WheelTool 1
WheelTool 1
Wheel/Roller/Marking Tool
for the
Murata Machinery USA
Turret Punch Press
September 15, 2005
This document provides instructional information for programming wheel and sheet marking
type tools. Due to the variety of tools and applications this document is only intended to provide
general guidelines. Refer to the tool manufacturers’ documentation for specific tool information.
Questions for specific tool applications should be directed to Murata or the tool manufacturer.
2
1 Tooling Installation Setup
1.1 It is important to recognize the orientation of the wheel when loading it into an auto-index
station. Programming is based on this orientation. Improper setup could cause the wheel to
run sideways and the wheel can be damaged. Unless the station or holder restricts direction
of installation, it is recommended to load the tool at 0°. This means the tool is installed so
that it is able to run in the plus or minus X direction when the C-axis is at 0°. If the wheel
is to be used in a fixed station it must be orientated to the angle of use.
1.2 When using the Rolling Pincher and Shear tools the dies must be free to compress
downward. If used in an auto-index station where the retaining ring holds the die on the
upper portion, it should not be tightened down on the die. The upper portion of the die
must be able to compress downwards to expose the tool for cutting.
1.3 The wheels should be removed from the turret after each program if it is not to be used
again. Leaving a wheel in the auto-index station can damage the wheel and possibly cause
the operator to punch with the wheel in another program. Punching with the wheel will be
detrimental to the wheel.
1.4 Always start the wheel on the material. Never off the edge of the sheet or in a punched
hole.
1.5 Never crossover holes with the wheel as it can cause the wheel to be damaged.
1.6 If using Spring Style tooling, verify that the overall tool length of is around 8.20”
(208mm). If the tool is too short, the machine may not have enough stroke to adjust the
tool down using the punch press control.
1.7 Define the tool in the Custom Tool Table on the control. Tool data required is based on the
type of tool used and the capabilities of the machine.
3
2 Tool Orientation
It is important to understand how the wheel tool indexes when commanded in a certain direction
or angle. PDR/ and PDL/ setup how the wheel will be controlled. Each is 180° different from the
other. This chart shows the basic four directions. The starting angle of the index station can be at
any angle and this will apply.
These are perfectly horizontal or vertical moves. Movements at other angles will result in
corresponding changes in rotational degrees. A 45° move with PDR/ will cause the tool to rotate
-45°. A PDL/ will be 180° different from the PDR/ and result in a +135° C-Axis movement.
If a wheel is oriented at 0° in the I/T station, the wheel tool NC code should always start
with a C90 orientation of the tool. Using PDR/, the tool angle will always reference in the
direction it is programmed. A form going from left to right will run with the tool at C0. A form
going from bottom to top will run with the tool at C90. This makes it a little easier to verify tool
direction when checking a program. For an offset tool, use PDL/ to run the tool 180° in the
opposite direction.
If a wheel is oriented at 90° in the I/T station, the wheel tool NC code should always start
with a C0 orientation of the tool. Using PDR/, the tool angle will always reference the correct
direction for forming, but displays 90° off on the display from the programmed direction.
Each time the tool is raised (PED/) and before it is lowered again, the tool must be
reoriented as described above.
These are the zone sizes on all Motorum and Vectrum machines. Add the usual .55” (13.5mm) if
touch switches are used on the machine. These sizes have to be larger than most tool safety zones
to allow the machine to stop axis movement at high speed before interference with the
workholders occur. Because the machine doesn’t move to a position and punch, but is
continuously at BDC, this is necessary. The Workholder Override button will disable the safety
zone check if the operator determines it is safe. The V5058 will use the same safety zones as the
KL stations.
4
4 Tooling Library Setup
Machines that don’t have the ramping capability must define tools this way. Machines that allow
ramping can define tools this way or as described in the next section, even if ramping is not used.
4.1.1 Define the tool as a standard Forming “Forming” or “Marking” type tool.
4.1.2 Use only the BDC ADJ field to control the tool stroke. Always start with the tool high by
setting the value to a -.200” (-5.00mm). Gradually increase this number (lowering the
tool) until the desired form or mark is achieved. If this is not possible, the tool may have
to be lengthened or mechanically shimmed. Start the procedure over again if this is done.
If ramping is not used, this same procedure can be used, but the Hover Height Adjust does not
need to be set.
