fanuc GFK-1702 User Manual
LEVEL 0
Milling
Gibbs and Associates
5400 Tech Circle
Moorpark, CA 93021
(805) 523-0004
May 1, 1996
PROPRIETARY NOTICE
This document contains propriety information of Gibbs and Associates and is to be used only
pursuant to and in conjunction with the license granted to you with respect to the accompanying Gibbs
and Associates licensed software. Except as expressly permitted in the license, no part of this document
may be reproduced, transmitted, transcribed, stored in a retrieval system, or translated into any language
or computer language, in any form or by any means, electronic, magnetic, optical, chemical, manual or
otherwise, without the prior written permission from a duly authorized representative of Gibbs and
Associates.
It is strongly advised that you carefully review the license in order that you understand your
rights and obligations related to the licensed software and the accompanying user documentation.
Use of the computer software and the user documentation has been provided pursuant to a
Gibbs and Associates license agreement.
© Copyright 1996 Gibbs and Associates, Inc.
All Rights Reserved
Acknowledgements:
Written by Shannon McConville.
Thanks to Tim Alvord, Sean Canterbury, Gary Esser, Bill Gibbs, Charles Haden, Tom Hubina, Pete
Jackson, Kristin Kelley, Michael Kelley, Israel Klain, James Moore, Jeff Myers and Robb Weinstein for
their input and assistance.
This application was ported to the DOS operating system using Bawamba Software Inc.'s Multiplatform
Compatibility Package.
Trademarks:
MS-DOS, Windows NT and Windows 95 are trademarks of Microsoft Corporation
Macintosh is a trademark of Apple Computer, Inc.
Printed in the United States of America
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Level 0 Milling GFK-1702
GFK-1702 T able of Contents
◆
Table of Contents
CHAPTER 1
:
INTRODUCTION 4
How to Learn the System ......................................................4
Balloons and Prompting .......................................................4
Operating Systems Glossary ....................................................4
System Overview ............................................................5
CHAPTER 2
:
INTERFACE 6
Cursors.....................................................................6
Actions.....................................................................7
Objects.....................................................................7
Shortcuts ..................................................................15
Selection ..................................................................15
Colors ....................................................................17
Clipboard..................................................................17
CHAPTER 3
:
PART SET-UP 18
Document Control Dialog.....................................................18
CHAPTER 4
:
GEOMETRY CREATION 21
Geometry Overview .........................................................21
Geometry Expert ............................................................21
Point Creation ..............................................................29
Edit Menu .................................................................31
Modify Menu ..............................................................32
Workgroup Summary ........................................................34
Printing the Part Geometry ....................................................35
Geometry Expert ............................................................36
CHAPTER 5
:
TOOL CREATION 51
Tool Creation Overview ......................................................51
Tool Creation Dialog.........................................................51
Tool List Summary ..........................................................54
Tool Offset.................................................................55
CHAPTER 6
:
MACHINING 57
Machining Overview.........................................................57
Creating an Operation ........................................................57
Multiple Process Programming.................................................58
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Table of Contents GFK-1702
Modifying an Operation ......................................................58
Machining Palette ...........................................................59
Process Dialogs .............................................................59
Operation Data .............................................................68
Clearance Moves............................................................69
Machining Markers ..........................................................72
Operation Summary .........................................................73
Printing the Toolpath.........................................................74
CHAPTER 7
:
VIEW CONTROL 75
Viewing the Part ............................................................75
View Control Palette.........................................................75
View Menu ................................................................76
CHAPTER 8
:
CUT PART RENDERING 78
Cut Part Rendering Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Cut Part Rendering Palette ....................................................78
Cut Part Rendering Preferences ................................................81
Printing the Cut Part Rendered Image ...........................................81
CHAPTER 9
:
POST PROCESSING 82
Post Processing Overview.....................................................82
Post Processor Dialog .......................................................82
Post Processor Preferences ....................................................84
CHAPTER 10
:
COMMUNICATIONS 85
Protocols ..................................................................85
Communicating with a CNC Machine ...........................................86
CHAPTER 11
:
TUTORIAL 88
Creating a New Part .........................................................88
Creating Part Geometry ......................................................92
Creating a Tool List .........................................................104
Creating Operations With the Process List .......................................109
Post Processing ............................................................133
Part Blueprint..............................................................136
APPENDIX 1
:
OPERATING SYSTEMS 137
Launching the System .......................................................137
Operating Systems Glossary ..................................................137
File Compatibility ..........................................................138
Standard Extensions.........................................................138
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GFK-1702 T able of Contents
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APPENDIX 2: PRINTING 139
Printing Preferences.........................................................139
DOS Systems..............................................................139
Windows NT • Windows 95 Systems ...........................................140
Macintosh Systems .........................................................140
APPENDIX 3
:
MENUS 141
File Menu.................................................................141
Edit Menu ................................................................144
View Menu................................................................145
Modify Menu..............................................................146
Help Menu ................................................................147
Part File Menu .............................................................148
APPENDIX 4
:
SHORTCUTS 149
DOS • Windows NT • Windows 95.............................................149
Macintosh ................................................................153
INDEX 155
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Level 0 Milling GFK-1702
CHAPTER 1
:
Introduction
HOW TO LEARN THE SYSTEM
Congratulations on receiving the most productive programming system available! The best
way to learn how to use this software is to do the exercise in the Geometry Creation Chapter and
then go through the Tutorial Chapter. For simple explanations of items on screen and their purpose,
use Balloons and Prompting provided in the Help menu or the reference information provided in
the manual.
BALLOONS AND PROMPTING
Balloons and Prompting are built-in documentation and training information, also known as
CAT (Computer Aided Training). They can be turned on from selections under the Help menu.
