Index

Manual V ..................................................................................................................... 6 Known Bugs in V3.0! ................................................................................................... 6 Installing the Software ................................................................................................. 8 The Dongle ............................................................................................................ 10 System Requirements............................................................................................ 11 PCLathe and the Keyboard.................................................................................... 11 Entering the PCLathe User Interface ..................................................................... 12 How PCLathe Works ................................................................................................. 12 How to Create a Drawing Preparations.............................................................. 13 The First Drawing................................................................................................... 14 Saving a New Drawing........................................................................................... 15 Starting a New Drawing ......................................................................................... 15 View Options.......................................................................................................... 15 Loading a Drawing ................................................................................................. 16 Starting Output....................................................................................................... 17 Deleting a Drawing................................................................................................. 17 Creating the Same Drawing by Entering Dimensions Directly ............................... 17 Moving Points ........................................................................................................ 18 Saving a Drawing................................................................................................... 19 Creating an Arc of a Circle ..................................................................................... 19 The Mill Program ....................................................................................................... 19 EXERCISE No. 1: Disk with Internal Circle and Four Drill Holes ............................... 20 EXERCISE No. 2 EXERCISE No. 3 EXERCISE No. 4 Exercise 4.1 Exercise 4.2 Exercise 4.3 Exercise 4.4 EXCERCISE No. 5 Surface Trimming ................................................................. 22 A Graduated Circle ................................................................ 25 A Con-rod ............................................................................ 30 Con-rod Eyes ............................................................................ 31 Interior Part .............................................................................. 31 External Contour ..................................................................... 32 Checking All Objects .............................................................. 36 Turning ....................................................................... 39

EXCERCISE No. 6 .................................................................................................... 44

EXCERCISE No. 7 EXCERCISE No. 8

Worm ............................................................................ 48 Train Wheel ...................................................................... 51

Exercise 8.2 Modifying an existing drawing. ........................................... 59 Exercise 8.2 Changing The Objects Sequences. ........................................ 65 Lathe EXERCISE No. 9 Turning Internal Contours ............................................ 69 Lathe EXERCISE No. 10 1.0 1.1 1.2 1.2 1.3 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 2.0 2.1 2.2 2.3 2.4 2.4 2.5 2.6 2.7 2.8 2.8 2.9 2.10 3.0 3.1 3.2 3.3 3.4 3.5 3.6 2 Importing a Rope Drum ................................................. 73

Main Menu ...................................................................................................... 82 On F1 ............................................................................................... 82 Start F2 ............................................................................................. 83 Start F2 ............................................................................................ 86 Contour F3 ......................................................................................... 89 SIM (Simulation) F3 ............................................................................ 90 La/Mi (Lathe/Mill) F4 .......................................................................... 90 EDIT Submenu F5 ............................................................................. 90 SCREEN F6 ....................................................................................... 91 Disp (Display) F7................................................................................ 91 SYSTEM Submenu F8 ........................................................................ 91 FILE Submenu F9 .............................................................................. 91 Exit F10 ......................................................................................... 92 EDIT Menu F5 From Main Menu. ............................. 93

Edit (Submenu) F1 ............................................................................. 93 Paste F2............................................................................................. 94 Cut (Remove) F3................................................................................ 95 Arc of a Circle F4 ............................................................................... 95 Rot. (Rotate) F4 ................................................................................. 96 Move F5 ............................................................................................. 96 Scale F6 ............................................................................................. 97 Undo F7 ............................................................................................. 98 Pause F8........................................................................................... 98 Copy F8............................................................................................. 98 mm/s F9 ............................................................................................ 99 MAIN F10 ....................................................................................... 99 SYSTEM Menu Matl (Material) Not Assigned Globl (Global) Not Assigned Not Assigned Not Assigned F8 From Main Menu. .......................... 100 F1 .............................................................................. 100 F2........................................................................... 101 F3............................................................................... 101 F4........................................................................... 102 F5........................................................................... 102 F6........................................................................... 102

3.7 3.8 3.9 3.10 4.0

Not Assigned F7........................................................................... 102 Tool F8 ............................................................................................ 102 mm/s (Feed Rate) F9 ........................................................................ 104 Main (Back to Main Menu) F10....................................................... 105 File Menu F9 From Main Menu. ........................... 106

4.1 New F1 ........................................................................................... 106 4.2 Del (Delete) F2 ................................................................................. 106 4.3 Save F3 ........................................................................................... 106 4.4 S as (Save as) F4............................................................................. 106 4.5 *.PLT (HPGL Import) F5.................................................................... 106 4.6 Not Assigned F6 ........................................................................... 107 4.7 *.KOO (Load Coordinates) F7 ............................................................. 107 4.9 Load F9 ........................................................................................... 108 4.10 Main F10...................................................................................... 108 5.0 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14 5.15 5.16 5.17 5.18 5.19 5.20 5.21 5.22 6.0 6.1 6.2 6.3 6.4 6.5 6.6 Keys .............................................................................................................. 109 ARROW Keys.............................................................................................. 109 ENTER ........................................................................................................ 109 SPACEBAR .................................................................................................. 109 PLUS/MINUS Keys....................................................................................... 109 PG/PG Keys........................................................................................... 109 ESC ............................................................................................................ 110 TAB ............................................................................................................ 110 CTRL .......................................................................................................... 110 X/Y keys .................................................................................................... 111 W Key (Angle)........................................................................................ 111 C Key..................................................................................................... 112 A Key (Circle/Ellipse)................................................................................. 112 R Key (Rectangle) ................................................................................. 113 HOME...................................................................................................... 113 END ........................................................................................................ 113 H Key..................................................................................................... 113 D Key ........................................................................................................ 113 T Key......................................................................................................... 114 MINUS Key ................................................................................................. 114 Z Key........................................................................................................ 114 M key......................................................................................................... 115 G Key ........................................................................................................ 115 Displays ........................................................................................................ 116 Abs.X and Abs.Y ....................................................................................... 116 Rel.X and Rel.Y......................................................................................... 116 F (mm/s).................................................................................................... 116 Angle ......................................................................................................... 116 File ............................................................................................................ 117 Curr. Point ................................................................................................. 117 3

6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 6.15 6.16 6.17 6.18 6.19 7.

Step........................................................................................................... 117 CS (m/min) ................................................................................................ 117 SRevs (rpm) .............................................................................................. 117 Mat ........................................................................................................ 118 Shaft ...................................................................................................... 118 Z mm......................................................................................................... 118 Tool ....................................................................................................... 118 Material Y .................................................................................................. 118 Material X .................................................................................................. 119 F (mm/s).................................................................................................... 119 X mm......................................................................................................... 119 Y mm......................................................................................................... 119 Z mm......................................................................................................... 119 The Calibration Program (SYNCUTIL.EXE) ................................................. 120

7.1 On F1 ............................................................................................. 120 7.2 Time (Time Adjustment) F2................................................................. 120 7.3 Gear (Determining Gear Reduction) F3 ................................................ 121 7.4 Manual (Manual Settings) F4 .............................................................. 121 7.5 Ctrl (Motor Control) F5 ...................................................................... 122 7.6 MOT (Stepper Motor Parameters) F6 .............................................. 122 7.7 Stick (Joystick Calibration) F7 ............................................................. 124 7.8 X-Y-Z F8......................................................................................... 124 7.8.4 Abs X (Absolute X ) F4 .................................................................. 124 7.8.5 Abs Y (Absolute Y) F5 ................................................................... 124 7.8.6 Abs Z (Absolute Z) F6.................................................................... 125 7.8.7 PlayX F7 ...................................................................................... 125 7.8.8 PlayY F8 ...................................................................................... 125 7.8.9 PlayZ F9 ...................................................................................... 125 7.8.10 Main F10.................................................................................... 125 7.9 mm/s F9 ........................................................................................... 125 7.10 Exit F10 ........................................................................................... 125 8. 9. 10. 11. 12. 13. 14. How to Start-up and Calibrate your machine. ................................................... 126 Time Adjustment .............................................................................................. 126 Absolute Path Length and Spindle Clearance .............................................. 126 Mechanical Components .............................................................................. 129 Handwheels .................................................................................................. 129 Gears for the Stepper Motors ....................................................................... 130 Mounting Brackets ........................................................................................ 131

15. 16. 17.

Tips and Tricks ............................................................................................. 132 Safety Notes ................................................................................................. 135 Hardware ...................................................................................................... 135

Signal Assignment at Parallel Port....................................................................... 135 Stepper Motor Control Board STEP 4020 ............................................................ 136 Stepper Motor Control Board STEP 5040 ............................................................ 139 Connection of Motors........................................................................................... 141 Two Machine Tools - One PCLathe ..................................................................... 143 Frequency Converter ........................................................................................... 144 General ................................................................................................................ 144 18. Troubleshooting ............................................................................................ 147

PCLathe ............................................................................................................... 147 Dongle.................................................................................................................. 148 Stepper Motor19. PC and DOS............................................................................ 149 19. PC and DOS ................................................................................................ 150

A Brief Introduction .............................................................................................. 150 Processor............................................................................................................. 150 Main Board........................................................................................................... 151 RAM Main Memory .............................................................................................. 151 Housing and Power Supply.................................................................................. 151 Harddisk............................................................................................................... 151 Floppy Disk .......................................................................................................... 152 CD ROM Drive ..................................................................................................... 152 Keyboard.............................................................................................................. 152 Graphics Adapter and Monitor ............................................................................. 153 DOS ..................................................................................................................... 153 Notes: ...................................................................................................................... 158 Project Sheet ........................................................................................................... 159 File ........................................................................................................................... 159

Welcome to PCLathe Ver.3.0 Rel.07.

Manual V
The program PCLathe has been specifically designed to provide PC control for conventional machine tools. PCLathe features both lathe and mill functions and has been developed from practical experience for practical use. Therefore, unnecessary bells and whistles have been left out deliberately. PCLathe`s Big advantage over other CAD/CAM programs is that it allows you to create objects on a co-ordinate paper GUI and then start machining your material immediately. The current tool position is always displayed on your screen enabling you to monitor each of your machining operations. The PCLathe systems have been tried tested and proven many times in practical operation-whether on small-size turning machines with a centre distance of 230mm or on large 2.5t milling machines- and has received the highest ratings for precision and ease of operation in either environment. This is achieved through numerous background operations such as keeping the lathe tool under constant speed and feed or automatic cleaning/finishing in milling operations. Of course the program also includes compensation for machine axis backlash. The PCLathe software is constantly being developed and enhanced, so that you can profit from updates. Finally I'd like to thank Heinz, Susi, Elmar, and all the others. Without you I wouldn't have been able to make PCLathe such a success. Enough rabbit! Let's get started! I hope you will enjoy turning and milling your parts. Best Regards Matthias Potthoff

5th English edition, HSE UK, 23rd July, 2002

Known Bugs in V3.0!

6

General: Circles look like ellipses: Remedy: Adjust image on monitor. Correction will be implemented in MILLPLUS. With drawings > 500mm, grid may disappear partially when zooming in strongly. Remedy: Ignore error. In EDIT menu, selection may 'slide' off the drawing. Remedy: Exit EDIT menu and open again [F5]. Mill: Machining direction: INSIDE/OUTSIDE mix up at some instances. Remedy: Reload drawing, reassign machining direction and type or reassign with swapped sides. When output is interrupted during Z feed motion, automatic tool move to origin is impossible. Remedy: Move to origin manually using the displayed X and Y (mm) values.

Installing the Software

If you have a previous version of PCLathe installed on your computer: The set-up program will check your system for an existing version of the PCLathe initialisation file (PCLATHE.INI). If there is one it will be renamed PCLATHE.BAK. The new one (from the installation disk) will be copied in your PCLATHE directory. Confirm prompts for overwriting existing files with Y(es). If you install PCLathe for the first time: With a computer running under DOS insert the CD into the drive. Copy INSTALL.BAT and PCLZIP.EXE onto a floppy disk (to use the install .bat program it must be in drive A:). Then type A:INSTALL the PCLATHE program will automatically be installed into a directory called PCLATHE and the program will run. If you havent a floppy disk drive named A: make a directory named PCLATHE and copy PCLZIP.EXE into it. Then type pclzip, the pclathe program will automatically be installed. If you are running windows (?), make a new folder, or directory named pclathe and copy PCLZIP.EXE into it. Then double click on the file PCLZIP.EXE. The pclathe program will automatically be installed. To run PCLATHE in DOS type PCLATHE. PCLathe is a DOS program, which, in general, also runs in Windows 3.x and Windows 95/98. However, when trying to create a part in Windows you may run into the following problem: PCLathe requires 100% of your processor resources. If your Windows OS wants to run another task such as updating swap files or even start a screen saver, the tool will halt for moment and thus give your part an irregular shape. To avoid this trouble, exit Windows 3.x or start Windows 95 or 98 in DOS mode (ALT + F4). NOT IN A DOS BOX. If you are using PCLathe on two or more machines from one PC install the software for as many different machines as you have. After initial installation change to your hard disk's root directory: 1. Enter [cd\]. 2. The C:\ prompt will appear. 3. Rename the PCLathe directory by typing: [move pclathe lathe] or [move pclathe mill] 4. Reinstall PCLathe. Now you have two instances of the PCLathe software installed on your hard drive-one in the PCLathe and the other in the Lathe or Mill directory. You can copy and rename the pclathe directory for as many machines or configurations as you have

Disk Contents: SYNCUTIL.EXE PCLathe calibration program BRUN45.EXE Internal system module GXCONV.EXE The executable of the DXF Converter V1.5 program ERROR.LST List of PCLathe error messages NOT ON DISK. HANDBUCH.TXT DOS manual for the DXF Converter (see 5 General.) INSTALL.BAT Installation file -->C:\PCLATHE<-NOT ON DISK. LIESMICH.TXT Information on the DXF Converter (see 5 General) PCLATHE.EXE PCLathe 3.0 executable DOS program PCLATHE.INI Initialisation file for PCLathe Platte-1.FRS Platte-2.FRS Platte-3.FRS Schnecke-1.FRS Schnecke-2.FRS Motor plate Exercise

Worm Exercise Train wheel Exercise

Rad-1.FRS through to Rad-7.FRS Innen-1.DAT Innen-2.DAT Trom.DXF Trom.FRS Trom.DAT Trom-2.DAT Trom-3.DAT Filename Extensions: *.EXE *.HLP *.DAT *.FRS *.KOO *.PLT *.DXF

Right angle tool Exercise Rope drum Exercise

Executable programs Help files Lathe files Mill files Profile coodinates HPGL plotter files DXF CAD files

The Dongle
The full version of PCLathe comes with a dongle that activates the stepper motor controls. Attach this dongle to your printer port and connect the control cable to the dongle's other end. Once you start the program, PCLathe will look for the dongle. On detection, the software will activate the full version-otherwise the program will start in demo mode. PCLathe will scan the port three times - indicated by dots appearing on the start screen (Initialising....). Retry if the program does not detect the dongle at once. If no dots appear on the screen even after several attempts, the parallel interface may be faulty. Contact your dealer in order to correct this problem. Even without the dongle, the full set of the program's functions (except for the stepper motor controls) are available to you. This offers the advantage that you can use PCLathe e.g. for creating and saving a drawing on another computer and then machine the part on the "lathe/mill computer". (Feel free to give copies of the program to your friends.)

10

System Requirements
The software executes on any 386 or higher PC. As the program uses a lot of floating point arithmetic, it is useful to have a mathematical co-processor installed. PCLathe requires about 1 Meg of hard disk capacity, a printer port and an EGA graphics monitor with 640x350 pixels (a 14" VGA colour monitor is quite enough). However, a 15" or 17" monitor may be the better choice for future use. An optional joystick provides additional control for the compound and saddle slides' movements. A mouse is not required. PCLathe runs on the following operating systems: DOS, Windows 3.x, and Windows 95/98, i.e. you can start the program and work with all of its functions. For controlling a machine tool, PCLathe must run in MS DOS mode. The program does not run in Windows NT.

PCLathe and the Keyboard

TAB

ENTER

PG UP / DOWN

CTRL

SPACE

ARROW
S

ENTER

The F1 - F10 function keys and the ESC key are located above the keys shown in the illustration.

11

Entering the PCLathe User Interface

After you started PCLathe, your monitor displays the Main menu screen of the mill program -indicated in the top left corner. The screen shows a blue millimetre grid that represents the material. The pencil (tool) rests on the origin - the little red cross on the lower left-hand side. This is a fixed point that you cannot move. The dashed yellow line on the co-ordinate grid is the centre line of your part.
Current Menu Status Bar Coordinate Paper

Program Displays

Origin

Function Keys F1 F10

The Program Displays at the left-hand side will show current parameters, settings and values for each of your parts. The status bar above the drawing will provide important PCLathe information or prompt you for entries. Using the function keys at the bottom of the screen you will access the various commands and functions of each menu.

How PCLathe Works

Initially, you will create a drawing on the co-ordinate grid. This drawing represents a path-rather than a part as it does in other programs. During output, the program will guide the lathe/milling tool exactly along this path. To enter a drawing into PCLathe, just imagine that you are turning the handwheels of the lathe to achieve the desired result. You will always draw lines connecting them with system points (nodes). These points are integral elements of your drawing. All operations in PCLathe will reference these points.

12

The PCLathe software includes all drawing functions required for easily creating even complex drawings. The program will output drawing data to N/C without acknowledgement via angle encoders or electronic calliper gauges. Make sure all of your components are matched appropriately in order to achieve maximum precision. PCLathe will determine the spindle clearance by performing an adjustment procedure and then use these values during output. As machining is mostly performed on certain spindle sections, this method provides an accuracy of up to 2/100 millimetres. Recirculating ball screws are not required. Note: For the first steps and operations in PCLathe that follow, we recommend you have the Menu Map from the back of this manual placed conveniently next to your keyboard. This will facilitate getting familiar with the program's features and options.

How to Create a Drawing Preparations

Material Settings From the Main menu, go into the lathe programme by pressing F4. Press F8 to open the System menu and F1 for Material. (also refer to the menu map included at the end of this manual). You can press ENTER to accept the default values proposed by the program. First, the program will prompt you to enter the Cutting Speed. Refer to a table book to look up this value. PCLathe will use the cutting speed and the current diameter (the tool's current position) to determine the desired spindle speed and displays this value in the RPM box on the Main menu screen. If you have a frequency converter, you can control it through PCLathe to enable machining at constant cutting speed. Otherwise, set the machine to the displayed value manually. Next, you are prompted for the Material Size (length) and Diameter. These parameters will be displayed as a grid to facilitate orientation. To change the length to e.g. 10mm, type in 10 and press ENTER. Then change the diameter to e.g. 5mm by again. typing 5 and press ENTER Finally, you are prompted to specify values for a possible drill hole. Press ENTER to accept the default 0. Pressing ENTER again returns you to the Main menu. Tool Settings From the System menu, press F8 to make the required Tool Settings. First, choose the desired tool shape. This specification is needed to move the tool in the right direction in Contour mode. If you are using a cutting tool, PCLathe will display the tool width as a grey line on the right side of the toolpath. When using a Contour tool, the program will generate automatic radius compensation. Type in 1 for the Tool shape and press ENTER. Next, enter e.g. 3 for a Tool width of 3mm and confirm with ENTER. Press ENTER again to return you to the Main menu.

13

The First Drawing

How to create a drawing using the ARROW KEYS: Use the arrow keys to move the pencil (tool) on the grid. The step size displays in the Step 1.00 box on the left side of your screen. Also note the automatic feed speed selection display Feed (mm/s) on the left which adjusts to the relative X and Y values. You will find these speeds in the System menu under mm/s (from the Main menu, press F8 and then F9). PCLathe always has an eye on your drawing and provides the correct feed speed values depending on your drawing direction. Press F6 Screen to return the pencil to the origin. Press the UP ARROW key once and then ENTER. Now the line has become green and you can see a small point at the pencil point's position. This system point (or node) indicates that the line has been saved to the memory of your PC. The point counter in the display area on the left-hand side has gone up to one-Curr. Point 1. Abs. Y shows a value of 1, and Shaft displays the diameter at this position. This shaft dimension is very important as you can use it for comparative measuring when turning a part on the lathe. E.g., when creating a journal, stop the output on a straight section by pressing ESC. Measure the journal and compare this value to the shaft value. If these values differ, you can switch to correction mode to adjust the tool position using the arrow keys. Now move the pencil to Abs. X = 5.00 by pressing the LEFT ARROW key five times and press ENTER. Abs. X/Y display values related to your part, the Rel. X/Y displays refer to the last point in your drawing. Now move the pencil back to Abs. Y = 0.00 by pressing the DOWN ARROW key once and press ENTER. The drawing is complete now. Pressing the spacebar allows you to switch material display mode on.

IMPORTANT ! You must save your drawing after you created it. There's hardly anything more annoying than loosing hours of work through inattentiveness.

14

Saving a New Drawing

Press F9 to open the File menu, and press F4 S. as (= Save as). Type in FIRST, and press ENTER. Confirm the message in the status bar with SPACE. Note: Avoid meaningless names such as TEST1, TEST2, etc. as they tend to cause confusion. The drawing is now saved to your hard disk under the name FIRST.DAT. Its name is displayed next to File in the display area on the left. If you are prompted to save the current configuration when exiting the program and you confirm with Yes, PCLathe will memorise the drawing displayed (if there is one).

Starting a New Drawing

Press F9 to open the File menu, and press F1 New. Status line: Object = 2 Sequence = 4 Drill. Press ENTER.

View Options
Increasing /Reducing Image Size: Lathe/Mill Press the PGUP key to enlarge the drawing. You can repeat this until maximum magnification. Note that the big blue field is a one square millimetre section. Press the PGDN key to reduce the detail view again. Pressing F6 resizes the drawing to radius of the material in lathe mode or material height in mill mode. Moving the Drawing: Lathe/Mill PCLathe allows you to move your drawing in both vertical and horizontal direction. Press TAB to enter this mode and then use the arrow keys to move the image. Once in the desired position press TAB again to leave this mode. You will use these view mode option frequently, as it will allow you to easily determine whether or not you moved a point by only one tenth of a millimetre and help you save time. Display Material: Lathe: Pressing SPACE allows you to display the material at any time. In this mode the program hides the system points and shows an image of the mirrored contour.

15

Display Toolpath: Mill: The mill program also features toolpath display. However, with many objects and a slow computer it may take quite some time to refresh the screen. Therefore, it is advisable to switch off the toolpath before performing actions that require a screen refresh (e.g. moving, zooming, toolpath on/off, etc.) and switch it on again once the new screen is built up. The vertical lines between the toolpath and the drawn lines, as well as the circles indicating the tool are automatically shown or hidden depending on the number of system points and the zoom factor currently used. Show/Hide System Points: Lathe/Mill: Press the D key or F7 to show or hide the system points. This feature also speeds up screen refresh rate when changing view settings. Switch off system points before changing the view, and then on again. In milling operations this also activates/deactivates the display of rapid moves (grey lines). Press the H key to access help on key assignment.

Loading a Drawing
From the Main menu, press F9 File to access the File submenu, and choose F9 Load. The top line of the next screen contains instructions for loading a file. Highlight the FIRST.DAT file using the arrow keys and press ENTER. PCLathe now loads the drawing. The pencil rests on the last point of the drawing. Pressing ENTER allows you to change the pencil to a cross-hair cursor. This is useful when trying to determine whether several system points are on the same line or not. Pressing ENTER again toggles between the two modes.

