Operators Manual Ultimax 3 612n22

The information in this document is subject to change without notice and does not represent a commitment on the part of Hurco Companies. The software described in this document is furnished under a license agreement to customers. It is against the law to copy the software on any medium except as specifically allowed in the license agreement. The purchaser may make copies of the software for backup purposes. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, for any purpose without the express written permission of Hurco. © 1994 Hurco Companies, Inc. All rights reserved. Printed in the United States of America. Ultimax 3, UltiPocket, and AutoSave are trademarks of Hurco Companies, Inc. IBM and PC/AT are ed trademarks of International Business Machines Corporation. DXF is a trademark of Autodesk, Inc.

Many of the designations used by manufacturers and sellers to distinguish their products are claimed as trademarks. Hurco has listed here all trademarks of which it is aware. For more information on Hurco products and services, the corporate headquarters in Indianapolis, Indiana or one of the subsidiaries listed below: Hurco Companies, Inc. One Technology Way

P.O. Box 68180

Autocon Technologies, Inc. 38455 Hills Tech Drive Farmington Hills, Michigan

48331-5751

Indianapolis, Indiana

46268-0180 TEL (317) 293-5309 FAX (317) 328-2812

Hurco .Europe Ltd. Lincoln Road Cressex Industrial Estates High Wycombe Buckinghamshire, England HP12 3TH TEL 001 44 494 442222 FAX 011 44 494 4444646

Suite "M" Riverside, CA 92504

TEL (810) 488-0440 FAX (810) 488-0430

TEL (909) 358-2340

Hurco GmbH Benzstrasse 8

Autocon GmbH Kolpingring 12

8011 Kirchheim

D-82041 Oberhaching

Munich,



TEL 011 4989 9050 9434 FAX 01 1 4989 9050 9450

TEL 001`4989 625 2012 FAX 011 4989 625 2014

Central Hurco s.a.r.l. Pare d'activite Charles de Gaulle 5, rue Jean Monet 95190 Goussainville

TEL 011 33 1 39886 400 FAX 011 33 1 39929 483 r.

Hurco West 5860 Arlington Ave.

FAX (909) 358-2335

Hurco Southeast Asia Pte Ltd No. 37 Lorong 23 Geylang #0501, Yu Li Industrial Building Singapore 1438 Republic of Singapore TEL 0116 742 6177 FAX 011 65 745 7664

Using this Manual The Operator' s Manual describes the machine tool operations , Ultimax functions , and screens used by a Hurco machine tool operator. This manual employs several conventions to'explain the system concepts and point out key concepts . These conventions are described in this section.

Sections of the Manual This manual is divided into these chapters: Chapter 1 - Getting Started Chapter 2 - Conversational Part Programming Chapter 3 - DXF File Translation Supplementary material is included in the Appendix section at the end of the manual and includes the following: •

Ultimax 3 console • layout

•

Ultimax 3 Screen Hierarchy

•

Coordinate System

•

Recommended Chip Loads

•

Feeds and Speeds for High Speed Tools

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There is also an index that cross-references the material presented in the manual.

Ultimax 3 System

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Using this Manual

References to Keys In this manual , the softkey selections are described using their numbered "F"' designation and/or the words displayed on the text screen beside it, such as Physical Parameters (Fl). Some important softkeys are referenced by name in the index. Others are described in a group and referenced by a general category in the index. Console keys are described by the name used on the console. For example, the operator may be instructed to press Enter or the Power On button. The capitalized words in the example indicate the names of the buttons as they are labeled on an Ultimax 3 console. While learning the Ultimax system, the operator may find it useful to remove the console layout chart in the "Appendix" section and keep it available while reading the manual and programming parts.

Style Guide Indexed are italicized within the text paragraphs that define them. Titles of books also appear in italic print to meet the English language,. convention for titles . References to chapter and section names within the text are set in quotation marks for the same reason. Screen titles, field names, and button names begin with capital letters within the text and in the index to help the reader identify the exact reference as it appears on the system screen or on the console.

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Standard Text Icons This manual contains several icons to mark important sections:

Where can we go from here? This icon and heading indicate that at this point in the description the operator has several possible options which are then listed under the heading.

Troubleshooting The toolbox icon indicates steps that can be taken to solve potential problems. These sections contain information for Hurco Technical Service representatives and customers.

Hints and Tricks The light bulb icon marks useful suggestions for the machine tool operator. These suggestions may show creative uses of the Ultimax features or just helpful hints.

Important The information marked with the exclamation icon must be carefully studied. to ensure proper operation of the machine and/or the control.

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Caution A "Caution" message tells the operator that the machine may be damaged or a part ruined if the described procedure is not followed.

Warning A "Warning" message indicates that the operator may be injured and the machine tool severely damaged if the described procedure is not followed.

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Sample Screens The sample screens in this manual were captured on a HAWK 5M machine tool. Here is a sample screen:

+* MANUAL ..

I F TOOL IN SPINDLE PART MACHINE VERTICAL 1 393 . 788 TOOL IN SPINDLE B I 177 . BOB SPINDLE 8 F MACHINE «^+ FEED MOTION STOPPED 2 DIAGNOSTICS

MACHINE 393.780 177 . 688 8.888

x Y Z.

F 3 F 4 1 F S U F 6 1 F 7 r F 8

Choose appropriate sottkey

PARX MACHINE

WARM UP MACHINE

TOOL HOME

RESET SERVOS AMD SPINDLE CALIBRATE MACHINE

Figure ]-]. Manual screen

Note that there are three areas of interest on these screens: •

Softkey names and key numbers down the right side of the screen. Note that these names may change even when the text and data entry area does not change.

•

Fields to the left of the softkeys. A "field" is an area on an Ultimax screen that displays information and may also receive information that the operator enters through pressing console keys.

•

Prompt and error message area at the bottom on the left ("Choose appropriate softkey" is the prompt on the sample shown above.)

A Figure List showing the titles of all of the illustrations is included after the following Table of Contents.

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Table of Contents Chapter 1 - Getting Started Machine Tool Components ................................................................................1-1 Safety and Equipment Maintenance ...................................................................1-2 Operator Safety and Apparel ..................................................................1-2 Part Fixturing and Cutting ......................................................................1-3 Equipment Maintenance .........................................................................1-4 Daily .....................................................................................1-4 Weekly .. ................................................................................... 1-4 Monthly . .................................................................................... 1-5 Quarterly .... ................................................................................. 1-5 Semi-Annually ...... ...................................................................... 1-5 Annually ... .................................................................................. 1-5 The Ultimax 3 Console ................................ ....................................................... 1-6 Types of Console Keys ...........................................................................1-7 Floppy Drive and Protection Keyswitch ................................................. 1-8 Hardware Options .............................................................................................1-11 Software Options .............................................................................................. 1-12 U l tiPocket .............................................................................................1-12 3-D Contour .9 ........................................................................................ 1-12 CAD Compatibility ( DXF) Option ....................................................... 1-12 Off-line Software .... ........ ................................................................... 1-13 Cutter Insert Routines ............................................................................ 1-13 Indexer .................................................................................................. 1-13 Rotary ................................................................................................... 1-13 Additional Language Files .................................................................... 1-14 Option-Access Security Key .................................................................1-14 Preparing for Power Up ....................................................................................1-15 Routine Daily Checks ........................................................................... 1-15 Machine Power ..................................................................................... 1-16

Powering Up .....................................................................................................1-17 Power Up Troubleshooting ............................................................................... 1-20 No Response on the Console ................................................................ 1-20 Initialization Error Messages ................................................................ 1-21 Error Messages on Machine Configuration Screen ............................... 1-23

NZ 1,

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Table of Contents Calibrating the Machine ...................................................................................1-24 Power on to Servos ...............................................................................1-25 Calibrating the "Z" Axis .......................................................................1-26 Calibrating the Remaining Axes ...........................................................1-26 Warming Up the Machine ................................................................................1-27 Configuring the System ....................................................................................1-29 Switching Part Programming Editor Type ........................................................ 1-36 Loading Part Programs .....................................................................................1-37 Selecting an Existing Part Program ......................................................1-38 Entering - a New Part Program Name ...... ...............................................1-42 Erase Functions ................................................................................................1-45 Part Programming Setup . ..................................................................................1-48 Jog Unit ................................................................................................1-49 Tool Loading and Part Fixturing ............ ...............................................1-51 Loading Tools into the Spindle .................................................1-51 Fixturing the Part ......................................................................1-52 Identifying Part Zero with a Tool ..........................................................1-53 Part Setup .............................................................................................1-54 Part Setup Screen ......................................................................1-57 Entering Part Setup Information ............................................... 1-59 Tool Setup ............................................................................................1-62 Tool Setup Screen .....................................................................1-63 Tool Setup Fields ......... ............................................................. 1-65 Automatic Feed and Speed Calculations ...................................1-70 General Parameters ...............................................................................1-73 Hole Parameters ........................................................................ 1-80 Milling Parameters .................................................................... 1-81 Program Parameters .................................................................. 1-85 Program Storing , Renaming , and Deleting ....................................................... 1-88 File Storage Principles .......................................................................... 1-88 Directory Options ....................... .......................................................... 1-90 Storing Part Programs ........................................................................... 1-92 Renaming a Program ..................................... .......................................1-95 Deleting a Program ...............................................................................1-97 Copying Part Programs ......................................................................... 1-98 Machine Diagnostics Errors ...... .....................................................................1-103 Reset Control .................................................................................................1-107

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Figure List Figure 2-135. Cutter Inserts softkeys ......................................................................................................2-218 Figure 2-136. Triangle Programming diagram ....................................................................................... 2-219 Figure 2-137. Completed Mill Triangle screen ........................... !........................................................... 2-220 Figure 2-138. Diamond I Face diagram .................................................................................................2-223 Figure 2-139. Diamond 2 Faces diagram ................................................................................................2-224 Figure 2-140: Completed Mill Diamond I Face screen ..........................................................................2-225 Figure 2-141. Hexagon diagram .............................................................................................................2-226 Figure 2-142. Completed Mill Hexagon screen ......................................................................................2-227 Figure 2-143. Inserts in Sample Program ...............................................................................................2-228 Figure 2-144. Typical Single-axis Rotary Table ("A" axis) ...................................................................2-230 Figure 2-145. Input Screen with rotary option .........................................................................................2-231 Figure 2-146. Input screen .......................................................................................................................2-232 Figure 2-147. Part Setup screen with Rotary Axis .................................................................................2-233 Figure 2-148. General Parameters ...................... ..................................................................................... 2-235 Figure 2-149. New Block screen with Rotary softkey .............................................................................2-236 Figure 2-150. Rotary Options on the New Block screen ........................................................................2-237 Figure 2-151. Rotary Parameters ............................................................................................................2-238 Figure 2-152. Rotary Position Block ......................................................................................................2-239 Figure 2-153. Rotary Milling Operations ...............................................................................................2-241 Figure 2-154. Rotary Line .......................................................................................................................2-242 Figure 2-155. Formula to calculate unknown rotary line and arc points ................................................2-243 Figure 2-156. Rotary Frame ....................................................................................................................2-244 Figure 2-157. Rotary Pattern Loop ................................................. :....................................................... 2-245 Figure 2-158. Rotary Locations ..............................................................................................................2-246 Figure 2-159. Part Drawing used for the sample Rotary program ..........................................................2-247 Figure 2-160. Illustration of Preliminary Calculation Program ..............................................................2-248 Figure 2-161. Graphics screen representation of Rotary Program .........................................................2-263 Figure 2-162. Auxiliary screen with / facility options ................................................2-267 Figure 2-163. Auxiliary screen with Protocol options ............................................................................2-271 Figure 2-164. Machine Control Console Buttons ...................................................................................2-273 2_275 --:' .......: ........................................... . -- Figure 2-165. Machine Operations Buttons ..:....:...

...•...... =2-277Figure 2-166. Manual Screen ............ ............................. Figure 2-167. Test Run screen ...... :......................................................................................................... 2-278 Figure 2-168. Feed and Speed Optimization screen ...............................................................................2-279 Figure 2-169. Single Cycle screen ..........................................................................................................2-281 Figure 2-170. Single Cycle with program information ...........................................................................2-282 Figure 2-171. Auto screen ......................................................................................................................2-283 Figure 2-172. Auto screen while the program is running .......................................................................2-284 Figure 2-173. Auto screen with Tool Change message ..........................................................................2-285 Figure 2-174. Auto screen with Emergency Stop message .....................................................................2-286 Figure 2-175. Auto screen with Start and End Block fields ...................................................................2-287 Figure 2-176. Auto screen with Starting Location selections .................................................................2-289 Figure 2-177. Auto screen with Milling Start Block selections ..............................................................2-290 Figure 3-1. Current Directory screen ..........................................................................................................3-3 Figure 3-2. Input screen ..............................................................................................................................3-4 Figure 3-3. Auxiliary screen .......................................................................................................................3-5 Figure 3-4. Current Directory screen ..........................................................................................................3-6 Figure 3-5. DXF graphics screen with main DXF options .........................................................................3-7 Figure 3-6. Parameters screen for DXF option ...........................................................................................3-8 Figure 3-7. Data Input dialog box .............................................................................................................3-I I Figure 3-8. Data Block Type Selection .....................................................................................................3-12 Figure 3-9. Accept screen button for Milling ...........................................................................................3-14

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Figure List Figure 3-10. Locations in the Holes data block ........................................................................................3-15 Figure 3-11. Mill Contour Start data block ...............................................................................................3-16 Figure 3-12. Zoom Box screen button for Milling ...................................................................................3-17 Figure 3-13. DXF Zoom options ...............................................................................................................3-18 Figure 3-14. Panned view .........................................................................................................................3-19 Figure 3-15. Layer options ........................................................................................................................3-21 Figure 3-16. Selecting Holes from the DXF drawing ...............................................................................3-22 Figure 3-17. DXF Default screen button and message .............................................................................3-24 Figure 3-18. Tool Path in the part program ..............................................................................................3-26 Figure 3-19. DXF Milling options ............................................................................................................3-27 Figure 3-20. DXF drawing with outside lines and arcs selected ...............................................................3-28 Figure 3-21. Mill Contour Start Segment .................................................................................................3-30 Figure 3-22. Mill Contour Arc Segment ...................................................................................................3-30 Figure 3-23. Selecting a Circle from a DXF drawing ...............................................................................3-31 Figure 3-24. Mill Circle data block created from the DXF file ................................................................3-32 Figure 3-25. Selecting the First Segment of a Frame ................................................................................3-33 Figure 3-26. 3-D DXF Drawing ................................................................................................................3-34 Figure 3-27. Selecting and Splitting Segments on a 3-D Contour ............................................................3-35 Figure 3-28. Creating a Mill 3D data block ..............................................................................................3-36 Figure 3-29. Completed Mill 3D data block .............................................................................................3-37 Figure 3-30. Part Program Illustration ......................................................................................................3-37 Figure 3-31. Start Segment for the Mill 3D data block ...........................................................................3-38 Figure 3-32. Segment I in the Mill 3D data block ....................................................................................3-38 Figure 3-33. Editing screen buttons ..........................................................................................................3-39 Figure 3-34. Extended lines ......................................................................................................................3-40 Figure 3-35. ed lines and arcs ............................................................................................................3-41 Figure 3-36. Select a segment to modify ..................................................................................................3-42 Figure 3-37. Modify segment data ............................................................................................................3-43 Figure 3-38. Split a segment ....................................................................................................................3-44 Figure 3-39. Tool Setup screen ........................................................................................................_.......3-45

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Table of Contents Shut Down Techniques .................................................................................. 1-109 Park Machine ...................................................................................... 1-110 Emergency Stop .................................................................................1-112 Infrequent System Changes ............................................................................1-114 Changing Language Files . ..................................................................1-114 Upgrading Ultimax Software .............................................................. 1-116

Table of Contents

Conversational Part Programming Conversational Programming Principles ............................................................2-1 Before Part Programming .......................................................................2-2 Access to Programming Functions .........................................................2-4 Part Programming Summary ...................................................................2-7 Data Block Options .....................................................................2-7 Data Block Creation and Navigation ..........................................2-8 Creating a Milling Data Block ....................................................2-9 Creating a Hole Drilling Data Block .........................................2-14 End of Program ..................... ....................................................2-22 Special Data Blocks ..............................................................................2-23 Position Block ...........................................................................2-23 Temporary Parameter Change ........ ...........................................2-26 Set a New Part Zero ..................................................................2-30 Automatic Calculations ........................................................................2-31 Graphics ...............................................................................................2-33 Views ................................................... ................................2-36 Zoom ...................................................................................2-38 Graphics Parameters ................................................................. 2-38 Data Block Search ....................................................................2-40 Graphics Error Checking ..........................................................2-42 Checking the Part Program ...... ................. :........................................... 2-43 Review Program .......... ..............................................................2-43 Error Checking and Run Time ..................................................2-44 Changing a Part Program ......................................................................2-45 Changing a Block ........................................ .............................2-45 Block Editor ..............................................................................2-46 Copying and Moving Blocks .. ..................................................2-49 Deleting Blocks .........................................................................2-50 Modifying Dimensions .............................................................2-51 Changing Feeds and Speeds ................... ...................................2-52 Running a Part Program .......................................................................2-54 Test Run ...................................................................................2-55 Feed and Speed Optimization ....................................................2-56 Auto ...................................................................................2-57

Concurrent Programming .....................................................................2-60 Printing a Program ................................................................................2-62 Program Identification and Storage ......................................................2-63 File Naming ..............................................................................2-63 File Storage Facilities .............. ..................................................2-65

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Table of Contents P

Holes Operations .............................................................................................. 2-66 Drill Operations .................................................................................... 2-68 Drill . .................................. ............... ... . ...........................2-74 Center Drill ...............................................................................2-75 Counterbore ..............................................................................2-76 Spotface ...................................................................................2-77 Countersink ...............................................................................2-78 Gun Drill ...................................................................................2-79 Locations .................................................................................. 2-84 Bolt Circle . ................................................................................ 2-86 Tap .....................................................................................................2-89 Bore and Ream Operations ................................................................... 2-91 Bore . .................................................................................. 2-93 Ream ...................................................................................2-94 Bore Rapid ................................................................................ 2-94 Bore Orient ............................................................................... 2-95 Ream Rapid .............................................................................. 2-95 Back Spotface .......................................................................................2-96 Sample Drilling Program ...................................................................... 2-99 Milling ............................................................................................................2-104 Segments ............................................................................................ 2-106 Cutter Compensation .......................................................................... 2-110 Climb Milling ....... .................................................................. 2-112 Conventional Milling . ............................................................. 2-112 Profile Left and Right ............................................................. 2-113 Maximum Offset ................................................................................ 2-114 Feed and Speed Options ... .................................................................. 2-115 Programming Lines and Arcs ............................................................. 2-116 Lines ....... .......................................................................... 2-116 Arcs ............. .................................................................... 2-119 Blend Arcs ....... ....................................................................... 2-121 Helix .................................................................................2-126 3-D Are .................. ............................................................... 2-128 Circle .......... ........................................................................................ 2-131 Frame ... ............................................................................................... 2-134 Face Milling ........................................................................................2-139 Ellipse ................................................................................................. 2-143 Lettering ............................................................................................. 2-147 3-D Milling Option ............................................................................. 2-150 Sample Milling Program ..................................................................... 2-151

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Table of Contents Pattern Operations ..........................................................................................2-163 Loop Rectangular ...............................................................................2-167 Loop Linear ........................................................................................2-169 Loop Angular ......................................................................................2-172 Loop Rotate ........................................................................................2-174 Pattern Locations ................................................................................2-176 Scale ...................................................................................................2-177 Mirror Image .......................................................................................2-180 Pattern End .........................................................................................2-182 Sample Pattern Program .....................................................................2-183 UltiPocket Option ...........................................................................................2-188 Pocket Boundary ................................................................................2-190 Spiral Outward - No Islands ....................................................2-190 Spiral Inward ...........................................................................2-190 Programming Islands ... .......................................................................2-191 Mill Contour .......................................................................................2-192 Mill Frame ................... .......................................................................2-194 Mill Circle ..........................................................................................2-195 Pattern .................................................................................................2-196 Sample UltiPocket Program ................................................................2-196 Cutter Insert Routines ........................................................................... ..........2-218 Triangles ...................... .......................................................................2-219 Diamond Faces ...................................................................................2-223 Hexagon ..............................................................................................2-226 Sample Cutter Insert Program .............................................................2-228

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Table of Contents Rotary .........................................:...................................................................2-230 General Information ............................................................................2-230 Rotary Part Programs ..........................................................................2-231

Program Definition .................................................................2-231 Part and Tool Setup.................................................................2-232 General Parameters .................................................................2-235 Rotary Programming Options ........ ..................................................... 2-236 Rotary Parameters ............................................................................... 2-238 Rotary Position Block .........................................................................2-239 Rotary Milling Operations .................................................................. 2-241 Lines and Arcs ....................................................................................2-242 Rotary Frame ......................................................................................2-244 Rotary Loop ........................................................................................2-245 Rotary Pattern Locations ....................................................................2-246 Sample Rotary Program ......................................................................2-247 Preliminary Calculation Program .......... ..................................2-248 Rotary Program .......................................................................2-263 ' and Programs ....................................................................2-266 Setup ...................................................................................................2-266 Access through the Auxiliary Screen ..................................................2-267

I

Receive or Send a Part Program .........................................................2-269 Print a Part Program ...........................................................................2-270 Ports ..................................................................................................2-271 Running Part Programs .................................... .............................................. 2-272 Console Buttons Used ........................................................ .............................. ':^q • -'.....2-273 Machine Control Buttons ..... ......... .............................. .......... 2-273 Machine Operations Buttons .. ........................................:.......2-275 Manual .....................................................................................:........2-277 Test Run .............................................................................................2-278 Feed and Speed Optimization ..........................................r............:...2-279 Single Cycle ..................................................................:.::..:.:::...... 2 281 Automatic Operation .................................................................S'%...2-283 Recovery and Restart ...................................................................::.....2-286

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Table of Contents

DXF File Translation General Capabilities ...........................................................................................3-1 AutoCAD Files and the DXF Option ......................................................3-1 Ultimax Programming Features ..............................................................3-2 Graphics Display .........................................................................3-2 Data Blocks .................................................................................3-2 DXF File Management .......................................................................................3-3 Creating a New Conversational Program ............................................................3-4 DXF File Display ................................................................................................3-5 Setting DXF Parameters .....................................................................................3-8 Building Data Blocks .......................................................................................3-12 General Concepts ..................................................................................3-13 Selecting DXF Drawing Elements ............................................3-13 Accept Screen Button ................................................................3-14 Conversational Data Blocks .......... ......................:..................... 3-15 Zoom Box Screen Button ..........................................................3-17 Layers ...................................................................................3-20 Holes .....................................................................................................3-22 Selecting Holes .........................................................................3-23 Intersect Screen Button .............................................................3-23 Accepting Holes .................. ......................................................3-24 Milling ..................................................................................................3-27 Lines/Ares .................................................................................3-27

-- -Circle-

-:3-31 .. .

Frame 3-D Option ............................... ................................................................................3-34 ................................................... 3-33 Editing a Drawing .................................................................................3-39

Extend ...................................................................................3-40 ...................................................................................3-41 Modify ...................................................................................3-42 Split ...................................................................................3-44 Completing the Program ...................................................................................3-45

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Table of Contents

Appendix ....................................................................................................A -1 Ultimax 3 Console .........................................................................................................A-2 Ultimax 3 Screen Hierarchy ...........................................................................................A-3 Coordinate System .......................................................................................................A-4 Suggested Cutting Speeds .............................................................................................A-5 Recommended Chip Loads ...........................................................................................A-6 Feeds and Speeds for High Speed Drills .......................................................................A-7

Index ............................................................................... ..............................I -1

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Figure List. Figure 1-1. Hurco Hawk 5M Machine Tool ................................................ :.............................................. 1-I Figure 1-2. Ultimax 3 Console ....................................................................................................................1-6 Figure 1-3. Part Program Protection Keyswitch and Right-side of.Console .............................................. 1-8 Figure 1-4. Partial Access "Protected" Input screen ..................................................................................1-9 Figure 1-5. "Unprotected" Input screen ................................................................:..................................1-10 Figure 1-6 . Software Option Security Key ............................................................ :.................................. 1-14 Figure 1-7. Side view showing electrical cabinet and power switch ....................................................... 1-16 Figure 1-8 . Machine Configuration screen ............................................................................................... 1-18 Figure 1- 9. Input screen (software version number ) ..... ........................................................................... 1-22 Figure 1- 10. Manual screen showing uncalibrated axes ................:..........................................................1-24 Figure 1-11. Manual screen ......................................................................................................................1-27 Figure 1-12. Auxiliary screen ...................................................................................................................1-29 Figure 1-13. System Parameters screen ..................................... :........................................................... ...1-30 Figure 1-14. AutoSave message on General Parameters screen ...... .......................................................... 1-32 Figure 1-15. System Parameters screen Figure 1 - 16. Machine Configuration ......................................................................................:.................1-34 ................. ........ ........................................................................... 1-33 Figure 1-17. Auxiliary screen ...................................................................................................................1-36 Figure 1-18. Input screen ..........................................................................................................................1-37 Figure 1-19. Auxiliary screen ................................................................................................................... 1-38 Figure 1-20. Current Program screen ..................................................................................................::...1-40 Figure 1-21. Current Directory screen ......................................................................................................1-40 Figure 1-22. Part Program Read into Memory .........................................................................................1-41 Figure 1-23. Letter Selection screen (graphics screen ) .............................................................................1-42 Figure 1-24. Input screen (text screen ) while entering new program name .......................................... :..1-43 ;Figure I-25 . Input screen after the operator presses Enter .......................................................................1-44 Figure 1-26. Input screen with Erase Functions softkey ...........................................................................1-45 Figure 1-27. Input screen with Erase functions ........................................................................................1-46 Figure 1 -28. Input screen with "Do you really want to Erase ?" message ...................... :.......................... 1-47 Figure 1-29. Jog Unit ....................................................................................................:.......................... 1-49 Figure 1 -30. Manual screen with jog parameters (in millimeters per minute ) .........................................1-50 Figure 1-31. Spindle, Tool Holder, and In/Out Buttons ......................................................................:..1-5I Figure 1-32. Part Zero Relationship to Machine Figure 1-33. Tool Zero Calibration Plane and Part Zero inZero Z ................................::.......:.......................1-55 Absolute ........ ...................... .......................... ....... 1-54 Figure 1-34. Spindle motion relative to Part Zero .......................................................... ..........................1-56 Figure 1-35. Completed Part Setup screen ..............................................................................................1-57 Figure 1 -36. Safety Work Region ..............................................................................................:......:.......1-60 Figure 1-37. Offset Z ...............................................................................................................................1-61 Figure 1-38. Tool Setup screen ............................................................. :....................................... :........... 1-63 Figure 1-39. Tool Setup screen .................................................................................................................1-65 Figure 1-40. Tool Setup screen with tool types ........................................................................................ 1-66 Figure 1-41. Cutter Compensation ............................................................................................................ 1-67 Figure 1-42. Tool Setup screen with Surface Speed field ......................................................................:..1-69 Figure 1-43. Input screen .................................... .................................................. .................................... 1-73 Figure 1-44. General Parameters screen for conversational programming .............................................. 1-74 Figure 1-45. Chord Error .................................................................................................................:........1-78 Figure 1-46. Hole Parameters screen ........................................................................................................ 1-80 Figure 1 -47. Milling Parameters screen .................................................................................................... 1-81

Ultimax 3 System

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Figure List Figure 1 -48. Cutter Compensation using the Insert Arc parameter .......................................................... 1-83 Figure 1 -49. Cutter Compensation using the Insert Line parameter......................................................... 1-84 Figure 1-50. Program Parameters screen .................................................................................................. 1-85 Figure 1-51. Current Program screen ....................................................................................................... 1-88 Figure 1-52. Directory Structure ...............................................................................................................1-89 Figure 1-53. Current Directory screen with directory softkeys ................................................................ 1-90 Figure 1 -54. Current Program screen .......................................................................................................1-92 Figure 1-55. Current Directory screen used for program storage ............................................................. 1-93 Figure 1-56. Current Program screen program name during save operation ............................................ 1-94 Figure 1-57. Program Renaming on the Current Directory screen ........................................................... 1-96 Figure 1-58 . Deletion Function 's "Are you sure ?" message .....................................................................1-97 Figure 1-59. Current Directory screen with directory softkeys ................................................................1-98 Figure 1-60. Current Directory screen with "More " softkeys ..................................................................1-99 Figure 1-61 . Limit Switches screen ........................................................................................................1-103 Figure 1-62. Manual screen with Way Lube error ..................................................................................1-104 Figure 1-63. Limit Switches screen with error condition ....................................................................... I-105 Figure 1-64. Auxiliary screen with Reset Master softkey ......................................................................1-107 Figure 1-65. "Reset Master" and "Diskette in Drive " messages ............................................................ 1-108 Figure 1-66. Manual screen with Park Machine softkey ........................................................................1-110 Figure 1-67. " Emergency Stop" message on the Manual screen ............................................................ 1-112 Figure 1-68 . Auxiliary screen with Change Language softkey ............................................................... 1-114 Figure 1-69. Language Selection screen .................................................................................................1-115 Figure 1-70. Auxiliary screen with More softkeys .................................................................................1-116 Figure 1 -71. Auxiliary screen with executive upgrade message ............................................................. 1-117 Figure 2-1 . Input screen ..............................................................................................................................2-3 Figure 2-2. Input screen .............................................................................................................................. 2-4 Figure 2-3 . New Block screen .....................................................................................................................2-5 Figure 24. New Block screen with milling options ...................................................................................2-9 Figure 2-5. Mill Frame screen ..................................................................................................................2-10 Figure 2-6. Mill Frame screen with tool number ......................................................................................2-11 Figure 2-7. Completed Mill Frame screen ................................................................................................2-12 Figure 2-8 . New Block screen ...................................................................................................................2-14 Figure 2-9. Holes screen with softkey options ..........................................................................................2-15 Figure 2-10 . Holes screen with Drill Operations softkeys ........................................................................2-16 Figure 2-11 . Holes screen with Center Drill fields ...................................................................................2-17 Figure 2-12. Holes screen with Drill fields ...............................................................................................2-18 Figure 2-13. Start a New Operation ...............................................................................................:..........2-19 Figure 2-14. Holes screen with Location coordinates ..............................................................................2-20 Figure 2-15 . Completed Holes Data Block ...............................................................................................2-21 Figure 2-16 . End of Program screen .........................................................................................................2-22 Figure 2-17. Position screen ..................................................................................................................... 2-23 Figure 2-18. New Block screen .................................................................................................................2-26 Figure 2-19. Change Parameters and Part Se tup ......................................................................................2-27 Figure 2-20 . Change General Parameters screen ......................................................................................2-28 Figure 2-21 . Change Part Setup screen ..................................................................................................... 2-30 Figure 2-22. Automatic Calculation of Values .........................................................................................2-31 Figure 2-23 . Ultimax Console ...................................................................................................................2-33 Figure 2-24 . Graphics screen ....................................................................................................................2-34 Figure 2-25 . New Block screen with Miscellaneous functions .................................................................2-35 Figure 2-26 . Graphics screen with isometric view ....................................................................................2-36 Figure 2-27 . Graphics screen showing All Planes ....................................................................................2-37 Figure 2-28 . Graphics Parameters screen .................................................................................................2-38

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Figure List Figure 2-29. Identifying a portion for the search ......................................................................................2-40 Figure 2-30. Data Block displayed after the search ..................................................................................2-41 Figure 2-31. Graphics screen error message ............ ........... :................... .................................................. 2-42 Figure 2-32. Review Program screen ...... :................................................................................................. 2-43 Figure 2-33. Part Program Error Checking ...............................................................................................2-44 Figure 2-34. Input screen ..........................................................................................................................2-45 Figure 2-35. Input screen with Copy and Change Blocks softkey ............................................................2-46 Figure 2-36. Block Editor screen ..............................................................................................................2-47 Figure 2-37. Block Editor features ................. .......................................................................................... 2-48 Figure 2-38. Block Editor with Copy Blocks fields ..................................................................................2-49 Figure 2-39. Block Editor with Delete Blocks fields ................................................................................2-50 Figure 2-40. Block Editor with Modify Dimensions fields ......................................................................2-51 Figure2-41 . Change All Tools' Feeds and Speeds ...................................................................................2-52 Figure 2-42. Change Feeds and Speeds for 1 Tool ...................................................................................2-53 Figure 2-43. Test Run screen ....................................................................................................................2-55 Figure 2-44. Feed and Speed Optimization screen ...................................................................................2-56 Figure 2-45. Auto screen with softkey options .........................................................................................2-57 Figure 2-46. Auto screen with a running program .............................. :..................................................... 2-58 Figure 2-47. Input screen with concurrent running program ....................................................................2-60 Figure 2-48. Auxiliary screen with Print Program softkey .......................................................................2-62 Figure 2-49. Current Program screen .......................................................................................................2-63 Figure 2-50. Letter Selection screen (graphics screen ) .............................................................................2-64 Figure 2-51 . Current Program screen .......................................................................................................2-65 Figure 2-52. Hole Operation Hierarchy Chart ..........................................................................................2-66 Figure 2-53. Holes screen with option softkeys ........................................................................................2-67 Figure 2-54. Holes screen with Drill Operations softkeys ........................................................................ 2-68 Figure 2-55 . Completed Drill Data Block .................................................................................................2-71 Figure 2-56. Reference Points Relative to Drill Operations .....................................................................2-72 Figure 2-57. Drill Bit ................................................................................................................................2-74 Figure 2-58. Center Drill Data Block ........................................................................................................2-75 Figure 2-59. Counterbore Operation .........................................................................................................2-76.. Figure 2-60. Spotface Operation ...............................................................................................................2-77 Figure 2-61. Countersunk screw head ......................................................................................................2-78 Figure 2-62. Countersink Operation .........................................................................................................2,78 Figure 2-63 . Gun Drilling .........................................................................................................................2-79 Figure 2-64. Completed Gun Drill Data Block ......................................................................................... 2-82 Figure 2-65. Gun Drill Positions ...............................................................................................................2-83 Figure 2-66. Locations for holes in a block ..............................................................................................2-84 Figure 2-67 . Bolt Circle operation ............................................................................................................ 2-86 Figure 2-68 . A Bolt Circle Pattern ............................................................................................................2-87 Figure 2-69. Tap operation fields ............................................................................................................. 2-89 Figure 2-70 . Bore and Ream softkeys .......................................................................................................2-91 Figure 2-71. Two-bladed Boring Bar with adjustment dial ......................................................................2-93 Figure 2-72.. Reaming Tool .......................................................................................................................2-94 Figure 2- 73. Back Spotface screen ...........................................................................................................2-96 Figure 2-74. Hole Drilling Example .........................................................................................................2-99 Figure 2-75. Milling Options Chart ........................................................................................................2-104 Figure 2-76. New Block screen with the Milling softkeys ......................................................................2-105 Figure 2- 77. Mill Contour New screen ...................................................................................................2-106 Figure 2-78. Mill Contour Start screen ...................................................................................................2-107 Figure 2-79. Completed Mill Contour Start screen ................................................................................2-108 Figure 2-80 . Cutter Compensation options .............................................................................................2-110 Figure 2-81 . Tool Paths for Cutter Compensation .................................................................................2-111

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Figure List Figure 2-82. Profile Left Cutter Compensation using a finish tool ........................................................2-113 Figure 2-83. Determining Maximum Offset ...........................................................................................2-114 Figure 2-84. Mill Contour: Line screen ..................................................................................................2-116 Figure 2-85. Mill Contour Line screen ...................................................................................................2-116 Figure 2-86. Length, Angle, and End Point Relationship .......................................................................2-117 Figure 2-87. Line Segment with Unknown Y End and XY Angle ..........................................................2-118 Figure 2-88. Mill Contour Arc screen .....................................................................................................2-119 Figure 2-89. Coordinates of a Clockwise Arc .........................................................................................2-119 Figure 2-90. Arc Segment with Unknown X End and X Center .............................................................2-120 Figure 2-91. Some Typical Blend Arcs ...................................................................................................2-121 Figure 2-92. Segment creating the Helix in the Blend Are example ......................................................2-123 Figure 2-93. Line segment to intersect with previous helix ....................................................................2-124 Figure 2-94. Mill Contour Blend Arc .....................................................................................................2-124 Figure 2-95. Sample Blend Arc on the Graphics screen .........................................................................2-125 Figure 2-96. Mill Contour Helix screen ..................................................................................................2-126 Figure 2-97. Mill Contour 3D Arc screen ...............................................................................................2-128 Figure 2-98. 180° 3-D Arc ......................................................................................................................2-129 Figure 2-99. Mill Circle screen ...............................................................................................................2-131 Figure 2-100. Mill Frame screen ............................................................................................................2-134 Figure 2-101. Inside Mill Frame Operation ...........................................................................................2-135 Figure 2-102. X & Y Length Directional Measurement .........................................................................2-137 Figure 2-103. Completed Mill Face screen .............................................................. :.............................. 2-139 Figure 2-104. Face Milling Types .................................................................................. .....................2-140 Figure 2-105. Mill Ellipse screen ............................................................................................................2-143 Figure 2-106. Mill Ellipse - Inside Type .................................................................................................2-144 Figure 2-107. Mill Lettering screen ........................................................................................................2-147 Figure 2-108. Completed Mill 3-D screen ..............................................................................................2-150 Figure 2-109. Part drawing used in the sample Milling program ...........................................................2-151 Figure 2-110. Pattern Options Hierarchy Chart ......................................................................................2-163 Figure 2-111. Pattern Softkeys ...............................................................................................................2-164 Figure 2-112. Sample Loop Rectangular operation ................................................................................2-167 Figure 2-113. Pattern Loop Rectangular screen .....................................................................................2-168 Figure 2-114. Sample Loop Linear.operation .........................................................................................2-169 Figure 2-115. Loop Linear screen ...........................................................................................................2-170 Figure 2-116. Sample Loop Angular operation ......................................................................................2-172 Figure 2-117. Pattern Loop Angular screen ............................................................................................2-173 Figure 2-118. Sample Loop Rotate operation .........................................................................................2-174 Figure 2-119. Pattern Loop Rotate screen ..............................................................................................2-175 Figure 2-120. Pattern Locations screen ..................................................................................................2-176 Figure 2-121. Sample Loop Angular operation ......................................................................................2-177 Figure 2-122. Pattern Scale screen .........................................................................................................2-178 Figure 2-123. Mirror Image example ......................................................................................................2-180 Figure 2-124. Pattern Mirror Image screen ............................................................................................2-181 Figure 2-125. Pattern End screen ...........................................................................................................2-182 Figure 2-126. Part used in the sample Pattern program .........................................................................2-183 Figure 2-127. Pocket Boundary with Inward Spiral Islands ...................................................................2-188 Figure 2-128. Isometric View of Inward Spiral Islands ..........................................................................2-189 Figure 2-129. Mill Contour with Pocket options .....................................................................................2-192 Figure 2-130. Mill Contour Start Segment with Pocket Island ...............................................................2-193 Figure 2-131. Mill Frame with Inward Spiral Boundary ............. ................................:...:...................... 2-194 Figure 2-132. Mill Circle with Outward Spiral Boundary ......................................................................2-195 Figure 2-133. Graphics screen illustration of the UltiPocket sample program .......................................2-196 Figure 2-134. Isometric view of the UltiPocket sample program ...........................................................2-197

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Chapter 1

Getting Started This chapter explains basic operations such as power up, part and tool setup, saving part programs, resetting the control, and shutting down the machine tool.

Machine Tool Components Before using the machine tool, the operator should become familiar with the machine 's components. The illustration below shows the main parts of the Hurco Hawk 5M machine. Lever to change Spindle Speed (on the side) Tool change In & Out buttons

Flood Coolant Nozzle Electrical Cabinet (Power Cabinet)

Ultimax 3 Console

Figure 1-1. Hurco Hawk 5M Machine Tool

The operator can see the approximate spindle speed range displayed in the dials above the spindle . To switch the spindle speed between low and high gears, the operator must manually flip the gear change lever on the side of the machine.

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Operator' s Manual

Safety and Equipment Maintenance To avoid serious personal injury, damage to the machine, and unproductive down-time, the operator must pay careful to safety precautions and proper maintenance of the machine. Machine tool operation is often a dangerous task, so operators must stay alert and be aware of potential hazards. Operators must also follow the safety regulations of their shops.

Operator Safety and Apparel Before attempting to operate the machine tool, the operator should study this manual and become familiar with the machine functions and safety features. While studying the manual, the operator should make special note of the caution and warning messages in the manual and all warning and instruction plates/decals on the machine tool. Since most machine tool operators are experienced machinists , they know that they should always wear eye protection and safety shoes while in the work area. Safety glasses with side shields are recommended. The operator should avoid wearing loose -fitting clothing , watches, rings, and neckties that could become caught in the moving parts of the machine.

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Getting Started

Part Fixturing and Cutting Machinists should always know the locations of the Emergency Stop buttons on the machine tool and console . The machinist must be very careful when working in the area of the spindle . To prevent injury, the spindle should be completely stopped before the machinist attempts to make adjustments to a work piece, the fixturing, and/or coolant nozzles. To prevent cutter breakage , the machinist should check the direction of spindle rotation. As a rule, the machine rotates the spindle in the clockwise direction for right-hand tools and in the counterclockwise direction for left-hand tools. Machinists must clamp the work pieces and fixture them securely before starting the machine . that loose objects, such as wrenches and chuck keys, can become flying projectiles if not removed from the table before the machine is started . Operators should be aware of protruding machine (such as hoses, piping, ductwork) when working around the machine.

1\

Warning

When running part programs , operators should always follow these rules: •

Never press the Start Cycle console button without knowing exactly what the machine will do!

•

Never start the machine when the cutter is in with the work piece.

•

Stand away while the machine is running a part program. Never lean on the machine while the spindle is moving.

• •

Ultimax 3 System

Do not leave the machine unattended.

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Equipment Maintenance Before any maintenance and/or repair operations are performed within the electrical cabinet , the machinist or maintenance representative must that the power switch has been turned to the "Off' position before the electrical cabinet door is opened. A regular schedule of lubrication and maintenance checks is required to ensure continued dependable operation of the machine. The following chart lists these recommendations . It should be noted that machine maintenance is dependent upon the amount of use, severity of operation, and machine environment. Therefore, maintenance frequency should also be determined on an individual basis and varied accordingly. For more details about these procedures, refer to the Maintenance Manual.

Recommended Routine Maintenance Daily ❑

Check all lubrication levels particularly in the Auto Lube system and the air line lubricator.

❑

Check air pressure at the Filter, Regulator, Lubricator (FRL) assembly in the pneumatic system.

❑ Check coolant level(s). ❑

Check the ways for proper lubrication and any scratches or excessive wear. Be certain that the way wipers are not damaged.

Weekly

1-4

❑

Check the moisture drains from the FRL Unit and check lube level.

❑

Refill Autolube tank with proper lubricant.

❑

Perform necessary cleaning of machine.

❑

Check filter screen on the spindle oil cooler (if installed).

❑

Inspect tools and tool holders and replace worn inserts, shims, and clamp screws as needed . It is important to keep the tools sharp since dull and damaged tools break easily.

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Getting Started Monthly ❑

Check condition of tool holders.

❑

Check the fasteners securing limit switches and the dogs to be certain they are tight.

0 Lubricate Counterbalance chains.

Quarterly ❑

Clean and inspect flood coolant system.

❑

Check ground installation).

impedance level

(during

first

year

of

Semi-Annually ❑

Replace Autolube tank suction filter.

Annually

Ultimax 3 System

❑

Check ground impedance level (resistance to true earth).

❑

Drain, flush, and refill the spindle oil cooler tank (if installed).

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The Ultimax 3 Console The Ultimax 3 control console allows an operator to program a job at the machine while reading directly from a blueprint or a program worksheet. The prompts on the console 's text screen lead the operator through each element of the part program . The operator responds to the various selections and prompts by pressing the appropriate keys and push buttons on the console (numerical keys , softkeys, and other buttons ) to enter the desired machine operations, part dimensions , and other parameters into the control ' s memory. a

Text screen

O

nkey buttons

Graphics screen

O O O rT rT-

0

V Jog unit

Number keys

/

Enter key

Dxecrlonal snow keys

Figure 1-2. Ullinwar 3 Console

The Ultimax console and the electrical equipment required to operate it are often called "the control " or the CNC (computer numeric control). The control ' s electrical equipment consists of printed circuit boards and cables to connect and operate the console functions . These boards are located in the console and in the electrical cabinet . Many internal components of the Ultimax console are similar to those in standard personal computers (PCs), so many operations, such as copying/deleting files and storing files in directories, on the Ultimax console are similar to PC operations.

Getting Started

Types of Console Keys There are two types of keys used for data entry operations: •

Softkeys

•

Console keys

The softkeys are the eight keys between the two screens. These keys are used to select options displayed to the left on the text screen. The possible selections for these softkeys change depending on the system screen displayed on the left-hand CRT (cathode ray tube). There are three methods operators use to select softkey options: •

Press the white softkey button between the two screens that corresponds to the desired softkey option.

•

Press and hold down either the Alt or Ctrl console key and press the number key that corresponds to the desired softkey option.

•

Press the console number key that corresponds to the softkey. The selected number appears at the top of the softkey menu list on the text screen. Then press the Enter key.

The console has buttons and keys on the lower and upper s. The major key groupings and significant individual keys are marked in the illustration on the previous page . There are usually two red Emergency Stop buttons on a Hawk 5M machine : one on the jog unit (left side of console) and one on the console key board ( right side). Since the primary Ultimax console does not have letters to use for data entry, the system will display a letter screen on the graphics monitor screen when the system needs to know the names of programs and other functions requiring letters. Then the operator uses the trackball to move a crosshair (+) on the letter screen and then presses the Select key to place the letter into a field on the text screen . Usually the operator presses the Enter key to tell the control to examine the new information typed onto the text screen.

The operator may wish to pull out the picture of the console keyboard included in the "Appendix " section of this manual and refer to that illustration while learning to use the system.

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Floppy Drive and Protection Keyswitch On the right side of the console are a floppy drive and the part program protection keyswitch. The floppy drive has a protective cover that should be closed when a diskette is not being inserted or removed so that the cover can protect the drive from dust and debris. This drive has three primary purposes: 1.

Read stored copies of older versions of Ultimax programs from a DOS diskette

2.

Read/save current Ultimax 3 conversational programs from/to a DOS diskette

3.

Read/save NC programs from/to a DOS diskette

The part program protection keyswitch, also on the right side of the console, limits access to the Ultimax Input screen functions used to access and change part programs . A key is inserted in the keyhole below the dotted indicators. Refer to the illustration below. When the key is turned to the right toward the dots that are connected to form an "X" in the middle, then the operator cannot change the program data blocks in part programs loaded into the control . To standardize programs in a shop or control the quality of programs produced , a supervisor may want to load programs into the control, switch the key to this "protected" position, and remove the key. Access to Input screen functions for part program editing are locked out

Part Program Protection Keyswitch

Floppy Drive (with protective cover) Figure 1 -3. Part Program Protection Keys witch and Right-side of Console

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Hawk 5M Machine

Getting Started When the keyswitch is turned to the right in protected position, the Input screen appears but only with a limited set of softkeys, as shown below. When the message "This mode is locked out by the program protect switch" appears at the bottom of the screen, it indicates that the part programming functions are locked out. In other words, the part programs on the control are partially protected from changes.

« INPUT « MASTER PROGRAM

u1 . 58

"An 5M

EDIT PAST PROGRAM

1.HD3 STANDARD

PROGRAM M EMORY AVAILABLE

I F PART SETUP 11er.22'94 1 1 F TOOL SETUP METRIC VERTICAL 2

99 s

P 3 F I 5 F 6

1M IS MODE IS LOCIED OUT BY THE PAOGIReI PROTECT SWITCH

7 P

B

Figure 1.4. Pardo" Access "Protected" Input screen

When the program is partially protected, the operator can change the Part Setup (Fl) and Tool Setup. (F2) parameters for the displayed program (1.HD3 in this example). In addition, the operator may cut a part using the displayed program or press the Auxiliary console key to retrieve a different part program. To lock out Part and Tool Setup options and, therefore, fully protect the programs, the supervisor selects the "Full" option for the Program Protect field on the Program Parameters screen. Refer to the "General Parameters" section of this chapter for more information.

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Operator' s Manual When the keyswitch is turned to the left, the part programming functions are "unprotected," and the operator can access all of the functions as shown in the screen below. In addition to the Part Setup and Tool Setup functions, "unprotected" mode gives the operator access to the following functions: • •

Part Programming (F3) Program Parameters (F4)

•

Copy and Change Blocks (F6)

•

Erase Functions (177)

INPUT IKSTER PROGRAM

IIAYR 91

EDIT PART PROGRAM

u1 . 50 1 . 11D3 STANDARD

PROG%OI MEMORY AVAILABLE

I F PART SETUP Mar . 22'94 1 METRIC VERTICAL

99 x

F TOOL SETUP 2 i F PART PROGRAMMING 3 F PROGRAM t PARAMETERS F

S F COPY AND CHANGE 6 BLOM F ERASE FRICTIONS Select eartlmy or Press ant•r) to chance part Program news

7 1 F B

Figure 1-5. "Unprotected" Input screen

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1

Getting Started

Hardware Options The Hawk 5M has several hardware options that the machine owner may use to adapt the machine to its operating environment. Here are the available options:

Option

Description

Table guard

a three-sided protective shield around the back of the table.

Chip enclosure

a complete table enclosure to protect the operator from flying debris (only for Hawk 5M machines sold in the United Kingdom).

Work light

an adjustable halogen lamp attached to the machine tool to provide extra light on the table.

Quad vise

a standard 6" vise for fixturing.

Draw bar for metric tools

converts the spindle so that it accepts metric (BT40) tools. No other changes to the machine are necessary for this conversion.

Indexer port

permits attachment of an indexer head to the machine tool . The indexer software is included in this option.

Rotary table system

adds an "A" axis to the Hawk 5M so that the operator can machine around the outside of a cylindrical part while the part is rotating. This option includes a rotary table , cabling, necessary drive, and the rotary software.

Rotary interface

this option includes the rotary cabling, necessary

drive, and the rotary software , but not the rotary table. Increase control memory from 4 Megabytes to 8

in shops where operators typically store large, complex part programs on the control ' s hard drive,

Megabytes

the owner may want to purchase the 8 Megabytes of memory option.

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Software Options The Ultimax control contains software used to process data and display screens in much the same manner that personal computers use software programs. As with other software systems , Ultimax has additional software options that can be purchased for the system.

UltiPocket The Ultipocket m programming option adds special milling routines for machining pocket boundaries with islands. This option provides complete clean out of odd- shaped pockets without cutting the islands programmed inside the boundary . The software automatically calculates the tool path around islands eliminating the long task of plotting these shapes. Islands may also be rotated , scaled, and repeated.

3-D Contour The Ultimax 3-D option provides 3-axis cutter compensation for machining three dimensional surfaces . Revolution and translation subroutines allow rapid programming of complex cavities, sections, or cores with full cutter compensation and automatic calculation assistance.

CAD Compatibility (DX9 Option The CAD Compatibility option allows the operator to transfer CAD data files directly into the Ultimax control . This option eliminates errors in data entry and significantly speeds up the part programming process. The CAD file format is called DXF. This Data eXchange Format , developed by AutoCAD, is now used by the majority of CAD software companies. When this Ultimax option is installed, the control reads DXF CAD files. Using the graphics screen of Ultimax, the operator selects geometric features of the part to be machined and translates these features into conversational data blocks . Hole locations and mill frames , circles, and contours are created by selecting the geometric features using the trackball. This is similar to the methods used on the CAD system to select items with a mouse.

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Getting Started

Off-line Software The Ultimax PC/PC Plus software gives operators Ultimax conversational part programming capabilities on a personal computer. Using this option, operators can program parts off-line, away from shop floor distractions, and leave the machine tool available to cut parts. All Ultimax control features are present in the PC/PC Plus software including graphics, part verification, estimated run times, and lettering for marking parts.

Cutter Insert Routines Cutter insert manufacturers use these special milling routines to mill pockets in triangular, diamond, and hexagon shapes. These routines can be defined in one program data block.

Indexer The indexer software is included with the indexer port hardware: This hardware/software option is needed when an indexer head is used to rotate a part at a fixed distance to position it for an operation. When the option is installed on a system, the indexer pulse value can be entered into a Position data block during part programming.

Rotary The rotary software is sold with the rotary table system and with the rotary interface hardware options . This hardware/software option is needed when the machinist needs an "A" axis to machine the outside of a cylindrical part while the part is rotating.

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Additional Language Files Additional translations of the messages and system screens can be purchased for the Ultimax control. The complete list of available languages is as follows: •

English

•

Japanese

•

Czech

•

Greek

•

Danish

•

Latin American Spanish

•

Dutch

•

Polish

•

Hungarian

•

Spanish

•

French

•

Swedish

•

German

•

Taiwanese

•

Italian

•

Thai

•

Finnish

Option-Access Security Key The Ultimax system checks for the software security key at power up time and periodically during operation to identify the software options being used. This key (shown below) is attached the bottom of the control cabinet within the electrical cabinet.

Kw

-*

Figure 16. Software Option Security Key

If the machine owner wishes to purchase an additional software option, Hurco exchanges the old key for a new one that provides access to the newly purchased option.

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Getting Started

Preparing for Power Up The operator must perform routine checks before attempting to power up the machine.

Routine Daily Checks Several mechanical elements require visual inspection, regular maintenance , and lubrication checks to ensure proper operation of the machine tool . Use this check list to inspect the machine before switching on the power. ❑

Check all lubrication levels particularly in the Auto Lube system and the air line lubricator.

❑

Check air pressure at the Filter, Regulator, Lubricator (FRL) assembly in the pneumatic system.

❑

Check coolant level(s). Check the ways for proper lubrication and any scratches or excessive wear. Be certain that the way wipers are not damaged.

❑

For detailed descriptions of these operations , refer to the Maintenance Manual.

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Machine Power The Hawk 5M's power switch is in the upper right comer of the electrical cabinet door. See illustration below. When it is switched on, information should appear on the console monitor screens. Hawk 5M Side View

Figure 1-7. Side view showing electrical cabinet and power switch

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Getting Started

Powering Up If the power has been shut off to the machine tool, the machinist should switch the power switch to the "On" position. When the power to the machine switches on, the following information displays on the Ultimax console's text screen: •

AMI BIOS Configuration information

•

"Loading executive - please wait"

•

Initialization messages

•

Scanning and loading language files

•

Any part program that was being created or used when the machine shut down will be automatically loaded

On the graphics screen (the right-hand monitor), information about the graphics card appears, and then the system displays the Ultimax 3 logo.

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Operator' s Manual On the text screen, the Machine Configuration screen appears (information on the screen varies based on machine options):

MACHINE CONFIGURATION r MACHINE TYPE MACHINE CLASS VERTICAI/HORI2ONTAL MAXIMA X TRAVEL. MAXIMA V TRAV®. MAMUR 2 TRAUEI. NUMBER OP AXES PRESENT

MAXIMA SPINDLE SPEED MAXIMUM RPM IN HIGH GEAR MINIMA RPM IN HIGH GEAR MAXIMA RAM IN LOW GEAR MINIMA RPM IN MAY GEAR

HAYS SM VERTICAL VERTICAL 31.000 IN 14.000 IN 6.000 IN 3

3000. 3000. 551. 558. 78.

I F 1 1 F 2 f F 3 F F 4 F S 1 F 6 P 7

Choose appropriate mftMey PRESS MANUAL MODE, POWER , AID START TO RESTORE POWER.

PUT a

Figure 1.8. Machine Configuration screen

The Machine Configuration screen displays machine setup information. Field service engineers use this information to be certain the machine is properly installed and configured. When there is a problem with the machine, the operator may be asked to check this screen and this information with a service representative. The information on this screen cannot be changed here. The operator presses the Exit (F8) softkey to continue. If the Machine Configuration screen does not appear or it contains error messages, refer to the "Power Up Troubleshooting " section.

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Hawk 5M Machine

Getting Started

Where can we go from here? After the Machine Configuration screen appears , the operator must press the Exit (F8) softkey to display the Input screen. The operator may edit and. run part programs . However, if the power has been shut off to the machine tool , the operator should then press the Manual console key and calibrate the machine . Refer to the "Calibrating the Machine" section in this chapter. Then, if necessary, warm up the machine, as described later. Or... In addition to warming up the machine , the operator may also want to check the System Parameters screen to be certain that the AutoSaveTm and Control Power Off times are correct or change the Current System Date and Time to time stamp any files saved during the session.

Operator' s Manual

Power Up Troubleshooting There are three symptoms of power-up problems that may occur: •

No messages appear on the console screen. The system may beep, but it does not start up.

•

Error messages appear during the initialization process before the Machine Configuration screen appears.

•

Error messages appear on the Machine Configuration screen when it is displayed.

The following troubleshooting instructions give the operator information to diagnose basic start-up problems.

No Response on the Console If no messages are displayed on the text screen after the power has been switched on, the power source for the machine tool must be carefully examined. The operator should check the following: •

Power supply cord to be certain it is completely connected to the power source • Power switch to see if it is in the "On" position If the power switch is in the "On" position and the power is properly connected to the machine , but the control still does not respond, the machine tool shop 's maintenance department or the machine tool manufacturer' s technical services department.

Warning Before testing "live" circuits or attempting any repairs to electrical connections , be certain that the power switch is in the "Off' position. Follow all established safety practices. that the power line from the power source to the machine tool may be "live" even though the machine tool is not receiving power.

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Hawk 5M Machine

Getting Started

Initialization Error Messages After the power has been switched on, the initialization messages begin to appear on the text screen. If an error message appears and initialization stops, there are several different types of errors that may have occurred. Many cannot be corrected by the operator; however, these messages indicate easily corrected conditions: "Non-system disk detected. Press any key."

This message means there is a diskette in the floppy drive, and the system is trying to find system software on that diskette. This often occurs when a backup diskette from the previous day was left in the floppy drive. Remove the diskette and turn the power off and then back on.

"Security device is invalid or has failed."

The software security key has been removed, is broken, or is not properly seated on the bottom of the control cabinet. Check and correct.

The remaining messages that may appear during initialization usually indicate missing or corrupted files. The common solutions for these problems are to restore or delete files . The machine tool manufacturer's service department needs to help solve these problems.

Ultimax 3 System

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Operator' s Manual

Important Before calling a technical services representative for assistance, always turn off the power at the power switch, wait a few minutes, and turn the power back on. If the problem is still present or continues to occur, call the machine tool manufacturer's technical services department and describe the symptoms. When calling for service, the operator needs to have the machine tool serial number and software version number, as well as a description of the problem. The software version number appears on the Input screen at the top near the softkey names, as shown in the screen below:

« INPUT .r

MASTER PROGM11

I F PART SETUP

(u1.58)

ISIS SM

EDIT PART PROGRAM

1 . HD3 STANDARD

PROGRAM MEMORY AVAILABLE

Msr.22'94 1 F TOOL SETUP METRIC VERTICAL 2 i

99 x

F PART PROGRAMING 3

F PROGRAM 1 PARAMETERS i F

Select uatkey or pans antm- > to theme Part prone. irwe

F COPY AND CHANGE 6 BLOCIIs i F ERASE FUNCTIONS 7 FF B

Figure 1-9. Input screen (software version number)

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Hawk 5M Machine

Getting Started

Error Messages on Machine Configuration Screen Occasionally, the system will go through all of the initialization steps, display the Machine Configuration screen, and then the console does not respond when keys are pressed. If the operator presses the Exit (F8) softkey, the Input screen will not appear nor will any other screen. If this occurs the operator should take careful note of any error messages on the Machine Configuration screen. If there are no error messages, the cable to the front may be loose or defective. If the shop has a maintenance department that repairs computers, a machine maintenance staff member may be able to check the cable . It is a custom cable inside a conduit. If it needs to be replaced , technical services must be called to perform the operation.

Important Before calling a service representative for assistance, always turn off the power at the power switch, wait a few minutes, and turn the power back on. If the problem is still present or continues to occur, call the service department and describe the symptoms. When calling for service, the operator needs to have the machine tool serial number, software version number, as well as a description of the problem.

Ultimax 3 System

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Operator' s Manual

Calibrating the Machine The calibration operation establishes the machine reference point (absolute zero) for each axis. Absolute zero is the location on the table, usually a comer or near a comer, where the X and Y axes intersect. This value does not change. The operator may begin the calibration operation when the Machine Configuration screen appears with no error messages . Then the operator presses the Exit softkey followed by the Manual console key to display the screen shown below. Note the "Uncal" messages in the Part field for each axis indicating that they are all uncalibrated.

w IYYBMIL "a X T Z

MACHINE 0.000 11.688 8.0101

I F TOOL IN SPINDLE

MACHINE VERTICAL I TOOL IN SPINDLE « I SPINDLE 01 F MACHINE F® MOTION STOPPED 2 DIAGNOSTICS F 3 F FARE MACHINE 4 P HAIR LIP MACHINE 5 i P TOOL HOME 6

Choose appropriate aortkey

F RESET SERVOS 7 AND SPINDLE

AX S ARE NOT CALIBRATED. TOOL IN SPINDLE NOT VERIFIED.

F CALIBRATE MACHINE a

Figure 1-10. Manual screen showing uncalibrated axes

There are several steps in calibrating a machine:

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•

Switching on servo power

•

Calibrating the "Z" axis

•

Calibrating the remaining axes

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Hawk 5M Machine

Getting Started

Power on to Servos If power to the machine servos is not switched on, perform the following: 1. Be certain that all Emergency Stop buttons have been released. To release an Emergency Stop button , twist the button in the direction indicated by the arrows and pull the button up. 2. Press the Power On console button to turn on the machine. When the machine is switched on, this button lights up. 3. Press the Reset Servos and Spindle (F7) softkey. This is only required to clear a servo or spindle error. 4. The Start Cycle console button begins to flash on and off. 5. Press the Start Cycle button to turn on the machine servos. The Start Cycle button stops flashing.

Ultimax 3 System

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Operator' s Manual

Calibrating the "Z" Axis To calibrate the "Z" axis (spindle head), follow these steps: 1. Press Calibrate Machine (F8) softkey. The Start Cycle console button begins to flash off and on. 2. Press the flashing Start Cycle console button. Observe screen display and machine movement. 3. After a few seconds, spindle head moves upward to seek its reference limit switch and a marker signal . This locates the "Z" axis machine zero calibration point.

