The Boxford 280 TH is a British made CNC lathe, and our objectives are to guide
the .... prior to CNC control being used. SPINDLE ..... ego G50 - S3000. Spindle ...
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BOXFORD 280B TURNMASTER
CNC MACHINE & PROGRAMMING
MANUAL
CONTENTS
SAFETY
INTRODUCTION SECTION 1:
FIRST STEPS.
1.1.1 1.1. 2
1. 2.1 1.2.2 1.2.3
1. 2.4
1. 3.1 1.3.2 1. 3.3
1.3.4 1.3.5
SECTION 2:
SECTION 3:
Installation.
Machine Specification.
Machine Function Keyboard. (Power On). Manual operation.
Pneumatic Facilities.
Machine Offset. Operations And Programming Sheets. Absolute And Incremental Co-Ordinates.
Program Format And Axis Directions.
Programming - G Codes.
Programming - M Codes.
FURTHER EXPLANATIONS OF G CODES.
2.1
GOO, GOL GOZ, G03.
2.2
G02 1n detail.
2.3
G03 in detail.
2.4
G70, GIL G80, G81, G82 Facing.'
2.5
G82, Grooving, G83.
2.6
G84, G90, G91.
2.7
G94, G95, G96, G9,.
MAIN MENU OPTIONS.
3.1
The Main Menu.
3.2
Yrite A New Program.
3.3
Edit/Continuation.
3.4
Test Run A Program.
3.5
Print A Program.
3.6
Execute A Program.
3.1
Help Date Library.
3.8
File Index.
3.9
Machine feedback/Offsets.
SECTION 4:
MAINTENANCE AND REPAIRS.
4.1.3 4.1.4
ElectricalOverview .. Electrical Power Supplies. Electrical fault Finding. Electrical Diagrams.
4.2.1 4.2.2
Foundation Diagram. LUbrication Diagram.
4.3.1
Arrangement Drawings.
4.1.1
4.1. 2
COPYRIGHT (C) Boxford Limited 1991.
~ll right~ reserved. No part of this publication may he reproduced, stored 1n a retr1eval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of Boxford Limited.
THE HEALTH AND SAfETY AT WORK ACT 1974. Under this Act information has to be made available to users of this equipment regarding its safe use. The equipment, when used in normal or prescribed applications within the parameters set for its mechanical and electrical performance, should Dot cause any danger or hazard to health and safety if normal engineering practices are observed and they are used in accordance with the instructions supplied. Many safety features have been incorporated in the design of this equipment including:
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Fully enveloping transparent chip/work guard with positive microswitch protection for spindle and feed hold. Positive microswitch protection on the pUlley end guard for spindle and feed hold. Delayed response to spindle forward/reverse and X/Z jog buttons to protect against accidental use in manual mode. Mandatory graphics run required for new programs before the machining cycle can be commenced and step by step execution of graphics in advance of the actual metal removal in the machining cycle. Ideal position for machines controls.
Feed rate over-ride to control jog rates.
Cycle stop. F'eed hold. Single block operation. Emergency stop push button • Power on indicator lamp. Low voltage control circuitry . Machine isolator switch. Fully enclosed main motor. Integrated electrical panel and power wiring. 'Power on' indicator lamp.
Whilst we attempt to give the fullest possible user informat~on in the manual if there is any doubt whatsoever about aspects relat1n~ ~o the proper' use of this equipment the user should contact Boxford L~m1ted, Wheatley, Halifax, West Yorkshire, HX) SAF. Tel: 0422 358311.
Fax: 0422 355924.