16

Starting Output
Press F2 Start to view an output run for your part on the monitor. Pressing ESC during this operation let's you cancel or halt output, or manually enter corrections at any stage (note the options offered in the status bar). Use the F3 Contour function key to let the program automatically machine the drawing contour.

Deleting a Drawing
Delete the current drawing to learn about another method of creating a drawing. To do so, press F9 to open the File menu, and then F1 New. Confirm the status bar prompt with ENTER. The drawing is now removed from the main memory (not from your hard disk) and PCLathe is in the initial zero position again just like after program start.

Creating the Same Drawing by Entering Dimensions Directly

Press Y and the status bar prompts you for a value. Type 1 and press ENTER. Press Enter again to confirm the system point. Now press X, type the value 5, and press ENTER twice? There are two possibilities to get back to Abs.Y 0.00 now: A) As before: Y, -1, ENTER, ENTER. B) After typing C then Y, directly ENTER, ENTER, without entering a value. As PCLathe keeps the X and Y values in memory you have to reset these first by pressing C. (After pressing the C key then the X or Y key followed by Enter, the pencil will jump to the respective zero line). You can also combine these entry methods. E.g.: UP ARROW, Y, .2, ENTER. To enter angles, press W. If your pencil is currently located on Rel.Y=0 and Rel.X=0, the system will prompt you to enter the radius. Otherwise PCLathe will use the current Rel.Y and Rel.X values. This also works for rectangles and circles in PCLathe mill mode. For further help on keyboard commands press H.

17

Moving Points
From the Main menu press F5 (Edit) to switch PCLathe to Edit mode (indicated in the MENU: Edit display in the upper left corner of the screen). Now let's change the rectangle to a trapeze. Make sure the step size is set to 1.00mm. If not, adjust using the +/- keys. Press CTRL + RIGHT ARROW to move the pencil to the first element of your drawing-Curr. Point=1. Press F5 Move. Now there are two options to move the selected point: A) LEFT ARROW. B) X, 1, ENTER. After you moved the point, you can fix it at its new position by pressing ENTER again. Note: Entering the desired values via X and Y on the keyboard is very useful if they include decimal places. E.g.: 12.84mm. For further help on key assignment, press H. Now we jump forward to the next point in the drawing: Hold CTRL depressed and press the LEFT ARROW key once until you are at the next point. Then press the RIGHT ARROW key again and confirm with ENTER. Press F5 again or ESC to exit move mode. You can use the spacebar to switch on material display mode. This mode only works properly if the material centre line is in the visible area of your screen.

Press F10 Main to return to the Main menu.

18

Saving a Drawing
From the Main menu, press F9 to access the File menu, and then press F3 Save. Now the drawing is saved under the (same) name FIRST.DAT on your hard disk.

Creating an Arc of a Circle

Press F5 to switch to the Edit menu. Press the RIGHT horizontal line (File: FIRST.DAT).
ARROW

key to select the

Now press F4 Circle, and the horizontal line changes to an arc of a circle. You can use the ARROW keys to set the radius-try it out yourself. To achieve a finer gradation, you can reduce the step size using the MINUS key. The Delta value specifies the distance between the arc and the horizontal line in millimetres. Press the ENTER key to confirm. To undo the arc, press F7 Undo. Version 3.0 now also allows you to create circle segments with an angle greater than 180 using the new F1 and F2 function keys. However, this kind of circle segments will turn up rarely in the Lathe program.

The Mill Program

Use the F4 key to toggle between the Lathe and Mill programs. As milling requires several objects to be machined, the following rule applies to distinguish between the beginning and the end of an object: The start point of an object must have the same coordinates as its end point. When drawing the first line in Mill mode, the system displays it as a dark grey line. PCLathe recognises that this is a line leading to an object. During output, this line is used for Z-axis motion. When you complete the object (circle, rectangle, or free-hand line), i.e. the start point has the same coordinates as the end point, the system will recognise the object. The status bar will prompt you to enter values and parameters for that object. The program displays the object in a bright blue colour now. The next line you draw to a new object will be display dark grey again. Continue this way until you have created all of your objects. 19

EXERCISE No. 1: Disk with Internal Circle and Four Drill Holes
First we need to start a new drawing: Press F9 (File) menu. Press F1 (New) Delete and re-initialise, ENTER. Set the following parameters in the System menu to: Press F8 (Syst.) to go into the system menu. Press F1 (Matl) to enter the material size: Material size (X mm) = 80 ENTER. Material size (Y mm) = 50 ENTER ,ENTER. Press F8 (Tool) for tool settings: Tool diameter in mm = 5 ENTER. Default Z depth in mm = 3 ENTER ,ENTER. Press F10 (Main) to return to the main menu. The external circle: Move the pencil to the material centre: X ,40 ,ENTER, Y, 25,ENTER ,ENTER. The circle: PRESS A. Circle radius in mm = 20 ENTER. End-radius in mm = 20 ENTER. Angle in degrees = 360 ENTER. Tool diameter = 5 ENTER. Z millimetres = 3 ENTER. Outside = 2 ENTER. Counterclockwise = PRESS ENTER FOR YES. The internal circle: Set the step size to 10.00 mm (PLUS/MINUS keys). Press the LEFT ARROW key twice, then ENTER, the pencil is back at the centre. Press the LEFT ARROW key once. PRESS A. End-radius in mm = 10 ENTER. Angle in degrees = 360 ENTER. Tool diameter = 5 ENTER. Z millimetres = 3 ENTER. Inside = 1 ENTER. 20 -

Counterclockwise = PRESS ESC FOR NO. Using the SPACEBAR you can view the toolpath. The drilling points Move the pencil to Abs. X 40 and Abs. Y 40 Press ENTER, ENTER. Drill Diameter = ENTER. Z Millimetres = ENTER. Repeat this procedure for the other drilling coordinates: (55,25) , (40,10) and (25,25)

Press the D key or F7 to display points. The yellow numbers next to the objects indicate the processing sequence, and we are now going to change these numbers. Open the Edit menu F5. Place the selection line on the first system point. Now the object appears red and you can edit it. You can use F5 to move the entire object, F8 to create a copy that you can paste with F2, F4 to rotate the object, F6 to scale it, and F1 to change its properties. Press F1 now. Obj: 1 Tool diameter = 5 ENTER. Obj: 1 Z millimetres = 3 ENTER. Object: 1Output sequence number = 6 ENTER. Counterclockwise = PRESS ENTER FOR YES. Use the arrow keys to select the various objects and put them in the correct sequence. Press the D key or F7 to hide points. Press F10 to return to the Main menu. To simulate output, press F3 Sim. Do not forget to save the new drawing. Press F9 to open the File menu, and then F4 S.as. Type in 'Drill' and press ENTER. Now the drawing is saved under DRILL.FRS on your hard disk. You can see the name now under the File display in the program display area on the left side of the monitor.

21

EXERCISE No. 2

Surface Trimming

This Exercise describes how to trim a 120x70x10mm material block with a 40mm cylindrical finishing cutter. First we need to start a new drawing: Press F9 (File) menu. Press F1 (New) Delete and re-initialise, ENTER.

- Set the following parameters in the System menu to: Press F8 (Syst.) to go into the system menu. Press F1 (Matl) to enter the material size: Material size (X mm) = 120 ENTER. Material size (Y mm) = 70 ENTER ,ENTER. Press F8 (Tool) for tool settings: Tool diameter in mm = 40 ENTER. Default Z depth in mm = 2 ENTER ,ENTER. Press F9 (mm/s) to adjust the feed speeds. Mill (X and Y mm/s) = 1.5mm/sec. Confirm the remaining values with ENTER. Press F10 (Main) to return to the main menu. We want the tool to plunge next to the right side of the block, then move in two paths across the material, and return along the upper edge next to the material. This results in X = -22 and Y = 18 starting point: Press X ,-22, ENTER, Y, 18, ENTER, ENTER The path length is calculated by the Material Length + Tool Diameter + (2 x 2mm Overlap). 120mm + 40mm + (2 x 2mm) = 164mm. Press X, 164, ENTER, ENTER Passing the material on the left and top side back to the upper return point which is located on AbsY = Material Length + (Tool Diameter / 2) + 2mm Overlap. 70mm + 20mm + 2mm = 92mm. Press Y, 74, ENTER, ENTER. Now to the upper right point: Press X, -164, ENTER, ENTER. Turning into the second path calculated by: 22

AbsY = Material Length - (Tool Diameter / 2) + 2mm Overlap. 70mm - 20mm + 2mm = 52mm. Press Y, -40, ENTER, ENTER. The second path: Press X, 164, ENTER, ENTER. Back to the upper return point: Press Y, 40, ENTER, ENTER. Back to the upper right return point: Press X, -164, ENTER, ENTER. To the object starting point to complete the object: Press Y, -74, ENTER, ENTER. Tool diameter = 40 ENTER. Z millimetres = .2 ENTER. Centre = 3 ENTER. Save the drawing as TRIMMING by pressing F4 from the File (F8) menu. After confirming with the SPACEBAR, you can immediately start the simulation with F3. Now adjust the drawing so that the material and tool path are visible on the screen. Using PGUP, PGDN Move drawing (tab) and arrow keys (Finishing is not possible in milling operations on the drawing's centre line and in drilling operations.) To speed up processing, you can also set non-cutting moves outside the material to rapid speed. To avoid unnecessary keystrokes, set the entire object to rapid speed and change only the two toolpaths to the low feed speed.

To do this: Open the Edit menu with F5, the object is highlighted in bright red. Press F9; the displayed value is for the first system point, which represents the entry path. Accept this value by pressing ENTER. Now the program will prompt

23

you for the new feed speed for this object. Enter your rapid speed (e.g. 11), and press ENTER. Now all system points within this object have this new speed. Now use the LEFT ARROW key to move the selection to the first path, and press F9 again. Enter the feed speed (e.g. 1.5), and press ENTER. PCLathe will ask you now, whether to change all system points. In this case NO i.e. ESC. Now press the LEFT ARROW key until you have highlighted the second path (Curr.Point = 6), and repeat the procedure as described above.

24

EXERCISE No. 3

A Graduated Circle

This procedure is also suitable for positioning objects other than drill holes on a graduated circle. First we need to start a new drawing: Press F9 (File) menu. Press F1 (New) Delete and re-initialise, ENTER.

- Set the following parameters in the System menu to: Press F8 (Syst.) to go into the system menu. Press F1 (Matl) to enter the material size: Material size (X mm) = 40 ENTER. Material size (Y mm) = 40 ENTER ,ENTER. Press F8 (Tool) for tool settings: Tool diameter in mm = 5 ENTER. Default Z depth in mm = 3 ENTER ,ENTER. Press F10 (Main) to return to the main menu. Subsidiary object: Centre point of drill hole: Move the pencil to the centre of your material and type in: Press X, 20, ENTER, Y, 20, ENTER, ENTER. Press ENTER to confirm the position of the centre hole. Tool diameter = 5 ENTER. Z millimetres = 3 ENTER.

25

The first drill hole: Press X, 13, ENTER, ENTER. Press ENTER to confirm the position of the hole. Tool diameter = 5 ENTER. Z millimetres = 3 ENTER.

Creating the remaining drill holes using cut &paste: The second drill hole: Press F5 to access the Edit menu. The centre drill hole is selected. Press CTRL + LEFT ARROW keys to select the first drill hole. Status line: Object = 2 Sequence = 2 Drill. Press F8 to copy the drill hole. Press F2 Paste, confirm with ENTER, to paste the copied drill hole. Press F2 again to deactivate the Paste function. To position the drill hole at the desired angle: F5, W, 72, ENTER, ENTER, ESC. Status line: Object = 2 Sequence = 3 Drill.

26

The third drill hole: Press F2, ENTER, F2. Angular positioning: F5, W (72), ENTER, W (72), ENTER, ENTER, ESC. Status line: Object = 2 Sequence = 4 Drill.

27

The fourth drill hole: Press F2, ENTER, F2. Angular positioning: F5, W (72), ENTER, W (72), ENTER, W (72), ENTER, ENTER, ESC. Status line: Object = 2 Sequence = 5 Drill.

The fifth drill hole: Press F2, ENTER, F2. Angular positioning: F5, W (72), ENTER, W (72), ENTER, W (72), ENTER, W (72), ENTER, ENTER, ESC. Status line: Object = 2 Sequence = 6 Drill.

28

Deleting the centre drill hole: Press CTRL + RIGHT ARROW to select the first drill hole. Press F3 to delete the drill hole and to complete the graduated circle.

NOTE: Instead of using W, ENTER, W, ENTER ... to advance the angular position, you can also type in the absolute angle values, e.g.: W, 72 / W, 144 / W, 216 and so on.

29

EXERCISE No. 4

A Con-rod

The con-rod belongs to a 10ccm four-stroke engine. Take a look at the drawing. The eyes' walls are 2mm thick.

First we need to start a new drawing: Press F9 (File) menu. Press F1 (New) Delete and re-initialise, ENTER. Set the following parameters in the System menu to: Press F8 (Syst.) to go into the system menu. Press F1 (Matl) to enter the material size: Material size (X mm) = 80 ENTER. Material size (Y mm) = 70 ENTER ,ENTER. Press F3 (Global) to access the global settings: Distance before cleaning in mm = 0.1 ENTER. Cleaning speed (mm/s) = 2 ENTER. Dwell (drill/plunge) = 0.5 ENTER. Circle resolution (1-15) = 15 ENTER. Create scaled drawing = 1 ENTER, ENTER.

As the con-rod is a precision part, set Circle Resolution to 15 (max. value). Press F8 (Tool) for tool settings: Tool diameter in mm = 6 ENTER. Default Z depth in mm = 7 ENTER ,ENTER. Press F10 (Main) to return to the main menu.

30

Exercise 4.1

Con-rod Eyes

To initially create the two drill holes, position the first drill point at X = 15 and Y = 15. Press X, 15, ENTER, Y, 15, ENTER, ENTER. Press ENTER to confirm the position of the first hole. Tool diameter = 6 ENTER. Z millimetres = 7.2 ENTER. (To go through the material). Set the step size to 10mm with the + and keys. Press the UP ARROW key 4 times to go to the upper eye's position and press ENTER. Press ENTER to confirm the position of the second hole. Tool diameter = 5 ENTER. Z millimetres = 7.2 ENTER. (To go through the material).

Exercise 4.2

Interior Part

In this step, you will create the interior part consisting of two circles and a rectangular centre part. Let's start with the two circles. Make sure the step size is still set to 10mm (using the + and keys). Press the DOWN ENTER.
ARROW

key 4 times to go to Abs. X = 15 and Y = 15

Press A to draw a circle: Circle radius in mm End radius in mm Angle in degree Tool diameter Z millimetres Outside Counterclockwise

= 5 ENTER. = 5 ENTER. = 360 ENTER. = 6 ENTER. = 1 ENTER. = 2 ENTER. = PRESS ESC FOR NO.

Now we go to the upper drill hole: Press X, 5, ENTER, Y, 40, ENTER, ENTER. Press A to draw a circle: Circle radius in mm End radius in mm Angle in degree Tool diameter Z millimetres Outside = 4.5 ENTER. = 4.5 ENTER. = 360 ENTER. = 6 ENTER. = 1 ENTER. = 2 ENTER. 31

Counterclockwise

= PRESS ESC FOR NO.

Next, we create the rectangle to add the required thickness to the centre part. Use the PGUP key to zoom into the drawing, set the step size to 1mm by using the minus key. Press the DOWN ARROW key five times and the RIGHT ARROW key once and then ENTER. This is the upper right starting point. Press R to draw a rectangle. Rectangle: X mm = 11 ENTER. Rectangle: Y mm = -29.5 ENTER. Tool diameter = 6 ENTER. Z millimetres = 1 ENTER. Inside = 1 ENTER. Counterclockwise = PRESS ENTER FOR YES. Now we can see the rectangle. Press the space bar to view the toolpath (see also illustration). Press the space bar again to hide the toolpath. At this stage, save the drawing by pressing F9 (File menu) and F4 (Save as). Type in

Rod_1_1 as file name and press ENTER. Pressing the space bar returns you to the Main menu.

Exercise 4.3

External Contour

On top of the existing circles, you will finally create the external contour for cropping the part. The pencil now rests on Abs.X = 9.5, Abs.Y = 50. Press X, 1, ENTER, Y, 5, ENTER, ENTER. Press X, 9, ENTER, ENTER. 32

Press Y, -40, ENTER. Now zoom into the picture (using the PGUP key) until the 1/10mm grid appears. Reduce the step size to 0.01mm (using the - key) and go up vertically until you hit the external circle. Confirm this point with ENTER. Press X, -9, ENTER, ENTER. Return the pencil to the starting point (Abs. X, 10.5 Y, 55.0) of the object to close it with ENTER. Tool diameter Z millimetres External = 6 ENTER. = 7.2 ENTER. = 2 ENTER.

Change to the Edit menu (F5). Press CTRL+LEFT ARROW until you are on object No. 6. Press LEFT ARROW once, to select the upper horizontal line segment and then F4 for Circle. Using the UP/DOWN ARROW keys, set a Radius of 4.5 mm. Make sure that the Delta value is also 4.5mm. As you cannot obtain these setting here you must press F2 (angle > 180). This will allow you to set the Radius and Delta value to 4.5mm. Confirm the semicircle with ENTER. You may need to adjust the step size (+ or keys) to attain these values.

Press the LEFT ARROW key twice to get to the lower horizontal line. Press F4. Press F2 so that the angle, is set to >180. Press the UP/DOWN ARROW keys to set the radius to 5mm and then press ENTER. With this operation the object structure is basically finished. 33

Press F10 once (Main menu) to return to the starting point. Press F6, to adjust the drawing to the centre of the screen. Press F5, to access the Editor again. Press the CTRL+LEFT ARROW key until object 6 is selected. For the following corrections, we recommend you isolate the object, i.e. move it to one side. Press the + key to set the step size to 10mm. Press F5 (Move). Press the LEFT ARROW key twice and confirm with ENTER. Press the F5 key to exit the move mode. Tool Radius Compensation in Object No. 6: You will have to delete the points resulting at the transition from the straight line to the circle in the lower area, otherwise the tool would move back and forth (see illustrations below). Now enlarge the objects and position the image: Press CTRL + LEFT ARROW key until object 6 is selected. Press LEFT ARROW until the pencil is on the lower arc. Now enlarge the objects and position the image: Press PGUP key (enlarge). Press TAB (move image) and ARROW keys until it is positioned as in the diagram on the next page. Press TAB to exit move image. Now display the system points and tool path: Press D (This can display or hide the system points). Press the SPACE BAR (This can display or hide the tool path). Now delete the ten offending system points: Select the second system point on the arc using the ARROW keys. Press F3 (cut). The pencil automatically moves onto the next system point. Press F3 (cut). The pencil automatically moves onto the next system point. Press F3 (cut). The pencil automatically moves onto the next system point. Press F3 (cut). The pencil automatically moves onto the next system point. Press F3 (cut). Press LEFT ARROW until the pencil is on the fourth from last system point on the arc. Press F3 (cut). The pencil automatically moves onto the next system point. Press F3 (cut). The pencil automatically moves onto the next system point. Press F3 (cut). The pencil automatically moves onto the next system point. 34

Press F3 (cut). The pencil automatically moves onto the next system point. Press F3 (cut). Press the SPACE BAR twice and your image should look similar to the lower diagram on the next page. Object No. 6 now needs to be replaced it at its original position. First hide the system points and tool path. (Leaving them displayed slows down the redrawing). Press D Press SPACE BAR Press PGDN, TAB (move image) and ARROW keys until all the image is displayed. Press TAB to exit move image. Move back to the starting point of object No. 6. Press F5. Press X-20 ENTER, ENTER. Press the F5 key to exit the move mode.

35

Exercise 4.4

Checking All Objects

While in the Edit menu, we go back to the starting point of the drawing to check all objects. Object No. 1, drill: Diameter 6mm, depth 7.2mm. Later, you can use the drill point positions for pilot/final drilling and reaming. Object No. 2, drill: Diameter 5mm, Z mm =7.2. Object No. 3, lower eye circle: Tool diameter 6mm, Zmm = 1. Machining outside (to be checked with SPACE) clockwise. Object No. 4, upper eye circle: Tool diameter 6mm, Zmm = 1. Machining outside (to be checked with SPACE) clockwise.

36

Object No. 5, the internal rectangle: Tool 6mm, Zmm = 1, counterclockwise direction. Object No. 6, crop outside: Tool 6mm, Z mm = 3.6 (with Auto Z Depth output x2), clockwise direction (must be changed in that case). Go to the beginning of object No.6. Press F1 Edit. Obj: 6 Tool diameter Obj: 6 Z millimetres Change all from 7.2 mm to 3.6 mm Outside Object: 6 Output sequence number Clockwise

= 6 ENTER. = 3.6 ENTER. = NO ESC. = 2 ENTER. = 6 ENTER. = PRESS ESC FOR NO.

With these settings you have changed the direction and machining depth of object No. 6. Go into the Main menu (F10) and open the File menu (F9). Press F4 S.as = Rod_1_3 ENTER. The top view of the part is now complete. To machine the con-rod, you have to start with the bottom side, which requires that you mirror the whole object and delete object No. 6 first. To delete this object go to the Edit menu (F5). Press CTRL + LEFT ARROW keys until object No. 6 is selected. Press F3 (CUT). One way to mirror the con rod is to swap each drill point along with its external diameter. You will have to use PLUS/MINUS keys to change the step size in this Exercise. Press F5 (as object No. 1 is already selected). Move the object up using the UP ARROW key to ABS. Y, 55.0. (Alternatively you can type Y and then the value you want to move by). Press ENTER. Press F5 to exit move. Press CTRL+LEFT ARROW keys once to select object No. 2. Press F5. Move the object down using the DOWN ARROW key to ABS. Y, 15.0. Press ENTER. Press F5 to exit move. Press CTRL+LEFT ARROW keys once to select object No. 3. Press F5. Move the object down using the UP ARROW key to ABS. Y, 55.0. Press ENTER. Press F5 to exit move. Press CTRL+LEFT ARROW keys once to select object No. 4. Press F5. 37

Move the object down using the DOWN ARROW key to ABS. Y, 15.0. Press ENTER. Press F5 to exit move. The rectangle, object No. 5, has to be move down by 0.5mm. Press CTRL+LEFT ARROW keys once to select object No. 5. Press F5. Move the object down by 0.5mm using the DOWN ARROW key to ABS. Y, 49.5.

The two origins of both drawings are identical. As a reference point for locating the two origins later, You can use both the upper and the lower drill hole. Save this drawing as "Rod_U". Press F10 (Main) to return to the main menu. Press F9 (File). Press F4 (S as). Press Rod_U Enter, Enter.

