The information in this document is subject to change without notice and does not represent acommitment on the part of Hurco Companies. The software described in this document isfurnished under a license agreement to customers. It is against the law to copy the software onany medium except as specifically allowed in the license agreement. The purchaser may makecopies of the software for backup purposes. No part of this document may be reproduced ortransmitted in any form or by any means, electronic or mechanical, including photocopying,for any purpose without the express written permission of Hurco.

© 1994 Hurco Companies, Inc. All rights reserved. Printed in the United States of America.

Ultimax 3, UltiPocket, and AutoSave are trademarks of Hurco Companies, Inc.IBM and PC/AT are registered trademarks of International Business Machines Corporation.DXF is a trademark of Autodesk, Inc.

Many of the designations used by manufacturers and sellers to distinguish their productsare claimed as trademarks. Hurco has listed here all trademarks of which it is aware.

For more information on Hurco products and services, contact the corporate headquartersin Indianapolis, Indiana or one of the subsidiaries listed below:

Hurco Companies, Inc. Autocon Technologies, Inc. Hurco WestOne Technology Way 38455 Hills Tech Drive 5860 Arlington Ave.P.O. Box 68180 Farmington Hills, Michigan Suite "M"Indianapolis, Indiana 48331-5751 Riverside, CA 92504

46268-0180TEL (317) 293-5309 TEL (810) 488-0440 TEL (909) 358-2340FAX (317) 328-2812 FAX (810) 488-0430 FAX (909) 358-2335

Hurco .Europe Ltd. Hurco GmbH Autocon GmbHLincoln Road Benzstrasse 8 Kolpingring 12Cressex Industrial Estates 8011 Kirchheim D-82041 OberhachingHigh Wycombe Munich, Germany GermanyBuckinghamshire, England

HP12 3TH TEL 011 4989 9050 9434 TEL 001`4989 625 2012TEL 001 44 494 442222 FAX 01 1 4989 9050 9450 FAX 011 4989 625 2014FAX 011 44 494 4444646

Central Hurco s.a.r.l.Pare d'activite Charles de Gaulle

5, rue Jean Monet

95190 Goussainville France

TEL 011 33 1 39886 400FAX 011 33 1 39929 483

Hurco Southeast Asia Pte LtdNo. 37 Lorong 23 Geylang

#0501, Yu Li Industrial Building

Singapore 1438

Republic of Singapore

TEL 0116 742 6177

FAX 011 65 745 7664r.

Using this Manual

The Operator ' s Manual describes the machine tool operations , Ultimaxfunctions , and screens used by a Hurco machine tool operator. Thismanual employs several conventions to'explain the system concepts andpoint out key concepts . These conventions are described in this section.

Sections of the ManualThis manual is divided into these chapters:

Chapter 1 - Getting Started

Chapter 2 - Conversational Part Programming

Chapter 3 - DXF File Translation

Supplementary material is included in the Appendix section at the end ofthe manual and includes the following:

• Ultimax 3 console • layout

• Ultimax 3 Screen Hierarchy

• Coordinate System

• Recommended Chip Loads

• Feeds and Speeds for High Speed Tools

There is also an index that cross-references the material presented in themanual.

Ultimax 3 System

i

i

Using this Manual

References to KeysIn this manual , the softkey selections are described using their numbered"F"' designation and/or the words displayed on the text screen beside it,such as Physical Parameters (Fl). Some important softkeys are referencedby name in the index. Others are described in a group and referenced by ageneral category in the index.

Console keys are described by the name used on the console. For example,the operator may be instructed to press Enter or the Power On button. Thecapitalized words in the example indicate the names of the buttons as theyare labeled on an Ultimax 3 console.

While learning the Ultimax system, the operator may find it useful toremove the console layout chart in the "Appendix" section and keep itavailable while reading the manual and programming parts.

Style GuideIndexed terms are italicized within the text paragraphs that define them.Titles of books also appear in italic print to meet the English language,.convention for titles . References to chapter and section names within thetext are set in quotation marks for the same reason.

Screen titles , field names, and button names begin with capital letterswithin the text and in the index to help the reader identify the exactreference as it appears on the system screen or on the console.

5/20/94 Hawk 5M Machine

Using this Manual

Standard Text IconsThis manual contains several icons to mark important sections:

Where can we go from here?

This icon and heading indicate that at this point in the description theoperator has several possible options which are then listed under theheading.

Troubleshooting

The toolbox icon indicates steps that can be taken to solve potentialproblems. These sections contain information for Hurco Technical Servicerepresentatives and customers.

Hints and Tricks

The light bulb icon marks useful suggestions for the machine tooloperator. These suggestions may show creative uses of the Ultimaxfeatures or just helpful hints.

Important

The information marked with the exclamation icon must be carefullystudied. to ensure proper operation of the machine and/or the control.

Operator's Manual i Revision A III

Using this Manual

Caution

A "Caution" message tells the operator that the machine may be damagedor a part ruined if the described procedure is not followed.

Warning

A "Warning" message indicates that the operator may beinjured and the machine tool severely damaged if thedescribed procedure is not followed.

iv 5/20/94 Hawk 5M Machine

Using this Manual

Sample ScreensThe sample screens in this manual were captured on a HAWK 5Mmachine tool. Here is a sample screen:

+* MANUAL .. IF TOOL IN SPINDLE

MACHINE PART MACHINE VERTICAL 1x 393.780 393 .788 TOOL IN SPINDLE B IY 177 . 688 177 . BOB SPINDLE 8 F MACHINEZ. 8.888 «^+ FEED MOTION STOPPED 2 DIAGNOSTICS

F3

Choose appropriate sottkey

Figure ]-]. Manual screen

F PARX MACHINE41

F WARM UP MACHINESU

F TOOL HOME61

F RESET SERVOS7 AMD SPINDLEr

F CALIBRATE MACHINE8

Note that there are three areas of interest on these screens:

• Softkey names and key numbers down the right side of thescreen. Note that these names may change even when the textand data entry area does not change.

• Fields to the left of the softkeys. A "field" is an area on anUltimax screen that displays information and may also receiveinformation that the operator enters through pressing consolekeys.

• Prompt and error message area at the bottom on the left("Choose appropriate softkey" is the prompt on the sampleshown above.)

A Figure List showing the titles of all of the illustrations is included afterthe following Table of Contents.

Operator's Manual Revision A v

Table of Contents

Chapter 1 - Getting Started

Machine Tool Components ................................................................................1-1Safety and Equipment Maintenance ...................................................................1-2

Operator Safety and Apparel ..................................................................1-2

Part Fixturing and Cutting ......................................................................1-3

Equipment Maintenance .........................................................................1-4

Daily .....................................................................................1-4Weekly .. ................................................................................... 1-4Monthly . .................................................................................... 1-5Quarterly .... ................................................................................. 1-5Semi-Annually ...... ...................................................................... 1-5Annually ... .................................................................................. 1-5

The Ultimax 3 Console ................................ ....................................................... 1-6Types of Console Keys ...........................................................................1-7

Floppy Drive and Protection Keyswitch ................................................. 1-8

Hardware Options .............................................................................................1-11Software Options .............................................................................................. 1-12

U l tiPocket .............................................................................................1-12

3-D Contour .9 ........................................................................................ 1-12

CAD Compatibility (DXF) Option ....................................................... 1-12

Off-line Software .... ........ ................................................................... 1-13

Cutter Insert Routines ............................................................................ 1-13

Indexer .................................................................................................. 1-13

Rotary ................................................................................................... 1-13

Additional Language Files .................................................................... 1-14

Option-Access Security Key .................................................................1-14

Preparing for Power Up ....................................................................................1-15Routine Daily Checks ........................................................................... 1-15

Machine Power ..................................................................................... 1-16

Powering Up .....................................................................................................1-17Power Up Troubleshooting ............................................................................... 1-20

No Response on the Console ................................................................ 1-20

Initialization Error Messages ................................................................ 1-21

Error Messages on Machine Configuration Screen ............................... 1-23

NZ 1,Ultimix 3 System Revision A'- A

Table of Contents

Calibrating the Machine ...................................................................................1-24Power on to Servos ...............................................................................1-25

Calibrating the "Z" Axis .......................................................................1-26

Calibrating the Remaining Axes ...........................................................1-26

Warming Up the Machine ................................................................................1-27Configuring the System ....................................................................................1-29Switching Part Programming Editor Type ........................................................ 1-36Loading Part Programs .....................................................................................1-37

Selecting an Existing Part Program ......................................................1-38

Entering - a New Part Program Name ...... ...............................................1-42

Erase Functions ................................................................................................1-45Part Programming Setup . ..................................................................................1-48

Jog Unit ................................................................................................1-49

Tool Loading and Part Fixturing ............ ...............................................1-51

Loading Tools into the Spindle .................................................1-51Fixturing the Part ......................................................................1-52

Identifying Part Zero with a Tool ..........................................................1-53

Part Setup .............................................................................................1-54

Part Setup Screen ......................................................................1-57Entering Part Setup Information ............................................... 1-59

Tool Setup ............................................................................................1-62

Tool Setup Screen .....................................................................1-63Tool Setup Fields ......... ............................................................. 1-65Automatic Feed and Speed Calculations ...................................1-70

General Parameters ...............................................................................1-73

Hole Parameters ........................................................................ 1-80Milling Parameters .................................................................... 1-81Program Parameters .................................................................. 1-85

Program Storing , Renaming , and Deleting ....................................................... 1-88File Storage Principles .......................................................................... 1-88Directory Options ....................... .......................................................... 1-90

Storing Part Programs ........................................................................... 1-92

Renaming a Program ..................................... .......................................1-95

Deleting a Program ...............................................................................1-97

Copying Part Programs ......................................................................... 1-98Machine Diagnostics Errors ...... .....................................................................1-103Reset Control .................................................................................................1-107

Operator's Manual Revision A vii

Figure List

Figure 2-135. Cutter Inserts softkeys ......................................................................................................2-218Figure 2-136. Triangle Programming diagram ....................................................................................... 2-219Figure 2-137. Completed Mill Triangle screen ........................... !........................................................... 2-220Figure 2-138. Diamond I Face diagram .................................................................................................2-223Figure 2-139. Diamond 2 Faces diagram ................................................................................................2-224Figure 2-140: Completed Mill Diamond I Face screen ..........................................................................2-225Figure 2-141. Hexagon diagram .............................................................................................................2-226Figure 2-142. Completed Mill Hexagon screen ......................................................................................2-227Figure 2-143. Inserts in Sample Program ...............................................................................................2-228Figure 2-144. Typical Single-axis Rotary Table ("A" axis) ...................................................................2-230Figure 2-145. Input Screen with rotary option .........................................................................................2-231Figure 2-146. Input screen .......................................................................................................................2-232Figure 2-147. Part Setup screen with Rotary Axis .................................................................................2-233Figure 2-148. General Parameters ...................... ..................................................................................... 2-235Figure 2-149. New Block screen with Rotary softkey .............................................................................2-236Figure 2-150. Rotary Options on the New Block screen ........................................................................2-237Figure 2-151. Rotary Parameters ............................................................................................................2-238Figure 2-152. Rotary Position Block ......................................................................................................2-239Figure 2-153. Rotary Milling Operations ...............................................................................................2-241Figure 2-154. Rotary Line .......................................................................................................................2-242Figure 2-155. Formula to calculate unknown rotary line and arc points ................................................2-243Figure 2-156. Rotary Frame ....................................................................................................................2-244Figure 2-157. Rotary Pattern Loop ................................................. :....................................................... 2-245Figure 2-158. Rotary Locations ..............................................................................................................2-246Figure 2-159. Part Drawing used for the sample Rotary program ..........................................................2-247Figure 2-160. Illustration of Preliminary Calculation Program ..............................................................2-248Figure 2-161. Graphics screen representation of Rotary Program .........................................................2-263Figure 2-162. Auxiliary screen with Upload/Download facility options ................................................2-267Figure 2-163. Auxiliary screen with Protocol options ............................................................................2-271Figure 2-164. Machine Control Console Buttons ...................................................................................2-273

2_275...........................................Figure 2-165. Machine Operations Buttons ..:....:... --:' .......: . -- -...•......

Figure 2-166. Manual Screen ............ ............................. =2-277-Figure 2-167. Test Run screen ...... :......................................................................................................... 2-278Figure 2-168. Feed and Speed Optimization screen ...............................................................................2-279Figure 2-169. Single Cycle screen ..........................................................................................................2-281Figure 2-170. Single Cycle with program information ...........................................................................2-282Figure 2-171. Auto screen ......................................................................................................................2-283Figure 2-172. Auto screen while the program is running .......................................................................2-284Figure 2-173. Auto screen with Tool Change message ..........................................................................2-285Figure 2-174. Auto screen with Emergency Stop message .....................................................................2-286Figure 2-175. Auto screen with Start and End Block fields ...................................................................2-287Figure 2-176. Auto screen with Starting Location selections .................................................................2-289Figure 2-177. Auto screen with Milling Start Block selections ..............................................................2-290

Figure 3-1. Current Directory screen ..........................................................................................................3-3Figure 3-2. Input screen ..............................................................................................................................3-4Figure 3-3. Auxiliary screen .......................................................................................................................3-5Figure 3-4. Current Directory screen ..........................................................................................................3-6Figure 3-5. DXF graphics screen with main DXF options .........................................................................3-7Figure 3-6. Parameters screen for DXF option ...........................................................................................3-8Figure 3-7. Data Input dialog box .............................................................................................................3-I IFigure 3-8. Data Block Type Selection .....................................................................................................3-12Figure 3-9. Accept screen button for Milling ...........................................................................................3-14

V

Operator's Manual ' Revision A xix

Figure List

Figure 3-10. Locations in the Holes data block ........................................................................................3-15Figure 3-11. Mill Contour Start data block ...............................................................................................3-16Figure 3-12. Zoom Box screen button for Milling ...................................................................................3-17Figure 3-13. DXF Zoom options ...............................................................................................................3-18Figure 3-14. Panned view .........................................................................................................................3-19Figure 3-15. Layer options ........................................................................................................................3-21Figure 3-16. Selecting Holes from the DXF drawing ...............................................................................3-22Figure 3-17. DXF Default screen button and message .............................................................................3-24Figure 3-18. Tool Path in the part program ..............................................................................................3-26Figure 3-19. DXF Milling options ............................................................................................................3-27Figure 3-20. DXF drawing with outside lines and arcs selected ...............................................................3-28Figure 3-21. Mill Contour Start Segment .................................................................................................3-30Figure 3-22. Mill Contour Arc Segment ...................................................................................................3-30Figure 3-23. Selecting a Circle from a DXF drawing ...............................................................................3-31Figure 3-24. Mill Circle data block created from the DXF file ................................................................3-32Figure 3-25. Selecting the First Segment of a Frame ................................................................................3-33Figure 3-26. 3-D DXF Drawing ................................................................................................................3-34Figure 3-27. Selecting and Splitting Segments on a 3-D Contour ............................................................3-35Figure 3-28. Creating a Mill 3D data block ..............................................................................................3-36Figure 3-29. Completed Mill 3D data block .............................................................................................3-37Figure 3-30. Part Program Illustration ......................................................................................................3-37Figure 3-31. Start Segment for the Mill 3D data block ...........................................................................3-38Figure 3-32. Segment I in the Mill 3D data block ....................................................................................3-38Figure 3-33. Editing screen buttons ..........................................................................................................3-39Figure 3-34. Extended lines ......................................................................................................................3-40Figure 3-35. Joined lines and arcs ............................................................................................................3-41Figure 3-36. Select a segment to modify ..................................................................................................3-42Figure 3-37. Modify segment data ............................................................................................................3-43Figure 3-38. Split a segment ....................................................................................................................3-44Figure 3-39. Tool Setup screen ........................................................................................................_.......3-45

xx 5/20/94 Hawk 5M Machine .

Table of Contents

Shut Down Techniques .................................................................................. 1-109Park Machine ...................................................................................... 1-110

Emergency Stop .................................................................................1-112

Infrequent System Changes ............................................................................1-114Changing Language Files . ..................................................................1-114

Upgrading Ultimax Software .............................................................. 1-116

Table of Contents

Conversational Part Programming

Conversational Programming Principles ............................................................2-1Before Part Programming .......................................................................2-2

Access to Programming Functions .........................................................2-4

Part Programming Summary ...................................................................2-7

Data Block Options .....................................................................2-7Data Block Creation and Navigation ..........................................2-8Creating a Milling Data Block ....................................................2-9Creating a Hole Drilling Data Block .........................................2-14End of Program ..................... ....................................................2-22

Special Data Blocks ..............................................................................2-23

Position Block ...........................................................................2-23Temporary Parameter Change ........ ...........................................2-26Set a New Part Zero ..................................................................2-30

Automatic Calculations ........................................................................2-31

Graphics ...............................................................................................2-33

Views ................................................... ................................2-36Zoom ...................................................................................2-38Graphics Parameters ................................................................. 2-38Data Block Search ....................................................................2-40Graphics Error Checking ..........................................................2-42

Checking the Part Program ...... ................. :........................................... 2-43

Review Program .......... ..............................................................2-43Error Checking and Run Time ..................................................2-44

Changing a Part Program ......................................................................2-45

Changing a Block ........................................ .............................2-45Block Editor ..............................................................................2-46Copying and Moving Blocks .. ..................................................2-49Deleting Blocks .........................................................................2-50Modifying Dimensions .............................................................2-51Changing Feeds and Speeds ................... ...................................2-52

Running a Part Program .......................................................................2-54

Test Run ...................................................................................2-55Feed and Speed Optimization ....................................................2-56Auto ...................................................................................2-57

Concurrent Programming .....................................................................2-60Printing a Program ................................................................................2-62

Program Identification and Storage ......................................................2-63File Naming ..............................................................................2-63File Storage Facilities .............. ..................................................2-65

Operator 's Manual . Revision A ix

Table of Contents

P Holes Operations .............................................................................................. 2-66Drill Operations .................................................................................... 2-68

Drill . .................................. ............... ... . ...........................2-74Center Drill ...............................................................................2-75Counterbore ..............................................................................2-76Spotface ...................................................................................2-77Countersink ...............................................................................2-78Gun Drill ...................................................................................2-79Locations .................................................................................. 2-84Bolt Circle . ................................................................................ 2-86

Tap .....................................................................................................2-89

Bore and Ream Operations ................................................................... 2-91

Bore . .................................................................................. 2-93Ream ...................................................................................2-94Bore Rapid ................................................................................ 2-94Bore Orient ............................................................................... 2-95Ream Rapid .............................................................................. 2-95

Back Spotface .......................................................................................2-96

Sample Drilling Program ...................................................................... 2-99

Milling ............................................................................................................2-104Segments ............................................................................................ 2-106

Cutter Compensation .......................................................................... 2-110

Climb Milling ....... .................................................................. 2-112Conventional Milling . ............................................................. 2-112Profile Left and Right ............................................................. 2-113

Maximum Offset ................................................................................ 2-114

Feed and Speed Options ... .................................................................. 2-115

Programming Lines and Arcs ............................................................. 2-116

Lines ....... ..........................................................................2-116Arcs ............. .................................................................... 2-119Blend Arcs ....... ....................................................................... 2-121Helix .................................................................................2-1263-D Are .................. ............................................................... 2-128

Circle .......... ........................................................................................ 2-131

Frame ... ............................................................................................... 2-134

Face Milling ........................................................................................2-139

Ellipse ................................................................................................. 2-143

Lettering ............................................................................................. 2-147

3-D Milling Option ............................................................................. 2-150

Sample Milling Program ..................................................................... 2-151

x 5/20/94 Hawk 5M Machine

. "li.

Table of Contents

Pattern Operations ..........................................................................................2-163Loop Rectangular ...............................................................................2-167

Loop Linear ........................................................................................2-169

Loop Angular ......................................................................................2-172

Loop Rotate ........................................................................................2-174

Pattern Locations ................................................................................2-176

Scale ...................................................................................................2-177

Mirror Image .......................................................................................2-180

Pattern End .........................................................................................2-182

Sample Pattern Program .....................................................................2-183

UltiPocket Option ...........................................................................................2-188Pocket Boundary ................................................................................2-190

Spiral Outward - No Islands ....................................................2-190Spiral Inward ...........................................................................2-190

Programming Islands ... .......................................................................2-191

Mill Contour .......................................................................................2-192

Mill Frame ................... .......................................................................2-194

Mill Circle ..........................................................................................2-195

Pattern .................................................................................................2-196

Sample UltiPocket Program ................................................................2-196

Cutter Insert Routines ........................................................................... ..........2-218Triangles ...................... .......................................................................2-219

Diamond Faces ...................................................................................2-223

Hexagon ..............................................................................................2-226

Sample Cutter Insert Program .............................................................2-228

Operator's Manual Revision A xi

Table of Contents

I

Rotary .........................................:...................................................................2-230General Information ............................................................................2-230

Rotary Part Programs ..........................................................................2-231

Program Definition .................................................................2-231Part and Tool Setup.................................................................2-232General Parameters .................................................................2-235

Rotary Programming Options ........ ..................................................... 2-236

Rotary Parameters ............................................................................... 2-238

Rotary Position Block .........................................................................2-239

Rotary Milling Operations .................................................................. 2-241

Lines and Arcs ....................................................................................2-242

Rotary Frame ......................................................................................2-244

Rotary Loop ........................................................................................2-245

Rotary Pattern Locations ....................................................................2-246

Sample Rotary Program ......................................................................2-247

Preliminary Calculation Program .......... ..................................2-248Rotary Program .......................................................................2-263 '

Upload and Download Programs ....................................................................2-266Setup ...................................................................................................2-266

Access through the Auxiliary Screen ..................................................2-267

Receive or Send a Part Program .........................................................2-269

Print a Part Program ...........................................................................2-270

Ports ..................................................................................................2-271

Running Part Programs .................................... .............................................. 2-272Console Buttons Used :.............................. ' ^q • -'.....2-273........................................................

Machine Control Buttons ..... ......... .............................. .......... 2-273Machine Operations Buttons .. ........................................:.......2-275

Manual .....................................................................................:........2-277

Test Run .............................................................................................2-278

Feed and Speed Optimization ..........................................r............:...2-279

Single Cycle ..................................................................:.::..:.:::...... 2 281

Automatic Operation .................................................................S'%...2-283

Recovery and Restart ...................................................................::.....2-286

xii 5/20/94 Hawk 5M Machine

Table of Contents

DXF File Translation

General Capabilities ...........................................................................................3-1AutoCAD Files and the DXF Option ......................................................3-1

Ultimax Programming Features ..............................................................3-2

Graphics Display .........................................................................3-2Data Blocks .................................................................................3-2

DXF File Management .......................................................................................3-3Creating a New Conversational Program ............................................................3-4DXF File Display ................................................................................................3-5Setting DXF Parameters .....................................................................................3-8Building Data Blocks .......................................................................................3-12

General Concepts ..................................................................................3-13

Selecting DXF Drawing Elements ............................................3-13Accept Screen Button ................................................................3-14Conversational Data Blocks .......... ......................:..................... 3-15Zoom Box Screen Button ..........................................................3-17Layers ...................................................................................3-20

Holes .....................................................................................................3-22

Selecting Holes .........................................................................3-23Intersect Screen Button .............................................................3-23Accepting Holes .................. ......................................................3-24

Milling ..................................................................................................3-27

Lines/Ares .................................................................................3-27- -:3-31 .. .-- -Circle

Frame............................... ................................................... 3-333-D Option ................................................................................3-34

Editing a Drawing .................................................................................3-39

Extend ...................................................................................3-40Join ...................................................................................3-41Modify ...................................................................................3-42Split ...................................................................................3-44

Completing the Program ...................................................................................3-45

Operator's Manual Revision A xiii

Table of Contents

Appendix ....................................................................................................A -1

Ultimax 3 Console .........................................................................................................A-2

Ultimax 3 Screen Hierarchy ...........................................................................................A-3

Coordinate System .......................................................................................................A-4

Suggested Cutting Speeds .............................................................................................A-5

Recommended Chip Loads ...........................................................................................A-6

Feeds and Speeds for High Speed Drills .......................................................................A-7

Index ............................................................................... ..............................I -1

xiv 5/20/94 Hawk 5M Machine

Figure List.

Figure 1-1. Hurco Hawk 5M Machine Tool ................................................ :.............................................. 1-IFigure 1-2. Ultimax 3 Console ....................................................................................................................1-6Figure 1-3. Part Program Protection Keyswitch and Right-side of.Console .............................................. 1-8Figure 1-4. Partial Access "Protected" Input screen ..................................................................................1-9Figure 1-5. "Unprotected" Input screen ................................................................:..................................1-10Figure 1-6 . Software Option Security Key ............................................................ :.................................. 1-14Figure 1-7. Side view showing electrical cabinet and power switch ....................................................... 1-16Figure 1-8 . Machine Configuration screen ............................................................................................... 1-18Figure 1-9. Input screen (software version number ) ..... ........................................................................... 1-22Figure 1- 10. Manual screen showing uncalibrated axes ................:..........................................................1-24Figure 1-11. Manual screen ......................................................................................................................1-27Figure 1-12. Auxiliary screen ...................................................................................................................1-29Figure 1-13. System Parameters screen ..................................... :........................................................... ...1-30Figure 1-14. AutoSave message on General Parameters screen ...... .......................................................... 1-32Figure 1-15. System Parameters screen

................. ........ ........................................................................... 1-33Figure 1 - 16. Machine Configuration ......................................................................................:.................1-34Figure 1-17. Auxiliary screen ...................................................................................................................1-36Figure 1-18 . Input screen ..........................................................................................................................1-37Figure 1-19. Auxiliary screen ................................................................................................................... 1-38Figure 1-20. Current Program screen ..................................................................................................::...1-40Figure 1-21. Current Directory screen ......................................................................................................1-40Figure 1-22 . Part Program Read into Memory .........................................................................................1-41Figure 1-23. Letter Selection screen (graphics screen ) .............................................................................1-42Figure 1-24. Input screen (text screen ) while entering new program name .......................................... :..1-43

;Figure I-25 . Input screen after the operator presses Enter .......................................................................1-44Figure 1-26. Input screen with Erase Functions softkey ...........................................................................1-45Figure 1-27. Input screen with Erase functions ........................................................................................1-46Figure 1 -28. Input screen with "Do you really want to Erase?" message ...................... :.......................... 1-47Figure 1-29 . Jog Unit ....................................................................................................:.......................... 1-49Figure 1 -30. Manual screen with jog parameters (in millimeters per minute ) .........................................1-50Figure 1-31. Spindle, Tool Holder, and In/Out Buttons ......................................................................:..1-5IFigure 1-32. Part Zero Relationship to Machine

Absolute Zero ........ ...................... .......................... ....... 1-54Figure 1-33. Tool Zero Calibration Plane and Part Zero in Z ................................::.......:.......................1-55Figure 1-34. Spindle motion relative to Part Zero .......................................................... ..........................1-56Figure 1-35. Completed Part Setup screen ..............................................................................................1-57Figure 1 -36. Safety Work Region ..............................................................................................:......:.......1-60Figure 1-37. Offset Z ...............................................................................................................................1-61Figure 1-38. Tool Setup screen ............................................................. :....................................... :........... 1-63Figure 1-39. Tool Setup screen .................................................................................................................1-65Figure 1-40. Tool Setup screen with tool types ........................................................................................ 1-66Figure 1-41. Cutter Compensation ............................................................................................................ 1-67Figure 1-42. Tool Setup screen with Surface Speed field ......................................................................:..1-69Figure 1-43. Input screen .................................... .................................................. .................................... 1-73Figure 1-44. General Parameters screen for conversational programming .............................................. 1-74Figure 1-45. Chord Error .................................................................................................................:........1-78Figure 1-46 . Hole Parameters screen ........................................................................................................ 1-80Figure 1 -47. Milling Parameters screen .................................................................................................... 1-81

Ultimax 3 System ., Revision A

Figure List

Figure 1 -48. Cutter Compensation using the Insert Arc parameter .......................................................... 1-83Figure 1 -49. Cutter Compensation using the Insert Line parameter......................................................... 1-84Figure 1-50. Program Parameters screen .................................................................................................. 1-85Figure 1-51. Current Program screen ....................................................................................................... 1-88Figure 1-52. Directory Structure ...............................................................................................................1-89Figure 1-53. Current Directory screen with directory softkeys ................................................................ 1-90Figure 1 -54. Current Program screen .......................................................................................................1-92Figure 1-55. Current Directory screen used for program storage ............................................................. 1-93Figure 1-56. Current Program screen program name during save operation ............................................ 1-94Figure 1-57. Program Renaming on the Current Directory screen ........................................................... 1-96Figure 1-58 . Deletion Function 's "Are you sure ?" message .....................................................................1-97Figure 1-59. Current Directory screen with directory softkeys ................................................................1-98Figure 1-60. Current Directory screen with "More " softkeys ..................................................................1-99Figure 1-61 . Limit Switches screen ........................................................................................................1-103Figure 1-62. Manual screen with Way Lube error ..................................................................................1-104Figure 1-63. Limit Switches screen with error condition ....................................................................... I-105Figure 1-64. Auxiliary screen with Reset Master softkey ......................................................................1-107Figure 1-65 . "Reset Master" and "Diskette in Drive" messages ............................................................ 1-108Figure 1-66. Manual screen with Park Machine softkey ........................................................................1-110Figure 1-67. "Emergency Stop" message on the Manual screen ............................................................ 1-112Figure 1-68 . Auxiliary screen with Change Language softkey ............................................................... 1-114Figure 1-69. Language Selection screen .................................................................................................1-115Figure 1-70. Auxiliary screen with More softkeys .................................................................................1-116Figure 1 -71. Auxiliary screen with executive upgrade message ............................................................. 1-117

Figure 2-1 . Input screen ..............................................................................................................................2-3Figure 2-2 . Input screen .............................................................................................................................. 2-4Figure 2-3 . New Block screen.....................................................................................................................2-5Figure 24 . New Block screen with milling options ...................................................................................2-9Figure 2-5. Mill Frame screen ..................................................................................................................2-10Figure 2-6. Mill Frame screen with tool number ......................................................................................2-11Figure 2-7. Completed Mill Frame screen ................................................................................................2-12Figure 2-8 . New Block screen...................................................................................................................2-14Figure 2-9. Holes screen with softkey options ..........................................................................................2-15Figure 2-10 . Holes screen with Drill Operations softkeys ........................................................................2-16Figure 2-11 . Holes screen with Center Drill fields ...................................................................................2-17Figure 2-12 . Holes screen with Drill fields ...............................................................................................2-18Figure 2-13. Start a New Operation ...............................................................................................:..........2-19Figure 2-14 . Holes screen with Location coordinates ..............................................................................2-20Figure 2-15 . Completed Holes Data Block ...............................................................................................2-21Figure 2-16 . End of Program screen .........................................................................................................2-22Figure 2-17. Position screen ..................................................................................................................... 2-23Figure 2-18 . New Block screen.................................................................................................................2-26Figure 2-19. Change Parameters and Part Se tup ......................................................................................2-27Figure 2-20 . Change General Parameters screen ......................................................................................2-28Figure 2-21 . Change Part Setup screen ..................................................................................................... 2-30Figure 2-22. Automatic Calculation of Values .........................................................................................2-31Figure 2-23 . Ultimax Console ...................................................................................................................2-33Figure 2-24 . Graphics screen ....................................................................................................................2-34Figure 2-25 . New Block screen with Miscellaneous functions .................................................................2-35Figure 2-26 . Graphics screen with isometric view ....................................................................................2-36Figure 2-27 . Graphics screen showing All Planes ....................................................................................2-37Figure 2-28 . Graphics Parameters screen .................................................................................................2-38

xvi 5/20/94 Hawk 5M Machine

Figure List

Figure 2-29. Identifying a portion for the search ......................................................................................2-40Figure 2-30. Data Block displayed after the search ..................................................................................2-41Figure 2-31. Graphics screen error message ............ ........... :................... .................................................. 2-42

Figure 2-32. Review Program screen ...... :................................................................................................. 2-43Figure 2-33. Part Program Error Checking ...............................................................................................2-44Figure 2-34. Input screen ..........................................................................................................................2-45Figure 2-35. Input screen with Copy and Change Blocks softkey ............................................................2-46Figure 2-36. Block Editor screen ..............................................................................................................2-47Figure 2-37. Block Editor features ................. .......................................................................................... 2-48Figure 2-38. Block Editor with Copy Blocks fields ..................................................................................2-49Figure 2-39. Block Editor with Delete Blocks fields ................................................................................2-50Figure 2-40. Block Editor with Modify Dimensions fields ......................................................................2-51Figure2-41 . Change All Tools' Feeds and Speeds ...................................................................................2-52Figure 2-42. Change Feeds and Speeds for 1 Tool ...................................................................................2-53Figure 2-43. Test Run screen ....................................................................................................................2-55Figure 2-44. Feed and Speed Optimization screen ...................................................................................2-56Figure 2-45. Auto screen with softkey options .........................................................................................2-57Figure 2-46. Auto screen with a running program .............................. :..................................................... 2-58Figure 2-47. Input screen with concurrent running program ....................................................................2-60Figure 2-48. Auxiliary screen with Print Program softkey .......................................................................2-62Figure 2-49. Current Program screen .......................................................................................................2-63Figure 2-50. Letter Selection screen (graphics screen ) .............................................................................2-64Figure 2-51 . Current Program screen .......................................................................................................2-65Figure 2-52 . Hole Operation Hierarchy Chart ..........................................................................................2-66Figure 2-53. Holes screen with option softkeys ........................................................................................2-67Figure 2-54. Holes screen with Drill Operations softkeys ........................................................................ 2-68Figure 2-55 . Completed Drill Data Block .................................................................................................2-71Figure 2-56. Reference Points Relative to Drill Operations .....................................................................2-72Figure 2-57. Drill Bit ................................................................................................................................2-74Figure 2-58 . Center Drill Data Block ........................................................................................................2-75Figure 2-59. Counterbore Operation .........................................................................................................2-76..Figure 2-60 . Spotface Operation ...............................................................................................................2-77Figure 2-61. Countersunk screw head ......................................................................................................2-78Figure 2-62 . Countersink Operation .........................................................................................................2,78Figure 2-63 . Gun Drilling .........................................................................................................................2-79Figure 2-64. Completed Gun Drill Data Block ......................................................................................... 2-82Figure 2-65. Gun Drill Positions ...............................................................................................................2-83Figure 2-66. Locations for holes in a block ..............................................................................................2-84Figure 2-67 . Bolt Circle operation ............................................................................................................ 2-86Figure 2-68 . A Bolt Circle Pattern ............................................................................................................2-87Figure 2-69 . Tap operation fields ............................................................................................................. 2-89Figure 2-70 . Bore and Ream softkeys .......................................................................................................2-91Figure 2-71. Two-bladed Boring Bar with adjustment dial ......................................................................2-93Figure 2-72.. Reaming Tool .......................................................................................................................2-94Figure 2-73. Back Spotface screen ...........................................................................................................2-96Figure 2-74. Hole Drilling Example .........................................................................................................2-99Figure 2-75. Milling Options Chart ........................................................................................................2-104Figure 2-76. New Block screen with the Milling softkeys ......................................................................2-105Figure 2-77. Mill Contour New screen ...................................................................................................2-106Figure 2-78 . Mill Contour Start screen ...................................................................................................2-107Figure 2-79. Completed Mill Contour Start screen ................................................................................2-108Figure 2-80 . Cutter Compensation options .............................................................................................2-110Figure 2-81 . Tool Paths for Cutter Compensation .................................................................................2-111

Operator's Manual Revision A xvii

Figure List

Figure 2-82. Profile Left Cutter Compensation using a finish tool ........................................................2-113Figure 2-83. Determining Maximum Offset ...........................................................................................2-114Figure 2-84. Mill Contour: Line screen ..................................................................................................2-116Figure 2-85. Mill Contour Line screen ...................................................................................................2-116Figure 2-86. Length, Angle, and End Point Relationship .......................................................................2-117Figure 2-87. Line Segment with Unknown Y End and XY Angle ..........................................................2-118Figure 2-88. Mill Contour Arc screen .....................................................................................................2-119Figure 2-89. Coordinates of a Clockwise Arc .........................................................................................2-119Figure 2-90. Arc Segment with Unknown X End and X Center .............................................................2-120Figure 2-91. Some Typical Blend Arcs ...................................................................................................2-121Figure 2-92. Segment creating the Helix in the Blend Are example ......................................................2-123Figure 2-93. Line segment to intersect with previous helix ....................................................................2-124Figure 2-94. Mill Contour Blend Arc .....................................................................................................2-124Figure 2-95. Sample Blend Arc on the Graphics screen .........................................................................2-125Figure 2-96. Mill Contour Helix screen ..................................................................................................2-126Figure 2-97. Mill Contour 3D Arc screen ...............................................................................................2-128Figure 2-98. 180° 3-D Arc ......................................................................................................................2-129Figure 2-99. Mill Circle screen ...............................................................................................................2-131Figure 2-100. Mill Frame screen ............................................................................................................2-134Figure 2-101. Inside Mill Frame Operation ...........................................................................................2-135Figure 2-102. X & Y Length Directional Measurement .........................................................................2-137Figure 2-103. Completed Mill Face screen .............................................................. :.............................. 2-139Figure 2-104. Face Milling Types .................................................................................. .....................2-140Figure 2-105. Mill Ellipse screen............................................................................................................2-143Figure 2-106. Mill Ellipse - Inside Type .................................................................................................2-144Figure 2-107. Mill Lettering screen ........................................................................................................2-147Figure 2-108. Completed Mill 3-D screen ..............................................................................................2-150Figure 2-109. Part drawing used in the sample Milling program ...........................................................2-151Figure 2-110. Pattern Options Hierarchy Chart ......................................................................................2-163Figure 2-111. Pattern Softkeys ...............................................................................................................2-164Figure 2-112. Sample Loop Rectangular operation ................................................................................2-167Figure 2-113. Pattern Loop Rectangular screen .....................................................................................2-168Figure 2-114. Sample Loop Linear.operation .........................................................................................2-169Figure 2-115. Loop Linear screen ...........................................................................................................2-170Figure 2-116. Sample Loop Angular operation ......................................................................................2-172Figure 2-117. Pattern Loop Angular screen ............................................................................................2-173Figure 2-118. Sample Loop Rotate operation .........................................................................................2-174Figure 2-119. Pattern Loop Rotate screen ..............................................................................................2-175Figure 2-120. Pattern Locations screen ..................................................................................................2-176Figure 2-121. Sample Loop Angular operation ......................................................................................2-177Figure 2-122. Pattern Scale screen .........................................................................................................2-178Figure 2-123. Mirror Image example ......................................................................................................2-180Figure 2-124. Pattern Mirror Image screen ............................................................................................2-181Figure 2-125. Pattern End screen ...........................................................................................................2-182Figure 2-126. Part used in the sample Pattern program .........................................................................2-183Figure 2-127. Pocket Boundary with Inward Spiral Islands ...................................................................2-188Figure 2-128. Isometric View of Inward Spiral Islands ..........................................................................2-189Figure 2-129. Mill Contour with Pocket options .....................................................................................2-192Figure 2-130. Mill Contour Start Segment with Pocket Island ...............................................................2-193Figure 2-131. Mill Frame with Inward Spiral Boundary ............. ................................:...:...................... 2-194Figure 2-132. Mill Circle with Outward Spiral Boundary ......................................................................2-195Figure 2-133. Graphics screen illustration of the UltiPocket sample program .......................................2-196Figure 2-134. Isometric view of the UltiPocket sample program ...........................................................2-197

xviii 5/20/94 Hawk 5M Machine

Chapter 1

Getting Started

This chapter explains basic operations such as power up, part and toolsetup, saving part programs, resetting the control, and shutting down themachine tool.

Machine Tool ComponentsBefore using the machine tool, the operator should become familiar withthe machine 's components . The illustration below shows the main parts ofthe Hurco Hawk 5M machine.

Lever to changeSpindle Speed(on the side)

Figure 1-1. Hurco Hawk 5M Machine Tool

Electrical Cabinet(Power Cabinet)

Ultimax 3Console

The operator can see the approximate spindle speed range displayed in thedials above the spindle . To switch the spindle speed between low and highgears, the operator must manually flip the gear change lever on the side ofthe machine.

Tool change Flood CoolantIn & Out Nozzlebuttons

Ultimax 3 System 5/10/94 1-1

Operator' s Manual

Safety and Equipment MaintenanceTo avoid serious personal injury, damage to the machine, andunproductive down-time, the operator must pay careful to safetyprecautions and proper maintenance of the machine. Machine tooloperation is often a dangerous task, so operators must stay alert and beaware of potential hazards. Operators must also follow the safetyregulations of their shops.

Operator Safety and Apparel

Before attempting to operate the machine tool, the operator should studythis manual and become familiar with the machine functions and safetyfeatures. While studying the manual , the operator should make specialnote of the caution and warning messages in the manual and all warningand instruction plates/decals on the machine tool.

Since most machine tool operators are experienced machinists , they knowthat they should always wear eye protection and safety shoes while in thework area . Safety glasses with side shields are recommended. Theoperator should avoid wearing loose -fitting clothing , watches, rings, andneckties that could become caught in the moving parts of the machine.

1-2 5/10/94 Hawk 5M Machine

Getting Started

Part Fixturing and Cutting

Machinists should always know the locations of the Emergency Stopbuttons on the machine tool and console . The machinist must be verycareful when working in the area of the spindle . To prevent injury, thespindle should be completely stopped before the machinist attempts tomake adjustments to a work piece , the fixturing , and/or coolant nozzles.

To prevent cutter breakage , the machinist should check the direction ofspindle rotation . As a rule , the machine rotates the spindle in theclockwise direction for right-hand tools and in the counterclockwisedirection for left-hand tools.

Machinists must clamp the work pieces and fixture them securely beforestarting the machine . Remember that loose objects, such as wrenches andchuck keys , can become flying projectiles if not removed from the tablebefore the machine is started . Operators should be aware of protrudingmachine members (such as hoses, piping , ductwork) when workingaround the machine.

1\ Warning

When running part programs , operators should alwaysfollow these rules:

• Never press the Start Cycle console buttonwithout knowing exactly what the machine willdo!

• Never start the machine when the cutter is incontact with the work piece.

• Stand away while the machine is running a part

program.• Never lean on the machine while the spindle is

moving.

• Do not leave the machine unattended.

Ultimax 3 System Revision A 1-3

Operator' s Manual

Equipment Maintenance

Before any maintenance and/or repair operations are performed within theelectrical cabinet , the machinist or maintenance representative must verifythat the power switch has been turned to the "Off' position before theelectrical cabinet door is opened.

A regular schedule of lubrication and maintenance checks is required toensure continued dependable operation of the machine. The followingchart lists these recommendations . It should be noted that machinemaintenance is dependent upon the amount of use, severity of operation,and machine environment. Therefore, maintenance frequency should alsobe determined on an individual basis and varied accordingly. For more -details about these procedures , refer to the Maintenance Manual.

Recommended Routine Maintenance

Daily

q Check all lubrication levels particularly in the Auto Lubesystem and the air line lubricator.

q Check air pressure at the Filter , Regulator , Lubricator (FRL)assembly in the pneumatic system.

q Check coolant level(s).q Check the ways for proper lubrication and any scratches or

excessive wear . Be certain that the way wipers are not damaged.

Weekly

q Check the moisture drains from the FRL Unit and check lubelevel.

q Refill Autolube tank with proper lubricant.

q Perform necessary cleaning of machine.

q Check filter screen on the spindle oil cooler (if installed).q Inspect tools and tool holders and replace worn inserts, shims,

and clamp screws as needed . It is important to keep the toolssharp since dull and damaged tools break easily.

1-4 5/10/94 Hawk 5M Machine

Getting Started

Monthly

q Check condition of tool holders.

q Check the fasteners securing limit switches and the dogs to becertain they are tight.

0 Lubricate Counterbalance chains.

Quarterly

q Clean and inspect flood coolant system.

q Check ground impedance level (during first year ofinstallation).

Semi-Annually

q Replace Autolube tank suction filter.

Annually

q Check ground impedance level (resistance to true earth).

q Drain, flush, and refill the spindle oil cooler tank (if installed).

Ultimax 3 System Revision A 1-5

Operator' s Manual

The Ultimax 3 ConsoleThe Ultimax 3 control console allows an operator to program a job at themachine while reading directly from a blueprint or a program worksheet.The prompts on the console 's text screen lead the operator through eachelement of the part program . The operator responds to the variousselections and prompts by pressing the appropriate keys and push buttonson the console (numerical keys , softkeys, and other buttons ) to enter thedesired machine operations, part dimensions , and other parameters intothe control 's memory.

a

Text screen O Graphics screenOOOrTrT-

0

V Number keys / Enter keyJog unit Dxecrlonal snow keys

Figure 1-2. Ullinwar 3 Console

nkey buttons

The Ultimax console and the electrical equipment required to operate itare often called "the control" or the CNC (computer numeric control). Thecontrol 's electrical equipment consists of printed circuit boards and cablesto connect and operate the console functions . These boards are located inthe console and in the electrical cabinet . Many internal components of theUltimax console are similar to those in standard personal computers(PCs), so many operations , such as copying/deleting files and storing filesin directories , on the Ultimax console are similar to PC operations.

Getting Started

Types of Console Keys

There are two types of keys used for data entry operations:

• Softkeys

• Console keys

The softkeys are the eight keys between the two screens. These keys areused to select options displayed to the left on the text screen. The possibleselections for these softkeys change depending on the system screendisplayed on the left-hand CRT (cathode ray tube). There are threemethods operators use to select softkey options:

• Press the white softkey button between the two screens thatcorresponds to the desired softkey option.

• Press and hold down either the Alt or Ctrl console key and pressthe number key that corresponds to the desired softkey option.

• Press the console number key that corresponds to the softkey.The selected number appears at the top of the softkey menu liston the text screen . Then press the Enter key.

The console has buttons and keys on the lower and upper panels. Themajor key groupings and significant individual keys are marked in theillustration on the previous page . There are usually two red EmergencyStop buttons on a Hawk 5M machine : one on the jog unit (left side ofconsole) and one on the console key board (right side).

Since the primary Ultimax console does not have letters to use for dataentry, the system will display a letter screen on the graphics monitorscreen when the system needs to know the names of programs and otherfunctions requiring letters. Then the operator uses the trackball to move acrosshair (+) on the letter screen and then presses the Select key to placethe letter into a field on the text screen . Usually the operator presses theEnter key to tell the control to examine the new information typed ontothe text screen.

The operator may wish to pull out the picture of the console keyboardincluded in the "Appendix" section of this manual and refer to thatillustration while learning to use the system.

Uldmax 3 System Revision A 1-7

Operator' s Manual

Floppy Drive and Protection Keyswitch

On the right side of the console are a floppy drive and the part programprotection keyswitch. The floppy drive has a protective cover that shouldbe closed when a diskette is not being inserted or removed so that thecover can protect the drive from dust and debris. This drive has threeprimary purposes:

1. Read stored copies of older versions of Ultimax programs froma DOS diskette

2. Read/save current Ultimax 3 conversational programs from/to aDOS diskette

3. Read/save NC programs from/to a DOS diskette

The part program protection keyswitch, also on the right side of theconsole, limits access to the Ultimax Input screen functions used to accessand change part programs . A key is inserted in the keyhole below thedotted indicators. Refer to the illustration below. When the key is turnedto the right toward the dots that are connected to form an "X" in themiddle , then the operator cannot change the program data blocks in partprograms loaded into the control . To standardize programs in a shop orcontrol the quality of programs produced , a supervisor may want to loadprograms into the control , switch the key to this "protected" position, andremove the key.

Part ProgramProtectionKeyswitch

Access to Input screenfunctions for part programediting are locked out

Floppy Drive(with protective cover)

Figure 1 -3. Part Program Protection Keys witch and Right-side of Console

1-8 5/10/94 Hawk 5M Machine

Getting Started

When the keyswitch is turned to the right in protected position, the Inputscreen appears but only with a limited set of softkeys, as shown below.When the message "This mode is locked out by the program protectswitch" appears at the bottom of the screen, it indicates that the partprogramming functions are locked out. In other words, the part programson the control are partially protected from changes.

« INPUT « IF PART SETUP

MASTER PROGRAM "An 5M u1 .58 11er.22'94 11

EDIT PAST PROGRAM 1.HD3 METRIC F TOOL SETUPSTANDARD VERTICAL 2

PPROGRAM MEMORY AVAILABLE 99 s 3

FI

5

F6

1M IS MODE IS LOCIED OUT BY THE PAOGIReI PROTECT SWITCH 7

PB

Figure 1.4. Pardo" Access "Protected" Input screen

When the program is partially protected, the operator can change the PartSetup (Fl) and Tool Setup. (F2) parameters for the displayed program(1.HD3 in this example). In addition , the operator may cut a part using thedisplayed program or press the Auxiliary console key to retrieve adifferent part program.

To lock out Part and Tool Setup options and, therefore, fully protect theprograms , the supervisor selects the "Full" option for the Program Protectfield on the Program Parameters screen . Refer to the "General Parameters"section of this chapter for more information.

Ultimax 3 System Revision A 1-9

Operator' s Manual

When the keyswitch is turned to the left, the part programming functionsare "unprotected," and the operator can access all of the functions as 1shown in the screen below. In addition to the Part Setup and Tool Setupfunctions, "unprotected" mode gives the operator access to the followingfunctions:

• Part Programming (F3)

• Program Parameters (F4)

• Copy and Change Blocks (F6)

• Erase Functions (177)

INPUT IF PART SETUP

IKSTER PROGRAM IIAYR 91 u1 . 50 Mar . 22'94 1

EDIT PART PROGRAM 1 . 11D3 METRIC F TOOL SETUPSTANDARD VERTICAL 2

PROG%OI MEMORY AVAILABLE 99 x

Select eartlmy or Press ant•r) to chance part Program news

Figure 1-5. "Unprotected" Input screen

i

F PART PROGRAMMING3

F PROGRAMt PARAMETERS

FS

F COPY AND CHANGE6 BLOM

F ERASE FRICTIONS71FB

1-10 5/10/94 Hawk 5M Machine

Getting Started

Hardware OptionsThe Hawk 5M has several hardware options that the machine owner mayuse to adapt the machine to its operating environment. Here are theavailable options:

Option Description

Table guard a three-sided protective shield around the back ofthe table.

Chip enclosure a complete table enclosure to protect the operatorfrom flying debris (only for Hawk 5M machinessold in the United Kingdom).

Work light an adjustable halogen lamp attached to the machinetool to provide extra light on the table.

Quad vise a standard 6" vise for fixturing.

Draw bar for metric tools converts the spindle so that it accepts metric(BT40) tools . No other changes to the machine arenecessary for this conversion.

Indexer port permits attachment of an indexer head to themachine tool . The indexer software is included inthis option.

Rotary table system adds an "A" axis to the Hawk 5M so that theoperator can machine around the outside of acylindrical part while the part is rotating. Thisoption includes a rotary table , cabling , necessarydrive , and the rotary software.

Rotary interface this option includes the rotary cabling , necessarydrive , and the rotary software , but not the rotarytable.

Increase control memory in shops where operators typically store large,from 4 Megabytes to 8 complex part programs on the control ' s hard drive,Megabytes the owner may want to purchase the 8 Megabytes

of memory option.

Ultimax 3 System Revision A

Operator' s Manual

Software OptionsThe Ultimax control contains software used to process data and displayscreens in much the same manner that personal computers use softwareprograms . As with other software systems , Ultimax has additionalsoftware options that can be purchased for the system.

UltiPocket

The Ultipocket m programming option adds special milling routines formachining pocket boundaries with islands. This option provides completeclean out of odd-shaped pockets without cutting the islands programmedinside the boundary . The software automatically calculates the tool patharound islands eliminating the long task of plotting these shapes. Islandsmay also be rotated , scaled, and repeated.

3-D Contour

The Ultimax 3-D option provides 3-axis cutter compensation formachining three dimensional surfaces . Revolution and translationsubroutines allow rapid programming of complex cavities, sections, orcores with full cutter compensation and automatic calculation assistance.

CAD Compatibility (DX9 Option

The CAD Compatibility option allows the operator to transfer CAD datafiles directly into the Ultimax control . This option eliminates errors indata entry and significantly speeds up the part programming process. TheCAD file format is called DXF. This Data eXchange Format , developedby AutoCAD, is now used by the majority of CAD software companies.

When this Ultimax option is installed, the control reads DXF CAD files.Using the graphics screen of Ultimax, the operator selects geometricfeatures of the part to be machined and translates these features intoconversational data blocks . Hole locations and mill frames , circles, andcontours are created by selecting the geometric features using thetrackball . This is similar to the methods used on the CAD system to selectitems with a mouse.

1- 12 5/10/94 Hawk 5M Machine

Getting Started

Off-line Software

The Ultimax PC/PC Plus software gives operators Ultimax conversationalpart programming capabilities on a personal computer. Using this option,operators can program parts off-line, away from shop floor distractions,and leave the machine tool available to cut parts. All Ultimax controlfeatures are present in the PC/PC Plus software including graphics, partverification , estimated run times, and lettering for marking parts.

Cutter Insert Routines

Cutter insert manufacturers use these special milling routines to millpockets in triangular , diamond, and hexagon shapes. These routines canbe defined in one program data block.

Indexer

The indexer software is included with the indexer port hardware: Thishardware/software option is needed when an indexer head is used to rotatea part at a fixed distance to position it for an operation. When the optionis installed on a system , the indexer pulse value can be entered into aPosition data block during part programming.

Rotary

The rotary software is sold with the rotary table system and with the rotaryinterface hardware options . This hardware/software option is needed whenthe machinist needs an "A" axis to machine the outside of a cylindricalpart while the part is rotating.

Ultimax 3 System Revision A 1-13

Operator' s Manual

Additional Language Files

Additional translations of the messages and system screens can bepurchased for the Ultimax control. The complete list of availablelanguages is as follows:

• English • Japanese

• Czech • Greek

• Danish • Latin American Spanish

• Dutch • Polish

• Hungarian • Spanish• French • Swedish

• German • Taiwanese• Italian • Thai

• Finnish

Option-Access Security Key

The Ultimax system checks for the software security key at power up timeand periodically during operation to identify the software options beingused. This key (shown below) is attached the bottom of the control cabinetwithin the electrical cabinet.

Kw -*

Figure 16. Software Option Security Key

If the machine owner wishes to purchase an additional software option,Hurco exchanges the old key for a new one that provides access to thenewly purchased option.

1- 14 5/10/94 Hawk 5M Machine

Getting Started

Preparing for Power UpThe operator must perform routine checks before attempting to power upthe machine.

Routine Daily Checks

Several mechanical elements require visual inspection , regularmaintenance , and lubrication checks to ensure proper operation of themachine tool . Use this check list to inspect the machine before switchingon the power.

q Check all lubrication levels particularly in the Auto Lubesystem and the air line lubricator.

q Check air pressure at the Filter, Regulator, Lubricator (FRL)assembly in the pneumatic system.

q Check coolant level(s).

q Check the ways for proper lubrication and any scratches orexcessive wear . Be certain that the way wipers are not damaged.

For detailed descriptions of these operations , refer to the MaintenanceManual.

Ultimax 3 System Revision A 1-15

Operator' s Manual

Machine Power

The Hawk 5M's power switch is in the upper right comer of the electricalcabinet door. See illustration below. When it is switched on, informationshould appear on the console monitor screens.

Hawk 5M Side View

Figure 1-7. Side view showing electrical cabinet and power switch

1- 16 5/10/94 Hawk 5M Machine

Getting Started

Powering UpIf the power has been shut off to the machine tool, the machinist shouldswitch the power switch to the "On" position.

When the power to the machine switches on, the following informationdisplays on the Ultimax console's text screen:

• AMI BIOS Configuration information

• "Loading executive - please wait"

• Initialization messages

• Scanning and loading language files

• Any part program that was being created or used when themachine shut down will be automatically loaded

On the graphics screen (the right-hand monitor), information about thegraphics card appears, and then the system displays the Ultimax 3 logo.

Uldmax 3 System Revision A 1-17

Operator' s Manual

On the text screen, the Machine Configuration screen appears(information on the screen varies based on machine options):

MACHINE CONFIGURATION r IF

MACHINE TYPE HAYS SM 1MACHINE CLASS VERTICAL 1VERTICAI/HORI2ONTAL VERTICAL F

2MAXIMA X TRAVEL. 31.000 IN fMAXIMA V TRAV®. 14.000 IN FMAMUR 2 TRAUEI. 6.000 IN 3NUMBER OP AXES PRESENT 3 F

F4

MAXIMA SPINDLE SPEED 3000. FMAXIMUM RPM IN HIGH GEAR 3000. SMINIMA RPM IN HIGH GEAR 551. 1MAXIMA RAM IN LOW GEAR 558. FMINIMA RPM IN MAY GEAR 78. 6

PChoose appropriate mftMey 7

PRESS MANUAL MODE, POWER , AID START TO RESTORE POWER. PUTa

Figure 1.8. Machine Configuration screen

The Machine Configuration screen displays machine setup information.Field service engineers use this information to be certain the machine isproperly installed and configured . When there is a problem with themachine, the operator may be asked to check this screen and verify thisinformation with a service representative . The information on this screencannot be changed here.

The operator presses the Exit (F8) softkey to continue.

If the Machine Configuration screen does not appear or it contains errormessages, refer to the "Power Up Troubleshooting" section.

1- 18 5/10/94 Hawk 5M Machine

Getting Started

Where can we go from here?

After the Machine Configuration screen appears , the operator must pressthe Exit (F8) softkey to display the Input screen . The operator may editand. run part programs . However, if the power has been shut off to themachine tool , the operator should then press the Manual console key andcalibrate the machine . Refer to the "Calibrating the Machine" section inthis chapter . Then , if necessary , warm up the machine , as described later.

Or...

In addition to warming up the machine , the operator may also want tocheck the System Parameters screen to be certain that the AutoSaveTm andControl Power Off times are correct or change the Current System Dateand Time to time stamp any files saved during the session.

Operator' s Manual

Power Up Troubleshooting

There are three symptoms of power-up problems that may occur:

• No messages appear on the console screen. The system maybeep , but it does not start up.

• Error messages appear during the initialization processbefore the Machine Configuration screen appears.

• Error messages appear on the Machine Configuration screenwhen it is displayed.

The following troubleshooting instructions give the operator informationto diagnose basic start-up problems.

No Response on the Console

If no messages are displayed on the text screen after the power has beenswitched on, the power source for the machine tool must be carefullyexamined . The operator should check the following:

• Power supply cord to be certain it is completely connected tothe power source

• Power switch to see if it is in the "On" position

If the power switch is in the "On" position and the power is properlyconnected to the machine , but the control still does not respond, contactthe machine tool shop 's maintenance department or the machine toolmanufacturer 's technical services department.

Warning

Before testing "live" circuits or attempting any repairs toelectrical connections , be certain that the power switch isin the "Off' position . Follow all established safetypractices. Remember that the power line from the powersource to the machine tool may be "live" even though themachine tool is not receiving power.

1- 20 5/10/94 Hawk 5M Machine

Getting Started

Initialization Error Messages

After the power has been switched on, the initialization messages begin toappear on the text screen. If an error message appears and initializationstops, there are several different types of errors that may have occurred.Many cannot be corrected by the operator; however, these messagesindicate easily corrected conditions:

"Non-system disk detected . This message means there is a diskettePress any key." in the floppy drive, and the system is

trying to find system software on thatdiskette. This often occurs when abackup diskette from the previous daywas left in the floppy drive. Removethe diskette and turn the power off andthen back on.

"Security device is invalid or The software security key has beenhas failed." removed, is broken, or is not properly

seated on the bottom of the controlcabinet. Check and correct.

The remaining messages that may appear during initialization usuallyindicate missing or corrupted files. The common solutions for theseproblems are to restore or delete files . The machine tool manufacturer'sservice department needs to help solve these problems.

Ultimax 3 System Revision A 1-21

/

Operator' s Manual

Important

Before calling a technical services representative for assistance, alwaysturn off the power at the power switch, wait a few minutes, and turn thepower back on. If the problem is still present or continues to occur, callthe machine tool manufacturer's technical services department anddescribe the symptoms. When calling for service, the operator needs tohave the machine tool serial number and software version number, as wellas a description of the problem. The software version number appears onthe Input screen at the top near the softkey names, as shown in the screenbelow:

« INPUT .r IF PART SETUP

MASTER PROGM11 ISIS SM (u1.58) Msr.22'94 1

EDIT PART PROGRAM 1 .HD3 METRIC F TOOL SETUPSTANDARD VERTICAL 2

i

F PART PROGRAMINGPROGRAM MEMORY AVAILABLE 99 x 3

Select uatkey or pans antm-> to theme Part prone. irwe

Figure 1-9. Input screen (software version number)

F PROGRAM1 PARAMETERSiF

F COPY AND CHANGE6 BLOCIIsiF ERASE FUNCTIONS7

FFB

1- 22 5/10194 Hawk 5M Machine

Getting Started

Error Messages on Machine Configuration Screen

Occasionally, the system will go through all of the initialization steps,display the Machine Configuration screen, and then the console does notrespond when keys are pressed. If the operator presses the Exit (F8)softkey, the Input screen will not appear nor will any other screen.

If this occurs the operator should take careful note of any error messageson the Machine Configuration screen. If there are no error messages, thecable to the front panel may be loose or defective. If the shop has amaintenance department that repairs computers , a machine maintenancestaff member may be able to check the cable . It is a custom cable inside aconduit. If it needs to be replaced , technical services must be called toperform the operation.

Important

Before calling a service representative for assistance, always turn off thepower at the power switch, wait a few minutes, and turn the power backon. If the problem is still present or continues to occur, call the servicedepartment and describe the symptoms. When calling for service, theoperator needs to have the machine tool serial number, software versionnumber, as well as a description of the problem.

Ultimax 3 System Revision A 1-23

Operator' s Manual

Calibrating the MachineThe calibration operation establishes the machine reference point(absolute zero) for each axis. Absolute zero is the location on the table,usually a comer or near a comer, where the X and Y axes intersect. Thisvalue does not change.

The operator may begin the calibration operation when the MachineConfiguration screen appears with no error messages . Then the operatorpresses the Exit softkey followed by the Manual console key to display thescreen shown below. Note the "Uncal" messages in the Part field for eachaxis indicating that they are all uncalibrated.

w IYYBMIL "a

MACHINEX 0.000T 11.688Z 8.0101

IF TOOL IN SPINDLE

MACHINE VERTICAL ITOOL IN SPINDLE « ISPINDLE 01 F MACHINEF® MOTION STOPPED 2 DIAGNOSTICS

F3

F FARE MACHINE4

P HAIR LIP MACHINE5i

P TOOL HOME6

Choose appropriate aortkey

AX S ARE NOT CALIBRATED.TOOL IN SPINDLE NOT VERIFIED.

Figure 1-10. Manual screen showing uncalibrated axes

There are several steps in calibrating a machine:

• Switching on servo power

• Calibrating the "Z" axis

• Calibrating the remaining axes

1- 24 5/10/94

F RESET SERVOS7 AND SPINDLE

F CALIBRATE MACHINEa

Hawk 5M Machine

Getting Started

Power on to Servos

If power to the machine servos is not switched on, perform the following:

1. Be certain that all Emergency Stop buttons have beenreleased . To release an Emergency Stop button , twist thebutton in the direction indicated by the arrows and pull thebutton up.

2. Press the Power On console button to turn on the machine.When the machine is switched on, this button lights up.

3. Press the Reset Servos and Spindle (F7) softkey. This is onlyrequired to clear a servo or spindle error.

4. The Start Cycle console button begins to flash on and off.

5. Press the Start Cycle button to turn on the machine servos.The Start Cycle button stops flashing.

Ultimax 3 System Revision A 1-25

Operator' s Manual

Calibrating the "Z" Axis

To calibrate the "Z" axis (spindle head), follow these steps:

1. Press Calibrate Machine (F8) softkey. The Start Cycleconsole button begins to flash off and on.

2. Press the flashing Start Cycle console button. Observe screendisplay and machine movement.

3. After a few seconds, spindle head moves upward to seek itsreference limit switch and a marker signal . This locates the"Z" axis machine zero calibration point.

