CNC Milling

Programming Manual
Boxford 190 VMC CNC Milling Machine Tool
Boxford
Boxford Ltd., Wheatley, Halifax, West Yorkshire, England, HX3 5AF. (Registered Office) Telephone: 01422 358311 Fax: 01422 355924 E-Mail: info@boxford.co.uk Web: www.boxford.co.uk
Boxford 190 VMC
Contents
Contents
1 Introduction 2 Running the Demonstration Program 3 Axes and Tooling
3.1 3.2 3.3 3.4 3.5 3.6 Fitting Tooling Axes, Datums and Offsets Tool Storage Tool Data Library and Catalogue Setting Up Datum Shift
4 Main Front End Menu 5 CAD

5.1 5.2 5.3 5.4 5.5 5.6 Cad Window Drawing Aids Drawing Tools Editing Objects Area Filling Machining Considerations Settings CAM Processor Error Messages
6.1 6.2 7.1 7.2
CAM Processor
7 File Imports
Drawing File Import G&M Code Program Import Access & Password Setting Tool Library Material Cutting Data Park Position and Units CAM Processor Default Settings Language Settings
8 Administration Mode
8.1 8.2 8.3 8.4 8.5 8.6
Boxford 190 VMC
Contents
9 Cutter Path CAM Programming

9.1 9.2 9.3 9.4 9.5 9.6 9.7 Functions Information Required Drawing a Component Example Defining Straight Line Moves Defining Arcs Pockets and PCD Drilling 9.7.1 Rectangular Pockets 9.7.2 Circular Pockets 9.7.3 Slots 9.7.4 PCD Drilling 9.7.5 Dish Milling Cutter Radius Compensation Tool Changing Processing a Cutter Path Editing a CAM Program
9.8 9.9 9.10 9.11 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8
10 Manual Data Input CNC Programming

Operations and Programming Sheets Absolute and Incremental Co-ordinates Speeds and Feeds Program Format Preparatory Functions (G Codes) Miscellaneous Functions (M Codes) Programming a Tool Change Inputting a New Program 10.8.1 Information required 10.8.2 Tabulated Format 10.8.3 ZOOM Facility 10.8.4 Compact Format 10.9 Saving a Program 10.10 Examining an Existing Program 10.10.1 PROGRAM Display 10.10.2 ZOOM and VIEW Facility
Boxford 190 VMC
Contents
10.10.3 Simulation of Machining 10.11 Editing a Program 10.11.1 New Programs 10.11.2 Existing Programs 10.11.3 MENU Editing Options 10.11.4 Changing the Initial Tool 10.12 Continuing a Program
11 CNC and CAM Machining

11.1 11.2 11.3 Initial Checks Manufacture Options During Machining
12 Manual Machining 13 Robotic Interfacing
Boxford 190 VMC
Contents
CNC Tutorials and Exercises

Tutorial 1: Exercise 1: Tutorial 2: Exercise 2: Tutorial 3: Exercise 3: Tutorial 4: Exercise 4: Tutorial 5: Exercise 5: Tutorial 6: Exercise 6: Tutorial 7: Exercise 7: Tutorial 8: Exercise 8: Tutorial 9: Exercise 9: Tutorial 10: Exercise 10: X and Y Co-ordinate Calculation Absolute and Incremental Co-ordinates Calculation of Co-ordinates Linear Interpolation Linear Interpolation - Absolute Co-ordinates Canned Cycles - Hole Drilling and Pocket Milling Canned Cycles - Programming a Tool Change Circular Interpolation - Clockwise and Counter-clockwise Circular Interpolation Combining Operations and Tool Changing Combining Operations Subroutines Subroutines Mirror Images Mirror Images Further Canned Cycles - Pitch Circle Drilling and Dish Milling Use of Canned Cycles - Pitch Circle Drilling and Dish Milling Subroutines, Mirror Images and Circular Interpolation Subroutines and Mirror Images Datum Shift and Jump to Line Datum Shift and Jump to Line
Operations Sheet Programming Sheet
1 Introduction
This manual gives guidance in using the 190VMC CAD/CAM software to create ISO G& M code programs for milled components. The 190VMC CAD/CAM software includes a demonstration program (called 190VMC), and a number of tutorial programs. It is suggested the manual is used as follows: 1. 2. 3. 4. 5. 6. 7. Refer to section 2 and run the demonstration. This will provide rapid familiarisation with the operation of the software and the machining process. Study Section 3 to become proficient in setting up the tooling. Refer to sections 4, 5 and 6 to demonstrate the ease of operation of the integrated CAD and CAM processor package. Refer to Section 7 to become familiar with the conventions for importing drawing files from third party CAD packages and G & M programs from CAM packages. Refer to Section 8 for details of the functions available to administrators (tutors) of the CAD/CAM system. Refer to section 9 for computer assisted cutter path generation. Use section 10 for detailed instruction in CNC programming. Tutorial 2 is used as an example to demonstrate the stages of programming and software operation. Use the Tutorials and Exercises in the order in which they appear, to progress from basic programming skills to proficiency in the more advanced features of CNC programming. When programs have been written and verified, refer to section 6 as required, to machine components.
8.
9.
Boxford 190 VMC
2 Running the Demonstration Program

The demonstration program contains examples of linear and circular interpolation, rectangular and circular pocket milling and pitch circle drilling, and a finished component can be machined from the billet supplied with the machine. Run the program as follows to provide a tutorial in programming and machining.
Setting Up the Machine
1.
Set up the tooling and billet as follows: 6mm slot drill fitted in cutter holder, secured in spindle. 3mm slot drill ready for the programmed toolchange. Billet: plastic, length 75.00 mm, width 60.00mm, height 10.00mm, securely fitted in vice.
2.
Run the software and check that the Simulation and Manufacture software is correctly configured by selecting CONFIG from the main menu. (Refer to Section 5 - Installation in the Installation and User manual, and Section 3 - Axes and Tooling). From the main menu, select MACHINE and then Tools to display the Tool Data Library. Check the setting of the reference tool, and the second tool, which should be as follows:
No. 1 2 Type 2 2 Pos 1 2 Description Slot drill Slot drill Diameter 6.00 3.00 Length 7.50 7.50 Offset 0.00 0.00
Check Tool Settings
3.
If the settings are incorrect, refer to Section 3 - Axes and Tooling, 3.5 - Setting Up. 4. Turn off the display. The screen shows: Main Menu
Boxford 190 VMC
5.
Select PROGRAM The screen shows:
6.
Select PROGRAM The screen shows the Catalogue Display. View the catalogue to identify the demonstration program, which is called VMC 190.
Boxford 190 VMC
7.
Select VMC 190 The screen shows the Program Display with a 2D view of the component.
Boxford 190 VMC
View the Component
8.
Select VIEW to produce a 3D view of the component. After a pause the display will show the 3D view:
Manipulate the 3D view as follows: Using a Mouse: Click on the control buttons Increase size Rotate clockwise Decrease size Rotate anticlockwise Restore original view
Boxford 190 VMC
Using the Keyboard:
Increase size
Rotate clockwise Decrease size
Rotate anticlockwise
HOME
Restore original view
Note: The time taken for the display to respond will depend on the speed of the PC and whether a co-processor is fitted. Show the Program Details 9. Select
INFO
to show the program details:
10.
Turn off the program details display. (Click off the display window or press Return).
Boxford 190 VMC
Display the Program
11.
Select
MENU
and then Display:
Scroll the display to examine the program: Using a Mouse: Click on the buttons
page down
1 line down
1 line up
page up
Using the Keyboard:
Press Press
or
to scroll 1 line Page down to scroll 1 page
Page up
or
12.
Turn off the program display.
Boxford 190 VMC
Zoom the Display
The ZOOM facility enables a rectangular area of the workpiece to be isolated and viewed in greater detail for editing purposes. Full use of the facility is explained in Section 10 Manual Data Input CNC Programming, 10.8.3 - ZOOM Facility. The following steps provide a brief demonstrations, returning to the display of the complete workpiece. 13. Select ZOOM . The screen displays a 2D view of the workpiece with a menu bar at the top, and sliders and arrow buttons arranged horizontally and vertically. Explore the use of the REDUCE and ENLARGE options, and the sliders and arrow buttons, to define a section of the workpiece with the rectangular selecting frame. (RESET restores the frame to its original size). 14. 15. Select ACCEPT . After a pause the screen shows the program EDIT display with a 3D view of the selected area of the workpiece. Select ZOOM , then Unzoom to restore the 3D view of the complete workpiece.
Boxford 190 VMC
Simulate Machining - 2D
16.
Select
MENU
, then 2D Simulate:
tool depth display
Repeatedly click the mouse button or press Return to move through the program line-byline. The simulation shows the tool movement and metal removed as each line of the program is executed. To move forward through the program to a specific line, select MENU , and then Go to Line. Type the required line number when prompted, and press Return. To produce a 3D view of the workpiece, select MENU and then Solid View. To return to the 2D view, click the mouse button or press Return. To run the simulation automatically, select MENU and then Fast Mode; the program will be run in a continuous sequence. To return to line-by-line simulation, select MENU and then Step Mode. To end the simulation before the end of the program, click on the 'off' button or press ESC . At the end of the program the screen returns to the program display.
Boxford 190 VMC
Simulate Machining - 3D
17.
Select
MENU
, then 3D Simulate:
Select MENU , and demonstrate the use of the options available as for the 2D simulation, until the screen again shows the program display. Machine the Component Refer to Section 11 - CNC and CAM Machining.
Boxford 190 VMC
Axes and Tooling
3 Axes and Tooling

3.1 Fitting Tooling (Figure 3.1)
The cutting tool fits directly into a tool holder and is secured in position by a single Allen screw. The tool holder in turn fits into the machine spindle taper and is orientated by two dogs which engage with the tool holder flange. The tool holder pull stud is then drawn upwards by the spindle drawbar thus securing the tool holder. The drawbar can be manually operated by a lever on the side of the spindle or an automatic tool changing device can be specified if required.
3.2 Axes, Datums and Offsets (Figure 3.1)

Axes
Figure 3.1 shows the movement of the tool in the X, Y and Z axes, in relation to the billet. (In the X and Y axes the billet moves in relation to the tool, but for simplicity and to conform with standard programming practice, it is the movement of the tool in relation to the billet which must be considered). On new machines, all Datum positions and Tool Offsets are set at the factory when tooling and clamping is ordered with the machine. The offsets of all required tools are set in relation to the machine Z datum. Before any Tool Offsets can be set, the Machine Z Datum has to be defined. From the machines Home Position, the Machine Z Datum is the measured distance from the underside of the of the spindle head to the machine table top as shown in the diagram overleaf. The X and Y Datum is the distance from the spindle centreline to a fixed point on the machine table where the same corner of every workpiece locates to. (on a standard Vice, this is the imaginary intersection of the vice rear jaw and the left hand end stop - a point where the Left Hand corner of a workpiece locates to). The datum position can be set to reference from Back Left, Back Right, Front Right and Front Left corners of the workpiece (see section 3.5 - point 15 onwards for further details).
Datum Position
Boxford 190 VMC
3.1 Axes and Tooling
Drawbar lever
DRAWING
Spindle Tool holder Cutting tool Tool X,Y datum
+Y
Billet Rectangular billet
Tool X,Y datum
+ Z - - X + Y-
+X
Drawing datum Tool X,Y datum
Workholding vice
+Y
Circular billet
+X
Drawing datum
Figure 3.1
Axes and Tool Datum
Boxford 190 VMC
Drawing Datum
Dimensions on drawings are measured from the drawing datum. For convenience this can be placed at the bottom left-hand corner of the billet and given X and Y coordinates of zero. When a component is manufactured, the difference between the Y co-ordinates of the tool and drawing datums is entered and the software compensates for this difference. The 190 software also allows the use of circular billets. For these, the X and Y datum is usually at the bottom left hand corner of a square enclosing the billet.
Offsets
Each tools offset is the distance from the Underside of the Spindle Head to the tool end (bottom).
Underside of Head Tool Z Offset
Machine Z Datum
Total Height of Workpiece & Clamp Machine Table Top
Boxford 190 VMC
Auto tool changer
Tool rack (basic 190VMC) Spindle Carousel
To pressure gauge
Figure 3.2
Tool Storage
Boxford 190 VMC
3.3 Tool Storage (Figure 3.2)

Tool Rack (Figure 3.2) On the basic 190 VMC a tool rack is provided, as shown in Figure 3.2, to facilitate storage of up to 5 tool holders and associated cutting tools. It is advisable to store the tools in the same order as they will be called for in the machining program. Auto Tool Changer (Figure 3.2) Automatic tool changing equipment is supplied as an optional extra . A carousel facilitates storage of up to 5 tool holders and associated cutting tools. Each tool holder must be loaded into the correct carousel station so as to correspond with the machining program prior to cycle start, i.e.: Tool No.1 = Station No.1 Tool No.2 = Station No.2 The machine cycle start cannot be activated until the carousel has been indexed to Tool No. 1, the reference tool station. Manual Operation The auto tool changer is a pneumatic device requiring a compressed air supply of 80 lbf/in2. Ensure therefore that the system pressure gauge reads 80 lbf/in2 prior to operating the auto tool changer controls. Pressing the Tool Change button on the main control panel will direct the auto tool changer to remove the tool holder currently in the spindle, place it in the correct carousel station, index the carousel to the next station, secure the next tool holder into the spindle and retract. Note: When using the Tool Change button ensure that the spindle is at least 5mm below the upper Z+ limit of its travel. Programming the Auto Tool Changer The CNC code for a tool change is the same as for a standard machine. Using the M code M06 you must define the tool type e.g. type 2 (a slot drill), the diameter of the tool and the station number 1 5 in the carousel, for example: M06 Where I J F I2 = = = J6 F4 a slot drill diameter of 6mm station No. 4.
On completion of the part-program the machine will automatically change back to tool 1 allowing batch quantities to be machined.
Boxford 190 VMC
3.4 Tool Data Library and Catalogue

The 190 software provides a Tool Data Library which enables details of tooling and offsets to be entered and a tool catalogue from which tools can be selected for inclusion in the library. The library is set up by means of a tooling menu. Before attempting to set up the tooling for the first time, view the library, the tooling menu and the catalogue to become familiar with the details, as follows: 1. 2. Tool Data Library Switch on the PC, run the 190 Software. From the main menu, select MACHINE and then Tools. The screen shows the Tool Data Library, (Figure 3.3). Practice selecting tools using the mouse and keyboard.
1 Details of selected tool are highlighted. When the display first appears, the initial tool is highlighted. Other tools can be selected as shown below. 2 3 4 7 5 6
1. Tool number used by CNC program to select required tool 2. Tool type (selected from tool catalogue) 3. Tool station (carousel) 4. Tool description (selected from tool carousel)
5. Scroll buttons 6. Tool offset 7. Tool flute length
To select a tool: Using a mouse Click on the scroll buttons (6) to highlight the required tool. Using the keyboard Press Figure 3.3 or to highlight the required tool.
Tool Data Library
Boxford 190 VMC
Tooling Menu
3.
Select MENU to display the tooling menu:
The use of these options for setting and editing the Tool Data Library is detailed later in this section. Note: After setting up or editing the library, always select Save Tool data. Tool Catalogue 4. From the tooling menu, select Display Tools. The screen shows the tool catalogue, (Figure 3.4). Turn off the tool catalogue display to reveal the Tool Data Library.
Figure 3.4
Tool Catalogue
Boxford 190 VMC
3.5 Setting Up
Note: A billet of the appropriate size will be required for this procedure. In order to run the demonstration program, a 5mm slot drill and a 5mm end mill are required. To run the program, set up the slot drill as the initial tool and the end mill as the second tool in the following procedure. If you want to fit a different initial tool or second tool, substitute the tool details as appropriate.
Fit Initial Tool

1.
Fit the billet into the workholder, then fit the tooling as detailed below: Basic 190 VMC with Tool Rack Fit the 5mm slot drill into the tool holder and secure the tool holder into the spindle by operating the drawbar lever (Figure 3.1). If the spindle is too close to the work holding vice to allow the tool to be fitted then use the manual controls to move the spindle up until sufficiently clear. (See Section 12 - Manual Machining). 2. 190 VMC with Auto Tool Changer Fit the 5mm slot drill into the tool holder and secure the tool holder into the carousel as shown in Figure 3.5. Ensure that the spindle is in the correct Z+ position to facilitate auto tool changing. Press the TOOL CHANGE button on the control panel. The carousel will then traverse left to the spindle position, perform the actions of removing a tool holder from the spindle, index to the reference tool, load and secure the reference tool into the spindle, and retract. The reference tool is now fitted in the spindle.
Spindle Carousel Direction of rotation
Fit reference tool here
Figure 3.5
190 VMC with Auto Tool Changer - Reference Tool Position
Boxford 190 VMC
Configure Software
3. 4. 5.
Check that the POWER ON RESET button on the machine control panel is lit. Run the 190 Software. From the main menu select CONFIG and then Program. Set the required values and turn off the display. The screen shows:
6. 7.
Select YES Select CONFIG and then Hardware. Make the required settings, turn off the display, and save the settings. The screen shows the Main Menu. From the main menu, select MACHINE and then Tools to display the Tool Data Library. The settings for the 5mm slot drill will be highlighted, for example:
Set Initial Tool Offset
8.
Check the tool details (excluding the offset). If they are correct, continue at step 10 to set the offset. 9. To edit the tool details, select
MENU
and then Edit tool.
The screen shows the tool editing display, with the first item (Tool type) highlighted, (Figure 3.6). Edit the display to show the correct settings.
Boxford 190 VMC
1 2 3
1 2 3
To check tool type, press Escape or select Display tools to view tool catalogue. Diameter of slot drill is 5.00mm Offset for reference tool is zero.
QUIT
, then select
MENU
and
To edit tool details: Type required number in highlighted box Press Return to highlight next box When last box is highlighted, press Return: highlight will disappear Press Return or click on OK to turn off display
Figure 3.6
Tool Editing Display
Boxford 190 VMC
10.
Select
MENU
, and then Set Tool Offset. The screen shows:
If the touch-on point is to be the top of the billet, enter the height of the billet. If the touch-on point is to be the base of the workholder, enter zero. 11. If the Software detects the machine is in Manual Mode, the user is prompted to Cancel Manual Mode The window below is shown.
1. 2.
2.
The machine RESET button is pressed. a. The Z+ and Z- keys are pressed simultaneously (this axis must reach home position before step b. can be started. b. The X+ and X- keys are pressed simultaneously. c. The Y+ and Y- keys are pressed simultaneously ALTERNATIVELY, the F1 function key on the PC keyboard can be pressed. This automatically performs steps a, b and c.
Boxford 190 VMC
12.
When the axes reach the home position, the screen shows:
On the machine control panel, select Manual mode. Using the axis control buttons, touch the point of the tool on to the top of the billet. 13. When the tool is in the correct position, select again shows the Tool Data Library.
EOB
or press Return. The screen
If additional tool offsets are to be set, continue at step 14. If not, continue at step 15 to set the machine datum position.
Set Additional Tool Offsets
14.
To set the offset of the next tool, fit or index the tool and repeat the procedure from step 8. Note: For setting the offsets of the second and any subsequent tools, it will not be necessary to enter the height of the billet or to home the axes (steps 10 and 11). When the offsets of all the required tools have been set, either select MENU and then Save Tool Data, or click the 'off' button of the Tool Data Library display. If the 'off' button is clicked, the screen shows the message:
Click on
YES
or press Return to save the offsets.
Boxford 190 VMC
Set Machine Datum Position

