MILLPWRG2 ACU-RITE ® User’s Manual
Controls of the MILLPWRG2 Controls of the MILLPWRG2 Numerical keys Key Function Keys on console ZERO key. Motion control keys Key Function ONE key. GO key (e.g. run a program). TWO key. STOP key (duel function: press once to pause, press twice to stop a program). THREE key. Data Entry keys Key FOUR key. Function CANCEL key cancels operation, i.e. form. FIVE key. CLEAR key clears selections, i.e. values in a field, a program step. SIX key. USE key completes operation, i.e.
Key Function LEFT ARROW key will move the table or display cursor depending on the function selected. RIGHT ARROW key will move the table or display cursor depending on the function selected. UP ARROW key will move the table or display cursor depending on the function selected. DOWN ARROW key will move the table or display cursor depending on the function selected. Calculator Function keys Key Function Milling Function keys Key Function TOOL key opens the SET TOOL Dialogue.
iv Controls of the MILLPWRG2
Manual Information Manual Information Message symbols Attention! This symbol indicates that there is one or more of the following risks when using the described function Danger to work piece Danger to fixtures Danger to tool Danger to machine Danger to operators Damage! This symbol indicates that there is risk of MILLPWRG2 damage, or electrical shock if instructions are not adhered to.
Manual Information Fonts Used in this manual Reference to the: Console HARD KEYS. Reference to the: Display Screen Soft Keys. Reference to the: Display Screen DIALOGUES. Reference to the: Display Screen FIELDS. Changes (errors) HEIDENHAIN CORPORATION is continuously striving to improve. Please help HEIDENHAIN CORPORATION by sending your request to the following e-mail address: sales@heidenhain.com Visit www.ACU-RITE.com for latest version of this manual.
Manual Information New Functions of Software 751005-01-01 Zero Incremental was added to Section 2.2.
Manual Information Changed Functions of Software 751005-01-01 Blend/Chamfer information input in Section 8.1 has been redefined. Preset Moves information input in Section 2.2 has been redefined. Display:Peck\Pass in Section 9.1 has a note added that the limit of pecks or passes is 9999. 751005-01-02 The off-line software described in Section 11.1now requires the purchase of a USB Protection Module for operation. Custom Pocket: The tool path for custom pockets and islands, described in Section 8.
MILLPWRG2 Access Code MILLPWRG2 Access Code Access Code Attention! The parameter access code is 8891 Access to Machine Parameter Operations The access code must be entered before the installation setup parameters can be accessed or changed. Press the SETUP key to enter the Job Setup dialogue. Press the Config Data soft key, and enter the access code in the yellow message bar. Attention! To prevent setup parameters from being changed, remove this page from the manual after initial system setup.
x MILLPWRG2 Access Code
Table of Contents Controls of the MILLPWRG2 Keys on console........................................................................................................ii Motion control keys .............................................................................................ii Data Entry keys....................................................................................................ii Function keys...................................................................................................
1.3 Console Operating Console ................................................................................................. 11 Rear Panel.............................................................................................................. 11 Screen Navigation.................................................................................................. 12 DRO Mode display............................................................................................ 12 PGM Mode display .........
2.2 Manual Machine Positioning Move Table ............................................................................................................ 27 Changing the Mode .......................................................................................... 27 Incremental Moves ........................................................................................... 27 Continuous Moves............................................................................................
4.2 Tool Data Tool-Length Offsets............................................................................................... 48 Teaching Tool Length Offsets in the Tool Table ............................................... 48 Diameter Offset in Tool Table................................................................................ 49 Tool Radius Offset ................................................................................................. 50 Moving without radius offset.....................
6.1 Conversational Programming Programming Considerations ................................................................................ 72 “From” and “To” points ................................................................................... 72 Depth of Cut ..................................................................................................... 72 Pass .................................................................................................................. 72 Tool Offset .......
Loading a MILLPWRG2 (MPT) Program ............................................................ 95 Importing a DXF drawing .................................................................................. 96 G-code Programs ................................................................................................... 97 Loading a G-code Program ............................................................................... 97 Running a G-Code Program ....................................................
8.1 Milling and Drilling Overview ............................................................................................................. 128 Selecting A Tool .............................................................................................. 129 Repeatable Tool Length Offsets .......................................................................... 131 Programming a Tool........................................................................................
Other Steps ......................................................................................................... 169 Engrave Line ................................................................................................... 170 Engrave Arc .................................................................................................... 171 Comment Step ............................................................................................... 172 Dwell......................................
Introduction
1.1 MILLPWRG2 1.1 MILLPWRG2 The ACU-RITE MILLPWRG2 control is a workshop-oriented contouring control that enables you to program conventional machining operations right at the machine in an easy-to-use conversational programming language. It is designed for milling and drilling machine tools, with up to 3 axes. MILLPWRG2 was developed to satisfy the wants and needs of tool and die makers and other machinists where manual and automated operation are both useful and needed.
1.1 MILLPWRG2 Powering Up The MILLPWRG2 console does not disconnect the power supply to the spindle motor. It can only be disconnected by turning off the main power supply. Turn the power switch On [1], (to the I position) on the MILLPWRG2 console which is located on the back of the unit. Follow the builder’s instructions to turn off the machine. The start up screen with 3 soft keys will be displayed; Shut Down, Find Home, and Cancel.
1.1 MILLPWRG2 E-STOP and Shutdown The E-STOP is used for emergency program shut down by turning off the servo motors. It does not shut down the spindle motor. The spindle motor must always be manually stopped using the spindle switch to stop the motor, and the cutting tool. When the E-STOP button is pressed, the servo motors are stopped, and the quill can be raised. When the STOP key is pressed once, the servo motors pause, but are still active. All axes are locked, and can not be moved.
1.1 MILLPWRG2 Emergency Stop (E-STOP) Press E-STOP to take all axes servos offline. This ends all machine movement, and allows the quill to be raised to move the tool out of the way. To reset the E-STOP, turn the rotary switch clockwise in the direction of the arrows. The switch pops outward, and is reset. Resetting E-STOP does not reactivate the servos. Activating/Resetting the Servos For safety reasons, the mill powers up with the servomotors disengaged.
1.1 MILLPWRG2 Find Home You should find home before a program is run, or immediately after startup. During start up, the Find Home soft key is provided on the start up screen soft key area. If the find home step is not performed at initial start up, it can be initiated at any time during operation. Press the Datum soft key, then press the Home soft key, and then press the Find Home soft key. A 3 axes system will move the table and quill.
1.1 MILLPWRG2 Disengage Z Axis feature MILLPWRG2 provides the flexibility to switch between 2 axes and 3 axes operation. Disengaging the Z axis drive: Leave the Z BEGIN field blank when programming a step, or a one time milling operation. Raise the quill, then loosen the quick release knob [1] on the front of the the Z axis drive system. When a program step, or milling operation is then performed, the operator is prompted to manually position the quill.
1.1 MILLPWRG2 Writing Programs Overview The MILLPWRG2 allows many features to be used without having to write a program. For operations that repeat, or complex machining it is best to write a program. Before writing a program, determine the work-holding device and the location of Part Zero (the point to which all movement is referenced).
1.2 Operating in 2 Axes and 3 Axes Modes 1.2 Operating in 2 Axes and 3 Axes Modes Overview The MILLPWRG2 is capable of running a 2 axes machine (manual Z) or a 3 axes machine with the Z being switched to manual as needed. This User's Manual covers 2 axes and 3 axes operation. This section provides some general guidelines. In 2 axes mode, all Z moves must be made manually. When running a program, the system will pause and provide a prompt whenever a Z move is required.
1.2 Operating in 2 Axes and 3 Axes Modes Selecting 2 Axis Mode on 3 Axis Systems To run a program in 2 axis mode, disengage the quill assembly before pressing the GO key. A prompt will appear indicating that the quill is disengaged. If this is intentional, press GO and the program will run in 2 axis mode. To program a specific step to run in 2 axis mode: Select POSITION for the Z operation type (drill steps). For pockets, clear the Z begin depth field.
1.3 Console 1.3 Console Operating Console The ACU-RITE MILLPWRG2 Console has a 12.1-inch Flat-Panel Color Screen Display. The following list of items are located on the front panel. See "DRO display screen" on page 21 for mapping information of the start up screen. See "Console Keypad" on page 20 for a full description of the console keypad layout. The individual keys are fully described on page ii of the inside front cover.
1.3 Console Screen Navigation The MILLPWRG2 display layout changes between DRO Mode and PGM (Program) Mode by pressing the DRO/PGM key. The following illustrates the differences between the two screen modes. DRO Mode display In general, the display changes as different functions are activated. Soft keys in the lower display area change per the function selected. Soft keys perform their associated function by pressing the key directly below it.
1.3 Console Dialogues, and Drop Down Menus This manual provides complete information where specific examples of actions are being explained. As a general overview of the dialogues provided by the MILLPWRG2, several fields are likely to be provided for input. To navigate a dialogue, use the ARROW keys to select the desired field. After entering the data into a field, press either the ENTER key, or the UP or DOWN ARROW keys to move to the next field.