38

EXCERCISE No. 5

Turning

170

,5

3 0 .0 3 R 8
R 6

1 7 .6 3

R1 8

9 .5 1
R 22

R 30

9 .1 6 1 5 .1 6 3 1 .5 1

1 4 .6 4 2 5 .0 3 6 6 .3 7 74

39

Procedure:

As we do not know the start and end points of the radii, we will draw subsidiary circles first. Next we will draw a contour line (consisting of straight segments) on the intersecting segments. After drawing this line we will form circular segments from these straight lines again. Finally we will delete the subsidiary circles and switch to the lathe program. P Pr re ep pa ar ra attiio on n:: First we need to start a new drawing: Press F9 (File) menu. Press F1 (New) Delete and re-initialise, ENTER. Set the following parameters in the System menu to: Press F8 (Syst.) menu. Press F1 (Matl) to enter the material size: Material size (X mm) = 85 ENTER. Material size (Y mm) = 170 ENTER ,ENTER. Press F10 (Main) to return to the main menu. 1 1..)) T Th he eS Su ub bs siid diia ar ry yC Ciir rc clle es s:: The following are the co-ordinates of the Circle Centres and their radii: 1. X = 17.63 Y = 6.0 R = 6mm 2. X = 30.03 Y = -0.5 R = 8mm 3. X = 25.03 Y = -9.16 R = 18mm 4. X = 14.64 Y = -15.16 R = 30mm 5. X = 66.37 Y = -9.51 R = 22mm To draw the first circle enter the following : Press X, 17.63, ENTER, Y, 6, ENTER, ENTER. Press A to draw a circle: Circle radius in mm End radius in mm Angle in degree Confirm the rest of the questions with procedure. Tool diameter Z millimetres Outside Counterclockwise = 6 ENTER. = 6 ENTER. = 360 ENTER. ENTER as they have no bearings on the turning = ENTER. = ENTER. = ENTER. = ENTER.

Now return the pencil to zero: Press C to set the X and Y values to zero. 40

Press X, ENTER, Y, ENTER. Follow the procedure described above for circles 2 through 5. 2 2..)) T Th he eS Se eg gm me en ntte ed dS Sttr ra aiig gh htt L Liin ne e:: Now go to the relevant intersecting points (where the profile runs) of the circles and insert straight lines. These points from the previous are (Rel. displays on the left should read) as follows: 1. 2. 3. 4. 5. 6. 7. X= X= X= X= X= X= X= 17.63 5.3 11.1 6.5 3.96 21.88 Y= 7.63 Y= 3.2 Y= 3.23 Y= -6.43 Y= -12.0 -19.51

To draw these type the following: Press C to set the X and Y values to zero. Press X, ENTER, Y, ENTER, ENTER. Press X, 17.63, ENTER, ENTER. Press X, 5.3, ENTER, Y, 3.2, ENTER, ENTER. Press X, 11.1, ENTER, Y, 3.23, ENTER, ENTER. Press X, 6.5, ENTER, Y, -6.43, ENTER, ENTER. Press X, 3.96, ENTER, Y, -12, ENTER, ENTER. Press X, 21.88, ENTER, Y, -19.51, ENTER, ENTER. Press X, 7.63, ENTER, ENTER. The Abs. displays on the left of the screen should now read X = 74.00 and Y = 31.51.

41

3 3..))

D Dr ra aw wiin ng g tth he eR Ra ad diiii::

Press F5 - Edit to change into Edit mode. The pencil rests on the first subsidiary circle. By pressing CTRL+LEFT ARROW keys you will jump from circle to circle and then onto the straight lines. When on these press only the LEFT ARROW key twice to move the pencil onto the last point of the second line, which is now highlighted. Expand the image so as you can work more easily. Press F4 (Circle) and ENTER. Press LEFT ARROW key. Press F4 (Circle) and ENTER. Press LEFT ARROW key. Press F4 (Circle) and ENTER. Press LEFT ARROW key. Press F4 (Circle) and ENTER. Press LEFT ARROW key. Press F4 (Circle) and ENTER. Press LEFT ARROW key. Press F4 (Circle) and ENTER. using the ARROW keys adjust the radius = 6 using the ARROW keys adjust the radius = 8 using the ARROW keys adjust the radius = 18 using the ARROW keys adjust the radius = 30 using the ARROW keys adjust the radius = 22 using the ARROW keys adjust the radius = 6

All the five straight lines should now be converted to radii. 4 4..)) D De elle ettiin ng g tth he eS Su ub bs siid diia ar ry yC Ciir rc clle es s::

Exit the Editor by pressing F10, and reopen it directly by pressing F5 to access the first circle in your drawing. Adjust the image to a more suitable size and position. Press F3 repeatedly, until all circles are deleted. The image should now be similar to the diagram below.

42

5 5..))

F Fiin na all S Stte ep p::

To put the cutter path on its correct position: Press F10 (Main). Press F4 (La/Mi) to change to the lathe program. Press F5 (Edit). Now you will reposition the path of the cutter in the Y direction: Press CTRL+RIGHT ARROW repeatedly to jump to the start of your drawing. Press M, Y, 31.51, ENTER, ENTER.

Do not forget to save your work at regular intervals so you can go back if make bad mistakes.

43

EXCERCISE No. 6

The material thickness is 8 mm. First we need to start a new drawing: Press F9 (File) menu. Press F1 (New) Delete and re-initialise, ENTER. Set the following parameters in the System menu to: Press F8 (Syst.) menu. Press F1 (Matl) to enter the material size: Material size (X mm) = 260 ENTER. Material size (Y mm) = 110 ENTER, ENTER.

The Drill Holes:

Press F8 (Tool) for tool settings: Tool diameter in mm = 6.5 ENTER. Default Z depth in mm = 9 ENTER ,ENTER. Press F10 (Main) to return to the main menu. The right side of the motor plate: Press X, 15, ENTER, Y, 10, ENTER, ENTER, ENTER. Confirm tool settings in the status bar. (Lower right drill hole). Press Y, 90, ENTER, ENTER, ENTER. Confirm tool settings in the status bar. (Upper right drill hole). Press X, 60, ENTER, ENTER, ENTER. Confirm tool settings in the status bar. (Upper left drill hole). Press Y, -90, ENTER, ENTER, ENTER. Confirm tool settings in the status bar. (Lower left drill hole). 44

Now the left side of the motor plate: Press C, X, ENTER, Y, ENTER. (Pencil sent to zero). Press X, 205, ENTER, Y, 55, ENTER. (Pencil at the centre of the left cut out). Press Y, -43.75, ENTER, ENTER, ENTER. Confirm tool settings in the status bar. (Lower drill hole). Press Y, 43.75, ENTER, Y, ENTER, ENTER, ENTER. Confirm tool settings in the status bar. (Upper drill hole). Press Y, -43.75, ENTER, X, 43.75, ENTER, ENTER , ENTER. Confirm tool settings in the status bar. (Left drill hole). Press X, -43.75, ENTER, X, ENTER, ENTER, ENTER. Confirm tool settings in the status bar. (Right drill hole). Now save the drawing: Press F9 (File) menu. Press F4 (S as) save to disk under new name. Press Mplate-1 ENTER, the file extension .FRS will automatically be added. Press Space bar to continue. The file Platte-1.FRS already exists which is the same as this diagram (so you can start from this position or compare).

The Circles:
Set the following parameters in the System menu to: Press F8 (Syst.) menu. Press F8 (Tool) for tool settings: Tool diameter in mm = 8 ENTER. Default Z depth in mm = 4.2 ENTER ,ENTER. 45

(Two times 4.2 punches through a material thickness of 8 mm). Press F10 (Main) to return to the main menu. Press C, X, ENTER, Y, ENTER. (Pencil sent to zero). Press X, 45, ENTER, Y, 55, ENTER, ENTER. Press X, 20, ENTER, A. Confirm tool settings in the status bar. (Circle 40mm cut out). Press X, 180, ENTER, ENTER. Press X, 32.5, ENTER, A. Confirm tool settings in the status bar. (Circle 65mm cut out).

The External Contour:

Press C, X, ENTER, Y, ENTER, ENTER. (Pencil sent to zero). Press X, 205, ENTER, Y, 110, ENTER. Press R to draw a rectangle. Tool diameter = 8 ENTER. Z millimetres = 4.2 ENTER. Outside = 2 ENTER. Counterclockwise = PRESS ESC FOR NO. Now save the drawing: Press F9 (File) menu. Press F4 (S as) save to disk under new name. Press Mplate-2 ENTER, the file extension .FRS will automatically be added. Press Space bar to continue. The file Platte-2.FRS already exists which is the same as this diagram (so you can start from this position or compare).

46

Completing the Contour:

Press F5 (Edit) to enter the Edit mode. Press CTRL+LEFT ARROW until object 11 is selected. Press LEFT ARROW key to select the left vertical line. Press F4 (Circle). Using the UP/DOWN ARROW keys, set a Radius of 55 mm. Make sure that the Delta value is also 55mm as shown below. If you cannot obtain these setting here you must press F2 (angle > 180). This will allow you to set the Radius and Delta value to 55mm. Confirm the semicircle with ENTER. You may need to adjust the step size (+ or keys) to attain these values. Now save the drawing: Press F10 (Main) to return to the menu. Press F9 (File) menu. Press F4 (S as) save to disk under new name. Press Mplate-3 ENTER, the file extension .FRS will automatically be added. Press Space bar to continue. The file Platte-3.FRS already exists which is the same as this diagram so you can compare.

47

EXCERCISE No. 7
First we need to start a new drawing: Press F9 (File) menu. Press F1 (New) Delete and re-initialise, ENTER. Set the following parameters in the System menu to: Press F8 (Syst.) to go into the system menu. Press F1 (Matl) to enter the material size: Material size (X mm) = 100 ENTER. Material size (Y mm) = 100 ENTER ,ENTER. Press F3 (Global) to access the global settings: Distance before cleaning in mm = 0.2 ENTER. Cleaning speed (mm/s) = 2 ENTER. Dwell (drill/plunge) = 0 ENTER. Circle resolution (1-15) = 15 ENTER. Create scaled drawing = 1 ENTER, ENTER. Press F10 (Main) to return to the main menu.

Worm

The Forward Movement:

Press X, 50, ENTER, Y, 50, ENTER, ENTER. Press X, 40, ENTER. Press A ENTER. End-radius in mm = 10 ENTER. Angle in degrees 3 x 360 = 1080 ENTER. Tool = 8 ENTER. Z millimetres = 4.2 ENTER. Outside = 2 ENTER. Counterclockwise = PRESS ENTER FOR YES.

48

Closing the object. Press X, -30, ENTER, ENTER. Tool = 8 ENTER. Z millimetres = 4.2 ENTER. Outside = 2 ENTER. Now save the drawing: Press F9 (File) menu. Press F4 (S as) save to disk under new name. Press Worm-1 ENTER, the file extension .FRS will automatically be added. Press Space bar to continue. The file Schneck1.FRS already exists which is the same as the diagram on the next page (so you can start from this position or compare).

Copying the worm for the reverse movement: Press F5 (Edit) to enter the Edit mode. Press F8 (Copy). Press F2 (Paste). Press ENTER. Press ESC. Drawing the reversed worm: Press CTRL + LEFT ARROW keys to select object 2. Press F1 (Edit). Obj: 2 Tool diameter = 8 ENTER. Obj: 2 Z millimetres = 4.2 ENTER. Inside = 1 ENTER. Object: 2 output sequence number = 1 ENTER. Continue Counterclockwise machining = PRESS ESC FOR NO. Now delete the horizontal linking line between the two worms: Press RIGHT ARROW key (The horizontal line is highlighted). Press F3 (Cut). Press F3 (Cut).

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Back to the start: Press F10 (Main). Press F5 (Edit). As various entries were purposefully input incorrectly we are going to correct them in (Edit) F5. Editing the worm: Press F1 (Edit). Obj: 1 Tool diameter = 8 ENTER. Obj: 1 Z millimetres = 4.2 ENTER. Inside = 3 ENTER. Object: 1 output sequence number = 1 ENTER. Press F10 (Main) to return to the Main menu. Now save the drawing: Press F9 (File) menu. Press F4 (S as) save to disk under new name. Press Worm-2 ENTER, the file extension .FRS will automatically be added. Press Space bar to continue. The file Schneck2.FRS already exists which is the same as the diagram on below (so you can compare if you want or compare).

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You can run a simulation to see how the program will run:

Press F3 (Sim). Number of loops Auto z depth loops Processing from object Processing to object With auto-clean Start output now

= 1 ENTER. = 1 ENTER. = 1 ENTER. = 1 ENTER. = PRESS ENTER FOR YES. = PRESS ENTER FOR YES.

EXCERCISE No. 8
The wheel dimensions are as follows: External diameter = 50mm. Internal diameter = 40mm. Wheel hub = 12 mm. Spoke thickness = 1mm. Number of spokes = 12 (30) First we need to start a new drawing: Press F9 (File) menu. Press F1 (New) Delete and re-initialise, ENTER. Set the following parameters in the System menu to: Press F8 (Syst.) to go into the system menu. Press F1 (Matl) to enter the material size: Material size (X mm) = 50 ENTER. Material size (Y mm) = 50 ENTER ,ENTER. Press F3 (Global) to access the global settings: Distance before cleaning in mm = 0.08 ENTER. Cleaning speed (mm/s) = 1.5 ENTER. Dwell (drill/plunge) = 0.5 ENTER. Circle resolution (1-15) = 15 ENTER. Create scaled drawing = 1 ENTER, ENTER.

Train Wheel

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Press F8 (Tool) to access the tool settings: Tool diameter in mm = 2 ENTER. Default Z depth in mm = 1.5 ENTER Press F10 (Main) to return to the main menu. Subsidiary Circles: Please note here we are going to use the ALT + X and the ALT + Y keys which allows you to input the absolute distances from anywhere on the work surface. Wheel hub circle: Press ALT + X 25, ENTER. Press ALT + Y 25, ENTER, ENTER. Press X 6, ENTER, ENTER. Press A (confirm all data). Internal rim circle: Press ALT + X ENTER, ENTER. Press X 20 ENTER, ENTER. Press A (Confirm all data). External rim circle: Press ALT + X ENTER, ENTER. Press X 25 ENTER, ENTER. Press A (Confirm all data).

Subsidiary Spokes: Please note here we are going to use the key, which allows you to change a value from positive to a negative value without altering the numbers (this cannot be used in reverse). Press ALT + X ENTER, ENTER. Press X 5 ENTER, ENTER. Press Y .5 ENTER, ENTER. 52

Press X 16 ENTER, ENTER Press Y 1 ENTER, ENTER. Press X ENTER, ENTER Press Y .5 ENTER, ENTER. Press X 5 ENTER, ENTER (Confirm all data).

Copying and pasting the subsidiary spokes. In the wheel there are 12 spokes with 12 spaces therefore each spoke is 30 apart (360 / 12 = 30). Rotating the first spoke by 15, and the second one by 15: Press F5 (Edit) to enter the Edit mode. Press CTRL + LEFT ARROW keys to select the spoke (OBJECT = 4). Press F8 (Copy). Press F2 (Paste). Press ENTER. Press ESC. Press F4 (Rot.). Press W 15 ENTER, ENTER. Press CTRL + LEFT ARROW keys to select the second spoke (OBJECT = 5). Press F4 (Rot.). Press W -30 ENTER, ENTER. Press F10 (Main) to return to the main menu. Now save the drawing: Press F9 (File) menu. Press F4 (S as) save to disk under new name. Press Wheel-1 ENTER, the file extension .FRS will automatically be added. Press Space bar to continue. The file Rad-1.FRS already exists which is the same as the diagram on below (so you can start from this position or compare).

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The first section: The first point is X = 6 so from this position we are going to move the pencil to the following positions to create the pie section: Top right: X = 31.00 Top left: X = 44.44 Bottom left: X = 44.44 Bottom right: X = 31.00 Y = 26.09 Y = 29.69 Y = 20.31 Y = 23.91

To create the pie section: Press X 6 ENTER, ENTER. Press ALT + Y 26.09 ENTER, ENTER. Press ALT + X 44.44 ENTER. Press ALT + Y 29.69 ENTER, ENTER. Press ALT + Y 20.31 ENTER, ENTER. Press ALT + X 31.00 ENTER. Press ALT + Y 23.91 ENTER, ENTER. Press ALT + Y 25.00 ENTER, ENTER (Confirm all data). 54

Now save the drawing: Press F9 (File) menu. Press F4 (S as) save to disk under new name. Press Wheel-2 ENTER, the file extension .FRS will automatically be added. Press Space bar to continue. The file Rad-2.FRS already exists which is the same as the diagram below (so you can start from this position or compare).

Now we are going to move the pie section 20mm to the left to work on it: Press F5 (Edit). Press CTRL + LEFT ARROW keys to select the pie section (OBJECT = 6). Press F5 (Move). Press X 20 ENTER, ENTER. Press ESC. Now we are going to put an arc with a radius of 20mm on the left side of the pie: Press LEFT ARROW key until the left vertical line is selected (highlighted). Press F4 (Circle). Press ARROW keys to set the radius = 20. Press ENTER. Press F10 (Main) to return to the main menu. Now save the drawing: Press F9 (File) menu. Press F4 (S as) save to disk under new name. Press Wheel-3 ENTER, the file extension .FRS will automatically be added. Press Space bar to continue.

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The file Rad-3.FRS already exists which is the same as the diagram below (so you can start from this position or compare).

You will have to delete some points in the corners to prevent the tool from cutting beyond the contour: Press F5 (Edit). Press CTRL + LEFT ARROW keys to select the pie section (OBJECT = 6). Press LEFT ARROW key until the pencil is positioned on the top left corner of the pie section. Press PGUP key to increase the drawing to suitable size. Press SPACE BAR to display the tool path. Press LEFT ARROW key to select the points at the top left to be deleted. Press F3 (Cut) until the offending points are deleted. Press LEFT ARROW key to select the points at the bottom left to be deleted. Press F3 (Cut) until the offending points are deleted. Please note: If you turn off the tool path display the redraw will be quicker when moving the drawing. Return to the start of the pie section, and move it 20mm back to the right side.

Press F10 (Main) to return to the main menu. Now save the drawing: 56

Press F9 (File) menu. Press F4 (S as) save to disk under new name. Press Wheel-4 ENTER, the file extension .FRS will automatically be added. Press Space bar to continue. Now copy the pie section and paste it at the desired angle. Finally you will have to rotate all pieces. When creating a wheel on your own, make sure the toolpath of the object you want to paste starts at the centre. In this case it is a subsidiary spoke but you can also use a drill hole. Press F5 (Edit). Press CTRL + LEFT ARROW keys to select the pie section (OBJECT = 6). Press F8 (Copy). Press F2 (Paste). Press ENTER. Press ESC. Press F5 (Move). Press W, 30, ENTER, ENTER. Press ESC. There are now two of the pie sections pasted. Now for the next one: Press F2 (Paste). Press ENTER. Press ESC. Press F5 (Move). Press W, ENTER. Press W, ENTER, ENTER. Press ESC. There are now three of the pie sections pasted. Repeat this procedure, another 9 times until all pie sections have been pasted (remember to add an extra 30 to each repetition). When using the W key for moving the object you do not have to enter the value 30 again as it is still in the memory. You can just type W ENTER, ... to move the parts on.

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Rotating all the parts: Press CTRL + LEFT ARROW keys to select the first pie section Pasted (Object = 16 Sequence = 7). Press F4 (Rot.). Press W, ENTER, ENTER. Press CTRL + RIGHT ARROW keys to select the next pie section. Press F4 (Rot.). Press W, ENTER, ENTER. Repeat this until all the pie sections are positioned. Deleting the two original spokes: Press CTRL + RIGHT ARROW keys to select a spoke. Press F3 (Cut) to delete. Press CTRL + LEFT ARROW keys to select the other spoke. Press F3 (Cut) to delete. Now save the drawing: Press F10 (Main) to return to the main menu. Press F9 (File) menu. Press F4 (S as) save to disk under new name. Press Wheel-5 ENTER, the file extension .FRS will automatically be added. Press Space bar to continue. The file Rad-4.FRS already exists which is the same as the diagram on the next page (so you can start from this position or compare).

The basic contour is completed.

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Exercise 8.2

Modifying an existing drawing.

NEXT WE ARE GOING TO SEE HOW EASY IT IS TO MODIFY AN EXISTING DRAWING AS WE ARE GOING TO CONVERT THIS WHEEL INTO A FLYWHEEL. Additional Object, Creating a Flywheel Mass: Draw a subsidiary circle with a diameter of 60 mm and its centre at X=25 and Y=25. Press Alt + X 25, ENTER. Press ALT + Y 25, ENTER, ENTER. Press X 30, ENTER. Press A (confirm all data). Obtaining the co-ordinates: Select the pie section the one in a clockwise direction from 6 Oclock (OBJECT = 5 SEQUENCE =5) and then the co-ordinates of the corners. Press F5 (Edit). Press CTRL + LEFT ARROW keys to select the pie section. Press LEFT ARROW key twice to select the lower left hand corner and make a note of the Abs. co-ordinates. The first pie section clockwise of 6 Oclock, (OBJECT = 5 SEQUENCE =5) its lower left hand co-ordinates are: Co-ordinates: X = 38.78 Y = 10.52

Once you have done this select the circle with the 60mm diameter. Press RIGHT ARROW key twice to select pie section (It turns red). Press CTRL + LEFT ARROW keys to select the circle. Press LEFT ARROW key. Press CTRL + LEFT ARROW keys. Once you are in the circle the pencil moves in larger steps. When at the bottom left of the circle get the closest X co-ordinate to X = 38.78 and make a note of the Abs. Y coordinate (-1.73). Move the 60mm diameter circle up 12.25mm (1.73 + 10.52). Press F10 (Main). Press F5 (Edit). Press CTRL + LEFT ARROW keys to select the circle. Press F5 (Move). Press Y, 12.25, ENTER, ENTER. Press ESC. Now save the drawing: Press F10 (Main) to return to the main menu. Press F9 (File) menu. 59

Press F4 (S as) save to disk under new name. Press Wheel-6 ENTER, the file extension .FRS will automatically be added. Press Space bar to continue. The file Rad-5.FRS already exists which is the same as the diagram below (so you can start from this position or compare).

For objects 5 through 7, you will insert a total of four points at the intersections of the spokes and the new circle. 1. Point: 2. Point: 3. Point: 4. Point: X = 30.16 X = 29.17 X = 20.85 X = 19.86 Y = 7.70 Y = 7.54 Y = 7.54 Y = 7.70 (see illustration below)

These are obtained by increasing the image size (PGUP) in the Main menu. Then moving pencil to the intersections of the spokes and the 60mm circle. Get as close as you can and make a note of the co-ordinates.

Creating the intersection points: Press F5 (Edit). Press CTRL + LEFT ARROW keys to select the pie section at 6 Oclock. 60

(OBJECT = 6 SEQUENCE =6). Press RIGHT ARROW key twice. This selects the right straight line in the pie section next to it in a clockwise direction (OBJECT = 5 SEQUENCE =5). Press F2 (Paste). Press X 3.1, ENTER (X= 30.16 27.06 = 3.1). Press Y 11.57, ENTER, ENTER (Y= 7.70 19.27 = 11.57). Press ESC. Press LEFT ARROW key five times to select the left straight line on the pie section at 6 Oclock (OBJECT = 6 SEQUENCE =6). Press F2 (Paste). Press X 0.53, ENTER (X= 29.17 29.70 = 0.53). Press Y 1.97, ENTER, ENTER (Y= 7.54 5.57 = 1.97). Press ESC. Press LEFT ARROW key until you select right straight line in the same pie section. Press F2 (Paste). Press X 3.07, ENTER (X= 20.85 23.92 = 3. 07). Press Y 11.47, ENTER, ENTER (Y= 7.54 19.01 = 11.47). Press ESC. Press LEFT ARROW key five times to select the left straight line on the pie section anticlockwise of the 6 Oclock pie section (OBJECT = 7 SEQUENCE =7). Press F2 (Paste). Press X 0.51, ENTER (X= 19.86 19.35 = 0.51). Press Y 1.87, ENTER, ENTER (Y= 7.70 5.83 = 1.87). Press ESC. If the position of these points are not accurate enough for your application, you can use the Move function with its 1/1000mm setting to adjust the position. Now delete all the points that are on the old radius (40mm Diameter circle). As you are already on the pie section anticlockwise of the 6 Oclock pie section (OBJECT = 7 SEQUENCE =7). Press LEFT ARROW key once. Press DELETE key repeatedly until all the old points on the 40mm diameter circle are deleted. Press RIGHT ARROW key repeatedly until you are at the beginning of the points you want to delete on the pie section at 6 Oclock (OBJECT = 6 SEQUENCE =6). Press DELETE key repeatedly until all the old points on the 40mm diameter circle are deleted. Press RIGHT ARROW key repeatedly until you are at the beginning of the points you want to delete on the pie section clockwise of the 6 Oclock one (OBJECT = 5 SEQUENCE =5).