Calibrating the Remaining Axes After the "Z" axis calibration (machine head 's absolute zero) is completed, the table travels to the right rear side of machine , seeking the appropriate reference limit switches and marker signals. This calibrates the "X" and "Y" axes. If an optional "A" axis is connected to the machine, this axis is also automatically calibrated at this time. The machine position display (at top of text screen) shows zero for all axes when the calibration process is complete.

Important Certain machines may have their setup intentionally altered to provide machine calibration in a different direction than described. The part zero reference point for the program is based on its relationship to the machine's absolute zero. For this reason, the direction of the machine calibration must not be changed for an existing part program.

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Hawk 5M Machine

Getting Started

Warming Up the Machine If the machine has been shut off, the operator may wish to warm up the machine before beginning work. Warming up the machine stabilizes the machine's operating condition to promote trouble-free operation and greater reliability. When the Machine Configuration screen appears with no error messages, the operator presses the Exit softkey and then the Manual console key to display the screen shown below:

+. MANUAL .. x T Z.

MACHINE

PART

393.70B 177.8819 6.600

39a.788 177.8BB ....w....

MACHINE

I F TOOL IN SPINDLE

VERTICAL

B TOOL IN SPINDLE B SPINDLE MOTION STOPPED FEED

1 F MACHINE 2 DIAGNOSTICS F 3 F PARK MACHINE 4 F WARM UP MACHINE 5 F TOOL HOME 6

Choose appropriate sot they

P RESET SERVOS 7 AND SPINDLE F CALIBRATE MACHINE B

Figure 1 -11. Manual screen

Follow these steps to warm up the machine tool:

1.

Power must be switched on to the servos as described in the previous section.

2.

The machine must be calibrated.

3.

Press the Tool In Spindle (Fl) softkey, and enter the number of the tool in the spindle into the field on the screen . Enter zero (0) if no tool is in spindle . Then press the Enter key.

Operator' s Manual 4.

Press the Warm Up Machine (F5) softkey. The prompt "Press Start to begin warm-up machine cycle" appears and the Start Cycle button begins to flash on and off.

5.

Press the flashing Start Cycle button and the "Z" axis retracts to machine position zero. •

•

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Press the Start Cycle console button. The "X" and "Y" axes travel between their respective limit switch settings at a feedrate of 100 inches-per-minute (i.p.m.) for this same period of time. After five minutes of clockwise operation , the spindle reverses direction and runs counter - clockwise at 1000 RPM for five minutes. The

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Hawk 5M Machine

Getting Started

Configuring the System To establish system parameters for time-outs and date /time stamps on files, press the Auxiliary console key above the number key pad. This screen appears:

- AUXILIARY EDITOR TYPE: COINSRSATIONAL

F STORAGE FUNCTIONS 1 F 2 F DOUKOAD i 3 F SYST@I 1 CO/%RAT ION S F CHMME EDITOR 6

Clore appropriate .attkay B

Figure 1-12. Auxitiary screen

Press the System Configuration (F4) softkey to access the system-wide parameters on the screen shown on the following page.

Ultimax 3 System

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Operator' s Manual The fields on the System Parameters screen should be checked and values entered as needed when the control is powered up or when the system is reset using the Reset Master softkey. Shutting the power off resets the control and erases these values , therefore, returning them to their default values. SYSTEM PARAMETERS CURRENT SYSTEM DATE

/ 1

CURRENT SYSTEM TIME

a

CONTROL POWER OFF TIME AUTO®AWE TINE SCREEN ELANII TIME

1 /

BB

2

17

F SET CURRENT I SYSTEM TIME F 2

30

MIN

120

SEC

is

"IN

F

F 3

F DISPLAY MACHINE 4 CONFIGURATION P DISPLAY SOFTWARE 5 CONFIGURATION F BACHUP MACHINE 6 CONFIGURATION F RESTORE MACHINE 7 CONFIGURATION

Enter the current nouth.

F EXIT B

Figure 1-13. System Parameters screen

Current System Date To enter today' s date into the system, the operator follows these steps: 1.

Type the number of the month and press Enter to move to the next portion of the field.

2.

Type the number of the day and press Enter.

3.

Type the last two digits of the year and press Enter.

4.

Press the Set Current System Time (F1) softkey to store this date in temporary memory so that the system can read it.

This data is useful when the operator is saving files from today's work because the system looks at the date entered here and date stamps the saved file. If a time stamp is also needed on these files , the operator can also enter the time in the Current System Time field and then press the F1 softkey once after entering the time to save both values.

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Hawk 5M Machine

Getting Started

Current System Time This field uses 24-hour clock times. So 1:30 in the afternoon is entered as 13:30. To enter the current time into the system, the operator follows these steps: 1.

Type the hour and press Enter to move to the next portion of the field.

2.

Type the minutes and press Enter.

3.

Type seconds, if desired, and press Enter.

4.

Press the Set Current System Time (Fl) softkey to store this date in temporary memory so that the system can read it when saving a file.

Control Power Off Time Use this parameter to set an automatic shut down time. Based on this parameter, the system shuts down automatically if none of the console keys, buttons, or trackball have been touched for this length of time specified in the field. Enter the time as number of minutes. The effect of this shut down is the same as an Emergency Stop shut down because the power to the servos is shut off and the lubrication stops pumping to the ways . However, the table is not centered as it is with the Park Machine shut down . For more information about machine tool shut down techniques, refer to the "Shut Down Techniques" section in this chapter.

Important It is a good idea to check the Control Power Off Time on this screen to be certain that there is a value in this field. If this field does not have a time limit in it, the system will not automatically shut down.

Ultimax 3 System

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Operator' s Manual

AutoSave Time The AutoSave feature periodically saves copies of the part program in the control's temporary memory to the hard drive. When the system is automatically saving the part program , the system displays the message shown on the screen below , and the operator will not be able to perform any system actions until the program is saved. GE®IAL PARAMETERS RETRACT CLEIRg1CE RAPID TRAVERSE PECK CLEARMICE PLAMB CHORD ERROR DEPLETION RETRACT INTERRUPT CYCLE Z RETRACT

>,

999.899 M 7679. PP" 1.278 MI 8.883 MI 8.127 MI YES

F 1 F 2 1 P 3 F 4 F HOLES S PARAMETERS

Enter clearance height above Z START at which tool nouns between operations START TO RESTORE POWER. INC PART PROGRAM...

P 6 M P 7 I F 8

MILLING PARAMETERS PROGRAM PARAMETERS EXIT

Figure 1-14. AutoSave message on General Parameters screen

The time limit in the AutoSave Time field on the System Parameters screen tells the system how often to save the program file currently in temporary memory. This makes a copy of the part program file at the time of the automatic save so that the file can be recalled if the power to the control is shut off. To switch off the AutoSave feature , the operator enters a zero in this field. If the file is not saved either with the AutoSave feature or by the operator onto the hard disk or a floppy diskette and the power shuts off, any work done on the program currently in temporary memory will be lost. In effect, the control would have no way to changes to the program.

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Hawk 5M Machine

Getting Started Screen Blank Time This parameter allows the operator to set a time limit in which the console screens will go blank. This is similar to screen saver programs on personal computers that prevent image bum-in on the CRT's. Type in a time in minutes and press Enter. Then if the console keys, buttons, and trackball are not touched for that length of time, the CRT's will go blank. To redisplay the screens, move the trackball or press other console keys.

Important Do not be concerned that pressing a key while the screen is blank will change system data. The control uses the first key stroke to re-activate the screen and then uses the second key stroke as input for the system.

SYSTEM PARAMETERS CURRENT SYSTEM DATE QWIRIT SYSTEM TIME cONTEOL POWER OFF TIME AUTOSAVE TIME

Is

/

I

SET QIRRDIT SYSTEM TIME

1/BB F 2

B: 2 : I? 38

NIN

P 3

129 SEC P DISPIAY NAQIINE 4 CONFIGURATION

SCREEN BmADI TIME

F DISPIAY SOFTWARE 5 CDWIQI TION P DAC10R NAQIINE 6 cOIVIQDNTION P RESTORE MAQII 7 cOIRIQJI TI

Enter the anent eonth.

IT

Figure 1-15. System Parameters screen

The operator may also use these softkey operations on the System Parameters: •

Ultimax 3 System

Set Current System Time (Fl) - Press this softkey if a time and date were entered. This saves the information entered into those two fields. Otherwise, the system will reset those fields to their defaults when the operator exits the screen.

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Operator' s Manual •

Display Machine Configuration (F4) - Press this softkey to display the Machine Configuration screen. This screen describes the machine tool with such information as machine type (Hurco model), the class such as vertical, horizontal, or universal and maximum travel limits. Here is a sample of this screen: » MACHINE CONFIGURATION »

MACHINE TYPE MACHINE CLASS UERTICA/HORIZONTA.

I1UX SN

VERTICAL VERTICAL

MAXIMUM X TRAVEL MAXIMUM V TRAVEL MXIMii Z TRAVEL NUMBER OP AMR PRESENT

31.000 IN 14 . 000 IN 6.000 IN 3

3000. 3000. 551. 550. 70.

MAXIMUM SPINDLE WED MXIMM I" IN HIGH GM NINIMM RPN IN HIGH GEAR INXIMM I" IN LOU GEAR NINIMM RPM IN Lau GRAB Ch•

appa

iota a•ftk•y

FRESS MANUAL NODS, PMIXII, AND START TO RESTORE POY111.

I F 1 I F 2 I F 3 I F 4 P5 ^F 6 I F 7 l F EXIT a

Figure 1-16. Machine Configuration

The operator may want to check this screen before using the backup or restore softkeys (F6 and F7). •

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Display Software Configuration (FS) - This softkey displays the Ultimax system options that are currently installed on the control and the international languages available in the system software. The system options are features such as DXF, 3-D package, UltiPockets, and Cutter Inserts. To purchase additional options, Hurco or a Hurco distributor.

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Hawk 5M Machine

Getting Started •

Backup Machine Configuration (F6) - Press this softkey to copy the following information onto a floppy diskette or the hard drive: o

o •

Machine Configuration data including the machine type and class (displayed on the Machine Configuration screen) Control power off time, AutoSave time , and screen blank time from the System Parameters screen

Restore Machine Configuration (F7) - Press this softkey to copy previously saved Machine Configuration data and the time limits from the System Parameters screen . The data may be stored on a floppy diskette or the control 's hard drive . This option is only used if a Machine Configuration error occurred during power up.

Caution The Machine Configuration should only be edited by a qualified technician because the information in the configuration file determinebasic machine operations. •

Ultimax 3 System

Exit ( F8) - Press this softkey to return to the Auxiliary screen.

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Operator' s Manual

Switching Part Programming Editor Type To switch the part programming editor between conversational and NC, the operator presses the Auxiliary console key above the number key pad. This screen appears:

AUXILIARY M 6D(SOA TYPE : CONYERSIITIOMAL

I F STORAGE FUNCTIONS 1 F 2 F DOYFUAAD / 3 1 F SYSTEM 4 CONFIGURATION F1

F OYYIGE EDITOR 6 Choose appropriate matkay

Figure 1-17. Auxi iwy screen

Then the operator presses the Change Editor (F6) softkey. The system switches to the NC editor. Note the name in the Editor Type field. The sample screen shows the current part programming editor is "conversational ." When switching from conversational programming to NC part programming , the system asks the operator to indicate whether the part program will use inch or metric units of measurement.

Important If there is a part program currently loaded into temporary memory on the control, the system displays the "Current program and part setup will be lost; OK to continue?" message. The operator answers Yes or No to the question by pressing the appropriate softkey.

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Hawk 5M Machine

Getting Started

Loading Part Programs After the machine is calibrated and warmed up, the operator may want to perform one of these operations: •

Edit a part program

•

Load in a previously created part program

•

Change from conversational part programming to NC

To edit a part program , the operator first presses the Input key on the console above the number pad. This screen appears:

00 INPUT -

I F PART SETUP I Mar .22'94 I

HAWK 5M 1.HD3

METRIC F TOOL SETUP VERTICAL 2 P PART PROGRAMMING 3

PROGRAM M®IORY AVAILABLE

F PROGRAM 4 PARAMETERS I F 5 F COPY AND CH N=E 6 BLOCBS F ERASE FUNCTIONS Select eartkey or Press anter> to change part Program name 7

P B

Figure 1-18. Input screen

If there was a program being edited on the previous day, that part program is automatically loaded during initialization . Check the Edit Part Program field (circled in example above ) for the name of the program currently loaded into the control . In the sample screen shown above, the "l.HD3" part program is loaded into the control.

Ultimax 3 System

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Operator' s Manual

Selecting an Existing Part Program To select a different part program, the operator should press the Auxiliary console key above the number key pad. This screen appears:

- AWILIARY EDITOR TYPE : CONVERSATIONAL

F STORAGE FUNCTIONS 1 F 2 F / 3 i F SYSTEM 4 CONFIGURATION F S

Choose appropriate softkey

Figure 1-19. Auxiliary screen

To access the stored part programs on the hard disk within the control or on the floppy diskette , the operator then presses the Storage Functions (Fl) softkey.

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Hawk 5M Machine

Getting Started The Current Program screen appears. The softkeys on this screen allow the operator to perform the following tasks:

Ultimax 3 System

•

Read Program from Disk (Fl) - makes a copy of a program on the hard disk and places it into temporary memory on the control allowing the operator to edit the copy or run the program.

•

Write Program to Disk (F2) - copies the program currently displayed onto the hard drive (permanent memory) or onto a floppy diskette.

•

Disk Operations List Directory (F3) - allows the operator to perform operating system functions such as changing to and creating different directories on the hard drive, deleting programs from the hard drive 's permanent memory, and renaming programs.

•

Format Diskette (F4) - prepares the diskette currently inserted into the floppy drive to allow it to receive a copy of a part program.

•

Select Current Storage Drive (F6) - allows the operator to specify which drive will receive a copy of the program when it is stored and the directory from which programs will be copied. The choices are usually the "A" drive (floppy drive) or "C" drive (the hard (rive).

Revision A

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Operator' s Manual Here is a Current Program screen. Note that the system is ready to read a program from the hard drive though the currently available program was read from the floppy drive. CURRENT PROGRAM A:'27-12-93.HD3 CURRENT DISK HARD DRIVE C

F READ PROGRAM 1 FROM DISK F WRITE PROGRAM 2 TO DISK

I

F DISK OPERATIONS 3 LIST DIRECTORY F FOR)NT DISKETTE 4 F

P SELECT CURRENT 6 STORAGE DRIVE Choose appropriate wt they

Figure 1-20. Current Program screen

To load a copy of a part program into the temporary memory on the control, the operator selects the Read Program from Disk (Fl) softkey. Then this screen appears: CURRENT PROGRAM A:S27- 12-93.HD3 CURRENT DIRECTORY 28796680 bytes free a bytes tagged.

4 directory ( a) B program(s). F REWIB: B programs tagged . 2 PROGRAM

GSAVEL

PROBE_M . H03

JR-AUTO RACECAR

I DIRECTORY

IID3 HD3

E DSUP H D3 PROBE HD3 PROBE-DB.HD3 RACE CAR . HD3 SA(IEPROG.HD3

F DELETE 3 PROGRAM P CREATE 4 DIRECTORY i P DELETE 5 DIRECTORY P SELECT CURRENT 6 STORAGE DRIVE

Use arrow keys to moue through progrow(s)aM Select . 1(D? Program to read Into aoay. Press ant.) to accept highlighted program name.

F -MORE7 I P EXIT 8

Figure 1-21. Current Directory screen

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Hawk 5M Machine

Getting Started Use the arrow keys to move the highlight to the desired program and then press the Enter key to select it. The Current Program screen reappears with the selected program name listed and a message as shown below:

Figure 1-22. Part Program Read into Memory

Ultimax 3 System

Revision A

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Operator' s Manual

Entering a New Part Program Name To type in a new program filename , display the Input screen either by pressing the Input key or by pressing the Exit (F8) softkey when the Machine Configuration screen appears at start -up. Then follow these steps to enter the filename: 1.

Press the Enter key to display the Letter Selection screen on the right monitor (shown below).

2.

Use the trackball on the console to move the crosshair indicator on this screen.

3.

When the crosshair is positioned over the desired character, press the Select key.

4.

The selected character then appears in the Edit Part Program field.

5.

Select up to 8 characters for the filename. The system adds the 3-character extension (usually HD3) to the end of the filename.

Space

!

"

#

e

+

,

-

4

5

6

7

8

9

>

?

@

A

B

C

H

I

J

K

L

R

S

T

U

\

$

%

&

'

(

)

/

0

1

2

3

;

<

D

E

F

G

M

N

0

P

Q

V

W

X

Y

Z

[

Back Space

Enter

Figure 1-23. Letter Selection screen (graphics screen)

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Hawk 5M Machine

Getting Started Here is the Input screen ready to receive a new program name:

Figure 1-24. Input screen (text screen) while entering new program name

Ultimax 3 System

Revision A

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Operator' s Manual Press the Enter key, and the system allows the operator to indicate whether the program will use inch or metric units of measurement:

Figure 1-25. Input screen after the operator presses Enter

After selecting the unit of measurement , the operator indicates whether the program will run on a Standard (3-axis) machine or a machine with an optional rotary table supplying an "A" axis. Then the operator can begin Part Setup and Tool Setup for the part program.

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Hawk 5M Machine

Getting Started

Erase Functions While the operator is creating or using a part program, it is stored in a temporary memory area on the control. This is not the permanent memory where programs are stored for later access. The erase functions do not affect the permanently stored programs. These functions only remove copies of programs and portions of programs in temporary memory. Operators use these functions to perform the following tasks: • • •

Throw away changes to a copy of a program that are no longer needed Clear out the entire work area to start fresh (using the Erase All softkey) Clear out the part program and keep the part setup and/or tool setup to use for a new program

The operator accesses these options by pressing the Erase Functions (F7) softkey on the Input screen.

Figure 1 -26. Input screen with Erase Functions soft key

Ultimax 3 System

Revision A

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Operator' s Manual The Input screen softkeys change to list the erase functions, as shown below:

Figure 1-27. Input screen with Ernst functions

The erase functions will only affect the part program currently displayed on the Input screen: •

Erase Part Setup (Fl) - resets all of the Part Setup to their default values.

•

Erase Tool Setup (F2) - deletes all tool data defined for the part.

•

Reset Program Parameters (F3) - resets the Program

Parameters to their default values.

1-46

•

Erase Program (P4) - deletes the part program data blocks from program memory.

•

Erase All (P5) - deletes the part program and its tool setup from program memory and then resets the Part Setup values and the Program Parameters to their default values.

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Hawk 5M Machine

Getting Started After the operator selects one of the erase functions , the system displays the message shown on the screen below and, therefore , allows the operator to confirm the erase operation.

Figure 1-28. Input screen with "Do you really want to Emu?" message

The erase functions only erase program descriptions from the temporary memory. This does not affect the stored version of the program on the hard drive. For an explanation of permanent program storage and deletion, refer to the "Program Storing, Renaming, and Deleting" section later in this chapter.

Ultimax 3 System

Revision A

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Operator ' s Manual

Part Programming Setup There are five main steps an operator must take before creating a conversational part program or an NC program on the Ultimax control. 1. Plan the part programming operations 2. Perform the tool loading and part fixturing operations 3. Enter the Part Setup in the Ultimax system 4. Enter the Tool Setup in the Ultimax system 5. Enter the Program Parameters Setup To perform many of the setup functions , the operator must use the jog unit to move the table or spindle and record positions.

Getting Started

Jog Unit The operator uses the jog unit to select the axis to move (jog) by pressing one of the buttons on the upper right side of the unit. To move the selected axis, the operator presses the Jog Direction buttons or uses the Incremental wheel. The jogging speed can be controlled by adjusting the Axis Feed Rate dial. To record the axis' current, real-time position in the part program setup screens, the operator presses the Store Position button. Note that the unit also has an Emergency Stop button.

Moves selected axis (plus or minus direction at Axis Feed Rate until released

Select the axis to jog 1 ""a

Places the current position of the selected axis into the part program

Fine control of jogging at Axis Feed Rate

Increase or decrease the jogging speed of the wheel or the + or - buttons for the selected axis

Figure 1-29. Jog Unit

Ultimax 3 System

Revision A

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Operator' s Manual The operator may want to set the parameters that control jogging speeds. To access the parameters , press the Manual console key to display the Manual screen . Then press Machine Diagnostics (F2) softkey to display the parameters shown below:

Figure 1-30. Manual screen with jog parameters(in millimeters per minute)

With the cursor at the Manual Jog Feed parameter , enter the desired manual jog feedrate . This value cannot be greater than 200 inches per minute ( i.p.m.) and is used when jogging the X, Y, and/or Z axes. When cursor is at the Rapid Detent parameter , the desired rapid feedrate for the X and/or Y axes can be entered (not to exceed 400 i.p.m.) This feedrate is used to jog these respective axes when the Axis Feedrate switch on the jog unit is placed at the Rapid position. The Z axis always uses the value of 150 i.p.m. when this switch is in the detent position. The Manual Spindle Speed parameter governs spindle speed for jogging when the operator has selected the Manual machine mode and pressed the Spindle On console key . The system does not permit this value to be greater than the maximum spindle speed for the machine.

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0

/x•"Hawk 5M Machine

Getting Started

Tool Loading and Part Fixturing Before entering data into the part and tool setup screens for a part program, the operator must first fixture the work piece to the table and load a tool into the spindle.

Loading Tools into the Spindle To load or remove a tool from the spindle, the spindle must be stopped, and the "Z" axis must be in its full retract position. To load a tool into the spindle, the operator first inserts the tool into a tool holder. Refer to the diagram below. Then the operator presses and holds down the In button while inserting the tool holder into the spindle so that the tool holder slots align with the spindle head guides. The machine ratchets the holder into a secure position in the spindle. When the ratcheting noise stops, the operator may release the In button and the tool holder. To remove the tool from the spindle, the operator grasps the tool, presses the Out button, and the ratcheting mechanism releases the tool . When the ratcheting noise stops, the operator pulls the released tool out of the spindle.

Figure 1-31. Spindle, Tool Holder, and 1n/Out Buttons

Ultimax 3 System ,

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Operator' s Manual

Fixturing the Part In order to determine the starting point (part zero) in the part, the operator must first attach the work piece (raw material or stock) to the machine tool table. This process, called fixturing, can be accomplished using a variety of clamping devices, such as vises and toe clamps. The operator selects the fixturing device that will hold the work piece securely without getting in the way of the cutting tool when the part is being made.

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Hawk 5M Machine

Getting Started

Identifying Part Zero with a Tool The operator may want to insert a tool in the spindle to use as an edge finder when identifying part zero.

Ultimax 3 System

1.

Find the Machine Mode button grouping. Press the Manual button to display the Manual screen. This screen has the Tool in Spindle field and softkey used to enter the tool number if needed.

2.

Press the Power On button and press the Start Cycle button to turn-on machine control power.

3.

If a tool is in the spindle , grasp the tool to prevent it from dropping onto table or work piece . Press and hold down the Out button until the gripping mechanism releases the tool . Then pull the tool downward from the spindle.

4.

To insert a different tool into spindle, press and hold the In button while inserting tool into the spindle.

5.

The tool will need to be calibrated as described later in the "Tool Setup" section.

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Operator' s Manual

Part Setup The part setup procedures establish the locations of part zero in X and Y relative to the machine's absolute zero. Refer to the diagram below. Absolute zero, identified during machine calibration, is the location on the table, usually a corner or near a corner, where the X and Y axes intersect. This value does not change. However, it is difficult for the operator to include the offsets between absolute zero and the comer of a part when determining locations on the part, so operators identify part zero for a work piece when it is fixtured to the table. Part zero is the X and Y intersection on the part itself. Then dimensions can be programmed from part zero without considering the offset distances from the absolute zero comer of the table . Part zero must be identified for each new part.

Programmed as a coordinate dimension from part zero

Y axis X is

Y Offset X Offset

Part Zero Absolute Zero (on the table) (Machine Absolute - X & Y axes) Figure! 1-32. Pan Zero Relationship to Machine Absolute Zero

Getting Started The location of part zero in Z is established during tool calibration. During setup, the tool zero calibration plane is established for each tool. The program dimensions for a part are relative to these points as shown below.

/Head Zero (Machine Absolute - Z axis) Tool Zero Calibration Plane (typical)

Part (Workpiece)

Figure 1-33. Tool Zero Calibration Plane and Part Zero in Z

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Operator' s Manual Programming of axis motion relative to part zero is shown in the previous illustration as viewed facing the front of the machine. When programming, that the X and Y coordinates define a position on the part. The operator programs the spindle to move within the coordinate system as shown below: Spindle moves up and away from the part Spindle moves right on part - Spindle moves away from operator

Spindle moves down and into the part

Y\ Spindle moves toward the operator

Figure I.34. Spindle motion relative to Pan Zero

Getting Started

Part Setup Screen After the name of the part program is entered into the Input screen, and the tools and work piece are in place, the operator is ready to begin the part setup process. Press the Part Setup (F1) softkey to begin the setup process. The Part Setup screen appears. The operator may type values into the fields or use the jog unit to position the tool and store positions identifying these values. PART SETUP MACHINE 12.6436 6.3224 -16.3488

X V Z

PART 9 . 8888 8 . 8988 8 . 7463

TOOL IN SPINDLE 1 SPINDLE 0 FEED NOTION STOPPED

I F 1

I

F TOOL SETUP 2

F PART PROGRAMMING 3 PART ZERO X V OFFSET Z

•

12.6436 6.3225 6 . 8888

SAFETY WORK REGION Z TOP (•) 99 .8888 Z BOTTOM (-) -99 . 8888 X LEFT (-) -16.BBeB X RIGHT (•) 5.8886 V FRONT (-) 4.8888 V BACK (•) 4.8888

Enter part mro If Imam or Jog nachrne to part rero pos iti on an d prose so rtk e9 t o s t ore pos iti on

F PROGRAM 4 PAPAMETERS F 5 I F 6 P STORE MACHINE 7 POSITION I F EXIT 8

Figure 1-35. Completed Part Setup screen

The top left section of the screen shows the position of the axes. The bottom left of the screen is the data entry area where the operator enters the values to identify part zero and the safety work region for this part program. The softkeys on this screen provide the following options:

Uhimax 3 System

•

Tool Setup (F2) - allows the operator to enter the descriptions of the tools that will be used in this part program.

•

Part Programming (F3) - allows the operator to enter the exact description of how the part will be cut.

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Operator' s Manual •

Program Parameters (F4) - displays the screens where the data common to all of the program data blocks can be entered. Refer to the "General Parameters" section in this chapter for more information.

•

Store Machine Position (F7) - pressing this softkey records the value displayed on the screen for the axis currently marked by the cursor. After these values are recorded , they become the offset values from absolute zero for the axes.

•

Exit (F8) - allows the operator to exit the setup process and return to the Input screen.

Getting Started

Entering Part Setup Information The operator begins part setup by entering the part zero values. There are a number of methods to accomplish this task; however, here are two of the most common methods: 1.

2.

With cursor at the "Part Zero - X" field, type the "offset" value of this dimension using the number keys on the console. Press the Enter key to store dimension . Use the same method to enter the value in the "Y" field. Or... Use an edge finder or indicator in the spindle and jog the machine axes to identify part zero. First , check to be certain that the Power On button is illuminated to indicate that the machine 's servos are powered up. Then follow these steps: a. Press Spindle On key to start and rotate spindle. Then press the Start Cycle button. If using an edge finder, the operator may need to reset the Manual Spindle Speed parameter. If not using an edge finder, the operator should use a tool with a known diameter and turn off the spindle. If using the Hawk 5M dial indicator, th operator must be certain the spindle is out of gear (in the Neutral position). b. Use the axis jog keys ( X, Y, +, -) on the remote jog unit to move the edge finder in the spindle to the part zero location on the part fixtured to the table. c. During this process , the system displays the X and Y positions , relative to absolute zero, onto the Part Setup screen in the Machine column in the upper left of the screen. d. Jog the edge finder until it touches the X part zero location. The operator then presses the white Store Position button on the jog unit. The same procedure is used to identify the Y part zero location. The dimension for X and Y in the Part column at top of screen becomes zero. e. The calculator functions of the control can be used to adjust the indicated X and Y parameters to compensate for the radius of the edge finder.

f. Press Spindle Off console key to stop rotation of the spindle.

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Operator' s Manual The operator should establish the dimensions of the Safety Work Region to prevent the cutting tool from moving into areas where it might collide with other equipment or the work piece and fixturing . The operator particularly needs to enter the Z Bottom (- Z) parameter to prevent the tool from drilling through the part and into the table. The operator may also want to use the Z Top (+Z) field to define the clearance above all portions of the part and/or fixture.

I/

I

Part Zero

x

I

I

+x

Z `/--------/

Figure 1 -36. Safety Work Region

If no values are entered in these fields , the system defaults to 99 inches for the positive and negative values. To enter values use one of these two methods: 1.

Use the number keys on the keyboard to enter the dimensional values of the safety region.

2.

The operator may want to use the axis jog functions on the jog unit to identify the X and Y safety region. Jog each axis out to the edge of the safety region and press the white Store Position button on the jog unit. To store the Z values using the Store Position button, a tool previously described on a Tool Setup screen for this program must be in the spindle.

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Hawk 5M Machines

Getting Started

Hints and Tricks Use the Z Top value to reduce rapid Z motion for all Position data blocks. The spindle will retract to the Z Top value above the tool zero calibration for position data blocks.

Important Entering a value in the Offset Z field on the Part Setup screen adds the entered amount of the offset to the tool zero calibration point. This is a quick method to adjust all tool calibration values in the Z axis to compensate for variations in the thickness of the work piece. For example, using all tools from a previous program and changing the Offset Z will reset all Z calibration points to the new work piece. The operator can use Tool #1, calibrate it, and press Offset Z to store the offset distance between the top of the first part (reference block) and the top of the work piece. Calibrate all tools here

N Reference Gauge Block

dl

Offset Z Work Piece Table

Figure 1-37. Offset Z

Press the Exit (F8) softkey to return to the Input screen or press the Tool Setup (F2) softkey to describe the tools used in the part program.

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Operator' s Manual

Tool Setup Use the Tool Setup screen to describe the tools that will be used for this part program. Each tool used in the part program must be described on the Tool Setup screens; otherwise, the system will not have enough information to draw the part on the graphics screen , and the machine will not be able to cut the part when the operator tries to run the program.

Caution

When an operator intends to run a previously created part program, the Tool Setup must be carefully checked to be certain the tools described for the old program match the tools planned for the new program. If a tool breaks or is not available when running a previously created part program, the operator must change the Tool Setup information.

Hints and Tricks Many operators create tool setup templates to simplify development of new part programs. To create a tool setup template, the operator enters tool description and then saves the information as a program (to the disk or a floppy) using a program name that indicates the type of tools described. To use the saved standard setup, the operator recalls the tool setup program, makes any necessary changes for the new part program, and saves the changed setup under a new name . Renaming preserves the original template file for later use. For information about saving programs to the hard disk or to a floppy diskette, refer to the "Program Storing , Renaming, and Deleting" section.

Getting Started

Tool Setup Screen To access the tool setup for this part program , the operator displays either the Input screen or the Part Setup screen and presses the Tool Setup (F2) softkey. The following screen appears:

TOOL SETUP NAQIINE 11.0000 0.0080 -4.4914

X V Z

PART 1. 0800 1 . 0800 essssssss

F 1 TOOL IN SPINDLE 1 SPINDLE 0 FEED NOTION STOPPED

F1 2 F PART PROGRAMMING 3

TOOL

F PROGRAM 4 PARAMETERS

I 1

F PART SETUP 5 F TOOL HOME 6 Press DITER to -. anotMr t oo l

tool Intonation or eMe nuabm of

F SET TOOL ZERO 7

r EXIT

R

Figure 1-38. Tool Setup screen

The top left section of the screen shows the real-time position of the axes. The bottom left of the screen is the data entry area where the operator enters the information describing a tool. When tool number I was entered into the screen shown above, no information appeared under the number. This means that there is no description for tool number 1, and it is currently available for this program. This information must be entered. There is no Machine or Part position display (top left on the screen) nor any softkey selections displayed when machine is not calibrated or when in concurrent programming. Note To move between the fields on the Tool Setup screen , use the arrow keys. Pressing the Exit (F8) softkey displays the Input screen.

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Operator' s Manual The softkeys on this screen provide the following options: •

Part Programming (F3) - allows the operator to enter the exact description of how the part will be cut.

•

Program Parameters (F4) - displays the screens where the data common to all of the program data blocks can be entered. Refer to the "General Parameters" section in this manual for more information.

•

Part Setup (F5) - allows the operator to return to the Part Setup and make changes.

•

Tool Home (F6) - press this softkey and then press the Start Cycle button to move the spindle to tool change height. This option allows the operator to move the tool quickly away from the part after finding the Zero Calibration value. Using this softkey is much faster than pressing the axis jog buttons on the jog unit.

•

Set Tool Zero (F7) - to use this softkey, the operator carefully jogs the tool in the spindle down to the top of the part and then presses this softkey. The system stores the position of the tool into the current part program and the number appears in the Zero Calibration field on the Tool Setup screen. This can also be accomplished by pressing the Store Position button on the jog unit. On the screen the part display for "Z" changes to zero.

Warning Be certain that the tool number in the Tool in the Spindle field matches the tool being edited when the zero calibration is stored. •

Exit (FS) - allows the operator to exit the tool setup process and return to the Input screen.

Getting Started

Tool Setup Fields To set up the tool descriptions for this part program, the operator follows these steps: 1.

Enter the tool number of the tool using the number keys on the console. If there is no tool in the spindle, enter a zero (0) for the tool number. TOOL SETUP

MACHINE 393 . 788 177. 900 0.088

X T Z.

PART 393 . 760 177.000 eeeeeeeee

I F DELETE TOOL 1 TOOL IN SPINDLE 0 I B F SPINDLE NOTION STOPPED 2 FEED F PART PROGRAMMING 3

TOOL TYPE DIAMETER ZERO CALIBRATION SPEED (RPM ) COOLANT

01

1

F PROGRAM 4 PARAMETERS

8.888

F PART SETUP 5 F TOOL HOME 6

B a"

Pray ENTER to eoeete tool l'tonotion or eater ,weber of eintlnr tool

P SET TOOL ZERO 7 I F EXIT B

Figure 1-39. Tool Setup screen

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Operator' s Manual 2.

Press the appropriate softkey to select Type (see example below). These tool types are listed as softkey options: •

Drill

•

Face Mill

•

Tap

•

Ball Nosed End Mill

•

Boring

•

Back Spotface

•

End Mill

If the tool is a tap, a Threads per Inch parameter must be programmed (or Pitch in millimeters per thread, if metric is the unit of measure).

TOOL SETUP E V Z.

M93.700 393.700 177.800 0.000

PART 393.700 177.000

TOOL IN SPINDLE SPINDLE 0 FEED MOTION STOPPED

F NOT ID(OUM 1 i F DRILL 2 F TAP 3

TOOL TYPE

1 DRILL

I,

DIANE= ZERO CALIBRATION SPEED (RPM) COOLANT SURFACE SPEED

F BORING 4 i F END MILL 5

0.1iS8 Cy

0 FlOOD 0.0

F FACE MILL 6 P BALL NOSED 7 END MILL i --ORS8

Select two of tool

Figure 1-40. Tool Setup screen with tool types

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Hawk 5M Machines

Getting Started 3.

Enter the Diameter of the tool. This information is used when determining cutter compensation during milling operations. Ultimax software automatically calculates the radius of the cutting tool and allows for this distance when performing milling operations . This means the operator does not need to the size of the cutting tool and manually calculate tool offsets when programming the part. Path compensating for Cj,,- cutter radius

Cutter radius = amount of cutter compensation offset

0

Figure 1-41. Cutter Compensation

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Operator' s Manual 4.

Use jog functions to calibrate the tool to the part or reference surface. Move the tool in the spindle down until the tool touches part zero. Press the Store Position button on the jog unit and the position of the Z axis appears in the Zero Calibration field. The position of the Z axis can also be stored using the Set Tool Zero (F7) softkey. Use the calculator functions of the keyboard to add or subtract shim stock dimensions (if used). For example, after pressing the Set Tool Zero (F7) softkey, the operator enters the thickness of the shim and presses the plus key (+) and then presses Enter to add the shim thickness.

5.

If the operator knows the correct speed to be used for this tool, enter it into the Speed field. This value will be copied into each new data block in the part program (but only for part program data blocks created after Tool Setup) which use this tool. If necessary, this parameter can be changed within the new data block when programming the part. The direction the spindle turns (clockwise for right-hand cutters) is also part of this parameter.

6.

The Coolant parameter defines the coolant type to be used for the tool and is programmable on a tool -by-tool basis.

Getting Started 7.

For drills or milling tools, the Surface Speed, Flutes, and Feed/Flute (Tooth) fields also appear on the screen, as shown below. The operator may enter a Surface Speed in inches or millimeters per minute. Then the Flutes and Feed/Flute fields appear. The operator enters values that indicate the number of the flutes (teeth) on the tool and the feedrate per flute. The system uses these values to calculate the feeds and speeds for the tool . Refer to the following "Automatic Feeds and Speeds Calculations" section.

TOOL SETUP NACNINE 0.6066 6.6666 -2.1767

X V. z

TOOL TYPE

PART -5.6066 -5.6606 5. 6553

1 20 MILL

F PAOGM tI 4 PARAMETERS

6.7566 7.2316

F PART SETUP 5 i T TOOL NONE 6

DIAMETER z6RO CALIRMITION SPEED (RPM) COOLANT SURFACE SPEED

an TOOL IN SPINDLE SPINDLE 6 NOTION STOPPED FEED

CY

6 OFF 1666.

FLUTES F111131/FLUTE (TOOTN)

12 6.6666

F SET TOOL ZERO 7

Enter amber of mttina [lutes

P EXIT a

Figure 1.42. Tool Setup screen with Surface Speed fold

The operator may also wish to consult the Machinist's Handbook or the feeds and speeds material in the "Appendix " of this manual for more information.

Important If a value was entered into the Speed field, the system ignores any data entered into the Surface Speed field. If the automatic speed calculation is wanted, do not enter a value in the Speed (rpm) field.

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Automatic Feed and Speed Calculations The control calculates the appropriate feedrates and spindle speeds for drilling and milling operations. The operator should understand the following information concerning automatic calculations of feeds and speeds:

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1.

The tool must be a drill, end mill or face mill.

2.

If a zero is entered for the Speed parameter, the speed and the feedrate are automatically calculated by the control. If a nonzero value is entered for Speed , this value is transferred to all data blocks using this tool and the feed is not calculated.

3.

The control makes no assumptions about material hardness and the amount of material being removed . The operator must check computed feeds and speeds to ensure they are appropriate and make any necessary adjustments.

4.

When all parameters are specified during Part Setup , entering a tool number in a drill or mill data block causes the feed rate and speed parameters to be computed and appear on the display; however, plunge feedrates for end mills and face mills are not calculated.

5.

If the tool diameter or speed parameters are changed from the initial selection, a message is displayed asking if the feeds and speeds should be recalculated . If any of the other relevant parameters are changed , feeds and speeds are recalculated automatically.

Revision A

Hawk 5M Machines

Getting Started The control system uses this equation to compute the drilling and milling feedrates in inches per minute (i.p.m.): ipm = Feed per Tooth x #of Teeth x rpm Using this equation the control calculates the following feeds per revolution for these drill diameters:

Drill Diameter

Feed per Revolution

1/4" to 5/16"

.004 to .010

3/8" to 7/16"

.006 to .012

1/2" to 9/16"

.010 to .014

5/8" to 11/16"

.012 to .016

3/4" to 13/16"

.013 to .018

7/8" to 1 1/8"

.015 to .025

1'/i' to 1'h"

.020 to .040

1'h" and over

.025 +

Important For kneemills using larger tools (5/8" to 1"), the feeds and speeds for drilling and milling should be manually reduced by approximately 15% to 20%% based on the machinist's experience.

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Operator ' s Manual The Ultimax control also automatically calculates spindle speeds using the following formulas .. The first four formulas produce the revolutions per minute (rpm) that apply to high- speed steel tooling and high-speed cobalt tooling used to cut work pieces of these common metals.

382 = rpm for plain carbon steel tool diameter 350 tool diameter

1240 tool diameter

365 tool diameter

= rpm for alloy steel

= rpm for aluminum

= rpm for gray cast steel

Caution High-speed steel cobalt tooling feedrates should be increased by .001 to .002 feed per revolution. For carbide and carbide coated tooling these formulas are used:

1530 tool diameter

= rpm for plain carbon steel

880 = rpm for alloy steel tool diameter 3440 = rpm for aluminum tool diameter 1240 rpm for gray cast steel tool diameter =

Getting Started

General Parameters The Program Parameters screen allows the operator to describe these groups of parameters: •

General - retract clearance, rapid traverse, peck clearance plane, chord error, depletion retract, interrupt cycle Z retract

•

Holes -

•

Milling - blend offset, blend overlap, finish feed, finish speed, finish XY, finish Z, milling direction, pocket overlap, cutter compensation parameter

•

Program - override lockout, program protect, tool change position

bore orient retract, drill dwell, bore dwell

Default values appear in these fields on the screens, but the operator may want to change some of the parameters. To display the General Parameters screen, press the Input console button to display the Input screen:

INPUT NASTER PROGAf111

I

e1.9R

HAIM 511

EDIT PART PROGRAM

S.M

INCH STANDARD

PROGRAM 1®IORV AIMIIARLR

F PANT SETUP IIar . 22'94 1

99 x

I

F TOOL SETUP 2 i P PART PROGRAMMING 3 F PROGRAM 4 PARAIBTEI F 5 P COPY AND CHANCE 6 DIACRS

P MIRSE FUNCTIONS Select adtIey w Frew antar> to change part Progra• nave 7 P B

Figure 1-43. Input screen

Press the Program Parameters (F4) softkey.

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Operator' s Manual Then the General Parameters screen appears:

GENERAL PARAKETERS RETRACT CLEARANCE RAPID TRAVERSE PECK CLEARANCE PLANE CHORD ERROR DEPLETION RETRACT INTERRUPT CYCLE Z RETRACT

?

999.008 7628. 1 . 270 0.003 0.127 YES

MM MMPM MM MM MM

I F 1 F F 2 F F 3

F

F 4

P HOLES 5 PARAMETERS

Enter clearance height above Z START at which tool woos between operations

PRESS MANUAL MODE . POWER . AND START TO RESTORE POWER. AUTOSSUING PART PROGRAM...

F MILLING 6 PARAMETERS i F PROGRAM 7 PARAMETERS i

F SKIS 8

Figure]-44. General Parameters screen for conversational progremming

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Hawk 5M Machines

Getting Started Here are the available parameters on this screen: General Parameters Fields Retract Clearance

Definitions Enter the distance that the tool should retract above the Z Start dimension before rapid table positioning (Rapid Traverse) between machining operations. This includes a tool moving from one drilled hole to another, from one milling operation to another (programmed in separate data blocks or generated as a patterns operation). The default values are 99.0000 inches and 999.000 mm. On the NC version of this screen, this field is the Clearance Plane. If the next operation has a different Z Start dimension, the control always retracts to the highest dimension. When a Position block is programmed, the tool always retracts to the safety plane programmed as Z Top of the Safety Work Region.

-Rapid Traverse

The feedrate that the table (X, Y, and Z axes) moves between one point in the part program to the next point in the program (rapid table positioning).

Peck Clearance Plane

The distance above the previous peck level to which the Z axis moves at rapid traverse . This parameter does not apply to NC programs. It only applies to conversational programs.

Chord Error

The maximum distance the cutter deviates from the true arc path. This value determines the method the control uses to generate information for executing arcs. If the operator enters 0 .0 in this field, the control will automatically calculate a chord error that maintains the programmed feedrate through the arcs.

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General Parameters Fields

1- 76

Definitions

Depletion Retract

The value programmed for this parameter specifies the dimension above the part surface that the Z axis retracts. The Z axis retracts while waiting for additional data to be transmitted into the current program during execution of an NC part program. This parameter does not apply to conversational part programs.

Interrupt Cycle Z Retract

This parameter allows the Z axis to retract to the Retract Clearance when the operator presses the Interrupt Cycle console button. Selecting "No" for this parameter means that the spindle will stay in its current position when the Interrupt Cycle button is pressed. The default value is "Yes."

Optional Program Stop

When this parameter is enabled , the system inserts a program stop at the appropriate M-code. This program stop command halts the spindle and coolant functions and terminates further program execution. It will require the operator to press the Start Cycle console key to continue with the program. This parameter is only used for NC programs.

Revision A

Hawk SM Machines

Getting Started

General Parameters Ranges and Default Values Parameter

Range

Default Value

Retract Clearance (conversational only)

0.0000 - 99 .9999 inches 0.000 - 999.999 mm

99.0000 inches 999.000 mm

Rapid Traverse

0.1 - 300.0 inches per min.

300.0 inches per min. 7620.0 mm per min.

1.0 - 7620.0 mm per min. Peck Clearance Plane (conversational only)

0.0000 - 99.9999 inches 0.00 - 999.999 mm

0.05 inches 0.127 mm

Chord Error

0.0000 - 1.0000 inches 0.000-25 .4mm

0.05 inches 0.127mm

Depletion Retract (NC only)

0.0000 - 99.9999 inches 0.000 - 999.999 mm

0.0050 inches 0.127 mm

Interrupt Cycle Z Retract

Yes and No

Yes

Optional Program Stop (NC only)

Enabled or Disabled

Enabled

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Operator' s Manual When calculating the chord error value for the General Parameters screen, the operator should understand several important concepts. The chord error for arcs is the maximum distance that the cutter deviates from the actual arc. As shown below, the machine actually cuts a series of very small lines when cutting an arc . However, these lines are indistinguishable from an arc when the machining is complete.

Figure 1-45. Chord Error

The values in the following tables list expected milling feedrates for various chord error and arc radii values in Ultimax 3. These tables may be used as guidelines for maximizing milling accuracy or feedrate.

Maximum Milling Feedrate for a 1 .0000 Inch Radius Arc at a Programmed Feedrate of 100 ipm Chord Error 0.0000 inches

Maximum Milling Feedrate 100.0 ipm

0.0001 inches (default)

56.4 ipm

0.0002 inches

79.9 ipm

0.0003 inches

98.2 ipm

0.0004 inches

100.0 ipm

Getting Started Maximum Milling Feedrate for a 0.0001 Inch (Default) Chord Error at a Programmed Feedrate of 100 ipm Arc Radius

Ult max 3 System

Maximum Milling Feedrate

0.2500 inches

28.4 ipm

0.5000 inches

39.9 ipm

0.7500 inches

49.1 ipm

1.0000 inches

56.4 ipm

2.0000 inches

79.9 ipm

3.0000 inches

97.8 ipm

3.1500 inches

100.0 ipm

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Operator' s Manual

Hole Parameters Press the Holes Parameters (175) softkey on the General Parameters screen to change any of the three parameters for holes. The most often changed parameter on this screen is Drill Dwell. This parameter controls the length of time the drill stays at the bottom of a hole after it has drilled the hole.

HOLES PARAMETERS BORE ORIENT RETRACT DRILL DWELL BORE DWELL

? B.5BB AN 0.5 SEC 1.8 SEC

I F 1 F F 2 F 3 F GENERAL 4 PARAMETERS F 5 F MILLING 6 PARAMETERS

Enter back away distance rrow Gored wall

F PROGRAM 7 PARAMETERS F EXIT 8

Figure 146. Hole Parameters screen

Fields

1- 80

Definitions

Drill Dwell

The pause (dwell) in seconds before the tool retracts at the bottom of a drill operation. The default value is 0.5 seconds. Many operators change this to 0.0 seconds so that the drill will immediately pull out of the hole after it is drilled. This parameter is not used for NC programs-

Bore Dwell

The pause in seconds before the tool retracts at the bottom of a bore operation. The default value is 1.0 seconds. This parameter is not used for NC programs.

Revision A

Hawk 5M Machines

Getting Started

Milling Parameters The milling parameters do not apply to NC programs . They only affect cutter motions during conversational milling operations.

MILLING PARAMETERS BLS OFFSET BLEND OVERLAP FINISH FEED FINISH SPEED FINISH XY FINISH Z MILLING DIRECTION POCKET OVERLAP

...

CUTTER CORP PARAMETER

3.888 3.008 I80 188 8 . 208 0.100 CLIMB 10

MM MM x x MM MM x

INSERT ARC

I F 1 i F 2 I F 3 i

F GENERAL 4 PARAMETERS F HOLES

5 PARAMETERS F 6 Enter distance free finished ell to tool edge on entry

F PROGRAM 7 PARAMETERS F EXIT a

Figure 147. Miffing Parameters screen

Milling Parameters Fields

Ultimax 3 System

Definitions

Blend Offset

The distance from the entry point of the part surface and the Z plunge point where the tool enters the work piece. This parameter is used in milling circles, frames, and ellipses. The default values are 0.1250 inches or 3.000 mm.

Blend Overlap

The distance the tool travels past the entry point before it is withdrawn from the part. This parameter is used in milling circles, frames, and ellipses. The default values are 0.1250 inches or 3.000 mm.

Finish Feed

The percentage of the programmed feedrate of the roughing used for the finish , if the finish is programmed for the part . The default is 100%.

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Operator' s Manual

Milling Parameters Fields

1- 82

Definitions

Finish Speed

The percentage of the programmed spindle speed of the roughing tool used for the finish tool. The default is 100%.

Finish X-Y

The amount of material in the X-Y axis direction to be removed by the finish . The default values are 0.0100 inches or 0.200 mm.

Finish Z

The amount of material in the Z axis dimension to be removed by the finish . The default values are 0.0050 inches or 0.100 mm.

Milling Direction

Allows selection of either Conventional or Climb milling for canned milling cycles (e.g., frame, circle, and ellipse). Climb milling is the default. This does not apply to lines and arcs.

Pocket Overlap

The percentage of tool diameter overlap for each in a 10% pocket milling operation.

Revision A

Hawk 5M Machines

Getting Started Cutter Comp Parameter This important milling parameters field relates only to controls equipped with the UltiPocketm software option and that use the inward spiral cutter compensation type in a pocket boundary to connect the cutter compensated non-intersecting mill line and arc segments . The parameter connects these milling segments as follows: 1.

If Insert Arc is selected a tangent arc is inserted to connect two line segments , or a line segment and an arc segment (when the two cutter compensated segments are offset and do not intersect). When using the Insert Arc method , the system creates the cutter compensated path as shown below:

Using the Insert A .\ Are parameter Cutter compensated path

Programmed Tool Path Figure 1-48. Cutter Compensation using the Insert Arc parameter

Some operators find the Insert Arc method inappropriate for their applications because the cutter remains in with the work piece and may drag a chip across a sharp angle on the part. In such circumstances, operators select the Insert Line parameter.

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Operator' s Manual 2.

If the Insert Line parameter is selected, the cutter compensated lines and arcs are ed as described below: a. Two line segments are extended until they intersect (provided they form a 90 degree or greater angle). If the lines form an angle of less than 90 degree, a line is inserted to connect them. b. Line and arc segments have the line segment extended, and a tangent line to the arc segment inserted and extended until the lines intersect (provided they form a 90 degree or greater angle). If the segments form an angle of less than 90 degree, a line is inserted to connect them. c. Two arc segments have tangent lines (to the arcs) inserted and extended until the lines intersect (provided the extended tangent lines form a 90 degree or greater angle). If the extended tangent lines form an angle of less than 90 degree, a line or arc is inserted to connect them.

Completed path using the Insert Line parameter

Cutter compensated path \

/

Programmed Tool Path Figure 1.49. Cutter Compensation using the Insert Line parameter

1- 84

Revision A

Hawk 5M Machines

Getting Started

Program Parameters The program parameters control three overall features of the control such as table positioning during a tool change.

PBOSPIw PARAMETERS OVERRIDE LOCKOUT PROGRAM PROTECT TOOL CHANGE POSITION

)OFF PARTIAL No

I F 1) OFF 1 I F 2) ON 2 i F 3 F GENERAL.

4 PARAMETERS F HOLES 5 PARAMETERS

F MILLING 6 PARAMETERS Axis feedrote and spindle speed override controls can be disabled

7

I

F SKIT 8

Figure ] -50. Program Parameters sereen

Program Parameters Fields Override Lockout Program Protect

Definitions When "On" is selected, the Axis Feed dial on the jog unit is disabled. The default is "Off." This parameter protects all of the part programs on this control from being altered. The keyswitch at the side of the control console must be in the "unprotected" position before a" supervisor can access this parameterand change it. To prevent programs from `being changed, the-`;' ' supervisor selects either'- or "Partial" in the Program Protect field. ")F 11 the supervisor selects "Full," the operator will not be able to change the part program or its tool and part setup information.

If "Partial" access is given, the operator will be able to change a part program's.tool and part setup only, but not the program itself. "Partial" is the default.

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Operator' s Manual

Program Parameters Fields

1-86

Definitions

Program Protect (continued)

The value entered into Program Protect field can be overridden by turning the keyswitch on the console to the "unprotected" position. Refer to the description of the keyswitch earlier in this chapter.

Tool Change Position

This parameter indicates whether or not the table will move to the right/front of the machine when the operator is changing a tool. If this field contains "Yes" when a part program block calls for a tool change, the table will move out of the way. The default is "No."

Revision A

Hawk 5M Macbines

Getting Started

Where can we go from here? After setting up the part program, the operator may want to begin programming the part. Refer to the appropriate part programming description, either conversational or NC part programming. Or... The operator may want to save the program to the hard drive's permanent memory or to a diskette . Refer to the "Program Storing, Renaming, and Deleting" section for more information about saving programs.

Or... The operator may want to switch off the machine tool. Refer to the "Shut Down Techniques " section.

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Operator' s Manual

Program Storing , Renaming , and Deleting To store a newly created or changed part program, the operator first presses the Auxiliary console key above the number key pad. The Auxiliary screen appears. To access the program storage and directory operations, the operator then presses the Storage Functions (Fl) softkey. The Current Program screen appears: CURRDIT PROGRAM QJRREIT DISK

F READ PROGRAM 1 PROM DISK

WARD DRIVE C

P WRITE PROGRAM 2 TO DISK F DISK OPERATIONS 3 LIST DIRECTORY F FORMAT DISKETTE 4 F 5 F SELECT CURRENT 6 STORAGE DRIVE Choose appropriate wftjmy

Figure 1-51. Current Program screen

File Storage Principles The operator stores part programs in directories on the control's hard drive or on floppy diskettes . The operator can create these directories (on the hard disk and on each diskette ) to enable convenient grouping of part programs. Each hard drive contains one main directory -the root directory. This directory cannot be created by an operator , but it can be subdivided into additional directories.

1- 88

Revision A

Hawk 5M Machines

Getting Started A directory may be compared to the label on a filing cabinet drawer holding a specific group of part program files. Operators select directory names that make it clear what types of part programs are stored within them. Multilevel directories (subdirectories) can also be created to permit further division of program groupings and enhance the filing system. A subdirectory can be compared to a specific file folder within the drawer (directory) of the filing cabinet (hard drive) as in the following illustration. Here is an illustration of directory and subdirectory structure for storage of part program files: Hard Drive (Root directory "C")

Part Program Files L

Figure 1-52. Directory Structure

When an operator selects an option to save a part program , the system will save it onto the root directory that exists on the hard disk and each formatted diskette unless a specific directory is selected.

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Operator' s Manual

Directory Options To access the hard drive and perform directory and part program tasks, press the Disk Operations List Directory (F3) on the Current Program screen . The available tasks are very similar to DOS (disk operating system) operations on personal computers. The can create and delete directories and subdirectories and store programs in those directories.

CURRIIMT PR06AM FCHA= TO 1 DIRECTORY

CURRENT DIRECTORY 259952M bytes tree B bytes tagged. 27-12-93.1813 DAYZ .103

(ir tory(a) 16 Fr46raa(a). F RD B programs tagged . 2 PROGRAM

6861 .103 CNAVE DR ILLTAP . 103 EIalSUP .1003

UNIF PROBE -011.1013 NOTARY HD3

PROBEJM .1X03 ROT-X X .103

OHAIR .1103 RACECRR .1013 SAOEPROG.10)3

CSAVE2 G2T

F DELETE 3 PROGIy l

JR_AUTO HD3 PROBE RD3 RACER .103 TARTEST HD3

F CREATE 4 DIRECTORY F DELETE 5 DIRECTORY

27-12-93.Im3 1733 bytes 01 -61-1988 12:87a Use arrow keys to now through pograe(a)and

F SELECT CIIRRU T 6 STORAGE DRIVE

F --+iOREPerforw disk operations. 7 Use cursor keys to ow bet ween program and choose sot they. I F EXIT B

Figure 1-53. Current Directory screen with directory sofikeys

The three directory functions that the operator uses to manage the files on the Uhimax control ' s hard drive are accessed through these softkeys: Change to Directory (Fl) - use the arrow keys to move the highlight and switch the list on the Current Directory screen and display a subdirectory and program names . The directory shown on the sample screen above has five subdirectories (highlighted items in shaded boxes with no extensions ). There are also programs stored in this directory. They have the HD3 extension.

Getting Started

Ultimax 3 System

•

Create Directory (F4) allows the operator to create a directory or a subdirectory in which to store part programs.

•

Delete Directory (F5) allows the operator to remove a directory or subdirectory from the hard drive. Directories and subdirectories containing part programs cannot be deleted. In addition, the root directory on the hard drive and the floppy drive ("A") cannot be deleted using this option.

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Operator' s Manual

Storing Part Programs To store a part program in permanent memory on the hard drive , press the Auxiliary key on the console and then press the Storage Functions (Fl) softkey. The Current Program screen appears:

CURRENT PROGRAM CURRENT DISK

F READ PROGRAM 1 FROM DISK

HARD DRIVE C

F 2 i F 3 i F 4

WRITE PROGRAM TO DISK DISK OPERATIONS LIST DIRECTORY FORMAT DISKETTE

P

F SELECT CURRENT 6 STORAGE DRIVE F 7

Choose appropriate sotthey

F EXIT 8

Figure 1-54. Current Program screen

1-92

Revision A

Hawk 5M Machines

Getting Started Then follow these steps to copy the part program currently in temporary memory to the control's permanent memory: 1.

Press the Write Program to Disk (F2) softkey. The Current Directory screen then appears.

CURRENT PROGRAM F CHAME TO I DIRECTORY

CURRENT DIRECTORY 25995261 bytes free B bytes tagged. 27-1293. 103 6861 .103 DAYZ . 103 DRILLTAP . 103 CMIp1 IUDV

PROBE_DB.103 ROTARY .1013

8 directory ( s) 16 progras (s). F RE"MM B program tagged . 2 PROGRAM CS.VE

RMDSUP

[IM

HD3

01131E HD3 NEVIN PROBE-M .103 RACECAR .103 ROTS( . 103 SAVEPROG.1013

CSAUEZ C2T JR fd1TO .10)3 PROBE .10)3 RACE-CAR.103 TARTEST MD3

F DELETE 3 PROGRAM F CREATE 4 DIRECTORY F DELETE

S DIRECTORY 27-12-93.103 1733 bytes 81-81-1988 12:87a Use arrow keys to now through program(o)and D INECTVR I ES

F SELECT CUSDEIT 6 STORAGE DRIVE

F-WAS-Perform disk operations. 7 Use cursor keys to sow between progress and Choose ear they. I

F EXIT 8

Figure 1-55. Current Directory screen used for program storage

2.

Use the arrow keys to highlight the name of the directory that will receive the program , or press the Select Current Storage Directory (F6) softkey to select either the hard drive or the floppy drive for storing the program.

3.

Press the Change to Directory (Fl) softkey to select the highlighted directory.

4.

The Letter Selection screen appears on the graphics monitor so that the operator may select a different name for the part program.

Hints and Tricks Operators may change the name of the programs when they are saving the programs as different versions of a currently saved program. They may also want to give the program a different , perhaps more descriptive, name than is currently being used.

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Operator' s Manual 5.

If the operator wants to change the program name, the operator uses the trackball on the console to move the crosshair indicator on the Letter Selection screen. When the crosshair is positioned over the desired character, press the Select key. The selected letters then appear at the bottom of the text screen above the "Enter part program filename; up to 8 characters" message.

CURRENT PROGRAM A:\TT.ND3

F I F 2 F 3 F 4 Fl 5 F 6

ITT Lnta' part Provrae F I lens.. ; up to a characters.

F 7

PRESS IWIIM. NODE. PCUfl, AND START TO MITOAR POWER.

F ABORT OPERATION B

Figurel -S6. Current Program screen program name during save operation

Press the Enter key when the new name is complete. 6.

To save the program with the same name , the operator simply presses the Enter key without selecting any letters from the Letter Selection screen.

7.

If a program with the same name is already stored on the directory, the "Program already exists . Overwrite it?" message appears . To copy the current version of the program over the older version on the hard drive , the operator then selects the Yes softkey.

8.

When the program has been successfully copied onto the hard drive, the "Part Program Written to Disk" message appears at the bottom of the screen.

Getting Started

Renaming a Program To get to the program renaming function , follow these steps: 1.

Press the Auxiliary console key above the number key pad. The Auxiliary screen appears.

2.

Press the Storage Functions (Fl) softkey. The Current Program screen appears.

3.

Select the Disk Operations List Directory (F3) on the Current Program screen.

4.

Use the arrow keys on the console to move the highlight over the name of the program in the directory listing.

To begin the renaming process , select the Rename Program (F2) softkey on the Current Directory screen, and the text screen changes as shown below. In addition, the Letter Selection screen appears on the graphics display monitor. 1.

Ultimax 3 System

Use the trackball on the console to move the crosshair indicator on the Letter Selection screen.

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Operator's Manual 2.

When the crosshair is positioned over the desired character, press the Select key. The selected letters then appear at the bottom of the text screen above the "Enter new name for program" message.

CURRENT PROGRAM

I

F 1

QIRBDIT DIRECTORY 25995264 bytes free 8 bytes tagged.

d1ractorg( a) 16 prograw(s). F 8 program tagged. 2

27-12-93.11103 DRY2 .103

6861 .14DB DRILLTAP . 103

PRORE_AB.103 ROTARY HD3

JRIILiTO . RD3 OH71IR .103 PROBE HD3 PROBE-M HD3 BRCECRR . 103 RPCE_CAR.103 ROT-P . 103 EWEPROC . 103 TRPTEET HD3

CSRUE

DI=P HD3

CSAVE2 GZT

UIN

BRCHCAR 103

15439 bytes 81-01 - 1980

12:84.