15.
Note It is only necessary to set the datum position if the workholder position is changed or the Datum position (back, front, left, right) is changed There are now a number of additional Datum Position options. Datum Position - Select CONFIG and then Hardware. The window below is shown.
With the DATUM POSITION option highlighted, the options can be accessed and selected using ALTER. The datum position is:- a point on the machine table where the same corner of every workpiece locates to. e.g. On a VMC machine fitted with a standard Vice, the workpiece BACK face locates to the fixed rear vice jaw and the workpiece LEFT face locates to the vice end stop - hence the setting would be BACK LEFT The Datum Position is selected and the settings saved. From the main menu, select MACHINE and then Datum Position.
Boxford 190 VMC
16.
Select SETUP . The screen shows the Enter a Tool display:
17.
Select a tool for which the offset has been set, (for example tool no. 1), and select ACCEPT or press Return. If the Software detects the machine is in Manual Mode, the user is prompted to Cancel Manual Mode The window below is shown.
1. 2.
2.
The machine RESET button is pressed. a. The Z+ and Z- keys are pressed simultaneously (this axis must reach home position before step b. can be started. b. The X+ and X- keys are pressed simultaneously. c. The Y+ and Y- keys are pressed simultaneously ALTERNATIVELY, the F1 function key on the PC keyboard can be pressed. This automatically performs steps a, b and c.
Boxford 190 VMC
18.
When the axes reach the home position, the screen shows:
Measure the dimension (from the underside of the spindle head to the machine table top), and enter the value. (This establishes the Z axis datum). 19. Select OK or press Return twice. The screen shows:
Note: The Face of the billet to touch on will depend on the Datum Position setting in the Hardware configuration - see point 15 On the machine control panel, press MAN to select Manual mode. Use the axis control buttons to touch the side of the tool on to the left face of the billet. (This establishes the X axis datum; the software compensates for the radius of the tool). 20. When the tool is in the correct position, select ENTER or press Return. The message on the display now prompts you to touch on to the rear face of the workpiece with the selected tool. Using the axis control buttons, follow the instructions to establish the Y datum in the same way as for the X datum.
Boxford 190 VMC
21.
When the tool is in the correct position, select ENTER or press Return. The screen shows:
Click on
YES
or press Return to save the offsets.
The screen returns to the main menu.
3.6 DATUM SHIFT

Datum Shift is a new feature which allows the user to input a temporary shift of the Datum Position for individual components which cannot be located to the standard datum position. To activate this facility, CONFIG followed by Hardware is selected. The Datum Shift option is highlighted and ALTER followed by ON selected To define default values, Machine followed by Datum Position is selected. The window below is shown.
The default X and Y Datum Shift values are entered (the distance from the standard datum position to the temporary datum position). These can be left at 0.00 and defined when individual components are manufactured.
4 Main Front End Menu

When the Boxford CADCAM package is started, the Main Front End Menu screen below is shown. This menu is the central manager of the CADCAM tools within the Boxford VMC package.
G&M Program Import & Administration Functions Program Simulate, Manufacture and Machine Tool Driver
CAD and CAM Processor
Exit to Windows Desktop
Boxford 190 VMC
4.1 Main Front End Menu
In Standard User mode this menu accesses the G&M code program import filter. (See section 7.2) In Administration mode (See section 8) additional CAM processor data settings can be accessed and modified. Accesses the Integrated Computer Aided Design package (See section 5) and CAM processor (See section 6) Also used to access CAD package to import drawing files (See section 7). Accesses the G&M program Simulator, Editor, Writer and Machine Tool driver. All the configurations for connecting the VMC machine to the PC are set in this section of the package (See separate Installation & User Manual together with this manual).
Exits to the Windows desktop.
Boxford 190 VMC
CAD
5 CAD
5.1 CAD Window The CAD program window provides a clear view of the current drawing, various information areas, and a selection of icons with tools to cover the most common drawing, editing and display functions.
Allows the setting of line type, thickness and colour
Coordinate data entry box allows accurate positioning and drawing at any time
Simple prompts tell you what to do next
Toolbar help explains each icon
Relocatable drawing aids toolbox has a range of commonly used functions
Workpiece area Pull out sub-menu. Select a toolbox icon to reveal the menu
Shows the angle from the last point located or drawn
Relocatable draw/edit toolbox allows easy access to all the main draw/edit functions Absolute coordinates shows the position of the cursor relative to the workpiece datum (the bottom left hand corner)
Help message bar
Shows the distance from the last point located or drawn
Menu Selection
Menu items are normally chosen from the menu bar or the toolbox, using the mouse (although keyboard alternatives are available). To choose a menu item from the toolbox, position the pointer over the appropriate icon and click the LH mouse button. Some items such as Grid, will cause the icon to stay depressed until it is chosen again. Many of the items in the LH toolbox have pull out toolbars.
Boxford 190 VMC
5.1 CAD
These are activated by positioning the pointer on the icon then clicking the LH mouse button. The required icon can be selected from the icon menu bar. This will select the item, and change the icon in the toolbar to that chosen. Most menu items, e.g., text, colour fill, etc., have a related dialogue box for settings. To access these dialogue boxes, double click on the appropriate icon with the LH mouse button, or click on the icon with the RH mouse button. Initial Set-up 1. 2. 3. 4. Before starting to use the CAD system, a number of Initial Set-up steps must be completed. Select the Set-up menu and complete the following:UNITS - Specify Millimetres or Inches. More advanced settings for Angle units and co-ordinate display are also available. WORKPIECE - Specify the X (length) and Y (width) dimensions. GRID and STEP - Specify the X and Y spacing for the Grid and Steps. (The Grid is visible and the Steps are graduations between the Grid points). SET AS DEFAULT - If you want the CAD system to default to settings 1, 2 and 3 each time you start a new workpiece, then select this option.
Boxford 190 VMC
5.2 CAD
5.2 Drawing Aids

Drawing Aids The right hand toolbox contains a number of drawing aids which are active when selected (icon is dark grey). Grid Display - Toggles the grid display on and off. Redraw - Refreshes the screen. Grid Lock - Locks the cursor movement to the grid spacing. Step Lock - Locks the cursor movement to the step spacing. Attach - Attaches the cursor to various points. Set-up can be accessed by Right clicking on the Attach icon.:Radial Lock - Constrains cursor movement to pre-defined angle increments. Set-up can be accessed by Right clicking on the icon. Zoom In - Performs a quick and simple zoom in facility on the workpiece area currently in the centre of the screen. Zoom Out - Performs a quick and simple zoom out facility on the workpiece area currently in the centre of the screen. Undo/Redo Last -Toggles between undo and redo of the last function Advanced Zooms These functions are available from the Left Hand Toolbox. Zoom In - Zooms in on a user defined window. Zoom Last - Reverts to the last specified zoom. Zoom Sheet - Displays the complete workpiece at maximum zoom. Zoom All - Displays all drawn entities at maximum zoom. Zoom = - Zooms in by a user defined magnification factor
Boxford 190 VMC
5.3 CAD
5.3 Drawing Tools
Drawing Tools
The left hand toolbox contains a variety of drawing tools and are grouped by the type of entity they are used to define. To view the options within each group, LH Click on an icon to display the full selection of group icons. With all drawing tools that require points to be specified, these can either be defined with the mouse (using the grid) or by co-ordinate entry. To enter a co-ordinate, type the values in the co-ordinate data entry field (see section 5.1). These values can be Absolute (distance from the bottom left hand corner of the workpiece) or Incremental/Relative (distance from the last point). To toggle between Absolute and Incremental/Relative Modes, Select the Abs or Rel icon to the left of the data entry field. Prompts and help for each icon are displayed on the toolbars to aid the user. Single Line - Defines a single straight line - The Start and End point are specified. Connected Lines - Draws a series of connected lines - The initial Start Point and then the subsequent End Points are defined. To finish, either double click the LH mouse button (this will fix the moving line), or click the RH mouse button (this will finish at the last fixed point). Chamfer - Draws a chamfer between two lines - The chamfer X and Y dimensions are entered and the two lines to be chamfered selected. To define a number of different sized chamfers, RH click on the Icon to access the dimensions.
Co-ordinate Entry
Help and Prompts Straight Lines
Circles Circle - Draws a circle with a given Centre and Point - The circle centre and a point on the circumference are specified (Note:- the Distance readout is equivalent to the circle radius). Circle - Draws a circle with a given Centre and Radius - The circle Radius is entered and the centre specified. To define a number of different sized circles, RH click the Icon to access the radius value.
Boxford 190 VMC
5.3 CAD
Circle - Draws a circle through 2 points - The two points on the circle circumference and the centre point are specified. (Note:- the Distance readout is equivalent to the circle radius). Circle - Draws a circle through 2 points with given radius - The radius is entered, the 2 points on the circle circumference and the centre point position specified. To define a number of different sized circles, RH click the Icon to access the radius value. Note :- If two points are specified through which it is impossible for a circle of the specified radius to pass, the error message NOT POSSIBLE is displayed. Circle - Draws a circle through 3 points - The 3 points on the circle circumference are specified. Arcs Arc - Draws an arc with a given Centre, Start and End points - The centre, start and end points are specified. (Note:- the Distance readout is equivalent to the arc radius). Arc - Draws an arc through 2 points - 2 points on the arc and the centre point are specified. (Note:- the Distance readout is equivalent to the arc radius). Arc - Draws an arc through 2 points with a given radius - The radius is entered, Minor or Major arc type selected and 2 points on the arc specified. To define a number of different sized arcs, RH click the Icon to access the Radius and Major/Minorvalues. Note :- If two points are specified through which it is impossible for an arc of the specified radius to pass, the error message NOT POSSIBLE is displayed. Arc - Draws and arc through 3 points. - The 3 points on the arc are specified.
Boxford 190 VMC
5.3 CAD
Fillet - Draws a fillet between two lines - The radius dimension is entered and the two lines to be chamfered selected. To define a number of different sized fillets, RH click on the Icon to access the radius value. Ellipse Ellipse - Draws an ellipse - The centre and corner of the box surrounding the box is specified (see diagram below). Theoretical box surrounding ellipse Corner
+ Centre
Shapes Rectangle - Draws a horizontal rectangle - Opposite corners of the rectangle are specified. Rectangle - Draws a rectangle at any angle - Two points define the first side of the rectangle (and its angle). The third point determines the length or width of the rectangle. Triangle - Draws a triangle at any angle - The 3 points of the triangle are defined. Parallelogram - Draws a parallelogram at any angle - Two point define the first side of the parallelogram (and its angle). The third point determines the angle and length of the opposite sides.
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Polygon - Draws a regular polygon with a given centre and vertex - The number of sides is entered via the dialogue box below. The start angle can be entered at this point or defined later. Clockwise or Anti-clockwise orientation of the angle can be specified. The side length or Internal Radius or External Radius can also be specified
Internal Radius External Radius Side Length
+
Start Angle
OK is selected and the centre point specified. If necessary, the external radius is set by specifying a second point.
Polygon - Draws a regular polygon with a given internal radius and centre. The Start Angle can be entered at this point or defined later. Clockwise or Anticlockwise orientation of the angle can be specified. The Internal Radius is specified.
OK
is selected and the centre point specified.
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Beziers Open Bezier - Draws an open ended bezier curve - The initial Start Point and then the subsequent End Points are defined. To finish, either double click the LH mouse button (this will fix the moving bezier), or click the RH mouse button (this will finish at the last fixed point). Closed Bezier - Draws a closed bezier curve - The initial Start Point and then the subsequent End Points are defined. To finish, and close the path either double click the LH mouse button, or click the RH mouse button. Open Polyline - Draws an open polyline (series of connected straight lines). The initial Start Point and then the subsequent End Points are defined. To finish, either double click the LH mouse button, or click the RH mouse button. Note :- An Open Polyline differs from a series of connected straight lines because when complete the lines are part of a single object). Closed Polyline - Draws a closed polyline (series of connected straight lines. To finish, and close the path either double click the LH mouse button, or click the RH mouse button. Text Strings Text - Defines Linear Text strings - The start point is located bringing up the dialogue box shown below.
At the prompt the required text is typed and
Settings
selected.
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The dialogue box below is shown.
Font The font type can be selected from the list of all the True Type fonts available on the system. Font styles can also be selected. Size The font height can be selected (this is very easy to manipulate later - see Editing Objects in section 5.4 for further details). Alignment The alignment from the previously defined start position can be set to Left, Right or Cantered. Attributes The Line Type, Line Colour, Fill Type and Fill Colour can all be set. The default setting is filled text with a thin outline. The relevance of these settings with regard to machining is covered in section 5.6 (CAD Machining Considerations). Once all the settings are correct, select OK The previous input box is displayed. Select OK The text object appears on the workpiece.
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5.4 CAD
5.4 Editing Objects

Selecting Objects Select - Objects can be selected by :1. Dragging a box around the objects to be selected. 2. Selecting Individual Objects with the LH mouse button and subsequent objects (if required) with the RH mouse button (or SHIFT + LH button). Once an object or group of objects are selected, the selected objects are drawn in pink and surrounded by a dotted box (a marquee box) with handles. This is shown below. These handles provide quick edit functions. For more advanced features, see Transformations described later in this section.
Re-Size Mirror Horizontally Re-Size Re-Size
Re-Position (move) Re-Size Mirror Vertically Re-Size Rotate
Copy Re-Size Re-Size Re-Size
Re-Sizing LH mouse clicking any square handle around the outside of the marquee box allows the current selection to be re-sized. Clicking again redraws the selection to the new specification. Warning:- moving these handles alters the aspect ratio of the current selection. To resize whilst maintaining aspect ratio, select the square handles with the RH mouse button.
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Re-Positioning (Moving) Mirroring Rotating Copying
LH clicking on the central square handle allows the current selection to be moved. Clicking again redraws the selection in the new position. The diamond (rhombic) handles, to the top and left, mirror the current selection horizontally and vertically respectively. The circular handle to the right allows the current selection to be rotated. The double square handle at the bottom performs a quick copy and paste of the current selection, leaving the new object selected.
Editing Objects When a selection is made, a toolbox appears in the right hand corner of the CAD window. Selecting Start Edit greys the selection and provides a number of coloured edit handles as shown below.
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The convention of these handle colours depends on the object selected and are generally as follows. Line Circles Arcs Closed Polylines (including Shapes) Open Polylines Closed Bezier Curves Green = Start Node, Red = End Node - Each can be re-positioned. Red = Node on Circumference, Yellow = Centre Node - Each can be repositioned. Green = Start Node, Red = End Node, Yellow = Centre Node - Each can be repositioned. Red = Start and Finish Node, Orange = Intermediate Nodes - Each can be repositioned. Green = Start Node, Red = End Node, Orange = Intermediate Nodes - Each can be re-positioned. Red = Start and Finish Node, Orange = Intermediate Nodes, Yellow = Node Handles - Each can be re-positioned individually. Additionally, moving the yellow node handles with the RH mouse button locks the angle between them allowing them to move together Green = Start Node, Red = End Node, Orange = Intermediate Nodes, Yellow = Node Handles - Movement as per Closed Beziers. Yellow = Bottom left hand corner of imaginary rectangular box enclosing each individual character. - Each character can be re-positioned.
Open Bezier Curves Text
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Transforming Objects
Selected objects can be transformed using a variety of tools :Move/Copy - Moves, and/or copies the current selection. The user can opt to replace the current selection or create a user-defined number of repeats. A reference point (usually on the selected object) is located and then a new position for the reference point. An example of a repeat Move/Copy is shown below.
Mirror - Mirrors the current selection. The user can opt to replace the current selection or repeat it. Two defined points define the axis of reflection. An example of a repeat Mirror is shown below.
Rotate - Rotates the current selection. The user defines the angle of rotation and can opt to replace the current selection or create a user-defined number of repeats. An example of repeat Rotate is shown below.
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Rectangular Array - Produces a grid of selected object copies. The number of columns and rows and the X and Y spacing between them are specified. An example is shown below.
Circular Array - Produces rotated copies of selected objects. The angle of rotation and number of repeats are specified. The centre of rotation is defined. An example is shown below.
Distort - Distorts the currently selected objects. The user can opt to replace the current selection or create a user-defined number of repeats. The selected objects are surrounded by a greyed outline with 4 handles. Re-positioning the handles and clicking away from the selection will produce a distorted object which best fits the new handle positions. An example of a replaced distort is shown below.
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5.4 CAD
Deleting Objects
There are a number of ways to delete objects using either icons from the toolboxes or Hot Key combinations. Delete Last - Deletes objects one at a time in the order they were drawn (most recent first). Delete Any - Deletes individual entities - A hand pointer is provided to select the individual objects to be deleted. Delete Inside Box - Deletes entities within a user defined box (by dragging). Delete Part of Entity Between two nearest intersections - Automatically trims a line back to the nearest intersection. A hand pointer is provided to select the part of the entity to be deleted. An example of tool use is shown below.
Before After
Useful Delete Hot Keys Ctrl + Del - Deletes the current selection. Ctrl + Backspace - Deletes the last drawn entities. Alt + Del - Deletes all drawing entities.
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5.4 CAD
Setting/Editing Object Attributes
The attribute of an object (entity) defines the way it is machined. For details see section 5.6 (Machining Considerations). Object attributes can be set before they are drawn, or the current selection can be edited in the following way:-
Line Thickness
From the top of the CAD window select The dialogue box below is shown.
The user can define:Line Type - continuous, dotted, dashes etc. Line Pitch - the pitch of dotted and dashed lines Width - Either Fine or Thick (with a user defined thickness).
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5.4 CAD
Line Colour
From the top of the CAD window select The dialogue box below is shown.
Warning - Choose only colours from the custom Pallet (the reason for this is explained in Section 5.6) OK is selected. Text When a Text selection is made, a toolbox appears in the right hand corner of the CAD window. Selecting Property brings up the text input box. The Text string, Font, Effects, Line and Fill properties can all de redefined. See Text Strings in section 5.3 for more details.
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5.5 CAD
5.5 Area Filling

