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SAFETY PRECAUTIONS

Preface

Safety precautions relating to the CNC unit (in the remainder of this manual, referred to simply as the NC unit) that is provided in this machine are explained below. Not only the persons who create programs, but also those who operate the machine must thoroughly understand the contents of this manual to ensure safe operation of the machine.

Read all these safety precautions, even if your NC model does not have the corresponding functions or optional units and a part of the precautions do not apply.

Rule

1.This section contains the precautions to be observed as to the working methods and states usually expected. Of course, however, unexpected operations and/or unexpected working states may take place at the user site.

During daily operation of the machine, therefore, the user must pay extra careful attention to its own working safety as well as to observe the precautions described below.

2.Although this manual contains as great an amount of information as it can, since it is not rare for the user to perform the operations that overstep the manufacturer-assumed ones, not all of “what the user cannot perform” or “what the user must not perform” can be fully covered in this manual with all such operations taken into consideration beforehand.

It is to be understood, therefore, that functions not clearly written as “executable” are “inexecutable” functions.

3.The meanings of our safety precautions to DANGER, WARNING, and CAUTION are as follows:

: Failure to follow these instructions could result in loss of life.

DANGER

: Failure to observe these instructions could result in serious harm to a human

life or body.

WARNING

: Failure to observe these instructions could result in minor injuries or serious

machine damage.

CAUTION

SAFETY PRECAUTIONS

Basics

! After turning power on, keep hands away from the keys, buttons, or switches of the operating panel until an initial display has been made.

WARNING ! 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

! Before using the following cutting conditions:

—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

Programming

!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.

SAFETY PRECAUTIONS

!For the machines of INTEGREX e-Series, programmed coordinates can be rotated using an index unit of the MAZATROL program and a G68 command (coordinate rotate command) of the EIA program. However, for example, when the B-axis is rotated through 180 degrees around the Y-axis to implement machining with the turning spindle No. 2, the plus side of the X-axis in the programmed coordinate system faces downward and if the program is created ignoring this fact, the resulting movement of the tool to unexpected positions may incite collisions.

To create the program with the plus side of the X-axis oriented in an upward direction, use the mirror function of the WPC shift unit or the mirror imaging function of G-code command (G50.1, G51.1).

!After modifying the tool data specified in the program, be sure to perform the tool path check function, the Virtual Machining function, and other functions, and confirm that the program operates properly. The modification of tool data may cause even a field-proven machining program to change in operational status.

If the user operates the machine without being aware of any changes in program status, interference with the workpiece could arise from unexpected operation.

For example, if the cutting edge of the tool during the start of automatic operation is present inside the clearance-including blank (unmachined workpiece) specified in the common unit of the MAZATROL program, care is required since the tool will directly move from that position to the approach point because of no obstructions being judged to be present on this path.

For this reason, before starting automatic operation, make sure that the cutting edge of the tool during the start of automatic operation is present outside the clearance-including workpiece specified in the common unit of the MAZATROL program.

!If axis-by-axis independent positioning is selected and simultaneously rapid feed selected

for each axis, movements to the ending point will not usually become linear. Before using

these functions, therefore, make sure that no obstructions are present on the path.

CAUTION

SAFETY PRECAUTIONS

Operations

!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.

!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

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.

1.Trouble associated with and caused by the use of any commercially available software products (including user-created ones)

2.Trouble associated with and caused by the use of any Windows operating systems

3.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.

CONTENTS

1 INTRODUCTION

Three-dimensional machining functions are automatic programming functions used for 3- dimensional curved-surface machining which presents difficulties for lineor face-machining programs.

Automatic programming functions in the easy-to-understand MAZATROL language (human language) enable 3-dimensional curved surfaces to be machined by performing simple operations.

This Programming Manual describes the programming procedures for machining 3-D curved surfaces with the MAZATROL MATRIX.

Read through this manual carefully in order to make the most of the 3-D machining functions available with the MAZATROL MATRIX.

In addition to this manual, reference should also be made to the Programming Manual and the Operating Manual.

2 GENERAL

2-1 General

The 3-dimensional machining functions enable 3-dimensional curved surfaces, which are difficult to machine with lineor face-machining programs, to be handled with relative ease.

Programs with a greater degree of flexibility can be prepared when these functions are used in conjunction with the lineand face-machining units.

The features of these 3-D machining functions are listed below:

1.Easy-to-understand MAZATROL language

Programming uses the MAZATROL language which allows programs to be created with the same kind of ease which characterizes ordinary MAZATROL programs. As a result, 3-D programming, which presented difficulties before, can now be handled with ease.

