The Broken Tool - Plunge Cycle

Introduction

This topic will explain the Broken Tool - Plunge cycle, will describe how to access it, will explain the options found in it, and will explain how to use it with quick steps.

The Broken Tool - Plunge Cycle

 

This broken tool cycle uses a plunge check, where the tool is moved into and out of the laser beam in the axis used for length setting. The cycle can also check for a ‘long tool’ condition, where the tool has possibly pulled out during machining.

 

Typically, a tool needs to be checked after a machining operation to verify that it is not broken before the next tool is selected.

 

The cycle can be used for checking most tools, particularly for rotating tool applications where the cutting teeth will intermittently interfere with the beam as it is positioned for tool checking.

 

This cycle is similar in operation to the broken tool detection for solid tools but is not as quick.

To access the Broken Tool - Plunge cycle:

 

  1. In the CAM Tree, right-click Milling Tools, and select Tool Crib.

    The Tool Crib dialog launches in the Data Entry Manager.

  2. Add all tools needed for the job.

  3. Click OK.

    The Tool Crib dialog closes.

  4. In the CAM Tree, locate the desired Machine Setup for the Probing cycle, right-click the Machine Setup, and select Probing.

    The Probing dialog launches in the Data Entry Manager.

  5. In the Machining Strategy list of the Feature page, click the Non-Contact Tool Setter operation.

    The Non-Contact Tool Setter operation replaces the Measure operation in Current Operations list.

  6. Click the Operations(s) tab.

  7. Select the appropriate cycle from the drop down list in the Cycle section of the Parameters tab.

The Data Entry Parameters

Parameters

Tool

  • Tool Name - This drop down will list all the tools currently in the tool crib.

  • Override Tool Data
    - With this check box selected, you will be able to update the Tool Number and Tool Diameter.
    - With this check box cleared, editing of the Tool Number and Tool Diameter is unavailable.

  • Tool Number - Lists the Tool Number of the currently selected tool.

  • Tool Diameter - Lists the diameter of the currently selected tool.

 

Options

  • Tool Offset - Tool length offset number. This is the offset location in which the measured tool length is stored when it needs to be different from the active tool number.

  • Tolerance - When this input is used, the tool offset is not updated if the tool length is found to be out of tolerance.

  • Broken Tool Flag - Tool out of tolerance flag. Use this flag to prevent a tool OUT OF TOLERANCE alarm from being raised. Enter the value to be called out with the flag.

 

  • Spindle Speed - The default spindle speed. Measurement cycles are optimized for a spindle speed of 3000 r/min. Some tools – for example, those that are unbalanced or large – must be run at speeds less than 3000 r/min. This is the responsibility of the user. Use the ‘S’ input to set the speed. Measurement cycle times increase with slower speeds. The minimum speed is 800 r/min.

  • Radial Stepover - This is the offset across the beam at which length measurement takes place. The value must be less than the radius of the tool. The tool always comes down first on the beam centre-line.

  • Solid Tools - This input is used to inhibit minimum r/min checking for solid tools, where it is not necessary to control the spindle speed. This is particularly useful for long gun drills, where the tool cannot be run unsupported at high spindle speeds.

  • Safety Plane - The distance along the spindle-axis by which the tool is retracted from the beam.

Quick Steps - Broken Tool - Plunge

  1. In the CAM Tree, right-click Milling Tools, and select Tool Crib.

    The Tool Crib dialog launches in the Data Entry Manager.

  2. Add all tools needed for the job.

  3. Click OK.

    The Tool Crib dialog closes.

  4. In the CAM Tree, locate the desired Machine Setup for the Probing cycle, right-click the Machine Setup, and select Probing.

    The Probing dialog launches in the Data Entry Manager.

  5. In the Machining Strategy list of the Feature page, click the Non-Contact Tool Setter operation.

    The Non-Contact Tool Setter operation replaces the Measure operation in Current Operations list.

