System Description

The Boxford 3D Machine Controller is a 3-axis control system designed

for training in CNC programming and computer controlled machining
from programs. It is a high quality control system, also capable of being
operated manually.

There is a touch- sensitive control panel on the machine for manual

operation.

The machine is usually operated in automatic mode from programs

generated in the CAD/CAM DESIGN TOOLS software, which is
installed on an IBM-compatible PC.

The CAD/CAM DESIGN TOOLS software is an integrated suite of CAD

and CAM tools, enabling International Industrial standard G and M code
programs to be produced by either :-

1. Automatically processing a drawing created with the integrated

CAD package or imported from any major package using the CAM
processor, or
2. Manual data inputting using a sophisticated program editor,
interactive help and in built error checking.

Screen graphics include 2D and 3D viewing with rotation, cross sections

and zooming and simulation of machining for program verification. This
manual contains instructions for installing and using the software.
If required, all aspects of programming, program editing and simulation
of machining can be practiced without the PC connected to the Machine
Controller. This enables training to be carried out on a number of PCs
simultaneously; completed programs can be transferred to a PC
connected to the Controller for machining and program verification.
Using the Manual
Using the Manual
This manual gives guidance in using the Mill CAD/CAM software to create Industrial
standard G&M code programs for turned components, and in component manufacture.

The Mill CAD/CAM software includes a demonstration program (called DEMO), and a
number of tutorial programs.

It is suggested the manual is used as follows:

1. Refer to section 'Running the Demonstration program'. This

will provide rapid familiarisation with the operation of the
software and the machining process.

2. Study the Section 'Tooling and Axes - Setting Up' to

become proficient in setting up the tooling.

3. Refer to the CAD sections to demonstrate the ease of

operation of the integrated CAD and CAM processor
package.

4. Refer to the Section 'File Imports - Drawing Files' to

become familiar with the conventions for importing drawing
files from third party CAD packages.

5. Refer to the Section 'Administration Mode' for details of the

functions available to administrators (tutors) of the
CAD/CAM system.

6. Use the sections 'Conversational programming' for details

of CNC programming through an intelligent wizard type
Working Practice

The moving parts of the machine are totally enclosed when both front
door guards are closed, and interlocks prevent the spindle and axis drives
from running when either guard door is open. The operator is therefore
well protected against the risk of injury; however the following
precautions should be observed to promote safe working procedures and
to prevent damage to the machine:

Clothing
Do not wear loose clothing or jewellery which can get caught in
machinery. Tie back long hair or contain it with a hat.

Cleanliness
Keep the work area tidy. Clean all swarf from the machine after use.

Securing Tooling and Workpiece

Make sure that tooling clamps, vice and chuck jaws are properly
tightened.
Make sure that all securing keys and other loose tools are removed before
closing either guard.

Care of Cutting Tools

Keep tools clean and sharp. Use the most suitable tool for the job.

Tool Settings
To avoid running a tool into the workpiece or vice, make sure that tool
offsets and workpiece datum are correctly set, and that the correct tool
types and positions have been selected.

Performance and Limitations

Know the capabilities and limitations of the machine. Do not overstress
the machine by selecting excessive feed rates and depth of cut.
Stopping the Machines

WARNING: DO NOT ATTEMPT TO STOP THE MACHINE BY

OPENING A GUARD. USE ONE OF THE METHODS GIVEN
BELOW, AND WAIT UNTIL THE SPINDLE HAS STOPPED
BEFORE OPENING THE GUARD.
When the machine is executing a production cycle, it can be stopped by
any of five methods:

Emergency Stop Button (E-STOP)

Pressing the button stops the machine, switches off machine electronics
and aborts the production cycle. The button must be turned to release it,
the hard reset button pressed and to resume production the machine must
be reinitialised and the cycle repeated from the beginning or from any
tool change within the cycle.

FEED HOLD button

Pressing this stops the tool feed but not the spindle.

Mains Isolator
Setting the isolator to OFF removes the power from the Machine
Controller. To resume production, the machine must be reinitialised and
the cycle repeated from the beginning or from any tool change within the
cycle.

Computer Mouse
Closing the manufacture window with the X in the top right corner of the
screen, stops the machine and interrupts the production cycle. Production
can be resumed from the point where it was interrupted by selecting the
relevant option.

Emergency Footswitch (if fitted)

Works as E-STOP button above, except that a manual reset button fitted
at side of machine must be pressed to restore power before production
can be resumed.
Guard Switches
The transparent front guard door operates a microswitch such that the
machine will only operate with the guard door closed.

For setting tool offsets, and when the Manual Mode option is used, the
machine is controlled manually from the control panel. For these
purposes it is necessary to gain access to the vice, workpiece and tooling.
The guard safety switch detects when the guard is closed and prevents
operation of the machine under manual control if the guard door is open.
Computer Requirements

The machine tool is designed to be operated by the software running on

an IBM-compatible PC. The minimum requirements of the PC are given
below, together with guidelines for setting up the computer before
connection to the machine and installation of the software.

Processor
The PC should be based on a Pentium 4 2GHz processor or higher.

Operating System
Microsoft Windows 2000, XP, VISTA or Win 7 (32 bit and 64 bit)

Disk Drives.
A Hard disk with 800 Mbyte free space and a DVD ROM drive are
required.

Memory (Min)

Windows 2000 (256 Mb), Windows 2000 Server (512Mb), Windows XP

(512Mb), Windows Vista (512Mb), Windows 2003 Server (1024Mb),
Windows 7 (512Mb).

Graphics

SVGA - 16 Bit (High Colour) - 800 x 600 min resolution (1024 x 768
recomended).

USB Port
The machine must be connected to a USB port on the PC.
Serial Port
The software enables programs to be exported to another PC. If this
facility is required, the second PC is connected to a free serial port on the
PC using a suitable serial data cable.

Mouse
The mouse should be connected to a spare USB or PS2 port.
Installing the Software
Installing the Software

Note: Unlike previous versions of Boxford software, each different Boxford CNC
machine type DOES NOT require a separate installation of software. The only variable
element between installations is the Registration CD which includes machine licensing
information for each individual site.

For Update/Maintenance of existing software, see section 'Updating/Maintaining

Existing Software'

For Software Installation on a Network, see Section 'Network Installations'

To Install the USB machine driver, see the section 'Installing the USB Drivers'

Note: In these instructions it is assumed that the CADCAM software will be installed to
the hard disk (drive C) using the Registration CD (in drive D) and the Boxford CADCAM
Design Tools DVD ROM (in drive D). If you are using different drive letters from these,
make the appropriate substitutions.
If you have purchased a software license for more than one machine type, the software
only has to be installed once.

Microsoft Windows NT, 2000, XP, 2003 Server, VISTA, Win 7 (32 bit and 64 bit).

1. Start Microsoft Windows

2. Insert the CADCAM Design Tools disk into the CD/DVD ROM drive.
3. Select Start > Run
4. Type d:\setup and press ENTER.
Configuring the Software
Configuring the Software

Before the machine is used, the software must be configured to suit your computer system
and programming preferences.

Refer to the section Section 'Using the software - Running the software' for details of
how to run the software.

It is configured by means of the Settings menu option on the front end menu.

All configurations can only be set in Administration mode. Refer to the section
'Administration mode' for details on accessing this mode then carry out the procedure
detailed below.

1. Select Settings - Machine - Edit. The window below is shown.

Select the options which are available on your machine. If you are unsure, consult the
delivery documentation which came with your machine.

In the serial number field, enter your machine serial number or if you prefer enter your
own text string to describe the machine.
If you have a number of machines of the same type, you may choose to number or
Control Panel

1. FEED HOLD
Acts as an interrupt control to the program when pressed, preventing any
further tool movement until canceled. During an Automatic cycle, after
canceling CYCLE START must be pressed to resume the cycle.
2. SINGLE BLOCK
With machine running in automatic mode controlled from the PC, this allows
 the operation of only a single block (line) of the program at a time to be
toggled on/off. Press CYCLE START to proceed.
3. CYCLE START
This sets the machine in automatic mode and starts the machining from the PC
program. Also used to resume an Automatic cycle after a FEED HOLD is
canceled and to action the next line if Single Block is active.
4. FEED SPEED CONTROL
Provides stepless control of tool feed speed in the X, Y and Z axes from 0 to
100% in 10% increments.
5. JOG TABLE AXIS CONTROLS
These four buttons control manual movement of the table in the X and Y axes.
Move the table in the X axis while held pressed.
Move the table in the Y-axis while held pressed.
6. JOG HEAD AXIS CONTROLS
Move the head in the Z axis while held pressed.
Pressing this button together with any of the other six axis control
buttons provides rapid movement of the axes in the indicated
direction.
7. MAN
When lit, machine is operated from control panel (Manual mode). Pressing
MAN puts light out and machine is controlled by computer (Automatic mode).
Press MAN again to revert to manual mode operation.
8. AIR MIST CONTROL
Switches on or off the optional air mist coolant when fitted.
9. DATUM M/C - PROGRAMME ABORT
After initially powering up the machine and pressing the Power Reset button
(16), with the machine in Manual mode (Manual mode button lit) press to
datum the machine axes.
With the machine in Manual mode, the machine can be re-datumed at any
point. This should always be done if a physical stall of the axes has occurred.
During an Automatic Cycle with a Feed Hold (1) active, pressing will Abort
the current job.
10. TOOL CHANGE
With auto toolchanger fitted, press to change to next tool automatically.
11. TOOL RELEASE
Releases the toolholder from the spindle if fitted with the auto toolchanger.
Guard door must be open and toolhoder held.
12 WORK HOLDING UN-CLAMP
Controls un-clamping of workpiece in pneumatic workholder vice, when fitted.
13. WORK HOLDING CLAMP
Controls clamping of workpiece in pneumatic workholder vice, when fitted.
14. DOOR OPEN
Controls opening of the automatic doors when fitted.
15. DOOR CLOSE
Controls closing of the automatic doors when fitted.
16. SPINDLE CONTROLS
These control the speed and direction of rotation of the spindle.
Spindle Forward - Pressing this button starts the spindle rotating
forward. Holding it down increases forward speed. Pressing and holding
the 'Spindle Reverse' button reduces speed in the forward direction.
Spindle Reverse - Pressing this button starts the spindle rotating in
reverse direction. Holding it down increases spindle speed in reverse
direction. Pressing and holding the 'Spindle Forward' button reduces
speed in the reverse direction.
Spindle Stop - Pressing this button stops spindle rotation.

17. EMERGENCY STOP

Pressing this pushbutton stops all machine movement and switches off the
electronics, and the button locks in the depressed position. If the machine is in
production, an appropriate message is displayed on the PC screen. The button
must be turned to release it and the Hard Reset button (16) pressed to enable
the machine to be started. The machine must be datumed using the Datum M/C
key (9). If the machine was performing a production cycle, the cycle must be
repeated from the beginning.
18. HARD RESET
Restores power to the control electronics. Requires pressing after initial power
on before pressing the Datum M/C button (9) and after pressing (and releasing)
Emergency Stop (17).
Running the Software
Running the Software

When the software is run from the Start menu, and the user has more than one Boxford
machine or a Dual lathe/mill machine, the machine selection screen is displayed.

The user selects the machine of their choice with the mouse.

The main Front End screen is displayed.

Move your mouse over the icon, menu or screen area you require help on and select
with the mouse.
Running the Demonstration Program
Running the Demonstration Program

The demonstration program contains examples of font, pocket and path machining,
and a finished component can be machined from a billet 100mm long x 70mm wide
x 10mm (or greater) thick.

Run the program as follows to provide a tutorial in programming and machining:

1. Fit Tooling Make sure the billet is securely fitted in the vice.
Set the tooling up as follows:
Fit the 2mm and 4mm Ø slot drills into a toolholder.

Manual Tool Change: Secure the 4mm Ø slot drill and toolholder assembly in
the machine spindle.
Ensure the 2mm Ø is ready for the programmed tool change During machining,
the machine will stop and it will be necessary to remove and replace the 4mm
Ø slot drill with the 2mm Ø slot drill.

Auto Tool Change: Fit the 2mm Ø slot drill in position 1 and the 4mm Ø slot
drill in position 2 of the tool carousel (See section 'Tooling and Axes - Setting
Up' for details of carousel loading and positions. ).

Configurations
2. Run the software and set configurations and tooling as required. See the section
'Tooling and Axes - Setting Up' for details.

3. Open the Program

From the front end menu, select File - Open Tutorials

From the list, select the file Demo.

The front end screen shows a 3d representation of the component created by the
 program.

4. View the Program Details

Select File - Program Information or the icon to show the program details.

Select OK to close the program info window.

5. Display the G&M Code Program

Select View - GM Listing or the icon to view the G&M code listing of
the program.

Close the view by selecting the X in the top right corner.

6. Simulating the Program

Select View - Simulation or the icon to launch the program simulation.

 For details of the simulation window, see the section 'Running the Software -
Program Simulation'.
Experiment with the various simulation and view controls.
Simulate the program to the end (when the M30 code is reached).
Close the simulation by selecting the X in the top right corner.

7. Machine the Component

Refer to the section 'Machining - Automatic'

Axis, Datums and Offsets
Axis, Datums and Offsets

Axes

The diagram below shows the movement of the tool in the X, Y and Z axes, in relation
to the billet (In the X and Y axes the billet moves in relation to the tool, but for
simplicity and to conform with standard programming practice, it is the movement of
the tool in relation to the billet which must be considered).

Datum Position

On new machines, all Datum positions and Tool Offsets are set at the factory when
tooling and clamping is ordered with the machine.
Tool Library
Tool Library

The software provides a Tool Data Library which enables details of tooling, offsets and
material cut data to be entered.

To access the library, the tool library icon is selected from the front end
menu.

Standard and Advanced Users

If the current user mode is Standard or Advanced, a view of the tool library is shown.
This view is for information only and tool data can not be edited.

The format of this view may be a list view or a graphical view depending on the
software settings.

Examples of each view types are shown below.

List View Graphical View

To print the tool library, File - Print is selected from the menu.
This initiates the print routine displaying the standard print window with an additional
section at the bottom as shown below.
Setting Up
Setting Up

Note:
All new Boxford machines are delivered with all the tool offsets and datum's pre-
set and configured on the software supplied with the machine.
The following procedure can be used to set up new tooling or resetting the original
tooling.
A workpiece of the appropriate size will be required for this procedure. In order to
run the demonstration program, a 2mm Ø and 4mm Ø slot drill are required. To
run the program, set up the 2mm Ø slot drill as the first tool and the 4mm Ø slot
drill as the second tool in the following procedure.

All tool and datum settings can only be set up when the current user is an
administrator. See section 'Administration Mode' for more details on accessing
this mode

1. Fit Tooling
Fit the required tools into the tool holding system supplied.

Manual tool change: Fit the first tool required. After setting the offset of the
first tool, it will be necessary to substitute the next tool before setting its
offset.
If the tool holder is too close to the chuck to allow the tools to be fitted, move
the tool holder away from the chuck under manual control, (see the Section
'Manual Machining' ).

Auto Tool Change: Index the carousel using the TOOL CHANGE button on
the machine control panel so that position the last position (5 or 6 depending
on machine) is opposite the spindle. Fit the tooling in the carousel as shown
in the diagram below (do not fit a tool in the last position at this stage).
 Ensure that the spindle is in the correct Z axis position to facilitate auto tool
changing.
Press the TOOL CHANGE button on the control panel.
The carousel will then traverse left to the spindle position, perform the
actions of removing a tool holder from the spindle, index to position 1, load
and secure the tool into the spindle, and retract. The first tool is now fitted in
the spindle.

2. Configure Software
Under administration mode, ensure the Communication port and appropriate
machine options are configured. Refer to the section 'Installation -
Configuring the Software' . Ensure the machine is switched on.

