anilam 3000 User Manual

3000M CNC

Programming and Operations

Manual for

Threeand Four-Axis Systems

www.anilam.com

CNC Programming and Operations Manual

P/N 70000504I - Contents

Section 1 - CNC Programming Concepts

Programs..........................................................................................................................................	1-1
Axis Descriptions..............................................................................................................................	1-1
X Axis ...........................................................................................................................................	1-2
Y Axis ...........................................................................................................................................	1-2
Z Axis ...........................................................................................................................................	1-2
Defining Positions ............................................................................................................................	1-2
Polar Coordinates.........................................................................................................................	1-3
Absolute Positioning .....................................................................................................................	1-3
Incremental Positioning ................................................................................................................	1-4
Tool-Length Offsets..........................................................................................................................	1-5
Tool Diameter Compensation...........................................................................................................	1-6
Using Tool Diameter Compensation and Length Offsets with Ball-End Mills .................................	1-10
Angle Measurement .......................................................................................................................	1-10
Corner Rounding............................................................................................................................	1-11
Line-to-Line Corner Rounding ....................................................................................................	1-11
Line-to-Arc Corner Rounding......................................................................................................	1-12
Arc-to-Arc Corner Rounding .......................................................................................................	1-12
Chamfering.....................................................................................................................................	1-13
Plane Selection ..............................................................................................................................	1-14
Arc Direction...................................................................................................................................	1-15

Section 2 - CNC Console and Software Basics

Console ............................................................................................................................................	2-1
Keypad .............................................................................................................................................	2-1
Programming Hot Keys ................................................................................................................	2-2
Editing Keys .................................................................................................................................	2-3
Manual Operation Keys ................................................................................................................	2-3
Operator Keys ..............................................................................................................................	2-4
Soft Keys (F1) to (F10).....................................................................................................................	2-5
Off-line Keyboard (Optional).............................................................................................................	2-5
Software Basics ...............................................................................................................................	2-5
Pop-up Menus ..............................................................................................................................	2-5
Screen Saver................................................................................................................................	2-6
Switching Selections with the Toggle Key ....................................................................................	2-6
Clear Key......................................................................................................................................	2-6
Operator Prompts .........................................................................................................................	2-6
ASCII Chart ..................................................................................................................................	2-6
Cursor and Highlight Functions ....................................................................................................	2-7
Entering Text ................................................................................................................................	2-7
Typing Over and Inserting Letters and Numbers ..........................................................................	2-7
Deleting Characters......................................................................................................................	2-8
Messages/Error Messages...............................................................................................................	2-8

Section 3 - Manual Operation and Machine Setup

Powering On the CNC......................................................................................................................	3-1
Shutting Down the CNC ...................................................................................................................	3-1
Emergency Stop (E-STOP) ................................................................................................................	3-1
Performing an Emergency Stop .......................................................................................................	3-1
Activating/Resetting the Servos .......................................................................................................	3-2
(Re-)Starting the Spindle..................................................................................................................	3-2

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Manual Mode Screen .......................................................................................................................			3-3
Primary Display Area Labels ........................................................................................................			3-4
Secondary Display Area Labels....................................................................................................			3-4
Position Display............................................................................................................................			3-5
Manual Machine Operation ..............................................................................................................			3-6
Manual Mode................................................................................................................................			3-6
Auto Mode ....................................................................................................................................			3-6
Mode Settings ..................................................................................................................................			3-7
Activating Manual Mode Rapid or Feed ...........................................................................................			3-8
Setting a Feedrate ........................................................................................................................			3-8
Adjusting Rapid Move Speed .......................................................................................................			3-8
Overriding the Programmed Spindle RPM....................................................................................			3-9
Absolute/Incremental Modes ........................................................................................................			3-9
Inch/MM Modes............................................................................................................................			3-9
Setting Absolute Zero .................................................................................................................			3-10
Defining Absolute Zero in X and Y Axes.....................................................................................			3-10
Presetting the X- or Y-Axis .........................................................................................................			3-10
Fixture Offsets (Work Coordinate System) .................................................................................			3-11
Setting Tool Change Position .....................................................................................................			3-12
Locating Tool #0, Z0...................................................................................................................			3-12
Presetting the Z-Axis ..................................................................................................................			3-13
Activating a Tool .........................................................................................................................			3-13
Activating a Plane.......................................................................................................................			3-13
Activating a Spindle RPM (Requires Programmable Spindle Option).........................................			3-14
Jog Moves......................................................................................................................................			3-14
Changing the Jog Mode .............................................................................................................			3-15
Jogging the Machine (Conventional) ..........................................................................................			3-15
Jogging the Machine (Continuous) .............................................................................................			3-16
Operating the Handwheel (Optional) ..............................................................................................			3-16
One-Shot Moves ............................................................................................................................			3-17
Manual Data Input..........................................................................................................................			3-17
Disengaging the Z-Axis Drive System............................................................................................			3-19
Section 4 - Writing Programs
Program Basics................................................................................................................................			4-1
Developing Part Programs ...............................................................................................................			4-1
Writing Program Blocks....................................................................................................................			4-3
Using Graphic Menus ...................................................................................................................			4-3
No Move Blocks ...............................................................................................................................			4-4
Programming an Absolute/Incremental Mode Change .................................................................			4-4
Programming an Inch/MM Mode Change.....................................................................................			4-4
Programming a Tool Change........................................................................................................			4-5
Activating a Tool ...........................................................................................................................			4-5
Activating Tool-Diameter Compensation ......................................................................................			4-6
Programming a Dwell ...................................................................................................................			4-7
Programming a Return to Machine Zero ......................................................................................			4-8
Programming Fixture Offsets........................................................................................................			4-9
Resetting Absolute Zero (Part Zero)...........................................................................................			4-11
Programming a Plane Change ...................................................................................................			4-13
Programming a Feedrate Change ..............................................................................................			4-14
Programming a Spindle RPM .....................................................................................................			4-15

