7.1 Program Examples

Program Examples - Introduction

This section has four program examples.

Cutoff Subprogram: Calls a subprogram in the G105 command to cut off the part. This programming style is most appropriate for solid stock where the cutoff program must cut to the centerline.

Cutoff in Program: Includes the cutoff in the part program. This programming style is most appropriate when the finished part has a hole through the center, and the cutoff program does not have to cut to the centerline.

Double Push: Describes a double push. This programming style is most appropriate to machine a length of bar shorter than the full part length, and then push to the full part length.

Q13 Facing Subprogram: Describes the use of Q13 to specify a subprogram to run at the beginning of each new bar. This programming style is most appropriate when you need a multiple-pass facing operation to clean the bar before machining. Q13 is the only Q-Code that works with the Next Generation Control.

Caution: The sample programs in this manual have been tested for accuracy, but they are for illustrative purposes only. The programs do not define tools, offsets, or materials. They do not describe workholding or other fixturing. If you choose to run a sample program on your machine, do so in GRAPHICS mode. Always follow safe machining practices when you run an unfamiliar program.

7.2 Cutoff Subprogram

Cutoff Subprogram

This example shows the preferred programming method with solid stock material, where the cutoff operation must cut to the centerline.

The material is 2" (51mm) diameter solid stock and the finished part is 1" (25mm) long. The cutoff tool is 0.125" wide. The spindle/tool clearance is 0.875". The amount of stock to remove from the face is 0.025".

The program uses these Bar Feeder variable values:

Variable Number / NGC Letter	Description	Value
#3100 (D)	Part Length + Cutoff Allowance + Facing Allowance	1.15
#3101 (F)	Initial Push Length	2.025
#3102 (G)	Minimum Clamping Length	1.0

%
O00023 (PART PROGRAM)
G105 P24 (CALL CUTOFF SUB PROGRAM THEN BAR FEED)
T303 (FACE & TURN)
G50 S1500
G96 S500 M03
G00 G54 X2.1 Z0 M08
G01 X-0.05 F0.005
G00 X1.95 Z.05
G01 Z-1.0 F0.01
X2.1
G53 G00 X0
G53 Z0
/M99
M30
%

%
O00024 (CUT-OFF SUB PROGRAM)
T404
G50 S1500
G96 S500 M03
G00 X2.1 Z0.1 M08
Z-1.125 (1" PART LENGTH PLUS THE TOOL WIDTH)
G01 X-0.05 F0.005
G00 X2.1
G53 X0
G53 Z0
M99
%

Command G105 in MDI mode to load a bar and push it to the initial push length. In this example, the initial push length includes the 0.875" spindle/tool clearance, the 0.125" width of the cutoff tool, and a 0.025" facing allowance.

This program starts with a call to the cutoff subprogram. The effect of this is different depending on whether this is a new bar or if it is the next program loop on a bar:

If this is a new bar, the cutoff subprogram faces and cleans the bar end at the initial push length (#3101(F)), and then the Bar Feeder pushes out the part length plus allowances (#3100(D)).
When the subprogram call repeats on a bar, the cutoff subprogram cuts off finished parts and leaves a clean bar end, and then the Bar Feeder pushes out the part length plus allowances (#3100(D)).

Note: When you write a bar feed program with a cutoff routine and then a bar feed command, or with a bar feed command that includes a Pxxxxx cutoff subprogram call, it is safest and most consistent to start the program with the bar feed command. This practice makes sure that a fresh piece of material, with a faced surface, in a consistent position, is always available for the rest of the operation.

Note: The main program has a block-deleted M99 command in the second-to-last line. This lets you turn on block delete if you want the program to run only one time.

Dimensions are not to scale.

[1] Shows the Bar After the Initial Push at MDI Setup.

[2] Shows the Bar During Subsequent Feeds.

[A] Reference Point, Variables as Defined Above.

7.3 CUTOFF IN PROGRAM

Cutoff in Program

This example shows the preferred programming method when the cutoff operation does not have to cut to the centerline, as when the finished part has a hole through the center. Unlike the first program example, which uses the same subprogram to both face a new bar and cut off finished parts, this program includes a facing operation and a separate cutoff operation for finished parts. The facing operation cuts to the workpiece centerline. To save machining time, the cutoff operation cuts only as far as the finished part’s inner diameter.

