CNC Lathe. CNC Technology prolight Turning Center. Teacher s Guide

Transcription

1 CNC Lathe CNC Technology prolight Turning Center Teacher s Guide

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3 CNC Lathe CNC Technology prolight Turning Center Teacher s Guide 1998 Light Machines Corporation Manchester, NH, U.S.A. February, 1998 and Intelitek

4 1998 Light Machines Corporation All Rights Reserved. The information contained in this guide was accurate at the time of its printing. Light Machines Corporation and Intelitek reserve the right to change specifications and operational performance of its products without notice. Any changes or corrections to the information contained in this publication will be incorporated in future issues. This publication ( , February, 1998) corresponds to the prolight Turning software program. Printed in U.S.A. spectracam and spectracad are trademarks of Light Machines Corporation. All other register marks or trademarks are of their respective holders.

5 WARNING The operation of rotating machinery should only be attempted by experienced, knowledgeable individuals! Read the entire contents of the Safety Section before running NC programs on the Turning Center. To avoid possible injury always observe the safety precautions described in this Activity Guide.

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7 Table of Contents Introduction Installation Pre-Test Worksheets Post-Test Answers About this Program... iii About SCANS Skills... iv SCANS Skills in this Program...v About the Activities Book... vi About the Turning Teklink Hardware Installation Installing the Control Program (Software) Pre Test Pre-Test Answer Sheet Worksheets Post-Test Post-Test Answer Sheet Pre-Test Answers Activity 1 Answers Activity 2 Answers Activity 3 Answers Activity 4 Answers Activity 5 Answers Activity 6 Answers Activity 7 Answers Activity 8 Answers Activity 9 Answers Teacher s Guide i CNC Technology: CNC Lathe

8 Activity 10 Answers Activity 11 Answers Activity 12 Answers Activity 13 Answers Activity 14 Answers Activity 15 Answers Post-Test Answers Teacher s Guide ii CNC Technology: CNC Lathe

9 Introduction About this Program This manufacturing technology program is a flexible, four-semester course of study, based on hands-on activities. It is designed to provide students with a broad base of competencies in modern manufacturing technology. The curriculum systematically covers turning and computer numerical control (CNC), allowing students to acquire the knowledge and skills greatly needed for success in industry. Students work in teams and are exposed to various core technologies on a rotation basis. The Teklink concept enables the program to be tailored to the needs of each class and student. By rotating through individual teklinks, students master the technical skills and procedural techniques necessary for competent operation of each piece of equipment. Once the students are comfortable with the basics, design projects emphasize and develop the need to combine stations to form islands of automation, or Flexible Manufacturing Systems (FMS). Ultimately, students will be exposed to Computer Integrated Manufacturing (CIM) systems, where they need to complete a project, from concept, through design and all the way to production. Teacher's Guide iii CNC Technology: CNC Lathe

10 About SCANS Skills In 1990 the United States Secretary of Labor appointed a group called the Secretary s Commission on Achieving Necessary Skills (SCANS) to determine the skills necessary to succeed in the workforce. The Commission was composed of 30 representatives of education, business, labor, and state government and was charged with defining a common core of skills that constitute job readiness in the current economic environment. The environment being one of fierce economic competition, new technologies, and rapidly changing skill requirements. Specifically, the Commission was asked to: w Define the skills needed for employment. w Propose acceptable levels of proficiency. w Suggest effective ways to assess proficiency. w Develop a dissemination strategy for the nation s schools, businesses, and homes. During the course of its work, SCANS produced several publications. The Commission s first report, What Work Requires of Schools, resulted from extensive meetings and discussions with a variety of organizations including business, industry, public employers, and unions. The report identified 36 workplace skills that high-performance workplaces require, and that high-performance schools should produce. These skills were divided into a Three-Part Foundation and the Five Competencies. The Three-Part Foundation includes: w Basic Skills, which include literacy and computational skills w Thinking Skills, described as necessary to put knowledge to work w Personal ualities, described as making workers dedicated and trustworthy The Five Competencies include: w The ability to manage resources w The Interpersonal Skills necessary to work amicably and productively with others w The ability to acquire and use information w Skills needed to master complex systems w Skills needed to work with technology It was the finding of the Commission that these skills lie at the heart of job performance and are essential preparation for all students, both those going directly to work and those planning further education. The Commission found that the most effective way of learning skills is in context, teaching learning objectives within a real environment. They also believe that the SCANS foundation and competencies should be taught and understood in an integrated fashion that reflects the workplace contexts in which they are applied. Source: ScansLink: The National Scan Skills Concern, Get the Facts. nlc/misc/scans/facts.htm Teacher's Guide iv CNC Technology: CNC Lathe

11 SCANS Skills in this Program The manufacturing technology program has been designed in recognition of the findings of the Secretary s Commission on Achieving Necessary Skills. The activities enable students to develop and reinforce both technical, occupational skills and the general (SCANS) skills which are required by all people, in any job or educational environment. Tasks enhance problem solving and decision making skills. Cooperative learning and team work promote interpersonal and leadership skills. Projects emphasize information and communication skills. Acquiring these skills will prepare students to successfully meet the social, economic and technological challenges of the 21st century. Teacher's Guide v CNC Technology: CNC Lathe