Lies error bays to cove through progree(s land I IHF.CTUN I CS

0Enter new ease for progree.

i F 7 1 F ABORT OPERATION

B

Figure 1-57. Program Renaming on the Current Directory screen

3.

Press the Enter key when the new name is complete.

4.

To stop the renaming process, the operator presses the Abort Operation (F8) softkey.

r 1-96

Revision A

Hawk 5M Machines

Getting Started

Deleting a Program To delete a part program from a directory, follow these steps: 1.

Press the Auxiliary console key above the number key pad. The Auxiliary screen appears.

2.

Press the Storage Functions (Fl) softkey. The Current Program screen appears.

3.

Select the Disk Operations List Directory (F3) on the Current Program screen. The Current Directory screen appears.

4.

Use the arrow keys to highlight the program to be deleted.

5.

Press the Delete Program (F3) softkey

6.

The system gives the operator a chance to reconsider the deletion of the program by displaying the message shown on the screen below . If the operator then presses the No softkey, the program will not be deleted. Pressing the Yes softkey erases the selected part program from the directory shown on the screen.

wiar(T

PA06IH I C:VtlIC[OAR . 11D3 ! DIDHCTOA? MOUNT 28768L6 bytes free B bytes tagged .

T 1) 1a 1

5 d/raetmy( s) 16 Program ( ). T 2) M . 2 s Trosrae

1188

.II' IC

3

.ND:

DLID

. DxP

ODTDIR

. 1113

D)JJATA DAT

® II1 .DATA.DAT JOQ.DATA.DAT JRJWTO . 1183 !DM-DATA . DAT PIODZ HD3 PROD-DB.1113 PROBE 11 .14D3 RAC cRR HD3 RACE OAR . 1113 SIWSPROG.M3 TAPTIET .1113

3

7)

I--T 4 5

RACICAP . 1m3 15139 bytes 61-01-1988 12:84. Use sera' Leua ta aere lhra,^sh Preara(s)*M S. you sera you wet to delete this program?

Figure 1-58. Deletion Function 's "Are you sure?" message

Ultimax 3 System

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Operator' s Manual

Copying Part Programs If the operator wants to reorganize the part programs of directories or copy programs between the hard and floppy drives, the operator must first follow these steps: 1.

Press the Auxiliary console key above the number key pad. The Auxiliary screen appears.

2.

Press the Storage Functions (Fl) softkey. The Current Program screen appears.

3.

Select the Disk Operations List Directory (F3) on the Current Program screen and the Current Directory screen appears:

CURRENT PROGRA M CURRENT DIRECTORY 25995264 bytes tree B bytes tagged.

F CHANCE TO 1 DIRECTORY

B directory(a) 16 programs). P REYgD B programs tagged . 2 PROGRAM

27-12-93.013 6861 HD3 CSnV4: CSIIUE2 DAY2 HD3 DRILLTAP . 1U3 ENDEUP .ND3 G7.T (;M611 ItOH HNC JR-AUTO HD3 .IIIDY P.F.VIN OIAIR HD3 PROBE .ID3 PROBE_DB . ID3 PROBBJI HD3 RRCSORR HD3 RACE _CAR.ID3 ROTARY . ID3 2010 HD3 SAV1P7DC . ID3 TAPTERT HD3

27-12-93. 103 1733 bytes 81-01-1988 12:87a Ilse arrw keys to now through pcgraw(s)aud

F DELETE 3 PROGRAM

F CREATE 1 DIRECTORY I P DELETE 5 DIRECTORY P SELECT CURRENT 6 STORAGE DRIVE

Select .10? Program to read into memory. Press CMer> to accept highlighted program name.

Figure 1-59. Current Directory screen with directory soft keys 4.

Select the More (F7) softkey.

Getting Started The softkeys change as shown below:

CURRENT PROGRAM F 1 i B directory(s) 16 proiIran tag(s). F 0 Programs tagged. 2

QJRR01T DIRECTORY 25995264 byte. free 0 bytes tagged. 27-12-93.HD3 DAY2 HD3

.103 CSAVE 6861 DRILLTAP . 103 ENDSUP

HD3

CSDVEL 62T

HNC JR_MTO HD3 OH AIR HD3 PROBE HD3 PROBE DB.HD3 PROBE-M . HD3 RACECAR HD3 RACE-CAR.HB3 HD3 ROTDM( HD3 SAUEPROG . 103 TAPTEST HD3 ROTARY GMDH JIIDV

HDU KEVIM

COPY PROGRAM TAG ALL PROGRAMS

F MMTAG ALL 3 PROGRAMS F TOGGLE 4 PROGRAM TAG F1 S

I

RACLCAR 103 15439 byte. 81-61- 1988 12:94a Use arses keys to cove through progree(s)and Select HD? Program to read into ae.cry. Press (Enter> to accept highlighted Program mans.

F 6 F CHMGE 7 PROGRAM 1VaUR P EXIT B

Figure 1.60. Current Directory screen with "More" so ikeys

These softkeys can be used to perform the following tasks: e

Copy Program (Fl) - allows the operator to select a part program from the directory listing and copy it to another directory or a floppy diskette for storage . Highlight the program name using the arrow keys. For example , to copy a program from the hard drive to a floppy diskette, follow these steps: 1. Press the Auxiliary button. 2. Press the Storage Functions (Fl) softkey on the Auxiliary screen. 3. Press the Disk Operations List Directory (F3) softkey. 4. Press the More (F7) softkey. 5. Use the arrow keys to highlight the program to be copied.

6. Press the Copy Program (Fl) softkey. 7. Select an "A" from the Letter Selection screen when the system asks for the destination drive.

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Operator' s Manual •

Tag All Programs (F2) - allows the operator to select all of the part programs in a directory to copy to another directory. When the operator presses this softkey, the system places a diamond symbol (•) to the left of the program names.

•

Untag All Programs (F3) - removes the tag markers from all the tagged programs in the directory.

•

Toggle Program Tag (F4) - the operator highlights a program in the directory list, presses this softkey, and changes the tagging of the highlighted program. Therefore, this softkey can be used to tag a few programs in a directory to copy them as a group or to remove the tagging from a few programs so that they will not be copied with the other programs.

Getting Started When one or more programs are tagged the following softkey also appears: Copy All Tagged Programs (F5) - allows the operator to copy all of the part programs that are tagged to another directory or a floppy diskette. The drive and directory are selected using softkeys and the arrow keys to highlight subdirectories. For example, to copy all programs from the hard drive to a floppy diskette, follow these steps: 1.

Press the Auxiliary button.

2.

Press the Storage Functions (Fl) softkey on the Auxiliary screen.

3.

Press the Disk Operations List Directory (F3) softkey.

4.

Move the highlight to the desired subdirectory name.

5.

Press the Change to Directory (Fl) softkey.

6. 7.

Press the More (F7) softkey.

8.

Press the Copy All Tagged Programs (F5) softkey. Press the Select Current Storage Drive (F6) softkey.

9. 10. 11.

t)ltimax 3 System

Press the Tag All Programs (F2) softkey or select the Toggle Program Tag (F4) to tag and untag programs.

Press the Floppy Drive A softkey. Press the Enter key.

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Operator' s Manual •

Change Program Mask (F7) - allows the operator to sort out the types of part programs that will be listed on the Current Directory screen . To control this display, follow these steps: 1. Press the Change Program Mask (F7) softkey. The Letter Selection screen appears. 2. Use the trackball to select the characters and letters for the sort criteria . Press the Select key to place the letters and characters into the data entry line on the text screen. 3. This function is the same as the DOS searches on a personal computer. For example, to see a listing of all the programs that begin with the letter "R," the operator types "R* . HD3" and presses the Enter key. 4. The directory listing then changes to show only the part program with "R" as the first letter of the program name. 5. To list all of the program in the directory, the operator types.,* .*" and presses Enter. The operator may want to use the multiplication symbol (X) on the console 's numeric key pad to enter this symbol.

Getting Started

Machine Diagnostics Errors The system may display error messages directing the operator to enter Machine Diagnostics. Here are some examples: "Way lube oil level is low; enter Machine Diagnostics." "Overload fault detected. Enter Machine Diagnostics." "Power cabinet temp too high; enter Machine Diagnostics." To confirm correction of any of these problems, the operator may display the Limit Switches screen to observe the Machine Diagnostics operations. The Limit Switches screen shows the current status of the machine tool limit switches. Follow these steps to display the Limit Switches screen: 1. Press the Manual console key. 2. Press the Machine Diagnostics (F2) softkey. 3. Press the ATC and Machine Diagnostics (F7) softkey. Then the Limit Switches screen appears:

naICTIOH

LIMIT SWITCHES P 1

ON

I

CHIP SUCLOSURS WAY LURE LWEI. POWER CABINET OVERTEIP

DOOR OPEN LOW LEVEL OVER TEMP

F 2

SPINDLE OVERLOAD TRIP AXIS IWTOR OVHKIDP

TRIPPED OVER TEMP

START PUSH BUTTON

F 3

Highlighted field indicates active limit witch state Choose appropriate satthsy

Figure 1-61. Limit Switches screen

In the example above, all of the " OK" status indicators are highlighted (surrounded by a gray, rectangular background ), so this machine does not have any limit switch error conditions.

Ultimax 3 System

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Operator' s Manual Below is an example of a system screen displaying one of the Machine Diagnostics error messages. Since this error is displayed on the Manual screen, the operator can press the Machine Diagnostics (F2) softkey to gain immediate access to the correction display screen shown on the previous page.

as MANUAL M

X V 2

MACHINE 6.001 B.BBB -9.0B1

PART ANAL IRICAL ANAL

MACHINE VERTICAL ar TOOL IN SPINDLE SPINDLE B FEED MOTION STOPPED

I

F TOOL IN SPINDLE 1

F MOIINE DIABOSTICS

F PARR MACHINE 4 I P WARM UP MACHINE F TOOL HOME

Choose appropriate aottkay LADE OIL LEVEL. IS L ; ENTER IIROIINE DIAU$OST1

F RESET SERVOS 7 AND SPINDLE i F CALIBRATE MACHINE B

Figure 162. Manual screen with Way Lube error

1-104

Revision A

Hawk 5M Machine

Getting Started Below is the Limit Switches screen showing the Way Lube error message from the previous example. Note that the Low Level field is highlighted. To correct the problem, the operator or a representative from the maintenance department pours more way lube into the lube reservoir. When the float in the reservoir senses that the oil has been replaced, the error message disappears from the bottom of this screen, and the highlight moves from the Low Level field to the OK field. The error is, therefore, cleared so that the operator can continue to work.

FUNCTION

I

LIMIT SWITCHES

F 1 START PIEIENTTON OIIP I CLOD JRE BAY LURE LIM POWER CABINET OVERTAIP

l

F OR

Deem TRIPPED

SPINDLE OVERLOAD TRIP AXIS ROTOR OVERTIDE

I

F 3

OVER TEMP 4

TOOL CHANGE R HEIGHT

I-

F SI. F S

l

Highlighted r/eld indicates active I aft pitch state Goose appropriate =Wtkay IfY WE OIL LEVf. IS LOB : ENTER MACHINE DIAGNOSTICS

F

F 8

Figure 163. Limit Switches screen with error condition

This screen may also be used to check the Start Cycle button to be certain it is functioning. Press the Start Cycle console button, and the highlight moves to the On field indicating that the console is receiving the starting signal. Hawk 5M machines sold in the United Kingdom have a Chip Enclosure and a limit switch to indicate whether or not the enclosure doors are open or closed . If the doors are not completely closed , the Door Open field will be highlighted . The operator must press the enclosure doors together to clear the error and begin machining.

Ultimax 3 System

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Operator' s Manual The Tool Changer Height field is highlighted on the Limit Switches screen if the spindle is fully retracted'to its zero position. This field is not highlighted if the spindle has moved down away from its home position. To clear the Power Cabinet Overtemp, Spindle Overload Trip, and the Axis Motor Overtemp, the operator or a representative from the Maintenance department must open the electrical cabinet to correct the problem and perhaps press reset switches . Refer to the Maintenance Manual for specific details. When the electrical cabinet overheats , this causes the machine to shut down until the cabinet 's temperature sensor s that the temperature has dropped to an acceptable level. If this error occurs, the operator should check the temperature around the electrical cabinet to be certain the cabinet is not subjected to an additional heat source such as a space heater or bright sunlight from a nearby window.

Where can we go from here? To exit the Limit Switches screen, the operator presses the Back arrow console key, and the Manual screen appears again. The operator may also press the Input or Auxiliary console keys to display one of those screens.

1-106

Revision A

Hawk 5M Machine

Getting Started

Reset Control To restart the control without switching the power to the machine tool off and back on again, follow these steps: 1.

Press the Auxiliary key on the Ultimax console.

2.

The first Auxiliary screen appears with softkeys for storage, and , system configuration, and changing the editor. Press the More (F8) softkey and the screen shown below appears:

Figure 1-64. Auriliary screen with Reset Master sojtkey

3.

Ultimax 3 System

Press the Reset Master (F7) softkey.

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Operator' s Manual After pressing the Reset Master softkey, the operator is given the option to stop the operation with the Yes and No softkeys.

ew AUXILIARY EDITOR TYPE : CONVERSATIONAL

A floppy diskette hu been detected in drive A.

l

Are you are WW rant to coM.inwe with RESET "ASTER?

P 7

I•

F B

Figure 165. "Reset Master" and "Diskette in Drive" messages Pressing the No (Fl) softkey aborts the reset process.

If a diskette is in the floppy drive on the control, a message displays in the center of the screen as shown in the sample above . Remove the diskette before pressing the Yes (F2) softkey.

Important Be sure to save any part program currently displayed to the hard disk or to a floppy diskette before pressing the Yes (F2) softkey, or the program will be erased during the reset process.

1-108

Revision A

Hawk 5M Machine

Getting Started

Shut Down Techniques At the end of a work day, most shops leave their machine tools powered up to simplify start up the next day. There are two methods used to shut down a machine without turning off the power: •

Parking the machine

•

Emergency stop

If the machine will not be used for several days or the shop has power surges/black-outs, the power to the machine should also be switched off after the machine has been shut down.

Important If power is going to be left on at the end of the day, the operator must either park the machine or press Emergency Stop to switch off the machine tool because both methods shut off power to the servos and stop the machine from pumping lubrication onto the ways. If lubrication to the ways continues to pump when the machine is not in use , the lubricant will flow out over the ways and require clean-up before the machine can be used again. As an extra precaution to protect the machine tool from these problems, the operator should set the Control Power Off Timer on the System Parameters screen . This parameter allows the machine to shut down automatically in the same manner as an Emergency Stop shut down. Refer to the "Configuring the System" section for more information about setting this important parameter.

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Operator's Manual

Park Machine The machine parking shut down method is a more organized shut down method than pressing the Emergency Stop. Parking the machine centers the table and leaves the spindle at the home position. This shut down procedure protects the table because it distributes the weight of the table and any attached equipment evenly. Follow this procedure to park the machine: 1.

Press the Manual key on the Ultimax console. This screen appears:

MANUAL X T Z.

MACHINE 393.788 177. 888 8.888

PART 393.788 177.888

-

I

F TOOL IN SPINDLE IAOIINE VERTICAL 1 0 TOOL IN SPINDLE I SPINDLE e F MAOIINE MOTION STOPPED 2 DIAGNOSTICS FEED 3 PARR IAOII 4 F IN88r-WFRnaI INE 5 I F TOOL HOME 6 F RESET SERVOS 7 AND SPINDLE i

CAowa apprnWiate eorthey

■ CALIBRATE MACHINE a

Figure 166. Manual screen with Park Machine soft key

1-110

2.

If the machine is not currently on, press Power On button to send power to the servos . The button is illuminated when the servo power is on.

3.

Press the Reset Servos and Spindle (F7) softkey. Observe that the Start Cycle button begins to flash.

4.

Press Start Cycle button to switch on the machine servos.

Revision A

Hawk 5M Machine

Getting Started 5.

Press Park Machine softkey. If there is a tool in the spindle, the appropriate messages are displayed on the screen allowing the operator to put away this tool. Before any prompt to press Start Cycle appears , the machine must be calibrated , and the tool in the spindle must be zero.

6.

If the tool in the spindle is zero , the Start Cycle button flashes and the message "Press start to park machine" appears on the screen. The machine then moves to its park position as described below . Be certain to follow the instructions displayed on the screen during this process. a. The spindle orients and the Z axis moves to its reference position. b. Machine movement places the X and Y axes at the center of their respective travels. c. All servos and the control-on relay shut-off. d. The screen displays the Manual screen with a prompt message with instructions to return to the power up condition. The message "Press manual mode key, power-on, reset servos and start" appears. e. Pressing the Manual button causes the preceding instructional message to be deleted from the screen.

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Operator' s Manual

Emergency Stop To shut down the machine tool quickly, the operator presses one of the Emergency Stop buttons. This shuts off the servo power and the way lubrication pumps. The message , shown on the screen below , appears on the text screen.

-X. V. Z.

MACHINE 8.8888 8.0808 0.8888

PART 0.0000 0.8088 ---------

NAMIAL

--

I

F TOOL IN SPINDLE MAOIINE VERTICAL 1 " TOOL IN SPINDLE I SPINDLE B F MAOIINE F® NOTION STOPPED 2 DIAGN F 3 F PARR NMOHINE 1 I F YAM UP MACHINE 5

Choose appropriate sot they V STOP HAS BEEN DEPRESSED. NIAL NODS. POWER . AND START TO RESTORE

F TOOL HONE 6 t r P RESET SERVOS 7 AND SPINDLE i F CALIBRATE IAOHIMB B

Figure 167. "Emergency Stop" message on the Manual screen

Warning Using this shut down method is not good for the machine tool table especially if the table is long and has heavy equipment attached to one end . The table should be centered using the parking shut down method to distribute the weight of the table and any equipment equally.

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Hawk 5M Machine

Getting Started

Where can we go from here? To restart the machine after the Emergency Stop has been pressed, the operator must first twist the Emergency Stop button and pull it up to release it . Then the operator must press these console buttons in the following order: Manual key, Power On, and Start Cycle.

Or... To restart the machine after it has been parked , the operator presses these console buttons in the following order. Manual key, Power On, and Start Cycle. Or... If the machine is not going to be used for several days or if the shop experiences power surges and outages, all power to the machine should be switched off at the main power switch . When this procedure is used, the operator will need to follow the calibration and warm -up procedures when restarting the machine.

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Operator's Manual

Infrequent System Changes There are two system features that an operator may seldom or never need to access:

• •

Language Selection Executive Upgrade

The operator can access these features from the Auxiliary screen by pressing the Auxiliary console key.

Changing Language Files The Ultimax language files contain text used on system screens and messages that appear at the bottom of screens. If optional language files were purchased for the Ultimax control, the operator may need to change the language file currently being used on the control. To change the language file, the operator presses the Auxiliary console key and this screen appears:

- AUXILIARY -

I F STORAGE !UNCTIONS

EDITOR TYPE: CONVERSATIONAL P 2 P DOIRGAAD / a P SYST®I 4 COIIFIQRMTION P QYO166 5 F OUOIGE EDITOR

Choose appropriate softhog

7

Figure 1-68. Ausitiary screen with Change Language softkey

The Change Language (F5) softkey will only appear if at least one additional language file has been installed on the system . If only two languages reside on the disk, the other residing language is transferred into memory when this softkey is pressed.

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Hawk 5M Machine

Getting Started If more than two languages are available on the control , a screen similar to the one shown below appears with all of the currently installed language files listed.

LANGUAGE SELECTION F F GERMAN SPANISH FRENCH ITALIAN SWEDISH DANISH HUNGARIAN TAIWAN ESE CZEC1IOSLOVASIAI

F 2 F F 3 l F 4 Y I. 5

Noce to language desired with arrow keys: select a language by Pressing IMTEII.

Fl 6 i F 7 F FOIIT

a

Figure 169. Language Selection screen

To select one of the listed languages , the operator uses the console arrow keys to move the cursor and highlight the language desired . (English is highlighted in the sample screen .) When the desired language ^ is highlighted, the operator presses the Enter key to select it . After the selected language has been loaded into memory , the Auxiliary screen appears again.

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Operator ' s Manual

Upgrading Ultimax Software Occasionally, Hurco will send current customers an Ultimax software upgrade. This software, called the "executive," is used to create and run part programs on the control. Upgrades usually improve system performance and add new features that customers have requested. When an upgrade arrives, it usually contains two 3.5 " floppy diskettes . They are labeled with the control and machine types , a version number, and a diskette number . They usually say "Disk 1 of 2" and "Disk 2 of 2." The diskette labeled "Disk 1 " is also referred to as the Executive 1 diskette. To perform the system upgrade , the operator should first save any part programs currently in temporary memory . The operator then presses the Auxiliary console key and the More (F8 ) softkey to display the screen shown below:

Figure 1-70. Auxiliary screen with More softkeys

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Hawk 5M Machine

Getting Started After the operator presses the Upgrade Executive (F6) softkey , this screen appears:

Figure 1-71. Auxiliary screen with executive upgrade message

If the operator pr esses the No (Fl) softkey, the system stops the upgrade process and displays the Auxiliary screen with the original group of softkeys. If the operator presses the Yes (F2) softkey, the system reads the diskette in the drive and displays instructions to guide the operator through the upgrade process. First, the system asks the operator to insert the Executive-1 diskette (Disk 1). When the proper diskette is inserted, the system copies files from the diskette onto the hard drive. If the operator accidentally inserts the wrong diskette into the floppy drive, the system continues to display the insert diskette message until the con-ect diskette is inserted in the drive. When. the file copying messages display, the operator knows that the correct diskette was inserted in the drive and the upgrade process has started.

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Operator's Manual When the system upgrade is complete, this message appears on the text screen: Executive Upgrade Complete - Remove the floppy diskette. - Power down the control. - Power up to start the new executive. At this point, the operator needs to switch off power to the control and then switch it back on to access the new software.

Important Save the executive software diskettes in a box away from heat, debris, and magnetic interference. These diskettes may be needed by the technical service representatives.

Troubleshooting Since the system always examines the floppy drive first during the start up process, the executive software diskettes may also be used to start up the control if the hard drive fails. To start up the Ultimax system and use the software from the diskettes, the operator inserts Disk 1 into the floppy drive and switches on the power to the control . The system displays messages telling the operator to insert any additional diskettes as needed. When the process is complete , the executive software will be loaded into temporary memory on the control. The operator may remove the diskette from the floppy drive in order to insert diskettes used to store part programs. However, this is only a temporary solution for . a hard drive failure because part program storage will be limited to floppy diskettes . Call technical to check and perhaps replace the control ' s hard drive.

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.,

Chapter 2

Conversational Part Programming The Ultimax 3 Control gives the operator both Hurco Conversational and NC (M and G codes) part programming capabilities . This chapter describes conversational programming. Refer to the NC Programming Instruction Manual for information about NC part programming. To switch between the two types of part programming editors, refer to the "Switching Part Programming Editor Type " section in the "Getting Started" chapter of this manual.

Conversational Programming Principles Conversational programming allows an operator to program a part at the machine while reading directly from a blueprint or program worksheet. When an operator is programming a part , the system displays operating selections and prompts on the left -hand CRT (text screen). A blinking cursor leads the operator through the programming steps necessary to enter the data for a part program. The operator responds by pressing the appropriate keys and push buttons to select machine operations or enter part dimensions. Conversational part programs can be automatically stored on the system's hard drive or diskette to minimize loss of input data if a manual save is not performed. This AutoSave parameter can be set to save the part program into a temporary memory area automatically during programming . When the control is switched off and back on, the last AutoSave version of the part program is presented allowing the operator to continue.

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Operator' s Manual

Before Part Programming All machine tool operators need to plan their jobs before they begin work. Operators plan the work piece placement, fixturing, and part cutting operations before cutting a part. After planning the part program, the operator loads the tools and fixtures the work piece to the table. Then the operators using CNC-equipped machines have the advantage of using the control's features to improve the efficiency of the part programming process. For more information about conversational part programming features, refer to the "Special Programming Features" later in this chapter. Before programming the part on the Ultimax control , the operator must describe the part and the tools that will be used to cut it . Each tool used in the part program must be described on the Tool Setup screens. If the Tool number, Type, and Diameter are not entered for a tool , the system will not have enough information to draw the part properly on the graphics screen. If the Zero Calibration value is not entered , the spindle will not switch on when the operator tries to run the part program , and the system will display the "Tool is not calibrated " error message.

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Hawk 5M Machine

Conversational Part Programming Operators must also enter the general parameters , particularly the Retract Clearance, that apply to the entire part program. These setup functions are described in the "Getting Started" chapter. The operator can access the setup functions, Tool Setup , Part Setup, and Program Parameter, from the Input screen. To display the Input screen , the operator presses the Input console button or the Exit (F8) softkey on the Machine Configuration screen.

Figure 2-1. Input screen

Operator' s Manual

Access to Programming Functions After the parameters are setup , the operator enters the machining operation information onto screens . This is stored within data blocks describing each operation to be performed . The operator creates and accesses the data blocks through the Input screen (shown below). To display the Input screen , the operator presses the Input console button or the Exit ( F8) softkey on the Machine Configuration screen. Then the operator presses the Part Programming (F3) softkey to begin programming.

INPUT MASTER PROGRAM

I

IUMX 5"

EDIT PART PROGRAM

.1.68 1.MD9 STNOARD

PROGRAM MEMORY AVAILABLE

99 R

F PART SETUP Mel.22'94 I i METRIC F TOOL SETUP VERTICAL 2 F PART FROGRA MI 3 F 4 PARAMETERS S

P COPY AND CHANGE 6 BLOCl6 M P ERASE FUNCTIONS Select sottimg er Pr Cntea> to csenps part Pew rows 7

P

R

Figure 2-2. Input screen

If the Part Programming ( F3) softkey does not appear on the Input screen, the system has been set to lock out part programming functions . Refer to the keyswitch and program protection material in the "Getting Started" chapter for more information and a supervisor to switch on the part programming functions.

Conversational Part Programming When the operator presses the Part Programming (F3) softkey on the Input screen, the system displays either the first block of an existing program currently loaded into temporary memory, or the system displays the New Block screen for new programs, as shown below:

BLOCK

1

I

• NEW BLOCK

F 1) POSITION 1 F 2) HOLES 2 F 3) NILLINO 3 , F 4) PATTERNS 4

F 5) NIScELLM4EO16 5 F 6) SPECIAL 6 F 7

cb c.e type of block PRESS IWK1L NODE. POBER , AND START TO 868708E POVER.

F EXIT 8

Figure 2-3. New Block screen

The part programming softkeys provide the following options:

tlltimax 3 System

•

Position (Fl) - allows the operator to insert instructions to move the tool away from the part (or fixture), or stop a program. A Position block is most often used to move the table to a X-Y location and is normally used at the end of the program and at any time the tool must be moved to the Z Top position of the Safety Work Region.

•

Holes (F2) - allows selection of Drill, Tap, Bore and Ream Operations, and Back Spotface hole drilling. The locations of these holes on the part can be specified using the Locations operation, and the holes can also be programmed in a bolt circle pattern-

•

Milling (F3) - allows programming of Lines and Arcs, Circle, Frame, Face, Ellipse and Lettering operations.

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Operator' s Manual •

Patterns (F4) - allows the operator to repeat or modify a sequence of one or more data blocks. A program sequence can be repeated in a rectangular, linear, angular, or rotated pattern OR at specified locations. This operation is also used to scale or mirror a programmed part.

•

Miscellaneous (F5) - provides access to operations used to turnoff or turn-on the drawing of the programmed part (on the graphics CRT) and to the change Program Parameters or Part Setup information.

•

Special (F6) - If the Tooling Cutter Insert Routines option is part of the control's software, this softkey allows the operator to program triangles, diamonds with one and two faces, and hexagons.

•

Rotary (F7) - (not shown here; refer to the "Rotary" section in this chapter) If the Rotary table option is part of the system, this softkey allows the operator to select rotary parameters and to program position blocks, lines and arcs, circles, frames, loops, locations and patterns.

•

Exit (F8) - return to the Input screen.

Conversational Part Programming

Part Programming Summary Operators using CNC-equipped machine tools plan for cutting a part using a part program in the same manner that they plan to cut a part manually. The only difference with using a CNC-equipped machine is that the operator communicates the plan to the machine through a part programming language-conversational or NC part programming. Then the operator can use the machine to store the part program and check the plan for errors. The operator also has several options when running the program: a dry run to test the program, feed and speed optimization, single cycle operation, and automatic running of the entire program. There are also recovery/restart facilities built into the Ultimax system.

Data Block Options A part program is made up of data blocks that store the information specific to the program.. These blocks are stored in numerical order. Operators use the following basic programming operations to create data blocks: •

Create a new data block or edit an existing data block through the Input screen.

•

Insert a new data block between two sequentially numbered blocks. Then the data blocks after the inserted block automatically renumber.

•

Delete an existing data block and the data blocks after the deleted block renumber automatically. View a list summarizing a part program ' s data blocks on the Review Program screen.

•

Copy, edit, or delete information in a data block using the Block Editor screen.

Data blocks within a part program contain specific machining information such as:

Ultimax 3 System

•

Operation type (position, holes, milling, patterns).

•

Tool number (to be used for the operation).

•

Dimension coordinates (relative to X, Y, Z axes).

•

Feedrate (at which the axes move).

•

Locations of operations on the part.

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Operator's Manual

Data Block Creation and Navigation When the operator is creating and editing data blocks, these basic concepts are helpful: •

When a different type of cutting (such as hole drilling or contour milling) is going to be performed, a different block must be created to describe it.

•

When a different tool is needed in a program, a new data block must be created to describe the actions of that tool. The exception to this rule is a data block describing a hole drilling operation. These data blocks can use multiple tools to perform multiple operations.

•

To move through the fields on a data block screen, press the Enter key or use the up and down keyboard arrows.

•

To tell the system to read and new data that is typed into a field, the operator must then press the Enter key. Pressing Enter also automatically advances the cursor to the next field.

•

A field can be skipped (allowed to remain unchanged ) simply by pressing the Enter key when the cursor is positioned on the field.

•

To move to other data blocks in the part program, press the Back or Advance arrow keys on the console.

•

While programming a Holes data block, the operator presses the Advance key to move between the operations within the data block. These operations describe separate portions of the hole drilling operation.

Conversational Part Programming

Creating a Milling Data Block Milling a frame is a simple operation to program . The operator begins a mill frame block by displaying the Input screen and pressing the Part Programming (F3) softkey. When the New Block screen appears, the operator presses the Milling (F3) softkey to display the milling options shown in the seven softkey selections. In this example, the operator is creating block # 1 in the part program.

L''0°'

1

(l Na elaclc 1) LINES AND 1 F 2) CIRCLE 2 i r 3) PRNat 3 4 F 4) 4 I

FACE

I

F 5) ELLIPSE 5 F 6) LEr7EEINC

cbm two of block

Figure 2.4. New Block screen with milling options

The 3D Option (F7) softkey only appears on this screen if the 3-D option software has been purchased and installed on the system. All other softkey selections are standard in Ultimax systems.

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Operator' s Manual When the operator presses the Frame (F3) softkey on the New Block screen, the Mill Frame screen appears: BLOCK

1

MILL FRAME

V CDRP=

0.a000

X LENGTH

0.0000

V LENGTH

0.0000

I F Z START 0.0000 1 i Z BOTTOM B.BBBa P 2 PLIDNGL FEED 0.0 1 F MILL FEBD B.B 3 1 SPEED (RPM ) B P PROGRAM 4 PARAMETERS PECK DEPTH 9.0000 ; F PART SETUP TOOL NOT PROGRIND® 5

Comm RADIUS

0.0000

P TOOL SETUP

TOOL

I a

TYPE

ON

FINISH TOOL

0

K COWIER

O.0008

Enter tool number

Figure 2 5. Mil Frame screen

Then the operator must type in the number of the tool that will be used to mill the frame and press the Enter key to tell the system to read and the information in the field. The tool numbers and their descriptions were entered in the Tool Setup. If the tool information has not been entered or the operator realizes at this point that another tool should be added to the program , the operator can press the Tool Setup (F6) softkey to update the tool descriptions for this program.

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Conversational Part Programming Entering a number in the Tool field pulls information from the tool setup and automatically loads it into fields on this screen . Note that the Mill Feed and Speed (RPM) fields filled in based on the information about Tool #3 in the example shown below. For additional assistance to the operator, the system also displays the selected tool's diameter and type below the second column in brackets . The brackets indicate that the tool data was entered on a different screen and is displayed here for informational purposes only. It cannot be changed on this screen.

MILL FRAME TOOL

3

TYPE

ON

I F 1) ON Z START

B.BBBB

Z BOTTOM

8 . 8008

1

x CORM

0 . 0B0B

MILL FEED

T 2) INSIDE 2 8.8 ' F 3) OUTSIDE 58.8

V CORNER

0.8880

SPEED (BPB)

ZSBB

X LENGTH

6.B880

PECK D

V LECTH

8.B®B

(TOOL DIAMETER (TYPE

CODIER RADIUS

B.00BB

PLAICE

FINISH TOOL

Select wttlug opentlon

4) INSIDE 1 TANGENT 8.0088 1 F 5) OUTSIDE 8.3B5) TMHT DID P 6) POCKET BOUNDARY 6 i P 7) POCKET 7 Islam

PRESS MANUAL MODE , PORE, AND START To RESTORE FUMES.

F EXIT 8

Figure 2-6. Mill Frame screen with tool number

The Pocket Boundary (F6) and Pocket Island (F7) softkeys, outlined by a rectangle in the example above, only appear on this screen if the UltiPocketm option was purchased for the system.

Operator' s Manual The fields on this screen describe how and where the frame will be milled on the work piece. For a machine equipped with the UltiPocket option, the operator may select a pocket boundary with an inward spiral cutter motion. The Pocket Overlap field appears at the bottom of the first column (circled below) when the operator selects a pocket operation. The operator may change this parameter . Many Ultimax system screens have fields that appear based on selections made in other fields. These are conditional fields because they only appear on a screen under certain conditions. The X and Y Corner fields define a reference corner from which the rectangular frame will be milled. This comer can be automatically identified using the jog unit to position a cutting tool over the reference comer. The operator presses the Store Position button on the jog unit to load the value into the field on the screen. The X and Y Length fields define the lengths of the sides of the rectangle. The four values defining the rectangle are outlined in a box in the example below. The operator may use the jog unit to identify the values or type in the values . to press the Enter key after entering each value.

BLOCK

I

I

TOOL TYPE POCKET TYPE FINISH TOOL

" ILL FEW 3 POCK BOUNDARY INIMIND N

Z START

1 P DELETE BLOCK B.B9B 1

Z BOTTOM

F INSERT BLOCK 2 BIPOAY

niecE n

E COWER

-4.7547

MILL F®

Y GORIER

1.7547

SPEED UIPM)

X LDICTN

18.7238

PECK DEPTH

F 3 t F PR06R Y1 4 PARAMETERS H.BBBB 1

Y LDUCTH

9.5894

(TOOL DIAMETER

F PART 31T11P 8.3758) 5

(TYPE COWER MRDNS POCKET OODnsp

0.8"

)OD MILL) I P TOOL RE71W 6

58

Enter a ^ lock au^m. use ENTER to edit ^ loek, m uw ADO/YICE. BALI, oe eTllsy PINS IMIEML MODE . POWER. AM STMT TO SECTORS POWER.

F 7 F B

IT

Figure 2-7. Completed Mill Frame screen

The fields on the Mill Frame screen are described in detail in the "Milling" section of this chapter . When the operator presses Enter on the Peck Depth field, the system displays additional softkey options as shown above.

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Conversational Part Programming At this point the operator may want to see a graphic representation of the programmed block. To display a picture of the.programmed block, the operator presses the Draw console key, and the illustration appears on the right-hand CRT screen. Refer to the "Graphics" section for more information about this feature.

Where can we go from here? Upon completion of the Mill Frame block, the operator may want to change information in the program setup using the Program Parameters (F4), Part Setup (F5), or the Tool Setup (F6) softkeys. Or... The operator may decide that the block should not be used in the program. So the operator presses the Delete Block (Fl) softkey to remove it from the program. Or... To create another data block before this mill frame block, the operator presses the Insert Block Before (F2) softkey. The New Block screen then appears. Or.„ To create another data block after this one, the operator presses the Advance (right arrow ) console key. If the milling data block was the last block in the program, the End of Program screen appears . Then the operator presses the Enter key to display the New Block screen. Or... To return to the Input screen, the operator presses the Exit (F8) softkey. If the operator presses the Exit softkey and did not intend to return to Input, the operator may return to the place in the program where the Exit softkey was pressed by selecting the Part Programming (F3) softkey on the Input screen.

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Operator' s Manual

Creating a Hole Drilling Data Block To begin a new data block describing a hole drilling operation, the operator presses the Holes (F2) softkey on the New Block screen. Note that in the example, the operator is creating block # 2.

Figure 2-8. New Block screen

Conversational Part Programming The Holes screen appears, as shown below. The word "New" on this screen indicates that the system is ready to receive the description of the holes data block. BLOCK

1

HOLES »4 NEW

F DRILL 1 OPERATIONS F TAP 2 F FORE AND MAN 3 OPERATIONS k F RACK SPOTFACE 4

F 5 F 6 F 7 1 F tClT e

Figure 2-9. Roks screen with softkey options

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Operator' s Manual The available hole operations on the Holes screen are Drill Operations, Tap, Bore and Ream , and Back Spotface. When the operator selects one of the hole operations using a softkey, the system displays the options for the selected operation. The fields and available softkey options for the Drill Operations are shown in the example below:

BACK

1

HOLES

TOOL

B

Z START

B . BBBB

2 BOTTOM

B.BBBB

PLUM FM

0.0

SPEED (RP")

B

PECK DEPTH PECM TYPE

)))I DRILL

B.BBBB STANDARD

I F DRILL 1 P CENTER DRILL 2 i F COUHTERBORE 3 F SPOTFACE 4

I F COIEITERSIMR 5

TOOL NOT PRocRIYD®

cho

opentloi F B

Figure 2-10. Holes screen with Dill Operations sofkeys

Conversational Part Programming The operator selects the Center Drill (F2) softkey for the first operation in the data block.

BLOCK

2

TOOL

HOLES I

Z START Z BOTTOM

CENTER DRILL

6 . 82180

i

--@ . ADDS

PLIMME FEED

7.5

SPEED ( RPM)

1566

(TOOL DIAMETER (TYPE

>>>

I F DELETE OPERATION I i F INSERT OPERATION 2 BEFORE F 3 i F PROGRAM 4 PARAMETERS i F PART SETUP 5

0.2818) DRILL)

Peers ENTER to edit this operation or wttkey

or lase ADVANCE , BACK,

F TOOL SETUP 6 i F 7 1 F EXIT B

Figure 2-11. Holes screen with. Center Drill fields

The structure of a hole drilling data block is more complex than other conversational data blocks. To describe a hole drilling process in a data block, the operator must enter different types of instructions . Each type of drilling instruction requires the operator to create a separate operation within the data block.

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Operator' s Manual To start a new operation, the operator presses the Advance key (right arrow console key). In the example, the operator plans to drill the same holes that were center drilled in the previous operation. Note that the operator is using a different tool for this operation.

BLOCA

2

TOOL

HOLES I

Z START Z BOTTOM

>>> 8.8288 -8..ciB8e

PLUNGE FEED

15.8

SPEED (RPM)

2588

FILE DEPTH PILE TYPE (TOOL DIAMETER (TYPE

CENTER DRILL DRILL

8 . 1800 STANDARD 8.2816) DRILL)

Press ENTER to edit this operation

m• use ADVANCE. BACK,

m• sortkey

I F DELETE OPERATION I I F INSERT OPERATION 2 BEFORE ; F 3 i F PROGRAM 4 PARAMETERS i F PART SETUP 5 i F TOOL 86111P 6 F 7

I. F EXIT B

Figure 2-12. Holes screen with DnU fields

Conversational Part Programming When the operator has completed a block, the system presents two additional softkey options, Bolt Circle (F5) and Locations (F6), as shown below:

BLOCK

2

HOLES

>>>I

CENTER DRILL DRILL NEW

F DRILL 1 OPERATIONS F TAP 2 F BORE AND REAM 3 OPERATIONS F BACK SPOTFACE t __ P BOLT CIRCLE 5 i F LOCATIONS 6

Choose appropriate sortIM9

F 7 F EXIT 8

Figure 2-13. Start a New Operation

Operator' s Manual When the operator selects the Locations (F6) softkey, the system displays columns for the X and Y coordinates of each location. The operator may type in these values if they are shown on the drawing or use the control to calculate them. A third method of entering these values is to move the tool using the jog unit to the actual hole locations on the part and press the Store Position button to load the coordinates quickly into these fields.

RLOCE

2 %

1 2

31

-8.1000 9.3000

HOLES Y 2.5000 -2.5000

>>>

CENTER DRILL DRILL LOCATIONS

I F I f F 2

4 F 3 F 4 PF

5

1 F S Enter another point m • ADDNNCE when Finished

Figure 2-14. Holes screen with Location coordinates

Conversational Part Programming When the operator completes the description of a drilling operation, the system presents these softkey options:

2

BLxx x 1 2

-8.1888 9.3888

"DIM Y 2 . 5800 -2.5800

>>>

CENTER DRILL DRILL LOCATIONS

I F DELETE OPERATION 1 F INSERT OPERATION 2 BEFORE i P F PROGRAM 4 PARAMETERS F PART SETUP 5 F TOOL SETUP 6

Paces BITER to edit this operation or sot they

w use ADVANCE. DAM.

P 7 I F EXIT 8

Figure 2-15. Completed Holes Data Block

•

Delete Operation (Fl) - removes the currently displayed operation from the holes data block.

•

Insert Operation Before (F2) - places another operation into the data block before the operation currently displayed on the screen.

•

Program Parameters (F4) - displays the part program parameters so that the operator may make changes.

•

Part Setup (F5) - displays the part setup information for this part so that the operator may make changes.

•

Tool Setup (F6) - displays the tool setup information for this part so that the operator may make changes.

For more information about programming data blocks, refer to the section later in this chapter describing the type of data block and the sample programs illustrating many of the programming features.

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Operator' s Manual

End of Program The End of Program screen shows the operator that there are no more program blocks after this location in the program. There are two methods to continue part programming from this screen: •

Press the Insert Block Before (F2) softkey.

•

Press the Advance console key and press the Enter key.

To move back to the previous program block, press the Back console key.

0

Em or

PROG I

I

F I i F INSERT BLOCQ 2 BEFORE P 3

Zeta a black eawber , use HITER to edit block, or m ADVAM= , BIKE, o wttkey

F PROGIV 1 4 PARWMTERS i F PART SETUP 5 , F TOOL SETUP 6 i F 7 I F EXIT

a

Figure 2-16. End of Program screen

To exit the part program and return to the Input screen , press the Exit (F8) softkey.

Conversational Part Programming

Special Data Blocks The operator may insert special data blocks between operational data blocks to change the position of the table, automatically stop a program, set a new part zero, or temporarily change the part program parameters.

Position Block An operator inserts a position block into apart program for one of these reasons:

BLOCK

•

Move the table to allow the operator to move or refixture the work piece.

•

Stop motion automatically during the part cutting operation to refixture or perform some other manual operation.

•

Move the table forward at the end of a program to give the operator easy access to the finished part.

1

POSITION F DELETE BLOCK 1

B

TOOL x

N,BBB

V

B.BBB

F INSERT BIRO[ 2 BEFORE F 3

YES

STOP

* PROGRAM * PARAMETERS Pi PART SETUP 5

TOOL NOT PROGRAMMED

Enter a black number . uaa ENTER to edit block, or use ADVANCE . BACK. or sottkey

P TOOL SETUP t I P 7 i F EEIT R

Figure 2-17. Position screen

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Operator' s Manual If the Indexer option (not shown on the sample screen) has been purchased, the Index Pulses field also appears on the Position screen. In this field, the operator usually enters the number of degrees that the indexer head will rotate before an operation will be performed on the part. A new Position block must be put into the part program each time the part needs to move to a new position.

Caution If the indexer option is not available on the Hawk 5m kneemill and the operator wants to use a part program created on a different Hurco machine tool, any Position blocks in the old program must be inspected to determine if there is a value in the Index Pulses field. If so, the program must be changed to remove the value before the program can be used on a kneemill without an indexer. If it is not changed, the kneemill software will ignore the Index Pulses value, and the program will not operate in the same manner that it did on the other machine tool.

Conversational Part Programming During execution of a Position block, the Z axis remains retracted with the spindle rotating. The table moves to the programmed X and Y dimensions at the rapid traverse rate selected in Program Parameters or Change Parameters. 1.

Press the Position softkey to display the screen. When this block first appears, the cursor is at the tool number parameter.

2.

Program tool number. Entering the tool number displays the tool diameter in parenthesis with the value entered in Tool Setup. This value cannot be changed in Part Programming mode.

3.

Enter X and Y coordinates for the Position to which tool should move (after Z Top position is reached). These dimensions are measured relative to Part Zero.

4.

When cursor advances to the stop parameter, Yes and No softkeys appear.

5.

Press the Yes softkey if the program must stop after executing this Position block. This response causes a message to be displayed (during program execution) requesting that Start be pressed to resume program in Auto Mode. If this Position block is not a stop block, press the No softkey.

If a rotary table ("A" axis) is being used, that axis has a separate Rotary Position block. Refer to the "Rotary" section for more information about the Rotary Position screen.

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Operator's Manual

Temporary Parameter Change For some programs, the operator may want to insert a parameter change block between data blocks. To accomplish this, the operator displays the data block for which the parameter change will first be used. Then the operator presses the Insert Block Before (F2) softkey. A New Block screen appears.

BLOCK

1

I NEW BLOCK F 1) POSITION

P 2) HOLES 2 F 3) MILLING 3 F 4) PATTERNS 4

5) MI 5 F 6) SPECIAL 6 Cline type of block PRIM MANUAL MODE, POWER. NW START TO RESTORE POWER.

F 7 F Df1T 8

Figure 2-18. New Block screen

The operator then presses the Miscellaneous (F5) softkey, and a new group of softkeys appears.

Conversational Part Programming The operator can change the program parameters and part setup by pressing the F3 and/or F4 softkeys.

Figure 2-19. Change Parameters and Part Setup

Ultimax 3 System

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2-27

Operator' s Manual Using this feature, the operator can change data stored within the General Parameters, Hole Parameters, and Milling Parameters. These special "Change Parameters" and "Change Part Setup" options allow the operator to change part program values so that they apply only to a certain portion of the program.

SLOGS

2

CHANGE GENERAL PARAMETERS

RETRACT CLEARANCE RAPID TRAVERSE PECK CLEARANCE PLANE CHORD ERROR DEPLETION RETRACT

I 99.0068 IN 400.0 IPM 0.0500 IN 0 .0001 IN 0.01158 IN

Enter clearance height above Z START at which tool wow between operation

I F 1 F F 2 F F 3 F P 4 P HOLES 5 PARAMETERS i P MILLING 6 PARAMETERS F F 7

F P EXIT 8

Figure 2-20. Change General Parameters screen

When a part program is executed , the data selected in the Program Parameters are in effect until the system encounters another Change Parameters data block or until the end of the program. The parameters that cannot be changed on these screens include Override Lockout, Program Protect, and Tool Change Position. Return to the Input screen and select Program Parameters (F4) softkey to change those three parameters.

Conversational Part Programming When planning a change to the Retract Clearance parameter, the operator should consider the following: 1. This parameter is defined relative to the Z Start dimension and can optimize Z axis tool motion between localized operations. 2. If all of the operations are at the same Z Start plane, there is no difference between a relative and an absolute clearance. But when groups of cutting operations are at different Z levels on the part, programming a relative Retract Clearance can be more efficient than an absolute retract dimension . It is possible to eliminate unnecessary tool motion to save time. 3. If the Z Start dimension of the next operation is different from that of the current operation, the control uses the higher of the two values for Retract Clearance before positioning the part in the X-Y axes. 4. To achieve a Retract Clearance close to the part may require the use of a Position data block. Programming a Position block causes the tool to retract to the Z Top (+) of the Safety Work Region which must be a dimension that denotes a clearance above all portions of the part and the fixture. Examples of problem areas in which a Position data block must be used rather than a simple parameter change are as follows:

Ultimax 3 System

•

Between operations , a clamp or raised portion of the part is higher than the programmed relative clearance.

•

Cutting occurs inside a cavity and is followed by work inside another cavity in which an optimal Retract Clearance for operations in the recessed areas is below the surface of the part.

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Operator' s Manual

Set a New Part Zero Pressing the Change Part Setup (F4) softkey from the Miscellaneous softkeys displays the screen shown below. This selection allows the to change the part zeros, Offset Z and Centerline values. The graphics will not reflect the new part setup . These values remain in effect until the next Change Part Setup block. The Auto screen will show the part position relative to the current part setup block.

HLOCJI

19

CHARGE PART SETUP PART

MACHINE % V Z A E

TOOL IN SPINDLE SPINDLE F®

1 F PART SETUP 1 F TOOL SETUP 2 F 3

PART ZERO X V OFFSET Z

•

R.RRR8 g.RRRR 8.eue8

F PROGRAM 4 PARAMETERS I F 5 F 6 i

Enter part eero it loam or Jog eaehlm to W^ ssra position and press sattiey to eta. position

F POST MACHINE 7 POSITION

F EEIT a

Figure 2-21. Change Part Setup screen

Part Zero A and Centerline A fields (not shown on the sample screen) appear on the screen when the rotary option is installed.

Conversational Part Programming

Automatic Calculations The Ultimax No-Calc (no calculation required by programmer) feature enables the control to calculate certain dimensions automatically after sufficient data has been programmed. If the control is to calculate a given dimension, leave that data parameter blank. After sufficient data is entered, the control automatically fills in the blank data field(s).

RLOCX

SEGMENT

16

1

F 1

LINE 1. 1109E

x no

I

HILL CONTOUR

(X START

(Y START V END

1 . 9000

2 END

-6.1000

(2 START

r

0.0000) F 0.0000) 2 -0 . 1000

F STORE CALQIA 3 VALIE

^ XV LENGTH

1.4142

XY ANGLE

45 . 000

P®

F 4

7.5

Enter XY length of eegeent, If known

F 5 i F 6 i P PREVIOUS SEGIEIT 7 n P E(1f

9

Figure 2-22. Automatic Calculation of Values

The screen displays a Store Calculated Value (F3) softkey function when editing a parameter with a calculated value (indicated by 'CAL" preceding the value). Press this softkey or the Enter key to store the displayed value into the part program.

Ultimax 3 System

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2-31

Operator' s Manual If a value is entered and later the operator decides to let the control calculate the data, the operator can clear the old value by following these steps: 1. Use the arrow keys (except Advance) to move the cursor to the parameter where the automatic calculation is needed. 2. Press the Clear and Enter console keys. The defined value is cleared from the program and the control calculated dimension is displayed (or the parameter is blank waiting for additional data to be entered).

Important The No- Calc feature is not available to calculate unknown line and arc points in rotary programs . Refer to the "Rotary" section for the recommended methods to determine the values for those points.

Conversational Part Programming

Graphics The right-hand CRT screen (see below) displays a graphical representation of the part program that the operator uses to part geometries. 2.

Soltkey buttons

Text wean

JH 0 anual key

Number keys

Enter key

Figure 2-23. Ultimax Console

Pressing the Draw console key for the first time starts up the graphic display on the right-hand screen . This key draws the part on the screen or stops a drawing in process. The crosshair cursor on the graphics screen disappears while the part is being drawn and reappears when the drawing is completed. (If the graphics cursor is not visible, the part is being drawn.)

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Operator' s Manual If there are no part programming instructions available, the graphics screen appears with only the scale and the graphics functions as shown below:

B.18

-8.68

-1.68 -2.18 y

-6.IB

0.98

Figure 224. Graphics screen

The screen buttons (boxes) at the bottom of the screen represent the available graphics functions . Screen buttons are used extensively by the DXF option software. Using these basic graphics functions , the operator can change the part program illustration on the screen by positioning the crosshair over the screen button and pressing the Select console key.

2-34

•

View - allows the operator to select a different perspective from which to display the part.

•

Full Scale - redraws the part currently displayed in full size. This is used after exiting the Zoom function.

•

Zoom Box - isolates a portion of the drawing and increases the size of that section to show the operator more detail.

•

Parameters - allow the operator to change the default settings for the graphics functions.

•

DB Search - (data block search) allows the operator to select a portion of the graphic representation of the part. Then the system displays the data block for that portion on the text screen . This is very helpful when the operator is tracking down a portion of the program that is incorrect.

Revision A

Hawk 5M Machine

Conversational Part Programming Drawing stops when a data block has incomplete (or incorrect) data and when new data blocks are being created. The part draws in the largest scale to fit the CRT before appearing on the screen. The message "Autoscaling part program" displays on the screen during this scaling process. To switch the graphics display on and off within a part program, the operator presses the Miscellaneous (F5) softkey on the New Block screen. The graphics softkeys then appear as shown below:

Figure 2-25. New Block screen with Miscellaneous functions

The Graphics Off (Fl) and Graphics On (F2) softkeys allow viewing selected part features in complex programs where certain operations tend to obliterate others such as facing and pocketing. Pressing either the Graphics Off or Graphics On softkey stores the selected function as a data block in the part program . The graphic drawing of the part is turned off and turned on at the point the block is encountered in the program. When graphics are switched on, the Trackball moves the graphics cursor to a desired menu function on the right -hand screen and within the representation area of the drawing . The control automatically scales the part dimensions for the screen before redrawing the part (to display the entire part). The Zoom function overrides this scale setting.

Ultimax 3 System

5/12/'94

2-35

Operator' s Manual

Views Graphics can be displayed in five views: •

XY Plane -

The part is displayed in XY projection.

•

XZ Plane -

The part is displayed in XZ projection.

•

YZ Plane -

The part is displayed in YZ projection.

•

Isometric -

A three-dimensional view of part is displayed.

•

All Planes - The part is displayed in all four of the views.

The operator may select any of these views by positioning the crosshair cursor on the View screen button and pressing the Select console key. Then using the same method, the operator selects the appropriate screen button from the next displayed set of screen buttons.

Here is a screen showing an isometric view of a bolt circle program:

Figure 2-26. Graphics screen with isometric view

Conversational Part Programming Scaled views appear to the left and at the bottom of the screen , except when using the isometric view . The displayed views are automatically proportioned by the control according to the programmed dimensions of the part. Here is a screen showing four views (All Planes option) of a bolt circle:

3.18V

3.18V

I

"""^^

1.B8

S.BB

y

$ -1.18

i

-1.18 Z

-3.281 -4.68 -2.58 -8.48

1. 78

3.88

i •

-3.28 -4.88 -1.90

8 .28

X 2.38

4.48

1.98 2 0.30J

____

-2.98 -3.88 -1.40

-----

8.28

1.88

3.40 I

Figure 2-27. Graphics screen showing All Planes

Views may be eliminated from the screen using one of the parameters described later in this section.

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Operator' s Manual

Zoom The Zoom function enlarges a selected portion of the drawing. A zoomed screen remains in that state until the operator selects the Full Scale option. Selecting the Zoom function for a plane view does not zoom the other plane views (i.e., zoom on XY plane does not zoom the XZ plane).

Graphics Parameters To change the graphics display parameters, position the crosshair cursor on the Parameters screen button and press the Select console key. This selection displays a screen with these options:

DRAW SCALES

=

Yes

C

DRAW TOOL PATH

=

Yes

C

DRAW PART SURFACE =

Yes

C O

DRAW RAPID MOVES

Yes

=

EXIT PARAMETER ENTRY

Figure 2-28. Graphics Parameters screen

To change the Yes/No value for a parameter, move the cursor to the box in front of the parameter and press the Select console key until the desired response appears after the equal sign.

2-38

Revision A

Hawk 5M Machine

Conversational Part Programming The menu selections displayed on the Parameters screen are as follows:

Parameter Fields

Definitions

Draw Scales

controls the display of scales that normally appear to the left and at the bottom of the screen(s). These scales can be removed by selecting the "No" response for this parameter.

Draw Tool Path

controls the display of the tool path (center line), shown as dashed lines on the graphics screen. This path is removed from the drawing representation by selecting the "No" response.

Draw Part Surface

controls the finished part surface, shown as solid lines on the screen drawing. This view is removed by selecting the "No" response.

Draw Rapid Moves Exit Parameter Entry

only functional when operating in NC. move the crosshair to the box before this parameter and press the Select console key to exit the screen and save a parameter changes.

After exiting the parameters screen , the system redisplays the graphic image of the part.

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Operator' s Manual

Data Block Search The data block search option allows the operator to move directly from a portion of the drawing that looks incorrect to the data block where it is programmed. To use this helpful function , follow these steps: 1.

Rotate the trackball to move the crosshair cursor to the DBSearch screen button in the lower right comer of the graphics screen. Press the Select console key, and the message shown in the illustration below appears.

3.18 Y

-3.78 -4.88

8.28 -1.90 2.38 Set trackball aavo* at waohim operation to find.

4.40

Figure 2-29. Identifying a portion for the search

2.

To stop the search, move the crosshair cursor to the Exit box and press the Select key.

Conversational Part Programming To select the search area, rotate the trackball to move the crosshair cursor to the desired point in the graphic view and press the Select key. The data block used to execute the area indicated by the crosshair appears on the text screen, as shown below.

3.

BLOCK

1

HOLES

NUMBER

5

x CENTER

0 . 8080

V GAITER

0.0000

RADIUS

3.0008

>>>

DRILL TAP BOLT CIRCLE

8.088

START ANGLE

I F DELETE OPERATION 1 I F INSERT OPERATION 2 BEFORE I F 3 F 4 I F 5 1 F 6

SKIP LIST

PROGRAM PARAMETERS PART SETUP

TOOL SETUP

i-

Press AITER to edit this operation or use ADVANCE. RACE. or softIM9

P 7 I

F EXITT 8

Figure 2-30. Data Block displayed after the search

4.

If the cursor is located near a point executed by two ading data blocks , the first data block in the program representing the operation nearest the cursor is displayed on the text screen.

5.

To return to the drawing, press the Draw console key.

Important The data block search function can only be used for the XY Plane view and is inoperative when viewing a running part program.

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Operator' s Manual

Graphics Error Checking If the graphics system encounters an error while drawing the part, an error message appears in the lower area of the graphics screen, as shown below:

1.40 -Y

0.48 j

4-

-8.6W

-1.68 -2.18

-1.19 8.98 -6 . 18 DROP IN BLOOM 2: TOOL 1 IS NOT IN TOOL LIBRARY.

1.98

Figure 2-31. Graphics screen error message

To respond to a drawing error message , the operator may do one of the following:

2-42

1.

Ignore the indicated error, place the cursor on the Exit parameter, and press the Select console key.

2.

Find the indicated error, position the cursor on the Find option, and press the Select key. The control automatically activates the edit functions and displays the data block with the error. After the operator corrects the error, the operator can press the Draw button again to be certain the part can be drawn without errors.

Revision A

Hawk 5M Machine

IY

Conversational Part Programming

Checking the Part Program The Ultimax system provides several methods to simplify review and modification of part programs.

Review Program Press the Review console key to display the Review Program screen as shown below . The Review Program screen displays a summary of the part program data blocks. This screen lists the numbered data blocks , the tools used and the operations within the holes data blocks . The number of locations for a Holes data block and the number of patterns executed in a Patterns data block are also displayed.

re REVIEW PROGRAM ee .ILL FRAN C 2 ROL&S CENTER DRILL DRILL LOCATIONS END OF PR06Rfl

POCK BOUNDARY

TOOL

3

TOOL TOOL NUMBER

1 4 2

I F 1

I'

F 2

F 3 F 4 F S

I'

F 6 PACE U. PACE DOW, error keys or enter block venter to I Vier progren; ENTER to edit highlighted block

F 7 1

1-

F D

Figure 2-32. Review Program screen

Pressing the Enter key with the Review Program screen displayed causes the control to change to the Part Programming mode for the data block indicated by the cursor (on Review Program screen). When the entire part program contains more data blocks than can be displayed on one screen, use Page Down and Page Up console keys (in the Text Screen grouping) to scroll through the listed data blocks. Press the End console key to move to the end of the screen, and Home key to jump to the top the of screen . (Simultaneously, press Ctrl plus End to jump the cursor to end of program ; Ctrl plus Home jumps the cursor to beginning of the program .) Press a numeric key to begin the screen listing at a specific data block number . Use the up and down arrow keys to move the cursor one data block in the direction selected.

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Operator' s Manual

Error Checking and Run Time The screens used to run a part program-Auto, Single, and Test- can all be used to check for errors in a part program. The operator presses any of these three buttons in the Machine Mode grouping on the console. Then the operator presses the Check for Errors (F4) softkey. The control begins its checking at the Start Block indicated on the screen and completes the test at the End Block. When the check is finished, the estimated run time and the error status of the program are displayed on the screen. The time required for the program to perform this check depends on the length of the part program and its complexity. If the system fords an error, the number of the block containing the error is listed in the error message . Then the operator must return to part programming (from the Input screen ) and make the necessary corrections. Refer to the following section for information about changing the part program.

Figure2-33. Part Program Error Checking

To see an estimate of the program running time , press the Compute Estimated Run Time (F5) softkey. The estimated run time for program execution is computed from the distances traveled and programmed feedrates.

2-44

Revision A

Hawk 5M Machine

Conversational Part Programming

Changing a Part Program When an operator wants to change a part program, there are two types of changes: •

Changing information within individual data blocks

•

Copying, moving, deleting, and modifying entire data blocks

Changing a Block Operators can return to a previously created part program and make changes to individual data blocks in exactly the same manner that the data blocks were first programmed. The operator accesses the part program from storage as described in the "Getting Started" chapter and presses the Part Programming (F3) softkey on the Input screen.

INPUT MASTER PRO07l

«

I

u1.58

NAYS SN

EDIT PART PROGRAM

1.Mm3 STANDARD

F PAST SETUP Nae . 22'94 1 'r METRIC F TOOL SETUP VERTICAL 2

k

F PART PROGRAMING

PROGRAM MEMORY AVAILABLE

99 x F PROGRAM 4 PARAMETERS i F

Select noftkeg or Press Cntee> to change part Proerow rowe

P COPY ADD CHANGE o ELOCRS i P ERASE FUNCTIONS 7 P B

Figure 2-34. Input screen

To locate the individual data blocks where the changes are needed, move through the data blocks using the console arrow keys and type in the changes on the appropriate screens.

