CNCMilling Boxford PDF

Programming Manual
Boxford 190 VMC

CNC Milling
Machine Tool
Boxford
Boxford Ltd.,
Wheatley, Halifax, West Yorkshire,
England, HX3 5AF.
(Registered Office)
Telephone: 01422 358311
Fax: 01422 355924
E-Mail: info@boxford.co.uk
Web: www.boxford.co.uk
Boxford 190 VMC Contents
Contents
1 Introduction
2 Running the Demonstration Program
3 Axes and Tooling
3.1 Fitting Tooling
3.2 Axes, Datums and Offsets
3.3 Tool Storage
3.4 Tool Data Library and Catalogue
3.5 Setting Up
3.6 Datum Shift
4 Main Front End Menu

5 CAD
5.1 Cad Window
5.2 Drawing Aids
5.3 Drawing Tools
5.4 Editing Objects
5.5 Area Filling
5.6 Machining Considerations
6 CAM Processor
6.1 Settings
6.2 CAM Processor Error Messages
7 File Imports
7.1 Drawing File Import
7.2 G&M Code Program Import
8 Administration Mode
8.1 Access & Password Setting
8.2 Tool Library
8.3 Material Cutting Data
8.4 Park Position and Units
8.5 CAM Processor Default Settings
8.6 Language Settings
9 Cutter Path CAM Programming

9.1 Functions
9.2 Information Required
9.3 Drawing a Component
9.4 Example
9.5 Defining Straight Line Moves
9.6 Defining Arcs
9.7 Pockets and PCD Drilling
9.7.1 Rectangular Pockets
9.7.2 Circular Pockets
9.7.3 Slots
9.7.4 PCD Drilling
9.7.5 Dish Milling
9.8 Cutter Radius Compensation
9.9 Tool Changing
9.10 Processing a Cutter Path
9.11 Editing a CAM Program
10 Manual Data Input CNC Programming

10.1 Operations and Programming Sheets
10.2 Absolute and Incremental Co-ordinates
10.3 Speeds and Feeds
10.4 Program Format
10.5 Preparatory Functions (G Codes)
10.6 Miscellaneous Functions (M Codes)
10.7 Programming a Tool Change
10.8 Inputting a New Program
10.8.1 Information required
10.8.2 Tabulated Format
10.8.3 ZOOM Facility
10.8.4 Compact Format
10.9 Saving a Program
10.10 Examining an Existing Program
10.10.1 PROGRAM Display
10.10.2 ZOOM and VIEW Facility
10.10.3 Simulation of Machining

10.11 Editing a Program
10.11.1 New Programs
10.11.2 Existing Programs
10.11.3 MENU Editing Options
10.11.4 Changing the Initial Tool
10.12 Continuing a Program
11 CNC and CAM Machining

11.1 Initial Checks
11.2 Manufacture
11.3 Options During Machining
12 Manual Machining
13 Robotic Interfacing
CNC Tutorials and Exercises

Tutorial 1: X and Y Co-ordinate Calculation -
Absolute and Incremental Co-ordinates
Exercise 1: Calculation of Co-ordinates
Tutorial 2: Linear Interpolation
Exercise 2: Linear Interpolation - Absolute Co-ordinates
Tutorial 3: Canned Cycles - Hole Drilling and Pocket Milling
Exercise 3: Canned Cycles - Programming a Tool Change
Tutorial 4: Circular Interpolation - Clockwise and Counter-clockwise
Exercise 4: Circular Interpolation
Tutorial 5: Combining Operations and Tool Changing
Exercise 5: Combining Operations
Tutorial 6: Subroutines
Exercise 6: Subroutines
Tutorial 7: Mirror Images
Exercise 7: Mirror Images
Tutorial 8: Further Canned Cycles - Pitch Circle Drilling and Dish Milling
Exercise 8: Use of Canned Cycles - Pitch Circle Drilling and Dish Milling
Tutorial 9: Subroutines, Mirror Images and Circular Interpolation
Exercise 9: Subroutines and Mirror Images
Tutorial 10: Datum Shift and Jump to Line
Exercise 10: Datum Shift and Jump to Line
Operations Sheet
Programming Sheet
1 Introduction
This manual gives guidance in using the 190VMC CAD/CAM software to create ISO
G& M code programs for milled components.
The 190VMC CAD/CAM software includes a demonstration program (called
190VMC), and a number of tutorial programs.
It is suggested the manual is used as follows:
1. Refer to section 2 and run the demonstration. This will provide rapid familiarisation
with the operation of the software and the machining process.
2. Study Section 3 to become proficient in setting up the tooling.
3. Refer to sections 4, 5 and 6 to demonstrate the ease of operation of the integrated CAD
and CAM processor package.
4. Refer to Section 7 to become familiar with the conventions for importing drawing files
from third party CAD packages and G & M programs from CAM packages.
5. Refer to Section 8 for details of the functions available to administrators (tutors) of the
CAD/CAM system.
6. Refer to section 9 for computer assisted cutter path generation.
7. Use section 10 for detailed instruction in CNC programming.
Tutorial 2 is used as an example to demonstrate the stages of programming and
software operation.
8. Use the Tutorials and Exercises in the order in which they appear, to progress from
basic programming skills to proficiency in the more advanced features of CNC
programming.
9. When programs have been written and verified, refer to section 6 as required, to
machine components.
Boxford 190 VMC
2 Running the Demonstration

Program
The demonstration program contains examples of linear and circular interpolation,
rectangular and circular pocket milling and pitch circle drilling, and a finished component
can be machined from the billet supplied with the machine. Run the program as follows
to provide a tutorial in programming and machining.
Setting Up the Machine 1. Set up the tooling and billet as follows:
6mm slot drill fitted in cutter holder, secured in spindle.
3mm slot drill ready for the programmed toolchange.
Billet: plastic, length 75.00 mm, width 60.00mm, height 10.00mm, securely fitted in vice.
2. Run the software and check that the Simulation and Manufacture software is correctly
configured by selecting CONFIG from the main menu. (Refer to Section 5 - Installation
in the Installation and User manual, and Section 3 - Axes and Tooling).
Check Tool Settings 3. From the main menu, select MACHINE and then Tools to display the Tool Data Library.
Check the setting of the reference tool, and the second tool, which should be as follows:
No. Type Pos Description Diameter Length Offset
1 2 1 Slot drill 6.00 7.50 0.00
2 2 2 Slot drill 3.00 7.50 0.00
If the settings are incorrect, refer to Section 3 - Axes and Tooling, 3.5 - Setting Up.
4. Turn off the display.
The screen shows: Main Menu
Boxford 190 VMC 2 Running the Demonstration Program
5. Select PROGRAM
The screen shows:
6. Select PROGRAM
The screen shows the Catalogue Display. View the catalogue to identify the demonstration
program, which is called VMC 190.
Boxford 190 VMC
7. Select VMC 190

The screen shows the Program Display with a 2D view of the component.
View the Component 8. Select VIEW to produce a 3D view of the component. After a pause the display will
show the 3D view:
Manipulate the 3D view as follows:
Using a Mouse:
Click on the control buttons -
Increase
size
Rotate Rotate
clockwise anticlockwise
Decrease Restore
size original view
Boxford 190 VMC
Using the Keyboard:

Increase
size
Rotate Rotate
Decrease
size
HOME Restore
original view
Note:
The time taken for the display to respond will depend on the speed of the PC and whether a co-processor
is fitted.
Show the Program 9. Select INFO to show the program details:
Details
10. Turn off the program details display. (Click off the display window or press Return).
Display the Program 11. Select MENU and then Display:
Scroll the display to examine the program:
Using a Mouse:
Click on the buttons
page 1 line 1 line page

down down up up
Using the Keyboard:

➔
➔
Press or to scroll 1 line
Press Page or Page to scroll 1 page

up down
12. Turn off the program display.

Boxford 190 VMC
Zoom the Display The ZOOM facility enables a rectangular area of the workpiece to be isolated and viewed
in greater detail for editing purposes. Full use of the facility is explained in Section 10 -
Manual Data Input CNC Programming, 10.8.3 - ZOOM Facility.
The following steps provide a brief demonstrations, returning to the display of the
complete workpiece.
13. Select ZOOM . The screen displays a 2D view of the workpiece with a menu bar at the
top, and sliders and arrow buttons arranged horizontally and vertically.
Explore the use of the REDUCE and ENLARGE options, and the sliders and arrow
buttons, to define a section of the workpiece with the rectangular selecting frame.
(RESET restores the frame to its original size).
14. Select ACCEPT . After a pause the screen shows the program EDIT display with a 3D
view of the selected area of the workpiece.
15. Select ZOOM , then Unzoom to restore the 3D view of the complete workpiece.
Simulate Machining 16. Select MENU , then 2D Simulate:

- 2D
tool
depth
display
Repeatedly click the mouse button or press Return to move through the program line-by-
line. The simulation shows the tool movement and metal removed as each line of the
program is executed.
To move forward through the program to a specific line, select MENU , and then Go
to Line. Type the required line number when prompted, and press Return.
To produce a 3D view of the workpiece, select MENU and then Solid View. To return
to the 2D view, click the mouse button or press Return.
To run the simulation automatically, select MENU and then Fast Mode; the program
will be run in a continuous sequence. To return to line-by-line simulation, select
MENU and then Step Mode.
To end the simulation before the end of the program, click on the 'off' button or press
ESC .
At the end of the program the screen returns to the program display.
Boxford 190 VMC
Simulate Machining 17. Select MENU , then 3D Simulate:

- 3D
Select MENU , and demonstrate the use of the options available as for the 2D
simulation, until the screen again shows the program display.
Machine the Refer to Section 11 - CNC and CAM Machining.
Component
Boxford 190 VMC Axes and Tooling
3 Axes and Tooling

3.1 Fitting Tooling (Figure 3.1)
The cutting tool fits directly into a tool holder and is secured in position by a single
Allen screw.
The tool holder in turn fits into the machine spindle taper and is orientated by two dogs
which engage with the tool holder flange.
The tool holder pull stud is then drawn upwards by the spindle drawbar thus securing
the tool holder.
The drawbar can be manually operated by a lever on the side of the spindle or an
automatic tool changing device can be specified if required.
3.2 Axes, Datums and Offsets (Figure 3.1)

Axes Figure 3.1 shows the movement of the tool in the X, Y and Z axes, in relation to the
billet. (In the X and Y axes the billet moves in relation to the tool, but for simplicity
and to conform with standard programming practice, it is the movement of the tool
in relation to the billet which must be considered).
Datum Position On new machines, all Datum positions and Tool Offsets are set at the factory when tooling and clamping
is ordered with the machine.
The offsets of all required tools are set in relation to the machine Z datum.
Before any Tool Offsets can be set, the Machine Z Datum has to be defined.
From the machines Home Position, the Machine Z Datum is the measured distance from
the underside of the of the spindle head to the machine table top as shown in the diagram overleaf.
The X and Y Datum is the distance from the spindle centreline to a fixed point on the machine
table where the same corner of every workpiece locates to. (on a standard Vice, this is the imaginary
intersection of the vice rear jaw and the left hand end stop - a point where the Left Hand
corner of a workpiece locates to).
The datum position can be set to reference from Back Left, Back Right, Front Right
and Front Left corners of the workpiece (see section 3.5 - point 15 onwards for further
details).
Boxford 190 VMC 3.1 Axes and Tooling
Drawbar lever
DRAWING
Spindle Tool X,Y datum
Tool holder
Cutting tool
+Y
Billet Rectangular
billet
+X
Tool X,Y datum +
Z
- - X +
Drawing datum
+
Y-
Tool X,Y datum
Workholding vice +Y
Circular
billet
+X
Drawing datum
Figure 3.1 Axes and Tool Datum

Drawing Datum Dimensions on drawings are measured from the drawing datum. For convenience this
can be placed at the bottom left-hand corner of the billet and given X and Y co-
ordinates of zero. When a component is manufactured, the difference between the Y
co-ordinates of the tool and drawing datums is entered and the software compensates
for this difference.
The 190 software also allows the use of circular billets. For these, the X and Y datum
is usually at the bottom left hand corner of a square enclosing the billet.
Offsets Each tools offset is the distance from the Underside of the Spindle Head to the
tool end (bottom).
Underside of Head
Tool Z Offset
Machine Z Datum
Total Height of
Workpiece & Clamp Machine Table Top
Auto tool changer
Tool rack
(basic 190VMC)
Spindle
Carousel
To pressure gauge
Figure 3.2 Tool Storage

3.3 Tool Storage (Figure 3.2)
Tool Rack On the basic 190 VMC a tool rack is provided, as shown in Figure 3.2, to facilitate
(Figure 3.2) storage of up to 5 tool holders and associated cutting tools.
It is advisable to store the tools in the same order as they will be called for in the
machining program.
Auto Tool Changer Automatic tool changing equipment is supplied as an optional extra .
(Figure 3.2)
A carousel facilitates storage of up to 5 tool holders and associated cutting tools. Each
tool holder must be loaded into the correct carousel station so as to correspond with
the machining program prior to cycle start, i.e.:
Tool No.1 = Station No.1
Tool No.2 = Station No.2
The machine cycle start cannot be activated until the carousel has been indexed to Tool
No. 1, the reference tool station.
Manual Operation The auto tool changer is a pneumatic device requiring a compressed air supply of 80
lbf/in2.
Ensure therefore that the system pressure gauge reads 80 lbf/in2 prior to operating the
auto tool changer controls.
Pressing the Tool Change button on the main control panel will direct the auto tool
changer to remove the tool holder currently in the spindle, place it in the correct
carousel station, index the carousel to the next station, secure the next tool holder into
the spindle and retract.
Note:
When using the Tool Change button ensure that the spindle is at least 5mm below the upper Z+
limit of its travel.
Programming the Auto Tool The CNC code for a tool change is the same as for a standard machine. Using the M
Changer code M06 you must define the tool type e.g. type 2 (a slot drill), the diameter of the
tool and the station number 1 5 in the carousel, for example:
M06 I2 J6 F4
Where I = a slot drill
J = diameter of 6mm
F = station No. 4.
On completion of the part-program the machine will automatically change back to tool
1 allowing batch quantities to be machined.
3.4 Tool Data Library and Catalogue
The 190 software provides a Tool Data Library which enables details of tooling and
offsets to be entered and a tool catalogue from which tools can be selected for inclusion
in the library. The library is set up by means of a tooling menu.
Before attempting to set up the tooling for the first time, view the library, the tooling
menu and the catalogue to become familiar with the details, as follows:
1. Switch on the PC, run the 190 Software.
2. From the main menu, select MACHINE and then Tools.
Tool Data Library The screen shows the Tool Data Library, (Figure 3.3). Practice selecting tools using
the mouse and keyboard.
1 2 3 4 7 5 6
Details of selected tool are highlighted.
When the display first appears, the initial
tool is highlighted. Other tools can be
selected as shown below.
1. Tool number used by CNC program to select 5. Scroll buttons

required tool 6. Tool offset
2. Tool type (selected from tool catalogue) 7. Tool flute length
3. Tool station (carousel)
4. Tool description (selected from tool carousel)
To select a tool:
Using a mouse
Click on the scroll buttons (6) to highlight the required tool.
Using the keyboard
Press or to highlight the required tool.
➔
➔
Figure 3.3 Tool Data Library

Tooling Menu 3. Select MENU to display the tooling menu:
The use of these options for setting and editing the Tool Data Library is detailed later
in this section.
Note:
After setting up or editing the library, always select Save Tool data.
Tool Catalogue 4. From the tooling menu, select Display Tools.
The screen shows the tool catalogue, (Figure 3.4).
Turn off the tool catalogue display to reveal the Tool Data Library.
Figure 3.4 Tool Catalogue

3.5 Setting Up
Note:
A billet of the appropriate size will be required for this procedure. In order to run the demonstration
program, a 5mm slot drill and a 5mm end mill are required. To run the program, set up the slot drill
as the initial tool and the end mill as the second tool in the following procedure. If you want to fit a
different initial tool or second tool, substitute the tool details as appropriate.
Fit Initial Tool Fit the billet into the workholder, then fit the tooling as detailed below:
1. Basic 190 VMC with Tool Rack
Fit the 5mm slot drill into the tool holder and secure the tool
holder into the spindle by operating the drawbar lever (Figure 3.1).
If the spindle is too close to the work holding vice to allow the tool to be fitted then
use the manual controls to move the spindle up until sufficiently clear. (See Section 12
- Manual Machining).
2. 190 VMC with Auto Tool Changer
Fit the 5mm slot drill into the tool holder and secure the tool holder into the carousel
as shown in Figure 3.5.
Ensure that the spindle is in the correct Z+ position to facilitate auto tool changing.
Press the TOOL CHANGE button on the control panel.
The carousel will then traverse left to the spindle position, perform the actions of
removing a tool holder from the spindle, index to the reference tool, load and secure
the reference tool into the spindle, and retract.
The reference tool is now fitted in the spindle.
Spindle Carousel Direction

of rotation
Fit reference
tool here
Figure 3.5 190 VMC with Auto Tool Changer - Reference Tool Position
Configure Software 3. Check that the POWER ON RESET button on the machine control panel is lit.
4. Run the 190 Software. From the main menu select CONFIG and then Program.
5. Set the required values and turn off the display.
The screen shows:
6. Select YES
7. Select CONFIG and then Hardware. Make the required settings, turn off the display,
and save the settings.
The screen shows the Main Menu.
Set Initial Tool Offset 8. From the main menu, select MACHINE and then Tools to display the Tool Data
Library. The settings for the 5mm slot drill will be highlighted, for example:
Check the tool details (excluding the offset). If they are correct, continue at step 10 to
set the offset.
9. To edit the tool details, select MENU and then Edit tool.
The screen shows the tool editing display, with the first item (Tool type) highlighted,
(Figure 3.6).
Edit the display to show the correct settings.
1 To check tool type, press Escape or select QUIT , then select MENU and
Display tools to view tool catalogue.
2 Diameter of slot drill is 5.00mm
3 Offset for reference tool is zero.
To edit tool details:

Type required number in highlighted box
Press Return to highlight next box
When last box is highlighted, press Return: highlight will disappear
Press Return or click on OK to turn off display
Figure 3.6 Tool Editing Display

10. Select MENU , and then Set Tool Offset. The screen shows:
If the touch-on point is to be the top of the billet, enter the height of the billet. If the
touch-on point is to be the base of the workholder, enter zero.
11. If the Software detects the machine is in Manual Mode, the user is prompted to
Cancel Manual Mode
The window below is shown.
1. The machine RESET button is pressed.