12 About the Teklink Activities Book The Teklink Activities Book is a lab manual which contains 15 Activities, each of which can be completed in one 45-minute lab session. Each activity begins with several lists: w Objectives are the goals students will achieve. w SCANS Skills are the competencies students will develop. w Materials are the specific items needed for each activity. The Overview section introduces the students to the subjects which will be explored in each activity. The Procedures contain series of Tasks, or operations. The first time an operation is to be performed, instructions are given in a tutorial manner. In subsequent tasks students should be able to perform these operations without guidance. uestions and tables for entering lab results appear within the tasks. uestions for discussion and review conclude each activity. All questions and tables are printed on a set of Worksheets supplied with this book. Students should record their answers in the worksheets, or as directed by the instructor. The Academics section at the end of each activity contains enrichment material, such as industrial applications and opportunities, or the scientific background upon which the teklink technology is based. In teklinks which include hardware (e.g., vise, tooling), students will be directed to perform inventory and safety checks at the beginning of every working session, and to shut down the system properly at the end of each activity. In teklinks which utilize software, it is assumed that students are familiar with the PC and are comfortable working in the Windows/DOS operating environment. However, instructions for operating the specific software are explicit and can be performed by novices. Teacher's Guide vi CNC Technology: CNC Lathe

13 Installation About the CNC Lathe Teklink The prolight Turning Center The prolight Turning Center is a two axis CNC lathe that can perform roughing, finishing, boring, grooving, facing, and cutoff operations. The prolight Control Program, which you load onto your computer, accepts standard EIA RS-274D G&M codes that CNC machine tools recognize. The CNC Lathe Teklink is designed to give students an introduction to Computer Numeric Control (CNC) by combining an easy to use interface with a basic benchtop lathe. The CNC Lathe Teklink contains the following elements: w w w w w w The prolight Lathe Computer and Controller box WPLT Control Program software for Windows A number of simple NC programs for students to run A tool turret for automatic tool changes Several 3 x.75 brass workpieces WPLT Control Program for Windows The prolight Control Program provides a simple to use graphical user interface to the turning center. Using colorful graphics and on line help, basic turning operations are easily executed. The prolight Control Program is shipped on two 3.5, 1.4MB disks. It must be installed on the hard drive of your computer, running either Windows 95, or Windows NT version 3.51 (or higher). You must have at least 5MB of free space on your hard drive to perform this installation. Teacher s Guide 1-1 CNC Technology: CNC Lathe

14 Materials Required for the Activities The following materials are supplied with the Turning Center, and are required for the CNC Lathe Teklink. In addition, students may also need a diskette or personal directory on the computer hard drive to store their files. w w w w w w w w w w w Tool Turret 1 Left hand Profiling tool and holder 1 Right hand Profiling tool and holder 1 45 degree tool and holder 1 Cutoff tool and holder 1 External Threading tool and holder 1 Internal Threading tool and collet 1/4, 3/8, and 1/2 Boring tools 1 Chuck Key Allen Keys 30 Brass Workpieces Teklink Requirements Computer Requirements: w Windows 95. w w w w w w 16MB RAM minimum for Windows 95 (24MB is recommended for best performance). A 3.5 in floppy drive. A hard drive with at least 5MB of available space. A full length ISA bus slot to install the interface card. A VGA graphics controller and monitor. A Microsoft-compatible mouse. Lab Station Requirements: w w A sturdy table or bench for the Turning Center and computer. Placing the table against a wall provides more stability. A 120VAC, 15 amp polarized outlet. Teacher s Guide 1-2 CNC Technology: CNC Lathe

15 Check Your Shipment The first thing you should do after receiving your Turning Center is inspect the packaging for any visible signs of damage. If there is damage to the outside of the packaging, contact the shipping company as well as Light Machines Corp. If there is no damage, locate the packing slip. This slip lists all of the items you should have received with your Turning Center. Check all of the items on the list. If any item is missing, contact Light Machines Customer Service Department (800/221/2763). Register Your Turning Center You ll find a registration card in the small box with the documentation and software disks. Clearly print all the requested information and return this card to Light Machines Corporation. Unpack the Turning Center 1. Position the pallet near the table on which you ll set the Turning Center. The table should be located against a wall for maximum support. 2. Remove the staples holding the bottom of the cardboard container to the pallet. 3. Lift the cardboard container off of the pallet. 4. Inspect the Turning Center chassis for visible signs of damage such as a broken shield, a dent in the chassis or damaged cables. If any damage is noted, or if you find any discrepancies between the packing slip and the items received, call Light Machines Customer Service Department at (800/221/2763). 5. From underneath the pallet, use a 9/16 wrench to remove the four bolts holding the Turning Center base to the pallet. Keep the bolts and other packaging materials in case you have to return the machine for any reason. Set Up the Turning Center 1. Lift the Turning Center off of the pallet and onto the table. 2. Once on the table, position the Turning Center correctly for turning. 3. Remove the protective paper from the safety shield. Teacher s Guide 1-3 CNC Technology: CNC Lathe

16 Hardware Installation The following paragraphs review the procedures for installing the hardware components of the prolight Turning Center. You should already have your personal computer set up in accordance with the directions in the computer owner s manual. WARNING The first thing you have to do is install the prolight Interface Card in your PC. Do not connect power to the turning center or the computer until instructed to do so in the following procedures. Installing the Interface Card in the PC The Interface Card can be installed in any full-size slot designated for expansion card use. Refer to your computer owner s manual to determine particular expansion card restrictions. Opening the PC Chassis WARNING To install the Interface Card, you must remove the cover of the PC. Refer to the installation instructions supplied with your PC for details on removing the cover. Generally, the cover is secured by four screws through the rear panel; however, some computers may have push latches, or screws in different locations. Disconnect power from your personal computer before opening its chassis cover! Turn off the power switch and remove the power cord to assure that no electrical potential is present when the cover is removed. Do not plug the power cord from the PC chassis into an AC outlet until all installation procedures have been completed and the chassis cover has been closed. Set the cover aside and locate an open slot in which to install the Interface Card. Remove the blank slot cover (if any). Removing the slot cover requires removing a screw at the top rail of the rear panel. You may choose to discard the cover, but save the screw for installing the Interface Card. Unpacking the Interface Card The card is shipped inside an antistatic envelope. Be careful not to create any static discharge when removing the card from the envelope; touch a grounded surface such as the PC chassis, first. Slide the card out of the envelope and inspect it for signs of damage, such as bent or broken components or a warped circuit card. If damage is found, contact Light Machines Corporation immediately Teacher s Guide 1-4 CNC Technology: CNC Lathe

