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PROGRAMMING MANUAL
for
MAZATROL MATRIX
(For INTEGREX IV)
MAZATROL Program
MANUAL No. : H740PA0031E
Serial No. :
Before using this machine and equipment, fully understand the contents of this
manual to ensure proper operation. Should any questions arise, please ask the
nearest Technical Center or Technology Center.
1. Be sure to observe the safety precautions described in this manual and the contents of the safety plates on the machine and equipment. Failure may cause serious personal injury or **material damage. Please replace any missing safety plates as soon as possible.
- No modifications are to be performed that will affect operation safety. If such modifications are** **required, please contact the nearest Technical Center or Technology Center.
- For the purpose of explaining the operation of the machine and equipment, some illustrations** may not include safety features such as covers, doors, etc. Before operation, make sure all **such items are in place.
- This manual was considered complete and accurate at the time of publication, however, due to** our desire to constantly improve the quality and specification of all our products, it is subject to change or modification. If you have any questions, please contact the nearest Technical Center **or Technology Center.
- Always keep this manual near the machinery for immediate use.
- If a new manual is required, please order from the nearest Technical Center or Technology** Center with the manual No. or the machine name, serial No. and manual name.
Issued by Manual Publication Section, Yamazaki Mazak Corporation , Japan
- 2006
IMPORTANT NOTICE
SAFETY PRECAUTIONS
S-
Basics
WARNING
! After turning power on, keep hands away from the keys, buttons, or switches of the operating panel until an initial display has been made. ! Before proceeding to the next operations, fully check that correct data has been entered and/or set. If the operator performs operations without being aware of data errors, unexpected operation of the machine will result. ! Before machining workpieces, perform operational tests and make sure that the machine operates correctly. No workpieces must be machined without confirmation of normal operation. Closely check the accuracy of programs by executing override, single-block, and other functions or by operating the machine at no load. Also, fully utilize tool path check, Virtual Machining, and other functions, if provided. ! Make sure that the appropriate feed rate and rotational speed are designated for the particular machining requirements. Always understand that since the maximum usable feed rate and rotational speed are determined by the specifications of the tool to be used, those of the workpiece to be machined, and various other factors, actual capabilities differ from the machine specifications listed in this manual. If an inappropriate feed rate or rotational speed is designated, the workpiece or the tool may abruptly move out from the machine. ! Before executing correction functions, fully check that the direction and amount of correction are correct. Unexpected operation of the machine will result if a correction function is executed without its thorough understanding. ! Parameters are set to the optimum standard machining conditions prior to shipping of the machine from the factory. In principle, these settings should not be modified. If it becomes absolutely necessary to modify the settings, perform modifications only after thoroughly understanding the functions of the corresponding parameters. Modifications usually affect any program. Unexpected operation of the machine will result if the settings are modified without a thorough understanding.
Remarks on the cutting conditions recommended by the NC
WARNING
! Before using the following cutting conditions:
- Cutting conditions that are the result of the MAZATROL Automatic Cutting Conditions Determination Function
- Cutting conditions suggested by the Machining Navigation Function
- Cutting conditions for tools that are suggested to be used by the Machining Navigation Function Confirm that every necessary precaution in regards to safe machine setup has been taken – especially for workpiece fixturing/clamping and tool setup. ! Confirm that the machine door is securely closed before starting machining. Failure to confirm safe machine setup may result in serious injury or death.