2. a. The Z+ and Z- keys are pressed simultaneously (this axis must reach
home position before step b. can be started.
b. The X+ and X- keys are pressed simultaneously.
c. The Y+ and Y- keys are pressed simultaneously
2. ALTERNATIVELY, the F1 function key on the PC keyboard can be
pressed. This automatically performs steps a, b and c.
12. When the axes reach the home position, the screen shows:
On the machine control panel, select Manual mode. Using the axis control buttons,
touch the point of the tool on to the top of the billet.
13. When the tool is in the correct position, select EOB or press Return. The screen
again shows the Tool Data Library.
If additional tool offsets are to be set, continue at step 14. If not, continue at step 15
to set the machine datum position.
Set Additional 14. To set the offset of the next tool, fit or index the tool and repeat the procedure from
Tool Offsets step 8.
Note:
For setting the offsets of the second and any subsequent tools, it will not be necessary to enter the height
of the billet or to home the axes (steps 10 and 11).
When the offsets of all the required tools have been set, either select MENU and
then Save Tool Data, or click the 'off' button of the Tool Data Library display. If the
'off' button is clicked, the screen shows the message:
Click on YES or press Return to save the offsets.

Set Machine Note

Datum Position It is only necessary to set the datum position if the workholder position is changed or the Datum
position (back, front, left, right) is changed
15. There are now a number of additional Datum Position options.
Datum Position - Select CONFIG and then Hardware.
With the DATUM POSITION option highlighted, the options can be accessed
and selected using ALTER.
The datum position is:- a point on the machine table where the same corner of every workpiece
locates to.
e.g. On a VMC machine fitted with a standard Vice, the workpiece BACK face locates
to the fixed rear vice jaw and the workpiece LEFT face locates to the vice end stop
- hence the setting would be BACK LEFT
The Datum Position is selected and the settings saved.
From the main menu, select MACHINE and then Datum Position.
16. Select SETUP . The screen shows the Enter a Tool display:
17. Select a tool for which the offset has been set, (for example tool no. 1), and
select ACCEPT or press Return.
If the Software detects the machine is in Manual Mode, the user is prompted to
Cancel Manual Mode

18. When the axes reach the home position, the screen shows:
Measure the dimension (from the underside of the spindle head to the machine table
top), and enter the value. (This establishes the Z axis datum).
19. Select OK or press Return twice. The screen shows:
Note:
The Face of the billet to touch on will depend on the Datum Position setting in the Hardware
configuration - see point 15
On the machine control panel, press MAN to select Manual mode. Use the axis control
buttons to touch the side of the tool on to the left face of the billet. (This establishes
the X axis datum; the software compensates for the radius of the tool).
20. When the tool is in the correct position, select ENTER or press Return. The message
on the display now prompts you to touch on to the rear face of the workpiece with the
selected tool.
Using the axis control buttons, follow the instructions to establish the Y datum in the
same way as for the X datum.
21. When the tool is in the correct position, select ENTER or press Return. The screen
shows:
Click on YES or press Return to save the offsets.

The screen returns to the main menu.
3.6 DATUM SHIFT

Datum Shift is a new feature which allows the user to input a temporary shift of the
Datum Position for individual components which cannot be located to the standard
datum position.
To activate this facility, CONFIG followed by Hardware is selected. The Datum
Shift option is highlighted and ALTER followed by ON selected
To define default values, Machine followed by Datum Position is selected.
The default X and Y Datum Shift values are entered (the distance from the standard
datum position to the temporary datum position). These can be left at 0.00 and defined
when individual components are manufactured.
4 Main Front End Menu
When the Boxford CADCAM package is started, the Main Front End Menu screen
below is shown.
This menu is the central manager of the CADCAM tools within the Boxford VMC
package.
G&M Program Import & Program Simulate, Manufacture
Administration Functions and Machine Tool Driver
CAD and CAM Processor Exit to Windows Desktop

Boxford 190 VMC 4.1 Main Front End Menu
In Standard User mode this menu accesses the G&M code program import filter. (See
section 7.2)
In Administration mode (See section 8) additional CAM processor data settings can be
accessed and modified.
Accesses the Integrated Computer Aided Design package (See section 5) and CAM
processor (See section 6)
Also used to access CAD package to import drawing files (See section 7).
Accesses the G&M program Simulator, Editor, Writer and Machine Tool driver. All
the configurations for connecting the VMC machine to the PC are set in this section
of the package (See separate Installation & User Manual together with this manual).
Exits to the Windows desktop.

Boxford 190 VMC CAD
5 CAD
5.1 CAD Window The CAD program window provides a clear view of the current drawing, various
information areas, and a selection of icons with tools to cover the most common
drawing, editing and display functions.
Allows the setting of Coordinate data entry

line type, thickness box allows accurate
and colour positioning and
drawing at any time
Simple prompts tell

you what to do next Relocatable drawing
aids toolbox has a
range of commonly
Toolbar help explains used functions
each icon
Workpiece area
Pull out sub-menu.
Select a toolbox icon
to reveal the menu Shows the angle from
the last point located
or drawn
Relocatable draw/edit
toolbox allows easy
access to all the main Help message bar
draw/edit functions
Absolute coordinates shows the position of Shows the distance from the
the cursor relative to the workpiece datum last point located or drawn
(the bottom left hand corner)
Menu Selection Menu items are normally chosen from the menu bar or the toolbox, using the mouse
(although keyboard alternatives are available). To choose a menu item from the
toolbox, position the pointer over the appropriate icon and click the LH mouse button.
Some items such as Grid, will cause the icon to stay depressed until it is chosen again.
Many of the items in the LH toolbox have pull out toolbars.
Boxford 190 VMC 5.1 CAD
These are activated by positioning the pointer on the icon then clicking the LH mouse
button. The required icon can be selected from the icon menu bar. This will select
the item, and change the icon in the toolbar to that chosen. Most menu items, e.g., text,
colour fill, etc., have a related dialogue box for settings. To access these dialogue boxes,
double click on the appropriate icon with the LH mouse button, or click on the icon
with the RH mouse button.
Initial Set-up Before starting to use the CAD system, a number of Initial Set-up steps must be
completed. Select the Set-up menu and complete the following:-
1. UNITS - Specify Millimetres or Inches. More advanced settings for Angle units and
co-ordinate display are also available.
2. WORKPIECE - Specify the X (length) and Y (width) dimensions.
3. GRID and STEP - Specify the X and Y spacing for the Grid and Steps. (The Grid
is visible and the Steps are graduations between the Grid points).
4. SET AS DEFAULT - If you want the CAD system to default to settings 1, 2 and 3
each time you start a new workpiece, then select this option.
5.2 Drawing Aids
Drawing Aids The right hand toolbox contains a number of drawing aids which are active when
selected (icon is dark grey).
Grid Display - Toggles the grid display on and off.
Redraw - Refreshes the screen.
Grid Lock - Locks the cursor movement to the grid spacing.
Step Lock - Locks the cursor movement to the step spacing.
Attach - Attaches the cursor to various points. Set-up can be accessed by Right clicking
on the Attach icon.:-
Radial Lock - Constrains cursor movement to pre-defined angle increments. Set-up can
be accessed by Right clicking on the icon.
Zoom In - Performs a quick and simple zoom in facility on the workpiece area currently
in the centre of the screen.
Zoom Out - Performs a quick and simple zoom out facility on the workpiece area
currently in the centre of the screen.
Undo/Redo Last -Toggles between undo and redo of the last function
Advanced Zooms These functions are available from the Left Hand Toolbox.
Zoom In - Zooms in on a user defined window.
Zoom Last - Reverts to the last specified zoom.
Zoom Sheet - Displays the complete workpiece at maximum zoom.
Zoom All - Displays all drawn entities at maximum zoom.
Zoom = - Zooms in by a user defined magnification factor

5.3 Drawing Tools
Drawing Tools The left hand toolbox contains a variety of drawing tools and are grouped by the type
of entity they are used to define. To view the options within each group, LH Click on
an icon to display the full selection of group icons.
Co-ordinate Entry With all drawing tools that require points to be specified, these can either be defined
with the mouse (using the grid) or by co-ordinate entry.
To enter a co-ordinate, type the values in the co-ordinate data entry field (see section
5.1). These values can be Absolute (distance from the bottom left hand corner of the
workpiece) or Incremental/Relative (distance from the last point). To toggle between
Absolute and Incremental/Relative Modes, Select the Abs or Rel icon to the left of
the data entry field.
Help and Prompts Prompts and help for each icon are displayed on the toolbars to aid the user.
Straight Lines
Single Line - Defines a single straight line - The Start and End point are specified.
Connected Lines - Draws a series of connected lines - The initial Start Point and then the
subsequent End Points are defined. To finish, either double click the LH mouse button
(this will fix the moving line), or click the RH mouse button (this will finish at the last
fixed point).
Chamfer - Draws a chamfer between two lines - The chamfer X and Y dimensions are
entered and the two lines to be chamfered selected. To define a number of different
sized chamfers, RH click on the Icon to access the dimensions.
Circles
Circle - Draws a circle with a given Centre and Point - The circle centre and a point on
the circumference are specified (Note:- the Distance readout is equivalent to the circle
radius).
Circle - Draws a circle with a given Centre and Radius - The circle Radius is entered and
the centre specified. To define a number of different sized circles, RH click the Icon
to access the radius value.
Circle - Draws a circle through 2 points - The two points on the circle circumference
and the centre point are specified. (Note:- the Distance readout is equivalent to the
circle radius).
Circle - Draws a circle through 2 points with given radius - The radius is entered, the
2 points on the circle circumference and the centre point position specified.
To define a number of different sized circles, RH click the Icon to access the radius
value.
Note :- If two points are specified through which it is impossible for a circle of the
specified radius to pass, the error message NOT POSSIBLE is displayed.
Circle - Draws a circle through 3 points - The 3 points on the circle circumference are
specified.
Arcs
Arc - Draws an arc with a given Centre, Start and End points - The centre, start and
end points are specified. (Note:- the Distance readout is equivalent to the arc radius).
Arc - Draws an arc through 2 points - 2 points on the arc and the centre point are
specified. (Note:- the Distance readout is equivalent to the arc radius).
Arc - Draws an arc through 2 points with a given radius - The radius is entered, Minor
or Major arc type selected and 2 points on the arc specified.
To define a number of different sized arcs, RH click the Icon to access the Radius and
Major/Minorvalues.
Note :- If two points are specified through which it is impossible for an arc of the
specified radius to pass, the error message NOT POSSIBLE is displayed.
Arc - Draws and arc through 3 points. - The 3 points on the arc are specified.
Fillet - Draws a fillet between two lines - The radius dimension is entered and the two
lines to be chamfered selected. To define a number of different sized fillets, RH click
on the Icon to access the radius value.
Ellipse
Ellipse - Draws an ellipse - The centre and corner of the box surrounding the box is
specified (see diagram below).
Theoretical box Corner

surrounding ellipse
+ Centre
Shapes
Rectangle - Draws a horizontal rectangle - Opposite corners of the rectangle are
specified.
Rectangle - Draws a rectangle at any angle - Two points define the first side of the
rectangle (and its angle). The third point determines the length or width of the
rectangle.
Triangle - Draws a triangle at any angle - The 3 points of the triangle are defined.
Parallelogram - Draws a parallelogram at any angle - Two point define the first side of
the parallelogram (and its angle). The third point determines the angle and length of
the opposite sides.
Polygon - Draws a regular polygon with a given centre and vertex - The number of sides
is entered via the dialogue box below. The start angle can be entered at this point or
defined later. Clockwise or Anti-clockwise orientation of the angle can be specified.
The side length or Internal Radius or External Radius can also be specified
Internal Radius
External
Radius
Side
Length +
Start
Angle
OK is selected and the centre point specified. If necessary, the external radius is
set by specifying a second point.
Polygon - Draws a regular polygon with a given internal radius and centre. The Start
Angle can be entered at this point or defined later. Clockwise or Anticlockwise
orientation of the angle can be specified. The Internal Radius is specified.
OK is selected and the centre point specified.

Beziers
Open Bezier - Draws an open ended bezier curve - The initial Start Point and then the
subsequent End Points are defined. To finish, either double click the LH mouse button
(this will fix the moving bezier), or click the RH mouse button (this will finish at the
last fixed point).
Closed Bezier - Draws a closed bezier curve - The initial Start Point and then the
subsequent End Points are defined. To finish, and close the path either double click
the LH mouse button, or click the RH mouse button.
Open Polyline - Draws an open polyline (series of connected straight lines). The initial
Start Point and then the subsequent End Points are defined. To finish, either double
click the LH mouse button, or click the RH mouse button.
Note :- An Open Polyline differs from a series of connected straight lines because
when complete the lines are part of a single object).
Closed Polyline - Draws a closed polyline (series of connected straight lines. To finish,
and close the path either double click the LH mouse button, or click the RH mouse
button.
Text Strings
Text - Defines Linear Text strings - The start point is located bringing up the
dialogue box shown below.
At the prompt the required text is typed and Settings selected.

The dialogue box below is shown.
Font
The font type can be selected from the list of all the True Type fonts available on the
system. Font styles can also be selected.
Size
The font height can be selected (this is very easy to manipulate later - see Editing
Objects in section 5.4 for further details).
Alignment
The alignment from the previously defined start position can be set to Left, Right or
Cantered.
Attributes
The Line Type, Line Colour, Fill Type and Fill Colour can all be set. The default setting
is filled text with a thin outline. The relevance of these settings with regard to
machining is covered in section 5.6 (CAD Machining Considerations).
Once all the settings are correct, select OK The previous input box is displayed.
Select OK The text object appears on the workpiece.
5.4 Editing Objects
Selecting Objects
Select - Objects can be selected by :-
1. Dragging a box around the objects to be selected.
2. Selecting Individual Objects with the LH mouse button and subsequent objects
(if required) with the RH mouse button (or SHIFT + LH button).
Once an object or group of objects are selected, the selected objects are drawn in pink
and surrounded by a dotted box (a marquee box) with handles. This is shown below.
These handles provide quick edit functions. For more advanced features, see
Transformations described later in this section.
Re-Size Re-Size Re-Size

Mirror Horizontally
Re-Position
(move)
Re-Size
Mirror Rotate
Vertically
Re-Size
Copy
Re-Size Re-Size Re-Size
Re-Sizing
LH mouse clicking any square handle around the outside of the marquee box allows
the current selection to be re-sized. Clicking again redraws the selection to the new
specification.
Warning:- moving these handles alters the aspect ratio of the current selection. To re-
size whilst maintaining aspect ratio, select the square handles with the RH mouse
button.
Re-Positioning (Moving) LH clicking on the central square handle allows the current selection to be moved.
Clicking again redraws the selection in the new position.
Mirroring The diamond (rhombic) handles, to the top and left, mirror the current selection
horizontally and vertically respectively.
Rotating The circular handle to the right allows the current selection to be rotated.
Copying The double square handle at the bottom performs a quick copy and paste of the current
selection, leaving the new object selected.
Editing Objects
When a selection is made, a toolbox appears in the right hand corner of the CAD
window. Selecting Start Edit greys the selection and provides a number of coloured
edit handles as shown below.
The convention of these handle colours depends on the object selected and are
generally as follows.
Line Green = Start Node, Red = End Node - Each can be re-positioned.
Circles Red = Node on Circumference, Yellow = Centre Node - Each can be repositioned.
Arcs Green = Start Node, Red = End Node, Yellow = Centre Node - Each can be re-
positioned.
Closed Polylines Red = Start and Finish Node, Orange = Intermediate Nodes - Each can be re-
(including Shapes) positioned.
Open Polylines Green = Start Node, Red = End Node, Orange = Intermediate Nodes - Each can be
re-positioned.
Closed Bezier Curves Red = Start and Finish Node, Orange = Intermediate Nodes, Yellow = Node Handles
- Each can be re-positioned individually. Additionally, moving the yellow node handles
with the RH mouse button locks the angle between them allowing them to move
together
Open Bezier Curves Green = Start Node, Red = End Node, Orange = Intermediate Nodes, Yellow = Node
Handles - Movement as per Closed Beziers.
Text Yellow = Bottom left hand corner of imaginary rectangular box enclosing each
individual character. - Each character can be re-positioned.
Transforming Objects Selected objects can be transformed using a variety of tools :-
Move/Copy - Moves, and/or copies the current selection. The user can opt to replace
the current selection or create a user-defined number of repeats. A reference point
(usually on the selected object) is located and then a new position for the reference
point. An example of a repeat Move/Copy is shown below.
Mirror - Mirrors the current selection. The user can opt to replace the current selection
or repeat it. Two defined points define the axis of reflection. An example of a repeat
Mirror is shown below.
Rotate - Rotates the current selection. The user defines the angle of rotation and can
opt to replace the current selection or create a user-defined number of repeats.
An example of repeat Rotate is shown below.
Rectangular Array - Produces a grid of selected object copies. The number of columns
and rows and the X and Y spacing between them are specified. An example is shown
below.
Circular Array - Produces rotated copies of selected objects. The angle of rotation and
number of repeats are specified. The centre of rotation is defined. An example is
shown below.
Distort - Distorts the currently selected objects. The user can opt to replace the current
selection or create a user-defined number of repeats. The selected objects are
surrounded by a greyed outline with 4 handles. Re-positioning the handles and clicking
away from the selection will produce a distorted object which best fits the new handle
positions. An example of a replaced distort is shown below.
Deleting Objects There are a number of ways to delete objects using either icons from the toolboxes or
Hot Key combinations.
Delete Last - Deletes objects one at a time in the order they were drawn (most recent
first).
Delete Any - Deletes individual entities - A hand pointer is provided to select the
individual objects to be deleted.
Delete Inside Box - Deletes entities within a user defined box (by dragging).
Delete Part of Entity Between two nearest intersections - Automatically trims a line back to the
nearest intersection. A hand pointer is provided to select the part of the entity to be
deleted. An example of tool use is shown below.
Before After
Useful Delete Hot Keys

Ctrl + Del - Deletes the current selection.
Ctrl + Backspace - Deletes the last drawn entities.
Alt + Del - Deletes all drawing entities.
Setting/Editing The attribute of an object (entity) defines the way it is machined. For details see section
Object Attributes 5.6 (Machining Considerations).
Object attributes can be set before they are drawn, or the current selection can be edited
in the following way:-
Line Thickness From the top of the CAD window select
The user can define:-

Line Type - continuous, dotted, dashes etc.
Line Pitch - the pitch of dotted and dashed lines
Width - Either Fine or Thick (with a user defined thickness).
Line Colour From the top of the CAD window select

Warning - Choose only colours from the custom Pallet (the reason for this is explained
in Section 5.6)
OK is selected.
Text
When a Text selection is made, a toolbox appears in the right hand corner of the CAD
window. Selecting Property brings up the text input box. The Text string, Font,
Effects, Line and Fill properties can all de redefined. See Text Strings in section 5.3 for
more details.
5.5 Area Filling
Area Filling One of the most important Tools to understand is colour filling as this largely dictates
what is actually machined (see Section 5.6 for more details on machining considerations).
Area - Fills areas between closed boundaries, accounting for islands.