Area Filling One of the most important Tools to understand is colour filling as this largely dictates what is actually machined (see Section 5.6 for more details on machining considerations). Area - Fills areas between closed boundaries, accounting for islands. On selecting the area tool, the following dialogue box is shown.
is selected bringing up the colour selection dialogue box. Warning:As with line colour settings, choose only colours from the custom Pallet (the reason for this is explained in Section 5.6).
OK
is selected.
The user is prompted to:1. Locate on edge of boundary on side for hatch - This is the outer boundary of the fill. In the example shown below, if the area between the 2 circles is to be filled, the larger circle is the outer boundary. The boundary is located with the hand pointer.
Outer Boundary
Island
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2.
The user is asked if there are any islands within the outer boundary.
Looking at the example on the previous page, the smaller circle is an island within the larger circle.
YES
is selected and the Island located with the Hand Pointer.
The window above is shown again allowing further islands to be defined. In this example there are no more. NO is selected. The area is filled.
Outer Boundary
Filled Area
Island
Note:- If a number of filled areas are to be defined, the colour can be redefined by RH clicking the fill icon.
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5.5 CAD
Text Strings
Text strings can be filled by setting the fill attribute when the string is initially defined (see 5.3), or by selecting Property (see 5.4) when the string is selected. Text strings can also be islands within a closed outer boundary. In this case, some characters constitute more than one island as shown below.
Outer Boundary
Islands
If the 2nd Island was not specified, the fill would be as diagram b below instead of the required fill shown in diagram a.
a. Correct b.Incorrect
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5.6 CAD
5.6 Machining Considerations

Machining Considerations Sections 5.1 - 5.5 have concentrated on the drawing tools within the CAD system. Some important machining considerations relating to the drawing will now be discussed. Sixteen custom colours are available in the colour palette dialogue box. When the drawing is Post Processed into a G&M code CNC programme, each colour can be assigned a different depth. At the Design Stage, all the user must consider is that any objects required to be cut to a different depth, MUST be assigned a different colour (up to a maximum of 16 colours). Objects that are machined are :1. Lines with a width setting (not thin lines) 2. Filled Areas Lines Any line with a width setting (other than thin) will be followed with a Slot Drill of the equivalent diameter or the nearest one available from the Machine Tool Library (See section 8 for more details). Any areas filled with colour can be:a. b. c. Pocketed out with a variety of tools - (cutter diameter compensation is automatically implemented) Profiled - around the outside (e.g. for cutting out a shape). Profiled - around the inside (e.g. for leaving a cut-out of the shape in a sheet of material). Pocketed out with a variety of tools - or Drilled with a drilling cycle using a drill of the equivalent diameter or the nearest one available from the Machine Tool Library (See section 8).
Colours
Machined Objects
Filled Areas
Additionally filled circles can be:a. b.
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Problem Objects
With the large variety of drawing tools available, it is important to understand:a: b: What can and what can not be machined. What will be machined. Lines with a width narrower than the smallest diameter Slot Drill will not be machined. Filled Circles with a diameter smaller than the smallest diameter Drill Filled areas which have sections narrower than the Edging Tool (see section 8 for details of edging tool). This often happens when the pocket is the internal fill of some fonts as shown below. The circles within the text represent where the cutter diameter can machine up to.
What cant be machined
1. 2.
Notice the difference between what was drawn and what will be machined.
Drawn Text
Machined Text
Warning :- If you draw text too small none of it may be machined. Please remember you are cutting resistant materials and not merely dropping ink onto paper.
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5.6 CAD
What will be machined
As described in the previous section, the system will attempt to machine EVERY Line with a width setting and Filled Area. For this reason it is important that Islands are correctly defined. If a filled object (1) is on top of another filled object (2). object (2) will still be machined even though it cannot be seen on the screen. In the example below object (1) has been drawn on top of the solid filled (no Islands) object (2). If object (1) is to be machined to a depth less than object (2) then it will be machined away when object (2) is machined.
Overlaid Objects 1 1
Objects When Seperated
Machining Order
The objects will be machined on an individual basis working from the back of the drawing (i.e. the back object is machined first and the front object last). This can be useful if for instance an object is to be profiled (cut out) as the last operation.
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6.1 CAM Processor
6 CAM Processor
6.1 Settings
When the CAD drawing is complete and ready to be processed into a G&M code CNC programme, select File To Mill The user is required to enter a filename for the drawing (Please ensure this is no longer than 8 characters). The CAM Processor Dialogue box shown below is displayed.
The various settings are as follows:Material Selecting the drop down provides a list of the available material types. (See Section 8 - Administrator Mode for details on adding user defined materials and cut data.). The required material is selected from the list
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6.1 CAM Processor
Edging Tool and Area Tool
The drop down for these two tools is a list of the slot drills available in the Machine Tool Library. The Edging and Area tool are used to remove (pocket) all Colour Filled areas in the drawing. There function is as follows. Edging Tool - This tool performs the finish path around the pocket as shown with the circular object below
The edging tool is also used to profile around a colour which has been set to Outside or Inside (see DEPTHS later in this section). Area Tool - This (usually larger) tool is used to remove the bulk of material from filled areas as shown with the circular pocket below.
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6.1 CAM Processor
Warning
To ensure filled areas are correctly removed, it is strongly recommended that the ratio between the Edging Tool and The Area tool is 1:2 (e.g. 2mm Edging Tool & 4mm Area Tool). It is permissible to set the Area and Edging Tools to be the same diameter to avoid tool changes during manufacture. Experienced users can experiment with different combinations for different drawing applications.
Edging & Area Finish
Determines the Surface finish produced by the Edging and Area Tools. Smooth or Coarse is selected. The X (Length) and Y (Width) dimensions are transferred from the drawing. The user must specify the Z (height or thickness) dimension.
Block Size
Depths
The Colour Depth and Filled area settings are accessed by selecting The dialogue box below is shown.
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6.1 CAM Processor
For each colour used in the drawing (the others are ignored), the total required depth is entered. This can include decimal values (2 Decimal places in Metric and 3 Decimal places in imperial). There are 16 colours available which match the 16 custom colours in the CAD colour palette. Hence 16 different depths can be defined. Warning If the user defines a depth which can not be achieved by the current tools in the machine library, the user will be warned upon processing the drawing (see section 6.2 - Error Messages). To the left of each colour is a drop down menu. These settings affect ONLY COLOUR FILLED AREAS and not lines with a defined width. AREA Pockets out all areas with this colour fill with the Area and Edging tools as described earlier in this section (Edging Tool and Area Tool). Uses a drilling cycle to drill circles with a drill of equivalent diameter or the nearest one (always smaller) available from the machine tool library. The system will first look for a twist drill of appropriate diameter. If one is not available, it will look for a spot drill and then a slot drill. Only colours made up entirely of individually filled circles should be assigned as a DRILL colour.
DRILL
Warning
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6.1 CAM Processor
INSIDE
Profiles around the inside of colour filled pockets using the Edging Tool. Compensation for the diameter is automatically implemented. This can be particularly useful when cutting profiles out of thin sheet material. An example is shown below.
OUTSIDE
Profiles around the outside of colour filled pockets using the Edging Tool. Compensation for the diameter is automatically implemented. An example is shown below.
When all the Colour Depths and Area Setting are complete,
OK
is selected.
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6.1 CAM Processor
Processing
To process the Drawing and create a G&M CNC programme, selected. The message below is displayed
is
Selecting
YES
saves the CAM processor settings with the drawing.
The processor analyses the Drawing and produces a G&M code CNC programme specifying Cutter Paths, Speeds, Feeds and Cut Depths appropriate to the material type selected and the tooling available. The following message is displayed.
Factors Affecting Processing
There are a number of factors which will affect the processing time. 1. 2. 3. 4. Pocketing out complicated areas (particularly text strings) will increase processing time. Processing lines with a defined Width will be relatively quick. The higher specification the PC Computers Main Processor the quicker processing will be. If the user has accidentally specified an unusually deep pocket, processing time will be significantly increased. If you suspect a mistake, press the ESC key on the keyboard to abort processing.
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6.1 CAM Processor
Tool Path Simulation
When the drawing has been processed the following dialogue box will be displayed (Please note if processing reveals any errors this dialogue box will be proceeded by an error message dialogue box - see section 6.2 for details).
The user is prompted to select a Catalogue number to place the file into. Catalogues - All manufacture programs (G&M programs) are filed in Catalogues. There are 9 catalogues available to the user. A catalogue is selected. If a file of the same name already exists in the selected catalogue, the following dialogue box appears.
1 2 7 8 9
The file can be overwritten by selecting the following dialogue box.
YES
or
NO
can be selected bringing up
The filename can be changed and/or the catalogue changed.
OK
is selected.
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6.1 CAM Processor
A 2 Dimensional simulation of the cutter path is shown. This is the final user check of the component that will Actually Be Machined. Any areas which can not be removed because of tooling limitations will be omitted. (see section 5.6 for more details) Warning :- Please check this 2 Dimensional View very carefully.
3 Dimensional View
For details on 3D Views, View Manipulation and Cycle Details see sections 2 and 10.
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6.1 2 CAM Processor
6.2 CAM Processor Error Messages

When Processing a drawing, the CAM processor compares the drawing requirements with the Cutting Tools available. If any drawing requirements can not be satisfied, then an error message (or messages) is displayed. An example is shown below.
The user can continue processing by selecting A program with the compromised settings (safe) is produced. or The user can abort processing by selecting and reprocess the drawing using different settings. Error Messages There are a number of error messages which can be reported. Their description and causes are as follows:Cut Depth - The Cut Depth (Total - not cut per pass) will never exceed the Tool Length value defined in the tool library (see Section 8 for more details) e.g. 2.0mm slot drill is unable to cut deeper than 10.000mm Cutter Diameter - If a Tool from the Tool Library cannot match a line with defined width, or a drilled hole with defined diameter, the processor will choose the nearest smaller diameter tool. e.g. 8.0mm drill was not found, using 6.0mm instead If a line width or hole diameter less than the smallest tool are specified, the objects will not be machined. e.g. could not find a drill 1.5mm or less
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7.1 File Imports
7 File Imports
7.1 Drawing File Import
File Types The following drawing file types can be imported. 1 2 3 4 5 6 File Export Rules Design Tools Files (*.dtd) Acorn Draw Files (*.aff) Designer V3 COMMS Files (*.dv3) DXF Files (*.dxf) Enhanced Metafiles (*.emf) Windows Metafiles (*.wmf)
Which ever drawing package you export from, there are some guidelines which will help you to successfully export files suitable for importing into the Boxford CADCAM package. Drawing Size - Set the drawing size (or custom paper size) to the Workpiece size you intend to use. Drawing Origin - Set the drawing Origin to be the Bottom Left corner of the Drawing (paper) area.
Length
Width
Drawing Area (Paper Size)
Drawing Origin
Line Width - Unless you can accurately set line widths to a specified value, do not export lines with a width. Line width attributes can be set in the Boxford CADCAM package after importing. Filled Areas - DO NOT export any colour filled areas. Colour filled areas are assigned in the Boxford CADCAM package after importing. Dimension Lines - DO NOT export any Dimension Lines.
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7.1 File Imports
Importing Drawing Files
The CAD Icon is selected from the Boxford CADCAM package.
CAD Icon
Workpiece Size - The workpiece size is set-up to suit the file intended for import. (this should be equivalent to the Drawing Area/Paper Size used to create the original file).
File Import File is selected bringing up the dialogue box shown below. The file type is selected from the drop down menu.
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7.1 File Imports
The file to be imported is located and Import Filters 1 3 2 5 6
Open
selected
The various import filters have differing import options, described as follows: Design Tools Files (*.dtd) Opens a Techsoft 2D Design Tools File. Designer V3 COMMS Files (*.dv3) Opens the file automatically (no user settings are required). Acorn Draw Files (*.aff) Enhanced Metafiles (*.emf) Windows Metafiles (*.wmf) On opening any of these file types, the following dialogue box appears.
The options are:Centre In Window - Centres the imported drawing entities in the centre of the workpiece. Not selecting this option will maintain the relationship between the drawn entities and the origin.
Centre In Window
= =
=
Imported Entities Workpiece
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7.1 File Imports
Group - Loads the imported entities as a single grouped object. Scale - Scales the imported entities by a user defined value.
DXF Files (*.dxf) On opening a DXF file the following dialogue box appears.
The options are:Interpret Units and Position - Allows the import units to be specified and maintains the relationship between the drawn entities and the origin. The Units Interpretation and Position options are:Inch or mm - set to suit the file to be imported Centre in Window - Centres the imported drawing entities in the centre of the workpiece (see previous page for details) Scale - Scales the imported entities by a user defined value.
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Fit to Media - Scales the imported entities to fit the workpiece whilst maintaining the aspect ratio. The scaling factor is limited by the first axis the entities fill (X or Y). In the example below, the scaling is limited by the workpiece width (Y axis) and the entities centred along the length (X axis). Fit To Media
Length (X)
Width (Y)
Imported Entities
Workpiece
Load as Group - Loads the imported entities as a single grouped object Dimensioning preference - Ignore these options - DO NOT attempt to import dimensions. Processing Imported Files Once imported, individual entity attributes and colour filled areas can be specified as described in Section 5. The drawing is processed as normal, see Section 6 for details.
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7.1 2 File Imports
7.2 G&M Code Programme Import

The following procedure imports a G&M code program produced on a Third Party CADCAM package. From the main front end menu is selected followed by
From the File Open dialogue box, the file to be opened is selected. The dialogue box below is shown.
The user is prompted to select a Catalogue number to place the file into. All manufacture programs (G&M programs) are filed in Catalogues. There are 9 catalogues available to the user. A catalogue is selected. If a file of the same name already exists in the selected catalogue, the following dialogue box appears.
The file can be overwritten by selecting the following dialogue box.
YES
or
NO
can be selected bringing up
The filename can be changed and/or the catalogue changed.
OK
is selected.
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7.1 2 File Imports
A 2 Dimensional simulation of the cutter path is shown. This simulation does not have to be completed. Pressing the ESC key will stop the simulation and write the file to disc ready for manufacturing. Manufacture File Import Specification For details on Manufacturing see section 11. The required Import file specification is as per the following example.
G71 G101 X125.000 Y75.000 Z10.000 G00 X0.000 Y0.000 Z20.000 M05 M06 I2 J4 M03 S3000 G00 X61.875 Y38.403 Z2.000 G01 Z-1.000 F600.000 ... G01 X56.422 F600.000 G00 Z2.000 G00 Z20.000 G00 X0.000 Y0.000 M05 M06 I2 J2 M03 S3000 G00 X56.422 Y37.602 Z2.000 G00 X62.909 Y38.194 G01 Z-1.000 F600.000 ... G01 X62.909 Y38.194 F600.000 G00 Z2.000 G00 Z20.000 G00 X0.000 Y0.000 M05 M30
Further Details
Units Workpiece Size X, Y, Z Park Position Spindle Stop I=Tool Dia. J=Type Start Spindle S=RPM
Body of Program G00 and G01 Moves F=Feedrate
Tool Change
Body of Program G00 and G01 Moves F=Feedrate
Cycle End-make another
For specific post processor specifications please contact Boxford direct.
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Administration Mode
8 Administration Mode
8.1 Access & Password Setting
An administration mode is built into the Boxford CADCAM package allowing authorised personnel to access and modify important CAM processor data files and machine tool data files. Any modifications that are defined will be applied to every future processed drawing. Network Administrators Setting a Password To be able to use the Boxford administration mode and write to the relevant data files, you must have read/write access to the Public Drive With the Front End menu screen displayed, the F10 key is pressed, to define a password, or modify and existing one. The dialogue box below is shown.
is selected. The dialogue box below is shown.
The user is prompted to Enter CURRENT Password. If an initial password is to be defined,

OK
is selected.
OK
If an existing password is to be re-defined, the existing password is input and selected.
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8.1 Administration Mode
The dialogue box below is shown.
The user is prompted to Enter NEW Password The new Password is input OK selected followed by :Accessing Admin. Mode Each time the software is started, the system defaults to Standard User mode. With the Front End menu screen displayed, Administration mode is accessed by:a. b. c. d. Pressing the F10 key Selecting Inputting the current password and selecting Selecting
OK
Selecting the Configuration Icon reveals a number of icons in addition to the Standard User Import G&M file option (see section 7.2 for details).
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8.2 Tool Library

Accesses the tool library shown below.
New tools can be defined and existing Tools modified or removed. Defining a New Tool Using the LH mouse button or keyboard cursor, Highlight an empty tool library line. Select
Edit Tool
The dialogue below is shown.
From the Tool Type drop down, select the Tool type to be defined. Input the Tool Diameter and Length. The length is the maximum depth the Tool can cut to, and is usually the flute length as shown in the diagram opposite. Edit an existing Tool Remove an existing Tool Saving Highlight the tool to be edited and Select Highlight the tool and select
Remove Finish Edit Tool
Flute Length
To close and save the tool library data, select
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8.3 Material Cutting Data

Accesses the Material Cutting Data shown below. This data is used by the CAM processor when creating a G&M code CNC programme from a drawing.
For each Material Type, Cutting data can be specified for differing Tool types and Tool Size ranges. New materials can be added and existing ones Modified or Deleted. Tool Type Slot Drill, Spot Drill and Drill can be selected (Note:- these are the only tools used by the CAM processor).
Tool Size
The Tool sizes are grouped in a range of diameters. Cutting parameters can be set for each range.
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Material
The Cutting Data file supplied with the software package includes a selection of Default material types. User-defined materials can be added up to a maximum of six material types in total.
Adding a New Material Add Material is selected. The dialogue box below is shown.
The user is prompted to Enter material to add to list. The material name is input and
OK
selected.
Deleting an Existing Material The material to be deleted is selected using the Material drop down menu. Delete Material is selected. The dialogue box below is shown.
YES
is selected to confirm the material delete.
Feedrate Speed
The rate at which the axes move in mm/min. The spindle speed in Revolution Per Minute (RPM)
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Cut Depth/Pass
The depth of cut per pass of a pocket, slot or hole. Note:- this is not to be mistaken for the maximum achievable depth which is limited by the tool length (see Section 8.2). The surface finish settings. Two options are available - Smooth and Coarse. Flatness For each surface finish setting, a flatness value in microns can be set. The flatness value determines the finish around curved paths. As the flatness value increases curves (arcs) will visibly comprise of a number of straight lines as shown in the diagram below. Smooth Coarse
Process
Drawn Curve Machined Curve
Note: The Default values have been carefully chosen and should only be changed by experienced users. Restoring Defaults Saving
Restore Defaults
is selected to return All Cutting Data to the Factory settings