Balloons provide reference information about any object that the cursor is placed over. Prompting
extends certain palettes in the system to provide useful suggestions about how to proceed. They are
very useful.
OPERATING SYSTEMS GLOSSARY
The MS-DOS®, Windows NT®, Windows 95® and MacOS® operating systems use different
terminology for certain common items. A short list has been provided to help eliminate possible
confusion. Refer to the Operating Systems Appendix for additional information on the differences
between the DOS, Windows NT, Windows 95 and Macintosh operating systems.
EQUIVALENT TERMS
file = document
program = application
directory = folder
backspace key (not delete or del) = delete key (not del)
Operating system symbol : This symbol appears throughout the manual to indicate when
there are variations in specific system functions depending on the operating system.
4
O
S
GFK-1702 Introduction
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SYSTEM OVERVIEW
This system is designed to be extremely flexible, to allow the user the freedom to create parts
in any way that comes naturally. The "modeless" interface allows the user to have geometry creation, tools, machining capabilities and post processing functions available at all times. However,
there are certain basic elements required to create a part. There must be geometry, a tool, and a toolpath (an operation) created before post processing. The Top Level Palette is organized in a logical
manner for building a part. A part does not have to be created in this order, it only serves as a guideline. Refer to the Tutorial in this manual for complete step-by-step instructions on part creation.
5
Create a new file.
Create part geometry.
Create a tool.
Create a toolpath.
Cut Part Render.
Post Process.
Change the view.
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Level 0 Milling GFK-1702
CHAPTER 2
:
Interface
This system uses a Graphic User Interface (GUI). This simply means that pictures or symbols
are used in place of text whenever possible. This section of the manual describes the different interface objects and their uses.
CURSORS
The cursor is the object moved with the mouse. Its appearance changes depending on its location. The different cursor appearances indicate different uses for the cursor.
Black Pointer : This cursor is used to select objects and geometry by clicking on them. Zoom
by dragging a rectangle around an area on the screen.
White Pointer : This cursor functions the same as the black pointer, except it is in multiple
selection mode. The white pointer appears when the Shift key is held down or when a geometry sub-palette is open. It allows more than one item to be selected at a time.
Mover Tool : This indicates that the cursor is placed on the edge of a palette or in a dialog’s
title bar. Move the palette or dialog by holding the mouse button down and dragging it to a
different location.
Pointing Finger : This indicates that the cursor is over a button. Push the button by clicking on
it.
Hand : This indicates that the cursor is over a draggable object such as a tile. Move the object
by clicking on it once and dragging it to the desired location. This cursor is also used to roll
the trackball.
Spot : The cursor changes to this while rolling the trackball.
I Beam : This indicates that the cursor is in a location where text input is accepted. It is a
flashing cursor.
Area Select : The cursor changes to this while doing a mouse drag or zooming in on an area.
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GFK-1702 Interface
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ACTIONS
There are a number of actions used throughout the system.
• Moving the cursor : The cursor is moved and positioned with the mouse.
• Click : A quick tap on any mouse button.
• Double-click : Two quick taps on the mouse button.
• Type : Using the keyboard.
• Drag : Position cursor, hold mouse button down, reposition cursor, release mouse button.
• Shift-click : Hold shift key down while clicking the mouse.
• Shift-double-click, Ctrl-click, Ctrl-double-click, etc. : Hold down stated key and
click (or double-click).
OBJECTS
Several interface objects are used throughout the system.
• Drawing Window
• Palettes
• Dialogs
• Tile Lists
• Menus
• Machining Markers
• Balloons/Prompts
• Wastecan
7
Menu Bar
Drawing
Window
Tile List
Palette
Prompt
Dialog
Balloon
Wastecan
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Level 0 Milling GFK-1702
DRAWING WINDOW
The drawing window is the full size of the screen. All drawing of geometry, toolpaths, and rendered images appears in the drawing window. It is not moveable. All other interface objects appear
in front of the drawing window.
PALETTES
A palette is a collection of functions grouped together in a logical manner for the user. Some
palettes are moveable, others are not.
Top Level Palette : This palette is made up of buttons. These buttons can be either “on”
(depressed) or “off” (raised). Clicking once on a button turns it on and accesses the
appropriate dialog or palette. Another click will turn the button off and put any dialogs or
palettes away. The top level palette cannot be moved.
Geometry Creation Palette : This palette is also
made up of a group of buttons. However,
when one of the buttons is clicked on, it
does not stay depressed. Instead, it brings up
the point sub-palette or the Geometry Expert Spreadsheet. The Geometry Creation Palette can be
moved to any location on the screen. Move the palette by placing the cursor in the title bar of the
palette. When the cursor changes to the mover tool, hold the mouse button down and move the
palette. This action is called “dragging the edge”.
Machining Palette : This palette is made up of Function Tiles
and buttons. The four Function Tiles are moveable objects that
can be dragged to the Process List to create operations. The
Machining Palette can be moved to any location on the screen.
Cut Part Rendering Palette : This palette provides control over the
cut part rendering process. It allows the user to control rendering speed, the operations that will be rendered, and the way the
tool will be displayed. This is also a moveable palette.
