Student

CNC Exercisesfor FANUC and OKUMA

MTS TeachWare Students Book

MTS Mathematisch Technische Software-Entwicklung GmbH Kaiserin-Augusta-Allee 101 D-10553 BerlinPhone: +49 / 30 / 349 960 0 Fax: +49 / 30 / 347 960 25 World Wide Web: http://www.mts-cnc.com email: [email protected]

CNC Exercises

MTS TeachWare Students Book

MTS Mathematisch Technische Software-Entwicklung GmbH

Kaiserin-Augusta-Allee 101 D-10553 Berlin

Phone: +49 / 30 / 349 960 0

Fax: +49 / 30 / 349 960 25

eMail: [email protected]

World Wide Web: http://www.mts-cnc.com

Created by BK,BM 1998.

All rights reserved, including photomechanical reproduction and storage on electric media

Contents

MTS GmbH Berlin 3

Contents

1 Introduction................................................................................................................. ....5

1.1 To the Learner ......................................................................................................................................5

2 Exercises CNC Basics ...................................................................................................6

2.1 NC program for CNC milling with control FANUC 16M.........................................................................6

2.2 NC program for CNC turning with control OKUMA OSP 5020 L ..........................................................8

3 Exercises CNC Milling with control FANUC 16M .......................................................11

3.1 NC programs using linear interpolation...............................................................................................12

3.2 NC programs using circular interpolation............................................................................................18

3.3 NC programs using canned cycles .....................................................................................................22

3.4 NC programs using macros ................................................................................................................28

3.5 NC programs using subprogram technology ......................................................................................32

3.6 Complex programs..............................................................................................................................36

4 Exercises CNC Turning with control OKUMA OSP 5020 L .......................................43

4.1 NC programs using linear interpolation...............................................................................................44

4.2 NC programs using circular interpolation............................................................................................48

4.3 NC programs using Compound Fixed Cycles.....................................................................................54

4.4 NC programs using Lathe Auto - Programming Function LAP ...........................................................58

4.5 NC programs using subprogram technology ......................................................................................62

4.6 Complex programs..............................................................................................................................66

To the Learner

MTS GmbH Berlin 5

1 Introduction

1.1 To the Learner

This set of exercises offers the opportunity to establish your knowledge and capabilities gained with handlingthe MTS CNC Simulator Turning & Milling as well as to extend and apply these.

As the proverb says, practice makes perfect! Provided that you are willing to learn, the book will support youby its systematic structure. The exercises serve two purposes. Firstly, you find your introduction into furtherstudying the CNC technique easily according to your individual preliminary knowledge and independently onthe CNC software available. Secondly, you can make handling the MTS CNC Simulator with its varied fieldsof application accessible for you or perfect it.

You will find out quickly how difficult it is to detect the optimum solution of a problem. Unfortunately, there isno royal road to learning! The best way of the single case does not only depend on the technical andorganizing environment and the workpart spectrum of the CNC manufacture but also on your personalpreference of one or the other working mode. Especially in this respect, the MTS system provides an efficientand multiple program package. It does not oblige you to apply a certain programming method but offers allaccess possibilities of up-dated CNC technique. With regard to this, our approaches are supposed to besuggestions and the prepared final solutions do not represent complete and optimum solutions.

The set of exercises has been created for flexible application. The beginner should start with simpleexercises on turning or milling. Parts or whole exercises should not be skipped unless you feel firm andrepetitions are not required anymore.

Finally, enjoy working with these exercises and have soon success! We are grateful for any suggestions toimprove the book and hints on mistakes or lack of clarity which can never be completely excluded.

Your MTS Training Team

Berlin, 1997

Exercises CNC Basics

6 MTS TeachWare CNC-Exercises Students Book

2 Exercises CNC Basics

2.1 NC program for CNC milling with control FANUC 16M

Exercise: ML-plate

The plate of the drawing is to be manufactured as individual workpart on a CNC vertical milling machine. Theblank is made of AlMg1 dimensioned 100 x 100 x 50 mm. Prepare the production on the MTS - Simulator.Define the workpart zero, plan the operation sequence, work out the process layout and the set-up form. Testand correct the program.