On selecting the area tool, the following dialogue box is shown.
is selected bringing up the colour selection dialogue box.

Warning:- As with line colour settings, choose only colours from the custom Pallet (the reason
for this is explained in Section 5.6).
OK is selected.
The user is prompted to:-
1. Locate on edge of boundary on side for hatch - This is the outer boundary of the fill.
In the example shown below, if the area between the 2 circles is to be filled, the larger
circle is the outer boundary. The boundary is located with the hand pointer.
Outer Boundary
Island
2. The user is asked if there are any islands within the outer boundary.
Looking at the example on the previous page, the smaller circle is an island within the
larger circle.
YES is selected and the Island located with the Hand Pointer.
The window above is shown again allowing further islands to be defined. In this
example there are no more. NO is selected.
The area is filled.
Outer Boundary
Filled Area
Island
Note:- If a number of filled areas are to be defined, the colour can be redefined by RH
clicking the fill icon.
Text Strings Text strings can be filled by setting the fill attribute when the string is initially defined
(see 5.3), or by selecting Property (see 5.4) when the string is selected.
Text strings can also be islands within a closed outer boundary. In this case, some
characters constitute more than one island as shown below.
Outer
Boundary Islands
If the 2nd Island was not specified, the fill would be as diagram b below instead of the
required fill shown in diagram a.
a. Correct b.Incorrect
5.6 Machining Considerations
Machining Considerations Sections 5.1 - 5.5 have concentrated on the drawing tools within the CAD system.
Some important machining considerations relating to the drawing will now be
discussed.
Colours Sixteen custom colours are available in the colour palette dialogue box. When the
drawing is Post Processed into a G&M code CNC programme, each colour can be
assigned a different depth.
At the Design Stage, all the user must consider is that any objects required to
be cut to a different depth, MUST be assigned a different colour (up to a
maximum of 16 colours).
Machined Objects Objects that are machined are :-

1. Lines with a width setting (not thin lines)
2. Filled Areas
Lines Any line with a width setting (other than thin) will be followed with a Slot Drill of the
equivalent diameter or the nearest one available from the Machine Tool Library (See
section 8 for more details).
Filled Areas Any areas filled with colour can be:-
a. Pocketed out with a variety of tools - (cutter diameter compensation is
automatically implemented)
b. Profiled - around the outside (e.g. for cutting out a shape).
c. Profiled - around the inside (e.g. for leaving a cut-out of the shape in a sheet
of material).
Additionally filled circles can be:-
a. Pocketed out with a variety of tools - or
b. Drilled with a drilling cycle using a drill of the equivalent diameter or
the nearest one available from the Machine Tool Library (See section 8).
Problem Objects With the large variety of drawing tools available, it is important to understand:-
a: What can and what can not be machined.
b: What will be machined.
What cant be machined 1. Lines with a width narrower than the smallest diameter Slot Drill will
not be machined.
2. Filled Circles with a diameter smaller than the smallest diameter Drill
Filled areas which have sections narrower than the Edging Tool (see
section 8 for details of edging tool). This often happens when the pocket
is the internal fill of some fonts as shown below. The circles within the
text represent where the cutter diameter can machine up to.
Notice the difference between what was drawn and what will be machined.
Drawn Text Machined Text
Warning :- If you draw text too small none of it may be machined. Please
remember you are cutting resistant materials and not merely dropping ink onto
paper.
What will be machined As described in the previous section, the system will attempt to machine EVERY Line
with a width setting and Filled Area.
For this reason it is important that Islands are correctly defined. If a filled object (1)
is on top of another filled object (2). object (2) will still be machined even though it
cannot be seen on the screen.
In the example below object (1) has been drawn on top of the solid filled (no Islands)
object (2). If object (1) is to be machined to a depth less than object (2) then it will be
machined away when object (2) is machined.
Overlaid Objects Objects When Seperated
1 1
2 2
Machining Order The objects will be machined on an individual basis working from the back of the
drawing (i.e. the back object is machined first and the front object last).
This can be useful if for instance an object is to be profiled (cut out) as the last operation.
Boxford 190 VMC 6.1 CAM Processor
6 CAM Processor
6.1 Settings
When the CAD drawing is complete and ready to be processed into a G&M code
CNC programme, select File To Mill
The user is required to enter a filename for the drawing (Please ensure this is no
longer than 8 characters).
The CAM Processor Dialogue box shown below is displayed.
The various settings are as follows:-

Material
Selecting the drop down provides a list of the available material types. (See Section
8 - Administrator Mode for details on adding user defined materials and cut data.).
The required material is selected from the list
Edging Tool and Area Tool The drop down for these two tools is a list of the slot drills available in the
Machine Tool Library.
The Edging and Area tool are used to remove (pocket) all Colour Filled areas in
the drawing. There function is as follows.
Edging Tool - This tool performs the finish path around the pocket as shown
with the circular object below
The edging tool is also used to profile around a colour which has been set to
Outside or Inside (see DEPTHS later in this section).
Area Tool - This (usually larger) tool is used to remove the bulk of material from
filled areas as shown with the circular pocket below.
Warning To ensure filled areas are correctly removed, it is strongly recommended

that the ratio between the Edging Tool and The Area tool is 1:2 (e.g. 2mm
Edging Tool & 4mm Area Tool).
It is permissible to set the Area and Edging Tools to be the same diameter to avoid
tool changes during manufacture. Experienced users can experiment with different
combinations for different drawing applications.
Edging & Area Finish Determines the Surface finish produced by the
Edging and Area Tools. Smooth or Coarse is
selected.
Block Size The X (Length) and Y (Width) dimensions are transferred from the drawing. The
user must specify the Z (height or thickness) dimension.
Depths The Colour Depth and Filled area settings are accessed by selecting
For each colour used in the drawing (the others are ignored), the total required
depth is entered. This can include decimal values (2 Decimal places in Metric and
3 Decimal places in imperial). There are 16 colours available which match the 16
custom colours in the CAD colour palette. Hence 16 different depths can be
defined.
Warning If the user defines a depth which can not be achieved by the current tools in the
machine library, the user will be warned upon processing the drawing (see section
6.2 - Error Messages).
To the left of each colour is a drop down menu. These settings affect ONLY
COLOUR FILLED AREAS and not lines with a defined width.
AREA Pockets out all areas with this colour fill with the Area and Edging tools as
described earlier in this section (Edging Tool and Area Tool).
DRILL Uses a drilling cycle to drill circles with a drill of equivalent diameter or the nearest
one (always smaller) available from the machine tool library.
The system will first look for a twist drill of appropriate diameter. If one is not
available, it will look for a spot drill and then a slot drill.
Warning Only colours made up entirely of individually filled circles should be assigned as a
DRILL colour.
INSIDE Profiles around the inside of colour filled pockets using the Edging Tool.
Compensation for the diameter is automatically implemented. This can be
particularly useful when cutting profiles out of thin sheet material.
An example is shown below.
OUTSIDE Profiles around the outside of colour filled pockets using the Edging Tool.
Compensation for the diameter is automatically implemented.
When all the Colour Depths and Area Setting are complete, OK is selected.
Processing To process the Drawing and create a G&M CNC programme, is

selected. The message below is displayed
Selecting YES saves the CAM processor settings with the drawing.
The processor analyses the Drawing and produces a G&M code CNC programme specifying
Cutter Paths, Speeds, Feeds and Cut Depths appropriate to the material type selected and the
tooling available.
The following message is displayed.
Factors Affecting Processing There are a number of factors which will affect the processing time.
1. Pocketing out complicated areas (particularly text strings) will increase

processing time.
2. Processing lines with a defined Width will be relatively quick.
3. The higher specification the PC Computers Main Processor the quicker
processing will be.
4. If the user has accidentally specified an unusually deep pocket, processing
time will be significantly increased. If you suspect a mistake, press the ESC
key on the keyboard to abort processing.
Tool Path Simulation When the drawing has been processed the following dialogue box will be displayed
(Please note if processing reveals any errors this dialogue box will be proceeded by
an error message dialogue box - see section 6.2 for details).
The user is prompted to select a Catalogue number to place the file into.
Catalogues - All manufacture programs (G&M 9
programs) are filed in Catalogues. There are 9 6
7
8
catalogues available to the user. 4

5
3
2
A catalogue is selected. If a file of the same 1
name already exists in the selected catalogue,

the following dialogue box appears.
The file can be overwritten by selecting YES or NO can be selected bringing up

the following dialogue box.
The filename can be changed and/or the catalogue changed. OK is selected.

A 2 Dimensional simulation of the cutter path is shown. This is the final user
check of the component that will Actually Be Machined. Any areas which can
not be removed because of tooling limitations will be omitted. (see section 5.6 for
more details)
Warning :- Please check this 2 Dimensional View very carefully.
3 Dimensional View For details on 3D Views, View Manipulation and Cycle Details see sections 2 and
10.
6.2 CAM Processor Error Messages
When Processing a drawing, the CAM processor compares the drawing

requirements with the Cutting Tools available. If any drawing requirements can
not be satisfied, then an error message (or messages) is displayed.
The user can continue processing by selecting

A program with the compromised settings (safe) is produced.
or
The user can abort processing by selecting and reprocess the drawing
using different settings.
Error Messages There are a number of error messages which can be reported. Their description
and causes are as follows:-
Cut Depth - The Cut Depth (Total - not cut per pass) will never exceed the Tool
Length value defined in the tool library (see Section 8 for more details)
e.g. 2.0mm slot drill is unable to cut deeper than 10.000mm
Cutter Diameter - If a Tool from the Tool Library cannot match a line with
defined width, or a drilled hole with defined diameter, the processor will choose
the nearest smaller diameter tool.
e.g. 8.0mm drill was not found, using 6.0mm instead
If a line width or hole diameter less than the smallest tool are specified, the objects
will not be machined.
e.g. could not find a drill 1.5mm or less
Boxford 190 VMC 7.1 File Imports
7 File Imports
7.1 Drawing File Import
File Types The following drawing file types can be imported.
1 Design Tools Files (*.dtd)
2 Acorn Draw Files (*.aff)
3 Designer V3 COMMS Files (*.dv3)
4 DXF Files (*.dxf)
5 Enhanced Metafiles (*.emf)
6 Windows Metafiles (*.wmf)
File Export Rules Which ever drawing package you export from, there are some guidelines which will
help you to successfully export files suitable for importing into the Boxford
CADCAM package.
Drawing Size - Set the drawing size (or custom paper size) to the Workpiece size
you intend to use.
Drawing Origin - Set the drawing Origin to be the Bottom Left corner of the
Drawing (paper) area.
Length
Drawing Area
Width (Paper Size)
Drawing Origin
Line Width - Unless you can accurately set line widths to a specified value, do not
export lines with a width. Line width attributes can be set in the Boxford
CADCAM package after importing.
Filled Areas - DO NOT export any colour filled areas. Colour filled areas are
assigned in the Boxford CADCAM package after importing.
Dimension Lines - DO NOT export any Dimension Lines.
Importing Drawing Files The CAD Icon is selected from the Boxford CADCAM package.
CAD Icon
Workpiece Size - The workpiece size is set-up to suit the file intended for import.
(this should be equivalent to the Drawing Area/Paper Size used to create the
original file).
File Import File is selected bringing up the dialogue box shown below. The file
type is selected from the drop down menu.
The file to be imported is located and Open selected

Import Filters The various import filters have differing import options, described as follows:
1 Design Tools Files (*.dtd)
Opens a Techsoft 2D Design Tools File.
3 Designer V3 COMMS Files (*.dv3)
Opens the file automatically (no user settings are required).
2 Acorn Draw Files (*.aff)
5 Enhanced Metafiles (*.emf)
6 Windows Metafiles (*.wmf)
On opening any of these file types, the following dialogue box appears.
The options are:-

Centre In Window - Centres the imported drawing entities in the centre of the
workpiece. Not selecting this option will maintain the relationship between the
drawn entities and the origin.
Centre = =
In Window
=
=
Imported Entities Workpiece
Group - Loads the imported entities as a single grouped object.

Scale - Scales the imported entities by a user defined value.
4 DXF Files (*.dxf)

On opening a DXF file the following dialogue box appears.
The options are:-

Interpret Units and Position - Allows the import units to be specified and
maintains the relationship between the drawn entities and the origin.
The Units Interpretation and Position options are:-
Inch or mm - set to suit the file to be imported
Centre in Window - Centres the imported drawing entities in the centre of the
workpiece (see previous page for details)
Scale - Scales the imported entities by a user defined value.
Fit to Media - Scales the imported entities to fit the workpiece whilst maintaining
the aspect ratio.
The scaling factor is limited by the first axis the entities fill (X or Y).
In the example below, the scaling is limited by the workpiece width (Y axis) and
the entities centred along the length (X axis).
Fit To Length (X)

Media
= =
Width (Y)
Imported Entities Workpiece
Load as Group - Loads the imported entities as a single grouped object

Dimensioning preference - Ignore these options - DO NOT attempt to
import dimensions.
Processing Imported Files Once imported, individual entity attributes and colour filled areas can be specified
as described in Section 5.
The drawing is processed as normal, see Section 6 for details.
7.2 G&M Code Programme Import
The following procedure imports a G&M code program produced on a Third

Party CADCAM package.
From the main front end menu is selected followed by
From the File Open dialogue box, the file to be opened is selected.
The user is prompted to select a Catalogue number to place the file into.
All manufacture programs (G&M programs) are filed in Catalogues. There are 9
catalogues available to the user.
A catalogue is selected. If a file of the same name already exists in the selected
catalogue, the following dialogue box appears.
The file can be overwritten by selecting YES or NO can be selected bringing up

the following dialogue box.
The filename can be changed and/or the catalogue changed. OK is selected.

A 2 Dimensional simulation of the cutter path is shown.

This simulation does not have to be completed. Pressing the ESC key will stop
the simulation and write the file to disc ready for manufacturing.
Manufacture For details on Manufacturing see section 11.
File Import Specification The required Import file specification is as per the following example.
G71 Units
G101 X125.000 Y75.000 Z10.000 Workpiece Size
G00 X0.000 Y0.000 Z20.000 X, Y, Z Park Position
M05 Spindle Stop
M06 I2 J4 I=Tool Dia. J=Type
M03 S3000 Start Spindle S=RPM
G00 X61.875 Y38.403 Z2.000
G01 Z-1.000 F600.000
... Body of Program
G01 X56.422 F600.000 G00 and G01 Moves
G00 Z2.000 F=Feedrate
G00 Z20.000
G00 X0.000 Y0.000
M05
M06 I2 J2 Tool Change
M03 S3000
G00 X56.422 Y37.602 Z2.000
G00 X62.909 Y38.194
G01 Z-1.000 F600.000 Body of Program
... G00 and G01 Moves
G01 X62.909 Y38.194 F600.000 F=Feedrate
G00 Z2.000
G00 Z20.000
G00 X0.000 Y0.000
M05
M30 Cycle End-make another
Further Details For specific post processor specifications please contact Boxford direct.
Boxford 190 VMC Administration Mode
8 Administration Mode
8.1 Access & Password Setting
An administration mode is built into the Boxford CADCAM package allowing
authorised personnel to access and modify important CAM processor data files and
machine tool data files.
Any modifications that are defined will be applied to every future processed drawing.
Network Administrators To be able to use the Boxford administration mode and write to the relevant data
files, you must have read/write access to the Public Drive
Setting a Password With the Front End menu screen displayed, the F10 key is pressed, to define a
password, or modify and existing one. The dialogue box below is shown.
is selected.
The user is prompted to Enter CURRENT Password.

If an initial password is to be defined, OK is selected.
If an existing password is to be re-defined, the existing password is input and OK
selected.
Boxford 190 VMC 8.1 Administration Mode
The user is prompted to Enter NEW Password

The new Password is input OK selected followed by :-
Accessing Admin. Mode Each time the software is started, the system defaults to Standard User mode. With
the Front End menu screen displayed, Administration mode is accessed by:-
a. Pressing the F10 key
b. Selecting
c. Inputting the current password and selecting OK
d. Selecting
Selecting the Configuration Icon reveals a number of icons in addition to the
Standard User Import G&M file option (see section 7.2 for details).
8.2 Tool Library
Accesses the tool library shown below.
New tools can be defined and existing Tools modified or removed.

Defining a New Tool Using the LH mouse button or keyboard cursor, Highlight an empty tool library
line.
Select Edit Tool The dialogue below is shown.
From the Tool Type drop down, select the Tool type
to be defined.
Input the Tool Diameter and Length.
The length is the maximum depth the Tool can cut Flute
to, and is usually the flute length as shown in the Length
diagram opposite.
Edit an existing Tool Highlight the tool to be edited and Select Edit Tool
Remove an existing Tool Highlight the tool and select Remove
Saving To close and save the tool library data, select Finish
8.3 Material Cutting Data
Accesses the Material Cutting Data shown below.