17 Inserting the Interface Card The following procedures describe how to insert and secure the Interface Card in the computer. 1. Grasp the Interface Card at the front and back. 2. Position the card above the bus connector at the chosen slot. The interface connector on the end of the card should face the rear panel of the computer chassis. 3. Slide the card into the bus connector. The interface connector on the card should protrude from the rear panel of the computer. Carefully wiggle the Interface Card back and forth to assure its tightness in the bus connector. Components on the Interface Card should not touch adjacent cards or other components. 4. Secure the Interface Card to the top rail of the rear panel with the screw you saved when removing the blank slot cover. 5. Pay particular attention to the location of the slot in which you inserted the Interface Card. Do not get the Interface Card mixed up with the parallel port which uses the same type of connector. Checking Your Installation After installing the Interface Card, replace the computer chassis cover. Connect the computer power cord and turn the computer on. The computer should perform an internal check, run the operating system and display the windows home screen. If the PC fails to start-up, turn off the power, open the chassis and check your installation to be sure that the Interface Card is located in an appropriate slot and is properly seated. When the Windows home screen appears, choose shut down from the Start menu and install the other hardware components. Connecting the Turning Center WARNING The following paragraphs review the procedures for connecting your computer with the turning center and Controller Box. The Interconnection Diagram has been provided as a visual aid for the recommended connections. Do not connect power to the turning center, the Controller Box or the computer until instructed to do so in the following procedures. Never connect or disconnect the cables with the power on! This will cause damage to the Controller Box drive components. Operate the turning center with all cables firmly secured. Teacher s Guide 1-5 CNC Technology: CNC Lathe

18 Connecting the Turning Center to the Controller Box The interface cables and power cords are long enough to allow the Controller Box to be located up to five feet away from the turning center. Make sure the turning center is placed on a stable, flat surface and leveled properly. The Controller Box can be placed beside the turning center, or mounted on a shelf beneath the turning center. Make sure the power switch on the front of the Controller Box is readily accessible. Keep in mind that you may need to check the fuses on the rear panel of the Controller Box. Locate the Controller Box in an area where it will not be exposed to metal chips or cutting fluid. 1. Route the interface and power cables from the turning center to the Controller Box as shown in the Interconnection diagram. 2. Insert the 15-pin plug from the turning center into the 15-pin receptacle marked A & B AXES on the rear panel of the Controller Box. 3. The Tool Turret uses the cable with an 8 pin connector on one end and a 9-pin connector on the other. Insert the 8-pin connector into the turret interface connection. Insert the 9-pin connector into the receptacle marked C AXIS on the rear panel of the Controller Box. 4. Insert the AC power plug from the turning center into the 120VAC, three-prong receptacle marked SPINDLE on the rear panel of the Controller Box. 5. Make sure all connectors are secured with screw locks. Connecting the Turning Center to the Computer The spindle cable is attached to the rear panel of the Turning Center and is terminated with a 9-pin plug. Insert this plug into the 9-pin receptacle on the computer Interface Card you installed earlier. Connecting the Computer to the Controller Box 1. Route the 25-pin cable between the Computer and the Controller Box. 2. Connect the end of the cable marked COMPUTER to the 25-pin connector protruding from the LMC Interface Card in the rear of the computer. As mentioned before, make sure you are plugging the cable into the Interface Card connector, not the parallel port. 3. Connect the other end of the cable to the 25-pin connector marked COMPUTER on the rear panel of the Controller Box. 4. Make sure all connectors are secured. Teacher s Guide 1-6 CNC Technology: CNC Lathe

19 STEPPERS MAIN 3A 12A AAC2 ACC1 SPINDLE 3A 3A 8A ONLY OPERATE WITH ALL CABLING SECURELY FASTENED BETWEEN THE MACHINE TOOL AND THIS BOX COMPUTER TTL I/O A&B AXES C AXIS STEPPERS MAIN 3A 12A AAC2 ACC1 SPINDLE 3A 3A 8A ONLY OPERATE WARNING WITH ALL CABLING DO NOT OPEN SECURELY FASTENED NO USER SERVICEABLE BETWEEN THE MACHINE PARTS INSIDE TOOL AND THIS BOX COMPUTER TTL I/O A&B AXES C AXIS SPINDLE CHUCK ACC 120V 60HZ COMPUTER prolight Turning Center 120V, 60Hz AC Outlet Controller Box Turning Center Power Cord LMC LMC Computer 9-Pin Interface Card/Spindle Cable 25-Pin Interface Card/Controller Cable 8-Pin/9-Pin Turret/Controller Cable 15-Pin Machine/Controller Cable Spindle Power Cord Controller Box Power Cord LMC LMC Teacher s Guide 1-7 CNC Technology: CNC Lathe