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Straight Moves ...............................................................................................................................	4-16
Programming a Rapid Move.......................................................................................................	4-16
Programming a Line Move..........................................................................................................	4-17
Programming a Modal Move.......................................................................................................	4-17
Teach Mode (Programming from the Part).....................................................................................	4-18
Line or Rapid Moves ......................................................................................................................	4-19
Programming a Move Using XY Location, Radii, or Angles........................................................	4-20
Arcs................................................................................................................................................	4-21
Selecting the Plane for an Arc ....................................................................................................	4-21
Programming an Arc Using an Endpoint and Radius .................................................................	4-21
Programming an Arc Using the Center and Endpoint.................................................................	4-23
Programming an Arc Using the Center and the Included Angle .................................................	4-25
Programming M-Code Blocks ........................................................................................................	4-27
Dry Run M-Codes.......................................................................................................................	4-28
U-Axis Synchronization M-Codes ...............................................................................................	4-28

Section 5 - Programming Canned Cycles, Ellipses, and Spirals

Drilling Cycles ..................................................................................................................................	5-1
Basic Drill Cycle............................................................................................................................	5-2
Peck Drilling Cycle........................................................................................................................	5-3
Boring Cycle .................................................................................................................................	5-4
Chip Break Cycle..........................................................................................................................	5-5
Tapping Cycle...............................................................................................................................	5-7
Drill Pattern...................................................................................................................................	5-8
Bolt Hole Pattern ..........................................................................................................................	5-9
Thread Milling Cycle ...................................................................................................................	5-11
Pocket Cycles ................................................................................................................................	5-16
Facing Cycle...............................................................................................................................	5-17
Rectangular Profile Cycle ...........................................................................................................	5-19
Circular Profile Cycle ..................................................................................................................	5-21
Rectangular Pocket Cycle ..........................................................................................................	5-23
Circular Pocket Cycle .................................................................................................................	5-25
Frame Pocket Cycle ...................................................................................................................	5-27
Hole - Mill Cycle..........................................................................................................................	5-29
Irregular Pocket Cycle ................................................................................................................	5-31
Pockets with Islands ...................................................................................................................	5-36
Subprograms..................................................................................................................................	5-39
Situation: 1 (Repetitive Drilling Cycle) ........................................................................................	5-39
Situation: 2 (Rough and Finish Cycles) ......................................................................................	5-39
Subprogram Structure ................................................................................................................	5-39
Subprogram Example.................................................................................................................	5-39
Organizing Programs Containing Subprograms .........................................................................	5-40
Calling Subprograms from the Main Program.............................................................................	5-40
Ending Main Programs ...............................................................................................................	5-40
Starting Subprograms.................................................................................................................	5-41
Ending Subprograms..................................................................................................................	5-41
Looping Subprograms ................................................................................................................	5-41
Rotating, Mirroring, and Scaling Subprograms (RMS)................................................................	5-42
Ellipses and Spirals........................................................................................................................	5-43
Plane Selection...........................................................................................................................	5-43
Programming an Ellipse .............................................................................................................	5-43
Programming a Spiral.................................................................................................................	5-45