3. Set Z Datum Position

Note It is only necessary to set the datum position if the workholder position
is changed, the Datum position (back, front, left, right, centre) changed, a
new workholding device added or if the original setting is lost. In order to set
the datum position, the information supplied with the machine will be
required; this information consists of a Z axis measurement.

Refer to the section 'Tooling and Axes - Axes, Datums and Offsets' for details
of datums .

Under administration mode, ensure the Z datum position is set by selecting

Settings - Machine Datums and entering the values into the dialogue shown
below.
 If an additional clamping device is to be defined, select the Add button and
define a name for the new clamp before selecting OK.

4. Set-up Clamping Device

Note It is only necessary to set-up the clamping device if the clamp position is
changed, the Datum position for the clamp (back, front, left, right, centre)
changed, a new clamping device added or if the original setting is lost.

Select the clamping device to be set-up from the drop down list.

Select the Datum position for the clamp. This defines a fixed point on the
clamp where the same corner of every workpiece locates to. The options are
shown below.

Back Left Back Right

Front Left Front Right

 centre

E.g. On a VMC machine fitted with a standard Vice, the workpiece BACK
face locates to the fixed rear vice jaw and the workpiece LEFT face locates
to the vice end stop - hence the setting would be BACK LEFT.
The Centre option is used for three jaw chucks usually used to clamp
cylindrical workpieces.

5. Select the Setup button. If the machine has not been homed since power on,
the prompt below is shown.
Select Auto Home or alternatively, with the machine in manual mode
(manual mode button lit), the Datum Machine button should be pressed. The
manual mode button is button No. 7 and the Datum Machine button No. 9 on
the diagram in the section 'Machine Controls - Control Panel'
6. The screen shows:

Follow the instructions, loading in a workpiece into the clamping device,

ensuring it is located against the clamp datums and the clamp is adequately
tightened. Select NEXT.
7. The screen shows:

Follow the instructions, fitting a tool of known diameter into the machine
spindle or for machines with auto-toolchangers, use the tool change button to
load the required tool.. Enter the diameter of the tool in the edit field and
select NEXT.
8. The screen shows:

Using the machine control panel (see the section 'Machine Controls - Control
Panel' for control details), select manual mode and start the spindle in
forward and increase the speed until it is approximately 1500 RPM. Use the
on screen feedback to set the speed.
9. The screen shows:

Manipulating a combination of the Axis Control Buttons and Feed Override

Knob, position the tool to touch the edge of the workpiece indicated. The
example below shows touching on a LEFT edge.

When the tool is in position, Select OK.

10. The screen shows:

Manipulating a combination of the Axis Control Buttons and Feed Override

Knob, position the tool to touch the edge of the workpiece indicated. The
example below shows touching on a BACK edge.

When the tool is in position, Select OK.

The screen will return to the Miller Datums window. Select OK to save the
new settings.

Move the tool clear of the workpiece and stop the spindle.
11. Enter the Tools into the Tool Library

From the front end menu, select View - Tools or select the icon to
display the tool data library.
Ensure all tool data excluding offset values is entered. For the demonstration
program, a 2mm Ø and 4mm Ø slot drill are required. The data for standard
tooling supplied by Boxford is as follows.

To add a new tool or edit tool values, see the section 'Tooling and Axes - Tool
Library - Add and Edit ' for further details.

12. Setting the Tool Offsets

Highlight the relevant tool. For the demonstration program the 2mm Ø slot
drill must be set.
Double click with the LH mouse button or select the edit tool icon

Select the 'Offsets Tab' and then the set-up button

13. The screen shows:

Follow the instructions, loading in a workpiece into the clamping device,

ensuring it is located against the clamp datums and the clamp is adequately
tightened. Select OK.

14. The screen shows:

Using a vernier or depth micrometer, accurately measure the distance from

the machine table top to the top face of the workpiece.
 Enter the value in the 'Height from Table' field.
Make a note of the measured values. Select OK.

15. The screen shows.

Follow the instructions, fitting the specified tool into the machine spindle or
for machines with auto-toolchangers, use the tool change button to load the
required tool.. Select OK.
16. The screen shows.

Using the machine control panel (see the section 'Machine Controls - Control
Panel' for control details), start the spindle in forward and increase the
speed until it is approximately 1500 RPM. Use the on screen feedback to set
the speed.
Select Manual Mode and then, manipulating a combination of the Axis
Control Buttons and Feed Override Knob, position the tool to touch the top
face of the workpiece as indicated.
When the tool is in position, Select OK - Apply - OK.
The screen returns to the tool library view. Notice the 2mm Ø slot drill now
has a Z offset value.

17. Setting Offsets for Additional Tools.

Highlight the relevant additional tool. For the demonstration program the
4mm Ø slot drill must be set.
Double click with the LH mouse button or select the edit tool icon

Select the 'Offsets Tab' and then the set-up button

The screen shows.
 This defaults to the value entered in step 14 above. Ensure this value is as
that entered in point 14 and select OK

18. The screen shows.

Follow the instructions, fitting the specified tool into the machine spindle or
for machines with auto-toolchangers, use the tool change button to load the
required tool. Select OK.
19. Repeat procedure 16 above.

20. To set offsets for other tools, highlight the relevant tool and repeat the
procedure from point 17 to 19 inclusive.
When all offsets are set, select the save icon .
CAD Window
CAD Window
Drawing Aids
Drawing Aids
The right hand toolbox contains drawing aids which are active when
selected (icon is dark grey).
Grid Display Toggles the grid display on and off.

Redraw Refreshes the screen.

Grid Lock Locks the cursor movement to the grid spacing.

Step Lock Locks the cursor movement to the step spacing.

Attach Attaches the cursor to various points. Set-up can

be accessed by Right clicking on the Attach icon.
Radial Lock Constrains cursor movement to predefined angle
increments. Set-up can be accessed by Right
clicking on the icon.
Zoom In Performs a quick and simple zoom in facility on
the workpiece area currently in the centre of the
screen.
Zoom Out Performs a quick and simple zoom out facility on
the workpiece area currently in the centre of the
screen.
Undo/Redo Last Toggles between undo and redo of the last
function

Advanced Zooms

These functions are available from the Left Hand Toolbox.

Zoom In Zooms in on a user defined window.

Zoom Last Reverts to the last specified zoom.

Drawing Tools
Drawing Tools

The left hand toolbox contains a variety of drawing tools and are grouped
by the type of entity they are used to define. To view the options within
each group, LH Click on an icon to display the full selection of group
icons.

Co-ordinate Entry
Co-ordinate Entry With all drawing tools that require points to be
specified, these can either be defined with the mouse (using the grid) or
by co-ordinate entry. To enter a co-ordinate, type the values in the co-
ordinate data entry field. These values can be Absolute (distance from the
bottom left hand corner of the workpiece) or Incremental/Relative
(distance from the last point). To toggle between Absolute and
Incremental/Relative Modes, Select the Abs or Rel icon to the left of the
data entry field.

Help and Prompts

Help and Prompts Prompts and help for each icon are displayed on the
toolbars to aid the user. Straight Lines

Straight Lines

Single Line
Defines a single straight line - The Start and End
point are specified.

Connected
Lines Draws a series of connected lines - The initial Start
Point and then the subsequent End Points are
defined. To finish, either double click the LH
Editing Objects

Selecting Objects

Select Objects can be selected by :-

1. Dragging a box around the objects to be

selected.
2. Selecting Individual Objects with the LH
mouse button and subsequent objects (if
required) with the RH mouse button (or
SHIFT + LH button).

Once an object or group of objects are selected,

the selected objects are drawn in pink and
surrounded by a dotted box (a marquee box)
with handles. This is shown below.
These handles provide quick edit functions. For
more advanced features, see Transformations
described later in this section.

Re-Sizing
LH mouse clicking any square handle around
Area Filling
Area Filling
One of the most important Tools to understand is colour
filling as this largely dictates what is actually machined (see
the Section 'Machining Considerations' for more details).
Area
Fills areas between closed boundaries, accounting for islands.
On selecting the area tool, the following dialogue box is
shown.

Col... is selected bringing up the colour selection dialogue

box.

Warning:- As with line colour settings, choose only colours

from the custom Pallet (the reason for this is explained in the
Section 'Machining Considerations').

OK is selected. The user is prompted to:-

1. Locate on edge of boundary on side for hatch - This is

the outer boundary of the fill. In the example shown
below, if the area between the 2 circles is to be filled,
the larger circle is the outer boundary. The boundary is
located with the hand pointer.
Machining Considerations
Machining Considerations

The previous CAD sections have concentrated on the drawing tools

within the CAD system.
Some important machining considerations relating to the drawing will
now be discussed.

Colours
Sixteen custom colours are available in the colour palette dialogue box.
When the drawing is Post Processed into a G&M code CNC programme,
each colour can be assigned a different depth.

At the Design Stage, all the user must consider is that any objects
required to be cut to a different depth, MUST be assigned a different
colour (up to a maximum of 16 colours).

Machined Objects

Objects that are machined are :-

1. Lines with a width setting (not thin lines).
2. Filled Areas

Lines
Any line with a width setting (other than thin) will be followed with a
Cutter, of User Specified Type, of the equivalent diameter or the nearest
one available from the Machine Tool Library (See section 'CAM
Processor - Settings' for more details ).
NOTE:- If a selection of adjoining lines (with a width) are selected in the
CAD package and Make path selected from the Edit menu, the cutter will
NOT lift out in the Z axis until the end point is reached.
This can be particularly useful if the Cutter Type to be specified can not
lift out whilst cutting. E.g. T-Slot Cutter.

Important

If using cutters which cannot plunge or pull out of the workpiece in the Z
axis, define paths which start and finish off the workpiece ensuring they
form a continuous path using the Make path menu option..

Filled Areas
Any areas filled with colour can be:-

1. Pocketed out with a variety of tools - (cutter diameter compensation

is automatically implemented)
2. Profiled - around the outside (e.g. for cutting out a shape).
3. Profiled - around the inside (e.g. for leaving a cut-out of the shape in
a sheet of material).

Additionally filled circles can be:-

1. Pocketed out with a variety of tools - or

2. Drilled with a drilling cycle using a drill of the equivalent diameter
or the nearest one available from the Machine Tool Library (See
section Tooling and Axis - Tool Library).

Problem Objects
With the large variety of drawing tools available, it is important to
understand:-

1. What can and what can not be machined.

 2. What will be machined.

What cant be machined

1. Lines with a width narrower than the smallest diameter Specified

Tool type will not be machined.
2. Filled Circles with a diameter smaller than the smallest diameter
Drill Filled areas which have sections narrower than the Edging
Tool (See section Tooling and Axis - Tool Library).
This often happens when the pocket is the internal fill of some fonts
as shown below. The circles within the text represent where the
cutter diameter can machine up to.
Notice the difference between what was drawn and what will be
machined.

Warning :- If you draw text too small none of it may be

machined. Please remember you are cutting resistant materials
and not merely dropping ink onto paper.

What will be machined

As described in the previous section, the system will attempt to machine

EVERY Line with a width setting and Filled Area.
For this reason it is important that Islands are correctly defined. If a filled
object (1) is on top of another filled object (2). object (2) will still be
machined even though it cannot be seen on the screen.

In the example below object (1) has been drawn on top of the solid filled
(no Islands) object (2). If object (1) is to be machined to a depth less than
object (2) then it will be machined away when object (2) is machined.

Machining Order

The objects will be machined on an individual basis working from the

back of the drawing (i.e. the back object is machined first and the front
object last).

This can be useful if for instance an object is to be profiled (cut out) as

the last operation.

Machining Finish and Processing Time

The machining finish can be set by selecting Set-up - Customise from the
CAD package.
The window below is shown.
The Tightness Value determines the finish around curved paths. As the
Tightness Value increases curves (arcs) will visibly comprise of a number
of straight lines as shown in the diagram below.

Note:- The Default values have been carefully chosen and should only be
changed by experienced users.
Changing this value will only effect future processed drawings.
Example

The diagram below shows a drawing of a component composed of

straight lines, an arc, text, circular pocket and a single drilled hole.

Start a new drawing, as detailed in the section 'CAD Window' and use the
File - Save option to name it EXAMPLE. Refer to the previous CAD
options for guidance in producing the profile shown below.

1. Select and set the line width to Thick with a value of

4.00mm.
2. Select and select the blue from the 16 custom colours. Select
OK.
3. Select the 'Connected Line' tool
4. Place the cursor within the workpiece outline. Note how the co-
ordinate readout changes as the cursor is moved.
5. Move the cursor to give a co-ordinate readout of X=90.00 Y=10.00
and select the LH Mouse Button.
6. A Cross is displayed which is connected to the point set in step 5 by
a straight line:

7. Watch the co-ordinate display and drag the cross-hairs to set the end
point of the line in the correct position. The line will behave like a
rubber band, and X and Y co-ordinates of the display will change as
the cross is moved; when they read X=10.00, Y=10.00, select the LH
mouse button. Ensure that grid snap is set to 1.00mm or less.
8. Repeat this procedure to draw the next two straight lines of the
component, dragging the cross to the end point of each line and
checking the co-ordinate display before selecting the LH mouse
button. When the second line is complete, end the connected lines by
selecting the RH mouse button. The drawing should be as shown
 below.

9. Select the 'Arc through 2 points with a given radius' tool

Set the radius to 50.00mm.
10. Move the cursor to the start point, X=40.00, Y=60.00 and select the
LH mouse button.
Move the cursor to the end point, X=90.00, Y=10.00 and select the
LH mouse button.

To fix the direction of the arc, move the cursor into the required
position and select the LH mouse button:

11. Select and set the line width to Fine.

Select and select the black from the 16 custom colours.
Select OK.
12. Select the 'Text' entry tool
13. Move the cursor to the bottom left corner of the character B,
 X=20.00, Y=20.00 and select the LH mouse button. In the text entry
dialogue box, type the character B.
Select the Settings option and select 'Arial' as the font and 'Bold' as
the style. Select OK - OK:

14. Select the 'Select' tool

Move the cursor over the text character B and select the LH mouse
button. The edit handles will be displayed.
15. Move the cursor over the left hand bottom edit handle and select the
LH mouse button.
The handle can now be moved. Move the cursor to the required
bottom left corner of the character B, X=20.00, Y=20.00 and select
the LH mouse button.
16. Repeat step 15 to set the position of the right hand top edit handle,
X=45.00, Y=50.00:

17. Select the 'Circle with a given centre point and radius' tool Set
the radius to 10.00
 Move the cursor to the centre of the circle, X=65.00, Y=30.00 and
select the LH mouse button.
18. Select the 'Circle with a given centre point and radius' tool using
the RH mouse button.
Set the radius to 2.50
Move the cursor to the centre of the circle, X=65.00, Y=30.00 and
select the LH mouse button.
19. Select the 'Circle with a given centre point and radius' tool using
the RH mouse button.
Set the radius to 2.00
Move the cursor to the centre of the circle, X=90.00, Y=60.00 and
select the LH mouse button:

20. Select the 'Area Fill' tool

Select Col... and select the Red from the 16 custom colours. Select
OK - OK:

Move the cursor over the outline of the 20.00 dia. circle and select
the LH mouse button.
Select Yes to the prompt 'Any Islands'.

Move the cursor over the outline 5.00 dia. Circle and select the LH
mouse button.

Select No to the prompt 'Any Islands'.