INTRODUCTION The Boxford 280 TH is a British made CNC lathe, and our objectives are to guide the user of a new lathe towards its safe operation, optimum performance and maximum useful life. We emphasise our belief however, that safety on the lathe relies to a very great extent upon the adoption of safe working practices, and that the useful life of the lathe, its performance and its accuracy depend largely on the care taken in its installation, operation and routine maintenance. We suggest therefore that the advice and information offered should be thoroughly digested and adhered to as closely as possible. Our commercial and technical departments will be pleased to supply further advice or information should this be required. Please quote the Lathe Model and Machine Serial Number (which may be found stamped at the lower right hand corner of the bed in all communications. BOXFORD LTD
HALIFAX (0422 358311)
1.1.1
INSTALLATION Siting The Machine The machine should be located on a firm, preferably concrete, floor which is capable of supporting the combined weights of Machine, Accessories, Equipment and an Operator, without noticeable deflection. sufficient space should be provided for cleaning and maintenance purposes. Machine Fixing Under normal operating conditions it is not essential for the machine to be bolted down, but for optimum accuracy and cutting performance foundation or clamp bolts are recommended and bolt holes are provided - refer to Foundation Diagram 4.2.1.
In cases where the machine is to be free standing some form of location should be provided to prevent the machine from being moved bodily once levelling and straightness checks have been completed. Electrical Supply The 280TM requires a 20A 3 phase 415V AC power supply (suitably earthed) plus a neutral line. A ~ariation of plus or minus 15 volts is tolerable on the 415 volts. \- Air Supply If the machine is supplied with a parts catcher, power chuck/collet or power tailstock, it will be necessary to run a suitable air supply to operate them. The supply required should be at 85 pounds per square inch pressure and capable of giving approximately 1.0 cubic feet per minute.
1.1.2
MACHINE CAPACITIES AND LIMITS 1.
Spindle Speeds: Spindle speeds are programmable and variable from 40 to 5000rpm. Spindle motor 3.75Kw (5HP) 3 phase.
2.
Feed Rates: Rapid traverse rate: 5m/min at 100%.
Program feed rates: 1 to 2000mm/min.
3.
X axis travel: 300mm
4.
Z axis travel: 300mm
5.
Spindle bored to pass: 58mm diameter.
6.
Metric dimensions format XXX.XXX (Expressed as X3,3).
7.
Imperial dimensions format XX.XXXX (Expressed as X2,4).
8.
System resolution (step measurement): O.0025mm (X axis) O.0050mm (Z axis)
1. 2.1
MACHINE FUNCTION KEYBOARD Power On Once the machine has been installed and the power supply connected then the . machine may be powered up. This is achieved by first switching on the isolator switch, located on the door at the right hand side of the machine, ensuring the emergency stop button is released and then pressing the POWER ON button on the machine function keyboard.
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OPERATION DESCRIPTION
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1. 3.2
ABSOLUTE AND INCREMENTAL CO-ORDINATES Co-ordinates are expressed as being either absolute or incremental. 1.
Absolute dimensions: In this system all co-ordinate locations are programmed from a fixed absolute zero point (origin).
2.
Incremental dimensions: 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 zero location.
Note that the machine's control system requires that the X axis values are expressed in diametral terms. The drawing below illustrates the different co-ordinate systems:
ABSOLUTE
-
DIMENSIONS
INCREMENTAL
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1.3 _3
PROGRAM FORMAT AND AXES DIRECTIONS A program is a series of "blocks" each showing a set of functions and/or co-ordinates Input of the program is via control system and is in tabular format. A typical format for the Boxford 280 lathe is:
LINE
G
M
x
z
I
K
F
s
W'here: LINE is the block number G
the prepatatory code
M
the miscellaneous function code
x
the X co-ordinate to change depth of cut
Z
the Z co-ordinate measured along the axis of the billet
I
additional information as needed
K
additional information as needed
F
feedrate
S
spindle speed
Axes Commands:
-z ......
+z
1
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1. 3. 4
PROGRAMMING - G CODES 1. Preparatory Codes (G Codes): Codes for the various preparatory functions have been standardised and are commonly known as G codes; the address letter G being followed by two digits.
2. Miscellaneous Functions (M Functions): These functions have been standardised (BS 3635:1972); the address
letter being M followed by two digits.
A summary of the G and M functions implemented on the Boxford 280TM
follows:
Preparatory Codes (G-codes)
Code No.