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Mold Cycles....................................................................................................................................			5-47
Programming a Mold Rotation ....................................................................................................			5-47
Rotations Around X- and Y- Axes (Small Radius) ......................................................................			5-48
Rotations Around X- and Y- Axes (Large Radius) ......................................................................			5-52
Rotation Around the Z-Axis ........................................................................................................			5-53
Programming an Elbow Milling Cycle .........................................................................................			5-55
Engraving, Repeat, and Mill Cycles ...............................................................................................			5-60
Engraving Cycle .........................................................................................................................			5-60
Repeat Cycle ..............................................................................................................................			5-62
Mill Cycle ....................................................................................................................................			5-64
Probing Cycles ...............................................................................................................................			5-66
Tool Probe Cycles ......................................................................................................................			5-66
Spindle Probe Cycles .................................................................................................................			5-83
Section 6 - Editing Programs
Activating the Program Editor...........................................................................................................			6-1
The Program Editor Screen..............................................................................................................			6-2
Saving Edits .....................................................................................................................................			6-3
Canceling Unsaved Edits .................................................................................................................			6-3
Deleting a Program Block.................................................................................................................			6-3
Inserting a Program Block................................................................................................................			6-4
Editing a Program Block...................................................................................................................			6-4
Searching Blocks for Words or Numbers......................................................................................			6-4
Scrolling the Program Listing........................................................................................................			6-4
Paging through the Program Listing .............................................................................................			6-5
Jumping to First or Last Block in the Program..............................................................................			6-5
Using Comments..............................................................................................................................			6-5
Writing a Comment Block .............................................................................................................			6-5
Commenting Out Existing Blocks .................................................................................................			6-5
Canceling a Comment ..................................................................................................................			6-6
Using Block Operations to Edit a Program.......................................................................................			6-6
Section 7 - Viewing Programs with Draw
Draw Modes .....................................................................................................................................			7-1
Starting Draw ...................................................................................................................................			7-2
Draw Screen Description..................................................................................................................			7-3
Putting Draw in Hold ........................................................................................................................			7-3
Canceling Draw................................................................................................................................			7-3
Draw Parameters .............................................................................................................................			7-4
Text On or Off...............................................................................................................................			7-4
Tool On or Off...............................................................................................................................			7-5
Drawing Compensated Moves......................................................................................................			7-5
Showing Rapid Moves..................................................................................................................			7-6
Setting Grid Line Type..................................................................................................................			7-6
Setting Grid Size...........................................................................................................................			7-6
Putting Draw in Motion, Single-Step, or Auto Mode......................................................................			7-7
Automatic Draw Restart................................................................................................................			7-8
Erasing Display.............................................................................................................................			7-8
Running Draw for Selected Blocks ...............................................................................................			7-8
Adjusting Draw Display ..................................................................................................................			7-10
Fitting the Display to the Viewing Window..................................................................................			7-10
Halving Display Size...................................................................................................................			7-10
Doubling Display Size.................................................................................................................			7-10
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Scaling the Display by a Factor ..................................................................................................	7-11
Zooming In .................................................................................................................................	7-11
Erasing Display...........................................................................................................................	7-11
Changing Draw Views ................................................................................................................	7-12
Selecting the View ......................................................................................................................	7-12

Section 8 - Running Programs

Selecting Programs for Running ......................................................................................................	8-1
Running a Program One Step at a Time ..........................................................................................	8-1
Single-Step Mode vs. Motion Mode..............................................................................................	8-2
Holding or Canceling a Single-Step Run ......................................................................................	8-2
Single-Step Execution of Selected Program Blocks .....................................................................	8-2
Switching from Single-Step to Auto ..............................................................................................	8-3
Auto Program Execution ..................................................................................................................	8-3
Holding or Canceling an Auto Run ...............................................................................................	8-3
Starting at a Specific Block...........................................................................................................	8-4
Clearing a Halted Program...............................................................................................................	8-4
Using Draw while Running Programs...............................................................................................	8-5
Parts Counter and Program Timer ...................................................................................................	8-6
Background Mode ............................................................................................................................	8-7

Section 9 - Program Management

Program Directory ............................................................................................................................	9-1
Changing the Program Directory Display .........................................................................................	9-2
Creating a New Program..................................................................................................................	9-2
Choosing Program Names ...............................................................................................................	9-2
Loading a Program for Running .......................................................................................................	9-2
Selecting a Program for Editing and Utilities ....................................................................................	9-3
Maximizing Program Storage Space................................................................................................	9-3
Program File Utilities ........................................................................................................................	9-3
Displaying Program Blocks (Listing a Program) ...........................................................................	9-4
Deleting a Program.......................................................................................................................	9-4
Reading Disks in Floppy Drives (Logging to Other Drives)...........................................................	9-4
Marking and Unmarking Programs ...............................................................................................	9-5
Deleting Groups of Programs .......................................................................................................	9-6
Restoring Programs......................................................................................................................	9-6
Copying Programs to Floppy Disks ..............................................................................................	9-6
Renaming Programs.....................................................................................................................	9-7
Printing Programs.........................................................................................................................	9-7
Formatting Floppy Disks...............................................................................................................	9-7
Converting G-Code Programs to CNC Conversational Format ....................................................	9-8
Checking Disks for Lost Data .........................................................................................................	9-14
Displaying System Information.......................................................................................................	9-15
Copying Programs from/to Unspecified Locations .........................................................................	9-16
Renaming Programs from/to Unspecified Locations ......................................................................	9-16
Printing from Floppy Drives ............................................................................................................	9-17