P la te

10

27.5

65

9010

0

51.1

41

Learning Objective: The learner is able to describe the structure of a simple NC milling program and towrite parts of it on his own. He knows the essential steps of set-up, edit andautomatic modes in the CNC Simulator for Milling and comprehends them in theproper sequence.

Special TrainingElements:

Set up and machine a blank at the simulator; select and set up tools.

NC program for CNC milling with control FANUC 16M

MTS GmbH Berlin 7

P la te

10

27.

5

65

9010

0

51.1

41

Exercises CNC Basics


2.2 NC program for CNC turning with control OKUMA OSP 5020 L

Exercise: bolt

The bolt on the drawing made of AlMg1 is to be made on a CNC lathe in higher batch quantity. Prepare themanufacturing process with the MTS CNC Simulator including following steps: define workpart zero, set upthe processing sequence, determine tools, fixtures and technological data; generate, set up, test and correctthe program at the CNC simulator. A bolt with an external diameter of 100 mm and the length of 94 mm isto be clamped for the test.

Use a maximal cutting depth of 5mm for the separate cuts.

B o lt

100

Learning Objective: The learner can accomplish simple steps at the MTS CNC Simulator such as tostart CNC simulation software, select operation modes, referencing, set up tools,define tool zeros, set up blank and fixture, generate, test and correct simple NCprograms.


Set up and machine a blank at the simulator; select and set up tools.

NC program for CNC turning with control OKUMA OSP 5020 L

MTS GmbH Berlin 9

B o lt

100

CNC milling

MTS GmbH Berlin 11

3 Exercises CNC Milling with control FANUC 16M

Tool Types

in the

S im ulator

for M illing

Exercises CNC Milling with control FANUC 16M


3.1 NC programs using linear interpolation

Exercise: Jig Plate 1

The jig plate on the drawing is to be produced on a CNC vertical milling machine from a blank of AlMg1dimensioned 100 x 100 x 50 mm. Prepare the production on the MTS CNC Simulator, work out the processlayout and set-up form.

Use the commands G00 and G01.

5x1 5

10

50

90

J ig p la te 1



Set up and machine a blank at the simulator; select and set up tools. Movementswith G00 and G01

NC programs using linear interpolation

MTS GmbH Berlin 13

5x1 5

10

50

90

J ig p la te 1





Use the commands G00 and G01.

5x1 5

J ig p la te 2





MTS GmbH Berlin 15

5x15

J ig p la te 2





Use the commands G00 and G01

5x 15

J ig p la te 3





MTS GmbH Berlin 17

5x 15

J ig p la te 3



3.2 NC programs using circular interpolation

Exercise: contourplate 1

The contourplate on the drawing is to be produced on a CNC vertical milling machine from a blank of AlMg1dimensioned 100 x 70 x 25 mm. Prepare the production on the MTS CNC Simulator, work out the processlayout and set-up form.

Use the cicular commands G02 or G03 and the cutter radius compensation.

C on tourp la te 1

Learning Objective: The learner is able to solve a CNC milling task with systematic planning of theprocedure and the application of existing system functions.


Cutter radius compensation, commands for circular arcs.

NC programs using circular interpolation

MTS GmbH Berlin 19

C ontourp la te 1



Exercise: contourplate 2

The contourplate on the drawing is to be produced on a CNC vertical milling machine from a blank of AlMg1dimensioned 100 x 100 x 25 mm. Prepare the production on the MTS CNC Simulator, work out the processlayout and set-up form.

Use the cicular commands G02 or G03 and the cutter radius compensation.

C ontou rp la te 2

Learning Objective: The learner is able to solve a CNC milling task with systematic planning of theprocedure and the application of existing system functions.


Cutter radius compensation, commands for circular arcs.


MTS GmbH Berlin 21

C ontourp la te 2



3.3 NC programs using canned cycles

Exercise: Plate 1

The plate on the drawing is to be produced on a CNC vertical milling machine from a blank of AlMg1dimensioned 100 x 100 x 50 mm. Prepare, test and correct the manufacturing process with the MTS CNCMilling Simulator. Define the workpart zero, work out the process layout, set-up form and NC program.