8
GFK-1702 Interface
◆
View Control Palette (Trackball) : The View Control Palette allows the user to
easily change the current view of the part. The buttons around the outside
provide standard view changes, redraws and unzooms. The center ball operates like a trackball and rolls to allow the part to be viewed from any orientation. When the cursor is placed over the ball, it changes into a hand, which
indicates that the ball can be rolled. Holding the mouse button down and
moving the mouse will roll the trackball. The black outlined box on the ball
represents the orientation of the part. The "T" identifies the top surface of the
part. The dimensions of the box do not change with the actual part size. X is the long axis. Once the
desired view is obtained, and the mouse button is released, the part is redrawn in the new view. The
ball has four small solid black rectangles around it, inside the ring of buttons (located at 12:00, 3:00,
6:00, 9:00). These are called ball "handles". Drag these handles for a single axis view change. The
trackball is a moveable palette, drag its edge to move it.
DIALOGS
Dialogs are used when information is required from the user. This information is conveyed
through text boxes, radio buttons, yes/no buttons, and pop-up menus.
Text Boxes : Items that require keyboard input
have a box next to them. If you click once in a
text box, a flashing text cursor will appear where
you clicked. Anything typed will begin at the
flashing text cursor. To move the text cursor, click
at the desired location. Double-clicking in a text box will select (highlight) everything in the text
box. Anything typed at this point will completely replace the current contents of the box. To select
only portions of the contents of the text box, click before or after the text to be edited, hold the
mouse button down and drag.
Moving from one text box to another can be accomplished by simply clicking in the desired
box, or hitting the Tab key. The Tab key moves the cursor from one box to another, and highlights
the entire contents of each box.
The contents of all text boxes can be cut, copied and pasted to and from the clipboard by
choosing items from the Edit Menu.
Math Input in a Text box : All number input boxes will accept the four standard math function symbols
(+ - x / ), as well as a number of special functions, (both * and x are used for multiplication). Hitting
the equal key or tab key on the keyboard will display the final value. Special math functions
include:
r = squareroot
s= sine
c= cosine
t= tangent
a= arctangent
m= convert from inch to millimeter (x 25.4)
i= convert from millimeter to inch (/ 25.4)
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Text Box
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Level 0 Milling GFK-1702
Angle values follow the standard Cartesian coordinate system, shown below. Negative values
are acceptable as input.
Radio buttons : Radio buttons come in groups. When one of the buttons in the group is
depressed (turned “on”), the other buttons in the group are “off.” The button that is
depressed displays a small red dot or “light” to indicate that it is “on.”
Yes/No buttons : Yes/no buttons come one per option. Depress the button for
yes, pop it up for no. The button that is depressed displays a small red dot or
“light” to indicate that it is “on.”
Pop-Up menus : Pop-up menus provide multiple choices. A
pop-up menu looks like a button, but has an arrow indicating that there are more choices available. The menu is accessed by depressing it and dragging the
cursor down to scroll through the list. When the desired item is highlighted, release the mouse button to select it.
Geometry Dialog : Geometry Dialogs are used
for input of specific geometric information
when creating points. These dialogs contain
options for creating single points or multiple
points.
10
(-270°)
90°
180°
0°
(-180°)
270°
(-90°)
GFK-1702 Interface
◆
Geometry Expert Spreadsheet:
All part geometry is created using the
Geometry Expert Spreadsheet. The
feature type buttons on the far left are
contained in a pull out graphic menu.
All other geometric information is entered in the feature rows in the various cells of the spreadsheet.
This is a moveable dialog that can be positioned anywhere on the screen. For more information on
Geometry Expert, refer to the Geometry Creation Chapter.
Moveable dialogs : Some dialogs
may be moved around on the
screen. The area at the top of
the dialog is called the title
bar. The title bar shows the
name of the dialog. Drag the
title bar to move the dialog.
The small box in the upper left
corner of the window is the
close box. Clicking in this box
puts the dialog away. Doubleclicking on the title bar will
hide the dialog and leave only
the title bar. An additional
double-click will restore the
dialog. This is useful for conserving screen space. Most of
the dialogs in the system can
be shrunk to the title bar in
this manner.
11
Close box
Dialog Name Title Bar
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Level 0 Milling GFK-1702
Open Dialog : The Open Dialog is used to locate, view, and open files. It comes up when Open is
selected from the File menu, or the Open button is depressed in the Document Control Dialog.
TILE LISTS
Tool Tiles, Process Tiles and Operation Tiles reside in
Tile Lists. Tile Lists have numbered positions or locations.
These positions can be empty or have a tile in them. Tiles may
be selected and dragged to any position in the list. To place a
tile between two tiles, drag the new tile to an insertion point
between two positions. Or, if you shift-double-click on an
insertion point, an empty location is created. Any tiles below
the insertion point will be moved down in the list. To move
tiles up in the list, shift-double-click on an empty position.
Depressing and holding down the scroll buttons located at the
top and bottom of the list, scroll the list in order to access tiles
higher or lower in the list. To scroll the list a “page” at a time,
12
Current Directory/
Folder: displays a list
of all available files in
the current directory
Material Information
and Part Comment
Pop-up menu to
access a higher level
directory, displays
current directory
Material Information
Button used to access the available drives and
disks contained on the system.
O
S
The name of the
current disk
On DOS, Windows NT and Windows
95 systems, it is the Drive button as
shown above. On Macintosh systems,
it is the Desktop button.
Part Preview:
displays the last
rendered image
of the part
Part Dimensions
Scroll
Button
Insertion
Point
Tile
Location
Number
Empty
Location
GFK-1702 Interface
◆
hold down the scroll button and move the mouse in the direction of the arrow. The arrow will turn
red when scrolling a page at a time.
Tiles : The four different types of tiles are:
Function Tiles (Machining Palette)
Tool Tiles (Tool List)
Process Tiles (Process List)
Operation Tiles (Operation List)
Although the functionality of each type of tile is different, they have common features. All tiles
have a similar appearance, grey and square. Tiles can be dragged to tile lists.