Section 10 - Tool Management

Tool Page.......................................................................................................................................	10-1
Entering the Tool Page...................................................................................................................	10-1
Tool Page Description....................................................................................................................	10-2

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Using the Tool Page.......................................................................................................................				10-3
Finding Tools by Number ...........................................................................................................				10-3
Changing Tool Page Values.......................................................................................................				10-3
Clearing a Tool (Whole Row)......................................................................................................				10-4
Clearing a Single Value ..............................................................................................................				10-4
Adjusting a Single Value.............................................................................................................				10-4
Setting Tool-Length Offset..........................................................................................................				10-4
Automatically Setting Tool-Length Offsets from the Tool Page				.................................................. 10-5
Manually Setting Tool-Length Offsets from the Tool Page .........................................................				10-5
Setting Tool-Length Offset for Ball-End Mills..............................................................................				10-5
Fixture Offsets ............................................................................................................................				10-5
Setting RefProg Offset................................................................................................................				10-6
Section 11 - Communication and DNC
Communication ..............................................................................................................................				11-1
Installing the RS-232 Cable............................................................................................................				11-1
Accessing the Communication Package ........................................................................................				11-2
Setting Communication Parameters...............................................................................................				11-3
Selecting the Communication Port .............................................................................................				11-3
Setting the Baud Rate ................................................................................................................				11-4
Setting Parity ..............................................................................................................................				11-4
Setting Data Bits.........................................................................................................................				11-4
Setting Stop Bits.........................................................................................................................				11-4
Software Settings .......................................................................................................................				11-4
Setting Data Type.......................................................................................................................				11-4
Testing the Data Link .....................................................................................................................				11-4
Activating the Test Link Screen......................................................................................................				11-5
Setting Test Link Display Modes ................................................................................................				11-5
Testing the Link ..........................................................................................................................				11-6
Clearing the Receive Area..........................................................................................................				11-6
Sending a Program ........................................................................................................................				11-6
Receiving a Program......................................................................................................................				11-7
Setting the Transmission and Receiving Display........................................................................				11-7
Holding Transmission/Receiving Operations..............................................................................				11-7
Running in DNC .............................................................................................................................				11-8
Using Data Control (DC) Codes .....................................................................................................				11-9
Using DC Codes In Receive Mode ...........................................................................................				11-10
Using DC Codes In Send Mode................................................................................................				11-10
Section 12 - Calculators
CNC Calculator Package ...............................................................................................................				12-1
Math Calculator ..............................................................................................................................				12-1
Math Calculator Basics...............................................................................................................				12-2
Operations Involving Two Numbers............................................................................................				12-3
Math with a Column of Numbers ................................................................................................				12-3
Using Parentheses .....................................................................................................................				12-3
Using Additional Functions .........................................................................................................				12-4
Storing Numbers from the Math Calculator ................................................................................				12-5
Right Triangle Calculator................................................................................................................				12-5
Activating the Triangle Calculator ...............................................................................................				12-5
Using the Triangle Calculator .....................................................................................................				12-6
Storing Right Triangle Calculator Results...................................................................................				12-6
Hiding the Right Triangle Calculator Screen...............................................................................				12-6
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Geometry Calculator ......................................................................................................................	12-7
Activating the Geometry Calculator ............................................................................................	12-7
Geometry Calculator Screen ......................................................................................................	12-7
Using the Geometry Calculator...................................................................................................	12-8
Point Templates..........................................................................................................................	12-9
Line Templates .........................................................................................................................	12-10
Circle Templates.......................................................................................................................	12-11
Deleting Selected Elements .....................................................................................................	12-11
Deleting All Elements ...............................................................................................................	12-11
Listing All Geometry Elements .................................................................................................	12-12
Calculating the Distance between Two Elements.....................................................................	12-12
Last Position Recall ..................................................................................................................	12-12
Recalling Values into a Program ..................................................................................................	12-13
Recalling Values from the Math Calculator...............................................................................	12-13
Recalling Values from the Right Triangle Calculator ................................................................	12-14
Recalling Values from the Geometry Calculator.......................................................................	12-15
Recalling Values from One Calculator into Another..................................................................	12-15