Use the canned cycle G73.

50

5 x35

P la te 1

Learning Objective: The learner is capable of preparing and testing the CNC milling of a workpart ofmedium complexity on a CNC simulating and programming desk by himselfincluding the work organization.


Use of the Canned Cycles.

NC programs using canned cycles

MTS GmbH Berlin 23

50

5 x35

P la te 1



Exercise: Plate 2


Use the canned cycle G83.

5 x35

P la te 2





MTS GmbH Berlin 25

5x35

P la te 2



Exercise: Plate 3


The borehole must be reamed. Use the canned cycle G85.

5H 7 x 30

P la te 3





MTS GmbH Berlin 27

5H 7 x 30

P la te 3



3.4 NC programs using macros

Exercise: plate a with bolt holes and a circular pocket

The plate a on the drawing with bolt holes and a circular pocket is to be produced on a CNC vertical millingmachine from a blank of AlMg1 dimensioned 150 x 150 x 50 mm. Prepare, test and correct themanufacturing process with the MTS CNC Milling Simulator. Define the workpart zero, work out the processlayout, set-up form and NC program.

Use the macro for circular pockets and bolt hole circle.

8X 35

depth of circle pocket 10mm

P la te A

Learning Objective: The learner can describe the function and the calling of macros.


Use of the macros.

NC programs using macros

MTS GmbH Berlin 29

8X 35

depth of circle pocket 10m m

P la te A



Exercise: plate B with bolt holes and a square pocket

The plate B on the drawing with bolt holes and a square pocket is to be produced on a CNC vertical millingmachine from a blank of AlMg1 dimensioned 150 x 150 x 50 mm. Prepare, test and correct themanufacturing process with the MTS CNC Milling Simulator. Define the workpart zero, work out the processlayout, set-up form and NC program.

Use the macro for square pockets and positioning on arc circle.

8X35

depth of square pocket 10mm

P la te B

Learning Objective: The learner can describe the function and the calling of macros.


Use of the macros.

MTS GmbH Berlin 31

8 X3 5

depth of square pocket 10m m

P la te B



3.5 NC programs using subprogram technology

Exercise: Plate S1

The plate on the drawing is to be produced on a CNC vertical milling machine from a blank of AlMg1dimensioned 100 x 100 x 50 mm. Prepare the production on the MTS CNC Simulator, work out the processlayout and set-up form.

Use a subprogram for programming the boring positions.

5 x1 51

0

50

90

P la te S1

Learning Objective: The learners are capable of optimizing program runs by the use the subprogramtechnology.


Subprogram.

NC programs using subprogram technology

MTS GmbH Berlin 33

5 x15

10

50

90

P la te S1



Exercise: Plate S2


Use a subprogram for programming the boring positions.

5 x1 5

P la te S 2



Subprogram.


MTS GmbH Berlin 35

5x15

P la te S2



3.6 Complex programs

Exercise: plate

The plate on the drawing is to be produced on a CNC vertical milling machine from a blank of AlMg1dimensioned 100 x 100 x 25 mm. Prepare the production on the MTS CNC Simulator, work out the processlayout and set-up form.

P la te

Learning Objective: He is capable of milling a workpart of medium complexity. He writes and tests anoperable CNC program.


Cutter radius compensation and canned cycles.

Complex programs

MTS GmbH Berlin 37

P la te



Exercise: contactplate

The contactplate on the drawing is to be produced on a CNC vertical milling machine from a blank of AlMg1dimensioned 100 x 100 x 25 mm. Prepare, test and correct the manufacturing process with the MTS CNCMilling Simulator. Define the workpart zero, work out the process layout, set-up form and NC program.

C ontactp la te

S ec tion

S ection

Learning Objective: He is capable of milling a workpart of medium complexity He writes and tests anoperable CNC program.


Cutter radius compensation, canned cycles and macros.

