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Spindle Clamp Speed Setting G50

Spindle clamp Speed Setting:-


Function and purpose:-
          The code G50 can be used to set the maximum and minimum spindle speeds at addresses S and Q, respectively.


Programming Format:-
          G50 S__ Q __ R__
          S        =        Maximum Spindle Speed
          Q       =        Minimum spindle speed
          R        =        Spindle for Speed Clamping




Detailed Description:-
          For gear change between the spindle and spindle motor, four steps of gear range can be set by the related parameters in steps of 1 min-1 (rpm). In range defined by two ways, parameter setting and G50 S__ Q__ setting, the smaller data will be used for the upper limit and the larger data for the lower limit.


Spindle for Speed Clamping is to be set by address R.
          R1: Turning Spindle 1st chuck
          R2 : Turning Spindle 2nd chuck
          R3: Milling Spindle


Notes:-
          The default value is “R1” (automatically set if argument R is omitted). In this case the speed of turning spindle 2 can be raised up to the highest value in accordance with the machine specification concerned

Feed Rate

Feed Rate
Feed rate is the velocity at which the cutter is fed, that is, advanced against the work piece. It is expressed in units of distance per revolution for turning and boring (typically inches per revolution [ipr] or millimeters per revolution). It can be expressed thus for milling also, but it is often expressed in units of distance per time for milling (typically inches per minute [ipm] or millimeters per minute), with considerations of how many teeth (or flutes) the cutter has then determining what that means for each tooth.
Feed rate is dependent on the:
§  Type of tool (a small drill or a large drill, high speed or carbide, a box tool or recess, a thin form tool or wide form tool, a slide knurl or a turret straddle knurl).
§  Surface finish desired.
§  Power available at the spindle (to prevent stalling of the cutter or work piece).
§  Rigidity of the machine and tooling setup (ability to withstand vibration or chatter).
§  Strength of the work piece (high feed rates will collapse thin wall tubing)
§  Characteristics of the material being cut, chip flow depends on material type and feed rate. The ideal chip shape is small and breaks free early, carrying heat away from the tool and work.
§  Threads per inch (TPI) for taps die heads and threading tools.
When deciding what feed rate to use for a certain cutting operation, the calculation is fairly straightforward for single-point cutting tools, because all of the cutting work is done at one point (done by "one tooth", as it were). With a milling machine or jointer, where multi-tipped/multi-fluted cutting tools are involved, then the desirable feed rate becomes dependent on the number of teeth on the cutter, as well as the desired amount of material per tooth to cut (expressed as chip load). The greater the number of cutting edges, the higher the feed rate permissible: for a cutting edge to work efficiently it must remove sufficient material to cut rather than rub; it also must do its fair share of work.
The ratio of the spindle speed and the feed rate controls how aggressive the cut is, and the nature of the formed.


Formula to determine feed rate:-


This formula can be used to figure out the feed rate that the cutter travels into or around the work. This would apply to cutters on a milling machine, drill press and a number of other machine tools. This is not to be used on the lathe for turning operations, as the feed rate on a lathe is given as inches per revolution.
FR = RPM X T X CL
Where:
§  FR = the calculated feed rate in inches per minute or mm per minute.
§  RPM = is the calculated speed for the cutter.
§  T = Number of teeth on the cutter.
§  CL = the chip load or feed per tooth. This is the size of chip that each tooth of the cutter takes.
Depth of cut:-
Cutting speed and feed rate come together with depth of cut to determine the material removal rate, which is the volume of work piece material (metal, wood, plastic, etc.) that can be removed per time unit.

Constant Surface Speed Control On-Off

Constant Surface Speed Control On/Off: G96/G97


Function and Purpose:-
          This function controls automatically the spindle speed as the coordinates are changed during cutting in diametric direction so as to execute cutting by keeping constant the relative speed between tool tip and work piece.