4.2.1 The tool definition in the tool parameter screen must be defined as a Forming “Special”
tool (ie 5. F: Forming Tool, then select 9. Special type)
4.2.2 Set the BDC ADJ to adjust the stroke to BDC, the bottom of the ramping stroke. Start
with a value of -.300” (-8.00mm) and increase the value with small increments after each
test run. Always start negative and work your way towards zero. The valid range is from -
.300” to .200” (-8.00mm to 5.00mm).
4.2.3 Set the HH ADJ to adjust the ram height where the ramping will start. Start with a value
of +.400” (+10.00mm) and decrease the value in relationship to the BDC position until
desired ramping distance is achieved. Use this to keep the top of the ramping position
.100” (2.5mm) or less above BDC. The closer the tool starts to the material, the better the
results will be and a shorter X/Y ramping movement will be needed. The valid range is
from -.200” to .400” (-5.00mm to 10.00mm).
5
5 General Programming Rules
5.1 An M321 M-code must be used prior to selecting the wheel tool and an M320 M-code is
used to turn off the wheel tool mode. If a M321 is not used, it will punch with the wheel.
5.2 If ramping is used, M323 is used prior to the down ramp movement. M324 is used prior to
the up ramp movement. The M323 must be used each time the tool is raised and is lowered
back on the material if ramping is required.
5.3 If a Sheetmarker Tool is used, M321 is still used to initiate “wheel mode”. Then M326 is
used to identify the tool as a Sheetmarker type tool. M325 then takes it out of Scribing
Mode. M320 is still used end “wheel mode”. The M326 is also used for a wheel tool in a
fixed station if a PDR/PDL will be used to control feedrate or if ramping is required.
Without the M326, the machine will try to index the fixed station resulting in an alarm.
5.4 When using a wheel tool in an auto-index station, a dummy command must be given prior
the PDR/PDL command to orient the wheel before it comes down on the material. Only a
short move distance of .010” to .100” (.25mm to 2.5mm) is needed. This dummy command
needs to be tangential to the path. Even with ramping it is a good idea to follow this
practice so the wheel orients itself before it gets anywhere near the material.
5.5 A PDR/PDL command is the starting point for the wheel. If ramping is not used, this is
where the tool will come down on the material. The “F” feedrate should be stated on this
line. If ramping is used, the ramp down position starts here. The tool must overlap the start
area when finishing to make an even form. Feedrate is controlled internally or with a
feedrate on the following line (see examples).
5.6 A PED command raises the wheel up. The wheel should be raised up at sharp intersections
or moves to other locations on the sheet. When moving to a new location, a tool in the
indexing station must be re-oriented before lowering it back onto the material.
5.7 Radiuses and material thickness should be used within the tool limitations. See the
manufacturers’ specifications for this and other tool specific data.
5.8 If possible, program so that the tool is moving away from the clamps. This will help
minimize sheet distortion.
5.9 Grip the sheet on its longest side. The closer you can program to the clamps, the better and
more accurate the results will be.
6
6 Ramping Programming Tips
The ramping function allows a smooth form to be made without the pinch mark that occurs if the
tool drops directly onto the sheet and starts moving. This is especially noticeable when a form
comes back together at the same location. The best results are achieved with a slow downward
movement of the ram axis and a faster X/Y axis movement. The downward movement of the ram
is controlled internally by the machine. The X/Y ramping speed can be controlled either through
an internal default value, or programmed through the NC code.
Based on the material and tool, the ramp height will have to be adjusted to create the best results.
A ramping height of .100” to .150” (2.5mm to 3.8mm) is a good place to start. The ramp height
needs to be just near the top of the material when starting. Starting too far above the material
requires a longer ramping distance and if too excessive, could cause a “Ram Access Error” alarm
on the Vectrum machines.
Based on the ramping height and table speed, the X/Y ramping distance will vary. If the ramping
distance is too short, the tool will drop to its BDC position at the end of the ramping distance and
cause pinch marks. If it is too long, the table will travel at the ramping feedrate longer, possibly
slowing production.
If the form comes back together, overlap far enough to cover the initial ramp down area.
For some tools ramping down may not be wanted. A shear tool that needs to start shearing at
specific spot will have to drop directly on the material and begin shearing. A ribbing tool that has
a defined start and ending point should also start forming without the ramping function.
6.3 Ramping Up
The ramping up function has limited usefulness and in general is probably not needed for most
forms. Once a form is completed, pulling the tool straight up doesn’t affect the formed shape
unless a gradual reduction in the form is needed at the end of the form. One case that this may
prove useful is when using a shear tool. The ramping up will allow the tool to roll free of the
material and eliminate some grabbing of the tool by the material.