This data is used by the CAM processor when creating a G&M code CNC
programme from a drawing.
For each Material Type, Cutting data can be specified for differing Tool types and
Tool Size ranges. New materials can be added and existing ones Modified or
Deleted.
Tool Type Slot Drill, Spot Drill and Drill can be selected (Note:- these are the only tools used
by the CAM processor).
Tool Size The Tool sizes are grouped in a range of diameters. Cutting parameters can be set
for each range.
Material The Cutting Data file supplied with the software package includes a selection of
Default material types. User-defined materials can be added up to a maximum of
six material types in total.
Adding a New Material

Add Material is selected. The dialogue box below is shown.
The user is prompted to Enter material to add to list.

The material name is input and OK selected.
Deleting an Existing Material

The material to be deleted is selected using the Material drop down menu.
Delete Material is selected. The dialogue box below is shown.
YES is selected to confirm the material delete.
Feedrate The rate at which the axes move in mm/min.

Speed The spindle speed in Revolution Per Minute (RPM)
Cut Depth/Pass The depth of cut per pass of a pocket, slot or hole.
Note:- this is not to be mistaken for the maximum achievable depth which is
limited by the tool length (see Section 8.2).
Process The surface finish settings. Two options are available - Smooth and Coarse.
Flatness
For each surface finish setting, a flatness value in microns can be set. The flatness
value determines the finish around curved paths.
As the flatness value increases curves (arcs) will visibly comprise of a number of
straight lines as shown in the diagram below.
Smooth Coarse
Drawn Curve
Machined Curve
Note:
The Default values have been carefully chosen and should only be changed by
experienced users.
Restoring Defaults Restore Defaults is selected to return All Cutting Data to the Factory settings
Saving To save the modified Cutting Data, select OK
To exit without saving changes, select Cancel

8.4 Park Position and Units
Park Position Accesses the park position settings shown below.
The Park Position is the position of the Tool in relation to the workpiece datum
(front left corner) at Tool Changes and the Start/End of Cycle.
X, Y and Z values are specified.
Restoring Defaults
Restore Defaults is selected to restore the Factory settings.
Saving
To save the modified Cutting Data, select OK
To exit without saving changes, select Cancel
Units Accesses the units settings for Administration mode as shown below.
Metric or Imperial units are selected. OK saves the setting.

8.5 CAM Processor Default Settings
CAM Default Settings Accesses the CAM Processor settings shown below.
These default settings are used with every NEW CAD Drawing created.
The various parameters are set as described in section 6 of this manual.
Selecting saves the default CAM settings.
8.6 Language Settings
Language Settings Accesses the Language options for the software.

Note:- This sets the language for the CAD and CAM software but not
for the G&M Code CNC Programme Simulator and machine driver
which has its own configuration menu. See Installation and User manual for
details.
The icon is selected displaying the dialogue box below.
From the drop down menu, the required language is specified.
OK is selected to confirm the selection.
For the new setting to take effect, the software must now be restarted by exiting to
the windows desktop and re-starting the software.
Boxford 190 VMC Cutter Path CAM Programming
9 Cutter Path CAM Programming

9.1 Functions
The CAM programming features of the 190 Software provide the following functions:
New Programs A new component is created by producing a cutter path on screen. When the cutter
path is complete, it is processed by the software which converts it into a CNC program
and saves the program. The appropriate G and M codes are included, and speeds and
feeds are incorporated into the program automatically.
Existing Programs Programs created in CAM format are presented in CNC format using absolute co-
ordinates. Programs stored in a CAM or CNC catalogue can only be viewed and edited
in CNC format.
Boxford 190 VMC 9.2 Cutter Path CAM Programming
9.2 Information Required
To create a new CAM program you will need the following information:
1. Drawing with co-ordinates:
For a rectangular billet, the work datum is the bottom left-hand corner of the billet;
for a circular billet it is the bottom left-hand corner of a square enclosing the billet, (see
Section 3, Figure 3.1). Dimensions along the X and Y axis should be marked from this
datum as shown in the example in 9.4.
2. Tools Used:
Choose the appropriate tools for each machining operation, and set up the tooling as
for CNC machining (see Section 11).
3. Details of the Billet:
Rectangular Billet Circular Billet
Length (along X-axis) Diameter
Width (along Y-axis) Total height (thickness)
Total height (thickness) Material (aluminium or plastic)
Material (steel, aluminium/brass, or plastic).
4. Program Name:
A name for your program (7 characters maximum - do not use spaces, . \ or / in the
name)
5. Configuration Settings:
Decide on the required configuration settings for the hardware and software.
9.3 Defining a Component
Check configuration 1. From the main menu, select CONFIG - Program. Check the UNITS MODE setting
and set GRID SNAP to the required degree of fineness.
Turn OFF the display and save settings.
Input Program Details 2. From the main menu select PROGRAM - Cam, and from the catalogue select NEW
PROGRAM. Input the program title, type of billet (rectangular or circular), billet
dimensions, and material type, as for CNC programming.
Select Initial Tool 3. After inputting the program details select OK or press Return. The screen shows
the Tool Data Library with a sub-menu listing the tools. Tool no. 1 is highlighted.
For the example given in 9.4 , accept tool no. 1, which should be a 5mm end mill. To
change the initial tool, select the required tool number from the pull-down menu.
4. Click on the highlighted tool details, or press Return; the screen shows the CAM
display, (Figure 9.1).
CAM Display
(Figure 9.1) The display enables a component to be difined using straight lines, arcs, and pocket
milling functions, superimposed on the outline of the billet (3). As each element of the
component is added, the corresponding line of the program appears in the program
display window (1), in CAM program format.
LINE Straight lines (grooves) can be drawn using a mouse, the keyboard, or by manual input
of data, (see section 9.5). The LINE option includes a Rapid function for
moving the tool to the next cutting position.
ARC Arcs can be drawn using a mouse or by manual input of data, (see 9.6 below).
POCKET Pocket functions comprise rectangular and circular pockets, slots, PCD drilling, dish
milling and tapping by manual input of data, (see 9.7 below).
OTHER This option provides the following functions:
Tool Change To be selected at the appropriate point in the program.
Program data Shows program title, billet dimensions, program length and tools used.
Dimension bar Places billet dimensions on the billet outline (3).
Grid on Superimposes a grid and the billet dimensions on the billet outline (3).
1. Program display window

2. Tool co-ordinates
3. Billet outline (rectangular or circular)
4. Initial tool position in X - Y plane
5. Tool control buttons (X - Y plane)
6. Tool depth indicator
1
5
2
3
6
4
END Saves program

LINE For manual input of straight line co-ordinates
ARC For manual input of arc co-ordinates
OTHER See text
POCKET For pocket milling functions (see text)
UNDO Deletes last line of program
MENU See text
Figure 9.1 CAM Display

Save program Saves the program (alternative to END option).

Compensation Makes automatic tool position correction for tool radius when machining profiles, (see
9.8 Profile Compensation).
MENU This option provides the following functions:
Redraw Re-draws the component after changes have been made.
Solid View Produces a 3D view of the workpiece.
Zoom and Unzoom Enable a selected area of the workpiece to be viewed in greater detail. For further
details, see Section 10 - CNC Programming, 10.8.3 Zoom Facility.
Show Dimensions 5. It will be more convenient to work with the dimensions and grid superimposed on the
and Grid billet. Select OTHER , then Dimension bar for dimensions only, Grid on for
dimensions and grid.
Note:
Once selected, these items can only be removed from the display during program-ming, by selecting Re-
draw.
9.4 Example (Figure 9.2)
Figure 9.2 shows a drawing of a component composed of straight lines, an arc, a

rectangular pocket and a single drilled hole..
The straight lines, arc and pocket are machined with a 5mm slot drill, and the single
hole is drilled with a 5mm spot drill so that a tool change will be included in the program.
It will be necessary to set up the spot drill and add it to the Tool Data Library, for
example as follows:
No. Type Tur Description Diameter Offset
2 4 2 Spot drill 5.00 as set
Create a new program as detailed in 9.3, and refer to 9.5, 9.6 and 9.7 for guidance in
producing the component shown in Figure 9.2.
45
Ø5 hole
5 deep
25
10
30
50
35,25
Rad 30
10
15
45
75
80
Material: 15mm thick Plastic
Slot: 5 wide x 2 deep
Tool used: 5mm Slot Drill
5mm Spot Drill
Tool change at: X 0, Y 0
Figure 9.2 Example of Drawing for CAM Program

9.5 Defining Straight Line Moves
Note:
Besides machining straight lines, the 'straight line' functions are also used to move the tool to each new
cutting position as detailed below.
Using a Mouse Horizontal and vertical lines can be defined by clicking on the tool control buttons.
Each line defined by this method will produce one line of the program. This method
cannot be used for diagonal lines.
Note:
Do not use this method for the first line in the example, as the first line required is a diagonal line.
The alternative method is to define the line using the cursor. In the example, the first
line moves the tool to the starting point of the first straight line as shown:
tool control buttons
cross-hairs at starting point

machining (45, 40)
sequence
initial tool
position
Move Tool to Starting Point

1. Place the cursor at approximately the starting point of the first straight line.
2. Press and hold down the left-hand mouse button; the cursor will be replaced by cross-
hairs which are connected to the initial tool position by a straight line which behaves
like a rubber band.
3. Holding down the mouse button, watch the program display and drag the cross-hairs
to set the starting point of the first line in the correct position. The X and Y co-ordinates
will change as the cross-hairs are moved; when they read X=45.00, Y=40.00, release
the mouse button.
4. The tool position will appear on the display as an empty circle since the tool depth is
positive, i.e. the tool is above the surface of the billet; (note that the program display
shows the Z co-ordinate as + 50.00):
Set Depth of Cut

5. The cutter depth for the straight line is 2mm. Place the cursor over the pointer on the
tool depth indicator and drag the pointer downwards, watching the value of the Z co-
ordinate in the program display.
When the Z value is -2.00, release the mouse button. The circle representing the tool
position will be filled in with a colour or tone matching that of the tool depth indicator.
Define Straight Lines
6. Use the cursor to set the end point of the first straight line, in the same way as for the
starting point. For the example, set the end point at X=15, Y=40.
The first straight line will appear on the display:
7. Repeat the procedure to define the second and third straight lines. There is no need
to alter the tool depth (the Z co-ordinate) as all grooves are the same depth:
X=15, Y=10 X=75, Y=10

➔
Using the Keyboard The arrow keys ➔ operate the corresponding tool control buttons to
➔
➔
move the tool in horizontal and vertical lines.
To move the tool to the starting point of the first straight line in the example, it would
be necessary to make a horizontal (X) and a vertical (Y) movement, adding two lines
to the program.
The tool depth cannot be altered using the keyboard directly.
Manual Input 1. Select LINE .

Move Tool to Starting Point
2. To move the tool to the starting position of the first cut, select Rapid. The screen
shows:
The co-ordinates of the initial tool position are shown. Edit the co-ordinates to show
the starting point of the first straight line (X=45.00, Y=40.00), and click OK or press
Return.
3. The display shows the tool position at the starting point of the first straight line.
Set Depth of Cut

4. Select LINE - Z only.
The screen shows:
Edit the display to show the required depth; (for the example, set 2.00).
5. Click outside the display window or press Return.
Define straight Lines
6. The LINE option gives the choice of X only, Y only or Diagonal lines.
Selecting X only or Y only produces a prompt for the end point of the line.
Selecting Diagonal requires the X and Y co-ordinates of the end point of the line.
For the example, select X only for the first line and set the value to 15. Repeat with
Y only for the second line and X only for the third line.
9.6 Defining Arcs
Using a Mouse Arcs are defined by means of the right hand mouse button. As a reminder, select
(Automatic Arcs) ARC and then Mouse Control - the screen shows the message:
Click OK or press Return.

An arc is drawn in three stages as follows:
1. Set End Points
Press and hold down the right hand mouse button, and drag the cross-hairs to the end
point of the arc. Check the co-ordinates on the display. Adjust the position of the cross-
hairs until the co-ordinates are correct, and release the mouse button.
Drag to end point of arc (X=45, Y=40)

then release button
'rubber band'
Start of arc (X=75, Y=10)

- end point of last straight line
2. Select Direction and Radius

Move the cross-hairs away from the end point (1); the cross-hairs will be joined to the
end point by a straight line.
Swing the cross-hairs around the end point (2); the arc will switch from counterclockwise
to clockwise, and the radius will vary as the cross-hairs are moved:
2 Counter clockwise arc
Clockwise arc
For the example, select a counterclockwise arc and set the radius at 30.00mm. Check
the program display for the correct setting:
N90 X=45.00 Y=40.00 Z=-2.00 RADIUS=30.00
3. Enter Setting
When the setting is correct, click either mouse button. The arc will appear on the
display:
If you make a mistake, select UNDO to erase the arc, and repeat the procedure.
Manual Input 1. Select ARC , and Clockwise arc (GO2) or Counterclockwise arc (GO3)
as required.
For the arc in the example, select Counterclockwise arc (GO3).
2. The screen shows:
Enter the radius of the arc. (For example, enter 30.00).

The X and Y co-ordinates shown are those of the end point of the last line drawn (A).
Enter the co-ordinates of the end point of the arc (B).
B
3. Press Return: the arc will appear on the display. If you make a mistake, select UNDO
to erase the arc, and repeat the procedure.
4. After completing the arc, raise the tool clear of the billet:
Drag the pointer of the tool depth indicator upwards with the mouse, or select
LINE - Z only and set the Z co-ordinate to a positive value.
9.7 Cutter Path CAM Programming
Boxford 190 VMC
9.7 Pockets and PCD Drilling
9.7.1 Rectangular Pockets

A rectangular pocket is defined by the X and Y co-ordinates of the centre, and the tool
movements in the X - Y plane symmetrically about the centre:
X move
Y move
centre
The depth of cut (on the Z axis) must also be specified; the software automatically
calculates the number of cuts required to produce the required depth.
Move Tool to Centre of Rectangle
1. Check that the tool is set clear of the billet.
2. Move the tool to the centre of the rectangle; (if necessary refer to 10.5 to use the mouse,
keyboard or manual input).
For the example, set the tool at X=35, Y=25.
Define Rectangle
3. Select POCKET - Rectangle. The screen shows:
Type in each value in turn, pressing Return after each entry.

For the example, set:
X move = 25.00
Y move = 10.00
Z depth = 2.00
Note:
The values can also be edited by clicking on the appropriate box and overtyping.
4. Click on OK or press Return. The display will simulate the machining of the pocket,
with the appropriate number of cuts (which will be included in the program as
parameter J):
9.7.2 Circular Pockets

1. A circular (ring-shaped) pocket is defined by the co-ordinates of the centre, and the
inner and outer diameters of the circle:
inner diameter
outer diameter
centre
For a plain circular pocket, the inner diameter is set to zero.

Boxford 190 VMC
Move Tool to Centre of Pocket

2. Check that the tool is set clear of the billet and move the tool to the centre of the pocket.
Define Circle
3. Select POCKET - Circle. The screen shows:
Type in the values in the same way as for a rectangular billet.

4. Click on OK or press Return. The display will simulate the machining of the pocket
parameter J).
9.7.3 Slots
A slot is defined by the starting point (the tool starting position), and the tool movement
on the X and Y axes required to reach the end point:
end point
Y move
tool starting
position
X move
Move Tool to Starting Position

1. Check that the tool is set clear of the billet, and move the tool to the starting point of
the slot in the same way as setting the tool at the centre of a rectangular or circular
pocket.
Define Slot
2. Select POCKET - Slot. The screen shows:
Type in the values in the same way as for a rectangular or circular pocket.
3. Click on OK or press Return. The display will simulate the machining of the slot
parameter J).
Boxford 190 VMC
9.7.4 PCD Drilling

Holes drilled on a PCD are defined by the centre of the PCD, the number of holes,
and the X and Y tool movement required to position the tool at the first hole. This
enables the radial orientation of the holes to be arranged as required. For example, a
circle of four holes on a circle of 20mm diameter can be defined as follows:
A 1st hole B
1st hole
X=0,Y=10 Y=7.07
X=7.07
Ø20 Ø20
centre centre
For the first hole in example B, the X and Y moves must first be calculated
trigonometrically.
The holes will be drilled in an anticlockwise sequence, starting with the first hole.
The depth of hole (on the Z axis) must also be specified.
Move Tool to Centre of Circle
1. Check that the tool is set clear of the billet, and move the tool to the centre of the circle
in the same way as setting the tool at the centre of a rectangular or circular pocket.
Define Holes
2. Select POCKET - PCD Holes. The screen shows:
Type in the values in the same way as for a rectangular or circular pocket.
3. Click on OK or press Return. The display will simulate the drilling of the holes.
9.7.5 Dish Milling

A dish (flat-bottomed, bowl shaped depression) is defined by the co-ordinates of its
centre point, its inner and outer diameters and its centre depth.
The flat, centre region diameter is defined by the inner diameter input which must not
be less than the tool diameter. The system automatically calculates the depth of each
circular cut required.
Outer diameter
Dish
depth
Inner flat section

diameter
Boxford 190 VMC
Move Tool to Centre of Dish

1. Check that the correct tool is programmed and it is clear of billet surface.
2. Move tool to centre of dish.
Define Dish
3. Select POCKET - Dish. The screen shows:-
Type in the three values required.