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Press DELETE key repeatedly until all the old points on the 40mm diameter circle are deleted. Now save the drawing: Press F10 (Main) to return to the main menu. Press F9 (File) menu. Press F4 (S as) save to disk under new name. Press Wheel-7 ENTER, the file extension .FRS will automatically be added. Press Space bar to continue. The file Rad-6.FRS already exists which is the same as the diagram below (so you can start from this position or compare).

As with the first pie section convert the straight lines into an arc. This time with a radius of 30mm. You are already on the first line you want to make into an arc. Press F5 (Edit). Press CTRL + LEFT ARROW keys to select the pie section clockwise of the 6 Oclock section. (OBJECT = 5 SEQUENCE =5). Press RIGHT ARROW key three times this selects the bottom line. Press F4 (Circl). Press UP / DOWN ARROW keys to set the radius to 30mm. Press ENTER. Press LEFT ARROW key to 6 times to select the next line to convert. Repeat the process for the rest of the straight lines needing this modification. Now delete the circle with a 30mm radius. Press LEFT ARROW key 3 times until the whole pie section anticlockwise to it is highlighted. Press CTRL + LEFT ARROW keys until the 30mm radius circle is highlighted. Press F3 (Cut) or the DELTE key. 62

Now save the drawing: Press F10 (Main) to return to the main menu. Press F9 (File) menu. Press F4 (S as) save to disk under new name. Press Wheel-8 ENTER, the file extension .FRS will automatically be added. Press Space bar to continue. Again, you will have to delete some points at the end of the arcs to provide space for the tool. Press F5 (Edit). Press CTRL + LEFT ARROW keys to select the pie section (OBJECT = 5 SEQUENCE 5). Press LEFT ARROW key twice until the pencil is positioned on the bottom left corner of the pie section. Press SPACE BAR to display the tool path. Press PGUP key to increase the drawing to suitable size. Press LEFT ARROW key to select the points at the top left to be deleted. Press F3 (Cut) until the offending points are deleted. Press LEFT ARROW key to select the points at the bottom right to be deleted. Press F3 (Cut) until the offending points are deleted. Do the same on the other two pie sections. Dont forget you can zoom in or out with the PGUP or PGDN keys. Dont forget you can increase the step with the + or - keys. Now save the drawing: Press F10 (Main) to return to the main menu. Press F9 (File) menu. Press F4 (S as) save to disk under new name. Press Wheel-9 ENTER, the file extension .FRS will automatically be added. Press Space bar to continue. The file Rad-7.FRS already exists which is the same as the diagram on the next page (so you can start from this position or compare).

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Next we are going to remove the part of the recess between the hub and the inner rim. To do this we will create three circles with a 5mm cutter and an overlap of 3 mm: Radius of the first circle = radius of hub + cutter compensation overlap. = 6mm + 5mm 3mm = 8mm. Press ALT + X 25, ENTER. Press ALT + Y 25, ENTER, ENTER. Press X 8, ENTER. Press A (confirm all data). Radius of the second circle = radius the first circle + cutter compensation overlap. = 8mm + 5mm 3mm = 10mm. Press ALT + X 25, ENTER, ENTER. Press X 10, ENTER. Press A (confirm all data). Radius of the third circle = radius the second circle + cutter compensation overlap. = 10mm + 5mm 3mm = 12mm. Press ALT + X 25, ENTER, ENTER. Press X 12, ENTER. Press A (confirm all data). Next we are going to put a hole for the spindle in the centre of the wheel. Press ALT + X 25, ENTER. Press ALT + Y 25, ENTER, ENTER. Press ENTER and confirm all data. Now save the drawing: Press F9 (File) menu. Press F4 (S as) save to disk under new name.

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Press Wheel-10 ENTER, the file extension .FRS will automatically be added. Press Space bar to continue.

Exercise 8.2

Changing The Objects Sequences.

Press F5 (Edit). Press CTRL + LEFT ARROW keys to select the spindle hole, we are going to make this 5mm. Press the D key or F7 to display points, the yellow numbers next to the objects indicate the processing sequence. Press F1 (Edit). Obj: 19 Tool diameter = 5 ENTER. Change all from 2mm to 5mm = ESC FOR NO. Obj: 19 Z millimetres = 5.2 ENTER. Change all from 1.2mm to 5.2mm = ESC FOR NO. Inside = 1, Outside = 2, Centre = 3 = 4 for drill. Object: 19 Output sequence number = 1 ENTER. The next sequences we are going to do are the 1.2mm deep recess between the hub and the inner rim. This is going to be machined with a 5mm-diameter cutter. Press CTRL + RIGHT ARROW keys to select the hub. Press F1 (Edit). Obj: 1 Tool diameter = 5 ENTER. Change all from 2mm to 5mm = ESC FOR NO. Obj: 1 Z millimetres = 1.2 ENTER. Inside = 1, Outside = 2, Centre = 3 = 2 ENTER. Object: 1 Output sequence number = 2 ENTER. Continue counterclockwise machining = ESC FOR NO. Press CTRL + LEFT ARROW keys to select the first circle. Press F1 (Edit). Obj: 16 Tool diameter = 5 ENTER. Change all from 2mm to 5mm = ESC FOR NO. Obj: 16 Z millimetres = 1.2 ENTER. Inside = 1, Outside = 2, Centre = 3 = 2 ENTER. Object: 16 Output sequence number = 3 ENTER. Continue counterclockwise machining = ESC FOR NO. Press CTRL + LEFT ARROW keys to select the second circle. Press F1 (Edit). Obj: 17 Tool diameter = 5 ENTER. Change all from 2mm to 5mm = ESC FOR NO. Obj: 17 Z millimetres = 1.2 ENTER. Inside = 1, Outside = 2, Centre = 3 = 2 ENTER. Object: 17 Output sequence number = 4 ENTER. Continue counterclockwise machining = ESC FOR NO.

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Press CTRL + LEFT ARROW keys to select the third circle. Press F1 (Edit). Obj: 18 Tool diameter = 5 ENTER. Change all from 2mm to 5mm = ESC FOR NO. Obj: 18 Z millimetres = 1.2 ENTER. Inside = 1, Outside = 2, Centre = 3 = 2 ENTER. Object: 18 Output sequence number = 5 ENTER. Continue counterclockwise machining = ESC FOR NO. Press CTRL + RIGHT ARROW keys to select the inner rim. Press F1 (Edit). Obj: 2 Tool diameter = 5 ENTER. Change all from 2mm to 5mm = ESC FOR NO. Obj: 2 Z millimetres = 1.2 ENTER. Inside = 1, Outside = 2, Centre = 3 = 1 ENTER. Object: 2 Output sequence number = 6 ENTER. Continue counterclockwise machining = ENTER FOR YES. The next sequences we are going to do are the 5.2mm deep as these are cut outs and we need them to cut all the way through the material. These are going to be machined with a smaller cutter of 2mm diameter. Press CTRL + LEFT ARROW keys to select the first pie section. Press F1 (Edit). Obj: 4 Tool diameter = 2 ENTER. Obj: 4 Z millimetres = 5.2 ENTER. Change all from 1.2mm to 5.2mm = ESC FOR NO. Inside = 1, Outside = 2, Centre = 3 = 1 ENTER. Object: 4 Output sequence number = 7 ENTER. Continue counterclockwise machining = ENTER FOR YES. Press CTRL + LEFT ARROW keys to select the second pie section. Press F1 (Edit). Obj: 5 Tool diameter = 2 ENTER. Obj: 5 Z millimetres = 5.2 ENTER. Change all from 1.2mm to 5.2mm = ESC FOR NO. Inside = 1, Outside = 2, Centre = 3 = 1 ENTER. Object: 5 Output sequence number = 8 ENTER. Continue counterclockwise machining = ENTER FOR YES. Press CTRL + LEFT ARROW keys to select the third pie section. Press F1 (Edit). Obj: 6 Tool diameter = 2 ENTER. Obj: 6 Z millimetres = 5.2 ENTER. Change all from 1.2mm to 5.2mm = ESC FOR NO. Inside = 1, Outside = 2, Centre = 3 = 1 ENTER. Object: 6 Output sequence number = 9 ENTER. Continue counterclockwise machining = ENTER FOR YES.

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Press CTRL + LEFT ARROW keys to select the fourth pie section. Press F1 (Edit). Obj: 7 Tool diameter = 2 ENTER. Obj: 7 Z millimetres = 5.2 ENTER. Change all from 1.2mm to 5.2mm = ESC FOR NO. Inside = 1, Outside = 2, Centre = 3 = 1 ENTER. Object: 7 Output sequence number = 10 ENTER. Continue counterclockwise machining = ENTER FOR YES. Press CTRL + LEFT ARROW keys to select the fifth pie section. Press F1 (Edit). Obj: 8 Tool diameter = 2 ENTER. Obj: 8 Z millimetres = 5.2 ENTER. Change all from 1.2mm to 5.2mm = ESC FOR NO. Inside = 1, Outside = 2, Centre = 3 = 1 ENTER. Object: 8 Output sequence number = 11 ENTER. Continue counterclockwise machining = ENTER FOR YES. Press CTRL + LEFT ARROW keys to select the sixth pie section. Press F1 (Edit). Obj: 9 Tool diameter = 2 ENTER. Obj: 9 Z millimetres = 5.2 ENTER. Change all from 1.2mm to 5.2mm = ESC FOR NO. Inside = 1, Outside = 2, Centre = 3 = 1 ENTER. Object: 9 Output sequence number = 12 ENTER. Continue counterclockwise machining = ENTER FOR YES. Press CTRL + LEFT ARROW keys to select the seventh pie section. Press F1 (Edit). Obj: 10 Tool diameter = 2 ENTER. Obj: 10 Z millimetres = 5.2 ENTER. Change all from 1.2mm to 5.2mm = ESC FOR NO. Inside = 1, Outside = 2, Centre = 3 = 1 ENTER. Object: 10 Output sequence number = 13 ENTER. Continue counterclockwise machining = ENTER FOR YES. Press CTRL + LEFT ARROW keys to select the eighth pie section. Press F1 (Edit). Obj: 11 Tool diameter = 2 ENTER. Obj: 11 Z millimetres = 5.2 ENTER. Change all from 1.2mm to 5.2mm = ESC FOR NO. Inside = 1, Outside = 2, Centre = 3 = 1 ENTER. Object: 11 Output sequence number = 14 ENTER. Continue counterclockwise machining = ENTER FOR YES.

Press CTRL + LEFT ARROW keys to select the ninth pie section. Press F1 (Edit). Obj: 12 Tool diameter = 2 ENTER. Obj: 12 Z millimetres = 5.2 ENTER. 67

Change all from 1.2mm to 5.2mm = ESC FOR NO. Inside = 1, Outside = 2, Centre = 3 = 1 ENTER. Object: 12 Output sequence number = 15 ENTER. Continue counterclockwise machining = ENTER FOR YES. Press CTRL + LEFT ARROW keys to select the tenth pie section. Press F1 (Edit). Obj: 13 Tool diameter = 2 ENTER. Obj: 13 Z millimetres = 5.2 ENTER. Change all from 1.2mm to 5.2mm = ESC FOR NO. Inside = 1, Outside = 2, Centre = 3 = 1 ENTER. Object: 13 Output sequence number = 16 ENTER. Continue counterclockwise machining = ENTER FOR YES. Press CTRL + LEFT ARROW keys to select the eleventh pie section. Press F1 (Edit). Obj: 14 Tool diameter = 2 ENTER. Obj: 14 Z millimetres = 5.2 ENTER. Change all from 1.2mm to 5.2mm = ESC FOR NO. Inside = 1, Outside = 2, Centre = 3 = 1 ENTER. Object: 14 Output sequence number = 17 ENTER. Continue counterclockwise machining = ENTER FOR YES. Press CTRL + LEFT ARROW keys to select the twelfth pie section. Press F1 (Edit). Obj: 15 Tool diameter = 2 ENTER. Obj: 15 Z millimetres = 5.2 ENTER. Change all from 1.2mm to 5.2mm = ESC FOR NO. Inside = 1, Outside = 2, Centre = 3 = 1 ENTER. Object: 15 Output sequence number = 18 ENTER. Continue counterclockwise machining = ENTER FOR YES. Now the last thing we need to do is cut the wheel out using the outside rim of the wheel. Press CTRL + RIGHT ARROW keys to select the outside rim of the wheel. Press F1 (Edit). Obj: 3 Tool diameter = 2 ENTER. Obj: 3 Z millimetres = 5.2 ENTER. Change all from 1.2mm to 5.2mm = ESC FOR NO. Inside = 1, Outside = 2, Centre = 3 = 2 ENTER. Object: 3 Output sequence number = 19 ENTER. Continue counterclockwise machining = ESC FOR NO.

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Lathe EXERCISE No. 9

Turning Internal Contours

This section provides instructions for turning an internal contour in a 60mm thick aluminium tube with a 13mm diameter hole drilled in the centre. First we need to start a new drawing: Press F9 (File) menu. Press F1 (New) Delete and re-initialise, ENTER. Change from mill to lathe: Press F4 (La/Mi) to change to the lathe program. Set the following parameters in the System menu to: Press F8 (Syst.) to go into the system menu. Press F1 (Matl) to enter the material size etc.: Cutting speed (m/min) = 100 ENTER. Material size (X mm) = 50 ENTER. Material size (Y mm) = 60 ENTER. Drill hole diameter (mm) = 13 ENTER. Drill hole length (mm) = 60 ENTER ,ENTER. Press F3 (Global) to access the global settings: Loop run path in mm = 0.5 ENTER. Finishing speed (mm/s) = 100 ENTER. Circle resolution (1-15) = 15 ENTER. Create scaled drawing = 1 ENTER, ENTER. Press F8 (Tool) to access the tool settings: Tool shape = 5 ENTER. Tool width in mm = 10 ENTER, ENTER. Press F9 (mm/s) to enter the default speeds: Compound slide forw.(Y in mm/s) = 1.00 ENTER. Compound slide back (Y in mm/s) = 1.00 ENTER. Saddle slide forw.(X in mm/s) = 1.00 ENTER. Saddle slide back (X in mm/s) = 1.00 ENTER. Compound slide (Y in mm/s) = 12.00 ENTER. Compound slide (X in mm/s) = 12.00 ENTER ,ENTER. Press F10 (Main) to return to the main menu.

Creating the Drawing below: Press Y, 10, ENTER, ENTER. Press X, 4, ENTER, Y, 3.5, ENTER, ENTER. 69

Press X, 5, ENTER, ENTER. Press X, 2, ENTER, Y, 2, ENTER, ENTER. Press ALT+Y, 20, ENTER, ENTER. Press X, 16, ENTER, Y, 3.5, ENTER, ENTER. Press ALT+X, 30, ENTER, ENTER. Press ALT+Y 0 ENTER, ENTER. This Exercise makes alternating use of relative and absolute dimension entry. Press the D key or F7 to display the numbers for the points. Now you should see the following picture. Now save the drawing: Press F9 (File) menu. Press F4 (S as) save to disk under new name. Press Int-1 ENTER, the file extension .DAT will automatically be added. Press Space bar to continue. The file Innen-1.DAT already exists which is the same as the diagram below (so you can start from this position or compare).

Now we are going to edit the drawing putting in a 2mm radius where the 45 angle is. This is shown on the next page. Press F5 (Edit) to enter the edit menu: Press the RIGHT ARROW key 4 times to select the 45 line. Press F4 (Circl) to insert a radius. Press the UP/DOWN ARROW keys to set the radius to 2 mm. (You may need to press the + or key to adjust the step). Press ENTER to confirm.

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Important: Opposite to conventional external machining, you will only draw those parts of the object that will be left over. The Tool Origin with internal machining is always at the intersection of the material face and the hole. Now save the drawing: Press F10 (Main) to return to the main menu. Press F9 (File) menu. Press F4 (S as) save to disk under new name. Press Int-2 ENTER, the file extension .DAT will automatically be added. Press Space bar to continue. The file Innen-2.DAT already exists which is the same as the diagram below (so you can start from this position or compare).

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Before you start machining the part in Contour mode, use the N key to set the new shaft diameter to 13 (Internal drill hole = starting point = tool position). Press N for new tool position: New tool position = 13 ENTER.

Press F3 (Contour) for internal lathe cutting: Max. rate of cut = 1 ENTER. Finishing cut = .16 ENTER. Start output = ENTER FOR YES. Press SPACE for finishing = SPACE. Done, press SPACE to continue = SPACE.

For situations where the feed rate would be too low or too high, I recommend to stay with 1mm/sec. and adjust the maximum rate of cut when starting Contour mode. The above cut rate can be increased to speed up the process when doing a simulation. i.e. 2. Now save the drawing: Press F9 (File) menu. Press F4 (S as) save to disk under new name. Press Int-3 ENTER, the file extension .DAT will automatically be added. Press Space bar to continue.

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Lathe EXERCISE No. 10

Importing a Rope Drum

This drum of a rope winch was created using the DRAFTBOARD CAD program. After just a few modifications you will be able to machine it using PCLathe. In general, we are only in the lower half of the drawingPCLathe will automatically create the mirrored other half. Machining the lower half, however, takes three different steps of machining: 1. The left side needs to be turned using the internal machining function. (See Exercise No. 9.) 2. The right side has to be turned using the facing function. In this mode there are no automatic features, so you will have to draw the toolpath manually. 3. The external profile itselfand this is what we are going to start with.

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First you need to isolate the profile, i.e. you have to use the CAD program to strip it of all lines that do not pertain to the external contour. Also delete any dimensions. The resulting figure looks like this:

As you can only use the Mill program of PCLathe 3.0 to import a DXF file, you will have to close the contour. When doing so, you have to make allowances for the tool on the right and left sides. Now the modified profile looks like this:

File: Trom.DXF After these steps you can export the profile as a DXF drawing from the CAD program. Select the Export function from the File menu, and choose DXF as file format. Specify your PCLathe directory as the target directory on your hard disk, and enter the file name. Confirm possible additional prompts. Now start the DXF converter GXCONV from your PCLathe directory. Type GXCONV, ENTER. Press arrow keys to select the file (TROM.DXF) THEN PRESS ENTER. The conversion will take only seconds, and the converter will exit automatically. Next start PCLathe, make sure you are in the Mill mode and load the file: Press PCLATHE ENTER. Press F9 (File) menu. Press F9 (Load) load from disk. Press the arrow keys to highlight TROM.FRS . Press ENTER.

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You will see the following screen:

Change to the Edit menu, and make sure that the Machining direction is set to Counterclockwise. ( press F3 to see simulation of machining direction and compensation ).If not, you will need to change the machining direction in Edit. Press F5 (Edit). Press F1 (Edit). Obj: 1 Tool diameter = Press ENTER. Obj: 1 Z millimetres = Press ENTER. Inside = 1, Outside = 2, Centre = 3 = 1 ENTER. Object: 1 Output sequence number = Press ENTER. Continue counterclockwise machining = ENTER FOR YES. Please note you have to change the cutting position ( inside outside of object ) to alter the clockwise/ counterclockwise direction. Return to the Main menu, and change to the Lathe program. Press F10 (Main). Press F4 (La/Mi). Access the Edit menu in Lathe mode to remove the lower horizontal line. Press F5 (Edit). Press F3 (Cut) to remove the first part of the line. Press CTRL + RIGHT ARROW keys to select the next part of the line. Press F3 (Cut) to remove the next part of the line. Press F3 (Cut) to remove the last part of the line. (See the illustration on the next page).

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Press F10 (Main) to return to the main menu. Set the following parameters in the System menu to: Press F8 (Syst.) to go into the system menu. Press F1 (Matl) to enter the material size etc.: Cutting speed (m/min) = 100 ENTER. Material size (X mm) = 180 ENTER. Material size (Y mm) = 202 ENTER. Drill hole diameter (mm) = 0 ENTER ,ENTER. Press F3 (Global) to access the global settings: Loop run path in mm = 0.5 ENTER. Finishing speed (mm/s) = 100 ENTER. Circle resolution (1-15) = 10 ENTER. Create scaled drawing = 1 ENTER, ENTER. Press F8 (Tool) to access the tool settings: Tool shape = 3 ENTER. Tool width in mm = 5 ENTER, ENTER. Press F10 (Main) to return to the main menu. Back in the Main menu you can see the following screen when you press the PGDN and then SPACE BAR:

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Press SPACE BAR again to show just the one contour. Now save the drawing: Press F9 (File) menu. Press F4 (S as) save to disk under new name. Press Drum-1 ENTER, the file extension .DAT will automatically be added. Press Space bar to continue. The file Trom.DAT already exists which is the same as the diagram above (so you can start from this position or compare). The left and right corner are still faultythe 5mm-lathe tool does not fit into the contour. The lines that have been inserted using the CAD program do not provide sufficient space. You may correct that in your CAD program or in PCLathe. The following is how to correct this in PCLathe. First we are going to modify the left side. Insert a new point near the corner (point 482 ) of the profile, 1mm to the right and 3mm up. Press F5 (Edit). Press RIGHT ARROW key once to select point 482 (the number is shown in the Curr.Poin on the left side of the screen). Press F2 (Paste). Press RIGHT ARROW once and UP ARROW three times. (Make sure the steps are set to 1.00 this is shown in the Step on the left side of the screen). Press ENTER Press ESC. 77

The next point we are going to move up 3mm, to be level with the point we have just inserted. Press LEFT ARROW key once to select the next point 483 . Press F5 (Move). Press UP ARROW key three times ENTER. Press ESC.

The final modification to this side of the drawing is to move the vertical line 4mm to the left using the M key. This is to allow enough space for the diameter of the cutter. Press the M key. 78

Press LEFT ARROW key four times. Press ENTER.

Now the tool fits the contour. Now save the drawing: Press F10 (Main) to return to the menu. Press F9 (File) menu. Press F4 (S as) save to disk under new name. Press Drum-2 ENTER, the file extension .DAT will automatically be added. Press Space bar to continue. The file Trom-2.DAT already exists which is the same as the diagram above. (So you can start from this position or compare).

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At the right side, you will only have to remove the third point. Then move all elements 1mm to the left using the M key. Press F5 (Edit). Press CTRL + RIGHT ARROW keys to get close to point 3. Press ARROW keys to actually select point 3. Press F3 (Cut). Press the M key. Press LEFT ARROW key once. Press ENTER to confirm.

The drawing is now complete all that is needed is for you to set the required speeds. Press F9 (mm/s) and input the values you require. 80

Go back to the main menu and see what the finished profile looks like. Press F10 (Main) to return to the menu. Press F6 (Scrn) to show the whole drawing. Press SPACE BAR to show the whole profile. Press PGDN twice the drawing should be the same as the diagram on next page.