Function Tiles: The four different types of functions are drilling, contouring,
pocketing, and thread milling. Function Tiles are dragged to a Process
List Location to create a Process Tile.
Tool Tiles : A Tool Tile is created by double-clicking on an empty Tool Tile Location. This
brings up a Tool Dialog. A Tool Tile displays a small tool symbol and the tool diameter.
Process Tiles : A Process Tile is created by dragging one Tool Tile and one Function Tile to a
Process List Location. A completed Process Tile displays the tool number with a box
around it, and a function symbol. When a Process Tile is created, a Process Dialog specific
to the selected machining function will appear on the screen. An incomplete Process Tile displays
either the tool number or the function symbol.
Operation Tiles : Operation Tiles are created from Process Tiles by clicking on the Do it but-
ton once the appropriate geometry has been selected for the cut shape. Each Operation Tile
represents one machining operation which contains the toolpath. An operation can either
drill or thread mill all selected points or circles, contour selected shapes, or pocket as much of the
selected geometry as possible without picking up the tool. An Operation Tile displays the tool number and function symbol.
MENUS
Menu Bar: The menu bar shown below is located at the top of the screen. It is available to the user at
all times. To access the menu bar, position the cursor over the menu bar title, hold the mouse button
down, drag the cursor until the desired item is highlighted, and release the mouse button. If a menu
item is grayed out it cannot be selected. Selecting geometry or some other appropriate item on the
screen may change the menu item so that it is available for selection. Some menu items are grayed
out because they are not supported by the Level 0 product. Refer to the Menus Appendix for a listing of these items.
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Level 0 Milling GFK-1702
Keyboard shortcuts: Many menu items can be accessed by the keyboard. The letter next to the menu item indicates what key on
the keyboard will activate that item. Refer to the Shortcuts
Appendix for specific information on using keyboard shortcuts.
The symbol next to the letter will be different depending on the operating system
and the selection made in the Interface Preference.
MACHINING MARKERS
Machining Markers allow the user to specify the start and end feature and start and end point
of the cut shape, the cut direction, and the offset position of the tool. These markers appear on the
screen when geometry is selected for contouring processes.
Start Feature : The geometry feature (line or circle) on which the tool will start cutting.
Start Point : The point on the start feature where the tool will start cutting.
End Feature : The geometry feature on which the tool will stop cutting.
End Point : The point on the end feature where the tool will stop cutting.
Cutter Side and Direction : The circles represent where on the geometry the tool will
cut: on the outside of the geometry, on the inside of the geometry, or on the centerline. The arrows indicate which direction the tool will travel, making either a
climb or conventional cut. Click on the desired circle and direction arrow.
BALLOONS/PROMPTS
Balloons and prompts provide on-line reference information about the objects and functions in
the system.
Balloons : Balloons are turned on in the Help menu. A bal-
loon containing reference information will appear when
the cursor is placed over an object on the screen.
14
Keyboard
Shortcut
O
S
GFK-1702 Interface
◆
Prompting : Prompting is also turned on in the Help menu.
Prompting extends the geometry and machining palettes to
include useful suggestions on how to use the software.
Error Balloons : Error balloons alert the user whenever an invalid value has
been entered. They are outlined in red and disappear when a valid entry is
made.
SHORTCUTS
Button Shortcuts : In some cases, buttons may be depressed by actions other than clicking on them.
When a button has a black outline around it, it can be depressed by hitting the enter
or return key.
Geometry dialogs give the user a choice of single or multiple point creation. To
create only one point, click on the single point button. To create more than one
point using the selected method, click on the multiple point button. One of the buttons will always
be highlighted. The highlighted button can be depressed by clicking on it, hitting the space bar, the
enter key, or the return key.
The Process button is found in some dialogs, primarily those found in the Modify
menu. It can be depressed by clicking on it, or by hitting the enter or return keys.
The system contains many other shortcuts that are described on platform specific Shortcuts
information cards and in the Shortcuts Appendix.
SELECTION
Three classes of objects may be selected in the system: text, geometry features and tiles. Text
and geometry can be cut, copied, and pasted to and from the clipboard within the same file by using
items in the Edit Menu. Selection techniques are described below.
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Level 0 Milling GFK-1702
TEXT SELECTION
To select text:
• Click and drag the cursor over some text.
The text will become selected.
• Double-click in a text box.
All text in the box will become selected.
• Hit the tab key to move from text box to another.
All text in the box will become selected.
GEOMETRY SELECTION
To select a single geometry feature:
• Click on a feature.
The feature will become selected. If any other features were selected, they will
become deselected.
To select multiple geometry features:
• Shift-click on a feature.
If the feature was unselected, it will become selected and added to any other currently
selected features. If the feature was selected, it will become deselected and removed from
the currently selected group.
Holding down the shift key changes the cursor to multiple selection mode which
allows more than one geometry feature to be selected at a time.
To select an entire connected shape:
• Double-click on a feature of the shape.
All connected features will become selected.
To select certain types of geometry:
• Use the Select items found under the Edit menu.
All geometry that matches the selected type will become selected and added to the
currently selected group.
TILE SELECTION
To select a single tile:
• Click on a tile.
The tile will become selected. If any other tiles were selected, they will become deselected.
To select multiple tiles:
• Shift-click on a tile.
If the tile was unselected, it will become selected and added to any other currently
selected tiles. If the tile was selected, it will become deselected and removed from the currently selected group.
Holding down the shift key changes the cursor to multiple selection mode which
16
GFK-1702 Interface
◆
allows more than one tile to be selected at a time.
