DRILL 5mm DEEP TOOL CHANGE POSITION CHANGE TOOL STAND OFF POSITION DRILL 7 HOLE x 20mm DEEP USING G83 CYCLE TOOL CHANGE POSITION CHANGE TOOL PART OFF TO LENGTH (1.6 PARTING TOOL) TOOL PARK POSITION END PROGRAM
2500 2000
2000 2500
50 RAPID 7
1750 1500
RAPID 50 RAPID 11 50 RAPID
2500 2000
40 35 32 20
25
23
Boxford 160 TCL

ABSOLUTE PROGRAMMING METRIC UNITS RAPID TO TOOL CHANGE

TITLE.
TUT 9
MATERIAL:
STEEL EN1A ALUMN

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 05 30 01 83 05 06 04 05 06 03 01 01 05 06 03 01 04
G
90 71
30.0 26.0 -1.0
10.0 0 70 1.0
2500 2000
FACE END OF MATERIAL RAPID CLEAR OF FACE RAPID TO START OF 23 CUT TURN 23 X 35 SPINDLE STOP - TOOL CHANGE CHANGE TO CENTRE DRILL
SPINDLE START FORWARD C/ DRILL 1mm STAND OFF
23.0 -35.0 30.0 10.0 5 0 1.0 -5.0 2.0 30.0 10.0 7 0 2.0 -20.0 30.0 10.0 11 25.0 -1.0 25.0 30.0 10.0 -33.6 70 2000 2500 7 0.9 50 7 1750 80 70
2500 2000
DRILL 5mm DEEP RETRACT DRILL SPINDLE STOP - TOOL CHANGE TOOL CHANGE - 7 DRILL
G83 PECK DRILL CYCLE SPINDLE STOP - TOOL CHANGE TOOL CHANGE - 1.6mm PARTING
SPINDLE START MOVE TO PARTING POSITION
PART OFF CLEAR WORK SPINDLE STOP - PARK POSITION END OF PROGRAM
Boxford 160 TCL
Exercise 9:
Canned Cycles - Deep Hole Peck Drilling
Note: A 5mm drill is required for this tutorial. You are required to produce a component which fulfils the following machining specification: a) b) c) d) e) f) g) Billet size 25 x 40mm stickout from chuck. Billet material -steel EN1A Face to a length of 40mm with one cut. Rough outside diameter to 19mm in cuts not exceeding 3mm on diameter. Centre drill. Peck drill a 5mm dia. hole 12mm deep. Part off to 30mm long.
Complete the following tasks: 1. 2. 3. Complete an operations sheet for the above machining operations. Using a programming sheet write a program for the component. Give your program a run and edit it if necessary. Use tutorials 6 and 9 to help you with this exercise.
Boxford 160 TCL
Tutorial 10 : Circular Interpolation - Partial Arcs

The topic of circular interpolation was introduced in Tutorial 4. These arcs were of 90 degrees and occupied a single quadrant. If the arc is less than 90 degrees, it is called a partial arc. Examples of partial arcs are shown below: 1. Two partial arcs programmed next to each other to form a groove. In this case, care has to be taken to ensure that the correct tools are chosen so that the toolholders do not rub against the edges of the groove. Four partial arcs connecting tapers. A partial arc as a fillet to a taper and a shoulder.
2. 3.
2
R
R
R
R
Boxford 160 TCL
Examine the operations sheet and drawing for TUT 10. The drawing shows a component turned with a taper together with two partial arcs one clockwise and the other one counter-clockwise. The operations sheet gives details of the roughing cuts. The I and K values are determined in the same way as for 90 arcs, i.e. (a) the I value is the incremental distance measured along the X axis and the K value is the distance measured along the Z axis to the arc centre from the tool position at the commencement of the cut, or the I value is the radius.
(b)
The X and Z values are the co-ordinates of the tool at the finish of the arc. The calculations required to determine these values may involve trigonometry. The program for TUT 10 is shown on the programming sheet. Test it and examine its operation.
Boxford 160 TCL

MATERIAL 25

O/DIA. 0 I/DIA. 40
OPERATION NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
OPERATION DESCRIPTION FACE TURN 23 x 29 21 x 28.5 19 x 28 17 x 27 15 x 21 13 x 13 11 x 7 9 x 2 7 x 1 FACE 2 (START OF RAD) TURN 4mm RAD TO 9.93 TURN TAPER TURN 4mm RAD TO 24 TURN 24 x 36.6 (1.6mm PARTING TOOL) TOOL PARK POSITION CHANGE TOOL PART OFF TO LENGTH (35mm) TOOL PARK POSITION END PROGRAM 40 35 30 R4 16.07 25 24 2 R4 9.93
2500 2000
RAPID 11 2000 2500 50 RAPID
3.48 26.53
Boxford 160 TCL