20 Connecting Power to the Hardware Components Both the turning center and the Controller Box must be plugged into a grounded 120VAC, 60Hz, 15A polarized wall outlet, as shown in the Interconnection Diagram. This outlet must be capable of supplying up to 12 amps of power to the Controller Box. Locate the loose power cord that came with the turning center; this is the power cord for the Controller Box. Insert the receptacle end of this cord into the 120VAC threeprong connector on the back of the Controller Box. Insert the plug end of this cord into a grounded, three-hole, 120VAC, 60Hz wall outlet. Before running the turning center it is important that all safety precautions are followed. If you are not familiar with the turning center, it is recommended that you read through the Users Guide and perform the Tutorial in Section D. We have included a Safety Checklist on the following page to ensure that there is always a copy posted near the turning center. Installing the Control Program (Software) The following instructions assume that your hard drive is drive C, and your floppy drive is drive A. 1. Turn on the computer. Wait for it to go through its internal checks and for it to complete the start up process. 2. When your Windows desktop appears, insert the prolight disk in the computer floppy drive. 3. Using the Windows Explorer, (Start Menu>Programs>Windows Explorer) open the floppy drive. Note: If you are installing on Windows NT, use either the File Manager to access the floppy drive, or select Run from the Program Manager. 4. Double click on Setup.exe to start the installation. 5. The Welcome screen appears. You are warned to exit all other running programs. If no other programs are running, click Next. 6. The next screen requests that you enter the destination directory for the Control Program. If you would like to place the Control Program in a directory other than the default directory, click on Browse and select an alternate destination. Otherwise, click Next. 7. A window appears, displaying installation progress, and prompting you on how to proceed. After installation is complete, you are prompted to view the Readme file. It is beneficial to view the Readme file at this time because it contains important information about the software and the machine that may not be included in the User s Guide. 8. Run the Control Program by double clicking the program icon. 9. If running Windows NT, you need to reboot the computer. Teacher s Guide 1-8 CNC Technology: CNC Lathe

21 Uninstalling the Control Program In the event you need to remove the Control Program from your hard drive, there is an uninstall program included on the software disks. The uninstall program was copied onto your hard drive when you installed the Control Program. To uninstall the Control Program, just double click the Remove Program icon (it should be in the same folder as the Control Program). A message appears asking if you are sure you wish to remove the program and all its files. Click on Yes to uninstall, or Cancel to exit the Uninstall program. Teacher s Guide 1-9 CNC Technology: CNC Lathe

22 Safety Checklist Before you enter the work area: q q q Put on safety glasses. Tie back loose hair and clothing. Remove jewelry including rings, bracelets and wristwatches. Before turning a part: q q q q q q q q q q q Make sure you have the correct tool for the job. Secure the tool properly. Make sure all tool positions have been properly initialized. Verify the NC program on the computer before turning. Remove all loose parts and pieces from the machine. Remove adjusting keys and wrenches from the machine. Close the safety shield. Only operate the machine after being properly trained in its use. Perform a dry run: q q q Set the spindle speed to lowest manual speed setting. Make certain there is no workpiece in place. Run the NC program to make sure all the moves make sense before running the program with a workpiece in place. After completing the dry run, properly secure the workpiece to the machine. Keep fluids away from all electrical connections, electronic or electrical devices, the computer and nearby electrical outlets. While turning a part: q q q q q q Do not touch moving or rotating parts. Press the Emergency Stop button before opening the safety shield. Only open the safety shield after the spindle has stopped rotating. Press the Emergency Stop button whenever changing tools or mounting or removing a workpiece. Pull the Emergency Stop button out only after closing the safety shield. Keep all unauthorized persons away from the work area. Teacher s Guide 1-10 CNC Technology: CNC Lathe

23 Pre-Test 1. On a lathe the stock mounts in the? A. Chuck B. Stepper motor C. Cross slide D. Workpiece 2. The work piece is? A. The same as a workbench B. The stock you turn C. A tool D. None of the above 3. Tool chatter is caused by A. Dissimilar metals B. A loose tool C. A talkative lab partner D. All of the above 4. CNC stands for A. Control for New Computers B. Computer Numeric Control C. Computational Numeric Catalyst D. Combined Numeral Components 5. An NC code block is A. An machined workpiece B. A character in an NC program C. A line in an NC program D. A way to stop a program from running Teacher's Guide 2-1 CNC Technology: CNC Lathe

24 6. Profiling and parting tools are A. Tools used for cutting B. Tools used for grinding C. Tools used for boring D. None of the above 7. The axes on a lathe are called the A. The R and T axes B. The X and Z axes C. The M and O axes D. The J and I axes 8. You should press the Emergency Stop button on the turning center when A. You want to ask the instructor a question B. You are changing stock on the lathe C. After you open the Safety shield D. Never 9. Tool path verification is used A. Before a part is turned B. After a part is turned C. To home the lathe D. To jog the lathe 10. An NC file A. Is used to fine tune the workpiece B. Is never stored on the computer C. Can be edited D. Is where you keep all of your NC programs Teacher's Guide 2-2 CNC Technology: CNC Lathe

25 11. You can make adjustments to the lathe A. When the lathe is running B. Whenever you want C. Only when the emergency stop button is pressed in D. When the lathe is paused during a program 12. The spindle axis is A. The Y axis B. The Z axis C. The X axis D. The A axis 13. Feed rate is A. How fast the lathe eats power B. How fast the lathe turns the spindle C. How fast the tool moves into the workpiece D. How fast the chips are removed from the workpiece 14. The Jog Control is used to A. Home the lathe B. Jog the cross slide C. Set the Origin D. All of the above 15. Machine Home is A. Where you store the lathe B. The point of origin on the workpiece C. The positive end of travel on both axes D. The middle of the axes Teacher's Guide 2-3 CNC Technology: CNC Lathe