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Operator' s Manual

Block Editor Occasionally, an operator may want to make changes to several data blocks at one time. The Block Editor simplifies this process. The operator can copy, move, and delete entire blocks and change feeds and speeds for the entire program. To access the Block Editor, the operator presses the Copy and Change Blocks (F6) soft key on the Input screen shown below:

» NASTER PROGRAM

INPUT

»

I

NSI HAWN

SPIT PART PROOMM

91.51 L.Im3 STANDARD

FROM M MEMORY AVAILABLE

99 x

F PART SETUP Mar.22'94 L METRIC VERTICAL

P TOOL SETUP 2 i F PART PROOANNHIG 3 , F PROGRAM 4 PARAMETERS F 5

F 131A4E FUNCTIONS Select aorthey or Preen enter> to change part Program name 7 F

Figure 2-35. Input screen with Copy and Change Blocks soft key

If the Copy and Change Blocks softkey does not appear on the Input screen, the system has been set to lock out part programming functions. Refer to the keyswitch and program protection material in the "Getting Started" chapter for more information and a supervisor to switch on the part programming functions.

Conversational Part Programming The Block Editor screen has these softkey options:

BLACK EDITOR F COPY BLOCKS

F MOVE BLOCKS 2 1 F DELETE BLACKS 3 F MODIFY 4 DIMENSIONS F CHANGE ALL TOOLS 5 FEEDS a SPEEDS F CHANGE FEEDS a 6 SPEEDS BY TOOL I F EMIT 7

Choose appropriate aoftiay

I

EMERGENCY STOP HAS BEEN DEPRESSED.

F

PRESS MAONL MODE. POYER . AND START TO RESTORE POYEI.

B

Figure 2-36. Block Editor screen

Uldmax 3 System

•

Copy Blocks (Fl) - allows the operator to indicate specific block numbers to be duplicated into another location in the part program.

•

Move Blocks (F2) - allows the operator to indicate specific block numbers to be moved to a different location in the part program.

•

Delete Blocks (F3) - allows the operator to indicate specific block numbers to removed from a part program.

•

Modify Dimensions (F4) - allows the operator to add offsets to the Y. Y, and Z axes coordinate dimensions currently stored in the part program.

•

Change All Tools Feeds & Speeds (F5) - allows the operator to substitute new feeds and speeds for all of the tools within the specified data block number range.

•

Change Feeds & Speeds by Tool (F6) - allows the operator to substitute new speeds and feedrates for a specified tool within a data block range.

•

Exit (F7) - displays the Input screen.

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Operator' s Manual All of the Block Editor functions require the range of blocks to be defined by a Start Block and an End Block number . Refer to the illustration below . The End Block number must be the same as or greater than the Start Block number, or an error message will appear. After entering data on the Block Editor screen , the operator must press the Make the Changes (F8) softkey to perform the change operation.

Figure 2-37. Block Editor features

If the operator presses the Exit (F7) softkey without first pressing the Make the Changes softkey , the data entered on the screen will not be applied to the part program. In other words , pressing the Exit softkey is a method of throwing away the changes and returning to the Input screen without altering the part program.

2-48

Revision A

Hawk 5M Machine

Conversational Part Programming

Copying and Moving Blocks When the operator selects the Copy Blocks ( Fl) or Move Blocks (F2) softkey, the operator must enter the number of the block that the blocks will be put before. The Put Before Block field marks the beginning location of the range of blocks that will be inserted in the program. The Put Before Block number must be outside the start /end range specified by the Start Block and End Block numbers (and can be greater than the last block in the part program.) The blocks are automatically renumbered after these functions are executed. Pressing the Copy Blocks (F1) softkey allows the specified data blocks to be duplicated at another location in the part program . Here is a Block Editor screen with the Copy Blocks fields displayed.

BLOCK EDITOR START BLOCK

F 1

0

i

F /IOUs BLOCKS 2

DID RACK PUT BEFORE BLACK

F DELETE RACKS 3 F 4 k F 5

Ente

MODIFY DIMENSIONS CHANCE ALL TOOLS FEEDS A SPEEDS

F CMeICE FEEDS A 6 SPEEDS BY TOOL i F EXIT 7

w bor of desired block

DMRCDICY STOP HAS BEEN DEPRESSED. PRESS MAM AL MODE. POWER . AND START TO RESTORE POWER.

F B

Figure 2-38. Block Editor with Copy Blocks fields

Pressing the Move Blocks (F2) softkey allows the specified data blocks to be removed from their current location and transferred at another location in the part program . The Move Block fields are identical to the Copy Block fields.

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Operator' s Manual

Deleting Blocks The Delete Blocks (F3) softkey allows the specified data blocks to be removed from the part program. The operator only needs to type in the Start Block and End Block numbers and to press the Make the Changes (F8) softkey to remove a group of data blocks from a part program. Here is a Block Editor screen with the Delete Blocks fields highlighted:

BLOCS EDITOR START BLOCK

0

EMD BLOM

F COPY BIACES T P MODE ELOCRS 2 F 3 F MODIFY

4 DIMENSIONS F OWNDE ALL TOOLS 5 FE®S a SPEEDS

Einar noaber of desired block

F CHANCE FEEDS & 6 SPEEDS BY TOOL i P EXIT 7

DIRNCDIICV STOP Wig BEEN DEPB68SED. FREES IWtIAL MODE . PORED , AND START To RESTORE PORED.

t S

Figure 2-39. Block Editor with Delete Blocks fields

Conversational Part Programming

Modifying Dimensions This softkey function allows offsets to be added. to the X, Y, and Z axes coordinate dimensions stored in the programmed data blocks.

BLOCK EDITOR STAIR BLOCK

F COPY BLOCKS 1

I

END BLOCK

F MOUE BLOCKS 2

X OFFSET

8.600

V OFFSET

B.BBB

Z OFFSET

B. BBB

F DELETE BLACKS 3 DON'T CHANGE E-START

FF 4

I

F CHANGE ALL TOOLS 5 FEEDS & SPEEDS F CHANGE FEEDS d 6 SPEEDS BY TOOL Enfmp nunbm of chaired block EMERGENCY STOP HAS BEEN DEPRESSED. PRESS VANDAL NODE. POWER, AND START TO RESTORE POWER.

PF EXIT 7 i F B

Figure 240. Block Editor with Modify Dimensions fields .

To modify the dimensions, enter the Start and End Block numbers defining the range of data blocks to be modified . Then type in the offsets that will be added to the dimensions of this range of data blocks. Enter only those values that need to change. When the cursor arrives at the Z Offset field, the Don 't Change Z-Start message and the Don' t Change Z-Start (FI) softkey appear on the screen. Us one of these methods to change the Z Offset value:

Ultimax 3 System

1.

To leave the Z Start values unchanged , the operator presses the Don't Change Z-Start softkey. But, the operator can enter the Z Offset value as required, and then all Z axis coordinates will be modified by the entered dimension except Z Start values.

2.

If the Z Start values must be changed , the operator presses the Don't Change Z-Start (Fl) softkey to remove the Don 't Change Z-Start message from the screen . Then the operator types in the new Z Offset value. All of the Z axis coordinates will be modified by the entered dimension including Z Start.

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Operator's Manual

Changing Feeds and Speeds The operator may change the speeds and feedrates for all of the tools used in a program or only specified tools. To make changes to all of the tools, the operator selects the Change All Tools Feeds and Speeds (F5) softkey, and the fields shown below appear on the Block Editor screen:

BLOCK EDITOR

1 F START DLALS 1 COPY HLOCES

END BLOCK

P MOOS DLOCDS 2

NEW SPEED (lip") NEW FEED NEW PLUNGE FEED

F DELETE DLOCES 3 , F MODIFY F DIMENSIONS F 5

MW TOOL NW FINISH TOOL

i

F CHA)GE FEEDS A 6 SPEEDS BY TOOL i

F' Enter amber or desired block

7

DIDOICtICY STOP IIAS BEEN DEPRESSED. PRESS HAIWIL MODE . POWER. AND START TO RESTORE PORED.

F B

SKIT

Figure 241. Change AU Tools ' Feeds and Speeds

Follow these steps to change the speeds and feeds: 1.

Program the Start Block and End Block to define the range of data blocks where the spindle speed , plunge feeds and mill feeds are to be changed.

2.

Enter the values for New Speed (RPM), New Feed and New Plunge Feed fields.

3.

Blank fields do not change. A programmed value can be changed back to a blank parameter by moving the cursor to the parameter and pressing the Clear and Enter keys to remove the new value.

4.

The New Tool and New Finish Tool parameters allow new tools to be programmed in the specified range of data.

Conversational Part Programming The Change Feeds and Speeds by Tool (F6) softkey allows new values to be substituted for the programmed speeds and feedrates of a specified tool within the defined range of data blocks. The fields shown below appear on the Block Editor screen:

BLOCK EDITOR F COPY BLOCKS 1

START BLOCK Elm BLOCK

F MOWS BLOCKS 2

CHAN=E TOOL MURDER F DELETE BLOCKS 3

NEW SPEED (RPM) NEW FEED

F MODIFY 4 DIMENSIONS i F OMME ALL TOOLS S FEEDS I SPEEDS

NEAT PLUM=E FEED NEW TOOL

F t7AAMW 722 614f!

NEW FINISH TOOL

F EXIT Enter number of desired block

7

PRESS MANUAL MODE. POWER . AND START TO RESTORE POWER.

F 8

Figure 2.42 . Change Feeds and Speeds for I Tool

Follow these steps to change the speeds and feeds for a tool: 1.

Program the Start Block and End Block to define the range of data blocks where the spindle speed, plunge feeds and mill feeds are to be changed for the selected tool.

2.

With cursor at the Change Tool Number field, enter the number of the tool to be affected. Changes will be made only to blocks using this tool.

3.

Enter the values for New Speed (RPM), New Feed and New Plunge Feed fields that apply to this tool.

4.

Blank fields do not change. A programmed value can be changed back to a blank parameter by moving the cursor to the parameter and pressing the Clear and Enter keys to remove the new value.

5.

The New Tool and New Finish Tool parameters allow new tools to be programmed in the specified range of data blocks to replace the tool specified by the change tool number.

Operator' s Manual

Running a Part Program After the part program contains all necessary information to cut the part, the operator often wants to perform a test run and then run the program to cut the part. The buttons to access these functions are on the elevated portion of the Ultimax console in the area labeled Machine Mode. There are three Machine Mode buttons used to run part programs: •

Auto - used to run an entire program or selected blocks

•

Single - allows the operator to run the program a block at a time

•

Test - permits the operator to run the part program above the work piece

Refer to the "Running Part Programs" section later in this chapter for more detailed information about running part programs and restarting stopped programs.

Conversational Part Programming

Test Run The Test button allows the operator to the part program using the screen shown below. Operators often use the Dry Run option as a safe way to run the part program and identify potential problems.

M TESTIM RUNNING PAST PROGRAM

6061.HD3

ESTIMATED RUN TIME

START RLOCR END BLOCII

F FEED a SPEED 2 OPTIMIZATION

I

1 36

F 3 F CIBCR FOR ERRORS 4 1 F COMPUTE ESTIMATED 5 RUN TIME FI 6

Enter amber of desired black

F 7 FI B

Figure 2.43. Test Run screen

When executing the part program in Dry Run, peck cycles and roughing es are skipped. When operating in a dry run , the tool traces the tool path with the spindle off and the tool above the work piece. Before attempting execution, the operator enters the minimum Z dimension for operating in this test cycle . During this test, the tool traces over the part at the dimension entered.

Caution If the Z Start dimensions are set below the surface of the rough stock, the minimum Z dimension for this operation must be programmed so the tool does not plunge into the part.

Operator' s Manual

Feed and Speed Optimization To fine tune the program execution, the operator presses the Feed and Speed Optimization (F2) softkey on the Test Run screen (shown on the previous page) to display this screen:

FEED a SPEED OPTIMIZATION « PART i.BBBB -6.0000

AXIS LOAD MONITOR 20 40 60 00 100 x

I F SET SPEED I TOOL IN SPINDLE B 1 SPINDLE B F PEED NOTION STOPPED 2

BI.OCII Na1BIBft PART CDUR

x V Z s S

Adjust cemrides rbile cutting and press eottksy to clan real union in prograc block PRESS START TO RBN PROGRAM.

P SET PLUME OR 3 SE61®IT PEED i B P 4 B 1 F SET FRED S i F 6 F 7 F B

Figure 2.44. Feed and Speed Optimization screen

Using the information displayed on this screen, the operator can use the Axis Feed Rate dial on the jog unit to adjust the values and produce the best results. The operator may also change the current values by pressing the Set Speed (Fl), Set Plunge or Segment Feed (F3) and Set Feed (F5) softkeys and typing in the desired values.

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Revision A

Hawk 5M Machine

Conversational Part Programming

Auto To run a part program, press the Auto console button in the Machine Mode grouping. This screen appears:

AUTO .. 6861.ND3

RUNING PART PROGRAM ESTIMATED RUM TIME

START BLOC! HID BLOC!

0:19:00

I

1 36

I F 1 F a P 3 F CIUC! FOR ERRORS

4 I F COMPUTE ESTIMATED 5 RUN TIME F RECOVERY 6 RESTART

Inter nowber of deelred block

F 7

NH ERRORS POUND IN PROGRM.

F IM PROGRAM

Figure 2-45. Auto screen with soft key options

Check the Start and End Block numbers and make any changes needed to run only a portion of the program.

Operator's Manual Press the Run Program (F8) softkey to start the program and display this screen:

AUTO « PART 8.8958 -8.8397 8.0250

X Y z

I

F RESET PART COUNT VERTICAL 1 1 I 2888H F 37.5 2

nACHINE TOOL IN SPINDLE SPINDLE PRO

F 3 AXIS LOAD MONITOR 20 48 E8 80

X S. 2

BLOCK MUDEI 188 R

PART COUNT

7 F MILL MAKE 4 2 f

F S L F S

FF 7 PROGRAM IS 11M11MG.

F 8

Figure 2-46. Auto screen with a running program

If the system identifies any errors during the part cutting process, error messages appear on this screen.

Conversational Part Programming If the operator observes a problem during the cutting process or simply wants to stop the machine to make some adjustments, the operator may press one of three buttons to stop motion: •

Motion Hold - stops all axes movement, except a tap operation when tool is in the programmed feedrate region. Pressing the button a second time allows machine positioning to resume without loss of position, provided no other button or key has been pressed.

•

Interrupt Cycle - halts machine operation during automatic execution of a program to allow manual functions to be performed. Pressing the button a second time returns the machine to the interrupted location and allows automatic program execution to resume from the point of interruption. Emergency Stop - all motion stops and power is shut -off to the spindle, relay control, and servo systems . An emergency stop message with recovery instructions appears at the bottom of left-hand screen. To release an Emergency Stop button, twist the button in the direction indicated by the arrows and pull the button up.

If the operator presses the Emergency Stop during the execution of a part program, the operator should jog the tool clear of the part before resuming operation.

Refer to the "Recovery and Restart" section at the end of this chapter for information about restarting a part program.

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Operator' s Manual

Concurrent Programming Concurrent Programming allows the operator to create or edit a part program and/or read a part program from disk into memory, while simultaneously machining a part using a different part program. Concurrent Programming is possible only when using the Auto screen to run the program. When using Concurrent Programming , two-part programs are simultaneously available. To enter Concurrent Programming while machining a part, press the Input key. The Auto screen is replaced by the Input screen.

INPUT ww MASTER PROGRAM

MANX SM

EDIT PART PROGRAM IMG PART PROGRAM

91.58P CYCLE5.103

F PART SETUP Msy.B6'94 i III VERTICAL

F TOOL SETUP 2

SASCVKU.HD3

PROGRAM MEMORY AVAILABLE

99 c

F PART PROGRAMING 3 4 PARAMETERS

l

F G

F COPY AND CHANGE 6 BLACKS so'tkey or Press ai,tn> to

Chang FSelct e Pert Program news 7

B

Figure 2-47. Input screen with program running concurrently

This screen has an extra field, Running Part Program , that identifies the program currently running . This screen always lists the program ID numbers for both the running part program and the edit part program. The graphics screen blanks to prepare for the new part program graphics. The ID number for the new part program may be entered in the Edit Part Program field. Then the operator can use the part programming features to create or change data blocks.

2-60

Revision A

Hawk SM Machine

Conversational Part Programming To run the new edit part program or to edit the running part program:

Ultimax 3 System

1.

Wait for the running program to finish , or stop this program from being executed by pressing Motion Hold console button and Spindle Off key.

2.

Press the Input key.

3.

Press the Exchange Edit/Run Programs softkey. This softkey is only displayed on the Input screen if machine is not running a concurrent program.

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Operator' s Manual

Printing a Program Many operators print copies of their programs to keep on file for future reference. To access the Ultimax printing facility, press the Auxiliary console key. Then press the / (F3) softkey, and this screen appears:

M MDIILIARY -

I F Make certain the proper cable is connected betreen the 1 RECEIVE selected pert on the will and the peripheral device. : 1) Press sot they . F PRINT CURRENT 2) Send program free peripheral device . 2 DIRECTORY : 1) Open file to receive data at the peripheral I 2) Press DOIRBAAD sot they . P 3) If necessary , Close the tile on the 3 SEND peripheral device attar transfer is done. PRINT: 1 ) Select the PRINT PROGRAM sot they. / All PPRINT PROGRAM PORT RIMIER PROTOCOL BAUD RATE CHARACTER LENGTH STOP BITE PARITY

1 XON/XOfl 96M 7 1.5 EVEN

5 P RESET PORT 6 PAPoRITERS F SERIAL PORT 7 SETUP

Choose appropriate sot they

F EXIT B

Figure 2-48. Auxiliary screen with Print Program so/tey

When the operator presses the Print Program (F4) softkey, the part program currently in temporary memory prints on the printer connected to the machine 's parallel port. Ultimax s the following dot matrix printers:

•

Epson FX

•

Citizen MSP-10 and MSP-55

Refer to any of the sample programs in this chapter to examine the structure of printed programs from the Ultimax printing facility.

2-62

Revision A

Hawk 5M Machine

Conversational Part Programming

Program Identification and Storage To store a part program in permanent memory on the hard drive, press the Auxiliary key on the console and then press the Storage Functions (Fl) softkey. The Current Program screen appears:

CUSIDDIT PROGRAM CURRENT DISK

HARD DRIVE C

F READ PROGRAM FROM DISK F WRITE PROGRAM 2 TO DISK F DISK OPERATIONS 3 LIST DIRECTORY 1 F FORMAT DISKETTE 4 F S F SELECT CURRENT 6 STORAGE DRIVE

Choose appropriate oaf they

F 7 F EXIT 8

Figure 249. Current Program screen

File Naming The part program name may contain up to eight characters. To type in a new program filename, display the Input screen either by pressing the Input key or by pressing the Exit (F8) softkey when the Machine Configuration screen appears at start-up. Then follow these steps to enter the filename: 1.

Press the Enter key to display the Letter Selection screen on the right monitor.

2.

Use the trackball on the console to move the crosshair indicator on this screen.

3.

When the crosshair is positioned over the desired character, press the Select key.

4.

The selected character then appears in the Edit Part Program field.

Operator 's Manual 5.

Select up to 8 characters for the filename. The system adds the 3-character extension (usually HD3) to the end of the filename. Use the numeric keys on the console to enter 0 through 9 into the name. Select letters for the name from the Letter Selection screen, shown below, using these steps. a. With text cursor indicating edit part program parameter, use trackball to move graphics cursor to select each character. b. When the crosshair cursor indicates the desired character, press the Select console key to record the selection onto the text screen c. Press Enter key to record the selected ID for the part program.

#

$

Space

!

%

&

•

+

,

-

/

0

4

5

6

7

8

9

?

@

A

B

C

D

H

I

J

K

L

M

R

S

T

U

V

W

Back Space

Enter

1

2

3

E

F

G

N

0

P

Q

X

Y

Z

;

Figure 2-50. Letter Selection screen (graphics screen)

2-64

Revision A

Hawk SM Machine

Conversational Part Programming

File Storage Facilities The operator may store a program on the control's hard drive or on a floppy disk. Press the Select Current Storage Drive (F6) softkey to indicate the name of the drive that will be used for storing the program.

I

CURRENT PROGRAM CURRENT DISK

F READ PROGRAM I FROM DISK

HARD DRIVE C

F WRITE PROGRAM 2 TO DISK

i F DISK OPERATIONS 3 LIST DIRECTORY I F FORMAT DISKETTE 4 F S

Choose appropriate sorthey

Figure 2-51. Current Program screen

Part programs can be stored on the control hard drive and/or floppy diskettes . The control ' s standard four (4) Megabytes of memory reserves approximately 1.6 Megabytes in active memory for storing conversational and NC part programs . An option is available to increase the memory size to eight (8) Megabytes. A 3.5" floppy disk drive is located at the right side of the console and provides up to 1.44 Megabytes of storage for conversational or NC part programs. The system reads, writes, and formats diskettes in the MS-DOS format; 1.44 Megabyte or 720 kilobyte diskette formats are ed.

Ultimax 3 System

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Operator's Manual

Holes Operations This section presents detailed descriptions of the Hole drilling options in Ultimax 3. The chart below shows the relationship of the hole drilling options to the Input button and its subsequent softkey selections.

Hole Operations Hierarchy Chart Input Button

Drill Operations (F1)

Part Setup (Fl)

- Drill (Fl)

Tool Setup (F2)

Part Programming (F3)

- Center Drill (F2) - Counterbore (F3)

Position (Fl)

- Spottace (F4)

Holes (F2)

- Countersink (F5) Milling (F3) Gun Drill (F6) Patterns (F4) Miscellaneous (F5)

Tap (F2)

Special (F6) Rotary (F7)

Bore and Ream Operations (F3)

Exit (F8) - Bore (Fl)

- Ream (F2) - Bore Rapid (F3) - Bore Orient (F4) - Ream Rapid (F5)

Back Spottace (F4)

Bolt Circle (F5)

Locations (F6)

Figun 2 52. Hok Operation Hierarchy Chart

2-66

Revision A

Hawk 5M Machine

k

Conversational Part Programming, To access the hole drilling options, the operator presses the Input button on the console and then the Part Programming (F3) softkey. When the New screen appears, the operator presses the Holes (F3) softkey to display the screen shown below:

BLOCK

I

I

HOLE

»>I

No

F DRILL I OPERATIONS F TAP 2 F BORE AND REAM 3 OPERATIONS F BACK SPOTPACE 4

S

I

F 6

F 7

Choose appropriate tattling

I

F EXIT 8

Figure 2-53. Holes screen with option soft keys

Ultimax 3 System

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Operator' s Manual

Drill Operations In a drilling operation, the table positions to the programmed X and Y dimensions followed by Z axis positioning to the programmed retract clearance. The rate of axis positioning is at rapid traverse. When these coordinates are reached, the Z axis moves at rapid traverse to Z Start and then at programmed plunge feed rate until reaching the Z Bottom dimension . The Z axis dwells the time specified and rapid traverses to the retract clearance. (The rapid traverse rate, retract clearance and drill dwell are selected in Program Parameters or Change Holes Parameters.) Select the Drill Operations softkey on Holes screen to display the screen shown below:

BLOCS

1

HOLES

TOOL

B

Z START

B.BBBB

2 BOTTOM

8.8088

PLIRIGS FEED

0.0

SPS® (M )

B

FECR DEPTH PEQ TYPE

)»I DRILL

0.001311 STANDARD

TOOL NOT PAOGRAM®

Clow opmrat)ot.

I F DRILL 1 F CENTER DRILL 2 ',---F COUNTERBORE 3 F SPOTFACE 4 ; F COIMTERSIMS 5

1 GIN DRILL 6 F 7 F B

Figure 2-54. Holes screen with Drill Operations soft keys

When the Drill Operations screen first appears, the cursor flashes at the Drill parameter. This flashing cursor indicates an operation that can be selected. Pressing the Enter key stores the indicated operation in memory and the cursor moves to the tool number parameter. (To choose any of the other operations, select the corresponding softkey and press Enter key.)

Conversational Part Programming The available drilling operations do not differ in the physical operation of the machine, with the exception of the gun drill operation. The operator determines the type of tool used for the operation and how the hole will be drilled. The common uses of the drill operation softkeys are described below: •

Drill (Fl) - creates holes that may be complete or may be used as the starting points for additional drilling operations.

•

Center Drill (F2) - used when the work piece is very rigid to create a guide hole for the drilling tool that will be used to complete the hole. Center drilling helps keep holes their proper locations and prevent runout.

•

Counterbore (F3) - enlarges the end of a previously drilled hole. This operation is often used to create an enlarged area at the end of the hole to accommodate a bolt, cap screw, or pin.

•

Spotface (F4) - this variation of counterboring smoothes and squares the surface around a previously drilled hole to provide a seat for a bolt head, a nut, or the shoulders on mating .

•

Countersink (F5) - enlarges the top end of a hole to a cone shape to accommodate the head of a flat or oval headed machine screw. The hole is enlarged so that when the screw is inserted in the hole the screw head will be flush with or slightly below the top of the work piece surface

•

Gun Drill (F6) - used to position and start a drilling operation using a very long tool that drills deep holes, as if drilling out the center of a gun barrel.

Important It is important to that all operations programmed in a given data block are performed at all locations specified in that block. For example, if Center Drill and Drill operations are programmed in the same data block, all locations specified in that block are center drilled and then drilled.

Ultimax 3 System

5/12/94

2-69 '

Operator's Manual The fields used to describe any of the Drill Operations are as follows: Fields

Definitions

Z Top

The starting point of the drill cycle. The tool moves rapidly to this point and then slowly moves into the starting location.

Z Start Z Bottom

2-70

The location where the spindle begins to rotate. The bottom of the finished hole.

Z Top Feed

Rate at which the tool moves from the Z Top position to the Z Start position.

Plunge Feed

Feedrate between the Z Start and the Z Bottom positions.

Speed (RPM)

Speed at which the spindle rotates to drill the hole.

Spindle Stop

Point at which the spindle stops rotating after drilling the hole. This may be set to be the Z Bottom or the Z Start position.

Peck Depth

Distance that the tool will drill down into the part before stopping to clear out or break the chips. If this parameter is used, it is usually not larger than the diameter of the tool.

Peck Type

This field has two options that indicate whether the drill will pull out to the Z Start after reaching the Peck Depth (Standard) or simply dwell at the Peck Depth (Chip Breaker).

Revision A

Hawk 5M Machine

Conversational Part Programming Here is a sample completed hole drilling screen:

BLOCK

I

TOOL Z START Z BOTTOM

HOLES 1

-0.58811 25.8

SPEED (RPM)

1588

PECK TYPE (TOOL DIAMETER (TYPE

DRILL LOCATIONS

0.0200

PLUNGE FEED

PECK DEPTH

>>>

F DELETE OPERATION 1 I F INSERT OPERATION 2 BEFORE I F 3 F PROGRAM 4 PARAMETERS I F PART SETUP 5 i F TOOL SETUP 6

6.110801 STANDARD 8.2918) DRILL)

Press ENTER to edit this operation or sotthey

m• use ADVANCE , BACK,

F 7 I F EXIT 8

Figure2-55. Completed Drill Data Block

When the Tool number for the operation is programmed (and the Enter key pressed), the tool diameter and type appear in parentheses . The values indicated are programmed during Tool Setup and cannot be changed in a drilling data block. (The Program Parameters, Part Setup and Tool Setup softkeys also appear to provide access to these programming options.)

Ultimaz 3 System

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Operator' s Manual The Z Start parameter is the dimension where the Z axis plunge feed rate begins. The Z Bottom parameter is the point of maximum Z-down and the dimension where the plunge feed rate ends. The diagram below shows the relationships of the field names to positions of the drilling tool to the work piece: Rapid Traverse

Head

Retract Clearance Plane Z Start Plane Plunge Feed Z Bottom

Part Table

Figure 2-56. Reference Points Relative to Drift Operations

The Plunge Feed parameter is the feedrate between Z Start and Z Bottom parameters. The value initially displayed is calculated by the control, based upon the values programmed for the tool during Tool Setup. If desired, a different value can be entered for this parameter (when it is indicated by the cursor). The value initially displayed in Speed (RPM) parameter was programmed for the designated tool during Tool Setup . If this parameter is to remain unchanged, press Enter key. A different speed can be programmed for this specific block (to override the displayed value). The Peck Depth parameter is the dimension the tool is to advance during each peck.

Hints and Tricks As a rule, the Peck Depth value should not exceed the tool diameter.

2-72

Revision A

Hawk 5M Machine

Conversational Part Programming If a specific number of pecks is desired, the value for Peck Depth can be calculated by determining the absolute distance between Z Start and Z Bottom and dividing that value by the desired number of pecks. For example: a distance of 1.0000 inch between Z Start and Z Bottom divided by peck depth of 0.2500 inch requires four (4) pecks to drill the hole. The Peck Type parameter provides a choice of Standard and Chip Breaker softkey functions: 1.

If Standard is selected, the tool retracts to the Z Start and then rapidly plunges to the peck clearance plane selected in Program Parameters or Change Parameters.

2.

If Chip Breaker is selected, the tool dwells at each peck level before continuing to feed to the next peck level. (Drill dwell is the time selected in Program Parameters or Change Holes Parameters.)

When all values are programmed, the available softkeys are Delete Operation, Insert Operation Before and Exit. 1.

Selecting the Delete Operation clears this programmed drill operation.

2.

Selecting the Insert Operation Before softkey to add another hole operation before the current one.

3.

Pressing Exit softkey returns to the previous screen level.

Pressing the Advance key displays a new Holes screen except the previous programmed operation appears above the multiple cursor (which now indicates new). The softkey functions of Bolt Circle and Locations added. Additional operations for this block can be programmed. If desired, the operator can program another Drill operation (i.e., a counterbore or spotface), a Tap operation, Bore and Ream Operations , Bolt Circle pattern, or hole Locations.

Ultimax 3 System

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Operator' s Manual

Drill The operator uses an Ultimax Drill operation to make a variety of holes using a wide range of drill bits. See illustration below. The holes produced from this operation are often used as the starting points for additional drilling operations such as boring, reaming, or tapping.

Figure 2-57. DriUBit

Caution For all drilling operations, the operator must be aware of the particular characteristics of the drill bits being used. The system does not keep track of the type and length of flutes on the bits nor the shapes of drills with pilots or other multiple-diameter drills. The operator must consider these tool features when programming a part and must re-evaluate the tool setup for programs that are being reused.

Conversational Part Programming

Center Drill

11

When an accurate and true center is needed for the start of a drilling operation , the operator selects the Center Drill (F2) softkey from the Drill Operations options. Center drilling the holes helps guide the drilling tool into the proper location. Usually center drills are special tools with short flutes, but a standard drilling tool may be used to create these starting holes. Center drilling is often used when the work piece is very rigid and, at the start of a drilling operation , the tool might "walk" away from the correct position. Center drilling is also used when centers are needed for parts that are being turned between two centers in following operations.

BLOCK

1

TOOL Z START Z BOTTOM

HOLES 1

CENTER DRILL

-6.5999

PLIRIf.'E FEED

8.5

SPEED ( RPM)

259

(TOOL DIAMETER (TYPE

>>>

B . am

I F DELETE OPERATION I i F INSERT OPERATION 2 BEFORE I F 3 P PROGRAM 4 PARAMETERS , T PART SETUP 5 i F TOOL SETUP

9.5899) DRILL)

Pews ENTER to edit this operative or use ADOAMCE , BACK. or satiny

7

Figure 2-58. Center Drill Data Block

Ultimax 3 System

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Operator' s Manual

Counterbore An operator uses the counterbore option to enlarge the end of a previously drilled hole. This operation creates an enlarged area at the end of the hole to accommodate a bolt, cap screw or pin. These square-shoulder fasteners can then be inserted flush with the top of the part or slightly below the surface of the material.

BLOCX

1

TOOL

HOLES 1

Z START Z BOTTOM

)» COIB(TERBORE

8 . 0388

F INSERT OPERATION 2 BEFORE I F 3

-8.6580

PLUNGE IUD

5.0

SPEED (RPM)

758

( F DELETE OPERATION 1

F PROGRAM 4 PARAMETERS F PART SETUP 5

(TOOL DIAMETER (TYPE

0.5000) DRILL)

F TOOL SETUP 6

Press ENTER to edit this operation or use ADVANCE, BACK, or sottkey

F 7 I F EXIT B

Figure 2-59. Counterbore Operation

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Revision A

Hawk 5M Machine

Conversational Part Programming Spotface The Ultimax Spotface operation smoothes and squares the surface around a previously drilled hole to provide a seat for a bolt head, a nut, or the shoulders on mating . The spotfacing operation is, therefore, a shallow counterboring operation . Spotfacing is commonly used when the surface of the part is uneven as it is on a casting.

BLOCK

I

TOOL

HOLES

I

F DELETE OPERATION 1

>>>

SPOTFACE

PLIEIOE FEED

5.0

P n6ER7 OPERATION 2 BEFORE i F 3

SPEED (EPM)

750

F PROO(dl

Z START Z BOTTOM

0.0400 -1.0808

4 PARAMETERS I

(TOOL DIAMETER (TYPE

B.S008) DRILL)

Press BITER to edit this operation or use ADII (tlICE. BACK. or softkey

P PART SETUP 5 i P TOOL SETUP I P 7 F EXIT a

Figure 2-60. Spotface Operation

Operator' s Manual

Countersink An operator uses the countersink operation to enlarge the top end of a hole to a cone shape to accommodate the head of a flat or oval headed machine screw. The hole is enlarged so that when the screw is inserted in the hole the screw head will be flush with or slightly below the top of the work piece surface (see below).

Figure 261. Countersunk screw head

The countersink operation may also be used to remove burrs or excess material that fell into drilled or counterbored holes. The standard countersink has an 82° included angle. Here is a completed Countersink operation screen:

BLOCS

1

TOOL Z START Z BOTTOM

I

HOLES I

COUNTELCINX

8.8388

F DELETE OPERATION 1 P INSERT OPERATION 2 BEFORE

-e.5888

PLINEE r®

5.8

SPEED (RPM)

758

(TOOL DIAMETER (TYPE

>> >

P 3 7 PROGRAM 4 PARAMETERS F PART SETUP 5 i P TOOL SETUP 6

8.51168) DRILL)

Prose ENTER to edit this operation or use ADUN$CE, BACK, or sorthey

P 7 I. P EXIT 8

Figure 262. Countersink Operation

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Revision A

Hawk 5M Machine

Conversational Part Programming

Gun Drill An operator selects the Gun Drill feature when using a very long tool and drilling deep holes, as if drilling out the center of a gun barrel. A long, rotating tool may whip off center when approaching the cutting surface, so a drilling cycle that controls the approach to the work piece and corrects positioning of the tool is required. The Ultimax Gun Drill selection positions the tool without rotating the spindle . This allows the tip of the tool to position precisely in a pre-drilled starting hole, as shown in the diagram below.

Long tool moves Into position with the spindle on to avoid whipping

Pm-drilled Starting Hole_

Figure 2-63. Gun Drilling

Ultimax 3 System

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Operator' s Manual To use the Gun Drill features, the operator must always perform three tasks: •

Describe the gun drill tool during Tool Setup

•

As the first step in part programming, create a starting hole for the drill

•

Then create a Gun Drill data block in the part program

Each Gun Drill data block must contain at least two operations: one describing the starting hole and one for the gun drill hole. To create a Gun Drill data block, the operator begins on a New data block screen and follows these general steps: 1.

Press the Drill Operations (Fl) softkey.

2.

Create the first paragraph of the data block by describing the starting hole portion of the data block . Select either the Drill (Fl) softkey or the Center Drill (F2) softkey. Type in the description of the starting hole into the fields displayed on the screen.

3.

When all of the starting hole data has been entered, the operator presses the Advance (right arrow) console key to begin the second paragraph in this data block.

4.

Press Drill Operations (Fl) softkey and then the Gun Drill (F6) softkey.

Conversational Part Programming The fields describing a Gun Drill operation vary slightly from the standard ' drilling operation fields:

Fields

Definitions

Z Top

The starting point of the gun drill cycle. The tool moves rapidly to this point and then slowly moves into the pre-drilled starting hole.

Z Start

The position inside the pre-drilled hole where the spindle begins to rotate.

Z Bottom

Ultimax 3 System

The bottom of the finished hole.

Z Top Feed

Rate at which the tool moves from the Z Top position to the Z Start position.

Plunge Feed

Feedrate between the Z Start and the Z Bottom positions.

Speed (RPM)

Speed at which the spindle rotates to drill the hole.

Spindle Stop

Point at which the spindle stops rotating after drilling the hole. This may be set to be the Z Bottom or the Z Start position.

Peck Depth

Distance that the tool will drill down into the part before stopping to clear out or break the chips. If this parameter is used , it is usually not larger than the diameter of the tool.

Peck Type

This field has two options that indicate whether the drill will pull out to the Z Start after reaching the Peck Depth (Standard) or simply dwell at the Peck Depth (Chip Breaker).

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Operator' s Manual Here is a sample, completed Gun Drill description:

BLOCS

1

HOLES

TOOL

I >>>

2 TOP Z START Z BOTTOM Z TOP FEED PLUNGE FEED

•

CENTER DRILL GUN DRILL

8.8888 -5.3888 -5.8888 28.8 18.8

I F I F F F 3

SPEED ( RPM) SPINDLE STOP PECK DEPTH

288 Z BOTTOM 8.2588

PECK TYPE

STANDARD

F PROGRAM 4 PARAMETERS I F PART SETUP 5

8 . 2588) GUN DRILL)

F TOOL SETUP 6

(TOOL DIAMETER (TYPE

Enter disensloe at which Z TOP feed'ate begins with the spindle at sere RPM.

FF 7 F E(IT 8

Figure 2.64. Completed Gun Drill Data Block

Conversational Part Programming The following illustration shows the Gun Drill program fields as they relate to a part and the drilling tool:

Move at Rapid Traverse teedrate down to Z Top

Figure 265. Gun Drill Positions

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Operator' s Manual

Locations This softkey function allows Hole operations to be placed at selected points in the part program. All Locations programmed in a block containing a Bolt Circle are executed in addition to the Bolt Circle pattern. Up to 999 Locations can be programmed into a single data block. A Hole data block can contain more than one Locations operation, if more than 999 Locations are required. The word "locations" appears by the cursor, and all operations previously programmed appear above this current operation.

BLOCK

2

x 1 2 3

HOLES

V

-0.1800 9.3000

2.5008 -2.5800

I F

CENTER DRILL DRIILL >>> LOCATIONS

t F 2 F 3 F 4 F 5 F 6

Enter awt>er pa tut or ADIMI

when finished

Figure 266. Locations for holes in a block

1.

Program the dimensions of the X and Y axis coordinates for location #1 and press the Enter key. If a wrong dimension for the X or Y coordinate is entered, move the cursor to the incorrect location coordinate (dimension) and program the correct dimension.

2.. Program the dimensions for the X and Y axis coordinates at all other locations. 3.

2-84

Use the arrow keys to move the cursor between locations and coordinate columns.

Revision A

Hawk 5M Machine

Conversational Part Programming 4.

The Delete Location softkey function deletes the location indicated by the cursor and renumbers all subsequent locations.

5.

The Insert Location Before softkey function creates a new location before an existing one (indicated by cursor). The new location is inserted with the number of the old location and with the coordinates from the previous location in the list. The coordinates of the new block can be changed to the desired values for the new location. The old existing location and all subsequent locations are renumbered as necessary.

6.

Only 15 locations can be displayed at one time. If there are more than 15 in the list, press the Next Screen softkey to view the non -displayed Locations. Press the Previous Screen softkey to return to a previous screen. When the cursor is at the end of the list , press the Advance key to continue to the next block in the part program sequence.

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Operator' s Manual

Bolt Circle A bolt circle routine provides automatic execution for a series of holes equally spaced on a common circle . This routine also permits skipping holes in the bolt circle (i.e., programming holes where the pattern is not to be executed).

BLOCK K/®ER X CENTER

2

HOLES 9 2 . B0011

V CENTER

1.am

RADIUS

4.901119

START ANGLE

DRILL ») BOLT CIRCLE

I F DELETE OPERATION 1 1 F INSERT OPERATION 2 BEFORE i F 3 P PROGRAM 4 PARAMETERS I F PART SETUP 5

8.898

SKIP LIST 3

F TOOL SETUP S

Press ENTER to edit this operation or sarthey

Figure 2-67. Bolt Circle operation

or use ADIMNCE , BACK,

F 7 F F EXIT B

Conversational Part Programming Here is a sample bolt circle pattern. The field definitions below refer to the numbered points in this diagram. 2

0 3

0

X& V Center 4

06

O 0 5

Figure 2-68. A Bob Circle Pattern

The fields describing a Bolt Circle operation are as follows: Fields

llttimax 3 System

Definitions

Number

indicates the number of holes in the pattern. Up to 250 holes can be programmed in one operation.

X Center

the X coordinate for the center of the Bolt Circle.

Y Center

the Y coordinate for the center of the Bolt Circle.

Radius

is the radius of the circle between the coordinate center and starting point at the center of the cutter.

Start Angle

is the angle of the circle measured counterclockwise from the 3 o'clock position to the first hole. This angle may be specified to the nearest one-thousandth of a degree.

Skip List

The skip list allows selecting holes that are not executed in the Bolt Circle pattern. For example, if hole #3 is not to be executed, press the 3 key to name it in the skip list and then press the Enter key. Up to 24 holes may be programmed in the skip list. To clear the list, press the Clear and Enter keys.

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Operator's Manual When all Hole operations in the current data block are programmed, specify the places where these operations are to be executed. These may be in a Bolt Circle pattern, or they can be random points selected in Locations . It is also possible to execute the operations within a given block in one or more Bolt Circle patterns and at other locations as specified in Locations.

Conversational Part Programming

Tap To cut threads inside a hole, the operator selects the Tap (F2) softkey on the Holes screen. The following screen appears:

BLOCX

1

HOLM

1

TOOL

>>>

10

Z START

B.BBBB

Z BOTTOM

0.1BB3

SPEED (RPM)

TAP

F 1 F 2 F 3

R

F PROGRAM 4 PARAMETERS

F PART SETUP s F TOOL SETUP 6

TOOL NOT PROGRAMMED

F Eutr tool mabe'

7

F EXIT B

Figure 2-69. Tap operation fields

Fields Tool

Z Start

Ultm)ax 3 System

Definitions Number of the tool in the tool used for the tap operation. After the operator enters the tool number and presses the Enter key, the tool diameter and tool type appear in parentheses. The values shown were programmed during Tool Setup and cannot be changed during part programmingStarting point of the Tap cycle.

Z Bottom

The bottom of the finished hole. It is the point of maximum Z down and where the spindle reverses direction..

Speed (RPM)

Speed at which the spindle rotates to bore or ream the hole. The value that initially appears in this field was entered Tool Setup . If this displayed speed should be used for the operation , press the Enter key. If a different speed is needed for this specific block, type in the value and press Enter. The maximum tap speed is 1250 rpm.

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Operator' s Manual During an Ultimax tap operation , the table positions to the programmed X and Y dimensions followed by Z axis positioning to the programmed retract clearance . (Axis positioning is at the rapid traverse rate selected in Program Parameters or Change Parameters.) After reaching this point, the Z axis moves at rapid traverse to Z Start and then at the control calculated feedrate until it reaches the Z Bottom dimension. At that point, the spindle reverses direction and the Z axis moves at the calculated feedrate back to the Z Start dimension (where the spindle begins rotating in the original direction). When tapping, the control calculates the plunge feedrate using the speed (rpm), tool diameter, and threads per inch/pitch programmed for the tool in Tool Setup. Approximately 20" per minute is a nominal feedrate in tapping most materials . When tapping aluminum , a feedrate two to three times 20" per minute can be attained productively. This formula is used to determine the feedrate for a given speed (RPM):

Threads per inch

x RPM = Feedrate

This formula determines the spindle speed (RPM)when the feedrate is known: Threads per inch x Feedrate = RPM

Hints and Tricks Here are some suggestions for the tapping process:

2-90

1.

Use a floating tap holder.

2.

When tapping hard materials, use tapping fluid (not coolant) and a tap drill one size larger than normal.

3.

Recommended Z Start is .200 minimum above the part surface to compensate for floating tap holder characteristics.

Revision A

Hawk 5M Machine

Conversational Part Programming

Bore and Ream Operations To enlarge and straighten the angle of an existing hole, the operator selects one of the three Bore operations. To clean out and smooth a hole, the operator selects a Ream operation. Reaming operations follow the angle of the existing hole while a boring operation makes a true , straight hole. To display the boring and reaming softkey options, press the Bore and Ream Operations (F3) softkey on the Holes screen.

BLOCK

1

HOLES

TOOL

B

Z START

e.eeee

Z BOTTOM

e . eeee

PLRIGE PEED

0.8

SPEED IRPMI

B

)))/ BORING

1\ P REAM 2 I r ROME RAPID 3 i F BORE ORIENT 4 (Fl REAM RAPID P 6

TOOL NOT PROGRAMMED

FF 7

Chose opent ton

FF a

Figure 2-70. Bore and Ream sofkeys .

If the operator presses the Enter key when the screen first displays as shown above, a Bore (Fl) operation can then be programmed . To select any of the bore or ream operations, the operator presses one of the five softkeys shown on the screen.

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Operator' s Manual All of the bore and ream operations have the same fields: Fields

Definitions

Tool

Number of the tool in the tool that will be used for the selected bore or ream operation. After the operator enters the tool number and presses the Enter key, the tool diameter and tool type appear in parentheses. The values shown were programmed during Tool Setup and cannot be changed during part programming.

Z Start

Starting point of the bore or ream cycle. The tool moves rapidly to this point.

Z Bottom

The bottom of the finished hole. It is the point of maximum Z-down and the dimension where the plunge feed rate ends.

Plunge Feed

Feedrate between the Z Start and the Z Bottom positions.

Speed (RPM)

Speed at which the spindle rotates to bore or ream the hole. The value that initially appears in this field was entered Tool Setup. If this displayed speed should be used for the operation, press the Enter key. If a different speed is needed for this specific block, type in the value and press Enter.

After entering the values into these fields, the operator may select one of the operation softkeys: Delete Operation, Insert Operation Before, or Exit. Selecting the Delete Operation clears the currently displayed drill operation. To add another hole operation before the current one, the operator selects the Insert Operation Before softkey. Pressing the Exit softkey returns to the previous screen level . Pressing the Advance key displays a new Holes screen with the name of the operation just programmed above the multiple cursor.

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Hawk 5M Machine

Conversational Part Programming

Bore An operator uses a bore when a straight and accurately round hole is needed. A boring bar usually has one or, at the most, two blades projecting out from the shank. On many types of boring bars, the blades can be adjusted in and out to increase or decrease the size of the hole. The illustration below shows a two-bladed boring bar:

Boring Bar

Shank

Blade depth adjustment dial Replaceable blades Figure 2-71. Two-bladed Boring Bar with adjustment dial

The Ultimax Bore cycle is similar to a drilling operation in positioning the table and Z axis; however, during a bore operation, the tool plunges from Z Start to Z Bottom at the programmed Plunge Feed then retracts from the hole at this same feedrate until it reaches Z Start position. No pecks are permitted.

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Operator' s Manual

Ream To size and/or clean out a previously drilled hole, the operator presses the Ream (F2) softkey. The reaming cycle clears burrs and other particles left from a drilling or boring operation. A reaming tool has multiple flutes that run vertically along the shank of the tool as shown below:

Figure 2 -72. Reaming Tool

During reaming, this cutter follows the angle of the existing hole and cannot be used to straighten the angle of the hole.

Bore Rapid The Bore Rapid (F3) softkey allows the operator to program a boring cycle with these steps:

2-94

1.

The Z axis plunges from Z Start to Z Bottom at the plunge feed programmed.

2.

When the tool reaches the programmed Z Bottom dimension, it retracts at the rapid traverse feedrate selected in Program Parameters or Change Parameters.

Revision A

Hawk 5M Machine

Conversational Part Programming

Bore Orient If the operator selects the Bore Orient (F4) softkey, the cycle will follow these steps: 1.

The Z axis plunges from Z Start to Z Bottom at the Plunge Feed programmed.

2.

The spindle stops , and the tool is oriented to its starting position.

3.

The cutting edge of the boring bar moves away from the surface of the bored hole so that during step 4 the cutting edge will not scrape the walls of the hole. The distance that the bar moves was set in the Bore Orient Retract field on the Holes Parameters screen.

4.

The tool retracts at the Rapid Traverse feedrate set on the General Parameters screen.

Ream Rapid If the operator selects the Bore Rapid (F5) softkey, the cycle follows these steps: 1. The Z axis plunges from z start to z bottom at the plunge feed programmed. 2. When the tool reaches the programmed z bottom dimension, it retracts at the rapid traverse feedrate selected in Program Parameters or Change Parameters.

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Operator's Manual

Back Spotface If the operator wants to cut out the underside of holes that must be cut through the work piece, the operator may use this feature. Press the Back Spotface (F4) softkey, and the following screen appears:

BLOCX

1

HOLES

TOOL

I

2 START Z PLUNGE Z BOTTOM 2 DEPTH Z CLEARANCE 2 RETRACT CLOSING F® CUTTING FEED

>>)

BACK SPOTFACE

8.8888 8.88B8 8.8888 8.8888 8.8888

•

F 2

8.0

3 2 P PROGRAM 4 PARAMETERS

B 8 8.9

F PART SETUP 5

B.BBBB 0.0

PLUNGE SPEED (RPM) CUTTING SPEED (RPM) REVERSE DWELL (SEC)

F 1

TOOL NOT PROGRAMMED

F TOOL SETUP 6

Enter Z dimension eefm- . d from the cutting edge of the tool at which closing feednte begins

F 7 F EXIT 8

Figure 2-73. Back Spotface screen

The fields on the Back Spotface screen have these uses: Fields

2-96

Definitions

Tool

Number of the tool that will be used for the selected operation . After the operator enters the tool number and presses the Enter key, the tool diameter and tool type appear in parentheses. The values shown were programmed during Tool Setup and cannot be changed during part programming.

Z Start

Starting point of the cycle. The tool moves rapidly to this point. Tool zero should be the end of the tool.

Z Plunge

The dimension within the hole that the bar will feed before rapid movement to Z Bottom. This assures that the cutter is fully closed to prevent damage to the tool and part.

Revision A

Hawk SM Machine

Conversational Part Programming

Fields

Definitions

Z Bottom

The dimension at which the tool ceases rapid travel. This dimension must be completely through the hole. Use the dimensions on the print as the cutter offset to extend the tool beyond the cutting surface. At this point, the tool pauses and reverses the spindle direction to open the cutting surface.

Z Depth

The tool feeds to this depth. to use the print dimensions as the cutter offset in Tool Setup to take the tool into .

Z Clearance

Incremental (positive value) distance to rapid the tool away from the cutting surface. At this point, the tool pauses , and the spindle returns to its original direction to close the cutter.

Z Retract

Distance that the tool feeds back up through the hole to be certain that the tool is properly closed before rapid movement to the Retract Clearance height.

Closing Feed

Feed at which the tool enters the hole at the top and bottom to be certain the tool is closed.

Plunge Speed (RPM)

Speed of the spindle with the tool closed while entering or exiting the hole.

Cutting Speed (RPM)

Speed of spindle with the tool open.

Reverse Dwell (Sec)

Number of seconds that the spindle dwells when it is reversing to give the tool time to open or close.

After entering the values into these fields, the operator may select one of the operation softkeys : Delete Operation, Insert Operation Before, or Exit. Selecting the Delete Operation clears the currently displayed drill operation. To add another hole operation before the current one, the operator selects the Insert Operation Before softkey . Pressing the Exit softkey returns to the previous screen level . Pressing the Advance key displays a new Holes screen with the name of the operation just programmed above the multiple cursor.

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Operator' s Manual The general steps in a Back Spotface operation are shown below: 1.

Rapid to Z Start minus cutter offset and set the spindle speed to a plunge speed.

2.

Move to Z Plunge minus cutter offset at a closing feedrate to close the cutter.

3.

Rapid to Z Bottom minus cutter offset.

4.

Dwell for a specified reverse dwell amount, reverse the spindle direction and ramp to cutting speed to open the cutter.

5.

Move up to Z Depth minus cutter offset at a cutting feedrate.

6.

Dwell for the drill dwell time (from program parameters).

7.

Rapid down a Z Clearance amount.

8.

Dwell for the Reverse Dwell time and reverse the spindle direction to plunge speed to close the cutter.

9.

Move to Z Retract minus cutter offset at a closing feedrate to insure the cutter is closed.

10. Rapid out of the hole.

Conversational Part Programming

Sample Drilling Program The following example demonstrates some basic Ultimax hole drilling capabilities . The job calls for drilling twelve holes with a 3/8" drill through a rectangular piece of alloy steel as shown in the diagram below: Part Zero

\ I 1" 1.25" A .75" 4' 4" 2.5

8.25" Material : Alloy Steel 8.25" x 4"x.25"

Tools 1/8" Center Drill 3/8" Drill

HSS HSS

Feeds 42 5.6

Speeds 2800 930

Figure 2-74. Hole Drilling Example

The program presented on the following pages is a copy of the printed part program developed for this drawing . This program is presented in the same format as an Ultimax 3 part program that was printed on a dot matrix printer from the control . Therefore, the program data may be presented in a different order than it is on the Ultimax screens. In the sample program , the operator added a tool setup for tool #99 to use only to draw the part outline block. Since the speed and feed information is missing from the tool description , the control will not execute any block using this tool. To prevent an error during running , the operator will delete that tool and the outline block before running the program.

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Operator' s Manual Since Ultimax allows considerable flexibility in developing part programs, this sample program does not represent the only way the part can be programmed. Watch for inserted explanations of the special features of this sample program. Hurco Ultimax Part Program Holes .HD3

1

Inch Standard

Part Setup Part Zero X Y Offset 2

5.0000 10.0000 0 .0000

Safety Work Region Z Top (+ ) 2 Bottom C- ) X Left C-) X Right C+ ) Y Front C- ) Y Back C+) Fixture Offset

99.0000 -0.4010 0.0000 8.2500 -4.0000 0.0000 1

General Parameters Retract Clearance Rapid Trauerse Peck Clearance Plane Chord Error Depletion Retract

0.2500 IN 400.0 IPM 0 . 0500 IN 0.0001 IN 0 . 0050 IN

Holes Parameters Bore Orient Retract Drill Dwell Bore Dwell

0 . 0200 IN 0.5 SEC 1.0 SEC

Milli ng P arame t ers Blend Offset Blend Ouerlap Finish Feed Finish Speed Finish XY Finish Z Milling Direction Pocket Ouerlap Cutter Comp Parameter

2 - 100

0.1250 IN 0 . 1250 IN

100 100 i 0.0100 IN 0 . 0050 IN .

Climb 10 Insert Arc

Revision A

Hawk 5M Machine

Conversational Part Programming . Hurco Ultimax Part Program Holes .HD3

Inch Standard

2

Program Parameters Off Partial Yes

Ouerride Lockout Program Protect Tool Change Position

Tool Setup The number to the left of the type name is the tool number. So this setup section lists three tools : 1, 2, and 99 . Since tool 99 is not going to be used in the program , the tool type was not identified in setup . Zero calibration values will, of course, vary for different work pieces and tools. 1

Type Diameter Zero Calibration Speed ( RPM) Coolant Gear range Tool Humber Diameter Offset Length Offset

Drill 0.1250 - 10000. 2800 CU Flood I 1 1 1

2

Type Diameter Zero Calibration Speed CRPM) Coolant Gear range Tool Humber Diameter Offset Length Offset

Drill 0.3750 - 10000. 930 CW Flood 1 2 2 2

99

Diameter Zero Calibration Speed ( RPM) Coolant Gear range Tool Humber Diameter Offset Length Offset

0.0000 -10000. 0 CW Off 1 99 99 99

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Operator' s Manual Hurco Ultimax Part Program Holes.HD3

3

Inch Standard

The number to the left of the following data block name is the block number in the part program. Data Blocks 1

Mill Frame Tool Type Finish Tool

X Corner Y Corner

X Length Y Length Corner Radius

Lead Length

99 Out/Tan 0 0.0000 0.0009 8.2500 -4.0000 0.0000 0.0000

2 Start 2 Bottom Plunge Feed Mill Feed Speed (RPM) Peck Depth

Lead Angle

0.0000 -0.2500 0.0 0.0 0 0.0000

0.0000

Block #1 creates an outline of the part for the graphics display. The operator will use this outline during programming to check the location of the programmed holes and delete the block before running the program. The Z Start parameter draws the surface of the part , and the Z Bottom draws the bottom . Block # 2 performs all of the hole drilling operations. Note that the tools are entered into the program in the order in which they are used. 2

2-102

Holes Center Drill Tool Finish Tool Z Start 2 Bottom Plunge Feed Speed CRPM) Peck Depth Peck Type

1 0 0.0500 -0.0125 4.2 2800 0.0000 Standard

Drill Tool Finish Tool 2 Start Z Bottom Plunge Feed Speed ( RPM) Peck Depth Peck Type

2 0 0.0500 -0.3000 5.6 930 0.1500 Standard

Revision A

Hawk 5M Machine

Conversational Part Programming Hurco Ultimax Part Program Holes.HD3

4

Inch Standard

Locations 1 2 3 4 5 6 7 8 9 10 11 12

x

Y

1.0000 2.2500 3.5000 4.7500 6.0000 7.2500 7.2500 6.0000 4.7500 3.5000 2.2500 1.0000

-0.7500 -0.7500 -0.7500 -0.7500 -0.7500 -0.7500 -3.2500 -3.2500 -3.2500 -3.2500 -3.2500 -3.2500

These hole locations are also a portion of Block #2 . They are programmed in the order that they will be cut . The operator used the Ultimax No-Calc feature to enter the location data. First, the operator entered the X and Y coordinates for hole #1 from the drawing. To calculate the X values for holes 2 through 6, the operator typed "1.25" and pressed the plus (+) console key and Enter for each of these values. The operator pressed the Enter key for each of the Y values since those values are all the same as the first hole. For hole #7, the operator pressed Enter on the X value to keep it the same as the previous value . Then the operator typed "-2.5" and pressed the plus (+) console key and Enter key to add -2.5 to the previous Y value and pressed Enter for each of the subsequent Y values. For the X value of holes 8 through 12, the operator typed " 1.25" and pressed the minus (-) console key and Enter to subtract 1.25 for each new position.

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Operator' s Manual

Milling This section presents detailed descriptions of the Milling options in Ultimax 3. The chart below shows the relationship of the milling options to the Input button and its subsequent softkey selections.

Milling Options Input Button

Part Setup (Fi ) Tool Setup (F2) Part Programming (F3) Position (Fl) Holes (F2) Milling (F3) Patterns (F4) Miscellaneous (F5) Special (F6)

Lines & Arcs (Fl)

Li ne ( Fl )

Circle (F2)

Arc (F2).

Frame (F3)

Blend Arc (F3)

Face (F4)

Helix (F4)

Ellipse (F5)

3D A rc ( F 5)

Rotary (F7)

Lette ri ng ( F6)

Exit (F8)

3D Option (F7) Exit (F8)

Figure 2-75. Milling Options Chart

2 - 104

Revision A

Hawk 5M Machine

Conversational Part Programming When the operator presses the Milling (F3) softkey , the milling option softkeys appear on the New Block screen as shown below:

BLOCK

I

NEW aIACII F 1)/Ln6S I F/2) CIRCLE 3) FRRItE 3 F 4) FACE 4 r F 5) ELLIPSE 5 6) LETTERING

F 7

Clore type of block

) 30 OPTION

F E)II a

Figure 2-76. New Block screen with the Milling soft keys

The following sections describe some general concepts that apply to many different milling operations:

Ultimax 3 System

•

Segments

•

Cutter Compensation

•

Maximum Offset

•

Feed and Speed Options

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Operator's Manual

Segments Mill contour data blocks use segments to create lines and arcs in a part program. A segment is any programmed single or combined X-Y-Z axis movement at a programmed feedrate. A series of lines and arcs can be programmed in a single data block, using different segments, to form a complete contour. A new segment, see below, begins where a different motion from the previous segment is programmed. Up to 999 segments can be programmed in one data block, if they all use the same tool and are all part of the same Mill Contour. These segments may be any combination of lines, arcs, blend arcs, helixes, or 3-D (three-dimensional) arcs. Note. these features listed in the softkeys below: BLOCB

1

'3661®17

1

I

1) LINE

\(LIe1 F 2) NBC 2 F 3) BLEND ARC 3 , F 4) HELIX 4 F 5) 3D NBC S

7,oose appropriate sotikey

Figure 2-77. Mill Contour New screen

When the . operator selects any of these softkeys, the screen used to create the selected segment lists "Mill Contour" beside the block number and then displays the type of segment beneath "Mill Contour." For example, a blend arc segment will have "Mill Contour Blend Arc" at the top of the screen.

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Revision A

Hawk 5M Machine

Conversational Part Programming Pressing the Lines and Arcs (Fl) softkey on the Mill Contour New screen displays the Mill Contour Start screen shown below. The block number displayed on this screen is determined by the position of the data block in the part program. The first segment in a Mill Contour block is always a Start block indicated by the segment zero (0). The operator cannot change a segment number to zero since segment numbers are system-generated. The cursor begins on the Tool field as shown in the sample below. The operator enters the number of the tool that will be used for the entire operation. All of the segments in this operation will use the same tool.

BLOCX

1

SEGMENT

a

F 1

ID

TOOL CUTTER 0011P. FINISH TOOL

PI.111GL F®

8.0 F 2

MO B

X START Y START Z START

0.0800

2 BOTTOM

B.BBBB

Ft 3 f PECX DEPTH B.BBBB F 4 TOOL NOT PROGRAMMED F 5

SPEED (RPM)

B

Enter tool metes

Figure 2-78. Mill Contour Start screen

Important While programming a part, the operator should plan groups of segments since during recovery restart the control can only restart at segment zero (0), not at a segment after the zero segment. Many operators break complex operations into different blocks so that if they need to restart the program they can start at any one of several zero segments.

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Operator' s Manual Here is a completed Start segment (segment zero):

BLOCK SEGMENT

I A 0

HILL CONTOUR START

TOOL

I

PLUNGE FEED 2

CUTTER COME .

PROFILE LEFT

FINISH TOOL

2

X START

8 . 5808

V START

-7.9859

Z START

8.6288

Z BOTTOM

-8.2588

MAX OFFSET

F 588 3

SPEED (RPM) PECK DEPTH (TOOL DIAMETER (TYPE (FINISH DIAMETER (FINISH TYPE

8.8888

F PROGRAM 4 PARAMETERS 8.2588) 1 DRILL) F PART SETUP 8.2588) 5 END MILL) F TOOL SETUP S

8.8888 F

BAcK wwhe', Mn ENTER to edit ssasent , or Mn 7 Znt@ a eB ADIMNCE , ACK. . or sot net'

F EXIT 8

Figure2-79. Completed Mill Contour Start screen

Here are the fields used to describe a group of segments: Fields

2 - 108

Definitions

Tool

number of the tool used to cut the segments in this group.