Calibrating the Remaining Axes

After the "Z" axis calibration (machine head 's absolute zero) iscompleted, the table travels to the right rear side of machine , seeking theappropriate reference limit switches and marker signals. This calibratesthe "X" and "Y" axes. If an optional "A" axis is connected to themachine , this axis is also automatically calibrated at this time.

The machine position display (at top of text screen) shows zero for allaxes when the calibration process is complete.

Important

Certain machines may have their setup intentionally altered to providemachine calibration in a different direction than described. The part zeroreference point for the program is based on its relationship to themachine's absolute zero. For this reason, the direction of the machinecalibration must not be changed for an existing part program.

1- 26 5/10/94 Hawk 5M Machine

Getting Started

Warming Up the MachineIf the machine has been shut off, the operator may wish to warm up themachine before beginning work. Warming up the machine stabilizes themachine's operating condition to promote trouble-free operation andgreater reliability.

When the Machine Configuration screen appears with no error messages,the operator presses the Exit softkey and then the Manual console key todisplay the screen shown below:

+. MANUAL .. IF TOOL IN SPINDLE

MACHINE PART MACHINE VERTICAL 1x 393.70B 39a.788 TOOL IN SPINDLE BT 177.8819 177.8BB SPINDLE B F MACHINEZ. 6.600 ....w.... FEED MOTION STOPPED 2 DIAGNOSTICS

F3

F PARK MACHINE4

F WARM UP MACHINE5

F TOOL HOME6

Choose appropriate sot theyP RESET SERVOS7 AND SPINDLE

F CALIBRATE MACHINEB

Figure 1 -11. Manual screen

Follow these steps to warm up the machine tool:

1. Power must be switched on to the servos as described in theprevious section.

2. The machine must be calibrated.

3. Press the Tool In Spindle (Fl) softkey, and enter the number ofthe tool in the spindle into the field on the screen . Enter zero (0)if no tool is in spindle . Then press the Enter key.

Operator' s Manual

4. Press the Warm Up Machine (F5) softkey. The prompt "PressStart to begin warm-up machine cycle" appears and the StartCycle button begins to flash on and off.

5. Press the flashing Start Cycle button and the "Z" axis retracts tomachine position zero.

• Press the Start Cycle console button. The "X" and"Y" axes travel between their respective limit switchsettings at a feedrate of 100 inches-per-minute(i.p.m.) for this same period of time.

• After five minutes of clockwise operation , the spindlereverses direction and runs counter -clockwise at 1000RPM for five minutes. The

1- 28 5/10/94 Hawk 5M Machine

Getting Started

Configuring the SystemTo establish system parameters for time-outs and date /time stamps onfiles, press the Auxiliary console key above the number key pad. Thisscreen appears:

- AUXILIARY -

EDITOR TYPE: COINSRSATIONALF STORAGE FUNCTIONS1

F2

F DOUKOAD i UPLOAD3

F SYST@I1 CO/%RAT ION

S

F CHMME EDITOR6

Clore appropriate .attkay

B

Figure 1-12. Auxitiary screen

Press the System Configuration (F4) softkey to access the system-wideparameters on the screen shown on the following page.

Ultimax 3 System Revision A 1-29

Operator' s Manual

The fields on the System Parameters screen should be checked and valuesentered as needed when the control is powered up or when the system isreset using the Reset Master softkey. Shutting the power off resets thecontrol and erases these values , therefore , returning them to their defaultvalues.

SYSTEM PARAMETERS

CURRENT SYSTEM DATE / 1 1 / BB

F SET CURRENTI SYSTEM TIME

CURRENT SYSTEM TIME a 2 17F2

FCONTROL POWER OFF TIME 30 MIN F

3AUTO®AWE TINE 120 SEC

SCREEN ELANII TIME is "INF DISPLAY MACHINE4 CONFIGURATION

P DISPLAY SOFTWARE5 CONFIGURATION

F BACHUP MACHINE6 CONFIGURATION

Enter the current nouth.F RESTORE MACHINE7 CONFIGURATION

F EXITB

Figure 1-13. System Parameters screen

Current System Date

To enter today's date into the system, the operator follows these steps:

1. Type the number of the month and press Enter to move to thenext portion of the field.

2. Type the number of the day and press Enter.

3. Type the last two digits of the year and press Enter.

4. Press the Set Current System Time (F1) softkey to store thisdate in temporary memory so that the system can read it.

This data is useful when the operator is saving files from today's workbecause the system looks at the date entered here and date stamps thesaved file . If a time stamp is also needed on these files , the operator canalso enter the time in the Current System Time field and then press the F1softkey once after entering the time to save both values.

1-30 5/10/94 Hawk 5M Machine

Getting Started

Current System Time

This field uses 24-hour clock times. So 1:30 in the afternoon is entered as13:30. To enter the current time into the system, the operator follows thesesteps:

1. Type the hour and press Enter to move to the next portion of thefield.

2. Type the minutes and press Enter.

3. Type seconds, if desired, and press Enter.

4. Press the Set Current System Time (Fl) softkey to store thisdate in temporary memory so that the system can read it whensaving a file.

Control Power Off Time

Use this parameter to set an automatic shut down time. Based on thisparameter, the system shuts down automatically if none of the consolekeys, buttons, or trackball have been touched for this length of timespecified in the field. Enter the time as number of minutes.

The effect of this shut down is the same as an Emergency Stop shut downbecause the power to the servos is shut off and the lubrication stopspumping to the ways . However, the table is not centered as it is with thePark Machine shut down . For more information about machine tool shutdown techniques , refer to the "Shut Down Techniques" section in thischapter.

Important

It is a good idea to check the Control Power Off Time on this screen to becertain that there is a value in this field. If this field does not have a timelimit in it , the system will not automatically shut down.

Ultimax 3 System Revision A 1-31

Operator' s Manual

AutoSave Time

The AutoSave feature periodically saves copies of the part program in thecontrol's temporary memory to the hard drive. When the system isautomatically saving the part program , the system displays the messageshown on the screen below , and the operator will not be able to performany system actions until the program is saved.

GE®IAL PARAMETERS

RETRACT CLEIRg1CERAPID TRAVERSEPECK CLEARMICE PLAMBCHORD ERRORDEPLETION RETRACTINTERRUPT CYCLE Z RETRACT

>, 999.899 M7679. PP"1.278 MI8.883 MI8.127 MI

YES

F1

F21

P3

F4

F HOLESS PARAMETERS

P MILLING6 PARAMETERSM

P PROGRAMEnter clearance height above Z START at which tool nouns 7 PARAMETERSbetween operations I

START TO RESTORE POWER. F EXITINC PART PROGRAM... 8

Figure 1-14. AutoSave message on General Parameters screen

The time limit in the AutoSave Time field on the System Parametersscreen tells the system how often to save the program file currently intemporary memory . This makes a copy of the part program file at the timeof the automatic save so that the file can be recalled if the power to thecontrol is shut off. To switch off the AutoSave feature , the operator entersa zero in this field.

If the file is not saved either with the AutoSave feature or by the operatoronto the hard disk or a floppy diskette and the power shuts off, any workdone on the program currently in temporary memory will be lost. In effect,the control would have no way to remember changes to the program.

1- 32 5/10/94 Hawk 5M Machine

Getting Started

Screen Blank Time

This parameter allows the operator to set a time limit in which the consolescreens will go blank. This is similar to screen saver programs on personalcomputers that prevent image bum-in on the CRT's. Type in a time inminutes and press Enter.

Then if the console keys, buttons, and trackball are not touched for thatlength of time, the CRT's will go blank. To redisplay the screens, movethe trackball or press other console keys.

Important

Do not be concerned that pressing a key while the screen is blank willchange system data. The control uses the first key stroke to re-activate thescreen and then uses the second key stroke as input for the system.

SYSTEM PARAMETERS

CURRENT SYSTEM DATE

QWIRIT SYSTEM TIME

cONTEOL POWER OFF TIME

AUTOSAVE TIME

SCREEN BmADI TIME

Is / 1/BB

B: 2 : I?

38 NIN

129 SEC

Enter the anent eonth.

Figure 1-15. System Parameters screen

ISET QIRRDITSYSTEM TIME

F2

P3

P DISPIAY NAQIINE4 CONFIGURATION

F DISPIAY SOFTWARE5 CDWIQI TION

P DAC10R NAQIINE6 cOIVIQDNTION

P RESTORE MAQII7 cOIRIQJI TI

IT

The operator may also use these softkey operations on the SystemParameters:

• Set Current System Time (Fl) - Press this softkey if a time anddate were entered. This saves the information entered into thosetwo fields. Otherwise, the system will reset those fields to theirdefaults when the operator exits the screen.

Ultimax 3 System Revision A 1-33

Operator' s Manual

• Display Machine Configuration (F4) - Press this softkey todisplay the Machine Configuration screen. This screen describesthe machine tool with such information as machine type (Hurcomodel), the class such as vertical, horizontal, or universal andmaximum travel limits. Here is a sample of this screen:

» MACHINE CONFIGURATION » I

MACHINE TYPE I1UX SNF1

MACHINE CLASS VERTICAL IUERTICA/HORIZONTA . VERTICAL F

2MAXIMUM X TRAVEL 31.000 IN IMAXIMUM V TRAVEL 14 . 000 IN FMXIMii Z TRAVEL 6.000 IN 3NUMBER OP AMR PRESENT 3 I

F4

-MAXIMUM SPINDLE WED 3000. PMXIMM I" IN HIGH GM 3000. 5NINIMM RPN IN HIGH GEAR 551. ^-INXIMM I" IN LOU GEAR 550. FNINIMM RPM IN Lau GRAB 70. 6

IF

Ch• appa iota a•ftk•y 7l

FRESS MANUAL NODS, PMIXII, AND START TO RESTORE POY111. F EXITa

Figure 1-16. Machine Configuration

The operator may want to check this screen before using thebackup or restore softkeys (F6 and F7).

• Display Software Configuration (FS) - This softkey displaysthe Ultimax system options that are currently installed on thecontrol and the international languages available in the systemsoftware . The system options are features such as DXF, 3-Dpackage , UltiPockets , and Cutter Inserts. To purchase additionaloptions, contact Hurco or a Hurco distributor.

1- 34 5/10/94 Hawk 5M Machine

Getting Started

• Backup Machine Configuration (F6) - Press this softkey tocopy the following information onto a floppy diskette or the harddrive:

o Machine Configuration data including the machine typeand class (displayed on the Machine Configurationscreen)

o Control power off time, AutoSave time , and screen blanktime from the System Parameters screen

• Restore Machine Configuration (F7) - Press this softkey tocopy previously saved Machine Configuration data and the timelimits from the System Parameters screen . The data may be storedon a floppy diskette or the control 's hard drive . This option isonly used if a Machine Configuration error occurred duringpower up.

Caution

The Machine Configuration should only be edited by a qualifiedtechnician because the information in the configuration file determine-basic machine operations.

• Exit (F8) - Press this softkey to return to the Auxiliary screen.

Ultimax 3 System Revision A 1-35

Operator' s Manual

Switching Part Programming Editor TypeTo switch the part programming editor between conversational and NC,the operator presses the Auxiliary console key above the number key pad.This screen appears:

AUXILIARY M IF STORAGE FUNCTIONS

6D(SOA TYPE : CONYERSIITIOMAL 1

F2

F DOYFUAAD / UPLOAD31F SYSTEM4 CONFIGURATION

1F

F OYYIGE EDITOR6

Choose appropriate matkay

Figure 1-17. Auxi iwy screen

Then the operator presses the Change Editor (F6) softkey. The systemswitches to the NC editor. Note the name in the Editor Type field. Thesample screen shows the current part programming editor is"conversational ." When switching from conversational programming toNC part programming , the system asks the operator to indicate whetherthe part program will use inch or metric units of measurement.

Important

If there is a part program currently loaded into temporary memory on thecontrol , the system displays the "Current program and part setup will belost; OK to continue?" message . The operator answers Yes or No to thequestion by pressing the appropriate softkey.

1- 36 5/10/94 Hawk 5M Machine

Getting Started

Loading Part ProgramsAfter the machine is calibrated and warmed up, the operator may want toperform one of these operations:

• Edit a part program

• Load in a previously created part program

• Change from conversational part programming to NC

To edit a part program , the operator first presses the Input key on theconsole above the number pad. This screen appears:

00 INPUT - I

PROGRAM M®IORY AVAILABLE

HAWK 5M

1.HD3

F PART SETUPI Mar .22'94 I

METRIC F TOOL SETUPVERTICAL 2

P PART PROGRAMMING3

F PROGRAM4 PARAMETERSIF5

F COPY AND CH N=E6 BLOCBS

F ERASE FUNCTIONSSelect eartkey or Press anter> to change part Program name 7

PB

Figure 1-18. Input screen

If there was a program being edited on the previous day, that part programis automatically loaded during initialization . Check the Edit Part Programfield (circled in example above ) for the name of the program currentlyloaded into the control . In the sample screen shown above , the "l.HD3"part program is loaded into the control.

Ultimax 3 System Revision A 1-37

Operator' s Manual

Selecting an Existing Part Program

To select a different part program, the operator should press the Auxiliaryconsole key above the number key pad. This screen appears:

- AWILIARY -

EDITOR TYPE : CONVERSATIONAL

Choose appropriate softkey

Figure 1-19. Auxiliary screen

F STORAGE FUNCTIONS1

F2

F DOWNLOAD / UPLOAD3i

F SYSTEM4 CONFIGURATION

FS

To access the stored part programs on the hard disk within the control oron the floppy diskette , the operator then presses the Storage Functions(Fl) softkey.

1-38 5/10/94 Hawk 5M Machine

Getting Started

The Current Program screen appears. The softkeys on this screen allowthe operator to perform the following tasks:

• Read Program from Disk (Fl) - makes a copy of a program onthe hard disk and places it into temporary memory on the controlallowing the operator to edit the copy or run the program.

• Write Program to Disk (F2) - copies the program currentlydisplayed onto the hard drive (permanent memory) or onto afloppy diskette.

• Disk Operations List Directory (F3) - allows the operator toperform operating system functions such as changing to andcreating different directories on the hard drive, deleting programsfrom the hard drive 's permanent memory, and renamingprograms.

• Format Diskette (F4) - prepares the diskette currently insertedinto the floppy drive to allow it to receive a copy of a partprogram.

• Select Current Storage Drive (F6) - allows the operator tospecify which drive will receive a copy of the program when it isstored and the directory from which programs will be copied. Thechoices are usually the "A" drive (floppy drive) or "C" drive (thehard (rive).

Ultimax 3 System Revision A 1-39

Operator' s Manual

Here is a Current Program screen. Note that the system is ready to read aprogram from the hard drive though the currently available program wasread from the floppy drive.

CURRENT PROGRAMA:'27-12-93.HD3CURRENT DISK HARD DRIVE C

F READ PROGRAM1 FROM DISK

F WRITE PROGRAM2 TO DISKIF DISK OPERATIONS3 LIST DIRECTORY

F FOR)NT DISKETTE4

F

P SELECT CURRENT6 STORAGE DRIVE

Choose appropriate wt they

Figure 1-20. Current Program screen

To load a copy of a part program into the temporary memory on thecontrol , the operator selects the Read Program from Disk (Fl) softkey.Then this screen appears:

CURRENT PROGRAMA:S27-12-93.HD3

28796680 bytes freea bytes tagged.

CURRENT DIRECTORY

GSAVEL

I DIRECTORY

4 directory (a) B program(s). F REWIB:B programs tagged . 2 PROGRAM

E DSUP H D3JR-AUTO IID3 PROBE HD3 PROBE-DB.HD3

PROBE_M . H03 RACECAR HD3 RACE CAR . HD3 SA(IEPROG.HD3

F DELETE3 PROGRAM

P CREATE4 DIRECTORYi

P DELETE5 DIRECTORY

P SELECT CURRENT6 STORAGE DRIVE

Use arrow keys to moue through progrow(s)aMF -MORE-

Select .1(D? Program to read Into aoay. 7Press ant.) to accept highlighted program name. I

P EXIT8

Figure 1-21. Current Directory screen

1-40 5/10/94 Hawk 5M Machine

Getting Started

Use the arrow keys to move the highlight to the desired program and thenpress the Enter key to select it. The Current Program screen reappearswith the selected program name listed and a message as shown below:

Figure 1-22. Part Program Read into Memory

Ultimax 3 System Revision A 1-41

Operator' s Manual

Entering a New Part Program Name

To type in a new program filename , display the Input screen either bypressing the Input key or by pressing the Exit (F8) softkey when theMachine Configuration screen appears at start -up. Then follow these stepsto enter the filename:

1. Press the Enter key to display the Letter Selection screen on theright monitor (shown below).

2. Use the trackball on the console to move the crosshair indicatoron this screen.

3. When the crosshair is positioned over the desired character,press the Select key.

4. The selected character then appears in the Edit Part Programfield.

5. Select up to 8 characters for the filename. The system adds the3-character extension (usually HD3) to the end of the filename.

Space ! " # $ % & ' ( )

e + , - / 0 1 2 3

4 5 6 7 8 9 ; <

> ? @ A B C D E F G

H I J K L M N 0 P Q

R S T U V W X Y Z [

\ BackSpace

Enter

Figure 1-23. Letter Selection screen (graphics screen)

1-42 5/10/94 Hawk 5M Machine

Getting Started

Here is the Input screen ready to receive a new program name:

Figure 1-24. Input screen (text screen) while entering new program name

Ultimax 3 System Revision A 1-43

Operator' s Manual

Press the Enter key, and the system allows the operator to indicatewhether the program will use inch or metric units of measurement:

Figure 1-25. Input screen after the operator presses Enter

After selecting the unit of measurement , the operator indicates whetherthe program will run on a Standard (3-axis) machine or a machine with anoptional rotary table supplying an "A" axis. Then the operator can beginPart Setup and Tool Setup for the part program.

1- 44 5/10/94 Hawk 5M Machine

Getting Started

Erase FunctionsWhile the operator is creating or using a part program, it is stored in atemporary memory area on the control. This is not the permanent memorywhere programs are stored for later access.

The erase functions do not affect the permanently stored programs. Thesefunctions only remove copies of programs and portions of programs intemporary memory. Operators use these functions to perform thefollowing tasks:

• Throw away changes to a copy of a program that are no longerneeded

• Clear out the entire work area to start fresh (using the Erase Allsoftkey)

• Clear out the part program and keep the part setup and/or toolsetup to use for a new program

The operator accesses these options by pressing the Erase Functions (F7)softkey on the Input screen.

Figure 1 -26. Input screen with Erase Functions soft key

Ultimax 3 System Revision A 1-45

Operator' s Manual

The Input screen softkeys change to list the erase functions, as shownbelow:

Figure 1-27. Input screen with Ernst functions

The erase functions will only affect the part program currently displayedon the Input screen:

• Erase Part Setup (Fl) - resets all of the Part Setup to theirdefault values.

• Erase Tool Setup (F2) - deletes all tool data defined for the part.

• Reset Program Parameters (F3) - resets the ProgramParameters to their default values.

• Erase Program (P4) - deletes the part program data blocks fromprogram memory.

• Erase All (P5) - deletes the part program and its tool setup fromprogram memory and then resets the Part Setup values and theProgram Parameters to their default values.

1-46 5/10/94 Hawk 5M Machine

Getting Started

After the operator selects one of the erase functions , the system displaysthe message shown on the screen below and, therefore , allows the operatorto confirm the erase operation.

Figure 1-28. Input screen with "Do you really want to Emu?" message

The erase functions only erase program descriptions from the temporarymemory. This does not affect the stored version of the program on thehard drive . For an explanation of permanent program storage and deletion,refer to the "Program Storing , Renaming , and Deleting" section later inthis chapter.

Ultimax 3 System Revision A 1-47

Operator ' s Manual

Part Programming SetupThere are five main steps an operator must take before creating aconversational part program or an NC program on the Ultimax control.

1. Plan the part programming operations

2. Perform the tool loading and part fixturing operations

3. Enter the Part Setup in the Ultimax system

4. Enter the Tool Setup in the Ultimax system

5. Enter the Program Parameters Setup

To perform many of the setup functions , the operator must use the jog unitto move the table or spindle and record positions.

Getting Started

Jog Unit

The operator uses the jog unit to select the axis to move (jog) by pressingone of the buttons on the upper right side of the unit. To move the selectedaxis, the operator presses the Jog Direction buttons or uses theIncremental wheel. The jogging speed can be controlled by adjusting theAxis Feed Rate dial. To record the axis' current, real-time position in thepart program setup screens, the operator presses the Store Position button.

Note that the unit also has an Emergency Stop button.

Movesselected axis

(plus or minus 1direction ""a

at Axis FeedRate until released

Fine controlof jogging

at AxisFeed Rate

Increase or decreasethe jogging speed of

the wheel or the+ or - buttons forthe selected axis

Figure 1-29. Jog Unit

Select the axisto jog

Places the currentposition of theselected axis

into the part program

Ultimax 3 System Revision A 1-49

Operator' s Manual

The operator may want to set the parameters that control jogging speeds.To access the parameters , press the Manual console key to display theManual screen . Then press Machine Diagnostics (F2) softkey to displaythe parameters shown below:

Figure 1-30. Manual screen with jog parameters(in millimeters per minute)

With the cursor at the Manual Jog Feed parameter , enter the desiredmanual jog feedrate . This value cannot be greater than 200 inches perminute (i.p.m.) and is used when jogging the X, Y, and/or Z axes.

When cursor is at the Rapid Detent parameter , the desired rapid feedratefor the X and/or Y axes can be entered (not to exceed 400 i .p.m.) Thisfeedrate is used to jog these respective axes when the Axis Feedrateswitch on the jog unit is placed at the Rapid position. The Z axis alwaysuses the value of 150 i .p.m. when this switch is in the detent position.

The Manual Spindle Speed parameter governs spindle speed for joggingwhen the operator has selected the Manual machine mode and pressed theSpindle On console key . The system does not permit this value to begreater than the maximum spindle speed for the machine.

1- 50 5/10/94 0 /x•"Hawk 5M Machine

Getting Started

Tool Loading and Part Fixturing

Before entering data into the part and tool setup screens for a partprogram, the operator must first fixture the work piece to the table andload a tool into the spindle.

Loading Tools into the Spindle

To load or remove a tool from the spindle, the spindle must be stopped,and the "Z" axis must be in its full retract position. To load a tool into thespindle, the operator first inserts the tool into a tool holder. Refer to thediagram below. Then the operator presses and holds down the In buttonwhile inserting the tool holder into the spindle so that the tool holder slotsalign with the spindle head guides. The machine ratchets the holder into asecure position in the spindle. When the ratcheting noise stops, theoperator may release the In button and the tool holder. To remove the toolfrom the spindle, the operator grasps the tool, presses the Out button, andthe ratcheting mechanism releases the tool . When the ratcheting noisestops, the operator pulls the released tool out of the spindle.

Figure 1-31. Spindle, Tool Holder, and 1n/Out Buttons

Ultimax 3 System , Revision A 1-51

Operator' s Manual

Fixturing the Part

In order to determine the starting point (part zero) in the part, the operatormust first attach the work piece (raw material or stock) to the machinetool table. This process, called fixturing, can be accomplished using avariety of clamping devices, such as vises and toe clamps. The operatorselects the fixturing device that will hold the work piece securely withoutgetting in the way of the cutting tool when the part is being made.

1- 52 5/10/94 Hawk 5M Machine

Getting Started

Identifying Part Zero with a Tool

The operator may want to insert a tool in the spindle to use as an edgefinder when identifying part zero.

1. Find the Machine Mode button grouping. Press the Manualbutton to display the Manual screen. This screen has the Tool inSpindle field and softkey used to enter the tool number ifneeded.

2. Press the Power On button and press the Start Cycle button toturn-on machine control power.

3. If a tool is in the spindle , grasp the tool to prevent it fromdropping onto table or work piece . Press and hold down the Outbutton until the gripping mechanism releases the tool . Then pullthe tool downward from the spindle.

4. To insert a different tool into spindle, press and hold the Inbutton while inserting tool into the spindle.

5. The tool will need to be calibrated as described later in the"Tool Setup" section.

Ultimax 3 System Revision A 1-53

Operator' s Manual

Part Setup

The part setup procedures establish the locations of part zero in X and Yrelative to the machine's absolute zero. Refer to the diagram below.Absolute zero, identified during machine calibration, is the location on thetable, usually a corner or near a corner, where the X and Y axes intersect.This value does not change.

However, it is difficult for the operator to include the offsets betweenabsolute zero and the comer of a part when determining locations on thepart, so operators identify part zero for a work piece when it is fixtured tothe table . Part zero is the X and Y intersection on the part itself. Thendimensions can be programmed from part zero without considering theoffset distances from the absolute zero comer of the table . Part zero mustbe identified for each new part.

Programmed as a coordinate dimension from part zero

Y Offset

Y axis

Xis

X Offset

Part Zero

Absolute Zero (on the table)(Machine Absolute - X & Y axes)

Figure! 1-32. Pan Zero Relationship to Machine Absolute Zero

Getting Started

The location of part zero in Z is established during tool calibration.During setup, the tool zero calibration plane is established for each tool.The program dimensions for a part are relative to these points as shownbelow.

/Head Zero(Machine Absolute - Z axis)

Tool ZeroCalibration Plane(typical)

Part (Workpiece)

Figure 1-33. Tool Zero Calibration Plane and Part Zero in Z

Ultimax 3 System 5/10/94 1- 55

Operator' s Manual

Programming of axis motion relative to part zero is shown in the previousillustration as viewed facing the front of the machine.

When programming, remember that the X and Y coordinates define aposition on the part. The operator programs the spindle to move within thecoordinate system as shown below:

Spindle moves upand away from

the part

Spindle movesright on part

- Spindlemoves away

from operator

Y\ Spindle

Spindle moves downand into the part

moves towardthe operator

Figure I.34. Spindle motion relative to Pan Zero

Getting Started

Part Setup Screen

After the name of the part program is entered into the Input screen, andthe tools and work piece are in place, the operator is ready to begin thepart setup process. Press the Part Setup (F1) softkey to begin the setupprocess. The Part Setup screen appears. The operator may type values intothe fields or use the jog unit to position the tool and store positionsidentifying these values.

PART SETUP IF

MACHINE PART 1X 12.6436 9 .8888 TOOL IN SPINDLE 1 IV 6.3224 8 .8988 SPINDLE 0 F TOOL SETUPZ -16.3488 8 .7463 FEED NOTION STOPPED 2

F PART PROGRAMMING3

PART ZERO X • 12.6436 SAFETY WORK REGION F PROGRAMV 6.3225 Z TOP (•) 99 .8888 4 PAPAMETERS

OFFSET Z 6 8888 Z BOTTOM (-) -99 8888.X LEFT (-)

.-16.BBeB F

X RIGHT (•) 5.8886 5V FRONT (-) 4.8888 IV BACK (•) 4.8888 F

6

P STORE MACHINEEnter part mro If Imam or Jog nachrne to part rero 7 POSITION

iti d rtk t t iti Ipos on an prose so e9 o s ore pos onF EXIT8

Figure 1-35. Completed Part Setup screen

The top left section of the screen shows the position of the axes. Thebottom left of the screen is the data entry area where the operator entersthe values to identify part zero and the safety work region for this partprogram.

The softkeys on this screen provide the following options:

• Tool Setup (F2) - allows the operator to enter the descriptions ofthe tools that will be used in this part program.

• Part Programming (F3) - allows the operator to enter the exactdescription of how the part will be cut.

Uhimax 3 System 5/10/94 1- 57

Operator' s Manual

• Program Parameters (F4) - displays the screens where the datacommon to all of the program data blocks can be entered. Referto the "General Parameters" section in this chapter for moreinformation.

• Store Machine Position (F7) - pressing this softkey records thevalue displayed on the screen for the axis currently marked by thecursor. After these values are recorded , they become the offsetvalues from absolute zero for the axes.

• Exit (F8) - allows the operator to exit the setup process andreturn to the Input screen.

Getting Started

Entering Part Setup Information

The operator begins part setup by entering the part zero values. There area number of methods to accomplish this task; however, here are two of themost common methods:

1. With cursor at the "Part Zero - X" field, type the "offset" valueof this dimension using the number keys on the console. Pressthe Enter key to store dimension . Use the same method to enterthe value in the "Y" field.

Or...

2. Use an edge finder or indicator in the spindle and jog themachine axes to identify part zero. First , check to be certain thatthe Power On button is illuminated to indicate that themachine 's servos are powered up. Then follow these steps:

a. Press Spindle On key to start and rotate spindle. Thenpress the Start Cycle button. If using an edge finder, theoperator may need to reset the Manual Spindle Speedparameter . If not using an edge finder, the operatorshould use a tool with a known diameter and turn offthe spindle. If using the Hawk 5M dial indicator, thoperator must be certain the spindle is out of gear (inthe Neutral position).

b. Use the axis jog keys (X, Y, +, -) on the remote jog unitto move the edge finder in the spindle to the part zerolocation on the part fixtured to the table.

c. During this process , the system displays the X and Ypositions , relative to absolute zero , onto the Part Setupscreen in the Machine column in the upper left of thescreen.

d. Jog the edge finder until it touches the X part zerolocation . The operator then presses the white StorePosition button on the jog unit . The same procedure isused to identify the Y part zero location. The dimensionfor X and Y in the Part column at top of screenbecomes zero.

e. The calculator functions of the control can be used toadjust the indicated X and Y parameters to compensatefor the radius of the edge finder.

f. Press Spindle Off console key to stop rotation of thespindle.

Ultimax 3 System 5/18/94 1- 59

Operator' s Manual

The operator should establish the dimensions of the Safety Work Regionto prevent the cutting tool from moving into areas where it might collidewith other equipment or the work piece and fixturing . The operatorparticularly needs to enter the Z Bottom (-Z) parameter to prevent the toolfrom drilling through the part and into the table. The operator may alsowant to use the Z Top (+Z) field to define the clearance above all portionsof the part and/or fixture.

I/ I

Part Zero

x I I +x

Z`/--------/

Figure 1 -36. Safety Work Region

If no values are entered in these fields , the system defaults to 99 inches forthe positive and negative values.

To enter values use one of these two methods:

1. Use the number keys on the keyboard to enter the dimensionalvalues of the safety region.

2. The operator may want to use the axis jog functions on the jogunit to identify the X and Y safety region. Jog each axis out tothe edge of the safety region and press the white Store Positionbutton on the jog unit.

To store the Z values using the Store Position button, a toolpreviously described on a Tool Setup screen for this programmust be in the spindle.

1-60 Revision A Hawk 5M Machines

Getting Started

Hints and Tricks

Use the Z Top value to reduce rapid Z motion for all Position data blocks.The spindle will retract to the Z Top value above the tool zero calibrationfor position data blocks.

Important

Entering a value in the Offset Z field on the Part Setup screen adds theentered amount of the offset to the tool zero calibration point. This is aquick method to adjust all tool calibration values in the Z axis tocompensate for variations in the thickness of the work piece. For example,using all tools from a previous program and changing the Offset Z willreset all Z calibration points to the new work piece. The operator can useTool #1, calibrate it, and press Offset Z to store the offset distancebetween the top of the first part (reference block) and the top of the workpiece.

Calibrate all tools here

NReference

GaugeBlock

dl OffsetZ

Work Piece

Figure 1-37. Offset Z

Table

Press the Exit (F8) softkey to return to the Input screen or press the ToolSetup (F2) softkey to describe the tools used in the part program.

Ultimax 3 System 5/10/94 1- 61

Operator' s Manual

Tool Setup

Use the Tool Setup screen to describe the tools that will be used for thispart program. Each tool used in the part program must be described on theTool Setup screens; otherwise, the system will not have enoughinformation to draw the part on the graphics screen , and the machine willnot be able to cut the part when the operator tries to run the program.

Caution

When an operator intends to run a previously created part program, theTool Setup must be carefully checked to be certain the tools described forthe old program match the tools planned for the new program. If a toolbreaks or is not available when running a previously created part program,the operator must change the Tool Setup information.

Hints and Tricks

Many operators create tool setup templates to simplify development ofnew part programs . To create a tool setup template , the operator enterstool description and then saves the information as a program (to the diskor a floppy) using a program name that indicates the type of toolsdescribed. To use the saved standard setup , the operator recalls the toolsetup program, makes any necessary changes for the new part program,and saves the changed setup under a new name . Renaming preserves theoriginal template file for later use.

For information about saving programs to the hard disk or to a floppydiskette , refer to the "Program Storing , Renaming , and Deleting" section.

Getting Started

Tool Setup Screen

To access the tool setup for this part program , the operator displays eitherthe Input screen or the Part Setup screen and presses the Tool Setup (F2)softkey. The following screen appears:

TOOL SETUPF

NAQIINE PART 1X 11.0000 1.0800 TOOL IN SPINDLE 1

1V 0.0080 1 .0800 SPINDLE 0 FZ -4.4914 essssssss FEED NOTION STOPPED 2

F PART PROGRAMMING3

TOOL I 1 F PROGRAM4 PARAMETERS

F PART SETUP5

F TOOL HOME6

Press DITER to -. tool Intonation or eMe nuabm ofF SET TOOL ZERO7

tM t lano r oor EXITR

Figure 1-38. Tool Setup screen

The top left section of the screen shows the real-time position of the axes.The bottom left of the screen is the data entry area where the operatorenters the information describing a tool. When tool number I was enteredinto the screen shown above, no information appeared under the number.This means that there is no description for tool number 1, and it iscurrently available for this program. This information must be entered.

There is no Machine or Part position display (top left on the screen) norany softkey selections displayed when machine is not calibrated or whenin concurrent programming.

Note

To move between the fields on the Tool Setup screen , use thearrow keys . Pressing the Exit (F8) softkey displays the Inputscreen.

Ultimax 3 System 5/10/94 1- 63

Operator' s Manual

The softkeys on this screen provide the following options:

• Part Programming (F3) - allows the operator to enter the exactdescription of how the part will be cut.

• Program Parameters (F4) - displays the screens where the datacommon to all of the program data blocks can be entered. Referto the "General Parameters" section in this manual for moreinformation.

• Part Setup (F5) - allows the operator to return to the Part Setupand make changes.

• Tool Home (F6) - press this softkey and then press the StartCycle button to move the spindle to tool change height. Thisoption allows the operator to move the tool quickly away from thepart after finding the Zero Calibration value . Using this softkey ismuch faster than pressing the axis jog buttons on the jog unit.

• Set Tool Zero (F7) - to use this softkey, the operator carefullyjogs the tool in the spindle down to the top of the part and thenpresses this softkey. The system stores the position of the tool intothe current part program and the number appears in the ZeroCalibration field on the Tool Setup screen . This can also beaccomplished by pressing the Store Position button on the jogunit. On the screen the part display for "Z" changes to zero.

Warning

Be certain that the tool number in the Tool in the Spindlefield matches the tool being edited when the zerocalibration is stored.

• Exit (FS) - allows the operator to exit the tool setup processand return to the Input screen.

Getting Started

Tool Setup Fields

To set up the tool descriptions for this part program, the operator followsthese steps:

1. Enter the tool number of the tool using the number keys on theconsole. If there is no tool in the spindle, enter a zero (0) for thetool number.

TOOL SETUP IF DELETE TOOL

MACHINE PART 1X 393 .788 393 .760 TOOL IN SPINDLE 0 IT 177.900 177.000 SPINDLE B FZ. 0.088 eeeeeeeee FEED NOTION STOPPED 2

F PART PROGRAMMING3

TOOL F PROGRAMTYPE 4 PARAMETERS

DIAMETERZERO CALIBRATION

8.888 F PART SETUP5

SPEED (RPM ) 01 B F TOOL HOMECOOLANT a" 6

P SET TOOL ZEROPray ENTER to eoeete tool l'tonotion or eater ,weber of 7eintlnr tool I

F EXITB

Figure 1-39. Tool Setup screen

1

Ulomax 3 System 5/10/94 1-65

Operator' s Manual

2. Press the appropriate softkey to select Type (see examplebelow). These tool types are listed as softkey options:

• Drill • Face Mill

• Tap • Ball Nosed End Mill

• Boring • Back Spotface

• End Mill

If the tool is a tap, a Threads per Inch parameter must beprogrammed (or Pitch in millimeters per thread, if metric is theunit of measure).

TOOL SETUP

M93.700E 393.700V 177.800Z. 0.000

I,

F NOT ID(OUM1iF DRILL2

F TAP3

TOOLTYPE

DIANE=ZERO CALIBRATION

PART393.700 TOOL IN SPINDLE177.000 SPINDLE 0

FEED MOTION STOPPED

1DRILL

0.1iS8

F BORING4iF END MILL5

F FACE MILL6

SPEED (RPM) Cy 0COOLANT FlOODSURFACE SPEED 0.0

Select two of tool

Figure 1-40. Tool Setup screen with tool types

P BALL NOSED7 END MILLi

--ORS-8

t- 66 Revision A Hawk 5M Machines

Getting Started

3. Enter the Diameter of the tool. This information is used whendetermining cutter compensation during milling operations.Ultimax software automatically calculates the radius of thecutting tool and allows for this distance when performingmilling operations . This means the operator does not need toremember the size of the cutting tool and manually calculatetool offsets when programming the part.

Path compensating forCj,,- cutter radius

Cutter radius = amountof cutter compensation

offset

0

Figure 1-41. Cutter Compensation

Uldmax 3 System 5/10/94 1- 67

Operator' s Manual

4. Use jog functions to calibrate the tool to the part or referencesurface. Move the tool in the spindle down until the tooltouches part zero. Press the Store Position button on the jog unitand the position of the Z axis appears in the Zero Calibrationfield. The position of the Z axis can also be stored using the SetTool Zero (F7) softkey.

Use the calculator functions of the keyboard to add or subtractshim stock dimensions (if used). For example, after pressing theSet Tool Zero (F7) softkey, the operator enters the thickness ofthe shim and presses the plus key (+) and then presses Enter toadd the shim thickness.

5. If the operator knows the correct speed to be used for this tool,enter it into the Speed field. This value will be copied into eachnew data block in the part program (but only for part programdata blocks created after Tool Setup) which use this tool. Ifnecessary , this parameter can be changed within the new datablock when programming the part. The direction the spindleturns (clockwise for right-hand cutters) is also part of thisparameter.

6. The Coolant parameter defines the coolant type to be used forthe tool and is programmable on a tool -by-tool basis.

Getting Started

7. For drills or milling tools, the Surface Speed, Flutes, andFeed/Flute (Tooth) fields also appear on the screen, as shownbelow. The operator may enter a Surface Speed in inches ormillimeters per minute. Then the Flutes and Feed/Flute fieldsappear. The operator enters values that indicate the number ofthe flutes (teeth) on the tool and the feedrate per flute. Thesystem uses these values to calculate the feeds and speeds forthe tool . Refer to the following "Automatic Feeds and SpeedsCalculations" section.

TOOL SETUP

NACNINE PARTX 0.6066 -5.6066 TOOL IN SPINDLE anV. 6.6666 -5.6606 SPINDLE 6z -2.1767 5.6553 FEED NOTION STOPPED

TOOLTYPE

120 MILL

DIAMETER 6.7566z6RO CALIRMITION 7.2316

SPEED (RPM) CY 6COOLANT OFF FLUTES 12SURFACE SPEED 1666. F111131/FLUTE (TOOTN) 6.6666

Enter amber of mttina [lutes

Figure 1.42. Tool Setup screen with Surface Speed fold

F PAOGM tI4 PARAMETERS

F PART SETUP5i

T TOOL NONE6

F SET TOOL ZERO7

P EXITa

The operator may also wish to consult the Machinist 's Handbook or thefeeds and speeds material in the "Appendix " of this manual for moreinformation.

Important

If a value was entered into the Speed field, the system ignores any dataentered into the Surface Speed field. If the automatic speed calculation iswanted, do not enter a value in the Speed (rpm) field.

Ulfimax 3 System 5/10/94 1- 69

Operator' s Manual

Automatic Feed and Speed Calculations

The control calculates the appropriate feedrates and spindle speeds fordrilling and milling operations.

The operator should understand the following information concerningautomatic calculations of feeds and speeds:

1. The tool must be a drill, end mill or face mill.

2. If a zero is entered for the Speed parameter, the speed and thefeedrate are automatically calculated by the control. If a non-zero value is entered for Speed , this value is transferred to alldata blocks using this tool and the feed is not calculated.

3. The control makes no assumptions about material hardness andthe amount of material being removed . The operator must checkcomputed feeds and speeds to ensure they are appropriate andmake any necessary adjustments.

4. When all parameters are specified during Part Setup , entering atool number in a drill or mill data block causes the feed rate andspeed parameters to be computed and appear on the display;however, plunge feedrates for end mills and face mills are notcalculated.

5. If the tool diameter or speed parameters are changed from theinitial selection, a message is displayed asking if the feeds andspeeds should be recalculated . If any of the other relevantparameters are changed , feeds and speeds are recalculatedautomatically.

1- 70 Revision A Hawk 5M Machines

Getting Started

The control system uses this equation to compute the drilling and millingfeedrates in inches per minute (i.p.m.):

ipm = Feed per Tooth x #of Teeth x rpm

Using this equation the control calculates the following feeds perrevolution for these drill diameters:

Drill Diameter Feed per Revolution

1/4" to 5/16" .004 to .010

3/8" to 7/16" .006 to .012

1/2" to 9/16" .010 to .014

5/8" to 11/16" .012 to .016

3/4" to 13/16" .013 to .018

7/8" to 1 1/8" .015 to .025

1'/i' to 1'h" .020 to .040

1'h" and over .025 +

Important

For kneemills using larger tools (5/8" to 1"), the feeds and speeds fordrilling and milling should be manually reduced by approximately 15% to20%% based on the machinist 's experience.

Ultimax 3 System 5/10/94 1- 71

Operator ' s Manual

The Ultimax control also automatically calculates spindle speeds usingthe following formulas .. The first four formulas produce the revolutionsper minute (rpm) that apply to high-speed steel tooling and high-speedcobalt tooling used to cut work pieces of these common metals.

382tool diameter

= rpm for plain carbon steel

350

tool diameter= rpm for alloy steel

1240

tool diameter

365

tool diameter

Caution

= rpm for aluminum

= rpm for gray cast steel

High-speed steel cobalt tooling feedrates should be increased by .001 to.002 feed per revolution.

For carbide and carbide coated tooling these formulas are used:

1530

tool diameter= rpm for plain carbon steel

880

tool diameter

3440= rpm for aluminum

tool diameter

= rpm for alloy steel

1240

tool diameter =rpm for gray cast steel

Getting Started

General Parameters

The Program Parameters screen allows the operator to describe thesegroups of parameters:

• General - retract clearance, rapid traverse, peck clearance plane,chord error, depletion retract, interrupt cycle Z retract

• Holes - bore orient retract, drill dwell, bore dwell

• Milling - blend offset, blend overlap, finish feed, finish speed,finish XY, finish Z, milling direction, pocket overlap, cuttercompensation parameter

• Program - override lockout, program protect, tool changeposition

Default values appear in these fields on the screens, but the operator maywant to change some of the parameters. To display the General Parametersscreen, press the Input console button to display the Input screen:

INPUT - IF PANT SETUP

NASTER PROGAf111 HAIM 511 e1.9R IIar .22'94 1I

EDIT PART PROGRAM S.M INCH F TOOL SETUPSTANDARD 2

i

P PART PROGRAMMINGPROGRAM 1®IORV AIMIIARLR 99 x 3

F PROGRAM4 PARAIBTEI

F5

P COPY AND CHANCE6 DIACRS

P MIRSE FUNCTIONSSelect adtIey w Frew antar> to change part Progra• nave 7

PB

Figure 1-43. Input screen

Press the Program Parameters (F4) softkey.

Ullimax 3 System 5/10/94 1- 73

Operator' s Manual

Then the General Parameters screen appears:

GENERAL PARAKETERS IF

RETRACT CLEARANCE ? 999.008 MM 1RAPID TRAVERSE 7628. MMPM FPECK CLEARANCE PLANE 1 .270 MM FCHORD ERROR 0.003 MM 2DEPLETION RETRACT 0.127 MM FINTERRUPT CYCLE Z RETRACT YES F

3

FF4

P HOLES5 PARAMETERS

F MILLING6 PARAMETERSi

F PROGRAMEnter clearance height above Z START at which tool woos 7 PARAMETERSbetween operations iPRESS MANUAL MODE . POWER . AND START TO RESTORE POWER. F SKISAUTOSSUING PART PROGRAM... 8

Figure]-44. General Parameters screen for conversational progremming

1- 74 Revision A Hawk 5M Machines

Getting Started

Here are the available parameters on this screen:

General Parameters DefinitionsFields

Retract Clearance Enter the distance that the tool should retract abovethe Z Start dimension before rapid table positioning(Rapid Traverse) between machining operations.This includes a tool moving from one drilled hole toanother, from one milling operation to another(programmed in separate data blocks or generated asa patterns operation). The default values are 99.0000inches and 999.000 mm. On the NC version of thisscreen, this field is the Clearance Plane.

If the next operation has a different Z Startdimension, the control always retracts to the highestdimension . When a Position block is programmed,the tool always retracts to the safety planeprogrammed as Z Top of the Safety Work Region.

-Rapid Traverse The feedrate that the table (X, Y, and Z axes) movesbetween one point in the part program to the nextpoint in the program (rapid table positioning).

Peck Clearance Plane The distance above the previous peck level to whichthe Z axis moves at rapid traverse . This parameterdoes not apply to NC programs. It only applies toconversational programs.

Chord Error The maximum distance the cutter deviates from thetrue arc path. This value determines the method thecontrol uses to generate information for executingarcs. If the operator enters 0 .0 in this field, thecontrol will automatically calculate a chord errorthat maintains the programmed feedrate through thearcs.

Ulumax 3 System 5/10/94 1- 75

Operator 's Manual

General Parameters DefinitionsFields

Depletion Retract The value programmed for this parameter specifiesthe dimension above the part surface that the Z axisretracts. The Z axis retracts while waiting foradditional data to be transmitted into the currentprogram during execution of an NC part program.This parameter does not apply to conversational partprograms.

Interrupt Cycle Z This parameter allows the Z axis to retract to theRetract Retract Clearance when the operator presses the

Interrupt Cycle console button . Selecting "No" forthis parameter means that the spindle will stay in itscurrent position when the Interrupt Cycle button ispressed . The default value is "Yes."

Optional Program When this parameter is enabled , the system inserts aStop program stop at the appropriate M-code. This

program stop command halts the spindle and coolantfunctions and terminates further program execution.It will require the operator to press the Start Cycleconsole key to continue with the program. Thisparameter is only used for NC programs.

1- 76 Revision A Hawk SM Machines

Getting Started

General Parameters Ranges and Default Values

Parameter Range Default Value

Retract Clearance 0.0000 - 99 .9999 inches 99.0000 inches(conversational only) 0.000 - 999 .999 mm 999.000 mm

Rapid Traverse 0.1 - 300.0 inches per 300.0 inches per min.min. 7620.0 mm per min.1.0 - 7620 .0 mm per min.

Peck Clearance Plane 0 .0000 - 99.9999 inches 0.05 inches(conversational only) 0 .00 - 999 .999 mm 0.127 mm

Chord Error 0.0000 - 1.0000 inches 0.05 inches0.000-25 .4mm 0.127mm

Depletion Retract 0 .0000 - 99.9999 inches 0.0050 inches(NC only) 0.000 - 999.999 mm 0.127 mm

Interrupt Cycle Z Retract Yes and No Yes

Optional Program Stop Enabled or Disabled Enabled(NC only)

Ultimax 3 System 5/10/94 1- 77

Operator' s Manual

When calculating the chord error value for the General Parametersscreen, the operator should understand several important concepts. Thechord error for arcs is the maximum distance that the cutter deviates fromthe actual arc. As shown below, the machine actually cuts a series of verysmall lines when cutting an arc . However, these lines are indistinguishablefrom an arc when the machining is complete.

Figure 1-45 . Chord Error

The values in the following tables list expected milling feedrates forvarious chord error and arc radii values in Ultimax 3. These tables may beused as guidelines for maximizing milling accuracy or feedrate.

Maximum Milling Feedrate for a 1 .0000 InchRadius Arc at a Programmed Feedrate of 100 ipm

Chord Error Maximum Milling Feedrate

0.0000 inches 100.0 ipm

0.0001 inches (default) 56.4 ipm

0.0002 inches 79.9 ipm

0.0003 inches 98.2 ipm

0.0004 inches 100.0 ipm

Getting Started

Maximum Milling Feedrate for a 0 .0001 Inch (Default)Chord Error at a Programmed Feedrate of 100 ipm

Arc Radius Maximum Milling Feedrate

0.2500 inches 28.4 ipm

0.5000 inches 39.9 ipm

0.7500 inches 49.1 ipm

1.0000 inches 56.4 ipm

2.0000 inches 79.9 ipm

3.0000 inches 97.8 ipm

3.1500 inches 100.0 ipm

Ult max 3 System 5/10/94 1-79

Operator' s Manual

Hole Parameters

Press the Holes Parameters (175) softkey on the General Parameters screento change any of the three parameters for holes. The most often changedparameter on this screen is Drill Dwell. This parameter controls the lengthof time the drill stays at the bottom of a hole after it has drilled the hole.

HOLES PARAMETERS IF

BORE ORIENT RETRACT ? B.5BB AN 1DRILL DWELL 0.5 SEC FBORE DWELL 1.8 SEC F

2

Enter back away distance rrow Gored wall

Figure 146. Hole Parameters screen

F3

F GENERAL4 PARAMETERS

F5

F MILLING6 PARAMETERS

F PROGRAM7 PARAMETERS

F EXIT8

Fields Definitions

Drill Dwell The pause (dwell) in seconds before the toolretracts at the bottom of a drill operation. Thedefault value is 0.5 seconds. Many operatorschange this to 0.0 seconds so that the drill willimmediately pull out of the hole after it isdrilled. This parameter is not used for NCprograms-

Bore Dwell The pause in seconds before the tool retracts atthe bottom of a bore operation. The default valueis 1.0 seconds. This parameter is not used forNC programs.

1- 80 Revision A Hawk 5M Machines

Getting Started

Milling Parameters

The milling parameters do not apply to NC programs . They only affectcutter motions during conversational milling operations.

MILLING PARAMETERS IF

BLS OFFSET 3.888 MM 1BLEND OVERLAP ... 3.008 MM iFINISH FEED I80 x FFINISH SPEED 188 x 2FINISH XY 8 .208 MM IFINISH Z 0.100 MM FMILLING DIRECTION CLIMB 3POCKET OVERLAP 10 x iCUTTER CORP PARAMETER INSERT ARC F GENERAL

4 PARAMETERS

F HOLES5 PARAMETERS

F6

F PROGRAMEnter distance free finished ell to tool edge on entry 7 PARAMETERS

F EXITa

Figure 147. Miffing Parameters screen

Milling Parameters DefinitionsFields

Blend Offset The distance from the entry point of the partsurface and the Z plunge point where the tool entersthe work piece . This parameter is used in millingcircles , frames, and ellipses. The default values are0.1250 inches or 3.000 mm.

Blend Overlap The distance the tool travels past the entry pointbefore it is withdrawn from the part . This parameteris used in milling circles , frames, and ellipses. Thedefault values are 0.1250 inches or 3.000 mm.

Finish Feed The percentage of the programmed feedrate of theroughing pass used for the finish pass, if the finishpass is programmed for the part . The default is100%.

Ultimax 3 System 5/10/94 1- 81

Operator' s Manual

Milling ParametersFields

Finish Speed

Finish X-Y

Finish Z

Milling Direction

Pocket Overlap

Definitions

The percentage of the programmed spindle speed ofthe roughing tool used for the finish tool. Thedefault is 100%.

The amount of material in the X-Y axis direction tobe removed by the finish pass. The default valuesare 0.0100 inches or 0.200 mm.

The amount of material in the Z axis dimension tobe removed by the finish pass. The default valuesare 0.0050 inches or 0.100 mm.

Allows selection of either Conventional or Climbmilling for canned milling cycles (e.g., frame,circle , and ellipse). Climb milling is the default.This does not apply to lines and arcs.

The percentage of tool diameter overlap for eachpass in a 10% pocket milling operation.

1- 82 Revision A Hawk 5M Machines

Getting Started

Cutter Comp Parameter

This important milling parameters field relates only to controls equippedwith the UltiPocketm software option and that use the inward spiral cuttercompensation type in a pocket boundary to connect the cuttercompensated non-intersecting mill line and arc segments . The parameterconnects these milling segments as follows:

1. If Insert Arc is selected a tangent arc is inserted to connect twoline segments , or a line segment and an arc segment (when thetwo cutter compensated segments are offset and do notintersect). When using the Insert Arc method , the system createsthe cutter compensated path as shown below:

Using the Insert A .\Are parameter

Cutter compensatedpath

Programmed Tool Path

Figure 1-48. Cutter Compensation using the Insert Arc parameter

Some operators find the Insert Arc method inappropriate for theirapplications because the cutter remains in contact with the workpiece and may drag a chip across a sharp angle on the part. In suchcircumstances , operators select the Insert Line parameter.

Ultimax 3 System 5/10/94 1- 83

Operator' s Manual

2. If the Insert Line parameter is selected, the cutter compensatedlines and arcs are joined as described below:

a. Two line segments are extended until they intersect(provided they form a 90 degree or greater angle). If the linesform an angle of less than 90 degree, a line is inserted toconnect them.

b. Line and arc segments have the line segment extended, and atangent line to the arc segment inserted and extended untilthe lines intersect (provided they form a 90 degree or greaterangle). If the segments form an angle of less than 90 degree,a line is inserted to connect them.

c. Two arc segments have tangent lines (to the arcs) insertedand extended until the lines intersect (provided the extendedtangent lines form a 90 degree or greater angle). If theextended tangent lines form an angle of less than 90 degree,a line or arc is inserted to connect them.

Completedpath usingthe Insert

Line parameter

Cutter compensatedpath

/ \

Programmed Tool Path

Figure 1.49. Cutter Compensation using the Insert Line parameter

1- 84 Revision A Hawk 5M Machines

Getting Started

Program Parameters

The program parameters control three overall features of the control suchas table positioning during a tool change.

PBOSPIw PARAMETERS IF 1) OFF

OVERRIDE LOCKOUT )OFF 1PROGRAM PROTECT PARTIAL ITOOL CHANGE POSITION No F 2) ON

2

iF3

F GENERAL.4 PARAMETERS

F HOLES5 PARAMETERS

F MILLING6 PARAMETERS

Axis feedrote and spindle speed override controls can be 7disabled

Figure ] -50. Program Parameters sereen

F SKIT8

I

Program DefinitionsParameters Fields

Override Lockout When "On" is selected, the Axis Feed dial on thejog unit is disabled. The default is "Off."

Program Protect This parameter protects all of the part programs onthis control from being altered. The keyswitch atthe side of the control console must be in the"unprotected" position before a" supervisor canaccess this parameterand change it.

To prevent programs from `being changed, the-`;' 'supervisor selects either'- or "Partial" in theProgram Protect field. ")F11 the supervisor selects"Full," the operator will not be able to change thepart program or its tool and part setup information.If "Partial" access is given, the operator will be ableto change a part program's.tool and part setup only,but not the program itself. "Partial" is the default.

Ullimax 3 System 5/10%94 1- 85

Operator' s Manual

Program DefinitionsParameters Fields

Program Protect The value entered into Program Protect field can be(continued) overridden by turning the keyswitch on the console

to the "unprotected" position. Refer to thedescription of the keyswitch earlier in this chapter.

Tool Change Position This parameter indicates whether or not the tablewill move to the right/front of the machine whenthe operator is changing a tool. If this field contains"Yes" when a part program block calls for a toolchange, the table will move out of the way. Thedefault is "No."

1-86 Revision A Hawk 5M Macbines

Getting Started

Where can we go from here?

After setting up the part program, the operator may want to beginprogramming the part. Refer to the appropriate part programmingdescription, either conversational or NC part programming.

Or...

The operator may want to save the program to the hard drive's permanentmemory or to a diskette . Refer to the "Program Storing, Renaming, andDeleting" section for more information about saving programs.

Or...

The operator may want to switch off the machine tool. Refer to the "ShutDown Techniques" section.

Ultimax 3 System 5/10/94 1- 87

Operator' s Manual

Program Storing , Renaming , and DeletingTo store a newly created or changed part program, the operator firstpresses the Auxiliary console key above the number key pad. TheAuxiliary screen appears. To access the program storage and directoryoperations, the operator then presses the Storage Functions (Fl) softkey.The Current Program screen appears:

CURRDIT PROGRAM

QJRREIT DISK WARD DRIVE C

Choose appropriate wftjmy

Figure 1-51. Current Program screen

F FORMAT DISKETTE4

F5

F READ PROGRAM1 PROM DISK

P WRITE PROGRAM2 TO DISK

F DISK OPERATIONS3 LIST DIRECTORY

F SELECT CURRENT6 STORAGE DRIVE

File Storage Principles

The operator stores part programs in directories on the control's harddrive or on floppy diskettes . The operator can create these directories (onthe hard disk and on each diskette ) to enable convenient grouping of partprograms. Each hard drive contains one main directory-the rootdirectory. This directory cannot be created by an operator , but it can besubdivided into additional directories.

1- 88 Revision A Hawk 5M Machines

Getting Started

A directory may be compared to the label on a filing cabinet drawerholding a specific group of part program files. Operators select directorynames that make it clear what types of part programs are stored withinthem. Multilevel directories (subdirectories) can also be created to permitfurther division of program groupings and enhance the filing system. Asubdirectory can be compared to a specific file folder within the drawer(directory) of the filing cabinet (hard drive) as in the followingillustration.

Here is an illustration of directory and subdirectory structure for storageof part program files:

Hard Drive(Root directory "C")

Part Program Files

L

Figure 1-52. Directory Structure

When an operator selects an option to save a part program , the system willsave it onto the root directory that exists on the hard disk and eachformatted diskette unless a specific directory is selected.

Ultimax 3 System 5/10)94 1- 89

Operator' s Manual

Directory Options

To access the hard drive and perform directory and part program tasks,press the Disk Operations List Directory (F3) on the Current Programscreen . The available tasks are very similar to DOS (disk operatingsystem) operations on personal computers. The user can create and deletedirectories and subdirectories and store programs in those directories.

CURRIIMT PR06AM

259952M bytes treeB bytes tagged.

CURRENT DIRECTORY

27-12-93.1813 6861 .103

FCHA= TO1 DIRECTORY

(ir tory(a) 16 Fr46raa(a). F RDB programs tagged . 2 PROGRAM

CNAVEDAYZ .103 DR ILLTAP . 103 EIalSUP .1003

PROBE -011.1013NOTARY HD3

PROBEJM .1X03ROT-X X .103

UNIFOHAIR .1103RACECRR .1013SAOEPROG.10)3

CSAVE2G2T

JR_AUTO HD3PROBE RD3RACER .103TARTEST HD3

F DELETE3 PROGIy l

F CREATE4 DIRECTORY

F DELETE5 DIRECTORY

27-12-93.Im3 1733 bytes 01-61-1988 12:87aUse arrow keys to now through pograe(a)and

F SELECT CIIRRU T6 STORAGE DRIVE

F --+iORE-Perforw disk operations. 7Use cursor keys to ow between program and choose sot they. I

F EXITB

Figure 1-53. Current Directory screen with directory sofikeys

The three directory functions that the operator uses to manage the files onthe Uhimax control 's hard drive are accessed through these softkeys:

Change to Directory (Fl) - use the arrow keys to move thehighlight and switch the list on the Current Directory screen anddisplay a subdirectory and program names . The directory shownon the sample screen above has five subdirectories (highlighteditems in shaded boxes with no extensions ). There are alsoprograms stored in this directory. They have the HD3 extension.

Getting Started

• Create Directory (F4) - allows the operator to create adirectory or a subdirectory in which to store part programs.

• Delete Directory (F5) - allows the operator to remove adirectory or subdirectory from the hard drive. Directories andsubdirectories containing part programs cannot be deleted. Inaddition, the root directory on the hard drive and the floppy drive("A") cannot be deleted using this option.

Ultimax 3 System 5/10/94 1- 91

Operator' s Manual

Storing Part Programs

To store a part program in permanent memory on the hard drive , press theAuxiliary key on the console and then press the Storage Functions (Fl)softkey. The Current Program screen appears:

CURRENT PROGRAM

CURRENT DISK HARD DRIVE C

Choose appropriate sotthey

Figure 1-54. Current Program screen

F READ PROGRAM1 FROM DISK

F WRITE PROGRAM2 TO DISKi

F DISK OPERATIONS3 LIST DIRECTORYi

F FORMAT DISKETTE4

P

F SELECT CURRENT6 STORAGE DRIVE

F7

F EXIT8

1-92 Revision A Hawk 5M Machines

Getting Started

Then follow these steps to copy the part program currently in temporarymemory to the control's permanent memory:

1. Press the Write Program to Disk (F2) softkey. The CurrentDirectory screen then appears.

CURRENT PROGRAM

25995261 bytes freeB bytes tagged.

CURRENT DIRECTORY

27-1293. 103 6861 .103

F CHAME TOI DIRECTORY

8 directory (s) 16 progras (s). F RE"MMB program tagged . 2 PROGRAM

CS.VE CSAUEZC2T

F DELETE3 PROGRAMDAYZ . 103 DRILLTAP .103 RMDSUP HD3

CMIp1

IUDV

PROBE_DB.103ROTARY .1013

NEVIN[IM01131E HD3

PROBE-M .103 RACECAR .103ROTS( .103 SAVEPROG.1013

JR fd1TO .10)3PROBE .10)3RACE-CAR.103TARTEST MD3

27-12-93.103 1733 bytes 81-81-1988 12:87aUse arrow keys to now through program(o)and D INECTVR I ES

F CREATE4 DIRECTORY

F DELETES DIRECTORY

F SELECT CUSDEIT6 STORAGE DRIVE

F --WAS-Perform disk operations. 7Use cursor keys to sow between progress and Choose ear they. I

F EXIT8

Figure 1-55. Current Directory screen used for program storage

2. Use the arrow keys to highlight the name of the directory thatwill receive the program , or press the Select Current StorageDirectory (F6) softkey to select either the hard drive or thefloppy drive for storing the program.

3. Press the Change to Directory (Fl) softkey to select thehighlighted directory.

4. The Letter Selection screen appears on the graphics monitor sothat the operator may select a different name for the partprogram.

Hints and Tricks

Operators may change the name of the programs when they are saving theprograms as different versions of a currently saved program . They mayalso want to give the program a different , perhaps more descriptive, namethan is currently being used.

Uldmax 3 System 5/10/94 1- 93

Operator' s Manual

5. If the operator wants to change the program name , the operatoruses the trackball on the console to move the crosshair indicatoron the Letter Selection screen.

When the crosshair is positioned over the desired character,press the Select key. The selected letters then appear at thebottom of the text screen above the "Enter part programfilename; up to 8 characters" message.

CURRENT PROGRAMA:\TT.ND3

ITTLnta' part Provrae F I lens.. ; up to a characters.

PRESS IWIIM. NODE. PCUfl, AND START TO MITOAR POWER.

FI

F2

F3

F4

lF5

F6

F7

F ABORT OPERATIONB

Figurel -S6. Current Program screen program name during save operation

Press the Enter key when the new name is complete.

6. To save the program with the same name , the operator simplypresses the Enter key without selecting any letters from theLetter Selection screen.

7. If a program with the same name is already stored on thedirectory, the "Program already exists . Overwrite it?" messageappears . To copy the current version of the program over theolder version on the hard drive , the operator then selects the Yessoftkey.

8. When the program has been successfully copied onto the harddrive, the "Part Program Written to Disk" message appears atthe bottom of the screen.

Getting Started

Renaming a Program

To get to the program renaming function , follow these steps:

1. Press the Auxiliary console key above the number key pad. TheAuxiliary screen appears.

2. Press the Storage Functions (Fl) softkey . The Current Programscreen appears.

3. Select the Disk Operations List Directory (F3) on the CurrentProgram screen.

4. Use the arrow keys on the console to move the highlight overthe name of the program in the directory listing.

To begin the renaming process , select the Rename Program (F2) softkeyon the Current Directory screen, and the text screen changes as shownbelow. In addition , the Letter Selection screen appears on the graphicsdisplay monitor.