26 16. What do you use to hold stock on the lathe? A. The chuck B. Your hands C. Your lab partner D. Wire 17. What is the purpose of the safety shield? A. Protect the operator from flying chips B. Keep foreign objects out of the enclosure C. Allow the operator to see the turning process D. All of the above 18. What is a Dry Run? A. Another way to verify your NC program B. Running the program with no stock mounted C. A way to check that all tool motions make sense D. All of the above 19. When you design a part to be turned, what is the first step? A. Write the program B. Perform a dry run C. Sketch the part D. Determine stock size 20. Safety is A. The least important thing to think about when operating a lathe B. Something to consider when operating a lathe C. The most important thing to think about when operating a lathe D. A position in Football Teacher's Guide 2-4 CNC Technology: CNC Lathe

27 Name: Pre-Test Pre-Test Answer Sheet. 20 uestions. 1 A B C D 2 A B C D 3 A B C D 4 A B C D 5 A B C D 6 A B C D 7 A B C D 8 A B C D 9 A B C D 10 A B C D 11 A B C D 12 A B C D 13 A B C D 14 A B C D 15 A B C D 16 A B C D 17 A B C D 18 A B C D 19 A B C D 20 A B C D Teacher's Guide 2-5 CNC Technology: CNC Lathe

28 Teacher's Guide 2-6 CNC Technology: CNC Lathe

29 Activity 1 Worksheet Name: Task 1-1 Safety Test Safety When using the Turning Center, are the following practices safe or unsafe? Write S (safe) or U (unsafe) on the line next to each statement. Wear safety glasses while operating the Turning Center. Roll your sleeves up above the wrists. Wear a loose chain around your neck while you operate the Turning Center. Leave a wrench in the work area so you can use it later, and turn on the Turning Center. Verify your part programs before actually running them on the Turning Center. Raise the safety shield while the Turning Center is operating. Plug the Turning Center into a two-prong extension cord. Use a brush to remove chips while the Turning Center is operating. Follow the safety rules every time you operate the Turning Center. Wear a loose, unbuttoned shirt when operating the Turning Center. Make sure the cutter is securely mounted to the spindle. Make adjustments while the Turning Center is operating. Turn on the Turning Center when it is sitting on a damp surface. Turn on the Turning Center before your instructor checks the setup. I have answered all of the safety questions correctly and understand every one of the safe practices explained in this lesson. I agree to follow these practices every time I work with the Turning Center. Student: Date: Instructor: Date: Teacher s Guide - Worksheets 3-1 CNC Technology: CNC Lathe

30 Activity 2 Worksheet Name: Getting Started Task 2-1 Inventory and Safety Checks o prolight Lathe and controller box o Computer with WPLT Control Program installed o Safety Checklist o Lab Station conforms to safety guidelines? What are the 6 things you do not do while turning a part? Why should items like wrenches and keys be removed from the work area before operating the turning center? Task 2-2 Identify Lathe components What is the difference between a lathe and the Turning Center? Teacher s Guide - Worksheets 3-2 CNC Technology: CNC Lathe

31 C O R P O R A T I O N MANCHESTER, NEW HAMPSHIRE, U.S.A. Name: Using your worksheet, fill in the names of the components indicated below. Safety Shield X Axis Drive Motor Cross Slide prolight Turning Center Spindle RPM Min Max Computer Spindle Speed EMERGENCY STOP Spindle Speed Switch Emergency Stop Button LIGHT MACHINES Z Axis Drive Motor (inside enclosure) Chuck What is the purpose of the Safety Shield, and when is it used? What control on the turning center should you use in an emergency? What part of the turning center rotates the workpiece? Teacher s Guide - Worksheets 3-3 CNC Technology: CNC Lathe

32 MANCHESTER, NEW HAMPSHIRE, U.S.A. Name: Task 2-3 Axes Identification Using the worksheet, draw and label the 2 axes, and the positive and negative directions on each. prolight Turning Center Spindle RPM Min Max Computer Spindle Speed EMERGENCY STOP LIGHT MACHINES C O R P O R A T I O N What parts of the Turning Center do the X axis and Z axis drive motors move? Teacher s Guide - Worksheets 3-4 CNC Technology: CNC Lathe

33 Name: Task 2-4 Controller Components Where is the controller power on/off switch located? Where is the controller fuse panel located? What does the Controller Box do? Task 2-5 Discussion and Review What have you learned about Lathes and turning? About Safety? List 3 things that you think are important to know when using the Turning Center. Teacher s Guide - Worksheets 3-5 CNC Technology: CNC Lathe

34 Activity 3 Worksheet Name: The Control Program Task 3-1 Inventory and Safety Checks o prolight Lathe and controller box o Computer with WPLT Control Program installed o Safety Checklist o Lab Station conforms to safety guidelines? Task 3-4 Standard Tool Bar There are 3 ways to save an NC program. List 2 of them. Task 3-6 Inputs Tool Bar What happens differently from when you did this exercise with the outputs toolbar? Task 3-8 Status Bar Which indicators are on and which are off? Does the clock read the correct time? Teacher s Guide - Worksheets 3-6 CNC Technology: CNC Lathe

35 Task 3-11 Discussion and Review Name: What are some of the advantages of having a computer control a lathe rather than a person? Why might it be a good idea to graphically verify a program before running it? Teacher s Guide - Worksheets 3-7 CNC Technology: CNC Lathe

36 Activity 4 Worksheet Name: Mounting Tools Task 4-1 Inventory and Safety Checks o prolight Lathe and controller box o Computer with WPLT Control Program installed o Safety Checklist o Lab Station conforms to safety guidelines? Task 4-5 Discussion and Review Which way do side tools cut from? What are side tools used for? What does a parting tool do? Why are cut off operations performed at a low speed? What should you do if the cutting tool chatters? Why are there frequent tool withdrawls during a boring operation? What are boring tools used for? Teacher s Guide - Worksheets 3-8 CNC Technology: CNC Lathe