Function
GOO
Rapid traverse positioning
GOl
Linear interpolation
G02
Circular interpolation clockwise (CV)
GOJ
Circular interpolation counter clockwise
G04
Time Dwell
G50
Set maximum spindle speed
G70
Programmable inch dimensions
G7l
Programmable metric dimensions
G80
Canned cycle - cancel
Gal
Canned cyc.le - roughing diameter
G82
Canned cycle - facing or grooving
G83
Canned cycle - deep hole- (peck drilling)
G84
Canned cycle - thread cutting
G90
Absolute data input
G91
Incremental data input
G94
Feed/min
G95
Feed/rev
G96
Constant surface speed (c.s.s.)
r,97
Const~nt
R.?~.
(cc~)
1. 3.5
MISCELLANEOUS FUNCTIONS Code Number
Function
M02
Marks the end of the program for a single quantity.
M03
Starts spindle forward. Enter spindle speed S.
M04
Starts spindle reverse. Enter spindle speed S.
M05
Stops spindle.
M06
Tool change. Enter I
=
tool turret number (1-8)
MOB
Coolant On
M09
Coolant Off
M30
Marks the end of the program for repeat quantities.
1139
Closes automatic chuck (if fitted}.
M40
Opens automatic chuck (if fitted).
M99
Continuation code. Entering M99 into a program causes the program to be saved the program is simulated on the screen point and then the prompt to "continue
partially written to disc. Recall of up to the break otf writing" is made.
2.1
FURTHER EXPLANATIONS OF G CODES GOO
Rapid movement. This code moves the tool along the X axis and then the Z axis to the specified X and Z values as quickly as possible. It is not used for cutting metal. When entering a program the computer has a default value of 00 in the 'G' column.
GOl
Linear interpolation. The tool will move at the specified feed rate in a straight line along each axis or diagonally from its presen~ position to the new X and Z values.
G02
Clockwise circular interpolation. This code moves the tool clockwise in a circular arc in a single
quadrant. After entering G02 the following extra information is
needed:
X value = the diameter to which movement is to be made.
Z value = the Z co-ordinate to which movement is to be made.
I value = the distance from the arc centre (incremental) to the tool
position at the start of the cut along the X axis. K value = the distance from the arc centre (incremental) to the tool position at the start of the cut along the Z axis. (Note that I and K ace unsigned values)
G03
Counter clockwise circular interpolation. This code moves the tool counter clockwise in a circular arc in a
single quadrant. After entering GO) the following extra information is
needed:
X value Z value I value
the diameter to which movement is to be made.
Z co-ordinate to which movement is to be made.
= the distance from the arc centre (incremental) to the tool
position at the start of the cut along the X axis. K value = the distance from the arc centre (incremental) to the tool position at the start of the cut along the Z axis. (Note that I and K are unsigned values). =
= the
Worked examples of G02 and GO) follow overleaf.
2.2
CLOCKYISE CIRCULAR INTERPOLATION (G02): 10
(a) Single quadrant 90 deQree arc:
To turn from A to B arc of centre C, ie clockwise interpolation (G02).
Tool is positioned at A on the previous line of the program.
G
= 02
x : : : 25
Z
= -(10
= -15
+ 5)
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K
= 0
(b) Single quadrant partial arc: Co
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3.2
3 of 4
Writing a New Program cont'd. On completion of the first page of tools, pressing the soft key labelled 'fwrd' will display the second page whereas pressing the soft key labelled 'back' displays the fourth page. After entering the tool type number for position eight the display changes and asks if a 'Yes/No check' is required after each line or block has been entered .
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Answering 'NO' to this prompt does not allow the user a second change once the EOB key has been pressed to enter a line. If a mistake has been made with the data in any column then the edit facility would need to be used to correct the fault.
Answering 'Yes' to this prompt allows the user to reflect on the data entered on the line after pressing the EOB key by asking if the line is correct. Pressing the soft key labelled 'Yes' accepts the line and moves on to prompt for the next line in the program where as answering 'No' moves the cursor to the beginning of the line and the line can then be corrected before being accepted.
NB.