1. Use the trackball on the console to move the crosshair indicatoron the Letter Selection screen.

Ultimax 3 System 5/10/94 1- 95

Operator's Manual

2. When the crosshair is positioned over the desired character,press the Select key. The selected letters then appear at thebottom of the text screen above the "Enter new name forprogram" message.

UIN

CURRENT PROGRAM

25995264 bytes free8 bytes tagged.

27-12-93.11103 6861 .14DB

IF1

d1ractorg(a) 16 prograw(s). F8 program tagged. 2

CSRUEDRY2 .103 DRILLTAP .103 DI=P HD3

QIRBDIT DIRECTORY

PRORE_AB.103 PROBE-M HD3 BRCECRR .103 RPCE_CAR.103ROTARY HD3 ROT-P .103 EWEPROC .103 TRPTEET HD3

OH71IR .103 PROBE HD3

0

r

BRCHCAR 103 15439 bytes 81-01-1980 12:84.

Enter new ease for progree.

Lies error bays to cove through progree(s land

CSAVE2GZTJRIILiTO . RD3

I IHF.CTUN I CS iF71

F ABORT OPERATIONB

Figure 1-57. Program Renaming on the Current Directory screen

3. Press the Enter key when the new name is complete.

4. To stop the renaming process, the operator presses the AbortOperation (F8) softkey.

1-96 Revision A Hawk 5M Machines

Getting Started

Deleting a Program

To delete a part program from a directory, follow these steps:

1. Press the Auxiliary console key above the number key pad. TheAuxiliary screen appears.

2. Press the Storage Functions (Fl) softkey. The Current Programscreen appears.

3. Select the Disk Operations List Directory (F3) on the CurrentProgram screen . The Current Directory screen appears.

4. Use the arrow keys to highlight the program to be deleted.

5. Press the Delete Program (F3) softkey

6. The system gives the operator a chance to reconsider thedeletion of the program by displaying the message shown on thescreen below . If the operator then presses the No softkey, theprogram will not be deleted . Pressing the Yes softkey erases theselected part program from the directory shown on the screen.

28768L6 bytes free

wiar(T PA06IH IC:VtlIC[OAR . 11D3 T 1) 1a

MOUNT 1! DIDHCTOA?

5 d/raetmy(s) 16 Program ( ). T 2) MB bytes tagged . s Trosrae . 2

1188 .II 'IC 3 .ND: 7)DLID DxP ODTDIR 1113 D)JJATA DAT 3. .

PROBE 11 .14D3 RAC cRR HD3 RACE OAR .1113 SIWSPROG.M3 4

® II1 .DATA.DAT JOQ.DATA.DAT JRJWTO . 1183 I---!DM-DATA . DAT PIODZ HD3 PROD-DB.1113 T

TAPTIET

Use sera ' Leua ta aere lhra ,̂ sh Preara(s)*M

5

.1113

RACICAP .1m3 15139 bytes 61-01-1988 12:84.

S. you sera you wet to delete this program?

Figure 1-58. Deletion Function 's "Are you sure?" message

Ultimax 3 System 5/10/94 1- 97

Operator' s Manual

Copying Part Programs

If the operator wants to reorganize the part programs of directories or copyprograms between the hard and floppy drives, the operator must firstfollow these steps:

1. Press the Auxiliary console key above the number key pad. TheAuxiliary screen appears.

2. Press the Storage Functions (Fl) softkey. The Current Programscreen appears.

3. Select the Disk Operations List Directory (F3) on the CurrentProgram screen and the Current Directory screen appears:

CURRENT PROGRA M

25995264 bytes treeB bytes tagged.

F CHANCE TOCURRENT DIRECTORY 1 DIRECTORY

B directory(a) 16 programs). P REYgDB programs tagged . 2 PROGRAM

27-12-93.013 6861 HD3 CSnV4:DAY2 HD3 DRILLTAP . 1U3 ENDEUP .ND3(;M611.IIIDY

ItOHP.F.VIN

HNC

CSIIUE2G7.T

JR-AUTO HD3OIAIR HD3 PROBE .ID3

PROBE_DB . ID3 PROBBJI HD3 RRCSORR HD3 RACE _CAR.ID3ROTARY . ID3 2010 HD3 SAV1P7DC . ID3 TAPTERT HD3

27-12-93. 103 1733 bytes 81-01-1988 12:87aIlse arrw keys to now through pcgraw(s)aud

Select .10? Program to read into memory.Press CMer> to accept highlighted program name.

F DELETE3 PROGRAM

F CREATE1 DIRECTORYI

P DELETE5 DIRECTORY

P SELECT CURRENT6 STORAGE DRIVE

Figure 1-59. Current Directory screen with directory soft keys

4. Select the More (F7) softkey.

Getting Started

The softkeys change as shown below:

CURRENT PROGRAM

25995264 byte. free0 bytes tagged.

QJRR01T DIRECTORY

27-12-93.HD3 6861 .103

F COPY1 PROGRAM

iB directory(s) 16

Programstag(s). F TAG ALLproiIran

0 Programs tagged. 2 PROGRAMS

CSAVEDAY2 HD3 DRILLTAP .103 ENDSUP HD3GMDHJIIDV

HDUKEVIM

HNC

CSDVEL62T

JR_MTO HD3

F MMTAG ALL3 PROGRAMS

F TOGGLE4 PROGRAM TAG

OH AIR HD3 PROBE HD3PROBE DB.HD3 PROBE-M . HD3 RACECAR HD3 RACE-CAR.HB3ROTARY HD3 ROTDM( HD3 SAUEPROG .103 TAPTEST HD3

RACLCAR 103 15439 byte. 81-61-1988 12:94aUse arses keys to cove through progree(s)and

Select HD? Program to read into ae.cry.Press (Enter> to accept highlighted Program mans.

Figure 1.60. Current Directory screen with "More" so ikeys

1FSIF6

F CHMGE7 PROGRAM 1VaUR

P EXITB

These softkeys can be used to perform the following tasks:

e Copy Program (Fl) - allows the operator to select a partprogram from the directory listing and copy it to another directoryor a floppy diskette for storage . Highlight the program nameusing the arrow keys.

For example , to copy a program from the hard drive to a floppydiskette , follow these steps:

1. Press the Auxiliary button.

2. Press the Storage Functions (Fl) softkey on theAuxiliary screen.

3. Press the Disk Operations List Directory (F3) softkey.

4. Press the More (F7) softkey.

5. Use the arrow keys to highlight the program to becopied.

6. Press the Copy Program (Fl) softkey.

7. Select an "A" from the Letter Selection screen whenthe system asks for the destination drive.

Ultimax 3 System 5/10/94 1- 99

Operator' s Manual

• Tag All Programs (F2) - allows the operator to select all of thepart programs in a directory to copy to another directory. Whenthe operator presses this softkey, the system places a diamondsymbol (•) to the left of the program names.

• Untag All Programs (F3) - removes the tag markers from all thetagged programs in the directory.

• Toggle Program Tag (F4) - the operator highlights a program inthe directory list, presses this softkey, and changes the tagging ofthe highlighted program. Therefore, this softkey can be used totag a few programs in a directory to copy them as a group or toremove the tagging from a few programs so that they will not becopied with the other programs.

Getting Started

When one or more programs are tagged the following softkey alsoappears:

Copy All Tagged Programs (F5) - allows the operator to copyall of the part programs that are tagged to another directory or afloppy diskette. The drive and directory are selected usingsoftkeys and the arrow keys to highlight subdirectories.

For example, to copy all programs from the hard drive to a floppydiskette, follow these steps:

1. Press the Auxiliary button.

2. Press the Storage Functions (Fl) softkey on theAuxiliary screen.

3. Press the Disk Operations List Directory (F3)softkey.

4. Move the highlight to the desired subdirectoryname.

5. Press the Change to Directory (Fl) softkey.

6. Press the More (F7) softkey.

7. Press the Tag All Programs (F2) softkey or selectthe Toggle Program Tag (F4) to tag and untagprograms.

8. Press the Copy All Tagged Programs (F5) softkey.

9. Press the Select Current Storage Drive (F6) softkey.

10. Press the Floppy Drive A softkey.

11. Press the Enter key.

t)ltimax 3 System 5/10/94 1-101

Operator' s Manual

• Change Program Mask (F7) - allows the operator to sort out thetypes of part programs that will be listed on the Current Directoryscreen . To control this display, follow these steps:

1. Press the Change Program Mask (F7) softkey. TheLetter Selection screen appears.

2. Use the trackball to select the characters and lettersfor the sort criteria . Press the Select key to place theletters and characters into the data entry line on thetext screen.

3. This function is the same as the DOS searches on apersonal computer . For example , to see a listing of allthe programs that begin with the letter "R," theoperator types "R* .HD3" and presses the Enter key.

4. The directory listing then changes to show only thepart program with "R" as the first letter of theprogram name.

5. To list all of the program in the directory, the operatortypes.,* .*"

and presses Enter. The operator may want to use themultiplication symbol (X) on the console 's numerickey pad to enter this symbol.

Getting Started

Machine Diagnostics ErrorsThe system may display error messages directing the operator to enterMachine Diagnostics. Here are some examples:

"Way lube oil level is low; enter Machine Diagnostics."

"Overload fault detected. Enter Machine Diagnostics."

"Power cabinet temp too high; enter Machine Diagnostics."

To confirm correction of any of these problems, the operator may displaythe Limit Switches screen to observe the Machine Diagnostics operations.The Limit Switches screen shows the current status of the machine toollimit switches. Follow these steps to display the Limit Switches screen:

1. Press the Manual console key.

2. Press the Machine Diagnostics (F2) softkey.

3. Press the ATC and Machine Diagnostics (F7) softkey. Thenthe Limit Switches screen appears:

naICTIOH LIMIT SWITCHESP1

START PUSHBUTTON ON ICHIP SUCLOSURS DOOR OPEN FWAY LURE LWEI . LOW LEVEL 2POWER CABINET OVERTEIP OVER TEMP

FSPINDLE OVERLOAD TRIP TRIPPED 3AXIS IWTOR OVHKIDP OVER TEMP

Highlighted field indicates active limit witch stateChoose appropriate satthsy

Figure 1-61. Limit Switches screen

In the example above, all of the "OK" status indicators are highlighted(surrounded by a gray, rectangular background ), so this machine does nothave any limit switch error conditions.

Ultimax 3 System 5/11/94 1-103

Operator' s Manual

Below is an example of a system screen displaying one of the MachineDiagnostics error messages. Since this error is displayed on the Manualscreen, the operator can press the Machine Diagnostics (F2) softkey togain immediate access to the correction display screen shown on theprevious page.

as MANUAL M

MACHINE PART MACHINE VERTICALX 6.001 ANAL TOOL IN SPINDLE arV B.BBB IRICAL SPINDLE B2 -9.0B1 ANAL FEED MOTION STOPPED

Choose appropriate aottkay

LADE OIL LEVEL. IS L ; ENTER IIROIINE DIAU$OST1

Figure 162. Manual screen with Way Lube error

IF TOOL IN SPINDLE1

F MOIINEDIABOSTICS

F PARR MACHINE4IP WARM UP MACHINE

F TOOL HOME

F RESET SERVOS7 AND SPINDLEiF CALIBRATE MACHINEB

1-104 Revision A Hawk 5M Machine

Getting Started

Below is the Limit Switches screen showing the Way Lube error messagefrom the previous example. Note that the Low Level field is highlighted.To correct the problem, the operator or a representative from themaintenance department pours more way lube into the lube reservoir.When the float in the reservoir senses that the oil has been replaced, theerror message disappears from the bottom of this screen, and the highlightmoves from the Low Level field to the OK field. The error is, therefore,cleared so that the operator can continue to work.

FUNCTION LIMIT SWITCHES IF1

START PIEIENTTON lOIIP I CLOD JRE F

BAY LURE LIM ORPOWER CABINET OVERTAIP Deem I

FSPINDLE OVERLOAD TRIP TRIPPED 3AXIS ROTOR OVERTIDE OVER TEMP

TOOL CHANGER HEIGHT 4I-FSI.

FSl

Highlighted r/eld indicates active I aft pitch state FGoose appropriate =Wtkay

FIfY WE OIL LEVf. IS LOB : ENTER MACHINE DIAGNOSTICS 8

Figure 163. Limit Switches screen with error condition

This screen may also be used to check the Start Cycle button to be certainit is functioning. Press the Start Cycle console button , and the highlightmoves to the On field indicating that the console is receiving the startingsignal.

Hawk 5M machines sold in the United Kingdom have a Chip Enclosureand a limit switch to indicate whether or not the enclosure doors are openor closed . If the doors are not completely closed, the Door Open field willbe highlighted . The operator must press the enclosure doors together toclear the error and begin machining.

Ultimax 3 System 5/11/94 1-105

Operator' s Manual

The Tool Changer Height field is highlighted on the Limit Switchesscreen if the spindle is fully retracted'to its zero position. This field is nothighlighted if the spindle has moved down away from its home position.

To clear the Power Cabinet Overtemp, Spindle Overload Trip, and theAxis Motor Overtemp, the operator or a representative from theMaintenance department must open the electrical cabinet to correct theproblem and perhaps press reset switches . Refer to the MaintenanceManual for specific details.

When the electrical cabinet overheats , this causes the machine to shutdown until the cabinet 's temperature sensor registers that the temperaturehas dropped to an acceptable level. If this error occurs, the operator shouldcheck the temperature around the electrical cabinet to be certain thecabinet is not subjected to an additional heat source such as a space heateror bright sunlight from a nearby window.

Where can we go from here?

To exit the Limit Switches screen, the operator presses the Back arrowconsole key, and the Manual screen appears again. The operator may alsopress the Input or Auxiliary console keys to display one of those screens.

1-106 Revision A Hawk 5M Machine

Getting Started

Reset ControlTo restart the control without switching the power to the machine tool offand back on again , follow these steps:

1. Press the Auxiliary key on the Ultimax console.

2. The first Auxiliary screen appears with softkeys for storage,download and upload , system configuration, and changing theeditor . Press the More (F8) softkey and the screen shown belowappears:

Figure 1-64. Auriliary screen with Reset Master sojtkey

3. Press the Reset Master (F7) softkey.

Ultimax 3 System 5/11/94 1-107

Operator' s Manual

After pressing the Reset Master softkey, the operator is given the option tostop the operation with the Yes and No softkeys.

ew AUXILIARY -

EDITOR TYPE : CONVERSATIONAL

A floppy diskette hu been detected in drive A.

lP

Are you are WW rant to coM.inwe with RESET "ASTER? 7

I•FB

Figure 165. "Reset Master" and "Diskette in Drive" messages

Pressing the No (Fl) softkey aborts the reset process.

If a diskette is in the floppy drive on the control , a message displays in thecenter of the screen as shown in the sample above . Remove the diskettebefore pressing the Yes (F2) softkey.

Important

Be sure to save any part program currently displayed to the hard disk or toa floppy diskette before pressing the Yes (F2) softkey, or the program willbe erased during the reset process.

1-108 Revision A Hawk 5M Machine

Getting Started

Shut Down TechniquesAt the end of a work day, most shops leave their machine tools poweredup to simplify start up the next day. There are two methods used to shutdown a machine without turning off the power:

• Parking the machine

• Emergency stop

If the machine will not be used for several days or the shop has powersurges/black-outs, the power to the machine should also be switched offafter the machine has been shut down.

Important

If power is going to be left on at the end of the day, the operator musteither park the machine or press Emergency Stop to switch off themachine tool because both methods shut off power to the servos and stopthe machine from pumping lubrication onto the ways. If lubrication to theways continues to pump when the machine is not in use , the lubricant willflow out over the ways and require clean-up before the machine can beused again.

As an extra precaution to protect the machine tool from these problems,the operator should set the Control Power Off Timer on the SystemParameters screen . This parameter allows the machine to shut downautomatically in the same manner as an Emergency Stop shut down. Referto the "Configuring the System" section for more information aboutsetting this important parameter.

Ultimax 3 System 5/11/94 1-109

Operator's Manual

Park Machine

The machine parking shut down method is a more organized shut downmethod than pressing the Emergency Stop. Parking the machine centersthe table and leaves the spindle at the home position. This shut downprocedure protects the table because it distributes the weight of the tableand any attached equipment evenly.

Follow this procedure to park the machine:

1. Press the Manual key on the Ultimax console. This screenappears:

MANUAL - IF TOOL IN SPINDLE

MACHINE PART IAOIINE VERTICAL 1X 393.788 393.788 TOOL IN SPINDLE 0 IT 177.888 177.888 SPINDLE e F MAOIINEZ. 8.888 FEED MOTION STOPPED 2 DIAGNOSTICS

3

4

CAowa apprnWiate eorthey

Figure 166. Manual screen with Park Machine soft key

PARR IAOII

F IN88r-WFRnaI INE5I

F TOOL HOME6

F RESET SERVOS7 AND SPINDLEi

n CALIBRATE MACHINEa

2. If the machine is not currently on, press Power On button tosend power to the servos . The button is illuminated when theservo power is on.

3. Press the Reset Servos and Spindle (F7) softkey. Observe thatthe Start Cycle button begins to flash.

4. Press Start Cycle button to switch on the machine servos.

1-110 Revision A Hawk 5M Machine

Getting Started

5. Press Park Machine softkey. If there is a tool in the spindle, theappropriate messages are displayed on the screen allowing theoperator to put away this tool. Before any prompt to press StartCycle appears , the machine must be calibrated , and the tool inthe spindle must be zero.

6. If the tool in the spindle is zero , the Start Cycle button flashesand the message "Press start to park machine" appears on thescreen . The machine then moves to its park position asdescribed below . Be certain to follow the instructions displayedon the screen during this process.

a. The spindle orients and the Z axis moves to itsreference position.

b. Machine movement places the X and Y axes at thecenter of their respective travels.

c. All servos and the control-on relay shut-off.

d. The screen displays the Manual screen with a promptmessage with instructions to return to the power upcondition. The message "Press manual mode key,power-on, reset servos and start" appears.

e. Pressing the Manual button causes the precedinginstructional message to be deleted from the screen.

Ultimax 3 System 5/11/94 1-111

Operator 's Manual

Emergency Stop

To shut down the machine tool quickly, the operator presses one of theEmergency Stop buttons. This shuts off the servo power and the waylubrication pumps. The message , shown on the screen below , appears onthe text screen.

-- NAMIAL -- IF TOOL IN SPINDLE

MACHINE PART MAOIINE VERTICAL 1X. 8.8888 0.0000 TOOL IN SPINDLE " IV. 8.0808 0.8088 SPINDLE B F MAOIINEZ. 0.8888 --------- F® NOTION STOPPED 2 DIAGN

F

Choose appropriate sot they

V STOP HAS BEEN DEPRESSED.NIAL NODS. POWER . AND START TO RESTORE

Figure 167. "Emergency Stop" message on the Manual screen

Warning

3

F PARR NMOHINE1I

F YAM UP MACHINE5

F TOOL HONE6trP RESET SERVOS7 AND SPINDLEiF CALIBRATE IAOHIMBB

Using this shut down method is not good for the machinetool table especially if the table is long and has heavyequipment attached to one end . The table should becentered using the parking shut down method to distributethe weight of the table and any equipment equally.

1-112 Revision A Hawk 5M Machine

Getting Started

Where can we go from here?

To restart the machine after the Emergency Stop has been pressed, theoperator must first twist the Emergency Stop button and pull it up torelease it . Then the operator must press these console buttons in thefollowing order : Manual key , Power On , and Start Cycle.

Or...

To restart the machine after it has been parked , the operator presses theseconsole buttons in the following order. Manual key , Power On, and StartCycle.

Or...

If the machine is not going to be used for several days or if the shopexperiences power surges and outages, all power to the machine should beswitched off at the main power switch . When this procedure is used, theoperator will need to follow the calibration and warm -up procedures whenrestarting the machine.

Ultimax 3 System 5/11/94 1-113

Operator's Manual

Infrequent System ChangesThere are two system features that an operator may seldom or never needto access:

• Language Selection

• Executive Upgrade

The operator can access these features from the Auxiliary screen bypressing the Auxiliary console key.

Changing Language Files

The Ultimax language files contain text used on system screens andmessages that appear at the bottom of screens. If optional language fileswere purchased for the Ultimax control, the operator may need to changethe language file currently being used on the control. To change thelanguage file, the operator presses the Auxiliary console key and thisscreen appears:

- AUXILIARY - I

EDITOR TYPE: CONVERSATIONAL

Choose appropriate softhog

Figure 1-68. Ausitiary screen with Change Language softkey

F STORAGE !UNCTIONS

P2

P QYO1665

P DOIRGAAD / UPLOADa

P SYST®I4 COIIFIQRMTION

F OUOIGE EDITOR

7

The Change Language (F5) softkey will only appear if at least oneadditional language file has been installed on the system . If only twolanguages reside on the disk , the other residing language is transferredinto memory when this softkey is pressed.

1-114 Revision A Hawk 5M Machine

Getting Started

If more than two languages are available on the control , a screen similarto the one shown below appears with all of the currently installedlanguage files listed.

LANGUAGE SELECTIONFF

GERMANSPANISH FFRENCH 2ITALIAN FSWEDISH FDANISH 3HUNGARIAN lTAIWAN ESE FCZEC1IOSLOVASIAI 4

YI.5

lF6iF

Noce to language desired with arrow keys: select a 7language by Pressing IMTEII. F

FOIITa

Figure 169. Language Selection screen

To select one of the listed languages , the operator uses the console arrowkeys to move the cursor and highlight the language desired . (English ishighlighted in the sample screen .) When the desired language ^ ishighlighted , the operator presses the Enter key to select it . After theselected language has been loaded into memory , the Auxiliary screenappears again.

Ultimax 3 System 5/11/94 1-115

Operator ' s Manual

Upgrading Ultimax Software

Occasionally, Hurco will send current customers an Ultimax softwareupgrade. This software, called the "executive," is used to create and runpart programs on the control . Upgrades usually improve systemperformance and add new features that customers have requested. Whenan upgrade arrives, it usually contains two 3.5 " floppy diskettes . They arelabeled with the control and machine types , a version number, and adiskette number . They usually say "Disk 1 of 2" and "Disk 2 of 2." Thediskette labeled "Disk 1 " is also referred to as the Executive 1 diskette.

To perform the system upgrade , the operator should first save any partprograms currently in temporary memory . The operator then presses theAuxiliary console key and the More (F8) softkey to display the screenshown below:

Figure 1-70. Auxiliary screen with More softkeys

1-116 Revision A Hawk 5M Machine

Getting Started

After the operator presses the Upgrade Executive (F6) softkey , this screenappears:

Figure 1-71. Auxiliary screen with executive upgrade message

If the operator pr esses the No (Fl) softkey, the system stops the upgradeprocess and displays the Auxiliary screen with the original group ofsoftkeys.

If the operator presses the Yes (F2) softkey, the system reads the diskettein the drive and displays instructions to guide the operator through theupgrade process. First, the system asks the operator to insert theExecutive-1 diskette (Disk 1). When the proper diskette is inserted, thesystem copies files from the diskette onto the hard drive.

If the operator accidentally inserts the wrong diskette into the floppydrive, the system continues to display the insert diskette message until thecon-ect diskette is inserted in the drive. When. the file copying messagesdisplay, the operator knows that the correct diskette was inserted in thedrive and the upgrade process has started.

Ultimax 3 System 5/11/94 1-1i7

Operator's Manual

When the system upgrade is complete, this message appears on the textscreen:

Executive Upgrade Complete

- Remove the floppy diskette.

- Power down the control.

- Power up to start the new executive.

At this point , the operator needs to switch off power to the control andthen switch it back on to access the new software.

Important

Save the executive software diskettes in a box away from heat, debris, andmagnetic interference. These diskettes may be needed by the technicalservice representatives.

Troubleshooting

Since the system always examines the floppy drive first during the start upprocess , the executive software diskettes may also be used to start up thecontrol if the hard drive fails. To start up the Ultimax system and use thesoftware from the diskettes , the operator inserts Disk 1 into the floppydrive and switches on the power to the control . The system displaysmessages telling the operator to insert any additional diskettes as needed.

When the process is complete , the executive software will be loaded intotemporary memory on the control . The operator may remove the diskettefrom the floppy drive in order to insert diskettes used to store partprograms.

However , this is only a temporary solution for . a hard drive failure becausepart program storage will be limited to floppy diskettes . Call technicalsupport to check and perhaps replace the control 's hard drive.

.,

1-118 Revision A Hawk 5M Machine

Chapter 2

Conversational Part Programming

The Ultimax 3 Control gives the operator both Hurco Conversational andNC (M and G codes) part programming capabilities . This chapterdescribes conversational programming. Refer to the NC ProgrammingInstruction Manual for information about NC part programming. Toswitch between the two types of part programming editors, refer to the"Switching Part Programming Editor Type " section in the "GettingStarted" chapter of this manual.

Conversational Programming PrinciplesConversational programming allows an operator to program a part at themachine while reading directly from a blueprint or program worksheet.When an operator is programming a part , the system displays operatingselections and prompts on the left-hand CRT (text screen). A blinkingcursor leads the operator through the programming steps necessary toenter the data for a part program. The operator responds by pressing theappropriate keys and push buttons to select machine operations or enterpart dimensions.

Conversational part programs can be automatically stored on the system'shard drive or diskette to minimize loss of input data if a manual save isnot performed. This AutoSave parameter can be set to save the partprogram into a temporary memory area automatically duringprogramming . When the control is switched off and back on, the lastAutoSave version of the part program is presented allowing the operatorto continue.

2-1Ultimax 3 System 5/12/94

Operator' s Manual

Before Part Programming

All machine tool operators need to plan their jobs before they begin work.Operators plan the work piece placement, fixturing, and part cuttingoperations before cutting a part. After planning the part program, theoperator loads the tools and fixtures the work piece to the table. Then theoperators using CNC-equipped machines have the advantage of using thecontrol's features to improve the efficiency of the part programmingprocess. For more information about conversational part programmingfeatures, refer to the "Special Programming Features" later in this chapter.

Before programming the part on the Ultimax control , the operator mustdescribe the part and the tools that will be used to cut it . Each tool used inthe part program must be described on the Tool Setup screens. If the Toolnumber, Type, and Diameter are not entered for a tool , the system will nothave enough information to draw the part properly on the graphics screen.If the Zero Calibration value is not entered , the spindle will not switch onwhen the operator tries to run the part program , and the system willdisplay the "Tool is not calibrated" error message.

2-2 Revision A Hawk 5M Machine

Conversational Part Programming

Operators must also enter the general parameters , particularly the RetractClearance, that apply to the entire part program. These setup functions aredescribed in the "Getting Started" chapter. The operator can access thesetup functions , Tool Setup , Part Setup , and Program Parameter , from theInput screen . To display the Input screen , the operator presses the Inputconsole button or the Exit (F8) softkey on the Machine Configurationscreen.

Figure 2-1. Input screen

Operator' s Manual

Access to Programming Functions

After the parameters are setup , the operator enters the machiningoperation information onto screens . This is stored within data blocksdescribing each operation to be performed . The operator creates andaccesses the data blocks through the Input screen (shown below). Todisplay the Input screen , the operator presses the Input console button orthe Exit (F8) softkey on the Machine Configuration screen. Then theoperator presses the Part Programming (F3) softkey to beginprogramming.

INPUT - IF PART SETUP

MASTER PROGRAM IUMX 5" .1.68 Mel.22'94 I

iEDIT PART PROGRAM 1.MD9 METRIC F TOOL SETUP

STNOARD VERTICAL 2

F PART FROGRA MIPROGRAM MEMORY AVAILABLE 99 R 3

F4 PARAMETERS

S

P COPY AND CHANGE6 BLOCl6M

P ERASE FUNCTIONSSelect sottimg er Pr Cntea> to csenps part Pew rows 7

PR

Figure 2-2. Input screen

If the Part Programming (F3) softkey does not appear on the Input screen,the system has been set to lock out part programming functions . Refer tothe keyswitch and program protection material in the "Getting Started"chapter for more information and contact a supervisor to switch on thepart programming functions.

Conversational Part Programming

When the operator presses the Part Programming (F3) softkey on the Inputscreen, the system displays either the first block of an existing programcurrently loaded into temporary memory, or the system displays the NewBlock screen for new programs , as shown below:

BLOCK 1 • NEW BLOCK

cb c.e type of block

IF 1) POSITION1

F 2) HOLES2

F 3) NILLINO3,

F 4) PATTERNS4

F 5) NIScELLM4EO165

F 6) SPECIAL6

F7

PRESS IWK1L NODE. POBER , AND START TO 868708E POVER. F EXIT8

Figure 2-3. New Block screen

The part programming softkeys provide the following options:

• Position (Fl) - allows the operator to insert instructions to movethe tool away from the part (or fixture), or stop a program. APosition block is most often used to move the table to a X-Ylocation and is normally used at the end of the program and atany time the tool must be moved to the Z Top position of theSafety Work Region.

• Holes (F2) - allows selection of Drill, Tap, Bore and ReamOperations, and Back Spotface hole drilling. The locations ofthese holes on the part can be specified using the Locationsoperation, and the holes can also be programmed in a bolt circlepattern-

• Milling (F3) - allows programming of Lines and Arcs, Circle,Frame, Face, Ellipse and Lettering operations.

tlltimax 3 System 5/12/94 2-5

Operator' s Manual

• Patterns (F4) - allows the operator to repeat or modify asequence of one or more data blocks. A program sequence can berepeated in a rectangular, linear, angular, or rotated pattern OR atspecified locations. This operation is also used to scale or mirror aprogrammed part.

• Miscellaneous (F5) - provides access to operations used to turn-off or turn-on the drawing of the programmed part (on thegraphics CRT) and to the change Program Parameters or PartSetup information.

• Special (F6) - If the Tooling Cutter Insert Routines option is partof the control's software, this softkey allows the operator toprogram triangles, diamonds with one and two faces, andhexagons.

• Rotary (F7) - (not shown here; refer to the "Rotary" section inthis chapter) If the Rotary table option is part of the system, thissoftkey allows the operator to select rotary parameters and toprogram position blocks, lines and arcs, circles, frames, loops,locations and patterns.

• Exit (F8) - return to the Input screen.

Conversational Part Programming

Part Programming Summary

Operators using CNC-equipped machine tools plan for cutting a partusing a part program in the same manner that they plan to cut a partmanually. The only difference with using a CNC-equipped machine isthat the operator communicates the plan to the machine through a partprogramming language-conversational or NC part programming. Thenthe operator can use the machine to store the part program and check theplan for errors. The operator also has several options when running theprogram: a dry run to test the program, feed and speed optimization,single cycle operation, and automatic running of the entire program. Thereare also recovery/restart facilities built into the Ultimax system.

Data Block Options

A part program is made up of data blocks that store the informationspecific to the program .. These blocks are stored in numerical order.Operators use the following basic programming operations to create datablocks:

• Create a new data block or edit an existing data block throughthe Input screen.

• Insert a new data block between two sequentially numberedblocks. Then the data blocks after the inserted blockautomatically renumber.

• Delete an existing data block and the data blocks after thedeleted block renumber automatically.

View a list summarizing a part program 's data blocks on theReview Program screen.

• Copy, edit, or delete information in a data block using theBlock Editor screen.

Data blocks within a part program contain specific machining informationsuch as:

• Operation type (position, holes, milling , patterns).

• Tool number (to be used for the operation).

• Dimension coordinates (relative to X, Y, Z axes).

• Feedrate (at which the axes move).

• Locations of operations on the part.

Ultimax 3 System 5/12194 2-7

Operator's Manual

Data Block Creation and Navigation

When the operator is creating and editing data blocks, these basicconcepts are helpful:

• When a different type of cutting (such as hole drilling orcontour milling) is going to be performed, a different blockmust be created to describe it.

• When a different tool is needed in a program, a new data blockmust be created to describe the actions of that tool. Theexception to this rule is a data block describing a hole drillingoperation. These data blocks can use multiple tools to performmultiple operations.

• To move through the fields on a data block screen , press theEnter key or use the up and down keyboard arrows.

• To tell the system to read and remember new data that is typedinto a field , the operator must then press the Enter key. PressingEnter also automatically advances the cursor to the next field.

• A field can be skipped (allowed to remain unchanged ) simplyby pressing the Enter key when the cursor is positioned on thefield.

• To move to other data blocks in the part program, press theBack or Advance arrow keys on the console.

• While programming a Holes data block, the operator presses theAdvance key to move between the operations within the datablock. These operations describe separate portions of the holedrilling operation.

Conversational Part Programming

Creating a Milling Data Block

Milling a frame is a simple operation to program . The operator begins amill frame block by displaying the Input screen and pressing the PartProgramming (F3) softkey. When the New Block screen appears, theoperator presses the Milling (F3) softkey to display the milling optionsshown in the seven softkey selections. In this example, the operator iscreating block # 1 in the part program.

L''0°' 1 (l Na elaclc

cbm two of block

Figure 2.4. New Block screen with milling options

1) LINES AND1

F 2) CIRCLE2ir 3) PRNat3

F4 4) FACE4

F 5) ELLIPSE5

F 6) LEr7EEINC

II

The 3D Option (F7) softkey only appears on this screen if the 3-D optionsoftware has been purchased and installed on the system. All other softkeyselections are standard in Ultimax systems.

Ultimax 3 System 5/12/94 2-9

Operator' s Manual

When the operator presses the Frame (F3) softkey on the New Blockscreen , the Mill Frame screen appears:

BLOCK 1 MILL FRAME IF

TOOL I a Z START 0.0000 1

iTYPE ON Z BOTTOM B.BBBa P

2FINISH TOOL 0 PLIDNGL FEED 0.0 1

FK COWIER O.0008 MILL FEBD B.B 3

1V CDRP= 0.a000 SPEED (RPM ) B P PROGRAM

4 PARAMETERSX LENGTH 0.0000 PECK DEPTH 9.0000 ;

F PART SETUPV LENGTH 0.0000 TOOL NOT PROGRIND® 5

Comm RADIUS 0.0000 P TOOL SETUP

Enter tool number

Figure 2 5. Mil Frame screen

Then the operator must type in the number of the tool that will be used tomill the frame and press the Enter key to tell the system to read andremember the information in the field.

The tool numbers and their descriptions were entered in the Tool Setup. Ifthe tool information has not been entered or the operator realizes at thispoint that another tool should be added to the program , the operator canpress the Tool Setup (F6) softkey to update the tool descriptions for this

program.

2-10 Revision A Hawk 5M Machine

Conversational Part Programming

Entering a number in the Tool field pulls information from the tool setupand automatically loads it into fields on this screen . Note that the MillFeed and Speed (RPM) fields filled in based on the information aboutTool #3 in the example shown below. For additional assistance to theoperator, the system also displays the selected tool's diameter and typebelow the second column in brackets . The brackets indicate that the tooldata was entered on a different screen and is displayed here forinformational purposes only. It cannot be changed on this screen.

MILL FRAME IF 1) ON

TOOL 3 Z START B.BBBB 1

TYPE ON Z BOTTOM 8 .8008 T 2) INSIDE2

FINISH TOOL PLAICE 8.8 'F 3) OUTSIDE

x CORM 0 .0B0B MILL FEED 58.8

V CORNER 0.8880 SPEED (BPB) ZSBB 4) INSIDE1 TANGENT

X LENGTH 6.B880 PECK D 8.0088 1F 5) OUTSIDE

V LECTH 8.B®B (TOOL DIAMETER 8.3B5) TMHT(TYPE DID

CODIER RADIUS B.00BB P 6) POCKET

Select wttlug opentlon

6 BOUNDARYiP 7) POCKET7 Islam

PRESS MANUAL MODE , PORE, AND START To RESTORE FUMES. F EXIT8

Figure 2-6. Mill Frame screen with tool number

The Pocket Boundary (F6) and Pocket Island (F7) softkeys, outlined by arectangle in the example above , only appear on this screen if theUltiPocketm option was purchased for the system.

Operator' s Manual

The fields on this screen describe how and where the frame will be milledon the work piece. For a machine equipped with the UltiPocket option,the operator may select a pocket boundary with an inward spiral cuttermotion . The Pocket Overlap field appears at the bottom of the firstcolumn (circled below ) when the operator selects a pocket operation. Theoperator may change this parameter . Many Ultimax system screens havefields that appear based on selections made in other fields. These areconditional fields because they only appear on a screen under certainconditions.

The X and Y Corner fields define a reference corner from which therectangular frame will be milled . This comer can be automaticallyidentified using the jog unit to position a cutting tool over the referencecomer . The operator presses the Store Position button on the jog unit toload the value into the field on the screen.

The X and Y Length fields define the lengths of the sides of the rectangle.The four values defining the rectangle are outlined in a box in the examplebelow . The operator may use the jog unit to identify the values or type inthe values . Remember to press the Enter key after entering each value.

BLOCK I I "ILL FEW

TOOL 3

TYPE POCK BOUNDARYPOCKET TYPE INIMINDFINISH TOOL N

E COWER -4.7547

Y GORIER 1.7547

X LDICTN 18.7238

Y LDUCTH 9.5894

COWER MRDNS 0.8"

POCKET OODnsp 58

Z START

Z BOTTOM

niecE n

MILL F®

SPEED UIPM)

F INSERT BLOCK2 BIPOAY

F3tF PR06R Y14 PARAMETERS

PECK DEPTH H.BBBB 1F PART 31T11P

(TOOL DIAMETER 8.3758) 5(TYPE )OD MILL) I

P TOOL RE71W6

Enter ►lock au►m. use ENTER to edit ►loek, m uwaADO/YICE. BALI, oe eTllsyPINS IMIEML MODE . POWER. AM STMT TO SECTORS POWER.

Figure 2-7. Completed Mill Frame screen

F7

F ITB

The fields on the Mill Frame screen are described in detail in the"Milling" section of this chapter . When the operator presses Enter on thePeck Depth field, the system displays additional softkey options as shownabove.

1P DELETE BLOCK

B.B9B 1

2-12 Revision A Hawk 5M Machine

Conversational Part Programming

At this point the operator may want to see a graphic representation of theprogrammed block. To display a picture of the.programmed block, theoperator presses the Draw console key, and the illustration appears on theright-hand CRT screen. Refer to the "Graphics" section for moreinformation about this feature.

Where can we go from here?

Upon completion of the Mill Frame block, the operator may want tochange information in the program setup using the Program Parameters(F4), Part Setup (F5), or the Tool Setup (F6) softkeys.

Or...

The operator may decide that the block should not be used in the program.So the operator presses the Delete Block (Fl) softkey to remove it fromthe program.

Or...

To create another data block before this mill frame block, the operatorpresses the Insert Block Before (F2) softkey. The New Block screen thenappears.

Or.„

To create another data block after this one, the operator presses theAdvance (right arrow) console key. If the milling data block was the lastblock in the program , the End of Program screen appears . Then theoperator presses the Enter key to display the New Block screen.

Or...

To return to the Input screen , the operator presses the Exit (F8) softkey. Ifthe operator presses the Exit softkey and did not intend to return to Input,the operator may return to the place in the program where the Exit softkeywas pressed by selecting the Part Programming (F3) softkey on the Inputscreen.

Ultimax 3 System 5/12/94 2-13

Operator' s Manual

Creating a Hole Drilling Data Block

To begin a new data block describing a hole drilling operation, theoperator presses the Holes (F2) softkey on the New Block screen. Notethat in the example, the operator is creating block # 2.

Figure 2-8. New Block screen

Conversational Part Programming

The Holes screen appears, as shown below. The word "New" on thisscreen indicates that the system is ready to receive the description of theholes data block.

BLOCK 1 HOLESF DRILL

»4 NEW 1 OPERATIONS

F TAP2

F FORE AND MAN3 OPERATIONS

kF RACK SPOTFACE4

F5

F6

F71

F tClTe

Figure 2-9. Roks screen with softkey options

Ultimax 3 System 5/12194 2-15

Operator' s Manual

The available hole operations on the Holes screen are Drill Operations,Tap, Bore and Ream , and Back Spotface.

When the operator selects one of the hole operations using a softkey, thesystem displays the options for the selected operation. The fields andavailable softkey options for the Drill Operations are shown in theexample below:

BACK 1 HOLES IF DRILL

TOOL B )))I DRILL 1

Z START B . BBBB P CENTER DRILL2

2 BOTTOM B.BBBB iF COUHTERBORE

PLUM FM 0.0 3

SPEED (RP") B F SPOTFACE4

PECK DEPTH B.BBBB IF COIEITERSIMR

PECM TYPE STANDARD 5

TOOL NOT PRocRIYD®

cho opentloi

FB

Figure 2-10. Holes screen with Dill Operations sofkeys

Conversational Part Programming

The operator selects the Center Drill (F2) softkey for the first operation inthe data block.

BLOCK 2

TOOL

HOLES

I >>> CENTER DRILL

IF DELETE OPERATIONIi

Z START 6 . 82180 F INSERT OPERATION2 BEFORE

Z BOTTOM --@ ADDS i.F

PLIMME FEED 7.5 3i

SPEED (RPM) 1566 F PROGRAM4 PARAMETERSi

F PART SETUP5

(TOOL DIAMETER 0.2818) F TOOL SETUP(TYPE DRILL) 6

i

FPeers ENTER to edit this operation or lase ADVANCE , BACK, 7or wttkey 1

F EXITB

Figure 2-11. Holes screen with. Center Drill fields

The structure of a hole drilling data block is more complex than otherconversational data blocks. To describe a hole drilling process in a datablock, the operator must enter different types of instructions . Each type ofdrilling instruction requires the operator to create a separate operationwithin the data block.

Ultimax 3 System 5/18/94 2-17

Operator' s Manual

To start a new operation, the operator presses the Advance key (rightarrow console key). In the example, the operator plans to drill the sameholes that were center drilled in the previous operation. Note that theoperator is using a different tool for this operation.

BLOCA 2 HOLES IF DELETE OPERATION

TOOL I CENTER DRILL I>>> DRILL I

Z START 8.8288 F INSERT OPERATION2 BEFORE

Z BOTTOM -8..ciB8e ;F

PLUNGE FEED 15.8 3

iSPEED (RPM) 2588 F PROGRAM

4 PARAMETERSFILE DEPTH 8 1800 i.

F PART SETUPPILE TYPE STANDARD 5

i(TOOL DIAMETER 8.2816) F TOOL 86111P(TYPE DRILL) 6

FPress ENTER to edit this operation m• use ADVANCE. BACK, 7m• sortkey I.

F EXITB

Figure 2-12. Holes screen with DnU fields

Conversational Part Programming

When the operator has completed a block, the system presents twoadditional softkey options, Bolt Circle (F5) and Locations (F6), as shownbelow:

BLOCK 2 HOLES

CENTER DRILLDRILL

>>>I NEW

F DRILL1 OPERATIONS

Choose appropriate sortIM9

F TAP2

F BORE AND REAM3 OPERATIONS

F BACK SPOTFACEt __

P BOLT CIRCLE5i

F LOCATIONS6

F7

F EXIT8

Figure 2-13. Start a New Operation

Operator' s Manual

When the operator selects the Locations (F6) softkey, the system displayscolumns for the X and Y coordinates of each location. The operator maytype in these values if they are shown on the drawing or use the control tocalculate them. A third method of entering these values is to move the toolusing the jog unit to the actual hole locations on the part and press theStore Position button to load the coordinates quickly into these fields.

RLOCE 2 HOLES IF

% Y CENTER DRILLDRILL

If

1 -8.1000 2.5000 >>> LOCATIONS F2 9.3000 -2.5000 231 4

F3

F4

FP51FS

Enter another point m • ADDNNCE when Finished

Figure 2-14. Holes screen with Location coordinates

Conversational Part Programming

When the operator completes the description of a drilling operation, thesystem presents these softkey options:

BLxx 2 "DIM IF DELETE OPERATION

x Y CENTER DRILL 1DRILL

1 -8.1888 2 .5800 >>> LOCATIONS F INSERT OPERATION2 9.3888 -2.5800 2 BEFORE

iP

F PROGRAM4 PARAMETERS

F PART SETUP5

F TOOL SETUP6

PPaces BITER to edit this operation w use ADVANCE. DAM. 7or sot they I

F EXIT8

Figure 2-15. Completed Holes Data Block

• Delete Operation (Fl) - removes the currently displayedoperation from the holes data block.

• Insert Operation Before (F2) - places another operation into thedata block before the operation currently displayed on the screen.

• Program Parameters (F4) - displays the part programparameters so that the operator may make changes.

• Part Setup (F5) - displays the part setup information for this partso that the operator may make changes.

• Tool Setup (F6) - displays the tool setup information for this partso that the operator may make changes.

For more information about programming data blocks , refer to the sectionlater in this chapter describing the type of data block and the sampleprograms illustrating many of the programming features.

Uldmax 3 System 5/12194 2-21

Operator' s Manual

End of Program

The End of Program screen shows the operator that there are no moreprogram blocks after this location in the program. There are two methodsto continue part programming from this screen:

• Press the Insert Block Before (F2) softkey.

• Press the Advance console key and press the Enter key.

To move back to the previous program block, press the Back console key.

0 Em or PROG I IFIi

F INSERT BLOCQ2 BEFORE

P3

F PROGIV 14 PARWMTERSiF PART SETUP5,

F TOOL SETUP6iF

Zeta a black eawber , use HITER to edit block, or m 7ADVAM= , BIKE, o wttkey I

F EXITa

Figure 2-16. End of Program screen

To exit the part program and return to the Input screen , press the Exit (F8)softkey.

Conversational Part Programming

Special Data Blocks

The operator may insert special data blocks between operational datablocks to change the position of the table, automatically stop a program,set a new part zero, or temporarily change the part program parameters.

Position Block

An operator inserts a position block into apart program for one of these

reasons:

• Move the table to allow the operator to move or refixture thework piece.

• Stop motion automatically during the part cutting operation torefixture or perform some other manual operation.

• Move the table forward at the end of a program to give theoperator easy access to the finished part.

BLOCK 1 POSITIONF DELETE BLOCK

TOOL B 1

x N,BBB F INSERT BIRO[2 BEFORE

V B.BBBF

STOP YES 3

* PROGRAM* PARAMETERS

iP PART SETUPTOOL NOT PROGRAMMED 5

P TOOL SETUPtIP

Enter a black number . uaa ENTER to edit block, or use 7

ADVANCE . BACK. or sottkey iF EEITR

Figure 2 -17. Position screen

Ultimax 3 System 5/12194 2-23

Operator' s Manual

If the Indexer option (not shown on the sample screen) has beenpurchased, the Index Pulses field also appears on the Position screen. Inthis field, the operator usually enters the number of degrees that theindexer head will rotate before an operation will be performed on the part.A new Position block must be put into the part program each time the partneeds to move to a new position.

Caution

If the indexer option is not available on the Hawk 5m kneemill and theoperator wants to use a part program created on a different Hurco machinetool, any Position blocks in the old program must be inspected todetermine if there is a value in the Index Pulses field. If so, the programmust be changed to remove the value before the program can be used on akneemill without an indexer. If it is not changed, the kneemill softwarewill ignore the Index Pulses value, and the program will not operate in thesame manner that it did on the other machine tool.

Conversational Part Programming

During execution of a Position block, the Z axis remains retracted withthe spindle rotating. The table moves to the programmed X and Ydimensions at the rapid traverse rate selected in Program Parameters orChange Parameters.

1. Press the Position softkey to display the screen. When thisblock first appears, the cursor is at the tool number parameter.

2. Program tool number. Entering the tool number displays thetool diameter in parenthesis with the value entered in ToolSetup. This value cannot be changed in Part Programmingmode.

3. Enter X and Y coordinates for the Position to which tool shouldmove (after Z Top position is reached). These dimensions aremeasured relative to Part Zero.

4. When cursor advances to the stop parameter, Yes and Nosoftkeys appear.

5. Press the Yes softkey if the program must stop after executingthis Position block. This response causes a message to bedisplayed (during program execution) requesting that Start bepressed to resume program in Auto Mode. If this Position blockis not a stop block, press the No softkey.

If a rotary table ("A" axis) is being used, that axis has a separate RotaryPosition block. Refer to the "Rotary" section for more information aboutthe Rotary Position screen.

Ultimax 3 System 5/12/44 2-25

Operator's Manual

Temporary Parameter Change

For some programs, the operator may want to insert a parameter changeblock between data blocks. To accomplish this, the operator displays thedata block for which the parameter change will first be used. Then theoperator presses the Insert Block Before (F2) softkey. A New Block screenappears.

BLOCK 1 I NEW BLOCKF 1) POSITION

P 2) HOLES2

F 3) MILLING3

F 4) PATTERNS4

55) MI

F 6) SPECIAL6

FCline type of block 7

PRIM MANUAL MODE, POWER. NW START TO RESTORE POWER. F Df1T8

Figure 2-18. New Block screen

The operator then presses the Miscellaneous (F5) softkey , and a newgroup of softkeys appears.

Conversational Part Programming

The operator can change the program parameters and part setup bypressing the F3 and/or F4 softkeys.

Figure 2-19. Change Parameters and Part Setup

Ultimax 3 System 5/12/94 2-27

Operator' s Manual

Using this feature, the operator can change data stored within the GeneralParameters, Hole Parameters, and Milling Parameters. These special"Change Parameters" and "Change Part Setup" options allow the operatorto change part program values so that they apply only to a certain portionof the program.

SLOGS 2 CHANGE GENERAL PARAMETERS IF

RETRACT CLEARANCE I 99.0068 IN 1RAPID TRAVERSE 400.0 IPM FPECK CLEARANCE PLANE 0.0500 IN FCHORD ERROR 0 .0001 IN 2DEPLETION RETRACT 0.01158 IN F

F3

FP4

P HOLES5 PARAMETERSi

P MILLING6 PARAMETERSFF

Enter clearance height above Z START at which tool wow 7between operation

Figure 2-20. Change General Parameters screen

FP EXIT8

When a part program is executed , the data selected in the ProgramParameters are in effect until the system encounters another ChangeParameters data block or until the end of the program. The parameters thatcannot be changed on these screens include Override Lockout, ProgramProtect , and Tool Change Position.

Return to the Input screen and select Program Parameters (F4) softkey tochange those three parameters.

Conversational Part Programming

When planning a change to the Retract Clearance parameter, the operatorshould consider the following:

1. This parameter is defined relative to the Z Start dimension andcan optimize Z axis tool motion between localized operations.

2. If all of the operations are at the same Z Start plane, there is nodifference between a relative and an absolute clearance. Butwhen groups of cutting operations are at different Z levels on thepart, programming a relative Retract Clearance can be moreefficient than an absolute retract dimension . It is possible toeliminate unnecessary tool motion to save time.

3. If the Z Start dimension of the next operation is different fromthat of the current operation, the control uses the higher of thetwo values for Retract Clearance before positioning the part inthe X-Y axes.

4. To achieve a Retract Clearance close to the part may require theuse of a Position data block . Programming a Position blockcauses the tool to retract to the Z Top (+) of the Safety WorkRegion which must be a dimension that denotes a clearanceabove all portions of the part and the fixture.

Examples of problem areas in which a Position data block must be usedrather than a simple parameter change are as follows:

• Between operations , a clamp or raised portion of the part ishigher than the programmed relative clearance.

• Cutting occurs inside a cavity and is followed by work insideanother cavity in which an optimal Retract Clearance foroperations in the recessed areas is below the surface of the part.

Ultimax 3 System 5/12194 2-29

Operator' s Manual

Set a New Part Zero

Pressing the Change Part Setup (F4) softkey from the Miscellaneoussoftkeys displays the screen shown below. This selection allows the userto change the part zeros, Offset Z and Centerline values. The graphics willnot reflect the new part setup . These values remain in effect until the nextChange Part Setup block. The Auto screen will show the part positionrelative to the current part setup block.

HLOCJI 19 CHARGE PART SETUP 1F PART SETUP

MACHINE PART 1% TOOL IN SPINDLEV SPINDLE F TOOL SETUPZ F® 2AE F

3

PART ZERO X • R.RRR8 F PROGRAMV g.RRRR 4 PARAMETERS

OFFSET Z 8.eue8 IF5

F6i

Enter part eero it loam or Jog eaehlm toF POST MACHINE

position and press sattiey to eta.W^ ssra 7 POSITION

positionF EEITa

Figure 2-21. Change Part Setup screen

Part Zero A and Centerline A fields (not shown on the sample screen)appear on the screen when the rotary option is installed.

Conversational Part Programming

Automatic Calculations

The Ultimax No-Calc (no calculation required by programmer) featureenables the control to calculate certain dimensions automatically aftersufficient data has been programmed. If the control is to calculate a givendimension, leave that data parameter blank. After sufficient data isentered , the control automatically fills in the blank data field(s).

RLOCX 16 HILL CONTOUR IF

SEGMENT 1 LINE 1r

x no 1. 1109E (X START 0.0000) F(Y START 0.0000) 2

V END 9000 (2 START1 -0 1000. .F STORE CALQIA

2 END^

-6.1000 3 VALIE

XV LENGTH 1.4142 F4

XY ANGLE 00045 .F

P® 7.5 5iF6iP PREVIOUS SEGIEIT

Enter XY length of eegeent, If known 7nP E(1f9

Figure 2-22. Automatic Calculation of Values

The screen displays a Store Calculated Value (F3) softkey function whenediting a parameter with a calculated value (indicated by 'CAL"preceding the value). Press this softkey or the Enter key to store thedisplayed value into the part program.

Ultimax 3 System 5112/94 2-31

Operator' s Manual

If a value is entered and later the operator decides to let the controlcalculate the data, the operator can clear the old value by following thesesteps:

1. Use the arrow keys (except Advance) to move the cursor tothe parameter where the automatic calculation is needed.

2. Press the Clear and Enter console keys. The defined value iscleared from the program and the control calculateddimension is displayed (or the parameter is blank waiting foradditional data to be entered).

Important

The No-Calc feature is not available to calculate unknown line and arcpoints in rotary programs . Refer to the "Rotary" section for therecommended methods to determine the values for those points.

Conversational Part Programming

Graphics

The right-hand CRT screen (see below) displays a graphicalrepresentation of the part program that the operator uses to verify partgeometries.

Text wean

HJ

Number keys

Figure 2-23. Ultimax Console

Enter key

2. Soltkey buttons

0

anual key

Pressing the Draw console key for the first time starts up the graphicdisplay on the right-hand screen . This key draws the part on the screen orstops a drawing in process. The crosshair cursor on the graphics screendisappears while the part is being drawn and reappears when the drawingis completed. (If the graphics cursor is not visible, the part is beingdrawn.)

Ultimax 3 System 5/12194 2 - 33

Operator' s Manual

If there are no part programming instructions available, the graphicsscreen appears with only the scale and the graphics functions as shownbelow:

B.18

-8.68

-1.68-2.18y

-6.IB 0.98

Figure 224. Graphics screen

The screen buttons (boxes) at the bottom of the screen represent theavailable graphics functions . Screen buttons are used extensively by theDXF option software.

Using these basic graphics functions , the operator can change the partprogram illustration on the screen by positioning the crosshair over thescreen button and pressing the Select console key.

• View - allows the operator to select a different perspective fromwhich to display the part.

• Full Scale - redraws the part currently displayed in full size. Thisis used after exiting the Zoom function.

• Zoom Box - isolates a portion of the drawing and increases thesize of that section to show the operator more detail.

• Parameters - allow the operator to change the default settings forthe graphics functions.

• DB Search - (data block search) allows the operator to select aportion of the graphic representation of the part. Then the systemdisplays the data block for that portion on the text screen . This isvery helpful when the operator is tracking down a portion of theprogram that is incorrect.

2-34 Revision A Hawk 5M Machine

Conversational Part Programming

Drawing stops when a data block has incomplete (or incorrect) data andwhen new data blocks are being created. The part draws in the largestscale to fit the CRT before appearing on the screen. The message"Autoscaling part program" displays on the screen during this scalingprocess.

To switch the graphics display on and off within a part program, theoperator presses the Miscellaneous (F5) softkey on the New Blockscreen. The graphics softkeys then appear as shown below:

Figure 2-25. New Block screen with Miscellaneous functions

The Graphics Off (Fl) and Graphics On (F2) softkeys allow viewingselected part features in complex programs where certain operations tendto obliterate others such as facing and pocketing.

Pressing either the Graphics Off or Graphics On softkey stores theselected function as a data block in the part program . The graphic drawingof the part is turned off and turned on at the point the block isencountered in the program.

When graphics are switched on, the Trackball moves the graphics cursorto a desired menu function on the right -hand screen and within therepresentation area of the drawing . The control automatically scales thepart dimensions for the screen before redrawing the part (to display theentire part). The Zoom function overrides this scale setting.

Ultimax 3 System 5/12/'94 2-35

Operator' s Manual

Views

Graphics can be displayed in five views:

• XY Plane - The part is displayed in XY projection.

• XZ Plane - The part is displayed in XZ projection.

• YZ Plane - The part is displayed in YZ projection.

• Isometric - A three-dimensional view of part is displayed.

• All Planes - The part is displayed in all four of the views.

The operator may select any of these views by positioning the crosshaircursor on the View screen button and pressing the Select console key.Then using the same method , the operator selects the appropriate screenbutton from the next displayed set of screen buttons.

Here is a screen showing an isometric view of a bolt circle program:

Figure 2-26. Graphics screen with isometric view

Conversational Part Programming

Scaled views appear to the left and at the bottom of the screen , exceptwhen using the isometric view . The displayed views are automaticallyproportioned by the control according to the programmed dimensions ofthe part.

Here is a screen showing four views (All Planes option) of a bolt circle:

3.18V I 3.18V """^^

S.BB 1.B8$ y

-1.18 i -1.18 i

-3.281 Z -3.28 • X

-4.68 -2.58 -8.48 1.78 3.88 -4.88 -1.90 8 .28 2.38 4.48

1.98 2

0.30J ____-----

-2.98-3.88 -1.40 8.28 1.88 3.40

Figure 2-27. Graphics screen showing All Planes

I

Views may be eliminated from the screen using one of the parametersdescribed later in this section.

Ultimax 3 System 5/12/94 2-37

Operator' s Manual

Zoom

The Zoom function enlarges a selected portion of the drawing. A zoomedscreen remains in that state until the operator selects the Full Scale option.Selecting the Zoom function for a plane view does not zoom the otherplane views (i.e., zoom on XY plane does not zoom the XZ plane).

Graphics Parameters

To change the graphics display parameters, position the crosshair cursoron the Parameters screen button and press the Select console key. Thisselection displays a screen with these options:

DRAW SCALES = Yes

C DRAW TOOL PATH = Yes

C DRAW PART SURFACE = Yes

C DRAW RAPID MOVES = Yes

O EXIT PARAMETER ENTRY

Figure 2-28. Graphics Parameters screen

To change the Yes/No value for a parameter , move the cursor to the boxin front of the parameter and press the Select console key until the desiredresponse appears after the equal sign.

2-38 Revision A Hawk 5M Machine

Conversational Part Programming

The menu selections displayed on the Parameters screen are as follows:

Parameter Fields Definitions

Draw Scales controls the display of scales that normally appearto the left and at the bottom of the screen(s).These scales can be removed by selecting the"No" response for this parameter.

Draw Tool Path controls the display of the tool path (center line),shown as dashed lines on the graphics screen.This path is removed from the drawingrepresentation by selecting the "No" response.

Draw Part Surface controls the finished part surface, shown as solidlines on the screen drawing. This view is removedby selecting the "No" response.

Draw Rapid only functional when operating in NC.Moves

Exit Parameter move the crosshair to the box before thisEntry parameter and press the Select console key to exit

the screen and save a parameter changes.

After exiting the parameters screen , the system redisplays the graphicimage of the part.

Ultimax 3 System 5/12194 2-39

Operator' s Manual

Data Block Search

The data block search option allows the operator to move directly from aportion of the drawing that looks incorrect to the data block where it isprogrammed . To use this helpful function , follow these steps:

1. Rotate the trackball to move the crosshair cursor to theDBSearch screen button in the lower right comer of thegraphics screen . Press the Select console key, and the messageshown in the illustration below appears.

3.18 Y

-3.78-4.88 -1.90 8.28 2.38

Set trackball aavo* at waohim operation to find.

Figure 2-29. Identifying a portion for the search

4.40

2. To stop the search, move the crosshair cursor to the Exit boxand press the Select key.

Conversational Part Programming

3. To select the search area, rotate the trackball to move thecrosshair cursor to the desired point in the graphic view andpress the Select key. The data block used to execute the areaindicated by the crosshair appears on the text screen, as shownbelow.

BLOCK 1 HOLES IF DELETE OPERATION

NUMBER 5 DRILL 1TAP I

x CENTER 0 .8080 >>> BOLT CIRCLE F INSERT OPERATION2 BEFORE

V GAITER 0.0000 IF

RADIUS 3.0008 3

START ANGLE 8.088 F PROGRAM4 PARAMETERS

SKIP LIST IF PART SETUP51

F TOOL SETUP6i-P

Press AITER to edit this operation or use ADVANCE. RACE. 7or softIM9 I

F EXITT8

Figure 2-30. Data Block displayed after the search

4. If the cursor is located near a point executed by two adjoiningdata blocks , the first data block in the program representing theoperation nearest the cursor is displayed on the text screen.

5. To return to the drawing , press the Draw console key.

Important

The data block search function can only be used for the XY Plane viewand is inoperative when viewing a running part program.

Ultimax 3 System 5/12194 2-41

Operator' s Manual

Graphics Error Checking

If the graphics system encounters an error while drawing the part, anerror message appears in the lower area of the graphics screen, as shownbelow:

1.40-Y

0.48 j

4-

-8.6W

-1.68 --2.18 -1.19 -6 . 18 8.98

DROP IN BLOOM 2: TOOL 1 IS NOT IN TOOL LIBRARY.1.98

Figure 2-31. Graphics screen error message

To respond to a drawing error message , the operator may do one of thefollowing:

1. Ignore the indicated error, place the cursor on the Exitparameter, and press the Select console key.

2. Find the indicated error, position the cursor on the Find option,and press the Select key. The control automatically activates theedit functions and displays the data block with the error. Afterthe operator corrects the error, the operator can press the Drawbutton again to be certain the part can be drawn without errors.

2-42 Revision A Hawk 5M Machine

IY

Conversational Part Programming

Checking the Part Program

The Ultimax system provides several methods to simplify review andmodification of part programs.

Review Program

Press the Review console key to display the Review Program screen asshown below . The Review Program screen displays a summary of the partprogram data blocks. This screen lists the numbered data blocks , the toolsused and the operations within the holes data blocks . The number oflocations for a Holes data block and the number of patterns executed in aPatterns data block are also displayed.

re REVIEW PROGRAM ee IF

.ILL FRAN C POCK BOUNDARY TOOL 3 12 ROL&S I'

CENTER DRILL TOOL 1 FDRILL TOOL 4 2LOCATIONS NUMBER 2

END OF PR06Rfl F3

F4

FSI'F6

FPACE U. PACE DOW, error keys or enter block venter to 7Vier progren; ENTER to edit highlighted block I 1 1-

FD

Figure 2-32. Review Program screen

Pressing the Enter key with the Review Program screen displayed causesthe control to change to the Part Programming mode for the data blockindicated by the cursor (on Review Program screen).

When the entire part program contains more data blocks than can bedisplayed on one screen , use Page Down and Page Up console keys (inthe Text Screen grouping) to scroll through the listed data blocks. Pressthe End console key to move to the end of the screen, and Home key tojump to the top the of screen . (Simultaneously , press Ctrl plus End tojump the cursor to end of program ; Ctrl plus Home jumps the cursor tobeginning of the program .) Press a numeric key to begin the screen listingat a specific data block number . Use the up and down arrow keys to movethe cursor one data block in the direction selected.

Ultimax 3 System 5/12/94 2-43

Operator' s Manual

Error Checking and Run Time

The screens used to run a part program-Auto, Single, and Test- can allbe used to check for errors in a part program. The operator presses any ofthese three buttons in the Machine Mode grouping on the console. Thenthe operator presses the Check for Errors (F4) softkey. The control beginsits checking at the Start Block indicated on the screen and completes thetest at the End Block . When the check is finished, the estimated run timeand the error status of the program are displayed on the screen. The timerequired for the program to perform this check depends on the length ofthe part program and its complexity.

If the system fords an error, the number of the block containing the erroris listed in the error message . Then the operator must return to partprogramming (from the Input screen ) and make the necessary corrections.Refer to the following section for information about changing the partprogram.