37 Name: Why are profiling tools popular in turning operations? What is the angle of a threading tool? What is one reason you might get tool chatter? What tool positions on a tool turret are used for side, profiling, or external threading tools? Teacher s Guide - Worksheets 3-9 CNC Technology: CNC Lathe

38 Activity 5 Worksheet Name: Initializing the Tool Turret Task 5-1 Inventory and Safety Checks o o o o prolight Lathe and controller box Computer with WPLT Control Program installed Safety Checklist Lab Station conforms to safety guidelines? Task 5-7 Discussion and Review If you had set up tools in the wrong tool stations, what do you think would happen when the NC program started to run? Why is it necessary to home the tool turret? Teacher s Guide - Worksheets 3-10 CNC Technology: CNC Lathe

39 Activity 6 Worksheet Name: Reference Positions Task 6-1 Inventory and Safety Checks o prolight Lathe and controller box o Computer with WPLT Control Program installed o Safety Checklist o Lab Station conforms to safety guidelines? Task 6-3Setting Machine Home What is Machine Home? Where is Machine Home? Task 6-4 Setting Machine Zero Do you think you could have the workpiece origin somewhere other than the front of the chuck? What would happen if you entered a width greater than.375? Task 6-5 Discussion and Review What do you think would happen if you set the workpiece origin first, and then homed the machine? Teacher s Guide - Worksheets 3-11 CNC Technology: CNC Lathe

40 Activity 7 Worksheet Name: Selecting an NC Program Task 7-1 Inventory and Safety Checks o prolight Lathe and controller box o Computer with WPLT Control Program installed o Safety Checklist o Lab Station conforms to safety guidelines? Task 7-3 Selecting an NC Program What is an NC program? What happens to the file in the Edit window? The Status Bar? Task 7-6 Adjust the Stock What might happen if you put the wrong sizes in the stock window? Task 7-9 Discussion and Review How does the computer file system make it easier to operate the computer? What are some of the things the NC program controls? Teacher s Guide - Worksheets 3-12 CNC Technology: CNC Lathe

41 Activity 8 Worksheet Name: Verify and Dry Run Task 8-1 Inventory and Safety Checks o prolight Lathe and controller box o Computer with WPLT Control Program installed o Safety Checklist o Lab Station conforms to safety guidelines? Task 8-4 Estimate Run Time What happens? What information does the dialog box give you? How long will the Turnone program run? How far will the tool travel? Why would you want to know how long a program will run? What other reasons are there for knowing the runtime? Task 8-5 Verify Turnone.NC How does tool path verification check the program for errors? Teacher s Guide - Worksheets 3-13 CNC Technology: CNC Lathe

42 Name: Did your program run through verification without any problems? If not, what were the problems? How did you fix them? Task 8-6 Dry Run the NC Program What is a Dry Run? What are the things to look for during a dry run? Did you get any error messages while the program was running? How would you correct them if you did? Task 8-7 Discussion and Review Why do you think it is so important to verify the NC program in different ways before actually cutting the part? What are some of the dangers of just running the program? Teacher s Guide - Worksheets 3-14 CNC Technology: CNC Lathe

43 Activity 9 Worksheet Name: Run the NC Program Task 9-1 Inventory and Safety Checks o prolight Lathe and controller box o Computer with WPLT Control Program installed o Safety Checklist o Lab Station conforms to safety guidelines? Task 9-9 Run the Program Where on the control program screen does it tell you the run time of the program? Check your worksheet from Activity 8. How long did it actually take to run the program? Was the Estimate Run Time function correct? Task 9-10 Discussion and Reveiw Did you encounter any problems while running the Turnone program? Would you like to learn more about NC programming, so that you could make your own parts? What kind of parts would you like to turn? Teacher s Guide - Worksheets 3-15 CNC Technology: CNC Lathe

44 Activity 10 Worksheet Name: NC Programming Inventory and Safety Checks o prolight Lathe and controller box o Computer with WPLT Control Program installed o Safety Checklist o Lab Station conforms to safety guidelines? Task 10-1 uestions 1. What is a part program? 2. What are the two parts of an NC word? 3. Here are some new terms you learned in this module. Write a brief definition of each term. Code- Address Character- Word- EIA RS-274D Standard Format- Teacher s Guide - Worksheets 3-16 CNC Technology: CNC Lathe

45 Name: Parameter- Block- Preparatory Code- 4. Match the NC words in the first column to their correct meaning in the second column. M02 a. Move the tool to 2.5 on the X axis (absolute) G90 T1 J.5 G00 X2.5 N12 G02 F1 Z.25 I.15 M05 b. Move the tool to.25 on the Z axis (absolute) c. Move the tool rapidly to the indicated position d. Make the center point of the arc.15 on the X axis e. Use clockwise circular interpolation f. End of program g. Turn off the spindle motor h. Make the center point of the arc.5 on the Y axis i. Use incremental coordinates j. Use absolute coordinates k. Move the tool at a feed rate of one inch per minute l. This is the block marked number twelve G91 m. Use tool #1 Teacher s Guide - Worksheets 3-17 CNC Technology: CNC Lathe

46 Name: 5. Some blocks from an NC program are listed below. Each block contains several words. Write an explanation of each word in the space provided. Block Explanation N0G0G90Z.1 N0 - G0 - G90 - Z.1 - N1M3 N1 - M3 - N2G1X2.5Y3F2 N2 - N43G0Z.1 N44M2 G1 - X2.5 - Y3 - F2 - N43 - G0 - Z.1 - N44 - M2 - Teacher s Guide - Worksheets 3-18 CNC Technology: CNC Lathe

