ALPHA

“MANUAL GUIDE” MODE TUTORIAL

THIS SIMPLE PROGRAMME OF WORK HAS BEEN DESIGNED AS A
FAMILIARISATION EXERCISE FOR FIRST TIME USERS IN THE SET UP AND OPERATION
OF THIS MACHINE IN THE ‘MANUAL GUIDE’ MODE OF OPERATION

IT IS ESSENTIAL THAT THE OPERATOR HAS APPROPRIATE SKILL

AND EXPERIENCE IN THE USE OF A CONVENTIONAL CENTRE LATHE, AND IS
FAMILIAR WITH THE MACHINE OPERATORS MANUAL, IN PARTICULAR THE
SAFETY NOTES.

i
BLANK PAGE

ii
INDEX

TOOL SETTING PROCEDURE 1–1

SET THE WORKSHIFT & OFFSET FOR TOOL NUMBER 1. 1–1
SET OFFSETS FOR TOOL NUMBER 2. 1 – 13
SET OFFSETS FOR TOOL NUMBER 3. 1 – 21
SET OFFSETS FOR TOOL NUMBER 4. 1 – 28
SET OFFSETS FOR TOOL NUMBER 5. 1 – 34

EDITING A MANUAL GUIDE PROGRAM. 2–1

1. EDIT G AT THE CONVERSATIONAL SCREEN. 2–1
2. EDIT G INDIVIDUAL VALUES. 2–4

GRAPHIC SIMULATION. 3–1

BILLET INFORMATION 3–1
TOOL INFORMATION 3–1
RUNNING THE GRAPHICS 3–2
VIEW FUNCTIONS 3–5

HARRISON XS SPECIFIC FUNCTIONS. 4–1

INTRODUCTION. 4–1
CYCLE FUNCTIONALITY:
(G105) TOOL CALL & START INFORMATION. 4–4
(G134) OPERATION LINKING – SAME TOOL. 4–7
(G106) PROGRAM END INFORMATION. 4–9
(G128) PART OFF COMPONENT 4 – 11

GENERAL PROGRAM CONSTRUCTION. 5–1

RESIDUAL MACHINING. 6–1

USE OF THE RESIDUAL CYCLE. 6–1
PROGRAM CONSTRUCTION. 6–2

OPTIMSED FINISH TURNING. 7–1

FIXED FORM PROCEDURE. 8–1

FIXED FORM SENTENCES. 8–1
FIXED FORM FORMAT. 8–8
ENTERING AFIXED FORM DURING PROGRAMMING. 8 – 11

THREAD REWORKING FUNCTION. 9–1

OPERATION METHOD. 9–1

INPUT / OUPUT VIA USB. 10 – 1

OUTPUT. 10 – 2
INPUT. 10 – 8

iii
INPUT OF “CAM” PROGRAMS VIA MANUAL GUIDE 11 – 1

NC CONVERSION OF MANUAL GUIDE FORMAT PROGRAMS 12 – 1

PROGRAMMING EXAMPLE 13 – 1
START A NEW PROGRAM. 13 – 2
PROGRAM START AND TOOL CALL (G105). 13 – 14
PROGRAM FACE OPERATION. 13 – 16
PROGRAM ROUGH TURN OPERATION. 13 – 27
TOOL CHANGE. 13 – 47
PROGRAM GROOVING OPERATION. 13 – 49
TOOL CHANGE. 13 – 64
PROGRAM DRILLING OPERATION. 13 – 67
TOOL CHANGE. 13 – 73
PROGRAM FINISH TURN OPERATION. 13 – 76
TOOL CHANGE. 13 – 80
PROGRAM THREADING OPERATION. 13 – 83
END THE PROGRAM. 13 – 93

iv
 TOOL SETTING PROCEDURE.

!
NOTE: Experienced programmers may have their own preferred
methods of tool setting. The general tool setting process follows that
used on any Fanuc control.
The ALPHA system method may be used for the input of the
WORKSHIFT, OFFSET, TOOL RADIUS and TOOL DIRECTION, but the
additional information required by Manual Guide i ( TOOL DATA
INFORMATION see page 8) must be added to allow running of the
completed program and / or simulation.

!
NOTE: Setting the tooling information from the ALPHA system
automatically writes the WORKSHIFT, OFFSET, TOOL RADIUS and
TOOL DIRECTION information to the WORKPIECE ORIGIN and
WORKPIECE SHIFT input fields. In this case ONLY the additional TOOL
DATA information must be input while in MANUAL GUIDE MODE.

SET THE WORKSHIFT AND OFFSET FOR TOOL NUMBER 1.

!
IMPORTANT: Prior to setting any Workshift or Offset via the
Manual Guide screens any active tool should be cancelled using the
following procedure.

To do this a short MDI program must be run.

Select

1-1
The following screen will appear.

Type T0000 then press the EOB (END OF BLOCK) key.

Press

Press to take the marker to the head of the program.

1-2
 !
NOTE: Close the machine guards.

Press

!
IMPORTANT: Ensure that the T Code area of the Manual Guide
screen now shows T0. You can now proceed with the tool setting
procedures shown below.

In this example TOOL number 1 is used as the DATUM tool.

Index to Tool number 1. (80 Deg ROUGHER)

Call tool number 1 and manually face the component to length.

Using the arrow key select the functions.

1-3
Select

Select

!
NOTE: The CHCURS (Chose cursor) key allows the selection of
three options.

1-4
 (i) TAB

(ii) ITEM

(iii) CHAR (Character)

Select and move to the Z input field.

1-5
Select

Type the value required (0) and press

The workshift will be calculated and registered.

1-6
Select

!
IMPORTANT: Prior to setting any Workshift or Offset via the
Manual Guide screens any active tool should be cancelled using the
following procedure.

To do this a short MDI program must be run – see pages 1-1 to 1-3

Using tool number 1 manually turn a component diameter.

Move tool off material in Z axis only and measure turned diameter.

Select

1-7
With the X –AXIS field highlighted select

Type the diameter value measured at the material.

Press

The offset value will be calculated and entered in the geometry offset list.

1-8
Move the RADIUS input field.

Type the RADIUS value and press

Move the VERT.TIP input field.

Select the tip direction required.

1-9
Using the cursor keys scroll through the
page.

!
NOTE: This page is not required in the initial setting of the tools.

Using the cursor keys continue to scroll until entering the

page.

1-10
Select the Tool Type required.

Move to the SET input field.

!
NOTE: This selects the tool direction code.

Type the TOOL (7) value and press

1-11
Move the CUT AN (cut angle) input field.

Type the CUT AN value and press

Move the NOS AN (cut angle) input field.

Type the NOS AN value and press

1-12
 !
NOTE: It is important that the two tool angle values are correct for
the actual tool being used. This then allows the system to check for
possible collisions when profile machining.

NOT POSSIBLE. (80Deg.) POSSIBLE. (35Deg.)

SET OFFSETS FOR TOOL NUMBER 2.

Index to Tool number 2. (35 Deg FINISH)

Call tool number 2 and manually TOUCH the tool on the turned diameter of
the component. (Previously turned to 48.23).

1-13
Select

Move the Tool NO. 002 input field.

With the X –AXIS tool NO. 002 field highlighted select

1-14
Type the diameter value previously measured at the material.

Press

The offset value will be calculated and entered in the geometry offset list.

Manually move the tool to the front face of the component and TOUCH the
tool on the front face (Previously turned and set to Z0.000).

1-15
Select

Move the Tool NO. 002 Z-AXIS input field.

With the Tool NO. 002 Z-AXIS input field highlighted select

Type the Z axis position (Z0.000) at the material.

Press

The offset value will be calculated and entered in the geometry offset list.

1-16
Move the RADIUS input field.

Type the RADIUS value and press

Move the VERT.TIP input field.

1-17
Select the tip direction required.

Using the cursor keys scroll through the

page.

!
NOTE: This page is not required in the initial setting of the tools.

Using the cursor keys continue to scroll until entering the

1-18
 page.

Select the Tool Type required.

Move to the SET input field.

!
NOTE: This selects the tool direction code.

Type the TOOL (7) value and press

1-19
Move the CUT AN (cut angle) input field.

Type the CUT AN value and press

Move the NOS AN (cut angle) input field.

1-20
Type the NOS AN value and press

!
NOTE: It is important that the two tool angle values are correct for
the actual tool being used. This then allows the system to check for
possible collisions when profile machining.

SET OFFSETS FOR TOOL NUMBER 3.

Index to Tool number 3. (THREAD)

Call tool number 3 and manually TOUCH the tool on the turned diameter of
the component. (Previously turned to 48.23).

Select

1-21
Move the Tool NO. 003 input field.