Figure2-33. Part Program Error Checking

To see an estimate of the program running time , press the ComputeEstimated Run Time (F5) softkey. The estimated run time for programexecution is computed from the distances traveled and programmedfeedrates.

2-44 Revision A Hawk 5M Machine

Conversational Part Programming

Changing a Part Program

When an operator wants to change a part program, there are two types ofchanges:

• Changing information within individual data blocks

• Copying, moving, deleting, and modifying entire data blocks

Changing a Block

Operators can return to a previously created part program and makechanges to individual data blocks in exactly the same manner that the datablocks were first programmed . The operator accesses the part programfrom storage as described in the "Getting Started" chapter and presses thePart Programming (F3) softkey on the Input screen.

INPUT « IF PAST SETUP

MASTER PRO07l NAYS SN u1.58 Nae .22'94 1'r

EDIT PART PROGRAM 1.Mm3 METRIC F TOOL SETUPSTANDARD VERTICAL 2

PROGRAM MEMORY AVAILABLE 99 x

Select noftkeg or Press Cntee> to change part Proerow rowe

Figure 2-34. Input screen

kF PART PROGRAMING

F PROGRAM4 PARAMETERSiF

P COPY ADD CHANGEo ELOCRSi

P ERASE FUNCTIONS7

PB

To locate the individual data blocks where the changes are needed, movethrough the data blocks using the console arrow keys and type in thechanges on the appropriate screens.

Ultimax 3 System 5/12/44 2-45

Operator' s Manual

Block Editor

Occasionally, an operator may want to make changes to several datablocks at one time. The Block Editor simplifies this process. The operatorcan copy, move, and delete entire blocks and change feeds and speeds forthe entire program.

To access the Block Editor, the operator presses the Copy and ChangeBlocks (F6) soft key on the Input screen shown below:

» INPUT » IF PART SETUP

NASTER PROGRAM HAWNNSI 91.51 Mar.22'94 L

SPIT PART PROOMM L.Im3 METRIC P TOOL SETUPSTANDARD VERTICAL 2

iF PART PROOANNHIG

FROM M MEMORY AVAILABLE 99 x 3,

F PROGRAM4 PARAMETERS

F5

F 131A4E FUNCTIONSSelect aorthey or Preen enter> to change part Program name 7

F

Figure 2-35. Input screen with Copy and Change Blocks soft key

If the Copy and Change Blocks softkey does not appear on the Inputscreen, the system has been set to lock out part programming functions.Refer to the keyswitch and program protection material in the "GettingStarted" chapter for more information and contact a supervisor to switchon the part programming functions.

Conversational Part Programming

The Block Editor screen has these softkey options:

BLACK EDITOR

Choose appropriate aoftiay

EMERGENCY STOP HAS BEEN DEPRESSED.PRESS MAONL MODE. POYER . AND START TO RESTORE POYEI.

Figure 2-36. Block Editor screen

F COPY BLOCKS

F MOVE BLOCKS21

F DELETE BLACKS3

F MODIFY4 DIMENSIONS

F CHANGE ALL TOOLS5 FEEDS a SPEEDS

F CHANGE FEEDS a6 SPEEDS BY TOOLIF EMIT7

IFB

• Copy Blocks (Fl) - allows the operator to indicate specific blocknumbers to be duplicated into another location in the part

program.

• Move Blocks (F2) - allows the operator to indicate specific blocknumbers to be moved to a different location in the part program.

• Delete Blocks (F3) - allows the operator to indicate specificblock numbers to removed from a part program.

• Modify Dimensions (F4) - allows the operator to add offsets tothe Y. Y, and Z axes coordinate dimensions currently stored inthe part program.

• Change All Tools Feeds & Speeds (F5) - allows the operator tosubstitute new feeds and speeds for all of the tools within thespecified data block number range.

• Change Feeds & Speeds by Tool (F6) - allows the operator tosubstitute new speeds and feedrates for a specified tool within adata block range.

• Exit (F7) - displays the Input screen.

Uldmax 3 System 5/12194 2-47

Operator' s Manual

All of the Block Editor functions require the range of blocks to be definedby a Start Block and an End Block number . Refer to the illustrationbelow . The End Block number must be the same as or greater than theStart Block number, or an error message will appear.

After entering data on the Block Editor screen , the operator must press theMake the Changes (F8) softkey to perform the change operation.

Figure 2-37. Block Editor features

If the operator presses the Exit (F7) softkey without first pressing theMake the Changes softkey , the data entered on the screen will not beapplied to the part program. In other words , pressing the Exit softkey is amethod of throwing away the changes and returning to the Input screenwithout altering the part program.

2-48 Revision A Hawk 5M Machine

Conversational Part Programming

Copying and Moving Blocks

When the operator selects the Copy Blocks (Fl) or Move Blocks (F2)softkey, the operator must enter the number of the block that the blockswill be put before . The Put Before Block field marks the beginninglocation of the range of blocks that will be inserted in the program. ThePut Before Block number must be outside the start /end range specified bythe Start Block and End Block numbers (and can be greater than the lastblock in the part program .) The blocks are automatically renumbered afterthese functions are executed.

Pressing the Copy Blocks (F1) softkey allows the specified data blocks tobe duplicated at another location in the part program . Here is a BlockEditor screen with the Copy Blocks fields displayed.

START BLOCK

DID RACK

PUT BEFORE BLACK

0

BLOCK EDITORF1iF /IOUs BLOCKS2

F DELETE RACKS3

F MODIFY4 DIMENSIONSk

F CHANCE ALL TOOLS5 FEEDS A SPEEDS

F CMeICE FEEDS A6 SPEEDS BY TOOLi

F EXITEnte w bor of desired block

DMRCDICY STOP HAS BEEN DEPRESSED.PRESS MAM AL MODE. POWER . AND START TO RESTORE POWER.

FB

7

Figure 2-38. Block Editor with Copy Blocks fields

Pressing the Move Blocks (F2) softkey allows the specified data blocks tobe removed from their current location and transferred at another locationin the part program . The Move Block fields are identical to the CopyBlock fields.

Ultimax 3 System 5/12194 2-49

Operator' s Manual

Deleting Blocks

The Delete Blocks (F3) softkey allows the specified data blocks to beremoved from the part program. The operator only needs to type in theStart Block and End Block numbers and to press the Make the Changes(F8) softkey to remove a group of data blocks from a part program.

Here is a Block Editor screen with the Delete Blocks fields highlighted:

START BLOCK

EMD BLOM

0BLOCS EDITOR

F COPY BIACEST

P MODE ELOCRS2

F3

F MODIFY4 DIMENSIONS

F OWNDE ALL TOOLS5 FE®S a SPEEDS

Einar noaber of desired block

F CHANCE FEEDS &6 SPEEDS BY TOOLi

P EXIT7

DIRNCDIICV STOP Wig BEEN DEPB68SED. tFREES IWtIAL MODE . PORED , AND START To RESTORE PORED. S

Figure 2-39. Block Editor with Delete Blocks fields

Conversational Part Programming

Modifying Dimensions

This softkey function allows offsets to be added. to the X, Y, and Z axescoordinate dimensions stored in the programmed data blocks.

BLOCK EDITOR

STAIR BLOCK I

END BLOCK

X OFFSET 8.600

V OFFSET B.BBB

Z OFFSET B. BBB DON'T CHANGE E-START

Enfmp nunbm of chaired block

F COPY BLOCKS1

F MOUE BLOCKS2

F DELETE BLACKS3

FF4

F CHANGE ALL TOOLS5 FEEDS & SPEEDS

I

F CHANGE FEEDS d6 SPEEDS BY TOOL

FP EXIT7i

EMERGENCY STOP HAS BEEN DEPRESSED. FPRESS VANDAL NODE. POWER, AND START TO RESTORE POWER. B

Figure 240. Block Editor with Modify Dimensions fields .

To modify the dimensions , enter the Start and End Block numbersdefining the range of data blocks to be modified . Then type in the offsetsthat will be added to the dimensions of this range of data blocks. Enteronly those values that need to change.

When the cursor arrives at the Z Offset field, the Don 't Change Z-Startmessage and the Don ' t Change Z-Start (FI) softkey appear on the screen.Us one of these methods to change the Z Offset value:

1. To leave the Z Start values unchanged , the operator presses theDon't Change Z-Start softkey. But, the operator can enter the ZOffset value as required, and then all Z axis coordinates will bemodified by the entered dimension except Z Start values.

2. If the Z Start values must be changed , the operator presses theDon't Change Z-Start (Fl) softkey to remove the Don 't ChangeZ-Start message from the screen . Then the operator types in thenew Z Offset value . All of the Z axis coordinates will bemodified by the entered dimension including Z Start.

Ultimax 3 System 5/12/94 2-51

Operator's Manual

Changing Feeds and Speeds

The operator may change the speeds and feedrates for all of the tools usedin a program or only specified tools. To make changes to all of the tools,the operator selects the Change All Tools Feeds and Speeds (F5) softkey,and the fields shown below appear on the Block Editor screen:

BLOCK EDITOR 1

F START DLALS 1 COPY HLOCES

END BLOCK P MOOS DLOCDS2

F DELETE DLOCESNEW SPEED (lip") 3

,NEW FEED F MODIFY

DIMENSIONSNEW PLUNGE FEED

F

FMW TOOL

NW FINISH TOOL

Enter amber or desired block

DIDOICtICY STOP IIAS BEEN DEPRESSED.PRESS HAIWIL MODE . POWER. AND START TO RESTORE PORED.

Figure 241. Change AU Tools ' Feeds and Speeds

5iF CHA)GE FEEDS A6 SPEEDS BY TOOLi

F' SKIT7

FB

Follow these steps to change the speeds and feeds:

1. Program the Start Block and End Block to define the range ofdata blocks where the spindle speed , plunge feeds and millfeeds are to be changed.

2. Enter the values for New Speed (RPM), New Feed and NewPlunge Feed fields.

3. Blank fields do not change. A programmed value can bechanged back to a blank parameter by moving the cursor to theparameter and pressing the Clear and Enter keys to remove thenew value.

4. The New Tool and New Finish Tool parameters allow new toolsto be programmed in the specified range of data.

Conversational Part Programming

The Change Feeds and Speeds by Tool (F6) softkey allows new values tobe substituted for the programmed speeds and feedrates of a specified toolwithin the defined range of data blocks. The fields shown below appear onthe Block Editor screen:

START BLOCK

Elm BLOCK

CHAN=E TOOL MURDER

NEW SPEED (RPM)

NEW FEED

NEAT PLUM=E FEED

NEW TOOL

NEW FINISH TOOL

BLOCK EDITORF COPY BLOCKS1

Enter number of desired block

PRESS MANUAL MODE. POWER . AND START TO RESTORE POWER.

Figure 2.42 . Change Feeds and Speeds for I Tool

F MOWS BLOCKS2

F DELETE BLOCKS3

F MODIFY4 DIMENSIONSiF OMME ALL TOOLSS FEEDS I SPEEDS

F t7AAMW 722614f!

F EXIT7

F8

Follow these steps to change the speeds and feeds for a tool:

1. Program the Start Block and End Block to define the range ofdata blocks where the spindle speed , plunge feeds and millfeeds are to be changed for the selected tool.

2. With cursor at the Change Tool Number field, enter the numberof the tool to be affected. Changes will be made only to blocksusing this tool.

3. Enter the values for New Speed (RPM), New Feed and NewPlunge Feed fields that apply to this tool.

4. Blank fields do not change . A programmed value can bechanged back to a blank parameter by moving the cursor to theparameter and pressing the Clear and Enter keys to remove thenew value.

5. The New Tool and New Finish Tool parameters allow new toolsto be programmed in the specified range of data blocks toreplace the tool specified by the change tool number.

Operator' s Manual

Running a Part Program

After the part program contains all necessary information to cut the part,the operator often wants to perform a test run and then run the program tocut the part. The buttons to access these functions are on the elevatedportion of the Ultimax console in the area labeled Machine Mode. Thereare three Machine Mode buttons used to run part programs:

• Auto - used to run an entire program or selected blocks

• Single - allows the operator to run the program a block at a time

• Test - permits the operator to run the part program above thework piece

Refer to the "Running Part Programs" section later in this chapter formore detailed information about running part programs and restartingstopped programs.

Conversational Part Programming

Test Run

The Test button allows the operator to verify the part program using thescreen shown below. Operators often use the Dry Run option as a safeway to run the part program and identify potential problems.

M TESTIM -

RUNNING PAST PROGRAM 6061.HD3

ESTIMATED RUN TIME F FEED a SPEED2 OPTIMIZATION

FSTART RLOCR I 1 3

END BLOCII 36 F CIBCR FOR ERRORS4

1

F COMPUTE ESTIMATED5 RUN TIME

Enter amber of desired black

IF6

IF

F7

B

Figure 2.43. Test Run screen

When executing the part program in Dry Run, peck cycles and roughingpasses are skipped . When operating in a dry run , the tool traces the toolpath with the spindle off and the tool above the work piece. Beforeattempting execution, the operator enters the minimum Z dimension foroperating in this test cycle . During this test, the tool traces over the part atthe dimension entered.

Caution

If the Z Start dimensions are set below the surface of the rough stock, theminimum Z dimension for this operation must be programmed so the tooldoes not plunge into the part.

Operator' s Manual

Feed and Speed Optimization

To fine tune the program execution, the operator presses the Feed andSpeed Optimization (F2) softkey on the Test Run screen (shown on theprevious page) to display this screen:

FEED a SPEED OPTIMIZATION « IF SET SPEED

PART Ii.BBBB TOOL IN SPINDLE B 1-6.0000 SPINDLE B F

PEED NOTION STOPPED 2

P SET PLUME OR3 SE61®IT PEEDi

AXIS LOAD MONITOR BI.OCII Na1BIBft B P4

20 40 60 00 100 x PART CDUR B 1x F SET FRED

SVZ s iS F

6

Adjust cemrides rbile cutting and press eottksy to clanreal union in prograc blockPRESS START TO RBN PROGRAM.

Figure 2.44. Feed and Speed Optimization screen

F7

FB

Using the information displayed on this screen, the operator can use theAxis Feed Rate dial on the jog unit to adjust the values and produce thebest results. The operator may also change the current values by pressingthe Set Speed (Fl), Set Plunge or Segment Feed (F3) and Set Feed (F5)softkeys and typing in the desired values.

2-56 Revision A Hawk 5M Machine

Conversational Part Programming

Auto

To run a part program, press the Auto console button in the MachineMode grouping. This screen appears:

AUTO .. IF

RUNING PART PROGRAM 6861.ND3 1

ESTIMATED RUM TIME 0:19:00 Fa

PSTART BLOC! I 1 3

HID BLOC! 36 F CIUC! FOR ERRORS4IF COMPUTE ESTIMATED5 RUN TIME

F RECOVERY6 RESTART

FInter nowber of deelred block 7

NH ERRORS POUND IN PROGRM.

Figure 2-45. Auto screen with soft key options

F IM PROGRAM

Check the Start and End Block numbers and make any changes needed torun only a portion of the program.

Operator 's Manual

Press the Run Program (F8) softkey to start the program and display thisscreen:

XYz

AUTO « IF RESET PART COUNT

PART nACHINE VERTICAL 18.8958 TOOL IN SPINDLE 1 I

-8.8397 SPINDLE 2888H F8.0250 PRO 37.5 2

F3

AXIS LOAD MONITOR BLOCK MUDEI 7 FMILL MAKE 4

20 48 E8 80 188 R PART COUNT 2 fX FS. S2 L

PROGRAM IS 11M11MG.

Figure 2-46. Auto screen with a running program

FS

FF7

F8

If the system identifies any errors during the part cutting process, errormessages appear on this screen.

Conversational Part Programming

If the operator observes a problem during the cutting process or simplywants to stop the machine to make some adjustments, the operator maypress one of three buttons to stop motion:

• Motion Hold - stops all axes movement, except a tap operationwhen tool is in the programmed feedrate region. Pressing thebutton a second time allows machine positioning to resumewithout loss of position, provided no other button or key hasbeen pressed.

• Interrupt Cycle - halts machine operation during automaticexecution of a program to allow manual functions to beperformed. Pressing the button a second time returns themachine to the interrupted location and allows automaticprogram execution to resume from the point of interruption.

Emergency Stop - all motion stops and power is shut -off to thespindle , relay control , and servo systems . An emergency stopmessage with recovery instructions appears at the bottom ofleft-hand screen . To release an Emergency Stop button, twistthe button in the direction indicated by the arrows and pull thebutton up.

If the operator presses the Emergency Stop during the execution of a partprogram, the operator should jog the tool clear of the part before resumingoperation.

Refer to the "Recovery and Restart" section at the end of this chapter forinformation about restarting a part program.

Uldmax 3 System 5/12/94 2-59

Operator' s Manual

Concurrent Programming

Concurrent Programming allows the operator to create or edit a partprogram and/or read a part program from disk into memory, whilesimultaneously machining a part using a different part program.Concurrent Programming is possible only when using the Auto screen torun the program.

When using Concurrent Programming , two-part programs aresimultaneously available. To enter Concurrent Programming whilemachining a part , press the Input key. The Auto screen is replaced by theInput screen.

INPUT ww

MASTER PROGRAM MANX SM 91.58P

EDIT PART PROGRAM CYCLE5.103

IMG PART PROGRAM SASCVKU.HD3

PROGRAM MEMORY AVAILABLE 99 c

F PART SETUPMsy.B6'94 i

III F TOOL SETUPVERTICAL 2

F PART PROGRAMING3

4 PARAMETERSl

FG

F COPY AND CHANGE6 BLACKS

F Selectso'tkey or Press ai,tn> toChang

e Pert Program news 7

B

Figure 2-47. Input screen with program running concurrently

This screen has an extra field, Running Part Program , that identifies theprogram currently running . This screen always lists the program IDnumbers for both the running part program and the edit part program. Thegraphics screen blanks to prepare for the new part program graphics. TheID number for the new part program may be entered in the Edit PartProgram field. Then the operator can use the part programming features tocreate or change data blocks.

2-60 Revision A Hawk SM Machine

Conversational Part Programming

To run the new edit part program or to edit the running part program:

1. Wait for the running program to finish , or stop this programfrom being executed by pressing Motion Hold console buttonand Spindle Off key.

2. Press the Input key.

3. Press the Exchange Edit/Run Programs softkey. This softkey isonly displayed on the Input screen if machine is not running aconcurrent program.

Ultimax 3 System 5/12194 2-61

Operator' s Manual

Printing a Program

Many operators print copies of their programs to keep on file for futurereference. To access the Ultimax printing facility, press the Auxiliaryconsole key. Then press the Download/Upload (F3) softkey, and thisscreen appears:

M MDIILIARY - IF UPLOAD

Make certain the proper cable is connected betreen the 1 RECEIVEselected pert on the will and the peripheral device.

UPLOAD : 1) Press UPLOAD sot they . F PRINT CURRENT2) Send program free peripheral device . 2 DIRECTORY

DOWNLOAD : 1) Open file to receive data at the peripheral I2) Press DOIRBAAD sot they . P DOWNLOAD3) If necessary , Close the tile on the 3 SEND

peripheral device attar transfer is done.All PRINT PROGRAMPRINT: 1 ) Select the PRINT PROGRAM sot they. /P

PORT RIMIER 1PROTOCOL XON/XOflBAUD RATE 96MCHARACTER LENGTH 7STOP BITE 1.5PARITY EVEN

Choose appropriate sot they

Figure 2-48. Auxiliary screen with Print Program so/tey

5

P RESET PORT6 PAPoRITERS

F SERIAL PORT7 SETUP

F EXITB

When the operator presses the Print Program (F4) softkey, the partprogram currently in temporary memory prints on the printer connected tothe machine 's parallel port . Ultimax supports the following dot matrixprinters:

• Epson FX

• Citizen MSP-10 and MSP-55

Refer to any of the sample programs in this chapter to examine thestructure of printed programs from the Ultimax printing facility.

2-62 Revision A Hawk 5M Machine

Conversational Part Programming

Program Identification and Storage

To store a part program in permanent memory on the hard drive, press theAuxiliary key on the console and then press the Storage Functions (Fl)softkey. The Current Program screen appears:

CUSIDDIT PROGRAM

CURRENT DISK HARD DRIVE C

Choose appropriate oaf they

Figure 249. Current Program screen

F READ PROGRAMFROM DISK

F WRITE PROGRAM2 TO DISK

F DISK OPERATIONS3 LIST DIRECTORY

1F FORMAT DISKETTE4

FS

F SELECT CURRENT6 STORAGE DRIVE

F7

F EXIT8

File Naming

The part program name may contain up to eight characters. To type in anew program filename, display the Input screen either by pressing theInput key or by pressing the Exit (F8) softkey when the MachineConfiguration screen appears at start-up. Then follow these steps to enterthe filename:

1. Press the Enter key to display the Letter Selection screen on theright monitor.

2. Use the trackball on the console to move the crosshair indicatoron this screen.

3. When the crosshair is positioned over the desired character,press the Select key.

4. The selected character then appears in the Edit Part Programfield.

Operator 's Manual

5. Select up to 8 characters for the filename. The system adds the3-character extension (usually HD3) to the end of the filename.Use the numeric keys on the console to enter 0 through 9 intothe name. Select letters for the name from the Letter Selectionscreen, shown below, using these steps.

a. With text cursor indicating edit part programparameter, use trackball to move graphics cursor toselect each character.

b. When the crosshair cursor indicates the desiredcharacter, press the Select console key to record theselection onto the text screen

c. Press Enter key to record the selected ID for the partprogram.

Space ! # $ % &

• + , - / 0 1 2 3

4 5 6 7 8 9 ;

? @ A B C D E F G

H I J K L M N 0 P Q

R S T U V W X Y Z

BackSpace

Enter

Figure 2-50. Letter Selection screen (graphics screen)

2-64 Revision A Hawk SM Machine

Conversational Part Programming

File Storage Facilities

The operator may store a program on the control's hard drive or on afloppy disk. Press the Select Current Storage Drive (F6) softkey toindicate the name of the drive that will be used for storing the program.

CURRENT PROGRAM

CURRENT DISK HARD DRIVE C

IF READ PROGRAMI FROM DISK

F WRITE PROGRAM2 TO DISKiF DISK OPERATIONS3 LIST DIRECTORYIF FORMAT DISKETTE4

FS

Choose appropriate sorthey

Figure 2-51. Current Program screen

Part programs can be stored on the control hard drive and/or floppydiskettes . The control ' s standard four (4) Megabytes of memory reservesapproximately 1.6 Megabytes in active memory for storing conversationaland NC part programs . An option is available to increase the memory sizeto eight (8) Megabytes.

A 3.5" floppy disk drive is located at the right side of the console andprovides up to 1.44 Megabytes of storage for conversational or NC partprograms. The system reads, writes, and formats diskettes in the MS-DOSformat; 1.44 Megabyte or 720 kilobyte diskette formats are supported.

Ultimax 3 System 5/12/94 2-65

Operator's Manual

Holes OperationsThis section presents detailed descriptions of the Hole drilling options inUltimax 3. The chart below shows the relationship of the hole drillingoptions to the Input button and its subsequent softkey selections.

Hole Operations Hierarchy ChartInput Button

Part Programming (F3)

Part Setup (Fl)

Tool Setup (F2)

Position (Fl)

Holes (F2)

Milling (F3)

Patterns (F4)

Miscellaneous (F5)

Special (F6)

Rotary (F7)

Exit (F8)

Drill Operations (F1)

- Drill (Fl)

- Center Drill (F2)

- Counterbore (F3)

- Spottace (F4)

- Countersink (F5)

Gun Drill (F6)

Tap (F2)

Bore and Ream Operations (F3)

- Bore (Fl)

- Ream (F2)

- Bore Rapid (F3)

- Bore Orient (F4)

- Ream Rapid (F5)

Back Spottace (F4)

Bolt Circle (F5)

Locations (F6)

Figun 2 52. Hok Operation Hierarchy Chart

2-66 Revision A Hawk 5M Machine

k

Conversational Part Programming,

To access the hole drilling options, the operator presses the Input buttonon the console and then the Part Programming (F3) softkey. When theNew screen appears, the operator presses the Holes (F3) softkey to displaythe screen shown below:

BLOCK I HOLE

»>I No

IF DRILLI OPERATIONS

Choose appropriate tattling

Figure 2-53. Holes screen with option soft keys

F TAP2

F BORE AND REAM3 OPERATIONS

F BACK SPOTPACE4

SIF6

F7

IF EXIT8

Ultimax 3 System 5/12194 2-67

Operator' s Manual

Drill Operations

In a drilling operation, the table positions to the programmed X and Ydimensions followed by Z axis positioning to the programmed retractclearance. The rate of axis positioning is at rapid traverse. When thesecoordinates are reached, the Z axis moves at rapid traverse to Z Start andthen at programmed plunge feed rate until reaching the Z Bottomdimension . The Z axis dwells the time specified and rapid traverses to theretract clearance. (The rapid traverse rate, retract clearance and drill dwellare selected in Program Parameters or Change Holes Parameters.)

Select the Drill Operations softkey on Holes screen to display the screenshown below:

BLOCS 1 HOLES IF DRILL

TOOL B )»I DRILL 1

Z START B.BBBB F CENTER DRILL2

2 BOTTOM 8.8088 ',----F COUNTERBORE

PLIRIGS FEED 0.0 3

SPS® (M ) B F SPOTFACE4

FECR DEPTH 0.001311 ;F COIMTERSIMS

PEQ TYPE STANDARD 5

TOOL NOT PAOGRAM®

Clow opmrat)ot.

Figure 2-54. Holes screen with Drill Operations soft keys

1 GIN DRILL6

F7

FB

When the Drill Operations screen first appears, the cursor flashes at theDrill parameter. This flashing cursor indicates an operation that can beselected. Pressing the Enter key stores the indicated operation in memoryand the cursor moves to the tool number parameter. (To choose any of theother operations, select the corresponding softkey and press Enter key.)

Conversational Part Programming

The available drilling operations do not differ in the physical operation ofthe machine, with the exception of the gun drill operation. The operatordetermines the type of tool used for the operation and how the hole will bedrilled. The common uses of the drill operation softkeys are describedbelow:

• Drill (Fl) - creates holes that may be complete or may be used asthe starting points for additional drilling operations.

• Center Drill (F2) - used when the work piece is very rigid tocreate a guide hole for the drilling tool that will be used tocomplete the hole. Center drilling helps keep holes their properlocations and prevent runout.

• Counterbore (F3) - enlarges the end of a previously drilled hole.This operation is often used to create an enlarged area at the endof the hole to accommodate a bolt, cap screw, or pin.

• Spotface (F4) - this variation of counterboring smoothes andsquares the surface around a previously drilled hole to provide aseat for a bolt head, a nut, or the shoulders on mating members.

• Countersink (F5) - enlarges the top end of a hole to a cone shapeto accommodate the head of a flat or oval headed machine screw.The hole is enlarged so that when the screw is inserted in the holethe screw head will be flush with or slightly below the top of thework piece surface

• Gun Drill (F6) - used to position and start a drilling operationusing a very long tool that drills deep holes, as if drilling out thecenter of a gun barrel.

Important

It is important to remember that all operations programmed in a givendata block are performed at all locations specified in that block.

For example, if Center Drill and Drill operations are programmed in thesame data block, all locations specified in that block are center drilled andthen drilled.

Ultimax 3 System 5/12/94 2-69 '

Operator's Manual

The fields used to describe any of the Drill Operations are as follows:

Fields

Z Top

Z Start

Z Bottom

Z Top Feed

Plunge Feed

Speed (RPM)

Spindle Stop

Peck Depth

Peck Type

Definitions

The starting point of the drill cycle. The toolmoves rapidly to this point and then slowly movesinto the starting location.

The location where the spindle begins to rotate.

The bottom of the finished hole.

Rate at which the tool moves from the Z Topposition to the Z Start position.

Feedrate between the Z Start and the Z Bottompositions.

Speed at which the spindle rotates to drill thehole.

Point at which the spindle stops rotating afterdrilling the hole. This may be set to be the ZBottom or the Z Start position.

Distance that the tool will drill down into the partbefore stopping to clear out or break the chips. Ifthis parameter is used , it is usually not larger thanthe diameter of the tool.

This field has two options that indicate whetherthe drill will pull out to the Z Start after reachingthe Peck Depth (Standard) or simply dwell at thePeck Depth (Chip Breaker).

2-70 Revision A Hawk 5M Machine

Conversational Part Programming

Here is a sample completed hole drilling screen:

BLOCK I

TOOL

HOLES

1 >>> DRILLF DELETE OPERATION1

LOCATIONS IZ START 0.0200 F INSERT OPERATION

Z BOTTOM -0.588112 BEFOREI

PLUNGE FEED 25.8F3

SPEED (RPM) 1588 F PROGRAM

PECK DEPTH 6.1108014 PARAMETERSI

PECK TYPE STANDARDF PART SETUP5i

(TOOL DIAMETER 8.2918) F TOOL SETUP(TYPE DRILL) 6

FPress ENTER to edit this operation m• use ADVANCE , BACK, 7or sotthey I

F EXIT8

Figure2-55. Completed Drill Data Block

When the Tool number for the operation is programmed (and the Enterkey pressed), the tool diameter and type appear in parentheses . The valuesindicated are programmed during Tool Setup and cannot be changed in adrilling data block. (The Program Parameters , Part Setup and Tool Setupsoftkeys also appear to provide access to these programming options.)

Ultimaz 3 System 5/12/94 2-71

Operator' s Manual

The Z Start parameter is the dimension where the Z axis plunge feed ratebegins. The Z Bottom parameter is the point of maximum Z-down and thedimension where the plunge feed rate ends.

The diagram below shows the relationships of the field names to positionsof the drilling tool to the work piece:

RapidTraverse Head

Part

Retract Clearance PlaneZ Start Plane

Plunge Feed

Z Bottom

Table

Figure 2-56. Reference Points Relative to Drift Operations

The Plunge Feed parameter is the feedrate between Z Start and Z Bottomparameters . The value initially displayed is calculated by the control,based upon the values programmed for the tool during Tool Setup. Ifdesired, a different value can be entered for this parameter (when it isindicated by the cursor).

The value initially displayed in Speed (RPM) parameter was programmedfor the designated tool during Tool Setup . If this parameter is to remainunchanged, press Enter key. A different speed can be programmed forthis specific block (to override the displayed value).

The Peck Depth parameter is the dimension the tool is to advance duringeach peck.

Hints and Tricks

As a rule, the Peck Depth value should not exceed the tool diameter.

2-72 Revision A Hawk 5M Machine

Conversational Part Programming

If a specific number of pecks is desired, the value for Peck Depth can becalculated by determining the absolute distance between Z Start and ZBottom and dividing that value by the desired number of pecks. Forexample: a distance of 1.0000 inch between Z Start and Z Bottom dividedby peck depth of 0.2500 inch requires four (4) pecks to drill the hole.

The Peck Type parameter provides a choice of Standard and Chip Breakersoftkey functions:

1. If Standard is selected, the tool retracts to the Z Start and thenrapidly plunges to the peck clearance plane selected in ProgramParameters or Change Parameters.

2. If Chip Breaker is selected, the tool dwells at each peck levelbefore continuing to feed to the next peck level. (Drill dwell isthe time selected in Program Parameters or Change HolesParameters.)

When all values are programmed, the available softkeys are DeleteOperation , Insert Operation Before and Exit.

1. Selecting the Delete Operation clears this programmed drilloperation.

2. Selecting the Insert Operation Before softkey to add anotherhole operation before the current one.

3. Pressing Exit softkey returns to the previous screen level.

Pressing the Advance key displays a new Holes screen except the previousprogrammed operation appears above the multiple cursor (which nowindicates new). The softkey functions of Bolt Circle and Locations added.

Additional operations for this block can be programmed. If desired, theoperator can program another Drill operation (i.e., a counterbore orspotface), a Tap operation , Bore and Ream Operations , Bolt Circlepattern , or hole Locations.

Ultimax 3 System 5/12/94 2-73

Operator' s Manual

Drill

The operator uses an Ultimax Drill operation to make a variety of holesusing a wide range of drill bits. See illustration below. The holes producedfrom this operation are often used as the starting points for additionaldrilling operations such as boring, reaming, or tapping.

Figure 2-57. DriUBit

Caution

For all drilling operations, the operator must be aware of the particularcharacteristics of the drill bits being used. The system does not keep trackof the type and length of flutes on the bits nor the shapes of drills withpilots or other multiple-diameter drills. The operator must consider thesetool features when programming a part and must re-evaluate the tool setupfor programs that are being reused.

Conversational Part Programming

Center Drill11

When an accurate and true center is needed for the start of a drillingoperation , the operator selects the Center Drill (F2) softkey from the DrillOperations options. Center drilling the holes helps guide the drilling toolinto the proper location. Usually center drills are special tools with shortflutes, but a standard drilling tool may be used to create these startingholes.

Center drilling is often used when the work piece is very rigid and, at thestart of a drilling operation , the tool might "walk" away from the correctposition . Center drilling is also used when centers are needed for partsthat are being turned between two centers in following operations.

BLOCK 1 HOLES IF DELETE OPERATION

TOOL 1 >>> CENTER DRILL Ii

Z START B .am F INSERT OPERATION2 BEFORE

Z BOTTOM -6.5999 IF

PLIRIf.'E FEED 8.5 3

SPEED (RPM) 259 P PROGRAM4 PARAMETERS,T PART SETUP5i

(TOOL DIAMETER 9.5899) F TOOL SETUP(TYPE DRILL)

Pews ENTER to edit this operative or use ADOAMCE , BACK. 7or satiny

Figure 2-58. Center Drill Data Block

Ultimax 3 System 5/12/94 2-75

Operator' s Manual

Counterbore

An operator uses the counterbore option to enlarge the end of a previouslydrilled hole. This operation creates an enlarged area at the end of the holeto accommodate a bolt, cap screw or pin. These square-shoulder fastenerscan then be inserted flush with the top of the part or slightly below thesurface of the material.

BLOCX 1 HOLES (F DELETE OPERATION

TOOL 1 )» COIB(TERBORE 1

Z START 8 .0388 F INSERT OPERATION2 BEFORE

Z BOTTOM -8.6580 IF

PLUNGE IUD 5.0 3

SPEED (RPM) 758 F PROGRAM4 PARAMETERS

F PART SETUP5

(TOOL DIAMETER 0.5000) F TOOL SETUP(TYPE DRILL) 6

FPress ENTER to edit this operation or use ADVANCE, BACK, 7or sottkey I

F EXITB

Figure 2-59. Counterbore Operation

2-76 Revision A Hawk 5M Machine

Conversational Part Programming

Spotface

The Ultimax Spotface operation smoothes and squares the surface arounda previously drilled hole to provide a seat for a bolt head, a nut, or theshoulders on mating members. The spotfacing operation is, therefore, ashallow counterboring operation . Spotfacing is commonly used when thesurface of the part is uneven as it is on a casting.

BLOCK I HOLES IF DELETE OPERATION

TOOL 1 >>> SPOTFACE

Z START 0.0400 P n6ER7 OPERATION2 BEFORE

Z BOTTOM -1.0808 iF

PLIEIOE FEED 5.0 3

SPEED (EPM) 750 F PROO(dl4 PARAMETERSI

P PART SETUP5i

(TOOL DIAMETER B.S008) P TOOL SETUP(TYPE DRILL)

IP

Press BITER to edit this operation or use ADII (tlICE. BACK. 7or softkey

F EXITa

Figure 2-60. Spotface Operation

Operator' s Manual

Countersink

An operator uses the countersink operation to enlarge the top end of a holeto a cone shape to accommodate the head of a flat or oval headed machinescrew. The hole is enlarged so that when the screw is inserted in the holethe screw head will be flush with or slightly below the top of the workpiece surface (see below).

Figure 261. Countersunk screw head

The countersink operation may also be used to remove burrs or excessmaterial that fell into drilled or counterbored holes. The standardcountersink has an 82° included angle. Here is a completed Countersinkoperation screen:

BLOCS 1 HOLES

TOOL I >>> COUNTELCINX

Z START 8.8388

Z BOTTOM -e.5888

PLINEE r® 5.8

SPEED (RPM) 758

(TOOL DIAMETER 8.51168)(TYPE DRILL)

IF DELETE OPERATION1

P INSERT OPERATION2 BEFORE

P3

7 PROGRAM4 PARAMETERS

F PART SETUP5

iP TOOL SETUP6

PProse ENTER to edit this operation or use ADUN$CE, BACK, 7or sorthey I.

Figure 262. Countersink Operation

P EXIT8

2-78 Revision A Hawk 5M Machine

Conversational Part Programming

Gun Drill

An operator selects the Gun Drill feature when using a very long tool anddrilling deep holes, as if drilling out the center of a gun barrel. A long,rotating tool may whip off center when approaching the cutting surface,so a drilling cycle that controls the approach to the work piece andcorrects positioning of the tool is required.

The Ultimax Gun Drill selection positions the tool without rotating thespindle . This allows the tip of the tool to position precisely in a pre-drilledstarting hole, as shown in the diagram below.

Long tool moves Intoposition with the spindle onto avoid whipping

Pm-drilledStarting Hole_

Figure 2-63. Gun Drilling

Ultimax 3 System 5/12/94 2-79

Operator' s Manual

To use the Gun Drill features, the operator must always perform threetasks:

• Describe the gun drill tool during Tool Setup

• As the first step in part programming, create a starting hole forthe drill

• Then create a Gun Drill data block in the part program

Each Gun Drill data block must contain at least two operations: onedescribing the starting hole and one for the gun drill hole.

To create a Gun Drill data block, the operator begins on a New data blockscreen and follows these general steps:

1. Press the Drill Operations (Fl) softkey.

2. Create the first paragraph of the data block by describing thestarting hole portion of the data block . Select either the Drill(Fl) softkey or the Center Drill (F2) softkey. Type in thedescription of the starting hole into the fields displayed on thescreen.

3. When all of the starting hole data has been entered, the operatorpresses the Advance (right arrow) console key to begin thesecond paragraph in this data block.

4. Press Drill Operations (Fl) softkey and then the Gun Drill (F6)softkey.

Conversational Part Programming

The fields describing a Gun Drill operation vary slightly from the standarddrilling operation fields: '

Fields Definitions

Z Top The starting point of the gun drill cycle. The toolmoves rapidly to this point and then slowly movesinto the pre-drilled starting hole.

Z Start The position inside the pre-drilled hole where thespindle begins to rotate.

Z Bottom The bottom of the finished hole.

Z Top Feed Rate at which the tool moves from the Z Topposition to the Z Start position.

Plunge Feed Feedrate between the Z Start and the Z Bottompositions.

Speed (RPM) Speed at which the spindle rotates to drill thehole.

Spindle Stop Point at which the spindle stops rotating afterdrilling the hole. This may be set to be the ZBottom or the Z Start position.

Peck Depth Distance that the tool will drill down into the partbefore stopping to clear out or break the chips. Ifthis parameter is used , it is usually not larger thanthe diameter of the tool.

Peck Type This field has two options that indicate whetherthe drill will pull out to the Z Start after reachingthe Peck Depth (Standard) or simply dwell at thePeck Depth (Chip Breaker).

Ultimax 3 System 5/12/94 2-81

Operator' s Manual

Here is a sample, completed Gun Drill description:

BLOCS 1 HOLES IF

TOOL I CENTER DRILL I>>> GUN DRILL

2 TOP • 8.8888 FZ START -5.3888

FZ BOTTOM -5.8888Z TOP FEED 28.8 FPLUNGE FEED 18.8 3

SPEED (RPM) 288 F PROGRAMSPINDLE STOP Z BOTTOM 4 PARAMETERSPECK DEPTH 8.2588 I

PECK TYPE STANDARDF PART SETUP5

(TOOL DIAMETER 8 .2588) F TOOL SETUP(TYPE GUN DRILL) 6

FFEnter disensloe at which Z TOP feed'ate begins with the 7spindle at sere RPM.

F E(IT8

Figure 2.64. Completed Gun Drill Data Block

Conversational Part Programming

The following illustration shows the Gun Drill program fields as theyrelate to a part and the drilling tool:

Move atRapid Traverse teedrate

down to Z Top

Figure 265. Gun Drill Positions

l/ltiimax 3 System 5/12/94 2-83

Operator' s Manual

Locations

This softkey function allows Hole operations to be placed at selectedpoints in the part program. All Locations programmed in a blockcontaining a Bolt Circle are executed in addition to the Bolt Circlepattern.

Up to 999 Locations can be programmed into a single data block. A Holedata block can contain more than one Locations operation, if more than999 Locations are required.

The word "locations" appears by the cursor, and all operations previouslyprogrammed appear above this current operation.

BLOCK 2 HOLES IF

x V CENTER DRILL tDRIILL

1 -0.1800 2.5008 >>> LOCATIONS F2 9.3000 -2.5800 23

F3

F4

F5

F6

Enter awt>er pa tut or ADIMI when finished

Figure 266. Locations for holes in a block

1. Program the dimensions of the X and Y axis coordinates forlocation #1 and press the Enter key.

If a wrong dimension for the X or Y coordinate is entered, movethe cursor to the incorrect location coordinate (dimension) andprogram the correct dimension.

2.. Program the dimensions for the X and Y axis coordinates at allother locations.

3. Use the arrow keys to move the cursor between locations andcoordinate columns.

2-84 Revision A Hawk 5M Machine

Conversational Part Programming

4. The Delete Location softkey function deletes the locationindicated by the cursor and renumbers all subsequent locations.

5. The Insert Location Before softkey function creates a newlocation before an existing one (indicated by cursor).

The new location is inserted with the number of the old locationand with the coordinates from the previous location in the list.The coordinates of the new block can be changed to the desiredvalues for the new location . The old existing location and allsubsequent locations are renumbered as necessary.

6. Only 15 locations can be displayed at one time.

If there are more than 15 in the list , press the Next Screensoftkey to view the non -displayed Locations. Press the PreviousScreen softkey to return to a previous screen.

When the cursor is at the end of the list , press the Advance keyto continue to the next block in the part program sequence.

Ultimax 3 System 5/12/94 2-85

Operator' s Manual

Bolt Circle

A bolt circle routine provides automatic execution for a series of holesequally spaced on a common circle . This routine also permits skippingholes in the bolt circle (i.e., programming holes where the pattern is not tobe executed).

BLOCK 2 HOLESFIDELETE OPERATION

K/®ER 9 DRILL 1») BOLT CIRCLE 1

X CENTER 2 . B0011 F INSERT OPERATION2 BEFORE

V CENTER 1.am iF

RADIUS 4.901119 3

START ANGLE 8.898 P PROGRAM4 PARAMETERS

SKIP LIST I3 F PART SETUP

5

F TOOL SETUPS

FPress ENTER to edit this operation or use ADIMNCE , BACK, 7or sarthey F

F EXITB

Figure 2-67. Bolt Circle operation

Conversational Part Programming

Here is a sample bolt circle pattern. The field definitions below refer tothe numbered points in this diagram.

4

30

O

20

X& V Center

06

05

Figure 2-68. A Bob Circle Pattern

The fields describing a Bolt Circle operation are as follows:

Fields Definitions

Number indicates the number of holes in the pattern. Upto 250 holes can be programmed in one operation.

X Center the X coordinate for the center of the Bolt Circle.

Y Center the Y coordinate for the center of the Bolt Circle.

Radius is the radius of the circle between the coordinatecenter and starting point at the center of thecutter. -

Start Angle is the angle of the circle measuredcounterclockwise from the 3 o'clock position tothe first hole. This angle may be specified to thenearest one-thousandth of a degree.

Skip List The skip list allows selecting holes that are notexecuted in the Bolt Circle pattern. For example,if hole #3 is not to be executed, press the 3 key toname it in the skip list and then press the Enterkey.Up to 24 holes may be programmed in the skiplist. To clear the list, press the Clear and Enterkeys.

llttimax 3 System 5/12/94 2-87.

Operator's Manual

When all Hole operations in the current data block are programmed,specify the places where these operations are to be executed. These maybe in a Bolt Circle pattern , or they can be random points selected inLocations . It is also possible to execute the operations within a givenblock in one or more Bolt Circle patterns and at other locations asspecified in Locations.

Conversational Part Programming

Tap

To cut threads inside a hole, the operator selects the Tap (F2) softkey onthe Holes screen. The following screen appears:

BLOCX 1 HOLM

TOOL 10 >>> TAP

Z START B.BBBB

Z BOTTOM 0.1BB3

SPEED (RPM) R

TOOL NOT PROGRAMMED

Eutr tool mabe'

Figure 2-69. Tap operation fields

1F1

F2

F3

F PROGRAM4 PARAMETERS

F PART SETUPs

F TOOL SETUP6

F7

F EXITB

Fields Definitions

Tool Number of the tool in the tool used for the tapoperation . After the operator enters the toolnumber and presses the Enter key, the tooldiameter and tool type appear in parentheses. Thevalues shown were programmed during ToolSetup and cannot be changed during partprogramming-

Z Start Starting point of the Tap cycle.

Z Bottom The bottom of the finished hole. It is the point ofmaximum Z down and where the spindle reversesdirection..

Speed (RPM) Speed at which the spindle rotates to bore or reamthe hole . The value that initially appears in thisfield was entered Tool Setup . If this displayedspeed should be used for the operation , press theEnter key . If a different speed is needed for thisspecific block, type in the value and press Enter.The maximum tap speed is 1250 rpm.

Ultm)ax 3 System 5/12/94 2-89

Operator' s Manual

During an Ultimax tap operation , the table positions to the programmed Xand Y dimensions followed by Z axis positioning to the programmedretract clearance . (Axis positioning is at the rapid traverse rate selected inProgram Parameters or Change Parameters.)

After reaching this point, the Z axis moves at rapid traverse to Z Start andthen at the control calculated feedrate until it reaches the Z Bottomdimension. At that point, the spindle reverses direction and the Z axismoves at the calculated feedrate back to the Z Start dimension (where thespindle begins rotating in the original direction).

When tapping, the control calculates the plunge feedrate using the speed(rpm), tool diameter, and threads per inch/pitch programmed for the toolin Tool Setup. Approximately 20" per minute is a nominal feedrate intapping most materials . When tapping aluminum , a feedrate two to threetimes 20" per minute can be attained productively.

This formula is used to determine the feedrate for a given speed (RPM):

Threads per inchx RPM = Feedrate

This formula determines the spindle speed (RPM)when the feedrate isknown:

Threads per inch x Feedrate = RPM

Hints and Tricks

Here are some suggestions for the tapping process:

1. Use a floating tap holder.

2. When tapping hard materials, use tapping fluid (not coolant)and a tap drill one size larger than normal.

3. Recommended Z Start is .200 minimum above the part surfaceto compensate for floating tap holder characteristics.

2-90 Revision A Hawk 5M Machine

Conversational Part Programming

Bore and Ream Operations

To enlarge and straighten the angle of an existing hole, the operatorselects one of the three Bore operations. To clean out and smooth a hole,the operator selects a Ream operation. Reaming operations follow theangle of the existing hole while a boring operation makes a true , straighthole.

To display the boring and reaming softkey options, press the Bore andReam Operations (F3) softkey on the Holes screen.

BLOCK 1 HOLES

TOOL B )))/ BORING 1\

Z START e.eeee P REAM2

Z BOTTOM e .eeee Ir ROME RAPID

PLRIGE PEED 0.8 3i

SPEED IRPMI B F BORE ORIENT4

(Fl REAM RAPID

TOOL NOT PROGRAMMED

Chose opent ton

Figure 2-70. Bore and Ream sofkeys .

P6

FF7

FFa

If the operator presses the Enter key when the screen first displays asshown above , a Bore (Fl) operation can then be programmed . To selectany of the bore or ream operations, the operator presses one of the fivesoftkeys shown on the screen.

Ultimax 3 System 5/12/94 2-91

Operator' s Manual

All of the bore and ream operations have the same fields:

Fields Definitions

Tool Number of the tool in the tool that will be used forthe selected bore or ream operation. After theoperator enters the tool number and presses theEnter key, the tool diameter and tool type appearin parentheses. The values shown wereprogrammed during Tool Setup and cannot bechanged during part programming.

Z Start Starting point of the bore or ream cycle. The toolmoves rapidly to this point.

Z Bottom The bottom of the finished hole. It is the point ofmaximum Z-down and the dimension where theplunge feed rate ends.

Plunge Feed Feedrate between the Z Start and the Z Bottompositions.

Speed (RPM) Speed at which the spindle rotates to bore or reamthe hole. The value that initially appears in thisfield was entered Tool Setup. If this displayedspeed should be used for the operation, press theEnter key. If a different speed is needed for thisspecific block, type in the value and press Enter.

After entering the values into these fields, the operator may select one ofthe operation softkeys: Delete Operation, Insert Operation Before, or Exit.Selecting the Delete Operation clears the currently displayed drilloperation.

To add another hole operation before the current one, the operator selectsthe Insert Operation Before softkey. Pressing the Exit softkey returns tothe previous screen level . Pressing the Advance key displays a new Holesscreen with the name of the operation just programmed above the multiplecursor.

2-92 Revision A Hawk 5M Machine

Conversational Part Programming

Bore

An operator uses a bore when a straight and accurately round hole isneeded. A boring bar usually has one or, at the most, two bladesprojecting out from the shank. On many types of boring bars, the bladescan be adjusted in and out to increase or decrease the size of the hole. Theillustration below shows a two-bladed boring bar:

Boring Bar

Shank

Blade depthadjustment dial

Replaceable blades

Figure 2-71. Two-bladed Boring Bar with adjustment dial

The Ultimax Bore cycle is similar to a drilling operation in positioning thetable and Z axis ; however, during a bore operation , the tool plunges fromZ Start to Z Bottom at the programmed Plunge Feed then retracts from thehole at this same feedrate until it reaches Z Start position. No pecks arepermitted.

Ultimax 3 System 5/12/94 2-93

Operator' s Manual

Ream

To size and/or clean out a previously drilled hole, the operator presses theReam (F2) softkey. The reaming cycle clears burrs and other particles leftfrom a drilling or boring operation. A reaming tool has multiple flutesthat run vertically along the shank of the tool as shown below:

Figure 2 -72. Reaming Tool

During reaming, this cutter follows the angle of the existing hole andcannot be used to straighten the angle of the hole.

Bore Rapid

The Bore Rapid (F3) softkey allows the operator to program a boringcycle with these steps:

1. The Z axis plunges from Z Start to Z Bottom at the plunge feedprogrammed.

2. When the tool reaches the programmed Z Bottom dimension, itretracts at the rapid traverse feedrate selected in ProgramParameters or Change Parameters.

2-94 Revision A Hawk 5M Machine

Conversational Part Programming

Bore Orient

If the operator selects the Bore Orient (F4) softkey, the cycle will followthese steps:

1. The Z axis plunges from Z Start to Z Bottom at the Plunge Feedprogrammed.

2. The spindle stops , and the tool is oriented to its startingposition.

3. The cutting edge of the boring bar moves away from the surfaceof the bored hole so that during step 4 the cutting edge will notscrape the walls of the hole. The distance that the bar moveswas set in the Bore Orient Retract field on the Holes Parametersscreen.

4. The tool retracts at the Rapid Traverse feedrate set on theGeneral Parameters screen.

Ream Rapid

If the operator selects the Bore Rapid (F5) softkey, the cycle follows thesesteps:

1. The Z axis plunges from z start to z bottom at the plunge feedprogrammed.

2. When the tool reaches the programmed z bottom dimension, itretracts at the rapid traverse feedrate selected in ProgramParameters or Change Parameters.

Ultimax 3 System 5/12194 2-95

Operator's Manual

Back Spotface

If the operator wants to cut out the underside of holes that must be cutthrough the work piece, the operator may use this feature. Press the BackSpotface (F4) softkey, and the following screen appears:

BLOCX 1 HOLES

TOOL I

2 START • 8.8888Z PLUNGE 8.88B8Z BOTTOM 8.88882 DEPTH 8.8888Z CLEARANCE 8.88882 RETRACT B.BBBBCLOSING F® 0.0CUTTING FEED 8.0PLUNGE SPEED (RPM) BCUTTING SPEED (RPM) 8REVERSE DWELL (SEC) 8.9

TOOL NOT PROGRAMMED

Enter Z dimension eefm- . d from the cutting edge of thetool at which closing feednte begins

F>>) BACK SPOTFACE 1

Figure 2-73. Back Spotface screen

F2

32

P PROGRAM4 PARAMETERS

F PART SETUP5

F TOOL SETUP6

F7

F EXIT8

The fields on the Back Spotface screen have these uses:

Fields

Tool

Z Start

Definitions

Number of the tool that will be used for theselected operation . After the operator enters thetool number and presses the Enter key, the tooldiameter and tool type appear in parentheses. Thevalues shown were programmed during ToolSetup and cannot be changed during partprogramming.

Starting point of the cycle. The tool moves rapidlyto this point . Tool zero should be the end of thetool.

Z Plunge The dimension within the hole that the bar willfeed before rapid movement to Z Bottom. Thisassures that the cutter is fully closed to preventdamage to the tool and part.

2-96 Revision A Hawk SM Machine

Conversational Part Programming

Fields Definitions

Z Bottom The dimension at which the tool ceases rapidtravel. This dimension must be completelythrough the hole. Use the dimensions on the printas the cutter offset to extend the tool beyond thecutting surface. At this point, the tool pauses andreverses the spindle direction to open the cuttingsurface.

Z Depth The tool feeds to this depth. Remember to use theprint dimensions as the cutter offset in Tool Setupto take the tool into account.

Z Clearance Incremental (positive value) distance to rapid thetool away from the cutting surface. At this point,the tool pauses , and the spindle returns to itsoriginal direction to close the cutter.

Z Retract Distance that the tool feeds back up through thehole to be certain that the tool is properly closedbefore rapid movement to the Retract Clearanceheight.

Closing Feed Feed at which the tool enters the hole at the topand bottom to be certain the tool is closed.

Plunge Speed(RPM)

Cutting Speed(RPM)

Reverse Dwell(Sec)

Speed of the spindle with the tool closed whileentering or exiting the hole.

Speed of spindle with the tool open.

Number of seconds that the spindle dwells when itis reversing to give the tool time to open or close.

After entering the values into these fields, the operator may select one ofthe operation softkeys : Delete Operation , Insert Operation Before , or Exit.Selecting the Delete Operation clears the currently displayed drilloperation.

To add another hole operation before the current one, the operator selectsthe Insert Operation Before softkey . Pressing the Exit softkey returns tothe previous screen level . Pressing the Advance key displays a new Holesscreen with the name of the operation just programmed above the multiplecursor.

Ultimax 3 System 5/12194 2-97

Operator' s Manual

The general steps in a Back Spotface operation are shown below:

1. Rapid to Z Start minus cutter offset and set the spindle speed toa plunge speed.

2. Move to Z Plunge minus cutter offset at a closing feedrate toclose the cutter.

3. Rapid to Z Bottom minus cutter offset.

4. Dwell for a specified reverse dwell amount, reverse the spindledirection and ramp to cutting speed to open the cutter.

5. Move up to Z Depth minus cutter offset at a cutting feedrate.

6. Dwell for the drill dwell time (from program parameters).

7. Rapid down a Z Clearance amount.

8. Dwell for the Reverse Dwell time and reverse the spindledirection to plunge speed to close the cutter.

9. Move to Z Retract minus cutter offset at a closing feedrate toinsure the cutter is closed.

10. Rapid out of the hole.

Conversational Part Programming

Sample Drilling Program

The following example demonstrates some basic Ultimax hole drillingcapabilities . The job calls for drilling twelve holes with a 3/8" drillthrough a rectangular piece of alloy steel as shown in the diagram below:

Part Zero

.75"

\ I 1" 1.25"

A

4'

2.5

8.25"

Material : Alloy Steel8.25" x 4"x.25"

Tools Feeds Speeds1/8" Center Drill HSS 42 28003/8" Drill HSS 5.6 930

Figure 2-74. Hole Drilling Example

4"

The program presented on the following pages is a copy of the printedpart program developed for this drawing . This program is presented in thesame format as an Ultimax 3 part program that was printed on a dotmatrix printer from the control . Therefore , the program data may bepresented in a different order than it is on the Ultimax screens.

In the sample program , the operator added a tool setup for tool #99 to useonly to draw the part outline block. Since the speed and feed informationis missing from the tool description , the control will not execute any blockusing this tool. To prevent an error during running , the operator will deletethat tool and the outline block before running the program.

Ultimax 3 System 5/12/94 2-99

Operator' s Manual

Since Ultimax allows considerable flexibility in developing part programs,this sample program does not represent the only way the part can beprogrammed. Watch for inserted explanations of the special features ofthis sample program.

Hurco Ultimax Part Program 1 InchHoles .HD3 Standard

Part Setup

Part Zero X 5.0000 Safety Work RegionY 10.0000 Z Top (+ ) 99.0000

Offset 2 0 .0000 2 Bottom C- ) -0.4010X Left C-) 0.0000X Right C+ ) 8.2500Y Front C- ) -4.0000Y Back C+) 0.0000Fixture Offset 1

General Parameters

Retract Clearance

Rapid Trauerse

Peck Clearance Plane

Chord Error

Depletion Retract

Holes Parameters

Bore Orient Retract

Drill Dwell

Bore Dwell

Milli P t

0.2500 IN

400.0 IPM

0 . 0500 IN

0.0001 IN

0 .0050 IN

0 .0200 IN

0.5 SEC

1.0 SEC

ng arame ers

Blend Offset

Blend Ouerlap

Finish Feed

Finish Speed

Finish XY

Finish Z

Milling Direction .

0.1250 IN0 . 1250 IN

100100 i

0.0100 IN

0 .0050 IN

ClimbPocket Ouerlap

Cutter Comp Parameter10

Insert Arc

2 - 100 Revision A Hawk 5M Machine

Conversational Part Programming

. Hurco Ultimax Part Program 2 Inch

Holes .HD3 Standard

Program Parameters

Ouerride Lockout Off

Program Protect Partial

Tool Change Position Yes

Tool Setup

The number to the left of the type name is the tool number . So this setupsection lists three tools : 1, 2, and 99 . Since tool 99 is not going to be usedin the program , the tool type was not identified in setup . Zero calibrationvalues will, of course , vary for different work pieces and tools.

1 Type Drill

Diameter 0.1250

Zero Calibration -10000.

Speed (RPM) CU 2800

Coolant Flood

Gear range I

Tool Humber 1

Diameter Offset 1

Length Offset 1

2 Type Drill

Diameter 0.3750

Zero Calibration -10000.

Speed CRPM) CW 930

Coolant Flood

Gear range 1

Tool Humber 2

Diameter Offset 2

Length Offset 2

99 Diameter 0.0000

Zero Calibration -10000.

Speed (RPM) CW 0

Coolant Off

Gear range 1

Tool Humber 99

Diameter Offset 99

Length Offset 99

Ultimax 3 System 5/12/94 2-101

Operator' s Manual

Hurco Ultimax Part Program 3 InchHoles.HD3 Standard

The number to the left of the following data block name is the blocknumber in the part program.

Data Blocks

1 Mill Frame

Tool 99 2 Start 0.0000Type Out/Tan 2 Bottom -0.2500Finish Tool 0 Plunge Feed 0.0X Corner 0.0000 Mill Feed 0.0Y Corner 0.0009 Speed (RPM) 0X Length 8.2500 Peck Depth 0.0000Y Length -4.0000

Corner Radius 0.0000

Lead Length 0.0000 Lead Angle 0.0000

Block #1 creates an outline of the part for the graphics display. Theoperator will use this outline during programming to check the location ofthe programmed holes and delete the block before running the program.The Z Start parameter draws the surface of the part , and the Z Bottomdraws the bottom . Block # 2 performs all of the hole drilling operations.Note that the tools are entered into the program in the order in which theyare used.

2 Holes

Center Drill

Tool 1

Finish Tool 0

Z Start 0.0500

2 Bottom -0.0125

Plunge Feed 4.2

Speed CRPM) 2800

Peck Depth 0.0000

Peck Type Standard

Drill

Tool 2

Finish Tool 0

2 Start 0.0500

Z Bottom -0.3000

Plunge Feed 5.6

Speed (RPM) 930

Peck Depth 0.1500

Peck Type Standard

2-102 Revision A Hawk 5M Machine

Conversational Part Programming

Hurco Ultimax Part Program 4 Inch

Holes.HD3 Standard

Locations

x Y1 1.0000 -0.7500

2 2.2500 -0.7500

3 3.5000 -0.7500

4 4.7500 -0.7500

5 6.0000 -0.7500

6 7.2500 -0.7500

7 7.2500 -3.2500

8 6.0000 -3.2500

9 4.7500 -3.2500

10 3.5000 -3.2500

11 2.2500 -3.2500

12 1.0000 -3.2500

These hole locations are also a portion of Block #2 . They are programmedin the order that they will be cut . The operator used the Ultimax No-Calcfeature to enter the location data.

First, the operator entered the X and Y coordinates for hole #1 from thedrawing. To calculate the X values for holes 2 through 6, the operatortyped "1.25" and pressed the plus (+) console key and Enter for each ofthese values. The operator pressed the Enter key for each of the Y valuessince those values are all the same as the first hole.

For hole #7, the operator pressed Enter on the X value to keep it the sameas the previous value . Then the operator typed "-2.5" and pressed the plus(+) console key and Enter key to add -2.5 to the previous Y value andpressed Enter for each of the subsequent Y values. For the X value ofholes 8 through 12, the operator typed " 1.25" and pressed the minus (-)console key and Enter to subtract 1.25 for each new position.

Ultimax 3 System 5/12194 2 - 103

Operator' s Manual

MillingThis section presents detailed descriptions of the Milling options inUltimax 3. The chart below shows the relationship of the milling optionsto the Input button and its subsequent softkey selections.

Milling OptionsInput Button

Part Setup (Fi )

Tool Setup (F2)

Part Programming (F3)

Position (Fl)Li Flne ( )Lines & Arcs (Fl)

Holes (F2)Circle (F2) Arc (F2).

Milling (F3)Frame (F3) Blend Arc (F3)

Patterns (F4)Face (F4) Helix (F4)

Miscellaneous (F5)3D A FEllipse (F5) rc ( 5)

Special (F6)L ri FRotary (F7) ette ng ( 6)

3D Option (F7)Exit (F8)Exit (F8)

Figure 2-75. Milling Options Chart

2 - 104 Revision A Hawk 5M Machine

Conversational Part Programming

When the operator presses the Milling (F3) softkey , the milling optionsoftkeys appear on the New Block screen as shown below:

BLOCK I NEW aIACII

Clore type of block

Figure 2-76. New Block screen with the Milling soft keys

F 1)/Ln6SI

F/2) CIRCLE

33) FRRItE

F 4) FACE4

rF 5) ELLIPSE5

6) LETTERING

F ) 30 OPTION7

F E)IIa

The following sections describe some general concepts that apply to manydifferent milling operations:

• Segments

• Cutter Compensation

• Maximum Offset

• Feed and Speed Options

Ultimax 3 System 5/18/94 2 - 105

Operator's Manual

Segments

Mill contour data blocks use segments to create lines and arcs in a partprogram. A segment is any programmed single or combined X-Y-Z axismovement at a programmed feedrate. A series of lines and arcs can beprogrammed in a single data block, using different segments, to form acomplete contour.

A new segment, see below, begins where a different motion from theprevious segment is programmed. Up to 999 segments can beprogrammed in one data block, if they all use the same tool and are allpart of the same Mill Contour. These segments may be any combinationof lines, arcs, blend arcs, helixes, or 3-D (three-dimensional) arcs. Note.these features listed in the softkeys below:

BLOCB 1 I1) LINE

3'661®17 1 \(LIe1

7,oose appropriate sotikey

Figure 2-77. Mill Contour New screen

F 2) NBC2

F 3) BLEND ARC3,

F 4) HELIX4

F 5) 3D NBCS

When the . operator selects any of these softkeys , the screen used to createthe selected segment lists "Mill Contour" beside the block number andthen displays the type of segment beneath "Mill Contour." For example, ablend arc segment will have "Mill Contour Blend Arc" at the top of thescreen.

2 - 106 Revision A Hawk 5M Machine

Conversational Part Programming

Pressing the Lines and Arcs (Fl) softkey on the Mill Contour New screendisplays the Mill Contour Start screen shown below. The block numberdisplayed on this screen is determined by the position of the data block inthe part program.

