2000 Series Universal Cylindrical Grinder Operating Manual

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Introduction

The 2000 Series Universal Cylindrical Grinder control is a two-axis CNC system for OD/ID grinders.

The system includes standard dressing and grinding macros for common straight, tapered and profile geometries with a more simplified G code program. With its familiar windows interface, intuitive graphics, and user friendly layout, the system is easy to learn. Allowing you to have the machine operational almost immediately

The control also accepts standard Fanuc standard G-code, as well as Fanuc Macro B programming compatibility, giving operators virtually unlimited capabilities for writing their own custom programs and macros.

This manual gives the process for basic operation of the 2000 Series Cylindrical Grinder control including a summary of the different features of the tabs and additional screens. 

To open the control software double-click on the profile icon on the desktop.

Screen Navigation

Run Page

The run page contains the necessary features for operating the machine. The left side of the screen contains buttons for loading, editing, and running programs as well as the live tool path window to see the path the machine will take when the program is run.

The center of the screen contains information about machine status. The feedrate, wheel head RPM, and workhead spindle RPM can be modified on the fly by typing a new value in the blue box.

On the right side of the screen is a dashboard that can be configured with any number of widgets based on the operator's preferences (See the Series 2000 User Manual). Seen in the example above is the tool wear offset input window which can be used to make slight adjustments to the part diameter, the part offset table (Part Correction Offset) which, when multiple features are being ground on the part, can be used in conjunction with an "E" variable in the program to allow adjustments to each feature individually.

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Conversational Page

The conversational screen is used to quickly and easily create new grinding and dressing programs without manually writing gcode. A program consists of a set of cycles that are included in the job. The cycles can be added to the job in any order and rearranged or removed as needed. Adding a cycle is a matter of selecting the type of cycle, inputting the dimensional data, and pressing Add to Job. Once all cycles are correct, the Post button will load the job for running. 

grinder_odid_conversational.PNG

Grinder Setup

The grinder setup screen is used to set up the grinding wheels, dresser options, and safety clearances. 

Wheel Head Setup

This page is for setting up wheel head parameters for the active wheel. These parameters affect how the cycles run and how the wheel is dressed.

grinder_odid_wheelhead.PNG

Dresser Setup

This page is for setting up the dresser diamonds on the machine. There are three types of diamonds supported here:

  1. Profile dresser: used for dressing circumference and or one side of wheel, as well as user developed wheel profiles.
  2. Universal dressers: two dressers are used for dressing forms that exceed 90 degrees of travel into or around the wheel that cannot be done with a single dresser. For example, a full radius dressed into or onto the circumference of the wheel, or radii or profiles on both corners of the wheel.
  3. Straight dressers: used for straight dressing of all three surfaces of the wheel.

grinder_odid_dresser_setup.PNG

Safety Clearances

This page sets the distances between wheel, part, and diamond that are considered safe. These should be configured before running parts or dressing a wheel.

grinder_odid_safety_setup.PNG

Rotary Dresser

If the machine has a rotary dresser, it's parameters are set on this page.

grinder_odid_rotary.PNG

Calibrate

The calibrate screen is used for calibrating the grinding wheel to the part and adjusting the part size. The axes are brought into position, touching the part, and taught that position. The part is then measured at that position, and the position is updated to adjust for any discrepancy.

grinder_odid_calibrate.PNG

Fixtures

The fixtures screen is used for setting fixture, machine, and or work offsets. 

grinder_odid_fixture.PNG

Service

The service screen gives access to machine settings and diagnostics. It also contains a second configurable dashboard that can be setup to user preferences.