With the X –AXIS tool NO. 003 field highlighted select

Type the diameter value previously measured at the material.

Press

The offset value will be calculated and entered in the geometry offset list.
1-22
Manually move the tool to the front face of the component and TOUCH the
tool on the front face (Previously turned and set to Z0.000).

Select

Move the Tool NO. 003 Z-AXIS input field.

With the Tool NO. 003 Z-AXIS input field highlighted select

1-23
Type the Z axis position (Z0.000) at the material.

Press

The offset value will be calculated and entered in the geometry offset list.

Move the RADIUS input field.

1-24
Type the RADIUS value (0) and press

Move the VERT.TIP input field.

Select the tip direction required.

1-25
Using the cursor keys scroll through the
page.

!
NOTE: This page is not required in the initial setting of the tools.

Using the cursor keys continue to scroll until entering the

page.

Select the Tool Type required.

1-26
Move to the SET input field.

!
NOTE: This selects the tool direction code.

Type the TOOL (7) value and press

Move the NOS AN (nose angle) input field.

1-27
Type the NOS AN value and press

!
NOTE: It is important that the nose angle value is correct as this
dictates the calculation of flank thread cutting.

SET OFFSETS FOR TOOL NUMBER 4.

Index to Tool number 4. (22 Dia U Drill)

Manually move the tool to the front face of the component and TOUCH the
tool on the front face (Previously turned and set to Z0.000).

1-28
Select

Move to the Tool NO. 004 Z-AXIS input field.

!
NOTE: The X –AXIS tool NO. 004 may remain at or must be set to
0.000 when using drills.

With the Tool NO. 004 Z-AXIS input field highlighted select

Type the Z axis position (Z0.000) at the material.

1-29
Press

The offset value will be calculated and entered in the geometry offset list.

Move the RADIUS input field.

Type the RADIUS value and press

!
NOTE: In the case of drills, this figure is used for the correct
scaling of the graphic.

1-30
Move the VERT.TIP input field.

Select the tip direction required. or

Using the cursor keys scroll through the

page.

!
NOTE: This page is not required in the initial setting of the tools.

1-31
Using the cursor keys continue to scroll until entering the

page.

Using the right arrow key select the next tooling list.

Select the Tool Type required.

1-32
Move to the SET input field.

!
NOTE: This selects the tool direction code.

Type the TOOL (2) value and press

Select

1-33
SET OFFSETS FOR TOOL NUMBER 5.

Index to Tool number 5. (3mm Groove tool)

Call tool number 5 and manually TOUCH the tool on the turned diameter of
the component. (Previously turned to 48.23).

Select

Move the Tool NO. 005 input field.

1-34
With the X –AXIS tool NO. 005 field highlighted select

Type the diameter value previously measured at the material.

Press

The offset value will be calculated and entered in the geometry offset list.

1-35
Manually move the tool to the front face of the component and TOUCH the
tool on the front face (Previously turned and set to Z0.000).

Select

Move the Tool NO. 005 Z-AXIS input field.

With the Tool NO. 005 Z-AXIS input field highlighted select

Type the Z axis position (Z0.000) at the material.

1-36
Press

The offset value will be calculated and entered in the geometry offset list.

Move the VERT.TIP input field.

Select the tip direction required.

1-37
Using the cursor keys scroll through the
page.

!
NOTE: This page is not required in the initial setting of the tools.

Using the cursor keys continue to scroll until entering the

page.

1-38
Select the Tool Type required.

Move to the SET input field.

!
NOTE: This selects the tool direction code.

Type the TOOL (7) value and press

1-39
Move the TIP W (Tip width) input field.

Type the TIP W value and press

Move the TIP L (Tip / Blade length) input field.

1-40
Type the TIP L value and press

!
NOTE: It is important that the two tool values are correct for the
actual tool being used. This then allows the system to check for
possible collisions when parting / grooving machining.

The tools are now set and may be used to machine the component.

1-41
Select CLOSE to shut down the tool setting screens.

1-42
 EDITING A MANUAL GUIDE PROGRAM.

Although a Manual Guide program is generated as individual blocks of macro

code, editing (making alterations to an existing program) may be performed in
several ways.

1. EDITING AT THE COVERSASIONAL SCREEN.

Select

Ensure that the complete block is highlighted. To do this move the cursor to
the left of the screen using the cursor keys.

2-1
Using the cursor keys move to the block required.

!
NOTE: When scrolling through the program blocks the block type
will be indicated at the bottom left of the programming screen.

Using the arrow key select the next page of key options.

Select

The conversational screen for this block will be called.

2-2
Using the cursor keys move to the field required.

Type the value (300) required and press to enter the value.

2-3
Select to store the modified value.

2. EDITING INDIVIDUAL VALUES.

As an alternative to using the conversational screen method, individual values

within a macro block may be changed in the usual c.s.s. editing method.

Using the cursor keys move to the block required.

Using the cursor keys move to the value required.

!
NOTE: When moving through the values, information re each value
will be indicated at the bottom left of the programming screen.
Example.

2-4
Type the new value require Z250.

2-5
Use the standard keypad ALTER key to change the value.

2-6
 GRAPHIC SIMULATION.

The Manual Guide i system allows a comprehensive graphic simulation

function to view a program prior to machining the component.

For this system to operate correctly the following information must be stored
correctly.

Billet Information.

At the start of the program the billet information must be added to the
program. This correctly scales the graphic relative to the component being
machined. (See programming example).

Tool Information.

All tool information must also be correctly set and the direction and radius (in
the case of drills / milling cutters) information added.

!
NOTE: If the radius information is missing the tool will not appear
on the simulation.

3-1
Running the graphics.

AUTO

Select

Select

The following options will now appear.

Run Functions.

Rewind resets the program to the head of the program prior to re

running.

Start commences the graphic simulation.

! AUTO
NOTE: Although the machine control is in the machine will
not run. The graphics may be run with the machine guards open if
required.

Process runs each individual operation within the program. The

simulation will stop when seeing a M0 or M1 and at any macro cycle
containing either of these codes.

Single runs the simulation be executing each line individually with the
press of the single key (single block operation).

Stop stops the program while simulating. Pressing start, process or

single following stop will re start the program from this point.

3-2
 Initial resets the graphic to the initial view prior to re running the
program.

= = =

Cut Display allows the selection of solid or partially cut graphic

simulation.

!
NOTE: 3D simulation must be selected for this option.

= =
X
Interference allows collision checking during the simulation of the
program.

!
NOTE: If the tool is not able to machine the drawn part safely a
warning will be displayed.

= = =

3-3
 Tool path allows the selection of tool path simulation or graphic
simulation. This key alternates depending on the current view method
selected.

= =

Graphic Off switches off the graphic simulation window.

View Functions.

The view of the component simulation may be changed by the operator.

To change the view:

Using the arrow key select the view functions.

3-4
 This key increases the size of the billet / simulation visible.

This key decreases the size of the billet / simulation visible.

This key automatically fits the billet / simulation to the available

screen area.

This key reverses the viewing angle of the simulation.

3-5
 Allows the selection of the viewing angle of the simulation.

In addition to the basic selections selectable from the keys shown below, each
of these fixed views may be modified.

Using the arrow key select the positioning functions.

3-6
 The move keys allow the positioning of the
billet within the simulation screen.

3-7
Returns the billet to the centre of the visible screen,

3-8
 HARRISON ALPHA X SPECIFIC FUNCTIONS.

INTRODUCTION.

Although the Manual Guide system was designed by as a

general conversational programming system, several cycles included in the
system fitted to the HARRISON ALPHA X lathes were developed at
specifically for these machines.

These cycles were designed to assist the programmer and have made the
programming of these specific machines as quick and easy as possible.

This section covers the functionality of these HARRISON ALPHA X specific

cycles. For detailed instruction in the use of the specific cycles,
please turn to the Fanuc manual guide manual supplied with the machine.

!
NOTE: An example of general programming using these
HARRISON ALPHA X specific cycles will be given at the end of the
manual.

When used in a program these HARRISON ALPHA X specific cycle functions

output a special G code followed by a set of macro instructions to perform
the moves and functions selected from the conversational screen.

Example: G105 TOOL CALL AND START INFO.

Select .

Cursor to the TOOL CALL tab.

4-1
Press .

Input the required information.

Press

4-2
One advantage of this method of programming is that the programs are
shorter than usual and editing of these cycles may be performed
conversationally (with associated text and graphic instructions) or by changing
individual characters in the usual c.n.c. method.

As an example, the single G105 block shown below performs the following
functions (if written as a standard ISO program).