SAFETY PRECAUTIONS
S-
Programming
WARNING
! Fully check that the settings of the coordinate systems are correct. Even if the designated program data is correct, errors in the system settings may cause the machine to operate in unexpected places and the workpiece to abruptly move out from the machine in the event of contact with the tool. ! During surface velocity hold control, as the current workpiece coordinates of the surface velocity hold control axes approach zeroes, the spindle speed increases significantly. For the lathe, the workpiece may even come off if the chucking force decreases. Safety speed limits must therefore be observed when designating spindle speeds. ! Even after inch/metric system selection, the units of the programs, tool information, or parameters that have been registered until that time are not converted. Fully check these data units before operating the machine. If the machine is operated without checks being performed, even existing correct programs may cause the machine to operate differently from the way it did before. ! If a program is executed that includes the absolute data commands and relative data commands taken in the reverse of their original meaning, totally unexpected operation of the machine will result. Recheck the command scheme before executing programs. ! If an incorrect plane selection command is issued for a machine action such as arc interpolation or fixed-cycle machining, the tool may collide with the workpiece or part of the machine since the motions of the control axes assumed and those of actual ones will be interchanged. (This precaution applies only to NC units provided with EIA functions.) ! The mirror image, if made valid, changes subsequent machine actions significantly. Use the mirror image function only after thoroughly understanding the above. (This precaution applies only to NC units provided with EIA functions.) ! If machine coordinate system commands or reference position returning commands are issued with a correction function remaining made valid, correction may become invalid temporarily. If this is not thoroughly understood, the machine may appear as if it would operate against the expectations of the operator. Execute the above commands only after making the corresponding correction function invalid. (This precaution applies only to NC units provided with EIA functions.) ! The barrier function performs interference checks based on designated tool data. Enter the tool information that matches the tools to be actually used. Otherwise, the barrier function will not work correctly. ! The system of G-code and M-code commands differs, especially for turning, between the machines of INTEGREX e-Series and the other turning machines. Issuance of the wrong G-code or M-code command results in totally non-intended machine operation. Thoroughly understand the system of G-code and M-code commands before using this system. Sample program Machines of INTEGREX e-Series Turning machines S1000M3 The milling spindle rotates at 1000 min –1. The turning spindle rotates at 1000 min –1. S1000M203 The turning spindle rotates at 1000 min –1. The milling spindle rotates at 1000 min –1.
SAFETY PRECAUTIONS
S-
Operations
WARNING
! Single-block, feed hold, and override functions can be made invalid using system variables #3003 and #3004. Execution of this means the important modification that makes the corresponding operations invalid. Before using these variables, therefore, give thorough notification to related persons. Also, the operator must check the settings of the system variables before starting the above operations. ! If manual intervention during automatic operation, machine locking, the mirror image function, or other functions are executed, the workpiece coordinate systems will usually be shifted. When making machine restart after manual intervention, machine locking, the mirror image function, or other functions, consider the resulting amounts of shift and take the appropriate measures. If operation is restarted without any appropriate measures being taken, collision with the tool or workpiece may occur. ! Use the dry run function to check the machine for normal operation at no load. Since the feed rate at this time becomes a dry run rate different from the program-designated feed rate, the axes may move at a feed rate higher than the programmed value. ! After operation has been stopped temporarily and insertion, deletion, updating, or other commands executed for the active program, unexpected operation of the machine may result if that program is restarted. No such commands should, in principle, be issued for the active program.
CAUTION
! During manual operation, fully check the directions and speeds of axial movement. ! For a machine that requires manual homing, perform manual homing operations after turning power on. Since the software-controlled stroke limits will remain ineffective until manual homing is completed, the machine will not stop even if it oversteps the limit area. As a result, serious machine damage will result. ! Do not designate an incorrect pulse multiplier when performing manual pulse handle feed operations. If the multiplier is set to 1000 times and the handle operated inadvertently, axial movement will become faster than that expected.
BEFORE USING THE NC UNIT
S-
BEFORE USING THE NC UNIT
Limited Warranty The warranty of the manufacturer does not cover any trouble arising if the NC unit is used for its non-intended purpose. Take notice of this when operating the unit. Examples of the trouble arising if the NC unit is used for its non-intended purpose are listed below.
- Trouble associated with and caused by the use of any commercially available software products (including user-created ones)
- Trouble associated with and caused by the use of any Windows operating systems
- Trouble associated with and caused by the use of any commercially available computer equipment
Operating Environment
1. Ambient temperature During machine operation: 0° to 50°C (32° to 122°F) 2. Relative humidity During machine operation: 10 to 75% (without bedewing) Note: As humidity increases, insulation deteriorates causing electrical component parts to deteriorate quickly.
Keeping the Backup Data
Note: Do not attempt to delete or modify the data stored in the following folder. Recovery Data Storage Folder: D:\MazakBackUp Although this folder is not used when the NC unit is running normally, it contains important data that enables the prompt recovery of the machine if it fails. If this data has been deleted or modified, the NC unit may require a long recovery time. Be sure not to modify or delete this data.