Section 13 - Off-line Software

Passwords......................................................................................................................................	13-1
Exiting the Software .......................................................................................................................	13-1
Windows Installation (Use Windows Installation Disk) ...................................................................	13-1
Running from Windows ..............................................................................................................	13-2
Setting up the Icon......................................................................................................................	13-2
System Settings .............................................................................................................................	13-3
Maximum Memory Allocated ......................................................................................................	13-3
Disabled Features ......................................................................................................................	13-3
Using Soft Keys from a Keyboard ..................................................................................................	13-4
Keypad Equivalent Keyboard Keys ................................................................................................	13-4
Editing with a Text Editor................................................................................................................	13-7

Section 14 - Four-Axis Programming

Axis Types......................................................................................................................................	14-1
Rotary Axis Programming Conventions..........................................................................................	14-2
Non-Synchronous or Synchronous Auxiliary Axis ..........................................................................	14-2
Programming Examples .................................................................................................................	14-3
Example 1: Drill (Sync-Off) ........................................................................................................	14-3
Example 2: Mill (Sync-On).........................................................................................................	14-5
Example 3: Mill (Sync-On).........................................................................................................	14-6

Section 15 - DXF Converter Feature

Requirements.................................................................................................................................	15-1
Off-line Software.........................................................................................................................	15-1
Machine Software.......................................................................................................................	15-1
Entry to the DXF Converter ............................................................................................................	15-2
Creating Shapes.........................................................................................................................	15-2
Contours.....................................................................................................................................	15-3
Drilling ........................................................................................................................................	15-3
CNC Code......................................................................................................................................	15-3
Mouse Operations..........................................................................................................................	15-4
DXF Hot Keys ................................................................................................................................	15-5
Toggle Entity Endpoints (ALT + F) .............................................................................................	15-5

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DXF Soft Keys................................................................................................................................			15-6
Miscellaneous DXF Soft Key, F6................................................................................................			15-7
Output Menu Options .....................................................................................................................			15-8
Shift X, Shift Y Descriptions........................................................................................................			15-8
Convert Polyline Description.......................................................................................................			15-9
Display Menu Options ....................................................................................................................			15-9
DXF Entities Supported................................................................................................................			15-10
Drawing Entities Not Supported................................................................................................			15-10
Files Created................................................................................................................................			15-11
DXF Example ...............................................................................................................................			15-11
Unedited Conversational Program Listing ................................................................................			15-13
Edited Conversational Tool Path ..............................................................................................			15-14
Edited Conversational Program Listing ....................................................................................			15-14
Using DXF for Pockets with Islands..........................................................................................			15-16
Section 16 - CNC Software
Machine Software Installation ........................................................................................................			16-1
Software Option Kit Installation ......................................................................................................			16-1
Procedure...................................................................................................................................			16-1
Using Soft Keys from a Keyboard ..................................................................................................			16-2
Keypad Equivalent Keyboard Keys ................................................................................................			16-2
Making Jog Moves from a Keyboard..............................................................................................			16-2
Index .......................................................................................................................................			Index-1

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Section 1 - CNC Programming Concepts

Programs

This manual describes CNC programming and operations for 3000M three-axis systems.

A program is the set of instructions used by the CNC to direct machine movement. Each instruction is called a block and each block executes independently.

Programs are stored in the CNC’s memory and accessed from the CNC’s Program Directory. You can create, delete, copy, and rename programs in the CNC’s Program Directory.

Axis Descriptions

The machine moves along its axes of motion. All movement along an axis is in either a positive or negative direction. Not all machines use the same system for identifying axes. The descriptions here are most commonly used for three axis mills. Refer to Figure 1-1.

NOTE: To keep directions straight when programming machine movements, consider tool motion rather than table motion. (When tool motion is positive, table motion in negative, and vice versa.)

Figure 1-1, Mill Axes of Motion (Tool Motion Orientation)

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X Axis

The table moves left and right along the X-axis. Positive motion is table movement to the left (tool, right); negative motion is table movement to the right (tool, left).

Y Axis

The table moves in and out along the Y-axis. Positive motion is table movement out (tool, in); negative motion is table movement in (tool, out).

Z Axis

In the Z-axis, the tool moves up and down on the spindle. Positive motion is tool movement up; negative motion is tool movement down (into the work).

Defining Positions

The intersection of the X, Y, and Z-axes is the reference point that defines most positions. This point is the X0, Y0, and Z0 position. Refer to

Figure 1-2.