The first segment in a Mill Contour block is always a Start blockindicated by the segment zero (0). The operator cannot change a segmentnumber to zero since segment numbers are system-generated. The cursorbegins on the Tool field as shown in the sample below. The operatorenters the number of the tool that will be used for the entire operation. Allof the segments in this operation will use the same tool.

BLOCX 1

SEGMENT a

TOOL

CUTTER 0011P.

FINISH TOOL

X START

Y START

Z START

2 BOTTOM

ID PI.111GL F®

F1

Enter tool metes

MO

B SPEED (RPM)

0.0800

B.BBBB

8.0 F2

tFB 3

fPECX DEPTH B.BBBB F

4TOOL NOT PROGRAMMED

F5

Figure 2-78. Mill Contour Start screen

Important

While programming a part, the operator should plan groups of segmentssince during recovery restart the control can only restart at segment zero(0), not at a segment after the zero segment. Many operators breakcomplex operations into different blocks so that if they need to restart theprogram they can start at any one of several zero segments.

Ulfimax 3 System 5/18/94 2-107

Operator' s Manual

Here is a completed Start segment (segment zero):

BLOCK I HILL CONTOUR

SEGMENT A 0 START

TOOL I PLUNGE FEED

CUTTER COME . PROFILE LEFT

FINISH TOOL 2 SPEED (RPM)

X START 8 .5808 PECK DEPTH

V START -7.9859

Z START 8.6288

Z BOTTOM -8.2588

MAX OFFSET 8.8888

(TOOL DIAMETER(TYPE(FINISH DIAMETER(FINISH TYPE

2

F588 3

8.8888 F PROGRAM4 PARAMETERS

8.2588) 1DRILL) F PART SETUP

8.2588) 5END MILL)

F TOOL SETUPS

Fwwhe', Mn ENTER to edit ssasent , or Mn 7Znt@ a eB K

ADIMNCE ,BAcACK. . or sot net'

F EXIT8

Figure2 -79. Completed Mill Contour Start screen

Here are the fields used to describe a group of segments:

Fields Definitions

Tool number of the tool used to cut the segments in thisgroup.

Cutter Comp indicates whether the system should automaticallycompensate for the diameter of the tool whendetermining tool path. The operator can selectdifferent types of cutter compensation asdescribed in the following section. If cuttercompensation is not selected, the center line of theprogrammed tool follows the part contour.

Finish Tool number of a tool used for finish pass . If a finishtool is selected, the first tool leaves the amount ofmaterial selected in Program Parameters orChange Milling Parameters . The finish toolremoves the remaining stock down to theprogrammed dimension.

X Start "X" coordinate for the starting point of the firstsegment.

Y Start "Y" coordinate for the starting point of the firstsegment.

2 - 108 Revision A Hawk 5M Machine

Conversational Part Programming

Z Start point above the part where the Z axis plunge feedrate begins.

Z Bottom point of maximum Z-down where the plunge feedrate ends.

Maximum Offset this conditional field appears if Cutter Comp.-Profile Left or Cutter Comp.- Profile Right wereselected. The value is the distance between theprogrammed contour and the tool center duringthe first pass. The number entered here must bemanually calculated.

Plunge Feed feedrate between the Z Start and the Z Bottompositions.

Speed (RPM) the spindle speed for the tool calculated in ToolSetup. Entering a value here overrides the ToolSetup value for this data block.

Peck Depth the maximum depth to be cut in one pass.

Ultimax 3 System 5/18/94 2-109

Operator' s Manual

Cutter Compensation

The default setting for cutter compensation is "No." When no cuttercompensation is used, the center line of the programmed tool follows thepart contour (print line). If the operator wants the system to calculatecutter compensation , there are six possible selections:

• Left - used for climb milling

• Right - used for conventional milling

• Profile Left - removes material from a closed contour forclimb milling

• Profile Right removes material from a closed contour forconventional milling

• Pocket Boundary - used to cut the outside perimeter of anUltiPocket operation

• Pocket Island - used to cut islands inside the perimeter of anUltiPocket operation

BLOCK 1 MILL CONTOUR ^F 1) NO

SEB1DIT D START 1

TOOL 1 PLIKIGE PEED 8.0 F LEFT

CUTTER COMP. • MO3) RIGHT

FINISH TOOL M SPEED (RPM) B 3

X START PECK DEPTH 9.0080 F 4) PROFILE LEFT4

Y START TOOL NOT PROGRAMMED IF 5) PROFILE HIGH

2 START a.aa99 5

iZ BOTTOM 9.99fi6 F 6) POCKET

6 ROIRO)RRY /

Select euttine operation

Figure 2-80. Cutter Compensation options

7) PO KKT7\ ISLRIw

F EKIa

If the operator selects one of these compensation options, the programmedtool automatically follows the finished contour of the part.

2 - 110 Revision A Hawk 5M Machine

Conversational Part Programming

Here is a diagram showing tool paths when no cutter compensation isused compared to left and right compensation:

Cutter Compensationto the left

Tool

No Cutter Compensation

Tool

1Center line of

Contour

Center line ofContour

Cutter Compensationto the right

Tool

Center line ofContour

Figure 2.81. Tool Paths for Cutter Compensation

When the operator selects either right or left compensation , the systemoffsets the tool from the print line (in the selected direction) by a distanceequal to the radius of the tool.

Ultimax 3 System 5/18/94 2-111

Operator's Manual

Climb Milling

Climb milling is preferred except when the rigidity of the fixturing is notsturdy enough to allow its use.

The cutting teeth move in the same direction as the feeding motion. Thisis also known as in-cut or "down milling." During a climb cut, the spindleturns in a clockwise motion. The tool is on the left-hand side of the cut asit travels away from the operator.

The advantages of using climb milling are as follows:

1. The chip starts thick and allows easy penetration into thesurface of the part causing less tool wear and less powerconsumption.

2. The tool force cuts in and down on the part helping to hold thepart in the fixture. The more rigid the fixture, the better the holdon the part.

3. Chip removal is greater, and there is less recutting of chips ormarring of the part surface.

4. The cutting fluid is more accessible to the cutting surface.

Conventional Milling

The cutting teeth move in the opposite direction to the feeding motion.This is known as "out-cut" or "up milling." While using conventionalmilling with a clockwise spindle, the tool moves away from the operatoron the right-hand side of the cut.

The advantages of using conventional milling are as follows:

1. The chip thickness starts at zero causing less impact on thecutting teeth. This is ideal for set-ups that are not very rigid.

2. The backlash in older machines is greatly diminished.

Conversational Part Programming

Profile Left and Right

The softkey functions of Profile Left and Profile Right enable material tobe removed inside or outside of a programmed closed contour, dependingon the part program and the function chosen. Select Profile Left for climbmilling and Profile Right for conventional milling; the enabled softkeydetermines if the tool remains inside or outside of the contour (dependingon the part program).

A mill contour with the same X-Y coordinates for both the end point andstart point is called a closed contour. Selecting cutter compensation withtool on the inside of a closed contour allows the control to compute thestart and end points of the tool path so it does not cut into the last or firstsegments of the contour. (When pocketing, all contours must be closed; ifnot closed, the control moves its tool in a direct line from the end point tothe start point at the current feedrate. Do not program start point in acorner of a closed contour.)

BLACK 1 HILL CONTOUR IF

SEGMENT 1 B START 1

TOOL 1 PLUNGE FEED 0.0 F

I9E* COtO' PROFILE LEP2

PSRI TOOL SPY® (RPM) B 3

X START Asaee PECX DEPTH 8.8880 F PROGRAM4 PARAMETERS

V START CM. 7. (TOOL DIAMETER 8.5888) 1HB^^-^--DB P PART SETUP

Z START 8.00@0 (PIMISN DIAMETER B. ZS@0)(FINISH TYPE END HILL)

Z BOTTOM 8.80@0 P TOOL SITUP6

MAX OFFSET 8.880 iP

Enter a eer.eSt aue)em, use D(T'ER to edit ueswent, m• use 7AD(NWCE , RACE. or eotthey

F EXIT8

Figure 2-82. Profile Left Cutter Compensation using a finish tool

After the tool removes material , the finish tool uses the same cuttercompensation and removes the remaining stock down to the programmedlevel. When a finish tool number is entered on this screen , the finish tooldiameter and type parameters are displayed in parentheses . The values forthese parameters are programmed in Tool Setup and cannot be changed inPart Programming mode.

Ultimax 3 System 5/18/94 2 - 113

Operator' s Manual

Maximum Offset

The maximum offset field displays when Cutter Comp.- Profile Left orCutter Comp.- Profile Right is selected. The value to be programmed mustbe calculated and manually programmed into the control. This value mustbe the distance between the programmed contour and the tool centerduring the first pass.

The value for maximum offset should equal the radius of the largestinscribed circle minus the radius of the tool which illustrates an examplecalculation of this value. The graphics screen is helpful in determining anoptimum value for this parameter.

Starting pointfor the tool

Figure 2-83. Determining Ma:tmum Offset

If the tool diameter is changed (i.e., cutter sharpened to a smallerdiameter), the value for the maximum offset must be recalculatedmanually and this new value programmed into segment 0 of the MillContour - Start block. The value for the tool diameter parameter isprogrammed in Tool Setup and cannot be changed in Part Programming.

If a .500" diameter-end mill is used to machine the part illustrated, thevalue to be programmed for the maximum offset parameter should be0.75".

Conversational Part Programming

Feed and Speed Options

The plunge feed parameter is the rate the tool is to enter the work pieceand is requested only for segment 0 of a Mill Contour.

The value displayed for the Speed (RPM) parameter is programmed (orcalculated) in Tool Setup and is the spindle speed for the tool. If desired,this value can be changed for this data block when the cursor indicatesthis parameter. Pressing the Enter key stores the displayed value in controlmemory.

The Ultimax control automatically calculated the spindle speeds using thefollowing formulas. The first four formulas produce the revolutions perminute (RPM) that apply to high-speed steel tooling and high-speedcobalt tooling used to cut work pieces of these common metals.

382

tool diameter

350

tool diameter

tool diameter

= RPM for plain carbon steel

= RPM for alloy steel

1240

3440

= RPM for aluminum

365= RPM for gray cast steel -

tool diameter

tool diameter= RPM for aluminum

1240 = RPM for gray cast steeltool diameter

Refer to the "Appendix" of this manual for more feeds and speedsinformation.

Ultimax 3 System 5/18)94 2-115

Operator' s Manual

Programming Lines and Arcs

After the Start segment is programmed, the Mill Contour screen becomessegment 1 of the data block and the cursor indicates New.

Lines

Selecting the Line (F1) softkey from the Mill Contour New screendisplays this Mill Contour screen:

ELOGX 1 HILL CONTOUR IF

SEW@IT 1 LINE I

X END 2.0060 (X START 0.5000) F(Y START CAL -7.9059) 2

Y 0101 4.0060 (2 START 6.0006) 1F STORE CALCULATED

Z Elm 0.0000 3 VALUE

I.XT LENGTH 12.0000 F

4XT ANGLE CALL 02.019 l

FFEED 0.0 5

F FIND ANOTHERANOTHER END POINT EXISTS 6 END POINT

i

P PREVIOUS SEGMENTRotor XV angle to sad point. counarcloekwlse from 3 o'clock 7If knorn 1

F EXITe

Figure 2-85. Mill Contour Line screen

The block and segment numbers are the same as on the New screen.Reference values for X Start , Y Start, and Z Start information. aredisplayed in parentheses and defines the start point of this segment. Theseparameters were programmed in the previous segment and cannot bechanged in this segment.

When programming a Line segment , the Ultimax No-Calc feature enablesthe control to calculate certain unknown dimensions automatically, aftersufficient data has been entered. A parameter with a calculated value isindicated by "CAL" (preceding the value). If the value for a parameter isleft blank, the control automatically fills in the value if enough data isavailable for the calculation . If a dimension is entered and it is laterdecided the control should calculate it, move the cursor to the parameterand replace it by pressing the Clear key.

Conversational Part Programming

If the X End and Y End coordinates are entered, the control automaticallycalculates the XY length and the XY angle parameters.

The XY angle parameter value is the angle of the line segment (from thestart point to the end point ), measured counterclockwise from the 3o'clock position.

0'P intStart o

Figure 246. Length, Angle, and End Point Relationship

If both end points are unknown, but XY length and XY angle areprogrammed, the control automatically calculates X End and Y Endparameters.

If one end point coordinate and the XY angle are programmed , the controlcan calculate the unknown end point and the XY length parameters.

If one end point coordinate and the XY length are programmed, thecontrol can calculate the unknown end point and the XY angleparameters . However, unless the XY angle is known , there are twopossible solutions for the unknown end point and the correct one must bedetermined for the program.

Ultimax 3 System 5/18/94 2 - 117

Operator' s Manual

When two possible solutions exist, the message, "Another end pointexists" appears and one of the two possible solutions appear in theunknown parameter.

Pressing Draw for the graphics screen displays a visual representation ofthe displayed solution. The other solution for the unknown parameter canbe displayed by pressing the Find Another End Point (F6) softkey andselecting graphics for this solution to displays a visual representation.Alternate display of each solution facilitates the appropriate choice forthe program. Press the Enter key when the correct choice is displayed.

X Known

KnownStart Point Y unknown

XY Angle unknown

Figure 2-87. Line Segment with Unknown Y End and XY Angle

The Z End value is the depth of the cut at the line end point. The valueinitially displayed is carried forward from the previous segment. Thedisplayed value can be retained, or a new value programmed (as required).

The feed parameter is initially displayed with a value carried forward fromthe previous segment. This value can be changed or stored.

Additional Line and Arc segments can be programmed in this same datablock (using two-axis, or three-axis moves). Press the Advance key toprogram an additional segment in this same data block.

2-118 Revision A Hawk 5M Machine

Conversational Part Programming

Arcs

Selecting the Arc (F2) softkey on the Mill Contour screen displays the Arcscreen . Here is a completed arc segment:

BLOCK 1 HILL CONTOUR

SS6M8NT I 1 ARC

DIRECTION C11 (X START(V STAR?

X END 2 .0000 (2 START

V END 3.0080

X CENTER CAL 2.4412

V CENTER CAL 8.5392

RADIUS 2.5880

F® 15.0

IF DELETE SEGM7171

0.0080) F INSERT SEGMENT0.0000) 2 BEFORE8. Bees) I

F3

F PROGRAM4 PARAMETERS

ANOTHER CENTER POINT EXISTS

Enter a eegnent weber . tats ENTER to edit cegeent, or tanAD'JN CE , BACX, or aurtkeg

Figure 2-88. Mil ContourArc screen

F PART SETUP5I

F TOOL SETUPb

F7

1

F EXITB

The block and segment numbers are the same as the New screen.Reference values for X Start, Y Start, and Z Start parameters are displayedin parentheses and define the start point of this segment . These parameterswere programmed in the preceding segment and cannot be changed in thissegment.

The direction parameter refers to the direction of the arc from the startpoint . Examples of these coordinates for a clockwise arc are shownbelow:

Figure 2-89. Coordinates of a Clockwise Are

Ultimax 3 System 5/18/94 2 - 119

Operator' s Manual

Data coordinates (values) used in the automatic calculations are asfollows:

• The values of center points, plus the start points OR end pointsfurnish the arc radius parameter value.

• The start points AND end points, plus the radius value providethe two possible center points.

• Either of the end point values AND the center point coordinatesupplies the value of the other end point and the radiusparameter.

• When a known center point, start point or end point and radiuscoordinate are provided, an unknown center point coordinate isfurnished.

Solution #2

End Point #2

Solution #1

End Point #1

Known : Y End and Y CenterUnknown : X End and X Center

Figure 2-90. Arc Segment with Unknown X End and X Center

The feed parameter is initially displayed with a value carried forward fromthe previous segment. This value can be changed or stored.

A series of Arcs and Lines can be programmed in a single data blockusing different segments to form a complete contour. Press the Advancekey to program an additional segment in this same data block.

Conversational Part Programming

Blend Arcs

A blend arc is an arc that joins two other segments and is tangent to both.A blend arc can be used to join:

• Two Line segments.

• A Line segment and an Arc segment.

• Two Arc segments.

• A Helix to another segment.

The segments to be joined must have a. theoretical point of intersection. Ifthe only information known about an arc is its radius, it is easier toprogram it as a blend arc (if the segments intersect). The diagram belowillustrates some examples of blend arcs.

Two Area Joined by aBlend Arc

X StartY Start

Two Lines Joined by a •^ Segment #1Blend Arc \ 3 (Arc)

Segment 1 End/Segment 3 Startpoint of intersection

X StartY Start

Segment 1 End/Segment 3 Startpoint of intersection

WSegmnt #3

Segment 1 End/Segment 3 Startpoint of intersection

Segment #1(Line)

X StartY Start X End

YEndLine and Are Joined by a

Blend Arc

Figure2-91. Some Typical Blend Ares

X EndY End

Ultimax 3 System 5/18/94 2 - 121

Operator' s Manual

Pressing the Blend Arc (F3) softkey on the Mill Contour's New screendisplays the blend arc fields. The block and segment numbers are thesame as the New screen . Reference values for parameters are displayed inparentheses . These values have been carried forward from previoussegments and cannot be changed in a blend arc segment.

Here are some guidelines that must be followed when creating a blendarc:

1. A blend arc segment should not be used to start or stop a MillContour. In other words , segment #1 and the last segment of thedata block cannot be a blend arc segment.

2. Two adjacent segments in the program cannot both be blend arcsegments , so if segment #2 is a blend arc, segment #1 and #3cannot be blend arc segments.

3. Segments that are adjacent to the blend arc segment mustintersect at some point in their theoretical plane. Therefore, ifsegment #2 is a blend are , segment #1 and #3 must theoreticallyintersect at some projected point.

4. 'Do not enter a value into the Radius field that is too large to betangent to both of the adjoining segments.

5. If any coordinate (start point, center point, or end point) isimportant to the construction of the two segments to beblended , the segment must be programmed as an arc and not asa blend arc.

6. The Feed field is initially displayed with a value carried forwardfrom the previous segment . This value can be changed orretained.

A series of arcs and lines can be programmed in a single data block, usingdifferent segments to form a complete contour . Press the Advance key toprogram an additional segment in this same data block.

2-122 Revision A Hawk 5M Machine

Conversational Part Programming

Operators use different methods to program blend arcs. Some operatorswork through the program segment by segment while others create all thegeometry surrounding the arc and then insert the blend arc betweenexisting segments.

The following screens show a programming example of a simple blendarc inserted between a helix and an intersecting line. Of course, theoperator created a start segment (segment zero) to begin the block. Thenthe operator created the helix followed by an intersecting line segment.Then using some of the values calculated on those screens, the operatorcreated the blend are between the helix and the line. The following threescreens show the finished block after the operator has programmed all ofthe segments. This screen in this series creates the helix. For moreinformation about programming a helix , refer to the following section.

BLOCK 1 KILL COIMOIRR 1 +.;F

SECM®IT 1 HELIX 11 -

DIRECTION CY SWEEP A)16LE CRI. 146.775 22

.E 2 2913 FED I 15 0 1x B . .F

Y END 1.01190 3I

2 DO) 11.0000 F4 -

X CENTER CAL -0.1893 (X START -2 .5000) 1(V START 1 .0080) F FIND MOTHER

V CENTER CAL 0.2853 (Z START 0.0080) 5 CENTER POINT

iRADIUS 2.5888 _ 6

600000 (MOTHER CENTER POINT EXISTSLEAD .

F PREUIOLIS SECIMTEnter feedrate - 7

EXIT8

Figure2-92: Segment creating the Helix in the Bknd Arc exampk

The screen on the following page creates a line segment to intersect withthis helix.

Ultimax 3 System 5/18/94 2 - 123

Operator' s Manual

BLOCK 1 MILL CONTOUR

SEGMENT $ 3 LINE

X END 5 .0080 (X START(Y START

V END 1 . 0000 (5 START

Z END 0.0000

XY LENGTH CAL 2.7861

XY ANGLE CAL 0.000

FEED 15.0

F

F PROGRAM4 PARAMETERSi

P PART SETUPS

fF TOOL SETUP6

FEnter a eegeent Huber , an ENTER to edit tega nt. or oae 7ADVANCE . BACK. or eatt)mg

Figure 2-93. Line segment to intersect with previous helix

F EXITa

To create the blend arc, the operator then inserted this blend arc segmentbetween the two previously created segments.

BLOCK 1 KILL CONTOUR IF DELETE SEGMENT

SEGMENT 1 2 BLED ABC 1i

RADIUS 0.2508 (DIRECTION CCU) F INSERT SEGMENT(X START CAL 2.2268 ) 2 BEFORE

F® 15.8 (Y START CAL 1 . 1361) l(X END CAL 2.44%) P(Y EE CAL 1.0800) 3(X CENTER CAL 2.44%) l(V CENTER CAL 1.7580) F PROGRAM

4 PARAMETERSM

F FART SETUP5M

F TOOL SETUP6

FEnter a ugQet

or soarwr

, an ENTER to edit aegimnt. or uw 7ADVANCE . BACK , er tkag i

F EXITa

Figure2-94. Mill Contour Blend Are

F DELETE SEGMENT1

2.2913) F INSERT SEGMENT1.0880) 2 BEFORE0.0908) 1

2 - 124 Revision A Hawk 5M Machine

Conversational Part Programming

Here is a graphic representation of the helix with the intersection line andthe blend arc the operator added between the two segments.

4.98 V

2.98

I

8.98

-1.18 --3. 88 1.88

Blend Areadded here

3.88 5.88

Figure2-95. Sample Blend Arc on the Graphics screen

Ultimax 3 System 5/18/94 2 - 125

Operator' s Manual

Helix

To create a helical segment in the data block, the operator presses theHelix (F4) softkey on the Mill Contour's New screen. Here is a completedhelix segment:

BLOCX 1 HILL CONTOUR IF

SEGMENT 1 HELIX 11

DIRECTION cu SWEEP MLLE CAL 116.775 F2

X Em 2 . 2913 FEED 0® 15 I'.F

V END 1.0080 3

Z Em 0.0000 F4

X CENTER CAL -0.1013 (X START -2.5000) IIT START 1.0000) F FIND ANOTHER

V CENTER CAL 0.2853 (Z START 0.0008) 5 CENTER POINT

AADIl18 2.5088 P6

LEAD 8 8080 ANOTIEN CENTER POINT EXISTS.P PREVIO

Enter f.MrateUS SEGMENT

7

P EXITe

Figure 2-96. MiU Contour Helix screen

These fields define a helix:

Fields Definitions

Direction direction of the helix from the starting point.

X, Y, and Z End coordinates of the ending point of the helix.

X & Y Center "X" and "Y" coordinates of the center point aboutwhich the helix is drawn.

Radius The dimension from the center point to the helix.

Lead change in the Z axis dimension for each 360° ofrevolution of the helix.

Sweep Angle total number of degrees in the helical arc to be cutand can be greater than 360 °. This angle valueprovides information for the calculation of the ZEnd value.

Feed rate from the previous segment . This value can bekept or changed.

2 - 126 Revision A , Hawk 5M Machine

Conversational Part Programming

The control uses the automatic calculation feature to determine unknownpoints . When there are two possible solutions for an unknown coordinate,one of the "Another point exists " messages appears with one of the twopossible solutions appearing in the data field for the unknown parameter.

The operator usually displays the current solution on the graphics screento evaluate it. To display the alternative solution , the operator presses the"Find another" softkey. In the example on the previous page, that softkeyis the Find Another Center Point (F5) softkey . The operator can switchbetween the two solutions and examine both on the graphics screen todetermine the better solution.

To perform automatic calculations , the Ultimax system uses the data inthe helix fields in the following ways:

• The Z End and Sweep Angle values provide data to calculatethe lead parameter.

• The Sweep Angle is used to calculate the Z End value.

• The X End , Y End and Lead values provide the Z End value.

• The Z End and Lead values provide the X End , Y End andSweep Angle values.

• The X End, Y End , X Center and Y Center values supply theRadius value.

• The Sweep Angle value and either the X or Y End pointcoordinate provide the unknown (X End or Y End ) end pointvalue.

2-127Ultimax 3 System 5/18/94

Operator' s Manual

3-D Arc

To create a three-dimensional arc segment , the operator presses the 3DAre (F5) softkey on the Mill Contour New screen. Then this screenappears:

BLOCK 4 MILL CONTOUR IF

SWIThT 1 3D ABC 1

X END X POINT 8.0808 F2

V END Y POINT 8.8888 1F

Z END 8.0888 Z POINT 8.8000 3

X CENTER 0 .8888 FEED 0.8 F4

V CENTER 6.0888 (X START 1 .8880) I.(V START 2.8880) F

Z CENTER 8.0888 (Z START 4.8880) 51F6

F PREY IOIS SEGMENTEuter coordinate 7

F EXIT8

Figure2-97. Mill Contour 3D Are screen

Important

Do not confuse this Mill Contour feature with the 3-D Milling option. The3D Arc feature is always included in the Ultimax 3 software; however, the3-D Milling option must be purchased separately. If 3-D Milling isavailable on the machine, refer to the 3D Programming InstructionManual for more information.

2 - 128 Revision A Hawk 5M Machine

Conversational Part Programming

These fields define a 3-D arc:

Fields Definitions

X, Y, and Z End coordinates define the end point for the arcsegment.

X, Y, and Z Center coordinates define the center point for the arcsegment.

X, Y, and Z Point coordinates define the plane of the arc when it is180° or greater. If the arc is less than 180°, thesevalues are not needed.

Feed rate from the previous segment. This value can bekept or changed.

This diagram shows the relationships of the coordinates to each other:

z

Figure 2-98. 180°3-D Are

Ultimax 3 System 5/18/94 2-129

Operator' s Manual

To calculate the centerline of cutter movement, the operator follows theseinstructions:

• Depending on the axis being worked, X can be interchangedwith Y or Z.

• The X and Z points must be calculated for an X-Z arc.

• The Y and Z points must be calculated for a Y-Z arc. (Allarcs travel through at least two axes.)

• To calculate the centerline in the X axis for a ball nose endmill, the operator uses this formula:

X. R(X.-X.)+X.R

Here are the elements of this formula:X. = Actual centerline dimension of cutter in X axis

X, = Arc reference starting point in the X axis

X, = X center point

R; = Radius of arc minus'/ cutter diameter

R = Radius of arc

Hints and Tricks

Operators follow these guidelines when programming 3-D arcs:

1. Never program cut right or cut left cutter compensation intoa block containing for a 3-D arc.

2. Always program the centerline of cutter movement.

3. Lower the tool calibration point by manually changing theTool Zero reference point one-half the cutter diameter.

For example, when the operator is using a 1/4" ball nose endmill with zero calibration of 2.2500" (ball tip touched towork surface), the new zero calibration is 2.3750" aftermanual change of reference . This change must beremembered when entering Z Up and Z Start dimensions(which must include the value of this manual change to thereference point).

2 - 130 Revision A Hawk 5M Machine

Conversational Part Programming

Circle

To mill a circle, the operator presses the Circle (F2) softkey on the NewBlock screen . Then this screen appears:

BLOCK 1 1 MILL CIRCLE IF DELETE BLOCK

TOOL I Z START 0.0300 1

TYPE ON Z BOTTOM -1.5888 F INSERT BLOCK2 BEFORE

FINISH TOOL B PLAICE FEED 0 0 I.F

K CENTER 0.BBBB MILL FEED 15.0 3i

V CENTER 0.0000 SPEED (RPM) 750 F PROGRAM4 PARAMETERS

RADIUS 3 5000 PECK DEPTH 0 0000 r. .F PART SETUP

(TOOL DIAMETER(TYPE

0.5000)DRILL)

5IF TOOL SETUP6IF

Enter a block aunber , use ENTER to edit block , or use 7ADVANCE . BACK , or sortkey

Figure 2-99. Mill Circle screen

F EXITB

The block number for this operation is determined by the position of thisdata block in the program . Note that this operation does not containsegments.

When the operator enters the Tool number for the operation , the ToolDiameter and Type parameters appear in parentheses on the right side ofthe screen . These values were entered during Tool Setup and cannot bechanged during the part programming.

Ultimax 3 System 5/18/94 2 - 131

Operator' s Manual

There are several softkey options available for the Type field:

• On (Fl) - locates the center of the tool on the programmedcontour of the circle.

• Inside (F2) - causes the tool to enter the part inside the contour ofthe circle and blend into the programmed contour using a 180°arc. Cutter compensation is automatically employed and theoutside edge of tool follows the programmed contour. (Thedirection the tool travels depends upon milling direction.) Thepoint where the tool enters the part is determined by the blendoffset and the point where the tool is withdrawn is determined bythe blend overlap and blend offset. (These parameters are definedin Program Parameters or Change Parameters.)

• Outside (F3) - is similar to the Inside function, except the toolenters the part outside the programmed contour and follows theoutside of the contour.

• Inside Tangent (F4) - causes the tool to enter the part adjacent tothe inside contour of the circle. Cutter compensation isautomatically used and the edge of the tool follows the inside ofthe programmed contour. The direction the tool travels dependsupon the milling direction. The tool is withdrawn from the partadjacent to the programmed contour.

• Outside Tangent (FS) - is similar to the Inside Tangent functionexcept that the tool enters the part adjacent to the outside contourof the circle. The tool's edge then follows the outside of theprogrammed contour. The tool is withdrawn from the partadjacent to the programmed contour.

• Pocket Boundary (F6) and Pocket Island (F7) softkeys aredisplayed only if the UltiPocket software option is installed. Referto the "Ultipockets" section for more information.

When On, Inside, Outside, Inside Tangent and Outside Tangent areselected, the tool enters the circle contour at the 3 o'clock position.

2 - 132 Revision A Hawk 5M Machine

Conversational Part Programming

The remaining fields on this screen have these definitions:

Fields Definitions

Finish Tool number of a tool used for finish pass. If a finishtool is selected, the first tool leaves the amount ofmaterial selected in Program Parameters OrChange Milling Parameters. The finish toolremoves the remaining stock down to theprogrammed dimension.

X Center "X" coordinate for the center point of the circle.

Y Center "Y" coordinate for the center point of the circle.

Radius this value with the X and Y center coordinatesdefine the location and size of the circle.

Z Start point above the part where the Z axis plungefeedrate begins.

Z Bottom where the mill feed rate begins.

Plunge Feed rate at which the tool initially enters the part.

Mill Feed is the X-Y feedrate. The value initially displayedhas been calculated by the control and can beretained, or changed to a different value.

Speed (RPM) the spindle speed for the tool calculated in ToolSetup. Entering a value here overrides the ToolSetup value for this data block.

Peck Depth the maximum depth to be cut in one pass. If thetotal depth is greater than this value , multiple toolpasses occur. Programming a zero (0) value forthis parameter causes the total programmed depthto be cut in one pass of the tool.

Ultimax 3 System 5/18/94 2 - 133

Operator's Manual

Frame

To mill a frame, the operator presses the Frame (F3) softkey on the NewBlock screen. Then this screen appears:

BLOCK ( 1

TOOL

MILL FRAME

I Z START 8.amF DELETE BLOCKI

TYPE POCK BOUNDARY Z BOTTOM -0.5888 F INSERT BLOCKPOCKET TYPEFINISH TOOL

IMMRDB PLI116E FEED 30.0

2 BEFOREI

K CORMDI -4.7547 MILL FEED 58.6F3

Y CORNER -4 .7547 SPEED (RPM) 2588 P PR09UM

X LENIN 18 .7238 PECK DEPTH 8.25884 PARAMETERSI

V LDCTH 9 . 5894 (TOOL DIAMETER 8.2590)F PART SETUP5

(TYPE DRILL) ICORNIIX RADIUS B . 88819 F TOOL SETUP

6POCKET OVERLAP 58

FEnter a block Dube'. uee BITER to edit block; or use 7ADVANCE . BACK. or eettke9

Figure 2-100. Mill Frame screen

F EXIT8

The block number for this operation is determined by the position of thisdata block in the program. Note that this operation does not containsegments.

When the operator enters the Tool number for the operation , the ToolDiameter and Type parameters appear in parentheses on the right side ofthe screen . These values were entered during Tool Setup and cannot bechanged during the part programming.

2 - 134 Revision A Hawk 5M Machine

Conversational Part Programming

The softkey selections for the Type field are as follows:

• On (Fl) - locates the center of the tool on the programmedcontour of the frame.

• Inside (F2) -causes the tool to enter the part inside the frame andblend into the programmed contour using a 180° arc. Cuttercompensation is automatically employed and the edge of toolfollows inside the programmed contour. (The direction the tooltravels depends upon milling direction.)

The point where the tool enters the part is determined by theblend offset and the point where the tool is withdrawn isdetermined by the blend overlap and blend offset. Theseparameters are defined in Program Parameters or ChangeParameters . Here is an example of an Inside frame:

Reference Comer

Figure 2-101 . Inside Mil Frame Operuion

Ultimax 3 System 5/18/94 2 - 135

Operator' s Manual

• Outside (F3) - is similar to the Inside function, except that thetool enters the part outside the programmed frame contour andthen follows the outside frame contour.

• Inside Tangent (F4) - causes the tool to enter the part adjacent tothe inside contour of the frame. Cutter compensation isautomatically used and the edge of tool follows the inside of theprogrammed contour. The direction the tool travels depends onmilling direction. The tool is withdrawn from the part adjacent tothe programmed frame contour.

• Outside Tangent (F5) - is similar to the Inside Tangent functionexcept the tool enters the part adjacent to the outside contour ofthe frame. The tool's edge then follows the outside programmedframe contour. The tool is withdrawn from the part adjacent tothe programmed frame.

• Pocket Boundary (F6) and Pocket Island (F7) softkeys aredisplayed only if the UltiPocket software option is installed. Referto the "Ultipockets" section for more information.

When On, Inside, Outside, Inside Tangent and Outside Tangent areselected, the tool enters the frame contour at the 6 o'clock position.

2 - 136 Revision A Hawk 5M Machine

Conversational Part Programming

The remaining fields on this screen have these definitions:

Fields Definitions

Finish Tool number of a tool used for finish pass. If a finishtool is selected, the first tool leaves the amount ofmaterial selected in Program Parameters orChange Milling Parameters. The finish toolremoves the remaining stock down to theprogrammed dimension.

X Corner "X" coordinate of any one of the four comers ofthe frame which then becomes the referencecorner.

Y Comer "Y" coordinate of the reference comer of theframe.

X Length "X" coordinate for this dimension as measuredfrom the reference comer. This value is positive ornegative relative to the reference comer. If thereference comer is at the left side of the rectangle,the x length is a positive (+) dimension. If thereference comer is at the right side, this parame:.rvalue is a negative (-).

Y Length "Y" coordinate for this dimension as measuredfrom the reference comer. This value is positive(+) if the reference comer is at the lower left, orlower right of the rectangular area and is negative(-) if the reference comer is at the top left, or topright of the rectangle.

Figure 2-102. X & Y Length Directional Measurement

Ultimax 3 System 5/18/94 2 - 137

Operator 's Manual

Frame Fields

Comer Radius

Z Start

Z Bottom

Plunge Feed

Mill Feed

Speed (RPM)

Peck Depth

Definitions (continued)

radius of the reference comer and is the same onall four comers.

point where plunge feed rate begins and z bottomis where the mill feed rate begins.

where the mill feed rate begins.

rate at which the tool initially enters the part.

is the X-Y feedrate. The value initially displayedhas been calculated by the control and can beretained or changed to a different value.

the spindle speed for the tool calculated in ToolSetup. Entering a value here overrides the ToolSetup value for this data block.

the maximum depth to be cut in one pass. If thetotal depth is greater than this value, multiple toolpasses occur. Programming a zero (0) value forthis parameter causes the total programmed depthto be cut in one pass of the tool.

2-138 Revision A Hawk 5M Machine

Conversational Part Programming

Face Milling

To perform a face milling operation, the operator presses the Mill Face(F4) softkey on the New Block screen. Then this screen appears:

BLACK $ 1 MILL FACE IF DELETE BLOCK

TOOL 1 Z START 9.0299 1i

TYPE X 1MIDIRECTIOMAL Z BOTTOM -B.ZSBB P INSERT BLOCS2 BEFORE

FINISH TOOL 8 PLUNGE FEED 5 8 I.F

X WIRIER 9.0988 MILL FEED 18.0 3j

Y WD®t 8.8®8 SPEED (RPM) 759 F PROGRAM4 PARAMETERS

X LENGTH 9 8000 PECK DEPTH 8 0000 I. .F PART SETUP

V LENGTH x.0080 (TOOL DIAMETER(TYPE

8.2508)DRILL)

SIF TOOL SETUP6

PEnter a block wuebw, use ENTER to edit block, or uaDVANCE B CK rtk

7A , A . or se ey

P EXITa

Figure 2-103.. Completed Mill Face screen

The block number for this operation is determined by the position of thisdata block in the program. Note that this operation does not containsegments.

When the operator enters the Tool number for the operation , the ToolDiameter and Type parameters appear in parentheses on the right side ofthe screen . These values were entered during Tool Setup and cannot bechanged during the part programming.

Ultimax 3 System Revision A 2 - 139

Operator 's Manual

The operator uses these types to describe the path of the cutter . Each toolpass is 60% of the tool diameter from the previous pass. Material isremoved using 60% of tool diameter, but the last pass may remove lessmaterial. The Type softkeys have these uses:

• X Unidirectional (Fl) - directs the tool to cut in one direction,parallel to the X axis and then move the spindle to the retractclearance value defined in Program Parameters or ChangeParameters . Axis movement occurs at rapid traverse to return thetool to the start point of the next cutting path determined by thecontrol.

n 11 n n n n It n R n

Blend Offset ' Unidirectional

'Y' Unidirectional

n

OBlend Onset

Figure 2 -104. Face Milling Types

O

E3 IV

.d

LUD

'Y' Bidirectional

The start point is the lower left or right corner of rectangular area,depending on the milling direction defined in ProgramParameters or Change Parameters. The start point for each cut isthe tool radius plus blend offset away from the starting edgecomer.

2 - 140 5/18/94 Hawk 5M Machine

Conversational Part Programming

• X Bi-directional (F2) - directs the tool to cut in one directionfrom the start point, parallel to the X axis. Axis positioningoccurs to place tool over the next cutting path and cutting is inthe opposite direction. The new cutting path for the tool isautomatically determined by the control. The tool zigzags overthe rectangular face area of the part, always using 60% of tooldiameter (but the last pass may be less).

The starting point is either the lower left or right comer of therectangular area, depending on milling direction defined inProgram Parameters or Change Parameters.

• Y Unidirectional (F3) - directs the tool to cut in one direction,parallel to the Y axis and then move the spindle to the retractclearance value defined in Program Parameters,or ChangeParameters. Axis movement occurs at rapid traverse to return thetool to the start point of the next cutting path determined by thecontrol.

Start point of operation is the lower left or right corner ofrectangular area, depending on milling direction defined inProgram Parameters or Change Parameters. The start point foreach cut is the tool radius plus blend offset away from the startingedge corner.

• Y Bi-directional (F4) - directs the tool to cut in one directionfrom the start point, parallel to the Y axis. Axis positioningoccurs to place tool over the next cutting path and cutting is inthe opposite direction. The new cutting path for the tool isautomatically determined by control. The tool zigzags over therectangular face area of the part, always using 60% of tooldiameter (but the last pass may be less).

The starting point is either the lower left or right comer of therectangular area , depending on milling direction defined inProgram Parameters or Change Parameters.

Ultimax 3 System Revision A 2 - 141 i"

Operator' s Manual

The remaining fields on this screen have these definitions:

Fields Definitions

Finish Tool number of a tool used for finish pass. If a finishtool is selected, the first tool leaves the amount ofmaterial selected in the parameters. The finishtool removes the remaining stock down to theprogrammed dimension.

X Comer "X" coordinate of any one of the four comers ofthe face which then becomes the referencecorner.

Y Comer "Y" coordinate of the reference comer of the face.

X Length "X" coordinate for this dimension as measuredfrom the reference corner. This value is positive ornegative relative to the reference corner. If thereference corner is at the left side of the rectangle,the x length is a positive (+) dimension. If thereference comer is at the right side, this parametervalue is a negative (-).

Y Length "Y" coordinate for this dimension as measuredfrom the reference comer. This value is positive(+) if the reference corner is at the lower left, orlower right of the rectangular area and is negative(-) if the reference corner is at the top left, or topright of the rectangle.

Z Start point where plunge feed rate begins and z bottomis where the mill feed rate begins.

Z Bottom where the mill feed rate begins.

Plunge Feed rate at which the tool initially enters the part.

Mill Feed is the X-Y feedrate.

Speed (RPM) the spindle speed for the tool calculated in ToolSetup. Entering a value here overrides the ToolSetup value for this data block.

Peck Depth the maximum depth to be cut in one pass. If thetotal depth is greater than this value, multiple toolpasses occur . Entering zero (0) value causes thetotal programmed depth to be cut in one pass ofthe tool.

2 -142 5/1 8/94 Hawk 5M Machine

Conversational Part Programming

Ellipse

To mill an elliptical shape , the operator presses the Mill Face (F4) softkeyon the New Block screen . Then this screen appears:

BLOCX I I MILL ELLIPSE

TOOL I

TYPE ON

FINISH TOOL

IF DELETE BLOCX

Z START 0.8100 1

Z BOTTOM -6.7580 F INSERT BLOCX2 BEFORE

B PLUNGE FEED 10.0 rF

X CENTER 0.0880 MILL FEED 79.8 3i

F CENTER 0.0800 SPEED (RPM) 1000 F PROGRAM4 PARAMETERS

X RADIUS 156 . 4260 PEX DEPTH 0.0000 IF PART SETUP

Y RADIUS IS6.4268 (TOOL DIAMETER 0.2500) 5(TYPE DRILL) I

F TOOL SETUP6

FEnter a block nue►er, nee ENTER to edit block , or use 7ADVANCE . BAcx. or sottkey

Figure 2-105. Mill Ellipse screen

FfliTEXIT

B

The block number for this operation is determined by the position of thisdata block in the program . Note that this operation does not containsegments.

When the operator enters the Tool number for the operation, the ToolDiameter and Type parameters appear in parentheses on the right side ofthe screen . These values were entered during Tool Setup and cannot bechanged during the part programming.

2 - 143Ultimax 3 System Revision A

Operator' s Manual

The operator uses the Ellipse types to describe the path of the cutter.These softkeys are used to select the type:

• On (Fl) - the center of the tool to follow the programmedelliptical contour.

• Inside (F2) - directs the tool to enter the part inside the ellipseand then blend into the programmed contour. Cuttercompensation is employed and the tool's edge follows the insideof the elliptical contour.

The tool enters the part at the larger area of either the 3 o'clock,or 6 o'clock position.

Direction of tool travel depends on milling direction as defined inProgram Parameters or Change Parameters. The tool enters thepart as defined by the elliptical pattern and blend offset. The toolis removed from the part as determined by the pattern, blendoffset and blend overlap. (Blending is defined in ProgramParameters and Change Parameters.)

Figure 2-106. Mill Ellipse - inside Type

• Outside (F3) - is similar to the Inside function, except the toolenters the part outside the programmed elliptical contour.

2 - 144 5/18/94 - Hawk 5M Machine

Conversational Part Programming

• Inside Tangent (F4) - programs the tool to enter the partadjacent to the inside contour of the ellipse. Cutter compensationis employed and the edge of tool follows the inside of theprogrammed elliptical contour. The direction the tool travelsdepends on milling direction. The tool is withdrawn from thepart adjacent to the programmed contour.

• Outside Tangent (F5) - is similar to the Inside Tangent functionexcept the tool enters the part adjacent to the outside contour ofthe ellipse. The tool' s edge then follows the outside of theprogrammed contour. The tool is removed from the part adjacentto the programmed elliptical contour.

• The Pocket softkeys clean out all material within the programmedelliptical contour . The tool enters the part at the center of theellipse and moves out to the perimeter (cleaning out the entirearea). The overlap for each tool path is programmable from 0%to 99% (determined by the pocket overlap value).

Ultimax 3 System Revision A 2 - 145

Operator' s Manual

The remaining fields on this screen have these definitions:

Fields Definitions

Finish Tool number of a tool used for finish pass. If a finishtool is selected, the first tool leaves the amount ofmaterial selected in the parameters . The finishtool removes the remaining stock down to theprogrammed dimension.

X Center "X" coordinate of the center of the ellipse.

Y Center "Y" coordinate of the center of the ellipse.

X and Y Radius identify the major and minor axes for the ellipse,respective to the appropriate axis. Major andminor axes of the ellipse must be programmedparallel to these respective axes of the machine.An ellipse with the major and minor axesnonparallel to the machine can be programmed byemploying the Pattern - Loop Rotate routine. Theellipse is rotated after it is initially programmed.

Z Start point where plunge feed rate begins and z bottomis where the mill feed rate begins.

Z Bottom where the mill feed rate begins. The value initiallydisplayed has been calculated by the control andcan be retained , or changed to a different value.

Plunge Feed rate at which the tool initially enters the part.

Mill Feed is the X-Y feedrate.

Speed (RPM) the spindle speed for the tool calculated in ToolSetup . Entering a value here overrides the ToolSetup value for this data block.

Peck Depth the maximum depth to be cut in one pass. If thetotal depth is greater than this value , multiple toolpasses occur . Entering zero (0) value causes thetotal programmed depth to be cut in one pass ofthe tool.

. 2 - 146 5/18/94 Hawk 5M Machine

Conversational Part Programming

Lettering

This routine permits milling up to thirty (30) block characters selectedfrom the graphics screen. Selection is made from a 64 character set,consisting of upper case letters, digits, 27 different symbols and a space.This data block may be rotated, mirror-imaged (for mold use), or repeatedin Patterns. Cutter compensation is not available for this routine, somilling is performed using the centerline of the tool.

To enter a lettering block, the operator selects the Lettering (F6) softkeyfrom the New Block screen . Then this screen appears:

BLOCK ! 33 HILL LETTERING

TOOL 8

X START -0.85811

V START -1.9780

HEIGHT

CHARACTER WIDTH S. 12M

F DELETE BLOCKZ START 8.82910 1

Z BOTTOM -0.8188 F IHSRRT BLOCK2 BEFORE

PLUNGE FEED 5.0 IF

MILL FEED 38.0

SPEED (RPM) 6988 P PROGRAM4 PARAMETERS

PECK DEPTH 0.8090 IF PART SETUP

(TOOL DIAMETER 8.0625) 5(TOR END MILLI

0.1699

iULTIHAK 111 F TOOL SETUP

6

FEnter a block mober . ece ENTER to edit block. er uee 7ADVANCE . BACK. or eoftkey

8

Figure 2-107. Mill Lettering screen

Ultimax 3 System Revision A 2 - 147

Operator' s Manual

The fields on this screen have these definitions:

Fields Definitions

X Start "X" coordinate for the lower left-hand corner ofthe first character to be milled.

Y Start "Y" coordinate for the lower left-hand comer ofthe first character to be milled.

Height determines the character size.

Character Width determines the character size. Width includes thecharacter left justified, plus some spacingbetween it and the next character to be milled.Spacing between the characters is equal to the tooldiameter. Because cutter compensation is notused in this routine and letter contouring followsthe center of the tool, character spacing can beadjusted by adjusting tool diameter in Tool Setup.

Z Start point where plunge feed rate begins and z bottomis where the mill feed rate begins.

Z Bottom where the mill feed rate begins. The value initiallydisplayed has been calculated by the control andcan be retained, or changed to a different value.

Plunge Feed rate at which the tool initially enters the part.

Mill Feed is the X-Y feedrate.

Speed (RPM) the spindle speed for the tool calculated in ToolSetup. Entering a value here overrides the ToolSetup value for this data block.

Peck Depth the maximum depth to be cut in one pass. If thetotal depth is greater than this value, multiple toolpasses occur. Entering zero (0) value causes thetotal programmed depth to be cut in one pass ofthe tool.

2 - 148 5/18/94 Hawk 5M Machine

Conversational Part Programming

The operator uses the trackball and Select console key to indicate (and

enter) the characters and spaces from the Letter Selection screen. Thenthese selections appear on the text line on the left-hand screen.

When the graphics cursor indicates the desired character or space, pressSelect key to display the character on the text screen. To delete acharacter from the text field, move the graphics cursor to the back spacebox in the grid and press the Select key (each depression removes onecharacter or space). The console keyboard can also be used to programnumbers, decimal points, and keyboard symbols into the field by pressingthe respective key.

Ultimax 3 System Revision A 2 - 149

Operator's Manual

3-D Milling Option

The 3-D Milling option is purchased separately from the basic Ultimax 3software. To enter a 3-D milling block, the operator presses the 3DContour (F7) softkey on the New Block screen. The Mill 3D screen(shown below) appears allowing the operator to describe the operation.

BLOCX 0 13 MILL 3D IF D E

TOOL 1 Z START 8.0288EL TE BLOCX

TYPE REVOLVE ABOUT X PLUNGE FEED 38.0 F INSERT BLOCK

CENTERLINE V 8 8888 MILL FEED 180 82 BEFORE

. .F

CRITERLINE E -1.1880 SPEED (RPM) 3688 3

START ANGLE 36.500 PECK DEPTH 8.8808 F PROGRAM4 PARAMETERS

Elm ANGLE 143 580 STOCK ALLOUJICE 0 8808 I. .F PART SETUP

CUT DIRECTION WITH CONTOUR (TOOL DIAMETER 0.3758) 5(TYPE BALL END BILL) I

BIDIRECTIONAL YES F TOOL SETUP6

STEP SIZE 8 8188.P

Enter a block amber . use ENTER to edit block, or useADVANCE BACK ftk

7. . or so ey

F EXIT8

Figure 2 -108. Completed Mill 3 -D screen

For complete 3-D programming information , refer to the 3DProgramming Instruction Manual sent with the optional software.

2 - 150 5/18/94 Hawk 5M Machine

Conversational Part Programming

Sample Milling Program

In this milling example, the finished part has a frame cut .15" around theouter edge of the part. The work piece is .65" thick. The bottom of themilled pocket on the left is .4" from the surface of the part. The ellipticalshape on the right is milled .2" deep. The operator will be using a .201(#7) drill and a 3/8 end mill.

Here is the drawing used to create the program:

.

80.2543 ®

.51® 1.72

80.2476®

Drill (8 Plaees)Through 3/8C'Bore . 5 Deep (7 Places)

T

1III F- 25t-- 2.25--J

4

.075 R(4 Places)

Figure 2-109. Pan drawing used in the sample Wiling program

7_

6 5

Ultimax 3 System Revision A 2 - 151

Operator' s Manual

Here is a copy of the part program developed for the drawing on theprevious page. Since Ultimax allows considerable flexibility in.developingpart programs, this is not the only way the part can be programmed.Watch for inserted explanations of the special features of this sampleprogram.

Hurco Ultimax Part Program

Milling.HD31 Inch

Standard

Part Setup

Part Zero X 5.0000 Safety Work Region

Y 10.0000 Z Top (•) 99.0000

Offset Z 0.0000 Z Bottom C- ) -1.0000

X Left C-) -99.0000

X Right C• ) 99.0000

Y Front C- ) -99.0000

Y Back C+l

Fixture Offset

99.0000

I

General Parameters

Retract Clearance 1.0000 INRapid Traverse 400.0 IPM

Peck Clearance Plane 0.0500 INChord Error 0.0001 INDepletion Retract 0.0050 IN

Holes Parameters

Bore Orient Retract 0.0200 INDrill Dwell 0.5 SEC

Bore Due 11 1.0 SEC

Milli P tng arame ers

Blend Offset 0.1250 INBlend Overlap 0.1250 INFinish Feed 100 %Finish Speed 100 iFinish XY 0.1250 IMFinish Z 0.0000 IMMilling Direction ClimbPocket Overlap 10

Cutter Comp Parameter Insert Arc

2 - 152 5/18/94 Hawk 5M Machine

Conversational Part Programming

Hurco Ultimax Part Program 2 Inch

Milling .HD3 Standard

Program Parameters

Ouerride Lockout Off

Program Protect Partial

Tool Change Position Yes

Tool Setup

1 Type Drill

Diameter 0.2010

Zero Calibration -10000.

Speed (RPM) CW 2000

Coolant Off

Gear range 1

Tool Humber 1

Diameter Offset 1

Length Offset 1

2 Type End Mill

Diameter 0.3750

Zero Calibration -10000.

Speed (RPM) CW 1000

Coolant Off

Gear range I

Tool Humber 2

Diameter Offset 2

Length Offset 2

99 Diameter 0.0000

Zero Calibration -10000.

Speed (RPM) CW 0

Coolant Off

Gear range 1

Tool Humber 99

Diameter Offset 99

Length Offset 99

There is no tool #99 available . The operator added a tool setup for tool#99 to use as a dummy tool for drawing purposes only.

Ultimax 3 System Revision A 2 - 153

Operator' s Manual

Hurco Ultimax Part Program 3 InchMilling.HD3 Standard

Data Blocks

1 Mill Frame

Tool 99 Z Start 0.0000Type Out/Tan Z Bottom -0.7500Finish Tool 0 Plunge Feed 0.0X Corner 0.0000 Mill Feed 0.0Y Corner 0.0000 Speed (RPM) 0X Length 7.0000 Peck Depth 0.0000Y Length 3.000Corner Radius 0.0000Lead Length 0.0000 Lead Angle 0.0000

This block creates an outline of the part on the graphics screen to use asan outline during programming . The operator will delete this block beforecutting the part.

2 Holes

Drill

Tool

2 Start

2 Bottom

Plunge Feed

Speed (RPM)

Peck Depth

Peck Type

Bolt Circle

Humber

X Center

Y Center

Radius

Start Angle

1

0.0200

-0.9000

10.0

2000

0.4600

Standard

8 Skip List4.0000

1.5000

0.8600

0.000

Block 2 drills the holes first using tool 1.

2-154 5/18/94 Hawk 5M Machine

Conversational Part Programming

Hurco Ultimax Part Program 4 Inch

Milling.HD3 Standard

Data Blocks

3 Mill Frame

Tool 2 Z Start

Type Outside Z Bottom

0.0200

-0.1500

Finish Tool

X Corner

Y Corner

X Length

Y Length

Corner Radius

Lead Length

2 Plunge Feed

0.2500 Mill Feed

0.2500 Speed (RPM)

6.5080 Peck Depth

2.5000

0.0750

0.0001 Lead Angle

10.0

10.01000

0.0000

0.0000

The finish tool is used for two passes to remove corner material . Refer tothe program parameters shown earlier in the program.

4 Change General Parameters

Retract Clearance 1.0000 INRapid Traverse 400.0 IPM

Peck Clearance Plane 0 . 0500 INChord Error 0.0001 IN

Depletion Retract 0.0050 IN

Change Holes ParametersBore Orient Retract 0 . 0200 INDrill Dwell

Bore Dwell

0.5 SEC

1.0 SEC

Change Milling ParametersBlend Offset 0.1250 IN

Blend Overlap 0.1250 INFinish Feed 100 i

Finish Speed 100 ZFinish XY 0 . 0150 IN

Finish Z 0.0050 IN

Milling Direction ClimbPocket Overlap 10 Z

This change parameters block restores the program parameters.

Ultimax 3 System Revision A 2-155

Operator' s Manual

Hurco Ultimax Part Program

Milling.HD3

5 Inch

Standard

5 Mill Contour

Segment 0 Start

Tool 2 Plunge Feed 10.0Cutter Comp Pock Boundary Mill Feed 10.0Finish Tool 2 Speed (RPM) 1000X Start 2.2500 Peck Depth 0.0000Y Start 1.5000

2 Start 0.0200

2 Bottom -0.4000

Pocket Ouerlap 40

Segment

X EndI Line

2.2500Y End CAL 2.2500XY Length 0.7500XY Angle 90.000

Segment 2 Blend Arc

Radius 0.2543 (Direction CCW)CX Start CAL 2.2500)CY Start CAL 1.9957)(X End CAL 1.9957)(Y End CAL 2.2500)

CX Center CAL 1.9957)CY Center CAL 1.9957)

Segment 3 LineX End CAL 0.5000

Y End CAL 2.2500

XY Length CAL 1.7500

XY Angle 180.000

Segment 4 Blend ArcRadius 0.5100 (Direction CCW)

(X Start CAL 1.0100)(Y Start CAL 2.2500)(X End CAL 0.5000)

CY End CAL 1.7400)(X Center CAL 1.0100)(Y Center CAL 1.7400)

2 - 156 5/18/94 Hawk 5M Machine

Conversational Part Programming

Hurco Ultimax Part Program

Milling . HD3

6 Inch

Standard

Segment 5 Line

X End CAL 0.5000

Y End CAL 0.7500

XY Length 1.5000

XY Angle -90.000

Segment 6 Blend Arc

Radius 0.5100 (Direction CCW)

CX Start CAL 0.5000)

CY Start CAL 1.2600)

CX End CAL 1.0100)

CY End CAL 0.7500)

CX Center CAL 1.0100)

CY Center CAL 1.2600)

Segment 7 Line

X End CAL 2.2500

Y End CAL 0.7500

XY Length 1.7500

XY Angle 0.000

Segment 8 Blend Arc

Radius 0.2476 (Direction CCW)

CX Start CAL 2.0024)

(Y Start CAL 0.7500)

CX End CAL 2.2500)

CY End CAL 0.9976)CX Center CAL 2.0024)

(Y Center CAL 0.9976)

Segment 9 Line

X End 2.2500

Y End 1.5000

XY Length CAL 0.7500XY Angle 90.000

Ultimax 3 System Revision A 2 - 157

Operator' s Manual

Hurco Ultimax Part Program

Milling.HD3

7 Inch

Standard

6 Mill Ellipse

Tool 2 Z Start 0.0200Type Pocket Z Bottom -0.2000Finish Tool 0 Plunge Feed 10.0X Center 5.8820 Mill Feed 10.0Y Center 1.5000 Speed (RPM) 1000X Radius 0.5000 Peck Depth 0.0000Y Radius 1.0000

7 Mill Circle

Tool 2 2 Start -0.1800Type Inside Z Bottom -0.7600Finish Tool 0 Plunge Feed 10.0X Center 5.8820 Mill Feed 10.0Y Center 1.5000 Speed (RPM) 1000X Radius 0.4500 Peck Depth 0.2867Y Radius 0.0001 Lead Angle 0.0000.

8

Note that the Z Start is below part zero in block #7. This is acceptable ifthe Retract Clearance parameter is large enough to clear the part for thenext block.

Holes

Counterbore

Tool

Z Start

2 Bottom

Plunge Feed

Speed CRPM)

Peck Depth

Peck Type

Bolt Circle

Humber

X Center

Y Center

Radius

Start Angle

20.0200

-0.50005.0

1008

0.0000

Standard

8 Skip List

4.0000 4

1.5000

0.86000.000

2 - 158 5/18/94 Hawk 5M Machine

Conversational Part Programming

Pattern OperationsThis section presents detailed descriptions of the Pattern options inUltimax 3. Operators use pattern operations to save programming time byduplicating part geometry to complete a part program or create multipleparts from one program.

The chart below shows the relationship of the pattern options to the Inputbutton and its subsequent menu selections.

Pattern Options Hierarchy Chart

Input Button

Part Setup (Fl )

Tool Setup (F2)

Part Programming (F3)

Special (F6)

Rotary (F7)

Exit (F8)

- Loop Rectangular (Fl)

- Loop Linear (F2)

- Loop Angular (F3)

Loop Rotate (F4)

- Pattern Locations (F5)

- Scale (F6)

- Mirror Image (F7)

-Pattern End (F8)

Figure 2-110. Pattern Options Hierarchy Chart

Ultimax 3 System

Position (Fl)

Holes (F2)

Milling (F3)

Patterns (F4)

Miscellaneous (F5)

Revision A 2-159

Operator' s Manual

Pattern operations repeat or modify a sequence of data blocks. To accessthe pattern programming options, press the Part Programming (F3)softkey and press the Patterns (F4) softkey to display this screen:

BLOCK 1 I NEW BLACK IP 1) LOOP1 AECTANQUAR

F 2) LOOP LINEAR2

F 3) LOOP ANGULAR3

F 4) LOOP ROTATE4i

F 5) PATTERN5 LOCATIONS

P 6) SCALE6

P 7) MIRROR IMAGEChoose two of block 7

F 0) PATTERN END8

Figure 2-111. Pattern Soft keys

These softkey options are available:

• Loop Rectangular (Fl) - used to repeat a pattern along linesparallel to the X and Y axes.

• Loop Linear (F2) - used to repeat a pattern along a line definedin the XY plane.

• Loop Angular (F3) - used to repeat a pattern along a circularpath.

• Loop Rotate (F4) - used to repeat pattern along a circular path.The pattern is rotated around the XY center point and onlyexecuted in specified locations.

• Pattern Locations (F5) - lists the locations where a pattern willbe repeated. The operator may enter up to 999 different locations.

• Scale (F6) - reduces or increases the size of a pattern by a factorranging from 10% to 1000%.

• Mirror Image (F7) - copies an existing part as a mirror image tocreate a new part.

• Pattern End (F8) - the last block in any pattern operation.

2 - 160 5/18/94 Hawk SM Machine

Conversational Part Programming

Hints and Tricks

The following basic pattern principles help operators to program Patterndata blocks successfully:

1. The block defining the operation to be performed must beinserted before the first block of the sequence being repeated ormodified.

2. The last data block in the sequence (being repeated or modified)must be followed by a Pattern End data block.

3. The number of Pattern End blocks must equal the number ofpattern routines.

4. A pattern sequence can be nested up to ten deep (i.e., entirelycontained within another pattern).

5. If Pattern sequences are nested, the control executes theinnermost patterns first, as in the following example:

Data Block #1 - Pattern Scale

Data Block #2 - Pattern Rotate

Data Block #3 - Pattern Mirror Image

Data Block #4 - Mill Contour

Data Block #5 - Pattern End

Data Block #6 - Pattern End

Data Block #7 - Pattern End

When the system executes these four blocks, the mill contour ismirrored . The mirrored image(s) are rotated one or more times;and the whole rotation pattern is then scaled.

6. To prevent excessive tool changes , the operator should programonly one tool for each pattern sequence . Here is sample list ofoperations that could be used to create a seven-hole bolt circlein one data block that can then become the pattern:

Data Block #1 : - Center Drill

Drill

Countersink

Tap

Bolt Circle

Ulumax 3 System Revision A 2 - 161

r

Operator' s Manual

7. Then the operator can use the bolt circle data to create a patternby programming a Patterns Locations and a Pattern End aroundeach tool as follows:

Data Block #1 -

Data Block #2 -

Data Block #3 -

Data Block #4 -

Data Block #5 -

Data Block #6 -

Data Block #7 -

Data Block #8 -

Data Block #9 -

Data Block #10 -

Data Block #11 -

Data Block #12 -

Pattern Location

Center Drill Bolt Circle

Pattern End

Pattern Location

Drill Bolt Circle

Pattern End

Pattern Location

Countersink Bolt Circle

Pattern End

Pattern Location

Tap Bolt Circle

Pattern End Data Block

To move the bolt circle data block, shown in #6 on the previouspage, to another location on the part, a Patterns Locations blockcan be programmed and inserted before the bolt circle block.However, if the Patterns Locations block is programmed beforethe bolt circle block and a Pattern End after it, a tool change isrequired for each tool during each Bolt Circle sequence.

2 - 162 5/18/94 Hawk 5M Machine

Conversational Part Programming

Loop Rectangular

This routine allows a given pattern to be repeated a specified number oftimes along lines parallel to the X and Y axes. The original pattern isalways milled at its programmed location.

Y Axis

X Number = 3Y Number = 2

Y I kX Distance-

Distan^^

OriginalPattern

Figure 2-112. Sample Loop Rectangular operation

X Axis

Ultimax 3 System Revision A 2 - 163

Operator's Manual

To display the Pattern Loop Rectangular screen, the operator presses theFl softkey. Here is a completed screen.