7
7 Wheel Tool Commands
PED/ This command raises the tool back to TDC. This is PED/
needed when ending use of the tool or moving to a
new start location on the part.
M-Code Description
M320 Wheel Tool Mode End
M321 Wheel Tool Mode Start
M322 Return to TDC (not normally used, automatic in the PED/)
M323 Wheel Tool Ramp Down
M324 Wheel Tool Ramp Up
M325 Scribing Tool Mode End
M326 Scribing Tool Mode Start
8
9 Wheel Tool Example NC Code
The tool stations should be setup in the tool parameters prior to running the wheel. When
running the wheel for the first time, it is recommend that you run the sample programs without
the wheel die assembly or material. Verify the ram height and tool orientation until you feel
comfortable with the code. This will also prevent any accidental punching of the wheel assembly
and running the tool sideways. The examples with auto-index assume the tool is installed at 0°.
Sample program to run a straight line, X1 -> X25 (in I/T station) w/o ramping:
O1111
MAT/B1 H.048 X48 Y48
M321
X1-.010 Y26 T01 C90 M03 (This offset allows tool to rotate before lowering.)
PDR/X1 Y26 F2000 (Specify the start point and feedrate)
X25
PED/
M320
C0 (Reset C-axis if another tool isn’t used)
X78.74 Y60.039 M30 (V3046α load position)
%
Sample program to run a straight line (in a standard station) w/o ramping:
O2222
MAT/B1 H.048 X48 Y48
M83 (If not using PDR/ or PDL/, use M80 – M83 to control feedrate)
M321
X1 Y26 T02
X25
PED/
M320
M80
X78.74 Y60.039 M30 (V3046α load position)
%
Sample program to run a 5” radius arc from 0° to 360° (in I/T station) w/ ramping:
O3333
MAT/B1 H.048 X48 Y48
M321
M323 Direction of movement
X15 Y15-.01 T01 C90 M03 (Setup orientation move)
PDR/X15 Y15 (Ramp using default vel)
CIR/10 15 10 (Ramp down 10°, ~2”) X15, Y15
Starting point
CIR/10 15 360 F2000 (Complete circle over-) X10, Y15
M324 ( lapping ramp area)
CIR/10 15 5 (Ramp up 5°)
PED/
M320
C0
X78.74 Y60.039 M30 (V3046α load position)
%
9
This example expects the tool to be installed at 0° in the index station. By commanding the C90
below, the wheel is pre-orientated so that the initial +X move rotates it -90° to 0° again. This
results in the C axis running at 0° in the +X direction, 90° in the +Y, and so on. Using a PDL/
would result in 180° difference in orientation. Note that a feedrate is used in the ramp down
movement overriding the default feedrate. Using a faster X/Y feedrate than the default will help
improve the form, but a longer ramping distance is probably required
With ramping:
X15, Y20 (start movement Æ)
O4444
MAT/B1 H.048 X48 Y48
M321 (Wheel Mode)
M323 (Ramp Down Mode)
X15-.01 Y20 T01 C90 M03 (Start position for wheel orientation)
PDR/X15 Y20 (Start ramp position with wheel oriented for +X)
X18 F1000 (Ramp down to this position with commanded feedrate)
X20 F2000 (Straight move, must have “F” feedrate)
CIR/20 25 180 F1000 (180° arc, 5” radius, feedrate may need to decrease on small arcs)
X15 Y30 F2000 (Straight move)
CIR/15 25 180 F1000 (180° arc)
X18 (Overlap beginning ramp in area)
M324 (Ramp Up Mode)
DX0.5 (Ramp up to this position)
PED/ (Move ram to TDC)
M320 (End Wheel Mode)
C0 (Reset axis orientation)
X49.213 Y49.213 M30 (M2044 load position)
Without ramping:
O5555
MAT/H.048 B1 X48 Y48
M321 (Wheel Mode)
X15-.01 Y20 T01 C90 M03 (Start position for wheel orientation)
PDR/X15 Y20 F2000 (Start position with wheel oriented for +X)
X20 (Straight move)
CIR/20 25 180 F1000 (180° arc, 5” radius, feedrate may need to decrease on small arcs)
X15 Y30 F2000 (Straight move)
CIR/15 25 180 F1000 (180° arc)
PED/ (Move ram to TDC)
M320 (End Wheel Mode)
C0 (Reset axis orientation)
X49.213 Y49.213 M30 (M2044 load position)
10
10 Scribing Mode Example NC Code
This example shows a Sheetmarker Tool used in a fixed station. The M326 will allow arcs
without trying to rotate the tool. This would also be true in an index station. On smaller arcs the
feedrate will have to be slowed down or deformation in the arcs will occur. When line length or
arc radius is less than 0.250” (6.35mm), the feedrate needs to be less than 60 inch/min
(1525mm/inch).