TITLE.
TUT 10
MATERIAL:
ALUMN STEEL EN1A

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 01 01 01 01 01 01 01 01 04
G
90 71
30.0 26.0 -1.0
10.0 0 70 1.0 2000 2500
FACE END OF MATERIAL RAPID CLEAR OF FACE RAPID TO FIRST CUT DIAMETER CUT 23 X 29mm LONG RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT 21 X 28.5 RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT 19 X 28 RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT 17 X 27 RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT 15 X 21 RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT 13 X 13 RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT 11 X 7 RAPID CLEAR OF WORK
23.0 -29.0 24.0 21.0 -28.5 22.0 19.0 -28.0 20.0 17.0 -27.0 18.0 15.0 -21.0 16.0 13.0 -13.0 14.0 11.0 -7.0 12.0 1.0 70 1.0 70 1.0 70 1.0 70 1.0 70 1.0 70 1.0 70
Boxford 160 TCL

POSITION FOR NEXT CUT CUT 9 X 2 RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT 7 X 1 RAPID CLEAR OF WORK
RAPID TO FACE 2 - (START OF RADIUS)

TITLE.
TUT 10
MATERIAL:
STEEL EN1A

9.0

70

280 290 300 310 320 330 340 350 360 370 380 390 400 410 420 430 440 450 05 30 01 03 01 02 01 05 06 04 01 01
SPINDLE SPEED S
Z
-2.0
10.0 7.0
1.0
-1.0 8.0 2.0 9.93 16.07 24.0 24.0 30.0 1.0 0 -3.48 -26.53 -30.0 -36.6 10.0 11 25.0 -1.0 25.0 30.0 10.0 -36.6 4 4
70
TURN RADIUS TURN TAPER TURN RADIUS TURN 24 SPINDLE STOP - TOOL CHANGE TOOL CHANGE - PARTING TOOL
START SPINDLE RAPID TO PART OFF POSITION
70 70 70 70
2000 2500 50
PART OFF RAPID CLEAR OF WORK SPINDLE STOP - PARK POSITION END OF PROGRAM
Boxford 160 TCL
Exercise 10:
Circular Interpolation - Partial Arcs.
You are required to produce the component drawn below. The billet size is 25 x 40mm stickout from chuck. The billet material is steel EN1A.
R10
25
10
15
12 22 6 29
Complete the following tasks: 1. 2. 3. Complete an operations sheet for the above component. Using a programming sheet write a program for the component. Give your program a test run and edit it if necessary.
23
R5
Boxford 160 TCL
Tutorial 11: Combining G Codes to Produce a Program.

In this tutorial a selection of preparatory codes (G codes) is used to produce the component shown. Test run the program and examine its operation.
34 28 19.5 16.75 10.75 DRILL 7
23
18
17
R1.5 20 DRILL POINT R6.5
THREAD 0.75mm PITCH L.H.
20
Boxford 160 TCL

ABSOLUTE PROGRAMMING METRIC UNITS TOOL PARK POSITION

TITLE.
TUT 11
MATERIAL:
STEELALUMN EN1A

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 03 01 02 01 01 04 01 81 01 01 01 01 01 04
G
90 71
30.0 26.0 -1.0
10.00 0
2500 2000
70
FACE END OF MATERIAL RAPID CLEAR OF FACE RAPID TO FIRST CUT DIAMETER CUT DIAMETER X 35mm LONG RAPID CLEAR OF WORK POSITION FOR NEXT CUT CUT DIAMETER X 23.5mm LONG RAPID CLEAR OF WORK CUT TAPER - TOOL CUTTING IN CUT TAPER - TOOL CUTTING OUT RAPID TO STAND OFF FOR G81 CYCLE
REDUCE DIAMETER BY 3mm IN 2 CUTS
1.00 23.0 -35.00 23.5 21.5 -23.50 22.0 20.0 23.5 -16.00 -19.50 -27.00 0.50 3.0 14.0 18.5 -2.80 0.50 12.0 18.5 -4.40 0 4.0 17.0 -6.50 -9.25 20.0 -10.75 -16.75 1.5 0 0 6.5 50 70 50 70 40 2000 2500 50 -10.50 2 80 70 70 80 0.50 80
POSITION FOR FIRST ANGLE CUT CUT CHAMFER RAPID CLEAR OF FACE POSITION FOR NEXT CUT CUT CHAMFER
CHANGE SPINDLE SPEED RAPID TO ZERO IN Z AXIS
RAPID TO 4mm CUT 6.5 RADIUS TO 17mm CUT DIAMETER X 9.25mm LONG CUT 1.5 RADIUS TO 20mm CUT DIAMETER X 16.75mm LONG
Boxford 160 TCL

