This month, we move onto simple profiling starting with the G12 and G13 circle cutting cycle and continue with straight cuts using the G41 offset left command. This is quite a long program as it cuts five holes and then cuts the profile. In future articles, unless very short, I will limit the program to the relevant bits and leave the beginning and end off. Program 1, lines N1 to N5 (with dimensions altered as necessary) will set up the start of your program and lines N55 to N57 will end the program. If you put these lines into a text document, leaving a gap to insert the different codes, you can use this as a basis for all your future programs. Note, you do not need the line numbers. They are optional. I have only put them in for your benefit.
It has been suggested that I explain the reason for the set up and also the cancel G codes in line one. They are there in case you stop a program in the middle. This could leave certain codes still active, which could be dangerous or the program may not work. As we learn the G codes to set an operation, we will also learn the G code that cancels that operation.
N1 G0 G15 G17 G21 G40 G49 G50 G69 G80 G90
N2 G91 G28 Z0. X0. Y0.
N3 M6 T1 S4000
N4 G54 G90 G0 X-16.5 Y0. Z100.
N5 G0 G43 H1 Z50.0 M3
N6 G99 G91 G81 X0. Y0. R1.5 Z-0.2 F30.
N9 G1 Z-0.2 F100
N10 G13 I0.5 F10
N11 G0 Z2.5
N13 G99 G91 G81 X0. Y0. R1.6 Z-0.2 F30.
N17G1 Z-0.2 F100
N18G13 I0.65 F10
N21 G99 G91 G81 X0. Y0. R1.5 Z-0.2 F30.
N24 G1 Z-0.2 F100
N25 G13 I0.5 F10
N26 G0 Z2.5
N28 G99 G91 G81 X0. Y0. R1.5 Z-0.4 F30.
N31 G1 Z-0.2 F100
N32 G13 I0.65 F10
N33 G0 Z2.5
N35 G99 G91 G81 X0. Y0. R1.6 Z-0.4 F30.
N38 G1 Z-0.2 F100
N39 G13 I0.5 D1 F10
N40 G0 Z2.5
N41 G0 G49 Z50.
N42 G91 G28 X0. Y0. Z0. M5
N44 G90 G0 X-30. Y15.
N45 G00 G43 H1 Z50.0 M3
N46 G0 Z3.
N47 G1 Z-0.5 F50
N48 G1 G41 Y12. F80
N53 G0 Z10
N55 G0 G49 Z50.
N56 G91 G28 X0. Y0. Z0. M5
G12 & G13 circle cutting cycle
G12 cuts a circle in the clockwise direction and G13 cuts the circle in a counter clockwise direction. On Mach3, both G12 and G13 ignore radius compensation. This means you have to program the radius of the circle less half the cutter dia. If the circle is too large or too small, you will have to alter the radius of the cycle dimension to get it right.
Say you want to cut a 10mm diameter circle with a 3mm cutter. The radius of the circle is 5mm and the radius of the cutter is 1.5mm. This means that you have to take the cutter radius (1.5mm) from the circle radius (5mm) making 3.5mm. This is the dimension you would program the G12 or G13 with. The radius is programmed using the letter I and you also need to add the feed using the F parameter so the code for a counter clockwise circle of 10mm diameter with a 3mm cutter using a feed of 10mm per minute would be as follows G13 I3.5 F10.
An example of this (with a different hole size and cutter diameter) is given in line ten in program 1. Fig. 1 shows how to work the I dimension out. The dotted line is the cutter path.
G13 will climb mill, counter clockwise. G12 will conventional mill clockwise. The diameter of the finished hole will be the same (subject to the cutter pushing off) whether you mill clockwise or counter clockwise. Note that the cycle will only cut a circle. If you need to cut a circular pocket, you will have to program two or more G13 (or G12) cycles with overlapping paths.
Unlike some programming systems, you have to program the cutter down to the depth that you require the cycle to cut. Please remember to raise the cutter up in the z direction so it is clear before moving the cutter to another X Y position. There is not a code to cancel the G12, G13 command. I think that covers all you need to know about the G12 and G13 cycles, It wasnt too bad was it?
Cutter compensation G41 and G42
Now we move on to lines N44 to N54. This uses cutter compensation command G41 to run round the outside of the profile of a component. I have used a simple rectangle as an example. Radiused profiles will be discussed next time.
G41 is cutter radius compensation left, Fig. 2. This means that the cutter is offset to the left of the job in direction of travel and is climb or down cut milling. The chip removed by the cutter starts large and tapers to nothing.
Climb milling is usually ok on machines with ball screws but not with normal leadscrews. This is because the cutter will pull the job (and the machine table) into the cutter unless restrained by a ball screw with minimal backlash.
G42 is cutter compensation right, Fig. 3. This means that the cuter is offset to the right in the direction of travel and is conventional or up cut milling. This pushes the job away from the cutter. The chip starts small and gets larger as the tooth digs into the work.
Cancelling compensation, G40
Cutter compensation is cancelled by G40. You need to be careful how you remove compensation as results can some times be unpredictable. If possible, I prefer to raise the cutter at the end of the cut prior to taking compensation off.
N44 G90 G0 X-30. Y15
Line N44 sets absolute (G90) and moves to the start position for the profile. This is outside the profile and far enough away so that the cutter does not encroach on the profile. The X dimension is 4mm to the left of the start of the profile. In practice, it is not a critical dimension, I picked it at random to avoid the profile.
N45 G00 G43 H1 Z50.0 M3
Line N45 sets cutter height and compensation as mentioned last time.
N46 G0 Z3
Line N46 stops the cutter above the material. (It is not advisable to plunge straight into the work even if there is no material in the way.)
N47 G1 Z-0.5 F50
Line N47 lowers the cutter to depth at a controlled feed rate.
N48 G1 G41 Y12. F80
Line N48 moves the cutter in a Y direction to the edge of the job but leaves it offset by the cutter diameter. Note, you must put the correct tool diameter in the tool offset table before running the program. The tool used in this program was 2mm diameter. (You can lie to the program about the tool diameter offset but the reasons for that will the subject of a later article.)
Line N49 moves the cutter to X 26 + tool radius = 26mm + 1mm making 27mm.
Line N50 moves the cutter in the Y direction to -12mm + the radius (1mm) making 13mm.
Line N51 moves the cutter to x-26 + the cutter radius making -27mm.
Line N52 moves the cutter in the Y direction to Y 14 + the cutter radius making Y 15mm. Again this finishing point is not critical as long as it goes past the edge of the profile.
N53 G0 Z10
Line N53 raises the cutter 10mm above the work.
Line N54 uses G40 to cancel the compensation.
Thats it, your first profile. The machining sequence of the component used as an example is shown in photos 1 through 5. It is a small component made from modellers plastic card. I started with a simple drilling program (not shown as we covered basic drilling last time) to put 5 holes into a piece of aluminium plate to use as a fixture.
The end holes (ignore the large one as that was already in the material) and the centre one was tapped M3 to hold the plastic down.
The plastic card was clamped on to the fixture with two small mole wrenches and the five holes pocketed. The machine then went to the home position and stopped so I could put the 3 screws in and remove the mole grips.
The machine then ran round the profile finishing the part off. In a simple fixture job like this, the centre hole is position X0, Y0. After you have drilled the holes when making the fixture, dont alter your G54 position. When you program the pockets and the profile using the same X 0 Y0, they will be automatically correct.
Next time we will look at a profile using radii and at the G2 and G3 arc commands.