BLOCK • 1 PATTERN LOOP RECTANGULARF DELETE BLOCK

K NUMBER 6 1

V NUMBER 2 F INSERT BLOCK2 BEFORE

X DISTANCE 1.2500 IF

V DISTANCE -2.5088 3

F PROGRAM4 PARAMETERSP

F PART SETUP5iF TOOL SETUP6

PEnter a block ausber . use ENTER to edit block . or use 7ADVANCE . BACK , or sattkey f

F EXITB

Figure 2-113. Pattern Loop Rectangular screen

The fields on this screen hold this information about the pattern:

Fields Definitions

X Number number of times the programmed routine will be.repeated along a line parallel to the "X" axis.

Y Number number of times the programmed routine will berepeated along a line parallel to the "Y" axis.

X Distance distance between the patterns along the "X" axis lines.(Negative values indicate direction.)

Y Distance distance between the patterns along the "Y" axis lines.(Negative values indicate direction.)

2-164 5/18/94 Hawk 5M Machine

Conversational Part Programming

Loop Linear

This routine allows a given pattern to be repeated a specified number oftimes along a line defined in the "X-Y" plane.

Even though the defined line of this pattern is not parallel to the X or Yaxes, the original pattern is always milled at its programmed location andorientation does not change with respect to the X and Y axes. Anexample of this type of routine is shown below.

Y Axis

X Axis

Figure 2-114. Sample Loop Linear operation

Ultimax 3 System Revision A 2 - 165

Operator' s Manual

To access the linear pattern screen, the operator presses the Loop Linear(F2) softkey. The Block number shown in the upper left corner of thescreen is determined by the position of this data block in the program.

BLOCX 2 PATTERN LOOP LINEAR

NUMBER 1

X DISTANCE 1.8600

V DISTANCE -2.8600

ANGLE • -63.435

DISTANCE 2.2361

F

F2

F3

F PROGRAM4 PARAMETERSi

F PART SETUP5

F TOOL SETUP6iF7

F EXITB

Enter angle of linear repeats, counterclocbiae Mean3 O'clock

Figure 2-115. Loop Linear screen

The fields on this screen hold this information about the pattern:

Fields Definitions

Number the number of times the pattern will be repeated alongthe defined line.

X Distance distance between the repeated pattern in the direction ofthe X axis (+ or -).

Y Distance distance between the repeated pattern in the direction ofthe Y axis (+ or -). If this or the X Distancemeasurements are entered , the control automaticallycalculates the remaining two values (indicated by"CAL" preceding the value . The calculated values maybe stored by pressing the Enter key when the cursor ison the field . If the operator does not want to use thecalculated value , the operator may type in a differentvalue.

2 - 166 5/18/94 Hawk 5M Machine

Conversational Part Programming

Here are the remaining Loop Linear fields:

Fields Definitions (continued)

Angle angle (in degrees) between the defined line and the Xpositive axis. A positive value is counterclockwise(CCW) from 3 o'clock position, and a negative value isclockwise (CW) from the 3 o'clock position.

Distance the dimensional value between repeated patterns alongthe defined line.

The operator must also program a Pattern End data block for the sequencethat is repeated in this Loop Linear block.

Ultimax 3 System Revision A 2 - 167

Operator' s Manual

Loop Angular

This routine allows a programmed pattern to be repeated a specifiednumber of times along a circular path.

Pattern orientation does not change with respect to the X and Y axes. Theoriginal programmed pattern is not executed at its original position, unlessthe routine places it at that location. The pattern is only shown in thelocations specified by the routine.

Y Axis

X & Y Center Points

Figure 2-116. Sampk Loop Angular operation

2 - 168 5/18/94 Hawk 5M Machine

Conversational Part Programming

To access the angular pattern screen, the operator presses the LoopAngular (F3) softkey. Here is s completed Pattern Loop Angular screen:

BLOCK 3 PATTERN LOOP ANGULAR

MIR®ER 1

X CENTER 1.0888

V CENTER -3.0888

START ANGLE 98.880

ROTATE ANGLE 18.888

X REFERENCE 4.0888

V RSPEIHICE • 2.8888

Enter refcn..c point of Pattern

Figure 2-117. Pattern Loop Angular screen

F1

2

F3

F PROGRAM4 PARAMETERS

F PART SETUP

F TOOL SETUP6

F

F EXIT8

Fields Definitions

Number number of times the pattern is repeated along thespecified circular path.

X Center "X" coordinate of the reference point about which thepattern is rotated.

Y Center "Y" coordinate of the reference point about which thepattern is rotated.

Start Angle angle value between the original pattern and thelocation of the first pattern created by this routine.

Rotate Angle the angle between the repeated patterns being executedby this routine.

X Reference "X" coordinate of the reference point (the only point inthe pattern always on the circular path defined by thisroutine).

Y Reference "Y" coordinate of the reference point (the only point inthe pattern always on the circular path defined by thisroutine).

The operator must also program a Pattern End data block for the sequencethat is repeated in this Loop Angular block.

Uhimax 3 System Revision A 2 - 169

Operator' s Manual

Loop Rotate

This routine is similar to the Loop Angular and allows a programmedpattern to repeated along a circular path defined in the program. However,the Loop Rotate operation rotates the pattern around the X-Y center pointand executes the pattern only at the locations identified in the program.

Y Axis

X Axis

Figure 2-118. Sample Loop Rotate operation

Important

The original programmed pattern is not executed at its original position,unless this routine places it at that location. The pattern is only shown inthe locations specified by the routine.

2 - 170 5/18/94 Hawk 5M Machine

Conversational Part Programming

To access the angular pattern screen, the operator presses the Loop Rotate(F4) softkey. Here is s completed Pattern Loop Rotate screen:

BLOCK I 4 PATTERN LOOP ROTATE IF DELETE BLOCK

MURDER 1 1

X GOITER 1 .0000 F INSERT BLOCK2 BEFORE

3 0000 iV COTTER .-F

START ANGLE 90.000 3

ROTATE MCLE 5.000 F PROGRAM4 PARAMETERS

F PART SETUP5I

F TOOL SETUP6

FEnter a block member, use OTTER to edit block . or use 7ADVANCE . BRCS. or softkey I

F EXITe

Figure 2 -119. Pattern Loop Rotate screen

The fields on this screen hold this information about the pattern:

Fields Definitions

Number number of times the pattern will be repeated along thespecified circular path.

X Center "X" coordinate used to define the circular path of therepeated pattern.

Y Center "Y" coordinate used to define the circular path of therepeated pattern.

Start Angle angle value between the original pattern and thelocation of the first pattern created by this routine. Ifthis location is the same as the original programmedpattern , the value in this field will be zero.

Rotate Angle the angle between the repeated patterns being executedby this routine.

The operator must also program a Pattern End data block for the sequencethat is repeated in this Loop Rotate block.

Operator' s Manual

Pattern Locations

This routine allows a programmed pattern to be repeated up to 999different locations . The pattern is repeated by offsetting the pattern witheach displacement specified in the list of locations.

To display the Pattern Locations screen , the operator presses the PatternLocation (F5) softkey.

BLOCK S PATTERN LOCATIONS

X OFFSET V OFFSET Z OFFSETF DELETE LOCATION

1 1.0880 0.0000 0.0800 P INSERT LOCATION21 1.8000 0.0000 -0.7500 2 BEFORE

I.F3

F4

lFS

F

Enter an offset to cove the pattern to a vier location

F EXIT8

Figure 2-120. Pattern Locations screen

The fields on this screen hold this information about the pattern:

Fields Definitions

X Offset location where the pattern is to be executed in the Xaxis. If this is Location #1 and the pattern is to be at itsoriginal location , this coordinate must be zero. Thevalue for this parameter is the offset for the X axis.

Y Offset location where the pattern is to be executed in the Yaxis . If this is Location #1 and the pattern is to be atthe original location , this coordinate must be zero. Thevalue for this parameter is the offset for the Y axis.

Z Offset dimensional offset for the Z axis used when a vise orother fixture holds multiple parts at different levels.

The operator must also program a Pattern End data block for the sequencethat is repeated in this Loop Locations block.

2 - 172 5/18/94 Hawk 5M Machine

Conversational Part Programming

Scale

This routine allows a programmed pattern to be scaled -down or scaled-upto a programmed factor ranging from 0.100 to 10.000 (10% to 1000%respectively). Scaling is executed around the specified X, Y and Zcoordinates for the point in the pattern where scaling occurs.

Original Pattern

X ReferenceY Reference

Figure 2-121. Sample Loop Angular operation

Original Pattern

X Scale = 0.5Y Scale = 0.5

X ReferenceY Reference

Ultimax 3 System Revision A 2 - 173

Operator' s Manual

To display the Pattern Scale screen, the operator presses the Scale (F6)softkey.

BLOCK 7

X REFBKBtICE

V REFERENCE

PATTERN SCALE

0.8808

8.0000

IF1

F2

2 REFERENCE 0.0008F

X SCALE 1.000 3

V SCALE 1.000 F PROGRAM1 PARAMETERS

2 SCALE 1.8100

Enter center point of ncaling

Figure 2-122. Pattern Scale screen

F PARS SETUP5

F TOOL SETUP6

F7

F EXITa

2 - 174 5/18/94 Hawk 5M Machine

Conversational Part Programming

The fields on this screen hold this information about the pattern:

Fields Definitions

X Reference "X" coordinate of the point from which the scaling willbe performed.

Y Reference "Y" coordinate of the point from which the scaling willbe performed.

Z Reference "Z" coordinate of the point from which the scaling willbe performed.

X Scale Factor scaling factor from the "X" axis. If scaling is notexecuted from this axis, enter 1.0000. A value that isless than 1.0000 scales down the pattern. Greater than1.0000 scales up the pattern.

Y Scale Factor scaling from the "Y" axis operates in the same manneras the "X" axis factor.

Z Scale Factor scaling from the "Z" axis operates in the same manneras "Y" and "X" axes' scaling.

The operator must also program a Pattern End data block for the sequencethat is repeated in this Loop Locations block.

Important

If the "X" and "Y" Scale Factors are different, the system will not performcutter compensation . Only centerline tool programming can be used.

If the operator selects cutter compensation for a block with different "X"and "Y" scaling factors , the system displays the error message , "Error inblock # Cutter Comp with different XY scaling." This error prevents thepart program from running.

Ultimax 3 System Revision A 2-175

Operator' s Manual

Mirror Image

This pattern routine allows a part to be programmed as a minor image ofan existing programmed part. The routine can be programmed to executeeither of these options:

• Only the mirror image

Or

• Original part and the mirror image

The mirror image about a line defined in the routine as shown in theexample operation shown below.

Y Axis

Mirrored Part

4.00 4.00

gle . 90`

2.00

Mirror Line

Figure 2-123. Mirror Image example

2.00

Original Part

X Axis

In this example , the X coordinate is 2.00, and the "Y" coordinate can beany value because the angle is 90 ° and the mirror line travels in the "Y"axis indefinitely . The mirror line is identified by a point and an anglebecause a single point identified on the axis cannot define a line. Themirror line shown above is parallel to the Y axis , so the angle is 90°.

As with all patterns, the operator must also program a Pattern End datablock for the sequence that is repeated in the Mirror Image block.

2-176 5/18/94 Hawk 5M Machine

Conversational Part Programming

If the original part is programmed to use conventional milling in ProgramParameters or Change Parameters , the mirror image part is also executedwith conventional milling. If climb milling produced the original part,climb milling executes the mirror image part.

To display the Pattern Mirror Image screen , the operator presses theMirror Image (F7) softkey.

BLOCII R PATTERN MIRROR IMAGE

DO ORIGINAL I NO

X 0.0888

V R.RRR9

ANGLE 9.088

Do original pattern too?

Figure 2-124. Pattern Mirror Image screen

F3I

F PROGRAM1 PARAMETERS

F PART SETUP5

F TOOL SETUP6

F7

F Exita

The fields on this screen hold this information about the pattern:

Fields

Ulumax 3 System

Definitions

select "Yes" for this field is the original will be cut aswell as the mirror image . If only the mirror image is tobe produced, select "No" for this field.

the "X" coordinate for a point on a line about whichthis routine occurs as measured from part zero to themirror line.

the "Y" coordinate for the same point.

to complete the identification of the line , enter theorientation in degrees of the mirror line (which passesthrough the X-Y dimensions above ). This is measuredfrom the 3 o 'clock position . A positive value is CCW..

Revision A 2 - 177

I

Operator' s Manual

Pattern End

BLOCa

The last data block in the operation sequence must be followed by aPattern End block. The block that defines the pattern operation to beperformed must precede the first block of the sequence and an end blockmust follow the last data block in the sequence.

Important

There must be an equal number of Pattern and Pattern End blocks.

To display the Pattern End screen, press the Pattern End (F7) softkey.

0 9 PATTERN ENDF DELETE BLOCK

P INSERT BLOCK2 BEFORE

Fa

F PROGRAM4 PARAMETERS

F PART SETUP5.

P TOOL SETUP6

PEnter a block nuwber. no ENTER to edit block, ar use 7ADVANCE. RACE. or sot flay

P EXITR

Figure 2-125. Pattern End screen

There are no fields to enter in this data block. The block is simply amarker at the end of the sequence of data blocks used to execute anoperation that is being repeated or that is modified by a pattern operation.

The operator may wish to press the Review console key to view asummary of part program and determine the required positioning of thePattern End data blocks.

Remember that the Advance and Back arrow keys on the console can beused to scroll through the blocks in a part program and the Insert BlockBefore (F2) softkey can be used to insert a Pattern End block before adisplayed program block.

2-178 5/18/94 Hawk 5M Machine

Conversational Part Programming

Sample Pattern Program

The following sample program creates the same part used in the earlierhole drilling example; however, this version uses pattern techniques. Itmay be useful to compare the two programs.

The job calls for drilling twelve holes with a 3/8" drill through arectangular piece of alloy steel as shown in the diagram below:

Part Zero

.75"

2.5"

A

8.25"

Material: Alloy Steel8.25" x 4" x 25"

Tools Feeds Speeds1/8" Center Drill HSS 4.2 28003/8" Drill HSS 5.6 930

Figure 2-126. Part used in the sample Pattern program

4"

Ultimax 3 System Revision A 2 - 179

Operator' s Manual

Here is a copy of a printed pan program developed for the drawing on theprevious page. Since Ultimax allows considerable flexibility in developingpart programs, this is not the only way the part can be programmed.Watch for inserted explanations of the special features of this sampleprogram.

Hurco Ultimax Part Program 1 InchPattern . HD3 Standard

Part Setup

Part Zero X 3.0000 Safety Work Region

Y 6.0000 2 Top (+) 99.0000Offset 2 0 . 0000 2 Bottom (-) -0.4010

X Left C-) 0.0000X Right (+ l 8.2500Y Front (-) -4.8000Y Back (+) 0.0000Fixture Offset 1

General Parameters

Retract Clearance 0.2500 IMRapid Traverse 400.0 IPM

Peck Clearance Plane 0.0500 IMChord Error 0.0001 IMDepletion Retract 0 . 0050 IM

Holes Parameters

Bore Orient Retract 0 . 0200 IMDrill Dwell 0.5 SECBore Dwell 1.0 SEC

Milli P tng arame ers

Blend Offset 0 . 1250 IMBlend Overlap 0 . 1250 IMFinish Feed 100Finish Speed 100 XFinish XY 0 . 0100 IMFinish Z 0 . 0050 IMMilling Direction

Pocket OverlapClimb

10 ''4Cutter Comp Parameter Insert Arc

2 - 180 5/18/94 Hawk 5M Machine

Conversational Part Programming

Hurco Ultimax Part Program 2 Inch

Pattern . HD3. Standard

Program Parameters

Ouerride Lockout Off

Program Protect Partial

Tool Change Position Yes

Tool Setup

i Type Drill

Diameter 0.1250

Zero Calibration -10000.

Speed (RPM) CW 2800

Coolant Flood

Gear range 1

Tool Humber 1

Diameter Offset 1

Length Offset 1

2 Type Drill

Diameter 0.3750

Zero Calibration -10000.

Speed CRPM) CU 930

Coolant Flood

Gear range 1

Tool Humber 2

Diameter Offset 2

Length Offset 2

99 Diameter 0.0000

Zero Calibration -10000.

Speed (RPM) CU 0

Coolant Off

Gear range 1

Tool Humber 99

Diameter Offset 99

Length Offset 99

There is no tool #99 available for the program . The operator added a toolsetup for tool #99 to use as a dummy tool for drawing purposes only.

Ulumax 3 System Revision A 2 - 181

Operator' s Manual

Hurco Ultimax Part Program 3 InchPattern.HD3 Standard

Data Blocks

The number to the far left in each section below is the data block number.

1 Mill Frame

Tool 99 Z Start 0.0000Type Out/Tan Z Bottom -0.2500Finish Tool 0 Plunge Feed 0.0X Corner 0.0000 Mill Feed 0.0Y Corner 0.0000 Speed (RPM) 0X Length 0.2500 Peck Depth 0.0000Y Length -4.0000

Corner Radius 0.0000

Lead Length 0.0001 Lead Angle 0.0000

This block creates an outline of the part on the graphics screen to use asan outline during programming . It will be deleted before running theprogram.

2 Pattern Loop Rectangular

X Humber 6V Humber 2X Distance 1.2500Y Distance -2.5000

3 Holes

Center Drill

Tool 1Z Start 0.0500Z Bottom -0.0125Plunge Feed 4.2Speed (RPM) 2800Peck Depth

Peck Type

0.0000

Standard

LocationsX Y

1 1.0000 -0.7500

Blocks 2 and 3 center drill all holes . Note that hole #1 is the pattern andblocks 2 and 4 make all 12 holes.

2 - 182 5/18/94 Hawk 5M Machine

Conversational Part Programming

Hurco Ultimax Part Program

Pattern.HD3

4 Inch

Standard

4 Pattern End

5 Pattern Loop Rectangular

X Humber 6

Y Humber 2

X Distance 1.2500

Y Distance -2.5000

l6 esHo

Drill

Tool 2

Z Start 0.0500

Z Bottom -0.4000

Plunge Feed 5.6

Speed (RPM) 930

Peck Depth 0.1500

Peck Type Standard

Locations

X Y

1 1.0000 -0.7500

7 Pattern End

Blocks 5 through 7 are copies of blocks 2 to 4 with a tool change to thedrill (tool #2). Note that the use of copied program blocks and thesystem 's pattern features simplifies the programming of this part.

Ultimax 3 System Revision A 2 - 183

Operator's Manual

UltiPocket Option

The UltiPocketTu programming option adds special milling routines formachining pocket boundaries with islands. This option provides completeclean out of odd-shaped pockets without cutting the islands programmedinside the boundary. The software automatically calculates the tool patharound islands eliminating the long task of plotting these shapes. Islandsmay also be rotated, scaled, and repeated.

This option allows operators to program closed contours with pockets andislands. The following two drawings show different views of an inwardspiral boundary with three differently shaped islands.

Figure 2-127. Pocket Boundary with Inward Spiral Islands

t

2 - 184 5/18/94 Hawk 5M Machine

Conversational Part Programming

Here is the isometric view of this UltiPocket part:

Figure 2-128. Isometric View of Inward Spiral lskm&

The operator may select pocket features when creating any of thesestandard Ultimax program data blocks:

• Mill Contour

• Mill Circle

• Mill Frame

• Pattern

Important

To use the UltiPocket feature , the operator must first establish the cuttercompensation parameter and then program any UltiPocket data blocks.Refer to the description of the Milling Parameters in the "Getting Started"chapter . The operator must select either Insert Arc or Insert Line for theCutter Comp Parameter field. If this field does not appear on the MillingParameters screen , the UltiPocket option has not been installed on thecontrol . Call Hurco or a Hurco distributor to purchase the option.

Ultimax 3 System , - Revision A 2 - 185

Operator' s Manual

Pocket Boundary

The Pocket Boundary is the outside frame of the part. The basicphilosophy of the UltiPocket option is to program the boundary and thentell the system which pockets or islands to avoid within that boundary.This approach eliminates complex calculations and shortens the partprogramming process.

The standard milling values for Tool number and Finish Tool, Z start andZ bottom, Plunge Feed, Mill Feed, Speed RPM, and Peck Depth areprogrammed in the Pocket Boundary data block . They are not needed inthe pocket block. The Pocket Overlap defined in the boundary block to bethe percentage of cutter diameter for overlap during machining.

There are two types of Pocket Boundaries : Spiral Outward (no islands)and Spiral Inward.

Spiral Outward - No Islands

This selection is only for Circle and Frame data blocks without islands.When this routine is selected , the tool begins in the center region of thepart and spirals outward to pocket the entire programmed boundary.

Spiral Inward

This selection is for a boundary with islands . When this routine isselected, the tool enters the part and begins following a path formed byoffsetting the boundary one-half the tool radius , plus (+) the pocketoverlap (a percentage of cutter diameter programmable in the boundarydata block).

After the first pass, the tool follows a path produced by offsetting theboundary by the tool radius , plus (+) the pocket overlap for each passwhile avoiding islands inside the boundary.

After pocketing the boundary , the tool cuts around the inside of theboundary and the outside of each island , using the selected blend offsetand the programmed tool radius.

2 - 186 5/18/94 Hawk 5M Machine

Conversational Part Programming

Programming Islands

After programming the mill data block for a boundary, an island can bedefined by creating a Pocket Island data block. As many islands as desiredmay be defined (subject to computer memory on the control), but all mustfit within the defined boundary.

The island data block can be a mill Frame, Circle, or Contour (provided itis a closed contour). The Pocket Island data blocks use the standardmilling values from the boundary data block and do not display theseparameters on the island programming screen. The pocket overlappercentage was also defined in the boundary data block.

Ultimax 3 System Revision A 2 - 187

Operator' s Manual

Mill Contour

To create a Mill Contour data block using the UltiPocket option, set upthe operation in the start segment (segment zero) as shown below. As instandard Ultimax milling, an U1tiPocket Mill Contour block consists ofsegments beginning with segment zero. In the Start segment the operatormust select one of the Pocket options (F6 or F7) to indicate whether thisblock is the boundary of the part or one of the islands within theboundary.

BLOCK

SEGMENT

1

a

MILL CONTOUR

START

IF 1) No

TOOL B PLUNGE FEED 0.8 F 2) LEFTz

F 3) RIGHTFINISH TOOL -*4L SPEED (RPM)

X START

Y START TOOL

Z START B.RBBB

Z BOTTOM B.BBBB

Select wttlog opwt(on

Figure 2-129. Mill Contour with Pocket options

b

IF 6) POCKET6 BOUNDARY

F 7) POCKET7 ISLAND

a

2 - 188 5/18/94 Hawk 5M Machine

Conversational Part Programming

Here is the Start segment for an island block:

BLOCK I

SEGMENT

3

B

MILL CONTOUR

STARTF BE ETE BLOCKI

F INSERT BLOCK2 BEFORE

ISLANDITTER COIF. POCKF3

X START 8 .6758 F PROGRAM4 PARAMETERS

V ST RT 2987-4 IA .F PART SETUP5

F TOOL SETUP6

FEnter a block comber, use ENTER to edit block, or use 7ADVANCE . BALE, or sartkeg IMOTION IS STOPPING , THE PROGRAM INS BEEN ABORTED. F SKIT

B

Figure2-130. Mill Contour Start Segment with Pocket Island

The segments after the Start segment are programmed in the same manneras standard milling lines and arcs. Automatic calculation of unknownpoints is available for these data blocks.

Ultimax 3 System Revision A 2-189

Operator' s Manual

Mill Frame

The Mill Frame data block is often used to create the part boundary. Hereis a completed frame using the inward spiral:

BLOCK i I MILL FRAME I

TOOL 1 Z START

POCIR Z BOTTOMi TYP6

FIMI B PUAIGE FEED

X CORER 8.0888 MILL F®

V GORIER 0.0088 SPEED (RPM)

X LENGTH COON PECI DEPTH

V LENGTH 5 .0000 (TOOL DIAMETER

F DELETE BLOCB8.8788 1

I

-8.2588 F INSERT BLOCX2 BEFORE

15.0 ;F

188.8 3

49M F PROGRAM4 PARAMETERS

8.8888 1F PART SETUP

8.2588) S(TYPE DRILL) 1

CORNER RADIUS 0.2588 F TOOL SETUP

T OVWAP

EwLw a block nwber , ae ENTER to edit block , or use 7ADVANCE . BNCII. or aaftRmy 1

F EXIT8

Figure 2-131. Mill Frame with Inward Spiral Boundary

This block is programmed in the same manner as the standard UltimaxMill Frame with the addition of the Pocket Overlap percentage.

2 - 190 5/18/94 Hawk 5M Machine

Conversational Part Programming

Mill Circle

The Mill Circle data block is used for both boundaries and islands. It issimilar to the standard Mill Circle data block except that if this block isused to create an island it uses the tool from the boundary data block.

Here is a Mill Circle block used to create a boundary with an outwardspiral:

BLO(:R R 2 MILL CIRCLEF DELETE BLOCK

TOOL 3 2 START 11.0200

POCK BOUDSRY Z BOTTOM -6.50011 F INSERT BLOCKIFAKET TYPE OuTUARD 2 BEFORE

Pull PLUM6E FEED 25.0F

X CENTER 0.0000 MILL FEED 32.0 3

V CENTER 0.0000 SPEED (RPH) 2508 F PR09VW4 PARAMETERS

PECK DEPTH 80008 1no WE 1.5008 .F PART SETUP

POT OVERIAP 10 (TOOL DIAMETEE(TYPE

0.3758) 5DID HILL) ;

F TOOL SETUP6iF

Enter a block iw ber, use ENTER to edit block, or use 7ADMAMCK , BACK , or eottke9

Figure 2-132. Mill Circle with Outward Spiral Boundary

F EXIT8

Uldmax 3 System Revision A 2-191

Operator' s Manual

Pattern

Pattern data blocks can be inserted to rotate, scale or repeat islands. OnlyPattern data blocks can be programmed between a boundary data blockand an island. As many islands as desired may be defined (subject toavailable memory), but all must fit within the defined boundary.

Sample UltiPocket Program

The following program is a complex UltiPocket program that illustratesmany of the option's features. Here is the graphics screen illustration ofthe finished part:

1.6-Y

l®1

I

-6.2 --2.3

OTW I0.3 2.9 5.5

Figure 2-133. Graphics screen illustration of die UltiPocket sample program

X0.1

2 - 192 5/18/94 Hawk 5M Machine

Conversational Part Programming

Here is the isometric view of the part:

Figure 2-134. Isometric view of the UIliPocket sample program

Ultimax 3 System Revision A 2 - 193

Operator's Manual

Hurco Ultimax Part Program 1 InchUltiPock.HD3 Standard

Part Setup

Part Zero X 8.7948 Safety Work RegionY 9.8726 Z Top (+) 99.0000

Offset z 0 . 0000 Z Bottom C- ) -99.0000X Left C -) -99.0000X Right C+ ) 99.0000Y Front C-) -99.0000Y Back C+) 99.0000Fixture Offset 1

General Parameters

Retract Clearance 0.0500 INRapid Trauerse 200.0 IPMPeck Clearance Plane 0 . 0500 INChord Error 0 . 0000 INDepletion Retract 0.0050 IN

Holes Parameters

Bore Orient Retract 0.0200 INDrill Dwell 0.0 SECBore Dwell 0.0 SEC

Millin Parametg ers

Blend Offset 0 . 0000 INBlend Ouerlap 0.0000 INFinish Feed 100 zFinish Speed 100 XFinish XY 0 . 0100 INFinish 2 0 . 0050 INMilling Direction

Pocket OuerlapClimb

10 XCutter Comp Parameter Insert Rrc

2 - 194 5/18/94 Hawk 5M Machine

Conversational Part Programming

Hurco Ultimax Part Program 2 Inch

UltiPock.HD3 Standard

Program Parameters

Ouerride Lockout Off

Program Protect Partial

Tool Change Position No

Tool Setup

1 Type Face Mill

Diameter 3.1500

Zero Calibration 10.4805Speed CRPM ) CW 5000

Coolant Flood

Flutes 6

Feed/Flute 0.0030

Gear range 1

Tool Humber 1

Diameter Offset 1

Length Offset 1

2 Type End Mill

Diameter 0.7500

Zero Calibration 9.1600

Speed (RPM) CU 5000

Coolant Off

Flutes 2

Feed/Flute 0.0010

Gear range 1

Tool Humber 2

Diameter Offset 2Length Offset 2

3 Type End Mill

Diameter 0.1500Zero Calibration 10.8115Speed (RPM) CW 6000Coolant

Gear range

Off

1

Tool Humber 3

Diameter Offset 3Length Offset 3

Ultimax 3 System Revision A 2-195

Operator's Manual

Hurco Ultimax Part Program 3 InchUitiPock . HD3 Standard

4 Type End Mill

Diameter 0.5000

Zero Calibration 10.7064Speed CRPM ) CU 5000Coolant Flood

Gear range 1

Tool Humber 4Diameter Offset 4Length Offset 4

5 Type DrillDiameter 0.2010Zero Calibration 10.3293Speed (RPM ) CU 3500Coolant FloodGear range 1Tool Humber 5Diameter Offset 5Length Offset 5

6 Type Tap

Threads per inch 20.0

Diameter 0.2500Zero Calibration 7.559

Speed (RPM) CW 600Coolant FloodGear range 1Tool Humber 6Diameter Offset 6

Length Offset 6

2-196 5/18/94 Hawk 5M Machine

Conversational Part Programming

Hurco Ultimax Part Program 4 Inch

UltiPock . HD3 Standard

Data Blocks

1 Mill Contour

Segment 0 Start

Tool 1 Plunge Feed 100.0

Cutter Comp No

Finish Tool 0 Speed (RPM) 5000

X Start 7. 8000 Peck Depth 0.0000

Y Start -3.0000

2 Start 0.0200

Z Bottom -0.0000

2 Mill Contour

Segment 0 Start

Tool 1 Plunge Feed 100.0

Cutter Comp ho

Finish Tool 0 Speed CRPM) 5000

X Start 7. 8000 Peck Depth 0.0000

Y Start -1.5000

2 Start 0.0200

2 Bottom -0.0000

3 Mill Contour

Segment 0 Start

Tool 2 Plunge Feed 100.0

Cutter Comp LeftFinish Tool 0 Speed (RPM) 5000

X Start -0.5000 Peck Depth 0.0000Y Start 0.0000

2 Start 0.0200

2 Bottom -0.7500Lead Rngle 0.00

Lead Length 0.0000

Operator's Manual

Hurco Ultimax Part Program 5 InchUltiPock . HD3 Standard

4 Mill Contour

Segment 0

ToolStart

3 Plunge Feed 100.0Cutter Comp

Finish ToolLeft

0 Speed (RPM) 6000X Start -0.5000 Peck Depth 0.0000Y Start 0.0000Z Start 0.0200Z Bottom -0.0800Lead Angle 0.00Lead Length 0.0000

5 PositionTool 3X 3Y 3

6

Stop

Pattern Location

Yes

X Offset Y Offset Z Offset1 -0.0200 -0 . 0100 -0.0300

7 Mill Contour

Segment 0

ToolStart

1 Plunge Feed 100.0Cutter Comp

Finish ToolMo

0 Speed (RPM) 5000X Start 7 . 8000 Peck Depth 0.0000Y Start -3.0000Z Start 0.02002 Bottom 0.0000

2 - 198 5/18/94 Hawk SM Machine

Conversational Part Programming

Hurco Ultimax Part Program

UltiPock.HD3

6 Inch

Standard

8 Mill Contour

Segment 0 StartTool

Cutter Comp

1

NoPlunge Feed 100.0

Finish Tool 0 Speed (RPM) 5000

X Start 7.8000 Peck Depth 0.0000

Y Start -1.5000

Z Start 0.0200

Z Bottom 0.0000

9 Mill Contour

Segment 0 StartTool

Cutter Comp

2Left

Plunge Feed 100.0

Finish Tool 0 Speed (RPM) 5000

X Start -0.5000 Peck Depth 0.0000

Y Start 0.0000

Z Start 0.0200

Z Bottom -0.6000Lead Angle 0.00

Lead Length 0.0000

10 Mill Contour

Segment 0 Start

Tool 4 Plunge Feed 100.0

Cutter Comp Pock Boundary Mill Feed 75Finish Tool 0 Speed (RPM) 6000X Start 3.0000 Peck Depth 0.0000Y Start -4.8000Z Start 0.0200Z Bottom -0.2000Pocket Overlap 20.0

Ultimax 3 System Revision A 2-199

Operator' s Manual

Hurco Ultimax Part Program

U1tiPock.HD3

7 Inch

Standard

11 Mill Contour

Segment 0 Start

Tool 4 Plunge Feed 15.0Cutter Camp Pock Boundary Mill Feed 75Finish Tool 4 Speed (RPM) 6000X Start 3.0000 Peck Depth 0.2100Y Start -3.7500Z Start -0.1800Z Bottom -0.6000

Pocket Duerlap 50.0

12 Mill Contour

Segment 0 Start

Cutter Camp

X StartPock Island

1.3800V Start -1.1000

13 Mill Contour

Segment 0 Start

Cutter Camp

X Start.Pock Island

5.2300Y Start -2.9000

14 Mill Contour

Segment 0 Start

Cutter Camp

X Start

Pock Island

4.5300Y Start -2.1400

2-200 5/18/94 Hawk 5M Machine

Conversational Part Programming

Hurco Ultimax Part Program

UltiPock.HD3

a Inch

Standard

15 Mill Contour

Segment 0 Start

Cutter Comp Pock Island

X Start 2.8000

Y Start -3.0750

16 Mill Contour

Segment 0 Start

Cutter Comp Pock Island

X Start 1.0000

Y Start -3.2180

17 Holes

Drill

Tool 5

Z Start -0.1500

2 Bottom -0.8000

Plunge Feed 6.0

Speed (RPM) 3500

Peck Depth 0.1625

Peck Type Standard

Locations

X Y

1 2.00 -3.50

2 4.00 -3.50

3 5.50 -2.00

4 4.00 -0.50

5 2.00 -0.50

6 0.50 -2.00

7 1.00 -3.00

8 1.35 -2.729 1.53 -2.3510 1.75 -2.0011 2.80 -2.70

12 3.40 -2.4013 3.15 -1.35

14 4.53 -1.92

15 4.42 -1.50

Ultimax 3 System Revision A 2-201

Operator's Manual

Hurco Ultimax Part Program

UltiPock . HD39 Inch

Standard

18 Mill Contour

Segment 0 StartTool 3 Plunge Feed 100.0Cutter Comp Left

Finish Tool 0 Speed CRPM) 6000X Start 5 .2500 Peck Depth 0.0000Y Start -4.2000Z Start 0.02002 Bottom -0.0800

Segment 1 Line

X End CAL 5.2580Y End -3.7500Z End -0.0800XY Length CAL 0.4500XY Angle 90.000Feed 80.000

Segment 2 LineX End 5.7500Y End CAL -3.7500

2 End -0.0800

XY Length CAL 0.5000

XY Angle 0.000Feed 80.00

Segment 3 Blend Arc

Radius 0.3000

Feed 80.00

Segment 4 LineX End CAL 5.7500Y End -0.7500Z End -0.0800

XY Length CAL 3.0000XY Angle 90.000Feed 80.000

2-202 5/18/94 Hawk 5M Machine

Conversational Part Programming

Hurco Ultimax Part Program

UltiPock. HD3

10 Inch

Standard

Segment 5 Blend Arc

Radius 0.2800

Feed 80.00

Segment 6 Line

X End 5.2500

Y End -0.2500

Z End -0.0800

XY Length CAL 0.7071

XY Angle CAL 135.0000

Feed 80.000

Segment 5 Blend Arc

Radius 0.2800

Feed 80.00

Segment 6 Line

X End 5.2500

Y End -0.2500

Z End -0.0000

XY Length CAL 0.7071

XY Angle CAL 135.000

Feed 80.000

Segment 7 Blend Arc

Radius 0.2800

Feed 80.00

Segment 8 LineX End 0.7500

Y End CAL -0.2500Z End -0.0800

XY Length CAL 4.5000

XY Angle 180.000

Feed 80.000

Segment 9 Blend Arc

Radius 0.2800Feed 80.00

Ultimax 3 System Revision A 2 - 203

Operator ' s Manual

Hurco Ultimax Part Program 11 InchU1tiPock . HD3 Standard

Segment 10 Line

X End 0.2500

Y End -0.7500

Z End -0.0800

XY Length CAL 0.7071

XY Angle CAL -135.00

Feed 80.000

Segment 11 Blend ArcRadius 0.2800

Feed 80.00

Segment 12 Line

X End 0.2500

Y End -3.7500

Z End -0.0800

XY Length CAL 3.0000

XY Angle -90.000

Feed 80.000

Segment 13 Blend Arc

Radius 0.3000

Feed 80.00

Segment 14 Line

X End 0.7500

Y End CAL -3.7500

Z End -0.0800

XY Length CAL 5.0000

XY Angle 0.000

Feed 80.000

Segment 15 LineX End 0.7500

Y End -3.9700

2 End -0.0800

XY Length CAL 0.2400XY Angle CAL -90.000Feed 80.000

2-204 5/18/94 Hawk 5M Machine

Conversational Part Programming

Hurco Ultimax Part Program

U1tiPock . HD3

12 Inch

Standard

Segment 16 Line

X End 0.0100Y End -3.9900

Z End -0.0800XY Length CAL 0.7400XY Angle CAL 180.000Feed 80.000

Segment 17 Blend Arc

Radius 0.2000

Feed 80.00

Segment 18 Line

X End 0.0100Y End 0.0000Z End -0.0800

XY Length CAL 3.9900

XY Angle CAL 90.000

Feed 80.000

Segment 19 Blend Arc

Radius 0.2000

Feed 00.00

Segment 20 LineX End 5.99

Y End 0.0000

Z End -0.0800XY Length CAL 5.9900XY Angle CAL 0.000

Feed 80.000

Segment 21 Blend Arc

Radius 0.2000

Feed 80.00

Ultimax 3 System Revision A 2 - 205

Operator' s Manual

Hurco Ultimax Part Program 13UltiPock.HD3

Segment 22 Line

X End 5.9900Y End -3.9900Z End -0.0800XY Length CAL 3.9900XY Angle CAL -90.000Feed 80.000

Segment 23 Blend ArcRadius 0.2000Feed 80.00

Segment 24 Line

X End 5.0000Y End -3.9900Z End -0.0800XY Length CAL 0.990 0XY Angle CAL 180.000Feed 80.000

End of Contour

19 Mill Contour

Inch

Standard

Segment 0 StartTool 3 Plunge Feed 100.0Cutter Comp LeftFinish Tool 0 Speed (RPM] 6000X Start 5 . 0400 Peck Depth 0.0000Y Start -3.99002 Start -1.18002 Bottom -0.2750

Lead Angle 0.00Lead Length 0.0000

2-206 5/18/94 Hawk 5M Machine

Conversational Part Programming

Hurco Ultimax Part Program 14 Inch

U1tiPock . HD3 Standard

20 Mill Contour

Segment 0 Start

Tool 3 Plunge Feed 100.0

Cutter Camp Left

Finish Tool 0 Speed [RPM) 6000

X Start 0 . 9500 Peck Depth 0.0000

Y Start -3.7500

Z Start -1.1800

2 Bottom -0.2750

Lead Angle 0.00

Lead Length 0.0000

21 Mill Contour

Segment 0 Start

Tool 3 Plunge Feed 100.0

Cutter Comp Left

Finish Tool 0 Speed [RPM) 6000

X Start 5 . 5000 Peck Depth 0.0000

Y Start -2.2200

2 Start -1.1800

Z Bottom -0.2750

Lead Angle 0.00

Lead Length 0.0000

22 Mill Contour

Segment 0 Start

Tool 3 Plunge Feed 100.0

Cutter Camp Left

Finish Tool 0 Speed (RPM) 6000

X Start 4.2200 Peck Depth 0.0000

Y Start -0.5000

2 Start -1.1800

2 Bottom -0.2750

Lead Angle 0.00

Lead Length 0.0000

Operator' s Manual

Hurco Ultimax Part Program

UltiPock.HD315 Inch

Standard

23 Mill Contour

Segment 0 StartTool 3 Plunge Feed 80.0Cutter Comp LeftFinish Tool 0 Speed (RPM) 6000X Start 2.2200 Peck Depth 0.0000Y Start -0.5000Z Start -1.1800Z Bottom -0.2750Lead Angle 0.00Lead Length 0.0000

24 Mill Contour

Segment 0 StartTool 3 Plunge Feed 100.0Cutter Comp Left

Finish Tool 0 Speed (RPM) 6000X Start 0 . 5000 Peck Depth 0.0000Y Start -1.7000Z Start -1.1800Z Bottom -0.2750Lead Angle 0.00Lead Length 0.0000

25 Mill Contour

Segment 0 StartTool 3 Plunge Feed 80.0Cutter Comp LeftFinish Tool 0 Speed CRPM) 6000X Start 1 . 5800 Peck Depth 0.0000Y Start CAL -0.90002 Start -1.18002 Bottom -0.2500Lead Angle 0.00Lead Length 0.0000

2-208 5/18/94 Hawk 5M Machine

Conversational Part Programming

Hurco Ultimax Part Program

UltiPock . HD3

16 Inch

Standard

26 Mill Contour

Segment 0 StartTool 3 Plunge Feed 80.0

Cutter Comp Left

Finish Tool 0 Speed (RPM) 6000

X Start 5. 4300 Peck Depth 0.0000

Y Start CAL -2.7000

Z Start -1.1800

Z Bottom -0.2750

Lead Angle 0.00

Lead Length 0.0000

27 Mill Contour

Segment 0 Start

Tool 3 Plunge Feed 80.0

Cutter Comp Left

Finish Tool 0 Speed (RPM) 60001

X Start 4. 5300 Peck Depth 0.0000

Y Start -2.1400Z Start -1.1800

Z Bottom -0.2750

Lead Angle 0.00

Lead Length 0.0000

28 Mill Contour

Segment 0 StartTool 3 Plunge Feed 80.0

Cutter Comp Left

Finish Tool 0 Speed (RPM) beau

X Start 2. 8000 Peck Depth 0.0000

Y Start -3.0750Z Start -1.1800Z Bottom -0.2750

Lead Angle 0.00

Lead Length 0.0000

Operator's Manual

Hurco Ultimax Part Program 17 InchUltiPock. HD3 Standard

0 Start

3 Plunge Feed 80.0

Left

0 Speed (RPM) 60001 .000 Peck Depth 0.0000

-3.2180

-1.1800

-0.27500.00

0.0000

5-0.1800

-0.310015.06000

0.0

Y

1 2':'00 -3.50

2., x`4. 00 -3.50

X

1.35 - -2.721.53 -2.35

2.00 -0.500.50 -2.00

:1.00 .. -3.00

4.00 -0.50

5.50 -2.00

-10 1.75 -2.00

29 Mill Contour

Segment

Tool

Cutter Comp

Finish Tool

X Start

Y Start

Z Start

Z Bottom

Lead Angle

Lead Length

30 Holes

Countersink

Tool

2 Start

Z Bottom

Plunge Feed

Speed CRPM)

Peck Depth

Locations

12 3.40

13 3.155

14 4.53

15 4.42

2-210

-2.70

-2.40

-1.35

-1.92

-1.50

5/18/94 Hawk 5M Machine

Conversational Part Programming

Hurco Ultimax Part Program 18 Inch

UltiPock.HD3 Standard

31 Mill Lettering

Tool

X Start

Y Start

Height

Character Width

TextZ StartZ Bottom

32 Mill Lettering

Tool

X Start

Y Start

Height

Character Width

Text

Z Start

Z Bottom

33 Holes

Tap

Tool

Z Start

Z Bottom

Plunge Feed

Speed (RPM)

Peck Depth

3

1.1500

-0.2000

0.15

0.08

HURCO ULTIMAX III

Plunge Feed

Mill Feed

Speed CRPM)

Peck Depth

80.0

60.0

6000

0.00

0.0200

-0.0060

3 Plunge Feed 10.0

Mill Feed 60.0

1.9500 Speed CRPM) 6000

-3.9500 Peck Depth 0.00

0.15

0.08

ULTIPOCXET

-0.1800

-0.2100

6

0.0

-0.6000

15.0

600

0.0

Ultimax 3 System Revision A 2 - 211

Operator' s Manual

Hurco Ultimax Part Program 19 InchUltiPock.HD3 Standard

Locations

x y1 2.00 -3.502 4.00 -3.503 5.50 -2.004 4.00 -0.505 2.00 -0.506 0.50 -2.007 1.00 -3.008 1.35 -2.729 1.53 -2.3510 1.75 -2.0011 2.80 -2.7012 3.40 -2.4013 3.15 -1.3514 4.53 -1.9215 4.42 -1.50

34 Pattern End

2-212 5/18/94 Hawk 5M Machine

Conversational Part Programming

Cutter Insert RoutinesCutter insert manufacturers use these special milling routines to millpockets in triangular, diamond, and hexagon shapes. These routines aresold as an Ultimax 3 option and can be defined in one program datablock.

To access the cutter insert features , press the Input console button todisplay the Input screen. Then press the Part Programming (F3) softkey. Ifthe option has been installed on the system , the next screen will have aSpecial (F6) softkey. Press that softkey and the following screen appears:

BLACK 1 1 NiEBLOCK IF 1) 7BIANGLE1

F 2) DIAMOND2 1 FACE

F 3) DIAMOND3 2 FACES

F 4) HEXAGON4

P5

P

Choose type or block 7

F EXITB

Figure 2-135. Cutup Inserts softkeys

All four of these options have similar screens . Refer to the Triangle screen.for a description of the standard fields. Additional fields used on theremaining three screens are described in those sections.

Ultimax 3 System Revision A 2 - 213

Operator' s Manual

Triangles

The triangle pocket shape has three equal 60° angles with one open faceas shown below. In addition, a relief cut can be programmed in the comerat point 1.

Point 3

OpenFace

Point 2

Figure 2-136. Triangle Programming diagram

Orientation =0

2 - 214 5/18/94 Hawk 5M Machine

Conversational Part Programming

Here is a completed Mill Triangle data block . The data on this screen alsoappears in the sample program at the end of this section.

BLOCK 2 MILL TRIANGLE IF DELETE BLOCK

TOOL 1 Z START 8.1800 1

iTYPE POCKET nVOUT Z BOTTOM x.1758 F INSERT BLOCK

2 BEFOREPLIK GE FEED 5 0 IX CENTER 1 .0008 I .

FV CENTER 1 . 0008 MILL FEED 10.0 3

RADIUS 0.2508 SPEED (RPM) 758 F PROGRAM4 PARAMETERS

ORIENTATION 12.500 PECK DEPTH 0.0000 IF PMT SETUP

(TOOL DIAMETER 0.0625) 5(TYPE END MILL) I

RELIEF 1 CENTER 8.1008 F TOOL SETUP6

Enter a block number , use ENTER to edit block, or useADVANCE , BACK. or softkey

Figure2-137. Completed MiUTriangle screen

F7

F SKITB

Ultimax 3 System Revision A 2 - 215

Operator' s Manual

These fields are the standard fields for all of the cutter insert screens.Refer to the descriptions of the other options for the additional fields onthose screens.

Fields Definitions

Tool number of the tool used to cut the insert pocket

Type defines cutter motion using these options:

Inside - cuts just the non-open faces of the pocket,including the relief cuts.Inside 2 Passes - cuts the same as Inside, except thisselection uses a roughing pass and a finishing pass.During roughing, material is left for the finish pass.Pocket Outside In - cuts along the faces of the insert,including the relief cuts and then steps inward andcleans out the entire insert by executing smallerversions of the shape until the center point is reached.Pocket 2 Passes Outside In - cuts in the same manneras Pocket Outside In, except this selection uses aroughing and a finishing pass.Pocket Inside Out - plunges tool at X-Y center of theinsert and cuts outward, executing larger versions of theshape until the faces and relief cuts are milled.Pocket 2 Passes Inside Out - Cuts the same as PocketInside Out, except this selection uses a roughing and afinishing pass.

X Center "X" axis coordinate of the inscribed circle's centerpoint of the shape.

Y Center "Y axis coordinate of the inscribed circle's centerpoint of the shape.

Radius this is 'f the length of the diameter of the inscribedcircle. This distance is used to determine the size of thepocket.

Orientation Angle of a vector perpendicular to the open face.

Relief 1 value provides the option of a right, center or left reliefcut (or none) in the corner at point 1

Z Start The location where the spindle begins to rotate.

Z Bottom The bottom of the finished hole.

Plunge Feed Feedrate between the Z Start and the Z Bottompositions.

2 - 216 5/18/94 Hawk 5M Machine

Conversational Part Programming

Fields Definitions (continued)

Mill Feed Feedrate for the X and Y axes. The control systemautomatically calculated the value that first appears onthe screen. The calculated value can be replaced with adifferent value or stored as it is.

Speed (RPM) Speed at which the spindle rotates to drill the hole.

Peck Depth Distance that the tool will drill down into the partbefore stopping to clear out or break the chips. If thisparameter is used, it is usually not larger than thediameter of the tool.

Ultimax 3 System Revision A 2 - 217

Operator's Manual

Diamond Faces

The diamond pocket shapes have four sides with opposite angles equal.The Diamond I Face has one open face and the option of a right, center,or left relief cut in the comers at point I and point 2 as shown below:

POINT 1

POINT 4

ORIENEA11ON = 0

OPENFACE

POINT 3

Figure 2-138. Diamond I Face diagram

2 - 218 5/18/94 Hawk 5M Machine

Conversational Part Programming

The Diamond 2 Faces pocket has two open faces and the option of aright, center, or left relief cut in the comer at point 1 as shown below:

POINT 1

POINT 4

ORIENWION = 0

OPENFACE

POINT 3

/ OPEN/ FACE

Figure 2-139. Diamond 2 Faces diagram

The diamond pocket data blocks are programmed in the same manner asthe triangle pockets ; however, there are two additional fields on thediamond screen.

Shape Angle the angle formed by points 1 and 3 defining the shapewith a range from 20° to 160°.

Relief 2 (for Diamond 1 Face only) this provides the option of aright, center, or left relief cut (or none) in the corner atpoint 2.

Ultimax 3 System Revision A 2-219

Operator' s Manual

Here is an example of a completed Diamond I Face data block:

BLOCK i 3 MILL DIAMOND I FACE IF E ETE BLOCK

TOOL 1 Z START 8.1000D L

1

TYPE INSIDE Z BOTTOM -0.1758 F INSERT BLOCK2 BEFORE

X CENTER 8 8800 PLUME FEED 5 8 I. .F

V CENTER 8.0080 MILL FEED 10.0 3

RADIUS 8.3758 SPEED (RPM) 758 F PROGRAM4 PARAMETERS

ORIENTATION 0 808 PECK DEPTH 8 8800 I. .F PART SETUP

E SCLB 90.808 (TOOL DIAMETER(TYPE

0.865)Em MILL)

5I

RELIEF I LEFT 0.1800 F TOOL SETUP6

IMP 2 NONE 8 0188.F

Enter a block number, use ENTER to edit black, or use 7ADVANCE. BACK, or . tks9 I

F EXIT8

Figure 2-140. Completed Mill Diamond I Face screen

2-220 5/18/94 Hawk 5M Machine

Conversational Part Programming

Hexagon

This pocket shape has six-sides and every other angle equal. In thediagram below, the shape has two open faces and the option of a relief cutin the corners at point 1, point 2 and point 3, and/or the option of a facerelief distance between points 0 and 1 and points 3 and 4.

Point 0

Orientation =0

ReliefPoint 3 Corners

Point 4

Figure 2-141. Hexagon diagram

The hexagon pocket data blocks are programmed in the same manner asthe triangle pockets; however, there two additional fields on the hexagonscreen.

Shape Angle the angle formed by points 0, 2 and 4 defining theshape with a range from 60° to 180°.

Relief 3 this provides the option of a right , center, or left reliefcut (or none) in the comer at point 3 or the option of aface relief distance between points 3 and 4.

Ultimax 3 System Revision A 2 - 221

Operator' s Manual

Here is a completed hexagon data block:

BLOCX $ 11 HILL HEXAGONF DELETE BLOCX

TOOL 1 2 START 8.1000 1

TYPE INSIDE Z BOTTOM -0.1258 F INSERT BLOCX2 BEFORE

X CENTER 8.8000 PLNMGE FEED 5.8 IF

I CENTER -2.0008 HILL FEED 10.0 3

RADIUS 0.2500 SPEED (RPM) 750 F PROGRAM4 PARAMETERS

ORIENTATION 8 .880 PECX DEPTH 8.0800 IF PART SETUP

SHAPE ANGLE 00.808 (TOOL DIAMETER 0.0625) 5(TYPE Ii" MILL) 1

RELIEF 1 FACE 8.1888 F TOOL SETUPRELIEF2 CENTER 8.1000 6RELIEF 3 LEFT 8.1888 I

FEater a block number , use ENTER to edit block , or use 7ADVANCE , BACE, or sottkey i

F EXIT8

Figure 2-142. Completed Mill Hexagon screen

kA

2-222 5/18/94 Hawk 5M Machine

Conversational Part Programming

Sample Cutter Insert Program

In order to demonstrate programming for all of the cutter insert shapes,this program shows separately programmed inserts that were not used tocreate a part. Here is the graphics screen representation of the sampleprogram.

Figure 2 -143. Inserts in Sample Program

Uttimax 3 System Revision A 2-223

Operator' s Manual

Hurco Ultimax Part Program 1 InchInsert . HD3 Standard

Part Setup

Part Zero X 5 . 0000 Safety Work RegionY 5.0000 2 Top (+) 99.0000

Offset Z 0 . 0000 Z Bottom C-) -99.0000X Left C-) -99.0000X Right C+ ) 99.0000

V Front C-) -99.0000

Y Back C+ ) 99.0000

Fixture Offset 1

General Parameters

Retract Clearance 99.0000 INRapid Trauerse 400.0 IPMPeck Clearance Plane 0.0500 INChord Error 0.0001 INDepletion Retract 0.0050 IN

Holes Parameters

Bore Orient Retract 0.0200 INDrill Dwell 0.5 SECBore Dwell 1.0 SEC

Milli P tng arame ers

Blend Offset 0.1250 INBlend Ouerlap 0.1250 INFinish Feed 100 ZFinish Speed 100Finish XY 0.0100 IMFinish Z 0.0050 IMMilling Direction ClimbPocket Ouerlap 10Cutter Comp Parameter Insert Arc

2 - 224 5/18/94 Hawk 5M Machine

Conversational Part Programming

Hurco Ultimax Part Program 2 Inch

Insert.HD3 Standard

Program Parameters

Duerride Lockout

Program Protect

Tool Change Position

Off

Partial

No

Tool Setup

1 Type End Mill

Diameter 0.0625Zero Calibration 4.3450

Speed CRPM)

Coolant

CW 750

Of f

Gear range 1

T l N b 1oo um er

Diameter Offset 1

Length Offset 1

Data Blocks

1 Mill Triangle

Tool 1 2 Start 0.1000

Type Inside 2 Bottom -0.1250

X Center 0.0000 Plunge Feed 5.0

Y Center 1.0000 Mill Feed 10.0

Radius 0.2500 Speed (RPM) 750

Orientation

Relief 1

0.000

Center 0.1080

Peck Depth 0.0000

2 Mill Triangle

Tool 1 2 Start 0.1000

Type Pocket In/Out 2 Bottom -0.1250X Center 1.0000 Plunge Feed 5.0

Y Center 1.0000 Mill Feed 10.0Radius 0.2500 Speed (RPM) 750

Orientation

Relief 1

12.5

Center 0.1000

Peck Depth 0.0000

Ultimax 3 System Revision A 2 - 225

Operator's Manual

Hurco Ultimax Part Program

Insert.HD3

3 Inch

Standard

3 Mill Diamond 1 Face

Tool 1 Z Start 0.1000Type Inside Z Bottom -0.1250X Center 0.0000 Plunge Feed 5.0Y Center 0.0000 Mill Feed 10.0Radius 0.3750 Speed CRPM) 750Orientation 0.0000 Peck Depth 0.0000Shape Angle 90.000

Relief 1 Left 0.1000Relief 2 None 0.0100

4 Mill Diamond 1 FaceTool 1 2 Start 0.1000Type Pocket Out/In Z Bottom -0.1250X Center 1.0000 Plunge Feed 5.0Y Center 0.0000 Mill Feed 10.0Radius 0.3750 Speed CRPM) 750Orientation 12.500 Peck Depth 0.0000Shape Angle 90.000

Relief 1 Left 0.1000Relief 2 None 0.0100

5 Mill Diamond 1 Face

Tool 1 Z Start 0.1000Type Pocket Out/In Z Bottom -0.1250X Center 2.0000 Plunge Feed 5.0Y Center 0.0000 Mill Feed 10.0Radius 0.3750 Speed (RPM) 750Orientation 0.000 Peck Depth 0.0000Shape Angle 75.000Relief 1 Left 0.1000Relief 2 Hone 0.0100

2-226 5/18/94 Hawk 5M Machine

Conversational Part Programming

Hurco Ultimax Part Program 4 Inch

Insert.HD3 Standard

6 Mill Diamond 1 Face

Tool 1 2 Start 0.1000

Type Pocket Out/In 2 Pass Z Bottom -0.1250

X Center 3.0000 Plunge Feed 5.0

Y Center 0.0000 Mill Feed 10.0

Radius 0.3750 Speed CRPM) 750

Orientation 12.500 Peck Depth 0.0000

Shape Angle 75.000

Relief 1 Left 0.1000

Relief 2 Mone 0.0100

7 Mill Diamond 2 Faces

Tool 1 Z Start 0.1000

Type Inside Z Bottom -0.1250

X Center 0.0000 Plunge Feed 5.0

Y Center -1.0000 Mill Feed 10.0

Radius 0.3750 Speed CRPM) 750

Orientation 0.000 Peck Depth 0.0000

Shape Angle 90.000Relief 1 Right 0.1000

8 Mill Diamond 2 Faces

Tool 1 Z Start 0.1000

Type Pocket Out/In Z Bottom -0.1250

X Center 1.0000 Plunge Feed 5.0Y Center -1.0000 Mill Feed 10.0Radius 0.3750 Speed (RPM) 750

Orientation 12.500 Peck Depth 0.0000

Shape Angle 90.000

Relief 1 Right 0.1000

9 Mill Diamond.2 Faces

Tool 1 Z Start 0.1000

Type Pocket Out/In 2 Bottom -0.1250X Center 2.0000 Plunge Feed 5.0

Y Center -1.0000 Mill Feed 10.0

Radius 0.3750 Speed CRPM) 750

Orientation 0.000 Peck Depth 0.0000

Shape Angle 75.000Relief 1 Right 0.1000

Ultimax 3 System Revision A 2 - 227

Operator's Manual

Hurco Ultimax Part Program 5 InchInsert.HD3 Standard

10 Mill Diamond 2 Faces

Tool 1 Z Start 0.1000Type Pocket Out/In . 2 Pass Z Bottom -0.1250X Center 3.0000 Plunge Feed 5.0Y Center -1.0000 Mill Feed 10.0Radius 0.3750 Speed (RPM) 750Orientation 12.500 Peck Depth 0.0000Shape Angle 75.000Relief 1 Right 0.1000

11 Mill Hexagon

Tool 1 2 Start 0.1000Type Inside Z Bottom -0.1250X Center 0.0000 Plunge Feed 5.0Y Center -2.0000 Mill Feed 10.0Radius 0.25000 Speed CRPM) 750Orientation 0.000 Peck Depth 0.0000Shape Angle 80.000Relief 1Relief 2

Face 0.1000

Center 0.1000

Relief 3 Left 0.1000

12 Mill Hexagon

Tool 1 Z Start 0.1000Type Pocket Out/In Z Bottom -0.1250.X Center 1.0000 Plunge Feed 5.0Y Center -2.0800 Mill Feed 10.0Radius 0.25000 Speed (RPM) 750Orientation 12.500 Peck Depth 0.0000Shape Angle 80.000Relief 1Relief 2

Face 0.1000

Center 0.1000

Belief 3 Left 0.1000

2-228 5/18/94 Hawk 5M Machine

Conversational Part Programming

Hurco Ultimax Part Program

Insert.HD3

13 Mill Hexagon

Tool

TypeX Center

Y Center

Radius

Orientation

Shape Angle

Belief 1

Belief 2

Belief 3

14 Mill Hexagon

Tool

Type

X Center

Y Center

Radius

Orientation

Shape Angle

Belief I

Belief 2

Belief 3

6

1Pocket In/Out

2.0000

-2.0000

0.25000.

0.000

75.000

Face 0.1000

Center 0.1000

Left 0.1000

1

Pocket In/Out 2 Pass

3.0000

-2.0000

0.25000

12.500

75.000

Face 0.1000

Center 0.1000

Left 0.1000

Inch

Standard

Z Start 0.1000

Z Bottom -0.1250Plunge Feed 5.0Mill Feed 10.0

Speed (RPM) 750Peck Depth 0.0000

Z Start 0.1000

Z Bottom -0.1250

Plunge Feed 5.0

Mill Feed 10.0

Speed (RPM) 750

Peck Depth 0.0000

1

Ultimax 3 System Revision A 2 - 229

Operator' s Manual

Rotary

Typically, operators use the optional rotary equipment and accompanyingsystem software when they need to cut around a cylindrical part while thepart is turning . When the Rotary Table Option is attached to the Hawk5M, the kneemill has a fourth axis of motion -the "A" axis. Programmingrotary data blocks is very similar to programming other conversationaldata blocks , so the operator must be familiar with conversational partprogramming before studying the material in this section.

1^r

Figure 2-144. Typical Single -axis Rotary Table ("A" axis)

General Information

When the Ultimax system begins to execute a conversational rotary datablock, the "Y" axis motion will stop and be replaced with the "A" axis.Normally the tool is in line with the center of the rotary table along the"Y" axis, but the tool can be positioned off center as well . To use both the"Y" and "A" axes simultaneously , the operator must create the partprogram using NC part programming. Refer to the NC ProgrammingInstruction Manual.

Programming ranges and resolutions for the Rotary Table are plus(+)/minus (-) 9999 .999 degrees absolute in a rotary contour and "+"/"-"360.0000 degrees for all other operations . Positive ("+") motion of theRotary Table is in a clockwise (CW) direction as it would appear to theoperator when standing at the "+X" end of the work table and facing theRotary Table.

2 - 230 5/18/94 Hawk 5M Machine

Conversational Part Programming

Rotary Part Programs

Rotary programs can only be created in Rotary programming mode.

Program Definition

To create a rotary part program, the operator first displays Input screenand enters the program name and then selects Inch or Metric unit ofmeasure and whether the program is Rotary or Standard (see below).

Figure 2 -145. Input Screen with rotary option

Important

If the operator requests another CRT screen before selecting the axisconfiguration, the part program defaults to the Standard axisconfiguration. Then the operator cannot create any rotary data blocks.

Ultimax 3 System Revision A 2-231

Operator' s Manual

Part and Tool Setup

For programs using a rotary axis, the operator must describe the tools thatwill be used and describe part zero and perhaps the safety work region.The operator displays the Input screen, and enters the program name.

- INPUT - I

MASTER PROGRAM HAUR 91 e1 .9 May.B5'94T SE

EDIT PART PROGRAM RTR.1m3 HIM ' TOOL SETUPROTARY A 1^

F PART PROGRAMINGPROGRAM NHIORV ANM ILABI ,6 99 X 3

P PROGRAM4 PARAMETERSirG

F COPY AND CHANGE6 BLOCIS

F ERASE FUNCTIONSSelect sottkey or preaa (Enter > to change Part Program name 7

Fa

Figure 2 -146. Input screen

2 - 232 5/18/94 Hawk 5M Machine

Conversational Part Programming

After the name of the part program is entered into the Input screen, andthe tools and work piece are in place , the operator is ready to begin thepart setup process . Press the Part Setup (F1) softkey to begin the setupprocess . The Part Setup screen appears . Type values into the fields or usethe jog unit to position the tool and store positions identifying thesevalues.

PART SETUP,

Machine Is not calibrated.

Y BACK (.) 99.8888 FV FRONT (-) -99.0000 1

X LEFT (-) -99.0800 F USE PART PROBEX RIGHT ( •) 99.6888 S

2 BOTTOM (-) -99.88082 TOP (.) 99.0800 4 PARAMETERS

F

F TOOL SETUP2

SAFETY YORK REGION F PROGRAM

6

)VV SKEW (deg.) B.BBBB FEnter part zero It known or Jog machine to part zero. 7position and press sot They to store position I

F EXIT8

Figure 2-147. Part Setup screen with Rotary Axis

When the machine is not calibrated or it is in concurrent programming,there are no machine and part position values displayed at the top of thescreen as shown in the example above.