(ISO FUNCTION)

G10 P0 Z-473.911 (Set machine workshift)

G50 S1500 (Max spindle speed)
G0 G99 G40 G80 X450. Z300. T0 (Return to tool change)
T0101 (Call selected tool and offset)
G96 S300 M3 (Start spindle in m/min - forward)
G0 X124.000 Z3.000 (Rapid to cycle start pos.)
M8 (Coolant on)

4-3
 CYCLE FUNCTIONALITY.
(1)
(G105) PROGRAM START AND TOOL CALL

FUNCTION.

1. Set maximum spindle speed

2. Return tool to tool change position.
3. Call tool and offset.
4. Start spindle at required speed.
5. Rapid to cycle start position.
6. Turn on / off coolant.

4
6
1 MAX SPEED

5 2

3 TOOL ?

!
NOTE: Any input field marked with a star is
optional and may be left blank if required.

Select

Select TOOL CALL

4-4
Select

Enter the values required under the DETAIL tab.

Enter the values required under the SPIN (SPINDLE) tab.

Enter the values required under the PROG STOP tab. (Optional).

4-5
Enter the values required under the WORKSHIFT tab. (Optional).

Select to enter the code in the program.

(ISO FUNCTION)

G10 P0 Z-473.911 (Set machine workshift)

M1 (M0) (Optional or program stop)
G50 S1500 (Max spindle speed)
G0 G99 G40 G80 X450. Z300. T0 (Return to tool change)
T0101 (Call selected tool and offset)
G96 S300 M3 (Start spindle in m/min - forward)
G0 X124.000 Z3.000 (Rapid to cycle start pos.)
M8 (Coolant on

4-6
(2)
(G134) OPERATION LINKING – SAME TOOL

FUNCTION.

1. Reset maximum spindle speed

2. Set spindle speed required for next cycle.
3. Reselect CSS or RPM.
4. Turn on / off coolant.
5. Optional program stop if required.

2
4
1 MAX SPEED

!
NOTE: Any input field marked with a star is
optional and may be left blank if required.

Select

Select TOOL CALL

4-7
Select

Enter the values required under the DETAIL tab.

Enter the values required under the PROG STOP tab. (Optional).

Select to enter the code in the program.

4-8
 (ISO FUNCTION)

M1 (M0) (Optional or program stop)

G50 S1500 (Max spindle speed)
G96 S300 (spindle speed - RPM or CSS)
M8 (Coolant on)

(3)
(G106) PROGRAM END INFORMATION.

FUNCTION.

1. Return tool to tool change position.

2. Coolant off.
3. Stop and rewind the program. (Stop spindle)

X
3 X 2

3
X

!
NOTE: Any input field marked with a star is
optional and may be left blank if required.

4-9
Select

Select PROG END

Select

Enter the values required under the DETAIL tab.

Select to enter the code in the program.

4-10
 (ISO FUNCTION)

G0 G99 G40 G80 X250. Z250. T0 (Return to tool change)

M9 (Coolant off)
M30 (Stop and rewind program spindle stop)

(4)
(G128) PART OFF COMPONENT.

FUNCTION.

1. Rapid to parts off start position.

2. Feed to first diameter of part off move.
3. Change spindle speed and feed for second move.
4. Feed to second diameter of part off move.
5. Rapid clear of workpiece.

1 5

!
NOTE: Any input field marked with a star is
optional and may be left blank if required.

Select

4-11
Select PROG END

Select

Enter the values required under the DETAIL tab.

Enter the values required under the PART OFF tab.

4-12
Select to enter the code in the program.

(ISO FUNCTION)

G0 X52. Z- 80. (Rapid to part off start position)

G1 X5. F.15 (Feed to stage 1 diameter)
G97 800 (Set stage two spindle speed)
G1 X-1.6 F.1 (Feed to stage 2 diameter)
G0 X60. (Rapid to cycle end diameter)

4-13
Blank Page
 GENERAL PROGRAM CONSTRUCTION.

As seen in the “Alpha X specific functions” section, several customised

macros (cycles) have been developed by Harrison to assist with the linking of
the standard Fanuc machining cycles contained within the Manual Guide i
system.
An example program is shown below highlighting the typical use of these
customised cycles and the position of these after full generation of the
program.

The program contains the following operations:

1. Face component.
2. Rough turn outside diameter.
3. Finish turn outside diameter.
4. Part off.

= FANUC CODES = HARRISON CUSTOM CODES.

%
O0015(MANUAL EXAMPLE)

G1900D50.L80.K1. (BILLET INFO)

(TOOL CALL AND START INFO)

G105U250.W250.Z22.T101I52.K3.H1.R2000S200M1.D1.C3.

G1128P3.F0.2L1.M1.Z22. (FACE MACHINING CYCLE)

(FACE MACHINING PROFILE INFORMATION)

G1450H0.V25.A0.
G1451H0.V-0.8K7.D-0.8L0.M0.T1.
G1451H1.V-0.8K1.C1.L0.M0.T1.
G1451H1.V25.K3.C1.D25.L0.M0.T2.
G1451H0.V25.K5.C0.D25.L0.M0.T2.
G1456

(OPERATION LINKING – SAME TOOL) (CHANGE SPEED FEED FOR

ROUGHING)
G134R3000S250D1.C1.B1
5-1
(BAR ROUGHING INFO)
G1120P1.Q2.H100.C0.5D0.1F0.2E0.1V0.2K100.W2.U1.L1.M1.Z22.
M98P6234 (PROFILE INFO SAVED AS SUB PROGRAM)

(TOOL CALL AND START INFO)

G105U250.W250.Z22.T202I52.K3.H1.R2000S250M1.D1.C3.

(BAR FINISHING INFO)

G1126P1.F0.1L1.M1.Z22.
M98P6234 (PROFILE INFO SAVED AS SUB PROGRAM)

(TOOL CALL AND START INFO)

G105U250.W250.Z22.T303I52.K-53.H1.R1800S150M1.D1.C3.

(PART OFF COMPONENT)

G128U52.W-53.Z22.F0.15I5.S800E0.1J-1.D2.X60.

(PROGRAM END INFORMATION)

G106U250.W250.Z22.

5-2
 RESIDUAL MACHINING.

The residual machining cycle loaded to the Manual Guide i programming

system allows the automatic removal of areas of excess material missed
during the roughing cycle due to the geometry of the roughing tool.

When using machining cycles, the system checks the profile of the component
to be machined and automatically misses areas where a collision with the rear
of the tool would occur.

In the example below it would not be possible to complete the roughing of the
undercuts due to the 80 degree nose angle of the roughing tool.

!
NOTE: Although the exact rear angle of the above tool is 80
degrees, it is advisable to add several degrees to the figure to prevent
any contact with material of the rear of the tool. In the above example 83
degrees has been programmed. This gives 3 degrees of clearance at the
rear of the tool.

USE OF THE RESIDUAL CYCLE.

The general programming method is identical to that outlined in the

programming example section of this manual.

Following the facing and external rough turning of the component however the
residual machining cycle must be used to remove un-machined areas of the
external form. This must be removed prior to the finish machining of the
component.

6-1
PROGRAM CONSTRUCTION.

(1) Start new program and set billet codes.

(2) Call tool 1 (roughing) and set spindle speed, feed and approach.

(3) Program roughing cycle and add profile.

6-2
 !
NOTE: The roughing cycle may be simulated at this stage if
required to check if residual material remains on the form.

(4) Change to tool number 2 and set spindle speed, feed and approach.

!
NOTE: Tool number 2 has an angle of 35 degrees allowing correct
removal of the residual material.

6-3
(5) Select and program the residual roughing cycle.

6-4
 !
IMPORTANT! : Due to the form and position of the residual
material it is important that the approach motion is set to X -> Z. (See
above).

Failure to do so would result in a collision with the material in this case.

2 AXIS
INCORRECT

X – Z CORRECT

6-5
 !
IMPORTANT! : A profile is not required for this cycle. The cycle
automatically removes any area (s) not removed by the previous
roughing cycle.

!
NOTE: Due to the residual machining being calculated from the
previous roughing cycle, it is not possible to run this cycle in isolation.

To rerun this cycle the program must be started at the start of the
previous roughing cycle.

(6) Add the finishing cycle (using the same tool) in the usual way.

6-6
(7) Add the program end information.

6-7
(8) Simulate the program.

(i) Roughing. (Note form achieved with roughing tool).

6-8
(ii) Residual machining.

(iii) Finish pass.

6-9
Blank Page
 OPTIMIZED FINISH TURNING.
Later Fanuc controls include the following additional function for finish turning (finish
pass) in the Manual Guide (conversational) system.

Selecting OPTM allows multi directional turning (calculated automatically) of a

component finish pass.

The finish pass will turn the diameters in a normal turning motion (Z motion towards
the chuck) but turn faces using a facing motion (predominantly X axis move) as per
the graphic below.