OK
To save the modified Cutting Data, select To exit without saving changes, select
Cancel
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8.4 Park Position and Units

Park Position Accesses the park position settings shown below.
The Park Position is the position of the Tool in relation to the workpiece datum (front left corner) at Tool Changes and the Start/End of Cycle. X, Y and Z values are specified. Restoring Defaults Restore Defaults is selected to restore the Factory settings. Saving To save the modified Cutting Data, select To exit without saving changes, select
OK
Cancel
Units
Accesses the units settings for Administration mode as shown below.
Metric or Imperial units are selected.
OK
saves the setting.
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8.5 CAM Processor Default Settings

CAM Default Settings Accesses the CAM Processor settings shown below.
These default settings are used with every NEW CAD Drawing created. The various parameters are set as described in section 6 of this manual. Selecting saves the default CAM settings.
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8.6 Language Settings

Language Settings Accesses the Language options for the software. Note:- This sets the language for the CAD and CAM software but not for the G&M Code CNC Programme Simulator and machine driver which has its own configuration menu. See Installation and User manual for details. The icon is selected displaying the dialogue box below.
From the drop down menu, the required language is specified.
OK
is selected to confirm the selection.
For the new setting to take effect, the software must now be restarted by exiting to the windows desktop and re-starting the software.
Boxford 190 VMC
Cutter Path CAM Programming
9 Cutter Path CAM Programming

9.1 Functions
The CAM programming features of the 190 Software provide the following functions:
New Programs
A new component is created by producing a cutter path on screen. When the cutter path is complete, it is processed by the software which converts it into a CNC program and saves the program. The appropriate G and M codes are included, and speeds and feeds are incorporated into the program automatically. Programs created in CAM format are presented in CNC format using absolute coordinates. Programs stored in a CAM or CNC catalogue can only be viewed and edited in CNC format.
Existing Programs
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9.2 Cutter Path CAM Programming
9.2 Information Required

To create a new CAM program you will need the following information: 1. Drawing with co-ordinates: For a rectangular billet, the work datum is the bottom left-hand corner of the billet; for a circular billet it is the bottom left-hand corner of a square enclosing the billet, (see Section 3, Figure 3.1). Dimensions along the X and Y axis should be marked from this datum as shown in the example in 9.4. Tools Used: Choose the appropriate tools for each machining operation, and set up the tooling as for CNC machining (see Section 11). Details of the Billet: Rectangular Billet Length (along X-axis) Width (along Y-axis) Total height (thickness) 4. Circular Billet Diameter Total height (thickness) Material (aluminium or plastic)
2.
3.
Material (steel, aluminium/brass, or plastic). Program Name: A name for your program (7 characters maximum - do not use spaces, . \ or / in the name) Configuration Settings: Decide on the required configuration settings for the hardware and software.
5.
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9.3 Defining a Component

Check configuration 1. From the main menu, select CONFIG - Program. Check the UNITS MODE setting and set GRID SNAP to the required degree of fineness. Turn OFF the display and save settings. From the main menu select PROGRAM - Cam, and from the catalogue select NEW PROGRAM. Input the program title, type of billet (rectangular or circular), billet dimensions, and material type, as for CNC programming. After inputting the program details select OK or press Return. The screen shows the Tool Data Library with a sub-menu listing the tools. Tool no. 1 is highlighted. For the example given in 9.4 , accept tool no. 1, which should be a 5mm end mill. To change the initial tool, select the required tool number from the pull-down menu. 4. Click on the highlighted tool details, or press Return; the screen shows the CAM display, (Figure 9.1). The display enables a component to be difined using straight lines, arcs, and pocket milling functions, superimposed on the outline of the billet (3). As each element of the component is added, the corresponding line of the program appears in the program display window (1), in CAM program format. LINE Straight lines (grooves) can be drawn using a mouse, the keyboard, or by manual input LINE option includes a Rapid function for of data, (see section 9.5). The moving the tool to the next cutting position. Arcs can be drawn using a mouse or by manual input of data, (see 9.6 below). Pocket functions comprise rectangular and circular pockets, slots, PCD drilling, dish milling and tapping by manual input of data, (see 9.7 below). This option provides the following functions: To be selected at the appropriate point in the program. Shows program title, billet dimensions, program length and tools used. Places billet dimensions on the billet outline (3). Superimposes a grid and the billet dimensions on the billet outline (3).
Input Program Details Select Initial Tool
2.
3.
CAM Display (Figure 9.1)
ARC POCKET OTHER Tool Change Program data Dimension bar Grid on
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1. 2. 3. 4. 5. 6.
Program display window Tool co-ordinates Billet outline (rectangular or circular) Initial tool position in X - Y plane Tool control buttons (X - Y plane) Tool depth indicator 1 2 5
3 4 6
END LINE ARC OTHER POCKET UNDO MENU
Saves program For manual input of straight line co-ordinates For manual input of arc co-ordinates See text For pocket milling functions (see text) Deletes last line of program See text
Figure 9.1
CAM Display
Boxford 190 VMC
Save program Compensation MENU Redraw Solid View Zoom and Unzoom
Saves the program (alternative to
END
option).
Makes automatic tool position correction for tool radius when machining profiles, (see 9.8 Profile Compensation). This option provides the following functions: Re-draws the component after changes have been made. Produces a 3D view of the workpiece. Enable a selected area of the workpiece to be viewed in greater detail. For further details, see Section 10 - CNC Programming, 10.8.3 Zoom Facility. It will be more convenient to work with the dimensions and grid superimposed on the billet. Select OTHER , then Dimension bar for dimensions only, Grid on for dimensions and grid. Note: Once selected, these items can only be removed from the display during program-ming, by selecting Redraw.
Show Dimensions and Grid
5.
Boxford 190 VMC
9.4 Example (Figure 9.2)

Figure 9.2 shows a drawing of a component composed of straight lines, an arc, a rectangular pocket and a single drilled hole.. The straight lines, arc and pocket are machined with a 5mm slot drill, and the single hole is drilled with a 5mm spot drill so that a tool change will be included in the program. It will be necessary to set up the spot drill and add it to the Tool Data Library, for example as follows: No. 2 Type 4 Tur 2 Description Spot drill Diameter 5.00 Offset as set
Create a new program as detailed in 9.3, and refer to 9.5, 9.6 and 9.7 for guidance in producing the component shown in Figure 9.2.
45
5 hole 5 deep 25
50 30
35,25
10 Rad 30
10
15 45 75 80 15mm thick Plastic 5 wide x 2 deep 5mm Slot Drill 5mm Spot Drill Tool change at: X 0, Y 0 Material: Slot: Tool used:
Figure 9.2
Example of Drawing for CAM Program
Boxford 190 VMC
9.5 Defining Straight Line Moves

Note: Besides machining straight lines, the 'straight line' functions are also used to move the tool to each new cutting position as detailed below.
Using a Mouse
Horizontal and vertical lines can be defined by clicking on the tool control buttons. Each line defined by this method will produce one line of the program. This method cannot be used for diagonal lines. Note: Do not use this method for the first line in the example, as the first line required is a diagonal line. The alternative method is to define the line using the cursor. In the example, the first line moves the tool to the starting point of the first straight line as shown:
tool control buttons
machining sequence
cross-hairs at starting point (45, 40)
initial tool position
Boxford 190 VMC
1. 2.
Move Tool to Starting Point Place the cursor at approximately the starting point of the first straight line. Press and hold down the left-hand mouse button; the cursor will be replaced by crosshairs which are connected to the initial tool position by a straight line which behaves like a rubber band. Holding down the mouse button, watch the program display and drag the cross-hairs to set the starting point of the first line in the correct position. The X and Y co-ordinates will change as the cross-hairs are moved; when they read X=45.00, Y=40.00, release the mouse button. The tool position will appear on the display as an empty circle since the tool depth is positive, i.e. the tool is above the surface of the billet; (note that the program display shows the Z co-ordinate as + 50.00):
3.
4.
5.
Set Depth of Cut The cutter depth for the straight line is 2mm. Place the cursor over the pointer on the tool depth indicator and drag the pointer downwards, watching the value of the Z coordinate in the program display.
Boxford 190 VMC
When the Z value is -2.00, release the mouse button. The circle representing the tool position will be filled in with a colour or tone matching that of the tool depth indicator. 6. Define Straight Lines Use the cursor to set the end point of the first straight line, in the same way as for the starting point. For the example, set the end point at X=15, Y=40. The first straight line will appear on the display:
7.
Repeat the procedure to define the second and third straight lines. There is no need to alter the tool depth (the Z co-ordinate) as all grooves are the same depth:
X=15, Y=10
X=75, Y=10
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To move the tool to the starting point of the first straight line in the example, it would be necessary to make a horizontal (X) and a vertical (Y) movement, adding two lines to the program. The tool depth cannot be altered using the keyboard directly.
Manual Input
1. 2.
Select
LINE
Move Tool to Starting Point To move the tool to the starting position of the first cut, select Rapid. The screen shows:
The co-ordinates of the initial tool position are shown. Edit the co-ordinates to show the starting point of the first straight line (X=45.00, Y=40.00), and click OK or press Return. 3. The display shows the tool position at the starting point of the first straight line.
Using the Keyboard
operate the corresponding tool control buttons to The arrow keys move the tool in horizontal and vertical lines.
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4.
Set Depth of Cut Select LINE - Z only. The screen shows:
Edit the display to show the required depth; (for the example, set 2.00). 5. 6. Click outside the display window or press Return. Define straight Lines The LINE option gives the choice of X only, Y only or Diagonal lines. Selecting X only or Y only produces a prompt for the end point of the line. Selecting Diagonal requires the X and Y co-ordinates of the end point of the line. For the example, select X only for the first line and set the value to 15. Repeat with Y only for the second line and X only for the third line.
Boxford 190 VMC
9.6 Defining Arcs

Using a Mouse (Automatic Arcs)
Arcs are defined by means of the right hand mouse button. As a reminder, select ARC and then Mouse Control - the screen shows the message:
Click OK or press Return. An arc is drawn in three stages as follows: 1. Set End Points Press and hold down the right hand mouse button, and drag the cross-hairs to the end point of the arc. Check the co-ordinates on the display. Adjust the position of the crosshairs until the co-ordinates are correct, and release the mouse button.
Drag to end point of arc (X=45, Y=40) then release button 'rubber band' Start of arc (X=75, Y=10) - end point of last straight line
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2.
Select Direction and Radius Move the cross-hairs away from the end point (1); the cross-hairs will be joined to the end point by a straight line. Swing the cross-hairs around the end point (2); the arc will switch from counterclockwise to clockwise, and the radius will vary as the cross-hairs are moved:
1
Counter clockwise arc
Clockwise arc
For the example, select a counterclockwise arc and set the radius at 30.00mm. Check the program display for the correct setting: N90 3. X=45.00 Y=40.00 Z=-2.00 RADIUS=30.00 Enter Setting When the setting is correct, click either mouse button. The arc will appear on the display:
If you make a mistake, select UNDO to erase the arc, and repeat the procedure.
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Manual Input
1.
Select ARC as required. The screen shows:
, and Clockwise arc (GO2) or Counterclockwise arc (GO3)
For the arc in the example, select Counterclockwise arc (GO3). 2.
Enter the radius of the arc. (For example, enter 30.00). The X and Y co-ordinates shown are those of the end point of the last line drawn (A). Enter the co-ordinates of the end point of the arc (B).
B
3. 4.
Press Return: the arc will appear on the display. If you make a mistake, select UNDO to erase the arc, and repeat the procedure. After completing the arc, raise the tool clear of the billet: Drag the pointer of the tool depth indicator upwards with the mouse, or select - Z only and set the Z co-ordinate to a positive value. LINE
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9.7 Pockets and PCD Drilling

9.7.1 Rectangular Pockets A rectangular pocket is defined by the X and Y co-ordinates of the centre, and the tool movements in the X - Y plane symmetrically about the centre:
X move
Y move
centre
The depth of cut (on the Z axis) must also be specified; the software automatically calculates the number of cuts required to produce the required depth. 1. 2. Move Tool to Centre of Rectangle Check that the tool is set clear of the billet. Move the tool to the centre of the rectangle; (if necessary refer to 10.5 to use the mouse, keyboard or manual input). For the example, set the tool at X=35, Y=25. 3. Define Rectangle Select POCKET - Rectangle. The screen shows:
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Type in each value in turn, pressing Return after each entry. For the example, set: X move = Y move = Z depth = 25.00 10.00 2.00
Note: The values can also be edited by clicking on the appropriate box and overtyping. 4. Click on OK or press Return. The display will simulate the machining of the pocket, with the appropriate number of cuts (which will be included in the program as parameter J):
9.7.2 1.
Circular Pockets A circular (ring-shaped) pocket is defined by the co-ordinates of the centre, and the inner and outer diameters of the circle:
inner diameter
outer diameter
centre
For a plain circular pocket, the inner diameter is set to zero. The depth of cut (on the Z axis) must also be specified; the software automatically calculates the number of cuts required to produce the required depth.
Boxford 190 VMC
2. 3.
Move Tool to Centre of Pocket Check that the tool is set clear of the billet and move the tool to the centre of the pocket. Define Circle Select POCKET - Circle. The screen shows:
Type in the values in the same way as for a rectangular billet. 4. Click on OK or press Return. The display will simulate the machining of the pocket with the appropriate number of cuts (which will be included in the program as parameter J). Slots A slot is defined by the starting point (the tool starting position), and the tool movement on the X and Y axes required to reach the end point: The depth of cut (on the Z axis) must also be specified; the software automatically calculates the number of cuts required to produce the required depth.
end point
9.7.3
Y move tool starting position
X move
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1.
Move Tool to Starting Position Check that the tool is set clear of the billet, and move the tool to the starting point of the slot in the same way as setting the tool at the centre of a rectangular or circular pocket. Define Slot Select POCKET - Slot. The screen shows:
2.
Type in the values in the same way as for a rectangular or circular pocket. 3. Click on OK or press Return. The display will simulate the machining of the slot with the appropriate number of cuts (which will be included in the program as parameter J).
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9.7.4
PCD Drilling Holes drilled on a PCD are defined by the centre of the PCD, the number of holes, and the X and Y tool movement required to position the tool at the first hole. This enables the radial orientation of the holes to be arranged as required. For example, a circle of four holes on a circle of 20mm diameter can be defined as follows: A
1st hole
B
Y=7.07 X=7.07
1st hole
X=0,Y=10
centre
20
centre
20
For the first hole in example B, the X and Y moves must first be calculated trigonometrically. The holes will be drilled in an anticlockwise sequence, starting with the first hole. The depth of hole (on the Z axis) must also be specified. 1. Move Tool to Centre of Circle Check that the tool is set clear of the billet, and move the tool to the centre of the circle in the same way as setting the tool at the centre of a rectangular or circular pocket.
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2.
Define Holes Select POCKET - PCD Holes. The screen shows:
Type in the values in the same way as for a rectangular or circular pocket. 3. 9.7.5 Click on OK or press Return. The display will simulate the drilling of the holes. Dish Milling A dish (flat-bottomed, bowl shaped depression) is defined by the co-ordinates of its centre point, its inner and outer diameters and its centre depth. The flat, centre region diameter is defined by the inner diameter input which must not be less than the tool diameter. The system automatically calculates the depth of each circular cut required.
Outer diameter
Dish depth
Inner flat section diameter
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1. 2. 3.
Move Tool to Centre of Dish Check that the correct tool is programmed and it is clear of billet surface. Move tool to centre of dish. Define Dish Select POCKET - Dish. The screen shows:-
Type in the three values required. 4. Click on OK or press Return. The display will simulate the machining of the dish with the appropriate number and depth of cuts (which will be included in the program as parameter J).
Boxford 190 VMC
9.8 Cutter Radius Compensation

The Compensation option enables profiles to be machined by defining the coordinates of the required profile, and automatically compensates for the radius of the cutter. Profiles may be external or internal, for example:
EXTERNAL PROFILE Billet INTERNAL PROFILE
Cutter
Machined slot
Co-ordinates
In the example, both profiles have the same co-ordinates. Profiles may be composed of straight lines and arcs. Two adjacent straight lines may be joined by a sharp corner or by an arc of radius equal to the cutter radius, depending on the change of direction of cutter movement:
sharp corner
radiused corner
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Invalid Profiles
The software will accept invalid profiles, but the resulting profile will be incorrect. For example, this profile is not valid because the cutter diameter is greater than the indentation in the profile:
10mm
8mm
Left and Right Compensation (Figure 9.3)
Compensation is defined as left or right in relation to the direction of cutter movement, and the cutter is displaced to left or right of the required profile by a distance equal to the cutter radius:
LEFT Compensation RIGHT Compensation
Profile
Profile
The selection of left or right compensation therefore depends on whether the profile is to be machined in a clockwise or anticlockwise direction, and whether an external or an internal profile is required, as shown in Figure 9.3.
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LEFT Compensation CLOCKWISE MACHINING
RIGHT Compensation
External profile
Internal profile ANTICLOCKWISE MACHINING
External profile
Internal profile
Figure 9.3
Direction of Compensation and Machining
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Start and End Point
When planning the machining of a profile, select a start and end point on a vertical or horizontal edge:
typical start and end points Billet
Profile
Tool parked position
Machining will then begin at the start and end point, traverse the profile in a clockwise or anticlockwise direction as required, and finish at the start and end point. Using a corner as a start and end point is not recommended as it may result in an incomplete profile or may cause the cutter to over-run the corner.
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Procedure
The procedure for applying the Compensation option is given below, using the following example, in which the start and end point has been placed on the left hand side and machining will be carried out in a clockwise direction:
Tool: 6mm slot drill Co-ordinates shown in the format: X, Y 80
20,40
60,40
50
20,25
External profile
20,10
60,10
Start and end point
Groove 3mm deep
To practice using the procedure, select PROGRAM and then Cam, and create a new program with the billet dimensions and tool details as shown.
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1. 2. 3.
Move Tool to Start and End Point Check that the tool is raised clear of the billet. Move the tool to the start and end point (X = 20, Y = 25). Define the Profile Select OTHER - Compensation. The screen shows:
4.
Select Left; (an external profile is required, and machining will be clockwise, so the cutter must be displaced to the left of the profile). The screen shows:
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5. 6. 7.
Type in the diameter of the tool (6.0mm), press Return to accept the setting, and click on OK or press Return. Lower the tool to the required depth (3.0mm). Program the profile in a clockwise direction, using the mouse or the option, and the co-ordinates shown in the example. Finish with the tool at the start and end point (X = 20, Y = 25). Note that the profile shown on the display is smaller than the required profile by an amount equal to the cutter radius.
LINE
8. 9.
Raise the tool clear of the billet. Cancel Compensation Select Compensation. The screen shows:
Click on
YES
or press Y or Return.
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The display now simulates machining with the applied tool displacement, showing the required profile and ending with the tool at the start and end point:
Boxford 190 VMC
9.9 Tool Changing