The area between the 20.00 and 5.00 dia. circles is filled with red.
21. Select the 'Area Fill' tool using the RH mouse button.
Select Col... and select the Dark Cyan from the 16 custom colours.
Select OK - OK:
Move the cursor over outline of the 4.00 dia. Circle and select the
LH mouse button.
Select No to the prompt 'Any Islands'.
The 4.00 dia. Circle is filled with dark cyan:

22. Select File - Save naming the file EXAMPLE.DTD if it is not

already.
CAM Settings
CAM Settings

When the CAD profile is complete and ready to be processed into a G&M code CNC
program, select File - To Mill .

If the profile has not being named and saved, the user is prompted to do so at this point.

The CAM Processor Dialogue box shown below is displayed.

The various settings are as follows:-

Cutter Info

Material
Selecting the drop down provides a list of the available material types. (See
'Administrator Mode' section for more details on adding user defined materials and cut
data). The required material is selected from the list.

Edging Tool and Area Tool

The drop down for these two tools is a list of the slot drills available in the Machine
Tool Library.

The Edging and Area tool are used to remove (pocket) all Colour Filled areas in the
drawing. There function is as follows.
Edging Tool - This tool performs the finish path around the pocket (filled area) as
shown below.

The edging tool is also used to profile around a colour which has been
set to Outside or Inside (see Options later in this section)
Area Tool - This (usually larger) tool is used to remove the bulk of material from
filled areas as shown with the pocket below.

Warning
To ensure filled areas are correctly removed, it is strongly
recommended that the ratio between the Edging Tool and The Area
 tool is 1:2 (e.g. 2mm Edging Tool & 4mm Area Tool).

It is permissible to set the Area and Edging Tools to be the same

diameter to avoid tool changes during manufacture. Experienced users
can experiment with different combinations for different drawing
applications.

Block Size
The X (Length) and Y (Width) dimensions are transferred from the drawing. The user
must specify the Z (height or thickness) dimension.

Depths
The Colour Depth settings are accessed by selecting the Depths... button.

The dialogue box below is shown.

For each colour used in the drawing (the others are ignored), the total required depth is
entered. This can include decimal values (2 Decimal places in Metric and 3 Decimal
places in imperial). There are 16 colours available which match the 16 custom colours
in the CAD colour palette. Hence 16 different depths can be defined.

Warning:- If the user defines a depth which can not be achieved by the current tools in
the machine library, the user will be warned upon processing the drawing (Refer to
section 'CAM Processor - Error Messages' for further details ).
When the required colour depths are set, OK is selected.
Options
The colour machining strategy settings are accessed by selecting the Options... button.

The dialogue box below is shown.

For each colour in the drawing (the others are ignored) a Style and Path Tool Option
can be defined.

The function of these options are described as follows:-

Style: These settings affect ONLY COLOUR FILLED AREAS and not
lines with a defined width.
AREA - Machines out all areas with this colour fill with the Area
and Edging tools as described earlier in this section (Edging Tool
and Area Tool).

DRILL - Uses a drilling cycle to drill circles with a drill of

equivalent diameter or the nearest one (always smaller) available
from the machine tool library. The system will first look for a twist
drill of appropriate diameter. If one is not available, it will look for
a spot drill and then a slot drill.
Warning - Only colours made up entirely of individually filled
circles should be assigned as a DRILL colour.

INSIDE - Profiles around the inside of colour filled pockets using

the Edging Tool. Compensation for the diameter is automatically
implemented. This can be particularly useful when cutting profiles
out of thin sheet material.
An example is shown below.
 OUTSIDE - Profiles around the outside of colour filled pockets
using the Edging Tool. Compensation for the diameter is
automatically implemented.
An example is shown below.

When all the Colour Depths and Area Setting are complete, OK is
selected.
These settings affect ONLY LINES WITH A DEFINED WIDTH
and not colour filled areas.

The user can define the type of tool to be used to follow ALL lines
with width in the colour.
Path Tool:
Any line with a width setting will be followed with a cutter of the
specified type and of the equivalent diameter or the nearest one
available from the Machine Tool Library.

Warning - When selecting certain tool types (E.g. Dovetail or T-

Slot), ensure the cutter does not plunge into the workpiece or pull
out of it. Refer to the section 'CAD - Machining considerations' for
more details .

Processing
To process the Drawing and create a G&M CNC programme, Process is selected.
The message below is displayed.

Selecting Yes saves the CAM processor settings with the drawing.

The processor analyses the Drawing and produces a G&M code CNC programme
specifying Cutter Paths, Speeds, Feeds and Cut Depths appropriate to the material type
selected and the tooling available.

Factors Affecting Processing

There are a number of factors which will affect the processing time.

1. Pocketing out complicated areas (particularly text strings) will increase processing
time.
2. Processing lines with a defined Width will be relatively quick.
3. The higher specification the PC Computers Main Processor the quicker processing
will be.
4. If the user has accidentally specified an unusually deep pocket, processing time
will be significantly increased.
If you suspect a mistake, press the ESC key on the keyboard to abort processing.

Tool Path Simulation

When the profile has been processed, the user is prompted to save the G&M code
programme (Please note if processing reveals any errors, this dialogue box will be
proceeded by an error message - see section 'Cam Error Messages' for details )..
The default name and path can be retained or new ones specified.

When OK is selected, a simulation of the cutting cycle is shown. This is the final user
check of the component that will Actually Be Machined. Any areas which can not be
removed because of tooling limitations will be omitted.
For details on Simulation and View manipulation, see the section 'Running the
Demonstration program'.
Error Messages
Error Messages

When Processing a drawing, the CAM processor compares the drawing

requirements with the Cutting Tools available.

If any drawing requirements can not be satisfied, then an error message

(or messages) is displayed.

An example is shown below.

The user can continue processing by selecting OK

A program with the compromised settings (safe) is produced.

Or

The user can abort processing by selecting Cancel and reprocess the
drawing using different settings.

Error Messages

There are a number of error messages which can be reported. Their

description and causes are as follows:-

Cut Depth - The Cut Depth (Total - not cut per pass) will never exceed
the Tool Length value defined in the tool library (see Section 'Tooling
and Axes - Tool Library' )
E.g. 2.0mm slot drill is unable to cut deeper than 9.000mm

Cutter Diameter - If a Tool from the Tool Library cannot match a line
with defined width, or a drilled hole with defined diameter, the processor
will choose the nearest smaller diameter tool.
E .g. 9.0mm drill was not found, using 8.0mm instead

If a line width or hole diameter less than the smallest tool are specified,
the objects will not be machined.
E.g. Could not find a drill 1.5mm or less
Importing Drawing Files
Importing Drawing Files

File Types The following drawing file types can be imported.

1. Design Tools Files (*.dtd)

2. Acorn Draw Files (*.aff)
3. Designer V3 COMMS Files (*.dv3)
4. DXF Files (*.dxf)
5. Enhanced Metafiles (*.emf)
6. Windows Metafiles (*.wmf)

File Export Rules Which ever drawing package you export from, there
are some guidelines which will help you to successfully export files
suitable for importing into the Boxford CADCAM package.

Drawing Size - Set the drawing size (or custom paper size) to the
Workpiece size you intend to use.

Drawing Origin - Set the drawing Origin to be the Bottom Left corner
of the Drawing (paper) area.

Line Width - Unless you can accurately set line widths to a specified
value, do not export lines with a width. Line width attributes can be set
in the Boxford CADCAM package after importing
Importing G&M Files
Importing G&M Files

Files of the appropriate file format (see below) can be imported from
third party CADCAM packages by selecting Import - Import G&M File
from the File menu.

The CAD/CAM (*.box) filter is selected from the drop down

The file to be imported is selected followed by OPEN.

The window below is shown.

The user is prompted to Find Material "unknown".

An appropriate material from the list is defined and OK selected.

The window below is shown.

Importing Boxford V4 &V5 G&M Files
Importing Boxford V4 & V5 G&M Files

Boxford Version 4 & Version 5 G&M files can be imported by selecting

Import - Import G&M File from the File menu.

The Boxford V4-5 (*.gm?) filter is selected from the drop down

The file to be imported is selected followed by OPEN.

The window below is shown.

The user is prompted to Find Material which in the example is

"PLASTIC".

An equivalent material from the list is defined and OK selected.

The window below is shown.

Importing NC Drill Files
Importing NC Drill Files

NC Drill files produced by third party PCB design packages can be

imported by selecting Import - Import NC Drill from the File menu.

The window below is shown.

The user is prompted to 'Open Tool Definition File'. This is a separate

file, containing tool information, exported by the PCB design package
with the drill file.
The tool definition file to be imported is selected followed by OPEN.

The window below is shown.

Administration Mode
Administration Mode

An administration mode is built into the Boxford CADCAM package allowing

authorised personnel to access and modify important data files including tool libraries,
material libraries and software preferences. Individual machines can also be deleted
from the software (see below),Tutorial files created (see below) and CAM Processor
default settings modified (see below).

Instructors and Network Administrators - To be able to use the Boxford

administration mode and write to the relevant data files, you must have read/write
access to the Public Drive (drive where the Boxford application is installed). If you do
not have this access, a write error will be reported and administrator mode will be
terminated after the password (see below) is entered.

Access & Password Setting

From the front end menu, Settings - Current User - Administrator is selected.

The window below is shown.

The current administrator password is entered and OK selected.

Note: as the software is not shipped with a password, the field is left blank.

The software front end now shows the word 'Administrator' across the bottom.

Tool Library (refer to sections 'Tooling and Axes - Tool Library' and 'Tooling and Axes -
Setting Up'), Material Library (see below) and Software Preferences (refer to section
'Installation - Configuring the Software') can all be edited and saved from this mode.
Conversational Programming
Conversational Programming

Conversational programming is a programming method which allows

G&M programs to be built up using an easy to use question and answer
wizard to define machining operations.
This method of programming can be used to write new G&M programs or
add additional operations to the end of existing G&M programs.

Note: Conversational programming can not be used to create, write or add

to subroutines.

This section describes the inputting of new programs using the

conversational method.

The component used in Tutorial 5 of the MDI programming tutorial is

shown below.
Operations and Programming Sheets
Operations and Programming Sheets

Before commencement of programming the following points require

consideration:

1. Drawing The work datum is usually at the front left corner of the
workpiece for rectangular work and at the front left corner of an
imaginary bounding square for circular work as shown below.. If
necessary re-dimension the drawing from this datum.

2. Machining
Decide on the material from which the part is to be machined. Consider
the machining operation and the sequence in which these operations
should be performed.

3. Tooling
Choose appropriate tools for each machining operation.

4. Workholding
Decide on the appropriate method, as it is important to avoid collisions
of the tool with the workpiece.
Absolute and Incremental Programming
Absolute and Incremental Programming

Co-ordinates are expressed as being either absolute or incremental.

1. Absolute Co-ordinates In this system all co-ordinate locations are

programmed from a fixed absolute zero point (datum).

2. Incremental Co-ordinates In an incremental numerical control

system each co-ordinate location is given in terms of distance and
direction along rectangular axes from the previous position and not
Speeds and Feeds
Speeds and Feeds

Calculating Speeds and Feeds

When writing a program the values for spindle speeds and feed rates
have to be entered.

With experience a programmer will use values which are known to

produce the required balance between surface finish, tool wear and
production time, but for the beginner the following notes of guidance are
offered. These are only basic principles and the tool manufacturers
catalogue should be consulted for specific information.

Cutting Speed

The cutting speed for a material is the speed at which the cutting edge of
the tool passes over the surface of the workpiece and is measured in
Metres per minutes.

Typical values of surface cutting speeds are as follows:

Cutting Speed (Metres/Minute)

Cutting Tool Aluminium
Brass Cast Iron Mild Steel
Alloy
Carbide 250 180 110 180
H.S.S. 120 75 18 28
The machine spindle speed can be calculated using the following
formula:

Spindle speed = m / min x 1000 or feet / min x 12

¶ x Ø of cutter (mm) ¶ x Ø of cutter (in.)

E.g. for 6.35mm (1/4 in.) dia. Mild Steel using a H.S.S. Cutter:

Spindle speed = 28 x 1000 = 1403 RPM or 92 x 12 = 1405 RPM

¶ x 6.35 ¶ x 0.25

program say, 1400 RPM

Feed Rates

The feed rate in the X Y plane is the speed of traverse of the workpiece.
In the Z plane it is the speed at which the tool is plunged into the work. It
is determined by:

Feed rate (mm/min) = Feed Rate (mm/rev) x Spindle Speed (rev/min)

With milling, two cutters of similar diameter may have different numbers
of cutting edges, and so the feed rate (mm/rev) is determined from:

Feed Rate (mm/rev) = Feed Rate (mm/tooth) x number of teeth

Typical values for the feed rate (mm/tooth) are given below, but once
again it is stressed that you use the values suggested by the tool
manufacturer for the quality and type of tool which you are using.
 Workpiece FEED RATE (mm/tooth)
Material HSS Carbide
End Face End Face
mills and mills and
and shell and shell
slot end slot end
drills mills drills mills
Aluminium
0.2 0.45 0.25 0.55
Alloy
Brass 0.15 0.36 0.15 0.35
Cast Iron 0.2 0.35 0.25 0.5
Mild Steel 0.14 0.25 0.2 0.4

E.g. for a 6.35mm Ø HSS 2 tooth slot drill rotating at 1400 RPM
machining Mild Steel:

Feed Rate = (0.14 x 2) x 1400 = 392mm/min

Program Format
Program Format

A program is a series of "blocks" or lines each showing a set of functions and/or coordinates.

A typical format for a mill or router is:

N G M X Y Z I J K F S P Q R T

These are the headings used on the programming sheet, where:

N = block or sequence number.

G = preparatory function.
M = miscellaneous function.
X = X co-ordinate (absolute or incremental depending on programming mode).
Y = Y co-ordinate (absolute or incremental depending on programming mode).
Z = Y co-ordinate (absolute or incremental depending on programming mode).
I = incremental move in X from start of arc to arc centre when circular interpolating.
J = incremental move in Y from start of arc to arc centre when circular interpolating.
K = incremental move in Z from start of arc to arc centre when circular interpolating.
F = feed rate in mm/min.
S = spindle Speed in RPM
P = Time dwell (in milli seconds) or a Canned cycle parameter.
Q = Canned cycle parameter.
R = Radius value when used with circular interpolation or a canned cycle parameter.
T = Tool Change.

Note: F and S values are modal throughout a program. I.e. they remain the active value until a
new value is specified.
Preparatory Codes (G Codes)
Preparatory Codes (G Codes)
Information Required

The address letter G is followed by two digits, and the following codes can be
used.
For further details, please see the Tutorials section.
Code Group Function Address Codes Used
G00 Rapid Traverse Movement XYZ
G01 Linear Interpolation XYZF
G02 1 Circular Interpolation (Clockwise) XYZIKFR
G03 Circular Interpolation (Counter XYZIKFR
Clockwise)
G04 0 Time Dwell P
G17 Select X - Y Plane
G18 2 Select X - Z Plane
G19 Select Y - Z Plane
G20 Imperial Programming Units
6
G21 Metric Programming Units
G40 Cancel Tool Path Compensation
G41 7 Tool Path Compensation Left
G42 Tool Path Compensation Right
G50 Cancel Mirror Imaging
11
G51 Mirror Imaging XYIJ
G53 0 Cancel Datum Shift
G61 Exact Positioning Machine Feed Mode
G64 15 Cutting Machine Feed Mode (Exact
Positioning Off)
G65 0 Macro Call P
G66 Macro Modal Call P
12
G67 Macro Modal Call Cancel
G80 9 Canned Cycle Cancel
G81 Drilling, Spot Drilling Cycle XYZKFR
G82 Drilling Cycle with Dwell, Counter XYZ KFPR
Boring
G83 Drilling Cycle with Peck XYZKFQR
 G85 Boring Cycle XYZKFR
G86 Boring Cycle with spindle stop XYZKFR
G89 Boring Cycle with Dwell XYZKFPR
G90 Absolute Co-ordinate Programming
3
G91 Incremental Co-ordinate Programming
G92 0 Datum Shift XY

Programming Notes:

1. A number of G codes from different groups can be specified in a single block.

2. With the exception of G codes in Group 0, all G codes are modal within their group. I.e. they remain active
until another code from within their group is specified.
3. Modal G codes within group 1 can also be cancelled using the G80 command.
4. Positional data and cycle parameters remain modal within a group.
E.g. to drill two holes 8mm deep at the co-ordinates X20 Y20 and X20 Y50 using the G81 Drilling Cycle, the
following data is the minimum required.
G X Y Z R F
81 20 20 -10 -8 200
50
Note how the G, X, Z, R and F values do not have to be re specified. Only the Y, which in this case
represents second hole position, is specified.