7-1
The initial set up of the finish pass is identical to the normal Z- function (see below)
but selection of OPTM adds a second TAB of information which requires completion.

After selection of OPTM

!
NOTE: This second TAB of information is required to set parameters for
the Optimisation cycle. Example: when you do / do not want optimisation to be
performed (what size of radius / chamfer, what depth of step e.t.c.).

7-2
After completion of the initial TAB information the OPTIMIZE tab will open.

Complete all options within the OPTIMIZE tab.

REVERSE FEED RATE

This allows a different feed rate to be programmed which is specific to the facing
motion.

7-3
ESCAPE AMOUNT

This sets the retraction of the tool following a face cut allowing the tool to rapid to the
next diameter of the component form.

LEVEL DIFFERENCE

This sets the minimum step length at which optimisation will take place.

!
NOTE: On small steps on the component it is not necessary to use the
optimized face move. Example – First diameter 20mm, second diameter 23mm.
Setting a value of 5mm will prevent this. The optimize function will only be
performed on steps of over 5mm.

7-4
LINE SLANT ANGLE

This sets the minimum line angle at which optimisation will take place.

!
NOTE: On a component with multiple chamfers setting this at 46
(degrees) would prevent chamfers from being optimized.
Additionally, on small angle moves (example 3 deg) this move is almost flat.
The above setting would prevent shallow angles from being optimized.

ARC RADIUS

This sets the radius value above which optimization will take place.

!
NOTE: On a component with multiple radius forms a setting of (example)
4mm will prevent all radius forms of less than 4mm from being machines with
a reverse X axis move.
Larger arc (example 25mm) would be machined in a face move around the arc
form.

7-5
ARC SLANT ANGLE

This sets the minimum allowed angle between the start and finish point of the arc.

!
NOTE: This is similar to and performs the same function as Line slant
angle (above).
On small ARC angle moves (example 3 deg) this move is almost flat. The
above setting would prevent shallow radius angles from being optimized.

After completion of all fields the cycle is saved into the program in the usual way.

7-6
7-7
BLANK PAGE

6-10
 FIXED FORM SENTANCES

Fanuc controls include the following additional function for producing “Fixed Form
Sentences”.

Although custom Manual Guide macros are included on Alpha models for (example)
Tool Call and Program End some operators with CNC experience may prefer to use
a “Fixed Form” written in standard Fanuc CNC language for these functions.

Standard Manual Guide Macro screen.

!
NOTE: If using the NC Convert function the custom macros for Tool
Change and Program End are not converted using this function.
The use of CNC Language (fixed form) for these functions allows for a fully
converted program which can then be used on a non-Manual Guide equipped
machine.

The procedure for producing a Fixed Form is as follows.

In EDIT mode move to the SETING key using the Right arrow shown below.

8-1
Press the SETTING key.

The following screen will appear.

Press SELECT

!
NOTE: On machines with a C Axis (milling – drilling) two options are
shown on the above page.

8-2
The procedure for entering the Fixed Form sentence for milling is identical to
the method shown below but will be accessed (see latter) via the C axis
programming key rather than the Turning programming keys.

Turning Programming Keys

Milling Programming Keys

The following screen will appear.

!
NOTE: At the top of the input screen there are 5 Form tabs.

At this stage you can select under which tab the Fixed Form is registered.

8-3
Use the navigation keys to move between TABS.

This sets from where the Fixed Form can be accessed.

Any Fixed form sentence registered in FORM 1 can be accessed via the START
button while programming.

Any Fixed form sentence registered in FORM 5 can be accessed via the END button
while programming.

Any Fixed form sentence registered in FORM 2, 3, and 4 can only be accessed via
the FIXFRM button while programming.

!
NOTE: In most cases for ease of use commonly used fixed forms will
normally be registered under TAB 1 or 5.

Select FORM 1

Select NEW

8-4
The following page to allow registration of the new FIXED FORM will appear.

Use the alpha numeric keypad to type the name of the Fixed Form. TOOL CALL in
this example.

8-5
After typing the REGISTERED NAME press INPUT on the keypad to move to the
REGISTERED SENTENCE field.

The REGISTERED SENTENCE must now be typed into the field.

!
NOTE: The entire Fixed Form must be typed in a continuous string. The
end of each line is indicated by the use of an end of block character ( ; ).
This will be correctly formatted when the string of code is saved.

8-6
After completion of the required string of code the fixed form sentence can be saved
using the INSERT option at the bottom of the screen.

This results in the addition of the fixed form for use and correctly formats the form
into individual lines of code.

!
NOTE: The Fixed Form may be modified using the ALTER function.

Using the ALTER function opens the original Fixed Form string. Select ALTER again
to save the modification.

8-7
FIXED FORM FORMAT

When writing a fixed form (Example TOOL CALL) you have the option of entering a
question mark ( ? ) symbol for values which are likely to be specific (different) each
time the Fixed Form is used.

When the Fixed Form is entered into the program these question marks will be
highlighted in red preventing the running of the Form until these are correctly
modified.

In addition, the following message will appear when first entered.

IMPERFECT WORD MUST BE CHANGED

The values may be edited to the correct values by highlighting the question mark,
typing the value required, and using ALTER (hard key) to change the value.

8-8
Typical TOOL CALL fixed form.

Note below a typical TOOL CALL fixed form including the question marks for
insertion of changeable values.

Initial string of code (input at set up of the fixed form)

;(TOOLCALL);G21G40G99G80;T0000;M9;G0X400Z200M5;M1;G50S2000;G97S?M3;T?;G0X?Z?;;

Resultant Fixed form after conversion.

;
(TOOL CALL);
G21G40G99G80;
T0000;
M9;
G0X400Z200M5;
M1;
G50S2000;
G97S?M3;
T?;
G0X?Z?;
;
;

!
NOTE: When writing a fixed form keep the number of question marks to
a minimum if possible. This reduces the amount of editing required each time
the sentence is used in a program.

In the example above the return to a safe tool change has been fixed at X400
Z200 (This will be dependant on the size of machine) to give a common
position at all time.

This can be changed by the operator at any time by editing the values after
insertion into the program or by changing the actual Fixed Form.

!
NOTE: The example above is only a typical format. An experienced
operator may prefer to write in a format typical of other methods used on other
CNC Lathe models.

8-9
Typical PROGRAM END fixed form.

Initial string of code (input at set up of the fixed form)

;(PROGRAM END);T0000;G0X400Z200M5;M9;M30;

Resultant Fixed form after conversion.

;
(PROGRAM END);
T0000;
G0X400Z200M5;
M9;
M30;

!
NOTE: No question marks ( ? ) are necessary in the PROGRAM END
fixed form.

The PROGRAM END fixed form would be entered (written) under TAB 5.

This would allow call via the END key of the programming options.

8-10
ENTERING A FIXED FORM DURING PROGRAMMING

Begin the new program in the usual way. (program number, blank information)

Select the START menu key.

8-11
The TOOL CALL fixed form will be seen under the first TAB.

Press INSERT to paste into the program

The FIXED FORM codes will be added to the program.

8-12
 THREAD REWORKING FUNCTION.

The Multi-Turn thread rework function allows existing and / or damaged

threads to be re cut using an automatic cycle.

OPERATION METHOD.

The tool to be used for thread reworking should be set in the usual way.

Wind the tool away from the threaded component.

9-1
Prior to generation of the thread repair program, the correct tool and offset
must be called and the spindle orientated to 0 degrees.

To do this a short MDI program must be run.

Select

The following screen will appear.

Type T0202 then press the EOB (END OF BLOCK) key.

Press

9-2
Type: G102 Q0 (SET ORIENTATION ANGLE TO ZERO)
M19 (SPINDLE ORIENTATE)
Then press the EOB (END OF BLOCK)

key.

Press

Press to take the marker to the head of the program.

9-3
 !
NOTE: Close the machine guards.

Press

!
NOTE: If a manual tool post is fitted the following message will
appear.

Press

9-4
This will enter the tool number into the thread macro program and activate tool
offset 2. Confirmation of this will be seen at the top right of the Manual Guide
screen

The spindle will now rotate and orientate the spindle to the zero datum
position. At spindle zero the spindle will stop.

!
NOTE: If the spindle is already at zero datum, no movement will
occur.

Press to restore the Manual Guide screen.

Select
9-5
The tool tip must now be positioned using the handwheels into the thread
form.

!
NOTE: The guard may now be opened to view the tip / thread form
position.

!
IMPORTANT: Leave the tool in this position while setting up the
thread rework cycle.

Select

Select

9-6
Type the program number required

Press

Using the arrow key select the turning functions.

Select

Select AUXIL

9-7
Select

Enter the values required under the CUT COND. tab. (Cutting condition).