2.Simple representation of curved surfaces

Wire-frame models that can be defined with figure lines and guide lines are used so that the 3-dimensional curved surfaces can be set as easily as possible. In addition, GL (guide line) and FL (figure line) figures can be input using methods similar to those for lineor facemachining.

3.Creation of wide variety of curved surfaces

A wide variety of complex curved surfaces can be handled by selecting any of the 11 types of units in accordance with the curved surface to be machined.

4.Automatic determination of tool paths for rough machining and finish machining

Simply by defining the final curved-surface figures, the tool paths for both rough machining and finish machining can be determined automatically.

5.Outstanding graphic check functions

Not merely the tool path and trace display but also the defined curved-surface figures can be displayed in wire-frame format, and this makes it easier to understand and check the defined curved-surface figures.

2-2 Creation of Curved-Surface Figures

A curved surface is formed when a curved line on a given plane is moved through 3-dimensional space.

A variety of curved-surface figures can be created by defining the following conditions.

—Movement of a constant curved line

—Movement of a changing curved line

The curved-surface figures thus defined are then shaped with a 3-D machining unit.

2-3 Movement of a Constant Curved Line

The movement of a curved line through 3-dimentional space is restricted to the following.

Furthermore, a curved-surface figure can be created by smoothly connecting a multiple number of curved lines on given plane within 3-dimensional space (ruled surface).

2-4 Changing Conditions of a Curved Line

A curved line that is moved through 3-dimensional space is referred to as the FL (figure line). Usually, one FL is defined as the starting curved line or two FLs are defined as the starting and ending curved lines. A GL (guide line) which is used to guide the defined FL is also defined.

The desired curved-surface figure is created by moving and changing the starting figure line (FL1) into the ending figure line (FL2) according to the above conditions and the guide line (GL).

FL2

GL

FL1

D735P0500

GENERAL 2

2-5 3-D Machining Units and Types of Curved Surfaces Created

3-1 Program Configuration

The 3-D machining units are handled in exactly the same manner as the point-, line-, and facemachining units. A 3-D program is therefore composed basically of the following 4 program units.

The 3-D machining unit can also be used with the point-, line-, and/or face-machining units.

3-2 Before Programming

Programming is done by following the same procedures as those prescribed for point-, line-, and face-machining.

For details on the methods for creating and editing programs, reference should be made to the Programming Manual (MAZATROL).

3-3 Programs for 3-D Machining Units

A 3-D machining units consist of unit definition, tool-sequence definition, curved-surface definition and machining area appointment. The curved-surface definition is subdivided into 3 parts: plane definition (definition of the plane on which curved lines are placed), figure definition and coordinate transfer.

3-3-1 Unit definition

The unit definition inputs the data required to automatically determine the tool sequence for 3-D machining. The tools required for machining are automatically determined by inputting the types of the units, FL movements/angles, material height, finishing allowance, and cutting processes.

These data are invalid once the tool sequence has been displayed.

[1]UNIT

Select the menu item in accordance with the machining method.

Input example: [ROTATE 1] → ROTATE 1 unit is set.

[2]GL-FL

The numbers of GLs/FLs used in this unit are displayed. Display example: 1-1 → One GL and one FL are used.

[3]ROT. AXIS

“Z” is displayed as the rotational axis for GL-FL when one of the [ROTATE 1] through [ROTATE 4] menu items has been selected for UNIT.

Display example: Z → Denotes that the rotational axis is Z.

[4]DIST/th.

Input the values for setting the parallel movement distance of FL or its angle of rotation. Input example: 30 → 30 mm movement or rotation by 30° in the positive direction

[5]MAT-HIGH

Input a numerical value to set the height of the material from the workpiece zero point. Input example: 50 → Material height of 50 mm

[6]FIN

Input a numerical value to set the section to be left uncut as a finishing allowance while rough machining is performed.

Input example: 2 → Finishing allowance of 2 mm

[7]CUT-PROCESS

Select a cutting process and rough machining method from among the menu items.

Input example: [ROUGH R1] → Rough machining only

denotes either items which can be selected from the menu or items for which numerical values are input.

denotes items which are automatically displayed.

Reference should be made to the following description for details on items [1] through [7].

1.UNIT

The unit name selected from the menu is displayed. The following 11 types are available as 3-D machining units.

2.GL-FL

The number of GLs (guide lines) and FLs (figure lines) is displayed as soon as the unit name appears.

3.ROT. AXIS

“Z” is displayed as the rotational axis when rotation unit name from among ROTATE 1 through ROTATE 4 is displayed

4.DIST/th.