Complex programs

MTS GmbH Berlin 39

C ontactp la te

S ection

S ection



Exercise: punchplate

The punchplate on the drawing is to be produced on a CNC vertical milling machine from a blank of AlMg1dimensioned 100 x 100 x 25 mm. Prepare the production on the MTS CNC Simulator, work out the processlayout and set-up form.

P unchp la te

S ec tion

S ec tion

Learning Objective: The learner is in an exam-like situation. He is capable of milling a workpart ofhigher complexity He writes and tests an operable CNC program.


Cutter radius compensation, canned cycles and macros.

Complex programs

MTS GmbH Berlin 41

P unchp la te

S ection

S ec tion

CNC Turning

MTS GmbH Berlin 43

4 Exercises CNC Turning with control OKUMA OSP 5020 L

Exercises CNC Turning with control OKUMA OSP 5020 L


4.1 NC programs using linear interpolation

Exercise: bolt with outside machining

The bolt on the drawing made of AlMg1 is to be made on a CNC lathe in higher batch quantity. Prepare themanufacturing process with the MTS CNC Simulator including following steps: define workpart zero, set upthe processing sequence, determine tools, fixtures and technological data; generate, set up, test and correctthe program at the CNC simulator. A bolt with an external diameter of 80 mm and the length of 82 mm is tobe clamped for the test.

B o lt 1



Set up and machine a blank at the simulator; select and set up tools, movementswith G00 and G01.


MTS GmbH Berlin 45

B o lt 1



Exercise: bolt with inside machining


B o lt I1



Set up and machine a blank at the simulator; select and set up tools, movementswith G00 and G01.


MTS GmbH Berlin 47

B o lt I1



4.2 NC programs using circular interpolation

Exercise: bolt with radii

The bolt on the drawing is to be manufactured on a CNC lathe using a blank made of AlMg1 dimensioned 100 x 107 mm. The roughing is to be done manually. Work out all necessary documentation for themachining. Prepare, test and correct the process on the MTS CNC Simulator. Program the external contourfor finish-turning using circular interpolation G02/G03 with the parameters I and K.

B o lt 2

Learning Objective: The learner can describe circular traverse motions of the tool.


Circular interpolation by using the parameters I and K; programming andfabrication of circular contours and tool nose compensation.


MTS GmbH Berlin 49

B o lt 2



Exercise: bolt with radii

The bolt on the drawing is to be manufactured on a CNC lathe using a blank made of AlMg1 dimensioned 100 x 107 mm. The roughing is to be done manually. Work out all necessary documentation for themachining. Prepare, test and correct the process on the MTS CNC Simulator. Program the external contourfor finish-turning using circular interpolation G02/G03 with the parameter L for the radius of circular arc.

B o lt 3



Circular interpolation by using the parameter L for the radius of circular arc;programming and fabrication of circular contours and tool nose compensation.


MTS GmbH Berlin 51

B o lt 3



Exercise: bolt with radii and and chamfers

The bolt on the drawing is to be manufactured on a CNC lathe using a blank made of AlMg1 dimensioned 100 x 107 mm. The roughing is to be done manually. Work out all necessary documentation for themachining. Prepare, test and correct the process on the MTS CNC Simulator. Program the external contourfor finish-turning using the automatic chamfering for radii and chamfers G75/G76.

B o lt 4



Automatic chamfering for radii and chamfers G75/G76; programming andfabrication of circular contours and chamfers and tool nose compensation.

MTS GmbH Berlin 53

B o lt 4



4.3 NC programs using Compound Fixed Cycles

Exercise: shaft with recess

The shaft on the drawing is to be manufactured on a CNC lathe using a blank made of AlMg1 dimensioned 80 x 102 mm. The roughing is to be done manually. Work out all necessary documentation for themachining. Prepare, test and correct the process on the MTS CNC Simulator.

Use for recessing the compound fixed cycle G73.

S ha ft 1

Learning Objective: The learner can describe the use of compound fixed cycle.


Compound fixed cycle.