Enter the NUMBER OF STARTS

!
NOTE: The default is 1. Press to skip to the next field or
type a new value.

This is the number of leads to the thread and may be used to rework a
multi start thread.

9-8
Enter the PULL OUT DISTANCE.

!
NOTE: The default is 1. Press to skip to the next field or
type a new value.

Type 2 Press

Enter the SPINDLE SPEED.

!
NOTE: This should be set reasonably slow to allow for handwheel
adjustments while feeding along the thread form.

Type 100 Press

9-9
Enter the SPIN. FWD / REV VALUE.

!
NOTE: The default is 3 (FORWARD). Press to skip to the
next field or type a new value.

TOOL NUMBER.

!
NOTE: This field will already contain the tool number selected
earlier in the MDI program.

Press to skip to the next field

9-10
Enter the ENTRANCE CLEARANCE.

!
NOTE: This is the distance from the front face required for the cut
start.

Enter the EXIT CLEARANCE.

!
NOTE: This is the distance past the thread end point required.

9-11
Enter the X SAFE RETRACT POSITION.

!
NOTE: This is the safe position in X for thread checking during
reworking. (See operation details)

Enter the Z SAFE RETRACT POSITION.

!
NOTE: This is the safe position in Z for thread checking during
reworking. (See operation details)

9-12
Move to the POS. / SIZE tab.

Enter the values required under the POS. / SIZE (Position) tab.

Enter the THREAD TYPE.

Press

Enter the FIGURE TYPE.

9-13
Press

Enter the START POINT (X).

!
NOTE: This should be the current outer diameter of the thread.

!
IMPORTANT: The PULL OUT DISTANCE programmed in CUT
COND is calculated from this point.

Enter the START POINT (Z).

9-14
 !
NOTE: This should be the current start point of the thread.

!
IMPORTANT: The ENTRANCE CLEARANCE programmed in CUT
COND is calculated from this point.

Enter the EXIT CLEARANCE.

!
NOTE: This is the actual length of thread prior to the addition of
the EXIT CLEARANCE programmed in CUT COND. (If used).

Enter the LEAD / T.P.I.

9-15
 !
NOTE: T.P.I. is only used for

Move to the DETAIL tab.

Enter the values required under the DETAIL.

Enter the CHAMFER AMOUNT.

!
NOTE: This is the distance prior to the end of the thread where pull
out will commence.

!
NOTE: If 0.000 is programmed chamfer will be 0.1 of the
programmed pitch.

9-16
Enter the CHAMFER ANGLE.

!
NOTE: This is the angle of pull out over the CHAMFER AMOUNT
programmed previously.

Move to the PICK UP tab.

!
IMPORTANT: The PICK UP information is for reference only and
may be used to ensure that the current tool position has been picked up
by the cycle.

9-17
Press to enter the program.

48.210
- 4.128

RUNNING THE CYCLE.

Select

Press

!
IMPORTANT: The first move of the tool after pressing cycle start is
a retraction in X. The tool then moves to the start of the thread pass.

It is not necessary to wind the tool out of the thread form before
pressing cycle start.

9-18
 !
NOTE: The cycle will now run continuously over the thread form.

At this time the handwheels are active and may be used to make minor
adjustments to the position of the tool in the thread form.

!
IMPORTANT: To view the alterations made by the handwheels the
positions being shown on screen must be changes to

using the key. The actual position

readout will not read the position changed by the handwheels.

9-19
 !
NOTE: If inspection of the thread is required press . This
returns the tool to the SAFE RETRACT POSITION (X and Z) and stops
the spindle.

X 150.000
Z 150.000

To restart the cycle press (switch off )

!
NOTE: Pressing at any time will immediately retract the
tool from the thread form and return to the cycle start position (X 54.000
Z10.000 in this case). The spindle will then stop.

To stop the cycle press to return the tool to SAFE RETRACT

POSITION (X and Z) followed by to clear the cycle.

9-20
 INPUT / OUTPUT OF PROGRAMS VIA MANUAL GUIDE
The following section covers the input / output of program files via the Manual Guide
system using USB.

The USB interface can be found on the front / left of the control screen.

!
NOTE: Fanuc will only guarantee correct operation on USB sticks of 2GB
or less.

Larger USB will work but this is dependant (over 2GB) of the file system used
internally by that manufacturer. SanDisk USB appear to be more reliable over
2GB but the general rule is to keep the USB as small as possible.

! 
NOTE: The following section shows the use of USB. The procedure for
using Memory Cards is identical to USB and the control automatically
recognises which is mounted at the screen. The key for INPUT / OUPUT will
show both symbols providing the correct parameters (for both) have been
factory set. (All current models are set to recognize both).

10‐1
Program Output.

Mount the USB at the control.

! 
NOTE: Wait a few seconds for the control to recognize the USB (or card)
is mounted.

Select O LIST (Program directory) from the main operation list.

The following screen will appear.

  10‐2
Press IN/OUT.

The following screen will now appear showing what is currently contained on the
USB. Select OUTPUT

  10‐3
Select OUTPUT    

The following screen will appear.

Use the Navigate keys to select the file to output. 

Select (USB in this case) OUTPUT

! 
NOTE: Two further options are available at this stage MLTOUT and
ALLOUT.

Allows multiple selected files to be output. (Individually stored files)

  10‐4
 Allows ALL the programs currently in the OLIST (Directory) to be output.
The use of ALLOUT however stores all the programs in a single file which cannot be
reloaded individually at a later time.

After selection of the following page will appear.

! 
NOTE: The OUTPUT PROG.NAME will default to the program number at
the head of the program being output.

The OUTPUT FILE NAME may be left blank (default) or edited to include a
description as below. Leaving the OUTPUT FILE NAME blank will store the
program to USB as the program number. Editing to include a description will
store the program to USB as the file name.

  10‐5
 ! 
NOTE: The option OUTPUT WITH SUBPROGRAM is given at this stage.

This allows both the MAIN program and all associated SUB PROGRAMS
(example a cycle shape figure stored as a subprogram) called from the MAIN
program to be saved within the same folder for use at a later time.

This is confirmed using the following:

Selecting OUTPUT will send the program to the USB.

The following message will appear

  10‐6
Press RETURN to exit the output screen.

  10‐7
 

Program Input.

Mount the USB at the control.

! 
NOTE: Wait a few seconds for the control to recognize the USB (or card)
is mounted.

Select O LIST (Program directory) from the main operation list.

The following screen will appear.

  10‐8
Press IN/OUT.

The following screen will now appear showing the files currently contained on the
USB.

  10‐9
Use the Navigate keys to select the file to INPUT. 

Press INPUT

Correct Input of the file will be confirmed with the following message. 

  10‐10
Press RETURN to exit the input screen.

The file can now be viewed in the program directory and opened in the usual way. 

  10‐11
 ! 
NOTE: Files should be copy / pasted to the USB in the usual way from
your given storage area on the PC / LAPTOP.

As standard the control will recognize (reliably) files with the extension .iso
.prg and .txt

  10‐12
 INPUT OF “CAM” PROGRAMS VIA MANUAL GUIDE
The following section covers the input of CAM program files via the Manual Guide
system using USB.

The USB interface can be found on the front / left of the control screen.

!
NOTE: Fanuc will only guarantee correct operation on USB sticks of 2GB
or less.

Larger USB will work but this is dependant (over 2GB) of the file system used
internally by that manufacturer. SanDisk USB appear to be more reliable over
2GB but the general rule is to keep the USB as small as possible.

!
NOTE: The following section shows the use of USB. The procedure for
using Memory Cards is identical to USB and the control automatically
recognises which is mounted at the screen. The key for INPUT / OUPUT will
show both symbols providing the correct parameters (for both) have been
factory set. (All current models are set to recognize both).

11-1
The standard method of loading a “CAM” program into the machine for use via the
ALPHA operating system is via the RS232 cable supplied with the Alphalink cad –
cam system package.

This standard method of communication (from PC / Laptop to Machine) is covered in

the Alpha Mode Tutorial from page (approx.) 139 onward. (Example below)

11-2
This standard method of communication requires:

• That the PC / Laptop is not prevented from communication by protection

software on the customers computer (firewalls e.t.c.).
• That the PC / Laptop actually has an RS232 (serial port) available. Many
modern laptops do not.

A USB to RS232 converter may be purchased if required to cover this function.

!
NOTE: Cheap USB to RS232 converters may be purchased but most will
not communicate correctly with the Fanuc controls due to the speed of
communication requirements of the control.

A fully tested USB to RS232 converter is available form the Alphalink producer
Superdraft Systems Ltd at www.superdraft.co.uk

An easier and more reliable method of getting “CAM” programs into the machine is
to use the available USB or CARD interface shown at the start of this section.