Canned Cycles
Codes G81, G82, G83, G85, G86 and G89 are referred to as 'canned cycles'. These codes are built in to the
control system of the mill; their use simplifies the programming of repetitive operations.
On completion of the cycle the tool will return to its start point.

Metric/Imperial
The following descriptions utilise metric dimensions. For imperial dimensions, substitute thousandths for
microns and in. for mm.

G81, 82 and 83 - Drilling Cycles

Fig. 8.2 Fig. 8.2 Fig. 8.3 Fig. 8.4 Fig. 8.5
G81 - Drilling/Spot Drilling
Drills/spots a hole at the X, Y position specified on in the G81 block. If no X, Y position is specified, the hole is
drilled in the current position.
The hole is drilled to the depth Z (see Fig 8.2)

An optional retraction plane can be specified under the R address (see Fig. 8.2). If specified, the tool rapids
to the R point from its current Z position, Feeds to Z, retracts to R and rapids to the initial point. R is
incremental from current Z position if G91 is active and absolute if G90 is active.

A hole repeat value can be specified under the K address (see Fig. 8.5). If a K value is used, the G81 block
must include an incremental X, Y value or the repeats will be drilled in the same position. This means the
current modal G code from Group 1 must be G91 or G91 must be included on the cycle line.

See Tutorial 3 for further details

G82 - Drilling cycle with Dwell

Drills a hole as per the G81 cycle described above with the same retraction and repeat features.
An additional P address allows a dwell at the bottom of the hole to be programmed (See Fig. 8.4). This is
particularly useful for counter boring holes.

P is defined in milli seconds. E.g. to program a 1 second dwell, a value of 1000 is entered.

G83 - Drilling with Peck

Drills a hole as per the G81 cycle described above with the same retraction and repeat features.
An additional Q address allows pecks to be defined (see Fig. 8.3). The Q value represents the depth of cut
for each peck and is always specified as an incremental +ve value (-ve values are ignored).

The R address is non optional.

In between pecks, the tool rapids to the retraction plane to clear the swarf then rapids back to a position just
above where the last cut was performed before feeding to the next peck depth.

See Tutorial 3 for further details

G85, 86 and 89 - Boring Cycles

Fig. 8.6 Fig. 8.7 Fig. 8.8 Fig. 8.9 Fig. 9.0

G85 - Drilling/Spot Drilling

Bores a hole at the X, Y position specified on in the G85 block. If no X, Y position is specified, the hole is
drilled in the current position.
The hole is bored to the depth Z (see Fig 8.6)

An optional retraction plane can be specified under the R address (see Fig. 8.7). If specified, the tool rapids
to the R point from its current Z position, Feeds to Z, retracts to R and rapids to the initial point. R is
incremental from current Z position if G91 is active and absolute if G90 is active.

A bore repeat value can be specified under the K address (see Fig. 9.0). If a K value is used, the G85 block
must include an incremental X, Y value or the repeats will be bored in the same position. This means the
current modal G code from Group 1 must be G91 or G91 must be included on the cycle line.

G86 - Boring with Spindle Stop

Bores a hole as per the G85 cycle described above with the same retraction and repeat features.

The spindle stops at the bottom of the hole and then the boring tool pulls out creating 1 linear machine mark
rather than the helical one created with the spindle running (see Fig. 8.8)

G89 - Boring with Dwell

Bores a hole as per the G85 cycle described above with the same retraction and repeat features.
An additional P address allows a dwell at the bottom of the hole to be programmed (See Fig. 8.9). This is
particularly useful for counter boring holes.

P is defined in milli seconds. E.g. to program a 1 second dwell, a value of 1000 is entered.

Custom Macros
Custom macros are similar to canned cycles in that they simplify the programming of repetitive operations.
They differ in that they are created by the user or machine tool vendor and are allocated a custom P address
code.

Boxford provides the following custom macros.

P address Description Details

P1079 Point to Point Linear Milling
P1086 P.C.D. Hole Drilling
P1088 Rectangular Pocket Milling
P1089 Circular Pocket Milling

Calling a Custom Macro

Custom Macros can be called using the G65 or G66 code depending whether a single or multi instance of the
macro is required.

G65 - Macro Call

This code allows custom macros to be executed from the X, Y position included in the G65 block or from the
current position if not specified.
The G65 code is not modal.
Macros are stored under a P address number.

See Tutorial 3-1 for an example.

G66 - Modal Macro Call

If a number of identical macros are required, the G66 code can be used.
All the macro parameters should be defined within the G66 block excluding axis positional commands.
On each subsequent line which includes a move along an axis, the macro is executed after the axis move is
completed.

G66 is cancelled with a G67 - macro modal call cancel command.

See Tutorial 3-1 for an example.

P1079 - Point to Point Milling

Fig. 79.1 Fig. 79.2

Mills a linear slot to a defined depth (see Fig 79.1 and 79.2)

X, Y = start position of slot (Current position assumed if not defined. Ignored if macro called with G66).
Z = Depth (absolute)
I = Incremental move in X axis to end of slot.
J = Incremental move in Y to end of slot.
F = Feedrate
Q = Number of equal passes to reach depth Z (must be an integer).
R = Retraction plane. The tool rapids to the R point from its current Z position, performs the number of cuts
defined in Q to reach Z depth, retracts to R and rapids to the initial point. R is incremental from current Z
position if G91 is active and absolute if G90 is active.

P1086 - P.C.D. Hole Drilling

Fig. 86.1 Fig. 86.2 Fig. 86.3

Drills a number of equally spaced holes around a Pitch Circle Diameter.

X,Y = Centre of Pitch Circle Diameter which holes are spaced around (see Fig. 86.1). (Current position
assumed if not defined. Ignored if macro called with G66).
Z = Absolute depth (see Fig. 86.2)
I = Incremental Distance in X axis to first hole from centre. (See Fig. 86.3)
J = Incremental Distance in Y axis to first hole from centre. (See Fig. 86.3)
F = Feedrate
Q = Number of equally spaced holes around P.C.D. (See Fig. 86.1)
R = Retraction plane (see Fig. 86.2). The tool rapids to the R point from its current Z position, drills the first
hole, retracts to R, rapids to the next hole, retracts to R ..... until Q no. of holes have been drilled when the
tool rapids to the initial point. R is incremental from current Z position if G91 is active and absolute if G90 is
active.

See Tutorial 8 for an example

P1088 - Rectangular Pocket Milling

Fig. 88.1 Fig. 88.2 Fig. 88.3 Fig. 88.4

Machines a rectangular pocket automatically compensating for cutter diameter.

X,Y = Centre of Pocket (see Fig. 88.1). (Current position assumed if not defined. Ignored if macro called with
G66).
Z = Absolute depth (see Fig. 88.2).
I = Pocket X length (see Fig. 88.2)
J = Pocket Y length (see Fig. 88.2)
K = Machining strategy. K = 0 (or omit ) removes the material within pocket. K = 1 machines outline only (see
Fig. 88.4).
F = Feedrate
Q = Number of equal passes to reach depth Z (see Fig. 88.3)..
R = Retraction plane. The tool rapids to the R point from its current Z position, performs the number of cuts
defined in Q to reach Z depth, retracts to R and rapids to the initial point. R is incremental from current Z
position if G91 is active and absolute if G90 is active.

See Tutorials 3-2 and 3-3 for further details

P1089 - Circular Pocket Milling

 Fig. 89.1 Fig. 89.2 Fig. 89.3

Machines a circular pocket with or without an island automatically compensating for cutter diameter.

X,Y = Centre of Pocket (see Fig. 89.1). (Current position assumed if not defined. Ignored if macro called with
G66).
Z = Absolute depth (see Fig. 89.2).
I = Pocket Outside diameter (see Fig. 89.2 - Ø1)
J = Pocket Inside diameter. If no island is required, enter a value of 0 (see Fig. 89.2 - Ø2).
F = Feedrate
Q = Number of equal passes to reach depth Z (see Fig. 89.3)..
R = Retraction plane. The tool rapids to the R point from its current Z position, performs the number of cuts
defined in Q to reach Z depth, retracts to R and rapids to the initial point. R is incremental from current Z
position if G91 is active and absolute if G90 is active.

See Tutorial 5 for further details

Miscellaneous (M Codes)
Miscellaneous Codes (M Codes)

Information Required

The address letter M is followed by two digits, and the following codes
can be used.

For further details, please see the Tutorials section.

Code Function Address Codes Used

M00 Programmed Intermediate Stop
M01 Programmed Optional Stop
M02 End of program (single quantity)
M03 Spindle Start Clockwise S
M04 Spindle Start Anticlockwise S
M05 Spindle Stop
M06 M06 Tool Change T
M08 Coolant On
M09 Coolant Off
M30 End of Program (Repeat)
M39 Close Automatic Chuck
M40 Open Automatic Chuck
M48 Open Automatic Guard
M49 Close Automatic Guard
M81 Turn output On/Off I (1 = on. 0 = off)
M97 Continuous Manufacture
M98 Subroutine Call P
M99 End of Subroutine
Inputting a New Program
Inputting a New Program

Information required

To input a new program, you will need the following information:

1. A completed programming sheet containing -

Program details
Type of co-ordinates used (absolute or incremental)
Tools used
Speeds and feeds.
2. Details of the billet -
Rectangular Billet Circular Billet
Length (Along the X axis) Diameter
Width (Along the Y axis) Length (Along the X, Y or Z axis depending on orientation).
Depth (Along the Z axis)
3. A name for your program

Input Program Details

From the front end menu, select File - New - G&M File or select the 'G&M new' icon

Enter the filename and select OK

The window below is shown.

Material Type A new material type can be selected from the

drop down. All feedrate and cut depth warnings
will be relevant to the new material.

X Billet length.
Y Billet width.
Z Billet height.
Metric
If checked the billet dimensions and program
coordinates will be in metric units (mm).
If not checked, the billet dimensions and
program coordinates will be in imperial units
(inches).
Programming a Tool Change
Programming a Tool Change

Tools are entered into the program with two lines of information.
The first line stops the spindle and moves the tool away from the work,
and the second line selects the next tool.

A typical example of this is:-

N G M X Y Z T
50 00 05 0 0 20 1
60 1 06 1 1 1 01

If the T number entered has not been used else where in the program, the
tool selection window is displayed.

This is shown below.

The required tool is highlighted and OK selected.

The new tool can be used at any point in the program by specifying the
same T number.

NOTE:- If the 'Programming Hints' are active (turned on/off using the
icon or the '?' key) and the current display mode is 'Tabulated', the
required tool can be selected directly from the help window when the
current edit field is 'T'. Tools shown in RED are tools already used in the
current program and have an associated 'T' number. Those shown in blue
have not yet been used and have T?. Selecting a previously unused tool
will enter it into the program allocating it the smallest unused 'T' number.
Examining an Existing Program
Examining an Existing Program

With a G & M program loaded, the View G & M program icon is selected
from the front end menu.

A view of the G&M code program is displayed as shown below.

The menu options available are as follows:-

File

Save As: Saves the current file as a new name.

Save Copy As: Saves a copy of the current file leaving the current file loaded.

Print: Launches the print routine displaying the standard print window with an
additional section at the bottom as shown below.

Options are as follows:-

Prints information about the program not

Print Options: Header contained in the GM listing. E.g. tools used,
material size etc.
GM Listing Print the full GM listing of the current program.
If GM listing is selected in Print Options, this
Editor Style: Compact
option produces a compact format output.
If GM listing is selected in Print Options, this
Tabulated option produces a tabulated format output with
labelled columns.
Machine Info: Interrogates the Boxford machine currently connected to the machine and
reports back machine information. E.g. maximum and minimum feeds, speeds etc.

Program Information: Displays the program information window as shown below.

Material Type All feedrate and cut depth warnings are

relevant to the material.
X Billet length.
Y Billet width.
Z Billet height.

Note:- The billet dimensions will differ for tubular workpieces.

A thumbnail will be shown detailing the dimensions.

Exit: Exits the edit program mode and return to the front end screen.

Edit

Tabulated - Toggles the G & M program display between tabulated and compact.
Help

Help Contents - Accesses the indexed help system which includes the complete machine
manual.

Help G&M Codes - Accesses detailed help on all the G&M codes available to the user.

Help On This - Accesses help on current screen.

Credits - Details of the development team and their roles in bringing you this product.

About - Displays registered licence holder information and lists specific versions of the
components which make up Boxford CADCAM Design Tools.
Editing a Program
Editing a Program

To edit the currently loaded program, Edit - Without Graphics is selected from the front
end menu.

Program Edit Window

The program write window below is displayed.

Move your mouse over the icon, menu or screen area you require help on and select
with the mouse.

When entering the program, type into the edit fields and precede each item with the
letter at the top of the corresponding column.

When the line is complete, press Return.

Continuing a Program
Continuing a Program

An incomplete program which has been saved can be continued at the

point where inputting was interrupted.

From the Front End Menu, with the incomplete G&M program loaded,
Edit - With Graphics or Edit - Without Graphics is selected

Edit without Graphics

In 'Edit Without Graphics' mode, program entry can be continued after

the last line.

See the section 'MDI - Editing a Program' for details on editing a

program.

Edit with Graphics

Selecting the icon from the video controls will simulate the
completed part of the program, stopping when the last line is reached.
Subsequently entered lines will produce a simulated move if appropriate.

See the section 'MDI - Inputting a New Program' for more details.
Manual Machining
Manual Machining

The manual machining feature enables the machine to be controlled directly using the
controls on the machine control panel (refer to the section 'Machine Controls').

It is not possible to run the machine from the PC once Manual mode is selected; the PC
simply displays tool movement and spindle speed.

From the Front End menu, select View - Feedback.

The screen shows the feedback panel as shown below.

Button functions are as follows:-

Zero Zeros the relevant axis readout. The

Readout readout changes colour to a light blue
indicating the readout is no longer
relative to the machine axis limits.
Selecting the button again will toggle
the readout back to been relative to the
machine axis limits.
Tool With the machine in Manual Mode
Change (Manual mode button lit) selecting this
button will display the window shown
below.

Highlighting a tool (with an offset

value set) and selecting OK will move
the position of the Z axis to account
for the new tool offset. The Axis
readout values will remain unchanged.
 Cycle This button can be used during an
Start automatic manufacture cycle instead
of the 'Cycle Start' button on the
machine control panel. This button is
not available in feedback mode.
Feed This button can be used during an
Hold automatic manufacture cycle instead
of the 'Feed Hold' button on the
machine control panel. This button is
not available in feedback mode.
Single This button can be used during an
Block automatic manufacture cycle instead
of the 'Single Block' button on the
machine control panel. This button is
not available in feedback mode.
Home With the machine in Manual Mode
Axis (Manual mode button lit) selecting this
button will automatically home the
axis (Z followed by Y followed by X).

Description of the feedback panel icon modes are as follows.

Machine is currently in
manual mode. Machine is in automatic
All manual axis and spindle mode.
controls controls can be All manual controls are
used. disabled.