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- 1 MAZATROL PROGRAM CONFIGURATION........................................ 1- Page
- 1-1 Program Configuration .......................................................................................1-
- 2 PROGRAM COORDINATE SYSTEM 2-
- 3 PROGRAM CREATION........................................................................ 3-
- 3-1 Procedure for Program Creation ........................................................................3-
- 3-2 Common Unit .....................................................................................................3-
- 3-2-1 Setting unit data (common data)............................................................................. 3-
- 3-3 Materials Shape Unit (MATERIAL) .....................................................................3-
- 3-3-1 Setting unit data...................................................................................................... 3-
- 3-3-2 Setting sequence data 3-
- 3-4 Types of the Milling Unit ...................................................................................3-
- 3-4-1 Planes to be machined and machining methods 3-
- 3-5 Point Machining Units.......................................................................................3-
- 3-5-1 Types of point machining units 3-
- 3-5-2 Procedure for selecting point machining unit........................................................ 3-
- 3-5-3 Unit data and automatic tool development of the point machining unit 3-
- 3-5-4 Automatic tool development for carbide drills 3-
- 3-5-5 New tapping auto-setting scheme 3-
- 3-5-6 Tool sequence data of the point machining unit 3-
- 3-5-7 Tool path of the point machining unit.................................................................... 3-
- 3-5-8 Shape sequence data of the point machining unit................................................ 3-
- 3-6 Line Machining Units ......................................................................................3- - C-
- 3-6-1 Types of line machining units 3-
- 3-6-2 Procedure for selecting line machining unit 3-
- unit 3- 3-6-3 Unit data, automatic tool development and tool path of the line machining
- 3-6-4 Tool sequence data of the line machining unit 3-
- 3-6-5 Shape sequence data of the line machining unit 3-
- 3-6-6 Precautions in line machining 3-
- 3-6-7 Automatic corner override................................................................................... 3-
- 3-7 Face Machining Units .....................................................................................3-
- 3-7-1 Types of face machining units 3-
- 3-7-2 Procedure for selecting face machining unit....................................................... 3-
- unit 3- 3-7-3 Unit data, automatic tool development and tool path of the face machining
- 3-7-4 Tool sequence data of the face machining unit 3-
- 3-7-5 Precautions in face machining............................................................................ 3-
- 3-7-6 Override in case of the overall width cutting 3-
- 3-7-7 Shape sequence data of the line/face machining unit 3-
- 3-8 Turning Units ..................................................................................................3-
- 3-8-1 Types of turning units 3-
- 3-8-2 Procedure for selecting turning unit 3-
- 3-9 Bar-Materials Machining Unit (BAR)...............................................................3-
- 3-9-1 Setting unit data.................................................................................................. 3-
- 3-9-2 Setting tool sequence data 3-
- 3-9-3 Setting shape sequence data 3-
- 3-10 Copy-Machining Unit (CPY) ...........................................................................3- - C-
- 3-10-1 Setting unit data.................................................................................................. 3-
- 3-10-2 Setting tool sequence data 3-
- 3-10-3 Setting shape sequence data 3-
- 3-11 Corner-Machining Unit (CORNER).................................................................3-
- 3-11-1 Setting unit data.................................................................................................. 3-
- 3-11-2 Setting tool sequence data 3-
- 3-11-3 Setting shape sequence data 3-
- 3-12 Facing Unit (FACING) ....................................................................................3-
- 3-12-1 Setting unit data.................................................................................................. 3-
- 3-12-2 Setting tool sequence data 3-
- 3-12-3 Setting shape sequence data 3-
- 3-13 Threading Unit (THREAD)..............................................................................3-
- 3-13-1 Setting unit data.................................................................................................. 3-
- 3-13-2 Setting tool sequence data 3-
- 3-13-3 Setting sequence data 3-
- 3-14 Grooving Unit (T. GROOVE) ..........................................................................3-
- 3-14-1 Setting unit data.................................................................................................. 3-
- 3-14-2 Setting tool sequence data 3-
- 3-14-3 Setting shape sequence data 3-
- 3-15 Turning Drilling Unit (T. DRILL) ......................................................................3-
- 3-15-1 Setting unit data.................................................................................................. 3-
- 3-15-2 Setting tool sequence data 3-
- 3-15-3 Setting shape sequence data 3-
- 3-16 Turning Tapping Unit (T. TAP) .......................................................................3- - C-