1.3 Console General Operating Guidelines General operating guidelines for the MILLPWRG2. Additional operation soft keys are located in the soft key area along with task selection, and dialogue. The soft keys change in relation to the task being performed. Selection of a particular soft key that requires additional information may open a popup menu [1]. A soft key may open a dialogue menu that requires input necessary to continue with the operation selected.
1.3 Console Operating Modes The MILLPWRG2 has two main operating modes: DRO, and PGM (Program). These are accessed from the front panel hard key. This is a toggle key. DRO mode shows the current position of each axis relative to current datum. In DRO mode, manual machining, and Single Cycles can be performed. Tool selection, units, along with most setup features can be accessed. Program mode PGM, displays the list of program steps and part-view graphics.
1.3 Console Popup Menus Within the soft keys, additional features may be available in program mode. A soft key that has a down arrow in the lower right hand corner indicates that additional soft keys are available for that feature. As an example, pressing the Program Steps soft key (in PGM mode) opens another set of soft keys available for this function. Then you will notice an up arrow on most of the soft keys. This indicates a popup menu will open when that key is pressed.
1.3 Console Keyboard An on screen QWERTY keyboard will automatically popup when you enter a field that requires text information input. The keyboard becomes visible (popup) when text, and numerical information is required for an action (e.g. saving a program, or entering text for engraving). Use the ARROW keys for navigation of the cursor to go to the desired character and press ENTER to select the character. When the information has been entered using the keyboard, press the Save soft key.
1.3 Console Editing Keys The following keys are available for editing text on the keyboard. The Copy key will copy the highlighted text in the text field. The Paste key will paste to the text field text that was previously highlighted, and copied. The Clear key will remove all text in the text field. The back space key will delete text in the text field one character at a time.
1.3 Console Context Sensitive Help The MILLPWRG2 uses an intuitive method to aid the user when assistance is required. When assistance is needed with a feature, the User Manual can be displayed directly at the point which describes the feature. To use this help, in this example, the console is in PGM mode, and a Linear Engraving cycle is being programed. It is desired to see descriptions of the cycle parameters, and the cycle itself. The following steps describe the actions needed to take.
1.3 Console Console Keypad The following keys are located on the console keypad. There is also a quick reference guide located at the beginning of this manual on page ii of the inside front cover. 1 2 3 4 5 6 7 8 9 10 11 12 13 20 Axis keys, use to select the required axis. Numeric keys, use to enter numeric data. CANCEL key, use to cancel current action. CLEAR key, use to clear selections such as values entered in a field. ARROW keys, use to navigate around the screen, and highlight dialogue fields.
1.4 Operating Mode Screens 1.4 Operating Mode Screens Display navigation The DRO mode is the default start up mode, and PGM mode can be selected from the front panel key after start up. A condensed description of these has been provided here on how to navigate, and become familiar with the information that is being provided. Complete descriptions, and details of these are provided later in this manual, see "DRO Screen" on page 31.
1.5 Accessories Program Display Screen From the DRO mode, press the DRO/PGM key, and the display changes to program mode showing the currently selected or loaded program. When Programing a job, the display activates a graphic view of the program. While the program is running, the operation that is being performed is graphically shown as well. The VIEW key provides features to configure the graphic area. For more information, see "Program Function Screen" on page 55. 1.
Machining Fundamentals
2.1 Conventions 2.1 Conventions Axis Conventions Count Direction When programming a part using MILLPWRG2, table movement and tool movement are determined by the use of positive or negative numbers. MILLPWRG2 has been factory set with the following positive and negative count directions for the X, Y and Z-axes: X axis The table will move to the left and the tool will move to the right for a positive count direction.
2.1 Conventions Absolute and incremental work piece positions Absolute work piece positions Absolute coordinates are position coordinates that are referenced to the datum of the coordinate system (origin). Each position on the work piece is uniquely defined by its absolute coordinates.
2.1 Conventions Setting the datum Overview Datum is the workpiece zero or absolute zero, and is a point of reference that the MILLPWRG2 bases all of the part's coordinates from. A datum must be established for every job. Datum's location may be indicated on the print; or the operator may establish a datum that allows most of the part's dimensions be entered directly using the least amount of calculations.
2.2 Manual Machine Positioning 2.2 Manual Machine Positioning Move Table Non Cutting Mode You can make or change jog moves when in DRO mode with the servos on. Jog Mode Description Rapid Default rapid speed for continuous jogs. Actual speed determined at machine setup, and can be over ridden using the potentiometer. Jog: 0.1 Conventional Jog increment set at 0.100”. Jog: 0.01 Conventional Jog increment set at 0.010”. Jog: 0.001 Conventional Jog increment set at 0.001”.
2.2 Manual Machine Positioning Adjusting the Feedrate The Feedrate Override potentionmeter can be used to override the currently active feedrate or rapid rate for machine moves. The switch provides a range of 0% to 150%. Setting the switch to 100% will allow the actual feedrate or rapid rate currently active to be used. The machine builder determines the default rapid rate and maximum feedrate at setup. If the MILLPWRG2 is shut down, the configuration file reloads these default rates at the next power up.
DRO Mode and Calculator
3.1 DRO Manual Data Input 3.1 DRO Manual Data Input Overview The MILLPWRG2 is in either DRO mode or PGM mode. DRO mode allows data input for short one step machining operations. Manual operation, single step operation, and single commands can be entered. DRO mode also allows the running of programs; See "DRO Operations" on page 38. The following describes the concepts, and formats used with the MILLPWRG2 which are being introduced in this chapter.
3.1 DRO Manual Data Input DRO Screen The DRO screen displays information per the current operation. The DRO mode allows the use of the milling function hard keys, or can be used as a DRO in manual machining operations. In addition to the information provided in Chapter 1 "DRO Mode display" on page 12, the following table describes what is being viewed on the display in DRO mode. When the console is first turned on, the soft keys Shut Down, Find Home, and Cancel are displayed.
3.1 DRO Manual Data Input Status Bar Display Status Bar Display Description Program State This field indicates the program state: Stop when program is not running, Run when program is running, or Pause when program is paused for operator. Feed This field indicates the current feedrate of the table or quill. Tool In DRO mode, this field indicates the current tool selection. In PGM mode, this field indicates the programmed tool for the highlighted step.
3.1 DRO Manual Data Input Move Table The Move Table soft key when pressed will turn on the servo motors. Pressing it again will turn the servo motors off. The desired feed rate can be set, or it can be left at 100% for rapid feed rate. See "Adjusting the Feedrate" on page 28. To move the table in increments, first select the soft key increment wanted (e.g. 0.001, or 0.01, or 0.1). A 3 axes system allows the Z axis to be moved by selecting the soft keys Move Z Up, or Move Z Down.
3.1 DRO Manual Data Input Zeroing an Axis Pressing the Zero X, Zero Y, or Zero Z soft keys will zero the incremental position for those axes. A datum must be set to establish the point from which all absolute dimensions are based. Teach Position Whenever X, Y or Z coordinates are being entered, the Teach Position soft key will appear, enabling MILLPWRG2 to be in teach mode and to use the current coordinate(s).
3.1 DRO Manual Data Input Electronic Edge Finder A HEIDENHAIN Electronic Edge Finder enables you to teach positions, find the center point of a circle, skew a part or locate datum (also referred to as workpiece zero) by simply touching off on the part. The advantage of an electronic edge finder is that it instantly senses when you’ve made contact with the point even when you over-travel. MILLPWRG2 lets you define the diameter and unit of measure for an electronic edge finder.
3.1 DRO Manual Data Input Skewing The skew function automatically compensates for the offset angle of the part when it is not perfectly parallel with either the X or Y axis. Press the DRO/PGM key to place the MILLPWRG2 in DRO mode. Press the ABS/INCR key to place the MILLPWRG2 in ABS mode. Press the Datum soft key to open the SET DATUM dialogue. Enter the Datum Number in the DATUM NUMBER field. Enter the Skew Angle in the SKEW ANGLE field.
3.1 DRO Manual Data Input Milling Function Keys The following describes in general, the milling function keys. Most milling functions can be used as one time machining operations. The BLEND key does not support single operation. Hard Key Function TOOL opens the SET TOOL dialogue where information regarding the tool can be entered. RECT opens the popup menu above the Rectangle soft key. Choose the type of rectangle milling that is to be done by selecting it from the popup menu.
3.1 DRO Manual Data Input DRO Operations The following explains a few of the machining operations that are available. This example is providing an overview to the operator of the MILLPWRG2 capabilities. The RECT, or CIRCLE keys as an example access popup menus to further refine the type of milling to be completed. Selecting the type of milling operation required will open the dialogue for that type of milling operation. An operation is run by pressing the USE key.
3.1 DRO Manual Data Input Circle milling Press the CIRCLE key on the front panel. The soft key CIRCLE is displayed, and a popup menu appears on the display listing the type of circles available for milling. Circle milling example (e.g. pocket, frame, ring, or helix) Select Pocket from the popup menu. The popup menu disappears, and the CIRCLE POCKET dialogue is displayed. Enter the data to mill the pocket. Press GO to run the circle pocket.