Programming Format:-
          G96 S__ P__ R__ ; Constant Surface Speed Control On
          S        =        Axis for constant surface speed control
          P        =        Surface speed
          R        =        Spindle for constant surface speed control


G97 ; ………………….Constant Surface Speed Control OFF


Detailed Description:-
1.   Axis for constant surface speed control is to be set by address P.


P1 : First axis


P2 : Second axis
X – Axis ( the first axis ) is automatically selected if argument p is omitted .


2.   Spindle for constant surface speed control is to be set by address R.


R1: Turning Spindle for 1st chuck (left side chuck –upper turret or Right side chuck – lower turret)


R2: Turning spindle for 2nd chuck (Right side chuck –Lower turret or left side chuck –upper turret)
3.   Control Change program and actual movement


G90 G96 G01 X20. Z50. S500 ; spindle Speed is controlled for a surface of 500 m/min
;
;
;
;


G97 G01 X20. Z50. F10. S500 ; Spindle Speed is controlled for 500 rpm
;
;
;
M02 ;


Notes:-
v  The function is not effective for blocks of rapid motion (G00).


v  The spindle speed calculated for the surface speed at the ending point is applied to the entire motion of a block of G00.


v  The last value of S in the control mode of G96 is stored during cancellation of the control (G97) and automatically made valid upon resumption of the control Mode (G96).


Example:-
o   G96 S500 ;   500 m/min or 500 Ft/min
o   G97 S1000 ;  1000 rpm
o   G96 X30.00 ;  500 m/min or 500 ft/min
v  The constant surface speed control is effective even during machine Lock.


v  Cancellation of the control mode G96 by a command of G97 without specification of S (revs/min) retains the spindle speed which has resulted at the end of the last spindle control I the G96 Mode.
Example:-
o   G97 S500 ;   500 rpm
o   G96 S350 ;   350 m/min or 350 ft/min  
o   G97 ;           x  Rpm
The speed X denotes the spindle speed of G96 mode at the end of the preceding block.
The constant surface speed control does not apply to the milling spindle.

Spindle Functions

Spindle function:-
          When the S5-digit function is added, this function must be set using the numerical command of five digits preceding an S code (0 to 99999) and for other case, two digits proceeding by an S code is used.
          S command binary outputs must be selected at this time.
By designating a 5-digit number following the S code, this function enable the appropriates gear signals, voltages corresponding to the commanded spindle (rpm) and start signals to be output.
          Processing and completion sequences are required for all commands.
The analog signal specifications are given below:-
Output Voltage       :____________
Resolution             :____________
Load conditions     :____________
Output Impedance :____________


If the parameters for up to 4 gear range steps are set in advance, the gear range corresponding to the S commanded will be selected by the NC unit and the gear signal will be output. The analog voltage is calculated in accordance with the input gear signal.
Parameter corresponding to individual gears
          Limit speed, maximum speed, gear shift speed and maximum speed during tapping.
Parameters corresponding to all gears
          Orient Speed, Minimum Speed






           

Define M code for Mazak machine , Okuma, Fanuc , Cincinnati, all control

Miscellaneous functions:-




          Miscellaneous functions, which are also referred to as M-code functions, give spindle forward /backward rotation and stop commands, coolant on/off commands and other auxiliary commands to the NC machine.


          For the NC unit, these functions must be selected using M3-digit data. Up to four sets of M3-digit data can be included in the block.


Example:-


          G00 X__ M__ M__ M___ M___ ;


          Notes:-
                   If five or more sets of M3-digit data are set, only the last four sets will become valid.


For M-codes M00, M01, M02, M30, M98, M99, M998, and M999, the next block of data is not read into input buffer since pre-reading is disabled automatically.
The M-codes can be included in any block that contains other command codes .if however, the M-codes are included in a block that contains move commands, than the execution priority will be either


The M-code functions are executed after completion of movement, or


The m-code functions are executed together with movement.


It depends on the machine specifications which type of processing is applied.
Processing and completion sequences are required in each case for all M commands except M98 and M99.