Most positions are identified by X, Y, and Z coordinates. A position two inches left, three inches back, and four inches up has the following coordinates:

X-2.0

Y3.0

Z4.0

+4

+3

-2

X+

Figure 1-2, Locating Positions

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Polar Coordinates

Polar Coordinates define points that lie on the same plane. Polar coordinates use the distance from the origin and an angle to locate points. Refer to Figure 1-3.

POLAR

Figure 1-3, Polar Coordinate System

Absolute Positioning

In the Absolute Mode, all positions are measured from the Absolute Zero Reference point. Absolute Zero is not a fixed position on the machine, but a point you select. Refer to Figure 1-4.

You can set the Absolute Zero Reference point (X0, Y0) anywhere. Usually the Absolute Zero Reference is set at a position that makes it easy use the dimensions from the blueprint. This is also called setting the Part Zero.

ABSOLUTE

Figure 1-4, Absolute Positioning

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Incremental Positioning

Measure incremental moves from the machine’s present position. This is convenient for performing an operation at regularly spaced intervals. Refer to Figure 1-5.

NOTE: An incremental 0-inch/0-mm move will not make a position change.

First increment

Second increment

Third increment

Fourth increment

Original Location

INCREMENTAL

Figure 1-5, Incremental Positioning

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Tool-Length Offsets

The operator sets the Z0 position of the quill, from which the CNC applies Tool-Length Offsets. Usually it is the fully retracted position of the quill.

NOTE: For machines without homing, it may be necessary to set machine home to make setting tool-length offsets easier. Either manually or by jogging take the Z-axis close to the top of travel. The servo must be turned on. Press MDI (F7), press Mill (F5), press More (F7), curse down to Home and press ENTER, press Z the z will light up, press Save, press Prev, press Exit, and press Start. The Z-axis will change to zero.

Because tools differ in length, Z0 axis (Part Zero) is not set the same way as X0 or Y0. The tool-length offset is the distance from the tip of the tool to the top of the part. Enter a length offset for each tool in the Tool Page. (Refer to “Section 10 - Tool Management.”)

Tool-length offset is the distance from Z0 Tool #0 to the tip of the tool at the part Z0 (usually the surface of the work). Refer to Figure 1-6.

With tool-length offsets active, the Z-axis position display reads 0.00 when the active tool moves to Part Zero. Tool-length offsets simplify programming. To move to a position 0.5 inch into the work, program a move to a Z-.5 position.

Tool # 0

Z 0.0

Part Zero

Figure 1-6, Tool-Length Offset

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Tool Diameter Compensation

When tool compensation is not active, the CNC positions the tools center on the programmed path. This creates a problem when programming a part profile because the cutting edge is half a diameter away from the path. Use tool diameter compensation to overcome this problem.

NOTE: Be familiar with basic CNC principles before attempting to write compensated moves.

When tool compensation is active, the CNC offsets the tool by half a diameter to position the cutting edge of the tool on the programmed path.

This allows you to program the coordinates along the part profile without adjusting the path to compensate for tool diameter.

Most moves can be compensated. Specify right or left compensation. Right or left refers to the side of the path to which the tool offsets, viewed from behind the tool as it moves.

NOTE: Tool compensation should be used only with lines and arcs.

With left-hand tool compensation active, the tool offsets to the left of the programmed path (looking from behind the tool as it moves). Refer to

Figure 1-7.

LHCOMP

Figure 1-7, Left-Hand Tool Compensation

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With right-hand tool compensation active, the tool offsets to the right of the programmed path (looking from behind the tool as it moves). Refer to

Figure 1-8.

RHCOMP

Figure 1-8, Right-Hand Tool Compensation

When the CNC encounters two consecutive, compensated moves, the tool follows the offset path for the first move until it reaches the offset path for the second move. Refer to Figure 1-9. The tool may intersect the offset path for the second move, either before or after the endpoint of the first move, depending on the geometry.

Move 2

Tool Path

Move 1

End Point

Move 1

COMP2

Figure 1-9, Consecutive Compensated Moves

The moves to and from compensated moves are called ramp moves. Ramp moves give the CNC time to position the tool. The ramp move must be at least half the active tool’s diameter in length.

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At the start of a ramp move, the tool centers on the programmed path. At the end of the ramp move (starting point of the compensated move), the tool centers perpendicular to the starting point, offset by half the tool’s diameter. Refer to Figure 1-10.

Figure 1-10, Ramping into a Compensated Move

Carefully consider how compensation will affect the position of the tool at the start and end of a move.

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When a compensated move starts and stops in a corner, the tool gouges the work because the tool offsets to a position perpendicular to the endpoint. Begin ramp moves at the side to avoid gouging the workpiece. Refer to Figure 1-11.