COLORS
The system uses colors to graphically display different items drawn on the screen. The color
scheme for geometry, toolpaths and rendering is listed below.
GEOMETRY
Color Meaning
Yellow Unconnected Geometry
Light Blue Connected Geometry
TOOLPATHS
Color Meaning
Dark Blue Cut Shape; selected area of a shape to be machined
Solid Orange Feed Move in a Toolpath
Dashed Orange Rapid Move in a Toolpath
Dashed Gray Rapid Move used for positioning moves and tool changes
Solid Gray Approach Feed Move
RENDERING
Color Meaning
Blue Stock
Yellow Rendering of selected operations, and/or selected tools
Gray Rendering of unselected operations and/or unselected tools
Red Tool Interference
CLIPBOARD
The Clipboard is used as a temporary storage place for geometry and text. Using the Cut
option from the Edit menu will delete whatever items are selected and replace the contents of the
Clipboard with them. Using Copy will leave the selected items in their current location and replace
the contents of the Clipboard with a duplicate of them. Choosing Paste can do two things. If something is selected it will replace that selection with the contents of the Clipboard. If nothing is selected the contents of the Clipboard will be pasted in either the drawing window or in an active text box
depending on whether the Clipboard contains text or geometry. The Clipboard can only hold one
selection at a time. This means that it can hold either text or geometry, but not both. If text is
copied into a Clipboard holding geometry, the geometry in the Clipboard will be lost. The contents
of the clipboard will also be lost, when a file is closed, the software is quit out of, or the computer is
shutdown. Therefore, geometry can not be cut, copied or pasted between different part files because
the contents of the clipboard are deleted when the part file is closed.
17
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Level 0 Milling GFK-1702
CHAPTER 3
:
Part Set-up
DOCUMENT CONTROL DIALOG
Clicking on the Document Control button will bring up the Document Control dialog.
This dialog is actually a combination of two linked dialogs. The top dialog contains file
management selections and also provides measurement type options.
The bottom dialog provides specific information about the part such as stock size,
clearance moves and tool change positioning.
The buttons used for file management, described below, are also available under the File menu.
Open Button : Clicking on the Open button will bring up the Open Dialog which allows the user to
select which file to open. If a file is currently open, it will be closed and the selected file will be
opened.
18
File
Management
Measurement
Type
Stock Size
Diagram
Tool Change
Position
GFK-1702 Part Set-up
◆
New Button : This button will create a new file by opening a dialog and asking for a file name and a
location to save the new file. If there is a file open, it will be closed.
Save Button : If there have been any changes made while the file was open, this button will save the
changes.
Save As Button : This button will open a dialog asking for a file name and a location to save the current file. The changes made since the last Save command will be written into the new file. The original file will not be affected. The new file will become the current, open file.
Save a Copy Button : This button is very similar to the the Save As button. The system will create a
duplicate copy of the open file. The original file remains the current, open file. The name of the
duplicate file can be changed.
On DOS systems, if the original file name is less than 8 characters, the system will add
underscores to make the duplicate file's name 8 characters in length. If the original file's
name is 8 characters, the system will change the last character to an underscore to distinguish the original file and the copy. On Macintosh, Windows NT and Windows 95 systems, the
word “copy”will be added at the end of the file name to distinguish it from the original.
Close Button : This button closes the current file. If the file has not been saved before clicking on the
Close Button, a dialog will come up asking if the file should be saved.
Measurement Type : These two radio buttons determine whether values input will be
based on an English or metric standard and entered in inches or millimeters. The
measurement type used by the post processor is determined by the post processor
itself. There are English and metric post processors. If an English post is used on a metric part, the
posted numbers will be converted from millimeters to inches. Likewise, metric posts will convert
values from inches to millimeters.
Stock Size Diagram : This section of the dialog is used to
specify the starting size of the part stock. The numbers
will be used to draw the stock outline and origin marker, and to draw the initial stock during the rendering
process. These values will not affect the programming
of the part, but it is recommended that they closely correspond to the actual stock being used.
Tl Change Pos : If Tool Change Position is on, the turret will be sent to the X
and Y dimensions specified before a tool change occurs. This option is
used on milling machines without automatic tool changers. It is also useful
when the table must be moved to avoid interference during a tool change
due to a tall part, fixtures or if a rotary table is being used.
19
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S
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Level 0 Milling GFK-1702
Clearance Plane : This position is used as a master Clearance Plane for the
part. This is the Z position the tool will rapid to and from during a tool
change. In addition, the tool will retract to this position between holes for
drilling operations, if the second Retract to Z option is selected in the
Drilling Process Dialog. This Clearance Plane is also used for multiple parts in the posted output.
Refer to the Machining and Post Processing Chapters for more information on clearance positioning.
Comment : Any text entered as a part comment will be shown in the part preview section of the Open
Dialog. In most cases, it will also appear in the posted output.
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CHAPTER 4
:
Geometry Creation
GEOMETRY OVERVIEW
Geometry must be created in order to machine a part. All part geometry is created
using the Geometry Expert spreadsheet and the Point sub-palette. Geometry Expert
combines the creation and connection of all geometry features in one powerful and easy
to use method. The Point sub-palette offers several methods for defining points. Once
created, geometry can be duplicated and modified using items in the Edit Menu and the
Modify Menu. There is an exercise at the end of this chapter that provides detailed
instructions on creating part geometry.
GEOMETRY EXPERT
Geometry Expert is a method of geometry creation which facilitates the fast creation of simple parts and the simplified creation of more complex parts, along with being very easy to learn
and use. Geometry Expert is designed to create a single, continuous, shape. It allows the user to
define, create and connect shape features while following along the path of the part.