Simplified, this involves copy / paste of the cam program from the storage directory
for the “CAM” programs onto the USB stick and then from the USB stick into the

control via the Manual Guide IN/OUT. function.

!
NOTE: The general procedure for both location and loading the relevant
file is outlined below.

11-3
Transfer File from Alphalink PROGRAMS directory to USB Stick.

To transfer the CAM file to USB the program file must be copied / pasted in the usual
way.

!
NOTE: After saving the CAM program and generating the file (as an
Alpha format program) this is stored in a directory call PROGRAMS. (Not ISO
which is the directory used if G-Code (ISO) was selected at the point of saving
the program).

The location of the folder can be seen below.

Select (double click) – windows (c:)

11-4
Select (double click) – windows-XS

!
NOTE: See the set up of a “shortcut” to this point at the end of this
section.

Select (double click) – Programs

The list of stored CAM programs will now appear.

11-5
The required file (CAM program) can now be copied / pasted or “sent to” the USB
drive that is currently active on the directory list.

Example.

Select the file required

Select the option required (Copy or Send to) to send to the USB drive (USB Drive E
in this case).

11-6
Send to will copy the file direct to the USB stick.

The file has now been added to the USB stick and can be transferred to the
machine.

11-7
 !
NOTE: These initial steps to find the PROGRAMS directory can be
bypassed for future use by setting up a “short cut” to the PROGRAMS
directory as shown below.

Right click on the Programs directory.

The following page will appear.

The shortcut will be now on the Desktop for easy access.

11-8
Program Input.

Mount the USB at the control.

!
NOTE: Wait a few seconds for the control to recognize the USB (or card)
is mounted.

Select O LIST (Program directory) from the main operation list.

The following screen will appear.

11-9
 !
NOTE: The program number of the CAM program file is always O0001.

The Alpha “CAM MODE” will only look for program O0001 and therefore any current
programs with the number O0001 will need to be deleted.

Attempting to load a second program O0001 will produce the following message.

Before loading the required program, the existing program O0001 must be deleted.

11-10
Press return (if necessary) to return to the OLIST

Use the Navigate keys to select the file to DELETE.

Select DELETE

11-11
The following request for confirmation will appear.

Select YES.

The new file (O0001) can now be loaded via USB.

Press IN/OUT.

11-12
The following screen will now appear showing the files currently contained on the
USB.

Use the Navigate

keys to select the file to INPUT.

Press INPUT

Correct Input of the file will be confirmed with the following message.

11-13
Press RETURN to exit the input screen.

The file can now be viewed in the program directory and opened in the usual way.

11-14
 !
NOTE: “CAM” programs are in a special format (See above) which are
only recognized via the Alpha system. Programs in this format will not run via
CNC / MANUAL GUIDE.

To run the input program, (O0001) switch back into ALPHA mode and select CAM.

11-15
Blank Page
NC CONVERTION OF MANUAL GUIDE FORMAT PROGRAMS
The following section covers the conversion of Manual Guide format programs into
standard ISO format programs.

Manual Guide programs contain special “macros” which would not be reconised by
non-Manual Guide Fanuc controls.

The NC-COVERT function interrogates these macros during the process and
converts these into standard ISO “long hand” programming moves.

!
NOTE: The conversion process retains the original Manual Guide formatted
program and produces new program (different program number) in ISO code so
either can be used from that point.

The converted program will indicate the points at which conversion took place.

12-1
Program Conversion.

Select and open the required program for conversion via the O-LIST (Directory).

!
NOTE: If the required program is already open skip this action.

Select O LIST (Program directory) from the main operation list.

The following screen will appear.

12-2
Use the Navigate keys to select the file to OPEN

Select OPEN

Select Auto mode on the machine.(hard key)

Scroll right until the NC CNV function is visible.

Select NC CNV

The following page will now appear.

12-3
Input the required program number for the converted program.

Then select CREATE

12-4
The following page will now appear.

The screen now shows the original (Manual Guide format) program (right column)
and the destination (ISO format) program (left column).

Select START to commence the conversion.

The control will automatically convert the Manual Guide format into ISO code.

12-5
When completed select Return

Both programs O1020 (Manual Guide) and O1021 (ISO) in this case now exist in the
O LIST (Directory) and can be opened in the usual way. (Select EDIT mode to
access the O LIST).

!
NOTE: If using the NC Convert function the custom macros for Tool
Change and Program End are not converted using this function.
The use of CNC Language (fixed form) for these functions allows for a fully
converted program which can then be used on a non-Manual Guide equipped
machine. (See the Fixed Form Procedure document for further details)

If the NC Conversion is to be used regularly to convert programs for use on

other (Non Manual Guide) Fanuc controlled machines it may be preferable to
always use the standard (ISO) FIXED FORMS for Tool call and Program End.

Standard Manual Guide Macro screen.

!
NOTE: Programs are converted using the ISO format in “long hand”
format. No tool nose radius compensation is called.
The move (cut positional moves) are generated to take account of the tip
radius (example turning tool) in use at the time of conversion.

If the tool used at the time of conversion was (example) 0.8mm tip radius you
cannot then start using a 0.4mm radius tip.

To do this you would need to delete the existing ISO program, change the tip
radius in the TOOL OFFSETS and then reconvert the Manual Guide version of
the program to ISO.

12-6
 PROGRAMMING EXAMPLE.

The following example outlines the general process of constructing a

component program. Not all cycle options are covered but the general
principles remain constant regardless of the cycle types required for any given
component.

MATERIAL: 50 Diameter Mild steel X 80 Long.

TOOLS:

1) 80 Deg Rougher 0.800mm Tip Radius.

2) 35 Deg Finisher 0.400mm Tip Radius.

13-1
 3) 1.5mm pitch Threading tool.

4) 22 Diameter U Drill.

5) 3mm Groove Tool.

PROGRAMMING.

START A NEW PROGRAM.

After powering the machine select the Manual Guide i system by selecting
CNC mode with the key and pressing MAN GUIDE on keypad. (This will take
a few seconds, please wait).

13-2
Select

The following page will now be viewed.

Select

Enter the program number required.

13-3
Press .

The following page will now be opened.

Using the arrow key select the turning functions.

Select

Select

= = =

Select

13-4
 =

Enter the Diameter, length, face removal amount (main spindle) and face
removal amount (sub spindle).

!
NOTE: The length value of the billet should be the finished length
of the component PLUS the combined values of the FACE REMOVAL
AMOUNTS.

!
NOTE: In all cases type the value required and press to
enter the value and move to the next input field.

13-5
Select .

The blank information will be added to the program.

Select

Select

= = =

Select

Enter the values required under the DETAIL tab.

13-6
 !
NOTE: In all cases type the value required and press to
enter the value and move to the next input field.

Enter the TOOL CHANGE POS. X

!
NOTE: Entering a value (150.) will produce a standard rapid move
to that position (G0 X150.)

Type in the value required and press

Enter the TOOL CHANGE POS. Z

!
NOTE: Entering a value (150.) will produce a standard rapid move
to that position (G0 Z150.)

13-7
Type in the value required and press

Select the T.C. APPROACH METHOD

!
NOTE: USE THE SELECTION KEYS AT THE BOTTOM LEFT OF
THE SCREEN.

Enter the TOOL NUMBER

!
NOTE: The tool number must also include the offset number
required. (101 or 202 e.t.c.).

13-8
Type 101 Press

Enter the START POS. X

!
NOTE: This is the X rapid to position move prior to commencing
the next cycle.

Type 52 Press

Enter the START POS. Z

13-9
 !
NOTE: This is the Z rapid to position move prior to commencing
the next cycle.

Type 3 Press

Bypass the RET. METHOD REVERSE by pressing

!
NOTE: RET. METHOD REVERSE is not active if 2 AXES MOVE has
been selected. See the “ REVERSE METHOD” section for a full
explanation of the function.

!
NOTE: After pressing the page will change to the
tab.

13-10
Enter the values required under the SPIN (Spindle) tab.

Enter the MAX. SPINDLE SPEED

!
NOTE: This is the maximum speed for the spindle while using the
machine in m/min (constant surface speed – G96) mode. This will not
restrict the speed when using r.p.m.

Type in the value required and press

Enter the SPINDLE SPEED

!
NOTE: This speed value will be R.P.M. or C.S.S. depending on the
latter selection.

Type 200 Press

13-11
Enter the FWD / REV (Spindle)

!
NOTE: USE THE SELECTION KEYS AT THE BOTTOM LEFT OF
THE SCREEN.

Enter the CSS / RPM (Spindle)

!
NOTE: USE THE SELECTION KEYS AT THE BOTTOM LEFT OF
THE SCREEN.