NC programs using Compound Fixed Cycles

MTS GmbH Berlin 55

S ha ft 1



Exercise: pipe length

The pipe length on the drawing is to be manufactured on a CNC lathe using a blank made of AlMg1dimensioned 36 x 92 mm. The roughing is to be done manually. Work out all necessary documentation forthe machining. Prepare, test and correct the process on the MTS CNC Simulator.

Use for boring the compound fixed cycle G74.

P ipe leng th

Learning Objective: The learner can describe the use of compound fixed cycle.


Compound fixed cycle.

MTS GmbH Berlin 57

P ipe leng th



4.4 NC programs using Lathe Auto - Programming Function LAP

Exercise: pressure pin

The pressure pin is to be made on a CNC lathe from a blank made of AlMg1 dimensioned 100 x 60 mm ina medium batch quantity. Work out the process layout and the set-up form. The manufacturing processshould be prepared, tested and corrected at the MTS CNC Simulator.

Apply the cross-roughing cycle G85 in transverse mode.

P essure P in

63

20

30 96

100

Learning Objective: The learners are capable of optimizing program runs by the use of machiningcycles.


LAP function G85 and G87 and contour description.

NC programs using Lathe Auto - Programming Function LAP

MTS GmbH Berlin 59

P essu re P in

6320

30 961

00





Use the LAP function G85 and G87 in longitudinal mode.

B o lt I2

Learning Objective: The learners are capable of optimizing program runs by the use of machiningcycles.


LAP function G85 and G87 and contour description.

NC programs using Lathe Auto - Programming Function LAP

MTS GmbH Berlin 61

B o lt I2



4.5 NC programs using subprogram technology

Exercise: shape bolt

The shape bolt on the drawing made of AlMg1 is to be made on a CNC lathe in higher batch quantity.Prepare the manufacturing process with the MTS CNC Simulator including following steps: define workpartzero, set up the processing sequence, determine tools, fixtures and technological data; generate, set up, testand correct the program at the CNC simulator. A bolt with an external diameter of 85 mm and the length of102 mm is to be clamped for the test.

Use subprogram technology and the LAP functions.

6862513277.3

20

8081

S hape B olt

Learning Objective: The learners are capable of optimizing program runs by the use of subprograms.


Subprogram, LAP functions and contour description.


MTS GmbH Berlin 63

6862513277.3

20

8081

S hape B olt





Use the subprogram technology and the LAP functions.

all rad ii 3m m

B o lt l3



Subprogram, LAP functions and contour description.


MTS GmbH Berlin 65

a ll rad ii 3m m

B o lt l3



4.6 Complex programs

Exercise: drill sleeve

The drill sleeve is to be produced on a CNC lathe as to the drawing from a blank made of AlMg1dimensioned 90 x 128 mm. The manufacturing process is to be prepared with the MTS CNC Simulatorincluding all planning documentation. Use the compound fixed cycle G71. Test, correct and print the NCprogram.

Use the compound fixed cycle G71.

D rill S leeve


Compound fixed cycle G71; LAP-function and contour description.

Complex programs

MTS GmbH Berlin 67

D rill S leeve



Exercise: shaft with recess

The shaft on the drawing is to be manufactured on a CNC lathe using a blank made of AlMg1 dimensioned 95 x 142 mm. Work out all necessary documentation for the machining. Prepare, test and correct theprocess on the MTS CNC Simulator.

Use the LAP function for roughing and the compound fixed cycle G73.

90

80

40

S ha ft 2


Compound fixed cycle G73; LAP-function and contour description.

Complex programs

MTS GmbH Berlin 69

90

80

40

S ha ft 2



Exercise: hollow pinhollow pin sleeve is to be produced on a CNC lathe as to the drawing from a blank made of AlMg1dimensioned 70 x 102 mm. The manufacturing process is to be prepared with the MTS CNC Simulatorincluding all planning documentation. Test, correct and print the NC program.

Use the compound fixed cycle G74 and the LAP-functions G85 and G87 in longitudinal mode.

H o llow P in


Compound fixed cycle G74, LAP-functions G85 and G87, contour description.

Complex programs

MTS GmbH Berlin 71

H o llow P in

Documents

Student