A tool change is incorporated into a program using the OTHER - Tool change option. For convenience in changing the tool during machining, it is usual to move the initial tool to the datum position; when CAM option is being used this is done automatically. In the example, the last machining operation ended with tool No.1 at the centre of the rectangular pocket. For the final operation (drilling the 5 hole with a 5mm spot drill), it is necessary to change the tool and move it to the correct position for drilling the hole:
tool change required to drill 5 hole
current tool position
The spot drill should be included in the Tool Data Library as Tool No.2, as detailed in 9.4 Example. 1. Move Tool to Datum Position Check that the tool is clear of the billet, and move it to the datum position (X=-5, Y=-5). Change Tool Select OTHER - Tool change. The screen will show the Tool data Library, with details of the current (initial) tool:
2.
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3.
Scroll the display (using the buttons or the keys) until the details of the required tool are shown. For the example, these should be:
No. 2 4. 5.
Type Description Diameter 4 Spot drill 5.00
Click on ACCEPT ; the screen will return to the CAM display. Move Tool to Starting Position Check that the tool is clear of the billet, and move the tool to the starting position. For the example, the position is X=75, Y=40. Program Machining Operation Program the machining operation as required. For the example, set the drill depth by means of the pointer of the tool depth indicator, - Z only option. or by using the LINE
6.
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9.10 Processing a Cutter Path

To process a Cutter Path: Select
END .
The screen shows the message:
To save the program, select
YES
or press Return.
The screen will briefly show the message: 'Saving file...', and will then show the Program display.
Boxford 190 VMC
9.11 Editing a CAM Program

If a program has not been saved, the UNDO option will enable the last line of the program to be deleted and amended. Further editing must be carried out in the CNC format as follows: If the program has not been saved, save the program and wait for the Program display to appear. If the program has been saved, select PROGRAM - Program and select the required program. Refer to Section 10 - CNC Programming, 10.11 - Editing a Program for further details.
Boxford 190 VMC
Manual Data Input CNC Programming
10 Manual Data Input CNC Programming

10.1
1.
Operations and Programming Sheets

Before commencement of programming the following points require consideration: Drawing Examine the drawing, choose a work datum and re-dimension from this datum if necessary, (see Section 3 - Axes and Tooling, 3.2 - Axes, Datums and Offsets).
2.
Machining Decide on the material from which the part is to be machined. Consider the machining operation and the sequence in which you think that these operations should be performed.
3.
Tooling Choose appropriate tools for each machining sequence.
4.
Work Holding Decide on the appropriate method, as it is important to avoid collisions of the tool with the workpiece.
5.
Programming Decide on incremental/absolute dimensions, feed mm/min, spindle speed rev/min. Use an operations sheet and a programming sheet to record your decisions. Blank sheets are included at the back of this manual for photocopying.
Boxford 190 VMC
10.2 Manual Data Input CNC Programming
10.2
Absolute and Incremental Co-ordinates

Co-ordinates are expressed as being either absolute or incremental.
1.
Absolute Co-ordinates In this system all co-ordinate locations are programmed from a fixed absolute zero point (datum).
1 1 6
2.
Incremental Co-ordinates In an incremental numerical control system each co-ordinate location is given in terms of distance and direction along rectangular axes from the previous position and not from a fixed datum.
1 1 5
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10.3
Calculating Speeds and Feeds
Speeds and Feeds

When writing a program the values for spindle speeds and feed rates have to be entered. With experience a programmer will use values which are known to produce the required balance between surface finish, tool wear and production time, but for the beginner the following notes of guidance are offered. These are only basic principles and the tool manufacturers catalogue should be consulted for specific information. The cutting speed for a material is the speed at which the cutting edge of the tool passes over the surface of the workpiece and is measured in metres per minutes. Typical values of surface cutting speeds are as follows:
Cutting Speed
SURFACE CUTTING SPEED (m/min)
Workpiece Material
Cutting Tool Material Carbide HSS Aluminium Alloy 250 120 Cast Iron 110 18 Mild Steel 180 28
Brass 180 75
The machine spindle speed can be calculated using the following formula: Spindle speed (rev/min) = 1000 x surface cutting speed (m/min) x cutter diameter (mm)
Boxford 190 VMC
Feed Rate
The feed rate in the X Y plane is the speed of traverse of the workpiece. In the Z plane it is the speed at which the tool is plunged into the work. It is determined by: feed rate (mm/min) = feed rate (mm/rev) x spindle speed (rev/min) With milling, two cutters of similar diameter may have different numbers of cutting edges, and so the feed rate (mm/rev) is determined from: feed rate (mm/rev) = feed rate (mm/tooth) x number of teeth Typical values for the feed rate (mm/tooth) are given below, but once again it is stressed that you use the values suggested by the tool manufacturer for the quality and type of tool which you are using.
FEED RATE (mm/tooth)
HSS
End mills and slot drills 0.2 0.15 0.2 0.14 Face and shell end mills 0.45 0.36 0.35 0.25 End mills and slot drills 0.25 0.15 0.25 0.2
Carbide
Face and shell end mills 0.55 0.35 0.5 0.4
Workpiece Material Aluminium Alloy Brass Cast Iron Mild Steel
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10.4
Program Format
A program is a series of 'blocks' or lines showing a set of functions and/or co-ordinates. Input of the program is usually in tabular form (although the CONFIG menu allows a change to compact form). A typical format for the 190 machine set up for milling is:
LINE G M X Y Z I J K F S
These are the headings used on the programming sheet, where LINE is the block or sequence number, and G the preparatory function M the miscellaneous function X the X co-ordinate Y the Y co-ordinate Z the Z co-ordinate I J interpolation parameter or additional information as needed the number of cuts required
K interpolation parameter or additional information as needed F feed rate (mm/min) S spindle speed (rev/min)
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10.5
Preparatory Functions (G Codes)

Note: The G codes can be displayed on the PC screen from the HELP menu. The address letter G is followed by two digits, and the following codes can be used: G00 G01 G02 G03 G04 G25 G26 G28 G40 G43 G44 G53 G57 G70 G71 G79 G81 G82 G83 G84 G85 G86 G87 G88 G89 G90 G91 Rapid movement (default value in absence of GO1) Linear interpolation Circular interpolation (clockwise) Circular interpolation (counter clockwise) Time dwell F = delay (secs) Jump to block Return from jump Mirror image Cutter compensation cancel Cutter compensation positive Cutter compensation negative Return to original datum Set new datum position Imperial units selected Metric units selected Point to point milling Drilling cycle Drilling cycle with dwell Drilling cycle with peck Tapping cycle Boring cycle P.C.D. drilling cycle Dish mill cycle Rectangle milling cycle Circle milling cycle Absolute programming selected Incremental programming selected
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10.6
Miscellaneous Functions (M Codes)

Note: The M codes can be displayed on the PC screen from the HELP menu. The address letter M is followed by two digits, and the following codes can be used: M01 M02 M03 M04 M05 M06 M08 M09 M30 M43 M44 M45 M99 Optional stop End of program (single quantity) Spindle start forward Spindle start reverse Spindle stop Tool change Coolant on Coolant off End of program (repeat) Subroutine Subroutine Subroutine Continuation code Entering M99 into the partially written program causes the program to be saved to disk. create terminate call
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10.7
Programming a Tool Change

The first cutter to be used enters the program as part of the initial programming information. The second and subsequent tools are entered in the program on two lines of information. The first line stops the spindle and moves the tool away from the work, the second line selects the next tool; a typical example of this is shown below:
LINE N120 N130 G M 05 06 X 0 Y 0 Z 25 2 6 I J F S
M06 I J
denotes a tool change gives the tool type is the tool diameter
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10.8 Inputting a New Program

10.8.1 Information Required To input a new program, you will need the following information: 1. A completed programming sheet containing Program details Type of co-ordinates used (absolute or incremental) Tools used Speeds and feeds Details of the billet Rectangular Billet: Length (along the X axis) Width (along the Y axis) Height (thickness) Material 3. 4. A name for your program (7 characters maximum - do not use spaces, . \ or / in the name). The type of format for the program display. The options are tabulated format and compact format. Tabulated format is easier to read and therefore more suitable for the earlier stages of programming. The programming sheets used in the Tutorials and Exercises use tabulated format. Compact format is more typical of the type of display used in industry, and is suitable for the more advanced programmer. The type of format can be changed by selecting CONFIG - Program from the main menu, and setting the DISPLAY TYPE to TABULATED or COMPACT as required. A program can be input and saved in either format, and can be displayed in either format by changing the DISPLAY TYPE. The main procedure (10.8.2 on the following page) deals with the use of tabulated format, and the example used is taken from Tutorial 2. Instructions for using compact format are given in 10.8.3. Circular Billet: Diameter Height (thickness) Material
2.
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5.
Other configuration settings required. The STANDOFF option automatically adds the depth of cut to a 2mm standoff (clearance between tool and workpiece) when using canned cycles. In MODAL PROGRAMMING, each of the following codes need only be typed once. Each code is then repeated automatically in subsequent lines until a different code is typed: G01 G02 G03 F : Linear interpolation : Circular interpolation (clockwise) : Circular interpolation (counter-clockwise) : Feedrate
These options can be activated by selecting CONFIG - Program from the main menu, and making the required settings.
Boxford 190 VMC
10.8.2
Tabulated Format Check Configuration
1.
From the main menu, select CONFIG - Program, and check the following settings: UNITS MODE PROGRAMMING MODE OUTPUT FORMAT GRID SNAP STANDOFF MODAL PROGRAMMING Input Program Details = as required (METRIC for Tutorial 2) = as required (ABSOLUTE for Tutorial 2) = TABULATED = as required = as required = as required
2.
From the main menu, select PROGRAM - Program, and from the catalogue select NEW PROGRAM. The following display will appear:
Type the name of the program (TUT2) and press Return. 3. Click on OK or press Return. The next display will appear:
Boxford 190 VMC
4.
Select the shape of billet to be used; (Click on the appropriate box, or type R for Rectangular, C for Circular). For Tutorial 2, select Rectangular. The next display will appear, prompting for the dimensions of the billet, and showing the dimensions of the last billet used: Rectangular billet:
If required, change the length by overtyping. When the correct value is shown, press Return; the next item (Width) will be highlighted. Set the remaining values and select the material in the same way. (A separate window shows the codes for material types). Circular billet:
Edit the diameter, height (maximum thickness) and material of the billet in the same way as for a rectangular billet.
Boxford 190 VMC
Note: The settings can also be edited by using the mouse or the values, and overtyping.
and
keys to highlight the required
If you enter a dimension which is too large, the screen shows an error message, for example:
Click on OK, or press O or Return to return to the previous display to edit the dimensions. Select Initial Tool 5. Click on OK or press Return. The screen shows the Tool Data Library with a submenu listing the tools. Details of tool no. 1 are highlighted:
Highlight the first tool to be used in the machining sequence; (For Tutorial 2, select Tool 1).
Boxford 190 VMC
5 1. 2. Text cursor * indicates that program has changed since it was last saved - save again if required. ! indicates that program has changed since simulation was last drawn select VIEW - Redraw to update display. 3. 4. 5. UNDO VIEW Simulation display Tool depth indicator (pointer shows depth of cut) Tool position Deletes last line entered. Redraw Solid view Zoom Unzoom - updates simulation display to include latest program changes. - changes simulation display to 3D view. - for viewing areas of billet in greater detail (see text - ZOOM facility).
HELP MENU
Displays information for reference during programming (see text). Options for saving and editing programs (see text).
Figure 10.1
Program WRITE Display
Boxford 190 VMC
Input Program 6. Click outside the Tool Data Library display or press Return. The screen shows the Program WRITE display, (Figure 10.1). The first line number (block number) N10 appears automatically at the left of the display, and the text cursor is in the G column. When typing in the program, precede each item with the letter at the top of the corresponding column. The cursor will move automatically to the appropriate column when the letter is typed in. Type in the first line of the program. For example, the first line of the program for TUT 2 is: LINE G N10 90 Type: G90 As the code number is typed, a message appears giving the meaning of the code. (Other messages give indications of errors such as incorrect speed feeds). When the line is complete, press Return. The next line number appears automatically and the cursor moves to the G column in the next line. Type the second line of the program. For TUT 2 the second line is: LINE G N20 71 Type: G71 (Return). Type the third line. The third line of TUT 2 is: LINE X Y Z N30 0 0 25 Type X0 Y0 Z25 (Return). The cursor moves automatically to the X, Y and Z columns. When Return is pressed the next line number appears and the cursor moves to the G column.
Boxford 190 VMC
Continue to input the whole of the Tutorial 2 program. CAUTION REMEMBER TO SAVE YOUR PROGRAM BEFORE SWITCHING OFF THE PC, EVEN IF IT IS NOT COMPLETE. (SEE 10.9 SAVING A PROGRAM). Correcting Errors You can place the text cursor anywhere in the program, and correct errors by overtyping or by deleting characters with the Backspace (Delete) key and re-typing. Using a Mouse Click on the required item in the program to place the text cursor at that position. Using the Keyboard
Although the display shows only three lines of the program, you can scroll the program to show any line by using the and keys.
For more extensive changes, use the editing facilities available from the MENU option, (see 10.11 Editing a Program). HELP HELP provides the following information which you may need to refer to when creating a program: G Codes M Codes Program Data meanings meanings Title Workpiece dimensions Material Program length (no. of lines) Estimated manufacture time Tools used
MENU
The features available from the MENU option are used for saving a program (see 10.9) and editing a program (see 10.11).
Use the and keys to move the text cursor vertically, and the keys to move from column to column.
and
Boxford 190 VMC
10.8.3
ZOOM Facility
The Zoom and Unzoom options on the VIEW menu enable a selected area of the billet to be enlarged and viewed, and the view then to be restored to normal size. To use the facility, select VIEW - Zoom; the screen shows the Zoom display, (Figure 10.2). The required area of the billet is defined by the selecting frame (8) which can be reduced in size (and its aspect ratio altered), and moved to the required position on the billet. To demonstrate the Zoom facility using Tutorial 2, input lines N10 - N80 of the program. This will produce the first of the two L-shaped grooves which can then be enlarged and viewed as shown in the examples below. To use the facility, first reduce the selecting frame to the required size, then move it into position as indicated: There are two methods of reducing the frame: For a quick reduction, select REDUCE as many times as necessary to give the required size. (This method gives no control over the aspect ratio of the frame). To increase the size of the frame, select ENLARGE as many times as necessary. To restore the frame to full size, select RESET . For accurate sizing, use the horizontal and vertical control bars to reduce the height and width of the frame (in any order) as follows:
Reduce Selecting Frame
Boxford 190 VMC
1. Left arrow 2. Slider 3. Right arrow 7. Billet 8. Selecting frame-(full size) 9. Reduced selecting frame REDUCE ENLARGE RESET ACCEPT Horizontal control bar
4. Up arrow 5. Slider 6. Down arrow Vertical control bar
Reduces size of selecting frame Enlarges selecting frame Restores selecting frame to full size Returns to program WRITE display, showing selected area
Figure 10.2
ZOOM Display
Boxford 190 VMC
1.
Reduce height
Using a Mouse Click on 6 or drag slider 5 downwards. Using the Keyboard Press If you reduce the height by too much, select 2. Reduce width
RESET
and repeat the operation.
2 3
Using a Mouse Click on 3 or drag slider 2 to the right. Using the Keyboard Press
RESET
If you reduce the width by too much, select width reduction.
and repeat the height and
Boxford 190 VMC
Position Selecting Frame
3.
Set Vertical Position
Using a Mouse Click on 4 or drag slider 5 upwards. (If you overshoot the required position, click on 6 or drag the slider 5 downwards). Using the Keyboard Press 4. . (If you overshoot the position, press ).
Set Horizontal Position

1
2 3
Using a Mouse
Click on 1 or drag slider 2 to the left. (If you overshoot the required position, click on 3 or drag the slider to the right). Using the Keyboard
Press
. (If you overshoot the position, press ).
Boxford 190 VMC
View Reduced Area
5.
When the size and position of the reducing frame are correct, select ACCEPT . The screen will return to the Program Display, showing the selected area of the billet. The horizontal and vertical scales will show the co-ordinates of the corners of the selected area. For a 3D view of the selected area, select appear.
VIEW
6.
- Solid view. A 3D view will
To turn off the 3D view, click outside the 3D view window or press Return. 7. To enlarge an area of the billet still further, select
ZOOM
- Zoom again. - Unzoom.
Restore Original View
8. 10.8.4
To restore the view to show the complete billet, select Compact format
VIEW
To input a program in compact format, first check the software configuration as for tabulated format but set the DISPLAY TYPE to COMPACT. Input the program information in the same way as for tabulated format. Select Continue; the screen will return to the Program Write Display. When the Program WRITE display appears, the panel where the program is input looks like this:
Compare this with Figure 10.1. The line number and the text cursor appear, but there are no columns with identifying letters. When typing in the program, precede each item with the letter at the top of the corresponding column on the programming sheet. There is no need to leave spaces between items in the line. When each line is complete, press Return. The next line number appears automatically and the cursor moves to the first (G) column in the same way as for tabulated format.
Boxford 190 VMC
In addition, spaces are automatically inserted between items, and numerical values standardised to show two decimal places. For example, in lines 30, 40 and 50 of Tutorial 1 (TUT 1): Line 30 type: X0YOZ25 Return 40 type: M03S1500 Return 50 type: X15Y15Z2 Return N30 N40 N50 X0 Y0 Z25.00 M30 S1500 X15.00 Y15.00 Z2.00
Display shows:
Error correction, and the other features of the Program WRITE display are the same as for tabulated format.
Boxford 190 VMC
10.9 Saving a Program