Now save the drawing: Press F9 (File) menu. Press F4 (S as) save to disk under new name. Press Drum-3 ENTER, the file extension .DAT will automatically be added. Press Space bar to continue. The file Trom-3.DAT already exists which is similar to the diagram above (so you can compare the end result).

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1.0 Main Menu

On this menu level, you will create your drawings, start output, and switch between Lathe and Mill mode. Some menu options such as Edit, System, File, etc. let you branch to additional submenus.

1.1

On

F1

Press F1 to activate the program's live or on-line mode, i.e. stepper motors on machine tools axes run in sync with the ARROW keys. You can deactivate this mode at any stage by pressing F1 again or ESC. If you have a joystick connected, you can use it simultaneously with the ARROW keys. Also, use the lower button to interrupt and the upper button to resume output. In which direction do the slides have to move? Here in the Main program:

Lathe:

Arrow left Arrow right Arrow up Arrow down Arrow left Arrow right Arrow up Arrow down Home End

Slide to the left Slide to the right Slide back Slide forward Slide to the right Slide to the left Slide forward Slide back Tool away from material Tool towards material

Milling machine:

Lathe/Mill New in version 3.0: Use the X, Y, and Z keys to move the slides directly. This allows you to position the slide at e.g. 18.43mm, a feature that is very helpful when moving to or from the origin. Besides that, you can use CTRL + LEFT/RIGHT ARROW to switch the saddle slide to continuous feed. Lathe If you are using a frequency converter, pressing F1 will activate the spindle drive motor. Its speed will automatically adjust to current diameter and cutting speed. Using this function, you can move your tool towards the material. Once you start output, the F1 On function remains activated. To set the feed speed for live operation, open the System menu (F8) and press F9 mm/s to access the settings screen. When 82

working on your lathe with revolving chuck and F1 On activated, always keep a finger on the ESC key. If you set the step size to 10mm or 100mm by mistake and press the LEFT ARROW key, the tool might quickly run into the chuck. Mill Now both axes rotate in reverse direction. Why? In turning operations, you move the tool and the part remains in a fixed position - with milling this is the other way round. The tool sits in a fixed position while you move the part. This results in a reverse function. Pressing HOME moves the Z axis up (away from the material), and END moves it down (towards the material). Use the +/- keys to set the step size.

1.2
Lathe

Start

F2

Press F2 to output your drawing to the stepper motors. To stop this process at any stage, press ESC. After you pressed [F2], the system prompts you to enter the number of output loops. Number of output loops = LOOP #. You can use LOOP to reproduce a drawing in both longitudinal and transverse direction. LOOP in transverse direction allows you to turn a journal on a shaft. The longitudinal LOOP function can be used to cut e.g. grooves.

(A) Drawing, (B) LOOP drawing 4 times, (C) Result

If you set LOOP to 1, the system will adjust your drawing to the screen automatically during output. If you increase the number of LOOPs, the drawing will not adjust automatically. When setting LOOP > 1, reduce the size of your drawing using the PGUP/DN keys so that all output loops will be visible on your screen. 83

Displays on the left-hand side of the screen: - Image: The current tool and its diameter. - Point : - Paths: - Curr. Path: - Time: The point that is currently processed. The total number of output loops. The current output loop. Elapsed time.

Cancel output with ESC:- If you press Esc to cancel output, the status bar prompts you to select one of the following options: -Yes -No = ENTER: = N: Yes, I want to stop output. No, I don't want to stop output. Allows you to adjust the tool position using the
ARROW

-Correction = C: keys.

For a different feed rate, change the step size with the PLUS/MINUS keys. After you made your changes press ENTER to exit correction mode and confirm with SPACE to continue processing. Attention: If you press ESC to stop the slide (while it moves away from the part) and correct its position to 0.3mm in the opposite direction, the stepper motor actually performs a feed motion. However, you may not notice the slide move because 0.3mm may be within the axis play range. Press ENTER, N, or C. If you press ENTER to cancel output, you will be asked whether or not to return the tool to the origin. If you press ENTER again, the tool will move to the origin otherwise it will not. If you are using a frequency converter, pressing F2 will activate the spindle drive motor. Its speed will automatically adjust to current diameter and cutting speed. The F8/F9 keys (now displayed red) allow you to modify the cutting speed at any stage (this also changes the motor speed). The program displays on the left-hand side show the current speed, Xmm, and Ymm. X and Y values can be seen as a virtual calliper gauge. This is how it works: Using the calibration program (SYNCUTIL.EXE), you adjust the absolute X/Y values (required steps/mm). If you want to move the tool 2mm in Y direction then, the program will calculate the required steps. The result of this calculation may also be a fraction, e.g. 123.45687 steps. The motors will perform the full steps and program will memorise the remainder.

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This remainder will be added to each new distance. With the full steps that the motor performs, the system calculates back to the actual mm value. Therefore, the Xmm and Ymm displays may differ from the values specified in your drawing. Once output is completed, the Time display shows the required time.

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1.2
Mill

Start

F2

Press F2 to start output of your drawing to the stepper motors. You can stop this process at any time by pressing ESC. Before starting output, check some important program settings: - Z axis operating speed adjusted? - Dwell time ? - Cleaning/finishing; distance and speed? (1) Number of Output Loops and Loop Spacing in X direction After you pressed F2, the system will prompt you to enter the number of output loops. This allows you to create multiple copies of individual parts or the entire drawing. If you enter a loop number greater than one, you will be asked for the spacing of the parts to be machined. Also keep the tool radius in mind, especially with objects that are cut out at the outer edge. Currently duplicating is only possible in longitudinal direction. (2) Auto Z Depth Loops Multiplying the depth of each object. The total object depth is the product of Z depth x loops. If you want to cut several objects of different total depths using the same loop number, you will have to set the appropriate Z depth before. In our example to the right, object 1 has a depth of 3x3mm = 9mm and object 2 3x0.5mm = 1.5mm. In drilling operations, Auto Z Depth can be used for chip breaking. Assign a depth of 5mm for a 10mm deep drill hole in your drawing, and set Auto Z Depth to 2. The tool will drill 5mm deep first, retract out of the material to Z = 0 position, and then complete the 10mm drill hole in the second run. The tool will dwell on the bottom of the drill hole after each plunge operation, see F8 System menu and F3 Global settings.

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(3) Z Path (Zero Pos.) over Material (mm) This parameter applies if your Z axis is PCLathe-controlled. The zero position is always the same for a complete drawing. You should place the zero position as close above the material as possible to avoid unnecessary Z axis moves.

ATTENTION Never leave the machine tool unattended when in operation!

Before starting output, set the tool to the correct height: Load the tool into the tool holder of your machine and use the quill to adjust the tool to material zero position. You can also use PCLathe to position the tool: 1. Switch on the tool motor. 2. Press F1 On from the Main menu. 3. Adjust the tool to material top surface level using the END key (use the PLUS/MINUS keys to set the step size). Press HOME to set the value for the Z Zero Position. The program default value is 2mm.

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(4) Processing from Object Use this parameter to specify the first object for processing. (5) Processing to Object Use this parameter to specify the last object for processing. Skipping individual objects is not possible. (6) Auto-Clean With automatic cleaning/finishing, a simulated larger tool (plus double the amount of the Distance before cleaning value from the F8 System menu's F3 Global option) will cut the object first. Then, the system switches to the appropriate tool diameter, and cuts the remaining material to size at small feed speed (0.1 mm/sec). The whole object will now be machined at cleaning/finishing speed.

When creating your drawing, make allowances for the simulated larger tool especially with internal milling!
High dimensional accuracy and well-finished surfaces largely depend on finishing operations. (7) Now you can start OUTPUT. Displays on the left-hand side of the screen: Obj. No.: Machining: Tool m: Z mm: Time: The drawing object currently processed. Type of machining. Tool diameter in millimetres. Z-axis depth in mm for the object. Elapsed time.

If you control the Z-axis manually, PCLathe awaits confirmation for each object until it continues output. If it is PCLathe-controlled, the Z-axis rapids to the upper material surface (Z zero position -0.5mm) after the tool has approached the next object to be cut. Subsequently the tool will plunge into the material (+0.5mm) at Z operating speed. Once the system has finished milling the object, the tool retracts out of the material and moves back to the Z=0 position. Now one object is completed and the tool moves to the next. Press F9 mm/s from the F8 System menu, to set the speeds. The system only displays the speed parameters for Z-axis operation and Z-axis rapid move if the Zaxis is PCLathe-controlled.

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1.3 Contour
Lathe

F3

In contour mode, you can instruct the system to automatically turn any shape on your lathe. Press F8 Tool from the F8 System menu to select a tool shape before you switch to Contour mode. The tool shape you select sets the machining direction. After you changed into contour mode, PCLathe prompts you to specify the following parameters: 1. Number of contour loops (see also 1.2 Start). 2. Max rate of cut. Subsequently, the program automatically computes the required number of runs. These tool runs may result in less material removed than the maximum value you entered. This is due to the fact, that the last tool run is always performed in chuck direction resulting in a different rate of cut depending on material thickness. 3. Finishing cut. If the system displays the error message "Check entry", you may have entered a greater value for the finish operation than for the rate of cut itself. The last tool run (finishing cut) is automatically performed in chuck direction (exception: LH Tool). This operation removes the amount of material previously specified for this parameter. New in version 3.0: The Finishing speed parameter is located under F3 Global in the F8 System menu. This speed is constant for each drawing and will also be saved along with it. When using the contour tool, you can decide whether or not to cut off automatically after machining the contour. If you select Yes, enter the Cut-off feed speed in mm. The Contour mode is designed for circle functions, freehand lines or cones (e.g. a chess piece), and allows bidirectional cutting. For operation in contour mode, X may not be negative at any system point. The bright red lines in the illustration (of a bad example) indicate exactly the positions where X is negative. Moreover, the last point must be on Y=0, otherwise a shift by the difference to Y=0 would result from each run. If you are using a frequency converter, pressing F3 Contour will activate the spindle drive motor. Its speed will automatically adjust to the current diameter and cutting speed. The F8/F9 keys (now displayed red) allow you to modify the cutting speed at any stage (this also changes the motor speed). Pauses in the tool run (F8 Pause from the F5 Edit menu) are not possible in contour mode. 89

When processing a drawing in contour mode, difficulties may arise from the fact that backward runs (if Xmm=0) are most often programmed using a faster speed than forward motions. If the system processes the drawing in a forward movement (contour tool), there will be no problem; in reverse motions, however, the system will use the programmed return speed for cutting off material. Therefore, the program sets such reverse motions automatically to the current Compound slide forward speed minus 0.01 (F8 System menu F9 mm/s). Subtracting 0.01 offers the advantage that the speeds changed by the program can be corrected manually later on. The changes made by the program become visible if e.g.: a forward run = 0.5mm/s and a reverse run = 3mm/s have changed to forward = 0.5mm/s and back = 0.49mm/s. (A rather difficult situation!) Displays on the left-hand side of the screen: see 1.2. Cancelling: see 1.2.

1.3
Mill

SIM (Simulation)

F3

This function is basically the same as F2 Start. Other than in Start, the program runs faster, does not prompt you for parameters, and skips the Z moves. The simulation enables you to check the object sequence during output, whether toolpaths touch, and whether they follow the correct coordinates. T TIIP P During output, you can zoom into your drawing for a detailed view. If the pencil is not near the area you want to zoom in on, open the F8 Main menu and move it closer to that point. Next, zoom into the drawing, and press F3 Sim to monitor the toolpath details. Displays on the left side of the screen: see 1.2. Cancelling: see 1.2.

1.4

La/Mi (Lathe/Mill)

F4

Switches between the lathe and mill programs. See also The Mill Program.

1.5

EDIT Submenu

F5

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Switches to edit mode. The menu display shows Edit (see also section 2.0). In edit mode you can manipulate points (move, delete, etc.), form circles from lines, scale the entire drawing size, or view the finished part (Lathe). In Mill mode, you can also manipulate objects if the selection line is on the grey path to an object. Changes will then be marked bright red. In this case the F1 and F4 keys will also change their functions. If an object is coloured bright red, it is selected/highlighted and can be modified.

1.6

SCREEN

F6

Displays the complete drawing on your screen. The cross-hair cursor moves to the last point of the drawing or to the origin. Use the SCREEN function to adjust your drawing to the size of your screen or to place the pencil/cross-hair cursor on the last system point in your drawing.

1.7

Disp (Display)

F7

Switches display of system points and object numbers on and off. It has the same function as the D key.

NEW: in Ver3.0 Rel 07:

Lathe If a line is parallel to the part the diameter displays directly at this position. If one point is displaced in Y direction, even if it is only 1/100 millimetre, the pitch (shaft dimension) will not display.

1.8

SYSTEM Submenu

F8

Switches to the System menu. The menu display shows System (see also section 3.0). This menu lets you set system parameters such as material height and width, tool settings and global definitions.

1.9

FILE Submenu

F9

Switches to the File menu. The menu display shows File (see also section 4.0). Here you can load, save or delete drawings. This menu also includes the HPGL Import and Read profile coordinates functions.

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1.10 Exit
Use this function if you need to exit the program.

F10

If you started a new drawing and have not yet assigned a file name, the program will ask you if you have saved the new drawing. If not and you want to save the drawing, press ESC to save the drawing in the File menu. If you press ENTER, the entered points will be lost. If you have loaded a file, PCLathe will ask you if you want to save the drawing again in order to save any changes. If you confirm Save current configuration? with Yes, the program will save your settings (e.g. used tools, speed settings, the file name of the last drawing) to you hard disk and reload them automatically on next program start.

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2.0 EDIT Menu

F5 From Main Menu.

Now the function keys have a different assignment (see below). The white and red dotted line displays the selection of a line segment. On initial switching into the EDIT menu, this selection is the last segment line or the last system point in your drawing. In PCLathe mill mode, the selection line jumps to the first drawing object. You can move this selection with the ARROW LEFT/RIGHT keys. All actions you can perform in the EDIT menu refer to this selection line. You can also use all other keys (see also keys listed in section 5.0).

2.1
Mill

Edit (Submenu)

F1

When the selection line is on an object, this object becomes bright red, and you can change its properties. Note the status bar displays. -Tool Diameter Enter the new diameter for the selected object. If the drawing contains other objects with the same diameter, PCLathe will ask you whether to change all objects. Press ESC to change only the current object and ENTER to change all objects. -Z Millimetres Enter the new Z depth for the selected object. If the drawing contains other objects with the same Z depth, PCLathe will ask you whether to change all objects. Press ESC to change only the current object and ENTER to change all objects. The tool plunge depth (Z Millimetres) relates to single output with Auto Z depth loops=1. If you want to cut deeper into the object than the amount of material the tool can remove in one operation, you will have to use Z depth loop settings >1. See also 1.2 (2). -Machining Here you can change the type of machining for the selected object. If you press SPACE to display cutter compensation, you can see the type of machining currently used for this part: Inside, Outside, or Centre. -Sequence No. Independent of the object's object number, you can assign a new number for the cutting sequence. The program will swap objects according to the number you entered, as it is impossible for two objects to have the same output sequence number. T TIIP P

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Deleting objects also removes any order assigned previously. Therefore, assign the sequence numbers for your objects in the final stage of your work. -Cutting direction If you confirm with ENTER, nothing will change; pressing ESC changes the cutting direction (only with objects having an inside or outside groove). The cutting direction is extremely important for deciding whether to use conventional or revolving milling. On a compound table with recirculating ball screws, the cutting direction is less important, but will still affect the cut groove's quality. T TIIP P Use clockwise direction for objects located at the outside and counterclockwise direction for objects on the inside.

Live milling results in a smooth surface.

2.2

Paste

F2

Lathe and Mill Insert a new system point into the selection line, and move the new point using the ARROW keys (also note the millimetre displays). Using the X and Y keys, you can also enter millimetre values directly. To undo the system point move press C. Press ENTER to accept the new point. The paste function remains active, and you can navigate with the ARROW keys to insert additional points. You may also press ENTER ten times and then move the points created on top of each other. Pressing F2 or ESC deactivates the function. Mill If you copied an object (using F8) and another (or the same) object is selected, you can paste the copied object. The ARROW keys allow you to move the object to its new position (note the millimetre displays). 94

Using the X and Y keys, you can enter millimetre values directly. To undo the new system point move press C. Pasting does not deactivate the paste function. Therefore you can continue to paste with ENTER until there are no more points available (or until you get tired of pasting). The INS key is coupled in parallel with the F2 function key.

2.3

Cut (Remove)

F3

Lathe and Mill This function deletes the current system point that forms the selection line. It does not affect other points. Pressing the DEL key repeatedly, allows you to delete complete sections in your drawing (e.g. with radii). Attention: You can only undo the last deleted point (using Undo F7). Mill Removes a selected object without copying it into the internal program buffer. Note that for technical reasons cutting will remove the output sequence of objects. The DEL key is coupled in parallel with the F3 function key.

2.4

Arc of a Circle

F4

Lathe / Mill The selection line becomes an arc of a circle. Use the ARROW keys to set the radius, and press ENTER to convert the line into an arc. The number of newly inserted points depends on the Circle resolution value from the SYSTEM menu's Global Settings (F3). Monitor information display: -Radius Radius display in mm -Delta Difference between selection line and arc in mm. Arcs do not support pauses (see 2.8) at individual points. The program sets the tool's feed speed (for turning operations) to the slowest speed set under F9 from the System menu. 95

T TIIP P The Scale function enables you to form ellipses from arcs (see 2.6 SCALE) The F1 and F2 function keys let you switch the angle from <180 to >180.

See illustrations above.

2.4
Mill

Rot. (Rotate)

F4

Allows you to rotate a selected object. Use the ARROW keys to rotate an object by 10, and CTRL + ARROWS to rotate it by 90, or press the W key to enter the desired angle. The advantage of using the W key is that the entered angle is stored for the next object to be rotated with the W key.

2.5

Move

F5

Lath and Mill You can use the ARROW keys to move or relocate the current point (display: Curr. Point) that defines the selection line. Alternatively, use the X and Y keys to enter the millimetre values directly. Pressing the W key allows you to change the angle of the selection line that shows the point to be moved. The other line of your selection will be adjusted automatically. Press ENTER to confirm the new position. The selection remains preserved, so you can move the same point again until it fits in its final position. Turn material display mode on (by pressing SPACE) to view the results of your move (turning). The M key enables you to move the entire drawing or part of it. E.g. if you are on Curr. Point=123 (shown in the left hand side of the screen), this command will move all points following this point (incl. 123). 96

T TIIP P With CTRL depressed, you can use the ARROW keys to jump to the next point without leaving move mode (see also keys listed in section 5.0). If you moved a point using the X or Y key, the value remains stored. The next time you use these keys to move a point you will just have to confirm with ENTER. This makes it really simple to move e.g. 13 points by 12.85 mm to the left or up (see also X and Y Keys). New in Ver3.0 Rel05: You can use the MINUS key to reverse these values. Mill Use F5 to move a selected object by the distance of the Step Size (or using the X and Y keys, see above), or press the W key to change the angle of the grey entry line (e.g. for positioning drill points).

2.6

Scale

F6

Lathe and Mill The Scale function let's you enlarge/reduce the size of your entire drawing, e.g. to adjust it to a different material diameter. If you wish to scale the entire drawing in Mill mode, you must make sure that no object is selected (i.e. highlighted in bright red). After pressing Scale, a horizontal black and white selection line becomes visible. Use the ARROW UP and DOWN keys to move this line. Initially this line is set to full material diameter (top of co-ordinate grid) in order to achieve a 1:1 height-width ratio. If you move the line to a certain point, this point will fasten to the line and all other points will adjust in the correct ratio. After you set the scaling centre line with ENTER, you can start scaling your drawing using the ARROW keys. You can also use the X and Y keys to enter millimetre values directly. Monitor information display: -X Factor: scaling factor in longitudinal direction - Y Factor: scaling factor in transverse direction The size changes with the currently set step size. Press ESC to restore the original drawing size without leaving scale mode. Pressing ESC again deactivates scale mode. To accept the new size of your drawing, confirm with ENTER.

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T TIIP P The Scale function allows you to mirror the entire drawing in both X and Y direction. Mill F6 allows you to scale a selected object (highlighted in bright red). Holding down CTRL and pressing the ARROW LEFT or RIGHT key simultaneously will scale the object evenly in X and Y direction. Scaling affects the external contour depending on the step width. Object scaling also enables you to mirror objects. If you reduce the object size using the ARROW RIGHT key until it is only a vertical line and then continue to press the key, the object mirrors over the object origin. (The displayed factor will change from 1.00 to 1.00). The reference point for scaling is the object origin.

2.7

Undo

F7

You can undo once all last actions you performed in Edit menu by pressing F7.

2.8

Pause

F8

Lathe and Mill Waiting period for which the program dwells at a given system point. Press any key to cancel waiting at any time. You can also enter pauses in milliseconds.

2.8
Mill

Copy

F8

After you selected an object (object is red), you can copy it. Press F8, and you will get the message: Object copied to internal buffer!. Now you can paste it at the same or any other position by pressing F2 (see 2.2). This method also enables you to copy objects from one drawing into another: Load a drawing, press F5 to access the Edit menu, select an object, and copy it to the internal buffer by pressing F8. Now load a new drawing (or start one). Use F5 to access the Edit menu again, select an object, and press F2 Paste. To paste your object in front of the selected object, press ENTER. If you want to paste it only once, press ESC, or F2 again. To paste the object several times, press ENTER repeatedly. Each time you press ENTER, a new instance of the object will be pasted. 98

2.9

mm/s

F9

Lathe / Mill Subsequent adjustment of feed speed for a line segment. If, after entering the new speed, the program detects that other points have the same (previous) value, it will ask you whether to change all system points. Confirming with ENTER will change all points with identical values, ESC will change only the selected point to the new value. Mill If you select an object (bright red), the program will prompt you to assign a new feed speed to the entire object. This value will be taken from the object's first line section.

2.10 MAIN
Returns you to the Main menu.

F10

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3.0 SYSTEM Menu

F8 From Main Menu.

In this menu you will set system parameters. Procedures on the different screens are similar as you either accept default values with ENTER, or enter new values directly. Note: The System menu items from version 2.0 are now located in the adjustment program (SYNCUTIL.EXE). ATTENTION: If you wish to change values in your drawing, you will have to do this via the Edit menu. The System menu values are designed for using the correct values when creating the drawing.

3.1

Matl (Material)

F1

Material Settings. Lathe -Cutting speed (m/min) The value is in m/min. Determine the required cutting speed for your application (e.g. from a reference book table). Cutting speed and material diameter/actual size will be used to calculate the spindle speed, displayed in SRevs (rpm), and will also be output to an attached speed regulator. Lathe / Mill -Material size (X mm) The value is in mm. The length is displayed as a blue grid. Length of material is from origin to chuck (for turning), and from origin to material end (for milling). -Material size/diameter (Y mm) The value is in mm. The width/diameter is displayed as a blue grid. The horizontal yellow dotted line at the centre represents the centre line of the part to be turned (grey points with milling). Lathe -Drill hole diameter (in mm) Here you can predefine an initial drill hole in millimetres. This drill hole is useful as a reference point when drawing. To remove a defined drill hole, enter the value -1. The drill hole diameter is of special importance when working with a right angle tool, as this is the position where the program starts working - basically the origin for output. -Drill hole length (in mm) After defining a drill hole, the program will prompt you to enter the drill hole length.

100

If Auto Cut-Off (Main menu, F2, F3) encounters a drill hole, it continues machining for the next 0.5mm and returns to the starting point.