3.1 DRO Manual Data Input DRO Mill Cycles The one step milling function are grouped in Four categories as shown in these groups.
3.2 Calculator 3.2 Calculator Accessing the calculator The built in calculator can be used for simple arithmetic, or other math functions. The calculator can be accessed at any time, during most operations. To access the calculator press the CALC key, and select the calculator function to be used.
3.2 Calculator More Commands, second menu. Soft key Description ArcSin Inverse function of Sine ArcCos Inverse function of Cosine ArcTan Inverse function of Tangent To exit the calculator press the CALC key a second time or press CANCEL. Press the CLEAR key to clear the entry field. Using the calculator to insert data The calculator can be used in the numeric field of dialogues.
Tool Table
4.1 Tool Table 4.1 Tool Table Overview When the MILLPWRG2 runs a program step that activates a tool, it only activates the diameter, and length values on that row of the Tool Table. The tool number, or tool type are not activated in dialogues that have these fields. The tool type must be entered in the dialogue. Tool Table values are automatically converted to their inch or millimeter equivalents when the MILLPWRG2 mode is changed. All typed values must match the current unit mode of the MILLPWRG2.
4.1 Tool Table Tool numbers / Tool names Each tool is identified by a number between 0 and 99. The tool name is its tool number. The tool number 0 is automatically defined as the zero tool (empty spindle) with the length L=0 and the diameter D=0. Sign for the length difference ΔL If the tool is longer than the T1 tool: ΔL > 0 (+). If the tool is shorter than the T1 tool: ΔL < 0 (–). The tool length offset can be entered as a known value, or use the Teach soft key.
4.1 Tool Table Tool Table Editing the tool table When the tool table is open, a new tool can be added, or an existing tool can be edited by changing the existing information for that tool. It is necessary to first select the unit of measurement before entering values into the tool table. To enter a new tool, a blank numbered row will need to be selected. Using the ARROW keys, highlight the next available blank row number.
4.1 Tool Table Editing an existing tool To edit an existing tool is similar to adding a new tool using the same dialogues. Highlight the desired field of the tool to be changed. Type in the new value, then press the ENTER key. When all changes have been made, press the Exit soft key, or USE key to save changes to the tool table. Only add the tool diameter and length if it is repeatable each time it is selected.
4.2 Tool Data 4.2 Tool Data Tool-Length Offsets Tool-length offset is the distance from Z0 Machine Home to the tip of the tool at the part Z0 (the surface of the work). Tool-length offsets allow each tool used in the part program to be referenced to the part surface. In an idle state, the MILLPWRG2 does not have a tool-length offset active. Therefore, Tool #0 (T0) is active. When T0 is active, all Z dimensions are in reference to the Z Home position.
4.2 Tool Data Diameter Offset in Tool Table When you activate a tool, you automatically activate the length offset and diameter values recorded on the Tool Table (DRO mode only activates a tool when GO is pressed). When a tool is activated, the length offset is applied immediately to provide an accurate Z axis position display. The active diameter value is important when you program compensated moves and use cycles with built-in tool compensation.
4.2 Tool Data Tool Radius Offset Tool radius offset is available with the MILLPWRG2. The tool center moves in the working plane along the programmed path or to the programmed coordinates. When programming a part profile, the path of the tool is a half of a diameter away from the depth of the cut. Offset the tool to the right-hand or left-hand of the cutting edge. “Right” or “Left” refers to the side of the cutting edge to which the tool offsets.
4.2 Tool Data Machining with radius offset The tool center moves along the contour at a distance equal to the radius. “Right” or “left” are to be understood as based on the direction of tool movement along the work piece contour as viewed from behind a moving tool.
4.2 Tool Data Radius offset: Machining corners Outside corners: A programmed path around the outside corners on a transitional arc should have the feed rate at the outside corners reduced to relieve machining stress. Typical for any great changes of direction. Inside corners: The operator must program the MILLPWRG2 for the intersection of the tool center paths at inside corners. From this point it then starts the next contour element. This prevents damage to the work piece.
Program Overview
5.1 Programming Introduction 5.1 Programming Introduction Program Display mode If the console has the Calculator active while in DRO mode, exit from Calc by pressing the Calc key, returning the MILLPWRG2 to DRO mode. Program Functions can not be accessed when the Calculator is active in DRO mode. From DRO mode, press the DRO/PGM key, and the display changes to PGM mode. If a program is loaded, it will be displayed, otherwise the display screen will be blank.
5.1 Programming Introduction Program Function Screen The Program Function screen displays several windows, and soft keys which are defined in the contents of this chapter. The display area window is briefly described in the following table. The Program Functions soft key provides access to Network or USB memory devices by pressing the Folder View soft key. The features of this soft key are explained on the following page.
5.1 Programming Introduction From Folder View, press the Folder View soft key to exit back to the Program Functions display. Press the Exit soft key to exit back to Program Mode. Program Drawing View While a program is running (or being created), individual steps being performed are graphically shown as they are being ran or created. Pressing the VIEW hard key displays different soft keys for viewing choices of the program.
5.1 Programming Introduction Program Screen Display When programming a machining step, the display changes according to the machining step selected. Once a machining step has been selected using the Program Steps soft key, the display will appear as shown here. The program steps display windows are described in the following table. 1 2 3 4 5 Current program steps. Dialogue for a new milling step (e.g. CIRCLE POCKET) Dialogue field graphic assistant.
5.1 Programming Introduction Program Mode Soft Keys When the DRO/PGM key is selected from DRO mode, the MILLPWRG2 screen changes to PGM mode, and the program default screen is displayed. When the MILLPWRG2 is set to program mode, types of milling functions specific to the hard key selected become available as soft keys. Keys Function Program Functions opens additional soft keys to Load, Save, Clear, or Copy a program along with several other functions listed on the following page.
5.1 Programming Introduction Program Functions Program Functions soft keys The Program Functions soft key provides access to the following soft keys for saving, clearing, or loading an existing program to either edit or run. Soft key Function The Load soft key will load the selected program. If a program is currently loaded, a prompt will be displayed asking for confirmation to clear the loaded program. If a program is currently loaded, it must be saved prior to pressing this key.
5.1 Programming Introduction Pressing the Select soft key feature opens a popup menu that provides these three choices: The Select feature will select one or more programs. Highlight each program to be selected, and choose Select for each program highlighted. The Select All feature will select all programs in the folder. The Clear feature will un-select one or more programs that have been highlighted. Clear does not delete a program, it will only un-select it.
5.1 Programming Introduction Choosing the Delete feature will delete one or more programs selected. The message bar will be displayed showing the first selected program asking for confirmation to delete it. Four soft keys are displayed for deleting options. Yes will delete the current program displayed in the message bar. Cancel will cancel out of the current operation. Cancel will not restore any prior deletions that had been made.
5.1 Programming Introduction View hard key Once a program is opened, the first step is to select how the part should be displayed in the graphics window. Pressing the VIEW key displays different soft keys for graphic viewing options of the program. Pressing the View key again, or pressing the CANCEL key will turn the view key display off. See "Program Drawing View" on page 56. The VIEW key provides access to the following soft keys for selecting how the part should be viewed.
5.1 Programming Introduction Step Functions soft keys The Step Functions soft key provides access to the following soft keys for assistance with programing steps, and modifying or arranging the programs steps. Soft key Function The Explode soft key will explode a program step e.g. such as a bolt circle converting it from a radius and number of holes equally spaced to individual coordinates for each hole. See "Explode" on page 160 for additional information.
5.1 Programming Introduction Program Steps soft keys The Program Steps soft key accesses the soft keys listed in the table below. Each soft key (except for the Tool key) provides additional selections on a popup menu. This allows to further define the milling action to be programmed. Soft key Function The Tool soft key opens a tool dialogue to enter the size and type of tool to be used for the following step(s). The Position/Milling soft key opens a popup menu to further define the milling operation e.g.
5.1 Programming Introduction Clear Program soft key This soft key provides a quick method to clear the current loaded program. It does not provide an option to save before exiting. Its function is meant to quickly clear a program (e.g. once it has been run and is no longer needed), so that a new program can be loaded, or a blank program is available, or return to DRO mode without having a program loaded. If the program has been edited the operator is asked to confirm the Clear operation.
5.1 Programming Introduction Run Options soft keys The Run Options soft key allows the program to be run and tested with various options for a program. These options allow the operator to test a program without actually cutting material. The Run Options must be set before you start to run the program. Soft key Function The Single Step soft key will move the machine one step at a time. The Dry Run soft key will run the program’s tool path at the speed defined in Job Setup.
5.1 Programming Introduction Program Saving When you create programs with the MILLPWRG2, they can be saved within MILLPWRG2's User folder, on a USB device, or a network location. MILLPWRG2 will retain a program in memory so it is not lost in the case of a power failure. Programs can be organized in MILLPWRG2, on a USB device, or a network location; or in personalized folders that the operator can create.