The last line of a program must consist of one of the following codes: M99 - if the program is unfinished M02 - for single part manufacture M30 - for multiple part manufacture Note: If you try to save a program which does not end with one of these codes, the software automatically adds the code M99 to the end of the program. There are three ways to save a program: a) b) At the last line of the program type M99, M02 or M30 as required and press Return; the program will automatically be saved. (This is the recommended method). from the MENU option, select Save program. The display will show the message:
Click on OK or press Return; the program will be saved with code M99 added at the last line.
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c)
Using a Mouse Click on the 'off' button at the top left hand side of the display:
Using the Keyboard Press

ESC
The display will show the message:
Click on YES the last line.
or press Return; the program will be saved with code M99 added at
Boxford 190 VMC
10.10 Examining an Existing Program

10.10.1 PROGRAM Display From the main menu select PROGRAM - Program, and from the catalogue select the required program. The screen shows the following display with a drawing of the component beneath it:
ZOOM VIEW INFO MENU Display Edit Continue 2D Simulate 3D Simulate Initial Tool -
see 10.10.2 below see Section 2 - Running the Demonstration Program see 10.11 - Editing a Program see 10.12 - Continuing a Program see 10.10.3 below see 10.11 - Editing a Program
Boxford 190 VMC
10.10.2
ZOOM and VIEW Facility The ZOOM option enables a selected area of the billet to be enlarged and viewed in 3D. The VIEW option provides a sectioned view in 3D, at any selected point in the billet. These two options can be used independently, or together to provide a sectioned view of a reduced area of the billet. To demonstrate these options using Tutorial 2, input lines N10 - N80 of the program. This will produce the first of the two L-shaped grooves which can be manipulated as shown in the examples below.
ZOOM 1.
Select Required Area of Billet Select ZOOM . This will produce a ZOOM display similar to that shown in Section 10, Figure 10.2. If necessary, refer to Section 10, 10.8.3 - Zoom Facility to use the horizontal and vertical control bars for selecting the required area of the billet. When you have defined the required area, select ACCEPT . After a pause, the screen will show:
2.
Control buttons
Boxford 190 VMC
Manipulate View
3.
Manipulate the view as follows: Using a Mouse

Increase size Rotate clockwise Decrease size Rotate anticlockwise Restore original view
Using the Keyboard

Increase size
Rotate clockwise Decrease size
Rotate anticlockwise
HOME
Restore original view
To produce a sectioned view, see To simulate machining, select
VIEW
below. - Unzoom.
To return to the full-size 3D view of the billet, select ZOOM

MENU
and then the required option (2D or 3D).
To restore the 2D view of the billet, close down the Program display (click on the 'off' button or press Return), and re-select the program from the PROGRAM option of the main menu.
Boxford 190 VMC
VIEW 4.
Produce Sectioned View Select

VIEW
- Slice. The screen shows:
The Coarse option will advance through the billet in a large step; the Fine option will advance in a small step. Select Coarse or Fine repeatedly to display the required section:
Using a Mouse Click on Coarse or Fine as required Using the Keyboard Highlight Coarse or Fine as required, and press Return.
Boxford 190 VMC
To advance the view automatically through the billet, select Exit or press Return. To return to the 2D view of the billet (with the full billet displayed in 3D), close down the Program display (click on the 'off' button or press Return), and re-select the program from the PROGRAM option of the main menu. 10.10.3 Simulation of Machining A guide to using the 2D Simulate and 3D Simulate options is given in Section 2 Running the Demonstration Program. In addition, each of these options provides a Zoom and Unzoom facility, enabling the machining of a selected area of the billet to be examined more closely. These options operate in a similar way to the ZOOM facility detailed in 10.10.2 above.
Boxford 190 VMC
10.11 Editing a Program

A new program which has been partly written can be edited, and an existing program can be edited, by using the MENU editing options described in 10.11.3 below. To access the options, refer to 10.11.1 New Programs or 10.11.2 Existing Programs as appropriate. 10.11.1 10.11.2 New Programs From the program WRITE display (Figure 10.1), select
MENU
Existing Programs Refer to 10.10 Examining an Existing Program, and select MENU - Edit. The screen shows the Program EDIT display:
1 Scrolling Buttons* 2 3 4
Scrolling Page down Line down Line up Page up
*Mouse Operation 1 2 3 4
Keyboard Operation Page Down
Page Up
Boxford 190 VMC
Amendments to the program can be made in the same way as detailed in 10.8.2 Tabulated Format - Input Program. Using a mouse, the text cursor can be moved to the required line by means of the scrolling buttons as indicated. To access the editing options, select 10.11.3 MENU Editing Options
MENU
Insert Line Inserts an additional line, and renumbers subsequent lines. Place the text cursor on the line above the required new line and press Return. Clear Line Deletes program data from a line, but leaves the line number intact. Place the text cursor on the required line and press Return. The prompt: "ARE YOU SURE? YES/ NO' provides a safeguard against accidental deletion. Go to Line Places the text cursor on a specified line:
Type in the required line number and press Return.
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Find and Replace Searches for a specific program item and enables it to be replaced by another specific item:
For example, to find all occurrences of code M03 (spindle start - reverse) and replace them with code M04 (spindle start - forward), starting the search from line 90 of the program, type in the following: Find Replace with Start line no. SELECTIVE Search A selective search will stop at each occurrence of the code, with a message such as: M03 M04 90 Return Return Return
To change the code to the replacement code and search for the next occurrence, select REPLACE. To leave the code unchanged and search for the next occurrence, select CONTINUE. At the end of the search a report will be displayed; for example:
Boxford 190 VMC
Click on OK or press Return. GLOBAL Search A global search will find each occurrence of the code and replace it with the replacement code. At the end of the search a report will be displayed as for a selective search. Header Edit Enables the name (title) of the program, and the dimensions of the billet (bar) to be changed. (Refer to 10.8.2 Tabulated Format - Input Program Information).
Boxford 190 VMC
10.11.4
Changing the Initial Tool The initial tool used by a program can be changed, and the new tool data saved, as follows:
1. 2.
From the main menu select PROGRAM - Program, and from the catalogue select the required program. From the Program display, select message:
MENU
- Initial tool. The screen will show the
3.
Select YES or press Return. The screen will show the Tool Data Library and a submenu listing the tool numbers. Select the required initial tool from the sub-menu. The screen will show the message:
4.
Select YES or press Return. The screen will briefly show the message 'Saving file.....', and the new tool data will be included in the program. To check the new tool details, select the program from the catalogue, and select from the program display. INFO
Boxford 190 VMC
10.12 Continuing a Program

An incomplete program which has been saved can be continued at the point where inputting was interrupted. Refer to 10.10 Examining an Existing Program, and select MENU - Continue. The display will simulate the completed part of the program in 2D, stopping when the last line is reached. The M99 code will be deleted from the last line of the program, enabling inputting to be continued.
Boxford 190 VMC
11.2 CNC and CAM Machining
11 CNC and CAM Machining

The procedure for machining a component produced by a CNC program or a CAM program is the same. The 190 software executes a CNC program to manufacture the component; CAM programs are converted to CNC format when they are saved, (see Section 9.10 - Processing a Cutter Path).
11.1 Initial Checks

Before attempting to machine a component, check: Reference 1. PC connected to190VMC machine, power switched on and 190 software running. 190 software correctly configured. Tooling and offsets for required program set and checked. Program verified by simulation 190 machine initialised. (Select MACHINE - Reset Machine if necessary). Billet of correct material and dimensions fitted in vice. Select PROGRAM - Program, then select the required program from the catalogue Select to check billet dimensions). INFO Guards closed Machine in Automatic mode. (Press MAN button on machine control panel) Installation and User Manual, Section 5, 5.1 Installation and User Manual, Section 5, 5.5 Section 3 Section 5
2. 3. 4. 5.
6.
7. 8.
Boxford 190 VMC
11.2 Manufacture
1. 2. From the main menu, select MACHINE, then Manufacture. The screen shows the MANUFACTURE CATALOGUE display. Select the required program. The software will read the machine file for the component, and the screen will then show:
1. 2.
2.
The machine RESET button is pressed. a. The Z+ and Z- keys are pressed simultaneously (this axis must reach home position before step b. can be started. b. The X+ and X- keys are pressed simultaneously. c. The Y+ and Y- keys are pressed simultaneously ALTERNATIVELY, the F1 function key on the PC keyboard can be pressed. This automatically performs steps a, b and c. The user is prompted to fit a workpiece of the required size. Please ensure the workpiece is to the correct dimensions. If the Datum Shift option is set to ON, the window below will be shown.
The default values will be automatically defined. The user can modify the values to suit. Setting the X Y values to 0.00 will use the standard datum position.
Boxford 190 VMC
3.
When the axes reach the home position, the screen below is shown:
Fit a workpiece of requested size. 4. Click on OK or press Return twice. The screen shows the message:
Enter the measured height from the machine table top to the workpiece top.
Boxford 190 VMC
5.
Select OK or press Return. The screen shows:
6.
Press CYCLE START on the machine control panel. The screen shows the Manufacture display together with a 2D simulation of the component. The display also gives a continuous indication of axis displacement and the line of the program being executed. If a tool change is required, the program will pause and an appropriate prompt will be displayed. Change the tool and select OK or Return to continue machining.
Boxford 190 VMC
7.
When the machining cycle is complete, if the program ends with the code M30 the screen shows:
8.
Select Yes or No as required. If Yes is selected, the screen will prompt for another billet to be fitted. If No is selected, the screen returns to the main menu.
Boxford 190 VMC
11.3 Options During Machining

Pressing ESC on keyboard during a machining cycle causes a Status message to be displayed:
Continue: Abort:
Programmed machining continues. Stops machining and cancels program.
Select option by clicking on appropriate button using the mouse or by pressing its first letter on the keyboard.
12 Manual Machining
The manual machining feature enables the 190 machine to be controlled from the machine control panel whilst the PC screen simultaneously displays axis displacement and spindle speed. 1. 2. 3. Selecting Manual Mode On the machine control panel ensure that MAN MODE is selected. On the PC select MACHINE from the main menu. Select Manual Mode from the sub-menu. The screen shows the Manual Mode display:
Using the Control Panel Pressing of the JOG TABLE buttons will move the table and produce corresponding X axis and Y axis displacements to be displayed on the PC screen. Pressing of the JOG HEAD buttons will move the head and produce corresponding Z axis displacements to be displayed on the PC screen. Operation of the SPINDLE controls will vary the direction of rotation and the speed of the spindle, and produce corresponding speed indication to be displayed on the PC screen. Zeroing Tool Displacement The X ZERO Y ZERO and Z ZERO buttons on the screen display enable the indicated tool displacement in any axis to be zeroed, so that the tool can be moved in relation to a selected datum. 1. 2. To use this facility: Set the tool in the required position in relation to the workpiece. Click on the appropriate ZERO button or buttons to zero the displacement value.
Boxford 190 VMC
Robotic Interfacing
13 Robotic Interfacing
13.1 Principles of Interfacing
The interface of Boxford machines into Cim Cells is quite simple although several things have to be taken into consideration. The following document outlines the way to connect, program and operate the Boxford machines within a Cim. When a robot port is fitted to a Boxford machine, a 37 way D connector is fitted to the rear of the machine. The pin out and circuitry is described later. The Robot interface provides all the inputs and outputs that would normally be required to connect to a cim, some of which will not be used in a basic system. If additional functions are required it would normally be possible to customise the port after consulting with the Boxford Design Department.
13.2 Hardware and Software Requirements

Hardware
The computer being used to run the machine must have 2 com ports and if a mouse is fitted it must be a bus mouse. In the case of the 8 machines the 2nd com port is fitted to the rear of the machine as standard. If a management system is being used to transmit programs to the machine tool then it must have an RS232 port available and assigned to Com1 or Com2.
Software
When using a machine within a Cim Cell then the configuration of the Boxford software must be set to say the FMS (Flexible Manufacturing System) is connected. The Fixture Height also needs to be input in the Machine Datums information. The reasons for the above are as follows: When the FMS is set to Connected in the configuration. the function of the M30 command changes. At the end of manufacture the machine will no longer run through the prompts asking if you wish to make another, alter offsets or alter datums, the prompt Press Cycle Start to continue appears. This allows the Robot controller to issue a Cycle start without user intervention. In addition to this when a program is designed in cam the machine busy flag (M81) is automatically set and unset in the program.
Boxford 190 VMC
13.3 Robotic Interfacing
13.3 Modes of Operation

There are two ways to run a program within a Cim, one is with for a system with a Master Control Computer the other for a simple machine / Robot combination. 1. If the system is simple then the machine can be set up manually then started with an external cycle start signal, at the end of manufacture the prompt make another appears. The robot can then issue a cycle start signal to make another or if a different component is to be made then the user must intervene and re set-up the machine for the next part. For a more complex system the program is downloaded from a master control computer, the cycle is started using the Go in Auto signal. The whole cycle will now run through with no user set-up required. To make another the Go in Auto is resent. If a different program is to be made then the new program is sent to the machine by the RS232 link then the Go in Auto start the new program again with no user intervention. IMPORTANT! When using the go in auto command it is very important that the following things are done. If not a collision could occur. 1. 2. The Fixture Height has been set in the Machine Datum menu. The component block details have been correctly specified when writing the program (the Block size and material type must be exactly the same as the component to be manufactured The Block is exactly the size specified in the program. The block is correctly positioned in the machine vice. The Go in Auto command uses the program header to get the block information, by so doing the need to make measurements at the start of manufacture is not required.
2.
3. 4.
Boxford 190 VMC
13.4 Programming Requirements

The machine busy signal is created in the G and M code program, an M81 command with I set to 1 indicates that the machine is busy or in cycle, If I is set to O then it indicates the machine is not busy. If a program is created in the Cam and the configuration is set to FMS connected, then the M81 commands will automatically be inserted. If the program is created using Manual Data Input, then the M81 will have to be inserted manually.
Notes
1.
After issuing a Cycle Start or Go in Auto there will be a delay before the busy flag is set. After the program is finished the busy flag will switch off there will again be a period of time after the program is finished, as the machine moves to its park position, when the machine is moving but the flag is off. The controller program must take account these delays when deciding when to service the machine. Typically the Cycle start signal or Go in Auto will be latched until the busy flag is set. After the Busy flag switches off there should be typically a 5 second delay prior to the robot servicing the machine.
2. 3. 4.
The Programmed park position in X and Y may need to be edited to give a position that the robot can easily access to load and unload the machine. If components are used that have a height lower than the vice jaws of the machine it may be necessary to change the Z park position to ensure the tool clears the vice. Programs created off-line must use the same tools that are available in the machine tool library. The programs sent down the RS232 from the master control computer will not be received correctly if they use unavailable tools.
Boxford 190 VMC
13.5 Connection Requirements

The connections to the 37 way D connector are as indicated below. PIN 1 2 3 4 5 6 7-10 11 12 13 14 16 17 18-21 22-25 26-37 FUNCTION M81 machine busy when on Guard Opened signal when on Guard Closed signal when on Vice / Chuck Opened signal when on Vice / Chuck Closed signal when on Machine Alarm (Air Low) when on Spare Vice clean (air blast) Go in Auto Cycle start request Close Guard request Open Vice/chuck request Close Vice/chuck request Spare 0V Spare INPUT/OUTPUT O/P O/P O/P O/P O/P O/P I/P I/P I/P I/P I/P I/P
The machine inputs for both are internally opto isolated using an ILQ 74 device. The anode of the internal diode is connected to the machine internal 24V rail via a pull up resistor. To activate any machine input the relevant input must be connected to the machine OV on pins 22-25 of the 37 way connector. The machine outputs for mills are pulled down to machine ground by a Darlington transistor Array type ULN 2803. These inputs will sink 500mA maximum and are internally pulled up to 24V. When a machine output is activated the pin on the 37way is pulled down to ground.
Boxford 190 VMC
13.6 RS232 File Transfer

The file transfer from one computer to another can be done in two ways, the first being with two computers running the Boxford Software the second is when one computer is running a control program and the other is running Boxford software. Cable Connection for RS232 File Transfer. 9 Way Female Pin 2 3 5 7 8 Colour RED BLU GRN YEL WH 9 Way Female Pin 3 2 5 8 7
LINK PINS 1, 4 and 6 at each connector. When using this file transfer the configuration of Hardware must first be set. The above cable must be connected to Com 1 or Com 2 of each computer. There are two types of possible file transfer which allow for Simple file transfer or Remote management of the manufactured programs.
1. Simple File Transfer
The machine tool controller should be configured so that the RS232 file transfer is set to the correct port, the machine will be connected to the other Com port. If transferring Programs from a remote computer running the Boxford software to the Machine Tool Controller, the remote computer must also have the RS232 file transfer set to the correct Com port. With both the Machine Tool Controller and remote computer displaying the opening software screen, select File, Export, RS232 from the top menu bar. Select the relevant program from the catalogue display. The program will now automatically be transferred into the current catalogue on the machine tool controller.
2. Remote Management
If transferring programs from a computer not running Boxford software to the Machine Tool Controller, the Machine Tool Controller must have the configuration set correctly and be on the opening screen awaiting a program.
Boxford 190 VMC
The remote computer will use the Transmit.exe program supplied by Boxford. From a Dos prompt type transmit then return to get help information. Type Transmit DEMO.GM1 O This will send the DEMO program out to the computer controlling the machine tool via Com port 1. Transmit is the command used to send the file. The Program name (DEMO) could be prefixed by for example C:\190H\190H\DEMO.GM1 this would transfer the program from the specified directory. The file extension GM indicates that it is a G and M code listing and the 1 indicates it is stored in catalogue 1. The final O indicates the com port used. NOTE: COM1=O, COM2=1.
Note:
Only use the transmit function when the CNC machine is not in cycle and the Machine Tool controller controlling is displaying the opening screen.
13.7 Fully Automated Manufacture

To use a system for fully automated manufacture the Cim Cell will have a master controller which is connected by RS232 to the Machine Tool Controller. The method of calling a program for manufacture is as follows: The command from the master computer is executed: 1. TRANSMIT DEMO.GM1 0 (program Part is transmitted automatically down Com 1 to the computer controlling the machine.) Connect pin 12 of the 37way D to ground (Go in Auto) The current program will now be manufactured. Once manufacture has started the G81output will switch on: at this time the input pin 12 should be disconnected from ground. To make another repeat 2. To make a different program repeat from 1, but transmit another program name.
2.
3. 4.
Boxford 190 VMC
Boxford 190 VMC
Tutorial 1 CNC Tutorials and Exercises
Tutorial 1:
X and Y Co-ordinate Calculation Absolute and Incremental Co-ordinates