Cutter Comp

indicates whether the system should automatically compensate for the diameter of the tool when determining tool path. The operator can select different types of cutter compensation as described in the following section. If cutter compensation is not selected, the center line of the programmed tool follows the part contour.

Finish Tool

number of a tool used for finish . If a finish tool is selected, the first tool leaves the amount of material selected in Program Parameters or Change Milling Parameters . The finish tool removes the remaining stock down to the programmed dimension.

X Start

" X" coordinate for the starting point of the first segment.

Y Start

"Y" coordinate for the starting point of the first segment.

Revision A

Hawk 5M Machine

Conversational Part Programming

Z Start

point above the part where the Z axis plunge feed rate begins.

Z Bottom

point of maximum Z-down where the plunge feed rate ends.

Maximum Offset

this conditional field appears if Cutter Comp.Profile Left or Cutter Comp.- Profile Right were selected. The value is the distance between the programmed contour and the tool center during the first . The number entered here must be manually calculated.

Plunge Feed

feedrate between the Z Start and the Z Bottom positions.

Speed (RPM)

the spindle speed for the tool calculated in Tool Setup. Entering a value here overrides the Tool Setup value for this data block.

Peck Depth

Ultimax 3 System

the maximum depth to be cut in one .

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Operator' s Manual

Cutter Compensation The default setting for cutter compensation is "No." When no cutter compensation is used, the center line of the programmed tool follows the part contour (print line). If the operator wants the system to calculate cutter compensation , there are six possible selections: •

Left - used for climb milling

•

Right - used for conventional milling

•

Profile Left - removes material from a closed contour for climb milling

•

Profile Right removes material from a closed contour for conventional milling

•

Pocket Boundary - used to cut the outside perimeter of an UltiPocket operation

•

Pocket Island - used to cut islands inside the perimeter of an UltiPocket operation

BLOCK

1

MILL CONTOUR

SEB1DIT

D

START

TOOL

1

CUTTER COMP. •

^ F 1) NO 1 PLIKIGE PEED

8.0

F

SPEED (RPM)

B

3

LEFT

MO 3) RIGHT M

FINISH TOOL X START

PECK DEPTH

Y START

9.0080 F 4) PROFILE LEFT 4 I F 5) PROFILE HIGH 5 i F 6) POCKET 6 ROIRO)RRY /

TOOL NOT PROGRAMMED

2 START

a.aa99

Z BOTTOM

9.99fi6

7) PO KKT 7\ ISLRIw

Select euttine operation

F EKI

a

Figure 2-80. Cutter Compensation options

If the operator selects one of these compensation options, the programmed tool automatically follows the finished contour of the part.

2 - 110

Revision A

Hawk 5M Machine

Conversational Part Programming Here is a diagram showing tool paths when no cutter compensation is used compared to left and right compensation: No Cutter Compensation Tool 1

Cutter Compensation to the left Tool

Center line of Contour

Center line of Contour

Cutter Compensation to the right Tool Center line of Contour

Figure 2.81. Tool Paths for Cutter Compensation

When the operator selects either right or left compensation , the system offsets the tool from the print line (in the selected direction) by a distance equal to the radius of the tool.

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Operator's Manual

Climb Milling Climb milling is preferred except when the rigidity of the fixturing is not sturdy enough to allow its use. The cutting teeth move in the same direction as the feeding motion. This is also known as in-cut or "down milling." During a climb cut, the spindle turns in a clockwise motion. The tool is on the left-hand side of the cut as it travels away from the operator. The advantages of using climb milling are as follows: 1.

The chip starts thick and allows easy penetration into the surface of the part causing less tool wear and less power consumption.

2.

The tool force cuts in and down on the part helping to hold the part in the fixture. The more rigid the fixture, the better the hold on the part.

3.

Chip removal is greater, and there is less recutting of chips or marring of the part surface.

4.

The cutting fluid is more accessible to the cutting surface.

Conventional Milling The cutting teeth move in the opposite direction to the feeding motion. This is known as "out-cut" or "up milling." While using conventional milling with a clockwise spindle, the tool moves away from the operator on the right-hand side of the cut. The advantages of using conventional milling are as follows: 1.

The chip thickness starts at zero causing less impact on the cutting teeth. This is ideal for set-ups that are not very rigid.

2.

The backlash in older machines is greatly diminished.

Conversational Part Programming

Profile Left and Right The softkey functions of Profile Left and Profile Right enable material to be removed inside or outside of a programmed closed contour, depending on the part program and the function chosen. Select Profile Left for climb milling and Profile Right for conventional milling; the enabled softkey determines if the tool remains inside or outside of the contour (depending on the part program). A mill contour with the same X-Y coordinates for both the end point and start point is called a closed contour. Selecting cutter compensation with tool on the inside of a closed contour allows the control to compute the start and end points of the tool path so it does not cut into the last or first segments of the contour. (When pocketing, all contours must be closed; if not closed, the control moves its tool in a direct line from the end point to the start point at the current feedrate. Do not program start point in a corner of a closed contour.)

BLACK SEGMENT

1 1 B

HILL CONTOUR

TOOL

1

9E* COtO' I

I F 1

START PLUNGE FEED

0.0 F 2

PROFILE LEP

SRI TOOL

SPY® (RPM)

F PROGRAM 4 PARAMETERS CM. 7. (TOOL DIAMETER V START 8.5888) 1 HB^^-^--DB P PART SETUP 8.00@0 B. ZS@0) Z START (PIMISN DIAMETER (FINISH TYPE END HILL) 8.80@0 Z BOTTOM P TOOL SITUP 6 MAX OFFSET 8.880 i P Enter a eer.eSt aue)em, use D(T'ER to edit ueswent, m• use 7 AD(NWCE , RACE. or eotthey F EXIT 8 X START

Asaee

PECX DEPTH

P B 3 8.8880

Figure 2-82. Profile Left Cutter Compensation using a finish tool

After the tool removes material , the finish tool uses the same cutter compensation and removes the remaining stock down to the programmed level. When a finish tool number is entered on this screen, the finish tool diameter and type parameters are displayed in parentheses . The values for these parameters are programmed in Tool Setup and cannot be changed in Part Programming mode.

Ultimax 3 System

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Operator' s Manual

Maximum Offset The maximum offset field displays when Cutter Comp.- Profile Left or Cutter Comp.- Profile Right is selected. The value to be programmed must be calculated and manually programmed into the control. This value must be the distance between the programmed contour and the tool center during the first . The value for maximum offset should equal the radius of the largest inscribed circle minus the radius of the tool which illustrates an example calculation of this value. The graphics screen is helpful in determining an optimum value for this parameter.

Starting point for the tool

Figure 2-83. Determining Ma:tmum Offset

If the tool diameter is changed (i.e., cutter sharpened to a smaller diameter), the value for the maximum offset must be recalculated manually and this new value programmed into segment 0 of the Mill Contour - Start block. The value for the tool diameter parameter is programmed in Tool Setup and cannot be changed in Part Programming. If a .500" diameter-end mill is used to machine the part illustrated, the value to be programmed for the maximum offset parameter should be 0.75".

Conversational Part Programming

Feed and Speed Options The plunge feed parameter is the rate the tool is to enter the work piece and is requested only for segment 0 of a Mill Contour. The value displayed for the Speed (RPM) parameter is programmed (or calculated) in Tool Setup and is the spindle speed for the tool. If desired, this value can be changed for this data block when the cursor indicates this parameter. Pressing the Enter key stores the displayed value in control memory. The Ultimax control automatically calculated the spindle speeds using the following formulas. The first four formulas produce the revolutions per minute (RPM) that apply to high-speed steel tooling and high-speed cobalt tooling used to cut work pieces of these common metals. 382 = RPM for plain carbon steel tool diameter

350 = RPM for alloy steel tool diameter 1240 = RPM for aluminum tool diameter 365 = RPM for gray cast steel tool diameter 3440

tool diameter

= RPM for aluminum

1240 = RPM for gray cast steel tool diameter Refer to the "Appendix" of this manual for more feeds and speeds information.

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Operator' s Manual

Programming Lines and Arcs After the Start segment is programmed, the Mill Contour screen becomes segment 1 of the data block and the cursor indicates New.

Lines Selecting the Line (F1) softkey from the Mill Contour New screen displays this Mill Contour screen: ELOGX

1

HILL CONTOUR

I

SEW@IT

1

LINE

F I

2.0060

X END Y 0101

4.0060

Z Elm

0.0000

XT LENGTH XT ANGLE FEED

(X START (Y START (2 START

CAL

0.5000) F -7.9059) 2 6.0006) 1 F STORE CALCULATED 3 VALUE

I.

12.0000 CALL

F 4 l F 5

02.019 0.0

F FIND ANOTHER 6 END POINT i P PREVIOUS SEGMENT Rotor XV angle to sad point. counarcloekwlse from 3 o'clock 7 If knorn 1 ANOTHER END POINT EXISTS

F EXIT e

Figure 2-85. Mill Contour Line screen

The block and segment numbers are the same as on the New screen. Reference values for X Start , Y Start, and Z Start information. are displayed in parentheses and defines the start point of this segment. These parameters were programmed in the previous segment and cannot be changed in this segment. When programming a Line segment, the Ultimax No-Calc feature enables the control to calculate certain unknown dimensions automatically, after sufficient data has been entered. A parameter with a calculated value is indicated by "CAL" (preceding the value). If the value for a parameter is left blank, the control automatically fills in the value if enough data is available for the calculation. If a dimension is entered and it is later decided the control should calculate it, move the cursor to the parameter and replace it by pressing the Clear key.

Conversational Part Programming If the X End and Y End coordinates are entered, the control automatically calculates the XY length and the XY angle parameters. The XY angle parameter value is the angle of the line segment (from the start point to the end point ), measured counterclockwise from the 3 o'clock position.

Start P o int

0'

Figure 246. Length, Angle, and End Point Relationship

If both end points are unknown, but XY length and XY angle are programmed, the control automatically calculates X End and Y End parameters. If one end point coordinate and the XY angle are programmed , the control can calculate the unknown end point and the XY length parameters. If one end point coordinate and the XY length are programmed, the control can calculate the unknown end point and the XY angle parameters. However, unless the XY angle is known , there are two possible solutions for the unknown end point and the correct one must be determined for the program.

Ultimax 3 System

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Operator' s Manual When two possible solutions exist, the message, "Another end point exists" appears and one of the two possible solutions appear in the unknown parameter. Pressing Draw for the graphics screen displays a visual representation of the displayed solution. The other solution for the unknown parameter can be displayed by pressing the Find Another End Point (F6) softkey and selecting graphics for this solution to displays a visual representation. Alternate display of each solution facilitates the appropriate choice for the program. Press the Enter key when the correct choice is displayed. X Known

Known Start Point

Y unknown XY Angle unknown

Figure 2-87. Line Segment with Unknown Y End and XY Angle

The Z End value is the depth of the cut at the line end point. The value initially displayed is carried forward from the previous segment. The displayed value can be retained, or a new value programmed (as required).

The feed parameter is initially displayed with a value carried forward from the previous segment. This value can be changed or stored. Additional Line and Arc segments can be programmed in this same data block (using two-axis, or three-axis moves). Press the Advance key to program an additional segment in this same data block.

2-118

Revision A

Hawk 5M Machine

Conversational Part Programming

Arcs Selecting the Arc (F2) softkey on the Mill Contour screen displays the Arc screen. Here is a completed arc segment:

BLOCK SS6M8NT

I

I

HILL CONTOUR

1

F DELETE SEGM717 1

ARC

1

DIRECTION

C11

X END

2 . 0000

V END

3.0080

X CENTER

CAL

2.4412

V CENTER

CAL

8.5392

(X START (V STAR? (2 START

0.0080) F INSERT SEGMENT 0.0000) 2 BEFORE 8. Bees) I F 3 F PROGRAM

4 PARAMETERS RADIUS F®

F PART SETUP 5I

2.5880

F TOOL SETUP b

15.0 ANOTHER CENTER POINT EXISTS

Enter a eegnent weber . tats ENTER to edit cegeent, or tan AD'JN CE , BACX, or aurtkeg

F 7 1 F EXIT B

Figure 2-88. Mil ContourArc screen

The block and segment numbers are the same as the New screen. Reference values for X Start, Y Start, and Z Start parameters are displayed in parentheses and define the start point of this segment . These parameters were programmed in the preceding segment and cannot be changed in this segment. The direction parameter refers to the direction of the arc from the start point. Examples of these coordinates for a clockwise arc are shown below:

Figure 2-89. Coordinates of a Clockwise Are

Ultimax 3 System

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Operator' s Manual Data coordinates (values) used in the automatic calculations are as follows: •

The values of center points, plus the start points OR end points furnish the arc radius parameter value.

•

The start points AND end points, plus the radius value provide the two possible center points.

•

Either of the end point values AND the center point coordinate supplies the value of the other end point and the radius parameter.

•

When a known center point, start point or end point and radius coordinate are provided, an unknown center point coordinate is furnished. Solution #2 End Point #2

Solution #1 End Point #1

Known: Y End and Y Center Unknown : X End and X Center

Figure 2-90. Arc Segment with Unknown X End and X Center

The feed parameter is initially displayed with a value carried forward from the previous segment. This value can be changed or stored. A series of Arcs and Lines can be programmed in a single data block using different segments to form a complete contour. Press the Advance key to program an additional segment in this same data block.

Conversational Part Programming

Blend Arcs A blend arc is an arc that s two other segments and is tangent to both. A blend arc can be used to : •

Two Line segments.

•

A Line segment and an Arc segment.

•

Two Arc segments.

•

A Helix to another segment.

The segments to be ed must have a. theoretical point of intersection. If the only information known about an arc is its radius, it is easier to program it as a blend arc (if the segments intersect). The diagram below illustrates some examples of blend arcs. Two Area ed by a Blend Arc X Start Y Start

Segment #1 •^ (Arc) \✓

Two Lines ed by a Blend Arc Segment 1 End/ Segment 3 Start point of intersection

Segment 1 End/ Segment 3 Start point of intersection

Segment 1 End/ Segment 3 Start point of intersection

X Start Y Start

Segment #1 (Line)

X End Y End

WSegmnt #3

X Start Y Start

Line and Are ed by a Blend Arc

X End YEnd

Figure2-91. Some Typical Blend Ares

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Operator' s Manual Pressing the Blend Arc (F3) softkey on the Mill Contour's New screen displays the blend arc fields. The block and segment numbers are the same as the New screen . Reference values for parameters are displayed in parentheses . These values have been carried forward from previous segments and cannot be changed in a blend arc segment. Here are some guidelines that must be followed when creating a blend arc: 1.

A blend arc segment should not be used to start or stop a Mill Contour. In other words , segment #1 and the last segment of the data block cannot be a blend arc segment.

2.

Two adjacent segments in the program cannot both be blend arc segments , so if segment #2 is a blend arc, segment #1 and #3 cannot be blend arc segments.

3.

Segments that are adjacent to the blend arc segment must intersect at some point in their theoretical plane. Therefore, if segment #2 is a blend are , segment #1 and #3 must theoretically intersect at some projected point.

4. 'Do not enter a value into the Radius field that is too large to be tangent to both of the ading segments. 5.

If any coordinate (start point, center point, or end point) is important to the construction of the two segments to be blended, the segment must be programmed as an arc and not as a blend arc.

6.

The Feed field is initially displayed with a value carried forward from the previous segment . This value can be changed or retained.

A series of arcs and lines can be programmed in a single data block, using different segments to form a complete contour . Press the Advance key to program an additional segment in this same data block.

2-122

Revision A

Hawk 5M Machine

Conversational Part Programming Operators use different methods to program blend arcs. Some operators work through the program segment by segment while others create all the geometry surrounding the arc and then insert the blend arc between existing segments. The following screens show a programming example of a simple blend arc inserted between a helix and an intersecting line. Of course, the operator created a start segment (segment zero) to begin the block. Then the operator created the helix followed by an intersecting line segment. Then using some of the values calculated on those screens, the operator created the blend are between the helix and the line. The following three screens show the finished block after the operator has programmed all of the segments. This screen in this series creates the helix. For more information about programming a helix , refer to the following section.

BLOCK

1

KILL COIMOIRR

SECM®IT

1

HELIX CY

DIRECTION x BE

2 . 2913

Y END

1.01190

2 DO)

11.0000

X CENTER

CAL

-0.1893

V CENTER

CAL

0.2853

RADIUS

2.5888

LEAD

0 . 0000

Enter feedrate

1 F 1

SWEEP A)16LE FED

( X START (V START (Z START

(MOTHER

-

CRI.

146.775 I 15 . 0

+.;

1 -

2 2 1. F 3 I

F 4 -2 . 5000) 1 1 . 0080) F FIND MOTHER 0.0080) 5 CENTER POINT i _ 6 6 CENTER POINT EXISTS F PREUIOLIS SECIMT 7 EXIT 8

Figure2-92: Segment creating the Helix in the Bknd Arc exampk

The screen on the following page creates a line segment to intersect with this helix.

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Operator' s Manual

BLOCK

1

SEGMENT

MILL CONTOUR

X END

5 . 0080

V END

1 . 0000

Z END

0.0000

XY LENGTH

CAL

XY ANGLE

CAL

FEED

F DELETE SEGMENT 1

LINE

$ 3

(X START (Y START (5 START

2.2913) F INSERT SEGMENT 1.0880) 2 BEFORE 0.0908) 1 F

2.7861

F PROGRAM 4 PARAMETERS i P PART SETUP S

0.000 15.0

f

F TOOL SETUP 6 F 7

Enter a eegeent Huber , an ENTER to edit tega nt. or oae

ADVANCE . BACK. or eatt)mg F EXIT a

Figure 2-93. Line segment to intersect with previous helix

To create the blend arc, the operator then inserted this blend arc segment between the two previously created segments.

BLOCK SEGMENT RADIUS F®

1 1 2

KILL CONTOUR BLED ABC 0.2508 15.8

(DIR ECTION (X START (Y START (X END (Y EE (X CENTER (V CENTER

CAL CAL CAL CAL CAL CAL

I F DELETE SEGMENT 1 i CCU) F INSERT SEGMENT 2.2268 ) 2 BEFORE 1 . 1361) l 2.44%) P 1.0800) 3 2.44%) l 1.7580) F PROGRAM 4 PARAMETERS M F FART SETUP 5 M F TOOL SETUP 6

F Enter a ugQet r soar , an ENTER to edit aegimnt. or uw ADVANCE . BACK , er o wr tkag

7 i F EXIT a

Figure2-94. Mill Contour Blend Are

2 - 124

Revision A

Hawk 5M Machine

Conversational Part Programming Here is a graphic representation of the helix with the intersection line and the blend arc the operator added between the two segments.

4.98 V

2.98

Blend Are added here I 8.98

-1.18 -3. 88

1.88

3.88

5.88

Figure2-95. Sample Blend Arc on the Graphics screen

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Operator' s Manual

Helix To create a helical segment in the data block, the operator presses the Helix (F4) softkey on the Mill Contour's New screen. Here is a completed helix segment:

BLOCX

1

HILL CONTOUR

SEGMENT

1

HELIX

DIRECTION

SWEEP MLLE

cu

X Em

2 . 2913

V END

1.0080

Z Em

0.0000

I

FEED

X CENTER

CAL

-0.1013

(X START

V CENTER

CAL

0.2853

IT START ( Z START

CAL

116.775 ® 15 . 0

F 4 -2.5000) I 1.0000) F FIND ANOTHER 0.0008) 5 CENTER POINT

2.5088

AADIl18

F 1 1 F 2 I' F 3

P 6

8 . 8080

LEAD

ANOTIEN CENTER POINT EXISTS P PREVIO US SEGMENT 7

Enter f.Mrate

P EXIT

e

Figure 2-96. MiU Contour Helix screen These fields define a helix:

Fields Direction X, Y, and Z End X & Y Center Radius

2 - 126

Definitions direction of the helix from the starting point. coordinates of the ending point of the helix. "X" and "Y" coordinates of the center point about which the helix is drawn. The dimension from the center point to the helix.

Lead

change in the Z axis dimension for each 360° of revolution of the helix.

Sweep Angle

total number of degrees in the helical arc to be cut and can be greater than 360 °. This angle value provides information for the calculation of the Z End value.

Feed

rate from the previous segment. This value can be kept or changed.

Revision A

, Hawk 5M Machine

Conversational Part Programming The control uses the automatic calculation feature to determine unknown points . When there are two possible solutions for an unknown coordinate, one of the "Another point exists " messages appears with one of the two possible solutions appearing in the data field for the unknown parameter. The operator usually displays the current solution on the graphics screen to evaluate it. To display the alternative solution , the operator presses the "Find another" softkey. In the example on the previous page, that softkey is the Find Another Center Point (F5) softkey . The operator can switch between the two solutions and examine both on the graphics screen to determine the better solution. To perform automatic calculations , the Ultimax system uses the data in the helix fields in the following ways:

Ultimax 3 System

•

The Z End and Sweep Angle values provide data to calculate the lead parameter.

•

The Sweep Angle is used to calculate the Z End value.

•

The X End, Y End and Lead values provide the Z End value.

•

The Z End and Lead values provide the X End , Y End and Sweep Angle values.

•

The X End, Y End , X Center and Y Center values supply the Radius value.

•

The Sweep Angle value and either the X or Y End point coordinate provide the unknown (X End or Y End ) end point value.

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Operator' s Manual

3-D Arc To create a three-dimensional arc segment , the operator presses the 3D Are (F5) softkey on the Mill Contour New screen. Then this screen appears: BLOCK

4

MILL CONTOUR

SWIThT

1

3D ABC

I F 1

X END

X POINT

8.0808

V END

Y POINT

8.8888 8.8000

Z END

8.0888

Z POINT

X CENTER

0 . 8888

FEED

V CENTER

6.0888

Z CENTER

8.0888

(X START (V START (Z START

F 2 1 F 3

0.8

F 4 1 . 8880) I. 2.8880) F 4.8880) 5

1

F 6

F PREY IOIS SEGMENT 7

Euter coordinate

F EXIT 8

Figure2-97. Mill Contour 3D Are screen

Important Do not confuse this Mill Contour feature with the 3-D Milling option. The 3D Arc feature is always included in the Ultimax 3 software; however, the 3-D Milling option must be purchased separately. If 3-D Milling is available on the machine, refer to the 3D Programming Instruction Manual for more information.

2 - 128

Revision A

Hawk 5M Machine

Conversational Part Programming These fields define a 3-D arc: Fields

Definitions

X, Y, and Z End

coordinates define the end point for the arc segment.

X, Y, and Z Center

coordinates define the center point for the arc segment.

X, Y, and Z Point

coordinates define the plane of the arc when it is 180° or greater. If the arc is less than 180°, these values are not needed.

Feed

rate from the previous segment. This value can be kept or changed.

This diagram shows the relationships of the coordinates to each other:

z Figure 2-98. 180°3-D Are

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Operator' s Manual To calculate the centerline of cutter movement, the operator follows these instructions: •

Depending on the axis being worked, X can be interchanged with Y or Z.

•

The X and Z points must be calculated for an X-Z arc.

•

The Y and Z points must be calculated for a Y-Z arc. (All arcs travel through at least two axes.)

•

To calculate the centerline in the X axis for a ball nose end mill, the operator uses this formula: X.

R(X.-X.)+X. R

Here are the elements of this formula: X. = X, =

Actual centerline dimension of cutter in X axis

X, =

X center point

R; =

Radius of arc minus'/ cutter diameter

R=

Radius of arc

Arc reference starting point in the X axis

Hints and Tricks Operators follow these guidelines when programming 3-D arcs: 1. Never program cut right or cut left cutter compensation into a block containing for a 3-D arc. 2. Always program the centerline of cutter movement. 3. Lower the tool calibration point by manually changing the Tool Zero reference point one-half the cutter diameter. For example, when the operator is using a 1/4" ball nose end mill with zero calibration of 2.2500" (ball tip touched to work surface), the new zero calibration is 2.3750" after manual change of reference . This change must be ed when entering Z Up and Z Start dimensions (which must include the value of this manual change to the reference point).

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Revision A

Hawk 5M Machine

Conversational Part Programming

Circle To mill a circle, the operator presses the Circle (F2) softkey on the New Block screen. Then this screen appears: BLOCK

1

1

TOOL

I

TYPE

ON

FINISH TOOL

I

MILL CIRCLE

B

Z START

0.0300

Z BOTTOM

-1.5888 0 .0

PLAICE FEED

K CENTER

0.BBBB

MILL FEED

V CENTER

0.0000

SPEED (RPM)

RADIUS

3 . 5000

PECK DEPTH (TOOL DIAMETER (TYPE

F DELETE BLOCK 1 F INSERT BLOCK 2 BEFORE

I

F 3 i 750 F 4 0 . 0000 r F 0.5000) 5 DRILL) I F 6 15.0

PROGRAM PARAMETERS PART SETUP TOOL SETUP

I

Enter a block aunber , use ENTER to edit block , or use ADVANCE . BACK , or sortkey

F 7 F EXIT B

Figure 2-99. Mill Circle screen

The block number for this operation is determined by the position of this data block in the program. Note that this operation does not contain segments. When the operator enters the Tool number for the operation, the Tool Diameter and Type parameters appear in parentheses on the right side of the screen. These values were entered during Tool Setup and cannot be changed during the part programming.

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Operator' s Manual

There are several softkey options available for the Type field: •

On (Fl) - locates the center of the tool on the programmed contour of the circle.

•

Inside (F2) - causes the tool to enter the part inside the contour of the circle and blend into the programmed contour using a 180° arc. Cutter compensation is automatically employed and the outside edge of tool follows the programmed contour. (The direction the tool travels depends upon milling direction.) The point where the tool enters the part is determined by the blend offset and the point where the tool is withdrawn is determined by the blend overlap and blend offset. (These parameters are defined in Program Parameters or Change Parameters.)

•

Outside (F3) - is similar to the Inside function, except the tool enters the part outside the programmed contour and follows the outside of the contour.

•

Inside Tangent (F4) - causes the tool to enter the part adjacent to the inside contour of the circle. Cutter compensation is automatically used and the edge of the tool follows the inside of the programmed contour. The direction the tool travels depends upon the milling direction. The tool is withdrawn from the part adjacent to the programmed contour.

•

Outside Tangent (FS) - is similar to the Inside Tangent function except that the tool enters the part adjacent to the outside contour of the circle. The tool's edge then follows the outside of the programmed contour. The tool is withdrawn from the part adjacent to the programmed contour.

•

Pocket Boundary (F6) and Pocket Island (F7) softkeys are displayed only if the UltiPocket software option is installed. Refer to the "Ultipockets" section for more information.

When On, Inside, Outside, Inside Tangent and Outside Tangent are selected, the tool enters the circle contour at the 3 o'clock position.

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Revision A

Hawk 5M Machine

Conversational Part Programming The remaining fields on this screen have these definitions: Fields Finish Tool

number of a tool used for finish . If a finish tool is selected, the first tool leaves the amount of material selected in Program Parameters Or Change Milling Parameters. The finish tool removes the remaining stock down to the programmed dimension.

X Center

"X" coordinate for the center point of the circle.

Y Center

"Y" coordinate for the center point of the circle.

Radius

this value with the X and Y center coordinates define the location and size of the circle.

Z Start

point above the part where the Z axis plunge feedrate begins.

Z Bottom Plunge Feed

Ultimax 3 System

Definitions

where the mill feed rate begins. rate at which the tool initially enters the part.

Mill Feed

is the X-Y feedrate. The value initially displayed has been calculated by the control and can be retained, or changed to a different value.

Speed (RPM)

the spindle speed for the tool calculated in Tool Setup. Entering a value here overrides the Tool Setup value for this data block.

Peck Depth

the maximum depth to be cut in one . If the total depth is greater than this value , multiple tool es occur. Programming a zero (0) value for this parameter causes the total programmed depth to be cut in one of the tool.

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Operator's Manual

Frame To mill a frame, the operator presses the Frame (F3) softkey on the New Block screen. Then this screen appears:

BLOCK(

1

TOOL TYPE POCKET TYPE FINISH TOOL

MILL FRAME I POCK BOUNDARY IMMRD B

Z START

8.am

Z BOTTOM

-0.5888

PLI116E FEED

30.0 58.6

K CORMDI

-4.7547

MILL FEED

Y CORNER

-4 . 7547

SPEED (RPM)

X LENIN

18 . 7238

PECK DEPTH

V LDCTH

9 . 5894

CORNIIX RADIUS

B . 88819

POCKET OVERLAP

(TOOL DIAMETER (TYPE

F DELETE BLOCK I F INSERT BLOCK 2 BEFORE I F 3

2588

P PR09UM 4 PARAMETERS I F PART SETUP 8.2590) 5 DRILL) I F TOOL SETUP 6 8.2588

58

Enter a block Dube'. uee BITER to edit block; or use ADVANCE . BACK. or eettke9

F 7 F EXIT 8

Figure 2-100. Mill Frame screen

The block number for this operation is determined by the position of this data block in the program. Note that this operation does not contain segments. When the operator enters the Tool number for the operation , the Tool Diameter and Type parameters appear in parentheses on the right side of the screen. These values were entered during Tool Setup and cannot be changed during the part programming.

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Revision A

Hawk 5M Machine

Conversational Part Programming The softkey selections for the Type field are as follows: •

On (Fl) - locates the center of the tool on the programmed contour of the frame.

•

Inside (F2) -causes the tool to enter the part inside the frame and blend into the programmed contour using a 180° arc. Cutter compensation is automatically employed and the edge of tool follows inside the programmed contour. (The direction the tool travels depends upon milling direction.) The point where the tool enters the part is determined by the blend offset and the point where the tool is withdrawn is determined by the blend overlap and blend offset. These parameters are defined in Program Parameters or Change Parameters. Here is an example of an Inside frame: Reference Comer

Figure 2-101. Inside Mil Frame Operuion

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Operator' s Manual

•

Outside (F3) - is similar to the Inside function, except that the tool enters the part outside the programmed frame contour and then follows the outside frame contour.

•

Inside Tangent (F4) - causes the tool to enter the part adjacent to the inside contour of the frame. Cutter compensation is automatically used and the edge of tool follows the inside of the programmed contour. The direction the tool travels depends on milling direction. The tool is withdrawn from the part adjacent to the programmed frame contour.

•

Outside Tangent (F5) - is similar to the Inside Tangent function except the tool enters the part adjacent to the outside contour of the frame. The tool's edge then follows the outside programmed frame contour. The tool is withdrawn from the part adjacent to the programmed frame.

•

Pocket Boundary (F6) and Pocket Island (F7) softkeys are displayed only if the UltiPocket software option is installed. Refer to the "Ultipockets" section for more information.

When On, Inside, Outside, Inside Tangent and Outside Tangent are selected , the tool enters the frame contour at the 6 o'clock position.

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Revision A

Hawk 5M Machine

Conversational Part Programming The remaining fields on this screen have these definitions: Fields

Definitions

Finish Tool

number of a tool used for finish . If a finish tool is selected, the first tool leaves the amount of material selected in Program Parameters or Change Milling Parameters. The finish tool removes the remaining stock down to the programmed dimension.

X Corner

"X" coordinate of any one of the four comers of the frame which then becomes the reference corner.

Y Comer

"Y" coordinate of the reference comer of the frame.

X Length

"X" coordinate for this dimension as measured from the reference comer. This value is positive or negative relative to the reference comer. If the reference comer is at the left side of the rectangle, the x length is a positive (+) dimension. If the reference comer is at the right side, this parame:.r value is a negative (-).

Y Length

"Y" coordinate for this dimension as measured from the reference comer. This value is positive (+) if the reference comer is at the lower left, or lower right of the rectangular area and is negative (-) if the reference comer is at the top left, or top right of the rectangle.

Figure 2-102. X & Y Length Directional Measurement

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Operator's Manual

Frame Fields

Definitions (continued)

Comer Radius

radius of the reference comer and is the same on all four comers.

Z Start

point where plunge feed rate begins and z bottom is where the mill feed rate begins.

Z Bottom Plunge Feed

2-138

where the mill feed rate begins. rate at which the tool initially enters the part.

Mill Feed

is the X-Y feedrate. The value initially displayed has been calculated by the control and can be retained or changed to a different value.

Speed (RPM)

the spindle speed for the tool calculated in Tool Setup. Entering a value here overrides the Tool Setup value for this data block.

Peck Depth

the maximum depth to be cut in one . If the total depth is greater than this value, multiple tool es occur. Programming a zero (0) value for this parameter causes the total programmed depth to be cut in one of the tool.

Revision A

Hawk 5M Machine

Conversational Part Programming

Face Milling To perform a face milling operation, the operator presses the Mill Face (F4) softkey on the New Block screen. Then this screen appears:

BLACK

$

1

MILL FACE

TOOL

1

TYPE

X 1MIDIRECTIOMAL

FINISH TOOL

8

Z START Z BOTTOM

-B.ZSBB

PLUNGE FEED

X WIRIER

9.0988

MILL FEED

Y WD®t

8.8®8

SPEED (RPM)

X LENGTH

9 . 8000

PECK DEPTH

x.0080

(TOOL DIAMETER (TYPE

V LENGTH

9.0299

Enter a block wuebw, use ENTER to edit block, or ua ADVANCE , BA CK . or se rtkey

5 .8 18.0 759 8 . 0000

I F DELETE BLOCK 1 i P INSERT BLOCS 2 BEFORE I F 3 j F PROGRAM 4 PARAMETERS

I

F PART SETUP 8.2508) S DRILL) I F TOOL SETUP 6 P 7 P EXIT a

Figure 2-103.. Completed Mill Face screen

The block number for this operation is determined by the position of this data block in the program. Note that this operation does not contain segments. When the operator enters the Tool number for the operation , the Tool Diameter and Type parameters appear in parentheses on the right side of the screen. These values were entered during Tool Setup and cannot be changed during the part programming.

Ultimax 3 System

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2 - 139

Operator 's Manual The operator uses these types to describe the path of the cutter. Each tool is 60% of the tool diameter from the previous . Material is removed using 60% of tool diameter, but the last may remove less material. The Type softkeys have these uses: •

X Unidirectional (Fl) - directs the tool to cut in one direction, parallel to the X axis and then move the spindle to the retract clearance value defined in Program Parameters or Change Parameters . Axis movement occurs at rapid traverse to return the tool to the start point of the next cutting path determined by the control.

n 11 n n n n It n R n

Blend Offset

' Unidirectional 'Y' Unidirectional

n

E3 IV LU D

O

.d

Blend Onset

O 'Y' Bidirectional

Figure 2 -104. Face Milling Types

The start point is the lower left or right corner of rectangular area, depending on the milling direction defined in Program Parameters or Change Parameters. The start point for each cut is the tool radius plus blend offset away from the starting edge comer.

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Hawk 5M Machine

Conversational Part Programming •

X Bi-directional (F2) - directs the tool to cut in one direction from the start point, parallel to the X axis. Axis positioning occurs to place tool over the next cutting path and cutting is in the opposite direction. The new cutting path for the tool is automatically determined by the control. The tool zigzags over the rectangular face area of the part, always using 60% of tool diameter (but the last may be less). The starting point is either the lower left or right comer of the rectangular area, depending on milling direction defined in Program Parameters or Change Parameters.

•

Y Unidirectional (F3) - directs the tool to cut in one direction, parallel to the Y axis and then move the spindle to the retract clearance value defined in Program Parameters,or Change Parameters. Axis movement occurs at rapid traverse to return the tool to the start point of the next cutting path determined by the control. Start point of operation is the lower left or right corner of rectangular area, depending on milling direction defined in Program Parameters or Change Parameters. The start point for each cut is the tool radius plus blend offset away from the starting edge corner.

•

Y Bi-directional (F4) - directs the tool to cut in one direction from the start point, parallel to the Y axis. Axis positioning occurs to place tool over the next cutting path and cutting is in the opposite direction. The new cutting path for the tool is automatically determined by control. The tool zigzags over the rectangular face area of the part, always using 60% of tool diameter (but the last may be less). The starting point is either the lower left or right comer of the rectangular area, depending on milling direction defined in Program Parameters or Change Parameters.

Ultimax 3 System

Revision A

2 - 141

i"

Operator' s Manual The remaining fields on this screen have these definitions: Fields Finish Tool

number of a tool used for finish . If a finish tool is selected, the first tool leaves the amount of material selected in the parameters. The finish tool removes the remaining stock down to the programmed dimension.

X Comer

"X" coordinate of any one of the four comers of the face which then becomes the reference corner.

Y Comer

"Y" coordinate of the reference comer of the face.

X Length

"X" coordinate for this dimension as measured from the reference corner. This value is positive or negative relative to the reference corner. If the reference corner is at the left side of the rectangle, the x length is a positive (+) dimension. If the reference comer is at the right side, this parameter value is a negative (-).

Y Length

"Y" coordinate for this dimension as measured from the reference comer. This value is positive (+) if the reference corner is at the lower left, or lower right of the rectangular area and is negative (-) if the reference corner is at the top left, or top right of the rectangle.

Z Start

point where plunge feed rate begins and z bottom is where the mill feed rate begins.

Z Bottom Plunge Feed Mill Feed

2 -142

Definitions

where the mill feed rate begins. rate at which the tool initially enters the part. is the X-Y feedrate.

Speed (RPM)

the spindle speed for the tool calculated in Tool Setup. Entering a value here overrides the Tool Setup value for this data block.

Peck Depth

the maximum depth to be cut in one . If the total depth is greater than this value, multiple tool es occur. Entering zero (0) value causes the total programmed depth to be cut in one of the tool.

5/1 8/94

Hawk 5M Machine

Conversational Part Programming

Ellipse To mill an elliptical shape , the operator presses the Mill Face (F4) softkey on the New Block screen . Then this screen appears:

BLOCX

I

I

MILL ELLIPSE

TOOL

I

TYPE

ON

FINISH TOOL

B

I F DELETE BLOCX Z START Z BOTTOM PLUNGE FEED

X CENTER

0.0880

MILL FEED SPEED ( RPM)

F CENTER

0.0800

X RADIUS

156 . 4260

PEX DEPTH

Y RADIUS

IS6.4268

(TOOL DIAMETER (TYPE

0.8100

1

-6.7580 F INSERT BLOCX 2 BEFORE 10.0 r F 79.8 3 i 1000 F PROGRAM 4 PARAMETERS 0.0000 I F PART SETUP 0.2500) 5 DRILL) I F TOOL SETUP 6

Enter a block nue^er, nee ENTER to edit block , or use ADVANCE . BAcx. or sottkey

F 7

fliT

F EXIT B

Figure 2-105. Mill Ellipse screen

The block number for this operation is determined by the position of this data block in the program. Note that this operation does not contain segments. When the operator enters the Tool number for the operation, the Tool Diameter and Type parameters appear in parentheses on the right side of the screen. These values were entered during Tool Setup and cannot be changed during the part programming.

Ultimax 3 System

Revision A

2 - 143

Operator' s Manual The operator uses the Ellipse types to describe the path of the cutter. These softkeys are used to select the type: •

On (Fl) - the center of the tool to follow the programmed elliptical contour.

•

Inside (F2) - directs the tool to enter the part inside the ellipse and then blend into the programmed contour. Cutter compensation is employed and the tool's edge follows the inside of the elliptical contour. The tool enters the part at the larger area of either the 3 o'clock, or 6 o'clock position. Direction of tool travel depends on milling direction as defined in Program Parameters or Change Parameters. The tool enters the part as defined by the elliptical pattern and blend offset. The tool is removed from the part as determined by the pattern, blend offset and blend overlap. (Blending is defined in Program Parameters and Change Parameters.)

Figure 2-106. Mill Ellipse - inside Type

•

2 - 144

Outside (F3) - is similar to the Inside function, except the tool enters the part outside the programmed elliptical contour.

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-

Hawk 5M Machine

Conversational Part Programming

Ultimax 3 System

•

Inside Tangent (F4) - programs the tool to enter the part adjacent to the inside contour of the ellipse. Cutter compensation is employed and the edge of tool follows the inside of the programmed elliptical contour. The direction the tool travels depends on milling direction. The tool is withdrawn from the part adjacent to the programmed contour.

•

Outside Tangent (F5) - is similar to the Inside Tangent function except the tool enters the part adjacent to the outside contour of the ellipse. The tool' s edge then follows the outside of the programmed contour. The tool is removed from the part adjacent to the programmed elliptical contour.

•

The Pocket softkeys clean out all material within the programmed elliptical contour. The tool enters the part at the center of the ellipse and moves out to the perimeter (cleaning out the entire area). The overlap for each tool path is programmable from 0% to 99% (determined by the pocket overlap value).

Revision A

2 - 145

Operator' s Manual The remaining fields on this screen have these definitions: Fields Finish Tool

Definitions number of a tool used for finish . If a finish tool is selected, the first tool leaves the amount of material selected in the parameters . The finish tool removes the remaining stock down to the programmed dimension.

X Center

"X" coordinate of the center of the ellipse.

Y Center

"Y" coordinate of the center of the ellipse.

X and Y Radius

identify the major and minor axes for the ellipse, respective to the appropriate axis. Major and minor axes of the ellipse must be programmed parallel to these respective axes of the machine. An ellipse with the major and minor axes nonparallel to the machine can be programmed by employing the Pattern - Loop Rotate routine. The ellipse is rotated after it is initially programmed.

Z Start

point where plunge feed rate begins and z bottom is where the mill feed rate begins.

Z Bottom

where the mill feed rate begins. The value initially displayed has been calculated by the control and can be retained, or changed to a different value.

Plunge Feed Mill Feed

rate at which the tool initially enters the part. is the X-Y feedrate.

Speed ( RPM) the spindle speed for the tool calculated in Tool Setup. Entering a value here overrides the Tool Setup value for this data block. Peck Depth

. 2 - 146

the maximum depth to be cut in one . If the total depth is greater than this value , multiple tool es occur. Entering zero (0) value causes the total programmed depth to be cut in one of the tool.

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Hawk 5M Machine

Conversational Part Programming

Lettering This routine permits milling up to thirty (30) block characters selected from the graphics screen. Selection is made from a 64 character set, consisting of upper case letters, digits, 27 different symbols and a space. This data block may be rotated, mirror-imaged (for mold use), or repeated in Patterns. Cutter compensation is not available for this routine, so milling is performed using the centerline of the tool. To enter a lettering block, the operator selects the Lettering (F6) softkey from the New Block screen. Then this screen appears:

BLOCK

!

33

HILL LETTERING

TOOL

8

Z START

X START

-0.85811

Z BOTTOM

V START

-1.9780

PLUNGE FEED

HEIGHT

0.1699

MILL FEED

CHARACTER WIDTH

S. 12M

SPEED (RPM) PECK DEPTH (TOOL DIAMETER (TOR

ULTIHAK 111

8.82910

F DELETE BLOCK 1

F IHSRRT BLOCK 2 BEFORE 5.0 I F 38.0

-0.8188

6988 P PROGRAM 4 PARAMETERS 0.8090 I F PART SETUP 8.0625) 5 END MILLI i F TOOL SETUP 6

Enter a block mober . ece ENTER to edit block. er uee ADVANCE . BACK. or eoftkey

F 7 8

Figure 2-107. Mill Lettering screen

Ultimax 3 System

Revision A

2 - 147

Operator' s Manual The fields on this screen have these definitions: Fields

Definitions

X Start

"X" coordinate for the lower left-hand corner of the first character to be milled.

Y Start

"Y" coordinate for the lower left-hand comer of the first character to be milled.

Height

determines the character size.

Character Width

determines the character size. Width includes the character left justified, plus some spacing between it and the next character to be milled. Spacing between the characters is equal to the tool diameter. Because cutter compensation is not used in this routine and letter contouring follows the center of the tool, character spacing can be adjusted by adjusting tool diameter in Tool Setup.

Z Start

point where plunge feed rate begins and z bottom is where the mill feed rate begins.

Z Bottom

where the mill feed rate begins. The value initially displayed has been calculated by the control and can be retained, or changed to a different value.

Plunge Feed Mill Feed

2 - 148

rate at which the tool initially enters the part. is the X-Y feedrate.

Speed (RPM)

the spindle speed for the tool calculated in Tool Setup. Entering a value here overrides the Tool Setup value for this data block.

Peck Depth

the maximum depth to be cut in one . If the total depth is greater than this value, multiple tool es occur. Entering zero (0) value causes the total programmed depth to be cut in one of the tool.

5/18/94

Hawk 5M Machine

Conversational Part Programming The operator uses the trackball and Select console key to indicate (and enter) the characters and spaces from the Letter Selection screen. Then these selections appear on the text line on the left-hand screen. When the graphics cursor indicates the desired character or space, press Select key to display the character on the text screen. To delete a character from the text field, move the graphics cursor to the back space box in the grid and press the Select key (each depression removes one character or space). The console keyboard can also be used to program numbers, decimal points, and keyboard symbols into the field by pressing the respective key.

Ultimax 3 System

Revision A

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Operator' s Manual

3-D Milling Option The 3-D Milling option is purchased separately from the basic Ultimax 3 software. To enter a 3-D milling block, the operator presses the 3D Contour (F7) softkey on the New Block screen. The Mill 3D screen (shown below) appears allowing the operator to describe the operation.

BLOCX

0

13

I

MILL 3D

F DELE TE BLOCX TOOL

1

TYPE

REVOLVE ABOUT X

CENTERLINE V

8 . 8888

CRITERLINE E

- 1.1880

START ANGLE Elm ANGLE

36.500 143 . 580

CUT DIRECTION WITH CONTOUR

Z START PLUNGE FEED

STEP SIZE

38.0

MILL FEED

F INSERT BLOCK 2 BEFORE

180 . 8

SPEED (RPM)

3688

F 3

PECK DEPTH

8.8808

STOCK ALLOUJICE

0 . 8808

(TOOL DIAMETER

0.3758) 5

(TYPE

BIDIRECTIONAL

8.0288

BALL END BILL)

YES

F PROGRAM 4 PARAMETERS I F PART SETUP I F TOOL SETUP 6

8 . 8188

Enter a block amber . use ENTER to edit block, or use ADVANCE . BACK . or softkey

P 7 F EXIT 8

Figure 2-108. Completed Mill 3 -D screen

For complete 3-D programming information , refer to the Programming Instruction Manual sent with the optional software.

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5/18/94

3D

Hawk 5M Machine

Conversational Part Programming

Sample Milling Program In this milling example, the finished part has a frame cut .15" around the outer edge of the part. The work piece is .65" thick. The bottom of the milled pocket on the left is .4" from the surface of the part. The elliptical shape on the right is milled .2" deep. The operator will be using a .201 (#7) drill and a 3/8 end mill. Here is the drawing used to create the program: Drill (8 Plaees)Through 3/8

C'Bore . 5 Deep (7 Places)

7_ 6 .5

80.2543

.51

®

® 1.72

T 80.2476®

III F- 25

1 .075 R (4 Places)

t-- 2.25--J 4

Figure 2-109. Pan drawing used in the sample Wiling program

Ultimax 3 System

Revision A

2 - 151

Operator' s Manual Here is a copy of the part program developed for the drawing on the previous page. Since Ultimax allows considerable flexibility in.developing part programs, this is not the only way the part can be programmed. Watch for inserted explanations of the special features of this sample program. Hurco Ultimax Part Program Milling.HD3

1

Inch Standard

Part Setup Part Zero X

5.0000

Y

10.0000

Z

0.0000

Offset

Safety Work Region Z Top (•) Z Bottom C- ) X Left C -) X Right C• ) Y Front C- ) Y Back C+l Fixture Offset

99.0000 - 1.0000 -99.0000 99.0000 -99.0000 99.0000 I

General Parameters Retract Clearance Rapid Traverse Peck Clearance Plane Chord Error Depletion Retract

1.0000 IN 400.0 IPM 0.0500 IN 0.0001 IN 0.0050 IN

Holes Parameters Bore Orient Retract Drill Dwell Bore Due 11

0.0200 IN 0.5 SEC 1.0 SEC

Milli ng P arame t ers Blend Offset

0.1250

IN

Blend Overlap Finish Feed Finish Speed Finish XY

0.1250 100 100

IN % i

0.1250 IM 0.0000 IM Climb 10 Insert Arc

Finish Z Milling Direction Pocket Overlap

Cutter Comp Parameter

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Hawk 5M Machine

Conversational Part Programming Hurco Ultimax Part Program Milling .HD3

Inch Standard

2

Program Parameters Off Partial Yes

Ouerride Lockout Program Protect Tool Change Position Tool Setup 1

Type Diameter Zero Calibration Speed ( RPM) Coolant Gear range Tool Humber Diameter Offset Length Offset

Drill 0.2010 - 10000. 2000 CW Off 1 1 1 1

2

Type Diameter Zero Calibration Speed ( RPM) Coolant Gear range Tool Humber Diameter Offset Length Offset

End Mill 0.3750 - 10000. 1000 CW Off I 2 2 2

99

Diameter Zero Calibration Speed ( RPM) Coolant Gear range Tool Humber Diameter Offset Length Offset

0.0000 -10000. 0 CW Off 1 99 99 99

There is no tool #99 available . The operator added a tool setup for tool #99 to use as a dummy tool for drawing purposes only.

Ultimax 3 System

Revision A

2 - 153

Operator' s Manual Hurco Ultimax Part Program Milling.HD3

3

Inch Standard

Data Blocks 1

Mill Frame Tool Type Finish Tool X Corner Y Corner

99 Out/Tan 0 0.0000 0.0000

Z Start Z Bottom Plunge Feed Mill Feed Speed (RPM)

X Length

7.0000

Peck Depth

0.0000 -0.7500 0.0 0.0 0 0.0000

Y Length Corner Radius Lead Length

3.000 0.0000 0.0000

Lead Angle

0.0000

This block creates an outline of the part on the graphics screen to use as an outline during programming. The operator will delete this block before cutting the part. 2

Holes Drill Tool 2 Start 2 Bottom Plunge Feed Speed (RPM) Peck Depth Peck Type

1 0.0200 -0.9000 10.0 2000 0.4600 Standard

Bolt Circle Humber X Center Y Center Radius Start Angle

8 4.0000 1.5000 0.8600 0.000

Skip List

Block 2 drills the holes first using tool 1.

2-154

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Hawk 5M Machine

Conversational Part Programming 4

Hurco Ultimax Part Program Milling.HD3

Inch Standard

Data Blocks 3

Mill Frame Tool Type Finish Tool X Corner Y Corner X Length Y Length Corner Radius Lead Length

2 Outside 2 0.2500 0.2500 6.5080 2.5000 0.0750 0.0001

Z Start Z Bottom Plunge Feed Mill Feed Speed ( RPM) Peck Depth

0.0200 -0.1500 10.0

10.0 1000 0.0000

Lead Angle

0.0000

The finish tool is used for two es to remove corner material . Refer to the program parameters shown earlier in the program. 4

Change General Parameters Retract Clearance Rapid Traverse Peck Clearance Plane Chord Error Depletion Retract

1.0000 IN 400.0 IPM 0 . 0500 IN 0.0001 IN 0.0050 IN

Bore Orient Retract Drill Dwell Bore Dwell

0 . 0200 IN 0.5 SEC 1.0 SEC

Blend Offset Blend Overlap Finish Feed

0.1250 0.1250 100

Change Holes Parameters

Change Milling Parameters

100

Z

0 . 0150 0.0050

IN IN

Finish Speed Finish XY Finish Z

IN IN i

Milling Direction Pocket Overlap

Climb 10 Z

This change parameters block restores the program parameters.

Ultimax 3 System

Revision A

2-155

Operator' s Manual Hurco Ultimax Part Program Milling.HD3

5

5

Mill Contour Segment Tool Cutter Comp Finish Tool

0

Start 2 Pock Boundary 2 2.2500 1.5000 0.0200 -0.4000 40

X Start Y Start

2 Start 2 Bottom Pocket Ouerlap

2 - 156

Inch Standard

Segment X End Y End XY Length XY Angle

I

Segment Radius

2

3

Segment Radius

4

10.0 10.0 1000 0.0000

Line CAL

Segment X End Y End XY Length XY Angle

Plunge Feed Mill Feed Speed (RPM) Peck Depth

2.2500 2.2500 0.7500 90.000

Blend Arc 0.2543

Line CAL CAL CAL

(Direction CX Start CY Start (X End (Y End CX Center CY Center

CAL CAL CAL CAL CAL CAL

CCW) 2.2500) 1.9957) 1.9957) 2.2500) 1.9957) 1.9957)

0.5000 2.2500 1.7500 180.000

Blend Arc 0.5100

5/18/94

( Direction

CCW)

(X Start

CAL

1.0100)

(Y (X CY (X (Y

CAL CAL CAL CAL CAL

2.2500) 0.5000) 1.7400) 1.0100) 1.7400)

Start End End Center Center

Hawk 5M Machine

Conversational Part Programming

Segment X End Y End XY Length XY Angle

5

Segment Radius

6

Segment X End Y End XY Length XY Angle

7

Segment Radius

8

Segment X End Y End

XY Length XY Angle

Ultimax 3 System

9

Inch Standard

6

Hurco Ultimax Part Program Milling . HD3 Line CAL CAL

0.5000 0.7500 1.5000 -90.000

Blend Arc 0.5100

Line CAL CAL

(Direction CX Start CY Start CX End CY End CX Center CY Center

CAL CAL CAL CAL CAL CAL

CCW) 0.5000) 1.2600) 1.0100) 0.7500) 1.0100) 1.2600)

(Direction CX Start (Y Start CX End

CAL CAL CAL

CCW) 2.0024) 0.7500) 2.2500)

CY End

CAL

0.9976)

CX Center (Y Center

CAL CAL

2.0024) 0.9976)

2.2500 0.7500 1.7500 0.000

Blend Arc 0.2476

Line 2.2500 1.5000

CAL

0.7500 90.000

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Operator' s Manual Hurco Ultimax Part Program Milling.HD3

6

Mill Ellipse Tool Type Finish Tool X Center Y Center X Radius

Y Radius 7

7

Inch Standard

2 Pocket 0 5.8820 1.5000 0.5000 1.0000

Z Start Z Bottom Plunge Feed Mill Feed Speed ( RPM) Peck Depth

0.0200 -0.2000 10.0 10.0 1000 0.0000

2 Inside 0 5.8820 1.5000 0.4500 0.0001

2 Start Z Bottom Plunge Feed Mill Feed Speed ( RPM) Peck Depth Lead Angle

-0.1800 -0.7600 10.0 10.0 1000 0.2867 0.0000.

Mill Circle

Tool Type Finish Tool X Y X Y

Center Center Radius Radius

Note that the Z Start is below part zero in block #7. This is acceptable if the Retract Clearance parameter is large enough to clear the part for the next block. 8

Holes Counterbore Tool Z Start 2 Bottom Plunge Feed Speed CRPM) Peck Depth Peck Type Bolt Circle Humber X Center Y Center Radius Start Angle

2 - 158

2 0.0200 -0.5000 5.0 1008 0.0000 Standard

8 4.0000 1.5000

Skip List 4

0.8600 0.000

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Conversational Part Programming

Pattern Operations This section presents detailed descriptions of the Pattern options in Ultimax 3. Operators use pattern operations to save programming time by duplicating part geometry to complete a part program or create multiple parts from one program. The chart below shows the relationship of the pattern options to the Input button and its subsequent menu selections.

Pattern Options Hierarchy Chart Input Button

Part Setup (Fl ) Tool Setup (F2) Part Programming (F3) Position (Fl) Holes (F2) - Loop Rectangular (Fl) Milling (F3) - Loop Linear (F2) Patterns (F4) - Loop Angular (F3) Miscellaneous (F5) Loop Rotate (F4)

Special (F6) Rotary (F7)

- Pattern Locations (F5) - Scale (F6)

Exit (F8)

- Mirror Image (F7) -Pattern End (F8) Figure 2-110. Pattern Options Hierarchy Chart

Ultimax 3 System

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Operator' s Manual Pattern operations repeat or modify a sequence of data blocks. To access the pattern programming options, press the Part Programming (F3) softkey and press the Patterns (F4) softkey to display this screen:

BLOCK

1

I NEW BLACK

I P 1) LOOP 1 AECTANQUAR F 2) LOOP LINEAR 2 F 3) LOOP ANGULAR 3 F 4) LOOP ROTATE 4 i F 5) PATTERN 5 LOCATIONS P 6) SCALE 6 P 7) MIRROR IMAGE 7

Choose two of block

F 0) PATTERN END 8

Figure 2-111. Pattern Soft keys

These softkey options are available:

2 - 160

•

Loop Rectangular (Fl) - used to repeat a pattern along lines parallel to the X and Y axes.

•

Loop Linear (F2) - used to repeat a pattern along a line defined in the XY plane.

•

Loop Angular (F3) - used to repeat a pattern along a circular path.

•

Loop Rotate (F4) - used to repeat pattern along a circular path. The pattern is rotated around the XY center point and only executed in specified locations.

•

Pattern Locations (F5) - lists the locations where a pattern will be repeated. The operator may enter up to 999 different locations.

•

Scale (F6) - reduces or increases the size of a pattern by a factor ranging from 10% to 1000%.

•

Mirror Image (F7) - copies an existing part as a mirror image to create a new part.

•

Pattern End (F8) - the last block in any pattern operation.

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Conversational Part Programming

Hints and Tricks The following basic pattern principles help operators to program Pattern data blocks successfully: 1.

The block defining the operation to be performed must be inserted before the first block of the sequence being repeated or modified.

2.

The last data block in the sequence (being repeated or modified) must be followed by a Pattern End data block.

3.

The number of Pattern End blocks must equal the number of pattern routines.

4.

A pattern sequence can be nested up to ten deep (i.e., entirely contained within another pattern).

5.

If Pattern sequences are nested, the control executes the innermost patterns first, as in the following example: Data Block #1 - Pattern Scale Data Block #2 - Pattern Rotate Data Block #3 - Pattern Mirror Image Data Block #4 - Mill Contour Data Block #5 - Pattern End Data Block #6 - Pattern End Data Block #7 - Pattern End When the system executes these four blocks, the mill contour is mirrored . The mirrored image(s) are rotated one or more times; and the whole rotation pattern is then scaled.

6.

To prevent excessive tool changes , the operator should program only one tool for each pattern sequence . Here is sample list of operations that could be used to create a seven-hole bolt circle in one data block that can then become the pattern: Data Block #1 :

- Center Drill Drill Countersink Tap Bolt Circle

Ulumax 3 System

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Operator' s Manual 7.

Then the operator can use the bolt circle data to create a pattern by programming a Patterns Locations and a Pattern End around each tool as follows: Data Block #1 -

Pattern Location

Data Block #2 -

Center Drill Bolt Circle

Data Block #3 Data Block #4 -

Pattern End Pattern Location

Data Block #5 -

Drill Bolt Circle

Data Block #6 -

Pattern End

Data Block #7 -

Pattern Location

Data Block #8 -

Countersink Bolt Circle

Data Block #9 -

Pattern End

Data Block #10 -

Pattern Location

Data Block #11 -

Tap Bolt Circle

Data Block #12 -

Pattern End Data Block

To move the bolt circle data block, shown in #6 on the previous page, to another location on the part, a Patterns Locations block can be programmed and inserted before the bolt circle block. However, if the Patterns Locations block is programmed before the bolt circle block and a Pattern End after it, a tool change is required for each tool during each Bolt Circle sequence.

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Conversational Part Programming

Loop Rectangular This routine allows a given pattern to be repeated a specified number of times along lines parallel to the X and Y axes. The original pattern is always milled at its programmed location. Y Axis X Number = 3 Y Number = 2

I

Y

kX Distance-

Distan^^

X Axis

Original Pattern Figure 2-112. Sample Loop Rectangular operation

Ultimax 3 System

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Operator's Manual To display the Pattern Loop Rectangular screen, the operator presses the Fl softkey. Here is a completed screen.

BLOCK

•

1

K NUMBER

PATTERN LOOP RECTANGULAR F DELETE BLOCK 1

6

V NUMBER

2

X DISTANCE

1.2500

V DISTANCE

-2.5088

F INSERT BLOCK 2 BEFORE I F 3 F PROGRAM 4 PARAMETERS P F PART SETUP 5 i F TOOL SETUP 6

Enter a block ausber . use ENTER to edit block . or use ADVANCE . BACK , or sattkey

P 7 f F EXIT B

Figure 2-113. Pattern Loop Rectangular screen

The fields on this screen hold this information about the pattern: Fields

2-164

Definitions

X Number

number of times the programmed routine will be. repeated along a line parallel to the "X" axis.

Y Number

number of times the programmed routine will be repeated along a line parallel to the "Y" axis.

X Distance

distance between the patterns along the "X" axis lines. (Negative values indicate direction.)

Y Distance

distance between the patterns along the "Y" axis lines. (Negative values indicate direction.)

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Hawk 5M Machine

Conversational Part Programming

Loop Linear This routine allows a given pattern to be repeated a specified number of times along a line defined in the "X-Y" plane. Even though the defined line of this pattern is not parallel to the X or Y axes, the original pattern is always milled at its programmed location and orientation does not change with respect to the X and Y axes. An example of this type of routine is shown below.

Y Axis

X Axis

Figure 2-114. Sample Loop Linear operation

Ultimax 3 System

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Operator' s Manual To access the linear pattern screen, the operator presses the Loop Linear (F2) softkey. The Block number shown in the upper left corner of the screen is determined by the position of this data block in the program.

BLOCX

2

PATTERN LOOP LINEAR F

NUMBER

1

X DISTANCE

1.8600

V DISTANCE

-2.8600

ANGLE

F 2 F 3

• -63.435

DISTANCE

2.2361

F PROGRAM 4 PARAMETERS i F PART SETUP 5

Enter angle of linear repeats, counterclocbiae Mean 3 O'clock

F TOOL SETUP 6 i F 7 F EXIT B

Figure 2-115. Loop Linear screen

The fields on this screen hold this information about the pattern: Fields

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Definitions

Number

the number of times the pattern will be repeated along the defined line.

X Distance

distance between the repeated pattern in the direction of the X axis (+ or -).

Y Distance

distance between the repeated pattern in the direction of the Y axis (+ or -). If this or the X Distance measurements are entered, the control automatically calculates the remaining two values (indicated by "CAL" preceding the value. The calculated values may be stored by pressing the Enter key when the cursor is on the field. If the operator does not want to use the calculated value, the operator may type in a different value.