The material is 2" (51 mm) diameter solid stock and the finished part is 1" (25 mm) long. The cutoff tool is 0.125" wide. The spindle/tool clearance is 0.875". The amount of stock to remove from the face is 0.025".

The program uses these Bar Feeder variable values:

Variable Number / NGC Letter	Description	Value
#3100 (D)	Part Length + Cutoff Allowance + Facing Allowance	1.15
#3101 (F)	Initial Push Length	2.025
#3102 (G)	Minimum Clamping Length	1.0

%
O00020 (PART PROGRAM);
T303 (FACE & TURN);
G50 S1500;
G96 S500 M03;
G00 G54 X2.1 Z0 M08;
G01 X-0.05 F0.005;
G00 X1.95 Z.05;
G01 Z-1.0 F0.01;
X2.1;
G53 G00 X0;
G53 Z0;
T404 (CUT OFF OPERATION);
G50 S1500;
G96 S500 M03;
G00 X2.1 Z0.1 M08;
Z-1.125 (1" PART LENGTH PLUS THE TOOL WIDTH);
G01 X-0.05 F0.005;
G00 X2.1;
G53 X0;
G53 Z0;
G105 (BAR FEED);
/M99;
M30;
%

Command G105 in MDI mode to load a bar and push it to the initial push length. In this example, the initial push length includes the 1" finished part length, 0.875" spindle/tool clearance, the 0.125" width of the cutoff tool, and a 0.025" facing allowance.

This program starts with the face and turn operation, then the cutoff operation, and the bar feed command at the end.

Note: The program has a block-deleted M99 command in the second-to-last line. This lets you turn on block delete if you want the program to run only one time.

7.4 Double Push

Double Push

This example demonstrates a double push on the workpiece. The program contains G105 commands. The first G105 uses the variables values set on the Bar Feeder current commands page. The second G105 uses J and K values to override the variable values.

Note: A G105 with a J code will not increment the counter. The J code is intended for double push operation to make a long part. This is the preferred programming method when, for example, you need the rigidity of a short bar for part of your operation, and then to machine the rest of the longer finished part.

The material is 2" (51 mm) diameter solid stock and the finished part is 4" (100 mm) long. The cutoff tool is 0.125" wide. The spindle/tool clearance is 0.875". The amount of stock to remove from the face is 0.025".

The program uses these Bar Feeder variable values. These values apply to the first G105 command, given without address codes:

Variable Number / NGC Letter	Description	Value
#3100 (D)	Part Length + Cutoff Allowance + Facing Allowance	1.15
#3101 (F)	Initial Push Length	2.025
#3102 (G)	Minimum Clamping Length	1.0

In the second G105 command, the program uses these address codes to override the values given in the bar feeder variables:

Address Code	Description	Value
J	Part Length + Cutoff Allowance + Facing Allowance	3.0
K	Minimum Clamping Length	1.0

%
O00021 (DOUBLE PUSH WITH Bar Feeder);
G105 (BAR FEED USING MACRO VARIABLES);
T303 (FACE & TURN);
M01;
G50 S1500;
G96 S500 M03;
G00 G54 X2.1 Z0 M08;
G01 X-0.05 F0.005;
G00 X1.95 Z.05;
G01 Z-1.0 F0.01;
X2.1;
G53 G00 X0;
G53 Z0;
G105 J3.0 K1.0 (BAR FEED WITH OPTIONAL VARIABLES);
M01;
T404 (CUT OFF TOOL);
G55 (WORK OFFSET CHANGE);
G50 S1500;
G96 S500 M03;
G00 G55 X2.1 Z0.1 M08;
Z-4.125;
G01 X-0.05 F0.005;
G00 X2.1;
G53 X0;
G53 Z0;
/M99;
M30;
%

Command G105 in MDI mode to load a bar and push it to the initial push length. In this example, the initial push length includes the 2" length to machine first and a 0.025" facing allowance.

Before you run this program for the first time after you load a bar in MDI mode, move the cursor to the block after the first G105 command in the program to bypass the first push. Remember that after the initial push, the bar is already in position to start machining.

Note: The program has a block-deleted M99 command in the second-to-last line. This lets you turn on block delete if you want the program to run only one time.

7.1 Q13 Facing Subprogram

Q13 Facing Subprogram

This example uses a two-pass facing operation that runs conditionally at the beginning of each new bar. The Q13 command in the G105 line specifies program O00025 as the new bar facing subprogram.