It is advised that the YES option be used until familiarisation with the input routine has been achieved.
4 of 4'
3.2
Writing a New Program cont'd. Vhichever of these two options are chosen pressing the relevant soft key accepts the option and the display changes to reveal the following: "".In TI!:'SiTl
o o oU o D.0 The first three lines or blocks of the program are compulsory in that
prompts as to the,data required appear across the VDU.
The first line of the program requests for either 90 or 91 to be entered in the G columns to set the mode of either absolute or incremental progr~mming. The second line requests for a 70 or 71 to be entered in the G column to set either imperial or metric input. The third line reqQests the input of a tool path po~ition and a tool or turret number. To enter this 'data press the address letter key on the alpha numeric keyboard and the cursor will jump into the relevant column. In this instance the X key would need to be pressed followed by the data relating to the X axis park position e.g. X50. Because there is more than one column. entry to be made then rather than pressing the EOB key to enter the data the INPUT key should be used. The cursor should now appear back in the line column awaiting the next address column to move to. Pressing the Z key will now move the cursor into the Z column where the data for the Z axis park position may be inserted. After entering the value (20), once again press the INPUT as there is one more piece of data to be input on the line. Press the I key and enter a 1 in the column to select tool 1. As this is the last piece of data required on the block, either the INPUT key followed by the EOB key may be pressed or just the EOB key alone. From line 40 onwards the user must decide what each line of program is going to contain to make the machine tool manufacture the component required. Should an error be made in keying in the data in a column there are several ways of correcting it depending on the position the error was noticed. If the error was noticed before the input key was pressed tben the cancel (CAN) key can be used to delete the erroneous characters. It may be that the error is not noticed until after the INPUT key has been pressed in which case the cursor will be in the line column. Pressing the same address letter as the one with the erroneous value in causes the cursor to move into that column and the old value can then be overtyped by the new. Pressing the INPUT key now displays the corrected value. Should the error not be noticed until after the EOB key has been pressed it is po~sible to answer 'No' to the prompt •CORRECT' providing the 'Yes/No' prompt option has been chosen. The column which is in error can then be corrected by pressing the address letter and keying in the correct value.
3.3
1 of 6
EDIT/CONTINUATION -This option allows programs to be altered, it errors are found, or to extend programs which may have been terminated during creation. To gain access to these facilities ensure the emergency stop button is released and press the edit key on the operators panel and enter the title of the program. Pressing the EOB key presents the following menu:
Selection of either of the four options is made by pressing the relevant numbered soft key.
'I'
= Continuation Pressing the soft key labelled 1 activates a graphical sl~ulation of the program up to the point at 'which it was terminated. The M code found at the end of the program determines how the software reacts. Should the program have an M9~ as its last block then the block containing the M99 is deleted and a prompt to continue is shown. The program may he extended to its conclusion at which point either M02 or M30 should be used. Should the program have an M02 or M30 at its end then the-display will revert to the program print menu and offer the facilities which are explained under Print a Program.
'2'
= Line
Edit
Choosing this option allows the user to scan through the program and make any corrections that may be necessary including inserting and deleting whole lines of data. Pressing the soft key labelled 2 changes the display and the program is read into the edit file.
3.3
2 of 6
Edit/continuation cont'd .
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The program title along with the dimensions of the material are
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The program may be scrolled up
and down by using the two cursor keys on the keyboard.
A LINE.
It may be necessary to insert lines of data to a program and this option allows this to be done. Using the cursor keys, scroll the program so that the line after the one that is to be inserted appears between the two arrow symbols. Press the soft key labelled 1 followed by the soft key labelled YES.
The line of data now jumps down a line and an empty line appears. Data may now be entered as required and on completion the EOB key pressed. The line number will now change to the next one in sequence and SUbsequent l~nes are renumbered. Further lines of data may be added until the program is as required. 2 ; DELETE A LINE
As well as adding lines to a program the facility to delete lines also exists. Scroll the line to be deleted so that it appears between the two arrow symbols. Press the soft key labelled 2 followed by the one labelled YES. Care must be taken as there is no second chance once the yes soft key has been pressed. Once again the line numbers are renumbered into sequence before any further action can be taken.