CUT TAPER - TOOL CUTTING IN CUT TAPER - TOOL CUTTING OUT
STOP SPINDLE - TOOL PARK POSITION

TITLE.
TUT 11
MATERIAL:
STEEL EN1A

18.0 23.0 05 06 03 0 3.00 -5.00 3.00 05 06 03 0 2.00 -20.00 05 06 04 22.0 -9.25 -10.25 05 06 04 25.0 -0.5 30.0 05 02 30.0 10.00 -34.00 30.0 10.0 11 30.0 10.00 4 7 30.0 10.00 7 30.0

70 50

280 290 300 310 320 330 340 350 360 370 380 390 400 410 420 430 440 450 460 470 480 490 01 84 83 01
SPINDLE SPEED S
G
01 01
Z
-19.50 -28.00 10.00 5
CHANGE TO TOOL 5 - C/DRILL

2000 2000
50
CUT TO DEPTH RAPID CLEAR OF FACE

STOP SPINDLE - TOOL PARK POSITION CHANGE TO TOOL 7 - 7mm DRILL
7 2000 1500 0.99 50
DRILL 20mm DEEP WITH G83 CYCLE STOP SPINDLE - TOOL PARK POSITION CHANGE TO TOOL 4
400
CUT THREAD WITH G84 CYCLE (106mm) STOP SPINDLE - TOOL PARK POSITION CHANGE TO TOOL 11 START SPINDLE - RAPID TO POSITION PART OFF TO LENGTH CLEAR WORK STOP SPINDLE - TOOL PARK POSITION END OF PROGRAM
0.92 0.82
10
0.75
2500 2000
40
Boxford 160 TCL
Exercise 11:
Using a Combination of G Codes
You are required to produce the component drawn below. The billet size is 25 x 40mm stickout from the chuck. The billet material is steel EN1A.
15 DRILL POINT R2
THREAD 0.75mm PITCH L.H.
DRILL 5
22
14
16
5 10 12 22 30 35
R5
Complete the following tasks: 1. 2. 3. Complete an operations sheet for the above component. Using a programming sheet write a program for the component. Give your program a test run and edit it if necessary.
20
OPERATIONS SHEET
OPERATIONS SHEETSHEET - TURNING DUET OPERATIONS

MATERIAL O/DIA. I/DIA. TYPE NO. STICKOUT SPINDLE SPEED TOOL FEED TOOL NO. TITLE
OPERATION NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
PROGRAMMING SHEET

TITLE. SEQUENCE PREP MISC No. FUNCTION FUNCTION N G M WRITTEN BY AXIS COORDINATES X Z I
MATERIAL: SHEET No. OF SPINDLE SPEED S
FEED RATE K F

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What are the different types of tools mentioned?

What are the different types of tools mentioned?

What are the different programming sheets described?

What are the different programming sheets described?

Programming Manual

Boxford 160 TCL CNC Turning Machine Tool

Boxford 160 TCL

4 Main Front End Menu 5 CAD and CAM Processing

6 DXF File Imports

Boxford 160 TCL

8 Manual Data Input CNC Programming

9 CNC and CAM Machining

10 Manual Machining 11 Robotic Interfacing

Boxford 160 TCL

CNC Tutorials and Exercises

Boxford 160 TCL

2 Running the Demonstration Program

2 Running the Demonstration Program

Set Up the Machine

Turret: Gang Plate: Quick Change:

Check Tool Settings

Boxford 160 TCL

2 Running the Demonstration Program

Select the Program

Boxford 160 TCL

2 Running the Demonstration Program

View the Component

Manipulate the 3D view as follows: Using a Mouse

Boxford 160 TCL

2 Running the Demonstration Program

Using the Keyboard

Restore original view

Show the Program Details

to show the program details:

Boxford 160 TCL

2 Running the Demonstration Program

Display the Program

, and then Display:

Boxford 160 TCL

2 Running the Demonstration Program

Boxford 160 TCL

2 Running the Demonstration Program

Machine the Component

Boxford 160 TCL

Axes and Tooling

3 Axes and Tooling

Figure 3.1 Machines with Turrets:

Boxford 160 TCL

3.1 Axes and Tooling

Centre Line of Spindle

Boxford 160 TCL

3.1 Axes and Tooling

Tool Z Offset Centre Line of Spindle

Figure 3.3 Tool Offsets:

Boxford 160 TCL

3.1 Axes and Tooling

External tools: 1, 3, 5, 7 Internal tools: 2, 4, 6, 8

7 8 1 Machines without homing switches: 1: Reference tool 7: Second tool

Turret Tool Positions

Boxford 160 TCL