Set the angle through which the FL (figure line) is to be rotated in order to create a curved surface when ROTATE 1 or ROTATE 2 has been selected. (As seen from the +Z direction, the selected FL rotates counterclockwise or clockwise if a positive or negative value is entered, respectively.)

PROGRAMMING 3

Set the distance through which the FL (figure line) is to be moved in parallel in order to create a curved surface when either the PARALL. 1 or PARALL. 2 unit has been selected. (The selected FL moves in parallel in the + (plus) direction if a positive value is entered and in the – (minus) direction if a negative value is entered.)

5.MAT-HIGH

Set the height from the workpiece zero point on the Z-axis to the top of the material.

+Z

MAT-HIGH

Material

+X

Workpiece zero point

Curved-surface figure

D735P0503

Note: A negative value cannot be used to set the material height. The workpiece zero point must therefore be set in the minus direction (in other words, below) from the top of the material.

6.FIN

Set the finishing allowance for the section to be left uncut by rough machining.

Rough machining

Finish machining

FIN

Curved-surface figure

D735P0504

3 PROGRAMMING

7.CUT-PROCESS

Select the cutting process from the following menu as well as whether rough machining is to be performed at high speed or at normal speed.

The data selected here are used to select the tools in the tool sequence. (The data become invalid once the tool sequence has been displayed.)

If the rough machining process is selected after reversing the display state of the menu item by pressing the [H SPEED RGH PRC.] menu key, the rough machining tool in the tool sequence will be displayed as below:

R1 END MILL

In this case, rough machining will be performed at high speed.

High-speed rough machining can be identified by observing whether or not the tool sequence “R” appears in red.

D735P0505

3-3-2 Tool-sequence definition

The tools to be used are automatically determined by the unit definition.

A tool is made operational by defining such factors as its normal diameter, approach coordinates, peripheral speed and feed rate.

[1]TOOL

The tool is automatically determined according to the CUT-PROCESS data set during unit definition.

[2]NOM-φ

Input a numerical value to set the diameter of the tool. Select a suffix from the menu if necessary.

[3]No.

Input a numerical value to set the operation priority number when the priority function for the same tool is to be used.

[4]APRCH-X, APRCH-Y

Input numerical values or press the [AUTO SET] menu key to set the coordinates which the tool will initially approach.

[5]TYPE

Select the cutting type from the menu.

Input example: [X BI-DIR] → X-axis bi-directional rough machining

[6]DEPTH

For rough machining, input the numerical value to set the depth for one cutting pass in an axial direction.

Input example: 5 → Cutting to a depth of 5 mm

For finish machining, input the numerical value to set the amount to be left uncut as the finishing allowance.

Input example: 2 → 2 mm is left as the finishing allowance.

[7]#T

Input the desired machining error tolerance level for the curved-surface figure using a number from 1 to 9.

Input example: 1 → Parameter E67 for machining error tolerance level is used.

[8]PITCH

Input a numerical value to set the desired pitch for cutting.

Input example: 10 → Cutting is performed by a pitch of 10 mm.

[9]C-SP, FR

Input numerical values to set the C-SP (peripheral speed) and FR (feed rate).

Input example: C-SP: 500 → Peripheral speed of 500 mm/min

FR: 50 → Feed rate of 50 mm/rev

3 PROGRAMMING

[10] M

Select from the menu the M-code to be output immediately after the tool has been automatically changed (ATC).

Input example: [50 AIR BLAST] → Air blasting operation

denotes either items which can be selected from the menu or items for which numerical values are input.

denotes items which are automatically displayed.

Reference should be made to the following description for details on items [1] through [10].

1.TOOL

The tool is automatically selected according to the data set during the cutting process selection for unit definition.

BAL EMIL (ball-end mill) is used for 3-D machining but END MILL (ordinary end mill) is used for high-speed rough machining.

2.NOM-φ

Use a value for the tool diameter so that it can be distinguished from the diametrical values of other tools (0.1 mm). Assign a suffix (identification code A to Z) (except I and O) from the menu to identify identical tools.

Note: The tool defined here must be registered on the TOOL FILE display beforehand.

3.No.

Set the operation priority number when the priority function for the same tool is to be used.

1)Operation to be done first (1 to 99)

2)No number

3)Operation to be done later (1 to 99)

(During machining the tools are selected in the order of 1 to 3.)

For further details reference should be made to “PRIORITY FUNCTION FOR THE SAME TOOL” in the Programming Manual (MAZATROL Programming).

4.APRCH-X, APRCH-Y

Set the coordinates to which the tool is to be approached initially after completing ATC (automatic tool changing). If the [AUTO SET] menu key is pressed, “?” is displayed and the coordinates are automatically calculated and set when the tool path is checked.