When setting up a rotary part, the "Y" axis zero is generally considered torun along the center of the rotary table. Most operators use the top of thepart as "Z" zero. Yet in some instances, the center of the rotary table maybe used as "Z" zero; especially if the piece being machined is notsymmetrical in shape.

The "A" centerline offsets for "Y" and "Z" are incremental distancesfrom true part zero. Therefore, if the "Y" dimension part zero is thecenterline of the rotary table, then the "Y" offset value will be zero. If "Z"part zero is the top of the part, then the "'Z" centerline offset will be anegative value equal to the radius of the part. Programming this value isalso important in allowing the control to draw the program properly on thegraphics screen.

Ultimax 3 System Revision A- 2 - 233

Operator's Manual

Follow these steps to enter rotary part setup information:

1. Establish axes coordinates (values) for part zero. Calibrationprocess includes finding part zero for the "A" axis and therotary axis centerline.

2. Establish the centerline of the Rotary Table. The centerline ofthe rotary axis ("A" axis) must be specified to perform rotarymilling operations. This centerline is also used by the graphicsdisplay. The centerline is defined by a "Y" value and a "Z"value which are part/tool zero relative. These values can bedetermined by jogging an indicator to the "A" centerline, OR toa known dimension of a part on the rotary table.

3. Then press Store Machine Position softkey for each value. Adisplayed value may be adjusted by: (1) entering the desiredadjustment value via the console keyboard, (2) entering theappropriate sign [plus (+) or minus (-) value], and (3)depressing the Enter key. This procedure will add, or subtract(depending upon the sign entered) the adjustment value to thecurrently stored value.

4. With the cursor at the Z Top (+) parameter, enter thedimensional values to establish a Safety Work Region using oneof the methods listed below. If no values are entered for thedisplayed parameters, the dimensions default to the displayedmeasure. Tool motion outside this safety plane stops theprogram and displays an appropriate error message.

a. Use the numerical and Enter keys to programdimensional values for each axis safety plane. The ZTop (+) parameter should denote a clearance aboveall portions of the part and/or fixture.

OR

b. Use the axis jog functions on the jog unit (<X>, <Y>,<+>, <-> keys) to move the X and Y axes to thesafety plane positions, and then press Store MachinePosition softkey to store each value.

5. To store Z Top (+) and Z Bottom (-) parameters, a calibratedtool must be in the spindle. The dimensional value enteredestablishes an offset in Z.

2-234 5/20/94 Hawk 5M Machine

Conversational Part Programming

General Parameters

For programs using a rotary axis, the operator must set up the programparameters just as they must be set up for any part program. The operatordisplays the Input screen and presses the Program Parameters (F4) softkeyto access the parameters screens as described in the "Getting Started"chapter. The default values appear in the fields on these screens; however,the operator may want to change some of the parameters, particularly onthe General Parameters (shown below).

GENERAL PARAMETERS

RETRACT CLEARANCERAPID TRAVERSEPECK CLEARANCE PLANECHORD ERRORDEPLETION RETRACTINTERRUPT CYCLE Z RETRACT

0F

99.0088 IN 1400.6 IPM0.0500 In F8.0801 IN 20.0858 IN I.

YES F3

F4

rP HOLES5 PARAMETERS

P MILLING6 PARAMETERS

P PROGRAMEnter clearance height ahoue E START at which tool moues 7 PARAMETERSbetween operations iPRESS MANUAL MODE, POWER, AND START TO RESTORE POWER. F EXIT

B

Figure 2-148. General Parameters

The Rapid Traverse field is an important parameter when using a rotaryaxis. The maximum "A" axis rapid traverse rate is 3780 degrees perminute or 10.5 rpm. This equals 400 inches per minute in the Ultimaxsystem. This value can be reduced to slow the rapid traverse by entering avalue less than 400 inches per minute . Then each time the rotary tablemoves past its 360 angle, the system will display the message "Axis Limit

. Switches : A-CAL."

Ultimax 3 System Revision A 2-235

Operator's Manual

Rotary Programming Options

To access the rotary programming options, the operator must haveselected the Rotary A (F2) softkey on the Input screen. Then the operatorpresses the Part Programming softkey on the Input screen to access thescreen shown below:

BLOCK 1 ® NEW BLOCK

Choose type of block

Figure 2-149 . New Block screen with Rotary soft key

40

2 - 236 5/20/94 Hawk 5M Machine

Conversational Part Programming

The operator presses the Rotary (F7) softkey. to access the rotary datablock options.

BLOCK 1 I NEW BLOCK

Choose type of block

F 1) ROTARY1 POSITION

F 2) ROTARY LINES2 AND ARCS

F 3) ROTARY CIRCLE3

F 4) ROTARY FRAME4

F 5) ROTARY LOOP5

F 6) ROTARY6 LOCATIONS

F 7) PATTERN END7

F 8) ROTARY8 PARAMETERS

Figure 2-150. Rotary Options on the New Block screen

The rotary options softkeys have.the following uses:

• Rotary Position (Fl) - a position block must be added beforeany other rotary option in the part program because this datablock defines the "A" reference position from which to work.

• Rotary Lines and Arcs (F2) - describes segments the will cutlines and arcs around a cylinder shaped part.

• Rotary Circle (F3) - describes a machined circle that wrapsaround the rotary center line.

• Rotary Frame (F4) - describes a machined frame that wrapsaround the rotary center line.

• Rotary Loop (F5) - describes the number of times a rotarypattern will be repeated.

• Rotary Locations (F6) - indicates the locations where a patternwill be repeated and the distances between repetitions on the part.

• Pattern End (F7) - marks the end of a rotary pattern in theprogram.

• Rotary Parameters (F8) - defines the two primary rotaryparameters: Cylinder Radius and Y Off of Centerline.

Ultimax 3 System Revision A 2 - 237

Operator's Manual

Rotary Parameters

Press the Rotary Parameters (F8) softkey option to display this screen.

BLOCK 1 ROTARY PARAMETERS IF

CYLINDER RADIUS ® 0.0000 1

V OFF OF CENTERLINE MO 02

Enter radius of cylinder on which cutter compensation iscomputed

Figure 2-151. Rotary Parameters

IF3

F PROGRAM1 PARAMETERS

iF PART SETUPSi

F TOOL SETUP6

F7

F EXIT0

Fields Definitions

Cylinder Radius is used to perform rotary cutter compensation androtary contour arcs. It must be a non-zero value onlyif computations are to be based on a cylinder otherthan the one that includes the Z Start point.

Y Off of if the tool should automatically position in "Y"Centerline directly over the centerline for rotary milling

operations, change this field to "Yes" to select theoption. When this option is selected, the RotaryPosition block must move the tool to the desired "Y"dimension before rotary milling.

Caution

If the operator does not enter a Cylinder Radius value for the part, themachine will mill the part as if it has a flat work surface.

2 - 238 5/20/94 Hawk 5M Machine

Conversational Part Programming

Rotary Position Block

A position block must be added before any other rotary data block in thepart program because the Position block defines the "A" referenceposition from which to work.

If a "Y" dimension other than zero is programmed and the "Y" off ofcenterline option is a "No" Rotary Parameters Block, the tool will positionto the "Y" value, but will reposition over the center of the rotary tablebefore performing any "A" axis movement.

BLOCK 1 ROTARY POSITIOII ITOOL B ROTARY SAFETY MOVE MO

F1I

x 0.0880 F2

Y 8 0080 I.F

A 0.888 31

F PROGRAM4 PARAMETERS

STOP No IF PART SETUP5

TOOL NOT PROGRAPHO F TOOL SETUP6

FEnter tool number 7

F EXIT8

Figure 2-152. Rotary Position Block

Important

If a position block is not added , the system displays an error messagewhen it encounters a rotary block and will not execute the rotaryinstructions in the block.

Ultimax 3 System Revision A 2-239

Operator's Manual

To create a position block, the operator presses the Rotary Position (Fl)softkey on the new Block screen, and this screen appears:

Fields Definitions

Tool is the number of the tool that will be used for therotary operation described in the next data block inthe part program. '

X enter the "X" coordinate (relative to part zero) of thedesired table position.

Y enter the "Y" coordinate (relative to part zero) of thedesired table position.

Rotary Safety select "Yes" or "No" indicating whether or not thisMove Position block is a safety move. If the operator selects

"Yes," the machine position fields appear so that theoperator can enter the location of absolute zero on thetable.

X Machine enter the "X" coordinate for absolute zero on thePosition table. This value does not change and is not relative

to the part. (This conditional field appears if "Yes" isselected in Rotary Safety Move.)

Y Machine enter the "Y" coordinate for absolute zero on thePosition table. This value does not change and is not relative

to the part. (This conditional field appears if "Yes" isselected in Rotary Safety Move.)

A enter the "A" axis coordinate (relative to part zero) ofthe desired table position.

Stop If the operator wants the program to stop and displaya message at this point in the program, press the"Yes" softkey. Then the operator will need to pressthe Start Cycle console button to restart the partprogram.

2-240 5/20/94 Hawk 5M Machine

Conversational Part Programming

Rotary Milling Operations

Rotary milling operations can be programmed as "X-A-Z" operations.The "Y" axis is normally held fixed at the "Y" centerline dimension, butan option in the Rotary Parameters allows "Y" to remain where it iscurrently positioned. The programmed feedrates are defined as surfaceinches-per-minute (ipm) for the part of the tool doing the most cutting(i.e., part of tool farthest from the rotary centerline). In most cases, thispoint corresponds to the Z Start dimension, but it can be the previouspeck level.

Milling operations constructed of segments begin with a Start segment(shown below) to define the tools, cutter compensation, and startingpoints for the segments that will be defined in subsequent segments.

BLOCK 1 ROTARY MILL CONTOUR 1F 1) NO

T R START 1

TOOL I PLUNGE FEED 8.8 P 2) LEFT2

Q)TTER COMP • No i.F-3) RIGHT

FINISH TOOL 0 SPEED (RPM) 8 3

X START PECK DEPTH 0.0808 P 4) PROFILE LEFT

A START TOOL NOT PROGRAMMED4

F 5) PROFILE RIGHT2 START 0.8080 S

2 BOTTOM 0.0080 P 6) POCKET

Select cutting operation

Figure 2-153. Rotary Milling Operations

6 BOUNDARY

iF 7) POCKET7 ISLAND

1F EXIT8

"X-A" cutter compensation (options shown in the softkey list above) issupported and occurs on the surface of the cylinder. These calculationsdefault to using the cylinder that includes the Z Start point, but theoperator can choose a cylinder of a different radius by programming aRotary Parameters block before milling blocks.

Ultimax 3 System Revision A 2 - 241

Operator's Manual

Lines and Arcs

After entering a Start segment , the operator presses the Advance key toadd a new segment . To describe the end points of a line, the operatorpresses the Line (F1) softkey. To define the direction , end and centerpoints of an arc, the operator presses the Arc (F2) softkey.

For rotary lines and arcs, the "Y" axis is disabled and the "A" axisreplaces it. The position of the tool in the "Y" axis is determined by theRotary Parameters and Rotary Position blocks.

BLOCK 1 ROTARY MILL CONTOURF

SEGMENT 1 LIME

X END (X START(A START

A END (Z START

2 END 8.8800

FEED 8.8

Enter coordinate of and point , if known

Figure 2-154. Rotary Line

tPS

iF6

iF PREVIOUS SEGMENT7

rF EXIT8

Contours can be built from "X-A-Z" line and arc segments.

2 - 242 5/20/94 Hawk 5M Machine

Conversational Part Programming

Important

Automatic calculation (Ultimax No-Calc) is not available for the rotaryaxis. The operator must calculate the values of unknown tangency points,end points, and center points for lines and arcs. The simple method toperform these calculation is to program the profile in normal lines andarcs (X, Y). Then the system calculates all unknowns. (Refer to thesample program at the end of this section.) All "Y" dimensions in thecalculation program must then be translated into "A" dimensions by usingthe formula shown below. In the equation, "r" is the radius of the cylinder.

A=180XY7Cxr

Figure 2-155. Formula to calculate unknown rotary line and arc points

Ultimax 3 System Revision A 2 - 243

Operator 's Manual

Rotary Frame

The main difference between Rotary Circles and Frames and standardCircles and Frames is that the rotary versions are wrapped around theradius of the cylinder, and the "Y" dimensions are now specified in "A"angular) dimensions.

BLOCK 1 ROTARY MILL

TOOL • 0

TYPE ON

FINISH TOOL 0

X CORNER 0 . 0000

A CORNER 0 . 008

X LENGTH 0.0888

A LENGTH 0 . 088

CORNER RADIUS 0.8000

FRAME

Z START 6.0008F1

Z BOTTOM 6.0008 F2

PLUNGE FEED 6 8 i.

MILL FEED 0.0F3

rSPEED (RPM) 0 F PROGRAM

4 PARAMETERSPECK DEPTH 0 0808 1.

TOOL NOT PROGRAMMEDF5

PART SETUP

iF TOOL SETUP

1 6

Eller tool numberF7

F EXITB

Figure 2 156. Rotary Frame

Important

If the dimensions on the blue print are given in "X" and "Y" dimensions,the. operator needs to use trigonometry to calculate the proper "A" values.

2 - 244 5/20/94 Hawk 5M Machine

Conversational Part Programming

Rotary Loop

A Rotary Pattern Loop is similar to a Loop Linear block except the "A"dimension replaces the "Y" dimension and allows the loop to revolveabout the cylinder, if desired. Nesting two Rotary Loop blocks couldsimulate a rectangular grid wrapped about the cylinder similar to LoopRectangular blocks in regular programming. The fields on this screenindicate the number of times the pattern will be repeated and the distancesbetween the repetitions:

BLOCK

NUMBER

1 ROTARY PATTERN LOOP

I 1FI

I.X DISTANCE 0.8008 F

2A DISTANCE 8.800

F3

F PROGRAM4 PARAMETERS

F PART SETUP5

P TOOL SETUP.6

Enter muber of patternsF7

F EXITB

Figure 2-157. Rotary Pattern Loop

A Rotary Pattern End block must follow at the end of the sequence toclose the pattern.

A Rotary Position block must follow any Rotary Pattern Block(s) in theprogram. Pattern blocks can only modify blocks contained within thepattern. This Rotary Position block gives the pattern a reference to workfrom when starting from the beginning or using Recovery Restart.

Ultimax 3 System Revision A ` 2 - 245

Operator's Manual

Rotary Pattern Locations

Rotary Pattern Location Blocks are identical to two-dimensional PatternLocation Blocks with the "A" axis being added to the end of eachlocation.

BLOCK I - ROTARY PATTERN LOCATIONSF DELETE LOCATION

X OFFSET V OFFSET Z OFFSET A OFFSET 1

11 8.8888 8 . 8688 8 . 8888 8 .888 F INSERT LOCATION2 BEFORE

F3

F4

F

F6

Enter an offset to moue the pattern to a neu location F

IF EXIT8

Figure 2-158. Rotary Locations

A Rotary Pattern End block must follow at the end of the sequence toclose the pattern.

A Rotary Position block must follow any Rotary Pattern Block(s) in theprogram. Pattern blocks can only modify blocks contained within thepattern. This Rotary Position Block gives the pattern a reference to workfrom when starting from the beginning or using Recovery Restart.

2 - 246 5/20/94 Hawk 5M Machine

Conversational Part Programming

Sample Rotary Program

Here is the rotary part drawing used to develop the sample programs:

Figure 2-159. Part Drawing usedfor the sample Rotary program

There are two programs included in this section. The first is used tocalculate values used in the second program. The second program is theactual rotary program.

Ultimax 3 System Revision A 2 - 247

Operator's Manual

Preliminary Calculation Program

Since the rotary software does not calculate unknown values for lines andarcs, Ultimax operators often create a simple 2-D program to determineunknown values. Then they place the calculated values from the 2-Dprogram into the rotary program.

Here is an illustration of the preliminary calculation program developedfor the rotary drawing shown on the previous page. Note that this issimply a flattened version of the edges of the rotary part.

Figure 2-160. Illustration of Preliminary Calculation Program

2 - 248 5/20/94 Hawk 5M Machine

Conversational Part Programming

Here is a copy of the preliminary calculation part program. Aftercompleting this program, the operator must print it to have a copy of thevalues for the actual rotary program.

Hurco Ultimax Part Program 1

Prlmcalc.HD3

Part Setup

Metric

Standard

Part Zero X 0.0000 Safety Work

Region

Y 0.0000 Z Top (+) 9999.0000

Offset Z 0 . 0000 Z Bottom (-)

9999.0000

Part Zero A 0.0000 X Left (-)

9999 0000.

X Right (+) 9999.0000

A. Centerline 32.000 Y Front (-)

Y 9999 0000.

Z 0.000 Y Back (+) 9999.0000

Fixture Offset 1

General Parameters

Retract Clearance 999.000 MM

Rapid Traverse 10160.0 MMPM

Peck Clearance Plane 1.270 MM

Chord Error 0.003 MM

Depletion Retract 0.127 MM

Holes Parameters

Bore Orient Retract 0.500 MM

Drill Dwell 0.5 SEC

Bore Dwell 1.0 SEC

Milling Parameters

Blend, Offset 3.000 MM

Blend Overlap 3.000 MM

Finish Feed 100 %

Finish Speed 100 %

Finish XY 0.200 MM

Finish Z 0.100 MM

Milling Direction

Pocket Overlap

Climb

10 %

Cutter Comp Parameter Insert Arc

Ultimax 3 System Revision A 2 - 249

Operator' s Manual

Hurco Ultimax Part Program 2

Prlmcalc.HD3

Program Parameters

Override Lockout Off

Program Protect Partial

Tool Change Position No

Tool Setup

1 Diameter 6.000

Zero Calibration -10000.

Speed (RPM) CW 1000

Coolant Off

Gear range 1

Tool Number 1

Diameter Offset 1

Length Offset 1

Metric

Standard

The number to the left of the following data block name is the blocknumber.

1 Mill Contour

Data Blocks

Segment 0 Start

Tool 1 Plunge Feed 500.0Cutter Comp. Left

Finish Tool 0 Speed (RPM) 1000

X Start -64.500 Peck Depth 0.000Y Start 0.000

Z Start 1.000Z Bottom -5.000

Lead Length 0.0000 Lead Angle 0.0000

This is the Start segment block used to identify the tools and otherfeatures of the following segments.

2 - 250 5/20/94 Hawk 5M Machine

Conversational Part Programming

Hurco Ultimax Part Program 3 Metric

Prlmcalc . HD3 - Standard

Segment 1 Arc

Direction CW

X End CAL -59.261

Y End CAL 9.371

X Center -53.500

Y Center 0.000

Radius CAL .11.000

Feed 500.0

Segment 2 Line

X End CAL -35.239

Y End CAL 24.140

Z End -5.000

XY Length CAL 28.199

XY Angle CAL 31.584

Feed 500.0

Segment 3 Arc

Direction CCW

X End

.Y End

X Center

Y Center AL

- 30.000

33.510

-41.000

33.510

Radius

Feed

Segment

Direction

4 -Arc

11.000

500.0

CCW

X End CAL. -35.239

Y End CAL 42.881

X Center -41.000

Y Center CAL 33.510

Radius 11.000

Feed 500.0

Ultimax 3 System Revision A 2 - 251

Operator' s Manual

Hurco Ultimax Part Program 4 Metric

Prlmcalc . HD3 Standard

Segment 5 Line

X

Y

Z

XY

XY

End

End

End

Length

Angle

CAL

CAL

CAL

CAL

-59.261

57.649

-5.000

28.198

148.418

Feed

Segment

Direction

6 Arc

500.0

CW

X End

Y End

X Center

Y Center

Radius

Feed

Segment

Direction

7

AL

Arc

-64.500

67.020

-53.500

67.020

11.000

500.0

CW

X End CAL -59.261

Y End CAL 76.391

X Center -53.500

Y Center CAL 67.020

Radius 11.000

Feed 500.0

Segment 8 Line

X End CAL -35.239

Y End CAL 91.159

Z End -5.000

XY Length CAL 28.199

XY Angle CAL 31.583

Feed 500.0

2 - 252 5/20/94 Hawk 5M Machine

Conversational Part Programming

Hurco Ultimax Part Program 5 Metric

Prlmcalc.HD3 Standard

Segment 9 Arc

.Direction CCW

X End -30.000

Y End 100.530

X Center -41.000

Y Center CAL 100.530

Radius 11.000

Feed 500.0

Segment 10 Arc

Direction CCW

X End CAL -35.239

Y End CAL 109.901

X Center -41.000

Y Center CAL 100.530

Radius 11.000

Feed 500.0

Segment 11 Line

X End CAL -59.261

Y End CAL 124.669

Z End -5.000

XY Length CAL 28.199

XY Angle CAL 148.417

Feed 500.0

Segment 12 Arc

Direction CW

X End -64.500

Y End 134.040

X Center -53.500

Y Center CAL 134.040

Radius 11.000

Feed 500.0

Ultimax 3 System Revision A 2 - 253

Operator's Manual

Hurco Ultimax Part Program 6 Metric

Pr1mcaic.HD3 Standard

Segment 13 Arc

Direction CW

X End CAL -59.261Y End CAL 143.411

X Center -53.500

Y Center CAL 134.040

Radius 11.000

Feed 500.0

Segment 14 Line

X End CAL -35.239Y End CAL 158.179Z End -5.000XY Length CAL 28.199

XY Angle CAL 31.583Feed 500.0

Segment 15 Arc

Direction CCW

X End -30.000Y End 167.550

X Center -41.000Y Center CAL 167.550Radius 11.000Feed 500.0

Segment 16 Arc

Direction CCW

X End CAL -35.239Y End CAL 176.921

X Center -41.000

Y Center CAL 167.550Radius 11.000Feed 500.0

2 - 254 5/20/94 Hawk 5M Machine

Conversational Part Programming

Hurco Ultimax Part Program 7 Metric

Prlmcalc.HD3 Standard

Segment 17 Line

X End

Y End

Z End

XY Length

XY Angle

CAL

CAL

CAL

CAL

-59.261

191.689

-5.000

28.199

148.417

Feed

Segment 18

Direction

Arc

500.0

CW

X End -64.500

Y End 201.060

X Center -53.500

Y Center CAL 201.060Radius 11.000

Feed 500.0

2 Graphics Off

3 Rotary Parameters

Cylinder Radius 32.000Y Off of

Centerline

Rotary Mill

Contour

Segment 0 tart

No

Tool 1 Plunge Feed 500.0

Cutter Comp. Left

Finish Tool 0 Speed (RPM) 1000X Start -64.500 Peck Depth 0.000A Start 0.000

Z Start 1.000

Z Bottom -5.000

Lead Length 0.0000 Lead Angle 0.0000

This is a rotary Start segment block used to identify the tools and otherfeatures for the following rotary segments. Note that the "Y" Start fieldhas been replaced with an "A" Start field.

Ultimax 3 System Revision A 2 - 255

Operator' s Manual

Hurco Ultimax Part Program 8 Metric

Prlmcalc . HD3 Standard

Segment 1 Arc

Direction CW

X End -58.833

A End 20.417

X Center -53.500

A Center 0.000

Feed 500.0

Segment 2 Line

X End -35.667

A End 47.677

Z End -5.000

Feed 500.0

Segment 3 Arc

Direction CCW

X End -30.000

A End 60.000

X Center -41.000

A Center 60.000

Feed 500.0

Segment 4 Arc

Direction CCW

X End

A End 0.000

* Center

A Center 0.000

Feed 500.0

2 - 256 5/20/94 Hawk 5M Machine

Conversational Part Programming

Rotary Program

The actual rotary program that the operator will use to cut the part usesvalues calculated in the previous program. Here is the graphicrepresentation of this program.

Figure 2-161. Graphics screen representation of Rotary Program

Due to the difference in perspectives, the graphic representation of arotary part on the control may not exactly match the part drawing, sooperators often use the Dry Run feature on the Test Run screen to test theprogram before cutting the part.

Ultimax 3 System Revision A 2 - 257

Operator' s Manual

Here is a copy of the rotary part program . Since Ultimax allowsconsiderable flexibility in developing part programs, this is not the onlyway the part can be programmed . Watch for inserted explanations of thespecial features of this sample program.

Hurco Ultimax Part Program 1 Metric

Rotary . HD3 Rotary A

Part Setup

Part Zero X 0.0000 Safety Work

Region

Y 0.0000 Z Top (+) 9999.0000

Offset Z 0.0000 Z Bottom (-)

9999.0000

Part Zero A 0.0000 X Left (-)

9999.0000

X Right (+) 9999.0000

A Centerline 0.000 Y Front (-). -Y 9999.0000

Z 32.000 Y Back (+) 9999.0000

Fixture Offset 1

General Parameters

Retract Clearance 999.000 MM

Rapid Traverse 10160.0 MMPM

Peck Clearance Plane 1.270 MM

Chord Error 0.003 MM

Depletion Retract 0.127 MM

Holes Parameters

Bore Orient Retract 0.500 MM

Drill Dwell 0.5 SEC

Bore Dwell 1.0 SEC

2 - 258 5/20/94 Hawk 5M Machine

Conversational Part Programming

Hurco Ultimax Part Program 2 Metric

Rotary.HD3 Rotary A

Milling Parameters

Blend Offset 3.000 MM

Blend Overlap 3.000 MM

Finish Feed 100 %

Finish Speed 100 %

Finish XY 0.200 MM

Finish Z

Milling Direction

0.100

Climb

MM

Pocket Overlap 10 %

Cutter Comp Parameter

Program Parameters

Insert Arc

Override Lockout Off

Program Protect Partial

Tool Change Position No

Tool Setup

1 Type End Mill

Diameter 6.000

Zero Calibration 0.000

Speed (RPM)

Coolant

CW 1000

Off

Gear range 1

Tool Number 1

Diameter Offset 1

Length Offset 1

2 Type Drill

Diameter 10.000

Zero Calibration 0.000

Speed (RPM)

Coolant

CW 1200

Off

Gear range 1

Tool Number 2

Diameter Offset 2

Length Offset 2

. Ultimax 3 System Revision A 2 - 259

Operator's Manual

Hurco Ultimax Part Program 3 MetricRotary. HD3 Rotary A

Data Blocks

1 Rotary Parameters

Cylinder Radius 32.000

Y Off

Centerline

of No

If the program will include cutter compensated lines and arcs, this RotaryParameters data block must be entered.

2 Position

Tool 2

X -53.500Y 0.000

Stop No

3 Rotary Position

Tool 2X -53.500Y 0.000A

Stop

Rotary Stop

0.000

No

No

4 Rotary Pattern

Loop

Number 3

X Distance 0.000

A Distance 120.000

5 Rotary Position

Tool 2

X -53.500

Y 0.000A

Stop

Rotary Stop

0.000

No

No

2 - 260 5/20/94 • Hawk 5M Machine

Conversational Part Programming

Hurco Ultimax Part Program

Rotary.HD3

6 Holes

Drill

Tool 2

Z Start 1.000

Z Bottom -5.000

Plunge Feed 500.0

Speed (RPM) 1200

Peck Depth 0.000

Peck Type Standard

Metric

Rotary A

Locations

X Y

1 -53.500 0.000

7 Pattern End

Rotary

Contour

Segment

Mill

0 Start

Tool 1 Plunge Feed 500.0

Cutter Comp.

Finish Tool

Left

0 Speed (RPM) 1000

X Start -64.500 Peck Depth 0.000

Y Start 0.000

Z Start 1.000

Z Bottom -5.000

Lead Length 0.0000 Lead Angle 0.0000

Ultimax 3 System Revision A 2 - 261

Operator' s Manual

Hurco Ultimax Part Program 5 Metric

Rotary . HD3 Rotary A

Segment 1 Arc

Direction CW

X End -59.261

A End 16.777

X Center -53.500

A Center 0.000

Feed 500.0

This segment uses the calculated "Y" End value (9.371) and the partradius (32) from the rotary part drawing. The operator put these valuesinto the formula:

A= 180 xYitxr

So that the "A" End value is calculated as follows:

180 x 9.371=16.7777tx32

Segment 2 Line

X End -35.240

A End 43.223

Z End -5.000

Feed 500.0

Segment 3 Arc

Direction CCW

X End -30.000

A End 60.000

X Center -41.000

A Center 60.000

Feed 500.0

2 - 262 5/20/94 Hawk 5M Machine

Conversational Part Programming

Hurco Ultimax Part Program 6 Metric

Rotary.HD3 Rotary A

Segment

Direction

4 Arc

CCW

X End -35.240

A End 76.777

X Center -41.000

A Center 60.000

Feed 500.0

Segment 5 Line

X End -59.261

A End 103.223

Z End -5.000

Feed 500.0

Segment 6 Arc

Direction CW

X End -64.500

A End 120.000

X Center -53.500

A Center 120.000

Feed 500.0

Segment 7 Arc.

Direction CW

X End -59.261

A End 136.777

X Center -53.500

A Center 120.000

Feed 500.0

Segment 8 Line

X End -35.240

A End 163.223

Z End -5.000

Feed 500.0

Ultimax 3 System Revision A 2 - 263

Operator's Manual

Hurco Ultimax Part Program 7 Metric

Rotary.HD3 Rotary A

Segment

Direction

9 Arc

CCW

X End

A End

X Center

A Center

Feed

Segment

Direction

0 rc

-30.000

180.000

-41.000

180.000

500.0

CCW

X End -35.240A End 196.777

X Center -41.000

A Center 180.000

Feed 500.0

Segment 11 Line

X End -59.261

A End 223.223

Z End -5.000

Feed 500.0

Segment 12 Arc

Direction CW

X End -64.500

A End 240.000

X Center -53.500

A Center 240.000

Feed 500.0

Segment 13 Arc

Direction CW

X End -59.561A End 256.777

X Center -53.500

A Center 240.000

Feed 500.0

2 - 264 5/20/94 Hawk 5M Machine

Conversational Part Programming

Hurco Ultimax Part Program 8 Metric

Rotary . HD3 Rotary A

Segment 14 Line

X End -35.240

A End 283.223

Z End -5.000

Feed 500.0

Segment 15 Arc

Direction CCW

X End -30.000

A End 300.000

X Center -41.000

A Center 300.000

Feed 500.0

Segment 16 Arc

Direction CCW

X End -35.240

A End 316.777

X Center -41.000

A Center 300.000

Feed 500.0

Segment 17 Line

X End -59.261

A End 343.223

Z End -5.000

Feed 500.0

Segment 18 Arc

Direction CW

X End -64.500

A End 360.000

X Center -53.500

A Center 360.000

Feed 500.0

Ultimax 3 System Revision A 2 - 265

Operator' s Manual

Upload and Download Programs

The Ultimax upload/download facility allows operators to transfer partprograms between the control and various peripheral devices (e.g., apersonal computer or an external disk drive). Programs are transferredfrom these devices over RS-232-C serial ports. This facility also allowsthe operator to download programs from the control to a parallel printer(connected to the machine tool's printer port).

For information about uploading and downloading NC part programs,refer to the NC Programming Instruction Manual.

Setup

Before attempting to communicate with any connected peripheral device,be certain that the correct cable is connected between the designated serialport and the device. Refer to the Maintenance Manual . for moreinformation about required cabling. Also, ensure that the Hurco serial portand the peripheral device are identically configured. Use the Serial PortSetup softkey, described in this section, to check and change theconfiguration.

Important

Improper cable connections and incompatible communications settingsare the most common problems encountered when attempting tocommunicate between two electronic devices.

2 - 266 5/20/94 Hawk 5M Machine

Conversational Part Programming

Access through the Auxiliary Screen

To access the upload/download facility, press the Auxiliary console key.Then press the Upload/Download (F3) softkey and this screen appears:

mm AUXILIARY a«

Make certain the proper cahle is connected betueen theselected port on the mill and the peripheral device.

UPLOAD: 1) Press UPLOAD softkey.2) Send program from peripheral device.

DOWNLOAD : 1) Open file to receive data at the peripheral2) Press DOWNLOAD sot they.3) If necessary , close the file on the

peripheral device after transfer is dane.PRINT : 1) Select the PRINT PROGRAM softkey.

PORT NUMBER 1PROTOCOL XON/XOFFBAUD RATE 9688CHARACTER LENGTH 7STOP BITS 1.5PARITY EVEN

Choose appropriate softkey

F UPLOAD1 RECEIUE

F PRINT CURRENT2 DIRECTORY

F DOWNLOAD3 SEND

iF PRINT PROGRAM4

F SELECT PORTS

F RESET PORT6 PARAMETERS

F SERIAL PORT7 SETUP

F EXIT8

Figure 2-162. Auxiliary screen with Upload/Download facility options

The following options are available from this screen:

• Upload Receive (Fl) - allows the control to receive of data fromproperly connected peripheral such as a personal computer.

• Print Current Directory (F2) - causes the directory of thecurrent storage device to be printed via a properly connectedprinter.

• Download Send (F3) - enables data to be sent to a properlyconnected peripheral.

• Print Program (F4) - enables a part program to be sent andprinted onto a parallel printer.

• Select Serial Port (F5) - switches between the two serial portsand the parallel printer port. When this softkey is pressed, thescreen changes to display the other serial port (and its settings)OR the parallel' printer port.

Ultimax 3 System Revision A 2 - 267

Operator's Manual

• Reset Port Parameters (F6) - resets the displayed serial port toits default values.

• Serial Port Setup (F7) - enables the selection of thecommunication settings for the displayed serial port.

• Exit (F8) - to the Auxiliary screen with the original softkeyoptions.

2 - 268 5/20/94 Hawk 5M Machine

Conversational Part Programming

Receive or Send a Part Program

The Upload Receive (Fl) and the Download Send (F3) softkeys havesimilar operations. Follow the screen displayed instructions correspondingto the enabled softkey to transfer data between the control and theconnected peripheral device. Be certain to identify the correct serial portnumber. The communication ports allow the following:

• Receiving of program data from a connected peripheral viaeither of the ports, but one port at a time.

• Sending program data from either port (one at a time) to aconnected peripheral device.

• If transferring data from one Ultimax 3 control to another, oneis receiving the program data; the other is sending. Follow thescreen directions appropriate to each device.

Data can be transferred between the Ultimax 3 control and a peripheral. Amessage is also displayed near the bottom of the screen to indicate thestatus of the selected operation.

To stop the transfer process, the operator presses the Abort Operation (F8)softkey.

Ultimax 3 System Revision A 2 - 269

Operator's Manual

Print a Part Program

When the operator presses the Print Program (F4) softkey, the partprogram currently in temporary memory prints on the printer connected tothe machine's parallel port. Ultimax supports the following dot matrixprinters:

• Epson FX

• Citizen MSP-10 and MSP-55

Refer to any of the sample programs in this chapter to examine thestructure of printed programs from the Ultimax printing facility.

2 - 270 5/20/94 Hawk 5M Machine

Conversational Part Programming

Ports

The Reset Port Parameters (F6) softkey resets the communication settingsof the displayed serial port to the following default values:

Protocol XON/XOFF

Baud Rate 9600

Character Length 8

Stop Bits 1

Parity NONE

Both serial ports have the same initial default values.

The Serial Port Setup (F7) softkey permits the selection of the specificcommunication settings for the selected serial port. Different softkeysappear depending on the cursor position. Refer to the example below.Select the softkey that is correct for the connected device.

er AUXILIARY ww

Make certain the proper cable is connected between theselected port on the mill and the peripheral device.

UPLOAD : 1) Press UPLOAD softkey.2) Send program from peripheral device.

DOWNLOAD: 1) Open file to receive data at the per iphera2) Press DOWNLOAD softkey. .3) It necessary , close the file on the

peripheral device after transfer}eldone.PRINT : 1) Select the PRINT PROGRAM sof F

4

ROTOCOL XON/XOFP PBAOC-'IBM' SCHARACTER LENGTH BSTOP BITS IPARITY NOME

Choose appropriate softkey

Figure 2-163. Auxiliary screen with Protocol options

Important

Before attempting to transmit data, be certain that the connected serialport at the control and peripheral port are identically configured. Bothmust have the same protocol, baud rate, character length, stop bits, andparity.

Ultimax 3 System `.Revision A

Operator's Manual

Running Part Programs

The Ultimax 3 system has a variety of program running options. Theoperator may wish to run an entire program or only a portion of it.Operators also use the test run facilities and error checking and programrun time estimates available from these options.

Warning

When running part programs, operators should alwaysfollow these rules:

• Never press the Start Cycle console buttonwithout knowing exactly what the machine willdo!

• Never start the machine when the cutter is incontact with the work piece.

• Stand away while the machine is running a part

program.• Never lean on the machine while the spindle is

moving.

• Do not leave the machine unattended.

2 - 272 5/20/94 Hawk 5M Machine

Conversational Part Programming

Console Buttons Used

Before running a part program the operator must be familiar with theconsole keys used to operate the machine and run programs. There are twosets of console buttons used to run part programs located under the CRTsand above the main console panel.

• Machine Control Buttons - four round buttons on the left

• Machine Operations Buttons - grouping of rectangular buttonson the right

Machine Control Buttons

The operator uses the machine control buttons (shown below) to start andstop the machine. These buttons are located on the upper left of theconsole under the text CRT.

Start Motion Interrupt PowerCycle Hold Cyde on

0000Figure 2-164. Machine Control Console Buttons

• Start Cycle Activates machine operation. When the machine isin an active mode, Start Cycle flashes to indicate the machine isready. After the operator pressed the button, the light switchesoff.

Warning

Never press the Start Cycle console button withoutknowing exactly what the machine will do!

Ultimax 3 System Revision A 2 - 273

Operator's Manual

• Power On - Enables the relay control system. Must be 'on'(illuminated) to operate the machine, but can be `off' whenentering or editing program data.

• Motion Hold - Stops all axes movement, except a tap operationwhen tool is in the programmed feedrate region. Pressing thebutton a second time allows machine positioning to resumewithout loss of position, provided no other button or key hasbeen pressed.

• Interrupt Cycle - Halts machine operation during automaticexecution of a program to allow manual functions to beperformed. Pressing the button a second time returns themachine to the interrupted location and allows automaticprogram execution to resume from the point of interruption.

If the operator presses the Emergency Stop during the execution of a partprogram, the operator should jog the tool, clear of the part before resumingoperation.

2 - 274 5/20/94 Hawk 5M Machine

Conversational Part Programming

Mach"Mod•

sprAv

Machine Operations Buttons

The button on the upper right side of the console under the graphics CRTare also needed to run a part program and control machine systems usedduring cutting.

0 v,

- Machine Operations°Tns o wuwt o AUto OrAnud

Too(nn mwwr nnDon

Coctonta h o o Mt

Figure 2-165. Machine Operations Buttons

Machine Mode Buttons

onwd

The four Machine Mode buttons in the upper left comer of this section ofthe console have these functions:

• Auto allows the operator to run a part program automatically.

• Single gives the operator access to the Single cycle screen. Inthis mode, the machine stops the spindle after each operation(e.g., contour segment , hole operation, mill subroutine).Pressing the flashing Start Cycle button causes the machiningoperation to resume.

• Test gives the operator access to test run facilities such as DryRun and Feed and Speed Optimization. This function is notavailable when operating the machine in NC.

• Manual gives the operator access to manual machineoperations that allow axis positioning with the jog unit.

Ultimax 3 System Revision A 2 - 275

Operator' s Manual

Spindle

• . On activates the spindle when operating when using Manualoperation . The Start Cycle button must also be pushed to startspindle rotation.

• Off If the Spindle On button was previously pressed, thisbutton stops spindle rotation when using Manual operation.

Tool Changer

These buttons are not used on the Hawk 5M since it does not have anautomatic tool changer.

Coolant

• Auto activates the use of the selected coolantprogrammed in Tool Setup. If the coolant has been selected fora specific tool, when this key is pressed, the selected coolantswitches on whenever the tool is below Retract Clearance plane.The coolant turns off when the tool moves above the RetractClearance plane.

• Mist Functional only on machines equipped.with mistcoolant system. This key activates the mist coolant system whenusing Auto operation. Key can be toggled to override Autocoolant key and switch coolant off and on. Key also enablesmist coolant system during Manual operation.

• Flood Functional only on machines equipped with floodcoolant system. This key activates the flood coolant systemwhen using Auto operation. Key can be toggled to overrideAuto coolant key and switch coolant off and on. Key alsoenables flood coolant system during Manual operation.

2 - 276 5/20/94 Hawk 5M Machine

Conversational Part Programming

Manual

This. Machine Mode provides access to machine operations that enableaxis positioning from the console, machine calibration and otheroperations indicated on the screen.

Pressing the control's Manual button displays the screen shown below.The information at the top of the screen includes the current position ofeach axis relative to machine absolute and part zero. To activate machinemovement, the operator must also press the Power On button.

-- MANUAL -- IF TOOL IN SPINDLE

MACHINE PART MACHINE VERTICAL 1x 393.788 393.788 TOOL IN SPINDLE 8 IV 177.888 177. 808 SPINDLE 0 F MACHINEZ. 0.888 FEED MOTION STOPPED 2 DIAGNOSTICS

iF3

F PARE MACHINE4

Choose appropriate softkey

F WARM UP MACHINE

F TOOL HOME6

F RESET SERVOS7 AND SPINDLEi

F CALIBRATE MACHINE8

Figure 2-166. Manual Screen

The following Manual screen softkeys are used when running a partprogram:

• Tool in Spindle (Fl) - When the machine is initially switchedon, the Tool in Spindle field (to the left of the softkey) is set to anundefined state and indicated with asterisks (**). If there is notool in the spindle, the operator enters zero (0).

• Tool Home (F6) - ensures that the Z axis is at the correct heightfor a tool to be inserted in the spindle.

• Reset Servos and Spindle (F7) - activates only to enablerecovery from certain types of electronic hardware faults such asoverloads.

Ultimax 3 System Revision A 2 - 277

Operator's Manual

Test Run

This operating mode enables verification of the part program, a means toadjust the programmed feedrates and spindle speeds while cutting thepart, and a routine for checking the part program for programming errors.

Press Test button in the Machine Mode console grouping to display theTest Run screen:

TEST RUN - 1F DRY RUN

RUM ING PART PROGRAM 6061.1603

ESTIMATED RUN TIME P FEED & SPEED2 OPTIMIZATION

iF

START BLOCK 0 1 3

END BLOCK 36 F CHECK FOR ERRORS4

F COMPUTE ESTIMATED5 RUM TIME

FF6

Enter nuwber of desired block

Figure 2-167. Test Run screen

F7

1Fa

When operating in this test cycle, the path of the tool can be traced byrunning the machine with the Spindle - Off at the Z Start dimension foreach data block (in the range of blocks specified). When executing thepart program in Dry Run, peck cycles and roughing passes are skipped.Before attempting execution, enter the minimum Z value for operating inthis test cycle. During this test, the tool traces over the part at theminimum Z level.

Caution

if the Z Start dimensions are set below the surface of the rough stock. theminimum Z value for this operation must be programmed so the tool doesnot plunge into the part.

2 - 278 5/20/94 Hawk 5M Machine

Conversational Part Programming

Feed and Speed Optimization

The Test screen provides an option to allow the operator to fine tune theexecution of the part 'program-the Feed & Speed Optimization (F2)softkey. The Start Block and End Block fields in the Test screen definethe area of the part program that will be tuned when the operator pressesthis softkey to display the screen shown below.

To make necessary changes, the operator uses the Axis Feed Rate dial onthe jog unit to adjust the values and produce the best results.

ra FEED & SPEED OPTIMIZATION « IF SET SPEED

PART Ix -5.8808 TOOL IN SPINDLE a iV -6.6886 SPINDLE B FZ. w-nn-^n FEED MOTION STOPPED 2

F SET PLUNGE OR3 SEGMENT FEED

AXIS LOAD MONITOR BLOCK NUMBER 0tF4

20 40 6B 80 108 S PART COUNT B ix F SET FEEDV SZa iS F

6iF

Adjust overrides while cutting and press eoftkey to store 7new value in prograw block iPRESS START TO RUN PROGRAM. F

B

Figure 2 -168. Feed and Speed Optimization screen

Two of the softkey selections available on this screen (Set Plunge OrSegment Feed and Set Feed) rewrite the currently displayed program'sfeed and speed values with adjusted values. When a change is made, thescreen displays the old value and the new value. These updated values arein a copy of the part program that is being executed. When the run iscompleted, the old values of the program are automatically erased andreplaced with the new values. The control uses the original programmedfeedrates for the entire program and the new values do not becomeeffective until the next execution of the program.

Ultimax 3 System Revision A 2 - 279

Operator's Manual

The softkeys have these functions:

• Set Feed (F5) - modifies the feedrate for a mill subroutine or allfeedrates in an entire contour. This softkey does not change thefeed to the Rapid Traverse value while the machine is moving inrapid traverse.

• Set Plunge Or Segment Feed (F3) - modifies the initial plungefeedrate of the displayed data block or the feedrate for just thecurrent segment of a mill contour.

Feed rates for drilling and boring operations can be adjusted using eitherthe Set Plunge Or Segment Feed softkey or the Set Feed softkeys.

• Set Speed (Fl) - is not used on the Hawk 5M.

2 - 280 5/20/94 Hawk 5M Machine

Conversational Part Programming

Single Cycle

When this operating mode is enabled, the machine halts with the spindlerunning after each hole operation, contour segment, or milling subroutine.Machining is resumed when the flashing Start Cycle button is pressed.

Pressing the Single console key displays the screen . When the SingleCycle screen first appears, the Start Block and End Block fields areinitially set to the first and last blocks of the program . If the operatorwants to execute only a certain portion of the program , these fields may bechanged to define the limits to be executed . These limits apply to eachpart produced until new limits are defined.

Figure 2-169. Single Cycle screen

The softkeys of Check For Errors (F4), Computer Estimates Run Time(F5), Recovery Restart (F6), and Run Program (F8) function in the samemanner as the softkeys on the Auto screen in the following section.

Ultimax 3 System Revision A 2 - 281

Operator' s Manual

To run a single block of a part program, identify the block with the Startand End Block fields and press the Run Program (F8) softkey. This screenappears:

+w SINGLE CYCLE ww IF RESET PART COUNT

PART MACHINE VERTICAL 1X -8.1258 TOOL IN SPINDLE 1 jY 8.8758 SPINDLE 480 FZ -8.1888 FRED MOTION STOPPED 2A 8.888. ;

F3

I-AXIS LOAD MONITOR RLOCX M UMBER 3 F

LIME 428 40 68 88 188 2 PART COUNT 8 F

X PV 52 I-S F

6

1F

CYCLE COMPLETE : PRESS START FOR NEXT CYCLE.

Figure 2-170. Single Cycle with program information

7

IF0

This screen displays the same information about the running program asthe Auto screen described in the next section.

During execution of the part program, the operator can switch between theAuto Cycle and Single Cycle operations by pressing the correspondingconsole key.

2 - 282 5/20/94 Hawk 5M Machine

Conversational Part Programming

Automatic Operation

The screen displays the name of the part program that will be executed inthe Running Part Program field at the top of the screen.

When the Auto Cycle screen first appears, the Start Block and End Blockfields are initially set to the first and last blocks of the program. If theoperator wants to execute only a certain portion of the program, thesefields may be changed to define the limits to be executed. These limitsapply to each part produced until new limits are defined.

». AUTO ..

RUNNING PART PROGRAM 6061.HD3

ESTIMATED RUN TIME 0:10:80

START BLOCK

END BLOCK

F3

F CHECK FOR ERRORS4

fF COMPUTE ESTIMATED

S RUM TIME

F RECOVERY6 RESTART

Enter number of desired block

NO ERRORS FOUMD IN PROGRAM.

Figure 2-171. Auto screen

F7

F RUM PROGRAM8

The Start Block and End Block fields define the limits of the part programto be executed. Different blocks can be selected to execute only a certainportion of the program when the softkeys Check For Errors (F4) and RunProgram (178) are pressed.

This softkey function starts checking the part program for errors andcalculates the Estimated Run Time for the specified data blocks. Whenthis softkey feature is selected, the control begins at the Start Blockindicated and completes the test at the End Block shown on the screen.When the check is finished, the Estimated Run Time and the error statusof the program are reported. The time required for the program to performthis check depends on the length of the part program and its complexity.The estimated time for program execution is computed from the distancestraveled and the average time required to change tools.

Ultimax 3 System Revision A 2 - 283

Operator' s Manual

The information reported in the top area of this Auto screen includes thecurrent relative positions of all axes, the tool in spindle number, spindlerpm, and the axes feedrates.

The lower area of the screen displays the Axis Load Monitor showing theinstantaneous percentage of full load on each axis. This screen area alsoidentifies the current data block number being executed, the currentoperation, and the part count. The last two lines on the screen are reservedfor information and error messages pertaining to the part program.

•* AUTO w

x

PART MACHINE VERTICAL 1x 0.8950 TOOL IN SPINDLE 1Y -0.8397 SPINDLE 28888 FZ 0.8258 FEED 37.5 2

1F3

IS LOAD MONITOR BLOCK NUMBER 7 F4

28 48 60 88 108 Y. /PMT COUNT 2

O06RAII IS wm IN

Figure 2-172. Auto screen while the program is running

F RESET PART

F7

F8

The Part Count parameter indicates the number of times that a programhas been executed. This is an accumulative number count and the controldoes not distinguish between one program and another. To return thisvalue to zero when a new program is being started, press the Reset PartCount (Fl) softkey.

2 - 284 5/20/94 Hawk 5M Machine

onversational Part Programming

When the system encounters a program block that requires tool change,machine motion stops and a message appears on the screen indicating therequired action from the operator. See example below.

-* AUTO » IF RESET PART COUNT

PART MACHINE VERTICAL IX -3.0586 TOOL IN SPINDLE 1 IY 8.0861 SPINDLE 2808L FZ 1.1425 FEED MOTION STOPPED 2

I-F3

I.AXIS LOAD MONITOR BLOCX NUMBER 14 F

TOOL CHANGE 428 40 68 88 108 x PART COUNT 2 -

X FY SZ I

F6

FF7

Ql1r TOOL 2 IN SPINDLE AND PRESS START. I.FrR0 T YS RMiIiNC. 8

Figure 2-173 . Auto screen with Tool Change message

The system also displays messages when it encounters a Position block orerrors.

Ultimax 3 System Revision A 2 -285

Operator' s Manual

Recovery and Restart

The Recovery and Restart function allows the operator to restart a partprogram at almost any point within the program. In most cases, this is thepoint in which the "running" program was interrupted and it needs to startup again. Usually the End Block is the last block in the program.

Here is a screen showing a part program that the operator stopped usingthe Emergency Stop button. This program was running Block # 7 when itstopped.

AUTO

XPART

4.4394MACHINETOOL IN SPINDLE

F RESET PART COURTVERTICAL 1

1 IY 8.1488 SPINDLE 2688H F2 -8.1325 FEED 37.5 2

IF3

AXIS LOAD MONI70R OCR WINDER 7

28 40 60 88 188 S PARMILL FRA

2 tX FY S2 l

F6

F7

ERGENCY STOP HAS BEEN DEPRESSED.ES,S_NANUAL MODE , POWER. AND START 70 RESTORE

Fa

Figure 2-174. Auto screen with Emergency Stop message

2 - 286 5/20/94 Hawk 5M Machine

Conversational Part Programming

To restart the program, the operator must first correct any physicalproblems such as fixturing or work piece placement. Then the operatormust restore power if it is necessary. If the Emergency Stop was used tostop the program, the operator presses the proper Start Block and EndBlock must be selected as shown in the screen below:

AUTO n*

RUNNING PART PROGRAM 1548. HD3

ESTIMATED RUM TIME

START BLOCK

END BLACK

Enter number of desired block

Figure 2-175: Auto screen with Start and End Block fields

FI

FF2

I.F3t

F CHECK FOR ERRORS4

FCOMPUTE ESTIMATEDS RUM TIME

F RECOVERY6 RESTART

7

F FM PROGRAM8

When restarting an aborted program, the End Block is normally the last

block in the program. Another selection can be made for the End Block.

But only if the Start Block is within a Patterns block and the End Block

for the Pattern is. included within the range of blocks selected for the

restart.

Ultimax 3 System Revision A 2 - 287

Operator' s Manual

Here is an example of the blocks in a program:

Block # Operation Numbers and Tools

1 Pattern Loop Rectangular Number 2

2 HolesCenter Drill Tool IDrill Tool 2Bolt Circle Number 5

3 Pattern Loop Linear Number 3

4 Contour A Tool 3

5 Contour B Tool 3

6 Pattern End

7 Frame Tool4

8 Pattern End

If the operator selected Block #1 as the Start Block and Block #2 as theEnd Block, a posted error results because the Loop Rectangular pattern isnot resolved with a Pattern End block. However, choosing Start Block #3and End Block #6 is acceptable since the Loop Linear pattern is resolvedwith a Pattern End block.

2 - 288 5/20/94 Hawk 5M Machine

Conversational Part Programming

If the Start Block is inside a Patterns block or a nested Patterns, thestarting repetition, location, or image (if mirrored) must be determined foreach relevant pattern. In the example below, the system needs to know thepattern location where the program will restart.

«. AUTO am IF

RIMING PART PROGRAM IS48.1m3 1

FSTART BLOCK 6 END BLOCK 23 F

2

FF3

FF4

I.F5

I PATTERN LOCATIONS LOCATIONS 1 FF

Starting location III 1 6

FEnter the number of desired starting location 7

FFB

Figure 2-176. Auto screen with Starting Location selections

Information about the applicable Patterns blocks and start block arescrolled on the screen while the necessary questions are being asked bythe control. The order in which the data is graphed is the order milled andis helpful in determining the correct start block parameter.

Ultimax 3 System Revision A 2 - 289

Operator' s Manual

If the start block is a Milling block with a roughing pass, finish pass, orpeck levels, the system asks for this information as in the example below.

AU TO IF

RUNNING PART PROGRAM 1549.HD3 1 .

START BLOCK 6 END BLOCK 23 F2

F1 PATTERN LOCATIONS LOCATIONS 1 4

START BMILL FRAME

PECK LEVELS 3

2 - 290

Starting peck level

Enter the nuaber of the starting peck level

Figure 2-177. Auto screen with Milling Start Block selections

F5

Important

During recovery restart, the control can restart only at segment 0 of a MillContour data block, not at a segment within a data block.

After the operator presses the Enter key on the control's last question, theAuto screen appears.

5/20/94 Hawk 5M Machine

A

Chapter 3

DXF File Translation

The Data Exchange Format (DXF) File Translation Option is a graphicand rapid means of creating Hurco conversational data blocks from CADdrawings. The Hurco DXF option allows the operator to select geometricdata in the CAD drawing and automatically load it into a conversationaldata block. Then the operator can use Ultimax screens to add part and toolsetup information to create a complete conversational part program.

General CapabilitiesBoth the Ultimax 3 and Ultimax PC software can read and store DXF filesin.memory and then display them graphically for conversion . The DXFgeometry describes X and Y two-dimensional objects. To convert thegeometry rapidly , the operator selects a line, circle, arc or point on thedisplayed drawing with a pointing device (usually a mouse or trackball).The software automatically converts the selected portion of the drawinginto Hurco conversational data blocks.

AutoCAD Files and the DXF Option

The DXF File Translation software is compatible with DXF filesgenerated with AutoCAD version .9 and later. The Header section, whichcontains settings of variables associated with the drawing, is ignored. Thelayer names from the Tables section are read. The Entities sectioncontains the geometry describing the drawing. The Circle, Line, Points,Polyline, and Arc entities are read from the DXF file. All other entities areignored.

Ultimax 3 System Revision A 3-1

Operator' s Manual

Ultimax Programming Features

To simplify part programming when using a DXF file as a source, theDXF option uses standard features of the Ultimax 3 software and the dualscreen. console. Operators can build the standard holes and milling datablocks and also have the flexibility to perform concurrent programmingfunctions while they are building the part program. For example, they maywatch a running program on the Auto screen while selecting and loadingportions of the DXF drawing into another part program file. However,most operators prefer to see the new program data blocks on the textscreen while working with the DXF file on the graphics screen.

Graphics Display

At any time during the process of selecting DXF geometry, the operatorcan display the Ultimax Tool, Part, and Parameter set up screens and enterdata. After the tools are defined for the new program, the control candisplay a graphic representation of the new part program when theoperator presses the Draw console key. To redisplay the original DXFdrawing on the graphics screen, the operator presses the Ctrl and Drawconsole keys.

Data Blocks

The operator selects the DXF geometry from the drawing, and the systemtranslates it into Hurco conversational data blocks. The system createsMill Contour (lines and arcs), Mill Circle, Mill Frame, Mill 3-D and Holedrilling and locations data blocks.

The following Ultimax data blocks cannot be automatically created usingthe DXF option software:

• Helix • Cutter Insert option

• Patterns • Rotary option Frame

• Bolt Hole Circle • Rotary option Pocket

3-2 5/20/94 ' Hawk 5M Machine

DXF File Translation

DXF File ManagementAfter operators create CAD drawings in AutoCAD, they copy the DXFonto 3.5" diskettes and take the diskettes to the machine consoles. Thenthey can either use the files directly from the diskettes or copy the filesonto one of the hard drive directories.

Important

Operators can only copy DXF files to the control from a diskette, notdownload them from the serial port.

The screen below shows a number of DXF files that have been copiedonto the control's root directory. Two of these files are circled. Note thatthe AutoCAD file names end with the "DXF" extension after the period inthe name.

CURRENT PROGRAM

306216% bytes free0 bytes tagged.

CURRENT DIRECTORY

123 HD3 - Z34 HD3SSSSS HMC A HD3DXFDEMOI . DXF DXFDEMOZ. DXF

IF CHANGE TOI DIRECTORY

1 directory(a) 27 program( s). F RENAME8 programs tagged. 2 PROGRAM

F 2DNASTY DXF F DELETEDXF .HD3 3 PROGRAMDXFDEMO4.DXF I

FAM1 F H F CREATEFANTEST HMC 4 DIRECTORYJAG HD3VIC HMC F DELETE

S DIRECTORY

EAGLE DXF FADAL CFG FFAMI HNC FAM1 .TAPFAMUCOM .CFG FAN"CFGNEYSPAR DXF TAP HNC

:IAS" iTEST .HD3

DEMO . DXF 34025 bytes 81-01-1980 12:45aUse arr a keys to moue through program(s)and y I RECTOR IES

F SELECT CURRENT6 STORAGE DRIVE

F -MORE-Perform disk operations. 7Use cursor keys to wue between programs and choose softkey. I

F EXIT8

Figure 3-1. Current Directory screen

Operators can copy and save files and group them into subdirectories asdescribed in the "Getting Started" chapter of this manual.

Ultimax 3 System Revision A 3-3

Operator's Manual

A`

Creating a New Conversational ProgramTo begin to build an Ultimax conversational part program from a DXFfile, the operator first creates a part program to receive the part geometry.This process is also described in the "Getting Started" chapter.

em INPUT aw IF PART SETUP

MASTER PROGRAM HAWK SM o1.50 Mar.72'94 I

EDIT PART PROGRAM

PROGRAM MEMORY AVAILABLE 99 V.F PART PROGRAMMING3

F PROGRAM4 PARAMETERS

FS

F COPY AND CHANGE6 BLOCKS

F ERASE FUNCTIONSSelect softke9 or press <Enter> to change part program name 7

Fa

Figure 3-2. Input screen

If the operator does not first create a conversational part program, theDXF software will not be able to save the selected DXF geometry and willdisplay the "No program in memory" message. Then the operator willneed to return to the Input screen, shown above, and enter a programname and select the unit of measure and machine type.

V3-4 5/20/94 Hawk 5M Machinet.

DXF File Translation •

DXF File DisplayTo access a DXF file stored in the control's memory, the operator pressesthe Auxiliary console key and then the More (F8) softkey to display thisscreen:

- AUXILIARY

EDITOR TYPE : CONVERSATIOMAL

Choose appropriate softkey

Figure 3-3. Auxiliary screen

F1

F CRT DEGAUSS2

1F3

1F

F UPGRADE EXECUTIVE6

F RESET MASTER7

F -MORE-B

Then the operator presses the Read DXF File (F5) softkey.

{Jlfimax 3 System Revision A 3-5

Operator's Manual

The system then displays a Current Directory screen allowing the operatorto select the DXF file to be used in this session. The operator highlightsthe needed file and presses the Enter console key.

mm AUXILIARY «wF CHANCE TO

CURRENT DIRECTORY I DIRECTORYIC-IS . DXFl I

306216% bytes free 1 directory (s) 9 program (s). F RENAME0 bytes tagged. 0 programs tagged . 2 PROGRAM...._._..__.____.._.._........ ..._...... __........ ___.__......._._.^_..___,_

3+i 3 "Y.r' ^' .t'? (F DELETE( zF iE tQ2 +X}' DXFDEM03 .DXF bY. LF.N04 b*'. E t zz' @ 3 PROGRAM

r

F CREATE34 DIRECTORY

F DELETE(S DIRECTORY

........... ....... ._... ................. "----'--_..............-IF SELECT CURRENTDXFDEMO3 . DXF 6458 bytes 01-01-1980 12:03a 6 STORAGE DRIVEUse arrow keys to move through srr.:;nan( aland

FSelect . DXF program to read Into memory. 7Press (Enter > to accept highlighted program name. F

Figure 3-4. Current Directory screen

F EXIT8

The original Auxiliary screen appears with a message saying that thesystem is reading the file.

3-6 5/20/94 Hawk 5M Machine

DXF File Translation

The DXF drawing automatically appears on the graphics screen. The fiveprimary screen buttons, circled below, provide access to all of the DXFsoftware features. To select a screen button, the operator moves thecrosshair cursor using the trackball to the screen button and then pressesthe Select console key.

Figure 3-5. DXF graphics screen with main DXF options

The screen buttons access these features:

• Build DB - accesses the automatic data block building features.

• Layers - allows the operator to select and display any or all of thelayers in the DXF drawing.

• Zoom Box - allows the operator to select a portion of the drawingto display as an enlarged view or to pull back and see the entiredrawing reduced.

• Parameters - accesses the display parameters that must be setbefore building data blocks from the DXF drawing.

• Quit CAD - ends the DXF session and exits the DXF file.

Ultimax 3 System Revision A 3-7

Operator's Manual

Setting DXF Parameters .To begin a DXF session, operators usually press the Parameters screenbutton to display the screen shown below:

PARAMETERS

Out Of Square Tolerance

End Point Tolerance

Part X Offset

Part V Offset

0.58 DEGREE

8.88880 IN

8.00088 IN

8.00000 IN

Dimensions are NOT being converted.

I

Convert values to inches

Display converted eam.

Autochain contours

OFF

1 ON

Move cursor to box and press to the a ammeter.

Figure 3-6. Parameters screen for DXF option

II

The Move Zero screen button is a quick and simple way to relocate partzero graphically on the drawing and automatically enter the values in thedata block. When the operator selects the Move Zero screen button, theDXF drawing appears on the graphics screen. Then the operator uses thetrackball to move the cursor onto the new location for the part zero andpresses the Select console button. Once the part zero location has beenselected, pressing the Exit screen button allows the operator to view thevalues on the Parameters screen.

Important

The new part zero location must be an endpoint of a line or the center ofan arc or circle

3-8 5/20/94 Hawk 5M Machine

DXF File Translation

The options on the Parameters screen have the following uses:

Parameters Uses

Out of Square used to enter an angular tolerance for a Mill Frame.Tolerance When the angular tolerance of a Mill Frame is

exceeded the frame becomes out of square and isconsidered a Mill Contour with lines and/or arcs.(default value = 0.5°, maximum = 360°, andminimum = 0°).

End Point determines when the end points of segments areTolerance close enough to be considered equal (or

coincident). Setting this parameter to a number thatdoes not exceed the cutting tolerance links thecontour segments. However, if the gap exceeds thecutting tolerance, the operator must decide how tomodify the drawing to complete the linking ofsegments of the contour. The default value is0.0001 inches (maximum is 1000.0000 inches,minimum is 0 inches).

Part X and Y "X" and "Y" coordinate points defining part zeroOffsets within the drawing. All dimensions are calculated

from this point. The part zero symbol is a circlewith cross hairs. To change this location manually,move the cursor to the box for Part X or Y Offsetand press the Select button. Use the data input boxto enter the X or Y Offset values. To change thislocation graphically and automatically, use theMove Zero box.