NOTE: Use canned cycles to cut profiles and pockets, when possible. The CNC automatically selects ramp On/Off positions in a canned cycle.

-

Figure 1-11, Ramp On/Off Choices for Milling Inside a Square

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Using Tool Diameter Compensation and Length Offsets with Ball-End Mills

When using a ball-end mill to cut contoured surfaces, use tool diameter compensation and tool-length offset together, if at all. Unlike an end cutter, the tool-length offset for a ball-end mill is not set to the tip of the tool.

Set the tool-length offset for a ball-end mill half the tool’s diameter back from the tip. Refer to Figure 1-12. For more details on how to set toollength offsets, refer to “Section 10 - Tool Management.”

Ball End Mill	Quill At Tool# 0, Z 0 Position

12 Tool Diameter From Tip

Tool Length Offset

Adjusted To Ball's Center

Part Zero

Figure 1-12, Setting Tool-Length Offset for Ball End Mill

Angle Measurement

Measure angles from the 3 o’clock position (0 degrees). Positive angles rotate in a counterclockwise direction; negative angles rotate in a clockwise direction. Refer to Figure 1-13.

Clock		Y+		Positive
Reference
		12		Angle
	11		1
	10		2	+30°
	9
X-			3	0°
				X+
	8		4	-30°
	7	6	5
				Negative

Angle

Y-

Figure 1-13, Absolute Angle Measurement

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Corner Rounding

Corner rounding permits the operator to blend the intersection of consecutive moves.

To activate corner rounding, the operator keys a radius value (positive) into the CornerRad field of the first move. When the program runs, it blends the endpoint of the first move with the starting point of the second. The blend starts where the radius is tangent to the first move, and extends to where the radius is tangent to the second.

Use corner rounding between two lines or two arcs. Also use corner rounding between non-tangent line and arc moves.

Line-to-Line Corner Rounding

When the first move contains a CornerRad value, the CNC automatically finds the radius center and the tangent points necessary to calculate the tool path. The resulting tool path follows the solid line. Refer to Figure 1-14.

Figure 1-14, Line-to-Line Corner Rounding

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Line-to-Arc Corner Rounding

When the first move contains a CornerRad value, the CNC automatically finds the radius center and the tangent points necessary to calculate the tool path. The resulting tool path follows the solid line. Refer to Figure 1-15.

NOTE: If the line move is already tangent to the arc move, the CNC ignores corner rounding.

Figure 1-15, Line-to-Arc Corner Rounding

Arc-to-Arc Corner Rounding

When a CornerRad value is programmed into the first move, the CNC automatically finds the radius center and the tangent points necessary to calculate the tool path. The resulting tool path follows the solid line. Refer to Figure 1-16.

Figure 1-16, Arc-to-Arc Corner Rounding

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Chamfering

Chamfer between two consecutive line moves. A chamfer starts at a specified distance before the endpoint of the first move and ends the same distance from the starting point of the second move. To program a chamfer move, enter a negative value into the CornerRad field of the first move. The entered value is the chamfer distance. The resulting tool path follows the solid line. Refer to Figure 1-17.

Figure 1-17, Chamfering

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Plane Selection

Circular moves and tool diameter compensation are confined to the plane you select (XY, XZ, or YZ).

CAUTION: A plane viewed from the wrong side causes arc directions, angle references, and axis signs to appear reversed.

Refer to Figure 1-18 for a description of the three available planes.

Figure 1-18, Plane Identification

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Arc Direction

The standard rule is to view arc direction for a plane from the positive toward the negative direction along the unused axis. From this viewpoint clockwise (Cw) and counterclockwise (Ccw) arc directions can be determined. For example, in the XY plane, you view along the Z-axis, from Z+ toward Z-, to determine Cw/Ccw directions. The Cw/Ccw arc directions for each plane are shown in Figure 1-19.

Figure 1-19, Clockwise and Counterclockwise Arc Directions

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Section 2 - CNC Console and Software Basics

Console

The CNC console consists of a 12.1” color, flat-panel Liquid Crystal Display (LCD), a keypad to the right of the monitor, and soft keys below the monitor. Refer to Figure 2-1.

LCD

Keypad

Soft Keys

3000M CONSOLE

Figure 2-1, CNC Console

Keypad

Refer to Figure 2-2. The keypad to the right of the monitor has four types of keys:

Programming Hot Keys

Editing Keys

Manual Operation Keys

Operator Keys

Programming

Hot Keys

Editing

Keys

Manual Operation Keys

Operator Keys

(with SPINDLE OVERRIDE)

3000M KEYPAD

Figure 2-2, Keypad

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Programming Hot Keys

Programming hot keys allow you to enter position coordinates and provide quick access to functions that speed up programming. They are active in the Edit and Manual Mode. Refer to Table 2-1.