  6. Click the Operations(s) tab.

  7. Select the appropriate cycle from the drop down list in the Cycle section of the Parameters tab.

  1. In the Parameter section, select the tool and adjust the select the Override Tool Data check box is necessary.

    If you select the Override Tool Data check box, adjust the Tool Number and Tool Diameter values as needed.

  2. In the Options section, select the check boxes for any and all calls required in the output and set their values as needed.

  3. Select the Raw Text tab in order to output any macros or code manually.

  4. In the Raw Text tab, select the Output in NC Program check box.

  5. Enter the data to be output in the text field.

  6. Click OK.

    The operation is added to the CAM Tree.

Example 1 - Broken Tool - Plunge (Alarm)

By default, If a broken tool, or a long tool is detected, the controller will alarm out and the operator will need to step in to decide how to handle.

 

In this example we: 

 

  • Setup the Tool Crib.
  • Select the Broken Tool - Plunge cycle.
  • Select the tool.

Part 1) Setting up the Tool Crib

  1. In the CAM Tree, right-click Milling Tools, and select Tool Crib.

    The Tool Crib dialog launches in the Data Entry Manager.

  2. Add all tools needed for the job.

  3. Click OK.

    The Tool Crib dialog closes.

Part 2) Selecting the Diameter cycle

  1. In the CAM Tree, locate the desired Machine Setup for the Probing cycle, right-click the Machine Setup, and select Probing.

    The Probing dialog launches in the Data Entry Manager.

  2. In the Machining Strategy list of the Feature page, click the Non-Contact Tool Setter operation.

    The Non-Contact Tool Setter operation replaces the Measure operation in Current Operations list.

  3. Click the Operations(s) tab.

By default the Tool Length is the selected cycle.

  1. Click the drop down and select Broken Tool - Plunge from the list.

Part 3) Selecting the Tool to be set

  1. In the Parameters section, select the tool to be set from the drop down list.

    By default the Tool Offset is set to the tool number of the selected tool.

  2. Click OK to create the Tool Diameter cycle and exit the dialog.

Example 2 - Broken Tool - Plunge (No Alarm) 

When preventing the alarm from being raised, creating if/then statements in the Raw Text tab of the Operation(s) page is necessary. This will allow you to program a set of steps for each possible outcome of the cycle.

 

In this example we: 

 

  • Setup the Tool Crib.
  • Select the Tool Diameter cycle.
  • Select the tool.
  • Prevent the alarm from being called.
  • Create the raw text needed for the results of the cycle.

Part 1) Setting up the Tool Crib

  1. In the CAM Tree, right-click Milling Tools, and select Tool Crib.

    The Tool Crib dialog launches in the Data Entry Manager.

  2. Add all tools needed for the job.

  3. Click OK.

    The Tool Crib dialog closes.

Part 2) Selecting the Tool Diameter cycle

  1. In the CAM Tree, locate the desired Machine Setup for the Probing cycle, right-click the Machine Setup, and select Probing.

    The Probing dialog launches in the Data Entry Manager.

  2. In the Machining Strategy list of the Feature page, click the Non-Contact Tool Setter operation.

    The Non-Contact Tool Setter operation replaces the Measure operation in Current Operations list.

  3. Click the Operations(s) tab.

By default the Tool Length is the selected cycle.

  1. Click the drop down and select Broken Tool - Plunge from the list.

Part 3) Selecting the Tool to be checked

  1. In the Parameters section, select the tool to be set from the drop down list.

Part 4) Preventing the Alarm and setting Radial Stepover

  1. In the Options section, select the check box for Broken Tool Flag.

    This prevents the alarm from being called.

  2. In the Options section, select the check box for Radial Stepover.

  3. Enter the value that should be used when moving the tool off center.

Part 5) Entering the Raw Text

  1. Select the Raw Text tab.

  2. Select the check box for Output in NC Program.

    By default the Add Line Numbers check box is already selected.

  3. In the text field, enter all if/then statements, macros, and/or code to handle the following possibilities: 

    Good Tool

    Broken Tool

    Long Tool

  4. Click OK to create the Tool Diameter cycle and exit the dialog.