costs. Custom postprocessors are required for each ma- chine and the creation and optimization of the postproces- sor is arduous and expensive. This problem grows worse because the results from the postprocessor only function for a specifi c machine. Over the long term, this means massive spending to support the postprocessor, and signifi cant time spent by programmers to learn the unique details of every machine setup.
These inconsistency fl aws move through the process to the operators and maintenance staff. With every machine being unique it will be diffi cult to operate and resolve issues on more than a few machines. Staff must be trained and given refresher courses on each type of application to remain current on solutions. As these individuals leave or retire, hiring new personnel causes increased expenditures.
Evolving to Consistency The manufacturing facility is key to the evolution to con- sistency, as it has the power to defi ne and enforce consistent practices. The best approach is for the organization to develop a manufacturing and programming process which is applicable to any machine for any part. Once the specifi cation for the new machinery is defi ned, there are clear expectations for the runoff, and this can help to verify the appropriate machine requirements. Organizations tend to only provide basic specifi cations such as number of axes, travel, speed, dimensions, etc. This is not enough to guarantee an effective and consistent project. Statements such as “fi ve-axis simultaneous,” “must manufacture within this tolerance,” and “needs to have prob- ing functionality” do not support consistent processes. The end-user is allowing other parties to defi ne the key param- eters for their own process.
FANUC offers a wide variety of CNC controls around which a consistent platform can be built.
Processing Consistently A consistent process begins by developing machine- independent programming practices. The traditional mindsets and postprocessor implementations require machines to be programmed in order to produce parts. It is much more ef- fi cient to “program parts” independent of a specifi c machine tool. By using the features and capabilities of a modern control system like the FANUC 30i-B series controller the pro- grammer can calculate how to move the machine to achieve the programmed path. By designing a process that takes advantages of these capabilities, programmers can focus on the part rather than spend signifi cant time fi guring out the requirements of a specifi c machine application. Driving consistency begins with generating programs in “part coordinates” rather than “ma- chine coordinates.” Modern CNC systems have offsets to defi ne the part coordinate system of the part program. The CNC processors are more than capable of handling the coordinate system measure- ments on the fl y. This allows the same part program points to be processed regardless of the part fi xturing on the machine without reposting the program. Part coor-
dinates are the foundation of making programs that can run on any machine. For example, the FANUC G54.4 (WSEC) offset can be used to defi ne the part coordinate system.
Multiaxis Machining For four, fi ve, or more axis machines, it can be diffi cult
Another sign of inconsistency is if part programmers need to be trained by the vendors in order to create a part program for the new equipment.
to program the rotary axes that change the tool and/or part orientation. In the past, four or more axis machines required functions like “inverse time” and intricate postprocessors us- ing trigonometry so the tool is in the exact location. Modern CNCs have functions typically referred to as Tool Center Point control or simply TCP. For reference, on a FANUC con- trol TCP is G43.4 or G43.5, which defi nes the tool orientation. TCP algorithms integrate the required mathematics in the CNC instead of in the postprocessor so that the part program
43 — Energy Manufacturing 2016
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