Table 2-1, Programming - Hot keys

Label or Name	Key Face	Purpose
X		Selects X-axis for position inputs.
Y		Selects Y-axis for position inputs.
Z		Selects Z-axis for position inputs.
U		Selects U-axis for position inputs.
ABS/INC		Switches CNC between Absolute and
		Incremental Modes.
0		Zero / Switches comment asterisk in
		edit mode. Switches resolution display
		between program and Dist. To Go.
1/RAPID	1	One / Hot key for programming a
	RAPID	Rapid move.
2/LINE	2	Two / Hot key for programming a
	LINE	Line move.
3/ARC	3	Three / Hot key for programming an
		Arc.
4/FEED	4	Four / Hot key for changing feedrate.
	FEED
5/TOOL	5	Five / Hot key for programming a
	TOOL	tool.
6/MCODE	6	Six / Hot key for programming an M-
		code.
7/UNIT	7	Seven / Hot key for switching
	UNIT	between inches (Inch) and
		millimeters (mm).
8/DWELL	8	Eight / Hot key for programming a
		Dwell.
9/PLANE	9	Nine / Hot key for selecting a plane.
	PLANE
+/-		Sign change / Toggle hot key.
DECIMAL/RPM		Decimal point / Hot key for
		programming the spindle RPM.
		(Continued…)

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Table 2-1, Programming - Hot keys (Continued)

Label or Name	Key Face Purpose
CALC	Calculators / Hot key to display the
	Select Type of Calculator: pop-up
	menu. See Figure 12-1, Calculator
	Selection Menu.

Editing Keys

Editing keys allow you to edit program blocks. These keys are located below the Programming Hot Keys. Refer to Table 2-2.

Table 2-2, Editing Keys

	Label or Name	Key Face				Purpose
	CLEAR					Clears the selected messages, values,
			L
			C
			E			commands, and program blocks.
			A
			R
	ARROW					Allows you to move highlight bars and
						cursor around the screen.
	ENTER					Selects blocks for editing, activates
						menu selections, activates number
						entry, or presets XYZ positions.
Manual Operation Keys

Manual Operation Keys allow you to control machine movements manually. These keys are located below the Editing Keys. Refer to

Table 2-3.

Table 2-3, Manual Operation Keys

Label or Name	Key Face				Purpose
JOG					Cycles the CNC through manual
					movement modes (JOG: RAPID,
					JOG: FEED, JOG: 100, JOG: 10,
					JOG: 1).
U+					Manually moves machine in positive
					U direction.
U-					Manually moves machine in negative
					U direction.
Z+					Manually moves machine in positive
					Z direction.
Z-					Manually moves machine in negative
					Z direction.
Y+					Manually moves machine in positive
					Y direction.
Y-					Manually moves machine in negative
					Y direction.

	(Continued…)
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Table 2-3, Manual Operation Keys (Continued)

Label or Name	Key Face	Purpose
X+		Manually moves machine in positive
		X direction.
X-		Manually moves machine in negative
		X direction.
SERVO RESET		Activates servo motors.
SPINDLE		Starts spindle in a clockwise direction
FORWARD		(viewed from the top of the motor).
		Optional.
SPINDLE		Starts spindle in a counterclockwise
REVERSE		direction (viewed from the top of the
		motor). Optional.
SPINDLE OFF		Stops the spindle.

Operator Keys

Operator Keys allow you to control machine movements manually. These keys are located below the Manual Operation Keys and on the right side panel of the CNC console. Refer to Table 2-4.

Table 2-4, Operator Keys

Label or Name Key Face	Purpose
FEEDRATE	Overrides the feed and/or rapid rate of the
OVERRIDE	axes in Manual, Auto, and Single Step
	modes. It is a 13-position rotary switch,
	which ranges from 0 to 120 percent.
	(Each increment adjusts the feedback
	override by 10%.)
	NOTE: The override range for rapid rate is
	100%. The CNC will not exceed the
	maximum rapid rate.
SPINDLE	Typically on the right side panel of the
OVERRIDE	CNC console. Overrides the programmed
SPINDLE	spindle RPM rate. It is a 13-position rotary
	switch that ranges from 40 to 160 percent.
	(Each increment adjusts the spindle
	override by 10%.) This feature can be
	used only on machines with programmable
	spindles.
E-STOP	The red emergency stop button
	disconnects the machine’s servos,
	stopping the spindle and all machine
	movement.

	(Continued…)
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