Guard open.
Guard closed.
The machine guard is open.
The machine guard is closed.
Single Block Mode Active.
Only one block of the
program is completed at a
time. Cycle start must be Single Block mode Inactive.
pressed to activate the next
block.

Feed Hold active Feed Hold Inactive.

Either the feed hold button
on the machine keyboard is
active (LED lit), or the feed
override is set to 0% or the
guard is open or the machine
is in overtravel.

Automatic Mode active.

Machine is in a
Automatic Mode Inactive.
manufacturing cycle.

The emergency stop button

on the machine is currently Emergency stop not active -
pressed. no other errors.

Overtravel active.
Either in manual mode or Low Air
whilst in an automatic The Compressed Air supply
manufacture cycle, one of to the machine is below the
the axes has activated a limit required pressure.
switch.

Indicates the current position

of the machine feed override
control.
Automatic Machining
Automatic Machining

Initial Checks

Reference Section.
1. PC connected to the Boxford Installation - Installing the Machine. . . .l
machine, power switched on and - Installation - Installing the software. . .
Mill software running.
2. Mill software correctly configured. - Installation - Configuring the software . .
3. Tooling and offsets for required Tooling and Axes - Setting Up . . . . . . . .
-
program set and checked.
4. Program verified by simulation. - Running the software - Program Simulation.

With a G & M program loaded, the manufacture icon is selected from the front
end menu
Note: If this option is greyed out, the program has not been satisfactorily simulated and may

contain errors. Select the 'Simulate Program' option and re-simulate.

The manufacture screen is displayed with the window shown below.

Move your mouse over the icon, menu or screen area you require help on and select with the
mouse.
Batch Machining
Batch Machining

Batch Manufacture allows a number of programs to be nested onto a single sheet of material
and manufactured in one continuous cycle.

Initial Checks

Reference Section.
PC connected to the Boxford
Installation - Installing the Machine. . . .l
1. machine, power switched on and -
Installation - Installing the software. . .
Mill software running.
2. Mill software correctly configured. - Installation - Configuring the software . .
Tooling and offsets for required
3. - Tooling and Axes - Setting Up . . . . . . . .
programs set and checked.
Programs to be batch
4. manufactured verified by - Running the software - Program Simulation.
simulation.

Program Requirements for Batch Manufacture

1. All Programs MUST use the same material type (E.g. Plastic)
2. All programs MUST use the same material thickness (Z).

From the front end menu, File - Batch Manufacture is selected.

The table below is shown.

Note: If Batch Manufacture has been used previously, the list of programs from the last
batch will be displayed.
The options are as follows:-
Button Function
Saves the current batch manufacture session.
Allows a new program to be selected and added to the list using
the open dialogue.
Deletes the currently highlighted program from the list.
Deletes all programs from the list.
Moves on to the next page of the Batch Manufacture Wizard.

When the all the programs required for batch manufacture are in the list, NEXT is selected.

The screen below is shown.

On this page, 'Cutout' parameters can be specified.

'Cutout' will, as the phrase suggests, will cut out each component from the sheet material as
the last operation of the batch manufacture cycle. The specified cutter machines around the
outside of the billet dimensions of each individual program. Snap out tabs can also be
specified allowing the individual components to be retained within the sheet material.
The parameters are as follows:-
Parameter Description
The tool required to perform the cutout operation is
selected from the dropdown which displays all the
available tooling.
If the cutout operation is not required, <No Tool> is
Cutout Tool selected.
Note:- When a tool is selected, the feedrate, spindle
speed and depth of cut for the selected tool, in the
material used in the batch programs, are displayed for
information only.
Height (A) The height of the 'snap out' Tab from the base of the
sheet, if required. If no Tabs are required,a value of
0.00 should be entered.
Gap (B) The distance (spacing) between the 'snap out' tabs.
Size (C) The width of the 'snap out' tabs.
The distance from the bottom of the sheet material to
Cut Through
the bottom of the cutout slot. To cut through the
Offset (D)
material a -ve (negative) value should be entered.

When the required 'Cutout' parameters are specified, is selected.

The screen below is shown.

On this page, each component can be positioned within the sheet material using either
Autofit functions, Coordinate Positioning or Manual Drag and Drop.

The parameters are as follows:

A variety of positioning tools are available for component positioning.
Parameter Description
The X (length), Y (width) and Z (depth) of the sheet material
Bar Size
to be used to cut the components from.
The minimum allowable spacing between adjacent
Spacing
components.
Checking this options allows components to overlap each
other and/or be moved off the sheet material to allow
repositioning.
Overlap
Note:- Machining issues a warning if any of the components
overlap each other and/or the sheet material edges.
Overlapped components are displayed as red rectangles.
Margin The minimum allowable spacing between the edge of the
 sheet material and the batch components.
From the two drop downs, a number of sorting and ordering
options are available (for further details see below).
Selecting the button will attempt to arrange the
components on the sheet material based on the currently
Ordering specified parameters.
Note:- If the components cannot be arranged based on the
current parameters, the message 'failed to fit parts into
workpiece' is displayed. The parameters should be modified
to produce a valid layout (all rectangles should be green).

Ordering Options
Place in Y-X order
Place in X-Y order
Components are positioned in
Components are positioned in rows
columns

No Sorting - Components are ordered as they appear in the initial list of

batch programs.

X Dim - Components are ordered by their X dimension, largest first.

Y Dim - Components are ordered by their Y dimension, largest first.

 Size - Components are ordered by their square area (XY), largest first.

Drag and Drop Positioning

Components can be repositioned by placing the mouse pointer over the required component,
pressing and holding down the LH mouse button and dragging to the new position before
releasing the mouse button.
With the 'Overlap' option unchecked (see above for details), components will can only be
dragged to the positions which allow for the currently specified 'Spacing' and 'Margin'
values (see above for details).
The grid snap can be modified and zoom tools are available to help with 'drag and drop'
placing.

Coordinate Positioning
Components can be repositioned using X, Y coordinates which define the position of the
bottom left hand corner of the component.
The component to be repositioned is selected by moving the mouse pointer over the required
component and clicking the LH mouse button. The 'Part' field displays the currently selected
component.
The currently selected component can be repositioned by modifying the values in the X and
Y edit fields next to the 'Part' field.

When the required valid 'Layout' has been specified (all rectangles should be green), is
selected.

If the window below is shown, an overlap of components has been detected and manufacture
will be aborted (The 'Overlap' option was not checked on the 'Layout Page').

To rectify, restart Batch Manufacture using the File - Batch Manufacture menu item and
rearrange the components on the 'Layout' page, ensuring all components are GREEN NOT
RED before selecting .
If the window below is shown, an overlap of components has been detected. Selecting YES
will continue through to manufacture. Selecting NO will abort manufacture.

Note: YES should only be selected by experienced users who are aware of the possible
consequences of having overlapped parts.

The Automatic Manufacture setup wizard starts. See the section 'Machining - Automatic' for
further details .

During the Batch manufacture cycle, at the end of one program, the next program is
automatically loaded and machining started.
The bottom of the feedback panel shows the current part number as shown below.

When all the batch components and any specified cutouts have been machined, the window
below is shown.

Selecting OK returns the software to the Front End screen.

To repeat the last batch, File - Batch Manufacture is selected followed by - -
Network FTP Queue
Network FTP Queue

Network FTP Machining allows G&M programs to be transmitted via a

LAN to the computer running the Machine Tool (or Boxford machine
with integrated control) which is running the same version of Boxford
software.

The Machine Tool Computer and Remote computer(s) should be

configured so that the TCP/IP file transfer is set to the correct IP
addresses. To do this, from the Front End Menu with the software in
Administrator mode, select Settings - Preferences and the
Communications Tab. Select the appropriate Host IP Address from the
drop down, enter the Default Remote IP Address and ensure that Enable
TCP/IP File Transfer is checked. Complete this for all computers.
Note: The Default Remote IP Address and the Host IP Address will be
identical on the Machine Tool Computer.
E.g. If the Machine Tool Computer IP Address was 192.50.2.1 and the
Remote Computer was 192.50.2.2 the settings would be as follows:

Default Remote IP
Computer Host IP Address
Address
Machine Tool 192.50.2.1 192.50.2.1
Remote 192.50.2.2 192.50.2.1

File Transfer Procedure - From the Front End screen on the Remote
Computer, select File - Network FTP - Send File. Select the file to be
transferred and select OPEN. The program is automatically copied to the
default G&M directory on the Machine Tool Computer and loaded into
the Network FTP Queue. Additional files can be transferred and added to
the Machine Tool Network FTP queue by repeating this procedure.

Using the Network FTP Queue - From the Front End screen on the
Machine Tool, select File - Network FTP - View Queue.
The window below is shown.

The programs currently in the queue are displayed.

The controls are as follows:

Deletes the currently highlighted G&M program from
the queue.
Loads the currently highlighted G&M program into the
Front End of the 'CAD/CAM Design Tools' software
making it the current program.

The program can now be manufactured.

See the section 'Machining - Automatic' for further details .

To load the next program, re-select File - Network FTP - View Queue
and repeat the above procedures.
CNC Tutorials and Exercises

CNC Tutorials and Exercises

Tutorial 1 - X and Y Co-ordinate Calculation - Absolute and
Incremental Co-ordinates
This tutorial gives examples of absolute co-ordinates and incremental co-
ordinates.

Absolute Co-ordinates

The code G90 is used to select this type of programming. Before

programming commences the points on the path to be machined are
defined relative to the workpiece datum:
Examples of these co-ordinates are shown in the table below.

The Z axis is the vertical axis and the datum used is normally the surface
of the work.

Z is positive when moving away from the surface and negative when
moving towards or into the surface.

Point Datum A B C D E F G H
X 0 5 10 -4 -9 -7 -4 7 5
Y 0 4 5 5 7 -3 -6 -5 -2

Incremental Co-ordinates
The code G91 is used to select this type of programming.

The points on the path to be machined are defined relative to the previous
position. The points for the example on the previous page are shown in
the table below.

The Z axis is again the vertical axis, and the points are defined relative to
the previous position; positive when moving away from the surface and
negative when moving towards or into the surface.

Point Datum A B C D E F G H
X 0 5 5 -14 -5 2 3 11 -2
Y 0 4 1 0 2 10 -3 1 3

EXERCISE 1 - Calculation of co-ordinates

Tabulate the positions of the points A to H shown in the illustration

below:

1. in absolute co-ordinates
2. in incremental co-ordinates
Tutorial 2 - Linear Interpolation

This tutorial illustrates the use of the G01 code; cutting takes place in a straight line
at a controlled feed rate.

Consider the component illustrated below; it is required to mill the two L shaped
slots.

Absolute Co-ordinates

The absolute co-ordinates of the points on the profile are tabulated below.

Point A B C D E F T.C.
X 15 15 45 65 65 35 0
Y 15 35 35 35 15 15 0

Tools used : 4mm Ø Slot Drill

The program is written as follows:

Notes:
G90 and G21 can be specified in the same block because they are from different
groups.
G00, G01, Feed Rates (F) and Axis Co-ordinates (X, Y, Z) are modal therefore only
changes are specified.

PROGRAMMING SHEET MATERIAL: PLASTIC

Drg No. WRITTEN
TITLE: TUT2-1 SHEET No. 1 OF 1
BY
Axis Co-
Prep Misc Feed Spindle Tool
ordinate
Description Code Code Rate Speed No.
s
N G M X Y Z I J K F S PQR T
Abs Cords 10 90
Metric Units 21
1st Tool 20 06 01
Park Position 30 00 0 0 25
Spindle on 40 03 2000
Above A 50 15 15 2
Feed to Depth 60 01 -2 200
A to B 70 35
B to C 80 45
Pull out 90 00 2
Above D 100 65
Feed to Depth 110 01 -2 200
D to E 120 15
E to F 130 35
Pull out 140 00 2
Park Position 150 05 0 0 25
End of Program 160 30

Incremental Co-ordinates

The incremental co-ordinates of the points on the profile are tabulated below.

Point Tool A B C D E F T.C.

 Change from F
X 0 35 0 30 20 0 -30 -35
Y 0 35 20 0 0 -20 0 -15

Using these co-ordinates the program can be written as follows:

PROGRAMMING SHEET MATERIAL: PLASTIC

Drg No. WRITTEN
TITLE: TUT2-2 SHEET No. 1 OF 1
BY
Prep Misc Axis Co- Feed Spindle Tool
Description Code Code ordinates Rate Speed No.
N G M X Y Z I J K F S PQR T
Abs Cords 10 90
Metric Units 21
1st Tool 20 06 01
Park Position 30 00 0 0 25
Spindle on 40 03 2000
Inc Cords
50 91 15 15 -23
Above A
Feed to Depth 60 01 -4 200
A to B 70 20
B to C 80 30
Pull out 90 00 4
Above D 100 20
Feed to Depth 110 01 -4 200
D to E 120 -20
E to F 130 -30
Pull out 140 00 4
Park Position 150 05 -35 -15 23
End of Program 160 30

1. Examine the program listed

2. Enter the program into the computer

 3. Simulate the machining process and compare the movement of the cutter with
the program.

Exercise 2 - Linear Interpolation - Absolute Co-ordinates

1. For the component shown below, use a programming sheet and write a program
for the cutter to cut a groove along the path from A to H.

2. Enter your program into the computer and give it a test run.

3. Edit your program if necessary.

Absolute Co-ordinates

Tool
Point A B C D E F G H
Change
X 0 20 60 20 20 60 20 60 60
Y 0 10 10 30 20 40 40 20 30
Tutorial 3 - Canned Cycles and Macros - Hole Drilling and Pocket Milling
Canned cycles and Macros are used to shorten and simplify the CNC program.
This tutorial gives examples of the G81 and G83 Hole Drilling Canned Cycles and G65 -
P1088 Pocket Milling cycle.

G81 - Drilling & Spot Drilling

This code drills a hole at the X, Y position specified on in the G81 block. If no X, Y
position is specified, the hole is drilled in the current position.
The hole is drilled to the depth Z.

A retraction plane can be specified under the R address. If specified, the tool rapids to the R
point, Feeds to Z, retracts to R and rapids to the initial point.

A hole repeat value can be specified under the K address. If a K value is used, the G81
block must include an incremental X, Y value or the repeats will be drilled in the same
position. This means the current modal G code from Group 1 must be G91 or G91 must be
included on the cycle line.

G83 - Drilling Cycle with Peck

This code is identical in its operation to G81 described above with the addition of a Q
address. The Q value represents the depth of cut for each peck and is always specified as an
incremental +ve value (-ve values are ignored). The R address is non optional.
In between pecks, the tool rapids to the retraction plane to clear the swarf then rapids back
to a position just above where the last cut was performed before feeding to the next peck
depth.

For the component shown below, holes A and B are to be drilled using G81 and C and D
drilled using G83.
Absolute Co-ordinates

Point A B C D
X 20 20 60 60
Y 15 35 35 15

The program is written as follows:

Notes:
Canned cycles are modal therefore to produce hole D after hole C, only the change in axis
position needs to be specified.

PROGRAMMING SHEET MATERIAL: PLASTIC

Drg No. WRITTEN
TITLE: TUT3-1 SHEET No. 1 OF 1
BY
Prep Misc Axis Co- Feed Spindle Tool
Description Code Code ordinates Rate Speed No.
N G M X Y Z I J K F S P Q R T
Abs Cords 10 90
Metric Units 21
1st Tool 20 06 01
Park Position 30 00 0 0 25
Spindle on 40 03 2000
Start Position 50 20 -5 10
Inc Cords 60 91
20 -18 2 200 -8
Drill Hole A & B 81
Cancel Cycle 70 80
Abs Cords 80 90
60 35 -8 200 5 2
Drill Hole C 83
Drill Hole D 90 15
Park Position 100 00 05 0 0 25
End of Program 110 30

G65 - Macro Call

This code allows custom macros to be executed from the X, Y position included in the G65
block or from the current position if not specified.
The G65 code is not modal.
Macros are stored under a P address number.