3.2 3.3

Not Assigned Globl (Global)

F2 F3

Global Settings: Lathe -Loop run path in mm: The loop run is a complement to compensation for play. A loop run is performed when the tool - coming from the back end - passes the material's left or right side on a parallel path.
no Loop run Loop run

The loop run keeps the turning tool under permanent pressure. Normally, this value should be slightly higher than the value of compensation for play. To test if the tool travels correctly along the loop, an even higher value can be set, e.g. one millimetre.

Lathe / Mill -Finishing speed (mm/s): In PCLathe 3.0. the finishing speed is no longer a default but a real speed specification. When saving a drawing, the finishing speed will be saved along with it. The entered value is used for both the finishing speed in turning and cleaning speed in milling operations. In milling operations, the finishing speed is called cleaning speed. Mill -Dwell (drill/plunge): When a milling tool approaches an object, the drill plunges into the material. After reaching the required Z depth, the tool dwells at the bottom of the hole. This allows it to produce a clean surface on the milled part. Lathe / Mill -Circle resolution 1-15. With this parameter, you can predefine how many points per circle segment the program will generate. 101

The circle resolution also affects the creation of radii in the Edit menu. A high value yields a high number of points and a low value a low one. Changing this value later is currently not possible. When creating contours with an outside or inside surface (milling), use a high value. With contours that are located within other contours you can reduce this value to keep the number of system points down. -Create scaled drawing: Factor : 1.0 the drawing is copied in full scale Factor : 2.0 values entered via the X and Y keys will be multiplied by the factor 2, a value of 0.5 divides the X and Y values by two. This allows you to enter an over/undersized model drawing at a scale that fits the required dimensions.

3.4 3.5 3.6 3.7 3.8

Not Assigned Not Assigned Not Assigned Not Assigned Tool

F4 F5 F6 F7 F8

Tool Settings. Lathe -Tool shape 1=RH 2=LH 3=Contour 4=Cutting Tool 5=Right Angle Tool (1) RH Tool The drawing is interpreted as the path for output. Machining direction in contour mode is unidirectional (towards the chuck). (2) LH Tool The drawing is interpreted as the path for output. Machining direction in contour mode is unidirectional (from chuck to tailstock).

102

(3) Contour Tool The program interprets the drawing as an envelope and generates tool radius compensation automatically. The envelope interpretation is due to the fact that the tool does not follow the drawing line, but rather the corrected one. In contour mode, machining is bidirectional, i.e. the tool cuts during both forward and reverse motions. Radius compensation in this context has the following peculiarities: Avoid extremely sharp angles when drawing (see illustrations), because points at the tip of angles will 'step across the zero line' processing. In case you need a sharp angle nevertheless, insert a second point at the angle. As a result, the drawing should look like a pyramid with its top cut off. It will do to insert the new point at a distance of e.g. 1/10mm in X direction before the point at the tip. Inserting this point is particularly important for tool moves in contour mode. If the tip is below the zero line radius/2, this point will be omitted during output and cause a fault. The Xmm and Ymm displays seem to show wrong values during output because X/Ymm are relative values measured from the starting position. Note that the contour tool centre starts machining outside the material at a distance of the cutter radius. (4) Cutting Tool The program interprets the drawing as a path. Machining direction in contour mode is also bi-directional (i.e. cutting during forward and reverse tool movements). When drawing with the cutting tool, its width its displayed as a dotted grey line on the right side of the tool (unless material display mode is activated, SPACEBAR). If you activate material display, the actual tool width will appear in your drawing. (5) Right Angle Tool When working with the right angle tool, make sure you create your drawing the normal way (i.e. starting point is origin, end point is on zero line). However, the starting point for output is not as usual in the lower right corner, but at the lower outside diameter of the drill hole. When creating your drawing, the last point must be located at absolute Y = 0.

103

Use the F3 Simulation command from the Main menu to make yourself familiar with right angle tool operations. If the tool is e.g. 12mm wide, the tool width specification = 12mm will show whether the tool or the boring bar will fit the drill hole or not. -Tool Width The program uses this parameter only with the contour tool. With the other tool types, the tool width serves for visual comparison of cutter geometry and drawing. Milling -Tool diameter in mm This value is used for tool radius compensation. If you press SPACE in mill mode, the tool displays as a grey circle on the monitor. The red path is the actual tool path. When creating your drawing, you will have to make allowances for cleaning. If you want to machine your part with 6mm tool, and you have set the Distance before cleaning (in System -> Global) to 0.2mm, you will have to test the contour of your drawing with 6.4mm tool. T TIIP P Specifying the tool diameter allows you to use a little trick to achieve a 3D effect: Create an object, copy it, and paste it e.g. three times. Now assign each pasted object a larger tool diameter. Simulate output using F3 Simulation. -Default Z depth in mm This is the pre-set Z depth you use when creating your drawing. If you set this parameter e.g. to 5mm and draw a drill hole and a groove, the system will propose this value when prompting for Z axis depth. You can accept this value with ENTER or overwrite it with a different one, e.g. 5mm for the drill hole and 7mm for the groove.

3.9
Lathe

mm/s (Feed Rate)

F9

-Compound slide forw -Compound slide reverse -Saddle slide forw -Saddle slide reverse Mill -Mill -Z axis operation controlled)

(Y in mm/s) = (Y in mm/s) = (X in mm/s) = (X in mm/s) =

(X u. Y in mm/s) = (Z in mm/s) =

(only if Z axis is PCLathe-

These values are pre-set values for automatic use in drawing.

104

If you start a new drawing, adjust these values first. Through practical experience in operating this program on your machine you will soon find out which values to enter for steel, aluminium or reverse movements. To change values later on, use the EDIT menu! Typical feed values for turning are app. 0.2mm/s to 1.5mm/s. Typical feed values for milling are app. 0.5mm/s to 3mm/s. Lathe / Mill Rapid moves have the following speeds: -Compound slide -Saddle slide -Z axis rapid move (mm/s) = (mm/s) = (mm/s) = (only if Z axis is PCLathe-controlled)

The program uses these values for live operations (Main menu F1), compensation for spindle play, and adjustment tasks. Set these values to the highest possible level to achieve a reasonable machining speed, but keep them within a range that ensures safe operation. Typical values for rapid speeds are about 5-15 mm/s.

3.10 Main (Back to Main Menu)

Returns you to the Main menu.

F10

105

4.0 File Menu

Loading, Saving, and Creating New Drawings

F9 From Main Menu.

F1

4.1

New

Creates a new drawing and re-initialises the program.

4.2

Del (Delete)

F2

Deletes a file (drawing) from your hard disk. You may be able to recover a deleted file using the DOS undelete command.

4.3

Save

F3

Saves your current file (drawing) under its current name to disk.

4.4

S as (Save as)

F4

Saves your current file (drawing) under a new name that you enter.

4.5

*.PLT (HPGL Import)

F5

The HPGL import function allows you to import program files (drawings) from third party programs. HPGL is an acronym for Hewlett Packard Graphics Language. HPGL enables you to use programs such as COREL-DRAW or Auto CAD to load drawings into PCLathe. However, you will have to modify these to some extent in PCLathe after import. Modifications include: Matching start and end points that are not congruent, assigning tool diameters, depths, speeds etc. COREL sometimes inserts a point at the first position of an object. An indication for this is that the small yellow numbers (MAIN F7 or D key) of other objects are no longer displayed. Simply delete this first point. If e.g. an imported COREL letter caption appears to be OK, perform a simulation run on it. Check tool diameter, depth, speeds, etc. in the Edit menu settings.

106

Letter captions created in CORELDRAW are perfectly suited for engraving. Spherical tools or engravers from the PROXON accessories produce good results in aluminium or brass. For these operations the material needs perfect horizontal adjustment. A height offset of 1/10mm will show immediately in your engraving. When creating your drawing on a third party program, make sure you save the drawing as closed polyline. Besides that, save only vectors, rather than Bezier curves. After creating your drawing, use the Export function from the File menu of your program (COREL etc.). Check that the file format for export is set to HPGL. Options such as pencil width, colours, etc. are not relevant. Specify C:\PCLATHE as the target directory for your drawing, and enter a name, e.g.: TEST.PLT. Note: If you wish to use a drawing in the Lathe program, you will have to process it in the Mill program first. See also EXCERCISE No. 5. The PCLathe installation disk comes with a file named Horse.plt. This file was created in Corel Draw and contains the drawing of - a horse. To make yourself familiar with this file, access the Main menu, and press F9 File. The MENU display in the top left corner of your screen tells you that you are in the File menu. Now press F5 *.PLT and you will see at least this file (HORSE.PLT). Select it using the ARROW keys. Next, press ENTER. The program will prompt you for a scale factor. The smaller the value you enter, the bigger the object will display in PCLathe, and vice versa. You may have to repeat this procedure once you find out that the drawing has been loaded with a too small or to large size. Alternatively, you can use the scaling functions from the Edit menu, F6 Scale, to scale the drawing to the required size. PCLathe V 3.0 includes the improved HPGL import version V1.1. If you run into problems with this feature, do not hesitate to contact your authorised dealer.

4.6 Not Assigned 4.7 *.KOO (Load Coordinates)

F6 F7

Loading profile coordinates. This function allows you to load co-ordinate sets (in our example HQ-15-8.KOO of an airfoil). As a profile has only one point at the end rail, PCLathe automatically inserts a second point at Y= +0.1mm to avoid a too sharp angle (see also Radius Compensation). 107

4.8 Not Assigned 4.9 Load

F8 F9

Loads a drawing from you hard disk into the computer. This action overwrites your current drawing in PCLathe.

4.10 Main
Returns you to the Main menu.

F10

108

5.0 Keys
5.1 ARROW Keys

In the Main menu, the ARROW keys move the pencil according to the value set for Step. If the motors are powered on (F1), you can use the key combinations CTRL + ARROW LEFT/RIGHT to activate continuous feed. Otherwise transverse and longitudinal feed run in sync with the step size. In the Edit menu, you will use ARROW LEFT/RIGHT only to select a line segment on which to perform editing functions.

5.2

ENTER

Pressing ENTER, you confirm (set) points; the coordinates of the point that you confirm will then be held in the main memory (program). Note the Abs and Rel X/Y displays. If you press ENTER without having drawn a new line, you will toggle between pencil and crosshair cursor display.

5.3

SPACEBAR

Toggles between material display mode On/Off. When activated, the program displays the full material diameter as a dark grey contour in the background. The part that you are currently working on displays in light grey colour. If the centre of your material moves out of the viewing area (e.g. when zoom into or moving the drawing), material display mode will deactivate. In the Mill program, the SPACE will toggle between 'visible/hidden' cutter radius compensation.

5.4

PLUS/MINUS Keys

Sets the step size in millimetres. Possible values are: = 0.01mm, 0.1mm, 1mm, 10mm, and 100mm. You can use the PLUS key to increase step size and the MINUS key to decrease it. Also When in the Edit menu, you can decrease the step size to 0.001mm. This became necessary as the general 0.01mm grid for the entire drawing was omitted for reasons of accuracy.

5.5

PG/PG Keys

Change image display size. PG zooms into the picture, PG zooms out.

109

5.6

ESC

General key for cancelling or Escaping from input. For a correct functioning of the ESC key, the keyboard's Num Lock function must be off (NUM LOCK key).

5.7

TAB

Moves the drawing on the screen (move mode). Pressing TAB once activates move mode, and you can use the ARROW keys to move the drawing. Pressing TAB again deactivates move mode. When using Circle or Move functions in the Edit menu, you can leave these active while moving your drawing.

5.8

CTRL

This key assumes a special role as it is only an auxiliary key. However, if you work a lot with this program, you will surely never want to miss it again. CTRL only works in combinations with either ARROW LEFT or RIGHT (see table below). Press CTRL first and hold it, and then press one of the ARROW keys simultaneously. Main menu Move drawing [F1] On With [F1] On: X key With [F1] On: Y key Edit menu Move drawing Mill: selected object Mill: rotate object Mill: scale object Mill: move object Move Circle Paste ARROW w/o CTRL small move move slide by steps rapid travel rapid travel step size one point step size one point rot. angle = 10 X and Y separate move object move point set radius past point ARROW + CTRL large move continuous feed travel at operating speed travel at operating speed step size ten points step size one object rot. angle = 90 X and Y in sync move to next object move to next point circle to next point paste into next point

110

5.9

X/Y keys

Entering values directly via the keyboard. After pressing X or Y, the status bar prompts you to enter a value in millimetres. If you enter e.g. X = 12.34 and press ENTER, the pencil will advance 12.34mm. For negative values enter a leading minus sign. e.g.: -12.34 (ENTER). If you enter nothing at all, and you just confirm with ENTER, the pencil will jump to the X or Y zero line of your drawing. If you have already entered a value and you want to place the pencil on zero, press the C key to clear this value from memory. The last value you entered (in the Edit menu) remains stored. This allows you to move many points quickly by e.g. 12.34mm. E.g. Press: -F5 Move -X 12.34 -enter 12.34 -ENTER Start: -CTRL+ARROW LEFT (move to next point) -X (value = 12.34 already in display) -ENTER, ENTER go back to the start and repeat the last three steps as often as required. NEW: in Ver3.0 Rel05: You can use the CTRL+X/Y key combinations to move the slide at operating speed. This is very useful when facing a surface in Mill mode or cutting off just one part in Lathe mode. Also have in mind that you can now use the MINUS key to reverse the sign of values that you entered. E.g.: 50mm to the left at operating speed, and then 50mm to the right at rapid speed. Enter: CTRL+X, 50, ENTER the slide travels 50mm to the left at operating speed, X, - , ENTER the slide travels 50mm to the right again at rapid speed. See also MINUS key. NEW: in Ver3.0 Rel07: Entering dimensions directly is now possible through Alt+X and Y key combinations. The values that you enter will remain stored separately from the others ( X/Y only, or CTRL+X/Y). E.g.: ALT+X, 33, ENTER.

5.10 W Key (Angle)

Entering Angles Directly. When drawing in Main menu: 111

If Rel X and Rel Y = 0, the program will first prompt you to enter the angle in degrees and then the radius of the new line. If either Rel X or Rel Y are not 0, the program will use this distance as the radius and will prompt you directly for the angle's degree value. In Edit menu: Enter angles: and in mill mode: to move points, to move and rotate objects.

To enter 0 you will have to enter 360 instead. You can also enter angles >360 and <0 (e.g. -10).

5.11 C Key
The CLEAR Key. Sets Rel X and Rel Y to zero when drawing in the Main menu or using functions from the Edit menu. Pressing C also resets the virtual calliper gauge displays (the small box on the right side with the X, Y, and V values).

5.12 A Key (Circle/Ellipse)

Mill Draws a circle when working in the Main menu (in mill mode). If Rel X and Rel Y = 0, PCLathe will prompt you to enter a radius. If either Rel X or Rel Y are not 0, this distance is used as the radius. If both Rel X and Rel Y are not 0, the program draws an ellipse with radius X = Rel X and radius Y = Rel Y. NEW: in Ver3.0 Rel07: The system prompts you for the end radius. Confirm the default value for normal circles. For the worm function, enter a different one (see also the Worm Exercise No.7). PCLathe prompts you to enter the angle of the circle in degrees. You can use the emerging link line between the end points to continue your drawing, or create an arc with an angle >180 using F4 Circle from the Edit menu. Next, PCLathe prompts you to enter tool diameter, Z millimetres, machining mode, and machining direction for output. T TIIP P For objects located on the outside, machining direction is Clockwise, and for objects on the inside Counterclockwise. See also 2.1 Machining direction 112

5.13 R Key (Rectangle)

Mill Draws a rectangle when working in the Main menu (mill mode). If Rel X and Rel Y = 0, PCLathe will prompt you to enter the X and Y distance. If Rel X is not 0, the program prompts you for the Y value and uses Rel X for X. If Rel Y is not 0, the program prompts you for the X value and uses Rel Y for Y. If both Rel X and Rel Y are not 0, both values will be used for the rectangle. Next, PCLathe prompts you for the remaining object specifications. T TIIP P // For objects located on the outside, machining direction is Clockwise, and for objects on the inside Counterclockwise.

5.14 HOME
Mill If you have powered on the motor with F1 On, the Z axis will move up by the Step size value, if it is PCLathe-controlled. The tool moves away from the material.

5.15 END
Mill If you have powered on the motor with F1 On, the Z axis will move down by the Step size value, if it is PCLathe-controlled. The tool moves towards the material.

5.16 H Key
Help on PCLathe key assignment. You can use the menus.
H

key in the Main and Edit

5.17 D Key
Toggles between system display points on or off (in both lathe and mill mode). In mill mode, it also switches the grey entry lines to the objects on or off. Usage: If your drawing contains many objects and you want to move these or use the zoom function, switch off system points (D key) display points and (SPACEBAR) material display mode first, move your object or zoom, and then reactivate point and material display. ??? In the Main menu, D and F7 perform the same function. 113

NEW: in Ver3.0 Rel07: Lathe If a line is parallel to a part the diameter at that point directly displays in your drawing.

5.18 T Key
Adds a text comment to your drawing. Always use this function. Even the smallest special detail of your drawing may slip your memory after a couple of month. A reminder entered in this way may save material and tool costs!

5.19 MINUS Key

Extremely useful: The Minus key allows you to reverse the sign of any value that you entered. This feature works in live operation F1=On and also when creating the drawing. 1. X=12.34, ENTER 2. X, then only , and ENTER

5.20 Z Key
Moves the Z axis if F1 is On. Positive values move the axis up, negative ones down.

114

5.21 M key
In Edit mode, you can use the M key to move the entire drawing or parts of it.

5.22 G Key
Displays or hides the blue grid. This is convenient when viewing a part to be turned or during milling operations.

115

6.0 Displays
6.1 Abs.X and Abs.Y

Distance between pencil and origin in absolute millimetres.

6.2

Rel.X and Rel.Y

Distance between pencil and current system point in relative millimetres.

6.3

F (mm/s)

Feed speed in millimetres per second. This value cannot be displayed in millimetres per revolution, as drive motor and feed drive operate independent of each other. If you normally work with mm/rev, the values are almost equal when related to a spindle speed of 1000 rpm.

6.4

Angle

Angle value of current drawing line in degrees.

116

6.5

File

Name of the drawing currently loaded in your main memory (program). The physical DOS name has the .DAT extension for lathe drawings and .FRS for mill drawings. The program automatically appends these extensions when saving a file and removes them on loading, e.g.: DOS=CUP.DAT, in program file=CUP.

6.6

Curr. Point

Number of the current system point. In the Edit menu, this number tells you immediately whether you are at the beginning or at the end of your drawing.

6.7

Step

Step size in drawing/live operation (F1 On). Possible values include: = 0.01mm, 0.1mm, 1mm, 10mm, and 100mm. Use the PLUS/ MINUS keys to increase/decrease the Step value. In the Edit menu, it is also possible to set a step size of 0.001mm.

6.8

CS (m/min)

Lathe Display Cutting speed in metres per minute. Predefined value under F1 Matl from the F8 Syst. menu. Look up the required cutting speed for your tool and material in a table, and enter the determined value. The program uses the cutting speed and the material diameter you enter to calculate the desired motor speed and to control the electronic speed regulator (if connected).

6.9

SRevs (rpm)

Lathe Display Display of desired spindle speed as calculated by the program.

117

6.10 Mat
Lathe Display Material diameter in mm. Entry under F1 Matl from the F8 Syst. menu.

6.11 Shaft
Lathe Display Shaft diameter in mm; the program calculates this value at the current position or takes it from the pencil position.

6.12 Z mm
Mill Display Pre-set Z depth, entry set up in F8 Tool from the F8 Syst. menu. Or actual Z depth, if an object is selected in Edit menu.

6.13 Tool
Mill Display Pre-set tool diameter, entry set up in F8 Tool from the F8 Syst. menu. Or actual tool diameter, if an object is selected in Edit menu.

6.14 Material Y
Mill Display Material width in mm. Pre-set size, entry set up in F1 Matl from the F8 Syst. menu.

118

6.15 Material X
Mill Display Material length in mm. Pre-set size, entry set up in F1 Matl from the F8 Syst. menu.

6.16 F (mm/s)
Feed speed of the actual distance. If you have a slow computer, the desired speed may exceed system performance and the F (mm/s) value is displayed in red. This value also represents the maximum speed and may vary for all axes, depending on the Steps/mm value. To test the relations of these values, create a drawing that includes a horizontal, an inclined, and a vertical line. Use F9 mm/s from the F5 Edit menu to assign these lines a speed of e.g. 78mm/sec. Then start output by pressing F2 Start from the F10 Main menu.

6.17 X mm
Millimetres moved in X direction, see 1.2 Start. The C key allows you to zero this value.

6.18 Y mm
Millimetres moved in Y direction, see 1.2 Start. The C key allows you to zero this value.

6.19 Z mm

NEW: in Ver3.0 Rel07: Actual travel in Z direction in, see 1.2 Start. Pressing the C key allows you to reset this value.

119

7.

The Calibration Program (SYNCUTIL.EXE)

This program serves to adjust and/or calibrate your new system. Exit PCLathe, and start the external SYNCUTIL program. Press syncutil, and press ENTER.

7.1

On

F1

The stepper motor at the axes run in sync with the ARROW keys. The program is in live operation mode. You can stop live operation at any time by pressing ESC. Pressing F1 again (or ESC) deactivates this function. In which direction do the slides have to move? Here in the Calibration program:

Lathe:

Arrow left Arrow right Arrow up Arrow down Arrow left Arrow right Arrow up Arrow down Home End

Slide to the left Slide to the right Slide back Slide forward Slide to the left Slide to the right Slide back Slide forward Tool away from material Tool towards material

Milling machine:

7.2

Time (Time Adjustment)

F2

As PCs have varying operating frequencies, this function allows you to make time adjustments in order to achieve correct feed speeds for all operations. Especially changes in hardware components e.g.: a new computer, a different video adapter, a new motherboard, or upgrading to a math co-processor (highly recommendable), and stepper motor modifications (step angle or gear reduction) require time settings to be readjusted. During time adjustment, the program adjusts the operating speed of your computer to the slides' feed speed in mm/sec. You may have to repeat this procedure several times because the program needs to determine your computer's processing speed first. However, these values should adjust after approximately three runs. You can also readjust these values manually (see 7.4). The varying operating frequencies result in an individual maximum program processing frequency (V in mm/sec) for each computer. To determine this frequency 120

initially, the program travels a certain distance without program delay. Therefore, slide feed speed on a 386 computer may be limited by its processor and not by the attached hardware (motor power and of slide friction). Next, the program applies a defined delay and travels the same distance again. The program uses the resulting difference to calculate the delay for a certain feed speed. The disk shipped with the program contains a small test drawing TIMES.DAT for verifying the calculated values in lathe mode. With a 10mm compound slide movement at 1mm/s, and a 10mm saddle slide movement at 1mm/s the time needed for each distance should equal 10secs. If tolerance >20%, repeat the adjustment procedure or readjust manually (see Adjustment 7.4). Also use different feed speeds and distances for testing e.g. distance=1mm at F=0.1mm/s.

7.3

Gear (Determining Gear Reduction)

F3

At this point the gear adjustment program (GETRIEBE.EXE) from PCLathe v2.0 is implemented. For details on operation refer to chapter Start-up and Calibration in this manual. This program is to be considered a pocket calculator. It does not save or modify values and it only serves to determine which gear reduction needs to be applied with a given number of steps per millimetre.