This tutorial gives examples of absolute co-ordinates and incremental co-ordinates. Absolute Co-ordinates The code G90 is used to select this type of programming. Before programming commences the points on the path to be machined are defined relative to the workpiece datum:
10 9 8 7 6 5 4 3 2 1
Y+
D C
B A
X-
X+
1 2 3 4 5 6 7 8 9 10
-10 -9 -8 -7 -6 -5 -4 -3 -2 -1 -1 -2 -3
H
ORIGIN X0 Y0
-4 -5
-6 -7 -8 -9 -10
Y-
Examples of these co-ordinates are shown in the first table on the next page.
Boxford 190 VMC
The Z axis is the vertical axis and the datum used is normally the surface of the work. Z is positive when moving away from the surface and negative when moving towards or into the surface.
POINT X Y DATUM 0 0 A 5 4 B 10 5 C -4 5 D -9 7 E -7 -3 F -4 -6 G 7 -5 H 5 -2
Incremental Co-ordinates The code G91 is used to select this type of programming. The points on the path to be machined are defined relative to the previous position. The points for the example on the previous page are shown in the table below. The Z axis is again the vertical axis, and the points are defined relative to the previous
POINT X Y
DATUM 0 0
A 5 4
B 5 1
C -14 0
D -5 2
E 2 -10
F 3 -3
G 11 1
H -2 3
position; positive when moving away from the surface and negative when moving towards or into the surface.
Boxford 190 VMC
Exercise 1 : Calculation of Co-ordinates
Tabulate the positions of the points A to H shown in the illustration below: a) b) in absolute co-ordinates in incremental co-ordinates
Y+ D
6 5
4 3 2
A B X+
1 2 3 4 5 6 7 8
X-8 -7 -6 -5 -4 -3 -2
1 -1 -1 -2 -3 -4
-5 -6
Y-
Boxford 190 VMC
Tutorial 2:
Linear Interpolation
This tutorial illustrates the use of the G01 code; cutting takes place in a straight line at a controlled feed rate. Consider the component illustrated below; it is required to mill the two L shaped slots.
45
B
50 20
15
A
15 20
F
30 80
Y X
Material: Grooves: Tool change at: Tool used:
15mm thick Plastic 5 wide x 2 deep X 0, Y 0, Z 25 5mm Slot Drill
Absolute Co-ordinates The absolute co-ordinates of the points are shown in the table below:
POINT X Y A 15 15 B 15 35 C 45 35 D 65 35 E 65 15 F 35 15 T.C. 0 0
The program can be written in tabulated format as shown on the following page. Note: G00 is a default value and need not be programmed. The first tool is selected when entering the program into the computer.
Boxford 190 VMC
DRAWING NUMBER
PROGRAMMING SHEET SHEET-MILLING DUET PROGRAMMING

TITLE
SHEET No.
1 OF
TUT 2/1
PROGRAMMED BY
CO-ORDINATES FEED RATE SPINDLE SPEED
NOTES
SEQUENCE PREP MISC No. FUNCTION FUNCTION
ABSOLUTE PROGRAMMING METRIC UNITS TOOL CHANGE SPINDLE 2mm ABOVE POINT A FEED TO 2 DEEP POINT B POINT C 2mm ABOVE WORK ABOVE POINT D FEED TO 5 DEEP POINT E POINT F 2mm ABOVE WORK PARK POSITION END OF PROGRAM
N10 N20 N30 N40 N50 N60 N70 N80 N90 N100 N110 N120 N130 N140 N150 N160
90 71 0 03 15 01 01 01 15 45 2 65 01 01 01 35 2 05 30 0 0 25 15 2 200 200 200 35 15 2 2 200 200 200 0 25 3000
Boxford 190 VMC
Using compact format, the program for the component shown previously will be as follows: N10 N20 N30 N40 N50 N60 N70 N80 N90 N100 N110 N120 N130 N140 N150 N160 Incremental Co-ordinates The incremental co-ordinates for the component are shown in the table below. Using these co-ordinates the program can be written as shown as follows:
POINT X Y TOOL CHANGE 0 0 A 35 35 B 0 20 C 30 0 D 20 0 E 0 -20 F -30 0 T.C. FROM F -35 -15
G90 G71 X0 M03 X15 G01 G01 G01 Z2 X65 G01 G01 G01 Z2 M05 M30
Y0 S3000 Y15 Z-2 X15 X45 Z-2 Y15 X35 X0
Z25 Z2 F200 Y35 F200 F200 F200 F200 F200 Y0 Z25
Boxford 190 VMC
Using these co-ordinates the program can be written as shown as follows:

PROGRAMMING SHEET DUET PROGRAMMING SHEET-MILLING
TITLE SHEET No.
DRAWING NUMBER
OF 1
TUT 2/2
PROGRAMMED BY
NOTES
ABSOLUTE PROGRAMMING METRIC UNITS TOOL CHANGE INCREMENTAL PROGRAMMING SPINDLE START RAPID TO 2mm ABOVE A FEED TO mm DEPTH FEED FROM A TO B FEED FROM B TO C RAPID TO CLEARANCE PLANE RAPID TO 2mm ABOVE D FEED TO 2mm DEPTH FEED FROM D TO E FEED FROM E TO F RAPID TO CLEARANCE PLANE STOP SPINDLE RAPID TO PARK POSITION END OF PROGRAM
N10 N20 N30 N40 N50 N60 N70 N80 N90 N100 N110 N120 N130 N140 N150 N160
90 71 0 91 03 01 01 01 0 30 20 0 4 20 01 01 01 0 30 20 0 4 05 30 35 15 23 0 4 200 200 200 15 15 23 4 200 200 200 3000 0 25
1. 2. 3.
Examine the program listed Enter the program into the computer Simulate the machining process and compare the movement of the cutter with the program
Boxford 190 VMC
Exercise 2: Linear Interpolation - Absolute Co-ordinates
1. 2. 3.
For the component shown below, use a programming sheet and write a program for the cutter to cut a groove along the path from A to H. Enter your program into the computer and give it a test run. Edit your program if necessary.
F C
50
E H G B
D A
Y X
Material: Slots: Tool change at: Tool used:
80 15mm thick Plastic 5 wide x 2 deep X 0, Y 0, Z 25 5mm Slot Drill
Absolute Co-ordinates
POINT X Y TOOL CHANGE 0 0 A 20 10 B 60 10 C 20 30 D 20 20 E 60 40 F 20 40 G 60 20 H 60 30
Boxford 190 VMC
Tutorial 3:
Canned Cycles Hole Drilling and Pocket Milling

Canned cycles are used to shorten and simplify the CNC program. This tutorial gives examples of the G81 Hole Drilling and G88 Pocket Milling cycles. G81 Hole Drilling This code drills a hole at the current X and Y values to a depth of Z measured incrementally from the face of the workpiece and then withdraws to the previous Z value i.e. 2mm clear. Enter Z incremental distance from the face of the workpiece to the bottom of the hole) F (feed rate)
B
50 20
C
4 x 5 holes 10 deep
15
A
20 40 80
Tool change at: X -5, Y -5 Tool used: 5mm Slot Drill
POINT X Y
A 20 15
B 20 35
C 60 35
D 60 15
Boxford 190 VMC
The program for the component is as follows:

DRAWING NUMBER
TUT3/1
SHEET No. 1
OF 1
TITLE
TUT 3/1
PROGRAMMED BY
NOTES
ABSOLUTE PROGRAMMING METRIC UNITS TOOL CHANGE RAPID TRAVERSE 2mm ABOVE HOLE A SPINDLE ON 1500 rev/min DRILL A 10mm DEEP RAPID TRAVERSE TO B DRILL B RAPID TRAVERSE TO C DRILL C RAPID TRAVERSE TO D DRILL D SPINDLE STOP TOOL CHANGE END OF PROGRAM
N
N10 N20 N30 N40 N50 N60 N70 N80 N90 N100 N110 N120 N130 N140
G
90 71
5 20 03 81 20 81 60 81 60 81 05 30 5
5 15
25 2 3000 10 200
35 10 35 10 15 10 5 25 200 200 200
Boxford 190 VMC
G88 Rectangular Milling This code mills a rectangular pocket. The tool should be positioned 2mm above the pocket centre on the previous line. Enter X Y Z J F the side length of the rectangle the side width of the rectangle the distance from the workpiece face to the bottom of the pocket the number of cuts feed rate
The tool returns to its start point when the cycle is complete.
50
15
2.5 Rad
40 80
Material: Pocket: Tool change at: Tool used:
15mm thick Plastic 8 deep X -5, Y -5 5mm Slot Drill
The program for the above component is shown on the following page:
Boxford 190 VMC
DRAWING NUMBER

TITLE
SHEET No. 1
OF 1
TUT3/2
PROGRAMMED BY
NOTES
ABSOLUTE PROGRAMMING METRIC UNITS RAPID TO TOOL CHANGE SPINDLE ON 1500 rev/min 2mm ABOVE CENTRE OF POCKET MILL POCKET SPINDLE STOP TOOL CHANGE END OF PROGRAM
N10 N20 N30 N40 N50 N60 N70 N80
90 71 5 03 40 88 05 30 40 5 25 15 5 2 8 25 4 200 5 25 3000
1. 2. 3.
Examine the two programs. Enter each program into the computer. Simulate the machining process for each program and compare the movement of the cutter with the program.
Boxford 190 VMC
Exercise 3:
Canned Cycles - Programming a Tool Change
For the component shown below: 1. 2. Tabulate the co-ordinates. Use a programming sheet and write a program to drill the holes mill the square pocket (For tool changing,refer to Section 9.9). 3. 4. Enter your program into the computer and give it a test run. Edit your program if necessary.
30
4 x 3 through holes
30
50
10
20
60 80 15mm thick Plastic Material: Square Pocket: 5mm deep Tool change at: X 0, Y O
30
Boxford 190 VMC
Tutorial 4:
Circular Interpolation Clockwise and Counter-clockwise

This tutorial illustrates the use of the code G02 (clockwise circular interpolation) and G03 (counter clockwise circular interpolation). Circular Interpolation Clockwise This code moves the table in such a way that a clockwise circular arc is cut in the work within a single quadrant. The cutter is positioned at the start of the arc on the previous line of the program. The arc may be in the X Y, X Z or Y Z plane:
Y X
X - Y Plane
X Z
X - Z Plane
Y Z
Y - Z Plane
- and can be complete (90) or partial (less than 90), within a single quadrant:
After entering G02 the following extra information is needed: X value Y value Z value two of these values specify the co-ordinates of where the curve finishes, the other value must be left blank.
Boxford 190 VMC
I value the distance from the arc centre (incremental) to the tool position at the start of the cuts measured along: a) b) the X axis when cutting in X-Y or X-Z plane the Y axis when cutting in the Y-Z plane J value the distance from the arc centre (incremental) to the tool position at the start of the cut measured along: a) b) the Y axis when cutting in the X-Y plane the Z axis when cutting in the X-Z or Y-Z plane Note that I and J are unsigned values. Alternatively the radius of the arc can be entered as the I value and J left blank. Clockwise Circular Interpolation (G02) a) Single quadrant 90 arc in the XY plane To mill from A to B arc of centre C clockwise interpolation (G02)
CUTTER STARTS AT A
G = 02
X = 35
Y = 20
I=0
J = 10
A B
10 R
Y
30
C
25
Datum
Boxford 190 VMC
b)
Single quadrant partial arc in the XY plane To mill from A to B arc of centre C clockwise interpolation (G02) G = 02 X = (25 + 5) = 30
A
30 o
Y = (20 + 8.66) = 28.66

10 R
I=0
J = 10
30
C
25
To calculate co-ordinates of B, construct triangle BCD CD = BD = 10 x cos60 10 x sin60 = 10 x 0.5 = 10 x 0.866 =5 = 8.66
Note that I and J are unsigned values
A B Y
60 o
X D
Boxford 190 VMC
Circular Interpolation Counter-clockwise This code moves the table in such a way that a counter-clockwise circular arc is cut in the work within a single quadrant. The cutter is positioned at the start of the arc on the previous line of the program. As with the G02 code, the arc may be in the X-Y, X-Z or Y-Z planes
Y X
X - Y Plane
X Z
X - Z Plane
Y Z
Y - Z Plane
- and can be complete (90) or partial (less than 90), within a single quadrant:
After entering G03 the following extra information is needed: X value Y value Z value two of these values specify the co-ordinates of where the curve finishes, the other value must be left blank.
I value the distance from the arc centre (incremental) to the tool position at the start of the cut measured along: a) b) the X axis when cutting in X-Y or X-Z plane the Y axis when cutting in the Y-Z plane
Boxford 190 VMC
J value the distance from the arc centre (incremental) to the tool position at the start of the cut measured along: a) b) the Y axis when cutting in the X-Y plane the Z axis when cutting in the X-Z or Y-Z plane Note that I and J are unsigned values. Alternatively the radius of the arc can be entered as the I value and J left blank. Counter-Clockwise Circular Interpolation (GO3) a) Single quadrant 90 arc in the XY plane To mill from B to A arc of centre C counter-clockwise interpolation (G03) G = 03 X = 25 Y = 30 I = 10 J=0
A B
10 R
Y
30
C
25
Datum
Boxford 190 VMC
b)
Single quadrant partial arc in the X-Y plane To mill from B to A arc of centre C G = 03 X = 25 Y = 30 I=5 J = 8.66
A
30 o
10 R
30
C
25
To calculate co-ordinates of B, construct triangle BCD CD BD = 10 x cos60 = 10 x sin60 = 10 x 0.5 = 10 x 0.866 =5 = 8.66
Note that I and J are unsigned values
A B Y
60 o
X D
Boxford 190 VMC
Example
D C B A
10
50
E F G
10 80 Cutter: Arcs: Radius: Tool change at: 5 2 deep 10 X -5, Y -5
POINT X Y
A 10 10
B 20 20
C 30 30
D 40 40
E 50 30
F 60 20
G 70 10
The program for the above component is shown on the following page. Note: Blocks N70 to N90 define the arc in terms of its radius. Blocks N100 to N120 define the arc in terms of the co-ordinates of its centre
Boxford 190 VMC
DRAWING NUMBER

TITLE
SHEET No.
OF 1
TUT4
PROGRAMMED BY
NOTES
ABSOLUTE PROGRAMMING METRIC UNITS TOOL CHANGE SPINDLE START POINT A FEED TO DEPTH A TO B B TO C C TO D D TO E E TO F F TO G RAPID OUT SPINDLE STOP TOOL CHANGE END OF PROGRAM
N10 N20 N30 N40 N50 N60 N70 N80 N90 N100 N110 N120 N130 N140 N150
90 71 5 03 10 01 02 03 02 02 03 02 20 30 40 50 60 70 20 30 40 30 20 10 2 05 30 5 5 25 10 2 2 10 10 10 0 10 0 10 0 10 200 5 25 3000
1. 2. 3.
Examine the program. Enter the program into the computer. Simulate the machining process and compare the movement of the cutter with the program.
Boxford 190 VMC
Exercise 4: Circular Interpolation
D
50
10 Rad
A
25
J C B E
10 Rad
10 Rad
10 80 Material: 15mm deep Plastic Slot: 5 wide, 2 deep Tool change at: X 0, Y 0
For the cutter path shown above: 1. 2. 3. 4. Tabulate the co-ordinates A to J. Use a programming sheet to write a program for the path of the cutter centre line. Enter your program into the computer and give it a test run. Edit your program if necessary. Note: The curve must be programmed in a series of quadrants (90).
Boxford 190 VMC
Tutorial 5:
Combining Operations and Tool Changing

This tutorial uses some cutters not supplied with the machine. It illustrates how tool changes can be made and a number of operation can be carried out on one component. Sequence of Operations
80
A E
50 20
30
D
4 x 5 holes
15
B
15 13
20
40
C
Material: Plastic Tool change at: X 0, Y 0
1. 2. 3.
Mill the steps Drill the holes Mill the 30mm diameter pocket
(8mm diameter cutter) (5mm diameter drill) (10mm diameter cutter)
Note: Tool Changing The program for the above component illustrates the method of programming a tool change; block N120 moves the cutter to a tool change position and block N130 calls up a new tool. M06 I J denotes a tool change gives the tool type, the tool diameter, and
Boxford 190 VMC
The program is as follows:

DRAWING NUMBER
SHEET No.
1 OF
TITLE
TUT 5
PROGRAMMED BY
NOTES
ABSOLUTE PROGRAMMING METRIC UNITS TOOL CHANGE CUTTER RAPID TRAVERSE 2mm ABOVE A SPINDLE ON 1500 rev/min FEED TO DEPTH MILL FIRST STEP RAPID TRAVERSE 2mm ABOVE C FEED TO DEPTH MILL SECOND STEP TOOL CHANGE POSITION TOOL CHANGE (5mm DRILL) RAPID TRAVERSE OVER HOLE D SPINDLE ON DRILL D 17mm DEEP RAPID TRAVERSE OVER HOLE DRILL E RAPID TRAVERSE OVER HOLE F DRILL F
N
N10 N20 N30 N40 N50 N60 N70 N80 N90 N100 N120 N130 N140 N150 N160 N170 N180 N190 N200
G
90 71
5 1 03 01 01 79 01 01 05 06 20 03 81 20 81 60 81 60 81 05 5 5
5 54
25 2 3000 2 200 200 2 2 200 200 25 8 5
5 5
55 5
15
2 3000 17 200
35 17 35 17 15 17 5 25 200 200 200
RAPID TRAVERSE OVER HOLE G N210 DRILL G TOOL CHANGING POSITION N220 N230
Boxford 190 VMC
DRAWING NUMBER
SHEET No.
OF 2
TITLE
TUT 5
PROGRAMMED BY
NOTES
TOOL CHANGE 10mm DRILL RAPID TRAVERSE 2MM ABOVE CENTRE OF POCKET SPINDLE ON MILL POCKET SPINDLE OFF, RAPID FEED TO TOOL CHANGE POSITION END OF PROGRAM
N
N240 N250 N260 N270 N280 N290
M
06
I
2
J
10
40 03 89 05 30 30 5
25
2 3000
0 5
5 25
200
1. 2. 3.
Examine the program. Enter the program into the computer. Simulate the machining process and compare the movements of the cutters with the program.
Boxford 190 VMC
Exercise 5: Combining Operations
80
O3
50
O2
5mm Groove
15
Material: 15mm thick Plastic Tool change at: X 0, Y 0
For the component shown above: 1. 2. 3. 4. 5. Write down the sequence of operations required to produce the part. Tabulate the co-ordinates required. Use a programming sheet to write a program. Enter your program into the computer and give it a test run. Edit your program if necessary.
Boxford 190 VMC
Tutorial 6:
Subroutines
A subroutine can be regarded as a personalised canned cycle for use in a program which has repetitive shapes. The illustration below shows such a component; the milled grooves can be programmed as a subroutine.
55
20
50
B
15
20 Material: Grooves: Tool change at: A,B : 15mm thick Plastic 5 wide x 3 deep X 0, Y 0 start positions for subroutines
The codes used for subroutines are: M43 subroutine create On entering M43, a prompt is made for an identifying number to be given to the routine. The number is entered in the I column and may have a value from 1 to 99. The user should note this reference number and the purpose of the routine. The mode of programming is now changed: the line number automatically reverts to 10 and co-ordinate entry, if absolute, becomes incremental. There is no restriction on the range of G codes (except G25) and all the canned cycles are available.
30
15
Boxford 190 VMC
M44 subroutine terminate On entry of the signal to end the subroutine the line numbers of the original program are restored and the current absolute position of the tool is shown in the X, Y and Z columns. If the program was previously being entered with absolute co-ordinates, it reverts to its former style. M45 subroutine call On entering M45 a prompt is made to input the reference number of the subroutine in the I column. A search is made in the subroutine file and the first file found with that reference number is executed. Note: Care is needed when allocating subroutine identification numbers. The program for the previous illustration shows subroutine blocks S10 onwards being typed into the system immediately after block N50. After this the cutter is repositioned before calling up the subroutine and completing the program. Editing of subroutines The program EDIT facility can be used. If this is brought into use the program is displayed for editing but a further option (SUB) is offered:
SUB MENU
If SUB is chosen, then the subroutine is displayed for editing. 1. 2. 3. Examine the program. Enter the program into the computer. Simulate the machining process and compare the movements of the cutters with the program.
Boxford 190 VMC
DRAWING NUMBER