4. Click on OK or press Return. The display will simulate the machining of the dish
with the appropriate number and depth of cuts (which will be included in the program
as parameter J).
9.8 Cutter Radius Compensation
The Compensation option enables profiles to be machined by defining the co-

ordinates of the required profile, and automatically compensates for the radius of the
cutter. Profiles may be external or internal, for example:
EXTERNAL PROFILE Billet INTERNAL PROFILE
Cutter
Machined slot
Co-ordinates
In the example, both profiles have the same co-ordinates. Profiles may be composed
of straight lines and arcs. Two adjacent straight lines may be joined by a sharp corner
or by an arc of radius equal to the cutter radius, depending on the change of direction
of cutter movement:
sharp corner radiused corner

Invalid Profiles The software will accept invalid profiles, but the resulting profile will be incorrect. For
example, this profile is not valid because the cutter diameter is greater than the
indentation in the profile:
10mm
8mm
Left and Right Compensation Compensation is defined as left or right in relation to the direction of cutter movement,
(Figure 9.3) and the cutter is displaced to left or right of the required profile by a distance equal to
the cutter radius:
LEFT RIGHT
Compensation Compensation
Profile Profile
The selection of left or right compensation therefore depends on whether the profile
is to be machined in a clockwise or anticlockwise direction, and whether an external
or an internal profile is required, as shown in Figure 9.3.
LEFT Compensation RIGHT Compensation

CLOCKWISE
MACHINING
External profile
Internal profile
ANTICLOCKWISE
MACHINING
External profile
Internal profile
Figure 9.3 Direction of Compensation and Machining

Start and End Point When planning the machining of a profile, select a start and end point on a vertical or
horizontal edge:
typical start and end points
Billet
Profile
Tool parked position
Machining will then begin at the start and end point, traverse the profile in a clockwise
or anticlockwise direction as required, and finish at the start and end point.
Using a corner as a start and end point is not recommended as it may result in an
incomplete profile or may cause the cutter to over-run the corner.
Procedure The procedure for applying the Compensation option is given below, using the
following example, in which the start and end point has been placed on the left hand
side and machining will be carried out in a clockwise direction:
Tool: 6mm slot drill
Co-ordinates shown in the format: X, Y
80
20,40 60,40
50 20,25 External profile
20,10 60,10
Start and end point Groove 3mm deep
To practice using the procedure, select PROGRAM and then Cam, and create a new
program with the billet dimensions and tool details as shown.
Move Tool to Start and End Point

1. Check that the tool is raised clear of the billet.
2. Move the tool to the start and end point (X = 20, Y = 25).
Define the Profile
3. Select OTHER - Compensation. The screen shows:
4. Select Left; (an external profile is required, and machining will be clockwise, so the
cutter must be displaced to the left of the profile).
The screen shows:
5. Type in the diameter of the tool (6.0mm), press Return to accept the setting, and click
on OK or press Return.
6. Lower the tool to the required depth (3.0mm).
7. Program the profile in a clockwise direction, using the mouse or the LINE
option, and the co-ordinates shown in the example.
Finish with the tool at the start and end point (X = 20, Y = 25).
Note that the profile shown on the display is smaller than the required profile by an
amount equal to the cutter radius.
8. Raise the tool clear of the billet.
Cancel Compensation
9. Select Compensation. The screen shows:
Click on YES or press Y or Return.

The display now simulates machining with the applied tool displacement, showing the
required profile and ending with the tool at the start and end point:
9.9 Tool Changing
A tool change is incorporated into a program using the OTHER - Tool change
option. For convenience in changing the tool during machining, it is usual to move the
initial tool to the datum position; when CAM option is being used this is done
automatically.
In the example, the last machining operation ended with tool No.1 at the centre of the
rectangular pocket. For the final operation (drilling the Ø5 hole with a 5mm spot drill),
it is necessary to change the tool and move it to the correct position for drilling the hole:
tool change required

to drill Ø5 hole
current tool
position
The spot drill should be included in the Tool Data Library as Tool No.2, as detailed
in 9.4 Example.
Move Tool to Datum Position
1. Check that the tool is clear of the billet, and move it to the datum position
(X=-5, Y=-5).
Change Tool
2. Select OTHER - Tool change. The screen will show the Tool data Library, with
details of the current (initial) tool:
3. Scroll the display (using the buttons or the keys) until the details of the
➔
➔
required tool are shown. For the example, these should be:
No. Type Description Diameter
2 4 Spot drill 5.00
4. Click on ACCEPT ; the screen will return to the CAM display.
Move Tool to Starting Position
5. Check that the tool is clear of the billet, and move the tool to the starting position.
For the example, the position is X=75, Y=40.
Program Machining Operation
6. Program the machining operation as required.
For the example, set the drill depth by means of the pointer of the tool depth indicator,
or by using the LINE - Z only option.
9.10 Processing a Cutter Path
To process a Cutter Path:

Select END .
The screen shows the message:
To save the program, select YES or press Return.

The screen will briefly show the message: 'Saving file...', and will then show the Program
display.
9.11 Editing a CAM Program
If a program has not been saved, the UNDO option will enable the last line of the
program to be deleted and amended.
Further editing must be carried out in the CNC format as follows:
If the program has not been saved, save the program and wait for the Program display
to appear.
If the program has been saved, select PROGRAM - Program and select the required
program.
Refer to Section 10 - CNC Programming, 10.11 - Editing a Program for further details.
Boxford 190 VMC Manual Data Input CNC Programming
10 Manual Data Input CNC

Programming
10.1 Operations and Programming Sheets
Before commencement of programming the following points require consideration:
1. Drawing
Examine the drawing, choose a work datum and re-dimension from this datum if
necessary, (see Section 3 - Axes and Tooling, 3.2 - Axes, Datums and Offsets).
2. Machining
Decide on the material from which the part is to be machined. Consider the machining
operation and the sequence in which you think that these operations should be
performed.
3. Tooling
Choose appropriate tools for each machining sequence.
4. Work Holding
Decide on the appropriate method, as it is important to avoid collisions of the tool with
the workpiece.
5. Programming
Decide on incremental/absolute dimensions, feed mm/min, spindle speed rev/min.
Use an operations sheet and a programming sheet to record your decisions. Blank
sheets are included at the back of this manual for photocopying.
Boxford 190 VMC 10.2 Manual Data Input CNC Programming
10.2 Absolute and Incremental Co-ordinates
Co-ordinates are expressed as being either absolute or incremental.

1. Absolute Co-ordinates
In this system all co-ordinate locations are programmed from a fixed absolute zero
point (datum).
1
1
6
2. Incremental Co-ordinates
In an incremental numerical control system each co-ordinate location is given in terms
of distance and direction along rectangular axes from the previous position and not
from a fixed datum.
1
1 5
10.3 Speeds and Feeds
Calculating Speeds When writing a program the values for spindle speeds and feed rates have to be entered.
and Feeds With experience a programmer will use values which are known to produce the
required balance between surface finish, tool wear and production time, but for the
beginner the following notes of guidance are offered. These are only basic principles
and the tool manufacturers catalogue should be consulted for specific information.
The cutting speed for a material is the speed at which the cutting edge of the tool passes
Cutting Speed over the surface of the workpiece and is measured in metres per minutes.
Typical values of surface cutting speeds are as follows:
SURFACE CUTTING SPEED (m/min)
Workpiece Material
Cutting Tool Aluminium Cast Mild

Material Alloy Brass Iron Steel
Carbide 250 180 110 180
HSS 120 75 18 28
The machine spindle speed can be calculated using the following formula:
Spindle speed = 1000 x surface cutting speed (m/min)
(rev/min) þ x cutter diameter (mm)

Feed Rate The feed rate in the X Y plane is the speed of traverse of the workpiece. In the Z plane
it is the speed at which the tool is plunged into the work. It is determined by:
feed rate (mm/min) = feed rate (mm/rev) x spindle speed (rev/min)
With milling, two cutters of similar diameter may have different numbers of cutting
edges, and so the feed rate (mm/rev) is determined from:
feed rate (mm/rev) = feed rate (mm/tooth) x number of teeth
Typical values for the feed rate (mm/tooth) are given below, but once again it is
stressed that you use the values suggested by the tool manufacturer for the quality and
type of tool which you are using.
FEED RATE (mm/tooth)

HSS Carbide
End mills Face and End mills Face and

Workpiece and slot shell end and slot shell end
Material drills mills drills mills
Aluminium Alloy 0.2 0.45 0.25 0.55
Brass 0.15 0.36 0.15 0.35
Cast Iron 0.2 0.35 0.25 0.5
Mild Steel 0.14 0.25 0.2 0.4

10.4 Program Format
A program is a series of 'blocks' or lines showing a set of functions and/or co-ordinates.
Input of the program is usually in tabular form (although the CONFIG menu allows
a change to compact form).
A typical format for the 190 machine set up for milling is:
LINE G M X Y Z I J K F S
These are the headings used on the programming sheet, where

LINE is the block or sequence number, and
G the preparatory function
M the miscellaneous function
X the X co-ordinate
Y the Y co-ordinate
Z the Z co-ordinate
I interpolation parameter or additional information as needed
J the number of cuts required
K interpolation parameter or additional information as needed
F feed rate (mm/min)
S spindle speed (rev/min)
10.5 Preparatory Functions (G Codes)
Note:
The G codes can be displayed on the PC screen from the HELP menu.
The address letter G is followed by two digits, and the following codes can be used:
G00 Rapid movement (default value in absence of GO1)
G01 Linear interpolation
G02 Circular interpolation (clockwise)
G03 Circular interpolation (counter clockwise)
G04 Time dwell F = delay (secs)
G25 Jump to block
G26 Return from jump
G28 Mirror image
G40 Cutter compensation cancel
G43 Cutter compensation positive
G44 Cutter compensation negative
G53 Return to original datum
G57 Set new datum position
G70 Imperial units selected
G71 Metric units selected
G79 Point to point milling
G81 Drilling cycle
G82 Drilling cycle with dwell
G83 Drilling cycle with peck
G84 Tapping cycle
G85 Boring cycle
G86 P.C.D. drilling cycle
G87 Dish mill cycle
G88 Rectangle milling cycle
G89 Circle milling cycle
G90 Absolute programming selected
G91 Incremental programming selected
10.6 Miscellaneous Functions (M Codes)
Note:
The M codes can be displayed on the PC screen from the HELP menu.
The address letter M is followed by two digits, and the following codes can be used:
M01 Optional stop
M02 End of program (single quantity)
M03 Spindle start forward
M04 Spindle start reverse
M05 Spindle stop
M06 Tool change
M08 Coolant on
M09 Coolant off
M30 End of program (repeat)
M43 Subroutine create
M44 Subroutine terminate
M45 Subroutine call
M99 Continuation code
Entering M99 into the partially written program causes the program to be
saved to disk.
10.7 Programming a Tool Change
The first cutter to be used enters the program as part of the initial programming
information.
The second and subsequent tools are entered in the program on two lines of
information.
The first line stops the spindle and moves the tool away from the work, the second line
selects the next tool; a typical example of this is shown below:
LINE G M X Y Z I J F S
N120 05 0 0 25
N130 06 2 6
M06 denotes a tool change

I gives the tool type
J is the tool diameter
10.8 Inputting a New Program
10.8.1 Information Required

To input a new program, you will need the following information:
1. A completed programming sheet containing -
Program details
Type of co-ordinates used (absolute or incremental)
Tools used
Speeds and feeds
2. Details of the billet -
Rectangular Billet: Circular Billet:
Length (along the X axis) Diameter
Width (along the Y axis) Height (thickness)
Height (thickness) Material
Material
3. A name for your program (7 characters maximum - do not use spaces, . \ or / in the
name).
4. The type of format for the program display.
The options are tabulated format and compact format. Tabulated format is easier to
read and therefore more suitable for the earlier stages of programming. The programming
sheets used in the Tutorials and Exercises use tabulated format. Compact format is
more typical of the type of display used in industry, and is suitable for the more
advanced programmer.
The type of format can be changed by selecting CONFIG - Program from the main
menu, and setting the DISPLAY TYPE to TABULATED or COMPACT as required.
A program can be input and saved in either format, and can be displayed in either
format by changing the DISPLAY TYPE.
The main procedure (10.8.2 on the following page) deals with the use of tabulated
format, and the example used is taken from Tutorial 2. Instructions for using compact
format are given in 10.8.3.
5. Other configuration settings required.

The STANDOFF option automatically adds the depth of cut to a 2mm standoff
(clearance between tool and workpiece) when using canned cycles.
In MODAL PROGRAMMING, each of the following codes need only be typed once.
Each code is then repeated automatically in subsequent lines until a different code is
typed:
G01 : Linear interpolation
G02 : Circular interpolation (clockwise)
G03 : Circular interpolation (counter-clockwise)
F : Feedrate
These options can be activated by selecting CONFIG - Program from the main menu,
and making the required settings.
10.8.2 Tabulated Format
Check Configuration
1. From the main menu, select CONFIG - Program, and check the following settings:
UNITS MODE = as required (METRIC for Tutorial 2)
PROGRAMMING MODE = as required (ABSOLUTE for Tutorial 2)
OUTPUT FORMAT = TABULATED
GRID SNAP = as required
STANDOFF = as required
MODAL PROGRAMMING = as required
Input Program Details

2. From the main menu, select PROGRAM - Program, and from the catalogue select
NEW PROGRAM. The following display will appear:
Type the name of the program (TUT2) and press Return.
3. Click on OK or press Return. The next display will appear:

4. Select the shape of billet to be used; (Click on the appropriate box, or type R for
Rectangular, C for Circular). For Tutorial 2, select Rectangular. The next display will
appear, prompting for the dimensions of the billet, and showing the dimensions of the
last billet used:
Rectangular billet:
If required, change the length by overtyping. When the correct value is shown, press
Return; the next item (Width) will be highlighted. Set the remaining values and select
the material in the same way. (A separate window shows the codes for material types).
Circular billet:
Edit the diameter, height (maximum thickness) and material of the billet in the same
way as for a rectangular billet.
Note:
The settings can also be edited by using the mouse or the and keys to highlight the required
➔
➔
values, and overtyping.
If you enter a dimension which is too large, the screen shows an error message, for
example:
Click on OK, or press O or Return to return to the previous display to edit the
dimensions.
Select Initial Tool
5. Click on OK or press Return. The screen shows the Tool Data Library with a sub-
menu listing the tools.
Details of tool no. 1 are highlighted:
Highlight the first tool to be used in the machining sequence; (For Tutorial 2, select
Tool 1).
1 2
5
1. Text cursor
2. * indicates that program has changed since it was last saved - save again if required.
! indicates that program has changed since simulation was last drawn -
select VIEW - Redraw to update display.
3. Simulation display
4. Tool depth indicator (pointer shows depth of cut)
5. Tool position
UNDO Deletes last line entered.

VIEW Redraw - updates simulation display to include latest program changes.
Solid view - changes simulation display to 3D view.
Zoom - for viewing areas of billet in greater detail (see text - ZOOM facility).
Unzoom
HELP Displays information for reference during programming (see text).
MENU Options for saving and editing programs (see text).
Figure 10.1 Program WRITE Display

Input Program
6. Click outside the Tool Data Library display or press Return. The screen shows the
Program WRITE display, (Figure 10.1). The first line number (block number) N10
appears automatically at the left of the display, and the text cursor is in the G column.
When typing in the program, precede each item with the letter at the top of the
corresponding column. The cursor will move automatically to the appropriate column
when the letter is typed in.
Type in the first line of the program. For example, the first line of the program for TUT
2 is:
LINE G
N10 90
Type: G90
As the code number is typed, a message appears giving the meaning of the code. (Other
messages give indications of errors such as incorrect speed feeds).
When the line is complete, press Return. The next line number appears automatically
and the cursor moves to the G column in the next line.
Type the second line of the program. For TUT 2 the second line is:
LINE G
N20 71
Type: G71 (Return).
Type the third line. The third line of TUT 2 is:
LINE X Y Z
N30 0 0 25
Type X0 Y0 Z25 (Return).
The cursor moves automatically to the X, Y and Z columns. When Return is pressed
the next line number appears and the cursor moves to the G column.
Continue to input the whole of the Tutorial 2 program.