7.4

Manual (Manual Settings)

F4

The following values can be entered directly via the keyboard: - Saddle slide: - Compound slide: - Z axis: Steps/mm Steps/mm Steps/mm

- Saddle slide clearance: Steps/mm - Comp. slide clearance: Steps/mm - Z axis clearance: Steps/mm - Delay frequency: kHz

Once you have calibrated your system, you can use this menu command to tweak these settings manually. Note: Increasing the Delay frequency value will slow down operating speed and vice versa, see also Time Adjustment 7.2.

121

7.5
Lathe

Ctrl (Motor Control)

F5

Parameters for electronic drive regulation. An external D/A converter generates a 010V regulating voltage (Art. No.: 202 0010). -Electronic drive control 1=NO, 2=YES Unless you are using drive control, set this value to 1, otherwise 2. -Maximum chuck speed Calculates from current gear reduction and motor speed. -Motor run-up time before slides move: Value in seconds. When outputting your drawing, the program activates the drive motors and halts for a pre-set period before starting to process data. -Motor braking period before program continues: Value in seconds. Once the program finishes output, it stops the drive motors first, waits until the braking period has elapsed, and continues operation.

7.6

MOT (Stepper Motor Parameters)

F6

Setting Stepper Motor Parameters: -Parallel Port Address The (CENTRONICS/LPT) parallel port of a PC is a female 25 pin SUB-D connector. (Printer port) for LPT 1 = 1 LPT 2 = 2 I/O address of PC = 378h I/O address of PC = 278h

LPT 3 and 4 are not supported. -Braking Delay (Acceleration/Delay Ramp) Value for setting the starting and braking delay of the motors. This delay is required as the motors tend to jolt with too strong acceleration, loose steps and finally stop moving at all or just hum and jerk. Enter a high value for a long and a low one for a short delay. To determine the correct value you will have to perform some testing. -Length Length of braking delay (ramp length). This value is identical with Steps, so that a delay of 150 equals 150 steps. If you have set your saddle slide to e.g. 150 steps/mm, the stepper motors will accelerate/brake over a distance of 300/150 = 2mm. 122

The goal is to keep both values at a minimum and still maintain operational safety; otherwise you would waste time (which is known to be precious). You will only encounter the appropriate setting through experimenting. The program uses both values only with high feed speeds; lower speeds do not require accelerating or braking delays. The following graphics illustrate this principle: mm sec. mm sec.

Fig. 1

Fig. 2
Distance Distance

mm sec.

mm sec.

Fig. 3
Distance

Fig. 4
Distance

Fig. 1: Short braking delay ; Fig. 2: Long braking delay ; Fig. 3: Small length ; Fig. 4: Great length ;

Ignore length. Ignore length. Ignore braking delay. Ignore braking delay.

-Delay with port output This value supplies a 'certain' pulse width for motor control. For 386 and 486 PCs, you may set this value to 1, for faster computers, you will have to determine the minimum value (> 1) through testing. If this value is too low, the stepper motors will not run properly (or even not at all), and if it is too high, the motors will not be able to run at their maximum speed. I have noticed that the time adjustment procedure results in values >800-900 (Pentium II/III 350-450 MHz) the delay will have to set to approximately 50-100. Note that changing this value also affects feed speeds and requires a new time adjustment (see also Time Adjustment 7.2).

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7.7

Stick (Joystick Calibration)

F7

If you have a joystick connected to your computer, the program will automatically detect it. Calibration is required: - on initial joystick operation, - after changing its zero position, - or when using a new joystick.

7.8

X-Y-Z

F8

Setting the absolute path lengths and spindle clearance for all axes. See Start-up and Calibration in this manual. 7.8.1 Not Assigned F1

7.8.2 Z Axis Mill

F2

If you use PCLathe in milling operations, this parameter allows you to set the Z axis to stepper motor or manual control. If set to manual control, PCLathe awaits manual confirmation for each Z axis move. At this point, you will advance the Z axis manually and confirm with any key. Subsequently the program will continue until the next Z axis move. 7.8.3 Not Assigned F3

7.8.4 Abs X (Absolute X ) Calibrating the absolute path length of your saddle slide. Press F4 and follow program instructions, see Adjustment.

F4

7.8.5 Abs Y (Absolute Y) Calibrating the absolute path length of your compound slide. Press F5 and follow program instructions, see also Adjustment.

F5

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7.8.6 Abs Z (Absolute Z) Calibrating the absolute path length of the Z axis. Press F6 and follow program instructions, see also Adjustment.

F6

7.8.7 PlayX Determining the spindle play of your saddle slide. Press F7 and follow program instructions, see Adjustment.

F7

7.8.8 PlayY Determining the play of your compound slide. Press F8 and follow program instructions, see Adjustment.

F8

7.8.9 PlayZ Determining the play of the Z axis. Press F9 and follow program instructions, see Adjustment.

F9

7.8.10 Main Return to Main adjustment menu.

F10

7.9

mm/s

F9

Here you can set the different speeds for testing purposes.

7.10 Exit
Exit adjustment program.

F10

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8.
-

How to Start-up and Calibrate your machine.

Determine the mounting positions for your motors. Determine the gear reduction/multiplication. To do so, press F3 in the calibration program (see section Gear 13.0). Mount the toothed wheels/belts and fasten the stepper motors with screws and angle brackets to your machine tool. Check the toothed wheel clearance wheels must run smoothly. Do not forget to protect the gear boxes and motors against chips. Connect your motors to the control board (for details see Control Board). Connect the power supply to the control board. Start PCLathe. Connect the control board to the parallel port of your computer. Set the correct printer port on your PC (see 7.6). Switch on the power supply. Now proceed as described in the Adjustment section.

9.

Time Adjustment

The time adjustment comes first because it is not dependent on the mechanisms you use. Start the SYNCUTIL.EXE program by typing SYNCUTIL, press F2 Time, and follow the program instructions. See also 7.2.

10. Absolute Path Length and Spindle Clearance

Once the motors are mounted and connected, start the adjustment program (SYNCUTIL.EXE), switch on the power supply, and press F1 On. The system is now in live operation mode. If you press the ARROW UP key, the compound slide should travel towards the chuck. If it doesn't, swap one pair of motor coils to reverse the direction. Next, check the saddle slide. If you press the Arrow Left key, the saddle slide should travel towards the chuck. If it doesn't, swap stepper motor coils again. Now the system is ready to operate and you can make the required adjustments. Initially you will calibrate the absolute path length of the saddle slide. 126

Length Calibration: 10.1 Mount an electronic calliper gauge to the tool mounting support for measuring the saddle slide path; make sure it is in parallel alignment with the engine bed. 10.2 10.3 Deactivate live operation mode by pressing F1. Press F8 (X-Y-Z), to access the Length and clearance menu.

10.4 Press F4 Abs X. Calibration: absolute distance in X direction = saddle slide. 10.5 10.6 10.7 10.8 Confirm with ENTER. The saddle slide will advance 1,000 steps to eliminate possible play. Zero the calliper gauge. The slide will advance 10,000 steps for measuring the absolute path length.

10.9 Now you are prompted to read the calliper gauge and enter this value. To continue, confirm with ENTER. 10.10 X axis calibration is now completed; the system will display the values determined for steps/mm and theoretical resolution. Press SPACE or ENTER to return to the System menu, and then F10 to switch to the Main menu. When prompted to save the new values to disk, confirm with ENTER. The Steps/mm value, for instance, is very important and will be written to the PCLATHE.INI system start file. Checking: 10.11 10.12 Use the PLUS/MINUS keys to set the step size to 10mm. Press F1 On.

10.13 Us the ARROW LEFT/RIGHT keys to move the slide continuously in one direction, and watch the calliper gauge. If you note an increase in values (e.g. 10.00 20.01 - 30.02), you can also readjust the Steps/mm value manually. Press F4 Manual, and slightly modify the saddle slide steps/mm value, e.g. from 210.34 to 209. This should enable a feed motion of 2/100mm. If not, repeat this procedure beginning with 10.11. 10.14 Use the PLUS/MINUS keys to set the step size to 1mm and check operation by pressing the ARROW LEFT/RIGHT keys. 10.15 Use the PLUS/MINUS keys to set the step size to 0.01mm and check operation by pressing the ARROW LEFT/RIGHT keys.. Depending on the steps/mm value, the system may show the following result: E.g. 0.01 - 0.02 - 0.02 - 0.04 - 0.05 - 0.05 - 0.07 ... this the fringe range (due to programming limitations). However, after 20 or 30 steps of 0.01mm the gauge display should be 0.20 or 0.30 (+/- 0.02 of tolerance). 127

If you have a low-tolerance machine tool and you want to squeeze out the last hundredth millimetre, you may improve accuracy by modifying the second digit in the manual settings of absolute path length (F4). However, this is only worth the effort, if you have a relatively constant deviation in one certain direction when testing with a step size of 100mm. E.g. 100.00 200.01 300.01 400.02 or 99.99 200.00 299.98 399.98 Compensation for Play: 10.16 Deactivate live operation by pressing F1. 10.17 Press F8 (X-Y-Z), to access the Length and clearance menu. 10.18 Press F7 PlayX. 10.19 Confirm with ENTER. 10.20 Press SPACEBAR the saddle slide will advance 1,000 steps to eliminate possible play. 10.21 Zero the calliper gauge Press SPACEBAR. 10.22 Press SPACEBAR, until the calliper gauge display changes. 10.23 Press ENTER to complete this procedure. 10.24 Press SPACE or ENTER to return to the F8 X-Y-Z menu, and then F10 to switch to the Main menu. When prompted to save the new values to disk, confirm with ENTER. The step/play value will be saved to PCLATHE.INI system start file. Checking: Perform the test at a machine bed position where you work frequently. 10.25 Use the PLUS/MINUS keys to set the step size to 1mm. 10.26 Press F1 On. 10.27 Advance the slide two or three times in one direction, zero the calliper gauge, and advance the slide in the other direction. The calliper gauge should display 1.00. If it doesn't, readjust it manually. Press F4 Man, Saddle slide clearance. Also note the inaccuracy of the calliper gauge. 10.28 Repeat this procedure until the compensation for play works well. Now repeat this procedure for the remaining slides.

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11. Mechanical Components

IMPORTANT: PCLathe's overall accuracy and speed performance on your machine tool depends on the precision of your machine tool's mechanical components, especially: - Lead screw linearity - Lead screw play - Smooth working of spindle nut - Lead screw bearing arrangement -Thrust bearing (deep groove ball thrust bearing) ? -Plain bearing (needle bearing) with toothed belt drive ? -Slide play -Slide bed accuracy Adjusting the slides Adjust the slides as tight as possible. Smaller motors, however, may suffer an overload, if the slides are adjusted too tight. Recommended method for small motors: Loosen the clamping profile screws. Set the step size to 100 mm, and move the slide. During slide motion, tighten the screws until the load changes the motor noise. Bigger motors from 900 mNm up are less critical: Adjust the clearance as usual (without using PCLathe). If you use the clasp nut for longitudinal feed, the nut must be perfectly adjusted. Make sure, the nut is locked after tightening; otherwise clearance will change and produce inaccurate results. Besides that, the nut must have full symmetric grip to avoid premature wear. The clasp nut is expose to extreme stress. Therefore install a protective cover.

12. Handwheels
Cranks of handwheels must be folded in - or best be removed completely. Rotating cranks do not represent a major hazard for the operator, but cause the stepper motor to loose steps turning your part into rubbish. I've seen it all happen - even on trade fairs!. If the handwheel is the size of a soup plate and made of solid material (as with e.g. a GOLMATIC machine tool), you will have to remove it. Otherwise the stepper motor has to accelerate and brake this mass, and will not start without loosing steps!

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13. Gears for the Stepper Motors

Choose a speed reducing/increasing ratio that requires the stepper motor to perform about 200-300 steps/mm. Avoid values < 100 steps/mm, as these will affect resolution. It is an erroneous assumption that the highest possible number of steps/mm yields a higher resolution. The program itself achieves this by using residual values resulting from a fraction of e.g. 2.5 steps/0.01mm for calculation. If you use values over 500-600 steps/mm, you will unnecessarily slow down the system. Proceed as follows to determine axis gear reduction: Check how many revolutions of your handwheel/shaft are required for 1mm slide motion (e.g. 2mm/handwheel revolution). The 1.8 motor performs 200 steps/rev. As the drive control operates in half cycle mode, you have to double these values (= 400 steps). Try to achieve a speed reducing ratio that needs 200-300 steps for 1mm. Start the adjustment program (SYNCUTIL.EXE) that is shipped with PCLathe, and press F3 Gear: Input: Slide move / handwheel revolution mm. Input: Motor step angle degrees. Output: Number of steps/mm when mounted directly, without gear. Input: Desired steps/mm value. Output: Required gear reduction for the desired steps. The determined reduction is a standard value that must not be observed unconditionally. Use Module-1 type toothed wheels. Attach steel wheels to the motor and low noise plastic wheels to the spindle. An intermediate third toothed wheel will allow for different gears using the same spindle wheel (the handwheel is on the spindle wheel). For correct mounting clearance, place a strip of paper between the toothed wheel. The paper will supply some hundredths millimetres clearance. If possible, use toothed belts as they are low noise and slip. Use only high quality materials.

130

Belt tension: Under soft finger pressure the belt should yield 3mm. Too tight belts produce friction losses and bearing damage. If the belt is too loose, it may skip and will also produce more play. If drill holes in toothed wheels/crown gear are too small, you cannot widen them by boring for reasons of concentricity. You will have to turn them out. The wheel on the spindle shaft most often has a stress-bearing function too, i.e. it also absorbs the shaft's axial force. For this reason, lock it with a stop nut. You must not use a grub screw. Lock the wheel in radial direction using a keyway. If keyway milling is not possible, use at least two strong grub screws. Axle clearance results from the following: -Spindle and nut -Axial clearance between handwheel (toothed wheel) and slide -Toothed wheel flank clearance (not with toothed belts, elongation instead) If you cut a keyway, the wheel must be mounted onto the wheel in a locked position (no friction). Otherwise the play may change under load (always lock it with grub screws!). PCLathe requires permanently constant play. Once assembly is complete, mount a protective cover (e.g. sheet aluminium or thermally formed Plexiglas).

14. Mounting Brackets

Here you can use all your talent as a precision mechanic. However, the mounting bracket should be as rigid as possible in order to avoid vibration and resonance. Try to use existing drill holes on your machine tool. Cutting long holes in your bracket will allow you to adjust play and test other gear reductions without problems. Finally, I would advise you against the possibility to mount the bracket with the stepper motor to your work bench, as this makes it extremely difficult to avoid vibrations.

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15. Tips and Tricks

PCLathe is just as good as its operator. As a result, PCLathe is only useful to operators with sound machine tool experience. The program is designed to facilitate lathe/milling machine operation and assists you in cutting parts that would be difficult to create without PC control. PCLathe is not the auto-CNC machine that delivers parts of 1/100mm precision on its own. Lathe/Mill -Backup Write down your current system parameters (e.g.: step sizes, play, time settings, etc.), or print them out (in DOS: print pclathe.ini and press ENTER). Create a backup copy of this .INI file on a regular basis (see chapter 19 for details).

-Text Editor You can also use a text editor to edit you drawings. When loading a file created in PCLathe, you can recognize the format immediately (DOS extensions: .DAT for lathe and .FRS for mill files). After exiting the program, on DOS level, enter: edit filename.dat. -Key Routines: - Load drawing = F9, F9 - Move last point = F5, F5 (in lathe mode) - Delete last point F5, F3 (in lathe mode) -Drawing Mistakes If you made mistake when drawing on a Main menu screen (e.g. you forgot to confirm a point), and you want to go back to Rel.X = 0 and Rel.Y = 0, press the C key. -Spindle Play

132

If you have calibrated the spindle play, and cutting circles or turning radii delivers results similar to those shown below, you will have to compensate for play manually.

Too much play

Too little play

The F4 Manual function from the adjustment program enables you to adjust the play of each axis manually. If a setting of e.g. 60 steps produces a part like the one shown above on the left side, reduce this value by the difference of the edge (measure it!). For this example (with 250 steps/mm and measured 0.08mm) you enter: 250 x 0.08 = 20 , 60 20 = 40. Q: How much play does my spindle have? How many millimetres are 60 steps? A: e.g.: with 250 steps/mm , 60/250 = 0.24 -Joystick The joystick may also be mounted to the machine tool or to the chip protection cover (if it is large enough). The drawing in the appendix shows you how to use single mechanisms with push-buttons instead of a joystick. -Rotating the Entire Drawing 1. Switch to Mill mode. Draw a line from the last point of your drawing to the first one to close the object. Confirm the tool diameter, speed, etc. values. Switch to the F5 Edit menu and use F4 Rot. to rotate the drawing. Then delete the last line and return to Lathe mode. 2. With Mill drawings, you will have to break up the object structure of your drawing first. To do so, move the last point of the first object 10mm to the left or to the right. Then draw a line to the first point in your drawing. This produces a single object that can be rotated by pressing F4 Rot..

133

Lathe -Techniques Always program, pardon me, 'draw' the tool direction towards your material, so that the tool is under pressure. A change of load may lead to inaccurate results. -Speeding Up Simulation When simulating an operation using F2 Start or F3 Contour, you can increase simulation speed dramatically. Start the adjustment program (SYNCUTIL.EXE), press F8, then F4 Delay time, and enter a value between 1-100 (depending on the PC). For machine output reset this parameter to its original value. -Spindle Speed When using electronic drive regulation, you can manipulate its dynamic range. F2 Ctrl from the System menu allows you increase maximum chuck speed to achieve a decrease in actual speed, e.g. when the tool plunges. Below you find a practical example. 1. NMax. = 5,000 2. NMax. = 10,000 = 1,250 NNom = 2,500 0-10V = 5.0V NAct = 2,500 NNom = 2,500 0-10V = 2.5V NAct

-Manual If you don't like the way F3 from the System menu processes your drawing, there is always the possibility to draw the paths that guide the tool manually. Mill -Cutting Grooves Normally a groove is a simple line. In PCLathe this line must include a forward and a reverse tool motion. The forward motion may be performed at cutting speed, and the reverse one at rapid speed in order to save time. -Cutting Semicircles The groove principle also applies to semicircles. When creating a semicircle, you will also start drawing a straight groove, including a forward and a reverse tool motion. Once you finished the groove, you will access the Edit menu and use the F4 function to convert the straight lines to circles.

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16. Safety Notes

Operating a machine tool requires responsibility, experience, and cleanliness. The same applies when using PC control. Always think of possible hazards when operating the machine tool simply with the PC keyboard in your hand. We recommend you install an emergency shutdown especially if you use an electronic regulator for the drive motor. It's quite easy to press the wrong button at the wrong time so that the program activates your lathe... ...or imagine a fault in your PC that does not deactivate the drive motor although you pressed ESC.

ATTENTION Never leave your machine tool unattended when in operation!

I do not accept any responsibility for personal injury or damages to your machine tool or your parts that may arise from using PCLathe.

17. Hardware
Signal Assignment at Parallel Port
PCLathe uses the following signals at the parallel/printer port:

Pin No. 1 2-9 11 14 16 17 25

Direction Line out Line out Line in Line out Line out Line out -

Function Direction for all axes Speed information for turning, 8 bit Dongle feedback X axis cycle Y axis cycle Z axis cycle Earth

135

Stepper Motor Control Board STEP 4020 General

The stepper motor control board transforms computer or control device signals into power impulses for the motors, using a phase current of about 2A at 36-38V operating voltage. The board includes a protective input circuit that prevents damage to the computer resulting from board faults and also reduces the current supplied to the motors during standstill (automatic current reduction). In addition to this the board is equipped with one 5V and another 15V secondary voltage terminal. They generate a voltage 15V from the operating voltage and then 5V from these 15V. Once all voltages are available the red LED lights up. Due to the generator function of the motors, the LED will also flash when turning the handwheels of your machine with motors attached.

Supply Voltages
The control board has to be operated with filtered D.C. voltage (about 2uF per mA of drawn current). Due to high power demand from the output transformers (pulsed current generated by chopper regulators), stabilised power packs are not suitable in general. If you still have a regulated power supply and you wish to use it, block its output voltage outside the control board with 2000-4000uF. ATTENTION: Make sure that the voltage applied to the control board does not exceed 36-38V- otherwise you may kill the output transformers. Non-stabilized power packs have a no-load voltage 1.4 times higher than their load voltage. Ideally suitable are toroidal core transformers with 22-24V.

Housing
When mounting the control board, make sure that the housing provides sufficient cooling. If you find that the output transformer heats up too much during continuous operation, install a fan. Mount the output transformers with 2cm clearance from the housing walls, in order to provide unhindered ventilation. Consider heat accumulation in closed housingsinside temperatures may easily range 50 above outside temperature. Large ventilation slots at the housing top and bottom are useful for avoiding heat accumulation.

136

STEP4020 - Wiring

Step Motor Direction X, Phase A Step Motor Direction X, Phase A Step Motor Direction X, Phase B Step Motor Direction X, Phase B Fuse 1.6 A Slo-blo Operating Voltage GND 15 V 100mA Line Out 5 V 100mA Line Out Step Motor Direction Y, Phase A Step Motor Direction Y, Phase A Step Motor Direction Y, Phase B Step Motor Direction Y, Phase B Step Motor Direction Z, Phase A Step Motor Direction Z, Phase A Step Motor Direction Z, Phase B Step Motor Direction Z, Phase B

To PC printer port Step Motor Direction X, Phase A Step Motor Direction X, Phase A Step Motor Direction X, Phase B Step Motor Direction X, Phase B Fuse 1.6 A Slo-blo Operating Voltage GND 15 V 100mA Line Out 5 V 100mA Line Out Step Motor Direction Y, Phase A Step Motor Direction Y, Phase A Step Motor Direction Y, Phase B Step Motor Direction Y, Phase B

Pin assignment at printer port:

PIN 14 Clock signal in X direction PIN 16 Clock signal in Y direction PIN 17 Clock signal in Z direction PIN 11 5V for the Dongle PIN 1 Direction for clock signal in pins PIN 25 Ground (PC has PIN 18-25 GND)

137

Connection of Motors
For initial operation the polarity of motor coils is not important at all. The motors will run with any combination of polarity. If you find that any of the slides moves in the wrong direction after connecting the motors, just swap the polarity of that coil (phase). First, connect one coil of the motor for longitudinal feed to the sockets marked 'X1a' and 'X1b', then the second coil to sockets 'X2a' and 'X2b'. Repeat this procedure for the transverse feed motors at the Y sockets.

Supply Voltage
Connect the positive potential to the socket marked '36V' and its earth to the one marked 'GND'.

PC Connection
Use the 25-pin connection cable to connect the control board to the printer port of your PC. (This PC port is a socket terminal strip).

138

Stepper Motor Control Board STEP 5040 General

The stepper motor control board transforms computer or control device signals into power impulses for the motors, using a phase current of about 4A at 40-50V operating voltage. The board includes a protective input circuit that prevents damage to the computer resulting from board faults and also reduces the current supplied to the motors during standstill (automatic current reduction). The red LED indicates availability of the 5V operating voltage for the logic. Once the 40-50V operating voltage is available, the motors will produce a noticeable holding torque. Due to the generator function of the motors, the LED will also flash when turning the handwheels of your machine with motors attached. Future versions of PCLathe will feature switch control for the two relays. This will enable activation/deactivation of drive motors and coolant flow.