- 3-16-1 Setting unit data.................................................................................................. 3-
- 3-16-2 Setting tool sequence data 3-
- 3-16-3 Setting shape sequence data 3-
- 3-17 Mill-Turning Unit (MILLTURN) ........................................................................3-
- 3-17-1 Setting unit data.................................................................................................. 3-
- 3-17-2 Setting tool sequence data 3-
- 3-17-3 Setting shape sequence data 3-
- 3-18 Other Units .....................................................................................................3-
- 3-19 Manual Program Machining Unit (MANL PRG) ..............................................3-
- 3-19-1 Setting unit data.................................................................................................. 3-
- 3-19-2 Setting sequence data 3-
- 3-20 M-Code Unit (M-CODE) .................................................................................3-
- 3-20-1 Setting unit data (M-code) 3-
- 3-21 Head Selection Unit (HEAD) ..........................................................................3-
- 3-21-1 Setting unit data.................................................................................................. 3-
- 3-22 Workpiece Transfer Unit (TRANSFER) ..........................................................3-
- 3-22-1 Setting unit data.................................................................................................. 3-
- 3-23 Subprogram Unit (SUB PRO).........................................................................3-
- 3-23-1 Setting unit data.................................................................................................. 3-
- 3-23-2 Setting sequence data 3-
- 3-24 Add-In MAZATROL Unit .................................................................................3-
- 3-24-1 Setting unit data.................................................................................................. 3-
- 3-24-2 Setting sequence data 3-
- 3-24-3 Help function on Add-in MAZATROL 3-
- 3-25 End Unit (END)...............................................................................................3-
- 3-25-1 Setting unit data.................................................................................................. 3-
- 3-25-2 Setting sequence data 3-
- 3-26 Simultaneous Machining Unit (SIMULTAN)....................................................3-
- 3-26-1 Procedure for calling up the SIMULTAN unit 3-
- 3-26-2 Setting unit data.................................................................................................. 3-
- 3-27 Two-Workpiece Machining Unit (2 WORKPC) ...............................................3-
- 3-27-1 Procedure for calling up the 2 WORKPC unit 3-
- 3-27-2 Setting unit data.................................................................................................. 3-
- 3-28 Coordinate Measuring Unit (MMS) .................................................................3-
- 3-28-1 Procedure for calling up the MMS unit................................................................ 3-
- 3-28-2 Setting unit data.................................................................................................. 3-
- 3-28-3 Setting sequence data 3-
- 3-28-4 Type of measurement......................................................................................... 3-
- 3-29 Workpiece Measuring Unit (WORK MES) ......................................................3-
- 3-29-1 Procedure for selecting workpiece measuring unit 3-
- 3-29-2 Setting the unit data............................................................................................ 3-
- 3-29-3 Setting the sequence data 3-
- 3-29-4 Selection of a measurement type 3-
- 3-29-5 Offset value and the direction of offset 3-
- 3-29-6 Offset judgment 3-
- 3-30 Tool Measuring Unit (TOOL MES)..................................................................3-
- 3-30-1 Procedure for selecting tool measuring unit 3-
- 3-30-2 Setting the unit data............................................................................................ 3- - C-
- 3-30-3 Setting the sequence data 3-
- 3-30-4 Measuring patterns 3-
- 4 PRIORITY FUNCTION FOR THE SAME TOOL................................... 4-
- 4-1 Priority Machining Order.....................................................................................4-
- 4-2 Priority Machining Zone......................................................................................4-
- 4-3 Editing Function and Input Method of Priority Numbers .....................................4-
- 4-3-1 Input of priority numbers 4-
- 4-3-2 Assignment of priority numbers 4-
- 4-3-3 Change of priority numbers 4-
- 4-3-4 Deletion of all the priority numbers 4-
- 4-3-5 How to use the SUB PROG PROC END function 4-
- Function............................................................................................................4- 4-4 Relation between the Subprogram Unit and the Priority Machining
- 4-5 Relation between the M-Code Unit and the Priority Machining Function..........4-
- 5 LOWER-TURRET CONTROL FUNCTIONS 5-
- 5-1 Machining with the Lower Turret ........................................................................5-
- 5-1-1 Independent machining with the lower turret 5-
- 5-1-2 Simultaneous machining with the upper and lower turrets 5-
- 5-1-3 Balanced cutting with the upper and lower turrets.................................................. 5- - turrets (optional)...................................................................................................... 5- 5-1-4 Simultaneous machining of processes 1 and 2, using the upper and lower