CAUTION
REMEMBER TO SAVE YOUR PROGRAM BEFORE SWITCHING OFF
THE PC, EVEN IF IT IS NOT COMPLETE. (SEE 10.9 SAVING A
PROGRAM).
Correcting Errors
You can place the text cursor anywhere in the program, and correct errors by
overtyping or by deleting characters with the Backspace (Delete) key and re-typing.
Using a Mouse
Click on the required item in the program to place the text cursor at that position.
Using the Keyboard
➔
➔
Use the and keys to move the text cursor vertically, and the ➔ and
➔ keys to move from column to column.
Although the display shows only three lines of the program, you can scroll the program
to show any line by using the and keys.
➔
➔
For more extensive changes, use the editing facilities available from the MENU option,
(see 10.11 Editing a Program).
HELP HELP provides the following information which you may need to refer to when
creating a program:
G Codes - meanings
M Codes - meanings
Program Data - Title
Workpiece dimensions
Material
Program length (no. of lines)
Estimated manufacture time
Tools used
MENU The features available from the MENU option are used for saving a program (see 10.9)
and editing a program (see 10.11).
10.8.3 ZOOM Facility The Zoom and Unzoom options on the VIEW menu enable a selected area of
the billet to be enlarged and viewed, and the view then to be restored to normal size.
To use the facility, select VIEW - Zoom; the screen shows the Zoom display,
(Figure 10.2). The required area of the billet is defined by the selecting frame (8) which
can be reduced in size (and its aspect ratio altered), and moved to the required position
on the billet.
To demonstrate the Zoom facility using Tutorial 2, input lines N10 - N80 of the
program. This will produce the first of the two L-shaped grooves which can then be
enlarged and viewed as shown in the examples below. To use the facility, first reduce
the selecting frame to the required size, then move it into position as indicated:
There are two methods of reducing the frame:
For a quick reduction, select REDUCE as many times as necessary to give the
required size. (This method gives no control over the aspect ratio of the frame). To
Reduce Selecting Frame increase the size of the frame, select ENLARGE as many times as necessary. To
restore the frame to full size, select RESET .
For accurate sizing, use the horizontal and vertical control bars to reduce the height
and width of the frame (in any order) as follows:
1 2 3
4
7
➠
8
➠ ➠
9 5
➠
6
1. Left arrow 4. Up arrow

2. Slider Horizontal control bar 5. Slider Vertical control bar
3. Right arrow 6. Down arrow
7. Billet
8. Selecting frame-(full size)
9. Reduced selecting frame
REDUCE Reduces size of selecting frame
ENLARGE Enlarges selecting frame
RESET Restores selecting frame to full size
ACCEPT Returns to program WRITE display, showing selected area
Figure 10.2 ZOOM Display

1. Reduce height
➠
5
➠
6
Using a Mouse
Click on 6 or drag slider 5 downwards.
Using the Keyboard
Press
➔
If you reduce the height by too much, select RESET and repeat the operation.
2. Reduce width
➠ 2
3
➠
Using a Mouse
Click on 3 or drag slider 2 to the right.
Using the Keyboard
Press ➔
If you reduce the width by too much, select RESET and repeat the height and
width reduction.
Position Selecting 3. Set Vertical Position

Frame
➠
4
➠➠
5
➠
Using a Mouse
Click on 4 or drag slider 5 upwards. (If you overshoot the required
position, click on 6 or drag the slider 5 downwards).
Using the Keyboard
Press . (If you overshoot the position, press ).
➔
➔
4. Set Horizontal Position

➠➠ 2
1 3
➠ ➠
Using a Mouse
Click on 1 or drag slider 2 to the left. (If you overshoot the required
position, click on 3 or drag the slider to the right).
Using the Keyboard
Press . (If you overshoot the position, press ➔ ).
➔
View Reduced Area 5. When the size and position of the reducing frame are correct, select ACCEPT . The
screen will return to the Program Display, showing the selected area of the billet. The
horizontal and vertical scales will show the co-ordinates of the corners of the selected
area.
6. For a 3D view of the selected area, select VIEW - Solid view. A 3D view will
appear.
To turn off the 3D view, click outside the 3D view window or press Return.
7. To enlarge an area of the billet still further, select ZOOM - Zoom again.
Restore Original View 8. To restore the view to show the complete billet, select VIEW - Unzoom.
10.8.4 Compact format

To input a program in compact format, first check the software configuration as for
tabulated format but set the DISPLAY TYPE to COMPACT.
Input the program information in the same way as for tabulated format. Select
Continue; the screen will return to the Program Write Display. When the Program
WRITE display appears, the panel where the program is input looks like this:
Compare this with Figure 10.1. The line number and the text cursor appear, but there
are no columns with identifying letters.
When typing in the program, precede each item with the letter at the top of the
corresponding column on the programming sheet. There is no need to leave spaces
between items in the line.
When each line is complete, press Return. The next line number appears automatically
and the cursor moves to the first (G) column in the same way as for tabulated format.
In addition, spaces are automatically inserted between items, and numerical values
standardised to show two decimal places. For example, in lines 30, 40 and 50 of Tutorial
1 (TUT 1):
Line 30 type: X0YOZ25 Return
40 type: M03S1500 Return
50 type: X15Y15Z2 Return
Display shows:
N30 X0 Y0 Z25.00
N40 M30 S1500
N50 X15.00 Y15.00 Z2.00
Error correction, and the other features of the Program WRITE display are the same
as for tabulated format.
10.9 Saving a Program
The last line of a program must consist of one of the following codes:
M99 - if the program is unfinished
M02 - for single part manufacture
M30 - for multiple part manufacture
Note:
If you try to save a program which does not end with one of these codes, the software automatically
adds the code M99 to the end of the program.
There are three ways to save a program:
a) At the last line of the program type M99, M02 or M30 as required and press Return;
the program will automatically be saved. (This is the recommended method).
b) from the MENU option, select Save program.
The display will show the message:
Click on OK or press Return; the program will be saved with code M99 added at
the last line.
c)
Using a Mouse
Click on the 'off' button at the top left hand side of the display:
Using the Keyboard

Press ESC
The display will show the message:
Click on YES or press Return; the program will be saved with code M99 added at
the last line.
10.10 Examining an Existing Program
10.10.1 PROGRAM Display

From the main menu select PROGRAM - Program, and from the catalogue select
the required program. The screen shows the following display with a drawing of the
component beneath it:
ZOOM see 10.10.2 below

VIEW
INFO see Section 2 - Running the Demonstration Program
MENU Display
Edit - see 10.11 - Editing a Program
Continue - see 10.12 - Continuing a Program
2D Simulate - see 10.10.3 below
3D Simulate -
Initial Tool - see 10.11 - Editing a Program
10.10.2 ZOOM and VIEW Facility

The ZOOM option enables a selected area of the billet to be enlarged and viewed
in 3D. The VIEW option provides a sectioned view in 3D, at any selected point
in the billet. These two options can be used independently, or together to provide a
sectioned view of a reduced area of the billet.
To demonstrate these options using Tutorial 2, input lines N10 - N80 of the program.
This will produce the first of the two L-shaped grooves which can be manipulated as
shown in the examples below.
ZOOM Select Required Area of Billet
1. Select ZOOM . This will produce a ZOOM display similar to that shown in Section
10, Figure 10.2. If necessary, refer to Section 10, 10.8.3 - Zoom Facility to use the
horizontal and vertical control bars for selecting the required area of the billet. When
you have defined the required area, select ACCEPT .
2. After a pause, the screen will show:
Control
buttons
Manipulate View 3. Manipulate the view as follows:

Using a Mouse
Increase
size
Rotate Rotate
Decrease Restore
size original view
Using the Keyboard

Increase
size
Rotate Rotate
Decrease
size
HOME Restore
original view
To produce a sectioned view, see VIEW below.

To return to the full-size 3D view of the billet, select ZOOM - Unzoom.
To simulate machining, select MENU and then the required option (2D or 3D).
To restore the 2D view of the billet, close down the Program display (click on the 'off'
button or press Return), and re-select the program from the PROGRAM option of
the main menu.
VIEW Produce Sectioned View

4. Select VIEW - Slice. The screen shows:
The Coarse option will advance through the billet in a large step; the Fine option will
advance in a small step. Select Coarse or Fine repeatedly to display the required
section:
Using a Mouse
Click on Coarse or Fine as required
Using the Keyboard
Highlight Coarse or Fine as required, and press Return.
To advance the view automatically through the billet, select Exit or press Return.
To return to the 2D view of the billet (with the full billet displayed in 3D), close down
the Program display (click on the 'off' button or press Return), and re-select the
program from the PROGRAM option of the main menu.
10.10.3 Simulation of Machining

A guide to using the 2D Simulate and 3D Simulate options is given in Section 2 -
Running the Demonstration Program.
In addition, each of these options provides a Zoom and Unzoom facility, enabling the
machining of a selected area of the billet to be examined more closely. These options
operate in a similar way to the ZOOM facility detailed in 10.10.2 above.
10.11 Editing a Program
A new program which has been partly written can be edited, and an existing program
can be edited, by using the MENU editing options described in 10.11.3 below. To
access the options, refer to 10.11.1 New Programs or 10.11.2 Existing Programs as
appropriate.
10.11.1 New Programs
From the program WRITE display (Figure 10.1), select MENU .
10.11.2 Existing Programs
Refer to 10.10 Examining an Existing Program, and select MENU - Edit. The screen
shows the Program EDIT display:
Scrolling Buttons*
1 2 3 4
Scrolling *Mouse Operation Keyboard Operation
Page down 1 Page

Down
Line down 2
➔
Line up 3
➔
Page up 4 Page
Up
Amendments to the program can be made in the same way as detailed in 10.8.2
Tabulated Format - Input Program.
Using a mouse, the text cursor can be moved to the required line by means of the
scrolling buttons as indicated.
To access the editing options, select MENU .
10.11.3 MENU Editing Options
Insert Line
Inserts an additional line, and renumbers subsequent lines. Place the text cursor on the
line above the required new line and press Return.
Clear Line
Deletes program data from a line, but leaves the line number intact. Place the text
cursor on the required line and press Return. The prompt: "ARE YOU SURE? YES/
NO' provides a safeguard against accidental deletion.
Go to Line
Places the text cursor on a specified line:
Type in the required line number and press Return.

Find and Replace

Searches for a specific program item and enables it to be replaced by another specific
item:
For example, to find all occurrences of code M03 (spindle start - reverse) and replace
them with code M04 (spindle start - forward), starting the search from line 90 of the
program, type in the following:
Find M03 Return
Replace with M04 Return
Start line no. 90 Return
SELECTIVE Search
A selective search will stop at each occurrence of the code, with a message such as:
To change the code to the replacement code and search for the next occurrence, select
REPLACE.
To leave the code unchanged and search for the next occurrence, select CONTINUE.
At the end of the search a report will be displayed; for example:
Click on OK or press Return.
GLOBAL Search
A global search will find each occurrence of the code and replace it with the
replacement code. At the end of the search a report will be displayed as for a selective
search.
Header Edit
Enables the name (title) of the program, and the dimensions of the billet (bar) to be
changed. (Refer to 10.8.2 Tabulated Format - Input Program Information).
10.11.4 Changing the Initial Tool

The initial tool used by a program can be changed, and the new tool data saved, as
follows:
1. From the main menu select PROGRAM - Program, and from the catalogue select
the required program.
2. From the Program display, select MENU - Initial tool. The screen will show the
message:
3. Select YES or press Return. The screen will show the Tool Data Library and a sub-
menu listing the tool numbers.
Select the required initial tool from the sub-menu. The screen will show the message:
4. Select YES or press Return. The screen will briefly show the message 'Saving
file.....', and the new tool data will be included in the program.
To check the new tool details, select the program from the catalogue, and select
INFO from the program display.
10.12 Continuing a Program
An incomplete program which has been saved can be continued at the point where
inputting was interrupted.
Refer to 10.10 Examining an Existing Program, and select MENU - Continue.
The display will simulate the completed part of the program in 2D, stopping when the
last line is reached. The M99 code will be deleted from the last line of the program,
enabling inputting to be continued.
Boxford 190 VMC 11.2 CNC and CAM Machining
11 CNC and CAM Machining

The procedure for machining a component produced by a CNC program or a CAM
program is the same. The 190 software executes a CNC program to manufacture the
component; CAM programs are converted to CNC format when they are saved, (see
Section 9.10 - Processing a Cutter Path).
11.1 Initial Checks

Before attempting to machine a component, check:
Reference
1. PC connected to190VMC machine, power Installation and User
switched on and 190 software running. Manual, Section 5, 5.1
2. 190 software correctly configured. Installation and User

Manual, Section 5, 5.5
3. Tooling and offsets for required program Section 3
set and checked.
4. Program verified by simulation Section 5
5. 190 machine initialised.
(Select MACHINE - Reset Machine if
necessary).
6. Billet of correct material and dimensions
fitted in vice.
Select PROGRAM - Program, then select
the required program from the catalogue
Select INFO to check billet dimensions).
7. Guards closed
8. Machine in Automatic mode.
(Press MAN button on
machine control panel)
11.2 Manufacture
1. From the main menu, select MACHINE, then Manufacture.

The screen shows the MANUFACTURE CATALOGUE display.
2. Select the required program. The software will read the machine file for the
component, and the screen will then show:

The user is prompted to fit a workpiece of the required size.

Please ensure the workpiece is to the correct dimensions.
If the Datum Shift option is set to ON, the window below will be shown.
The default values will be automatically defined.

The user can modify the values to suit.
Setting the X Y values to 0.00 will use the standard datum position.
3. When the axes reach the home position, the screen below is shown:
Fit a workpiece of requested size.
4. Click on OK or press Return twice. The screen shows the message:
Enter the measured height from the machine table top to the workpiece top.
5. Select OK or press Return.

The screen shows:
6. Press CYCLE START on the machine control panel.

The screen shows the Manufacture display together with a 2D simulation of the
component. The display also gives a continuous indication of axis displacement and
the line of the program being executed.
If a tool change is required, the program will pause and an appropriate prompt will be
displayed. Change the tool and select OK or Return to continue machining.
7. When the machining cycle is complete, if the program ends with the code M30 the
screen shows:
8. Select Yes or No as required.

If Yes is selected, the screen will prompt for another billet to be fitted.
If No is selected, the screen returns to the main menu.
11.3 Options During Machining
Pressing ESC on keyboard during a machining cycle causes a Status message to be

displayed:
Continue: Programmed machining continues.

Abort: Stops machining and cancels program.
Select option by clicking on appropriate button using the mouse or by pressing its first
letter on the keyboard.
12 Manual Machining
The manual machining feature enables the 190 machine to be controlled from the machine
control panel whilst the PC screen simultaneously displays axis displacement and spindle
speed.
Selecting Manual Mode
1. On the machine control panel ensure that MAN MODE is selected.
2. On the PC select MACHINE from the main menu.
3. Select Manual Mode from the sub-menu. The screen shows the Manual Mode display:
Using the Control Panel

Pressing of the JOG TABLE buttons will move the table and produce corresponding X
axis and Y axis displacements to be displayed on the PC screen.
Pressing of the JOG HEAD buttons will move the head and produce corresponding Z
axis displacements to be displayed on the PC screen.
Operation of the SPINDLE controls will vary the direction of rotation and the speed of
the spindle, and produce corresponding speed indication to be displayed on the PC screen.
Zeroing Tool Displacement
The X ZERO Y ZERO and Z ZERO buttons on the screen display enable the indicated
tool displacement in any axis to be zeroed, so that the tool can be moved in relation to a
selected datum.
1. To use this facility:
2. Set the tool in the required position in relation to the workpiece.
Click on the appropriate ZERO button or buttons to zero the displacement value.
Boxford 190 VMC Robotic Interfacing
13 Robotic Interfacing
13.1 Principles of Interfacing
The interface of Boxford machines into Cim Cells is quite simple although several
things have to be taken into consideration. The following document outlines the way
to connect, program and operate the Boxford machines within a Cim.
When a robot port is fitted to a Boxford machine, a 37 way D connector is fitted to
the rear of the machine. The pin out and circuitry is described later.
The Robot interface provides all the inputs and outputs that would normally be
required to connect to a cim, some of which will not be used in a basic system.
If additional functions are required it would normally be possible to customise the port
after consulting with the Boxford Design Department.
13.2 Hardware and Software Requirements

Hardware The computer being used to run the machine must have 2 com ports and if a mouse
is fitted it must be a bus mouse. In the case of the 8 machines the 2nd com port is fitted
to the rear of the machine as standard.
If a management system is being used to transmit programs to the machine tool then
it must have an RS232 port available and assigned to Com1 or Com2.
Software When using a machine within a Cim Cell then the configuration of the Boxford
software must be set to say the FMS (Flexible Manufacturing System) is connected.
The Fixture Height also needs to be input in the Machine Datums information.
The reasons for the above are as follows:
When the FMS is set to Connected in the configuration. the function of the M30
command changes. At the end of manufacture the machine will no longer run through
the prompts asking if you wish to make another, alter offsets or alter datums, the
prompt Press Cycle Start to continue appears. This allows the Robot controller to
issue a Cycle start without user intervention. In addition to this when a program is
designed in cam the machine busy flag (M81) is automatically set and unset in the
program.
Boxford 190 VMC 13.3 Robotic Interfacing
13.3 Modes of Operation
There are two ways to run a program within a Cim, one is with for a system with a Master
Control Computer the other for a simple machine / Robot combination.
1. If the system is simple then the machine can be set up manually then started with an
external cycle start signal, at the end of manufacture the prompt make another appears.
The robot can then issue a cycle start signal to make another or if a different component
is to be made then the user must intervene and re set-up the machine for the next part.
2. For a more complex system the program is downloaded from a master control
computer, the cycle is started using the Go in Auto signal. The whole cycle will now
run through with no user set-up required. To make another the Go in Auto is resent.
If a different program is to be made then the new program is sent to the machine by
the RS232 link then the Go in Auto start the new program again with no user
intervention.
IMPORTANT!
When using the go in auto command it is very important that the following things are
done. If not a collision could occur.
1. The Fixture Height has been set in the Machine Datum menu.
2. The component block details have been correctly specified when writing the program
(the Block size and material type must be exactly the same as the component to be
manufactured
3. The Block is exactly the size specified in the program.
4. The block is correctly positioned in the machine vice.
The Go in Auto command uses the program header to get the block information, by
so doing the need to make measurements at the start of manufacture is not required.
13.4 Programming Requirements
The machine busy signal is created in the G and M code program, an M81 command
with I set to 1 indicates that the machine is busy or in cycle, If I is set to O then it
indicates the machine is not busy.
If a program is created in the Cam and the configuration is set to FMS connected, then
the M81 commands will automatically be inserted. If the program is created using
Manual Data Input, then the M81 will have to be inserted manually.
Notes 1. After issuing a Cycle Start or Go in Auto there will be a delay before the busy flag is
set. After the program is finished the busy flag will switch off there will again be a
period of time after the program is finished, as the machine moves to its park position,
when the machine is moving but the flag is off.
The controller program must take account these delays when deciding when to service
the machine. Typically the Cycle start signal or Go in Auto will be latched until the busy
flag is set. After the Busy flag switches off there should be typically a 5 second delay
prior to the robot servicing the machine.
2. The Programmed park position in X and Y may need to be edited to give a position
that the robot can easily access to load and unload the machine.
3. If components are used that have a height lower than the vice jaws of the machine it
may be necessary to change the Z park position to ensure the tool clears the vice.
4. Programs created off-line must use the same tools that are available in the machine tool
library. The programs sent down the RS232 from the master control computer will not
be received correctly if they use unavailable tools.
13.5 Connection Requirements
The connections to the 37 way D connector are as indicated below.
PIN FUNCTION INPUT/OUTPUT