Geometry Expert has a tabular format which operates much like a standard spreadsheet.
Features are defined by entering dimensions into the cells (text boxes) of the feature rows. Each
row creates a different feature. Features are defined in the same order as they are encountered
along the shape path.
Creating a shape using Geometry Expert is akin to “walking” around the path of the shape,
indicating such items as location, direction and the distance being traveled. While this is similar to
standard shape creation techniques, Geometry Expert goes one step further. It applies its inherent
knowledge of geometric principles and follows a logical course which allows for the creation of
complete, connected, geometrically correct shapes requiring the least amount of input from the
user.
Geometry Expert, as the name implies, provides the user with a built-in consultant on the
rules and principles of geometry. The creation of simple shapes, containing primarily horizontal
and vertical lines, such as shafts, is almost effortless using Geometry Expert. The default settings
and automatic angle toggling allow the user to create alternating, intersecting horizontal and vertical lines in the fastest manner possible. The user only needs to enter one value in order to define
the line. The creation of more complex shapes, containing multiple arcs and angled lines, is greatly simplified due to the fact that Geometry Expert constantly applies its built in logic and knowledge of geometry to guide the user through the process.
Finally, Geometry Expert is a very powerful editing tool. The associative capabilities of
Geometry Expert make editing any existing shape a very easy process. The system handles the
dimension changes while maintaining all the proper connections and relationships between pieces
of geometry (eg. intersections and tangencies). Feature dimensions can be adjusted by simply
changing the values in the spreadsheet. Geometry Expert handles all of the calculations and
adjustments to the other features that are affected by the changes. Geometry Expert frees the user
from needing to understand complex geometrical relationships and calculate feature dimensions.
Instead, the user can simply enter the specifications provided on the part blueprint and let
Geometry Expert do the rest.
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HOW GEOMETRY EXPERT WORKS
Geometry Expert is set up much like a standard spreadsheet. Feature specifications are
entered into cells which are contained in rows. Each row of the spreadsheet defines a feature.
Features are defined in the order that they appear along the path of the shape. When the
Geometry Expert spreadsheet is open on the screen the user can create fully connected shapes by
entering feature specifications in each of the rows. Because Geometry Expert creates connected
shapes, each feature is dependent on and aware of the preceding and following features.
The feature row that is being worked on at any given time is referred to as the “current row”.
The current row has an upraised frame and is outlined in either yellow or black. When the current
row contains adequate information, it is outlined in yellow. The prompt at the bottom of the
spreadsheet, which gives the status of the current row, will indicate what will happen when the
row is entered.
The current row will be outlined in black if it does not contain enough information. The
prompt will indicate what additional information is needed to define the row. If the user attempts
to enter a row that does not contain enough information, an error balloon will come up, again indicating what other information is required. When the current feature row contains the appropriate
information, the row is entered into the spreadsheet by hitting the enter or return key. Entering a
new row moves the cursor down to the next row in the spreadsheet, which will now be the current
row. The enter and return keys only move the current row down in the spreadsheet if a new row is
being created. Otherwise, the arrow keys or the cursor must be used to maneuver through the
rows in the spreadsheet.
Each feature is drawn on the screen as soon as the spreadsheet contains the necessary information. Some features cannot be drawn until later features are defined. These are referred to as
“floating features” and are explained later in this section.
Creating part geometry with Geometry Expert is accomplished by walking along the path of
a shape, and defining features as they are encountered. In this way, all features are automatically
connected to the preceding and following features. Because of this methodology, sometimes it is
necessary to specify the correct direction of a feature, in addition to indicating its magnitude.
For arcs, the selected feature type indicates the direction, either clockwise or counter-clockwise. For lines, the angle value indicates the direction. For example, a horizontal line can either
be defined with an angle value of 0° or 180°; both will draw the same line, but in the opposite
direction. Specifying the correct line direction is only an issue if the previous or next feature is
going to be an arc. When that is the case, it is necessary to indicate to the system what direction
the line is moving. Again, checking the line direction should only be necessary when the line is
being connected to an arc.
Cell
Feature Row
Scroll Bar
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CREATING SHAPES USING GEOMETRY EXPERT
When creating a part using Geometry Expert, the first thing that must be decided is the starting feature and the direction to travel around the part, either clockwise or counter-clockwise.
When the spreadsheet is first opened, the first row will default to a line with an angle of 90°. The
information in this row will need to be added to and/or changed in order to define the first feature.
The prompts indicate what additional information can be entered to define the feature. As
soon as the first row contains enough information to fully define the feature, the frame of the row
will become yellow. When the frame is yellow, the prompting information tells the user how the
feature will be created. A yellow frame around the row indicates that the user can press enter
without getting an error message. Hitting enter or return will create the feature and start a new
row. The reference number of the feature that was created will be placed in the Ref cell in its row.
The new row’s feature type will default to a line, and the angle will default to either 0°/180°
or 90°/270°. The angle value of the line will automatically toggle between either 0°/180° or
90°/270°. Once again, the prompt will indicate what information can be added to further define
the line.
In this case, and many others, the frame of the row will be yellow even if the row does not
contain enough information to fully define the feature. This is because it is still possible to add
information in subsequent rows that will fully define the feature. At this point, information can be
added to or removed from the row to define the next feature of the shape as dimensioned on the
print. When the information is correct, the feature is created by hitting the enter or return key.
This process continues until the last feature of the shape is defined. When the last feature of
the shape is created it should intersect with the first feature of the shape. At this point the feature
must be connected using the Close Shape feature type.
Geometry Expert button: The Geometry Expert button is located in the last position in the
Geometry Creation palette. Clicking on this button brings up the Geometry Expert
spreadsheet, shown below, which allows the user to create connected shapes by entering
feature dimensions in the rows of the spreadsheet.