5.2 Program Mode Functions 5.2 Program Mode Functions Program Type Filter In PGM mode, press the Program Functions soft key to display the Folder View, and Program Type soft keys. Program type aids with locating programs by type, and reduces the number of programs that are displayed. To select what type of programs to show, press the Program Type soft key, and select which program type(s) to display using the ARROW keys.
5.3 Creating programs overview 5.3 Creating programs overview New Part Program The following briefly describes how a new program is created. See "Fundamentals for Creating a Program" on page 75 for more complete information. Press the DRO/PGM key from DRO mode to enter PGM mode. A new program can be created from an existing program, or create a completely new program. To create a new program from an existing program: Press the Program Functions soft key.
70 5 Program Overview 5.
Programming
6.1 Conversational Programming 6.1 Conversational Programming Programming Considerations “From” and “To” points Lines and arcs are defined by their FROM point (the point where they begin) and TO point (the point where they end). Depth of Cut When programming the depth of cut, MILLPWRG2 will prompt for the BEGIN and END locations for the Z axis. The location that is entered into the Z BEGIN field tells MILLPWRG2 where the quill is to begin cutting at the programmed feed rate.
6.1 Conversational Programming Tool Offset MILLPWRG2 will calculate the actual tool path when using left and right offsets. Program the dimensions of the part as identified by the part drawing. Program a line, arc, frame, etc. using the “Tool Offset” field to tell MILLPWRG2 which side of the line the tool is to be on. See "Tool Radius Offset" on page 50. To determine which offset to use: If the tool needs to be on the left side of the line, use a LEFT offset.
6.1 Conversational Programming Absolute vs. Incremental Dimensions MILLPWRG2 allows both absolute and incremental dimensions to be entered. A dimension measured from the point you defined as datum is an absolute dimension. A dimension measured from any other point is an incremental dimension. See "Absolute and incremental work piece positions" on page 25. The dimension moves of 8, then 8 again are incremental moves. The dimension moves of 8, then 16 are absolute moves.
6.1 Conversational Programming Fundamentals for Creating a Program In DRO mode press the DRO/PGM key to enter program mode. Programs are created by developing a list of milling steps to be performed. As steps are added to the list, each will immediately be drawn on the screen so that it can be displayed graphically, showing the part machining in progress. MillPwr G2 allows a maximum of 9999 program steps.
6.1 Conversational Programming Adding/Inserting milling steps A new program step number automatically appears following the last step entered, and the new step is highlighted. If the cursor was moved for any reason, use the arrow keys to highlight the new step, then select the milling function to be added. To insert a step between two existing steps, position the cursor to the step below where the new step is to be placed.
6.1 Conversational Programming Program Errors When an error is detected in a program, the step with the error is highlighted in the program listing with a red "x" symbol. Edit the program step to correct the error. Additional information about the error is added to the error log. See "Error Log" on page 183. After correcting the errors, remember to delete them from the error log. A quick method for deleting all errors in the log is to press the “0” on the numeric keypad.
6.1 Conversational Programming Running a Program Skewing a Part For some machining operations it is more convenient to use the Skew feature rather than indicating in the work piece. With MILLPWRG2, it may save time setting up a job by skewing the part. The Skew feature automatically compensates for the offset angle of the part by touching off one straight edge with an electronic edge finder or a mechanical indicator. To skew a part touch off on two or more points along one axis, either X or Y.
6.1 Conversational Programming Setting the skew angle with an electronic edge finder: Press the Datum softkey to open the DATUM dialogue. Highlight the Angle field. Press the Probe soft key. Touch off on two or more points along any single straight edge of your part. You’ll notice that the Angle and Points fields change as you enter points. Press the Finish soft key. Press the USE soft key to accept all of the points and return to the DRO screen.
6.1 Conversational Programming Establishing a Datum Overview Datum is the workpiece zero or absolute zero, and is a point of reference that the MILLPWRG2 bases all of the part's coordinates from. A datum must be established for every job. Datum's location may be indicated on the print; or the operator may establish a datum that allows most of the part's dimensions be entered directly using the least amount of calculations.
6.1 Conversational Programming Steps to Establish the datum Where and how you establish the datum will vary from job to job. The following step, by step process is a common method of establishing a datum. Being familiar with the basics, the same principles will apply for other parts, making adjustments to the procedure as needed when setting the datum. From the DRO mode, press the Datum soft key. In the datum number field, enter a number for the datum to be defined.
6.1 Conversational Programming X Axis Datum: Lower the tip of the tool so that it falls below the top surface of the part. Move the table along the X axis, slowly spinning the tool by hand as you go. When the tool contacts the part, stop the table. Using the numerical keypad, enter the radius of the tool (the distance from the center of the tool to the edge of your part) into the X: field. Be sure to specify if it’s a negative value.
6.1 Conversational Programming Retract Z Now either enter the Z axis retract position (the position that the quill should return to between steps) which is the location above the top surface of your part. Or press the CLEAR key to clear the value. If no value is set, the quill will retract to the upper travel limit between steps. Press the ENTER or USE Key to save the datum location and return to DRO mode. Datum and the Z axis retract position have now been established.
6.1 Conversational Programming Select the datum field that is to be set (X, Y or Z axes), then press the Probe soft key. The datum is set for the axis that was last used when the edge finder was triggered. If moving the X axis when the edge finder is triggered, the X datum will be set and the X datum field will be set to 0.0000. With the Probe soft key activated, select the type of probing to be performed by pressing the appropriate softkey: Edge, Centerline, or Circle Center.
6.1 Conversational Programming Setting the datum at the centerline The position of the centerline is determined by probing two edges, either in the X or Y direction. Press the Probe soft key. Press the Centerline soft key. The message Move to first edge appears in the message bar. Move the edge finder until it makes contact with the work piece edge, and the message changes to Move to second edge.
6.1 Conversational Programming Test the Datum Setting It's recommended to test the datum setting before beginning a program. To confirm the datum setting use the Pos key. To quickly move to the datum for X and Y, press the Pos key. With the Z axis at its retract position, enter 0.0000 for the go to position for both the X and Y (leave the Z field blank). Press the GO key. The table will move to the datum position X 0.0000, Y 0.0000. Lower the tool until it touches the part.
6.1 Conversational Programming Testing a MILLPWRG2 Program Before machining a part, test the program for things like correct tool path, count direction, feed rate, and sequence of operations. MILLPWRG2 provides several run-time choices to assist doing this. Always verify a program when it was loaded, or edited. Whenever a program is about to run, check that the handles are recessed.
6.1 Conversational Programming Press any soft key to activate the option; press it again to deactivate it. Before pressing the GO key to begin the Single Step, Dry Run features, check that the tool will not touch the workpiece when the quill begins to move. To avoid interference, do one or more of the following: • Lower the knee • Remove the tool or workpiece • Reestablish datum away from the part. Single Step Normally, a continuous contour will be machined without stopping.
6.1 Conversational Programming Machining Your Part Before running a program step, check the Status bar (located along the top of the MILLPWRG2 screen) to ensure that the tool identified by MILLPWRG2 matches the tool in the spindle. If there’s no tool identified, or if it’s incorrect, start with a SET TOOL step that accurately identifies the tool that is to be used. To move quickly to a step, use the up/down ARROW keys to highlight the required step, or just enter a step number using the numeric keypad.
6.1 Conversational Programming MILLPWRG2 will automatically pause at points that require action to be taken (e.g., change tools). After each task has been completed, press the GO key. A 2 axes system requires the Z axis to be moved manually into position. If the STOP key is pressed once while cutting, the tool will pause in its cutting path and an Operator Intervention Message will appear. Press GO to resume machining, or STOP again to end the program.
6.1 Conversational Programming Manually Positioning the Quill Programs that do not include a BEGIN depth will require the operator to manually position the Z axis during machining. The same is true when the Z axis has been disengaged during setup. If an END depth is programmed, when it is time to manually position the Z axis, a preset value will be displayed in the Z axis display. The DRO screen will appear, along with the prompts shown.
6.2 Folders 6.2 Folders Folder Functions The soft keys available are described in the previous chapter, see "Program Functions soft keys" on page 59. MILLPWRG2 offers several versatile features for loading, saving, deleting, and backing up programs. Programs can be organized by creating folders. Folders can be quickly selected, created, make a backup copy, or if necessary, deleted. Folders Organize programs by saving them in folders.
6.2 Folders Naming a new folder Using the on screen Keyboard, enter the name of the new folder. If the keyboard is not automatically displayed, press the Keyboard soft key. Once the new folder’s name has been entered, press the Save/ Create soft key to create the new folder. Deleting a Folder MILLPWRG2 will delete folders that contain programs, or files. MILLPWRG2 will prompt the operator that there are files within the folder, and ask for confirmation if they are to be deleted.
6.2 Folders Naming a Program Before you can save a program, MILLPWRG2 requires it to be named. Enter the program name using the ARROW keys to navigate the keyboard. Highlight the key to be used (e.g. letter, or number), then press the ENTER key to add the selection into the Program Name: Field. Continue in the same manner until the name is complete. To add numbers to your program name, press any of the number keys on the numerical keypad, or from the keyboard display. Press the Save/Create soft key.