Variable Number / NGC Letter	Description	Value
#3100 (D)	Part Length + Cutoff Allowance + Facing Allowance	1.15
#3101 (F)	Initial Push Length	2.025
#3102 (G)	Minimum Clamping Length	1.0

%
O00022;
G105;
G105 Q13 P25 (RUN FACING SUBPROGRAM AT A NEW BAR);
T303 (FACE & TURN);
G50 S1500;
G96 S500 M03;
G00 G54 X2.1 Z0 M08;
G01 X-0.05 F0.005;
G00 X1.95 Z.05;
G01 Z-1.0 F0.01;
X2.1;
G53 G00 X0;
G53 Z0;
M01;
(CUT-OFF PROGRAM);
T404;
G50 S1500;
G96 S500 M03;
G00 X2.1 Z0.1 M08;
Z-1.125 (1" PART LENGTH PLUS THE TOOL WIDTH);
G01 X-0.05 F0.005;
G00 X2.1;
G53 X0;
G53 Z0;
M99;
%

%
O00025;
T303 (FACING PROGRAM FOR BEGINNING OF NEW BAR);
G50 S1500;
G96 S500 M03;
G00 G54 X2.1 Z.1 M08;
G01 X-0.05 F0.005 (1ST FACING PASS);
G00 Z.15;
X2.1;
Z.05;
G01 X-0.05 (2ND FACING PASS);
G53 X0;
G53 Z0;
M99;
%

Each time the control loads a new bar, it gives variable #3114 a value of 1. This prompts the control to run the specified subprogram at Q13. The control then changes the value of variable #3114 to 0 until it loads another new bar. While variable #3114 has a value of 0, the control does not run the facing subprogram.

7.6 Program Examples

Bar Feeder - Counter

The Bar Feeder can count either the number of parts made, or the length of material run. A non-zero value set in, Maximum Number of parts determines the active counting modes. The first non-zero value stops the cycle if more than one is present.

To stop the machine after a chosen number of parts, set Maximum Number of Parts to the chosen quantity. The counter increments at each G105 command. If G105 is at the beginning of the program, the counter increments before each part starts machining. If G105 is at the end of the program, the counter increments after each part finishes machining.

Note: A G105 with a J code will not increment the counter. The J code is intended for double push operation to make a long part.

To view the counters exit the Devices tab and navigate to the Timers tab.

7.7 Bar Feeder - Macro Variables

Bar Feeder - Macro Variables

Variable Number / NGC Letter	Name	Description
#3100	Part Length + Cutoff Allowance + Facing Allowance	Bar feed increment (Length of bar pushed out with each G105 after the bar is loaded). Finished part length + cutoff length + face cleanup allowance.
#3101	Initial Push Length	Initial bar feed length (Length of bar pushed out past the reference position when loaded).
#3102	Minimum Clamping Length	Minimum length for clamping (Length of bar required to support the length pushed past the collet face).
#3103	MAX # PARTS	Maximum number of parts.
#3104	MAX # BARS	Maximum number of bars.
#3105	MAX LENGTH TO RUN	Maximum length to run.
#3106	CURRENT # PARTS RUN	Part counter.
#3107	CURRENT # BARS RUN	Bar counter.
#3108	CURRENT LENGTH RUN	Length counter.
#3109	LENGTH OF LONGEST BAR	Length of the longest bar (set to 48, if unknown). Setting the length close to the size of the bar stock allows faster measurement of shorter bars. This length must be longer than the bar stock being used.
#3110 (READ ONLY)	CURRENT BAR LENGTH	Current bar length measured by the machine.
#3112 (INTERNAL ONLY)	REFERENCE POSITION	Established using G105 Q4 Jog To Reference Position.
#3113	MIN RETRACT POSITION	Adjust this to make sure the push rod retracts out of the spindle liner after each G105 push. Jog the V Axis until there is a safe gap between the end of the push rod and the spindle liner (approximately 1 inch/25 mm). Look at your V-Axis position, it will be a negative number (example: -13.0). Enter this number, as a positive value under variable #3113 (example: #3113=13.0).
#3114	NEW BAR	This variable has a value of 1 if the last Bar Feeder operation loaded a new bar. It has a value of 0 if the last Bar Feeder operation did not load a new bar.

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