Vertical (Y) Coordinate
of End Point
Angle of Line/
Radius of Circle
Close Box
Reference #
Feature Type
Current Row
Prompt
Horizontal (X) Coordinate
of Endpoint
Horizontal (X) Coordinate
of Line Point/Centerpoint
Length of Line
or Chamfer
Vertical (Y) Coordinate
of Line Point/Centerpoint
Size Box
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Feature Type: There are seven options available for the
feature type. They are (from left to right): line, chamfer,
fillet, clockwise arc, counter-clockwise arc, and close shape. Each row must have a
feature type selected. To select the feature type, click on the feature type button which will
access the possible selections. Drag the mouse to the desired feature so that the button
appears depressed, and let go of the mouse button. That feature will now appear as the
feature type for the row. In some cases, depending on the previous feature, some of the
feature type options may be grayed out to indicate they are not valid selections. Also,
depending on the feature type selected, some cells may be grayed out indicating that the
selected feature type does not require that dimension. The feature type can also be selected
using keyboard shortcuts. Refer to the Shortcuts information card or the Shortcuts Appendix
for information on keyboard shortcuts for Geometry Expert.
Reference #: Every feature that is created is assigned a reference number by the system. The
letter indicates what type of feature it is, L for line, C for circle, and the number indicates the
creation order. These reference numbers may change during the course of creating geometry,
but will not affect the shape.
EP X: The number entered in this cell is the horizontal or X coordinate of the endpoint of the
current feature. When a feature is defined with an endpoint, the system will draw the feature
and trim it at the specified endpoint. Endpoint specifications are required if the next feature
needs a start point in order to be correctly defined.
EP Y: The number entered in this cell is the Y or vertical coordinate of the endpoint of
the current feature.
EXAMPLE: The row shown below will create a 45° line with an endpoint drawn at
X -2, Y 3. The next feature that is defined in the spreadsheet will start at the end
point of this feature.
Angle/Rad: The number entered in this cell is dependent on the feature type selected.
If the feature type is a line, this number specifies the angle of the line. The angle value for a
line defaults to either 90°/270° or 0°/180° allowing for the creation of vertical or horizontal
lines, respectively. The system toggles between these angle values which makes the creation
of intersecting horizontal and vertical lines a very quick and easy process. The user can
change the default values by simply entering the new numbers in the cells. If the feature
type is a arc or fillet, this number specifies the radius.
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EXAMPLE: The row shown below will create a fillet between the previous and following feature with a radius of 0.25.
Length: The number entered in this cell is the length of the current feature. The length cell
is only active if the feature type is either a line or a chamfer.
LP/CP X: The number entered in this cell is dependent on the feature type selected. If the
feature type selected is a line, this number is the X or horizontal coordinate of a line point
(LP). A line point is any point that lies somewhere on the line. Line points are only
used to draw and calculate the line, they are not part of the shape. Line points are not drawn
on the screen. Geometry Expert defaults to the LP/CP cell so it is more efficient when
creating lines to use line points whenever possible in order to reduce the number of key
strokes necessary. If the feature type selected is a circle, this number is the horizontal
coordinate of the centerpoint of the circle.
LP/CP Y: The number entered in this cell is dependent on the feature type selected.
If the feature type selected is a line, this number is the Y or vertical coordinate of a line
point. If the feature type selected is a circle, this number is the horizontal coordinate of the
centerpoint of the circle.
EXAMPLE: The row shown below will create a 90° (vertical) line that goes through
the point at X 4. When defining either horizontal (0°/180°) or vertical (90°/270°)
lines, only one LP coordinate is required. Refer to the section on Half Points in this
chapter for more information.
EXAMPLE: The row shown below will create a circle with a radius of 0.5 and a
centerpoint at X -3, Y 2.
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Prompt: The information contained in the prompt indicates the status of the current row.
When a feature row is outlined in yellow, the prompt tells the user what specifications have
been entered for this feature and what will happen when the row is entered. If the feature row
is outlined in black indicating that more information is required, the prompt will tell the
user what additional information is required. The prompt also indicates if the system has automatically deleted a cell value because the feature row contained too much information that
overdefined the feature, this aspect of Geometry Expert is referred to as the “auto delete”
function which is explained in the Expert Aids section of this chapter.
Close box: Clicking in this box will close Geometry Expert. When Geometry Expert is closed,
all information is cleared out of the spreadsheet. When the Geometry Expert button is
depressed again, the spreadsheet will come up empty. In order to load or reload a shape into
the spreadsheet, double click on any feature of the shape while the spreadsheet is open
on the screen. All connected feature dimensions will be entered into the spreadsheet.
Size box : The size box allows the user to adjust the size of the Geometry Expert spreadsheet.
To adjust the size of the spreadsheet, click in the Size box and drag the window to the desired
size. The width cannot be changed, but the length can be adjusted.
Scroll Bar: The scroll bar and arrows allow the user to scroll through the rows contained in
the spreadsheet to make adjustments and check the values entered. This is useful if the spreadsheet needs to stay relatively small to fit on the screen, and/or if it contains many features.
EXPERT AIDS
There are several items built in to Geometry Expert that are designed to guide the user
through geometry creation. They include prompting, auto delete, and error balloons.
Prompting
The prompting information appears across the bottom of the Geometry Expert spreadsheet.
The prompt tells the user what actions are being taken by the system based on the information provided by the user. The user should be able to follow the prompts through the creation process to
get a good idea of what is happening.