Rectangular Pocket Macro

The P address for a rectangular pocket macro used in this tutorial is P1088.
X,Y = Centre of Pocket.
Z = Absolute depth
I = pocket X length
J = Pocket Y length
F = Feedrate
P = Macro address number.
Q = Number of equal passes to reach depth Z.
R = Retraction plane as used with drilling cycles described above.
The tool returns to its start point after the macro is complete.

The program to produce the component shown above is as follows:

PROGRAMMING SHEET MATERIAL: PLASTIC

Drg No. WRITTEN
TITLE: TUT3-2 SHEET No. 1 OF 1
BY
Prep Misc Axis Co- Feed Spindle Tool
Description Code Code ordinates Rate Speed No.
N G M X Y Z I J K F S P Q R T
Abs Cords 10 90
Metric Units 21
1st Tool 20 06 01
Park Position 30 00 0 0 25
Spindle on 40 03 2000
Macro call 50 65 40 25 -8 40 15 200 1088 4 2
Park Position 60 00 05 0 0 25
End of Program 70 30

G66 - Modal Macro Call

If a number of identical macros are required, the G66 code can be used.
All the macro parameters should be defined within the G66 block excluding axis positional
commands.

On each subsequent line which includes a move along an axis, the macro is executed after
the axis move is completed.

G66 is cancelled with a G67 - macro modal call cancel command.

An example program is shown below.

PROGRAMMING SHEET MATERIAL: PLASTIC

Drg No. WRITTEN
TITLE: TUT3-3 SHEET No. 1 OF 1
BY
Axis Co-
Prep Misc Feed Spindle Tool
ordinate
Description Code Code Rate Speed No.
s
N G M X Y Z I J K F S P QR T
Abs Cords 10 90
Metric Units 21
1st Tool 20 06 01
Park Position 30 00 0 0 25
Spindle on 40 03 2000
Modal Macro call 50 66 -8 25 20 200 1088 4 2
Execute Macro 60 20 20
Execute Macro 70 60 30
Cancel Modal Macro 80 67
Park Position 90 00 05 0 0 25
End of Program 100 30

1. Examine the three programs

2. Enter each program into the computer.

 3. Simulate the machining cycle for each program and compare the movement of the
cutter with the program.

Exercise 3- Canned Cycles - Macros - programming a Tool Change

For the component shown below:

1. Tabulate the co-ordinates

2. Use a programming sheet and write a program to

l drill the holes
l mill the square pocket
(For tool changing, refer to the section 'MDI - Programming a Tool change' )

3. Enter the program into the computer and simulate it.

4. Edit your program as necessary.

Tutorial 4 - Circular Interpolation This gives an explanation of the G02 and G03 codes
for clockwise and anticlockwise circular interpolation respectively (see Fig 23-1).

Circular Interpolation (G02 and G03) To program an arc from the current position, it is
necessary to define a FINISH point (See Fig. 23-2 and 23-3) and either;
a) the arc centre point or
b) the arc radius. (See Fig. 23-4 and 23-5)

Fig. 23-1 Fig. 23-2 Fig. 23-3 Fig. 23-4 Fig. 23-5

Interpolation Planes:- Circular interpolation can be used on any plane with plane X-Y
selected by using the command G17, plane X-Z using G18 and plane Y-Z with G19.
The information required to define the arc depends on the active plane. This is
summarised as follows:

Active Finish Point Arc Centre

Plane
G17 X, Y (& Z for helical I, J
interpolation)
G18 X, Z I, K
G19 Y,Z J,K
Specifying a Finish Point :- The end point of an arc can be expressed as an absolute or
incremental value depending if G90 or G91 is the active co-ordinate programming mode.
If no finish point is specified, the start and finish points are the same and a 360 degree arc
(circle) around the defined centre point or radius is the result.

Specifying an Arc Centre Point :- The centre point of an arc is specified by addresses I,
J, and K for the X, Y and Z axes respectively. Two from the three available addresses are
used depending on the active plane (see above).
The values specified are the incremental distance (irrespective of G90 and 91) from the
start point to the centre of the arc.
I, J and K must be signed according to the direction.

Examples:
a) To define a 90 deg. Counterclockwise (G03) arc in the XY plane from B to A around
centre C as shown in the diagram below requires the following data.

G X Y I J F
03 25 30 -10 0 200

b) To define a partial Counterclockwise (G03) arc in the XY plane from B to A around

centre C as shown in the diagram below requires the following data.

G X Y I J F
03 25 30 -5 -8.66 200
To calculate co-ordinates of B, construct triangle BCD
CD = 10 x cos60 = 10 x 0.5 = 5
BD = 10 x sin60 = 10 x 0.866 = 8.66

Specifying an Arc Radius:- The arc centre can be defined by specifying an arc radius
using the R address instead of I,K and K.
When defining an arc radius using R, 2 arcs around the centre point are possible, one is
less than and one greater than 180 deg.
To define the arc less than 180 deg, a +ve R value is specified.
To define the arc greater than 180 deg, a -ve R value is specified.

Example
 POINT A B C D E F G
X 10 20 30 40 50 60 70
Y 10 20 30 40 50 60 70

The program to produce the component shown above is as follows:-

Note:
Blocks N60 to N90 define the arc in terms of its radius.
Blocks N100 to N110 define the arc in terms of the co-ordinates of its centre

PROGRAMMING SHEET MATERIAL: PLASTIC

Drg No. WRITTEN
TITLE: TUT4 SHEET No. 1 OF 1
BY
Prep Misc Axis Co- Feed Spindle Tool
Description Code Code ordinates Rate Speed No.
N G M X Y Z I J K F S P Q R T
Abs Cords 10 90
Metric Units 21
1st Tool 20 06 01
Park Position 30 00 0 0 25
Spindle on 40 03 2000

Above A 50 10 10 2
Feed to Depth 60 01 -2 200
A to B 70 02 20 20 10
B to C 80 03 30 30 10
C to D 90 02 40 40 10
D to E 100 50 30 10
E to F 110 03 60 20 10 0
F to G 120 02 70 10 0 -10
Pull out 130 00 2
Park Position 140 05 0 0 25
End of Program 150 30

1. Examine the the program

2. Enter the program into the computer.

3. Simulate the machining cycle for each program and compare the movement of the
cutter with the program.

Exercise 4 - Circular Interpolation

This exercise involves using both the G02 and G03 codes.

For the cutter path shown above:

1. Tabulate the absolute co-ordinates of points A to F on the profile.

2. Using a programming sheet write a program for the path of the cutter.
3. Enter the program into the computer, simulate and edit if necessary.
Tutorial 5 - Combining Operations and Tool Changing
This tutorial uses some cutters not supplied with the machine. It illustrates how tool
changes can be made and a number of operation can be carried out on one component.

Sequence of Operations

1. Mill the steps (8mm diameter slot drill)

2. Drill the holes (4mm diameter slot drill)

3. Mill the 30mm diameter pocket (8mm diameter slot drill)

Circular Pocket Macro

The P address for a circular pocket macro used in this tutorial is P1089.
X,Y = Centre of Pocket.
Z = Absolute depth
I = Pocket outside diameter
J = Pocket inside (island) diameter. Enter a value of 0.000 for no island.
F = Feedrate
P = Macro address number.
Q = Number of equal passes to reach depth Z.
R = Retraction plane as used with drilling cycles described above.
The tool returns to its start point after the macro is complete.

Programming a Tool Change

The first tool is specified by entering an M06 T01 command, selecting the tool from
the library list and entering a park position on the next line as the above tutorials
show.
The second and subsequent tools are entered into the program with two lines of
information. The first line stops the spindle and moves the tool away from the work
and the second line selects the next tool. Entering a T number already used in the
program will change back to that tool.
A typical example of this is:-

Line G M X Y Z I J K F S P Q R T
120 00 05 0.000 0.000 25.000
130 06 02

The program is as follows:

PROGRAMMING SHEET MATERIAL: PLASTIC

Drg No. WRITTEN
TITLE: TUT5 SHEET No. 1 OF 1
BY
Axis Co-
Prep Misc Feed Spindle Tool
ordinate
Description Code Code Rate Speed No.
s
N G M X Y Z I J K F S P QR T
Abs Cords 10 90
Metric Units 21
1st Tool-8mmØ 20 06 01
Park Position 30 00 0 0 25
Spindle on 40 03 2000

Above A 50 1 54 2

Feed to Depth 60 01 -2 200

A to B 70 -5
Above C 80 00 79 2
Feed to Depth 90 01 -2
C to D 100 55
Pull out 110 00 2
Park Position 120 05 0 0 25
2nd Tool- 130 06 02
4mmØ
Above E 140 00 05 20 15 10
Spindle on 150 03 2000
Drill hole E 160 81 -8 200 2
Drill hole F 170 35
Drill hole G 180 60
Drill hole H 190 15
Park Position 200 00 05 0 0 25
1st Tool 210 06 01
Spindle on 220 03 2000
Circular pocket 230 65 40 25 -5 30 0 200 1089 3 2
Park Position 240 00 05 0 0 25
End of program 250 30

1. Examine the program

2. Enter the program into the computer.

3. Simulate the machining cycle for each program and compare the movement of
the cutter with the program.

Exercise 5 - Combining Operations

This exercise involves the use of circular interpolation and the circular pocket macro.
For the component shown above:

1. Write down the sequence of operations required to produce the part.

2. Tabulate the co-ordinates required.

3. Use a programming sheet to write a program.

4. Enter your program into the computer and simulate it.

5. Edit your program if necessary.

Tutorial 6-1 - Subroutines

A subroutine can be regarded as a personalised canned cycle for use in a program which
has repetitive shapes.
A subroutine is a program within a program which can be called at any time from the
main program.

Subroutines are generally programmed in incremental co-ordinates so they can be

called at any position.

M98 = Subroutine Call

P = Subroutine Number = 0001

The illustration below shows such a component; the milled slots can be programmed as
a subroutine.

The program is as follows:

PROGRAMMING SHEET MATERIAL: PLASTIC

Drg No. WRITTE
TITLE: TUT6-1 SHEET No. 1 OF 1
N BY
Prep Misc Axis Co- Feed Spindle Tool
Description Code Code ordinates Rate Speed No.
N G M X Y Z I J K F S P QR T
Abs Cords 10 90
Metric Units 21
1st Tool 20 06 01
Park Position 30 00 0 0 25
Spindle on 40 03 2000

Above A 50 5 5 2

Subroutine call 60 98 0001

Above B 70 55 30
Subroutine call 80 98 0001
Park Position 90 05 0 0 25
End Program 100 30

Subroutine 0001
Inc Cords 10 91
Feed to depth 20 01 -5 200
Slot 1 30 15 2000
Slot 2 40 20
Slot 3 50 -15
Slot 4 60 -20
Pull out 70 00 5
Abs Cords 80 90
End Subroutine 90 99

1. Examine the program

2. Enter the program into the computer.

3. Simulate the machining cycle for each program and compare the movement of the
cutter with the program.

Tutorial 6-2 - Nested Subroutines

In this tutorial, a subroutine and a nested subroutine are used to create the component
shown below.
Subroutines can call other subroutines. This is known as nesting.

The program is as follows:

PROGRAMMING SHEET MATERIAL: PLASTIC

Drg No. WRITTE
TITLE: TUT6-2 SHEET No. 1 OF 1
N BY
Prep Misc Axis Co- Feed Spindle Tool
Description Code Code ordinates Rate Speed No.
N G M X Y Z I J K F S P QR T
Abs Cords 10 90
Metric Units 21
1st Tool 20 06 01
Park Position 30 00 0 0 25
Spindle on 40 03 2000

Above A 50 5 5 2

Subroutine call 60 98 0001

Above B 70 55 30
Subroutine call 80 98 0001
Park Position 90 05 0 0 25
End Program 100 30

Subroutine 0001
Inc Cords 10 91
Feed to depth 20 01 -5 200
Slot 1 30 15 2000
Slot 2 40 20
Slot 3 50 -15
Slot 4 60 -20
Pull out 70 00 5
Subroutine Call 80 98 0002
Inc Cords 90 91 1 -4
Subroutine Call 100 98 0002
Abs Cords 110 90
End Subroutine 120 99

Subroutine 0002
Inc Cords 10 91
Move to start 20 00 5 5
Feed to depth 30 01 -3 200
Slot 1 40 2
Slot 2 50 2
Pull Out 60 3
Abs Cords 70 90
End Subroutine 80 99

1. Examine the program

2. Enter the program into the computer.

3. Simulate the machining cycle for each program and compare the movement of the
cutter with the program.
Exercise 6 - Subroutines

For the component shown above:

1. Tabulate the co-ordinates required.

2. Use a programming sheet to write a program;

the L shaped grooves can be programmed using a subroutine.

3. Use a programming sheet to write a program.

4. Enter your program into the computer and simulate it.

5. Edit your program if necessary.

Tutorial 7 - Mirror Images This tutorial demonstrates how a program written as a subroutine can
be reflected about the X axis or about the Y axis or about both the X and the Y axes.
It supports both linear and circular interpolation.

Consider the shape shown in

illustration A, which has been
drawn in the sequence 1- 2, 2-3, 3-
4 and 4-1.

If the X co-ordinates are reflected

with Y co-ordinates unchanged, the
shape becomes as illustration B
with the 1-2, 2-3, 3-4 and 4-1
sequence maintained

Alternatively, if the X co-ordinates

are kept constant and the Y co-
ordinates reflected, the outcome is
as illustration C.

If both the X and y co-ordinates are

reflected the result becomes as
illustration D.

If a program which calls a subroutine containing the original shape is written, then any or all of the
above variations may be implemented.
The as programmed case is achieved by the usual method of calling the subroutine. The mirror
facility is accomplished by inserting a line in the program after positioning the tool at the start of
the cycle but prior to calling the subroutine.

The entry is:

G - value 51
X - axis of reflection
Y - axis of reflection
-value either 1000 or
I
-1000
- value either 1000 or
J
-1000
For example
To reflect the X co-ordinate with Y unchanged:

Enter G51 with I = -1000, J = 1000 B

To reflect the Y co-ordinate with X unchanged:

Enter G51 with I = 1000, J = -1000 C

To reflect both the X and the Y co-ordinates:

Enter G51 with I = -1000, J = -1000 D

To cancel the mirror facility enter G50

Example

The program is as follows:

PROGRAMMING SHEET MATERIAL: PLASTIC

Drg No.
TITLE: TUT7 WRITTEN BY SHEET No. 1 OF 1
Prep Misc Axis Co- Feed Spindle Tool
Description Code Code ordinates Rate Speed No.
N G M X Y Z I J K F S P QR T
Abs Cords 10 90
Metric Units 21
1st Tool 20 06 01
Park Position 30 00 0 0 25
Spindle on 40 03 2000
Start of A 50 30 20 2

Subroutine call 60 98 0001

Start of B 70 50 20
Mirror X cords 80 51 50 20 -1000 1000
Subroutine call 90 98 0001
Cancel Mirror 100 50
Start of C 110 00 30 30
Mirror Y cords 120 51 30 30 1000 -1000
Subroutine call 130 98 0001
Cancel Mirror 140 50
Start of D 150 00 50 30
Mirror X & Y Cords 160 51 50 30 -1000 -1000
Subroutine Call 170 98 0001
Cancel Mirror 180 50
Park Position 100 00 05 0 0 25
End Program 110 30

Subroutine 0001
Inc Cords 10 91
Feed to depth 20 01 -5 200
Slot 1 30 -10 2000
Slot 2 40 -10
Slot 3 50 10 -5
Slot 4 60 15
Pull out 70 00 5
Abs Cords 80 90
End Subroutine 90 99

Exercise 7- Mirror Imaging

For the component shown above:

1. Write a program to machine the grooved triangles using the mirror image technique.

2. Enter your program into the computer and simulate it.

3. Edit your program if necessary.

Tutorial 8 - Modal Pitch Circle Drilling Macro
The manufacture of the component below uses the P1086 pitch circle drilling macro
called with the G66 modal macro call.