6.2 Folders Loading a MILLPWRG2 (MPT) Program The Load soft key allows you to open programs in the folder listing. The steps below explain how to load a program from MILLPWRG2 User folder, a USB device, or from a network location. Program extensions: MILLPWRG2 programs have a .mpt extension. G-code programs have a .G or .NC extension. DXF files must have a .DXF extension. If a program is loaded, save the open program, it does not have to be cleared.
6.2 Folders Importing a DXF drawing Save any running programs. Locate the folder containing the DXF drawing. If a program is loaded, save the open program, it does not have to be cleared. From the PGM screen, press the Program Functions soft key. When a DXF drawing is not located in the current folder, select the location of the DXF drawing using the Folder View soft key, and Change Window soft key as needed. Verify that DXF Drawing is selected in the Program Type popup menu.
6.2 Folders G-code Programs MILLPWRG2 has the ability to read and run G-code programs, however those programs can not be edited. It is important to fully test the G-code program before machining a part. Loading a G-code Program A G-code program can be loaded into MILLPWRG2 in the same manner as MILLPWRG2 programs. Once loaded, MILLPWRG2 will indicate with an "x" the first error regardless of the cursor location.
6.2 Folders Running a G-Code Program MILLPWRG2 has the ability to read and run G-code programs, however those programs can not be edited by the MILLPWRG2. It is important to create and proof the G-code program before attempting to machine a part. Verify the program in the CAD/CAM system that generated the program. MILLPWRG2 will draw the program when Loaded. Finally, lower the knee and dry run the program to verify that the tool path, feeds and speeds are correct.
6.2 Folders G-code and M-Code Definitions G-code The following is a list of supported, and unsupported G-codes. † Represents supported G-codes.
6.2 Folders G-code Description Comment Return to Home Reference MILLPWRG2 does not have a method for establishing a "home" position. If one or more coordinates are specified in the block, the table/quill will rapid to that location. Program execution will continue with the next program block.
Description G61 † Set "stop" Path Mode G64 † Set "continuous" Path Mode G70 † Set Program Units (INCH) G71 † Set Program Units (MM) G80 † Cancel Motion Mode G81 † Basic Drill Cycle Comment These commands set the path mode. The setting applies to current and subsequent blocks. The default is G64 (continuous). Same functions as G20 and G21. These commands set the unit of measure. The setting applies to current and subsequent blocks. The default is G70 (INCH).
6.2 Folders G-code Description Comment This is the chip-breaker peck-drilling cycle, generally used to : Peck-drill medium to deep holes. The cycle feeds from the begin depth to the first peck depth in Z, rapid retracts the chip-break increment (W), feeds to the next calculated peck depth (initial peck less J), and continues this sequence until it reaches a U depth, or until final hole depth is reached. The peck distance is never more than I or less than K.
6.2 Folders M-Code Definition The following is a list of available M-Codes. Be advised that many M-codes are machine dependant, and often machine manufacturers will add, and/or remove some M-Codes. † Represents supported M-codes. M-Code List M-Code Description M* † Comment All other M codes not listed will generate a run-time error. M0 † Program Stop This command pauses the program. Press GO to resume.
6.2 Folders M-Code Description Comment M48 Enable Speed/Feed Override It is not possible to disable feed rate override on MILLPWRG2. These commands are ignored. M49 Disable Speed/Feed Override M60 Program Stop w/ Pallet Shuttle 104 MILLPWRG2 does not support control of a pallet changer. This code has the same effect as M0.
Description Comment F† Set Feed Rate The feed rate uses the current program units in effect (ipm or mmpm). The setting applies to current and subsequent blocks. The default is determined from MILLPWRG2's configuration setup. I† Arc center coordinate parallel to X axis J† Arc center coordinate parallel to Y axis K† Arc center coordinate parallel to Z axis N† Line Number Line numbering is optional and for readability only. MILLPWRG2 does not make use of this information.
6.2 Folders Additional G-code Conventions for MILLPWRG2 The following lists some of the expectations and limitations of programs ran in MILLPWRG2. Blocks may contain multiple commands and are executed with the following precedence: Messages Tool Change Spindle Control Coolant Control Dwell Motion Stop Operator comments should be enclosed in parentheses. An operator comment with “MSG” appearing within the text is considered a message.
6.2 Folders Backing Up a Program To back up a program is similar to saving a program. A backup program can be saved to another location (e.g. memory device, or on a network), or to the same program location. If it is saved to the same program location, then it can be with the same name plus an indication in the name that it is a backup copy. The MILLPWRG2 Copy and Paste functions do this automatically, and is further explained below. In the same manner, this can also apply to backing up a G-code program.
6.2 Folders Use the arrow keys to highlight the program to be copied, then press the Select soft key. A popup menu will open where either the highlighted program can be selected, or all programs in the folder can be selected. Highlight Select, or Select All, then press the ENTER key. If the program that was selected is not the correct one, select the Clear feature, and press ENTER. The program is un selected, and another program can now be selected.
Demonstration Program
7.1 Demonstration Program 7.1 Demonstration Program Overview The following steps and key stroke sequences will guide you through creating a demonstration program based upon information from the part drawing shown. All dimensions are in inches. This will help introduce you to MILLPWRG2 and familiarize you with how it operates. Selecting Datum Although there is no clear "zero point" identified on this print, use the center of the bolt hole pattern as datum.
7.1 Demonstration Program Begin Programming From the DRO mode, begin by pressing the DRO/PGM key to enter the PGM mode. If a program is loaded, save the open program, it does not have to be cleared. This is example is done in INCH mode. Make sure INCH is selected. Selecting A Tool The first step for this program is to choose the tool that will be used to begin the machining. For this step, a 1/4” diameter FLAT END MILL will be used. Press the TOOL key to access the SET TOOL Dialogue.
7.1 Demonstration Program Programming a line For this example, the part will begin at the upper left hand corner, and cut in a clockwise (CW) direction. Press the LINE key. The cursor will default to the FROM: X1 field in the MILL LINE dialogue. Using the numerical keypad, enter the following information: In the FROM: X1 field enter -3, and press the ARROW Down key. In this case, pressing the ENTER key twice is required to move the cursor down to the next field because a negative number was entered.
7.1 Demonstration Program Programming an Arc Press the ARC key. The cursor defaults to the TO: X1 field in the MILL ARC dialogue. MILLPWRG2 assumes that the program is continuing from the last step, so it automatically fills in the FROM: X1, and Y1 fields, the Z: fields, TOOL: fields, FEED: fields, and the OFFSET field. Using the numerical keypad, enter the following information: In the TO: X2 field enter 0, and ARROW Down. In the TO: Y2 field enter -1.5, and ARROW Down.
7.1 Demonstration Program Programming the connecting Line Step 001 is now highlighted. ARROW Down to the last blank step number (004) to highlight that step. The next step to program is the line that starts at the bottom of the arc. Press the LINE key. Again, MILLPWRG2 assumes that the program is continuing from the last step. So it has automatically filled in the FROM: X1, and Y1 fields, the Z: fields, TOOL: fields, FEED: fields, and the OFFSET field.
7.1 Demonstration Program Programming the lower vertical Line Next, the line that starts vertical from the bottom line at the end of the arc will be entered. Press the LINE key. Again, MILLPWRG2 assumes that the program is continuing from the last step. So it has automatically filled in the FROM: X1, and Y1 fields, the Z: fields, TOOL: fields, FEED: fields, and the OFFSET field. Using the numerical keypad, enter the following information: In the TO: X2 field enter -3.0, and ARROW Down.
7.1 Demonstration Program Programming the lower angle Line Next, the line that angles in to the part from the lower vertical line will be added. Press the LINE key. MILLPWRG2 has again assumed that it will continue from where it left off, and all fields are filled in except for the TO: fields. The cursor is also located here, in the first field. Using the numerical keypad, enter the following information: In the TO: X2 field enter .75. Now press the ABS/INCR key.
7.1 Demonstration Program Programming the upper angle Line The upper line that angles away from the part will now be added. Press the LINE key. With MILLPWRG2 assuming that it is continuing from where it was left off, all fields are filled in except for the TO: fields. Which is also where the cursor is located in the first TO: field. Using the numerical keypad, enter the following information: In the TO: X2 field enter -3.0, and ARROW Down. In the TO: Y2 field enter .838. Press the USE key.
7.1 Demonstration Program Programming a Blend In this step, a BLEND will be inserted between program steps 6 and 7. ARROW up one step to highlight program step 7. Press the BLEND key. In the TYPE field be sure that Blend is selected. Program Step 7 has now moved to program Step 8, and the BLEND program step is now Step 7. Also notice that the continuous line in the program steps between steps 6 and 8 is now broken. This indicates that these steps will be blended.
7.1 Demonstration Program Closing the contour The contour of the part will now be closed, and all milling steps entered will be one continuous machining operation. Press the LINE key. As MILLPWRG2 assumes that you are continuing from where it was left off, all fields are filled in except for the TO: fields. Which is also where the cursor is located in the first TO: field. Using the numerical keypad, enter the following information: In the TO: X2 field enter -3.0, and ARROW Down.
