Course Description

MACHINE SAFETY

Compile a list of general safety rules that apply to chip removal machines.

Explain the safety measures and problems with automated movements of machine tables with varying heights of workpieces and fixture parts.

COMMAND CODES

Theory

Describe the binary system and how it works.

Name the computer languages and describe their general characteristics.

Define the various codes and functions used in CNC programming.

Discuss the related machine tool movements resulting from the codes entered into the programmable controller.

Define the auxiliary function commands.

Explain g-words and m-words, what their function is, and how they affect programming the controller.

Application

Write programs using all the computer words needed to set machine feeds, speeds, and linear and circular interpolation.

Test the program and correct any errors.

PROGRAM LOADING

Theory

Describe the methods available to load programs into a controller.

Identify the major functions of a postprocessor.

Loading

Load a program into the controller explaining each function and what the machines reaction should be.

Demonstrate the setting of zero and radius center points.

Computations

Compute the feeds and speeds to establish S-words and F-words to be programmed.

Compute tool path with tool offset programmed into the controller.

MACHINE SETUP  

Program selection

Select the program and determine the tooling acquired, fixturing and/or workholding devices needed.

Test run

Use machinable wax for a test workpiece to reduce possible damage during the first run.

Alignment

Use a dial indicator to align workpiece or work holding device.

Analyze the part so clamps and parts of fixtures will not be placed in the path of the cutting tool of spindle.

Single stepping

Explain how to run the program one line at a time to insure a safe operation can be completed.

PROCESS CONTROL

Theory

Define manual process control methods, random sampling, destructive and nondestructive testing and explain how these are used in process control.

Explain the difference between attributes and variables.

Set up control charts for both attributes and variables.

Explain the difference between automated self monitoring machines which shutdown when out of adjustment and self correcting machines.

Application

Prepare a schedule for tool wear compensation and tool changes due to excessive wear and explain the basis for each decision.

Design a schedule for random sampling of parts and create a means of plotting the ranges of variations.