3.3
3 of 6
Edit/Continuation cont'd.
= EDIT A LINE
3
It may be required to alter one specific piece of data in a program. This could be an X co-ordinate or maybe a spindle speed but whichever value it was, it would be easier to change the specific value than to delete the whole line and type it again. Scroll the line that contains the value to be altered until it appears between the two arrow symbols. Press the soft key labelled 3 and confirm you wish to edit the line with the soft key labelled YES. The flashing cursor will now be-positioned at the beginning of the line. Key in the address letter of the value to be altered and the cursor jumps to the start of the column. Key in the new value followed by either the EOB key, if it is the only value to alter, or INPUT, should you wish to alter another value on the same line. To delete a value from a column scroll the line to be edited between the two arrow symbols. Press the soft key labelled 3 followed by the soft key labelled YES. Move the cursor into the relevant column and press the decimal point key to overtype the characters. Pressing EOB will now delete the column.
= GO
4
TO A LINE
~hen
editing long programs there is usually a need to skip from a line near the beginning of the program to a line near to the end of the program. Press the soft key labelled 4 and the soft key labelled YES. Enter the number of the line to be moved to and press the EOB key. The requested line will now appear between the two arrow symbols.
= RECORD
5
CHANGES
Once the program has been edited it must then be saved into the memory of the machine. Pressing the soft key labelled 5 followed by the one labelled YES saves the edited version of the program to memory and returns the display to the MAIN MENU. '3' = Column Edit This method of editing would be used if many identical values in any column were required to be altered to a new value. An example of where column edit would be both quicker and easier than line edit would be if all of the feedrate values currently set at 150mm/min (maybe 13 of them) were required to be altered to 175mm/min. Press the soft key labelled 3 and the following display will appear .
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As with the line edit option a menu with 5 options is displayed. 3 editing options.1 scroll option and the facility to save the changes and return to the menu.
3.3
4 of 6
Edit/Continuation cont'd.
'1'
= IF
COLUMN (?)
=
(?)
THEN CHANGE COLUMN (?) TO (?)
Pressing the soft key labelled 1 displays the prompt 'IF COLUMN'. The address letter of the column to edit should now be inserted. In our example this would be F for feedrate. Now enter the value that is to be searched for e.g. 150 and press EOB. The prompt now appears 'THEN CHANGE COLUMN' and it is now that the address letter once again is pressed. Enter the new value for the feedrate e.g. 175 and press EOB. The whole line is now displayed along with the question 'ALL CORRECT (YiN)?' Answering NO at this point aborts the operation and reverts to the column edit menu. Pressing the soft key labelled YES displays the prompt that asks whether confirmation is required before changing a block, or whether to change all of the blOCKS which match the given data. Answering 'NO' to this prompt, the control searches through the program (the block numbers are displayed) makes the changes requested and then displays the Column Edit Menu. Answering 'YES' the control searches through th~ program until it finds a block which matches the line requested value of 150 in the F column. When a block is found the whole block of data is displayed and a prompt to alter is given. Answering 'YES' will change the value but answering 'NO' leaves the value unchanged. Whichever is chosen the control takes the appropriate action then continues to search for the next occurrence. On reaching the end at the program the display reverts to the Column Edit Menu. Options 2 and 3 of the Column Edit Menu work in an identical way to option 1 only more data may be specified to achieve a more specific search.
'4'
=
SCROLL PROGRAM
This option allows the program to be scrolled from beginning to end to view any changes that may have been requested using options 1, 2 and 3. Press the soft key labelled '4' and enter the block number from which you wish to scroll from followed by the EOa key. The block which was entered now appears at the top of the display with a prompt to use the cursor keys to scroll the program up or down. To terminate the scroll mode press the soft key labelled '5' Which returns the display to the Column Edit Menu.