13-12
Enter the COOL. OFF / ON

!
NOTE: USE THE SELECTION KEYS AT THE BOTTOM LEFT OF
THE SCREEN. The SECOND key allows a second pump to be started
(using a different code) if fitted to the machine (customer option).

!
NOTE: After pressing the page will change to the
tab.

13-13
 !
NOTE: Any input field marked with a star is
optional and may be left blank if required.

Type 1 and press

!
NOTE: After pressing the page will change to the
tab.

!
NOTE: Any input field marked with a star is
optional and may be left blank if required.

!
NOTE: This input box allows the workshift value of the component
(calculated at tool set up) to be entered into the program for safety.
13-14
Select to enter the code in the program.

(G105) PROGRAM START AND TOOL CALL

FUNCTION.

1. Set maximum spindle speed

2. Return tool to tool change position.
3. Call tool and offset.
4. Start spindle at required speed.
5. Rapid to cycle start position.
6. Turn on / off coolant.

4
6
1 MAX SPEED

5 2

3 TOOL ?

13-15
PROGRAM FACE OPERATION.

Select

Select TURNING

Select

Enter the values required under the CUT COND. tab. (Cutting condition).

13-16
Enter the CUTTING DIRECTION.

Enter the FEED RATE.

Type 0.15 and press

13-17
Enter the X-AXIS CLEARANCE.

Type 2. and press

Enter the Z-AXIS CLEARANCE.

Type 2. and press

Select the APROCH MOTION.

13-18
Select .

The TURNING FIG call will now be automatically selected.

Press .

Enter the START POINT values required.

50 = =0= Press .

13-19
This start point of the first line may now be viewed on screen.

Select next element type required

Select line direction required .

Enter finish point of line.

-1.6 = Press .

This line may now be viewed on screen.

13-20
Select next element type required

Select line direction required .

Enter finish point of line.

1 = Press .

This line may now be viewed on screen.

13-21
 !
IMPORTANT: The billet profile must now be added to the existing
component profile.

Two methods are available to the operator depending on the complexity

of the billet profile required.

(1) Auto generation of the billet profile. (Recommended)

Press the right arrow key three times until the following symbol appears.

Select the BL CONT (BILLET CONTOUR) Key.

Two options are available.

Contour to the right of the profile.

Contour to the left of the profile.

13-22
Select

The following message will now be displayed.

Select

(Move to the SAVE THE PROFILE section.) (Page26)

(2) Manual generation of the billet profile. (Useful for

castings)

Select next element type required

Select line direction required .

Enter finish point of line.

13-23
50 = Press .

!
IMPORTANT: The ELEMENT TYPE must now be change to allow
the drawing of the current billet material size. In this case an extra 1mm
of clearance has been allowed by drawing the bottom line to +1mm clear

of the Z0.000 point. Press 3 times to move the cursor to the

ELEMENT TYPE input field.

Select Press .

This line may now be viewed on screen.

13-24
Select next element type required

Select line direction required .

Enter finish point of line.

0 = Press .

This line may now be viewed on screen.

!
IMPORTANT: Part lines and Blank lines must be
connected to form a complete profile.

13-25
SAVE THE PROFILE.

Select .

The following input screen will appear.

!
NOTE: This input screen allows the component figure (form) to be
saved in two ways.

Outputs the figure code directly to the

program (long hand).

Saves the figure code

as a sub program and enters the sub program call into the program. This
allows the call of this form for more than one cycle (e.g. Roughing and
Finishing).

As this for is only to be used once Select

Select to enter the code in the program.

13-26
PROGRAM ROUGH TURN OPERATION.

!
NOTE: Following the facing operation the tool will have returned to
the X52.000 Z 3.000 start point of the cycle. (Use this as the start point of
the next cycle).

It may be required however to change the spindle speed for the next
operation. (Rough turn external).

To achieve this without the need for a full tool change routine, use the
OPS LINKING (SAME TOOL) function.

Select

Select TOOL CALL

Select OPERATION LINKING – SAME TOOL

13-27
Press

The following page will appear.

!
NOTE: Any input field marked with a star
is optional and may be left blank if
required.

As in this case only the SPINDLE SPEED requires changing, move to this

input field by pressing

Type 250 and press

13-28
Press
The code will be added to the program.

Select

Select TURNING

13-29
Select

Enter the values required under the CUT COND. tab. (Cutting condition).

Enter the CUTTING DIRECTION.

13-30
Enter the CUT DEPTH.

Type 2.5 and press

Enter the RATE OF CUT DEPTH %.

!
NOTE: This allows a reduction in cut depth on each pass. To
maintain cut depth (2.5 in this case) keep value at 100%.

Press to skip this input field.

Enter the X-AXIS FINISH AMT.

13-31
Type 1.and press

Enter the Z-AXIS FINISH AMT.

Type 0.1 and press

Enter the CUT DIRC FEEDRATE.

!
NOTE: This is the feed rate of the tool when travelling in the Z-
direction.

Type 0.25 and press

13-32
Enter the CUT DEPTH FEEDRATE.

!
NOTE: This is the feed rate of the tool when sinking into material.

Type 0.1 and press

Enter the CUT RISE FEEDRATE.

!
NOTE: This is the feed rate of the tool when exiting from material.

!
NOTE: Any input field marked with a star is
optional and may be left blank if required.

13-33
Type 0.2 and press

Select DETAIL

Enter the values required under the DETAIL. tab. (Cutting condition).

Enter the 1ST FEED OVERRIDE.

!
NOTE: This allows a reduction in feed for the first pass of the
cycle. To maintain the original feed (0.25 in this case) keep value at
100%.

13-34
Press to skip this input field.

Enter the CUT RISE METHOD.

!
NOTE: Two methods of retraction are available.

Rapid retract at end point of cut (45 deg pull out).

Feed out over cut depth following the contour.

Select

13-35
Enter the ESCAPE AMOUNT.

!
NOTE: Retraction distance clear of previous cut.

Type 0.5 and press

Enter the X and Z – AXIS CLEARANCE.

!
NOTE: This is the position the tool will rapid to prior to
commencing the cycle. The default in both fields is 2.000mm. This may
be altered if required.

Press to skip the fields and retain the default values.

13-36
Select the APROCH MOTION.

Select .

The TURNING FIG call will now be automatically selected.

13-37
Press .

Enter the START POINT values required.

26 = =0= Press .

This start point of the first line may now be viewed on screen.

13-38
Select next element type required

Select line direction required .

Enter finish point of line.

28. = Press .

- 2. = Press .

This line may now be viewed on screen.

13-39
Select next element type required

Select line direction required .

Enter finish point of line.

- 30. = Press .

This line may now be viewed on screen.

Select next element type required

Select line direction required .

Enter finish point of line.

13-40
40. = Press .

- 35. = Press .

This line may now be viewed on screen.

Select next element type required

Select line direction required .

Enter finish point of line.

13-41
- 55. = Press .

This line may now be viewed on screen.

Select next element type required

Type the radius value required

.

2. = Press .

!
NOTE: The element will be added to the list but will not be visible
until the completion of the next line.

13-42
Select next element type required

Select line direction required .

Enter finish point of line.

50. = Press .

This line may now be viewed on screen.

13-43
 !
IMPORTANT: The billet profile must now be added to the existing
component profile.

Auto generation of the billet profile. (Recommended)

Press the right arrow key three times until the following symbol appears.

Select the BL CONT (BILLET CONTOUR) Key.

Two options are available.

Contour to the right of the profile.

Contour to the left of the profile.

Select

The following message will now be displayed.

13-44
Select

!
IMPORTANT: Part lines and Blank lines must be
connected to form a complete profile.

Select .

The following input screen will appear.

!
NOTE: This input screen allows the component figure (form) to be
saved in two ways.

Outputs the figure code directly to the

program (long hand).

Saves the figure code as a

sub program and enters the sub program call into the program. This
allows the call of this form for more than one cycle (e.g. Roughing and
Finishing).

As this form is to be used for the roughing and finishing cycles

Select

13-45
Type the sub program number required 6001. Press

!
NOTE: To allow the sub program to be called from the INSERT
TURNING FIGURE menu (and reused as the Finish Turn profile) it must
be saved as a program number between 6001 and 6999. (See Finish turn
programming section).

Type the sub program name required R – F FORM. Press

Select to save the sub program and enter the code in the program.

13-46
TOOL CHANGE.

Enter the values for tool 5 (Grooving) .

Select

Select

= = =

Select

Enter the values required under the DETAIL, SPIN, PROG STOP and
WORKSHIFT tabs.

13-47
13-48
Select to enter the code in the program.

PROGRAM GROOVING OPERATION.

13-49
Select

Select T-GROOVING

Select

Enter the values required under the CUT COND. tab. (Cutting condition).