1 M81 machine busy when on O/P
2 Guard Opened signal when on O/P
3 Guard Closed signal when on O/P
4 Vice / Chuck Opened signal when on O/P
5 Vice / Chuck Closed signal when on O/P
6 Machine Alarm (Air Low) when on O/P
7-10 Spare
11 Vice clean (air blast) I/P
12 Go in Auto I/P
13 Cycle start request I/P
14 Close Guard request I/P
16 Open Vice/chuck request I/P
17 Close Vice/chuck request I/P
18-21 Spare
22-25 0V
26-37 Spare
The machine inputs for both are internally opto isolated using an ILQ 74 device. The
anode of the internal diode is connected to the machine internal 24V rail via a pull up
resistor.
To activate any machine input the relevant input must be connected to the machine
OV on pins 22-25 of the 37 way connector.
The machine outputs for mills are pulled down to machine ground by a Darlington
transistor Array type ULN 2803. These inputs will sink 500mA maximum and are
internally pulled up to 24V.
When a machine output is activated the pin on the 37way is pulled down to ground.
13.6 RS232 File Transfer
The file transfer from one computer to another can be done in two ways, the first being
with two computers running the Boxford Software the second is when one computer
is running a control program and the other is running Boxford software.
Cable Connection for RS232 File Transfer.
9 Way Female 9 Way Female
Pin Colour Pin
2 RED 3
3 BLU 2
5 GRN 5
7 YEL 8
8 WH 7
LINK PINS 1, 4 and 6 at each connector.
When using this file transfer the configuration of Hardware must first be set. The above
cable must be connected to Com 1 or Com 2 of each computer.
There are two types of possible file transfer which allow for Simple file transfer or
Remote management of the manufactured programs.
1. Simple File Transfer The machine tool controller should be configured so that the RS232 file transfer is set
to the correct port, the machine will be connected to the other Com port.
If transferring Programs from a remote computer running the Boxford software to
the Machine Tool Controller, the remote computer must also have the RS232 file
transfer set to the correct Com port.
With both the Machine Tool Controller and remote computer displaying the opening
software screen, select File, Export, RS232 from the top menu bar. Select the relevant
program from the catalogue display. The program will now automatically be transferred
into the current catalogue on the machine tool controller.
2. Remote Management If transferring programs from a computer not running Boxford software to the
Machine Tool Controller, the Machine Tool Controller must have the configuration
set correctly and be on the opening screen awaiting a program.
The remote computer will use the Transmit.exe program supplied by Boxford. From
a Dos prompt type transmit then return to get help information.
Type Transmit DEMO.GM1 O
This will send the DEMO program out to the computer controlling the machine tool
via Com port 1.
Transmit is the command used to send the file.
The Program name (DEMO) could be prefixed by for example
C:\190H\190H\DEMO.GM1 this would transfer the program from the specified
directory. The file extension GM indicates that it is a G and M code listing and the 1
indicates it is stored in catalogue 1.
The final O indicates the com port used. NOTE: COM1=O, COM2=1.
Note: Only use the transmit function when the CNC machine is not in cycle and the
Machine Tool controller controlling is displaying the opening screen.
13.7 Fully Automated Manufacture

To use a system for fully automated manufacture the Cim Cell will have a master
controller which is connected by RS232 to the Machine Tool Controller.
The method of calling a program for manufacture is as follows:
The command from the master computer is executed:
1. TRANSMIT DEMO.GM1 0
(program Part is transmitted automatically down Com 1 to the computer controlling
the machine.)
2. Connect pin 12 of the 37way D to ground (Go in Auto)
The current program will now be manufactured. Once manufacture has started the
G81output will switch on: at this time the input pin 12 should be disconnected from
ground.
3. To make another repeat 2.
4. To make a different program repeat from 1, but transmit another program name.
Boxford 190 VMC CNC Tutorials and Exercises
CNC Tutorials and Exercises

Boxford 190 VMC Tutorial 1 CNC Tutorials and Exercises
Tutorial 1: X and Y Co-ordinate Calculation -

Absolute and Incremental Co-ordinates
This tutorial gives examples of absolute co-ordinates and incremental co-ordinates.

Absolute Co-ordinates
The code G90 is used to select this type of programming.
Before programming commences the points on the path to be machined are defined
relative to the workpiece datum:
10 Y+
9
8
D
7
6
C B
5
A
4
3
2
X- 1 X+
-10 -9 -8 -7 -6 -5 -4 -3 -2 -1-1 1 2 3 4 5 6 7 8 9 10
-2
-3
H
E -4 ORIGIN
-5 X0 Y0
-6 G
F
-7
-8
-9
-10 Y-
Examples of these co-ordinates are shown in the first table on the next page.
The Z axis is the vertical axis and the datum used is normally the surface of the work.
Z is positive when moving away from the surface and negative when moving towards
or into the surface.
POINT DATUM A B C D E F G H
X 0 5 10 -4 -9 -7 -4 7 5
Y 0 4 5 5 7 -3 -6 -5 -2
Incremental Co-ordinates
The code G91 is used to select this type of programming.
The points on the path to be machined are defined relative to the previous position.
The points for the example on the previous page are shown in the table below.
The Z axis is again the vertical axis, and the points are defined relative to the previous
POINT DATUM A B C D E F G H
X 0 5 5 -14 -5 2 3 11 -2
Y 0 4 1 0 2 -10 -3 1 3
position; positive when moving away from the surface and negative when moving
towards or into the surface.
Exercise 1 : Calculation of Co-ordinates
Tabulate the positions of the points A to H shown in the illustration below:

a) in absolute co-ordinates
b) in incremental co-ordinates
Y+
6
D
5
4
C A
3
B
2
1
X- X+
-8 -7 -6 -5 -4 -3 -2 -1 1 2 3 4 5 6 7 8
-1
F -2 G
-3
-4 H
E
-5
-6
Y-
Tutorial 2: Linear Interpolation
This tutorial illustrates the use of the G01 code; cutting takes place in a straight line
at a controlled feed rate.
Consider the component illustrated below; it is required to mill the two L shaped slots.
45
B C D
20
50
A F E
15
15 20 30
Y
80

X
Grooves: 5 wide x 2 deep
Tool change at: X 0, Y 0, Z 25
The absolute co-ordinates of the points are shown in the table below:
POINT A B C D E F T.C.
X 15 15 45 65 65 35 0
Y 15 35 35 35 15 15 0
The program can be written in tabulated format as shown on the following page.
Note:
G00 is a default value and need not be programmed. The first tool is selected when entering the program
into the computer.
DRAWING DUET PROGRAMMING

PROGRAMMING SHEET SHEET-MILLING SHEET No. 1 OF 1
NUMBER
TITLE TUT 2/1 PROGRAMMED BY
SEQUENCE PREP MISC FEED SPINDLE

No. FUNCTION FUNCTION CO-ORDINATES RATE SPEED
NOTES
N G M X Y Z I J F S
ABSOLUTE PROGRAMMING N10 90
METRIC UNITS N20 71
TOOL CHANGE N30 0 0 25
SPINDLE N40 03 3000
2mm ABOVE POINT A N50 15 15 2
FEED TO 2 DEEP N60 01 –2 200
POINT B N70 01 15 35 200
POINT C N80 01 45 200
2mm ABOVE WORK N90 2
ABOVE POINT D N100 65
FEED TO 5 DEEP N110 01 –2 200
POINT E N120 01 15 200
POINT F N130 01 35 200
2mm ABOVE WORK N140 2
PARK POSITION N150 05 0 0 25
END OF PROGRAM N160 30
Using compact format, the program for the component shown previously will be as
follows:
N10 G90
N20 G71
N30 X0 Y0 Z25
N40 M03 S3000
N50 X15 Y15 Z2
N60 G01 Z-2 F200
N70 G01 X15 Y35 F200
N80 G01 X45 F200
N90 Z2
N100 X65
N110 G01 Z-2 F200
N120 G01 Y15 F200
N130 G01 X35 F200
N140 Z2
N150 M05 X0 Y0 Z25
N160 M30
Incremental Co-ordinates
The incremental co-ordinates for the component are shown in the table below.
Using these co-ordinates the program can be written as shown as follows:
POINT TOOL A B C D E F T.C. FROM

CHANGE F
X 0 35 0 30 20 0 -30 -35
Y 0 35 20 0 0 -20 0 -15
Using these co-ordinates the program can be written as shown as follows:
PROGRAMMING
DUET SHEET
PROGRAMMING SHEET-MILLING SHEET No. 1 OF 1
DRAWING
NUMBER

NOTES
N G M X Y Z I J F S

METRIC UNITS N20 71
INCREMENTAL PROGRAMMING N40 91
SPINDLE START RAPID N50 03 15 15 –23 3000
TO 2mm ABOVE A
FEED TO mm DEPTH N60 01 –4 200
FEED FROM A TO B N70 01 0 20 200
FEED FROM B TO C N80 01 30 0 200
RAPID TO CLEARANCE PLANE N90 4
RAPID TO 2mm ABOVE D N100 20 0
FEED TO 2mm DEPTH N110 01 –4 200
FEED FROM D TO E N120 01 0 –20 200
FEED FROM E TO F N130 01 –30 0 200
RAPID TO CLEARANCE PLANE N140 4
STOP SPINDLE RAPID N150 05 –35 –15 23
TO PARK POSITION
1. Examine the program listed

2. Enter the program into the computer
3. Simulate the machining process and compare the movement of the cutter with the
program
Exercise 2: Linear Interpolation - Absolute Co-ordinates
1. For the component shown below, use a programming sheet and write a program for
the cutter to cut a groove along the path from A to H.
2. Enter your program into the computer and give it a test run.
3. Edit your program if necessary.
F E
C H
50
D G
A B
Y 80

Slots: 5 wide x 2 deep
X
Tool change at: X 0, Y 0, Z 25
POINT TOOL CHANGE A B C D E F G H

X 0 20 60 20 20 60 20 60 60
Y 0 10 10 30 20 40 40 20 30
Tutorial 3: Canned Cycles -

Hole Drilling and Pocket Milling
Canned cycles are used to shorten and simplify the CNC program. This tutorial gives
examples of the G81 Hole Drilling and G88 Pocket Milling cycles.
G81 Hole Drilling
This code drills a hole at the current X and Y values to a depth of Z measured
incrementally from the face of the workpiece and then withdraws to the previous Z
value i.e. 2mm clear.
Enter Z incremental distance from the face of the workpiece to the bottom of the hole)
F (feed rate)
B C
4 x Ø 5 holes
20
50
10 deep
A D
15
20 40
80
Tool change at: X -5, Y -5

POINT A B C D
X 20 20 60 60
Y 15 35 35 15
The program for the component is as follows:
PROGRAMMING
DUET SHEET
DRAWING
TUT3/1
NUMBER

NOTES
N G M X Y Z I J F S
METRIC UNITS N20 71
TOOL CHANGE N30 –5 –5 25
RAPID TRAVERSE 2mm N40 20 15 2
ABOVE HOLE A
SPINDLE ON 1500 rev/min N50 03 3000
DRILL A 10mm DEEP N60 81 – 10 200
RAPID TRAVERSE TO B N70 20 35
DRILL B N80 81 – 10 200
RAPID TRAVERSE TO C N90 60 35
DRILL C N100 81 – 10 200
RAPID TRAVERSE TO D N110 60 15
DRILL D N120 81 – 10 200
SPINDLE STOP TOOL CHANGE N130 05 –5 –5 25
G88 Rectangular Milling

This code mills a rectangular pocket. The tool should be positioned 2mm above the
pocket centre on the previous line.
Enter
X the side length of the rectangle
Y the side width of the rectangle
Z the distance from the workpiece face to the bottom of the pocket
J the number of cuts
F feed rate
The tool returns to its start point when the cycle is complete.
2.5 Rad
15
50
40
80

Pocket: 8 deep
The program for the above component is shown on the following page:
PROGRAMMING
DUET SHEET
DRAWING
NUMBER TUT3/2
TITLE PROGRAMMED BY

NOTES
N G M X Y Z I J F S
METRIC UNITS N20 71
RAPID TO TOOL CHANGE N30 –5 –5 25
2mm ABOVE CENTRE N50 40 25 2
OF POCKET
MILL POCKET N60 88 40 15 8 4 200
1. Examine the two programs.

2. Enter each program into the computer.
3. Simulate the machining process for each program and compare the movement of the
cutter with the program.
Exercise 3: Canned Cycles - Programming a Tool Change
For the component shown below:

1. Tabulate the co-ordinates.
2. Use a programming sheet and write a program to
drill the holes
mill the square pocket
(For tool changing,refer to Section 9.9).
30 4 x Ø 3 through holes
30
30
50
10
20 60
80

Square Pocket: 5mm deep
Tool change at: X 0, Y O
Tutorial 4: Circular Interpolation -

Clockwise and Counter-clockwise
This tutorial illustrates the use of the code G02 (clockwise circular interpolation) and
G03 (counter clockwise circular interpolation).
Circular Interpolation Clockwise
This code moves the table in such a way that a clockwise circular arc is cut in the work
within a single quadrant. The cutter is positioned at the start of the arc on the previous
line of the program.
The arc may be in the X Y, X Z or Y Z plane:
Y X Y
X Z Z
X - Y Plane X - Z Plane Y - Z Plane
- and can be complete (90°) or partial (less than 90°), within a single quadrant:
After entering G02 the following extra information is needed:

X value
Y value two of these values specify the co-ordinates of where the curve finishes, the
Z value other value must be left blank.
I value the distance from the arc centre (incremental) to the tool position at the start
of the cuts measured along:
a) the X axis when cutting in X-Y or X-Z plane
b) the Y axis when cutting in the Y-Z plane
J value the distance from the arc centre (incremental) to the tool position at the start
of the cut measured along:
a) the Y axis when cutting in the X-Y plane
b) the Z axis when cutting in the X-Z or Y-Z plane
Note that I and J are unsigned values.
Alternatively the radius of the arc can be entered as the I value and J left blank.
Clockwise Circular Interpolation (G02)

a) Single quadrant 90° arc in the XY plane
To mill from A to B arc of centre C clockwise interpolation (G02)
CUTTER STARTS AT A
G = 02 X = 35 Y = 20 I=0 J = 10
A 10 R
Y
C B
30
25
X
Datum
b) Single quadrant partial arc in the XY plane

To mill from A to B arc of centre C clockwise interpolation (G02)
G = 02 X = (25 + 5) = 30 Y = (20 + 8.66) = 28.66 I=0 J = 10
10 R
A
30 o B
Y
C
30
25
X
To calculate co-ordinates of B, construct triangle BCD

CD = 10 x cos60 = 10 x 0.5 =5
BD = 10 x sin60 = 10 x 0.866 = 8.66
Note that I and J are unsigned values
A
B Y
60 o X
C D
Circular Interpolation Counter-clockwise

This code moves the table in such a way that a counter-clockwise circular arc is cut in
the work within a single quadrant. The cutter is positioned at the start of the arc on the
previous line of the program.
As with the G02 code, the arc may be in the X-Y, X-Z or Y-Z planes
Y X Y
X Z Z
X - Y Plane X - Z Plane Y - Z Plane
- and can be complete (90°) or partial (less than 90°), within a single quadrant:
After entering G03 the following extra information is needed:

X value
two of these values specify the co-ordinates of where the curve finishes, the other
Y value
value must be left blank.
Z value
I value the distance from the arc centre (incremental) to the tool position at the start
a) the X axis when cutting in X-Y or X-Z plane
b) the Y axis when cutting in the Y-Z plane
J value the distance from the arc centre (incremental) to the tool position at the start
a) the Y axis when cutting in the X-Y plane
b) the Z axis when cutting in the X-Z or Y-Z plane
Note that I and J are unsigned values.
Alternatively the radius of the arc can be entered as the I value and J left blank.
Counter-Clockwise Circular Interpolation (GO3)

a) Single quadrant 90° arc in the XY plane
To mill from B to A arc of centre C counter-clockwise interpolation (G03)
G = 03 X = 25 Y = 30 I = 10 J=0
A 10 R
Y
C B
30
25
X
Datum
b) Single quadrant partial arc in the X-Y plane

To mill from B to A arc of centre C
G = 03 X = 25 Y = 30 I=5 J = 8.66
10 R
A
30 o B
Y
C
30
25
X
To calculate co-ordinates of B, construct triangle BCD

CD = 10 x cos60 = 10 x 0.5 =5
BD = 10 x sin60 = 10 x 0.866 = 8.66
Note that I and J are unsigned values
A
B Y
60 o X
C D
Example
C E
50 B F
10 A G
10
80
Cutter: Ø5
Arcs: 2 deep
Radius: 10
POINT A B C D E F G
X 10 20 30 40 50 60 70
Y 10 20 30 40 30 20 10
The program for the above component is shown on the following page.
Note:
Blocks N70 to N90 define the arc in terms of its radius.
Blocks N100 to N120 define the arc in terms of the co-ordinates of its centre
PROGRAMMING
DUET SHEET
DRAWING
NUMBER TUT4
TITLE PROGRAMMED BY

NOTES
N G M X Y Z I J F S
METRIC UNITS N20 71
TOOL CHANGE N30 –5 –5 25
SPINDLE START N40 03 3000
POINT A N50 10 10 2
FEED TO DEPTH N60 01 –2 200
A TO B N70 02 20 20 10
B TO C N80 03 30 30 10
C TO D N90 02 40 40 10
D TO E N100 02 50 30 0 10
E TO F N110 03 60 20 10 0
F TO G N120 02 70 10 0 10
RAPID OUT N130 2
1. Examine the program.