Supply Voltages
The control board has to be operated with filtered D.C. voltage (about 2uF per mA of drawn current). Due to high power demand from the output transformers (pulsed current generated by chopper regulators), stabilized power packs are not suitable in general. If you still have a regulated power supply and you wish to use it, block its output voltage outside the control board with 2000-4000uF. ATTENTION: Make sure that the voltage applied to the control board does not exceed 50V- otherwise you may kill the output transformers. Non-stabilised power packs have a no-load voltage 1.4 times higher than their load voltage. Ideally suitable are toroidal core transformers with 30V A.C. voltage.

Housing
When mounting the control board, make sure that the housing provides sufficient cooling. If you find that the output transformer heats up too much during continuous operation, install a fan. Mount the output transformer with 2cm clearance from the housing walls, in order to provide unhindered ventilation. Consider heat accumulation in closed housingsinside temperatures may easily go 50 above outside temperature. Large ventilation slots at the housing top and bottom are useful for avoiding heat accumulation.

139

STEP5040 - Wiring
Step Motor Direction X, Phase A Step Motor Direction X, Phase A Step Motor Direction X, Phase B Step Motor Direction X, Phase B To PC Printer Port

Step Motor Direction Y, Phase A Step Motor Direction Y, Phase A Step Motor Direction Y, Phase B Step Motor Direction Y, Phase B

Relays 1a 1b 2a 2b

Step Motor Direction Z, Phase A Step Motor Direction Z, Phase A Step Motor Direction Z, Phase B Step Motor Direction Z, Phase B

Mains 220V L1 PE N

140

Connection of Motors
For initial operation the polarity of motor coils is not important at all. The motors will run with any combination of polarity. If you find that any of the slides moves in the wrong direction after connecting the motors, just swap the polarity of that coil (phase). First, connect one coil of the motor for longitudinal feed to the sockets marked 'Step Motor Direction X, Phase A', then the second coil to socket ' Step Motor Direction X, Phase B' (for details, see wiring diagram above). Repeat this procedure for the Y and Z sockets. Important: Before switching on power supply, use an ohmmeter to check for possible shorts. The measured resistance for both the 'Phase A' terminals (screws 1 and 2) and the 'Phase B' terminals (screws 3 and 4) must rate above 0.5Ohm. If the measured value is lower than 0.5Ohm, there might be a short in the wiring. If you use the PD connector system, the colours for Phase A are yellow and black, and for Phase B brown and blue.

Connecting the Power Supply

Connect the four opposing connectors with a wire or stranded wire. Connect the 220V supply cable to the triple terminal. Here, L1 and N are the live wires, and PE is the protective ground.

PC Connection
Use the 25-pin connection cable to connect the control board to the printer port of your PC. (This PC port is a socket terminal strip). Pin assignment at printer port: PIN 14 Clock signal in X direction PIN 16 Clock signal in Y direction PIN 17 Clock signal in Z direction PIN 11 5V for the Dongle PIN 1 Direction for clock signal in pins PIN 25 Ground PIN 4/5 Relay Line In

141

@ HSE 2000 Software Converter Board Art.No.: 291 0001 Version: ParSerConV2.0 The board is designed for running software that uses separate pulse- and direction signals with HSE STEPxxxx electronic components. A microprocessor provides the possibility to switch the input PIN pattern. When the board is inactive, disconnect and connect again the cables to perform a reset.

Default factory setting: PIN 9 on controller ship is open (logic high) ~

PIN 9 on controller ship is set to GND (soldering to PIN 10) (logic low) ~

142

Two Machine Tools - One PCLathe

Based on the 2A control boards, the following connection diagrams show examples that allow you to control both the lathe and the milling machine with one PC. 1.) Switching with a Relay. Drawbacks: Extensive circuitry and good chances for shorts. Advantage: Inexpensive (without calculating working hours).

2.)

Switching via a Parallel Port. Advantage: Avoids the drawbacks mentioned above. Easier to control both machines separately (using a second PC).

143

Frequency Converter General

Frequency converters are used to regulate the drive motor speed. This cuts out the need for frequently changing drive belts. Frequency converters have an input voltage of 220V and an output voltage of 380V. If your machine tool is equipped with a 380V three-phase AC motor, you can use a frequency converter. You can also operate several machine tools using one converter (by switching). The optional speed regulator board (Art.No.:2020010) enables PCLathe to control the frequency converter, so that you can e.g. turn a part at a constant cutting speed.

Block Diagram

144

Joystick Connection Diagram

The PC reads changes in resistance between pins 1 and pin 3 and/or pins 1 and pin 6 as analogue values.

145

Using the Joystick Buttons as Emergency Stop Buttons for the Axes
The PC reads changes in resistance between pin 1 and pin 3 and/or pin 1 and pin 6 as analog values. ESC Undo ESC

X Axis

Y Axis

Axis

Contacts 2 and 4 allow you to connect a make contact. If the machine slide touches and/or releases this contact, it will trigger ESC. Therefore you will have to connect a second (break) contact in series, to be able to escape the ESC condition.

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18. Troubleshooting
PCLathe

PCLathe 3.0 Rel07 has frequently proven its powerful performance in practical environments. It works. However, if you encounter a problem that seems to be software-related, thoroughly check all other possible sources of error first. This also applies for the control boards. All control boards undergo lengthy testing and precision checks on a reference machine tool. In spite of these quality assurance measures, components may fail during operation or cold welding spots may result in faulty operation. Before you consider your control board to be faulty, check the following items with diligence: o Are the stepper motors connected properly? o Did you use the original PC connection cable from HSE? o Is the dongle directly connected to your PC's printer port? To exclude dongle-related malfunctioning, remove the dongle after you started the full version of PCLathe, and connect the PC connection cable directly to the printer port of your PC. o Is your PC equipped with a 386 processor (minimum!)? o Does your PC feature an integrated co-processor? To check these items: 1) Read the BIOS information when starting your PC to look for installed components. 2) If you have MSDOS Version 6.x installed on your machine, you can enter MSD (MicroSoft Diagnose). o Set the rapid moves of all axes to a feed speed of 1 mm / sec! o Set the operating speeds of all axes to a feed speed of 1 mm / sec! o The Delay Frequency value (as computed by the SYNCUTIL program) must be higher than 50 (approximately). o If you have a fast PC (<300 MHz processor speed), you will have to set the Delay with Port Output parameter to a value <50 to widen the impulses that are output through the parallel port. o Experience has shown that many problems relate to PC errors. If possible test your machine tool with another PC connected.

147

Dongle
To enable correct detection of the dongle, the parallel interface address must be set to the following values: 378 (Hex) for LPT 1 and/or 278 (Hex) for LPT 2. You can adjust these values in the BIOS Setup of your PC. If you are not familiar with changing BIOS Setup values, do not hesitate to contact HSE for support, or ask a savvy friend. If the address values are set correctly and the program start in Demo mode nevertheless, the initialisation of the dongle's microprocessor may have failed. In this case remove the dongle from the control board and PC connectors. Wait for some seconds and connect it again to the powered-on control board and then to your PC. HSE performs functional tests on all dongles before shipping them to their customers. Varying signal levels at the PC interfaces may cause dongle problems from time to time. Contact HSE for reporting such problems.

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Stepper Motor

Motor shows no reaction at all

Jerks only right / left

Motor runs, but w/o power

One output transformer defective! Haltemoment ?

YES NO

Fast PC ? Delay with port output > 50 ? Slides/Spindle nut too sluggish!

- Demo Mode? - Manual Z Axis?

Check Fuse!

Motors zigzag after start

Whistles/ beeps only

Looses steps in operation

- Calibrate/check Joystick

- Vmm/sec to high - Time adjustment? - Steps/mm ?

Co-processor installed? Delay frequency > 50?

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19.

PC and DOS

A Brief Introduction
Microsoft started to sell its disk operating system (DOS) operating system back in the Stone Age of computing. Today it is slowly fading away-but still has the advantage of operational reliability with realtime application. Many people like it - many others hate it. Anyway, we will rather discuss the basics of working with files in the DOS environment. A PC has the following components: Processor Motherboard RAM (main memory) Housing w power pack Harddisk Floppy disk CD ROM drive Keyboard Graphics adapter and monitor DOS

Processor
The first processors were XT 8086s with a frequency of 4.77 - 8MHz and an 8 Bit wide data bus (transmitting digital ones and zeroes through eight lines). The next generation, AT 80286, were faster (12-24MHz with 16Bit data bus). Both these types are not suitable for operation with PCLathe. The third generation of processors, 80386s with frequencies of 20-33MHz and a 32Bit data bus, is the first that can be used with PCLathe. This processor (CPU=Central Processing Unit) is only able to process whole numbers (fixed point numbers) swiftly. As the numbers you enter in PCLathe have floating points (e.g. X = 12.34mm), another so-called 80387 mathematical co-processor is needed. If you still have an old 386 PC and wish to install a co-processor, make sure its frequency is identical to that of your CPU. The co-processor will plug into a separate socket on your motherboard and most PCs detect this processor automatically after installation. Such a system represents the bottom line for operating PCLathe. The better choice is an 80486 CPU with a 32Bit data bus and frequencies of 20120MHz. Moreover, the processor comes with an integrated co-processor and offers another piece of memorythe cache memory. Relieving the CPU from frequent RAM access, the cache memory speeds up the program. Make sure you use a 486 DX processor, since some 486 SX processors lack the co-processor. Intel calls the next generation of processors (80586s) PENTIUM. It features a 64Bit data bus at frequencies of 60-166MHz. This is the first processor type with integrated pipelining technology, which enables parallel processing of commands and thus reduces processing time. In PCLathe this results in quicker monitor refresh rates 150

which is convenient when working frequently with the program. The actual lathe/mill functions do not require pipelining. The latest Pentium processors (II, III, ...) use even more sophisticated techniques to speed up data processingwhich PCLathe unfortunately cannot profit from.

Main Board
This board (also called motherboard) links the individual components of a PC. If you open your PC case and remove all the turnings and borings that are in it, you will find the motherboard underneath the cabling.

RAM Main Memory

RAM = Random Access Memory. When you start PCLathe, the contents of the PCLATHE.EXE file is copied from your harddisk into the RAM, where the CPU can directly access it and run the program. The useful main memory for PCLathe is limited to a maximum of 640kB. As the operating system also reserves a part of this amount of RAM, good values range between 590kB and 610kB. If you wish to check the available RAM on your computer, exit PCLathe, type in the [mem] DOS command, and press ENTER. The amount of available RAM will display after Maximum size for executable program. When working with large PCLathe drawings, every free kilobyte is valuable as they provide more free points. An optimized PC will provide as much as 6,000-7,000 free points, while 530kB of available RAM will reduce the number of points to about 4,200. You can adjust the amount of available RAM in the AUTOEXEC.BAT and CONFIG.SYS system filesbut we will not go into details here. If you encounter memory problems, ask someone who knows for assistance.

Housing and Power Supply

Are also part of your PC as you need something to grab and the device needs power.

Harddisk
A harddisk consists of a disk that has a magnetic surface (like the old recording tapes) and a read/write head (almost like the old tape recorders). The disk rotates, and the head can read and/or write data. The hard disk is used to save data to or read data from it in the form of files. Typical storage capacities for 386/486 PCs are 60-250MB. The letter assigned to your hard disk in DOS is C:. Sometimes the physical disk is subdivided into logical drives named C:, D:, E:, etc. In active operation, hard disks are relatively susceptible to shocks. Therefore, never beat your 151

PC with your fists when in a rage! XT and AT disks have a size of 5", normal disks 3", and modern ones are even smaller.

Floppy Disk
Similar to your hard disk regarding the construction principle, but removable and flexible. As the read/write head does not get as close to the surface as it does on the hard disk, floppy disks store less data. While XT and AT computers still used 5" floppy disks of 360KB storage capacity, you will now find only 3" disks with 1.44MB. We recommend to save your PCLathe drawings on a floppy disk from time to time, because hard disks of old PCs sometimes decide to deceasemaking you mourn day and night. Prevention pays off! The DOS drive letter for your floppy drive is A:

CD ROM Drive
This is a medium for optical data storage. As suggested by its name ROM (= Read Only Memory) you can only read data. Its storage capacity is about 650MB and the reading speed is specified as a multiple of that of a floppy disk; thus it is considerably slower than a hard disk. The DOS drive letter for your CD ROM is D: (unless you have a second hard disk installed).

Keyboard
The main means for data entry. You will use the keyboard to communicate commands to your PC. It is the interface between man and machine. Why your PC understands what you want will be explained later in this chapter. A distinction is made between XT and AT keyboards. XT keyboards with their function keys on the left side of the board are almost extinct. If you get hold of such a relic, put it straight into the rubbish bin. Today, only AT keyboards are in use. The following paragraphs provide some facts about different keyboard models and their use with machine tools: Normal AT Keyboard Low-cost: about 6-10. Very rugged. To which extent you protect it from turnings and borings or operate it with greasy fingers is left to you; but have in mind what damage this may cause: If F1 = On is active, the step size is set to 100 mm, and the keyboard triggers the ARROW LEFT key, the tool, the material, and possibly the machine also will turn into rubbish.

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 Mini Keyboard (285mm x140mm) Advantage: its small size provides convenient working space on the workbench. Drawbacks: the increased price of about 40, and the risk that due to narrow spacing between keys you may not be able to press them immediately. The same applies to the use of notebook computers with PCLathe. Flexible Keyboard Can be rolled up and is sealed against fluids and chips. The two samples I used in tests were nicely coloured, stank like hell, and sometimes sent random signals to the PC. Therefore, they are completely unsuitable and dangerous for operation with PCLathe. Wireless Keyboards The infrared models are not recommendable, as reliable communication becomes impossible when objects block the path of transmission. Radio-type keyboards offer increased communication reliability and a flexible operating radiusbut again, they are not 100% fail-safe (i.e. batteries will go weak, or the huge metal presence of the machine may corrupt signal transmission).

Graphics Adapter and Monitor

The graphics adapter converts the digital CPU signals into analogue ones for the monitor. The XT had four colour CGA adapters with a resolution of 320x200 pixels. Next came the 16 colour EGA adapter with 640x350 pixels. This is the mode that PCLathe uses. For a long time, VGA was the standard: 640x480 pixels, 16 colours and/or. SUPER VGA with 640x480 pixels and 256 colours. Such adapters have 1MB graphics memory and can be found in old 386 and 486 PCs. The VESA mode and more memory provide resolution values of up to 1600x1280 pixels with millions of colours. Earlier all monitors were 14; today typical sizes are 17 or 19. PCLathe just requires a simple EGA adapter and a 14 monitor (of course you may use more powerful adapters and bigger monitors as well).

DOS
DOS stands for Disk Operating System and has almost been replaces by the WINDOWS operating system. When booting your PC, it automatically activates a program called COMMAND.COM. This is the command line interpreter that interprets your entries. If you enter [hello pc] and press ENTER, COMMAND.COM will not be able to interpret this and display the message: COMMAND OR FILENAME NOT FOUND. IIm mp po or rtta an ntt T Te er rm ms sa an nd d tth he eiir rM Me ea an niin ng g:: Files Your data on the hard disk (floppy disk, etc.)

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Program Filename

An executable file that you can launch; thus the filename extension .EXE The name of your file on the hard disk. This name may be to eight characters long and followed by a three-character extension separated by a dot (.). ATTENTION: Do not include special characters (e.g. ?, !, /, *, etc.) or spaces in filenames and extensionsnot in PCLathe, and not in DOS. Exceptions are: - and _. Files are divided into groups, and in most cases the extension allows to determine the file type e.g.: .TXT = Text files .BMP, PCX, GIF, JPG... = Images .EXE = Executable files .BAT = Batch files (executable) .SYS = System files .DAT = PCLathe lathe files .TMP = Temporary files .FRS = PCLathe mill files .PLT = HPGL files .DXF = DXF files .COM = Executable file and so on. or folder also. Imagine a cabinet full of folders. That is your hard disk. The cabinet may also contain loose documents, which are files. So a directory is a folder containing other documents (files). also called main directory. This directory is always C:\. see Directory, e.g..: C:\PCLATHE.

File Extension

Directory

Root Directory Subdirectory

Current Directory is the directory you are currently working in, displayed by the DOS prompt. Prompt Path What COMMAND.COM tells you, when your press ENTER. In most cases the path. C:\PCLATHE>

Specifies the folders to search for COMMAND.COM, if you enter something. D DO OS SC Co om mm ma an nd ds s Instructions that COMMAND.COM is able to interpret. Used for viewing a directory. E.g.: [dir] , ENTER creating a directory. E.g.: [md] , [ ] , [lathe] , ENTER.

Command Long Name dir md cd rd deltree 154 directory make directory

change directory changing to another directory remove directory deleting a directory (empty ones only). delete tree deleting a full directory.

mem type

memory type

viewing the main memory. viewing the contents of a file. E.g.: [type] , [ ] , [error.lst] , ENTER If the file to view is larger than your screen, enter: [type] , [ ] , [error.lst] , [ ] , [|] , [ ] , [more] , ENTER copying files. deleting files. renaming files. E.g.: [ren] , [ ] , [old_file] , [ ] , [new_file] opening DOS help on DOS commands. specifying which directories are to be searched for commands that you enter.

copy del ren help path

copy delete rename help path

D DIIR R The first command we will take a look at is the DIR command. It allows you to view the contents of a drive (A: =Floppy, C: =Hard disk) or a subdirectory. When working in DOS, you will use some symbols, one of them being the backslash (\). It is used for separating subdirectories, e.g.: C:\PCLATHE or C:\DATA\CLIENTS. If you refer to a storage location (drive or folder), the \ represents the root directory. Once you exit PCLathe, the prompt will display: C:\PCLATHE, this is the current directory. If you now type in [dir] and press ENTER, you will see a list of all files contained in the PCLATHE directory on hard disk C:\. To view the contents of the floppy disk, type in: [dir] , [ ] , [a:] , and press ENTER. C CO OP PY Y The COPY command allows you to copy files from on location to another or create a copy of a specific file in the same location. Using this command you can easily create a backup copy of your PCLathe initialisation file PCLATHE.INI. Type: [copy] , [ ] , [pclathe.ini] , [ ] , [pclathe.inx] , and press ENTER. If you typed in wrong values when using the calibration program, and you want to restore your old settings, just swap the filenames: [copy] , [ ] , [pclathe.inx] , [ ] , [pclathe.ini] , and press ENTER. Now we will have a look at how to save PCLathe drawings to a floppy disk. To begin with, let me introduce some other special DOS characters: wildcards. Wildcards include the question mark (?) and the asterisk (*) and can be used to replace filenames/extensions and characters. The question mark replaces one the asterisk all characters up to the separating dot (.). We remember that the dot separates the 155

filename from the extension. So if you wish to save all mill drawings to a floppy disk, type: [copy] , [ ] , [*.frs] , [ ] , [a:] , and press ENTER. A short list of different possibilities: copy *.* a: copy *.dat a: copy whe*.* a: copies all files to drive a: copies all lathe files to drive a: copies all files that begin with 'whe' to drive a: e.g.: wheel_1.frs or wheel2.dat copy pclathe.in? a: copies all PCLathe ini files to drive a: If you want to copy data from a floppy disk to your hard disk, always make sure you are in the directory where you want to copy your files (destination directory). Another way would be to specify the target location for your databut the first method is more reliable. So if your want to copy all drawings beginning with Spo (spoke...) from a: to your PCLathe directory, make sure your prompt reads C:\PCLATHE>, type: [copy] , [ ] , [a:\spo*.*] , and press ENTER. By the way the ? and * wildcards also work with all other DOS commands, e.g.: with the DIR command. If you want to know how many PCLathe program files are in your directory, type: [dir pclathe.*] and press ENTER.

T Tw wo oM Ma ac ch hiin ne eT To oo olls s -- O On ne eP PC C? ? If you have two machine tools that you want to control with one PC, you will have to install the program twice. With two instances of PCLathe installed on your PC, you may want to configure your system in such a way that you can access the lathe program by entering lathe and the mill program by entering mill. The general procedure to achieve this is: install PCLathe, rename the directory to lathe, install PCLathe again, and rename this directory to mill. Next create a BATCH folder, then two BATCH files and include the path in your AUTOEXEC.BAT. The step-by-step procedure is as follows: Install PCLathe (I suppose you have already done that). To rename the PCLathe directory: Go to the ROOT directory by typing [cd \] or [cd ..], then type [ren pclathe lathe], and press ENTER (from now on I will leave this out). Install PCLathe again from the CD Go to the ROOT directory again Rename: [ren pclathe mill] Are you still in the root directory? The prompt displays c:\> ! To create the BATCH folder: [md batch] Note: Batch files are small files containing textmainly DOS commands. Batch files have the extension .BAT and can be executed in DOS just like .EXE files. 156 To change to the BATCH folder: type [cd batch]

Create the lathe file using the DOS Editor. Type: [edit lathe.bat], the screen turns blue, and you can enter text. Enter: C:\ CD C:\LATHE PCLATHE Open the File menu by pressing the ALT key, and use the ARROW DOWN key to choose the Exit command. When prompted to save the file, confirm with Yes. Now we repeat this procedure for the mill file. Type: [edit mill.bat] and then: C:\ CD C:\MILL PCLATHE Exit the Editor again confirming the Save prompt with Yes. To check if both files exist type: [dir] ; LATHE.BAT and MILL.BAT. To change back to the ROOT directory, type: [cd ..] To create a backup copy of your AUTOEXEC.BAT system file, type: [copy autoexec.bat autoexec.bak] To include the path in your Autoexec.bat, type: [edit autoexec.bat]. Look for the line containing the PATH. It will probably look like this: PATH=C:\DOS;C:\WINDOWS. A semicolon (;) is used to separate the individual paths Append [;C:\BATCH] at the end of this line which might then like this: PATH=C:\DOS;C:\WINDOWS;C:\BATCH. Use the ALT key to exit the Editor (do not forget to save the file). Back in DOS, type: [path] , to see if your new path has been implemented. You will find that this has not happened! For the new path to become valid, you must reboot (switch off and on again) or reset your computer. If you enter [lathe] after the reboot/reset, you should end up in the PCLathe program from your LATHE directory, and with [mill] in the one from the MILL directory.

This is where the introduction ends. Theoretically, the DOS world could fill an entire book. By now you should be able to view files, create backup copies, and copy files from your hard disk to a floppy disk and vice versa.

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Notes:

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Project: P roject Sheet

Date:__________

File

Obj. X * Distanc Z * From- Clea e To ning

Note

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Products and Demo-Software from our Website

www.pcdreh.de

There is always a selection of PCLathe-controlled machine tools available for demonstration in our show room. Please contact us for an appointment to allow us plan sufficient time to meet your specific requirements. How to find us: From the autobahn A4 Cologne (Kln)-Olpe, Take the exit (Ausfahrt) Engelskirchen. Immediately after the exit turn left. At the next junction turn left again in the direction of Rnderoth. Continue straight on up to a T-junction. Turn right in the direction of Gummersbach (B55). In the village of Rnderoth, cross over two Sets of railway lines. Oststrasse is a section of the B55 and Number 13 is a white house on the left hand side. HSE GmbH Oststrasse 13 D 51766 Engelskirchen Germany Director Matthias Potthoff (State Approved Computer Scientist)

PC Control of Machine Tools

Tel Fax D2 : Email Web:

+49 (0) 22 63 - 95 21 70 +49 (0) 22 63 - 95 21 71 +49 (0) 172 - 938 59 14 hse@pcdreh.de www.pcdreh.de

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