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Hawk 5M Machine

Conversational Part Programming Here are the remaining Loop Linear fields: Fields

Definitions (continued)

Angle

angle (in degrees) between the defined line and the X positive axis. A positive value is counterclockwise (CCW) from 3 o'clock position, and a negative value is clockwise (CW) from the 3 o'clock position.

Distance

the dimensional value between repeated patterns along the defined line.

The operator must also program a Pattern End data block for the sequence that is repeated in this Loop Linear block.

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Operator' s Manual

Loop Angular This routine allows a programmed pattern to be repeated a specified number of times along a circular path. Pattern orientation does not change with respect to the X and Y axes. The original programmed pattern is not executed at its original position, unless the routine places it at that location. The pattern is only shown in the locations specified by the routine. Y Axis

X & Y Center Points

Figure 2-116. Sampk Loop Angular operation

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Conversational Part Programming To access the angular pattern screen, the operator presses the Loop Angular (F3) softkey. Here is s completed Pattern Loop Angular screen:

BLOCK

PATTERN LOOP ANGULAR

3

F 1

1

MIR®ER X CENTER

1.0888

V CENTER

-3.0888

2 START ANGLE

98.880

ROTATE ANGLE

18.888

F 3 F PROGRAM

4 PARAMETERS X REFERENCE

4.0888 F PART SETUP

V RSPEIHICE

•

2.8888 F TOOL SETUP 6 F

Enter refcn..c point of Pattern F EXIT 8

Figure 2-117. Pattern Loop Angular screen

Fields Number

Definitions number of times the pattern is repeated along the specified circular path.

X Center

"X" coordinate of the reference point about which the pattern is rotated.

Y Center

"Y" coordinate of the reference point about which the pattern is rotated.

Start Angle

angle value between the original pattern and the location of the first pattern created by this routine.

Rotate Angle

the angle between the repeated patterns being executed by this routine.

X Reference

"X" coordinate of the reference point (the only point in the pattern always on the circular path defined by this routine).

Y Reference

"Y" coordinate of the reference point (the only point in the pattern always on the circular path defined by this routine).

The operator must also program a Pattern End data block for the sequence that is repeated in this Loop Angular block.

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Operator' s Manual

Loop Rotate This routine is similar to the Loop Angular and allows a programmed pattern to repeated along a circular path defined in the program. However, the Loop Rotate operation rotates the pattern around the X-Y center point and executes the pattern only at the locations identified in the program. Y Axis

X Axis

Figure 2-118. Sample Loop Rotate operation

Important The original programmed pattern is not executed at its original position, unless this routine places it at that location. The pattern is only shown in the locations specified by the routine.

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Conversational Part Programming To access the angular pattern screen, the operator presses the Loop Rotate (F4) softkey. Here is s completed Pattern Loop Rotate screen:

BLOCK

PATTERN LOOP ROTATE

4

I

1

MURDER X GOITER

1 . 0000

V COTTER

-3 . 0000 90.000

START ANGLE

5.000

ROTATE MCLE

I F DELETE BLOCK 1 F INSERT BLOCK 2 BEFORE i F 3 F PROGRAM 4 PARAMETERS

F PART SETUP 5 I F TOOL SETUP

6 Enter a block member, use OTTER to edit block . or use ADVANCE . BRCS. or softkey

F 7 I

F EXIT e

Figure 2-119. Pattern Loop Rotate screen

The fields on this screen hold this information about the pattern: Fields Number

Definitions number of times the pattern will be repeated along the specified circular path.

X Center

"X" coordinate used to define the circular path of the repeated pattern.

Y Center

"Y" coordinate used to define the circular path of the repeated pattern.

Start Angle

angle value between the original pattern and the location of the first pattern created by this routine. If this location is the same as the original programmed pattern, the value in this field will be zero.

Rotate Angle

the angle between the repeated patterns being executed by this routine.

The operator must also program a Pattern End data block for the sequence that is repeated in this Loop Rotate block.

Operator' s Manual

Pattern Locations This routine allows a programmed pattern to be repeated up to 999 different locations . The pattern is repeated by offsetting the pattern with each displacement specified in the list of locations. To display the Pattern Locations screen , the operator presses the Pattern Location (F5) softkey.

BLOCK

1

21

S

PATTERN LOCATIONS F DELETE LOCATION

X OFFSET

V OFFSET

Z OFFSET

1.0880 1.8000

0.0000 0.0000

0.0800 -0.7500

P INSERT LOCATION 2 BEFORE FI. 3 F 4 Fl S F

Enter an offset to cove the pattern to a vier location F EXIT 8

Figure 2-120. Pattern Locations screen

The fields on this screen hold this information about the pattern: Fields

Definitions

X Offset

location where the pattern is to be executed in the X axis. If this is Location # 1 and the pattern is to be at its original location, this coordinate must be zero. The value for this parameter is the offset for the X axis.

Y Offset

location where the pattern is to be executed in the Y axis. If this is Location #1 and the pattern is to be at the original location, this coordinate must be zero. The value for this parameter is the offset for the Y axis.

Z Offset

dimensional offset for the Z axis used when a vise or other fixture holds multiple parts at different levels.

The operator must also program a Pattern End data block for the sequence that is repeated in this Loop Locations block.

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Conversational Part Programming

Scale This routine allows a programmed pattern to be scaled -down or scaled-up to a programmed factor ranging from 0.100 to 10.000 (10% to 1000% respectively). Scaling is executed around the specified X, Y and Z coordinates for the point in the pattern where scaling occurs. Original Pattern

Original Pattern

X Scale = 0.5 Y Scale = 0.5

X Reference Y Reference

X Reference Y Reference

Figure 2-121. Sample Loop Angular operation

Ultimax 3 System

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Operator' s Manual To display the Pattern Scale screen, the operator presses the Scale (F6) softkey.

BLOCK X REFBKBtICE

7

PATTERN SCALE I

F 1

0.8808

V REFERENCE

8.0000

2 REFERENCE

0.0008

X SCALE

1.000

V SCALE

1. 000

2 SCALE

1.8100

F 2 F 3 F PROGRAM 1 PARAMETERS F PARS SETUP 5 F TOOL SETUP 6 F 7

Enter center point of ncaling

F EXIT a

Figure 2-122. Pattern Scale screen

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Conversational Part Programming The fields on this screen hold this information about the pattern: Fields

Definitions

X Reference

"X" coordinate of the point from which the scaling will be performed.

Y Reference

"Y" coordinate of the point from which the scaling will be performed.

Z Reference

"Z" coordinate of the point from which the scaling will be performed.

X Scale Factor

scaling factor from the "X" axis. If scaling is not executed from this axis, enter 1.0000. A value that is less than 1.0000 scales down the pattern. Greater than 1.0000 scales up the pattern.

Y Scale Factor

scaling from the "Y" axis operates in the same manner as the "X" axis factor.

Z Scale Factor

scaling from the "Z" axis operates in the same manner as "Y" and "X" axes' scaling.

The operator must also program a Pattern End data block for the sequence that is repeated in this Loop Locations block.

Important If the "X" and "Y" Scale Factors are different, the system will not perform cutter compensation . Only centerline tool programming can be used. If the operator selects cutter compensation for a block with different "X" and "Y" scaling factors , the system displays the error message , "Error in block # Cutter Comp with different XY scaling." This error prevents the part program from running.

Ultimax 3 System

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Operator' s Manual

Mirror Image This pattern routine allows a part to be programmed as a minor image of an existing programmed part. The routine can be programmed to execute either of these options: •

Only the mirror image Or

•

Original part and the mirror image

The mirror image about a line defined in the routine as shown in the example operation shown below. Y Axis

Original Part

Mirrored Part

4.00

4.00

gle . 90`

2.00 X Axis

2.00

Mirror Line

Figure 2-123. Mirror Image example

In this example, the X coordinate is 2.00, and the "Y" coordinate can be any value because the angle is 90 ° and the mirror line travels in the "Y" axis indefinitely . The mirror line is identified by a point and an angle because a single point identified on the axis cannot define a line. The mirror line shown above is parallel to the Y axis , so the angle is 90°. As with all patterns, the operator must also program a Pattern End data block for the sequence that is repeated in the Mirror Image block.

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Hawk 5M Machine

Conversational Part Programming If the original part is programmed to use conventional milling in Program Parameters or Change Parameters , the mirror image part is also executed with conventional milling. If climb milling produced the original part, climb milling executes the mirror image part.

To display the Pattern Mirror Image screen, the operator presses the Mirror Image (F7) softkey.

BLOCII

R

PATTERN MIRROR IMAGE

DO ORIGINAL

I NO

X

0.0888

V

R.RRR9 F 3I

9.088

ANGLE

F PROGRAM 1 PARAMETERS F PART SETUP 5 F TOOL SETUP 6 F 7

Do original pattern too?

F Exit a

Figure 2-124. Pattern Mirror Image screen

The fields on this screen hold this information about the pattern: Fields

Definitions select "Yes" for this field is the original will be cut as well as the mirror image . If only the mirror image is to be produced, select "No" for this field. the "X" coordinate for a point on a line about which this routine occurs as measured from part zero to the mirror line.

the "Y" coordinate for the same point. to complete the identification of the line , enter the orientation in degrees of the mirror line (which es through the X-Y dimensions above ). This is measured from the 3 o 'clock position . A positive value is CCW..

Ulumax 3 System

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I

Operator' s Manual

Pattern End The last data block in the operation sequence must be followed by a Pattern End block. The block that defines the pattern operation to be performed must precede the first block of the sequence and an end block must follow the last data block in the sequence.

Important There must be an equal number of Pattern and Pattern End blocks. To display the Pattern End screen, press the Pattern End (F7) softkey.

BLOCa

0

9

PATTERN END F DELETE BLOCK

P INSERT BLOCK 2 BEFORE F a F PROGRAM 4 PARAMETERS F PART SETUP 5 . P TOOL SETUP 6 Enter a block nuwber. no ENTER to edit block, ar use ADVANCE. RACE. or sot flay

P 7 P EXIT R

Figure 2-125. Pattern End screen

There are no fields to enter in this data block. The block is simply a marker at the end of the sequence of data blocks used to execute an operation that is being repeated or that is modified by a pattern operation. The operator may wish to press the Review console key to view a summary of part program and determine the required positioning of the Pattern End data blocks. that the Advance and Back arrow keys on the console can be used to scroll through the blocks in a part program and the Insert Block Before (F2) softkey can be used to insert a Pattern End block before a displayed program block.

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Conversational Part Programming

Sample Pattern Program The following sample program creates the same part used in the earlier hole drilling example; however, this version uses pattern techniques. It may be useful to compare the two programs. The job calls for drilling twelve holes with a 3/8" drill through a rectangular piece of alloy steel as shown in the diagram below: Part Zero

A

.75"

4" 2.5"

8.25" Material: Alloy Steel 8.25" x 4" x 25"

Tools 1/8" Center Drill 3/8" Drill

HSS HSS

Feeds 4.2 5.6

Speeds 2800 930

Figure 2-126. Part used in the sample Pattern program

Ultimax 3 System

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Operator' s Manual Here is a copy of a printed pan program developed for the drawing on the previous page. Since Ultimax allows considerable flexibility in developing part programs, this is not the only way the part can be programmed. Watch for inserted explanations of the special features of this sample program. Hurco Ultimax Part Program Pattern . HD3

1

Inch Standard

Part Setup Part Zero X

Offset

Y 2

3.0000

Safety Work Region

6.0000 2 Top (+) 0 . 0000 2 Bottom (-)

99.0000 -0.4010

X Left C-) X Right (+ l Y Front (-) Y Back (+) Fixture Offset

0.0000 8.2500 -4.8000 0.0000 1

General Parameters Retract Clearance Rapid Traverse

0.2500 IM 400.0 IPM

Peck Clearance Plane

0.0500

IM

Chord Error Depletion Retract

0.0001 0 . 0050

IM IM

Holes Parameters Bore Orient Retract Drill Dwell Bore Dwell

0 . 0200 IM 0.5 SEC 1.0 SEC

Milli ng P arame t ers

2 - 180

Blend Offset Blend Overlap Finish Feed Finish Speed Finish XY Finish Z Milling Direction Pocket Overlap

0 . 1250 0 . 1250 100 100 0 . 0100 0 . 0050 Climb 10

Cutter Comp Parameter

Insert Arc

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IM IM X IM IM ''4

Hawk 5M Machine

Conversational Part Programming Hurco Ultimax Part Program Pattern . HD3.

Inch Standard

2

Program Parameters Ouerride Lockout Program Protect Tool Change Position

Off Partial Yes Tool Setup

i

Type Diameter Zero Calibration Speed ( RPM) Coolant Gear range Tool Humber Diameter Offset Length Offset

Drill 0.1250 - 10000. CW 2800 Flood 1 1 1 1

2

Type Diameter Zero Calibration Speed CRPM) Coolant Gear range Tool Humber Diameter Offset Length Offset

Drill 0.3750 - 10000. CU 930 Flood 1 2 2 2

99

Diameter Zero Calibration Speed ( RPM) Coolant Gear range Tool Humber Diameter Offset Length Offset

0.0000 - 10000. CU 0 Off 1 99 99 99

There is no tool #99 available for the program . The operator added a tool setup for tool #99 to use as a dummy tool for drawing purposes only.

Ulumax 3 System

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Operator' s Manual Hurco Ultimax Part Program Pattern.HD3

3

Inch Standard

Data Blocks

The number to the far left in each section below is the data block number. 1

Mill Frame Tool Type Finish Tool X Corner

99 Out/Tan 0 0.0000 0.0000

Y Corner X Length Y Length Corner Radius Lead Length

Z Start Z Bottom Plunge Feed Mill Feed Speed (RPM)

0.2500

Peck Depth

0.0000 -0.2500 0.0 0.0 0 0.0000

-4.0000 0.0000 0.0001

Lead Angle

0.0000

This block creates an outline of the part on the graphics screen to use as an outline during programming . It will be deleted before running the program. 2

Pattern Loop Rectangular X Humber 6 V Humber 2 X Distance 1.2500 Y Distance -2.5000

3

Holes Center Drill Tool

1

Z Start Z Bottom Plunge Feed Speed ( RPM)

0.0500 -0.0125 4.2 2800

Peck Depth Peck Type

0.0000 Standard

Locations 1

X 1.0000

Y -0.7500

Blocks 2 and 3 center drill all holes . Note that hole # 1 is the pattern and blocks 2 and 4 make all 12 holes.

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Conversational Part Programming Hurco Ultimax Part Program Pattern.HD3

4

4

Pattern End

5

Pattern Loop Rectangular 6 X Humber 2 Y Humber 1.2500 X Distance -2.5000 Y Distance

6

Ho l es Drill Tool Z Start Z Bottom Plunge Feed Speed (RPM) Peck Depth Peck Type

Inch Standard

2 0.0500 -0.4000 5.6 930 0.1500 Standard

Locations 1

7

X 1.0000

Y -0.7500

Pattern End

Blocks 5 through 7 are copies of blocks 2 to 4 with a tool change to the drill (tool #2). Note that the use of copied program blocks and the system ' s pattern features simplifies the programming of this part.

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Operator's Manual

UltiPocket Option The UltiPocketTu programming option adds special milling routines for machining pocket boundaries with islands. This option provides complete clean out of odd-shaped pockets without cutting the islands programmed inside the boundary. The software automatically calculates the tool path around islands eliminating the long task of plotting these shapes. Islands may also be rotated, scaled, and repeated. This option allows operators to program closed contours with pockets and islands. The following two drawings show different views of an inward spiral boundary with three differently shaped islands.

Figure 2-127. Pocket Boundary with Inward Spiral Islands

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Hawk 5M Machine

Conversational Part Programming Here is the isometric view of this UltiPocket part:

Figure 2-128. Isometric View of Inward Spiral lskm&

The operator may select pocket features when creating any of these standard Ultimax program data blocks: •

Mill Contour

•

Mill Circle

•

Mill Frame

•

Pattern

Important To use the UltiPocket feature , the operator must first establish the cutter compensation parameter and then program any UltiPocket data blocks. Refer to the description of the Milling Parameters in the "Getting Started" chapter. The operator must select either Insert Arc or Insert Line for the Cutter Comp Parameter field. If this field does not appear on the Milling Parameters screen, the UltiPocket option has not been installed on the control. Call Hurco or a Hurco distributor to purchase the option.

Ultimax 3 System

,

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Operator' s Manual

Pocket Boundary The Pocket Boundary is the outside frame of the part. The basic philosophy of the UltiPocket option is to program the boundary and then tell the system which pockets or islands to avoid within that boundary. This approach eliminates complex calculations and shortens the part programming process. The standard milling values for Tool number and Finish Tool, Z start and Z bottom, Plunge Feed, Mill Feed, Speed RPM, and Peck Depth are programmed in the Pocket Boundary data block . They are not needed in the pocket block. The Pocket Overlap defined in the boundary block to be the percentage of cutter diameter for overlap during machining. There are two types of Pocket Boundaries : Spiral Outward (no islands) and Spiral Inward.

Spiral Outward - No Islands This selection is only for Circle and Frame data blocks without islands. When this routine is selected , the tool begins in the center region of the part and spirals outward to pocket the entire programmed boundary.

Spiral Inward This selection is for a boundary with islands . When this routine is selected, the tool enters the part and begins following a path formed by offsetting the boundary one-half the tool radius, plus (+) the pocket overlap (a percentage of cutter diameter programmable in the boundary data block). After the first , the tool follows a path produced by offsetting the boundary by the tool radius , plus (+) the pocket overlap for each while avoiding islands inside the boundary. After pocketing the boundary , the tool cuts around the inside of the boundary and the outside of each island , using the selected blend offset and the programmed tool radius.

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Conversational Part Programming

Programming Islands After programming the mill data block for a boundary, an island can be defined by creating a Pocket Island data block. As many islands as desired may be defined (subject to computer memory on the control), but all must fit within the defined boundary. The island data block can be a mill Frame, Circle, or Contour (provided it is a closed contour). The Pocket Island data blocks use the standard milling values from the boundary data block and do not display these parameters on the island programming screen. The pocket overlap percentage was also defined in the boundary data block.

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Operator' s Manual

Mill Contour To create a Mill Contour data block using the UltiPocket option, set up the operation in the start segment (segment zero) as shown below. As in standard Ultimax milling, an U1tiPocket Mill Contour block consists of segments beginning with segment zero. In the Start segment the operator must select one of the Pocket options (F6 or F7) to indicate whether this block is the boundary of the part or one of the islands within the boundary.

BLOCK

1

MILL CONTOUR

SEGMENT

a

START

I

F 1) No

TOOL

B

PLUNGE FEED

0.8

F 2) LEFT

z F 3) RIGHT FINISH TOOL

-*4L

SPEED (RPM)

X START Y START

TOOL

Z START

B.RBBB

b

Z BOTTOM

B.BBBB

F 6) POCKET 6 BOUNDARY

I F 7) POCKET 7 ISLAND

Select wttlog opwt(on

a

Figure 2-129. Mill Contour with Pocket options

2 - 188

5/18/94

Hawk 5M Machine

Conversational Part Programming Here is the Start segment for an island block:

BLOCK

I

SEGMENT

3

MILL CONTOUR

B

START

F BE ETE BLOCK I F INSERT BLOCK 2 BEFORE

ITTER COIF.

POCK ISLAND F 3

X START

8 . 6758

V START

-4 . 2987

F PROGRAM 4 PARAMETERS I F PART SETUP 5 F TOOL SETUP 6

Enter a block comber, use ENTER to edit block, or use ADVANCE . BALE, or sartkeg MOTION IS STOPPING , THE PROGRAM INS BEEN ABORTED.

F 7 I F SKIT B

Figure2-130. Mill Contour Start Segment with Pocket Island

The segments after the Start segment are programmed in the same manner as standard milling lines and arcs. Automatic calculation of unknown points is available for these data blocks.

Ultimax 3 System

Revision A

2-189

Operator' s Manual

Mill Frame The Mill Frame data block is often used to create the part boundary. Here is a completed frame using the inward spiral:

BLOCK

i

I

MILL FRAME

TOOL

1 POCIR

Z START Z BOTTOM

i TYP6 FIMI

B

X CORER

I F DELETE BLOCB 8.8788 1 I -8.2588 F INSERT BLOCX 2 BEFORE

PUAIGE FEED

8.0888

MILL F®

V GORIER

0.0088

SPEED (RPM)

X LENGTH

COON

PECI DEPTH

V LENGTH

5 . 0000

(TOOL DIAMETER (TYPE

CORNER RADIUS

0.2588

15.0 ; 188.8

F 3

49M F PROGRAM 4 PARAMETERS 8.8888 1 F PART SETUP 8.2588) S DRILL) 1 F TOOL SETUP

T OVWAP EwLw a block nwber , ae ENTER to edit block , or use ADVANCE . BNCII. or aaftRmy

7 1 F EXIT 8

Figure 2-131. Mill Frame with Inward Spiral Boundary

This block is programmed in the same manner as the standard Ultimax Mill Frame with the addition of the Pocket Overlap percentage.

2 - 190

5/18/94

Hawk 5M Machine

Conversational Part Programming

Mill Circle The Mill Circle data block is used for both boundaries and islands. It is similar to the standard Mill Circle data block except that if this block is used to create an island it uses the tool from the boundary data block. Here is a Mill Circle block used to create a boundary with an outward spiral:

BLO(:R

R

MILL CIRCLE

2

F DELETE BLOCK

3

TOOL IFAKET TYPE Pull

POCK BOUDSRY OuTUARD

2 START Z BOTTOM

11.0200 -6.50011

PLUM6E FEED

25.0

X CENTER

0.0000

MILL FEED

32.0

V CENTER

0.0000

SPEED (RPH)

2508

no WE

1.5008

PECK DEPTH

8 . 8000

F INSERT BLOCK 2 BEFORE F 3 F PR09VW 4 PARAMETERS

1

F PART SETUP 0.3758) 5 DID HILL) ; F TOOL SETUP 6 i F 7 Enter a block iw ber, use ENTER to edit block, or use AMCK , BACK , or eottke9 F EXIT 8

POT OVERIAP

10

(TOOL DIAMETEE (TYPE

Figure 2-132. Mill Circle with Outward Spiral Boundary

Uldmax 3 System

Revision A

2-191

Operator' s Manual

Pattern Pattern data blocks can be inserted to rotate, scale or repeat islands. Only Pattern data blocks can be programmed between a boundary data block and an island. As many islands as desired may be defined (subject to available memory), but all must fit within the defined boundary.

Sample UltiPocket Program The following program is a complex UltiPocket program that illustrates many of the option's features. Here is the graphics screen illustration of the finished part:

1.6-Y

l®1

-6.2 -

-2.3

I

OTW

I

0.3

2.9

X 0.1

5.5

Figure 2-133. Graphics screen illustration of die UltiPocket sample program

2 - 192

5/18/94

Hawk 5M Machine

Conversational Part Programming Here is the isometric view of the part:

Figure 2-134. Isometric view of the UIliPocket sample program

Ultimax 3 System

Revision A

2 - 193

Operator's Manual Hurco Ultimax Part Program UltiPock.HD3

1

Inch Standard

Part Setup Part Zero X Y Offset z

8.7948 9.8726 0 . 0000

Safety Work Region Z Top (+) Z Bottom C- ) X Left C -) X Right C+ ) Y Front C-) Y Back C+)

99.0000 -99.0000 -99.0000 99.0000 -99.0000 99.0000

Fixture Offset

1

General Parameters

Retract Clearance

0.0500

Rapid Trauerse Peck Clearance Plane Chord Error Depletion Retract

200.0 IPM 0 . 0500 IN 0 . 0000 IN 0.0050 IN

IN

Holes Parameters Bore Orient Retract Drill Dwell Bore Dwell

0.0200 IN 0.0 SEC 0.0 SEC

Millin g Paramet ers

2 - 194

Blend Offset

0 . 0000

IN

Blend Ouerlap

0.0000

IN

Finish Feed Finish Speed Finish XY Finish 2 Milling Direction Pocket Ouerlap Cutter Comp Parameter

100 z 100 X 0 . 0100 IN 0 . 0050 IN Climb 10 X Insert Rrc

5/ 18/94

Hawk 5M Machine

Conversational Part Programming 2

Hurco Ultimax Part Program UltiPock.HD3

Inch Standard

Program Parameters Off Partial No

Ouerride Lockout Program Protect Tool Change Position Tool Setup 1

Type Diameter

Face Mill 3.1500

10.4805

Zero Calibration Speed CRPM ) Coolant Flutes Feed/Flute Gear range Tool Humber Diameter Offset Length Offset

CW

2

Type Diameter Zero Calibration Speed ( RPM) Coolant Flutes Feed/Flute Gear range Tool Humber Diameter Offset Length Offset

End Mill 0.7500 9.1600 CU 5000 Off 2 0.0010 1 2 2 2

3

Type

Diameter Zero Calibration Speed (RPM)

5000 Flood 6 0.0030 1 1 1 1

End Mill

0.1500 10.8115 CW 6000 Off 1 3

Coolant Gear range Tool Humber

Diameter Offset

3

Length Offset

3

Ultimax 3 System

Revision A

2-195

Operator's Manual Hurco Ultimax Part Program UitiPock . HD3

3

4

Type Diameter Zero Calibration Speed CRPM ) Coolant Gear range Tool Humber Diameter Offset Length Offset

End Mill 0.5000 10.7064 CU 5000 Flood 1 4 4 4

5

Type Diameter Zero Calibration Speed (RPM ) Coolant Gear range Tool Humber Diameter Offset Length Offset

Drill 0.2010 10.3293 CU 3500 Flood 1 5 5 5

6

Type Threads per inch Diameter Zero Calibration Speed (RPM) Coolant Gear range Tool Humber Diameter Offset Length Offset

Tap 20.0 0.2500 7.559 CW 600 Flood 1 6 6 6

2-196

5/18/94

Inch Standard

Hawk 5M Machine

Conversational Part Programming Inch Standard

4

Hurco Ultimax Part Program UltiPock . HD3

Data Blocks

1

Mill Contour Segment Tool Cutter Comp Finish Tool X Start Y Start 2 Start Z Bottom

2

Start 1

Plunge Feed

100.0

0 7. 8000 -3.0000 0.0200 -0.0000

Speed ( RPM) Peck Depth

5000 0.0000

1

Plunge Feed

100.0

0 7. 8000 -1.5000 0.0200 -0.0000

Speed CRPM) Peck Depth

5000 0.0000

2

Plunge Feed

100.0

0

Speed ( RPM)

5000

No

Mill Contour Segment Tool Cutter Comp Finish Tool X Start Y Start 2 Start 2 Bottom

3

0

0

Start ho

Mill Contour Segment Tool

Cutter Comp Finish Tool

0

Start

Left

X Start

-0. 5000

Y Start 2 Start

0.0000 0.0200

2 Bottom Lead Rngle

Lead Length

-0.7500 0.00

0.0000

Peck Depth

0.0000

Operator's Manual Hurco Ultimax Part Program UltiPock . HD3 4

5

Mill Contour Segment Tool Cutter Comp Finish Tool X Start Y Start Z Start Z Bottom Lead Angle

0

Start 3

Plunge Feed

100.0

0 -0.5000 0.0000 0.0200 -0.0800 0.00

Speed ( RPM) Peck Depth

6000 0.0000

Left

Lead Length 5

Inch Standard

0.0000

Position Tool X

3 3

Y

3

Stop

6

Yes

Pattern Location X Offset -0.0200

1

7

Z Offset -0.0300

Mill Contour Segment Tool Cutter Comp Finish Tool

0

Start 1

Plunge Feed

100.0

0

Speed ( RPM)

5000

Mo

X Start

7 . 8000

Y Start Z Start

-3.0000 0.0200

2 Bottom

2 - 198

Y Offset -0 . 0100

Peck Depth

0.0000

0.0000

5/18/94

Hawk SM Machine

Conversational Part Programming 6

Hurco Ultimax Part Program UltiPock.HD3 8

Mill Contour Segment Tool Cutter Comp Finish Tool X Start

0

Start Plunge Feed

100.0

0 7.8000 -1.5000 0.0200 0.0000

Speed ( RPM) Peck Depth

5000 0.0000

2

Plunge Feed

100.0

0 -0.5000 0.0000 0.0200 -0.6000 0.00 0.0000

Speed ( RPM) Peck Depth

5000 0.0000

4

Plunge Feed

100.0

Mill Feed Speed ( RPM) Peck Depth

75 6000 0.0000

Mill Contour Segment

0

Tool Cutter Comp Finish Tool

Start Left

X Start Y Start

Z Start Z Bottom Lead Angle Lead Length 10

1

No

Y Start Z Start Z Bottom 9

Inch Standard

Mill Contour Segment Tool

Cutter Comp Finish Tool X Start Y Start Z Start

Z Bottom Pocket Overlap

Ultimax 3 System

0

Start

Pock Boundary 0 3.0000 -4.8000 0.0200 -0.2000 20.0

Revision A

2-199

Operator' s Manual Hurco Ultimax Part Program U1tiPock.HD3

11

7

Mill Contour Segment Tool Cutter Camp Finish Tool X Start

0

Start 4 Pock Boundary 4 3.0000 -3.7500 -0.1800 -0.6000 50.0

Y Start Z Start Z Bottom Pocket Duerlap

12

0

Cutter Camp X Start V Start

Start Pock Island 1.3800 -1.1000

0

Cutter Camp X Start.

Start Pock Island 5.2300 -2.9000

Y Start Mill Contour Segment Cutter Camp X Start Y Start

2-200

15.0 75 6000 0.2100

Mill Contour Segment

14

Plunge Feed Mill Feed Speed (RPM) Peck Depth

Mill Contour Segment

13

Inch Standard

0

Start Pock Island 4.5300 -2.1400

5/18/94

Hawk 5M Machine

Conversational Part Programming Hurco Ultimax Part Program UltiPock.HD3 15

0

Cutter Comp X Start Y Start Mill Contour Segment

17

Inch Standard

Mill Contour Segment

16

a

Start Pock Island 2.8000 -3.0750

0

Start

Cutter Comp X Start Y Start

Pock Island 1.0000 -3.2180

Holes Drill Tool Z Start 2 Bottom Plunge Feed Speed ( RPM) Peck Depth Peck Type

5 -0.1500 -0.8000 6.0 3500 0.1625 Standard

Locations X 2.00 4.00 5.50 4.00 2.00 0.50 1.00

Y -3.50 -3.50 -2.00 -0.50 -0.50 -2.00 -3.00

-2.72 -2.35 -2.00

12

1.35 1.53 1.75 2.80 3.40

13 14 15

3.15 4.53 4.42

-1.35 -1.92 -1.50

1 2 3 4 5 6 7

8 9 10 11

Ultimax 3 System

-2.70

-2.40

Revision A

2-201

Operator's Manual Hurco Ultimax Part Program UltiPock . HD3

18

Inch Standard

Mill Contour Segment Tool Cutter Comp Finish Tool X Start Y Start Z Start 2 Bottom

0

Segment X End Y End Z End XY Length XY Angle Feed

1

Segment

2

Start 3

Plunge Feed

100.0

0 5 .2500 -4.2000 0.0200 -0.0800

Speed CRPM) Peck Depth

6000 0.0000

Left

Line CAL

CAL

X End Y End 2 End XY Length XY Angle Feed

5.2580 -3.7500 -0.0800 0.4500 90.000 80.000

Line CAL CAL

5.7500 -3.7500 -0.0800 0.5000 0.000 80.00

Segment Radius Feed

3

Blend Arc 0.3000 80.00

Segment

4

Line

X End Y End Z End

CAL

5.7500 -0.7500 -0.0800

XY Length XY Angle

CAL

3.0000 90.000

Feed

2-202

9

80.000

5/18/94

Hawk 5M Machine

Conversational Part Programming Hurco Ultimax Part Program UltiPock. HD3

Inch Standard

10

Segment Radius Feed

5

Blend Arc 0.2800 80.00

Segment X End Y End Z End XY Length XY Angle Feed

6

Line

Segment Radius Feed

5

Blend Arc 0.2800 80.00

Segment X End Y End Z End XY Length XY Angle Feed

6

Line

Segment Radius Feed

7

Blend Arc 0.2800 80.00

Segment

8

Line

CAL CAL

0.7500

Y End

CAL

Z End XY Length XY Angle Feed

Radius Feed

Ultimax 3 System

5.2500 -0.2500 -0.0000 0.7071 135.000 80.000

CAL CAL

X End

Segment

5.2500 -0.2500 -0.0800 0.7071 135.0000 80.000

CAL

9

-0.2500 -0.0800 4.5000 180.000 80.000

Blend Arc

0.2800 80.00

Revision A

2 - 203

Operator ' s Manual

11

Hurco Ultimax Part Program U1tiPock . HD3 Segment X End Y End Z End XY Length XY Angle Feed

10

Segment

11

Inch Standard

Line 0.2500 -0.7500 -0.0800 0.7071 -135.00 80.000

CAL CAL

Blend Arc

Radius Feed

0.2800 80.00

Segment X End Y End Z End XY Length XY Angle Feed

12

Segment Radius Feed

13

Segment X End Y End Z End XY Length XY Angle Feed

14

Segment

15

Line

CAL

Blend Arc 0.3000 80.00 Line CAL CAL

2-204

0.7500 -3.7500 -0.0800 5.0000 0.000 80.000

Line

X End Y End 2 End

XY Length XY Angle Feed

0.2500 -3.7500 -0.0800 3.0000 -90.000 80.000

0.7500 -3.9700 -0.0800

CAL CAL

0.2400 -90.000 80.000

5/18/94

Hawk 5M Machine

Conversational Part Programming 12

Hurco Ultimax Part Program U1tiPock . HD3 Segment

16

Inch Standard

Line

X End

0.0100

Y End Z End XY Length XY Angle Feed

CAL CAL

Segment Radius Feed

17

Segment

18

-3.9900 -0.0800 0.7400 180.000 80.000

Blend Arc 0.2000 80.00 Line

0.0100 0.0000

X End Y End Z End XY Length XY Angle Feed

CAL CAL

Segment Radius Feed

19

Segment

20

-0.0800 3.9900 90.000 80.000

Blend Arc 0.2000 00.00

Line

X End Y End

5.99 0.0000

Z End XY Length

CAL

XY Angle Feed Segment Radius Feed

Ultimax 3 System

-0.0800 5.9900

CAL

21

0.000 80.000

Blend Arc 0.2000 80.00

Revision A

2 - 205

Operator' s Manual Hurco Ultimax Part Program UltiPock.HD3 Segment X End Y End Z End XY Length XY Angle Feed

22

Segment Radius Feed

23

Segment X End Y End Z End XY Length XY Angle Feed

24

13

Inch Standard

Line

CAL CAL

5.9900 -3.9900 -0.0800 3.9900 -90.000 80.000

Blend Arc 0.2000 80.00 Line

CAL CAL

5.0000 - 3.9900 -0.0800 0.990 0 180.000 80.000

End of Contour 19

Mill Contour Segment Tool Cutter Comp Finish Tool X Start Y Start 2 Start 2 Bottom Lead Angle Lead Length

2-206

0

Start 3

Plunge Feed

100.0

0 5 . 0400 -3.9900 -1.1800 -0.2750 0.00 0.0000

Speed ( RPM] Peck Depth

6000 0.0000

Left

5/18/94

Hawk 5M Machine

Conversational Part Programming

20

Mill Contour Segment Tool Cutter Camp Finish Tool X Start Y Start Z Start 2 Bottom Lead Angle Lead Length

21

0

Start 3

Plunge Feed

100.0

0 0 . 9500 -3.7500 -1.1800 -0.2750 0.00 0.0000

Speed [RPM) Peck Depth

6000 0.0000

3

Plunge Feed

100.0

0 5 . 5000 -2.2200 -1.1800 -0.2750 0.00 0.0000

Speed [ RPM) Peck Depth

6000 0.0000

3

Plunge Feed

100.0

0 4.2200 -0.5000 -1.1800 -0.2750 0.00 0.0000

Speed ( RPM) Peck Depth

6000 0.0000

Left

Mill Contour Segment Tool Cutter Comp Finish Tool X Start Y Start 2 Start Z Bottom Lead Angle Lead Length

22

Inch Standard

14

Hurco Ultimax Part Program U1tiPock . HD3

0

Start Left

Mill Contour Segment Tool Cutter Camp Finish Tool X Start Y Start 2 Start 2 Bottom Lead Angle Lead Length

0

Start Left

Operator' s Manual Hurco Ultimax Part Program UltiPock.HD3 23

15

Mill Contour Segment Tool Cutter Comp Finish Tool X Start Y Start Z Start Z Bottom Lead Angle

0

Start Plunge Feed

80.0

0 2.2200 -0.5000 -1.1800 -0.2750 0.00 0.0000

Speed ( RPM) Peck Depth

6000 0.0000

3

Plunge Feed

100.0

0 0 . 5000 -1.7000 -1.1800 -0.2750 0.00 0.0000

Speed ( RPM) Peck Depth

6000 0.0000

3

Plunge Feed

80.0

0 1 . 5800 -0.9000 -1.1800 -0.2500

Speed CRPM) Peck Depth

6000 0.0000

Mill Contour Segment Tool Cutter Comp Finish Tool X Start Y Start Z Start Z Bottom Lead Angle Lead Length

25

3 Left

Lead Length 24

Inch Standard

0

Start Left

Mill Contour Segment

0

Start

Tool Cutter Comp Finish Tool X Start Y Start 2 Start 2 Bottom

Lead Angle Lead Length

2-208

Left

CAL

0.00 0.0000

5/18/94

Hawk 5M Machine

Conversational Part Programming Hurco Ultimax Part Program UltiPock . HD3 26

Mill Contour

Segment

0

Tool Cutter Comp Finish Tool X Start Y Start Z Start Z Bottom Lead Angle Lead Length 27

Start 3

Plunge Feed

80.0

0 5. 4300 -2.7000 -1.1800 -0.2750 0.00 0.0000

Speed ( RPM) Peck Depth

6000 0.0000

3

Plunge Feed

80.0

0 4. 5300

Speed ( RPM) Peck Depth

60001 0.0000

3

Plunge Feed

80.0

0 2. 8000

Speed (RPM) Peck Depth

0.0000

Left

CAL

Mill Contour Segment Tool Cutter Comp Finish Tool X Start

28

Inch Standard

16

0

Start Left

Y Start

-2.1400

Z Start Z Bottom Lead Angle Lead Length

-1.1800 -0.2750 0.00 0.0000

Mill Contour Segment Tool Cutter Comp Finish Tool X Start

0

Start Left

Y Start Z Start

-3.0750 -1.1800

Z Bottom Lead Angle Lead Length

-0.2750 0.00 0.0000

beau

Operator's Manual Hurco Ultimax Part Program UltiPock. HD3 29

Inch Standard

Mill Contour Segment Tool Cutter Comp Finish Tool X Start Y Start Z Start Z Bottom Lead Angle Lead Length

30

17

0

Start 3

Plunge Feed

80.0

0 1 .000 -3.2180 -1.1800

Speed (RPM) Peck Depth

6000 0.0000

Left

-0.2750 0.00 0.0000

Holes Countersink Tool 2 Start Z Bottom Plunge Feed Speed CRPM) Peck Depth

5 -0.1800

-0.3100 15.0 6000 0.0

Locations X 2':'00 x`4. 00 5.50 4.00 2.00 0.50 :1.00 ..

Y -3.50 -3.50 -2.00 -0.50 -0.50 -2.00 -3.00

1.35 1.53

-2.72 -2.35

-10

1.75

12 13 14 15

3.40 3.155 4.53 4.42

-2.00 -2.70 -2.40 -1.35 -1.92 -1.50

1 2.,

2-210

5/18/94

Hawk 5M Machine

Conversational Part Programming Hurco Ultimax Part Program UltiPock.HD3 31

Mill Lettering 3

Tool X Start Y Start Height Character Width

Text Z Start Z Bottom 32

1.1500 -0.2000 0.15 0.08 HURCO ULTIMAX III 0.0200 -0.0060

Plunge Feed Mill Feed Speed CRPM) Peck Depth

80.0 60.0 6000 0.00

Plunge Feed Mill Feed Speed CRPM) Peck Depth

10.0 60.0 6000 0.00

Mill Lettering 3

Tool X Start Y Start Height Character Width Text Z Start Z Bottom 33

Inch Standard

18

Holes Tap Tool Z Start Z Bottom Plunge Feed Speed (RPM) Peck Depth

Ultimax 3 System

1.9500 -3.9500 0.15 0.08 ULTIPOCXET -0.1800 -0.2100

6 0.0 -0.6000 15.0 600 0.0

Revision A

2 - 211

Operator' s Manual Hurco Ultimax Part Program UltiPock.HD3

19

Inch Standard

Locations 1 2 3 4 5 6 7 8

x 2.00 4.00 5.50 4.00 2.00 0.50 1.00 1.35

y -3.50 -3.50 -2.00 -0.50 -0.50 -2.00 -3.00 -2.72

9

1.53

-2.35

10 11 12 13 14 15

1.75 2.80 3.40 3.15 4.53 4.42

-2.00 -2.70 -2.40 -1.35 -1.92 -1.50

34

Pattern End

2-212

5/18/94

Hawk 5M Machine

Conversational Part Programming

Cutter Insert Routines Cutter insert manufacturers use these special milling routines to mill pockets in triangular, diamond, and hexagon shapes. These routines are sold as an Ultimax 3 option and can be defined in one program data block. To access the cutter insert features , press the Input console button to display the Input screen. Then press the Part Programming (F3) softkey. If the option has been installed on the system , the next screen will have a Special (F6) softkey. Press that softkey and the following screen appears:

BLACK

1

I

EBLOCK 1 Ni

F 1) 7BIANGLE 1 F 2) DIAMOND 1 FACE 2 F 3) DIAMOND 3 2 FACES F 4) HEXAGON 4 P 5 P

7

Choose type or block

F EXIT B

Figure 2-135. Cutup Inserts softkeys

All four of these options have similar screens . Refer to the Triangle screen. for a description of the standard fields. Additional fields used on the remaining three screens are described in those sections.

Ultimax 3 System

Revision A

2 - 213

Operator' s Manual

Triangles The triangle pocket shape has three equal 60° angles with one open face as shown below. In addition, a relief cut can be programmed in the comer at point 1. Point 3

Open Face

Orientation =0

Point 2

Figure 2-136. Triangle Programming diagram

2 - 214

5/18/94

Hawk 5M Machine

Conversational Part Programming Here is a completed Mill Triangle data block . The data on this screen also appears in the sample program at the end of this section.

BLOCK

2

MILL TRIANGLE

TOOL

1

TYPE

POCKET nVOUT

X CENTER

1 . 0008

Z START Z BOTTOM

8.1800 x.1758 5 .0

PLIK I GE FEED

V CENTER

1 . 0008

MILL FEED

RADIUS

0.2508

SPEED (RPM)

ORIENTATION

12.500

PECK DEPTH (TOOL DIAMETER (TYPE

RELIEF 1

I F DELETE BLOCK

CENTER 8.1008

10.0

1 i F INSERT BLOCK 2 BEFORE I F 3

F PROGRAM 4 PARAMETERS I 0.0000 F PMT SETUP 0.0625) 5 END MILL) I F TOOL SETUP 6

Enter a block number , use ENTER to edit block, or use ADVANCE , BACK. or softkey

758

F 7 F SKIT B

Figure2-137. Completed MiUTriangle screen

Ultimax 3 System

Revision A

2 - 215

Operator' s Manual These fields are the standard fields for all of the cutter insert screens. Refer to the descriptions of the other options for the additional fields on those screens. Fields

Definitions

Tool

number of the tool used to cut the insert pocket

Type

defines cutter motion using these options: Inside - cuts just the non-open faces of the pocket, including the relief cuts. Inside 2 es - cuts the same as Inside, except this selection uses a roughing and a finishing . During roughing, material is left for the finish . Pocket Outside In - cuts along the faces of the insert, including the relief cuts and then steps inward and cleans out the entire insert by executing smaller versions of the shape until the center point is reached. Pocket 2 es Outside In - cuts in the same manner as Pocket Outside In, except this selection uses a roughing and a finishing . Pocket Inside Out - plunges tool at X-Y center of the insert and cuts outward, executing larger versions of the shape until the faces and relief cuts are milled. Pocket 2 es Inside Out - Cuts the same as Pocket Inside Out, except this selection uses a roughing and a finishing .

X Center

"X" axis coordinate of the inscribed circle's center point of the shape.

Y Center

"Y axis coordinate of the inscribed circle's center point of the shape.

Radius

this is 'f the length of the diameter of the inscribed circle. This distance is used to determine the size of the pocket.

Orientation Relief 1 Z Start Z Bottom Plunge Feed

2 - 216

Angle of a vector perpendicular to the open face. value provides the option of a right, center or left relief cut (or none) in the corner at point 1 The location where the spindle begins to rotate. The bottom of the finished hole. Feedrate between the Z Start and the Z Bottom positions.

5/18/94

Hawk 5M Machine

Conversational Part Programming

Fields Mill Feed

Speed (RPM) Peck Depth

Ultimax 3 System

Definitions (continued) Feedrate for the X and Y axes. The control system automatically calculated the value that first appears on the screen. The calculated value can be replaced with a different value or stored as it is. Speed at which the spindle rotates to drill the hole. Distance that the tool will drill down into the part before stopping to clear out or break the chips. If this parameter is used, it is usually not larger than the diameter of the tool.

Revision A

2 - 217

Operator's Manual

Diamond Faces The diamond pocket shapes have four sides with opposite angles equal. The Diamond I Face has one open face and the option of a right, center, or left relief cut in the comers at point I and point 2 as shown below: POINT 1

POINT 4 ORIENEA11ON = 0

OPEN FACE

POINT 3

Figure 2-138. Diamond I Face diagram

2 - 218

5/18/94

Hawk 5M Machine

Conversational Part Programming The Diamond 2 Faces pocket has two open faces and the option of a right, center, or left relief cut in the comer at point 1 as shown below: POINT 1

POINT 4 ORIENWION = 0

OPEN FACE

/ /

OPEN FACE

POINT 3

Figure 2-139. Diamond 2 Faces diagram

The diamond pocket data blocks are programmed in the same manner as the triangle pockets ; however, there are two additional fields on the diamond screen. Shape Angle the angle formed by points 1 and 3 defining the shape with a range from 20° to 160°. Relief 2

Ultimax 3 System

(for Diamond 1 Face only) this provides the option of a right, center, or left relief cut (or none) in the corner at point 2.

Revision A

2-219

Operator' s Manual Here is an example of a completed Diamond I Face data block:

BLOCK

i

3

MILL DIAMOND I FACE

TOOL

1

Z START

TYPE

INSIDE

Z BOTTOM

X CENTER

8 . 8800

PLUME FEED

V CENTER

8.0080

MILL FEED

RADIUS

8.3758

SPEED (RPM)

ORIENTATION

0 . 808

E SCLB

90.808

RELIEF I

LEFT

0.1800

IMP 2

NONE

8 . 0188

PECK DEPTH (TOOL DIAMETER (TYPE

8.1000 -0.1758 5 .8 10.0

I F D EL ETE BLOCK 1 F INSERT BLOCK 2 BEFORE I F 3

F 4 8 . 8800 I F 0.865) 5 Em MILL) I F 6

Enter a block number, use ENTER to edit black, or use ADVANCE. BACK, or . tks9

758

PROGRAM PARAMETERS PART SETUP TOOL SETUP

F 7 I F EXIT 8

Figure 2-140. Completed Mill Diamond I Face screen

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Conversational Part Programming

Hexagon This pocket shape has six-sides and every other angle equal. In the diagram below, the shape has two open faces and the option of a relief cut in the corners at point 1, point 2 and point 3, and/or the option of a face relief distance between points 0 and 1 and points 3 and 4.

Point 0

Orientation =0

Point 3

Relief Corners

Point 4 Figure 2-141. Hexagon diagram

The hexagon pocket data blocks are programmed in the same manner as the triangle pockets; however, there two additional fields on the hexagon screen.

Ultimax 3 System

Shape Angle

the angle formed by points 0, 2 and 4 defining the shape with a range from 60° to 180°.

Relief 3

this provides the option of a right , center, or left relief cut (or none) in the comer at point 3 or the option of a face relief distance between points 3 and 4.

Revision A

2 - 221

Operator' s Manual Here is a completed hexagon data block:

BLOCX

$

11

HILL HEXAGON

TOOL

1

TYPE

INSIDE

Z BOTTOM

X CENTER

8.8000

PLNMGE FEED

I CENTER

-2.0008

RADIUS

0.2500

2 START

HILL FEED

8.1000

F DELETE BLOCX 1

F INSERT BLOCX 2 BEFORE 5.8 I F 10.0 3

-0.1258

SPEED ( RPM)

750 F PROGRAM 4 PARAMETERS 8.0800 I F PART SETUP SHAPE ANGLE 00.808 (TOOL DIAMETER 0.0625) 5 (TYPE Ii" MILL) 1 RELIEF 1 FACE 8.1888 F TOOL SETUP RELIE F2 CENTER 8.1000 6 RELIEF 3 LEFT 8.1888 I F Eater a block number , use ENTER to edit block , or use 7 ADVANCE , BACE, or sottkey i F EXIT 8 ORIENTATION

8 . 880

PECX DEPTH

Figure 2-142. Completed Mill Hexagon screen

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k

A

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Hawk 5M Machine

Conversational Part Programming

Sample Cutter Insert Program In order to demonstrate programming for all of the cutter insert shapes, this program shows separately programmed inserts that were not used to create a part. Here is the graphics screen representation of the sample program.

Figure 2 -143. Inserts in Sample Program

Uttimax 3 System

Revision A

2-223

Operator' s Manual Hurco Ultimax Part Program Insert . HD3

1

Inch Standard

Part Setup Part Zero X Offset

Y Z

5 . 0000 Safety Work Region 5.0000 0 . 0000

2 Top (+) Z Bottom C-) X Left C -) X Right C+ ) V Front C-) Y Back C+ ) Fixture Offset

99.0000 -99.0000 -99.0000 99.0000 -99.0000 99.0000 1

General Parameters Retract Clearance Rapid Trauerse

99.0000 IN 400.0 IPM

Peck Clearance Plane Chord Error Depletion Retract

0.0500 0.0001 0.0050

IN IN IN

Holes Parameters Bore Orient Retract Drill Dwell Bore Dwell

0.0200 IN 0.5 SEC 1.0 SEC

Milli ng P arame t ers

2 - 224

Blend Offset Blend Ouerlap Finish Feed Finish Speed Finish XY

0.1250 0.1250 100 100 0.0100

IN IN Z

Finish Z

0.0050

IM

Milling Direction Pocket Ouerlap

Climb 10

Cutter Comp Parameter

Insert Arc

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IM

Hawk 5M Machine

Conversational Part Programming Hurco Ultimax Part Program Insert.HD3

Inch Standard

2

Program Parameters Off Partial No

Duerride Lockout Program Protect Tool Change Position Tool Setup 1

Type Diameter Zero Calibration Speed CRPM) Coolant

Gear range T oo l N umb er Diameter Offset Length Offset

End Mill

0.0625 4.3450 CW 750 Of f 1 1 1 1 Data Blocks

1

Mill Triangle Tool Type

X Center Y Center Radius Orientation Relief 1

2

1 Inside 0.0000 1.0000 0.2500 0.000 Center 0.1080

Mill Triangle Tool

Type X Center Y Center Radius Orientation Relief 1

Ultimax 3 System

1 Pocket In/Out 1.0000

1.0000 0.2500 12.5 Center 0.1000

Revision A

2 Start 2 Bottom Plunge Feed Mill Feed Speed (RPM) Peck Depth

2 Start 2 Bottom Plunge Feed

Mill Feed Speed (RPM) Peck Depth

0.1000 -0.1250 5.0 10.0 750 0.0000

0.1000

-0.1250 5.0 10.0 750 0.0000

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Operator's Manual Hurco Ultimax Part Program Insert.HD3

3

Type X Center Y Center Radius Orientation Shape Angle Relief 1 Relief 2

Relief 1 Relief 2

Mill Diamond 1 Face Tool Type

X Center Y Center

Radius Orientation Shape Angle Relief 1 Relief 2

2-226

1 Inside 0.0000 0.0000 0.3750 0.0000 90.000 Left 0.1000 None 0.0100

Z Start Z Bottom Plunge Feed Mill Feed Speed CRPM) Peck Depth

0.1000 -0.1250

1 Pocket Out/In 1.0000 0.0000 0.3750

2 Start Z Bottom Plunge Feed Mill Feed Speed CRPM)

Peck Depth

0.1000 -0.1250 5.0 10.0 750 0.0000

1 Pocket Out/In 2.0000 0.0000

Z Start Z Bottom Plunge Feed Mill Feed

0.1000 -0.1250 5.0 10.0

0.3750 0.000

Speed (RPM) Peck Depth

0.0000

5.0 10.0 750 0.0000

Mill Diamond 1 Face Tool Type X Center Y Center Radius Orientation Shape Angle

5

Inch Standard

Mill Diamond 1 Face

Tool

4

3

12.500 90.000 Left 0.1000 None 0.0100

750

75.000 Left 0.1000 Hone 0.0100

5/18/94

Hawk 5M Machine

Conversational Part Programming Hurco Ultimax Part Program Insert.HD3

6

Mill Diamond 1 Face Tool Type Pocket X Center Y Center Radius

Orientation Shape Angle Relief 1 Relief 2 7

8

Mill Diamond 2 Faces Tool Type X Center Y Center Radius Orientation Shape Angle Relief 1 Mill Diamond 2 Faces Tool Type Pocket

X Center

Inch Standard

2 Start

1

Z Bottom Plunge Feed Mill Feed Speed CRPM) Peck Depth

Out/In 2 3.0000 0.0000 0.3750 12.500 75.000 Left 0.1000 Mone 0.0100

1 Inside 0.0000 -1.0000

Z Start Z Bottom Plunge Feed Mill Feed

0.3750

Speed CRPM)

0.000

Peck Depth

0.1000 -0.1250 5.0 10.0 750 0.0000

90.000

1 Out/In

12.500

Shape Angle Relief 1

0.1000 -0.1250 5.0 10.0 750 0.0000

Right 0.1000

1.0000 -1.0000 0.3750

Y Center Radius Orientation

9

4

Z Start Z Bottom Plunge Feed Mill Feed Speed (RPM)

Peck Depth

0.1000 -0.1250

5.0 10.0 750 0.0000

90.000

Right 0.1000

Mill Diamond.2 Faces

Tool Type X Center

Y Center Radius

Orientation Shape Angle Relief 1

Ultimax 3 System

1

Pocket

Z Start

2 Bottom

Out/In 2.0000 -1.0000

Plunge Feed Mill Feed

0.3750 0.000 75.000

Speed CRPM) Peck Depth

0.1000

-0.1250 5.0 10.0 750 0.0000

Right 0.1000

Revision A

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Operator's Manual Hurco Ultimax Part Program Insert.HD3

10

11

Mill Diamond 2 Faces Tool Type Pocket X Center Y Center Radius Orientation Shape Angle Relief 1

1 Out/In . 2 3.0000 -1.0000 0.3750 12.500 75.000 Right 0.1000

Z Start Z Bottom Plunge Feed Mill Feed Speed (RPM) Peck Depth

0.1000 -0.1250 5.0 10.0 750 0.0000

1

2 Start Z Bottom Plunge Feed Mill Feed Speed CRPM) Peck Depth

0.1000 -0.1250 5.0 10.0 750 0.0000

1 Pocket Out/In 1.0000 -2.0800

Z Start Z Bottom Plunge Feed Mill Feed

0.1000 -0.1250. 5.0 10.0

0.25000

Speed ( RPM)

Inside 0.0000 -2.0000

Radius

0.25000

Mill Hexagon Tool

Type X Center Y Center Radius

Orientation Shape Angle Relief 1 Relief 2 Belief 3

2-228

Inch Standard

Mill Hexagon Tool Type X Center Y Center Orientation Shape Angle Relief 1 Relief 2 Relief 3

12

5

0.000 80.000 Face 0.1000 Center 0.1000 Left 0.1000

12.500 80.000 Face 0.1000 Center 0.1000 Left 0.1000

5/18/94

Peck Depth

750 0.0000

Hawk 5M Machine

Conversational Part Programming Hurco Ultimax Part Program Insert.HD3

13

14

6

Inch Standard

Mill Hexagon Tool Type X Center Y Center Radius Orientation Shape Angle Belief 1 Belief 2 Belief 3

1 Pocket In/Out 2.0000 -2.0000 0.25000. 0.000 75.000 Face 0.1000 Center 0.1000 Left 0.1000

Z Start Z Bottom Plunge Feed Mill Feed Speed (RPM) Peck Depth

0.1000 -0.1250 5.0 10.0 750 0.0000

Mill Hexagon Tool Type X Center Y Center Radius Orientation Shape Angle Belief I Belief 2 Belief 3

1 In/Out 2 3.0000 -2.0000 0.25000 12.500 75.000 Face 0.1000 Center 0.1000 Left 0.1000

Z Start Z Bottom Plunge Feed Mill Feed Speed ( RPM) Peck Depth

0.1000 -0.1250 5.0 10.0 750 0.0000

Ultimax 3 System

Pocket

Revision A

2 - 229

1

Operator' s Manual

Rotary Typically, operators use the optional rotary equipment and accompanying system software when they need to cut around a cylindrical part while the part is turning . When the Rotary Table Option is attached to the Hawk 5M, the kneemill has a fourth axis of motion -the "A" axis. Programming rotary data blocks is very similar to programming other conversational data blocks , so the operator must be familiar with conversational part programming before studying the material in this section.

1^r Figure 2-144. Typical Single -axis Rotary Table ("A" axis)

General Information When the Ultimax system begins to execute a conversational rotary data block, the "Y" axis motion will stop and be replaced with the "A" axis. Normally the tool is in line with the center of the rotary table along the "Y" axis, but the tool can be positioned off center as well. To use both the "Y" and "A" axes simultaneously , the operator must create the part program using NC part programming. Refer to the NC Programming Instruction Manual.

Programming ranges and resolutions for the Rotary Table are plus (+)/minus (-) 9999. 999 degrees absolute in a rotary contour and "+"/"-" 360.0000 degrees for all other operations . Positive ("+") motion of the Rotary Table is in a clockwise (CW) direction as it would appear to the operator when standing at the "+ X" end of the work table and facing the Rotary Table.

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Conversational Part Programming

Rotary Part Programs Rotary programs can only be created in Rotary programming mode. Program Definition To create a rotary part program, the operator first displays Input screen and enters the program name and then selects Inch or Metric unit of measure and whether the program is Rotary or Standard (see below).

Figure 2 -145. Input Screen with rotary option

Important If the operator requests another CRT screen before selecting the axis configuration, the part program defaults to the Standard axis configuration. Then the operator cannot create any rotary data blocks.

Ultimax 3 System

Revision A

2-231

Operator' s Manual

Part and Tool Setup For programs using a rotary axis, the operator must describe the tools that will be used and describe part zero and perhaps the safety work region. The operator displays the Input screen, and enters the program name.

-

INPUT

-

I T SE

MASTER PROGRAM

HAUR 91

EDIT PART PROGRAM

PROGRAM NHIORV ANM ILABI ,6

e1 . 9 RTR.1m3

May.B5'94

ROTARY A

HIM

' TOOL SETUP 1^

99 X

F PART PROGRAMING 3 P PROGRAM 4 PARAMETERS i r G F COPY AND CHANGE 6 BLOCIS

F ERASE FUNCTIONS Select sottkey or preaa (Enter > to change Part Program name 7 F a

Figure 2 -146. Input screen

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Hawk 5M Machine

Conversational Part Programming After the name of the part program is entered into the Input screen, and the tools and work piece are in place , the operator is ready to begin the part setup process . Press the Part Setup (F1) softkey to begin the setup process . The Part Setup screen appears . Type values into the fields or use the jog unit to position the tool and store positions identifying these values.

PART SETUP, F Machine Is not calibrated. F TOOL SETUP 2

SAFETY YORK REGION F PROGRAM 2 TOP (.) 99.0800 4 PARAMETERS 2 BOTTOM (-) -99.8808 X LEFT (-) -99.0800 F USE PART PROBE X RIGHT ( •) 99.6888 S V FRONT (-) -99.0000 1 Y BACK (.) 99.8888 F 6 )VV SKEW ( deg.) B.BBBB F Enter part zero It known or Jog machine to part zero. 7 position and press sot They to store position I F EXIT 8

Figure 2-147. Part Setup screen with Rotary Axis

When the machine is not calibrated or it is in concurrent programming, there are no machine and part position values displayed at the top of the screen as shown in the example above. When setting up a rotary part, the "Y" axis zero is generally considered to run along the center of the rotary table. Most operators use the top of the part as "Z" zero. Yet in some instances, the center of the rotary table may be used as "Z" zero; especially if the piece being machined is not symmetrical in shape. The "A" centerline offsets for "Y" and "Z" are incremental distances from true part zero. Therefore, if the "Y" dimension part zero is the centerline of the rotary table, then the "Y" offset value will be zero. If "Z" part zero is the top of the part, then the "'Z" centerline offset will be a negative value equal to the radius of the part. Programming this value is also important in allowing the control to draw the program properly on the graphics screen.

Ultimax 3 System

Revision A-

2 - 233

Operator's Manual

Follow these steps to enter rotary part setup information: 1.

Establish axes coordinates (values) for part zero. Calibration process includes finding part zero for the "A" axis and the rotary axis centerline.

2.

Establish the centerline of the Rotary Table. The centerline of the rotary axis ("A" axis) must be specified to perform rotary milling operations. This centerline is also used by the graphics display. The centerline is defined by a "Y" value and a "Z" value which are part/tool zero relative. These values can be determined by jogging an indicator to the "A" centerline, OR to a known dimension of a part on the rotary table.

3.

Then press Store Machine Position softkey for each value. A displayed value may be adjusted by: (1) entering the desired adjustment value via the console keyboard, (2) entering the appropriate sign [plus (+) or minus (-) value], and (3) depressing the Enter key. This procedure will add, or subtract (depending upon the sign entered) the adjustment value to the currently stored value.

4.

With the cursor at the Z Top (+) parameter, enter the dimensional values to establish a Safety Work Region using one of the methods listed below. If no values are entered for the displayed parameters, the dimensions default to the displayed measure. Tool motion outside this safety plane stops the program and displays an appropriate error message. a. Use the numerical and Enter keys to program dimensional values for each axis safety plane. The Z Top (+) parameter should denote a clearance above all portions of the part and/or fixture. OR b. Use the axis jog functions on the jog unit (<X>, , <+>, <-> keys) to move the X and Y axes to the safety plane positions, and then press Store Machine Position softkey to store each value.