2. Enter the program into the computer.
3. Simulate the machining process and compare the movement of the cutter with the
program.
Exercise 4: Circular Interpolation
10 Rad
D
A J H G
50
C E
25
B 10 Rad
F 10 Rad
10
80
Material: 15mm deep Plastic

Slot: 5 wide, 2 deep
For the cutter path shown above:

1. Tabulate the co-ordinates A to J.
2. Use a programming sheet to write a program for the path of the cutter centre line.
Note:
The curve must be programmed in a series of quadrants (90°).
Tutorial 5: Combining Operations and Tool Changing
This tutorial uses some cutters not supplied with the machine. It illustrates how tool
changes can be made and a number of operation can be carried out on one component.
Sequence of Operations
80
A D
4 x Ø 5 holes
E F
Ø30
20
50
D G
15
B 20 40 C
15
13
Material: Plastic
5 5
1. Mill the steps (8mm diameter cutter)

2. Drill the holes (5mm diameter drill)
3. Mill the 30mm diameter pocket (10mm diameter cutter)
Note: Tool Changing
The program for the above component illustrates the method of programming a tool change; block N120
moves the cutter to a tool change position and block N130 calls up a new tool.
M06 denotes a tool change -
I gives the tool type,
J the tool diameter, and
The program is as follows:
PROGRAMMING
DUET SHEET
DRAWING
NUMBER
TITLE TUT 5 PROGRAMMED BY

NOTES
N G M X Y Z I J F S
METRIC UNITS N20 71
TOOL CHANGE ø CUTTER N30 –5 –5 25
RAPID TRAVERSE 2mm ABOVE A N40 1 54 2
MILL FIRST STEP N70 01 –5 200
RAPID TRAVERSE 2mm ABOVE C N80 79 –5 2
MILL SECOND STEP N100 01 55 200
TOOL CHANGE POSITION N120 05 –5 –5 25
TOOL CHANGE (5mm DRILL) N130 06 8 5
RAPID TRAVERSE OVER HOLE D N140 20 15 2
SPINDLE ON N150 03 3000
DRILL D 17mm DEEP N160 81 – 17 200
RAPID TRAVERSE OVER HOLE N170 20 35
DRILL E N180 81 – 17 200
RAPID TRAVERSE OVER HOLE F N190 60 35
DRILL F N200 81 – 17 200
RAPID TRAVERSE OVER HOLE G N210 60 15
DRILL G N220 81 – 17 200
TOOL CHANGING POSITION N230 05 –5 –5 25

NUMBER

NOTES
N G M X Y Z I J F S
TOOL CHANGE 10mm DRILL N240 06 2 10
RAPID TRAVERSE 2MM ABOVE
CENTRE OF POCKET N250 40 25 2
SPINDLE ON N260 03 3000
MILL POCKET N270 89 30 0 5 3 200
SPINDLE OFF, RAPID FEED TO
TOOL CHANGE POSITION N280 05 –5 –5 25

3. Simulate the machining process and compare the movements of the cutters with the
program.
Exercise 5: Combining Operations
80
5
O3
5 5
O2
50
5mm
Groove
15
5
For the component shown above:

1. Write down the sequence of operations required to produce the part.
2. Tabulate the co-ordinates required.
3. Use a programming sheet to write a program.
Tutorial 6: Subroutines
A subroutine can be regarded as a personalised canned cycle for use in a program which
has repetitive shapes.
The illustration below shows such a component; the milled grooves can be programmed
as a subroutine.
55 20
15
50
30
15
A
5
20
5
A,B : start positions for subroutines
The codes used for subroutines are:

M43 subroutine create
On entering M43, a prompt is made for an identifying number to be given to the
routine. The number is entered in the I column and may have a value from 1 to 99. The
user should note this reference number and the purpose of the routine.
The mode of programming is now changed: the line number automatically reverts to
10 and co-ordinate entry, if absolute, becomes incremental.
There is no restriction on the range of G codes (except G25) and all the canned cycles
are available.
M44 subroutine terminate

On entry of the signal to end the subroutine the line numbers of the original program
are restored and the current absolute position of the tool is shown in the X, Y and Z
columns. If the program was previously being entered with absolute co-ordinates, it
reverts to its former style.
M45 subroutine call
On entering M45 a prompt is made to input the reference number of the subroutine
in the I column. A search is made in the subroutine file and the first file found with
that reference number is executed.
Note:
Care is needed when allocating subroutine identification numbers.
The program for the previous illustration shows subroutine blocks S10 onwards being
typed into the system immediately after block N50. After this the cutter is repositioned
before calling up the subroutine and completing the program.
Editing of subroutines
The program EDIT facility can be used. If this is brought into use the program is
displayed for editing but a further option (SUB) is offered:
SUB MENU
If SUB is chosen, then the subroutine is displayed for editing.

3. Simulate the machining process and compare the movements of the cutters with the
program.
PROGRAMMING
DUET SHEET
DRAWING
NUMBER

NOTES
N G M X Y Z I J F S
N10 90
N20 71
N40 03 3000
POINT A N50 5 5 1
SUBROUTINE FOR GROOVES N60 45 1
POINT B N70 55 30
SUBROUTINE FOR GROOVES N80 45 1
N90 05 0 0 25
N100 30
ENTERED S10 43 1
IMMEDIATELY AFTER BLOCK S20 01 –3 200
N50
S30 01 15 200
S40 01 20 200
THE SUBROUTINE S50 01 – 15 200
MACHINES THE GROOVES S60 01 – 20 200
(INCREMENTALLY) S70 3
S80 44
Exercise 6: Subroutines
20
20
20
50
20
25
20
20
15
5
20
5
30
55
80


1. Tabulate the co-ordinates required.
2. Use a programming sheet to write a program; the L shaped grooves can be programmed
using a subroutine.
Tutorial 7: Mirror Images
This tutorial demonstrates how a program written as a subroutine can be reflected

about the X axis or about the Y axis or about both the X and the Y axes. It supports
both linear and circular interpolation.
Consider the shape shown in illustration A, which has been drawn in the sequence 1-
2, 2-3, 3-4 and 4-1.
2 1
A
3
If the X co-ordinates are reflected with Y co-ordinates unchanged, the shape becomes:
1 2
B 3
with the 1-2, 2-3, 3-4 and 4-1 sequence maintained
Alternatively, if the X co-ordinates are kept constant and the Y co-ordinates reflected,
the outcome is:
3
C
2 1
If both the X and y co-ordinates are reflected the result becomes:
3
D
1 2
If a program which calls a subroutine containing the original shape is written, then any
or all of the above variations may be implemented. The as programmed case is
achieved by the usual method of calling the subroutine. The mirror facility is
accomplished by inserting a line in the program after positioning the tool at the start
of the cycle but prior to calling the subroutine.
The entry is:
G value 28
X value 0 or 1
Y value either 0 or 1
For example
To reflect the X co-ordinate with Y unchanged:
Enter G28 with X = 1, Y = 0 B
To reflect the Y co-ordinate with X unchanged:
Enter G28 with X = 0, Y = 1 C
To reflect both the X and the Y co-ordinates:
Enter G28 with X = 1, Y = 1 D
To cancel the mirror facility:
Enter G28 WITH X = 0, Y =0
Note:
For mirror image programming incremental co-ordinates must be used.
Example
C D
D' C'
50
A' B'
10
30
15
A B
20
10
30
50
80

In the program for the above illustration, note that blocks S10 to S80 onwards are typed
into the system immediately after block N40.
1. Study the program.
3. Simulate the machining process and compare the cutter movements with the program.

NUMBER

NOTES
N G M X Y Z I J F S
METRIC UNITS N20 71
SPINDLE ON POINT A N40 03 30 20 1 3000
CALL SUBROUTINE N50 45 7
POINT B N60 50 20
N70 91
MIRROR IMAGE REFLECT X N80 28 1 0
CO-ORDINATE Y UNCHANGED
S20 TI S80 REPEAT
CANCEL MIRROR IMAGE N100 28 0 0
START OF SHAPE C N120 30 30
MIRROR IMAGE REFLECT Y N140 28 0 1
CO-ORDINATE X UNCHANGED
S20 TO S80 REPEATS
START OF SHAPE D N180 50 30
MIRROR IMAGE REFLECT BOTH N200 28 1 1
X AND Y CO-ORDINATES
Boxford 190 VMC Tutorial 7 CNC Tutorials andTutorial
Exercises
7
PROGRAMMING
DUET SHEET
DRAWING
NUMBER

NOTES
N G M X Y Z I J F S
CALL SUB ROUTINE N210 45 7
S20 TO S80 REPEATS
TOOL CHANGE N240 05 0 0 25
SUBROUTINE CREATE S10 43 7

FEED TO DEPTH S20 01 0 0 –3 200
SUBROUTINE SHAPE A S30 01 – 10 0 0 200
INCREMENTAL
S40 01 0 – 10 0 200
S50 01 10 –5 0 200
S60 01 0 15 0 200
S70 0 0 3
SUBROUTINE TERMINATE S80 44
Exercise 7: Mirror Images
50
30
15
20
20
30
50
80

1. Write a program to machine the grooved triangles using the mirror image technique.
2. Enter your program on the computer and simulate the cutting action.
The manufacture of the component shown below uses the G86 and G87 canned cycles.
Tutorial 8: Further Canned Cycles -

Pitch Circle Drilling and Dish Milling
The manufacture of the component shown below uses the G86 and G87 canned cycles.
80
6 x Ø 5 holes
5 deep
on 40mm PCD
50
Dished pocket
Ø30, 5 deep
Ø10 at bottom

G86 Canned Cycle Pitch Circle Diameter Drilling

This code produces a series of holes on a circular pitch.
The tool is positioned at a 2mm stand off point above the centre of a hole on the PCD
on the previous line.
Enter:
X number of holes to be drilled (must not be less than two)
Z incremental distance from the face of the workpiece to the bottom
of the hole
I the distance from the circle centre (incremental) to the first hole
measured along the X axis
J as the I value but measured along the Y axis
F Feed rate
G87 Canned Cycle Dish Milling

This code will mill out a circular dish-shaped pocket. The dish is produced by cutting
a series of concentric circular pockets starting at X diameter, with successive circles
getting deeper as they reduce in diameter, until the last circle is at Y diameter and depth
Z. The total number of circles is J. Increasing the number of cuts will produce a better
dish but the time taken will be greater.
Enter
X the top diameter
Y the bottom diameter of the dish
Z The incremental distance from the face of the workpiece to the
bottom of the dish
I For a complete dish enter zero, or for hollow circles (an outline
around the edge) enter a value
J is the number of cuts to produce the dish
F the feed rate at which the dish is to be milled
The cycle is best used in two stages. For the first stage enter I = 0; this will rough out
a pocket, leaving a stepped profile. On calling the code again for the second stage enter
a value for I = 1; this will mill around the circumference of the circles, thus smoothing
the profile.
The program for the illustration shown earlier is shown on the following page.
3. Simulate the machining process and compare the cutter movement with the program.
4. View the component in 3D.
PROGRAMMING
DUET SHEET
DRAWING
NUMBER TUT 8
TITLE PROGRAMMED BY

NOTES
N G M X Y Z I J F S
METRIC UNITS N20 71
TOOL CHANGE ø5 DRILL N30 0 0 25
SPINDLE ON, Move to Centre N40 03 40 25 2 3000
of P.C.D.
DRILL HOLES ON P.C.D. N50 86 6 5 0 20 200
TOOL CHANGE N60 05 0 0 25
SPINDLE ON, Move to Centre N80 03 40 25 2 3000
of Pocket
ROUGH MILL DISH N90 87 30 10 5 0 5 200
FINISH MILL DISH N100 87 30 10 5 1 5 200
PARK POSITION N110 05 0 0 25
Exercise 8: Use of Canned Cycles -

Pitch Circle Drilling and Dish Milling
80
8 x Ø 5 holes
5 deep
on 40mm PCD
50
25 Dished pocket
Ø25, 5 deep
Ø10 at bottom


1. Write a program to machine
the holes on the P.C.D.
the dished pocket.
2. Enter your program on the computer and simulate the cutting action.
Tutorial 9: Subroutines, Mirror Images and

Circular Interpolation
4 2
All grooves
15 radius
3 1 2 deep
50
45
7 5 wide
5
30
6 8
20
5
20
35
45
60
80
The following program uses a subroutine which will mill a 90° arc of radius 15mm
counter-clockwise and 2mm deep. It then uses the G28 Mirror Image routine to mill
the other three arcs.
The program is shown on the following page.
2. Key in the program and run the simulation.
3. Compare the cutter movements with the program.
PROGRAMMING
DUET SHEET
DRAWING
NUMBER TUT 9
TITLE PROGRAMMED BY

NOTES
N G M X Y Z I J F S
METRIC UNITS N20 71
TOOL CHANGE POSITION N30 0 0 25
SPINDLE START N40 03 3000
OVER POINT 1 N50 60 30 1
SUBROUTINE CREATE S10 43 9
FEED TO DEPTH S20 01 -3 200
MILL QUADRANT S30 03 -15 15 15 200
WITHDRAW TOOL S40 3
SUBROUTINE TERMINATE S50 44
SUBROUTINE CALL N60 45 9
POINT 2 N70 90 45 45 1
ABOVE POINT 3 N80 20 30
INCREMENTAL PROGRAM N90 91
MIRROR IMAGE N100 28 1 0
REFLECT X, Y UNCHANGED
POINT 4 N130 90 35 45 1
REFLECT BOTH X AND Y
PROGRAMMING
DUET SHEET
DRAWING
NUMBER TUT 9
TITLE PROGRAMMED BY

NOTES
N G M X Y Z I J F S
POINT 6 N190 90 35 5 1
REFLECT X, Y UNCHANGED
POINT 8 N250 90 45 5 1
SPINDLE STOP. TOOL CHANGE N260 05 0 0 25
Exercise 9: Subroutines and Mirror Images
All grooves
15 radius
60
2 deep
44
5 wide
29
21
6 21
36
44
59
80

1. Write a program to mill the curved slots using a subroutine and mirror images.
Tutorial 10: Datum Shift and Jump to Line
For programs with repetitive elements, and as an alternative to creating a subroutine

(M43), a datum shift (G57) can be used in conjunction with Jump to Block (G25) and
Return from Jump (G26).
Details of the above codes are:
G25 Jump to Block
This code enables a section of a program to be executed again. There are two
restrictions on the use of G25:
(a) a G25 loop must not be called from within a subroutine,
(b) a subroutine must not be called from within a G25 loop.
Enter in the S column the line number to which the jump is to be made.
G26 Return from Jump
After using a G25 the program executes from the line specified in the S column until
a G26 is encountered. The program then reverts to the line following that from where
the G25 call was made. The G26 is only operative after a G25 loop has been called.
At all other times it is transparent.
G57 Datum Shift
This code enables the X Y datum to be altered by an amount specified in the X and
Y columns.
Enter X value - new absolute X datum
Enter Y value - new absolute Y datum
Note:
The Z datum cannot be altered with G57.
G53 Cancel Datum Shift
This code is used to cancel a G57 datum shift, i.e. it makes X and Y shift equal to zero.
The above techniques are illustrated in the following example.
15
50
15
15
20
10 15
20
50
80
The program is shown on the following page.

3. Compare the cutter movements with the program.
PROGRAMMING
DUET SHEET
DRAWING
NUMBER TUT 10
TITLE PROGRAMMED BY

NOTES
N G M X Y Z I J F S
METRIC UNITS N20 71
TOOLPARK POSITION N30 0 0 25
DATUM SHIFT TO X20 Y10 N40 57 20 10
SPINDLE START N50 03 0 0 2 3000
MOVE OVER NEW DATUM
FEED TO DEPTH N70 01 -4 200
CUT FIRST L SHAPE N80 01 15 200
CUT FIRST L SHAPE N90 01 15 200
RAPID TO CLEAR N100 4
RAPID TO NEW POSITION N110 -15 -15
ABSOLUTE PROGRAMMING N120 90 -15 -15
RETURN FROM JUMP N130 26
CANCEL DATUM SHIFT N140 53
DATUM SHIFT TO X50 Y20 N150 57 50 20
JUMP TO BLOCK N60 N160 25 60
CANCEL DATUM SHIFT N170 53
TOOL PARK N180 0 0 25
STOP SPINDLE N190 05
Exercise 10: Datum Shift and Jump to Line
25
50
25
20
20
10
20
10
45
80

1. Write a program to mill the L-shaped slots using the Datum Shift and Jump to Line
codes.
OPERATIONS SHEET
DRAWING DUET OPERATIONS

OPERATIONS SHEET - MILLING
SHEET SHEET No. OF
NUMBER
TITLE MATERIAL
OPERATIONS SPINDLE TOOL TOOL

NUMBER OPERATION FEED FEED REQUIRED
PROGRAMMING SHEET

PROGRAMMING SHEET-MILLING
SHEET SHEET No. OF
NUMBER
TITLE PROGRAMMED BY

NOTES
N G M X Y Z I J F S

CNCMilling Boxford PDF

Încărcat de

Informații document

Descriere originală:

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

CNCMilling Boxford PDF

Încărcat de

Drepturi de autor:

Formate disponibile

Programming Manual

Boxford 190 VMC

4 Main Front End Menu

9 Cutter Path CAM Programming

10 Manual Data Input CNC Programming

10.10.3 Simulation of Machining

11 CNC and CAM Machining

CNC Tutorials and Exercises

2 Running the Demonstration

7. Select VMC 190

Manipulate the 3D view as follows:

Using the Keyboard:

Display the Program 11. Select MENU and then Display:

Scroll the display to examine the program:

page 1 line 1 line page

Using the Keyboard:

Press or to scroll 1 line

Press Page or Page to scroll 1 page

12. Turn off the program display.

Simulate Machining 16. Select MENU , then 2D Simulate:

Simulate Machining 17. Select MENU , then 3D Simulate:

3 Axes and Tooling

3.2 Axes, Datums and Offsets (Figure 3.1)

Spindle Tool X,Y datum

Figure 3.1 Axes and Tool Datum

Auto tool changer

Figure 3.2 Tool Storage

3.3 Tool Storage (Figure 3.2)

3.4 Tool Data Library and Catalogue

1. Tool number used by CNC program to select 5. Scroll buttons

Figure 3.3 Tool Data Library

Tooling Menu 3. Select MENU to display the tooling menu:

Figure 3.4 Tool Catalogue

Spindle Carousel Direction

To edit tool details:

Figure 3.6 Tool Editing Display

1. The machine RESET button is pressed.

Click on YES or press Return to save the offsets.

Set Machine Note

1. The machine RESET button is pressed.

Click on YES or press Return to save the offsets.

3.6 DATUM SHIFT

G&M Program Import & Program Simulate, Manufacture

Administration Functions and Machine Tool Driver

CAD and CAM Processor Exit to Windows Desktop

Exits to the Windows desktop.

Allows the setting of Coordinate data entry

Simple prompts tell

5.2 Drawing Aids

Redraw - Refreshes the screen.

Grid Lock - Locks the cursor movement to the grid spacing.

Step Lock - Locks the cursor movement to the step spacing.

Zoom In - Zooms in on a user defined window.

Zoom Last - Reverts to the last specified zoom.

Zoom Sheet - Displays the complete workpiece at maximum zoom.

Zoom All - Displays all drawn entities at maximum zoom.

Zoom = - Zooms in by a user defined magnification factor

5.3 Drawing Tools

Theoretical box Corner

OK is selected and the centre point specified.

At the prompt the required text is typed and Settings selected.

The dialogue box below is shown.

The user is prompted to Enter CURRENT Password.

The user is prompted to Enter NEW Password

a. Pressing the F10 key

The user is prompted to Enter material to add to list.