Auto Delete
The auto delete function of Geometry Expert is intended to reduce errors resulting from fea-
tures being overdefined because too much information has been entered in the feature row.
Geometry Expert is designed so that the user need only enter the minimum amount of information
to define a feature. The system will automatically delete the first entry made in the feature row
when the feature is overdefined. Auto delete is necessary in order to facilitate the associative
capabilities of Geometry Expert. Note that the default values, such as the line angle, are considered the first entry rather than any information entered by the user. The prompt will indicate what
information is being deleted.
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Error Balloons
Geometry Expert also contains Error Balloons which appear on the screen whenever a problem occurs. The most common error messages appear when the system requires more information
for a feature being entered. For example, if a line needs another value for an end point, an Error
Balloon will come up indicating that a V or H value is needed to calculate the end point. The
Error Balloons and Prompting use the letters V and H, indicating Vertical and Horizontal.
Another common error message indicates that the feature being defined cannot intersect with
the previous feature. The non-intersecting feature can still be created, but the message indicates to
the user that the continuity of the shape has been broken and the subsequent features being created
will not connect to the existing shape.
ADDITIONAL INFORMATION
Defaults
When entering features in the Geometry Expert spreadsheet, the system contains defaults for
the feature type and line angle. The standard feature type default is a line. When Geometry
Expert defaults to a line, it also enters an angle value, either 90°/270° or 0°/180°, depending on
the angle of the last line entered. Sometimes a line is not a possible feature type option, in which
case the system defaults to an arc. This only occurs when the previous feature is a floating line.
Geometry Expert dimensions the line according the preceding and following feature specifications.
Floating features are not drawn on the screen until the system contains the necessary information.
Post Targeting
Despite all of its expertise, Geometry Expert can’t always know the correct intersection point
to use for a connector. When there are two or more, equally valid points of intersection, the system will draw both points. This is referred to as post targeting. When post targeting is required, a
dialog will come up that asks the user to select the appropriate point and click on the OK button.
Once the user has selected the desired intersection point, Geometry Expert will make the appropriate connection and continue along in the spreadsheet defining and connecting features.
The Edit menu contains an item that will change the intersection point selected in a post targeting dialog to the other possible point of intersection. The menu item toggles between Use
Intersection #1 and Use Intersection #2, depending on the point selected and where it lies along
the path of the shape. This option will be an active item when a feature that required post targeting is selected on the screen.
Half Points
In certain cases, only one coordinate, either the horizontal or vertical, is required to define
the feature. This is referred to as a half point case. Half points are valid when Geometry Expert is
able to calculate the other half of the coordinate value from information contained in the spreadsheet. (Either preceding or following features.)
When a valid half point is entered, the row will be highlighted in yellow, allowing the user to
enter the feature row. If the half point entered is not valid, the row will be highlighted in black
and the prompt will indicate what additional information is necessary to enter the row. If an
incomplete row is entered, an error ballon will come up indicating what additional information is
required. There are three cases where half points are valid. They are listed and explained below.
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Half Line Point: A half line point is valid only when creating either a horizontal line (angle
value = 0° or 180°) or vertical line (angle value = 90° or 270°). If creating a horizontal line, a
V coordinate must be given for a valid half line point. If creating a vertical line, an H coordinate must be given for a valid half line point. Line points are not part of the shape, but are
only used to calculate the position of the line.
Half End Point: A half end point is only valid if the line is otherwise completely defined.
Given either the vertical or horizontal coordinate of the end point along with the other information that defines the line, the system can calculate the other half of the end point. If a half end
point is used in the case of 0°/180° or 90°/270° lines, the half end point will function like a
half line point, in that an end point will not be drawn, although the correct line will be created.
Half Center Point: A half center point is valid when a circle has a radius value and is tangent to
the preceding feature. (There must be a preceding feature.) Given the radius and the vertical
or horizontal component of the centerpoint, the system can calculate the other half of the
centerpoint by the assumed tangencies.
Floating Features
Floating features are features whose defining row does not contain all of the information necessary to draw the feature. Floating feature rows are different from incomplete feature rows. With
floating feature rows, the information contained in the current feature row and the preceding rows
is inadequate to completely define the feature and draw it. However, subsequent features, defined
in following rows, could provide the necessary information to define the floating feature. Floating
feature rows are outlined in yellow and can be entered.
Incomplete feature rows do not contain enough information to create the feature, and no
amount of information entered in following rows will make the feature definable. Incomplete feature rows are outlined in black and cannot be entered without getting error messages.
Again, the row outline and the prompting information will indicate if the feature row can be
entered, and if it is, how the floating feature will be incorporated into the shape after later features
have been defined.
Inserting and Deleting Rows
The Edit menu contains options for inserting and deleting rows in the spreadsheet. When
inserting rows in the spreadsheet, the system will create a new row above the current row. To
insert a row, select the row beneath the row to be inserted. Then, select the Insert row option in
the Edit menu. When an inserted row is entered, the system will recalculate the shape and attempt
to incorporate the new feature into the existing shape, if possible.
To delete a row, simply select the row to be removed, and choose the Delete Row option in
the Edit menu. When rows are deleted, Geometry Expert will recalculate the shape, and attempt
to keep it continuous and connected. If that is not possible, error balloons will appear indicating
that features do not intersect and the shape cannot be connected.
Arcs vs. Fillets
Arcs with only a radius value and fillets appear to be very similar at first glance, but actually
use two completely different methods for calculating the circles. A fillet takes a sharp point produced by an intersection between two other features and changes it into a radius. It is created after
the intersection between the two features is completed. Because of this, it is dependent on the
intersection of the other two features to exist. This means that the system cannot use the fillet to
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