Ultimax 3 System Revision A 3-9

Operator's Manual

Parameters Uses (continued)

Convertvalues to converts selected geometry to inches or toinches millimeters and changes the dimensional values of

the DXF file to match the Hurco Part Programunits. For example, if the Inches softkey wasselected from the Input screen for the Hurco PartProgram and the DXF file was drawn inmillimeters, the X and Y dimension values for thecursor position will be unusually large. These largedimensions, unless changed, will be used in all newdata blocks because the software expects thedimension values for both the Hurco Part Programand the DXF file to be in inches.

To convert the metric values of the DXF to inchesselect the "Convert values to inches" button. Ifmetric was selected from the Input file and theDXF file was in inches , the dimension valueswould be unusually small . The convert button willnow say "Convert values to mm." Select this buttonto convert inches to millimeters.

Display converted When this option is switched "On," the convertedgeometry lines are displayed on the graphics screen in a

different color and line style to help the operatorsee which elements have been converted and whichhave not.

Autochain contours By default, segments are automatically chained tocreate contours. This parameter allows autochaining to be turned off so that a contour may becreated by individually selecting segments into achained contour. This is particularly useful forcreating open-ended contours that are swept into a3-D shape within a conversational data block.

Selecting the Exit screen button after changing these parameters displaysthe main DXF system options. '

3-10 5/20/94 Hawk 5M Machine

DXF File Translation

The parameters at the top of the screen, Out Of Square Tolerance, EndPoint Tolerance, Part X Part or Y Offset, require data input to makechanges. When the operator selects one of these parameters, the data inputbox appears:

PARAMETERS

Out Of Square Tolerance 0.58

End Point Tolerance 0.08888

Part X Offset 0.08888

Part V Offset 1 0.88088

fconuert values to inches

Displa converted 9eom.

Autochain contours

Enter End Point Tolerance.F

DEGREE

IN

IN

IN

Dimensions a

OFF

ON

1

Figure 3-7. Data Input dialog box

I I

The system ignores any numbers entered on the console when this box ison the screen. To use the dialog, box, the operator positions the crosshaircursor on the number or function in the dialog box and presses the Selectconsole key. The selected numbers appear at the top of the box.

On the left side of the box, there are three function buttons:

ESC - use this escape button to exit the data input dialog boxwithout storing any data entry.

CLR - the clear button erases any numbers previously entered.

ENT - the enter button loads the numeric value into theparameter field.

Selecting ESC or ENT clears the dialog box from the screen.

Ultimax 3 System Revision A 3-11

Operator' s Manual

Building Data BlocksTo begin building data blocks, the operator must first select one of thescreen buttons circled in the example below:

^̀ mT GAD

Select wem op

I

Figure 3-8. Data Block Type Selection

The system creates either hole drilling or milling data blocks.

The More screen button gives the operator access to the Edit and Zoomfunctions.

3-12 5/20/94 Hawk 5M Machine

DXF File Translation

General Concepts

There are several general concepts used in the process of building Hurcoconversational data blocks from a DXF drawing file. As mentionedearlier, the operator must first create a part program to receive the datablock information from the DXF drawing.

Selecting DXF Drawing Elements

To select elements of the DXF drawing, the operator uses the trackball toposition the crosshair cursor on drawing element, such as a hole or a line,and presses the Select console' key. The system then highlights theselected element. When selecting holes in a drawing, the operator maywish to outline a group of holes using the Window screen button andpress the Select console key to select all of the holes outlined by thewindow.

To remove the selection of an element, position the crosshair cursor on thehighlighted element and press the Select console key again. This methodcan also be used to "deselect" segments of a chained contour.

Ultimax 3 System Revision A 3-13

Operator's Manual

Accept Screen Button

After the operator has selected an element from the drawing and modifiedit if necessary, the operator presses the Accept screen button to load thedescription of the element into a conversational data block.

Figure 3-9. Accept screen button for Milling

After the operator presses the Accept button, the selected element remainshighlighted for a couple of seconds, and then the system automaticallyloads its description into a data block.

3-14 5/20/94 Hawk 5M Machine

DXF File Translation

Conversational Data Blocks

The system creates a data block describing the circles, line/arcs, frames,and holes and their locations, but the operator will need to add the tooland machine instructions to the data blocks to make them complete.

Here is part of a hole drilling data block showing the locations of the

holes automatically loaded into the block from a DXF drawing:

BLOCK 2 HOLES IF DELETE OPERATION

x Y DRILL 1>>> LOCATIONS I

1 B.490S 7 .9273 F INSERT OPERATION2 6.7428 7. 2833 2 BEFORE3 4.9950 7.9273 I4 4.2711 9.6758 F5 4.9958 - 11.4227 36 6.7428 12.14677 8.4985 11.4227 F PROGRAM8 9.2145 9 .6758 4 PARAMETERS9 16.0957 9.6758 I10 16 . 5648 10.8875 F PART SETUP11 17.6973 11.2767 512 18.8299 10.8075 I13 19. 2990 9 . 6758 F TOOL SETUP14 18 . 8299 8.5425 615 17.6973 8.0733 I

FPress ENTER to edit this operation or use ADVANCE, BACK, 7or sottkey I

F EXIT8

Figure 3-10. Locations in the Holes data block

Ultimax 3 System - Revision A 3-15

Operator's Manual

Here is a sample milling data block built from a DXF file. Note that theoperator has added the tool and machining data.

BLOCK 2

SEGMENT 0

MILL CONTOUR

STARTF1

TOOL 1 PLUNGE FEED 0.0 F2

CUTTER COMP . POCK BOUNDARY MILL FEED 0.0

FINISH TOOL ® e SPEED (RPM) 8F3

iX START 18.8968 PECK DEPTH 0.8088 F

4V START 7.1923 (TOOL DIAMETER 8.1250) 1

Z START 8.8808(TYPE DID MILL) F

5

Z BOTTOM 8.8800 F6

POCEET OVERLAP 58 l

Enter the tool number for the finish pass or enter 6F7

it no finish pass is desired I.F EXITB

Figure 3-11. Mill Contour Start data block

Hints and Tricks

To examine the new data blocks as the system creates them from the DXFdrawing selections, the operator should press the Input console key andselect the Part Programming (F3) softkey.

All Hurco data blocks will be inserted after the. current block in the partprogram-

3-16 5/20/94 Hawk 5M Machine

DXF File Translation

Zoom Box Screen Button

Many of the data block building screens have a Zoom Box screen button,shown below, that allows the operator to enlarge an area of the drawing orzoom out to see a full view.

Figure 3-12 . Zoom Box screen button for Milling

Ultimax 3 System Revision A 3-17

Operator' s Manual

After the operator presses the Zoom Box screen button, the message"Select the first window corner" appears on the screen above a group ofnew screen buttons.

Figure 3-13. DXF Zoom options

There are three Zoom options accessed from the screen buttons shownabove:

• Zoom Out - pulls back from the drawing incrementally to theprevious magnification level without recentering the part in thedrawing.

• Fit To View - gives a full scale of the drawing with auto-centering the part in the drawing.

• Pan - relocates the center of the drawing on screen.

To identify the "zoom" area, the operator first positions the. crosshaircursor on a corner of the area and presses the Select console button. Tocreate the window over the area to be magnified, the operator moves thecrosshaircursor to the opposite corner of the window and presses theSelect console key again.

3-18 5/20/94 Hawk 5M Machine

DXF File Translation

To use the Pan option, the operator moves the crosshair cursor to theplace on the screen where the new center of the drawing should be. Thethen operator presses the Select console key. To turn off the panningoption, the operator selects the Pan screen button again or the Fit To Viewor Zoom Out screen buttons. Here is a "panned" view of the previousdrawing:

4X: -38.5391 Y:-53.3758Selwt the t window corner or nom a ion.

I i

Figure 3-14. Panned view

The Exit screen button returns to the previous screen.

Ultimax 3 System Revision A 3-19

Operator' s Manual

Layers

Many DXF drawings use layers. These layers are an electronic method ofrepresenting transparent acetate overlays used in hand-drawn draftingwork. A layer is a logical grouping of data to be viewed individually or incombination.

Layers are used to organize a drawing into different components andparticularly useful for large, complex drawings. Some typical layers seenare drawing (DWG), center reference (CEN), dimension lines (DIM), andassigned numbered layers (e.g., 0, 1, 2). When DXF files are read into theHurco Part Program, only used layers are read, while unused layers areignored.

To access the Layers function, the operator displays the DXF drawing andpresses the Layers screen button.

3-20 5/20/94 Hawk 5M Machine

DXF File Translation

All layers are turned ON by default when a DXF file is first loaded intomemory. To turn OFF layers 0, 1 and DIM, select Layers after the DXFimage is displayed.

CURRENT DXF PROGRAM : C:\DXF\DEMO.DXFLayers

ON

OM

ON

ON

0

1

1 CEN

1DIM

DUG

Place cursor in box and press select to toggle On/Off.®p ^N T.- PACE-1

Figure 3-15. Layer options

i ) E i

The Next Page and Prev Page screen buttons access more than one page oflayers. The layers in a drawing are often numbered so that it is easy toselect a range of layers to turn on or off. When the operator selects theRange screen button, a data input dialog box appears. This dialog boxfunctions in the same manner as the Parameters dialog box.

The More screen button allows the operator to turn off all layers with theAll Off screen button or switch them all on with the All On screen button.

Ultimax 3 System Revision A 3-21

Operator's Manual

Holes

To create a holes data block, the operator presses Build DB screen buttonon the first DXF screen and then the Holes screen button. The Holesoptions appear in the screen buttons as shown below:

EDED (B (9) G&@GS 0E

ED

S EDEE)

e ^ aGD) E) ED

X: -1.4562 Y:-3.6745Use cursor to select/deselect locations , or select hem option.

R0rMT Y NWY goal eox INTERSECT

Figure 3-16. Selecting Holes from the DXF drawing

I TNNDO

3-22 5/20/94 Hawk 5M Machine

DXF File Translation

Selecting Holes

To select holes from the drawing and load their locations into the

conversational part program, the operator uses the crosshair cursor andpresses the Select console key or presses the Window screen button toselect a group of holes on the drawing..

To "deselect" a hole, the operator positions the crosshair cursor andpresses the Select console key or simply presses the Exit/Undo screenbutton. The description of that hole will not be loaded into the data block.

The order in which the holes are selected may be important when thesystem is building the data block from the information , so the operatormay want to consider this order when selecting the holes . If the holes areselected using the Window screen button, default order is the order thatthe holes were drawn in the original AutoCAD drawing . Refer to the"Accepting Holes " section for more information about optimizing toolpath for hole drilling operations.

Intersect Screen Button

Some AutoCAD drawings use small intersecting lines to mark holelocations. Since these holes were not drawn as holes, the operator usingDXF software cannot use the crosshair to select these holes without firstpressing the Intersect screen button. After the hole locations are selected,the system draws a hole center at the intersection of two selected lines andrepresents the centers with highlighted pluses (+).

The operator may also select holes drawn with intersecting lines using theWindow screen button.

Ultimax 3 System Revision A 3-23

Operator's Manual

Accepting Holes

After selecting the holes, the operator presses the Accept screen button toload the information into a data block.

At this point, the operator needs to decide the order that the machine willdrill the holes. The system displays the Default screen button and amessage telling the operator to select the first location. Refer to the screenbelow:

G-&(BE)G)

='ED (1)

X: -1.4977 V:-2.9926 +Select the First location to be drilled or DEFAULT to accept selected order.

DEFAULT I I

Figure 3-17. DXF Default screen button and message

1 0n TNl4DO

The operator can control the order in which the holes will be drilled orallow the system to determine the order.

3-24 5/20/94 Hawk 5M Machine

DXF File Translation

There are three methods to select and optimize the hole drilling tool path:

I. Press the Default screen button, and the system will use theorder that the holes were drawn in AutoCAD if they wereselected using a Window or it will use the order that they wereselected if the operator individually selected the holes.

2. Position the cursor on the first hole and press Select. Thenposition the cursor on the last hole to be drilled and pressSelect. The system will determine the shortest path between thetwo holes.

3. Position the cursor on the first hole to be drilled and pressSelect . But then press the Default screen button to tell thesystem to find the shortest tool path.

If the order that the holes are drilled is of no concern, the operator willprobably select method #1. To optimize the tool path, the operator shouldselect either method #2 or #3.

Ultimax 3 System Revision A 3-25

Operator's Manual

To see the tool path that the system has determined, the operator needs toexamine the conversational data block created from the DXF informationand add tool and machining information. Then the operator presses theDraw console button to display a graphic image of the tool path. Here is asample tool path for the holes selected from the DXF drawing on theprevious page and accepted using method #3:

1.70-Y

I

0.58J

-8.7C

-1.98 --2.68uIw 1

V &-P-e- e0 0 "a q

m d °

® 'S

-1.48 -8.28

Figure 3-18. Tool Path in the part program

The operator selectedthis as the first hole

1.88 2.28

3-26 5/20/94 Hawk 5M Machine

DXF File Translation

Milling

To create a milling data block, the operator presses Build DB screenbutton on the first DXF screen and then the Milling screen button. Thefour milling options appear in the screen buttons as shown below:

Figure 3-19. DXF Milling options

Lines/Arcs

Selecting the Lines/Arcs screen button will create a Mill Contour datablock. When the operator selects this screen button, the Reverse, ZoomBox or Exit/Undo screen buttons appear, and a message "Select firstsegment" appears above them. The Zoom Box and Exit/Undo function asdescribed previously. The operator can use the Reverse screen button toreverse the contour direction. The direction of the contour is determinedby the selection point.

Since the geometry is defined as individual segments, contours must bedefined by autochaining lines and arcs together. The DXF software assistsin the chaining and thus avoids the need to select every line or arc in thecontour.

Ultimax 3 System Revision A 3-27

Operator' s Manual

When attempting to create a contour, sometimes two segments will notmeet due to the method used to draw them originally. There may be a gapthat is greater than the End Point Tolerance defined in Parameters. Toclose the gap, Edit Drawing is selected and the Extend, Join, or Modifyoptions may be used.

A highlighted contour may be trimmed by selecting the segment where theoperator wants the contour to be trimmed. The segment the operatorselects and all segments following it will be trimmed from the highlightedcontour.

In the example below, the operator selected one line and all of the attachedlines and arcs were automatically selected.

Figure 3-20. DXF drawing with outside lines and arcs selected

3-28 5/20/94 Hawk 5M Machine

DXF File Translation

When a contour segment is selected, the start point of the contour will bethe end point closest to the selection point. A contour will be chainedbeginning with that segment.

Important

If, during the autochaining sequence, two or more segments are foundthat connect to the current segment, they are highlighted and the operatoris prompted to select one branch. If the draftsman drew two segments inthe same location (e.g., the same line drawn twice), the software detects abranch and highlights the two lines. However, the operator will only seeone line highlighted since one is on top of the other. When this occurs,select the highlighted segment and continue with closing the contour.

Ultimax 3 System Revision A 3-29

Operator's Manual

Here is the Start Segment created for the DXF drawing shown on theprevious page. Note that the operator will need to enter the tool numberand cutter compensation type:

BLOCK

SEGMENT I

I

B

MILL CONTOUR

STARTF1

TOOL B PLUNGE FEED 8.0 F2

CUTTER COMP. NO IFINISH TOOL B SPEED (RPM) 0

F3

X START 4.0578 PECK DEPTH 8.8888 F PROGRAM

V START 5.9261 TOOL NOT PROGRAMMED4 PARAMETERS

Z START 0.8808F PART SETUP5

2 BOTTOM 0.6008 F TOOL SETUP6

Enter a segment ,usher, use ENTER to edit segment, or useF7

ADVANCE, BACK, or softke9 lF EXITB

Figure 3-21. Milt Contour Start Segment

This data block also contains a large number of automatically created lineand arc segments. This obviously saves the operator a great deal of work.Here is the first segment:

BLOCK 1 MILL CONTOURF DELETE SEGMENT

SEGMENT I 1 ARC

DIRECTION CCU (X START 4 .0578) F INSERT SEGMENT(V START 5.9261) 2 BEFORE

X END 4.7649 (Z START 0.0mo ) lF

V END 5.2190 3

K CENTER 4.4113 F PROGRAM4 PARAMETERS

V CENTER 5.5725 iF PART SETUP

BAD IUS 8.5088 5

FEED 0.0 F TOOL SETUP6

PEnter a segment number, use ENTER to edit segment, or use 7ADVANCE, BACK, or mftke9 l

F EXIT8

Figure 3-22. Mill Contour Arc Segment

3-30 5/20/94 Hawk 5M Machine

DXF File Translation

Circle

To load circle milling information into a data block, operator selects theBuild DB screen button and Milling from the next group of screen

buttons. When the operator selects the Circle screen button, the systemdisplays the "Select a circle to be milled" message as shown below:

Figure 3-23. Selecting a Circle from a DXF drawing

When the operator selects a circle, it is automatically translated into aconversational data block.

Ultimax 3 System Revision A 3-31

Operator's Manual

Here is the data block the system created for the circle shown in theprevious DXF drawing. The system automatically loaded the X Center, YCenter, and Radius values, and the operator added the Tool and Typeinformation.

BLOCY 1 MILL CIRCLE IF

TOOL 1 Z START 0.0808 1

ITYPE INSIDE Z BOTTOM 0.8888 F

2FINISH TOOL 0 PLUNGE FEED 0 0 F.

F

X CENTER 7.2398 MILL FEED 8.0 3i

V CENTER 8 . 4810 SPEED (RPM) 8 F PROGRAM4 PARAMETERS

RADIUS 2 5888 PECK DEPTH 8 0888 I. .F PART SETUP

LEAD ANGLE 0.088 (TOOL DIAMETER(TYPE

0.1258)DRILL)

5I

LEAD LENGTH 8.0088 F TOOL SETUP6

FEnter the tool number for the finish pass or enter 0it no finish pass is desired.

7

F EXIT8

Figure 3-24. Mill Circle data block created from the DXF file

3-32 5/20/94 Hawk 5M Machine

DXF File Translation

Frame

The Frame option functions in a similar manner to the Lines and Arcsoption. The system chains segments to create the frame. There are someguidelines for DXF frames:

• Segments must consist of four lines with optional arcs forcorners.

• All corners must have the same radius.

• The frame must be intersecting or lying at right angles to the Xand Y axes.

The degrees of rotation are limited to the Out Of Square Tolerance valueset on the Parameters screen.

To access the Frame option, select the Build DB screen button, then theMilling button, and finally the Frame screen button. The system displaysthe "Select first segment" message above the screen buttons as shownbelow:

(D ED

I

X: -3.8721 V:-2.8835Select first segment.

I I I

Figure 3-25. Selecting the First Segment of a Frame

I

If the selected frame does not comply with the guidelines, the systemdisplays a message stating that the frame is not valid.

Ultimax 3 System Revision A 3-33

Operator's Manual

3-D Option

To use this feature, the system must have the 3-D Milling option installed.The operator loads a DXF drawing containing 3-D features and pressesthe Build DB screen button, then the Milling screen button, and finallythe 3-D Option button.

The 3-D option is similar to Lines and Arcs option in that the operatormust identify segments and accept them to build the data blocks. Thesesegments must form an open contour or the system will indicate that thepart cannot be machined when the operator examines the part program.An open contour is a group of segments that do not have joining ends. Inother words, the ends to the chained segments do not meet.

The screen below shows a 3-D DXF drawing ready for the operator toselect the first segment as indicated by the message above the screenbuttons. Note that this is a closed contour, so the operator needs to selecthalf of the segments to form an open contour.

X: 1.6443 y:1.4879Select first segnent.

0 REVERSE z!oon sox

Figure 3-26. 3-D DXF Drawing

I I IX I ViDIDa

3-34 5/20/94 Hawk 5M Machine

DXF File Translation

In many cases, the operator needs to modify the DXF drawing to properlyselect a 3-D Contour. Refer to the "Editing Drawing" section for anexplanation of how to use Extend, Join, Split, and Modify. In thisexample, the operator uses the Split button to divide the arcs at each endof the drawing.

This splitting operation creates an open contour that the 3-D optionsoftware can quickly recognize. In the example below, the operator splitsthe closed contour in half to select the top half of the bulb shape. Theresulting open contour will then be rotated about an axis. When splittingthe segments, the operator selects large arc and then selects the pointwhere it will be split. Then the operator selects the small arc and the splitpoint.

Figure 3-27. Selecting and Splitting Segments on a 3-1) Contour

The operator exits the editing functions and selects the 3D Option screenbutton from the Milling buttons. To complete the selection of this contour,the operator positions the crosshair on the top of the contour and selectsthe contour. Then the operator positions the cursor on the bottom half ofthe contour and "deselects" it to. remove those segments from the chain.

From this point the operator must work with the part programmingscreens to complete the program.

Ultimax 3 System Revision A 3-35

Operator's Manual

The tools, cutter comp, feeds and speeds are set to their normal defaultvalues. From the selected contour, the system creates a Mill 3-D datablock with a default type of Draw 2D contour as shown below. Theoperator must select one of the 3-D types: XY Revolved about X (F2), XZRevolved about Z (F3), and XZ Translated in Y (F4).

BLOCX 1 MILL 3D IF 1) DRAW 2D

TOOL 1 1 c

TYPE DRAW 2D CONTOUR

5

tF6

Choose a surface of revolution or translationgenerated using a ZD contour

a

Figure 3-28. Creating a Mill 3D data block

3-36 5/20/94 Hawk 5M Machine

DXF File Translation

The operator entered the Type, Start Angle, End Angle, and Step Size tocomplete this block:

BLOCK 1 MILL 3D

TOOL 1

6PE REVOLVE ABOUT

CENTERLINE V 0.8008

CENTERLINE 2 0.0888

CUT DIRECTION WITH CONTOUR

BIDIRECTIONAL NO

EP SIZE 0.

Enter a block number, use ENTERADVANCE , BACK , or sof tkey

2 START 0.8000F DELETE BLOCK1

PLUNGE FEED 0.8 F INSERT BLOCK

MILL FEED 0.82 BEFORE

I

SPEED (RPM) 0F3

PECK DEPTH 8.8800 F PROGRAM

STOCK ALLOWANCE 8.88884 PARAMETERS1

( TOOL DIAMETER 8.1258)F PART SETUP5

(TYPE DRILL) IF TOOL SETUP6i

to edit block, or useF7

IF EXIT6

Figure 3-29. Completed Mill 3D data block

The operator then presses the Draw console key and any of the Viewoptions to see the graphic illustration of the part program:

2.18 -Vit

\dl

3.16 V

8.681 8.981

-0.98

-2.40 L_ 2 -3.58

Ilan! ) .loss

x

-4.80 -2.50 -1.88 0.58 2.88 -2.30 -0.10 2 . 18 4.30 6.50

2.28 2

O W EZZZ'4r..rci?Fc

JJ

8.08

-2.28

-4.48-2.38 -8.10 2.18 4 .38 6.58

Figure 3-30. Part Program Illustration

Ultimax 3 System Revision A 3-37

Operator's Manual

The system automatically created segments in the data block from theDXF file. Here is the Start Segment:

BLOCK

SEGMENT

X START

Y START

MILL 3D

START

-2.8800

-0.8000

FI

F2

F3

F PROGRAM4 PARAMETERS

F PART SETUP5

F TOOL SETUP6

iF

Enter a segment number, use ENTER to edit segment , or use 7ADVANCE, BACK , or sot tkey I

F EXIT8

Figure 3-31. Start Segment for the Mill 3D data block

The screen below shows the first arc segment:

BLOCK 1 MILL 3DF DELETE SEGMENT

SEGMENT v 1 ARC 1f

DIRECTION Cu (X START -2.0080 ) F INSERT SEGMENT(V START -0.8888 ) 2 BEFORE

X END 8 9607 I.F

V END 1.7497 3

X CENTER x.0880 F PROGRAM4 PARAMETERS

V CENTER 8 8888 I.F PART SETUP

RADIUS 2.8888 5

F TOOL SETUP6

fF

Enter a segment number, use ENTER to edit segment, or use 7ADVANCE, RACE, or sottkey I

F EXIT8

Figure 3-32. Segment 1 in the Mill 3D data block

The operator should examine all of the segments in the data block andmake any changes necessary to run the part program.

3-38 5/20/94 Hawk 5M Machine

DXF File Translation

Editing a Drawing

The Edit Drawing option allows the operator to Extend, Join, Modify orSplit segments that need to be edited in order to create the propergeometry for the part program. To access the editing functions, theoperator selects the Build DB screen button, then the More button, andfinally the Edit Drawing screen button. The editing screen buttons appearas shown below:

Figure 3-33. Editing screen buttons

Ultimax 3 System Revision A 3-39

Operator' s Manual

Extend

When selecting lines in a DXF drawing, the operator may need extend oneof more lines. Use the Extend screen button to locate the intersection oftwo lines and extend one or both of the lines to the intersection point.

To extend lines, select the Edit Drawing screen button and then theExtend button. Select the two lines that need to be extended. Both linesare highlighted when selected and extended to their points of intersectionas shown in the two examples below:

Original Editeddrawing drawing

Extended line

Originaldrawing

Figure 3-34. Extended lines

Editeddrawing

Both lines were extended

3-40 5/20/94 . Hawk 5M Machine

DXF File Translation

Join

To join segments, the operator selects Edit Drawing and then the Joinscreen button. The Join option movess a selected line endpoint to theendpoint of a line or arc segment. The operator always selects as the firstendpoint the point that will be joined to the second endpoint.

The end point at the opposite end of the first selected segment remainsstationary and becomes a pivoting point as shown in the examples below.In the examples, point #1 is the endpoint of the segment that will move,and point #2 is the location where the segments will join.

Important

The first endpoint cannot be an arc endpoint.

Original 2

Stationaryendpointy_

drawing

Selectedsegmentendpoint

Joiningendpoint

Originaldrawing

endpoint

Joiningstationary \ endpoint

segmenti71endpoint

Selected

Figure 3-35. Joined tines and arcs

Edited 2/draawing

Newly joinedsegment

Editeddrawing

Newly j finedsegment

2

Both segments are highlighted when selected and the screen is redrawn toreflect the joining of the two segments.

Ultimax 3 System Revision A 3 - 41 .

Operator' s Manual

Modify

Modify is used to view or modify the actual geometry data of segments.The software prompts the operator to select up to three segments. Afterselecting the segment(s), the operator selects the Accept screen button toview the segment data. In the DXF drawing below, the operator plans touse the Modify function to view the geometry of the line segment markedwith the crosshair cursor.

Figure 3-36. Select a segment to modify

3 - 42 5/20/94 Hawk 5M Machice

DXF File Translation

The modification data entry screen appears displaying the data for theselected segment. The data for each variable may be modified by selectingthe box using the cursor.

First Selected Curve

End Pointl X

End Pointl V

End Pointl X

End Pointl Y

Len th

XV A le

•7.418634 INCH

•S.474321 INCH

•18.896753 INCH

•7.192328 INCH

•10.815441 INCH

•9.140014 DEGREE

11

Use cursor to select field to edit . Select ACCEPT to confirm EXIT to CancelACC 0 i i i

Figure 3-37. Modify segment data

If the operator selects one of the geometry parameters, the pop-up DataInput Dialog Box appears allowing the operator to enter a new value. Endpoints, X & Y angles and length for line segments are displayed.However, Length cannot be edited. Start angle, sweep angle, direction,radius, and X & Y center points are displayed for arcs.

Ultimax 3 System Revision A 3-43

Operator's Manual

Split

Split is used to divide segments for selection, deselection, chaining, andoften for 3-D operations. Segments may be split at a midpoint or anypoint of intersection with other segments.

To split a segment, the operator first selects the segment and then selectsthe point where the segment will be divided. When a segment is selectedfor splitting, all points where the segments intersect with other lines andarcs and the segments midpoints are marked with a crosshair.

Figure 3-38. Split a segment

3-4 5/20/94 Hawk 5M Machine

DXF File Translation

Completing the ProgramBefore an operator can run a part program created from a DXF drawingfile, the Tool Setup, Part Setup, and Program Parameter data must beentered. Refer to the "Getting Started" chapter for more information aboutthese screens.

xV2AB

TOOLTYPE

The operator may display and enter data at any time during the partprogramming process. The screen shown below is a Tool Setup screen. Ifthe operator wants to view a graphic representation of the part during theprogramming process the tool information must be entered. Otherwise, thegraphics screen will not have enough information to produce a picture ofthe new part.

TOOL SETUPF

MACHINE PART ITOOL IN SPINDLE ^-SPINDLE FFEED 2

P PART PROGRAMMING3

DIAMETERZERO CALIBRATION

SPEED (RPM)COOLANTSURFACE SPEED

Jog tool down to

I F PROGRAMEND MILL 4 PARAMETERS

0. Sam--------------

.F PART SETUP5

CY B P TOOL HOMEOFF 60. I

F SET TOOL ZEROzero point and use softkey to set too I zero 7

P EXIT8

Figure 3-39. Tool Setup screen

Ultimax 3 System Revision A 3-45

Operator's Manual

3-46

After the setup information is entered for the program, the operator mustenter specific tool and machining information for each data block withinthe program. The operator can enter this data as the data blocks are beingcreated from the DXF part geometry or after all the DXF information hasbeen loaded into data blocks.

Caution

The operator must examine the tool path for the part program and performall of the normal dry run and error testing procedures before attempting torun a program created from DXF geometries. Remember the systemcannot determine the tooling and machining information from the DXFfile. The operator must create that portion of the part program.

5120/94 Hawk 5M Machine

Operator' s Manual

Input Screen Hierarchy Chart

Input button

I

Part Setupscreen

Part ZeroSafety Work

Region

Tool Setupscreen

Set Tool ZeroDescribe

each toolused in theprogram

ProgramParameterscreens

RetractClearance

Optimize Drilling& Boring Routines

Optimize Milling

RoutinesProgram ProtectTool Change

Position

PartProgramming

Copy & ChangeBlocks

Copy & Relocateportions of aprogram

Move blocks withina program

Delete blocksModify dimensionsChange feeds &

speeds

Appendix

EraseFunctions

Erase Part Setup,Tool Setup, &Part Program

Reset ProgramParameters

Erase All

MilliHoles ngPosition

Center Drill Circle Patterns Miscellaneous

Y PositioningX Drill Frame Loop Rectangular Graphics Off,Index Pulses Gun Drill Face Loop Linear Graphics On

(if installed) Counterbore Ellipse Loop Angular Change ParametersStop Blocks Spot Face Contour Loop Rotate Change Part Setup

Countersink Lines & Arcs Pattern LocationsTap Blend Arc ScaleBore Standard Helix Mirror ImageBore Orient Lettering Pattern EndBore Rapid 3-D Mold

Ream (if installed)

Ream RapidBack Spotface

Ultimax 3 System Revision A A -3

Operator's Manual Appendix

Coordinate Systemshowing spindle (tool) movement relative to

Part Zero

Spindle moves upand away from

the part

Spindle movesright on part

ySpindle

moves awayfrom operator

Spindle moves downand into the part

Y Spindlemoves towardthe operator

A-4 4/29/94 Hawk 5M Machines

Appendix

This section contains charts and diagrams that customers have foundhelpful when learning to use their Hawk 5M machines. Included in thissection are a diagram of the Ultimax 3 console, the Ultimax Input screenhierarchy chart , a coordinate system diagram , recommended chip loads,and feeds and speeds information.

Ultimax 3 System Revision A A-1

Appendix Operator's Manual

Start Notion Interrupt PoverCyde Hold Cyde on

0000

I

Machine OperationsO Auto OSeple O Test Olbnuot O uta OHOnuel

HoeM 0000 c^oer 0oSpindle

-Program Entry-

o rrput 0 P "qv O Au+dbry

J==C

o Auto 0 Met onaod

Coolant

0 0 0

Cursor Control

Teat Screen

Hone

0 0 0 0 Ne DNetl I a

000E Ertl

Grophts Screen

Droe

C JSNect

O O O 0 U ^tK Hord Drive Floppy Drive

Ultimax 3 Console Layout

00 a ^.e ^tre0 0 0000

0

Clear Nt Ctrl Dod. Advance

a o, o orr

00

OpnC ie, I ho

w rated^

Ultirl ox "3

EnergencyStop

0

J

Ultimax 3 System Revision A A-2

Operator ' s Manual Appendix

Suggested Cutting Speeds in Feet-per-MinuteFor High Speed Steel Endmills

MaterialSteel

Up to 240 Brinell (24Rc)

Cutting Speed (FPM)

90-175

240 to 320 Brinell (24-35 Rc) 50-90

320 to 500 Brinell (35-50 Rc) 5-50

Cast 60-90

Stainless 30-80

Cast Iron Formulas:

Regular 80-120

Hard 5-30 Surface Ft. Per Minute = (RPM x 3.14 x Tool Diameter) / 12

Non-Ferrous Chip Load = Feed in IPM / (RPM x Number of Teeth)

Brass 150-500 Feed in IPM = Chip Load x RPM x Number of Teeth

Magnesium 150-1000 RPM = (12 x SFPM) / (3.14 x Tool Diameter)

Copper 100-500

Regular 90-150

Hard 30-70

Titanium

Unalloyed 35-55

Alloyed 15-35

Ultimax 3 System Revision A A -5

Operator' s Manual

Materials

Alumi A, iloys'

Free Gutting Brassand Bronze

Medium Brass and Bronze

Hard Brass and BronzeNNE/[.^' 'M

t̂ ron,=med (180-220 BH),

Cast Iron, ,hard (2

MedyCrb"on Stee

Alloy Steel (180-220^BI

Alloy Steel(220-300 BH)

Alloy Sigel (300-400BHH)

Appendix

Recommended Chip Loads

MOW End MMills> ';?

RelievedCutters

.013 .010 .008 .007 .004

.022 .018 .013 .011 .007

.022 .018 .013 .011 .007

.022 .018 .013 .011 .007

.014 .011 .008 .007 .004

.009 .007 .006 .005 .003

.013 .010 .007 .006 .004

.016 .013 .009 .008 .005

.013 .010 .007 .007 .004

.010 .008 .006 .006 .003

.012 .010 .007 .006 .004

.010 .008 .006 .005 .003

.008 .007 .005 .004 .003

.006 .005 .004 .003 .002

.004 .003 .003 .002 .002

.006 .005 .004 .003 .002

Hawk 5M Machines4/29/94A -6

Operator ' s Manual Appendix

Feed and Speeds for High Speed Drills

The feeds and speeds in the following tables apply to average working conditions and materials. They are

recommended with due regard to conserving drills and avoiding excessive machine tool wear. Under many conditions,these feeds and speed may be considerably increased (increase in feed often helps break up chips), while under otherconditions they must be decreased. In order to secure the best results, both the speed and feed should be increased ordecreased in proper proportion. The liberal use of cooling compound will increase the life of tools. Always keep drills

sharp.

Feed per Revolution Material and Surface Feet per Minute

Drill Diameter Feed per Revolution Alloy Steel 20 - 30

up to 1/8 0.001 - 0.003 Aluminum and its alloys 200 - 300

1/8 to 1/4 0.002 - 0.006 Brass, Bronze 10 - 20

1/4 to 1/2 0.004 - 0010 Hard Chilled Cast Iron 10 - 20

1 /2 to 1 0.007 - 0.015 Monel 30 - 50

1 and over 0.015 - 0.025 Magnesium 250 - 400

Mild Steel 80 - 110

Soft Cast Iron 70 - 125

Stainless Steel 50

Tool Steel 50 - 60

Titanium 10 - 60

Ultimax 3 System Revision A A -7

Index

AAbsolute zero, 1-24, 1-54, 1-58, 2-240Advance key, 2-13, 2-18Arcs, 2-119

3-D, 2-128blend, 2-121chord error, 1-78clockwise, 2-119rotary, 2-242

Auto button , 2-54, 2-275AutoSave, 1-32

backup time limit, 1-35set time, 1-32

Autoscaling, 2-35Auxiliary screen, 1-29

change program editor type, 1-36copying programs, 1-98DXF option, 3-5printing programs, 2-62renaming a program, 1-95reset master, 1-107_..-__.serial port protocol, 2-271storage functions, 1-38, 1-88, 1-97system configuration, 1-29upload/download, 2-267

AxisA axis, 1-44, 2-230A axis calibration, 1-26feed rate dial, 1-49, 1-85jogging, 1-49load monitor, 2-284motor over temperature, 1-106X & Y axes calibration, 1-26Z axis calibration, 1-26

Ultimax 3 System

BBack spotface, 2-96Blend arc, 27121

guidelines, 2-122programming example, 2-123programming methods, 2-123types, 2-121

Bolt circle, 2-73, 2-86fields, 2-87maximum number of holes, 2-87radius, 2-87skip list, 2-87softkey, 2-19start angle, 2-87

Bore, 2-91, 2-93boring bar, 2-93cycle, 2-93dwell parameter, 1-80orient, 2-95rapid, 2-94

CADcompatibility software, 1-12files to DXF option, 3-1to conversational data blocks 3-1

Calculation (automatic), 2-31, 2-116arcs, 2-120forcing recalculation, 2-32helix, 2-127methods to calculate, 2-103store-values, 2-31two possible solutions, 2-118

Calibrate Machine softkey, 1-26Calibration

machine tool, 1-24tool, 1-68

Revision A I - 1

•4

Operator's Manual

Center drill, 2-69, 2-75Change Editor softkey, 1-36Change Program Mask softkey, 1-102Change to Directory softkey, 1-93Chip breaker, 2-73Chip enclosure (UK only)

hardware, 1-11limit switch, 1-105

Chord Error, 1-75, 1-77, 1-78Circle, 2-131

fields, 2-133type, 2-132

Climb milling , 1-82, 2-112, 2-181Clockwise arc, 2-119CNC, 1-6Concurrent programming, 2-60

access from Input screen, 2-60while using DXF, 3-2

Conditional fields, 2-12Console, 1-6, 2-33

floppy drive, 178Machine Mode group, 1-53

i power up, 1-17program protection keyswitch, 1-8,

1-85---screen blank "time, 1=33 --

top panel, 2-273Console keys, 1-7

Advance, 2-8, 2-22Alt, 1-7arrow keys, 1-63, 2-8, 2-43Auto, 2-57, 2-275Auxiliary, 1-9, 1-29, 1-38, 1-88,

1-95, 1-97Back, 1-106,•2-8, 2-22Clear, 2-32Ctrl, 1-7, 3-2Draw, 2-33, 3-2Emergency Stop, 1-3, 1-7, 2-59End, 2-43Enter, 1-7, 1-42, 2-8Home, 2-43Input, 1-37Interrupt Cycle, 1-76, 2-59, 2-274Machine operations, 2-275

Console keys (continued)Manual, 1-113, 2-275Motion Hold, 1-28, 2-59, 2-61,

2-274Page Up & Down, 2-43Power On, 1-25,•1-110, 1-113,

2-274Review, 2-43, 2-182Select, 1-7, 2-34Single, 2-275Spindle Off, 1-59, 2-61, 2-276Spindle On, 1-59, 2-276Start Cycle, 1-3, 1-25, 1-28, 1-110,

1-113, 2-272, 2-273, 2-276Test, 2-275

Contourclosed, 2-113, 2-191Mill, 2-106open (for 3-D), 3-34

Control power off time, 1-31Conventional milling, 2-112, 2-181Conversational part program

editing, 2-45print program, 2-62, 2-270receive, 2-269running; 2=272`send, 2-269upload/download, 2-272

Conversational part programming, 2-1automatic value calculation, 2-31,

2-103concurrent, 2-60data blocks, 2-7general parameters, 1-74manual run, 2-277milling parameters, 1-81principles of, 2-1recovery/restart, 2-286rotary data blocks, 2-230setup, 1-48single cycle, 2-281summary, 2-7switching editor type, 1-36test run, 2-278

1 - 2 5120/94 Hawk 5M

Coolant, 1-68auto, 2-276buttons, 2-276flood, 2-276mist, 2-276

Copy and Change Blocks softkey, 2-46Copy Program softkey, 1-99Counterbore, 2-69, 2-76Countersink, 2-69, 2-78Crash prevention, 1-60Crosshair cursor, 1-7, 2-36, 2-38, 2-40CRT, 1-7

blank screen, 1-33for graphics, 2-33

Cutter compensation, 1-67, 2-110climb milling, 2-112conventional milling, 2-112field, 2-108left & right, 2-111profile left & right, 2-113rotary, 2-241UltiPocket parameters, 2-189

Insert Arc, 1-83Insert Line, 1-84

when scaling, 2-179Cutter insert option, 1-13, 2-6, 2-218

diamond faces, 2-223hexagon,2-226orientation, 2-221radius, 2-221relief 1, 2-221sample program, 2-228standard fields, 2-221triangles, 2-219type, 2-221

Cuttinginside a cavity, 2-29problems while, 2-59safety, 1-3

DData block, 2-4, 2-7

building from DXF, 3-2, 3-12, 3-15general concepts, 3-13

changing feeds and speeds, 2-52

Operator's Manual

Index

Data block (continued)copying, 2-49creation & navigation, 2-8deleting, 2-13, 2-50editor, 2-46fields, 2-8graphics on/off, 2-35hole drilling, 2-9, 2-14modifying dimensions, 2-51moving, 2-49number, 2-9, 2-102, 2-251Position, 2-23rotary, 2-230search, 2-34search from graphics, 2-40special types of, 2-23start & end

for restart, 2-287for running, 2-283

start new block, 2-13suppress execution of, 2-99

Date, 1-30Delete Block softkey, 2-13Delete Operation softkey, 2-21Delete Program softkey, 1-97Depletion'retract, 1-76, 1-77Diamonds, 2-6, 2-223

one face, 2-223two faces, 2-224

Directories, 1-88changing display lists, 1-102creating, 1-91deleting, 1-91options, 1-90print current, 2-273reorganize, 1-98root directory, 1-88, 1-89, 1-91structure, 1-89switching between, 1-90

Disk Operations List Directory softkey,1-39,1-90,1-95,1-97

Diskette, 2-65boot from, 1-118copy program to, 1-99, 1-101formatting in the console, 1-39

Operator' s Manual

Don't Change Z-Start softkey, 2-51Download

conversational part program; 2-272 .Send softkey, 2-273

Draw key, 2-13, 2-33Drilling, 2-68

basic drill operation, 2-74bits, 2-74center drill, 2-75completed block, 2-71, 2-73counterbore, 2-76countersink, 2-78dwell parameter, 1-80field descriptions, 2-70gun drill, 2-79softkeys, 2-69spotface, 2-77

Drivesdirectories on, 1-88external .

transfer from, 2-272floppy, 1-39hard, 1-39

failure, 1-118increase size, 1-11updating software on, 1-117

program storage, 2-65protection fr out deletion , 1-91-"-

. Dry run,, 2-55DXF option , 1-12,3-1

3-D option, 3-34Accept screen button , 3,-~14.11 1autochain , 3-10, 3=13„3=27, 3-29basic options screen, 3-,7

,Build

3-7building data blocks,,3=12

general concepts; 31 13capabilities, 3-1compatibility, 3-1completing program; 3-45create new program, 3-4Current Directory screen, 3-3data input dialog box, 3-11Default screen button ,, 3-24, 3-25

DXF option (continued)editing drawings, 3-39

extend, 3-40join, 3-41modify, 3-42split, 3-35, 3-44

Exit/Undo screen button, 3-23'file management, 3-3file names, 3-3geometry, 3-10, 3-42graphics,'3-2holes, 3-22''

accepting, 3-24deselecting, 3-23

.'selecting, 3-23Intersect screen button, 3-23layers, 3-7, 3-20'milling, 3-27

3-D option, 3-34circle, 3-31frame, 3-33line and ares;i3:27

More screen button, 3-12, 3-39Move Zer

ro ?button

', 3-8

optimize tool'path, 3-25parameters , 3-7, 3-8, 3-9

convert values to inches, 3-10end point tolerance , 3-9,,3=28<<.out of square tolerance , 3-9;' 3-33part X & Y offsets, 3-9 -

Quit CAD' 377,redisplay drawing, 3-2screen buttons, 3-7selecting DXF elements, 3-13tool and part setup, 3-2, 3-45Ultimax ,features, 3-2zoom, 3-7, 'Zoom Box screen button, 3-17

-fit to view , 3-18_identify area, 3-18pan, 3-18, 3-19zoom out, 3-18

Index

EEditor type, 1-36Electrical cabinet, 1-1

over temperature, 1-106Ellipse, 2-143

fields, 2-146types, 2-144

Emergency Stop, 1-109, 2-59button locations, 1-7button release, 1725during restart, 1-113for shut down, 1-112message, 1-112stopping a running program, 2-286

End of program, 2-13, 2-22Erase functions, 1-45, 1-46

part setup, 1-46reset program parameters, 1-46tool setup, 1-46

Error checking, 2-34, 2-44Error messages

DXF, 3-4initialization, 1-21limit switches, 2-235Machine Configuration, 1-23machine diagnostics, 1-103on graphics screen, 2-42when scaling, 2-179without Zero Calibration, 2-2

Exit softkey, 2-13,N

FFace milling, 2-139

fields, 2-142reference corner, 2-142types,2-140X bi-directional, 2-.141X unidirectional, 2-140Y bi-directional, 2-141Y unidirectional, 2-141

Feedrate, 1-71change for all tools, 2-52chord error, 1-78finish, 1-81high-speed cobalt tools, 1-72

Feedrate (continued)in run time estimate, 2-44mill feed, 2-222plunge , 1-70, 2-70, 2-72, 2-221

Feeds and speeds, 1 -69, 2-115automatic calculation of, 1-70, 1-71changing throughout program, 2-52optimization, 2-279tapping, 2-90

Fieldsbrackets around, 2-11conditional, 2-12while part programming, 2-8

Find, 2-42Fixturing, 1-3, 1-52

optional 6, 1-11safety, 1-3

Floppy drive, 1-8copy program to, 1-39diskette in, 1-108errors at start -up, 1-21selection for storage , 1-39, 2-65

Frame, 2-134fields, 2-137from DXF file, 3-9reference corner, 2-12, 2-137softkey, 2-10types, 2-135

GGear

change,1-1Graphics, 1-62, 2-2, 2-33

data block search, 2-34, 2-40Draw key, 2-13,'2-33drawing stops, 2-35error checking, 2-34;,2-42isometric view, 2-36on or off block, 2-35parameters, 2-38, 2-39rotary, 2-263' 1screen buttons, 2-34stop drawing, 2-33views, 2-36

Operator's Manual Revision A

Operator's Manual

Graphics (continued)while using DXF option, 3-2XY plane view, 2-41zoom, 2-38

Gun drill, 2-69, 2-79fields, 2-81purpose, 2-79

HHawk 5M, 1-1

console, 1-6hardware options, 1-11power up, 1-17routine maintenance, 1-4safety, 1-2shut down, 1-109side view, 1-16software options, 1-12

Helix, 2-126Hexagons, 2-6, 2-226Highlighted fields, 1-103Holes, 2-66

bolt circle, 2-86completed block options, 2-21locations, 2-20, 2-84, 3-23operations, 2-17parameters, 1-80softkey, 2-5

IIn/Out buttons, 1-51

Inch, 1-36, 1,-44

in DXF, 3-10Threads per, 1-66

Indexer option, 1-11, 2-24index pulse value, 1-13, 2-24software, 1-13

Input screen, 1-44 .concurrent programming, 2-60DXF option, 3-4erase functions; 1746loading part programs, 1-37part programming access, 2-4part setup, 1-57, 2-3, 2-233partially protected, 1-9

program parameters , 1-73, 2-3program protect parameter, 1-85software version It, 1-22tool setup, 1-63, 2-3unprotected, 1-10

Insert Block Before softkey, 2-13Insert Operation Before softkey, 2-21Interrupt Cycle button, 1-76, 2-59,

2-274Interrupt cycle Z retract, 1-76, 1-77Isometric view, 2-36

JJog unit, 1-49, 1-85

axes jog buttons , 1-59, 1-60Axis Feed Rate dial, 1-49, 2-56,

2-279buttons, 1-49Emergency Stop button , 1-7, 1-49identifying reference comer, 2-12manual operation for, 2-275parameters, 1-50Store Position button, 1-49, 1-59,

1-60, 1-64, 1-68, 2-12Jogging

axes, 1-49to identify part zero, 1-59

KKeyswitch, 1-8, 1-85

protected, 1-9unprotected, 1-10

LLanguage files, 1-17

additional, 1-14changing, 1-114multiple languages, 1-115two languages only, 1-114

Lettering, 2-1,47cutter compensation, 2-147delete a character, 2-149fields, 2-148select a letter, 2-149

Limit, 1-103

1-6 5/20/94 Hawk 5M

Index

Limit switcheserror, 2-235

Lines, 2-116rotary, 2-242

Locations, 2-69, 2-84programming, 2-20softkey, 2-19

Loopangular, 2-172linear, 2-169rectangular, 2-167rotate, 2-174

Lubrication, 1-4, 1-15, 1-112to the ways, 1-109 .

MMachine Configuration

backup,1-35restore, 1-35screen, 1-18

display, 1-34error messages on, 1-23

Machine diagnostics, 1-103Machine mode buttons, 2-275

Auto, 2-54, 2-275Manual, 2-275, 2-277Single, 2-54, 2-275Test, 2-54, 2-275to run programs, 2-54

Machine tool, 1-1calibrate, 1-24Emergency Stop for shut down,

1-112jog unit, 1-49maintenance, 1-4

annually, 1-5daily, 1-4monthly, 1-5quarterly, 1-5semi-annually, 1-5weekly, 1-4

major components, 1-1options, 1-11parameters used, 1-30park for shut down, 1-110

Machine tool (continued)power switch, 1-16powering up, 1-17prepare for power up, 1-15shutdown , 1-109, 1-113standard, 1-44warm up, 1-27

Make the Changes softkey, 2-48Manual button , 2-275, 2-277Manual screen , 1-27, 2-277

calibrate machine tool, 1-24jog parameters, 1-50loading tools, 1-53park machine, 1-110warm-up machine, 1-27

Measurementunits of, 1-36, 1-44

Memory, 2-65increase size option, I-11permanent , 1-45, 1 -92, 1-93, 2-63temporary , 1-30, 1-32, 1-45, 1-47,

'1=118Metric, 1-44

draw, 1-11in DXF, 3-10`e..

pitch in mm per thread, 1-66Milling, 2-104

3-D arc, 2-128calculate centerline, 2-130fields, 2-129guidelines, 2-00

3-D option , 1-12, 2-150used in DXF, 3-34

arcs, 2-119blend arcs, 2-121circle, 2-131climb, 2-112, 2-181conventional, 2-112, 2-181direction, 1-82ellipses, 2-143face, 2-139 .feeds and speeds, 2-115frame, 2-134helix, 2-126lines, 2-116

Operator's Manual Revision A 1-7

Operator' s Manual

Milling (continued)options, 2-9parameters, 1-81segments, 2-106softkey, 2-5

Minor image, 2-180Miscellaneous

features, 2-27softkey,2-6

Modifydimensions, 2-51part programs, 2-45

Motion Hold button, 1-28, 2-59, 2-61,2-274

Multiple parts, 2-163, 2-176

NNC part programming

optional stop, 1-76parameters, 1-76rotary, 2-230setup, 1-48switching editor type, 1-36

0Offset, 1-61

blend, 1-81maximum, 2-109, 2-114modifying all, 2-51pattern locations, 2-176

Operation, 2-17delete, 2-21insert before, 2-21

Optional program stop , 1-76, 1-77Orientation, 2-221Overlap

blend, 1-81pocket, 1-82

PParameters

bore dwell, 1-80bore orient retract, 2-95change within a program, 2-26conversational part program, 1-75cutter compensation, 1-83

Parameters (continued)drill dwell, 1-80erase program, 1-46for DXF option, 3-8general , 1-75, 1-77graphics , 2-38, 2-39jog unit, 1-50manual jog feed, 1-50manual spindle speed, 1-50, 1-59milling, 1-81, 2-189NC part program, 1-76program, 1-85program protect, 1-9rapid detent, 1-50rapid traverse, 2-280retract clearance, 2-29rotary, 2-235, 2-238system, 1-30Z Top & Bottom, 1-60

Park Machine softkey, 1-111Part features

ellipses, 2-143face milling, 2-139lettering, 2-147

Part outline block, 2-99Part program

automatic stop, 2-23changing, 2-45checking, 2-43copy into temporary memory, 1-40deleting, 1-97editing, 2-45end, 2-22enter new name, 1-42erase copy of, 1-45error checking, 2-44loading, 1 -17, 1-37

from program directory, 1-38last program used, 1-37

overwrite, 1-94part setup, 1-57, 2-233

access to, 1-9erase, 1-46importance of, 2-2

permanent storage, 1'-92

HawkSM

Index

printing, 2-62renaming, 1-95rotary, 2-231running, 1-62, 2-2, 2-54save current, 1-93select and save, 1-99set units of measure, 1-44storage, 2-63, 2-65summary, 2-43templates, 1-62tool setup, 1-62

access to, 1-9erase, 1-46importance of, 2-2

working with entire blocks, 2-46Part programming, 2-1

access to functions, 1-10concurrent, 2-60conversational, 1-48, 2-1data blocks, 2-8general parameters, 1-73

ranges and defaults, 1-77holes, 2-66letters, 2-147milling, 2-104mirror image, 2=180NC, 1-48part setup, 1-54patterns, 2-163planning, 1-48position block,.2-23protection keyswitch, 1-8switch editor type, 1-36tool setup, 1-62

Part Programming softkey, 1-57, 1-64,2-4,2-13Part setup, 1-57, 2-233

access to, 1-9erase, 1-46importance of, 2-2softkey, 1-64, 2-21Z axis offset, 1-61

Part zero, 1-54, 2-25, 2-240for rotary parts, 2-233identifying, 1-59

on DXF drawing, 3-8, 3-9Pattern operations, 2-163, 2-164

basic principles, 2-165end, 2-165, 2-182locations, 2-176loop angular, 2-172loop linear, 2-169loop rectangular, 2-167loop rotate, 2-174mirror image, 2-180purpose,2-163sample program, 2-183scale, 2-177softkeys, 2-164

Patterns softkey, 2-6PC/PC Plus option, 1-13Peck

clearance plane, 1-75, 1-77depth, 2-70, 2-72, 2-73, 2-109, 2-133,2-222type, 2-70, 2-73

Personal computers, 1-6, 1-90transfer programs from, 2-272Ultimax off-line software, 1-13

Pocketcutter compensation parameter, 1-$3cutter insert-option, 2-218overlap parameter, 2-12softkeys, 2-11

Portsparallel printer, 2-62, 2-270serial , 2-266, 2-271

Position block, 2-23, 2-29access softkey, 2-5indexer option, 1-13operations, 2-25reduce rapid Z motion, 1-61

Poweroff, 1-109problems, 1-20up, 1-107

Power cabinet, 1-1over temperature, 1-106

Power On button, 1-25, 2-274Print, 2-62 .

Operator 's Manual Revision A 1-9

Operator' s Manual

conversational part program, 2-62,2-273, 2-276current directory, 2-273

Printers, 2-62, 2-276Program parameters, 1-73Program Parameters softkey, 1-58, 1-64,1-74,2-21Protect program from change, 1-9

full protect parameter, 1-85partial protect parameter, 1-85partial protect with keyswitch, 1-8

RRadius, 2-221

Rapid traverse, 1-77during optimization, 2-280for X, Y, & Z axes, 1-75rotary, 2-235

Ream , 2-91, 2-94rapid, 2-95reaming tool, 2-94

Reboot, 1-107Recovery Restart softkey, 2-286Reference comer, 2-12, 2-137, 2-142Rename Program softkey, 1-95Reset Master softkey, 1-30, 1-107 _Reset Servos and Spindle softkey, 1-25,1-110,2-277Restart, 1-113, 2-59, 2-274

conversational part program, 2-286rotary program, 2-245start & end blocks, 2-287starting segment , 2-107, 2-290

Retract Clearance, 1-75, 1-77, 2-29,2-162, 2-276

Review, 2-43Rotary, 1-44, 2-230

arc, 2-242centerline offsets, 2-233cylinder radius parameter, 2-238formula for point calculations, 2-243graphic representation, 2-263hardware option, 1-11line, 2-242line & arc calculations , 2-243, 2-268

5120/94

options, 2-237parameters; 2-238part programs, 2-231part zero, 2-30, 2-233pattern end, 2-245, 2-246position block; 2-25, 2-239, 2-245rapid traverse, 2-235sample program, 2-247softkey, 2-6software, 1-13start segment, 2-241Y Off of Centerline parameter, 2-238

Run, 2-272conversational part program, 2-283manual, 2-277test, 2-278time estimate, 2-44, 2-283

SSafety, 1-2

glasses, 1-2while running program, 1-3, 2-272work region, 1-60, 1-75

Sample programscutter insert, 2-228drilling, .2-99- ------- ----,---milling,2-151patterns, 2-183rotary, 2-247UltiPocket, 2-196

Saving a program, 1-89to hard drive, 1-93with date/time stamp, 1-30

Scale, 2-177cutter compensation, 2-179factor, 2-179

ScreensAuto, 2-57, 2-58, 2-283, 2-284,

2-285Auxiliary, 1-29, 1-38, 1-107, 2-273,

3-5Back Spotface, 2-96Block Editor, 2-47Change General Parameters, 2-28Change Part Setup, 2-30

Hawk 5M

Index,

Screens (continued)Current Directory, 1-40, 1-90, 1-93,

1-102,3-3Current Program, 1-40, 1-88, 1-92,

1-94,2-63DXF graphics, 3-7DXF Parameters, 3-8End of Program, 2-22Feed and Speed Optimization, 2-56,

2-279General Parameters, 1-74highlighted fields, 1-103Holes, 2-15, 2-16, 2-17Holes Parameters, 1-80Input, 1-9, 1-10, 1-22, 1-37, 1-73,

2-3,2-4Language Selection, 1-115Letter Selection, 1-42, 1-93, 1-95,

2-64Limit Switches, 1-103, 1-105Loop Linear, 2-170Machine Configuration, 1-18, 1-23,

1-34Manual, 1-24, 1-27, 1-50, 1-53,

1-110, 2-277Mill 3D, 2-150Mill Circle, 2-131Mill Contour 3D Arc, 2-128Mill Contour Arc, 2-119Mill Contour Blend Arc, 2-124Mill Contour Helix, 2-126Mill Contour Line, 2-116Mill Contour New, 2-106Mill Contour Start (segment 0),

2-107, 2-108Mill Diamond, 2-225Mill Ellipse, 2-143Mill Face, 2-139Mill Frame, 2-10, 2-12, 2-134Mill Hexagon, 2-227Mill Lettering, 2-147Mill Triangle, 2-220Milling Parameters, 1-81New Block, 2-5, 2-9, 2-13, 2-14,

2-105

Screens (continued)Part Setup, 1-57Pattern End, 2-182Pattern Locations, 2-176Pattern Loop Angular, 2-173Pattern Loop Rectangular, 2-168Pattern Loop Rotate, 2-175Pattern Minor Image, 27181Pattern Scale, 2-178Position, 2-23Program Parameters, 1-85Review Program, 2-43Rotary Mill Contour, 2-242Rotary Pattern Loop, 2-245Rotary Position, 2-239Single Cycle, 2-281, 2-282System Parameters, 1-30, 1-33Test Run, 2-55, 2-278, 2-279Tool Setup, 1-63, 1-65, 1-69

Security key, 1-14initialization error, 1-21

Segments, 2-106fields, 2-108maximum number, 2-106numbers, 2-107planning for recovery, 2-107segment zero, 2-107

Select Current Storage Directorysoftkey, 1-93

Serial portreset parameters, 2-274select, 2-273setup, 2-274

Set Current System Time softkey, 1-30Set Tool Zero softkey, 1-64Shut down, 1-109

automatic, 1-31Emergency Stop method, 1-112park machine method, i-110

Single button, 2-54, 2-275Skip list, 2-87Softkeys, 1-7Special softkey, 2-6

e

Operator's Manual Revision A I - 11

Operator's Manual

Speed , 1-68, 1-69, 1-70, 2-72finish, 1-82for drilling, 2-70milling, 2-109, 2-133, 2-138tap, 2-90

Spindlechange speed, 1-1in/out buttons, 1-53loading tool into, 1-51manual speed, 1-50on/off buttons , 2-61, 2-276overload trip error, 1-106speed, 1-72, 2-90speed range display, 1-Istop parameter, 2-70

Spotface , 2-69, 2-77back, 2-96

StandardHawk 5M machine tool, 1-44peck type, 2-73

Start Cycle -button , 1-25,-1-28, 2-273check operation of, 1-105warning, 1-3

Start machine, 1-17Start segment, 2-108

rotary, 2-241 .UltiPocket, 2-192

Storage Functions softkey, 1-38, 1-88,1-92, 1-95, 1-97, 2-63

Store Calculated Value softkey, 2-31Store Machine Position softkey, 1-58Store Position button, 1-49System Configuration softkey, 1-29

TTable, 1-1

fixturing part, 1-52move forward at program end, 2-23protection , 1-60, 1=110

Tagging, 1-100Tap, 2-89

feeds and speeds, 2-90holder, 2-90maximum speed, 2-89operation, 2-90

Tap (continued)tapping fluid, 2-90threads per inch, 1-66, 2-90

Technical servicespreparation for call, 1-22

Test button, 2-54, 2-275Test run, 2-278Time, 1-31Toggle Program Tag softkey, I-100Tool, 2-108

broken, 1-62calibration , 1-61, 1-68carbide, 1-72changer buttons, 2-276cobalt, 1-72descriptions in the system, 1-63diameter, 1-67, 1-70,,1-71, 1-72,

2-2, 2-72finish, 2-108, 2-133holder, 1-51In and Out buttons, 1-51in Spindle softkey, 1-27, 2-277maintenance, 1-4number, 1-65, 2-2, 2-11, 2-71, 2-101number zero, 1-27setup, 1-9,1,,46, 1-62, 2-10

activate coolant selection 276changing, 2-21checking, 1-62importance of, 2-2screen, 1-63templates, 1-62

Setup softkey, 1-57, 2-10steel, 1-72-types, 1-66, 2-2zero, 1-64

Tool changer height, 1-106Tool Home softkey, 2-277Tools '

changing all feedrates, 2-52changing one feedrate, 2-53

Trackball, 1-7, 2-40Triangles, 2-6, 2-219

1-12 5!20/94 Hawk 5M

Index

Troubleshootinghard drive failure, 1-118power up problems, 1-20.-

UUltimax

3-D option, 1-12, 2-150automatic calculation, 2-31console, 1-6cutter insert option, 2-218DXF option, 3-1erase functions, 1-45executive, 1-116restart, 1-113software

off-line, 1-13options, 1-12, 1-34upgrade,'1-116version #, 1-22

UltiPocket option, 2-188UltiPocket option, 1-12 , 2-11, 2-12,

2-18811boundary, 2-190circle, 2-195Cutter Comp parameter, 1-83frame, 2-194lines & arcs, 2-192milling parameters, 2-189milling values, 2-190pattern, 2-196programming islands, 2-191sample program, 2-196

Untag All Programs.softkey, 1-100Upload

conversational part program, 2-272Receive softkey, 2-273

VVersion number, 1-22

Work piece, 1-61, 2-72alloy steel, 1-72aluminum, 1-72carbon steel, 1-72compensate for thickness, 1-61feeds & speeds, 1-72fixturing, 1-52gray cast steel, 1-72part zero, 1-54safety region, 1-60

Write Program to Disk softkey, 1-93

ZZ axis, 1-26

drill parameters, 2-70offset, 1-61, 2-51rotary, 2-233start parameter, 2-278

Z Bottom parameter, 1-60, 2-70, 2-72,2-73, 2-97, 2-109, 2-133

Z Clearance, 2-97Z Depth, 2-97Z Retract, 2-97Z Start parameter, 2-29; 2-51, 2-55,

2-70, 2-72, 2-73, 2-90, 2-96,2-162

Z Top parameter, 1-60Zero calibration, 1-64, 1-68, 2-2Zoom, 2-38

WWarm Up Machine softkey, 1-28Ways

lube reservoir, 1-1, 1-105maintenance, 1-4stop'p lubrication to, 1-109