7.1 Demonstration Program Tool Change for the Bolt hole Pattern Begin first by changing the tool. Press the TOOL key. The tool form will open with the cursor in the SIZE: DIAMETER field. Enter 0.25 in the SIZE: DIAMETER field using the numeric keypad. Press ARROW Down to highlight the TOOL TYPE field (the LENGTH field will be left blank). In the TOOL TYPE field, press the Tool Types soft key to open the TOOL TYPE drop down menu. ARROW down to highlight the DRILL.
7.1 Demonstration Program Programming the Bolt circle Press the HOLES key. A popup menu will appear for selecting the type of hole pattern to be used. Select the Bolt Circle selection. The BOLT CIRCLE input dialogue will be displayed. In the CENTER X field enter 0.00, and Y field enter 0.00. For this program it is also the CENTER location for the Bolt Circle (which is also where datum X 0 and Y0 was set).
7.1 Demonstration Program Tool Change for the Rectangular Pocket Begin by changing the tool. Press the TOOL key. In the SET TOOL dialogue enter 0.125 in the SIZE: DIAMETER field. ARROW Down to highlight the TOOL TYPE field. With the TOOL TYPE field highlighted, press the Tool Types soft key to open the TOOL TYPE drop down menu. ARROW down to highlight the FLAT END MILL. Press the ENTER key to select the tool. ARROW down to highlight the SPINDLE field.
7.1 Demonstration Program Programming the Rectangular Pocket Press the RECT key. A popup menu will appear for selecting the type of rectangle to be milled. Highlight Pocket and press the ENTER key. The RECTANGLE POCKET dialogue will be displayed. The cursor will default to the first field (X1). In the 1st CORNER: X1 field enter -2.0. In the 1st CORNER: Y1 field enter -1.0. ARROW down to SIZE: X field and enter 0.5 ARROW down to SIZE: Y field and enter 2.0.
7.1 Demonstration Program Testing the Program Whenever a new program has been created, it should always be tested first. Graphics only The following steps will run the program graphically only, and there will be no table movement. Press the Run Options soft key. Press the Graphics Only soft key. Use the arrow up key to highlight step 001 of the program. Press the Exit soft key. Press the GO soft key (there will be no table movement).
Press the Run Options soft key. Press the Graphics Only soft key to display the machining steps. Displaying the graphics is not required, but can be of assistance when executing the dry run feature. Press the Dry Run soft key. Use the arrow up key to highlight step 001 of the program. Press the Exit soft key. Press the GO soft key (the table will move). 7.1 Demonstration Program Running the Program The first step in running a new program is to establish datum.
7.1 Demonstration Program Tool Changes Whenever you encounter a SET TOOL step, MILLPWRG2 will display the DRO screen and let you know which tool to load. If no tool diameter was programmed in the Tool Step, a prompt will be displayed to provide one. Use the Move Table soft key and ARROW keys to move the workpiece away from the tool. Insert the required tool into the spindle. Using the Move Table soft key, position the surface of a known depth on the workpiece under the tool.
Milling and Drilling
8.1 Milling and Drilling 8.1 Milling and Drilling Overview Most of the program steps described in this section can be performed as one-step milling functions from the DRO screen or be included as steps in a program. Many of the dialogues are similar in the way that the data is entered. Much of the information in this chapter should be familiar after performing the demonstration program in Chapter 7. SET TOOL defines the tool and should appear as the first step in a program.
8.1 Milling and Drilling Selecting A Tool The first step for a program is to choose the tool that will be used to begin the machining. For this example, a 1/4” diameter FLAT END MILL will be used as an example. Press the DRO/PGM key to enter PGM mode. Press the Program Steps soft key. Press the Tool soft key to open the SET TOOL Dialogue. In the SET TOOL dialogue the cursor defaults to the SIZE: DIAMETER field. Enter 0.25 in the SIZE / DIAMETER field.
8.1 Milling and Drilling ARROW DOWN to highlight the SPINDLE: field. Press the Forward soft key ARROW DOWN to the SPEED: field (RPM) and enter the speed required (e.g. 1300) using the numeric keypad. ARROW DOWN to tool position and enter the location where it is best to make a tool change away from the part and fixtures. MILLPWRG2 moves to the TOOL POSITION before prompting the user for a tool change, making it unnecessary to program a POSITION/DRILL step before a tool change.
8.1 Milling and Drilling Repeatable Tool Length Offsets Programming a Tool When a program is using the Tool Length function, there are two requirements that must be followed to ensure that the tip of all additional tools is actually where MILLPWRG2 has calculated it to be. All tools used must have a fixed, repeatable length. The surface that the tool touches off on must be a repeatable surface and used for all tools added to the program. This also applies to all tools added to the Tool Table.
8.1 Milling and Drilling Enter the necessary data in the remaining fields where applicable. Press the GO key. An Operator intervention message will appear asking you to “use” the selected tool. Press the GO key to confirm that you have installed the tool. At this point, your program’s tool length offsets are not valid. Follow the steps below to reestablish the Z axis datum and tool length offsets for your program.
8.1 Milling and Drilling Changing to a Tool of unknown length in a program When running a program, it is possible to switch between tools of known length, to using a tool that has a non-repeatable length. When the tool which has a non-repeatable length is mounted, it’s length will be established in the same manner as above in DRO mode. Place the tool in the spindle. In the SET TOOL Dialogue, enter the necessary data in the fields where applicable, but delete any data in the LENGTH field.
8.1 Milling and Drilling Position / Drill The Position / Drill function will move the table to specific position based upon the X and Y axes coordinates entered. From the PGM screen, press the Pos key to access the POSITION / DRILL Dialogue. In the POINT field enter the X and Y axes coordinates. In the Z field enter the BEGIN and END depths. Enter either the number of pecks or the distance between each peck (also know as Chip Break).
8.1 Milling and Drilling Line Lines are defined by their “From” point (the point where they begin) and “To” point (the point where they end). There are two ways you can program a line: With four coordinates (X1, Y1, X2, Y2). With three of the coordinates above (X1, X2, Y2 or X1, Y1, X2, etc.) and an angle. Choose a method based upon the information available from your print. Entering Data: From the PGM screen, press the LINE key to access the MILL LINE Dialogue.
8.1 Milling and Drilling Arc An arc can be defined several ways: With a From point, To point and a radius With a From point, To point and a center point With a From, To and a 3rd point along the arc With a start point to an end point for a sweep angle Choose a method based upon the information available from part drawing. While programming, keep in mind that the arc's sweep angle is measured from the X axis.
8.1 Milling and Drilling If you need to enter a center coordinate, 3rd point and/or sweep angle press the More soft key: CENTER field: Enter the center coordinate’s position for the X and Y axes. 3rd POINT field: Enter your 3rd coordinate’s position for the X axis (X3) and Y axis (Y3). SWEEP ANGLE field: Enter the sweep angle. Information that appears in blue has been calculated.
8.1 Milling and Drilling Blend Highlight a step within your program where you want to place a blend. The blend step can be added prior to adding the connecting line in the program step, or between two connecting lines. When placed before the connecting line is added, it will not be displayed until the connecting line is placed in the program. From the PGM screen, press the BLEND key to access the BLEND Dialogue. Select the blend type. A blend is tangent to the two steps.
8.1 Milling and Drilling From the PGM screen, locate the lines where the chamfer is to be inserted between. Highlight the second line. Press the BLEND key. Press the Chamfer soft key after the dialogue opens. Check that the steps listed in the FROM and TO fields are the steps to be blended. If they're incorrect, press the CANCEL key and highlight the appropriate step. For Length 1, enter the distance from the common point to the FROM line.
8.1 Milling and Drilling Rectangular Milling Functions MILLPWRG2 offers several rectangular milling functions that let you program pockets, frames, faces and slots. For 2 axes systems, Refer to Chapter 1, "Operating in 2 Axes and 3 Axes Modes" on page 9. Rectangle Pocket A pocket is a cavity or area on the part where material is removed when you machine. You can program a rectangular pocket two ways: Using the coordinates of two diagonal corners.
8.1 Milling and Drilling ARROW down or press the More soft key and enter the table’s feed rate. If you need to program a corner blend radius, tilt angle and/or finish cut: You can tilt a rectangular pocket by identifying a tilt angle. Highlight the ANGLE field and enter an angle measured from the X axis. Finish Finish allows you to leave some excess material that will be removed during the finish cut reducing tool marks. The finish cut will automatically arc on and arc off.
8.1 Milling and Drilling Rectangle Frame When you program a rectangular frame, you define it by its first corner, and its size or diagonal corner. You can program a frame in one of two ways: Using the coordinates of two diagonal corners. Using the coordinates of one corner and the size of the pocket. To program a rectangular frame: From the PGM screen, press the RECT key to access the RECT popup Menu. Select Frame from the popup Menu.