5.

2-234

To store Z Top (+) and Z Bottom (-) parameters, a calibrated tool must be in the spindle. The dimensional value entered establishes an offset in Z.

5/20/94

Hawk 5M Machine

Conversational Part Programming

General Parameters For programs using a rotary axis, the operator must set up the program parameters just as they must be set up for any part program. The operator displays the Input screen and presses the Program Parameters (F4) softkey to access the parameters screens as described in the "Getting Started" chapter. The default values appear in the fields on these screens; however, the operator may want to change some of the parameters, particularly on the General Parameters (shown below).

GENERAL PARAMETERS RETRACT CLEARANCE RAPID TRAVERSE PECK CLEARANCE PLANE CHORD ERROR DEPLETION RETRACT INTERRUPT CYCLE Z RETRACT

0

99.0088 400.6 0.0500 8.0801 0.0858 YES

IN IPM In IN IN

F 1 F 2 I. F 3 F 4 r P HOLES 5 PARAMETERS P MILLING 6 PARAMETERS

Enter clearance height ahoue E START at which tool moues between operations PRESS MANUAL MODE, POWER, AND START TO RESTORE POWER.

P PROGRAM 7 PARAMETERS i F EXIT B

Figure 2-148. General Parameters

The Rapid Traverse field is an important parameter when using a rotary axis. The maximum "A" axis rapid traverse rate is 3780 degrees per minute or 10.5 rpm. This equals 400 inches per minute in the Ultimax system. This value can be reduced to slow the rapid traverse by entering a value less than 400 inches per minute . Then each time the rotary table moves past its 360 angle, the system will display the message "Axis Limit . Switches : A-CAL."

Ultimax 3 System

Revision A

2-235

Operator's Manual

Rotary Programming Options To access the rotary programming options, the operator must have selected the Rotary A (F2) softkey on the Input screen. Then the operator presses the Part Programming softkey on the Input screen to access the screen shown below:

BLOCK

1

® NEW BLOCK

Choose type of block

Figure 2-149. New Block screen with Rotary soft key

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Hawk 5M Machine

40

Conversational Part Programming The operator presses the Rotary (F7) softkey. to access the rotary data block options.

BLOCK

1

I NEW BLOCK F 1) ROTARY 1 POSITION F 2) ROTARY LINES 2 AND ARCS F 3) ROTARY CIRCLE 3 F 4) ROTARY FRAME 4 F 5) ROTARY LOOP 5 F 6) ROTARY 6 LOCATIONS F 7) PATTERN END 7

Choose type of block

F 8) ROTARY 8 PARAMETERS

Figure 2-150. Rotary Options on the New Block screen

The rotary options softkeys have.the following uses:

Ultimax 3 System

•

Rotary Position (Fl) - a position block must be added before any other rotary option in the part program because this data block defines the "A" reference position from which to work.

•

Rotary Lines and Arcs (F2) - describes segments the will cut lines and arcs around a cylinder shaped part.

•

Rotary Circle (F3) - describes a machined circle that wraps around the rotary center line.

•

Rotary Frame (F4) - describes a machined frame that wraps around the rotary center line.

•

Rotary Loop (F5) - describes the number of times a rotary pattern will be repeated.

•

Rotary Locations (F6) - indicates the locations where a pattern will be repeated and the distances between repetitions on the part.

•

Pattern End (F7 ) - marks the end of a rotary pattern in the program.

•

Rotary Parameters (F8) - defines the two primary rotary parameters: Cylinder Radius and Y Off of Centerline.

Revision A

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Operator's Manual

Rotary Parameters Press the Rotary Parameters (F8) softkey option to display this screen.

BLOCK

1

ROTARY PARAMETERS

CYLINDER RADIUS ®

0.0000

V OFF OF CENTERLINE

MO

I F 1 0 2 I F 3 F 1 i F S i F 6

Enter radius of cylinder on which cutter compensation is computed

PROGRAM PARAMETERS PART SETUP

TOOL SETUP

F 7 F EXIT 0

Figure 2-151. Rotary Parameters

Fields Cylinder Radius

Definitions is used to perform rotary cutter compensation and rotary contour arcs. It must be a non-zero value only if computations are to be based on a cylinder other than the one that includes the Z Start point.

Y Off of if the tool should automatically position in "Y" Centerline directly over the centerline for rotary milling operations, change this field to "Yes" to select the option. When this option is selected, the Rotary Position block must move the tool to the desired "Y" dimension before rotary milling.

Caution If the operator does not enter a Cylinder Radius value for the part, the machine will mill the part as if it has a flat work surface.

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Hawk 5M Machine

Conversational Part Programming

Rotary Position Block A position block must be added before any other rotary data block in the part program because the Position block defines the "A" reference position from which to work. If a "Y" dimension other than zero is programmed and the "Y" off of centerline option is a "No" Rotary Parameters Block, the tool will position to the "Y" value, but will reposition over the center of the rotary table before performing any "A" axis movement. BLOCK

1

I

ROTARY POSITIOII

TOOL

B

x

0.0880

Y

8 . 0080

A

0.888

ROTARY SAFETY MOVE

MO

F 1 I F 2 I

F

STOP

3 1 F PROGRAM 4 PARAMETERS I F PART SETUP 5

No

TOOL NOT PROGRAPHO

F TOOL SETUP 6 F 7

Enter tool number

F EXIT 8

Figure 2-152. Rotary Position Block

Important If a position block is not added , the system displays an error message when it encounters a rotary block and will not execute the rotary instructions in the block.

Ultimax 3 System

Revision A

2-239

Operator's Manual

To create a position block, the operator presses the Rotary Position (Fl) softkey on the new Block screen, and this screen appears:

Fields Tool

Definitions is the number of the tool that will be used for the rotary operation described in the next data block in the part program. '

X enter the "X" coordinate (relative to part zero) of the desired table position. Y enter the "Y" coordinate (relative to part zero) of the desired table position. Rotary Safety Move

select "Yes" or "No" indicating whether or not this Position block is a safety move. If the operator selects "Yes," the machine position fields appear so that the operator can enter the location of absolute zero on the table.

X Machine Position

enter the "X" coordinate for absolute zero on the table. This value does not change and is not relative to the part. (This conditional field appears if "Yes" is selected in Rotary Safety Move.)

Y Machine Position

enter the "Y" coordinate for absolute zero on the table. This value does not change and is not relative to the part. (This conditional field appears if "Yes" is selected in Rotary Safety Move.)

A enter the "A" axis coordinate (relative to part zero) of the desired table position. Stop

2-240

If the operator wants the program to stop and display a message at this point in the program, press the "Yes" softkey. Then the operator will need to press the Start Cycle console button to restart the part program.

5/20/94

Hawk 5M Machine

Conversational Part Programming

Rotary Milling Operations Rotary milling operations can be programmed as "X-A-Z" operations. The "Y" axis is normally held fixed at the "Y" centerline dimension, but an option in the Rotary Parameters allows "Y" to remain where it is currently positioned. The programmed feedrates are defined as surface inches-per-minute (ipm) for the part of the tool doing the most cutting (i.e., part of tool farthest from the rotary centerline). In most cases, this point corresponds to the Z Start dimension, but it can be the previous peck level. Milling operations constructed of segments begin with a Start segment (shown below) to define the tools, cutter compensation, and starting points for the segments that will be defined in subsequent segments.

BLOCK T

1

ROTARY MILL CONTOUR

R

START

TOOL

I

Q)TTER COMP . •

1

F 1) NO 1 PLUNGE FEED

8.8

SPEED (RPM)

8

No

FINISH TOOL

0

X START

P 2) LEFT 2 i F-3) RIGHT

PECK DEPTH

3

0.0808 P 4) PROFILE LEFT

4 TOOL NOT PROGRAMMED

A START

F 5) PROFILE RIGHT 2 START

0.8080

S

2 BOTTOM

0.0080

P 6) POCKET 6 BOUNDARY i F 7) POCKET 7 ISLAND

Select cutting operation

F1 EXIT 8

Figure 2-153. Rotary Milling Operations

"X-A" cutter compensation (options shown in the softkey list above) is ed and occurs on the surface of the cylinder. These calculations default to using the cylinder that includes the Z Start point, but the operator can choose a cylinder of a different radius by programming a Rotary Parameters block before milling blocks.

Ultimax 3 System

Revision A

2 - 241

Operator's Manual

Lines and Arcs After entering a Start segment , the operator presses the Advance key to add a new segment . To describe the end points of a line, the operator presses the Line (F1) softkey. To define the direction , end and center points of an arc, the operator presses the Arc (F2) softkey. For rotary lines and arcs, the "Y" axis is disabled and the "A" axis replaces it. The position of the tool in the "Y" axis is determined by the Rotary Parameters and Rotary Position blocks.

BLOCK

1

ROTARY MILL CONTOUR

SEGMENT

1

LIME

F

X END

( X START (A START ( Z START

A END 2 END

FEED

8.8800

8.8

Enter coordinate of and point , if known

t P S i F 6 i F PREVIOUS SEGMENT 7 r F EXIT 8

Figure 2-154. Rotary Line

Contours can be built from "X-A-Z" line and arc segments.

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Hawk 5M Machine

Conversational Part Programming

Important Automatic calculation (Ultimax No-Calc) is not available for the rotary axis. The operator must calculate the values of unknown tangency points, end points, and center points for lines and arcs. The simple method to perform these calculation is to program the profile in normal lines and arcs (X, Y). Then the system calculates all unknowns. (Refer to the sample program at the end of this section.) All "Y" dimensions in the calculation program must then be translated into "A" dimensions by using the formula shown below. In the equation, "r" is the radius of the cylinder.

A=180XY 7Cxr Figure 2-155. Formula to calculate unknown rotary line and arc points

Ultimax 3 System

Revision A

2 - 243

Operator 's Manual

Rotary Frame The main difference between Rotary Circles and Frames and standard Circles and Frames is that the rotary versions are wrapped around the radius of the cylinder, and the "Y" dimensions are now specified in "A" angular) dimensions.

BLOCK

1

ROTARY MILL FRAME F

TOOL

• 0

TYPE

ON

FINISH TOOL

0

X CORNER

0 . 0000

A CORNER

0 . 008

X LENGTH

0.0888

A LENGTH

0 . 088

Z START

6.0008

1

Z BOTTOM

6.0008

F 2 i F 3

PLUNGE FEED

6.8

MILL FEED

0.0

r

CORNER RADIUS

SPEED (RPM) PECK DEPTH

0 0 . 0808

TOOL NOT PROGRAMMED

0.8000

F 4 1 F 5 i F

6

1

PROGRAM PARAMETERS PART SETUP

TOOL SETUP

F 7

Eller tool number

F EXIT B

Figure 2 156. Rotary Frame

Important If the dimensions on the blue print are given in "X" and "Y" dimensions, the. operator needs to use trigonometry to calculate the proper "A" values.

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Hawk 5M Machine

Conversational Part Programming

Rotary Loop A Rotary Pattern Loop is similar to a Loop Linear block except the "A" dimension replaces the "Y" dimension and allows the loop to revolve about the cylinder, if desired. Nesting two Rotary Loop blocks could simulate a rectangular grid wrapped about the cylinder similar to Loop Rectangular blocks in regular programming. The fields on this screen indicate the number of times the pattern will be repeated and the distances between the repetitions:

BLOCK NUMBER

1

ROTARY PATTERN LOOP

I

F I

1

X DISTANCE

0.8008

A DISTANCE

8.800

I.

F 2 F 3 F PROGRAM 4 PARAMETERS F PART SETUP 5 P TOOL SETUP. 6 F 7

Enter muber of patterns

F EXIT B

Figure 2-157. Rotary Pattern Loop

A Rotary Pattern End block must follow at the end of the sequence to close the pattern. A Rotary Position block must follow any Rotary Pattern Block(s) in the program. Pattern blocks can only modify blocks contained within the pattern. This Rotary Position block gives the pattern a reference to work from when starting from the beginning or using Recovery Restart.

Ultimax 3 System

Revision A

`

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Operator's Manual

Rotary Pattern Locations Rotary Pattern Location Blocks are identical to two-dimensional Pattern Location Blocks with the "A" axis being added to the end of each location.

BLOCK

11

I

-

ROTARY PATTERN LOCATIONS

X OFFSET

V OFFSET

Z OFFSET

A OFFSET

8.8888

8 . 8688

8 . 8888

8 . 888

F DELETE LOCATION 1 F INSERT LOCATION 2 BEFORE F 3 F 4 F

F 6 Enter an offset to moue the pattern to a neu location

F

I F EXIT 8

Figure 2-158. Rotary Locations

A Rotary Pattern End block must follow at the end of the sequence to close the pattern. A Rotary Position block must follow any Rotary Pattern Block(s) in the program. Pattern blocks can only modify blocks contained within the pattern. This Rotary Position Block gives the pattern a reference to work from when starting from the beginning or using Recovery Restart.

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Hawk 5M Machine

Conversational Part Programming

Sample Rotary Program Here is the rotary part drawing used to develop the sample programs:

Figure 2-1 59. Part Drawing usedfor the sample Rotary program

There are two programs included in this section. The first is used to calculate values used in the second program. The second program is the actual rotary program.

Ultimax 3 System

Revision A

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Operator's Manual

Preliminary Calculation Program Since the rotary software does not calculate unknown values for lines and arcs, Ultimax operators often create a simple 2-D program to determine unknown values. Then they place the calculated values from the 2-D program into the rotary program.

Here is an illustration of the preliminary calculation program developed for the rotary drawing shown on the previous page. Note that this is simply a flattened version of the edges of the rotary part.

Figure 2-160. Illustration of Preliminary Calculation Program

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Hawk 5M Machine

Conversational Part Programming Here is a copy of the preliminary calculation part program. After completing this program, the operator must print it to have a copy of the values for the actual rotary program. Hurco Ultimax Part Program

Metric Standard

1

Prlmcalc.HD3

Part Setup Part Zero X

0.0000

Safety

Work

Region

Offset

Y Z

(+) Z Top Z Bottom (-)

0.0000 0 . 0000

9999.0000 9999.0000

Part Zero A

X Left (-)

0.0000

9999 . 0000 9999.0000

X Right (+)

A. Centerline

32.000

Y Front (-) 9999 . 0000 9999.0000 1

Y

Z

0.000

Y Back (+) Fixture Offset

General Parameters

999.000 MM MMPM 10160.0

Retract Clearance Rapid Traverse Peck Clearance Plane

1.270

MM

Chord Error

0.003

MM

Depletion Retract

0.127

MM

Holes Parameters

0.500

Bore Orient Retract

MM

Drill Dwell

0.5 SEC

Bore Dwell

1.0 SEC Milling Parameters

Finish XY

3.000 3.000 100 100 0.200

MM MM % % MM

Finish Z

0.100

MM

Milling Direction Pocket Overlap

Climb

Blend, Offset Blend Overlap Finish Feed Finish Speed

10

Cutter Comp Parameter

Ultimax 3 System

Revision A

%

Insert Arc

2 - 249

Operator' s Manual

Hurco Ultimax Part Program

2

Metric

Prlmcalc.HD3

Standard Program Parameters

Override Lockout

Off

Program Protect

Partial

Tool Change Position

No

Tool Setup 1

Diameter

6.000

Zero Calibration Speed (RPM)

-10000. CW

1000

Coolant

Off

Gear range

1

Tool Number

1

Diameter Offset

1

Length Offset

1

The number to the left of the following data block name is the block number. Data Blocks 1

Mill Contour Segment

0

Start

Tool

1

Cutter Comp.

Plunge Feed

500.0

Left

Finish Tool

0

Speed (RPM)

X Start Y Start Z Start Z Bottom Lead Length

-64.500 0.000 1.000 -5.000 0.0000

Peck Depth

Lead Angle

1000

0.000

0.0000

This is the Start segment block used to identify the tools and other features of the following segments.

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Hawk 5M Machine

Conversational Part Programming

Hurco Ultimax Part Program

3

Metric

Prlmcalc . HD3

Segment

-

1

Arc

Direction

CW

X End

CAL

Y End

CAL

X Center Y Center Radius Feed

CAL

2

-59.261 9.371

-53.500 0.000 .11.000 500.0

Line CAL

-35.239

CAL

24.140

Z End XY Length

CAL

-5.000 28.199

XY Angle

CAL

31.584

Segment X End Y End

500.0

Feed Segment

3

Arc

Direction

CCW

X End

- 30.000

.Y End

33.510

X Center

-41.000

Y Center

AL

Radius

33.510 11.000

500.0

Feed

Segment

4

-Arc CCW

Direction

X End

CAL.

Y End

CAL

X Center Y Center

Radius Feed

Ultimax 3 System

Standard

-35.239 42.881

-41.000 CAL

33.510

11.000 500.0

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4

Hurco Ultimax Part Program

Metric

Prlmcalc . HD3

Standard

X End

Line CAL

Y End

CAL

Segment

5

-59.261 57.649 -5.000

Z End XY Length

CAL

28.198

XY Angle

CAL

148.418

500.0

Feed

Segment

6

Arc CW

Direction

-64.500 67.020 -53.500 67.020 11.000 500.0

X End Y End X Center

AL

Y Center Radius Feed

Segment

7

Arc CW

Direction

X End

CAL

-59.261

Y End

CAL

76.391

-53.500

X Center CAL

Y Center

11.000 500.0

Radius Feed

Line CAL

-35.239

Y End

CAL

91.159

Z End XY Length XY Angle Feed

CAL CAL

-5.000 28.199 31.583 500.0

Segment X End

2 - 252

67.020

8

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Hawk 5M Machine

Conversational Part Programming

5

Hurco Ultimax Part Program

Metric

Standard

Prlmcalc.HD3 Segment

9

Arc CCW

.Direction

X End Y End X Center Y Center Radius Feed

Segment

CAL

10

-30.000 100.530 -41.000 100.530 11.000 500.0

Arc CCW

Direction X End

CAL

-35.239

Y End

CAL

109.901 -41.000

X Center

CAL

Y Center Radius Feed

Segment

11

100.530 11.000 500.0

Line

X End

CAL

-59.261

Y End

CAL

124.669

-5.000

Z End XY Length

CAL

28.199

XY Angle

CAL

148.417

500.0

Feed

Segment

12

Arc CW

Direction

-64.500 134.040 -53.500

X End Y End X Center Y Center

Radius Feed

Ultimax 3 System

CAL

134.040

11.000 500.0

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Hurco Ultimax Part Program

6

Metric

Pr1mcaic.HD3 Segment

Standard 13

Arc

Direction

CW

X End

CAL

Y End

CAL

X Center

Y Center Radius Feed

Segment

CAL

14

X End

-59.261 143.411

-53.500 134.040 11.000 500.0

Line

CAL CAL

-35.239 158.179 -5.000

XY Length

CAL

28.199

XY Angle

CAL

31.583 500.0

Y End Z End

Feed

Segment

15

Arc

Direction

CCW

X End Y End X Center

CAL

Y Center Radius

Feed

Segment

16

-30.000 167.550 -41.000 167.550 11.000 500.0

Arc

Direction

CCW

X End

CAL

Y End

CAL

X Center Y Center

Radius Feed

2 - 254

CAL

-35.239 176.921

-41.000 167.550 11.000 500.0

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Hawk 5M Machine

Conversational Part Programming

Hurco Ultimax Part Program

7

Metric

Prlmcalc.HD3

Standard

Segment X End

17

Line CAL

-59.261

Y End

CAL

191.689

Z End

-5.000

XY Length

CAL

28.199

XY Angle

CAL

148.417

Feed

500.0

Segment

18

Arc

Direction

CW

X End Y End X Center Y Center Radius Feed

CAL

2

Graphics Off

3

Rotary Parameters

Cylinder Radius Y

-64.500 201.060 -53.500 201.060 11.000 500.0

32.000

Off

of

No

Centerline Rotary

Mill

Contour Segment

0

tart

Tool Cutter Comp.

Finish Tool X Start A Start Z Start

Z Bottom Lead Length

1

Plunge Feed

500.0

Speed (RPM) Peck Depth

1000 0.000

Lead Angle

0.0000

Left

0 -64.500 0.000 1.000

-5.000 0.0000

This is a rotary Start segment block used to identify the tools and other features for the following rotary segments. Note that the "Y" Start field has been replaced with an "A" Start field.

Ultimax 3 System

Revision A

2 - 255

Operator' s Manual

Hurco Ultimax Part Program

8

Metric

Prlmcalc . HD3 Segment

Standard 1

Arc

Direction

CW

X End A End X Center A Center Feed

Segment

-58.833 20.417 -53.500 0.000 500.0

2

Line

X End A End Z End

-35.667 47.677 -5.000

Feed

Segment

500.0

3

Arc

Direction

CCW

X End A End X Center A Center Feed

Segment

-30.000 60.000 -41.000 60.000 500.0

4

Arc

Direction

CCW

X End A End

0.000

* Center

2 - 256

A Center

0.000

Feed

500.0

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Hawk 5M Machine

Conversational Part Programming

Rotary Program The actual rotary program that the operator will use to cut the part uses values calculated in the previous program. Here is the graphic representation of this program.

Figure 2-161. Graphics screen representation of Rotary Program

Due to the difference in perspectives, the graphic representation of a rotary part on the control may not exactly match the part drawing, so operators often use the Dry Run feature on the Test Run screen to test the program before cutting the part.

Ultimax 3 System

Revision A

2 - 257

Operator' s Manual

Here is a copy of the rotary part program . Since Ultimax allows considerable flexibility in developing part programs, this is not the only way the part can be programmed . Watch for inserted explanations of the special features of this sample program. Hurco Ultimax Part Program

1

Metric

Rotary . HD3

Rotary A Part Setup

Part Zero X

0.0000

Y Z

0.0000 0.0000

Safety Region Z Top (+) Z Bottom (-)

Part Zero A

0.0000

X Left (-)

Offset

Work 9999.0000 9999.0000 9999.0000 9999.0000 9999.0000 9999.0000

X Right (+)

A Centerline Y Z

0.000 32.000

Y Front (-). Y Back (+) Fixture Offset

1

General Parameters Retract Clearance

999.000

Rapid Traverse

10160.0 MMPM

MM

Peck Clearance Plane

1.270

MM

Chord Error

0.003

MM

Depletion Retract

0.127

MM

Holes Parameters Bore Orient Retract

2 - 258

0.500

MM

Drill Dwell

0.5 SEC

Bore Dwell

1.0 SEC

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Hawk 5M Machine

Conversational Part Programming

2

Hurco Ultimax Part Program

Metric

Rotary.HD3

Rotary A

Milling Parameters Blend Offset Blend Overlap Finish Feed

3.000 3.000 100 100 0.200 0.100 Climb 10

Finish Speed Finish XY Finish Z Milling Direction Pocket Overlap Cutter Comp Parameter

MM MM % % MM MM %

Insert Arc

Program Parameters Override Lockout

Off

Program Protect

Partial

Tool Change Position

No

Tool Setup 1

Type

End Mill

6.000 0.000

Diameter Zero Calibration Speed (RPM)

CW

1000 Off

Coolant Gear range

1

Tool Number

1

Diameter Offset

1 1

Length Offset

2

Type

Drill 10.000 0.000

Diameter

Zero Calibration Speed (RPM)

CW

1200

Coolant

Off

Gear range

1

Tool Number Diameter Offset

2 2

Length Offset

2

. Ultimax 3 System

Revision A

2 - 259

Operator's Manual

Hurco Ultimax Part Program

3

Metric

Rotary. HD3

Rotary A

Data Blocks

1

Rotary Parameters

Cylinder Radius Y

Off

32.000 of

No

Centerline

If the program will include cutter compensated lines and arcs, this Rotary Parameters data block must be entered.

2

3

Position

Tool X Y

2 -53.500 0.000

Stop

No

Rotary Position

Tool X Y

2 -53.500 0.000

A

4

0.000

Stop

No

Rotary Stop

No

Rotary

Pattern

Loop

Number X Distance A Distance

5

3 0.000 120.000

Rotary Position Tool

2 - 260

2

X Y

-53.500 0.000

A

0.000

Stop

No

Rotary Stop

No

5/20/94

• Hawk 5M Machine

Conversational Part Programming

Hurco Ultimax Part Program

Metric

Rotary.HD3

6

Rotary A

Holes Drill 2

Tool Z Start

1.000

Z Bottom

-5.000 500.0

Plunge Feed

1200

Speed (RPM) Peck Depth

0.000

Peck Type

Standard

Locations

1

7

X

Y

-53.500

0.000

Pattern End

Rotary

Mill

Contour Segment

0

Start

1

Tool Cutter Comp.

Plunge Feed

500.0

0

Speed (RPM)

-64.500 0.000 1.000 -5.000

Peck Depth

1000 0.000

Lead Angle

0.0000

Left

Finish Tool X Start Y Start Z Start Z Bottom Lead Length

Ultimax 3 System

0.0000

Revision A

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Operator' s Manual

Hurco Ultimax Part Program

5

Metric

Rotary . HD3

Rotary A

Segment

1

Arc

Direction

CW

X End

-59.261

A End

16.777

X Center

-53.500

A Center

0.000

Feed

500.0

This segment uses the calculated "Y" End value (9.371) and the part radius (32) from the rotary part drawing. The operator put these values into the formula:

A= 180 xY itxr So that the "A" End value is calculated as follows: 180 x 9.371=16.777 7tx32

Segment X End A End Z End

2

Line -35.240 43.223 -5.000

Feed

Segment

500.0

3

Arc

Direction X End A End

60.000

X Center

-41.000

A Center

60.000

Feed

2 - 262

CCW -30.000

500.0

5/20/94

Hawk 5M Machine

Conversational Part Programming

6

Hurco Ultimax Part Program

Metric Rotary A

Rotary.HD3

Segment

4

Arc CCW

Direction

-35.240 76.777 -41.000 60.000 500.0

X End A End X Center A Center Feed Segment X End A End Z End

5

Line -59.261 103.223 -5.000 500.0

Feed

Segment

6

Arc

Direction

CW

-64.500 120.000 -53.500 120.000 500.0

X End A End X Center A Center Feed

Segment

7

Arc. CW

Direction

-59.261

X End A End

136.777

X Center

-53.500

A Center

120.000

500.0

Feed Segment

X End A End Z End Feed

Ultimax 3 System

8

Line

-35.240 163.223 -5.000 500.0

Revision A

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Operator's Manual

Hurco Ultimax Part Program Rotary.HD3

Segment

7

Metric Rotary A

Arc

9

Direction

CCW

X End

-30.000 180.000 -41.000 180.000 500.0

A End X Center A Center Feed

Segment

0

rc

Direction

CCW

X End

-35.240

A End

196.777

X Center

-41.000

A Center

180.000

Feed Segment

500.0 11

Line

X End

-59.261

A End Z End

223.223 -5.000

Feed

Segment

500.0

12

Arc

Direction

CW

X End A End X Center A Center Feed

Segment

-64.500 240.000 -53.500 240.000 500.0

13

Arc

Direction

2 - 264

CW

X End

-59.561

A End

256.777

X Center A Center Feed

-53.500 240.000 500.0

5/20/94

Hawk 5M Machine

Conversational Part Programming

Hurco Ultimax Part Program

8

Metric

Rotary . HD3 Segment

Rotary A 14

Line

X End A End Z End

-35.240 283.223 -5.000 500.0

Feed

Segment

15

Arc

Direction

CCW

X End

-30.000

A End

300.000

X Center

-41.000

A Center

300.000

Feed

Segment

500.0

16

Arc

Direction

CCW -35.240

X End A End

316.777

X Center

-41.000

A Center

300.000 500.0

Feed Segment

17

Line

X End

-59.261

A End

343.223

Z End

-5.000

500.0

Feed

Segment

18

Arc

Direction

CW

X End

-64.500

A End

360.000

X Center

-53.500

A Center

360.000

Feed

Ultimax 3 System

500.0

Revision A

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Operator' s Manual

and Programs The Ultimax / facility allows operators to transfer part programs between the control and various peripheral devices (e.g., a personal computer or an external disk drive). Programs are transferred from these devices over RS-232-C serial ports. This facility also allows the operator to programs from the control to a parallel printer (connected to the machine tool's printer port). For information about ing and ing NC part programs, refer to the NC Programming Instruction Manual.

Setup Before attempting to communicate with any connected peripheral device, be certain that the correct cable is connected between the designated serial port and the device. Refer to the Maintenance Manual . for more information about required cabling. Also, ensure that the Hurco serial port and the peripheral device are identically configured. Use the Serial Port Setup softkey, described in this section, to check and change the configuration.

Important Improper cable connections and incompatible communications settings are the most common problems encountered when attempting to communicate between two electronic devices.

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Hawk 5M Machine

Conversational Part Programming

Access through the Auxiliary Screen To access the / facility, press the Auxiliary console key. Then press the / (F3) softkey and this screen appears:

mm AUXILIARY a« Make certain the selected port on : 1) 2) : 1) 2) 3) PRINT :

proper cahle is connected betueen the the mill and the peripheral device. Press softkey. Send program from peripheral device. Open file to receive data at the peripheral Press sot they. If necessary , close the file on the peripheral device after transfer is dane. 1) Select the PRINT PROGRAM softkey.

PORT NUMBER PROTOCOL BAUD RATE CHARACTER LENGTH STOP BITS PARITY

1 XON/XOFF 9688 7 1.5 EVEN

F 1 RECEIUE F PRINT CURRENT 2 DIRECTORY F 3 SEND i F PRINT PROGRAM 4 F SELECT PORT S F RESET PORT 6 PARAMETERS F SERIAL PORT 7 SETUP

Choose appropriate softkey

F EXIT 8

Figure 2-162. Auxiliary screen with / facility options

The following options are available from this screen:

Ultimax 3 System

•

Receive (Fl) - allows the control to receive of data from properly connected peripheral such as a personal computer.

•

Print Current Directory (F2) - causes the directory of the current storage device to be printed via a properly connected printer.

•

Send (F3) - enables data to be sent to a properly connected peripheral.

•

Print Program (F4) - enables a part program to be sent and printed onto a parallel printer.

•

Select Serial Port (F5) - switches between the two serial ports and the parallel printer port. When this softkey is pressed, the screen changes to display the other serial port (and its settings) OR the parallel' printer port.

Revision A

2 - 267

Operator's Manual

2 - 268

•

Reset Port Parameters (F6) - resets the displayed serial port to its default values.

•

Serial Port Setup (F7) - enables the selection of the communication settings for the displayed serial port.

•

Exit (F8) - to the Auxiliary screen with the original softkey options.

5/20/94

Hawk 5M Machine

Conversational Part Programming

Receive or Send a Part Program The Receive (Fl) and the Send (F3) softkeys have similar operations. Follow the screen displayed instructions corresponding to the enabled softkey to transfer data between the control and the connected peripheral device. Be certain to identify the correct serial port number. The communication ports allow the following:

•

Receiving of program data from a connected peripheral via either of the ports, but one port at a time.

•

Sending program data from either port (one at a time) to a connected peripheral device.

•

If transferring data from one Ultimax 3 control to another, one is receiving the program data; the other is sending. Follow the screen directions appropriate to each device.

Data can be transferred between the Ultimax 3 control and a peripheral. A message is also displayed near the bottom of the screen to indicate the status of the selected operation. To stop the transfer process, the operator presses the Abort Operation (F8) softkey.

Ultimax 3 System

Revision A

2 - 269

Operator's Manual

Print a Part Program When the operator presses the Print Program (F4) softkey, the part program currently in temporary memory prints on the printer connected to the machine's parallel port. Ultimax s the following dot matrix printers: •

Epson FX

• Citizen MSP-10 and MSP-55 Refer to any of the sample programs in this chapter to examine the structure of printed programs from the Ultimax printing facility.

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Hawk 5M Machine

Conversational Part Programming

Ports The Reset Port Parameters (F6) softkey resets the communication settings of the displayed serial port to the following default values: Protocol

XON/XOFF

Baud Rate

9600

Character Length

8

Stop Bits

1

Parity

NONE

Both serial ports have the same initial default values. The Serial Port Setup (F7) softkey permits the selection of the specific communication settings for the selected serial port. Different softkeys appear depending on the cursor position. Refer to the example below. Select the softkey that is correct for the connected device.

er AUXILIARY ww Make certain the selected port on : 1) 2) : 1) 2) 3) PRINT :

proper cable is connected between the the mill and the peripheral device. Press softkey. Send program from peripheral device. Open file to receive data at the per iphera Press softkey. . It necessary , close the file on the peripheral device after transfer}eldone. 1) Select the PRINT PROGRAM sof

ROTOCOL BAOC-'IBM' CHARACTER LENGTH STOP BITS PARITY

XON/XOFP

F 4 P S

B I NOME

Choose appropriate softkey

Figure 2-163. Auxiliary screen with Protocol options

Important Before attempting to transmit data, be certain that the connected serial port at the control and peripheral port are identically configured. Both must have the same protocol, baud rate, character length, stop bits, and parity.

Ultimax 3 System

`.Revision A

Operator's Manual

Running Part Programs The Ultimax 3 system has a variety of program running options. The operator may wish to run an entire program or only a portion of it. Operators also use the test run facilities and error checking and program run time estimates available from these options.

Warning When running part programs, operators should always follow these rules:

2 - 272

•

Never press the Start Cycle console button without knowing exactly what the machine will do!

•

Never start the machine when the cutter is in with the work piece.

•

Stand away while the machine is running a part program.

•

Never lean on the machine while the spindle is moving.

•

Do not leave the machine unattended.

5/20/94

Hawk 5M Machine

Conversational Part Programming

Console Buttons Used Before running a part program the operator must be familiar with the console keys used to operate the machine and run programs. There are two sets of console buttons used to run part programs located under the CRTs and above the main console . •

Machine Control Buttons - four round buttons on the left

•

Machine Operations Buttons - grouping of rectangular buttons on the right

Machine Control Buttons The operator uses the machine control buttons (shown below) to start and stop the machine. These buttons are located on the upper left of the console under the text CRT.

Start Cycle

Motion Hold

Interrupt Cyde

Power on

0000 Figure 2-164. Machine Control Console Buttons

•

Start Cycle Activates machine operation. When the machine is in an active mode, Start Cycle flashes to indicate the machine is ready. After the operator pressed the button, the light switches off.

Warning Never press the Start Cycle console button without knowing exactly what the machine will do!

Ultimax 3 System

Revision A

2 - 273

Operator's Manual •

Power On - Enables the relay control system. Must be 'on' (illuminated) to operate the machine, but can be `off' when entering or editing program data.

•

Motion Hold - Stops all axes movement, except a tap operation when tool is in the programmed feedrate region. Pressing the button a second time allows machine positioning to resume without loss of position, provided no other button or key has been pressed.

•

Interrupt Cycle - Halts machine operation during automatic execution of a program to allow manual functions to be performed. Pressing the button a second time returns the machine to the interrupted location and allows automatic program execution to resume from the point of interruption.

If the operator presses the Emergency Stop during the execution of a part program, the operator should jog the tool, clear of the part before resuming operation.

2 - 274

5/20/94

Hawk 5M Machine

Conversational Part Programming

Machine Operations Buttons The button on the upper right side of the console under the graphics CRT are also needed to run a part program and control machine systems used during cutting.

- Machine Operations °Tns

o wuwt

nn

Mach" Mod•

0 v,

o AUto OrAnud

mwwr nn Too(

Don

a h o o Mt

onwd

Coctont

sprAv

Figure 2-165. Machine Operations Buttons

Machine Mode Buttons The four Machine Mode buttons in the upper left comer of this section of the console have these functions:

Ultimax 3 System

•

Auto allows the operator to run a part program automatically.

•

Single gives the operator access to the Single cycle screen. In this mode, the machine stops the spindle after each operation (e.g., contour segment, hole operation, mill subroutine). Pressing the flashing Start Cycle button causes the machining operation to resume.

•

Test gives the operator access to test run facilities such as Dry Run and Feed and Speed Optimization. This function is not available when operating the machine in NC.

•

Manual gives the operator access to manual machine operations that allow axis positioning with the jog unit.

Revision A

2 - 275

Operator' s Manual Spindle •.

On activates the spindle when operating when using Manual operation . The Start Cycle button must also be pushed to start spindle rotation.

•

Off If the Spindle On button was previously pressed, this button stops spindle rotation when using Manual operation.

Tool Changer These buttons are not used on the Hawk 5M since it does not have an automatic tool changer.

Coolant

2 - 276

•

Auto activates the use of the selected coolant programmed in Tool Setup. If the coolant has been selected for a specific tool, when this key is pressed, the selected coolant switches on whenever the tool is below Retract Clearance plane. The coolant turns off when the tool moves above the Retract Clearance plane.

•

Mist Functional only on machines equipped.with mist coolant system. This key activates the mist coolant system when using Auto operation. Key can be toggled to override Auto coolant key and switch coolant off and on. Key also enables mist coolant system during Manual operation.

•

Flood Functional only on machines equipped with flood coolant system. This key activates the flood coolant system when using Auto operation. Key can be toggled to override Auto coolant key and switch coolant off and on. Key also enables flood coolant system during Manual operation.

5/20/94

Hawk 5M Machine

Conversational Part Programming

Manual This. Machine Mode provides access to machine operations that enable axis positioning from the console, machine calibration and other operations indicated on the screen.

Pressing the control's Manual button displays the screen shown below. The information at the top of the screen includes the current position of each axis relative to machine absolute and part zero. To activate machine movement, the operator must also press the Power On button.

-MACHINE 393.788 177.888 0.888

x V Z.

MANUAL

PART 393.788 177. 808

--

MACHINE VERTICAL TOOL IN SPINDLE 8 SPINDLE 0 FEED MOTION STOPPED

I

F TOOL IN SPINDLE 1 I F MACHINE 2 DIAGNOSTICS i F 3 F PARE MACHINE 4 F WARM UP MACHINE

F TOOL HOME 6 F RESET SERVOS 7 AND SPINDLE i F CALIBRATE MACHINE 8

Choose appropriate softkey

Figure 2-166. Manual Screen

The following Manual screen softkeys are used when running a part program:

Ultimax 3 System

•

Tool in Spindle (Fl) - When the machine is initially switched on, the Tool in Spindle field (to the left of the softkey) is set to an undefined state and indicated with asterisks (**). If there is no tool in the spindle, the operator enters zero (0).

•

Tool Home (F6) - ensures that the Z axis is at the correct height for a tool to be inserted in the spindle.

•

Reset Servos and Spindle (F7) - activates only to enable recovery from certain types of electronic hardware faults such as overloads.

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Operator's Manual

Test Run This operating mode enables verification of the part program, a means to adjust the programmed feedrates and spindle speeds while cutting the part, and a routine for checking the part program for programming errors.

Press Test button in the Machine Mode console grouping to display the Test Run screen:

TEST RUN RUM ING PART PROGRAM

6061.1603

ESTIMATED RUN TIME

START BLOCK END BLOCK

1 F DRY RUN

0

P FEED & SPEED 2 OPTIMIZATION i F 3

1 36

F CHECK FOR ERRORS 4 F COMPUTE ESTIMATED 5 RUM TIME

F

F 6

F 7

Enter nuwber of desired block

F1 a

Figure 2-167. Test Run screen

When operating in this test cycle, the path of the tool can be traced by running the machine with the Spindle - Off at the Z Start dimension for each data block (in the range of blocks specified). When executing the part program in Dry Run, peck cycles and roughing es are skipped. Before attempting execution, enter the minimum Z value for operating in this test cycle. During this test, the tool traces over the part at the minimum Z level.

Caution if the Z Start dimensions are set below the surface of the rough stock. the minimum Z value for this operation must be programmed so the tool does not plunge into the part.

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Conversational Part Programming

Feed and Speed Optimization The Test screen provides an option to allow the operator to fine tune the execution of the part 'program-the Feed & Speed Optimization (F2) softkey. The Start Block and End Block fields in the Test screen define the area of the part program that will be tuned when the operator presses this softkey to display the screen shown below. To make necessary changes, the operator uses the Axis Feed Rate dial on the jog unit to adjust the values and produce the best results.

ra FEED & SPEED OPTIMIZATION «

I

F SET SPEED I

PART x V Z.

-5.8808 -6.6886 w-nn-^n

TOOL IN SPINDLE a i SPINDLE B F FEED MOTION STOPPED 2 F SET PLUNGE OR 3 SEGMENT FEED BLOCK NUMBER

AXIS LOAD MONITOR 20 40 6B 80

108 S

PART COUNT

x V Za S

Adjust overrides while cutting and press eoftkey to store new value in prograw block PRESS START TO RUN PROGRAM.

t

0 B

F

4 i F SET FEED S i F 6 i F 7 i F B

Figure 2 -168. Feed and Speed Optimization screen

Two of the softkey selections available on this screen (Set Plunge Or Segment Feed and Set Feed) rewrite the currently displayed program's feed and speed values with adjusted values. When a change is made, the screen displays the old value and the new value. These updated values are in a copy of the part program that is being executed. When the run is completed, the old values of the program are automatically erased and replaced with the new values. The control uses the original programmed feedrates for the entire program and the new values do not become effective until the next execution of the program.

Ultimax 3 System

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2 - 279

Operator's Manual The softkeys have these functions: •

Set Feed (F5) - modifies the feedrate for a mill subroutine or all feedrates in an entire contour. This softkey does not change the feed to the Rapid Traverse value while the machine is moving in rapid traverse.

•

Set Plunge Or Segment Feed (F3) - modifies the initial plunge feedrate of the displayed data block or the feedrate for just the current segment of a mill contour.

Feed rates for drilling and boring operations can be adjusted using either the Set Plunge Or Segment Feed softkey or the Set Feed softkeys. •

2 - 280

Set Speed (Fl) - is not used on the Hawk 5M.

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Conversational Part Programming

Single Cycle When this operating mode is enabled, the machine halts with the spindle running after each hole operation, contour segment, or milling subroutine. Machining is resumed when the flashing Start Cycle button is pressed. Pressing the Single console key displays the screen . When the Single Cycle screen first appears, the Start Block and End Block fields are initially set to the first and last blocks of the program . If the operator wants to execute only a certain portion of the program , these fields may be changed to define the limits to be executed. These limits apply to each part produced until new limits are defined.

Figure 2-169. Single Cycle screen

The softkeys of Check For Errors (F4), Computer Estimates Run Time (F5), Recovery Restart (F6), and Run Program (F8) function in the same manner as the softkeys on the Auto screen in the following section.

Ultimax 3 System

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Operator' s Manual To run a single block of a part program, identify the block with the Start and End Block fields and press the Run Program (F8) softkey. This screen appears:

+w SINGLE CYCLE ww PART -8.1258 8.8758 -8.1888 8.888.

X Y Z A

AXIS LOAD MONITOR 28

40

68 88 188 2

I F RESET PART COUNT MACHINE VERTICAL 1 TOOL IN SPINDLE 1 j SPINDLE 480 F FRED MOTION STOPPED 2 ; F 3

RLOCX M UMBER PART COUNT

X V 2 S

3 LIME 8

IF 4 F P 5 IF 6 F1 7

CYCLE COMPLETE : PRESS START FOR NEXT CYCLE.

FI

0

Figure 2-170. Single Cycle with program information

This screen displays the same information about the running program as the Auto screen described in the next section. During execution of the part program, the operator can switch between the Auto Cycle and Single Cycle operations by pressing the corresponding console key.

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Conversational Part Programming

Automatic Operation The screen displays the name of the part program that will be executed in the Running Part Program field at the top of the screen. When the Auto Cycle screen first appears, the Start Block and End Block fields are initially set to the first and last blocks of the program. If the operator wants to execute only a certain portion of the program, these fields may be changed to define the limits to be executed. These limits apply to each part produced until new limits are defined.

». AUTO .. RUNNING PART PROGRAM

6061.HD3

ESTIMATED RUN TIME 0:10:80

START BLOCK

F 3

END BLOCK

F CHECK FOR ERRORS 4 f F COMPUTE ESTIMATED

S RUM TIME F RECOVERY 6 RESTART

Enter number of desired block

F 7

NO ERRORS FOUMD IN PROGRAM.

F RUM PROGRAM

8

Figure 2-171. Auto screen

The Start Block and End Block fields define the limits of the part program to be executed. Different blocks can be selected to execute only a certain portion of the program when the softkeys Check For Errors (F4) and Run Program (178) are pressed. This softkey function starts checking the part program for errors and calculates the Estimated Run Time for the specified data blocks. When this softkey feature is selected, the control begins at the Start Block indicated and completes the test at the End Block shown on the screen. When the check is finished, the Estimated Run Time and the error status of the program are reported. The time required for the program to perform this check depends on the length of the part program and its complexity. The estimated time for program execution is computed from the distances traveled and the average time required to change tools.

Ultimax 3 System

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2 - 283

Operator' s Manual The information reported in the top area of this Auto screen includes the current relative positions of all axes, the tool in spindle number, spindle rpm, and the axes feedrates.

The lower area of the screen displays the Axis Load Monitor showing the instantaneous percentage of full load on each axis. This screen area also identifies the current data block number being executed, the current operation, and the part count. The last two lines on the screen are reserved for information and error messages pertaining to the part program.

•* AUTO w PART 0.8950 -0.8397 0.8258

x Y Z

IS LOAD MONITOR

x

28 48 60 88

MACHINE TOOL IN SPINDLE SPINDLE FEED

F RESET PART VERTICAL 1 1 28888 F 37.5 2 1 F 3

BLOCK NUMBER 108 Y.

/PMT COUNT

7

F 4

2

F 7

F 8

O06RAII IS wm IN

Figure 2-172. Auto screen while the program is running

The Part Count parameter indicates the number of times that a program has been executed. This is an accumulative number count and the control does not distinguish between one program and another. To return this value to zero when a new program is being started, press the Reset Part Count (Fl) softkey.

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onversational Part Programming

When the system encounters a program block that requires tool change, machine motion stops and a message appears on the screen indicating the required action from the operator. See example below. -* PART -3.0586 8.0861 1.1425

X Y Z

AUTO

I

»

F RESET PART COUNT VERTICAL I MACHINE 1 TOOL IN SPINDLE I 2808L F SPINDLE MOTION STOPPED 2 FEED

I-

X

F 3 I. 14 F TOOL CHANGE 4 2 F

Y

S

AXIS LOAD MONITOR 28 40 68 88 108 x

BLOCX NUMBER PART COUNT

I

Z

F 6 FF 7 Ql1r TOOL 2 IN SPINDLE AND PRESS START. T YS RMiIiNC. rR0

FI. 8

Figure 2-173 . Auto screen with Tool Change message

The system also displays messages when it encounters a Position block or errors.

Ultimax 3 System

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Operator' s Manual

Recovery and Restart The Recovery and Restart function allows the operator to restart a part program at almost any point within the program. In most cases, this is the point in which the "running" program was interrupted and it needs to start up again. Usually the End Block is the last block in the program.

Here is a screen showing a part program that the operator stopped using the Emergency Stop button. This program was running Block # 7 when it stopped. AUTO PART 4.4394 8.1488 -8.1325

X Y 2

MACHINE TOOL IN SPINDLE SPINDLE FEED

VERTICAL 1 2688H 37.5

F RESET PART COURT 1 I F 2 FI 3

AXIS LOAD MONI70R

OCR WINDER

7 MILL FRA

28

40

60

88

188 S

PAR

X Y

2

2

t F S

l F 6 F 7 ERGENCY STOP HAS BEEN DEPRESSED. ES,S_NANUAL MODE , POWER. AND START 70 RESTORE

F a

Figure 2-174. Auto screen with Emergency Stop message

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Conversational Part Programming

To restart the program, the operator must first correct any physical problems such as fixturing or work piece placement. Then the operator must restore power if it is necessary. If the Emergency Stop was used to stop the program, the operator presses the proper Start Block and End Block must be selected as shown in the screen below:

AUTO n* RUNNING PART PROGRAM

1548. HD3

F I

F

ESTIMATED RUM TIME

F 2

I.

F 3 t F CHECK FOR ERRORS 4

START BLOCK END BLACK

FCOMPUTE ESTIMATED S RUM TIME F RECOVERY 6 RESTART

Enter number of desired block

7 F FM PROGRAM 8

Figure 2-175: Auto screen with Start and End Block fields When restarting an aborted program, the End Block is normally the last block in the program. Another selection can be made for the End Block. But only if the Start Block is within a Patterns block and the End Block for the Pattern is. included within the range of blocks selected for the restart.

Ultimax 3 System

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2 - 287

Operator' s Manual Here is an example of the blocks in a program:

Block #

Operation

Numbers and Tools

1

Pattern Loop Rectangular

Number 2

2

Holes Center Drill Drill Bolt Circle

Tool I Tool 2 Number 5

3

Pattern Loop Linear

Number 3

4

Contour A

Tool 3

5

Contour B

Tool 3

6

Pattern End

7

Frame

8

Pattern End

Tool4

If the operator selected Block #1 as the Start Block and Block #2 as the End Block, a posted error results because the Loop Rectangular pattern is not resolved with a Pattern End block. However, choosing Start Block #3 and End Block #6 is acceptable since the Loop Linear pattern is resolved with a Pattern End block.

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Conversational Part Programming If the Start Block is inside a Patterns block or a nested Patterns, the starting repetition, location, or image (if mirrored) must be determined for each relevant pattern. In the example below, the system needs to know the pattern location where the program will restart.

«. AUTO

am

RIMING PART PROGRAM

IS48.1m3

START BLOCK

END BLOCK

I F 1

F 6

23

F 2

F

F 3

F

F

4

I.

F I

LOCATIONS

PATTERN LOCATIONS

Starting location

III

1

1

Enter the number of desired starting location

5 F F 6 F 7

F F B

Figure 2-176. Auto screen with Starting Location selections

Information about the applicable Patterns blocks and start block are scrolled on the screen while the necessary questions are being asked by the control. The order in which the data is graphed is the order milled and is helpful in determining the correct start block parameter.

Ultimax 3 System

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2 - 289

Operator' s Manual If the start block is a Milling block with a roughing , finish , or peck levels, the system asks for this information as in the example below.

AU TO RUNNING PART PROGRAM

1549.HD3

START BLOCK

END BLOCK

1

6

PATTERN LOCATIONS

I F 1 . F 2

23

LOCATIONS

1

START B MILL FRAME PECK LEVELS

F 4 F 5

3

Starting peck level

Enter the nuaber of the starting peck level

Figure 2-177. Auto screen with Milling Start Block selections

Important During recovery restart, the control can restart only at segment 0 of a Mill Contour data block, not at a segment within a data block. After the operator presses the Enter key on the control's last question, the Auto screen appears.

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A

Chapter 3

DXF File Translation The Data Exchange Format (DXF) File Translation Option is a graphic and rapid means of creating Hurco conversational data blocks from CAD drawings. The Hurco DXF option allows the operator to select geometric data in the CAD drawing and automatically load it into a conversational data block. Then the operator can use Ultimax screens to add part and tool setup information to create a complete conversational part program.

General Capabilities Both the Ultimax 3 and Ultimax PC software can read and store DXF files in.memory and then display them graphically for conversion . The DXF geometry describes X and Y two-dimensional objects. To convert the geometry rapidly, the operator selects a line, circle, arc or point on the displayed drawing with a pointing device (usually a mouse or trackball). The software automatically converts the selected portion of the drawing into Hurco conversational data blocks.

AutoCAD Files and the DXF Option The DXF File Translation software is compatible with DXF files generated with AutoCAD version .9 and later. The Header section, which contains settings of variables associated with the drawing, is ignored. The layer names from the Tables section are read. The Entities section contains the geometry describing the drawing. The Circle, Line, Points, Polyline, and Arc entities are read from the DXF file. All other entities are ignored.

Ultimax 3 System

Revision A

3-1

Operator' s Manual

Ultimax Programming Features To simplify part programming when using a DXF file as a source, the DXF option uses standard features of the Ultimax 3 software and the dual screen. console. Operators can build the standard holes and milling data blocks and also have the flexibility to perform concurrent programming functions while they are building the part program. For example, they may watch a running program on the Auto screen while selecting and loading portions of the DXF drawing into another part program file. However, most operators prefer to see the new program data blocks on the text screen while working with the DXF file on the graphics screen.

Graphics Display At any time during the process of selecting DXF geometry, the operator can display the Ultimax Tool, Part, and Parameter set up screens and enter data. After the tools are defined for the new program, the control can display a graphic representation of the new part program when the operator presses the Draw console key. To redisplay the original DXF drawing on the graphics screen, the operator presses the Ctrl and Draw console keys.

Data Blocks The operator selects the DXF geometry from the drawing, and the system translates it into Hurco conversational data blocks. The system creates Mill Contour (lines and arcs), Mill Circle, Mill Frame, Mill 3-D and Hole drilling and locations data blocks. The following Ultimax data blocks cannot be automatically created using the DXF option software:

3-2

•

Helix

•

Cutter Insert option

•

Patterns

•

Rotary option Frame

•

Bolt Hole Circle

•

Rotary option Pocket

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DXF File Translation

DXF File Management After operators create CAD drawings in AutoCAD, they copy the DXF onto 3.5" diskettes and take the diskettes to the machine consoles. Then they can either use the files directly from the diskettes or copy the files onto one of the hard drive directories.

Important Operators can only copy DXF files to the control from a diskette, not them from the serial port.

The screen below shows a number of DXF files that have been copied onto the control's root directory. Two of these files are circled. Note that the AutoCAD file names end with the "DXF" extension after the period in the name. I

CURRENT PROGRAM

F CHANGE TO I DIRECTORY

CURRENT DIRECTORY 306216% bytes free 0 bytes tagged.

123 SSSSS DXFDEMOI EAGLE FAMI FAMUCOM NEYSPAR

HD3 - Z34 HD3 HMC A HD3 . DXF DXFDEMOZ. DXF DXF FADAL CFG HNC FAM1 .TAP . CFG FAN"CFG DXF TAP HNC

1 directory(a) 27 program( s). F RENAME 8 programs tagged. 2 PROGRAM F

F :IAS" TEST

i .HD3

2DNASTY DXF DXF .HD3 DXFDEMO4.DXF FAM1 FH FANTEST HMC JAG HD3 VIC HMC

34025 bytes 81-01- 1980 12:45a DEMO . DXF Use arr a keys to moue through program(s)and y I RECTOR IES

F DELETE 3 PROGRAM I

F CREATE 4 DIRECTORY F DELETE S DIRECTORY F SELECT CURRENT 6 STORAGE DRIVE

F -MORE7 Perform disk operations. Use cursor keys to wue between programs and choose softkey. I F EXIT 8

Figure 3-1. Current Directory screen

Operators can copy and save files and group them into subdirectories as described in the "Getting Started" chapter of this manual.

Ultimax 3 System

Revision A

3-3

Operator's Manual A`

Creating a New Conversational Program To begin to build an Ultimax conversational part program from a DXF file, the operator first creates a part program to receive the part geometry. This process is also described in the "Getting Started" chapter.

em MASTER PROGRAM

INPUT aw

I

HAWK SM

o1.50

F PART SETUP Mar.72'94 I

EDIT PART PROGRAM

PROGRAM MEMORY AVAILABLE

99 V.

F PART PROGRAMMING 3 F PROGRAM 4 PARAMETERS F S F COPY AND CHANGE 6 BLOCKS

F ERASE FUNCTIONS Select softke9 or press <Enter> to change part program name 7 F a

Figure 3-2. Input screen

If the operator does not first create a conversational part program, the DXF software will not be able to save the selected DXF geometry and will display the "No program in memory" message. Then the operator will need to return to the Input screen, shown above, and enter a program name and select the unit of measure and machine type.

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Hawk 5M Machine t.

DXF File Translation •

DXF File Display To access a DXF file stored in the control's memory, the operator presses the Auxiliary console key and then the More (F8) softkey to display this screen:

- AUXILIARY EDITOR TYPE : CONVERSATIOMAL

F 1 F CRT DEGAUSS 2

1

F 3 1 F

F UPGRADE EXECUTIVE 6 F RESET MASTER 7

Choose appropriate softkey

F -MOREB

Figure 3-3. Auxiliary screen

Then the operator presses the Read DXF File (F5) softkey.

{Jlfimax 3 System

Revision A

3-5

Operator's Manual The system then displays a Current Directory screen allowing the operator to select the DXF file to be used in this session. The operator highlights the needed file and presses the Enter console key.

mm AUXILIARY «w F CHANCE TO I DIRECTORY I

CURRENT DIRECTORY IC-IS . DXFl

306216% bytes free 1 directory ( s) 9 program ( s). F RENAME 0 bytes tagged. 0 programs tagged . 2 PROGRAM ...._._..__.____.._.._........ ..._...... __........ ___.__......._._.^_..___,_ 3+i 3 "Y.r' ^' ( zF iE tQ2 +X}' DXFDEM03 .DXF r

.t'? bY. LF.N04 b*'.

E

t zz'

(F DELETE @ 3 PROGRAM

F 34

CREATE DIRECTORY

F

DELETE (S DIRECTORY ._... ........... ....... ................. "----'--_..............-IF SELECT CURRENT DXFDEMO3 . DXF 6458 bytes 01-01-1980 12:03a 6 STORAGE DRIVE Use arrow keys to move through srr.:;nan( aland Select . DXF program to read Into memory. Press (Enter > to accept highlighted program name.

F 7 F F EXIT 8

Figure 3-4. Current Directory screen

The original Auxiliary screen appears with a message saying that the system is reading the file.

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Hawk 5M Machine

DXF File Translation The DXF drawing automatically appears on the graphics screen. The five primary screen buttons, circled below, provide access to all of the DXF software features. To select a screen button, the operator moves the crosshair cursor using the trackball to the screen button and then presses the Select console key.

Figure 3-5. DXF graphics screen with main DXF options The screen buttons access these features:

Ultimax 3 System

•

Build DB - accesses the automatic data block building features.

•

Layers - allows the operator to select and display any or all of the layers in the DXF drawing.

•

Zoom Box - allows the operator to select a portion of the drawing to display as an enlarged view or to pull back and see the entire drawing reduced.

•

Parameters - accesses the display parameters that must be set before building data blocks from the DXF drawing.

•

Quit CAD - ends the DXF session and exits the DXF file.

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Operator's Manual

Setting DXF Parameters . To begin a DXF session, operators usually press the Parameters screen button to display the screen shown below:

PARAMETERS Out Of Square Tolerance

0.58

DEGREE

End Point Tolerance

8.88880

IN

Part X Offset

8.00088

IN

8.00000

IN

Part V Offset

I

Convert values to inches

Dimensions are NOT being converted.

Display converted eam.

OFF

Autochain contours

1

ON

Move cursor to box and press to the a ammeter. II

Figure 3-6. Parameters screen for DXF option

The Move Zero screen button is a quick and simple way to relocate part zero graphically on the drawing and automatically enter the values in the data block. When the operator selects the Move Zero screen button, the DXF drawing appears on the graphics screen. Then the operator uses the trackball to move the cursor onto the new location for the part zero and presses the Select console button. Once the part zero location has been selected, pressing the Exit screen button allows the operator to view the values on the Parameters screen.

Important The new part zero location must be an endpoint of a line or the center of an arc or circle

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Hawk 5M Machine

DXF File Translation The options on the Parameters screen have the following uses:

Parameters

Ultimax 3 System

Uses

Out of Square Tolerance

used to enter an angular tolerance for a Mill Frame. When the angular tolerance of a Mill Frame is exceeded the frame becomes out of square and is considered a Mill Contour with lines and/or arcs. (default value = 0.5°, maximum = 360°, and minimum = 0°).

End Point Tolerance

determines when the end points of segments are close enough to be considered equal (or coincident). Setting this parameter to a number that does not exceed the cutting tolerance links the contour segments. However, if the gap exceeds the cutting tolerance, the operator must decide how to modify the drawing to complete the linking of segments of the contour. The default value is 0.0001 inches ( maximum is 1000.0000 inches, minimum is 0 inches).

Part X and Y Offsets

"X" and "Y" coordinate points defining part zero within the drawing. All dimensions are calculated from this point. The part zero symbol is a circle with cross hairs. To change this location manually, move the cursor to the box for Part X or Y Offset and press the Select button. Use the data input box to enter the X or Y Offset values. To change this location graphically and automatically, use the Move Zero box.

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Operator's Manual

Parameters Convertvalues to inches

Uses (continued) converts selected geometry to inches or to millimeters and changes the dimensional values of the DXF file to match the Hurco Part Program units. For example, if the Inches softkey was selected from the Input screen for the Hurco Part Program and the DXF file was drawn in millimeters, the X and Y dimension values for the cursor position will be unusually large. These large dimensions, unless changed, will be used in all new data blocks because the software expects the dimension values for both the Hurco Part Program and the DXF file to be in inches. To convert the metric values of the DXF to inches select the "Convert values to inches" button. If metric was selected from the Input file and the DXF file was in inches , the dimension values would be unusually small . The convert button will now say "Convert values to mm." Select this button to convert inches to millimeters.

Display converted geometry

When this option is switched "On," the converted lines are displayed on the graphics screen in a different color and line style to help the operator see which elements have been converted and which have not.

Autochain contours

By default, segments are automatically chained to create contours. This parameter allows auto chaining to be turned off so that a contour may be created by individually selecting segments into a chained contour. This is particularly useful for creating open-ended contours that are swept into a 3-D shape within a conversational data block.

Selecting the Exit screen button after changing these parameters displays the main DXF system options. '

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Hawk 5M Machine

DXF File Translation The parameters at the top of the screen, Out Of Square Tolerance, End Point Tolerance, Part X Part or Y Offset, require data input to make changes. When the operator selects one of these parameters, the data input box appears:

PARAMETERS Out Of Square Tolerance

0.58

DEGREE

End Point Tolerance

0.08888

IN

Part X Offset

0.08888

IN

0.88088

IN

Part V Offset

1

fconuert values to inches Displa

converted 9eom.

Dimensions a OFF ON

Autochain contours

Enter End Point Tolerance. F

1

I

I

Figure 3-7. Data Input dialog box

The system ignores any numbers entered on the console when this box is on the screen. To use the dialog, box, the operator positions the crosshair cursor on the number or function in the dialog box and presses the Select console key. The selected numbers appear at the top of the box. On the left side of the box, there are three function buttons:

ESC -

use this escape button to exit the data input dialog box without storing any data entry.

CLR -

the clear button erases any numbers previously entered.

ENT -

the enter button loads the numeric value into the parameter field.

Selecting ESC or ENT clears the dialog box from the screen.