13-50
Enter the ROUGHING TYPE.

Select the cycle type using the following keys.

!
NOTE:

CENTER Pecks to the full groove depth (less finishing amounts

e.g. 0.100) before moving over for the next cut.

LAYER cuts to the peck depth and then moves over to the next
cut. This is repeated until the groove form at that depth is completed.
The tool then cuts to the next peck depth and opens the form at this next
depth. This is repeated until the full form (less finishing) is completed.

Select

Enter the SIDE FINISH AMOUNT.

Type 0.1 and press

13-51
Enter the BOTTOM FINISH AMT.

Type 0.1 and press

Enter the ROUGH FEEDRATE.

Type 0.15 and press

13-52
Enter the FINISH FEEDRATE.

Type 0.1 and press

Enter the PECKING.

!
NOTE: If is selected the next three input fields are deleted
from the screen and the system moves directly to the DETAIL tab
information.

If is selected the peck information must now be entered.

13-53
Enter the PECKING CUT DEPTH.

Type 2. and press

Enter the RATE OF CUT DEPTH.

!
NOTE: This allows each peck to be reduced. If 80 (%) was
programmed the second cut (peck) would be 20% smaller than the last.
This reduction would continue until finish depth had been achieved.

Type 100 and press

13-54
Enter the RETURN AMOUNT.

!
NOTE: This is the retraction value after each peck.

Type .5 and press

!
NOTE: After entering this last value the page will automatically
switch to the page.

Enter the values required under the DETAIL. tab.

Enter the CLEARANCE.

!
NOTE: This is the cut start point value above the groove form.

Type 2. and press

13-55
Enter the DWELL.

!
NOTE: This is the dwell in seconds at full roughing depth (not
each peck).

Type 2. and press

Select the APROCH MOTION.

13-56
Select the CUT END POSITION.

!
NOTE: If is selected the cycle will revert to the cut
condition page and the cycle is ready to be saved.

If is selected a retract value must also be programmed prior to

saving the cycle.

Select to enter the code in the program.

The TURNING FIG call will now be automatically selected.

13-57
Select

= =

Select

Enter the values required under the tab.

Enter the BASE POINT SETTING.

13-58
 !
NOTE: If is selected the groove is programmed from right
to left.

!
NOTE: If is selected the groove is programmed from left to
right..

Enter the BASE POINT (X).

Type 40. and press

Enter the BASE POINT (Z).

13-59
Type -39. and press

Enter the DEPTH.

Type 8. and press

Enter the WIDTH.

Type 10. and press

13-60
 !
NOTE: After entering this last value the page will automatically
switch to the page.

Enter the values required under the (Corner information) tab.

Enter the CORNER TYPE-1 information.

Select

Enter the CORNER SIZE.

Type 2. and press

13-61
Enter the CORNER TYPE-2 information.

Select

Enter the CORNER TYPE-3 information.

Select

13-62
Enter the CORNER TYPE-4 information.

Select

Enter the CORNER SIZE.

Type 2. and press

!
NOTE: After entering this last value the page will automatically
switch to the page. This page allows multiple repeats of the
same groove form along the workpiece and is not required in this case.

13-63
Select to enter the code in the program.

TOOL CHANGE.

Enter the values for tool 4 (Drilling).

Select

Select

13-64
 = = =

Select

Enter the values required under the DETAIL, SPIN, PROG STOP and
WORKSHIFT tabs.

13-65
Select to enter the code in the program.

13-66
PROGRAM DRILLING OPERATION.

Select

Select HOLE MACH.

13-67
Select

Enter the values required under the CUT COND. tab. (Cutting condition).

Enter the PECKING CUT DEPTH.

!
NOTE: As a U drill is being used no peck is required.

!
NOTE: This input field is marked with a star * and is optional.

Press to skip this field.

13-68
Enter the GO PAST AMOUNT.

!
NOTE: As a U drill is being used (Flat front face) this may be set at
0. When using standard drills this function allows the full diameter hole
depth to be programmed with the addition of this value to represent the
extra distance required by the drill point.

This allows simple modification of drilling depth to take account of

variations in drill point geometry.

Type 0. and press

Enter the CLEARANCE.

Type 5 and press

13-69
Enter the FEED RATE.

Type .1 and press

Enter the DWELL TIME.

!
NOTE: This input field is marked with a star * and is optional.

Press to skip this field.

13-70
Select the APROCH MOTION.

!
NOTE: After entering this last value the page will automatically
switch to the page.

Enter the BASE POS.

!
NOTE: This is the point from which the drill cycle depth
measurements are taken and allows cycles to be started at positions
other than the front face of the component.

Type 0 and press

13-71
Enter the CUT DEPTH.

Type -26 and press

!
NOTE: After entering this last value the page will automatically
switch to the page.

!
NOTE: Non of the detail options are required for this operation.

These options allow a reduction / increase in the programmed feed rate

at the start and end of the drilling cycle over a set distance.

13-72
Select to enter the code in the program.

TOOL CHANGE.

Enter the values for tool 2 (Finish turn).

Select

Select

13-73
 = = =

Select

Enter the values required under the DETAIL, SPIN, PROG STOP and
WORKSHIFT tabs.

13-74
Select to enter the code in the program.

13-75
PROGRAM FINISH TURN OPERATION.

Select

Select TURNING

Select
13-76
Enter the values required under the CUT COND. tab. (Cutting condition).

Enter the CUTTING DIRECTION.

NOTE: On later models of control the options as shown below are

available. Instruction for the use of OPTIMIZE can be found in section 7
of this manual

Enter the FEED RATE.

Type 0.1 and press

13-77
Enter the X and Z – AXIS CLEARANCE.

!
NOTE: This is the position the tool will rapid to prior to
commencing the cycle.

Press to skip the fields and retain the default values.

Select the APROCH MOTION.

13-78
Select .

The TURNING FIG call will now be automatically selected.

Select SUBPROGRAM

!
NOTE: To allow the sub program to be called from the INSERT
TURNING FIGURE menu it must be saved as a program number between
6001 and 6999.

13-79
Press .

The turning figure subprogram call will be added to the program.

TOOL CHANGE.

Enter the values for tool 3 (Threading).

Select

Select

13-80
 = = =

Select

Enter the values required under the DETAIL, SPIN, PROG STOP and
WORKSHIFT tabs.

13-81
Select to enter the code in the program.

13-82
PROGRAM THREADING OPERATION.

Select

Select THREADING

13-83
Select

Enter the values required under the CUT COND. tab. (Cutting condition).

Enter the CUTTING METHOD.

Enter the FINISH AMOUNT.

13-84
 !
NOTE: This is the depth of the finish pass.

Type 0.05 and press

Enter the NUMBER OF FINISHING.

!
NOTE: This is the number of finish passes required.

Type 1 and press

Select the CUT TYPE.

13-85
 !
NOTE: If NUMBER is selected the number of threading passes
required is programmed.
If DEPTH is selected the depth of the first pass is programmed. The
number of passes required will be automatically calculated by the
control.

Enter the CUT DEPTH NUMBER.

!
NOTE: This is the number of passes required.

Type 8 and press

13-86
 !
NOTE: After entering this last value the page will automatically
switch to the page.

Select the APROCH MOTION.

Enter the SURFACE CLEARANCE.

!
NOTE: This is the retraction distance above the thread outside
diameter after each pass.

Type 1 and press

13-87
Enter the ENTRANCE CLEARANCE.

!
NOTE: This is the lead in distance at the thread start point.

Type 5 and press

Enter the EXIT CLEARANCE.

!
NOTE: This is the lead out distance at the thread end point. This
may be used to drive the tool into a pre machined undercut if required.

Type 0 and press

13-88
Select to enter the code in the program.

The TURNING FIG call will now be automatically selected.

Select

= =

Select

Enter the values required under the tab.

Select the FIGURE TYPE.

13-89
Enter the THREAD DIAMETER.

Type 30 and press

Enter the START POINT (Z).

Type 0 and press

13-90
Enter the LEAD.

Type 1.5 and press

Enter the LENGTH.

Type 23 and press

13-91
Enter the THREAD DEPTH.

!
NOTE: If this figure is known or requires a non standard value this
may be typed in. If this is not known use CALCULATE.

Press

Select to enter the code in the program.

13-92
END THE PROGRAM.

Select

Select PROG END

Enter the values required under the DETAIL. tab.

Enter the SAFE END POS. X

Type 250. and press

13-93
Enter the SAFE END POS. Z

Press to skip to new field and retain default value.

Select the END APPROACH METHOD using the keys available.

13-94
Select to enter the code in the program.

Simulation of the program may now take place. (See simulation section).

13-95
Blank Page