The P address for a Pitch Circle Drilling macro used in this tutorial is P1086.
X,Y = Centre of Pitch Circle Diameter which holes are spaced around. (Ignored if
macro called with G66).
Z = Absolute depth
I = Incremental Distance in X axis to first hole from centre.
J = Incremental Distance in Y axis to first hole from centre.
F = Feedrate
P = Macro address number.
Q = Number of equally spaced holes around P.C.D.
R = Retraction plane as used with drilling cycles described in tutorial 3.
The tool returns to its start point after the macro is complete.

The program is written as follows:

PROGRAMMING SHEET MATERIAL: PLASTIC

Drg No. WRITTEN
TITLE: TUT8 SHEET No. 1 OF 1
BY
Axis Co-
Prep Misc Feed Spindle Tool
ordinate
Description Code Code Rate Speed No.
s
N G M X Y Z I J K F S P QR T
Abs Cords 10 90
Metric Units 21
1st Tool 20 06 01
Park Position 30 00 0 0 25
Spindle on 40 03 2000
Modal Macro 50 66 -5 0 10 200 1086 6
P.C.D. Drilling 1 60 20 25
P.C.D. Drilling 2 70 60 25
Modal Macro
80 67
Cancel
Park Position 90 00 05 0 0 25
End of Program 100 30

Exercise 8 - Use of Macros - Pitch Circle Drilling

For the component shown above:

1. Write a program to machine the holes on the P.C.D. Use the G65 single macro call
in this case.

2. Enter your program into the computer and simulate it.

3. Edit your program if necessary.

Tutorial 9 - Subroutines, Mirror Imaging and Circular Interpolation

The following program uses a subroutine which will mill a 90° arc of radius 15mm
Counterclockwise and 2mm deep. It then uses the G51 Mirror Image routine to mill the other
three arcs.

The program is shown below.

PROGRAMMING SHEET MATERIAL: PLASTIC

Drg No.
TITLE: TUT9 WRITTEN BY SHEET No. 1 OF 1
Prep Misc Axis Co- Feed Spindle Tool
Description Code Code ordinates Rate Speed No.
N G M X Y Z I J K F S P Q R T
Abs Cords 10 90
Metric Units 21
1st Tool 20 06 01
Park Position 30 00 0 0 25
Spindle on 40 03 2000

Above 1 50 60 30 2

Subroutine call 60 98 0001

Above 3 70 00 20 30
Inc Cords 91
80
Mirror X cords 51 0 0 -1000 1000
Subroutine call 90 98 0001
Cancel Mirror 100 50
Above 5 110 00 20 20
Inc Cords 91
120
Mirror XY cords 51 0 0 -1000 -1000
Subroutine call 130 98 0001
Cancel Mirror 140 50
Above 7 150 00 60 20
Inc Cords 91
160
Mirror Y cords 51 0 0 1000 -1000
Subroutine call 170 98 0001
Cancel Mirror 180 50
Park Position 190 00 05 0 0 25 0001
End of program 200 30

Subroutine 0001
Inc Cords 10 91
Feed to Depth 20 01 -4 200
Cut 15mm R Arc 30 03 -15 15 15
Pull out 40 00 4
Abs Cords 50 90
End Subroutine 60 99

1. Study the program.

2. Key in the program and run the simulation.

3. Compare the cutter movements with the program.

Exercise 9: Subroutines and Mirror Imaging

For the component shown above:

1. Write a program to mill the curved slots using a subroutine and mirror images.

2. Key in the program and run the simulation.

3. Edit your program if necessary.

Tutorial 10 - Datum Shift
Datum shift is called with the address code G92 and allows the X Y datum to be
moved by an amount specified in the X and Y columns.
All absolute co-ordinates are taken from the new datum position until the shift is
cancelled with the G53 code.

Note: The Z datum cannot be moved with G92.

Example

PROGRAMMING SHEET MATERIAL: PLASTIC

Drg No. WRITTEN
TITLE: TUT10 SHEET No. 1 OF 1
BY
Axis Co-
Prep Misc Feed Spindle Tool
ordinate
Description Code Code Rate Speed No.
s
N G M X Y Z I J K F S PQR T
Abs Cords 10 90
Metric Units 21
1st Tool 20 06 01
Park Position 30 00 0 0 25
Datum Shift 40 92 20 10
Above slot 1 50 00 03 0 0 2 2000

Feed to Depth 60 01 -2 200

Cut Slot 1 70 15
Cut Slot 2 80 15
Pull Out 90 00 2
Cancel Datum
100 53
Shift
Datum Shift 110 92 50 20
Above slot 3 120 00 0 0
Feed to Depth 130 01 -2 200
Cut Slot 3 140 15
Cut Slot 4 150 15
Pull Out 160 00 2
Cancel Datum
170 53
Shift
Park Position 180 00 05 0 0 25
End of program 190 30

1. Study the program.

2. Key in the program and run the simulation.

3. Compare the cutter movements with the program.

Exercise 10 - Datum Shift

For the component shown above:

1. Write a program to mill the L-shaped slots utilising the Datum shift code..

2. Key in the program and run the simulation.

3. Edit your program if necessary.

Tutorial 11 - Cutter Compensation
The Compensation option enables profiles to be machined by defining the co-
ordinates of the required profile, and automatically compensates for the radius of
the cutter.
Compensation if activated using either the G41 (compensate left) or G42
(compensate right) address codes with the R address used to define the cutter
radius. See below for details.
Compensation is cancelled with the address code G40.

Profiles may be external or internal, for example:

In the example, both profiles have the same co-ordinates. Profiles may be
composed of straight lines and arcs. Two adjacent straight lines may be joined by a
sharp corner or by an arc of radius equal to the cutter radius, depending on the
change of direction of cutter movement:
Invalid Profiles
The software will accept invalid profiles, but the resulting profile will be incorrect.
For example, this profile is not valid because the cutter diameter is greater than the
indentation in the profile:

Left and Right Compensation

Compensation is defined as left or right in relation to the direction of cutter
movement, and the cutter is displaced to left or right of the required profile by a
distance equal to the cutter radius:

The selection of left or right compensation therefore depends on whether the profile
is to be machined in a clockwise or anticlockwise direction, and whether an
external or an internal profile is required, as shown below.
Start and End Point
When planning the machining of a profile, whenever possible, select a start and end
point on a vertical or horizontal edge:

Machining will then begin at the start and end point, traverse the profile in a
clockwise or anticlockwise direction as required, and finish at the start and end
point.

Using a corner as a start and end point is not recommended as it may result in an
incomplete profile or may cause the cutter to overrun the corner.

Example
In the following example, the start and end point has been placed on the left hand
side and machining will be carried out in a clockwise direction:

Tool: 4mm Ø slot drill

Co-ordinates shown in the format X, Y

The program is written as follows:

PROGRAMMING SHEET MATERIAL: PLASTIC

Drg No. WRITTEN
TITLE: TUT11 SHEET No. 1 OF 1
BY
Axis Co-
Prep Misc Feed Spindle Tool
ordinate
Description Code Code Rate Speed No.
s
N G M X Y Z I J K F S PQR T
Abs Cords 10 90
Metric Units 21
1st Tool 20 06 01
Park Position 30 00 0 0 25
Start Spindle 40 03 2000
Start Point 50 20 24 2
Move in
Direction of 60 25
Move 1
Compensation
70 41 2
Left - 2 Radius
Feed to depth 80 01 -2 200
Move 1 90 40
Move 2 100 60
Move 3 110 10
Move 4 120 20
Move 5 130 25
Pull Out 140 2
Cancel
150 40
compensation
Park Position 160 00 05 0 0 25
End of program 170 30

1. Study the program.

2. Key in the program and run the simulation.

3. Compare the cutter movements with the program.

Exercise 11 - Cutter Compensation

For the component shown above:

1. Write a program to mill around the external profile using a 4mm Ø slot drill
and compensation.

2. Key in the program and run the simulation.

3. Edit your program if necessary.

Operations Sheet
Operations Sheet
Programming Sheet
Programming Sheet

PROGRAMMING SHEET MATERIAL:

Drg No. WRITTEN
TITLE: SHEET No. OF
BY
Prep Misc Axis Feed Spindle Tool
Description Code Code Coordinates Rate Speed No.
N G M X Y Z I J K F S PQR T
Fault Diagnosis
Fault Diagnosis

Software Fails to Run

1. The message shown below is displayed.

The file user.dat does not exist in the application directory.

Solution:- Copy the file user.dat from the licence disk to the
application directory.
If there is not a user.dat file on the disk, contact Boxford Customer
Service Department.

2. The message shown below is displayed.

The file setup2.lic does not exist in the application directory.

Solution:- Copy the file setup2.lic from the licence disk to the
application directory.
If there is not a setup2.lic file on the disk, contact Boxford Customer
Service Department.
Maintenance
Maintenance

Installing New Machine Firmware

If when using the 'Boxford CAD/CAM Design Tools' application,

messages similar to those shown below are displayed, then the machine
firmware requires upgrading.

The procedure for updating machine firmware is as follows:-

1. Ensure the machine is powered on and connected to a computer

COM (RS232) port.
2. Ensure the 'Boxford CADCAM Design Tools' application is closed
down.
3. On the PC, browse the 'Boxford CADCAM Design Tools'
installation directory.
Portable Appliance Testing (PAT)
Portable Appliance Testing (PAT)

IMPORTANT NOTES REGARDING PORTABLE APPLIANCE TESTING (PAT) OF

BOXFORD CNC MACHINES

The majority of Boxford's CNC machine tools are fitted with variable speed drives
(VSD) to control the spindle motor. VSDs are fitted with EMC filters and often there is a
significant current flow through the filters to earth (around 6mA), under normal
conditions. This can be indicated as a failure during an earth leakage current
measurement performed as part of a PAT test even though it is a normal characteristic
of the VSD. It is therefore necessary to disconnect the drive's incoming power supply
prior to conducting this test or alternatively to measure and record the earth leakage
current value to ensure it remains at a similar level at each yearly retest.

In addition, as part of the PAT test, an insulation resistance test may be performed. This
test is usually a hi-pot or flash test at 500V dc. This test should NOT be performed on
the machine as it may damage insulation and may also indirectly damage low voltage
electronic circuits. It is preferable to conduct the protective conductor/touch current
measurement which is an alternative to the in-service insulation test. However, as for
the earth leakage test, it is imperative to disconnect the VSD prior to carrying out this
test as the drive's EMC filter will have a leakage current higher than 3.5mA and will
therefore cause the machine to fail the test.

In the event of a Boxford CNC machine tool being PAT tested, it is imperative to
carefully carry out the following procedure BEFORE carrying out any tests.

Warnings:
" Only qualified and authorised personnel should access the electrical control panel.
" Failure to disconnect the spindle drive prior to PAT testing the machine could result in
extensive damage to the spindle drive and/or machine control system.

1. Turn machine OFF at the isolator and disconnect power lead.

2. WAIT 10 MINUTES for the drive capacitors to fully discharge!!!!
3. Remove the electrical control panel access hatch located at the back or side of the
machine.
4. Locate the spindle drive module.
5. Disconnect the INCOMING power to the drive's EMC filter. This can either be a
separate stand alone unit or can in some cases be built into the drive. Refer to the
electrical diagrams in the help file for details.
6. Insulate the disconnected power cable ends and secure.
7. Replace access hatch.
Updating/Maintaining Existing Boxford CADCAM Design Tools Software Installations.
This section describes the update/maintenance process for STAND ALONE installations.
For update/maintenance of Network Installations, see the section Updating/Maintaining
Network Installations

There are three distinctly different types of updates/maintenance to existing software.

1. Updating the application files to enhance existing features or add new ones (E.g. add
Network Login Administrator or Techsoft Mill Design).

2. Updating the application license information to add new machine types and/or new
machines (of types already on site) and/or convert single user licenses into site
licenses.

3. A combination of 1 & 2

The update procedure for 1, 2 and 3 is as follows:

Insert the new or your existing CADCAM Design Tools disk into the CD/DVD ROM
drive.

Insert the NEW or your existing Boxford Registration Disk.

Select Start > Run

Type D:\setup and press ENTER.

The installation program detects a version of the application is currently installed and
the screen shows:
Select the Modify option followed by NEXT.

Accept the license agreement.

Enter the user name and company (school, college).

The screen shows:

- To update the license, enter the serial number of your NEW registration disk in the
'Serial Number' field as printed on the Boxford Registration Disk.
- To modify the application files only, enter the serial number of the existing Boxford
Registration disk.
Select NEXT.

The screen shows:

To upgrade the license information only from the NEW registration disk, select YES.
To upgrade the program files only or both license and program files select NO.

If only the license Information is upgraded, the installation completes.

If the program files are updated, the full installation program is executed. See point 9
onwards in the section 'Installing the Software'
Important

If you have added new machine types, configure the paths and preferences for
l
each one as described in the section 'Installation - Configuring the Software'

If you have upgraded to a site license and/or added the Boxford Network Client
l Administrator application configure the network Login as described in the section
'Network Installations'

If you have added new machine types and currently use the Boxford Network
Client Administrator application, ensure the new machine types are added to the
l
required user groups to allow users to access them as described in the section
'Network Installations'
Network Installations

Follow the installation procedures 1 to 13 outlined in the section 'Installation - Installing the Software' ensuring the
'Network Administration' option is selected in point 9.
Note: You can specify a Network Path in point 8 for the Destination folder and do a remote installation but if this is
done, all future application administration must be performed using the Network Installation Manager application.

From the start menu, select the Network Client Administrator icon located with the Boxford V10 CADCAM application.

The user is prompted to enter a password. This will be the same password as that used to enter Administration mode
in the Boxford CADCAM software.
Initially no password is set so selecting OK will access the screen shown below.
Note:- It is strongly recommended that an administration password is set - refer to the section 'Administration Mode'

for details on password setting

The Boxford network administration software allows different paths and/or User Groups and/or Users to be specified
when the software is run on a Workstation from an installation on a Network server.
Note: If the Boxford CADCAM application is run from a local installation the network Login settings are not used.

Conversion of Site License Machine into Remotely Administrable installation.

Implements remote client/user preferences for machines, permitted application

setting, and user restriction.
View/Modify the current CAD/CAM Design Tools Licensing agreement, enables
instant upgrade without using install DVD.
Perform Maintenance operations such as Add/Remove Components, Repair and
UnInstall from any Networked PC.

If the top arrow is blue as shown above, you will need to convert your site for remote administration.

Converting an Existing Site - Why Conversion?

When Boxford CAD/CAM Design Tools was originally conceived it was intended for NT Server installation, where the
Network Administrator could physically go to the NT Primary Domain Controller. Subsequently we have had to modify
our setup to cater to the needs of Novel Users, who cannot physically go to the FileStore. So we have introduced a
compromise, between the two systems.

If you convert your site using the blue arrow, you will be able to remotely maintain your site from any PC in your site.
But in order to complete a successful conversion you must have administration right to the local machine, and you
must also have the original installation PC. Since the original installation has created an installation log which must
now be updated to include the new remote setup.