Ultimax 3 System

Revision A

3-11

Operator' s Manual

Building Data Blocks To begin building data blocks, the operator must first select one of the screen buttons circled in the example below:

T

^`

m

GAD

Select wem op I

Figure 3-8. Data Block Type Selection

The system creates either hole drilling or milling data blocks. The More screen button gives the operator access to the Edit and Zoom functions.

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Hawk 5M Machine

DXF File Translation

General Concepts There are several general concepts used in the process of building Hurco conversational data blocks from a DXF drawing file. As mentioned earlier, the operator must first create a part program to receive the data block information from the DXF drawing.

Selecting DXF Drawing Elements To select elements of the DXF drawing, the operator uses the trackball to position the crosshair cursor on drawing element, such as a hole or a line, and presses the Select console' key. The system then highlights the selected element. When selecting holes in a drawing, the operator may wish to outline a group of holes using the Window screen button and press the Select console key to select all of the holes outlined by the window. To remove the selection of an element, position the crosshair cursor on the highlighted element and press the Select console key again. This method can also be used to "deselect" segments of a chained contour.

Ultimax 3 System

Revision A

3-13

Operator's Manual

Accept Screen Button After the operator has selected an element from the drawing and modified it if necessary, the operator presses the Accept screen button to load the description of the element into a conversational data block.

Figure 3-9. Accept screen button for Milling

After the operator presses the Accept button, the selected element remains highlighted for a couple of seconds, and then the system automatically loads its description into a data block.

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DXF File Translation

Conversational Data Blocks The system creates a data block describing the circles, line/arcs, frames, and holes and their locations, but the operator will need to add the tool and machine instructions to the data blocks to make them complete. Here is part of a hole drilling data block showing the locations of the holes automatically loaded into the block from a DXF drawing:

BLOCK

2 x

I

HOLES Y >>>

DRILL LOCATIONS

F DELETE OPERATION 1

I F INSERT OPERATION 2 BEFORE I F

1 2 3 4

B.490S 6.7428 4.9950 4.2711

7 .9273 7. 2833 7.9273 9.6758

5

4.9958

- 11.4227

3

6 7 8 9 10 11 12 13

6.7428 8.4985 9.2145 16.0957 16 . 5648 17.6973 18.8299 19. 2990

12.1467 11.4227 9 .6758 9.6758 10.8875 11.2767 10.8075 9 . 6758

F 4 I F 5 I F

14

18 . 8299

8.5425

6

15

17.6973

8.0733

I F 7 I

Press ENTER to edit this operation or use ADVANCE, BACK, or sottkey

PROGRAM PARAMETERS PART SETUP

TOOL SETUP

F EXIT 8

Figure 3-10. Locations in the Holes data block

Ultimax 3 System

-

Revision A

3-15

Operator's Manual

Here is a sample milling data block built from a DXF file. Note that the operator has added the tool and machining data.

BLOCK

2

MILL CONTOUR

SEGMENT

0

START

F 1

TOOL CUTTER COMP . FINISH TOOL

1 POCK BOUNDARY

®

e

X START

18.8968

V START

7.1923

Z START

8.8808

Z BOTTOM

8.8800

POCEET OVERLAP

PLUNGE FEED

0.0

MILL FEED

0.0

SPEED ( RPM) PECK DEPTH (TOOL DIAMETER (TYPE

8 0.8088

F 2 F 3

i

F 4 8.1250) 1 DID MILL) F 5

58

Enter the tool number for the finish or enter 6 it no finish is desired .

F 6 l F 7 I F EXIT B

Figure 3-11. Mill Contour Start data block

Hints and Tricks To examine the new data blocks as the system creates them from the DXF drawing selections, the operator should press the Input console key and select the Part Programming (F3) softkey. All Hurco data blocks will be inserted after the. current block in the part program-

3-16

5/20/94

Hawk 5M Machine

DXF File Translation

Zoom Box Screen Button Many of the data block building screens have a Zoom Box screen button, shown below, that allows the operator to enlarge an area of the drawing or zoom out to see a full view.

Figure 3-12. Zoom Box screen button for Milling

Ultimax 3 System

Revision A

3-17

Operator' s Manual After the operator presses the Zoom Box screen button, the message "Select the first window corner" appears on the screen above a group of new screen buttons.

Figure 3-13. DXF Zoom options

There are three Zoom options accessed from the screen buttons shown above: •

Zoom Out - pulls back from the drawing incrementally to the previous magnification level without recentering the part in the drawing.

•

Fit To View - gives a full scale of the drawing with autocentering the part in the drawing.

•

Pan - relocates the center of the drawing on screen.

To identify the "zoom" area, the operator first positions the. crosshair cursor on a corner of the area and presses the Select console button. To create the window over the area to be magnified, the operator moves the crosshaircursor to the opposite corner of the window and presses the Select console key again.

3-18

5/20/94

Hawk 5M Machine

DXF File Translation

To use the Pan option, the operator moves the crosshair cursor to the place on the screen where the new center of the drawing should be. The then operator presses the Select console key. To turn off the panning option, the operator selects the Pan screen button again or the Fit To View or Zoom Out screen buttons. Here is a "panned" view of the previous drawing:

4 X: -38.5391 Y:-53.3758 Sel wt the

t window corner or nom a ion. I

i

Figure 3-14. Panned view

The Exit screen button returns to the previous screen.

Ultimax 3 System

Revision A

3-19

Operator' s Manual

Layers Many DXF drawings use layers. These layers are an electronic method of representing transparent acetate overlays used in hand-drawn drafting work. A layer is a logical grouping of data to be viewed individually or in combination. Layers are used to organize a drawing into different components and particularly useful for large, complex drawings. Some typical layers seen are drawing (DWG), center reference (CEN), dimension lines (DIM), and assigned numbered layers (e.g., 0, 1, 2). When DXF files are read into the Hurco Part Program, only used layers are read, while unused layers are ignored. To access the Layers function, the operator displays the DXF drawing and presses the Layers screen button.

3-20

5/20/94

Hawk 5M Machine

DXF File Translation All layers are turned ON by default when a DXF file is first loaded into memory. To turn OFF layers 0, 1 and DIM, select Layers after the DXF image is displayed.

CURRENT DXF PROGRAM : C:\DXF\DEMO.DXF Layers ON

0

OM

1

ON

1

ON

CEN DIM

1

DUG

Place cursor in box and press select to toggle On/Off. ®p ) E ^N T.- PACE-1

i

i

Figure 3-15. Layer options

The Next Page and Prev Page screen buttons access more than one page of layers. The layers in a drawing are often numbered so that it is easy to select a range of layers to turn on or off. When the operator selects the Range screen button, a data input dialog box appears. This dialog box functions in the same manner as the Parameters dialog box. The More screen button allows the operator to turn off all layers with the All Off screen button or switch them all on with the All On screen button.

Ultimax 3 System

Revision A

3-21

Operator's Manual

Holes To create a holes data block, the operator presses Build DB screen button on the first DXF screen and then the Holes screen button. The Holes options appear in the screen buttons as shown below:

ED (B (9) G&@GSED 0 ED E EE) S ED

e GD)

^a

E)

ED

X: -1.4562 Y:-3.6745 Use cursor to select/deselect locations , or select hem option. R0rMT Y NWY goal eox INTERSECT

I TNNDO

Figure 3-16. Selecting Holes from the DXF drawing

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5/20/94

Hawk 5M Machine

DXF File Translation

Selecting Holes To select holes from the drawing and load their locations into the conversational part program, the operator uses the crosshair cursor and presses the Select console key or presses the Window screen button to select a group of holes on the drawing.. To "deselect" a hole, the operator positions the crosshair cursor and presses the Select console key or simply presses the Exit/Undo screen button. The description of that hole will not be loaded into the data block. The order in which the holes are selected may be important when the system is building the data block from the information , so the operator may want to consider this order when selecting the holes . If the holes are selected using the Window screen button, default order is the order that the holes were drawn in the original AutoCAD drawing . Refer to the "Accepting Holes " section for more information about optimizing tool path for hole drilling operations.

Intersect Screen Button Some AutoCAD drawings use small intersecting lines to mark hole locations. Since these holes were not drawn as holes, the operator using DXF software cannot use the crosshair to select these holes without first pressing the Intersect screen button. After the hole locations are selected, the system draws a hole center at the intersection of two selected lines and represents the centers with highlighted pluses (+). The operator may also select holes drawn with intersecting lines using the Window screen button.

Ultimax 3 System

Revision A

3-23

Operator's Manual

Accepting Holes After selecting the holes, the operator presses the Accept screen button to load the information into a data block. At this point, the operator needs to decide the order that the machine will drill the holes. The system displays the Default screen button and a message telling the operator to select the first location. Refer to the screen below:

GE)G) &(B ED (1) =' X: -1.4977

V:-2.9926

+

Select the First location to be drilled or DEFAULT to accept selected order. DEFAULT

I

I

1

0n TNl4DO

Figure 3-17. DXF Default screen button and message

The operator can control the order in which the holes will be drilled or allow the system to determine the order.

3-24

5/20/94

Hawk 5M Machine

DXF File Translation There are three methods to select and optimize the hole drilling tool path: I.

Press the Default screen button, and the system will use the order that the holes were drawn in AutoCAD if they were selected using a Window or it will use the order that they were selected if the operator individually selected the holes.

2.

Position the cursor on the first hole and press Select. Then position the cursor on the last hole to be drilled and press Select. The system will determine the shortest path between the two holes.

3.

Position the cursor on the first hole to be drilled and press Select. But then press the Default screen button to tell the system to find the shortest tool path.

If the order that the holes are drilled is of no concern, the operator will probably select method #1. To optimize the tool path, the operator should select either method #2 or #3.

Ultimax 3 System

Revision A

3-25

Operator's Manual To see the tool path that the system has determined, the operator needs to examine the conversational data block created from the DXF information and add tool and machining information. Then the operator presses the Draw console button to display a graphic image of the tool path. Here is a sample tool path for the holes selected from the DXF drawing on the previous page and accepted using method #3:

1.70-Y

The operator selected this as the first hole

V 0

e- &-P- e 0"

q

a

0.58J

m d

°

-8.7C

® 'S

-1.98 -2.68 I

uIw

-1.48

-8.28

1.88

2.28

1

Figure 3-18. Tool Path in the part program

3-26

5/20/94

Hawk 5M Machine

DXF File Translation

Milling To create a milling data block, the operator presses Build DB screen button on the first DXF screen and then the Milling screen button. The four milling options appear in the screen buttons as shown below:

Figure 3-19. DXF Milling options

Lines/Arcs Selecting the Lines/Arcs screen button will create a Mill Contour data block. When the operator selects this screen button, the Reverse, Zoom Box or Exit/Undo screen buttons appear, and a message "Select first segment" appears above them. The Zoom Box and Exit/Undo function as described previously. The operator can use the Reverse screen button to reverse the contour direction. The direction of the contour is determined by the selection point. Since the geometry is defined as individual segments, contours must be defined by autochaining lines and arcs together. The DXF software assists in the chaining and thus avoids the need to select every line or arc in the contour.

Ultimax 3 System

Revision A

3-27

Operator' s Manual When attempting to create a contour, sometimes two segments will not meet due to the method used to draw them originally. There may be a gap that is greater than the End Point Tolerance defined in Parameters. To close the gap, Edit Drawing is selected and the Extend, , or Modify options may be used. A highlighted contour may be trimmed by selecting the segment where the operator wants the contour to be trimmed. The segment the operator selects and all segments following it will be trimmed from the highlighted contour.

In the example below, the operator selected one line and all of the attached lines and arcs were automatically selected.

Figure 3-20. DXF drawing with outside lines and arcs selected

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5/20/94

Hawk 5M Machine

DXF File Translation When a contour segment is selected, the start point of the contour will be the end point closest to the selection point. A contour will be chained beginning with that segment.

Important If, during the autochaining sequence, two or more segments are found that connect to the current segment, they are highlighted and the operator is prompted to select one branch. If the draftsman drew two segments in the same location (e.g., the same line drawn twice), the software detects a branch and highlights the two lines. However, the operator will only see one line highlighted since one is on top of the other. When this occurs, select the highlighted segment and continue with closing the contour.

Ultimax 3 System

Revision A

3-29

Operator's Manual Here is the Start Segment created for the DXF drawing shown on the previous page. Note that the operator will need to enter the tool number and cutter compensation type:

BLOCK SEGMENT

I

I

MILL CONTOUR

B

START

TOOL

F 1 B

CUTTER COMP.

PLUNGE FEED

8.0

SPEED (RPM)

0

FINISH TOOL

B

X START

4.0578

V START

5.9261

Z START

0.8808

2 BOTTOM

0.6008

F 2

I

NO

PECK DEPTH

8.8888

F 3

F PROGRAM 4 PARAMETERS

TOOL NOT PROGRAMMED F PART SETUP 5 F TOOL SETUP 6

Enter a segment ,usher, use ENTER to edit segment, or use ADVANCE, BACK, or softke9

F 7 l F EXIT B

Figure 3-21. Milt Contour Start Segment

This data block also contains a large number of automatically created line and arc segments. This obviously saves the operator a great deal of work. Here is the first segment:

BLOCK

1

MILL CONTOUR F DELETE SEGMENT

SEGMENT DIRECTION

I 1

ARC CCU

X END

4.7649

V END

5.2190

K CENTER

4.4113

V CENTER

5.5725

BAD IUS

8.5088

FEED

(X START (V START ( Z START

4 .0578) F INSERT SEGMENT 5.9261) 2 BEFORE 0.0mo ) l F 3 F PROGRAM 4 PARAMETERS i F PART SETUP 5

0.0

F TOOL SETUP 6

Enter a segment number, use ENTER to edit segment, or use ADVANCE, BACK, or mftke9

P 7 l F EXIT 8

Figure 3-22. Mill Contour Arc Segment

3-30

5/20/94

Hawk 5M Machine

DXF File Translation

Circle To load circle milling information into a data block, operator selects the Build DB screen button and Milling from the next group of screen buttons. When the operator selects the Circle screen button, the system displays the "Select a circle to be milled" message as shown below:

Figure 3-23. Selecting a Circle from a DXF drawing

When the operator selects a circle, it is automatically translated into a conversational data block.

Ultimax 3 System

Revision A

3-31

Operator's Manual Here is the data block the system created for the circle shown in the previous DXF drawing. The system automatically loaded the X Center, Y Center, and Radius values, and the operator added the Tool and Type information.

BLOCY

1

MILL CIRCLE

TOOL

1

TYPE

INSIDE

FINISH TOOL

0

Z START Z BOTTOM PLUNGE FEED

X CENTER

7.2398

MILL FEED

V CENTER

8 . 4810

SPEED (RPM)

RADIUS

2 . 5888

PECK DEPTH

LEAD ANGLE LEAD LENGTH

0.088

(TOOL DIAMETER (TYPE

8.0088

Enter the tool number for the finish or enter 0 it no finish is desired.

I F 0.0808 1 I 0.8888 F 2 0 .0 F F 8.0 3 i 8 F 4 8 . 0888 I F 0.1258) 5 DRILL) I F 6

PROGRAM PARAMETERS PART SETUP

TOOL SETUP

F 7 F EXIT 8

Figure 3-24. Mill Circle data block created from the DXF file

3-32

5/20/94

Hawk 5M Machine

DXF File Translation

Frame The Frame option functions in a similar manner to the Lines and Arcs option. The system chains segments to create the frame. There are some guidelines for DXF frames: •

Segments must consist of four lines with optional arcs for corners.

•

All corners must have the same radius.

•

The frame must be intersecting or lying at right angles to the X and Y axes.

The degrees of rotation are limited to the Out Of Square Tolerance value set on the Parameters screen. To access the Frame option, select the Build DB screen button, then the Milling button, and finally the Frame screen button. The system displays the "Select first segment" message above the screen buttons as shown below:

(D ED

X: -3.8721 V:-2.8835 Select first segment. I I

I

I

I

Figure 3-25. Selecting the First Segment of a Frame

If the selected frame does not comply with the guidelines, the system displays a message stating that the frame is not valid.

Ultimax 3 System

Revision A

3-33

Operator's Manual

3-D Option To use this feature, the system must have the 3-D Milling option installed. The operator loads a DXF drawing containing 3-D features and presses the Build DB screen button, then the Milling screen button, and finally the 3-D Option button. The 3-D option is similar to Lines and Arcs option in that the operator must identify segments and accept them to build the data blocks. These segments must form an open contour or the system will indicate that the part cannot be machined when the operator examines the part program. An open contour is a group of segments that do not have ing ends. In other words, the ends to the chained segments do not meet. The screen below shows a 3-D DXF drawing ready for the operator to select the first segment as indicated by the message above the screen buttons. Note that this is a closed contour, so the operator needs to select half of the segments to form an open contour.

X: 1.6443 y:1.4879 Select first segnent. REVERSE 0

z!oon sox

I

I

IX I ViDIDa

Figure 3-26. 3-D DXF Drawing

3-34

5/20/94

Hawk 5M Machine

DXF File Translation In many cases, the operator needs to modify the DXF drawing to properly select a 3-D Contour. Refer to the "Editing Drawing" section for an explanation of how to use Extend, , Split, and Modify. In this example, the operator uses the Split button to divide the arcs at each end of the drawing. This splitting operation creates an open contour that the 3-D option software can quickly recognize. In the example below, the operator splits the closed contour in half to select the top half of the bulb shape. The resulting open contour will then be rotated about an axis. When splitting the segments, the operator selects large arc and then selects the point where it will be split. Then the operator selects the small arc and the split point.

Figure 3-27. Selecting and Splitting Segments on a 3-1) Contour

The operator exits the editing functions and selects the 3D Option screen button from the Milling buttons. To complete the selection of this contour, the operator positions the crosshair on the top of the contour and selects the contour. Then the operator positions the cursor on the bottom half of the contour and "deselects" it to. remove those segments from the chain.

From this point the operator must work with the part programming screens to complete the program.

Ultimax 3 System

Revision A

3-35

Operator's Manual The tools, cutter comp, feeds and speeds are set to their normal default values. From the selected contour, the system creates a Mill 3-D data block with a default type of Draw 2D contour as shown below. The operator must select one of the 3-D types: XY Revolved about X (F2), XZ Revolved about Z (F3), and XZ Translated in Y (F4).

BLOCX

1

MILL 3D

TOOL

1

TYPE

DRAW 2D CONTOUR

I F 1) DRAW 2D 1 c

5 Ft 6

Choose a surface of revolution or translation generated using a ZD contour a

Figure 3-28. Creating a Mill 3D data block

3-36

5/20/94

Hawk 5M Machine

DXF File Translation The operator entered the Type, Start Angle, End Angle, and Step Size to complete this block:

BLOCK

1

MILL 3D 1

TOOL 6PE

0.8000

2 START

REVOLVE ABOUT

PLUNGE FEED

0.8 0.8

CENTERLINE V

0.8008

MILL FEED

CENTERLINE 2

0.0888

SPEED (RPM)

CUT DIRECTION WITH CONTOUR BIDIRECTIONAL

0

PECK DEPTH

8.8800

STOCK ALLOWANCE

8.8888

F INSERT BLOCK 2 BEFORE I F 3 F PROGRAM 4 PARAMETERS 1

F PART SETUP 8.1258) 5

( TOOL DIAMETER (TYPE

DRILL)

NO

EP SIZE

F DELETE BLOCK 1

0.

Enter a block number, use ENTER to edit block, or use ADVANCE , BACK , or sof tkey

I F TOOL SETUP 6 i F 7

I

F EXIT 6

Figure 3-29. Completed Mill 3D data block

The operator then presses the Draw console key and any of the View options to see the graphic illustration of the part program:

2.18 -V

3.16 V

it

\dl

loss )

8.981

8.681

Ilan! .

-0.98 -2.40 L_ -4.80

-2.50

2 -1.88

0.58

2.88

x

-3.58 -2.30 -0.10

2 . 18

4.30

6.50

2.18

4 . 38

6.58

2.28 2

O W EZZZ' 4r..rci?Fc

8.08 JJ

-2.28

-4.48 -2.38 -8.10

Figure 3-30. Part Program Illustration

Ultimax 3 System

Revision A

3-37

Operator's Manual The system automatically created segments in the data block from the DXF file. Here is the Start Segment:

BLOCK

MILL 3D

SEGMENT

START

X START

-2.8800

Y START

-0.8000

F I F 2 F 3 F PROGRAM 4 PARAMETERS F PART SETUP 5

Enter a segment number, use ENTER to edit segment , or use ADVANCE, BACK , or sot tkey

F TOOL SETUP 6 i F 7 I F EXIT 8

Figure 3-31. Start Segment for the Mill 3D data block

The screen below shows the first arc segment:

BLOCK

SEGMENT DIRECTION

v

1

MILL 3D

1

ARC Cu

X END

8 . 9607

V END

1.7497

(X START (V START

F DELETE SEGMENT 1 f -2.0080 ) F INSERT SEGMENT -0.8888 ) 2 BEFORE

I

F X CENTER

x.0880

V CENTER

8 . 8888

RADIUS

2.8888

3 F PROGRAM 4 PARAMETERS I F PART SETUP 5 F TOOL SETUP 6 f

Enter a segment number, use ENTER to edit segment, or use ADVANCE, RACE, or sottkey

F 7 I F EXIT 8

Figure 3-32. Segment 1 in the Mill 3D data block

The operator should examine all of the segments in the data block and make any changes necessary to run the part program.

3-38

5/20/94

Hawk 5M Machine

DXF File Translation

Editing a Drawing The Edit Drawing option allows the operator to Extend, , Modify or Split segments that need to be edited in order to create the proper geometry for the part program. To access the editing functions, the operator selects the Build DB screen button, then the More button, and finally the Edit Drawing screen button. The editing screen buttons appear as shown below:

Figure 3-33. Editing screen buttons

Ultimax 3 System

Revision A

3-39

Operator' s Manual

Extend When selecting lines in a DXF drawing, the operator may need extend one of more lines. Use the Extend screen button to locate the intersection of two lines and extend one or both of the lines to the intersection point. To extend lines, select the Edit Drawing screen button and then the Extend button. Select the two lines that need to be extended. Both lines are highlighted when selected and extended to their points of intersection as shown in the two examples below:

Original drawing

Edited drawing

Extended line

Edited drawing

Original drawing

Both lines were extended Figure 3-34. Extended lines

3-40

5/20/94

.

Hawk 5M Machine

DXF File Translation

To segments, the operator selects Edit Drawing and then the screen button. The option movess a selected line endpoint to the endpoint of a line or arc segment. The operator always selects as the first endpoint the point that will be ed to the second endpoint. The end point at the opposite end of the first selected segment remains stationary and becomes a pivoting point as shown in the examples below. In the examples, point #1 is the endpoint of the segment that will move, and point #2 is the location where the segments will .

Important The first endpoint cannot be an arc endpoint. Edited /draawing

2

Original

drawing

2

ing endpoint

Stationary endpoint

y_

Newly ed

Selected segment endpoint

segment

Edited drawing

Original drawing ing \ endpoint

stationary endpoint

2 Selected segmenti71 endpoint

Newly j fined segment

Figure 3-35. ed tines and arcs

Both segments are highlighted when selected and the screen is redrawn to reflect the ing of the two segments.

Ultimax 3 System

Revision A

3 - 41 .

Operator' s Manual

Modify Modify is used to view or modify the actual geometry data of segments. The software prompts the operator to select up to three segments. After selecting the segment(s), the operator selects the Accept screen button to view the segment data. In the DXF drawing below, the operator plans to use the Modify function to view the geometry of the line segment marked with the crosshair cursor.

Figure 3-36. Select a segment to modify

3 - 42

5/20/94

Hawk 5M Machice

DXF File Translation The modification data entry screen appears displaying the data for the selected segment. The data for each variable may be modified by selecting the box using the cursor.

First Selected Curve

End Pointl X

•7.418634 INCH

End Pointl V

•S.474321 INCH

End Pointl X

•18.896753 INCH

End Pointl Y

•7.192328 INCH

Len th

1

XV A le

1 •9.140014

•10.815441 INCH DEGREE

Use cursor to select field to edit . ACC 0

i

Select ACCEPT to confirm EXIT to Cancel

i

i

Figure 3-37. Modify segment data

If the operator selects one of the geometry parameters, the pop-up Data Input Dialog Box appears allowing the operator to enter a new value. End points, X & Y angles and length for line segments are displayed. However, Length cannot be edited. Start angle, sweep angle, direction, radius, and X & Y center points are displayed for arcs.

Ultimax 3 System

Revision A

3-43

Operator's Manual

Split Split is used to divide segments for selection, deselection, chaining, and often for 3-D operations. Segments may be split at a midpoint or any point of intersection with other segments. To split a segment, the operator first selects the segment and then selects the point where the segment will be divided. When a segment is selected for splitting, all points where the segments intersect with other lines and arcs and the segments midpoints are marked with a crosshair.

Figure 3-38. Split a segment

3-4

5/20/94

Hawk 5M Machine

DXF File Translation

Completing the Program Before an operator can run a part program created from a DXF drawing file, the Tool Setup, Part Setup, and Program Parameter data must be entered. Refer to the "Getting Started" chapter for more information about these screens. The operator may display and enter data at any time during the part programming process. The screen shown below is a Tool Setup screen. If the operator wants to view a graphic representation of the part during the programming process the tool information must be entered. Otherwise, the graphics screen will not have enough information to produce a picture of the new part.

TOOL SETUP MACHINE

PART

x

TOOL IN SPINDLE SPINDLE FEED

V 2 A

F I ^F 2 P PART PROGRAMMING 3

B TOOL TYPE

I END MILL

F PROGRAM 4 PARAMETERS

0. Sam --------------

.F PART SETUP 5

DIAMETER ZERO CALIBRATION

P TOOL HOME 6 I F SET TOOL ZERO Jog tool down to zero point and use softkey to set too I zero 7 SPEED (RPM) COOLANT SURFACE SPEED

CY

B OFF 0.

P EXIT 8

Figure 3-39. Tool Setup screen

Ultimax 3 System

Revision A

3-45

Operator's Manual After the setup information is entered for the program, the operator must enter specific tool and machining information for each data block within the program. The operator can enter this data as the data blocks are being created from the DXF part geometry or after all the DXF information has been loaded into data blocks.

Caution The operator must examine the tool path for the part program and perform all of the normal dry run and error testing procedures before attempting to run a program created from DXF geometries. the system cannot determine the tooling and machining information from the DXF file. The operator must create that portion of the part program.

3-46

5120/94

Hawk 5M Machine

Appendix

Operator' s Manual

Input Screen Hierarchy Chart Input button I Part Setup screen Part Zero Safety Work Region

Position X , Y Positioning Index Pulses

(if installed) Stop Blocks

Tool Setup screen Set Tool Zero Describe each tool used in the program

Program Parameter screens Retract

Part Programming

Clearance Optimize Drilling & Boring Routines Optimize Milling Routines Program Protect Tool Change Position

Holes Center Drill Drill Gun Drill

Counterbore Spot Face Countersink Tap Bore Standard Bore Orient Bore Rapid Ream

Copy & Change Blocks

Erase Functions

Copy & Relocate portions of a program Move blocks within a program Delete blocks Modify dimensions Change feeds & speeds

Erase Part Setup, Tool Setup, & Part Program Reset Program Parameters Erase All

Milli ng Circle Frame Face Ellipse

Contour Lines & Arcs Blend Arc Helix

Lettering 3-D Mold (if installed)

Patterns

Miscellaneous

Loop Rectangular Loop Linear Loop Angular Loop Rotate

Graphics Off Graphics On Change Parameters Change Part Setup

Pattern Locations

Scale Mirror Image Pattern End

Ream Rapid Back Spotface

Ultimax 3 System

Revision A

A -3

Appendix

Operator's Manual

Coordinate System showing spindle (tool) movement relative to Part Zero

Spindle moves up and away from the part Spindle moves right on part

y Spindle moves away from operator Y

Spindle moves down and into the part

A-4

4/29/94

Spindle moves toward the operator

Hawk 5M Machines

Appendix This section contains charts and diagrams that customers have found helpful when learning to use their Hawk 5M machines. Included in this section are a diagram of the Ultimax 3 console, the Ultimax Input screen hierarchy chart, a coordinate system diagram , recommended chip loads, and feeds and speeds information.

Ultimax 3 System

Revision A

A-1

Operator's Manual

Appendix

Ultimax 3 Console Layout Start Cyde

Notion Hold

Interrupt Cyde

Machine Operations

Pover on

O Auto

0000

OSeple O Test Olbnuot

0000 00

HoeM

a o, Spindle

Teat Screen

==C

er

0o

o Auto 0 Met onaod

Coolant 0

0

0

Cursor Control

Hone

O Au+dbry

0 P "qv

c^o

o orr

-Program Entryo rrput

O uta OHOnuel

J

0 0 0 0 Ne 000E U ^tK ^.e ^tre 00 a 0 0 0000 DNetl

I a

Grophts Screen Droe

C J SNect

Ultirl ox "3 Energency Stop

Ertl

O

O

O

0

Hord Drive

Floppy Drive

0

0

Clear

Nt

Ctrl

Dod.

Advance

Opn C ie, I ho w rated ^

J I

Ultimax 3 System

Revision A

A-2

Appendix

Operator ' s Manual

Suggested Cutting Speeds in Feet-per-Minute For High Speed Steel Endmills Material Steel Up to 240 Brinell (24Rc) 240 to 320 Brinell (24-35 Rc) 320 to 500 Brinell (35-50 Rc) Cast Stainless Cast Iron Regular Hard Non-Ferrous Brass Magnesium Copper Regular Hard Titanium Unalloyed Alloyed

Ultimax 3 System

Cutting Speed (FPM) 90-175 50-90 5-50 60-90 30-80 Formulas: 80-120 5-30 150-500 150-1000 100-500 90-150 30-70

Surface Ft. Per Minute = (RPM x 3.14 x Tool Diameter) / 12 Chip Load = Feed in IPM / (RPM x Number of Teeth) Feed in IPM = Chip Load x RPM x Number of Teeth RPM = (12 x SFPM) / (3.14 x Tool Diameter)

35-55 15-35

Revision A

A -5

Appendix

Operator' s Manual

Recommended Chip Loads MOW

Materials

End M

Mills> ';?

Relieved

Cutters

.013

.010

.008

.007

.004

.022

.018

.013

.011

.007

.022

.018

.013

.011

.007

and Bronze Free Gutting Brass

.022

.018

.013

.011

.007

Medium Brass and Bronze

.014

.011

.008

.007

.004

Hard Brass and Bronze

.009

.007

.006

.005

.003

.013

.010

.007

.006

.004

.016

.013

.009

.008

.005

t^ ron,=med (180-220 BH),

.013

.010

.007

.007

.004

Cast Iron,,hard (2

.010

.008

.006

.006

.003

.012

.010

.007

.006

.004

MedyCrb"on Stee

.010

.008

.006

.005

.003

Alloy Steel (180-220^BI

.008

.007

.005

.004

.003

Alloy Steel (220-300 BH)

.006

.005

.004

.003

.002

Alloy Sigel (300-400BHH)

.004

.003

.003

.002

.002

.006

.005

.004

.003

.002

Alumi

A, iloys'

NNE/[.^' 'M

A -6

4/29/94

Hawk 5M Machines

Appendix

Operator ' s Manual

Feed and Speeds for High Speed Drills The feeds and speeds in the following tables apply to average working conditions and materials. They are recommended with due regard to conserving drills and avoiding excessive machine tool wear. Under many conditions, these feeds and speed may be considerably increased (increase in feed often helps break up chips), while under other conditions they must be decreased. In order to secure the best results, both the speed and feed should be increased or decreased in proper proportion. The liberal use of cooling compound will increase the life of tools. Always keep drills sharp.

Material and Surface Feet per Minute

Feed per Revolution Drill Diameter

Feed per Revolution

Alloy Steel

20 - 30

up to 1/8

0.001 - 0.003

Aluminum and its alloys

200 - 300

1/8 to 1/4

0.002 - 0.006

Brass, Bronze

10 - 20

1/4 to 1/2

0.004 - 0010

Hard Chilled Cast Iron

10 - 20

1 /2 to 1

0.007 - 0.015

Monel

30 - 50

1 and over

0.015 - 0.025

Magnesium

250 - 400

Mild Steel

80 - 110

Soft Cast Iron

70 - 125

Stainless Steel

50

Tool Steel

50 - 60

Titanium

10 - 60

Ultimax 3 System

Revision A

A -7

Index A Absolute zero, 1-24, 1-54, 1-58, 2-240 Advance key, 2-13, 2-18 Arcs, 2-119 3-D, 2-128 blend, 2-121 chord error, 1-78 clockwise, 2-119 rotary, 2-242 Auto button , 2-54, 2-275 AutoSave, 1-32 backup time limit, 1-35 set time, 1-32 Autoscaling, 2-35 Auxiliary screen, 1-29 change program editor type, 1-36 copying programs, 1-98 DXF option, 3-5 printing programs, 2-62 renaming a program, 1-95 reset master, 1-107_..-__. serial port protocol, 2-271 storage functions, 1-38, 1-88, 1-97 system configuration, 1-29 /, 2-267 Axis A axis, 1-44, 2-230

A axis calibration, 1-26 feed rate dial, 1-49, 1-85 jogging, 1-49 load monitor, 2-284 motor over temperature, 1-106 X & Y axes calibration, 1-26 Z axis calibration, 1-26

Ultimax 3 System

•4

B Back spotface, 2-96 Blend arc, 27121

guidelines, 2-122 programming example, 2-123 programming methods, 2-123 types, 2-121 Bolt circle, 2-73, 2-86 fields, 2-87 maximum number of holes, 2-87 radius, 2-87 skip list, 2-87 softkey, 2-19 start angle, 2-87

Bore, 2-91, 2-93 boring bar, 2-93 cycle, 2-93 dwell parameter, 1-80 orient, 2-95

rapid, 2-94 CAD compatibility software, 1-12 files to DXF option, 3-1 to conversational data blocks 3-1 Calculation (automatic), 2-31, 2-116 arcs, 2-120 forcing recalculation, 2-32 helix, 2-127 methods to calculate, 2-103 store-values, 2-31 two possible solutions, 2-118 Calibrate Machine softkey, 1-26 Calibration machine tool, 1-24 tool, 1-68

Revision A

I-1

Operator's Manual

Center drill, 2-69, 2-75 Change Editor softkey, 1-36 Change Program Mask softkey, 1-102 Change to Directory softkey, 1-93 Chip breaker, 2-73 Chip enclosure (UK only) hardware, 1-11

Console keys (continued) Manual, 1-113, 2-275 Motion Hold, 1-28, 2-59, 2-61, 2-274 Page Up & Down, 2-43 Power On, 1-25,•1-110, 1-113, 2-274

limit switch, 1-105

Review, 2-43, 2-182 Select, 1-7, 2-34 Single, 2-275 Spindle Off, 1-59, 2-61, 2-276 Spindle On, 1-59, 2-276

Chord Error, 1-75, 1-77, 1-78 Circle, 2-131 fields, 2-133 type, 2-132 Climb milling , 1-82, 2-112, 2-181 Clockwise arc, 2-119 CNC, 1-6 Concurrent programming, 2-60 access from Input screen, 2-60 while using DXF, 3-2 Conditional fields, 2-12 Console, 1-6, 2-33 floppy drive, 178 Machine Mode group, 1-53 i power up, 1-17

Start Cycle, 1-3, 1-25, 1-28, 1-110, 1-113, 2-272, 2-273, 2-276 Test, 2-275 Contour closed, 2-113, 2-191 Mill, 2-106 open (for 3-D), 3-34 Control power off time, 1-31 Conventional milling, 2-112, 2-181 Conversational part program editing, 2-45 print program, 2-62, 2-270 receive, 2-269

program protection keyswitch, 1-8, 1-85 ---screen blank"time, 1=33 -top , 2-273

running; 2=272` send, 2-269 /, 2-272

Console keys, 1-7 Advance, 2-8, 2-22 Alt, 1-7 arrow keys, 1-63, 2-8, 2-43 Auto, 2-57, 2-275 Auxiliary, 1-9, 1-29, 1-38, 1-88, 1-95, 1-97 Back, 1-106,•2-8, 2-22 Clear, 2-32 Ctrl, 1-7, 3-2 Draw, 2-33, 3-2

Conversational part programming, 2-1 automatic value calculation, 2-31, 2-103 concurrent, 2-60 data blocks, 2-7 general parameters, 1-74 manual run, 2-277 milling parameters, 1-81 principles of, 2-1 recovery/restart, 2-286 rotary data blocks, 2-230 setup, 1-48 single cycle, 2-281 summary, 2-7 switching editor type, 1-36 test run, 2-278

Emergency Stop, 1-3, 1-7, 2-59 End, 2-43 Enter, 1-7, 1-42, 2-8 Home, 2-43 Input, 1-37 Interrupt Cycle, 1-76, 2-59, 2-274 Machine operations, 2-275

1-2

5120/94

Hawk 5M

Index Coolant, 1-68 auto, 2-276 buttons, 2-276 flood, 2-276 mist, 2-276 Copy and Change Blocks softkey, 2-46 Copy Program softkey, 1-99 Counterbore, 2-69, 2-76 Countersink, 2-69, 2-78 Crash prevention, 1-60 Crosshair cursor, 1-7, 2-36, 2-38, 2-40 CRT, 1-7 blank screen, 1-33 for graphics, 2-33 Cutter compensation, 1-67, 2-110 climb milling, 2-112 conventional milling, 2-112 field, 2-108 left & right, 2-111 profile left & right, 2-113 rotary, 2-241 UltiPocket parameters, 2-189 Insert Arc, 1-83 Insert Line, 1-84 when scaling, 2-179 Cutter insert option, 1-13, 2-6, 2-218 diamond faces, 2-223 hexagon,2-226 orientation, 2-221 radius, 2-221 relief 1, 2-221 sample program, 2-228 standard fields, 2-221 triangles, 2-219 type, 2-221 Cutting

inside a cavity, 2-29 problems while, 2-59 safety, 1-3 D Data block, 2-4, 2-7

building from DXF, 3-2, 3-12, 3-15 general concepts, 3-13 changing feeds and speeds, 2-52

Operator's Manual

Data block (continued) copying, 2-49 creation & navigation, 2-8 deleting, 2-13, 2-50 editor, 2-46

fields, 2-8 graphics on/off, 2-35 hole drilling, 2-9, 2-14 modifying dimensions, 2-51 moving, 2-49 number, 2-9, 2-102, 2-251 Position, 2-23 rotary, 2-230 search, 2-34 search from graphics, 2-40 special types of, 2-23

start & end for restart, 2-287 for running, 2-283 start new block, 2-13 suppress execution of, 2-99 Date, 1-30 Delete Block softkey, 2-13 Delete Operation softkey, 2-21 Delete Program softkey, 1-97 Depletion'retract, 1-76, 1-77 Diamonds, 2-6, 2-223 one face, 2-223 two faces, 2-224 Directories, 1-88 changing display lists, 1-102 creating, 1-91

deleting, 1-91 options, 1-90 print current, 2-273 reorganize, 1-98 root directory, 1-88, 1-89, 1-91 structure, 1-89 switching between, 1-90

Disk Operations List Directory softkey, 1-39,1-90,1-95,1-97 Diskette, 2-65 boot from, 1-118 copy program to, 1-99, 1-101 formatting in the console, 1-39

Operator' s Manual Don't Change Z-Start softkey, 2-51 conversational part program; 2-272 . Send softkey, 2-273 Draw key, 2-13, 2-33 Drilling, 2-68 basic drill operation, 2-74 bits, 2-74

center drill, 2-75 completed block, 2-71, 2-73 counterbore, 2-76 countersink, 2-78 dwell parameter, 1-80 field descriptions, 2-70 gun drill, 2-79 softkeys, 2-69 spotface, 2-77 Drives directories on, 1-88 external . transfer from, 2-272 floppy, 1-39

hard, 1-39 failure, 1-118 increase size, 1-11 updating software on, 1-117 program storage, 2-65 protection fr out deletion , 1-91-". Dry run,, 2-55 DXF option, 1-12,3-1 3-D option, 3-34 Accept screen button , 3,-~14 .11 1

autochain , 3-10, 3=13„3=27, 3-29 basic options screen, 3-,7 , 3-7 building data blocks,,3=12 Build general concepts; 31 13 capabilities, 3-1 compatibility, 3-1 completing program; 3-45 create new program, 3-4 Current Directory screen, 3-3 data input dialog box, 3-11 Default screen button,, 3-24, 3-25

DXF option (continued) editing drawings, 3-39 extend, 3-40 , 3-41 modify, 3-42 split, 3-35, 3-44 Exit/Undo screen button, 3-23 'file management, 3-3 file names, 3-3 geometry, 3-10, 3-42 graphics,'3-2 holes, 3-22'' accepting, 3-24 deselecting, 3-23 .'selecting, 3-23 Intersect screen button, 3-23 layers, 3-7, 3-20' milling, 3-27 3-D option, 3-34 circle, 3-31 frame, 3-33 line and ares;i3:27 More screen button, 3-12, 3-39 r ' Move Zero?button , 3-8

optimize tool'path, 3-25 parameters , 3-7, 3-8, 3-9 convert values to inches, 3-10 end point tolerance , 3-9,,3=28<<. out of square tolerance , 3-9;' 3-33

part X & Y offsets, 3-9 Quit CAD' 377, redisplay drawing, 3-2 screen buttons, 3-7

selecting DXF elements, 3-13 tool and part setup, 3-2, 3-45 Ultimax ,features, 3-2 zoom, 3-7, ' Zoom Box screen button, 3-17 -fit to view , 3-18_ identify area, 3-18 pan, 3-18, 3-19 zoom out, 3-18

Index E Editor type, 1-36 Electrical cabinet, 1-1 over temperature, 1-106 Ellipse, 2-143 fields, 2-146 types, 2-144 Emergency Stop, 1-109, 2-59 button locations, 1-7 button release, 1725 during restart, 1-113 for shut down, 1-112 message, 1-112 stopping a running program, 2-286 End of program, 2-13, 2-22 Erase functions, 1-45, 1-46 part setup, 1-46 reset program parameters, 1-46 tool setup, 1-46 Error checking, 2-34, 2-44 Error messages DXF, 3-4 initialization, 1-21 limit switches, 2-235 Machine Configuration, 1-23 machine diagnostics, 1-103 on graphics screen, 2-42 when scaling, 2-179 without Zero Calibration, 2-2 Exit softkey, 2-13 ,N F Face milling, 2-139 fields, 2-142 reference corner, 2-142 types,2-140 X bi-directional, 2-.141 X unidirectional, 2-140 Y bi-directional, 2-141 Y unidirectional, 2-141 Feedrate, 1-71

Feedrate (continued) in run time estimate, 2-44 mill feed, 2-222 plunge , 1-70, 2-70, 2-72, 2-221 Feeds and speeds, 1 -69, 2-115 automatic calculation of, 1-70, 1-71 changing throughout program, 2-52 optimization, 2-279 tapping, 2-90 Fields brackets around, 2-11 conditional, 2-12 while part programming, 2-8 Find, 2-42 Fixturing, 1-3, 1-52 optional 6, 1-11 safety, 1-3 Floppy drive, 1-8

copy program to, 1-39 diskette in, 1-108 errors at start-up, 1-21 selection for storage , 1-39, 2-65 Frame, 2-134 fields, 2-137 from DXF file, 3-9 reference corner, 2-12, 2-137 softkey, 2-10

types, 2-135 G Gear change,1-1

Graphics, 1-62, 2-2, 2-33 data block search, 2-34, 2-40 Draw key, 2-13,'2-33 drawing stops, 2-35 error checking, 2-34;,2-42 isometric view, 2-36 on or off block, 2-35 parameters, 2-38, 2-39 rotary, 2-263' 1

change for all tools, 2-52 chord error, 1-78 finish, 1-81 high-speed cobalt tools, 1-72

Operator's Manual

screen buttons, 2-34 stop drawing, 2-33 views, 2-36

Revision A

Operator's Manual Graphics (continued) while using DXF option, 3-2 XY plane view, 2-41 zoom, 2-38 Gun drill, 2-69, 2-79 fields, 2-81 purpose, 2-79

program parameters, 1-73, 2-3 program protect parameter, 1-85 software version It, 1-22 tool setup, 1-63, 2-3 unprotected, 1-10 Insert Block Before softkey, 2-13 Insert Operation Before softkey, 2-21 Interrupt Cycle button, 1-76, 2-59, 2-274 Interrupt cycle Z retract, 1-76, 1-77 Isometric view, 2-36

H Hawk 5M, 1-1

console, 1-6 hardware options, 1-11 power up, 1-17 routine maintenance, 1-4 safety, 1-2 shut down, 1-109 side view, 1-16 software options, 1-12 Helix, 2-126 Hexagons, 2-6, 2-226 Highlighted fields, 1-103 Holes, 2-66

J Jog unit, 1-49, 1-85 axes jog buttons , 1-59, 1-60 Axis Feed Rate dial, 1-49, 2-56, 2-279 buttons, 1-49 Emergency Stop button , 1-7, 1-49 identifying reference comer, 2-12 manual operation for, 2-275 parameters, 1-50 Store Position button, 1-49, 1-59, 1-60, 1-64, 1-68, 2-12 Jogging axes, 1-49 to identify part zero, 1-59

bolt circle, 2-86 completed block options, 2-21 locations, 2-20, 2-84, 3-23 operations, 2-17 parameters, 1-80 softkey, 2-5

K Keyswitch, 1-8, 1-85

I In/Out buttons, 1-51 Inch, 1-36, 1,-44

protected, 1-9 unprotected, 1-10

in DXF, 3-10 Threads per, 1-66 Indexer option, 1-11, 2-24

L Language files, 1-17 additional, 1-14 changing, 1-114 multiple languages, 1-115 two languages only, 1-114 Lettering, 2-1,47

index pulse value, 1-13, 2-24 software, 1-13

Input screen, 1-44 . concurrent programming, 2-60 DXF option, 3-4

cutter compensation, 2-147 delete a character, 2-149 fields, 2-148

erase functions; 1746 loading part programs, 1-37 part programming access, 2-4 part setup, 1-57, 2-3, 2-233 partially protected, 1-9

1-6

select a letter, 2-149 Limit, 1-103

5/20/94

Hawk 5M

Index Limit switches error, 2-235 Lines, 2-116 rotary, 2-242 Locations, 2-69, 2-84 programming, 2-20 softkey, 2-19 Loop angular, 2-172 linear, 2-169 rectangular, 2-167 rotate, 2-174 Lubrication, 1-4, 1-15, 1-112 to the ways, 1-109 . M Machine Configuration backup,1-35 restore, 1-35 screen, 1-18

display, 1-34 error messages on, 1-23 Machine diagnostics, 1-103 Machine mode buttons, 2-275 Auto, 2-54, 2-275 Manual, 2-275, 2-277 Single, 2-54, 2-275 Test, 2-54, 2-275 to run programs, 2-54 Machine tool, 1-1 calibrate, 1-24 Emergency Stop for shut down, 1-112 jog unit, 1-49 maintenance, 1-4 annually, 1-5 daily, 1-4 monthly, 1-5 quarterly, 1-5 semi -annually, 1-5 weekly, 1-4

Machine tool (continued) power switch, 1-16 powering up, 1-17 prepare for power up, 1-15 shutdown , 1-109, 1-113 standard, 1-44 warm up, 1-27 Make the Changes softkey, 2-48 Manual button , 2-275, 2-277 Manual screen , 1-27, 2-277 calibrate machine tool, 1-24 jog parameters, 1-50 loading tools, 1-53 park machine, 1-110 warm-up machine, 1-27 Measurement units of, 1-36, 1-44 Memory, 2-65 increase size option, I-11 permanent , 1-45, 1 -92, 1-93, 2-63 temporary, 1-30, 1-32, 1-45, 1-47, '1=118 1-44 Metric, draw, 1-11 in DXF, 3 -10`e..

pitch in mm per thread, 1-66 Milling, 2-104

3-D arc, 2-128 calculate centerline, 2-130 fields, 2-129 guidelines, 2-00 3-D option , 1-12, 2-150 used in DXF, 3-34 arcs, 2-119

blend arcs, 2-121 circle, 2-131 climb, 2-112, 2-181 conventional, 2-112, 2-181 direction, 1-82

ellipses, 2-143 face, 2-139 .

major components, 1-1 options, 1-11 parameters used, 1-30 park for shut down, 1-110

Operator's Manual

feeds and speeds, 2-115 frame, 2-134

helix, 2-126 lines, 2-116

Revision A

1-7

Operator' s Manual Milling (continued) options, 2-9 parameters, 1-81 segments, 2-106 softkey, 2-5 Minor image, 2-180 Miscellaneous features, 2-27 softkey,2-6 Modify dimensions, 2-51 part programs, 2-45 Motion Hold button, 1-28, 2-59, 2-61, 2-274

Multiple parts, 2-163, 2-176 N NC part programming optional stop, 1-76 parameters, 1-76 rotary, 2-230 setup, 1-48

switching editor type, 1-36 0 Offset, 1-61 blend, 1-81 maximum, 2-109, 2-114 modifying all, 2-51 pattern locations, 2-176 Operation, 2-17

delete, 2-21 insert before, 2-21 Optional program stop , 1-76, 1-77 Orientation, 2-221 Overlap blend, 1-81 pocket, 1-82 P Parameters bore dwell, 1-80

bore orient retract, 2-95 change within a program, 2-26 conversational part program, 1-75 cutter compensation, 1-83

Parameters (continued) drill dwell, 1-80 erase program, 1-46 for DXF option, 3-8 general , 1-75, 1-77 graphics , 2-38, 2-39 jog unit, 1-50 manual jog feed, 1-50 manual spindle speed, 1-50, 1-59 milling, 1-81, 2-189 NC part program, 1-76 program, 1-85 program protect, 1-9 rapid detent, 1-50 rapid traverse, 2-280 retract clearance, 2-29 rotary, 2-235, 2-238 system, 1-30 Z Top & Bottom, 1-60 Park Machine softkey, 1-111 Part features ellipses, 2-143 face milling, 2-139 lettering, 2-147 Part outline block, 2-99 Part program

automatic stop, 2-23 changing, 2-45 checking, 2-43 copy into temporary memory, 1-40 deleting, 1-97 editing, 2-45 end, 2-22 enter new name, 1-42 erase copy of, 1-45 error checking, 2-44 loading, 1 -17, 1-37 from program directory, 1-38 last program used, 1-37 overwrite, 1-94

part setup, 1-57, 2-233 access to, 1-9 erase, 1-46 importance of, 2-2 permanent storage, 1'-92

HawkSM

Index printing, 2-62 renaming, 1-95 rotary, 2-231 running, 1-62, 2-2, 2-54 save current, 1-93 select and save, 1-99 set units of measure, 1-44 storage, 2-63, 2-65 summary, 2-43 templates, 1-62 tool setup, 1-62 access to, 1-9 erase, 1-46 importance of, 2-2 working with entire blocks, 2-46 Part programming, 2-1 access to functions, 1-10 concurrent, 2-60 conversational, 1-48, 2-1 data blocks, 2-8 general parameters, 1-73 ranges and defaults, 1-77 holes, 2-66 letters, 2-147 milling, 2-104 mirror image, 2=180 NC, 1-48 part setup, 1-54 patterns, 2-163 planning, 1-48 position block,.2-23 protection keyswitch, 1-8 switch editor type, 1-36 tool setup, 1-62 Part Programming softkey, 1-57, 1-64, 2-4,2-13 Part setup, 1-57, 2-233 access to, 1-9 erase, 1-46 importance of, 2-2 softkey, 1-64, 2-21 Z axis offset, 1-61 Part zero, 1-54, 2-25, 2-240 for rotary parts, 2-233 identifying, 1-59

Operator 's Manual

on DXF drawing, 3-8, 3-9 Pattern operations, 2-163, 2-164 basic principles, 2-165 end, 2-165, 2-182 locations, 2-176 loop angular, 2-172 loop linear, 2-169 loop rectangular, 2-167 loop rotate, 2-174 mirror image, 2-180 purpose,2-163 sample program, 2-183 scale, 2-177 softkeys, 2-164 Patterns softkey, 2-6 PC/PC Plus option, 1-13 Peck clearance plane, 1-75, 1-77

depth, 2-70, 2-72, 2-73, 2-109, 2133,2-222 type, 2-70, 2-73 Personal computers, 1-6, 1-90 transfer programs from, 2-272 Ultimax off-line software, 1-13 Pocket cutter compensation parameter, 1-$3 cutter insert-option, 2-218 overlap parameter, 2-12 softkeys, 2-11 Ports parallel printer, 2-62, 2-270 serial , 2-266, 2-271 Position block, 2-23, 2-29 access softkey, 2-5 indexer option, 1-13 operations, 2-25 reduce rapid Z motion, 1-61 Power off, 1-109 problems, 1-20 up, 1-107 Power cabinet, 1-1 over temperature, 1-106 Power On button, 1-25, 2-274 Print, 2-62 .

Revision A

1-9

Operator' s Manual

conversational part program, 2-62, 2-273, 2-276

options, 2-237 parameters; 2-238 part programs, 2-231 part zero, 2-30, 2-233 pattern end, 2-245, 2-246 position block; 2-25, 2-239, 2-245 rapid traverse, 2-235 sample program, 2-247 softkey, 2-6 software, 1-13 start segment, 2-241 Y Off of Centerline parameter, 2-238 Run, 2-272

current directory, 2-273 Printers, 2-62, 2-276 Program parameters, 1-73 Program Parameters softkey, 1-58, 1-64, 1-74,2-21

Protect program from change, 1-9 full protect parameter, 1-85 partial protect parameter, 1-85 partial protect with keyswitch, 1-8 R Radius, 2-221 Rapid traverse, 1-77 during optimization, 2-280 for X, Y, & Z axes, 1-75 rotary, 2-235 Ream , 2-91, 2-94 rapid, 2-95 reaming tool, 2-94 Reboot, 1-107 Recovery Restart softkey, 2-286 Reference comer, 2-12, 2-137, 2-142 Rename Program softkey, 1-95

conversational part program, 2-283 manual, 2-277 test, 2-278 time estimate, 2-44, 2-283 S Safety, 1-2 glasses, 1-2 while running program, 1-3, 2-272 work region, 1-60, 1-75 Sample programs cutter insert, 2-228

Reset Master softkey, 1-30, 1-107 _ Reset Servos and Spindle softkey, 1-25, 1-110,2-277

drilling, .2-99- ------- ----,--milling,2-151 patterns, 2-183 rotary, 2-247 UltiPocket, 2-196 Saving a program, 1-89 to hard drive, 1-93 with date/time stamp, 1-30 Scale, 2-177 cutter compensation, 2-179 factor, 2-179

Restart, 1-113, 2-59, 2-274 conversational part program, 2-286 rotary program, 2-245 start & end blocks, 2-287 starting segment, 2-107, 2-290 Retract Clearance, 1-75, 1-77, 2-29, 2-162, 2-276 Review, 2-43 Rotary, 1-44, 2-230 arc, 2-242 centerline offsets, 2-233 cylinder radius parameter, 2-238 formula for point calculations, 2-243 graphic representation, 2-263 hardware option, 1-11 line, 2-242 line & arc calculations , 2-243, 2-268

Screens Auto, 2-57, 2-58, 2-283, 2-284, 2-285 Auxiliary, 1-29, 1-38, 1-107, 2-273, 3-5 Back Spotface, 2-96 Block Editor, 2-47 Change General Parameters, 2-28 Change Part Setup, 2-30

5120/94

Hawk 5M

Index,

Screens ( continued)

Current Directory, 1-40, 1-90, 1-93, 1-102,3-3

Current Program, 1-40, 1-88, 1-92, 1-94,2-63 DXF graphics, 3-7 DXF Parameters, 3-8 End of Program, 2-22 Feed and Speed Optimization, 2-56, 2-279 General Parameters, 1-74 highlighted fields, 1-103 Holes, 2-15, 2-16, 2-17 Holes Parameters, 1-80 Input, 1-9, 1-10, 1-22, 1-37, 1-73, 2-3,2-4 Language Selection, 1-115 Letter Selection, 1-42, 1-93, 1-95, 2-64 Limit Switches, 1-103, 1-105 Loop Linear, 2-170 Machine Configuration, 1-18, 1-23, 1-34 Manual, 1-24, 1-27, 1-50, 1-53, 1-110, 2-277 Mill 3D, 2-150 Mill Circle, 2-131 Mill Contour 3D Arc, 2-128 Mill Contour Arc, 2-119 Mill Contour Blend Arc, 2-124 Mill Contour Helix, 2-126 Mill Contour Line, 2-116 Mill Contour New, 2-106

Mill Contour Start (segment 0), 2-107, 2-108 Mill Diamond, 2-225 Mill Ellipse, 2-143 Mill Face, 2-139 Mill Frame, 2-10, 2-12, 2-134 Mill Hexagon, 2-227 Mill Lettering, 2-147 Mill Triangle, 2-220 Milling Parameters, 1-81

Screens (continued) Part Setup, 1-57 Pattern End, 2-182 Pattern Locations, 2-176 Pattern Loop Angular, 2-173 Pattern Loop Rectangular, 2-168 Pattern Loop Rotate, 2-175 Pattern Minor Image, 27181 Pattern Scale, 2-178 Position, 2-23 Program Parameters, 1-85 Review Program, 2-43 Rotary Mill Contour, 2-242 Rotary Pattern Loop, 2-245 Rotary Position, 2-239 Single Cycle, 2-281, 2-282 System Parameters, 1-30, 1-33 Test Run, 2-55, 2-278, 2-279 Tool Setup, 1-63, 1-65, 1-69 Security key, 1-14 initialization error, 1-21 Segments, 2-106 fields, 2-108 maximum number, 2-106 numbers, 2-107 planning for recovery, 2-107 segment zero, 2-107 Select Current Storage Directory softkey, 1-93

Serial port reset parameters, 2-274 select, 2-273

setup, 2-274 Set Current System Time softkey, 1-30 Set Tool Zero softkey, 1-64 Shut down, 1-109 automatic, 1-31

Emergency Stop method, 1-112 park machine method, i-110 Single button, 2-54, 2-275 Skip list, 2-87 Softkeys, 1-7 Special softkey, 2-6

New Block, 2-5, 2-9, 2-13, 2-14, 2-105 e Operator's Manual

Revision A

I - 11

Operator's Manual Speed, 1-68, 1-69, 1-70, 2-72 finish, 1-82 for drilling, 2-70 milling, 2-109, 2-133, 2-138 tap, 2-90 Spindle change speed, 1-1 in/out buttons, 1-53 loading tool into, 1-51 manual speed, 1-50 on/off buttons , 2-61, 2-276 overload trip error, 1-106 speed, 1-72, 2-90 speed range display, 1-I stop parameter, 2-70 Spotface , 2-69, 2-77 back, 2-96 Standard Hawk 5M machine tool, 1-44 peck type, 2-73 Start Cycle -button, 1-25,-1-28, 2-273 check operation of, 1-105 warning, 1-3 Start machine, 1-17 Start segment, 2-108 rotary, 2-241 . UltiPocket, 2-192 Storage Functions softkey, 1-38, 1-88, 1-92, 1-95, 1-97, 2-63 Store Calculated Value softkey, 2-31 Store Machine Position softkey, 1-58 Store Position button, 1-49 System Configuration softkey, 1-29

Tap (continued) tapping fluid, 2-90 threads per inch, 1-66, 2-90 Technical services preparation for call, 1-22 Test button, 2-54, 2-275 Test run, 2-278 Time, 1-31 Toggle Program Tag softkey, I-100 Tool, 2-108 broken, 1-62 calibration , 1-61, 1-68 carbide, 1-72 changer buttons, 2-276 cobalt, 1-72 descriptions in the system, 1-63 diameter, 1-67, 1-70,,1-71, 1-72, 2-2, 2-72 finish, 2-108, 2-133 holder, 1-51 In and Out buttons, 1-51 in Spindle softkey, 1-27, 2-277 maintenance, 1-4 number, 1-65, 2-2, 2-11, 2-71, 2-101 number zero, 1-27 setup, 1-9,1,,46, 1-62, 2-10 activate coolant selection 276 changing, 2-21 checking, 1-62 importance of, 2-2 screen, 1-63 templates, 1-62

Setup softkey, 1-57, 2-10 steel, 1-72-

T

types, 1-66, 2-2 zero, 1-64 Tool changer height, 1-106 Tool Home softkey, 2-277 Tools '

Table, 1-1 fixturing part, 1-52 move forward at program end, 2-23 protection, 1-60, 1=110

Tagging, 1-100 Tap, 2-89 feeds and speeds, 2-90 holder, 2-90 maximum speed, 2-89 operation, 2-90

1-12

changing all feedrates, 2-52 changing one feedrate, 2-53 Trackball, 1-7, 2-40 Triangles, 2-6, 2-219

5!20/94

Hawk 5M

Index Troubleshooting hard drive failure, 1-118 power up problems, 1-20.U

Ultimax 3-D option, 1-12, 2-150 automatic calculation, 2-31 console, 1-6 cutter insert option, 2-218 DXF option, 3-1 erase functions, 1-45 executive, 1-116 restart, 1-113 software off-line, 1-13 options, 1-12, 1-34 upgrade,'1-116 version #, 1-22 UltiPocket option, 2-188 UltiPocket option, 1-12 , 2-11, 2-12, 1 2-188 boundary, 2-190 circle, 2-195 Cutter Comp parameter, 1-83 frame, 2-194 lines & arcs, 2-192 milling parameters, 2-189 milling values, 2-190 pattern, 2-196 programming islands, 2-191 sample program, 2-196

Untag All Programs.softkey, 1-100 conversational part program, 2-272 Receive softkey, 2-273 V Version number, 1-22 W Warm Up Machine softkey, 1-28 Ways lube reservoir, 1-1, 1-105 maintenance, 1-4

stop'p lubrication to, 1-109

Work piece, 1-61, 2-72 alloy steel, 1-72 aluminum, 1-72 carbon steel, 1-72 compensate for thickness, 1-61 feeds & speeds, 1-72 fixturing, 1-52 gray cast steel, 1-72 part zero, 1-54 safety region, 1-60

Write Program to Disk softkey, 1-93 Z Z axis, 1-26 drill parameters, 2-70 offset, 1-61, 2-51 rotary, 2-233 start parameter, 2-278

Z Bottom parameter, 1-60, 2-70, 2-72, 2-73, 2-97, 2-109, 2-133 Z Clearance, 2-97 Z Depth, 2-97 Z Retract, 2-97 Z Start parameter, 2-29; 2-51, 2-55, 2-70, 2-72, 2-73, 2-90, 2-96, 2-162

Z Top parameter, 1-60 Zero calibration, 1-64, 1-68, 2-2 Zoom, 2-38