Functions of M-codes:-


          There are six types of special M-code functions
1.   
    Program Stop: M00
When this M-code is read, the tape reader will stop reading subsequent block. Whether the machine function such as spindle rotation and coolant will also stop depends on the machine specifications. The machine operation is restarted by pressing the cycle start button on the operation panel .whether resetting can be initiated by M00 or not also depends on the machine specifications.


2.   Optional Stop:M01
         
When the M01 code is read with the OPTIONAL STOP menu faction set to ON, the tape reader will stop operating to perform the same function as M00.
The M01 command will be ignored if the OPTIONAL STOP menu function is set to OFF.
Example:-
          ;
          N10 G00 X50.0 ;
          N11 M01;
          N12 G01 X25.0 Z25.0 F10.;
          ;
          ;
          If the optional stop function is on, operation stops at N11.
          If the optional stop function is off, operation does not stop at N11 and N12 is executed.


3.   Program End: M02 or M30
         
Usually, the program end command is given in the final block of marching program. Use this command mainly for reading data back to the head of the program during memory operation, or rewinding the tape in the tape operation mode (use an M30 command to rewind the tape.) The NC unit is automatically reset after tape rewinding and execution of other command codes included in that block.
Automatic resetting by this command cancels both modal commands and offsetting data, but the designated-position display counter is no cleared to zero.
The NC Unit will stop operating when the tape rewinding is completed (the automatic run mode lamp goes out). To restart the NC unit, the cycle start button must be pressed.
Beware that if, during the restart of the NC unit following completion of M02 or M30 execution ,the first movement command has been set in coordinate word only, the valid mode will be the interpolation mode existing when the program ended. It is recommended, therefore, that the first movement command be given with an appropriate G-code.


4. Subprogram Call/End: M98 / M99
                    Use M98 or M99 to branch the control into a subprogram or to recall it back to the calling program.
As M98 and M99 are internally processed by the NC M-code signals and strobe signals are not output.


Internal processing by the NC unit when M00. M01, M02 or M30 is used.
After M00, M01, M02 or M30 has been read ,data pre reading is automatically aborted .Other tape rewinding operations and the initialization of modals by resetting differ according to the machine specification .


Notes:-
M00, M01, M02, and M30 output independent signals, which will be cancelled by RESET Key.
Tape rewinding is performed only when the tape reader has a rewinding function.




















         








How to make Thread Program In G32 Fanuc Machine

Thread Programming : -  (G32)
          Function and purpose:-
                   The G32 command control the federate of the tool in synchronization with the spindle rotation and so this enables both the straight and scrolled thread cutting of constant leads and the continuous thread cutting.
         
          Detailed Description:-


1.   Constant surface speed control function should not be used here.


2.   The spindle speed should be kept constant throughout from the Roughing until Finishing.


3.    When a threading command is programmed  during tool nose R compensation ,the compensation is temporarily cancelled and the threading executed.


4.  The threading command waits for the single rotation synchronization signal of the rotary encoder and start movement.
              Notes:-
The number of thread in the long axis direction is assigned as the number of thread per inch










Programming Format:-


          Straight thread:-
                   G00 X__                (  Thread cutting Diameter )
                   G32 Z__ F__          ( Thread Length  &  F= pitch )
                   G00 X__                ( X axis Position return )
          Taper thread:-
                   G00 X__
                   G32 X__ Z__ F__
                   G00 X__
Example:-


M20 x 1.5 P x 4MM Length
         
( OD THREAD )
N1 G28 U0.0 W0.0 ;         ( Home Position )
N2 G00 T0101 ;               ( Number One Tool Selection )
N3 G97 S500 M03;            ( Spindle Speed And Direction Selection )
N4 G00  X22.0 Z1.0 M08; ( safe position  & coolant on )
N5 G00 X18.50       ;        ( Thread cutting point X Axis )
N6 G32  Z-4.00 F1.5;       ( Thread cutting 4MM length )
N7 G00 X22.0;                 ( Position Return )
N8 M09 M05 ;                  ( coolant off , spindle stop )
N9 G28 U0.0 W0.0;          ( Home Position Return )
M30;                                ( Program End )
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