1. Ensure you have administration rights to the network, and to the local machine, that you have all the necessary
details for the installation, including administration passwords, installation serial numbers, and locations on your
network to application, as seen by the remote users.
 2. Select the blue arrow.
3. Complete any Administration question you may be asked to answer, such as Serial Number, or Administrator
passwords.
4. When prompted, find the Specified File (iKernel.ex_) it can be found in the Root Directory of the Boxford
CAD/CAM Design Tools DVD.
5. Specify the Network Specific path to the application directory.
The dialog allows the Server Name to be used, if you uncheck the "Exact Path", the SERVER name will be the
name of the current PC you are currently viewed as by the network. With Exact Path Required checked,
whatever you enter into the Path edit field is then implemented as the network aware exact path for all network
usage, if you use a public drive system such as (P:\) this should be entered here, and "Exact Path Required"
ticked.
NOTE: Networked drives letters will be converted to UNC File Paths. An error may appear explaining that the
software was unable to determine if the file path you have entered is correct for your users. It is assumed the
details you supply are correct. If you have supplied invalid details you must edit the file "
<APPPATH>\InstallInfo\Setup.ini" the section marked [NETWORK], re-detailing the NetPath, and NetUNCPath.
NOTE: UNC (Universal Naming Convention) Syntax : A computer called FRED with a folder called DATA
would be known in UNC as \\FRED\DATA

When you have completed your installation the Network Administrator front menu will change. The Blue arrow
is now grayed out, and a Red Arrow appears. The RED arrow allow you to modify the actual installation from
any location across your network.

Standard Network Installation

Select the Yellow Arrow from the Network Client Administrator application.
The screen below is shown.

On initial use, a User group named 'Guest Account' containing the user 'Everybody' is provided. This account is
suitable for a network installation where each user has the same access privileges to software features and/or Boxford
machine types and a password Login is NOT required.. For an installation with different groups and users, see the
section Advanced Network Installation below.

1. Select the Paths Management Tab.

The screen shows:
2. Enter your 'Server Name'. This is an optional field and will simplify path definition later in this setup procedure.

3. If you installed the Techsoft Mill Design CAD package in the main installation, define the path to the directory
where the Mildes32.exe file is installed. The path to the exe file can be typed into the edit field or located using
the '...' button.
Note - If your site has the full version of Techsoft 2D Design Tools and has purchased the Boxford Extension for
it, the path should point to the directory where the 2ddes32.exe file is installed.

4. If you have purchased and installed the MiniCAM plugin (from Boxford), which provides a manufacturing link
from any solid modeling package which produces either an AutoCAD DXF (*.dxf), 3D Studio (*.3ds) or
Steriolithography (*.stl )file, define the path to the directory where the minicam.exe file is installed.

5. In the left hand pane, the machine types which are licensed for network use are displayed.
Select the first one in the list. A directory tree is shown in the right hand pane.
Select the .\ under the CAD Path branch.
The screen shows:

Enter the path where the users cad drawings will be stored. If you have multi machine types it may be useful to
keep the cad drawings in a directory incorporating the machine name.
Note: UN-checking the 'Exact Path Required' option will use the 'Server Name' (entered in point 2 above) as the
start of the path.

6. Repeat point 5 for the G&M path.

7. Repeat points 6 & 7 for each machine type listed in the left hand pane.
Note:- If any of the machine types are dual purpose Mills and Lathes, CAD and G&M paths for Lathe and Miller
 must be defined. An example of this is shown in the screen shot in point 1 above.

8. Select the Com Port Control Tab.

The screen shows:

9. Explore the Machine Types tree by selecting the +. The machine types which are licensed for network use are
displayed.
Select the first one in the list and explore the tree by selecting +. The individual machines, of the selected type,
installed on the site are displayed.
Expand the tree of the first machine listed. Double click on the branch 'RS232 Port = ...'
The screen shows:

Select the RS232 Machine Port (COM Port) which the selected machine tool is connected to.
If the machine is used in an FMS or CIM system and File Transfer by RS232 port is required, select the
appropriate COM Port.

10. Repeat point 9 for all the individual machines within each machine type.

11. When all paths are set, select SAVE.

The screen shows:
 A summary of the settings are shown.
Select OK to save the settings.

12. Network Client Administrator application

13. When the application is run across the network, the defined paths will be used.

Network Workstation Installation

If your network management system does not automatically add system patches to each workstation on the network,
complete the following procedure.

The Boxford CAD/CAM Design tool application requires an number of existing Microsoft Components to correctly
function, depending on the age and vintage of your operating system. This also includes any Service Packs you have
applied to you operating system, and will largely determine which PC require the system patch modules (Patches.exe).

In General, the application requires OpenGL, HTML Help (IE4.0 components, and HH.EXE, HCTRL.OCX), and
Macromedia Shockwave Flash Viewer, MFC40, MFC42, MSVCRT, OLE32. The following table is a list of operating
system, as originally shipped from Microsoft, and the required components that need to be updated. It is likely that if
you are running on NT SP5 or above, you may not have into install these Patches.exe to your workstations.

Windows 95A Requires Common Controls(ComCtrl32.dll), OpenGL support(OpenGL32.dll,

Glu32.dll, GDI32.dll), MSVCRT, MFC40, MFC42 and associated DLLs. Also required
is HTML Help, Internet Explorer 4.0.1 ModulesMacromedia Shockwave Flash Viewer
NOTE: Always Launch Patches.exe from the Boxford DVD
Windows 95B As Win95A
Windows 95C As Win95A
Windows 98 OpenGL now ships with Win98, and MSVCRT should also be located on the hard
drive SYSTEMDIR, as standard, but depending on the Install Date largely depends
whether HTML Help is included.
NOTE: Therefore you should attempt to launch Patches.exe from the Boxford DVD.
Windows 98SE Macromedia Shockwave is normally missing, you can run InstallSWFlash.exe found
inside the Boxford CAD/CAM Design Tools application directory, on all workstation
which fail to run flash movies.
Windows ME WindowME with MS InternetExplorer 5.0 will have all components.
Windows NT Workstation 4.0 WindowNT has OpenGL, but early version may not have the correct HTML Help, run
the Patches.exe from the Boxford DVD. Occasionally MFC42 may be missing.
Windows NT Server 4.0 Same as NT Workstation 4.0
Windows 2000 MFC42 may be missing but HTML Help and OpenGL should be installed on your
machine.

1. From each workstation execute the Patches.exe file located with the application files on the server.
2. Follow the on screen instructions to update the workstation operating system.
3. Reboot as necessary.
4. If the workstation Internet browser does not have the Flash plugin installed, run the file InstallSWFlash.exe
located with the Boxford application files. (Without this installed, images will be missing from the help pages).

NOTE: Windows 95/98/ME/NT all have different version of OpenGL, and MFC. You should always run our
Patches.exe as we automatically install the correct DLL for your operating system. If any of your workstations fail to
start, then you should run Patches.exe from the Boxford DVD.
If HTML Help components are required on a particular PC, it may take several minutes as Internet Explorer 5.0 Core
Components will have to be installed. This installation doesn't effect your current browser, and only a minimum
installation is performed to enable HTML Help.

Advanced Network Installation

In addition to the Standard Network Installation settings described above, account management allows mufti user
groups and mufti users with differing access levels can be defined.

1. Set up the paths as described in steps 1 to 11 of the Standard Network Installation above.

2. Select the Account Management tab.

If you have performed a standard installation, you might to be familiar with the facilities available to aid the task
for client administration. Shown below is a summary of the icons that operate on the "Account Management"
Panel, the principle control for all Advanced Installations.

Using the toolbar Icons

Open can be used at anytime to reload the Save Icon, used to save the database at any
original database. It will reload all Accounts, given point in time.
Paths, and COM Port Settings.

Print, enables the user to printout the

database, can be selected at anytime.

Create Group, used to start a new group, Remove Group, used to destroy a group and
can be selected at any time. will destroy all attached user memberships.

View/Modify Group Properties, can be

used from any selected group, or user
member.
 Create User, in order to create a user you Remove User, to remove a user you must
must highlight a group to insert the user highlight the user with a group. This facility
into. Users are members of the group, that works on the currently selected user.
share the groups rights, but may have their
own password.

View/Modify User Properties, applies to Move User, operates on the currently selected
the currently selected user, allows the User user, this icon allows a user to be transferred
Name and Password to be modified from one group to another.

NOTE: Any operation that you can perform from the Menu, can be performed from the icons. Icons will gray out
when not available.

3. The default User Group 'Guest Account' is shown. Expanding the tree shows the User 'Everybody'.

4. New User Groups can be added or existing ones modified using the following buttons:
Group Management

Create Group -
(View/Modify Group Properties) Displays the window shown below.

A new group name is entered. E.g. The group name could refer to a class, year
group etc.

Create Directories on User(s) machine/drives

If using the Paths Management and you have specified folders on the users drive
then checking this option will instruct Boxford CAD/CAM Design Tools to
automatically create these storage location.
NOTE: All that is required is that when the user logs in the location specified in
"Paths Management" section is writeable to the user, and the directories will be
created as specified.

Restrict User(s) Access to machines

Checking this option restricts the group to accessing only the Boxford machines
checked in the list in the left hand pane of the window.

User(s) require password logins

Checking this option requires all users within the group to enter a password to log
in to the software.
 Set User(s) access level.
Checking this option allows the level of software access for every user within the
group to be set.
Standard - Defaults the software to run in Standard user mode which allows full
use of CAD, CAM, Simulation and Manufacture but disables G&M code editing.
Advanced User - Defaults the software to run in advanced user mode without the
need for a password enabling G & M code editing.

REMEMBER: Modifying Group Properties effects all user within the group.

Remove Group-
Deletes the currently selected group and all users within it.

View/Modify Group Properties - Displays the properties of the currently selected group. Group properties can be
edited as for a new group described above.

User Management

New User-
Displays the window shown below.

A user name and password is entered. The user name could refer to an individual, or a class, or a
year group.
Note: The password will only be required when the user logs in if the 'User(s) require password
logins' option is selected in the group properties described above.

Remove User- Deletes the currently selected user.

Edit User- Allows the user name and/or password to be edited as for a new user described above.

Move User- Displays the window shown below.

Allows the user to be moved from its present group to the group highlighted.
Example - An example of the use of groups and users is shown in the screen below.
The group Year 7 contains the Users Class 1 and Class 2. This allows user access levels to be differentiated by Class.
Alternatively, the User group could be a Class and individual user names defined within is allowing access levels to be
differentiated by individual user.

Other Buttons

ReOpen - Cancels the current changes and restarts the Network Administrator with the previously saved settings.

Save - Saves the current settings. (A summary is displayed).

Print - Prints a summary of the current group, user and path settings.

Using the Boxford CADCAM Design Tools Application.

If multi groups and users have been defined, when the user runs the application, the Network Logon window below is
shown.
The user must enter a valid Username and Password (if required) to start the application.
Note: If only one group and one user with no password is defined, this window is not shown.
Installing the USB Driver.

1. IMPORTANT - DO NOT CONNECT THE MACHINE until the USB

driver has being installed.

2. Insert the Boxford CADCAM Design Tools USB drivers disk into the CD/DVD ROM
drive.

3. The driver installation should boot up automatically, if not:

4. Select Start > Run
5. Type d:\setup and press ENTER.
6. After a pause, the driver installer launches and displays the screen below.

Select a destination folder for the driver install followed by INSTALL

7. The window below is shown.

The scan may take a few minutes to complete depending on your system.
 8. When the driver installation is complete, the window below is shown.

Select OK

9. Connect one end of the USB cable to the machine and the other end to a free USB
slot on the PC.

NOTE: The machine must be connected to the PC before the 'CAD/CAM Design Tools'
application is run. The USB connection will self configure.
Program Simulation
Program Simulation

With a G & M program loaded, the simulator icon is selected from the front end menu.

Move your mouse over the icon, menu or screen area you require help on and select with the mouse.
Add Adds a new tool to the library.
Tool The required tool type and geometric data is defined for the
new tool.
For details of the geometric data required for each tool type,
see the dimensions indicated in the thumbnail.

Delete Deletes the currently highlighted tool from the tool library.
Tool

Tool Toggles the tool library view between tabulated and graphical.
Library
View

Move Moves the currently selected tool up the tool library one
Up position at a time.

Move Moves the currently selected tool down the tool library one
Down position at a time.

Edit Edits the currently selected tool.

The window below is shown (the tool thumbnail and type may
be different than the example shown depending on the tool
selected).
The function of each tab in this window is as follows:-

Offsets Offset X,Y,Z - Allows X, Y and Z

tool offsets to be edited manually.
This should only be done by
experienced users as incorrect entries
could cause major damage to the
Boxford machine tool.

Tool Position - The position within

the automatic tool changer (if fitted).
See section 'Tooling and Axes - Tool
Storage' for details of carousel
positions.

Fitted to Machine - Specifies if the

tool is available for use by the
automatic CAM processor. This
allows the current tooling to be
reconfigured without the need to
 delete tools from the library.

Accesses the
conversational offset
setting routine. See the
section 'Tooling and Axes -
Setting Up' for further
details.

Used to specify dimensional data

about the tool.
Tool and Shank Info The data requirements for each tool
type are different and are indicated in
the dimensioned thumbnail.

OK - Accepts the current settings

Apply - Applies the current data and constructs a scaled

Thumbnail of the tool. If the data specified can not construct a
valid tool shape, a thumbnail will not be shown and reasons
for the failure will be given. The user MUST edit the data to
enable a valid tool to be constructed.

Cancel - Cancels and changes and/or closes the window.

Help - Provides help on the current tool type.

Saves Saves the changes to the tool library.

Print Launches the print routine displaying the standard print

 window with an additional section at the bottom as shown
below.

Options for Tool Library printing are as follows:-

Prints a table of the tool

Options: Partial Info library giving position, offset
and limited dimensional data.
Prints a graphical view of all
the tools in the library and in
Full Info addition to 'Partial Info',
comprehensive dimensional
data is given.
Print a graphical
representation of all the tool
Tool Type Library
type available in the
mill/router software.

Help Accesses general help on the tool library.

Updating/Maintaining Existing Boxford CADCAM Design Tools NETWORK Software
Installations. This section describes the performing of maintenance mode operations.

Launching Maintenance Mode

When you have performed

site conversion you can
remotely administrate the
Boxford CAD/CAM Design
Tool Installer from anywhere
on your network site. To
perform remote installer
application maintenance
you must confirm
administration rights by
clicking RED ARROW, the
installer will be launched in
Maintenance Mode.

NOTE: If the RED arrow is

grayed out, and a BLUE
arrow is visible then you
need to perform site
conversion to go any further.
See Site Conversion. If all
the arrows are grayed out,
then the application has
been uninstalled. Your
registry should now be
cleaned, and you can start
the reinstallation process.

Automatic Maintenance Mode

Automatic maintenance mode is entered whenever the Boxford CAD/CAM Design Tools
DVD is AutoRun on a machine that has previously been used to remotely administrate the
Boxford CAD/CAM Design Tools application. If you insert the DVD into a machine that has
never remotely administrated the Boxford CAD/CAM Design Tools product, the installer will
enter standard install mode.
Tool Storage
Tool Storage

Tool Rack

On the basic machine a tool rack is provided, as shown in the diagram bellow, to
facilitate storage of tool holders and associated cutting tools.

It is advisable to store the tools in the same order as they will be called for in the
machining program.

Auto Tool Changer

Automatic tool changing equipment is supplied as an optional extra .

A carousel facilitates storage of tool holders and associated cutting tools. Each tool
holder must be loaded into the correct carousel station so as to correspond with the
software tool library position value prior to cycle start, i.e.:

Position No. 1 = Station No. 1

Position No. 2 = Station No. 2

The machine cycle start cannot be activated until the carousel has been indexed to Tool
No. 1, the reference tool station.