47 Name: 6. What is wrong with the following NC blocks? Some of these blocks will actually work, but are not written in the best way according to the programming rules. N1X.5Y.5G90 N29G0X.5Y.5M2M47 N3X.5Y.5F2 N4X.5Y1.5F2 N04X0.50Y0.7500F2.00 N5G0X.25X.5Y1 N6G91X2Y3; MOVE TO ABSOLUTE POSITION X=2 Y=3 N12G1X2Y3,RAPID TRAVERSE TO X2,Y3 N2G9OX2Y3;F1 Task 10-2 Discussion and Review If you do not have the control program running on your computer, start it now. Locate and open the Turnone program. Does the code in the program make more sense to you than it did before? Can you pick out specific blocks of instruction, such as starting and stopping the spindle? Can you tell what the programmed feed rate was? What else can you see? Teacher s Guide - Worksheets 3-19 CNC Technology: CNC Lathe

48 Activity 11 Worksheet Name: Coordinate Systems Task 11-1 Inventory and Safety Checks o prolight Lathe and controller box o Computer with WPLT Control Program installed o Safety Checklist o Lab Station conforms to safety guidelines? Task 11-2 uestions What is a coordinate? What is the theory of René Descartes coordinate system? What is the point where the axes meet called, and what is the value on each axis at this point? Task 11-3 uestions How is a three-dimensional coordinate system different from a two-dimensional coordinate system? Teacher s Guide - Worksheets 3-20 CNC Technology: CNC Lathe

49 Name: Draw a two-dimensional coordinate system with X and Y axes. a) Show these four points: X-2,Y3; X4,Y5; X5,Y-1; X-1,Y-1 b) In which quadrant is each of these coordinates located? Task 11-4 Discussion and Review If you wanted to program all negative Z coordinates, where would you locate the origin? Is it possible to set the origin right at the chuck without using a measurable workpiece? Teacher s Guide - Worksheets 3-21 CNC Technology: CNC Lathe

50 Activity 12 Worksheet Name: Developing an NC Program Task 12-1 Inventory and Safety Checks o prolight Lathe and controller box o Computer with WPLT Control Program installed o Safety Checklist o Lab Station conforms to safety guidelines? Task 12-8 Create Your Own NC Program 0 Z X Teacher s Guide - Worksheets 3-22 CNC Technology: CNC Lathe

51 Name: PROGRAM NAME: WIDGET.NC DATE: AUTHOR: STOCK: Brass STOCK SIZE (length, diameter): 2.5" x.75" TOOLING: Right-Hand Tool N G X Z F S M COMMENTS Note: Sometimes it's helpful to add arrows to the comments to show the general direction of each motion, even when the tool is not cutting. Sheet of Teacher s Guide - Worksheets 3-23 CNC Technology: CNC Lathe

52 Name: PROGRAM NAME: WIDGET.NC DATE: N G X Z F S M COMMENTS Note: Sometimes it's helpful to add arrows to the comments to show the general direction of each motion, even when the tool is not cutting. Sheet of Teacher s Guide - Worksheets 3-24 CNC Technology: CNC Lathe

53 Task 12-9 uestions Briefly answer the following questions. 1. Put these steps in the correct sequence (1 6). a) Determine stock and tool. b) Enter NC code on coding sheet. c) Determine feed and depth of cut. d) Sketch the part. e) Determine cutting sequence. f) Draw the part to scale. Name: 2. Greater feed rates and depths of cut can be specified when cutting a soft material like: a) Steel. b) Machinable wax. c) Aluminum. 3. When cutting a part on a Turning Center, Z values are normally: a) Negative values. b) Positive values. 4. Stock size should be: a) As large as possible. b) As small as possible. c) Any size, as long as it fits on the Turning Center. 5. All of the following could be used to turn a profile on a Turning Center, except: a) A right-hand tool. b) A profiling tool. c) A left-hand tool. d) A boring bar. Teacher s Guide - Worksheets 3-25 CNC Technology: CNC Lathe

54 Activity 13 Worksheet Name: Editing your NC Program Task 13-1 Inventory and Safety Checks o prolight Lathe and controller box o Computer with WPLT Control Program installed o Safety Checklist o Lab Station conforms to safety guidelines? Task 13-6 Discussion and Review What types of problems did you run into writing your NC program? What do you think would be the result of improper coding in an NC program? 1. After editing a part program, the program remains in the computer: A) Forever B) Until the program is deleted C) Until the computer is turned off, unless you save the program 2. List two (2) mistakes that commonly occur when entering a part program. 3. When entering a part program, the address characters must be typed as: A) Upper-case letters B) Lower-case letters C) Upper- and/or lower-case letters 4. Before adding a comment to a line of NC Code, type a: A) Space B) Semicolon C) Command D) None of the above Teacher s Guide - Worksheets 3-26 CNC Technology: CNC Lathe

55 Name: 5. Complete the following sentences. A) An address character together with its parameter is called a. B) A line of NC code is called a. Teacher s Guide - Worksheets 3-27 CNC Technology: CNC Lathe

56 Activity 14 Worksheet Name: Verify and Run Your Program Task 14-1 Inventory and Safety Checks o prolight Lathe and controller box o Computer with WPLT Control Program installed o Safety Checklist o Lab Station conforms to safety guidelines? Task Verify the Program Did your program run through verification without any problems? If not, what were the problems? How did you fix them? Task Dry Run the NC Program Do you get any error messages while the program is running? How would you correct them if you did? Task Discussion and Review Why do you think it is so important to verify the nc program in different ways before actually cutting the part? What are some of the dangers of just running the program? Teacher s Guide - Worksheets 3-28 CNC Technology: CNC Lathe