8.1 Milling and Drilling Add a corner blend radius to the corners of the rectangular frame. For DIRECTION, press either the CW soft key for a clockwise cutting direction or the CCW soft key for a counter-clockwise cutting direction. ARROW DOWN or press the More soft key and select the TOOL OFFSET. ARROW DOWN or press the More soft key and enter the table’s feed rate. You can tilt a rectangular frame by identifying a tilt angle.
8.1 Milling and Drilling Rectangle Face The “Rectangle Face” step provides a quick way to face off your workpiece. Simply enter the coordinates from one corner and either the size of the area to be faced off or the coordinates for a diagonal corner. MILLPWRG2 will position your table at the lower left end of the area you've programmed. You can program a rectangle face in one of two ways: Using the coordinates of two diagonal corners. Using the coordinates of one corner and the size of the pocket.
8.1 Milling and Drilling Tool Path Description: Machining of the face begins near the first corner. The tool plunges at the Z feed rate. The tool makes back and forth passes in the XY plane along the defined length of the face. Tool motion extends beyond the ends of the rectangle by an amount equal to the tool radius. The XY step size is determined by the system and will not exceed the specified percentage of the tool diameter.
8.1 Milling and Drilling Rectangle Slot You can program a slot two ways: By entering the center point of each arc and the slot's width By entering the center point of one arc, the length and width of the slot, and an angle. Choose a method based upon the information available from your print. To program a slot: From the PGM screen, press the RECT key to access the RECT popup Menu. Select Slot from the popup Menu. Entering Data: Enter the 1st ARC CENTER X1 and Y1 axes coordinates.
8.1 Milling and Drilling The TOOL fields will automatically be filled in with the current tool loaded. If a different tool is to be used, enter a SET TOOL step prior to this program step. You can tilt a rectangular slot by identifying a tilt angle. Highlight the ANGLE field and enter an angle measured from the X axis. The FINISH fields will assume the same as the previous finish fields in the program if it exists. Otherwise this data must be added if necessary to include it.
8.1 Milling and Drilling Circular Milling Functions MILLPWRG2 offers several circular milling functions that let you program pockets, frames, ring, and helix. Refer to Chapter 1, "Operating in 2 Axes and 3 Axes Modes" on page 9 for information regarding 2 Axes Systems. Circle Pocket A pocket is a cavity or area on your part where material is removed when you machine. You can program a circular pocket by indicating the center point and radius.
8.1 Milling and Drilling ARROW DOWN or press the More soft key. The FINISH fields will assume the same as the previous finish fields in the program if it exists. Otherwise this data must be added if required, or leave it blank if not required. For DIRECTION, press either the CW soft key for a clockwise cutting direction or the CCW soft key for a counter-clockwise cutting direction. Enter a stepover percentage (how much the tool to is to overlap on each pass).
8.1 Milling and Drilling Circle Frame A frame is a cavity or area on your part where material is removed when you machine. You can program a circular frame by indicating the center point and radius. To program a circle frame: From the PGM screen, press the CIRCLE key to access the Circle popup Menu. Select Frame from the popup Menu. Entering Data: Enter the X and Y axes coordinates for the center of the frame. Enter the BEGIN and END depths for Z.
8.1 Milling and Drilling ARROW DOWN or press the More soft key. The FINISH and FEED fields will assume the same as the previous finish fields in the program if it exists. Otherwise this data must be added if required, or leave it blank if not required. For DIRECTION, press either the CW soft key for a clockwise cutting direction or the CCW soft key for a counter-clockwise cutting direction. Press the USE key.
8.1 Milling and Drilling Circle Ring A ring is a circular pocket with a circular island in the center. A ring is determined by its center point, outside radius (radius of the pocket) and inside radius (radius of the island). The direction of the cut on the inside radius will determine whether you are climb cutting or conventional cutting. MILLPWRG2 will reverse the tool direction on the outside radius so that the cutting direction stays the same.
8.1 Milling and Drilling ARROW DOWN or press the More soft key. The FINISH and FEED fields will assume the same as the previous finish fields in the program if it exists. Otherwise this data must be added if required, or leave it blank if not required. For DIRECTION, press either the CW soft key for a clockwise cutting direction or the CCW soft key for a counter-clockwise cutting direction. Press the USE key.
8.1 Milling and Drilling Circle Helix The circle helix can only be performed with a 3 axes system. A helix is defined by one of two ways: By the radius, depth and pitch By the radius, depth and number of revolutions To program a helix: From the PGM screen, press the CIRCLE key to access the CIRCLE popup Menu. Select Helix from the popup Menu.
8.1 Milling and Drilling Hole Patterns MILLPWRG2 includes several built-in routines that let you program hole patterns quickly and easily.
8.1 Milling and Drilling Entering data: Select the Row of Holes from the popup Menu. In the FROM field, enter the X and Y axes coordinates for the center of the first hole and ARROW DOWN to the next field. Now either: Enter the X and Y axes coordinates for the center of the last hole in the TO field; or perform the following step instead.
8.1 Milling and Drilling Hole Frame and Array HOLE FRAME and HOLE ARRAY patterns require the same information, but their patterns differ slightly. Hole frames limit holes to the outside edge of a rectangular shape, while hole arrays allow holes along the outside edge and throughout the center. Hole Frames and Hole Arrays can be defined three ways: By the position of the 1st Corner, size, and the number of holes.
8.1 Milling and Drilling Entering data: From the PGM screen, press the HOLES key to access the HOLES popup Menu. Select the Rectangle Array from the popup Menu. Enter the 1st CORNER X1 and Y1 axes coordinates. Now enter either the SIZE of the array or the 2nd CORNER coordinates. Either data entry will automatically fill in the fields for the for the other option. To enter the SIZE, enter the length of the array along the X and Y axes.
8.1 Milling and Drilling Bolt Circle Patterns A Bolthole Circle pattern is defined by its center point, radius and number of holes. You can program partial bolthole patterns by pressing the More soft key and entering a start angle and an end angle. Entering Data From the PGM screen, press the HOLES key to access the HOLES popup Menu. Select the Bolt Circle from the popup Menu. Enter the CENTER X and Y axes coordinates. Enter the BEGIN and END depths for Z.
8.2 Additional Milling Functions 8.2 Additional Milling Functions Step Functions soft key Additional functions are available from the PGM screen by pressing the Step Functions soft key. Explode When in PGM mode there are certain functions that can be exploded. Pressing the Explode soft key will explode a program step into several, more detailed steps.
8.2 Additional Milling Functions Reverse Step The reverse step feature instantly switches the FROM and TO points and TOOL OFFSET. To reverse a milling function: From the PGM screen, use the arrow keys to highlight the step that you want to reverse. Press the Step Functions soft key. Press the Reverse Step soft key. Reverse Path With the reverse path option, you can reverse any continuous tool path. This will especially come in handy when you're working with DXF files.
8.2 Additional Milling Functions Change Steps The Change Steps feature gives you the ability to change or edit the depth, offset and feed rate of several steps simultaneously. You can use this feature from anywhere within your program and does not require the specific step to be highlighted. To Change Steps: From the PGM screen, press the Step Functions soft key. Press the Change Steps soft key. Enter the first and last step numbers that you would like to change in the STEP RANGE field.
8.2 Additional Milling Functions Delete Steps MILLPWRG2 provides options for deleting steps in two ways: using the Delete Steps soft key or using the CLEAR key. When deleting single steps, highlight the step, then press the CLEAR key. When deleting a range of steps, the Delete Steps feature is usually the best option. To delete a group of steps from a program: From the PGM screen, press the Step Functions soft key. Press the Delete Steps soft key.
8.2 Additional Milling Functions Custom Pockets A custom pocket step must immediately follow a closed contour. You can create a custom pocket from any closed contour. A closed contour is any shape consisting of lines, arcs, and/or blends (or chamfer), where the last step ends at the same point where the first step begins. MILLPWRG2 will indicate a closed contour with double lines to the right of the applicable steps in the program list.
8.2 Additional Milling Functions Island An island is a raised area (e.g. a boss) within a custom pocket that remains after material has been removed from around all of its sides. Though islands are easy to program, they must be placed correctly within the program sequence. Steps for the island's continuous tool path must appear first, followed by the Island step. Steps for the custom pocket's continuous tool path must appear next, followed by the Custom Pocket step.
8.2 Additional Milling Functions Contour The Contour step enables you to approach and/or depart from your part on a straight line or with an arc. The contour step must immediately follow the contour steps. Contours can only be associated with lines, arcs, blends and chamfers. By adding contours before and/or after a continuous tool path, you'll avoid starts and stops striking against the workpiece edge.
8.2 Additional Milling Functions Enter how far from the part you want your tool to travel in the DISTANCE field. If you would like to program a FINISH CUT, enter the amount of material to be removed during the finish cut. Enter the FEED RATE. Press the USE key. Tool Path Description: The tool path follows the profile of the contour steps. The Z step size is determined by the system and will not exceed the specified distance or number of passes.
8.2 Additional Milling Functions Repeat, Rotate, ... The Repeat, Rotate, ... soft key provides milling functions available with the MILLPWRG2 product. Repeat Using this step you can repeat sections of programs with any combination of X, Y or Z offsets. To program a repeat: From the PGM screen, press the Program Steps soft key. Press the Repeat, Rotate, ... soft key. Enter the number of the FIRST step and the LAST step in the STEP RANGE that you want to repeat.