- 5-2 Retraction of the Lower Turret..........................................................................5-
- 5-3 Other Setup Items ............................................................................................5-
- 5-3-1 LTUR DIA in common unit 5- - C-
- 6 TPC DATA SETTING 6-
- 6-1 Operating Procedure for Setting TPC (Tool-Path Control) Data.........................6- - Unit .....................................................................................................................6- 6-2 Description of Each TPC Data Item of Turning Unit and Measurement
- 7 PROGRAM EDITING............................................................................ 7-
- 7-1 Operating Procedures for Editing Programs.......................................................7-
- 7-2 Search ................................................................................................................7-
- 7-3 Insertion..............................................................................................................7-
- 7-4 Deletion ............................................................................................................7-
- 7-5 Copy .................................................................................................................7-
- 8 PROGRAM CREATING/EDITING FUNCTIONS 8-
- 8-1 Help Function .....................................................................................................8-
- 8-2 Automatic Crossing-Point Calculation Function..................................................8-
- 8-2-1 Automatic crossing-point calculation in the line and face machining units 8-
- 8-2-2 Automatic crossing-point calculation function in the turning unit 8-
- 8-3 Automatic Cutting-Conditions Setting Function ................................................8-
- 8-4 Desk Calculator Functions................................................................................8-
- 8-5 Tool Data Window ............................................................................................8-
- 8-6 Tool File Window ..............................................................................................8-
- 9 SAMPLE PROGRAMS 9-
- 10 THREE-DIGIT G-FORMAT................................................................. 10-
- 10-1 Outline ..............................................................................................................10-
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- 10-2 Detailed Description .........................................................................................10-
- 10-3 Three-Digit G-Format of MAZATROL Program ................................................10-
- 10-4 Various Data Description Using G10 ..............................................................10-
MAZATROL PROGRAM CONFIGURATION 1
1 MAZATROL PROGRAM CONFIGURATION
1-1 Program Configuration
MAZATROL programs are each made up of a set of data referred to as unit. The following types of units are prepared for this NC equipment: Common unit Materials shape unit Machining unit Milling unit Point machining unit Drilling Counterbore machining Inversed faced hole machining Reaming Tapping Boring Through hole Non-through hole Stepped through hole Stepped non-through hole Back boring Circular milling Counterbore-tapping Line machining unit Central linear machining Right-hand linear machining Left-hand linear machining Outside linear machining Inside linear machining Right-hand chamfering Left-hand chamfering Outside chamfering Inside chamfering Face machining unit Face milling End milling-top End milling-step Pocket milling Pocket milling-mountain Pocket milling-valley End milling slot Turning unit Bar-materials machining Manual program machining unit Copy-machining End unit Corner-machining M-code unit Facing Subprogram unit Threading Coordinate measuring unit Grooving Workpiece measuring unit Drilling (turning) Tool measuring unit Tapping (turning) Head selection unit Mill-turning Workpiece transfer unit Process end unit Simultaneous machining unit Two-workpiece machining unit Add-in MAZATROL unit
Ex
PROGRAM COORDINATE SYSTEM 2
2 PROGRAM COORDINATE SYSTEM
In general, machining dimensions on a drawing are indicated as the distances from a specific reference point. Likewise, within a program, a machining pattern is defined by setting the coordinates from a specific reference point. This reference point is referred to as the program origin and the coordinate system based on the program origin is referred to as the program coordinate system. For MAZATROL programs, the following coordinate system is used to define machining patterns:
T3P
Program origin +X
+C
+Z
Program origin
+Y
The program origin of X-Z-coordinates system can be set anywhere on the center line of the workpiece. Usually, however, the crossing point of the center line of the workpiece and its finishing edge surface should be taken as the program origin. The program origin of C-axis (rotational axis) can be set at any position convenient for programming. For MAZATROL programs, set X-coordinates as diameter data. That is, the workpiece diameter indicated on the drawing must be set as it is. Example: For the workpiece shape shown in the diagram below: The coordinates (x, z) of point A are (50, 20), and the coordinates (x, z) of point B (20, 30).
T3P
φ 20 φ 50
20 30
A
B
Note 1: For manual program machining units (MANL PRG) and facing units (FACING), the direction of Z-axis is opposite to the one shown in the diagram above. See the relevant items in Chapter 3 for further details. Note 2: Refer to the sections of milling units for details on the C- and Y-axes.
2 PROGRAM COORDINATE SYSTEM
- NOTE -
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