O6666
MAT/B1 H.048 X48 Y48
M321 (Wheel Mode)
M326 (Scribing Mode)
X15 Y20 T02 M03 (Position and command tool)
PDR/X15 Y20 F5000 (Identify feedrate and start scribing)
X20 (Straight move)
CIR/20 25 180 F2000 (180 degree arc, 5” radius)
X15 F5000 (Straight move)
CIR/15 25 180 F2000 (180 degree arc)
PED/ (Move ram to TDC)
M325 (End Scribing Mode)
M320 (End Wheel Mode)
X49.213 Y49.213 M30 (Load position for M2044)
11
11 Multiple Pass Programming
Except for the Rolling Shear tool, it is sometimes recommended or required that more than one
pass be made with a tool to get good results. Special setup and programming will be needed to
do this on both the Motorum and Vectrum machines.
Multiple passes require the second and any following passes to be deeper than the previous. To
do this, an entry will have to be made in the Custom Tool Table for each pass. For each entry,
the BDC ADJ field should increase the depth of BDC until the required form is made. If ramping
is used, corresponding changes to the HH ADJ field should also be made.
The multiple passes will then have to be programmed in the NC code. An efficient way to do
this may be to program the tool movement in a pattern command (PAT/). Note, PAT1/ will be
processed the first time through unless parameters have been changed to allow single part testing
of a Macro Grid (MGR/). To access the different entries in the Tool Table, the M1nnn M-code is
used. The “nnn” of this code corresponds to the three-digit tool number entry in the Tool Table.
Use the M1nnn code on a line by itself to active the Tool Table entry for the pass being made.
Use M1000 to cancel the last M1nnn code used. This is required to allow any following tool
changes to process correctly.
This function can be used so the same tool will make different forms on the same sheet. In an
automated system, the same tool can be setup for multiple material types and thickness. M1nnn
can be used with all standard and forming tools in a similar fashion.
This example uses data from Tool Table entries 295, 296, and 297. Entries don’t have to be
sequential, but may make setup easier. M1295 will use of data from entry 295.
O7777
MAT/B1 H.048 X48 Y48
M321 (Wheel tool mode)
M1295 (Activate entry 295)
PAT1/
M323 (Ramp down mode)
X15 Y15-.01 T01 C90 M03 (Setup orientation move)
PDR/X15 Y15 (Ramp using default velocity)
CIR/10 15 10 (Ramp down 10°, ~2”)
CIR/10 15 360 F2000 (Complete circle overlapping ramp area)
M324 (Ramp up mode)
CIR/10 15 5 (Ramp up 5°)
PED/
END1
M1296 (Activate entry 296)
PAT1 (Do circle again)
M1297 (Activate entry 297)
PAT1 (Do circle again)
M320 (Cancel wheel tool mode)
M1000 (Cancel M1nnn processing)
C0
X78.74 Y60.039 M30 (V3046α load position)
12
12 Common NC Parameter Data
[SYSTEM] + <PARAM>
13
13 Motorum Software and Parameter Data
The M2044 and M2048 with 18iP controls are the only Motorums currently that will run the
wheel with ramping and scribing tools in fixed stations. Type II Motorums with 16PB controls
can run wheel tools without ramping and scribing tools in an indexing station. All M2048LT and
M2044EZ machines have been prepared and will support wheel tool operations.
Data
Address (deg/min) Description
D588 50 Ram Axis Ramping Feedrate
14
Custom Parameters: [CUSTOM] + <3> + <CUSTOM>
15
14 Vectrum Software and Parameter Data
The wheel tool can be run on all V3α and V5058 machines except Type I and Hybrids.
16
Ram Axis Programs: [CUSTOM] + [AXIS PARAM] + [AXIS PROG]
17
Custom List Parameters: [CUSTOM] + <PARAM EDIT> + <LIST>
18