8.2 Additional Milling Functions Mirror The steps being mirrored must precede the Mirror step. With Mirror you can create a mirror image of an entire program or a section of a program. To program a MIRROR: From the PGM screen, press the Program Steps soft key. Press the Mirror soft key. Enter the first and last steps in the STEP RANGE that you would like to mirror. Enter the X and Y axes coordinates which define the line across which the step range is mirrored. Enter the Z offset.
8.2 Additional Milling Functions Engrave Line All ASCII characters within the range of x032 - x126 are allowed, which includes Uppercase, Lowercase, Numbers, and Punctuation. From the PGM screen, press the Program Steps soft key. Then press the Other Steps soft key. In the popup menu select Engrave Line. With the cursor in the TEXT input field, press the Alphanumeric Keyboard soft key, and insert the desired text.
8.2 Additional Milling Functions Engrave Arc All ASCII characters within the range of x032 - x126 are allowed, which includes Uppercase, Lowercase, Numbers, and Punctuation. From the PGM screen, press the Program Steps soft key. Then press the Other Steps soft key. In the popup menu select Engrave Arc. Highlight the TEXT input field, press the Alphanumeric Keyboard soft key, and insert the desired text.
8.2 Additional Milling Functions Comment Step With MILLPWRG2, you have the ability to insert messages anywhere within a program. These messages can be displayed during machining (at run-time) or as Operator Intervention Messages (OIM). These messages become operational steps within the program and communicate pertinent information like "ROTATE PART" or "ACTIVATE COOLANT".
8.2 Additional Milling Functions Dwell This is where the time is set for the machine to pause it’s movement, and stay in its current position for a programmed amount of time measured in seconds. From PGM screen, press the Program Steps soft key, then press the Other Steps soft key. Select Dwell in the popup Menu. Enter the Dwell time in seconds, tenth of seconds can also be entered. Press the USE key. A Dwell of 0 will cause the program to Pause until the operator presses GO.
174 8 Milling and Drilling 8.
Setup
9.1 Setup 9.1 Setup Overview The MILLPWRG2 has a set of parameters that can be setup as default values. Some of these values can be over-ridden per the program step dialogue, while others remain in affect until changed in the setup dialogue. Setup Press the SETUP key to access the setup parameters. The setup parameters are grouped into two categories: Job Setup and Installation Setup (e.g. Config Data). Job Setup parameters can be changed to accommodate specific machining requirements for each job.
9.1 Setup Job Setup Three soft keys: Job Setup, Tool Table, and Error Log are used to setup the MILLPWRG2 for operation, programing, and DRO mode. Job Setup Press the Job Setup soft key to access the Job setup parameters. In the JOB SETUP dialogue there are four parameters that can be set which the MILLPWRG2 will default to when not overridden by another setting. SCALING: Typically most jobs are scaled at 1 to 1 (full scale).
9.1 Setup Scale Factor Scale factor is a multiplier that lets you expand or shrink the print’s dimensions without performing complex calculations, or affecting the proportion of your part. Enter the number that the dimensions should be multiplied by, then run the program normally. MILLPWRG2 will adjust the programmed dimensions (but not the tool size) automatically. There is no limit, or restrictions when using a scale factor. The MILLPWRG2 scale default setting is 1.0000. A value greater than 1.
9.1 Setup Job Clock - Parts Counter The parts counter appears on the status bar when in DRO mode, or running a program. This is useful to track how many times the current program has run and therefore how many parts have been completed. Here, setting the parts counter, stopping or starting the Job Clock are setup. The Job Clock will provide an estimate of time to machine the part, provide a stop watch, parts counter, and overall Job time.
9.1 Setup Display Grid When in PGM mode, and a program is selected, the graphic view of the part is displayed. A grid overlay can be added to the display. The grid spacing is defined in this field. The grid spacing is relative to the actual size of the part, and not the display size. For an example; if the part size is 3.0 x 3.0 inches, and the selected grid spacing is .5”, then the grid shown would have 5 horizontal, and 5 vertical lines displayed. If the part size is 6.0 x 6.
9.1 Setup To set the X axis Travel Limits: Select the TRAVEL LIMITS X Axis field. Move the table by pressing the Move Table soft key, then use the right and left ARROW keys, or manually move the table with the hand wheel. Move the table to the left to locate the right side table travel limit stop. With the table in the required location, press the Set Right softkey. Move the table to the right to locate the left table travel limit stop is to be set, and press the Set Left softkey.
9.1 Setup To set the Z axis Travel Limits: ARROW down to the TRAVEL LIMITS Z Axis field. Move the quill by pressing the Move Table soft key, then use the Move Z Up and Move Z down soft keys. The axis can also be manually moved with the hand lever, or wheel. Move the quill up to where the top of the quill travel limit stop is to be set with the Move Z Up soft key, or done manually. With the quill set in the required location, press the Set Top softkey.
9.1 Setup Tool Table MILLPWRG2 contains a tool table that can store the diameter, length, unit of measure, and tool type for up to 99 tools. MILLPWRG2 only requires that you provide the tool's diameter; however, it may be helpful to the operator if additional information is provided so that each tool is easier to identify from the tool list. Chapter 4 provides complete information regarding the tool table. See "Tool Table" on page 44 Set up the tool table so that the tools used most often appear first.
9.1 Setup Service Files Occasionally, it may be necessary to provide files that document problems. These are known as service files. The service files can be generated by pressing the Log Files soft key and then pressing the Service Files soft key (accept the default name and press the OK soft key). The services files take a few seconds to generate. Once generated they can be found in V:\ with the name service1.zip. Use features in Program Functions to copy the service file (i.e.: service1.
Software Update
10.1 Updating System Software 10.1 Updating System Software Software Update If desired as a precautionary method, a backup of the control's internal drive can be made prior to updating the system software, by using the included USB Recovery Drive (684138-xx). Please refer to the manual included with the drive for the backup procedure. Use a blank USB memory stick (1 GB or larger) to update the software. Do not use any memory stick with a smaller storage capacity.
Off-Line Software
11.1 MILLPWR Off-Line Software 11.1 MILLPWR Off-Line Software Off-Line Simulator The off-line software provides a convenient way to write part programs and simulate machine behavior using a standard Windows® computer. Features and functionality are virtually identical to that of the MILLPWRG2 control itself. System Requirements Platform: IBM compatible PC. Operating System: All 32-bit and 64-bit editions of ** Windows Vista®, and Windows® 7 are supported. Available Drive Space: 2GB or higher.
11.1 MILLPWR Off-Line Software Installation The software is installed in the usual manner by launching the setup program, selecting an installation destination, and choosing the desired features to be installed. Using the default setting for a "Complete" feature installation is highly recommended to ensure proper functionality. On some systems, you may be required to restart the computer after installation before the application will display properly.
11.1 MILLPWR Off-Line Software On Screen Keypad The MILLPWRG2 Off-Line software includes an on-screen keypad application. This can be used to simulate the hard keys that are normally available on the machine console. Pressing the buttons on the keypad application will activate the same operation that would occur when pressing the corresponding buttons on the machine console. The FEED slider only allows a range of 1% - 100%. The SPEED slider only functions with certain software versions and configurations.
11.
11.1 MILLPWR Off-Line Software Soft keys Shortcut 1 F1 2 F2 3 F3 4 F4 5 F5 6 F6 7 F7 8 F8 Numeric, and arrow keys: The arrow keys on a standard PC keyboard will simulate the console arrow keys, and the number keys will simulate the console number keys (using number lock). When number lock is turned off, the arrow keys on the number keys (2, 4, 8, 6) will simulate the console arrow keys. Updating It is not necessary to un-install the software before installing updates.
A Absolute work piece positions 25 Access to Machine Parameter Operations ix Activating/Resetting the Servos 5 Advanced Functions Change Window 92, 93 C Calculator 18, 41 Change Window Folder Contents 94 Folder Tree 92, 93 Preview Window 93 Clear Program 126 Clear Program soft key 65 Console 11 Calculator 18 Key Pad 20 Keyboard 17 PGM Mode 12, 54 Rear Panel 11 Screen Navigation 12 Context Sensitive Help 19 Continuous Table Move 27 Conversational Programming 72 Copy 107 Creating a Program 75 D Diameter Offse
Index Run Options 58 Dry Run 66 Graphics Only 66 Optional Stop 66, 87 Single Step 66 Save/Discard 58 Shutdown 58 Step Functions 58 Change Steps 63 Copy / Move Steps 63 Delete Steps 63 Explode 63 Reverse Path 63 Reverse Step 63 Shift Steps 63 View Adjust View 62 Block Form 62 Line View 62 Reset Graphics 62 Shaded View 62 Show Contour 62 Special Characters 17 Step Functions soft keys 63 STOP hard key 4 194 T Teach Position 34 Tool Table 44 Tool Table Structure 47 Tool-Length Offsets 48 Travel Limits 180 U
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