TITLE
SHEET No.
1 OF 1
TUT 6
PROGRAMMED BY
NOTES
N10 N20 TOOL CHANGE N30 N40 POINT A SUBROUTINE FOR GROOVES POINT B SUBROUTINE FOR GROOVES N50 N60 N70 N80 N90 N100
90 71 0 03 5 45 55 45 05 30 0 0 25 30 1 5 1 1 0 25 3000
ENTERED IMMEDIATELY AFTER BLOCK N50
S10 S20 S30 S40 01 01 01 01 01
43 3 15 20 15 20 3 44
1 200 200 200 200 200
THE SUBROUTINE MACHINES THE GROOVES (INCREMENTALLY)
S50 S60 S70 S80
Boxford 190 VMC
Exercise 6: Subroutines
20
50
20
20
20
20 30 55 80
Material: Grooves:
15mm thick Plastic 5 wide x 2 deep
For the component shown above: 1. 2. 3. 4. Tabulate the co-ordinates required. Use a programming sheet to write a program; the L shaped grooves can be programmed using a subroutine. Enter your program into the computer and give it a test run. Edit your program if necessary.
15
20
25
20
Boxford 190 VMC
Tutorial 7:
Mirror Images
This tutorial demonstrates how a program written as a subroutine can be reflected about the X axis or about the Y axis or about both the X and the Y axes. It supports both linear and circular interpolation. Consider the shape shown in illustration A, which has been drawn in the sequence 12, 2-3, 3-4 and 4-1.
2 1
If the X co-ordinates are reflected with Y co-ordinates unchanged, the shape becomes:
1 2
with the 1-2, 2-3, 3-4 and 4-1 sequence maintained Alternatively, if the X co-ordinates are kept constant and the Y co-ordinates reflected, the outcome is:
4
C
1
Boxford 190 VMC
If both the X and y co-ordinates are reflected the result becomes:

4
D
1 2
If a program which calls a subroutine containing the original shape is written, then any or all of the above variations may be implemented. The as programmed case is achieved by the usual method of calling the subroutine. The mirror facility is accomplished by inserting a line in the program after positioning the tool at the start of the cycle but prior to calling the subroutine. The entry is: G X Y value 28 value 0 or 1 value either 0 or 1
For example To reflect the X co-ordinate with Y unchanged: Enter G28 with X = 1, Y = 0 B
To reflect the Y co-ordinate with X unchanged: Enter G28 with X = 0, Y = 1 C
To reflect both the X and the Y co-ordinates: Enter G28 with X = 1, Y = 1 To cancel the mirror facility: Enter G28 WITH X = 0, Y =0 Note: For mirror image programming incremental co-ordinates must be used. D
Boxford 190 VMC
Example
C
D' C' A' B'
50
30
10
15
20
10 30 50 80 Material: 15mm thick Plastic Slots: 5 wide x 3 deep Tool change at: X 0, Y 0
In the program for the above illustration, note that blocks S10 to S80 onwards are typed into the system immediately after block N40. 1. 2. 3. Study the program. Enter the program into the computer. Simulate the machining process and compare the cutter movements with the program.
Boxford 190 VMC
DRAWING NUMBER
SHEET No.
1 OF
TITLE
TUT 7
PROGRAMMED BY
NOTES
ABSOLUTE PROGRAMMING METRIC UNITS TOOL CHANGE SPINDLE ON POINT A CALL SUBROUTINE POINT B
N
N10 N20 N30 N40 N50 N60 N70 MIRROR IMAGE REFLECT X CO-ORDINATE Y UNCHANGED CALL SUBROUTINE N80 N90
G
90 71
0 03 45 50 91 28 45 1 30
0 20
25 1 7 3000
20
0 7
S20 TI S80 REPEAT CANCEL MIRROR IMAGE ABSOLUTE PROGRAMMING START OF SHAPE C INCREMENTAL PROGRAMMING MIRROR IMAGE REFLECT Y CO-ORDINATE X UNCHANGED CALL SUBROUTINE N100 N110 N120 N130 N140 N150 91 28 45 S20 TO S80 REPEATS CANCEL MIRROR IMAGE ABSOLUTE PROGRAMMING START OF SHAPE D INCREMENTAL PROGRAMMING MIRROR IMAGE REFLECT BOTH X AND Y CO-ORDINATES N160 N170 N180 N190 N200 91 28 1 1 28 90 50 30 0 0 0 1 7 28 90 30 30 0 0
Boxford 190 VMC
Tutorial 7 CNC Tutorials andTutorial Exercises 7
DRAWING NUMBER

TITLE
SHEET No.
2 OF
TUT 7
PROGRAMMED BY
NOTES
CALL SUB ROUTINE
N210
45 S20 TO S80 REPEATS
CANCEL MIRROR IMAGE ABSOLUTE PROGRAMMING TOOL CHANGE END OF PROGRAM
N220 N230 N240 N250
28 90 05 30
25
SUBROUTINE CREATE FEED TO DEPTH SUBROUTINE SHAPE A INCREMENTAL
S10 S20 S30 S40 S50 S60 S70 01 01 01 01 01
43 0 10 0 10 0 0 44 0 0 10 5 15 0 3 0 0 0 0 3
7 200 200 200 200 200
SUBROUTINE TERMINATE
S80
Boxford 190 VMC
Exercise 7: Mirror Images
50 30
20
20 30 50 80 Material: 15mm thick Plastic Slots: 5 wide x 2 deep Tool change at: X 0, Y 0
For the component shown above: 1. 2. 3. Write a program to machine the grooved triangles using the mirror image technique. Enter your program on the computer and simulate the cutting action. Edit your program if necessary. The manufacture of the component shown below uses the G86 and G87 canned cycles.
15
Boxford 190 VMC
Tutorial 8:
Further Canned Cycles Pitch Circle Drilling and Dish Milling

The manufacture of the component shown below uses the G86 and G87 canned cycles.
80
6 x 5 holes 5 deep on 40mm PCD 50 Dished pocket 30, 5 deep 10 at bottom
G86 Canned Cycle Pitch Circle Diameter Drilling This code produces a series of holes on a circular pitch. The tool is positioned at a 2mm stand off point above the centre of a hole on the PCD on the previous line. Enter: X Z I J F number of holes to be drilled (must not be less than two) incremental distance from the face of the workpiece to the bottom of the hole the distance from the circle centre (incremental) to the first hole measured along the X axis as the I value but measured along the Y axis Feed rate
Boxford 190 VMC
G87 Canned Cycle Dish Milling This code will mill out a circular dish-shaped pocket. The dish is produced by cutting a series of concentric circular pockets starting at X diameter, with successive circles getting deeper as they reduce in diameter, until the last circle is at Y diameter and depth Z. The total number of circles is J. Increasing the number of cuts will produce a better dish but the time taken will be greater. Enter X Y Z I J F the top diameter the bottom diameter of the dish The incremental distance from the face of the workpiece to the bottom of the dish For a complete dish enter zero, or for hollow circles (an outline around the edge) enter a value is the number of cuts to produce the dish the feed rate at which the dish is to be milled
The cycle is best used in two stages. For the first stage enter I = 0; this will rough out a pocket, leaving a stepped profile. On calling the code again for the second stage enter a value for I = 1; this will mill around the circumference of the circles, thus smoothing the profile. The program for the illustration shown earlier is shown on the following page. 1. 2. 3. 4. Study the program. Enter the program into the computer. Simulate the machining process and compare the cutter movement with the program. View the component in 3D.
Boxford 190 VMC
DRAWING NUMBER
SHEET No.
1 OF 1
TITLE
TUT 8
PROGRAMMED BY
NOTES
ABSOLUTE PROGRAMMING METRIC UNITS TOOL CHANGE 5 DRILL SPINDLE ON, Move to Centre of P.C.D. DRILL HOLES ON P.C.D. TOOL CHANGE TOOL CHANGE SPINDLE ON, Move to Centre of Pocket ROUGH MILL DISH FINISH MILL DISH PARK POSITION END OF PROGRAM
N
N10 N20 N30 N40 N50 N60 N70 N80 N90 N100 N110 N120
G
90 71
0 03 86 05 06 03 87 87 05 30 40 30 30 0 40 6 0
0 25
25 2 5 0 20 200 3000
25 2 5 3000 0 1 5 5 200 200
25 10 10 0
2 5 5 25
Boxford 190 VMC
Exercise 8: Use of Canned Cycles Pitch Circle Drilling and Dish Milling
80
8 x 5 holes 5 deep on 40mm PCD 50 Dished pocket 25, 5 deep 10 at bottom
25
For the component shown above: 1. Write a program to machine 2. 3. the holes on the P.C.D. the dished pocket.
Enter your program on the computer and simulate the cutting action. Edit your program if necessary.
Boxford 190 VMC
Tutorial 9:
Subroutines, Mirror Images and Circular Interpolation
4 3
2 1 7 All grooves 15 radius 2 deep 5 wide
50 45
30
20
20 35 45 60 80 Tool change at: X 0, Y 0
The following program uses a subroutine which will mill a 90 arc of radius 15mm counter-clockwise and 2mm deep. It then uses the G28 Mirror Image routine to mill the other three arcs. The program is shown on the following page. 1. 2. 3. Study the program. Key in the program and run the simulation. Compare the cutter movements with the program.
Boxford 190 VMC
DRAWING NUMBER

TITLE
SHEET No.
1 OF
TUT 9
PROGRAMMED BY
NOTES
ABSOLUTE PROGRAMMING METRIC UNITS TOOL CHANGE POSITION SPINDLE START OVER POINT 1 SUBROUTINE CREATE FEED TO DEPTH MILL QUADRANT WITHDRAW TOOL SUBROUTINE TERMINATE SUBROUTINE CALL POINT 2 ABOVE POINT 3 INCREMENTAL PROGRAM MIRROR IMAGE REFLECT X, Y UNCHANGED SUBROUTINE CALL CANCEL MIRROR IMAGE POINT 4 ABOVE POINT 5 INCREMENTAL PROGRAM MIRROR IMAGE REFLECT BOTH X AND Y SUBROUTINE CALL
N10 N20 N30 N40 N50 S10 S20 S30 S40 S50 N60 N70 N80 N90 N100 N110 N120 N130 N140 N150 N160 N170
90 71 0 03 60 43 01 03 -15 15 3 44 45 90 45 20 91 28 45 28 90 0 35 20 91 28 45 1 1 9 0 45 20 1 1 0 9 45 30 1 9 -3 15 30 1 9 200 200 0 25 3000
Boxford 190 VMC
DRAWING NUMBER

TITLE
SHEET No.
2 OF
TUT 9
PROGRAMMED BY
NOTES
CANCEL MIRROR IMAGE POINT 6 ABOVE POINT 7 INCREMENTAL PROGRAM MIRROR IMAGE REFLECT X, Y UNCHANGED SUBROUTINE CALL CANCEL MIRROR IMAGE POINT 8 SPINDLE STOP. TOOL CHANGE END OF PROGRAM
N N180
G 28
X 0
Y 0
N190 N200 N210 N220 N230 N240 N250 N260 N270
90
35 60
5 20
91 28 45 28 90 05 30 0 45 0 0 5 0 1 25 0 1 9
Boxford 190 VMC
Exercise 9: Subroutines and Mirror Images
All grooves 15 radius 2 deep 5 wide

29 21 6
60 44
21 36 44 59 80 15mm thick Plastic Material: Tool change at: X 0, Y 0 5mm Slot Drill Tool used:
For the component shown above: 1. 2. 3. Write a program to mill the curved slots using a subroutine and mirror images. Key in the program and run the simulation. Edit your program if necessary.
Boxford 190 VMC
Tutorial 10:
Datum Shift and Jump to Line

For programs with repetitive elements, and as an alternative to creating a subroutine (M43), a datum shift (G57) can be used in conjunction with Jump to Block (G25) and Return from Jump (G26). Details of the above codes are: G25 Jump to Block This code enables a section of a program to be executed again. There are two restrictions on the use of G25: (a) (b) a G25 loop must not be called from within a subroutine, a subroutine must not be called from within a G25 loop.
Enter in the S column the line number to which the jump is to be made. G26 Return from Jump After using a G25 the program executes from the line specified in the S column until a G26 is encountered. The program then reverts to the line following that from where the G25 call was made. The G26 is only operative after a G25 loop has been called. At all other times it is transparent. G57 Datum Shift This code enables the X Y datum to be altered by an amount specified in the X and Y columns. Enter X value - new absolute X datum Enter Y value - new absolute Y datum Note: The Z datum cannot be altered with G57. G53 Cancel Datum Shift This code is used to cancel a G57 datum shift, i.e. it makes X and Y shift equal to zero. The above techniques are illustrated in the following example.
Boxford 190 VMC
50
15
15
15 10
15 20 50 Material: Slots: Tool change at: Tool used: 80 15mm thick Plastic 5 wide x 2 deep X 0, Y 0 5mm Slot Drill
The program is shown on the following page. 1. 2. 3. Study the program. Key in the program and run the simulation. Compare the cutter movements with the program.
20
Boxford 190 VMC
DRAWING NUMBER

TITLE
SHEET No.
1 OF 1
TUT 10
PROGRAMMED BY
NOTES
ABSOLUTE PROGRAMMING METRIC UNITS TOOLPARK POSITION DATUM SHIFT TO X20 Y10 SPINDLE START MOVE OVER NEW DATUM INCREMENTAL PROGRAMMING FEED TO DEPTH CUT FIRST L SHAPE CUT FIRST L SHAPE RAPID TO CLEAR RAPID TO NEW POSITION ABSOLUTE PROGRAMMING RETURN FROM JUMP CANCEL DATUM SHIFT DATUM SHIFT TO X50 Y20 JUMP TO BLOCK N60 CANCEL DATUM SHIFT TOOL PARK STOP SPINDLE END OF PROGRAM
N10 N20 N30 N40 N50 N60 N70 N80 N90 N100 N110 N120 N130 N140 N150 N160 N170 N180 N190 N200
90 71 0 57 03 91 01 01 01 15 15 4 -15 90 26 53 57 25 53 0 05 30 0 25 50 20 60 -15 -15 -15 -4 200 200 200 20 0 0 10 0 2 3000 25
Boxford 190 VMC
Exercise 10: Datum Shift and Jump to Line
50
25
25
20
10
20 10 45 Material: Slots: Tool change at: Tool used: 80 15mm thick Plastic 5 wide x 2 deep X 0, Y 0 5mm Slot Drill
For the component shown above: 1. 2. 3. Write a program to mill the L-shaped slots using the Datum Shift and Jump to Line codes. Key in the program and run the simulation. Edit your program if necessary.
20
OPERATIONS SHEET
DRAWING NUMBER OPERATIONS NUMBER
DUET OPERATIONS SHEET - MILLING OPERATIONS SHEET

TITLE OPERATION MATERIAL SPINDLE FEED
SHEET No.
OF
TOOL FEED
TOOL REQUIRED
PROGRAMMING SHEET
DRAWING NUMBER
DUET PROGRAMMING SHEET-MILLING PROGRAMMING SHEET

TITLE
SHEET No.
OF
PROGRAMMED BY
NOTES

CNC Milling

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Programming Manual

Boxford 190 VMC CNC Milling Machine Tool

Boxford 190 VMC

4 Main Front End Menu 5 CAD

6.1 6.2 7.1 7.2

Boxford 190 VMC

9 Cutter Path CAM Programming

10 Manual Data Input CNC Programming

Boxford 190 VMC

11 CNC and CAM Machining

12 Manual Machining 13 Robotic Interfacing

Boxford 190 VMC

CNC Tutorials and Exercises

Operations Sheet Programming Sheet

Boxford 190 VMC

2 Running the Demonstration Program

2 Running the Demonstration Program

Setting Up the Machine

Check Tool Settings

Boxford 190 VMC

2 Running the Demonstration Program

Select PROGRAM The screen shows:

Boxford 190 VMC

2 Running the Demonstration Program

Boxford 190 VMC

2 Running the Demonstration Program

View the Component

Boxford 190 VMC

2 Running the Demonstration Program

Using the Keyboard:

Rotate clockwise Decrease size

Restore original view

to show the program details:

Boxford 190 VMC

2 Running the Demonstration Program

Display the Program

and then Display:

Using the Keyboard:

to scroll 1 line Page down to scroll 1 page

Turn off the program display.

Boxford 190 VMC

2 Running the Demonstration Program

Zoom the Display

Boxford 190 VMC

2 Running the Demonstration Program

tool depth display

Boxford 190 VMC

2 Running the Demonstration Program

Boxford 190 VMC

Axes and Tooling

3 Axes and Tooling

3.2 Axes, Datums and Offsets (Figure 3.1)

Boxford 190 VMC

3.1 Axes and Tooling

Tool X,Y datum

Drawing datum Tool X,Y datum

Axes and Tool Datum

Boxford 190 VMC

3.2 Axes and Tooling

Underside of Head Tool Z Offset

Total Height of Workpiece & Clamp Machine Table Top

Boxford 190 VMC

3.2 Axes and Tooling