57 Activity 15 Worksheet Name: Final Project Task 15-1 Inventory and Safety Checks o o o o prolight Lathe and controller box Computer with WPLT Control Program installed Safety Checklist Lab Station conforms to safety guidelines? Task 15-1 Final Project Choose one of the following projects: 1. Pawn: The pawn is cut from 3 x.75 brass stock. Use a profiling tool if available, and use the table in Activity 12 to determine feed rates, spindle speed, and cut depth. 0 Z X 0 Z X Teacher s Guide - Worksheets 3-29 CNC Technology: CNC Lathe

58 Name: PROGRAM NAME: AUTHOR: STOCK SIZE (length, diameter): DATE: STOCK: TOOLING: N G X Z F S M COMMENTS Note: Sometimes it's helpful to add arrows to the comments to show the general direction of each motion, even when the tool is not cutting. Sheet of Teacher s Guide - Worksheets 3-30 CNC Technology: CNC Lathe

59 Name: PROGRAM NAME: DATE: N G X Z F S M COMMENTS Note: Sometimes it's helpful to add arrows to the comments to show the general direction of each motion, even when the tool is not cutting. Sheet of Teacher s Guide - Worksheets 3-31 CNC Technology: CNC Lathe

60 Name: 2. Bowling Pin: The bowling pin, while it looks easier, may be more difficult. The program was initially developed to use.5 diameter stock, as the drawing below indicates. Since this Teklink supplies.75 diameter stock, you can do this either of two ways: Develop the NC program to turn the bowling pin using the full diameter of the brass stock; or have it rough away.25 and then turn the bowling pin on the remaining.5. Again, a profiling tool is the best tool for this application, and the stock is 3 x.75 brass. 0 Z X 0 Z X Teacher s Guide - Worksheets 3-32 CNC Technology: CNC Lathe

61 Name: PROGRAM NAME: AUTHOR: STOCK SIZE (length, diameter): DATE: STOCK: TOOLING: N G X Z F S M COMMENTS Note: Sometimes it's helpful to add arrows to the comments to show the general direction of each motion, even when the tool is not cutting. Sheet of Teacher s Guide - Worksheets 3-33 CNC Technology: CNC Lathe

62 Name: PROGRAM NAME: DATE: N G X Z F S M COMMENTS Note: Sometimes it's helpful to add arrows to the comments to show the general direction of each motion, even when the tool is not cutting. Sheet of Teacher s Guide - Worksheets 3-34 CNC Technology: CNC Lathe

63 Post-Test 1. The software program that controls the lathe is called A. Lotus B. Control Program C. DOS D. Lathe Program 2. Tool path verification is used A. Before a part is cut B. After a part is cut C. To home the lathe D. To jog the lathe 3. While operating a lathe, you should always A. Wear Safety Glasses B. Keep the safety shield closed C. Secure the workpiece in the chuck D. All of the above 4. A part drawing is A. A quick sketch of something you want to turn B. A one dimensional drawing of a part and its points C. A detailed illustration of a part showing the shape of the part and all dimensions D. What you see in the verification window 5. What is a Dry Run? A. Another way to verify your NC program B. Running the program with no stock mounted C. A way to check that all tool motions make sense D. All of the above Teacher's Guide 4-1 CNC Technology: CNC Lathe

64 6. Tool chatter is caused by A. Dissimilar metals B. A loose tool C. A talkative lab partner D. All of the above 7. Before running an NC program you must A. Perform a safety check B. Perform a verification C. Perform a dry run D. All of the above 8. You should press the Emergency Stop button on the turning center when A. You want to ask the instructor a question B. You are changing stock C. After you open the Safety shield D. Never 9. The point at which the axes meet is A. The middle B. The point of origin C. The end of travel D. Machine Home 10. Position 3 on the tool turret is reserved for a A. Profiling tool B. Boring tool C. Parting tool D. Facing tool Teacher's Guide 4-2 CNC Technology: CNC Lathe

65 11. A quadrant is A. A graphical representation of the workpiece B. One quarter of a plane divided by two axes C. Part of the cross slide D. A four sided cutting tool 12. You should save your NC programs A. After you enter it B. After you edit it C. Often D. All of the above 13. You can make adjustments to the lathe A. When the lathe is running B. When ever you want C. Only when the emergency stop button is pressed in D. When the lathe is paused during a program 14. Workpiece origin is usually set so A. Z axis motions are negative and X axis motions are positive B. All motions are negative C. X axis negative are positive and Z axes motions are positive D. All motions are in the positive quadrant 15. A common programming error is A. Using the letter "l" instead of the number 1 B. Using the letter "O" instead of a zero C. Entering code in the wrong sequence D. All of the above Teacher's Guide 4-3 CNC Technology: CNC Lathe

66 16. The part of the lathe that rotates the stock is the A. Stepper motor B. Spindle C. Cross slide D. Z axis 17. A coordinate is A. Lathe home B. Workpiece origin C. A point in a quadrant D. One of a set of numbers that describes a point on a plane 18. The Jog Control is used to A. Home the lathe B. Jog the cross slide C. Set the origin D. All of the above 19. Machine Home is A. Where you store the lathe B. The point of origin on the workpiece C. The positive end of travel on both axes D. The middle of the axes 20. An NC code block is A. An unmachined workpiece B. A character in an NC program C. A line in an NC program D. A way to stop a program from running Teacher's Guide 4-4 CNC Technology: CNC Lathe