'5'
=
RETURN TO MAIN MENU
To return to the MAIN MENU press the soft key labelled '5' and either the 'YES' or 'NO' soft key to confirm whether or not the changes are to be saved. The display will now return to the MAIN MENU irrespective of which option was chosen. NOTE: Alterations to tool numbers are best performed using the Line Edit facility and must be followed by a continuation run. The purpose of this is to update the tool offset library with the new tool numbers. '4'
= Header
Edit
This facility allOWS the user to alter the header information of a program. The header intormation being the material type, the material size, the ~rogram title or the tool types chosen.
3.3
5 of 6
Edit/Contiuation cont'd.
Pressing the soft key labelled '4' presents another menu with four items which are available to be edited. Access to tbese items is by pressing the relevant soft key.
'1' = MATERIAL SIZE This option allows the size of material to be altered which would be of great use should a different material size, from that originally planned, be available for use. Pressing the soft key labelled '1' presents a display of the program title followed by the current workpiece dimensions and a prompt to enter the new values. To change a dimension ente~ the new value and press the EGB key otherwise press the EOa key only to leave the current value unaltered. Pressing the EOB key after entering the length value automatically reverts the Qisplay back to the Header Edit menu.
'2'
= MATERIAL
TYPE
This option allows the type of material being used to be changed. Pressing the soft key labelled '2' presents you with a choice of 3 types of material. Press the soft key 1, 2 or 3 to make the change and the display reverts back to the Header Edit menu. ··r
'3'
= PROGRAM
TITLE
As the heading suggests this third option allows the program title to be changed. This may be useful if alterations to the original program are required without loosing the original. To change the title press the soft key labelled '3' and enter the new title. The title must not exceed 'SIX' characters in length (a title exceeding SIX characters will be rejected). After keying in the new title press the EOB key and the display returns to the Header Edit menu. '4' ::; TOOL TYPE
This option allows the user to alter the tool types chosen in the eight tool stations.
3.3
6 of 6
Edit/Continuation cont'd.
Pressing the soft key labelled '4' presents the first tool position and a number relating to the type of tool currently assigned there. To alter the tool type for position 1, enter the number of the tool type required (from the tool library) and press the EOB key.
Should there be no change required- then pressing the EOB key alone increments the position number by one and displays the tool type number for that position. On completion of the eighth tool position and type the display returns to the Header Edit menu. Once all the editing of the header information has been completed, pressing the soft key labelled 'MENU' presents an option to 'SAVE CHANGES' before returning to the MAIN MENU. Pressing the soft key labelled 'YES' saves all of the changes that have been made in any of the four Header Edit options.
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3.4
TEST RUN A PROGRAM After either writing a new program or editing an existing program it may be necessary to step through it on simulation prior to running it on the machine tool. This option allows this to be carried out with no danger to operator or machine. Press the TEST RUN button on the operators panel 'and enter the program title. Pressing the EOB key causes the display to change to the follo~ing.
'URUE HilUS
o [)h. 35,000
'.OJto 0.000
l...r"~ l
h SO. OO()
Pressing the EOB key allows the program to be stepped through line by line and checked for accuracy.
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ou oB
Should a fault be noticed then it may be corrected using the edit facility and a second test run carried out.
On completion of the test run the display returns to the MAIN MENU so the appropriate action may be taken.
3.5
1 of 2
PRINT A PROGRAM Choosing this option from the MAIN MENU allows the user to view the program listing, taKe a hard copy of the program listing or view a quick simulation of a program. To access these facilities press the print button on the operators panel and enter the program title. Pressing the EOB key brings up the following display:
You will notice a sub menu appears offering three options which will now be explained in detail.
1.
Display Program
To display on the VDU a listing of the program, press the soft key labelled 1 and the first page of the program is displayed: Depending on the length of the program, pressing the EOB key will either return the user to the program print sub menu if the program does not exceed 25 blocKs or display the next page of the program if it does exceed 25 blocks. 2.
Print Program This option allows the program listing to be printed out on paper, providing an Epson compatible printer is connected to the side of the machine. Press the soft key labelled 2 and confirm that a printer is connected by pressing the soft key labelled YES.
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