Maintenance

The service screen is used for control set up, diagnostics, and getting remote help from the support team. 

grinder_odid_maintenance.PNG

Machine I/O

This page allows the operator to see the state of all configured signals and I/O that are in use on the machine.

grinder_odid_machineio.PNG

Operations

Before Running A Part

Before running parts on the control, be sure the following steps have happened after starting the control software:

  • Machine is homed
  • Wheel is loaded and calibrated
  • Dresser diamond positions have been taught
  • Safety clearance positions have been taught
  • Centerline of part is correct

Calibrating a Wheel

  1. Navigate to the Calibrate tab
  2. Select the tool number near the bottom of the screen to save the settings to
  3. Mount the wheel in the machine
  4. Navigate to the Grinder Setup - Wheel Head Setup page
  5. Fill in all known wheel data
  6. Dress the wheel
  7. Navigate to the Calibrate tab
  8. Touch Z axis to a shoulder of a part and press Teach Z
  9. Enter the desired Z position in the Measured Z field and press Update
  10. Touch X axis to the part and press Teach X
  11. Measure the X axis at that position and enter the value into Measured X and press Update

Use the X Correction and Z Correction fields to adjust the part positions by distance values and pressing Update

Adding a New Dresser

  1. Navigate to the Grinder Setup - Dresser Setup page
  2. Select the type of dresser that is on the machine to enable the teach buttons

    If the teach buttons do not enable, verify that the tool number loaded is not 0 in the TOOL DISPLAY section

  3. For each diamond, jog the wheel into place and press the corresponding Teach buttons for X and Z axes
  4. If dressing a form or taper on a new wheel. enter the desired offsets in the "New Wheel Teach Offsets" box to shift the dress start positions.
  5. Select the “Tip Radius box, enter the radius size of the dresser point.

Loading a Job to Run

  1. Navigate to the Run page
  2. In the File group, press the Load button
  3. Use the File Navigator window to select the job file to run.

    The file extension must be .nc or .tap

Creating a New Conversational Job

  1. Navigate to the Conversational page
  2. Press the icon for a new file, near the top left corner
    new_file.PNG
  3. Add cycles to the job
  4. Press the Post button near the bottom left corner to save and load the job for execution

Loading a Conversational Job for Edit

  1. Navigate to the Conversational page
  2. Press the icon for load file, near the top left corner
    load_file.PNG
  3. Use the File Navigator window to select the job for edit

    The file extension must be .ini

    The job file must have been previously created by the conversational page

  4. Double-click on cycles to edit them or add more cycles to the job
  5. Press the Post button near the bottom left corner to save and load the job for execution

Configuring Flagging Device

  1. Navigate to the Grinder Setup - Measuring Devices page
  2. Jog the X and Z axis to a safe position for the flag to use as the Swivel Position and press the two yellow TEACH buttons.
  3. Enter the probe stylus/tip diameter in the DRO labeled Tip Diameter
  4. Enter the appropriate feedrate to be used on the initial search for the shoulder into the DRO labeled Fast Feedrate.
  5. Enter the appropriate feedrate to be used on the final search for the shoulder into the DRO labeled Slow Feedrate.
  6. Enter the appropriate distance for the probe to back away from the shoulder on the second touch into the DRO labeled Back-Off Distance.
  7. Press the button labeled Calibrate Flag to open the calibration wizard and setup the X and Z axis offsets for the probe.

Grinding Cycles

Dressing Cycles

Positioning to Dress

When a dressing cycle is called the machine will always follow the following path from the part to the dresser, in order to avoid collisions with the part and the diamond.

G251: Dress Taper Face 1, Left

The G251 cycle dresses a taper on the left face. It can increment in on just the X axis, just the Z axis, or on both axes.

The size of the phase height, relief height, and relief angle are all set on the Wheel Head Setup page.

Parameters:

    • D: The infeed increment to remove from the wheel on each pass.
    • E: The number of passes to make across the wheel.
    • F: The feedrate to use while dressing wheel.
    • I: The height of the taper to put on the wheel (X direction).
    • J: The angle of the taper to put on the wheel.
    • K: The length of the taper to put on the wheel (Z direction).
    • [M]: Passing in a 1 to the M parameter will force dressing. If the parameter is not given and the number of parts per dressing has not been met, then dressing will be skipped.
    • [R]: Passing in a 1 to the R parameter will skip setting tool offsets and wheel sizes.
    • [Q]: Selects the compensation direction used during the dressing cycles. By default, the compensation is only in the X direction, changing the diameter of the wheel. If a 1 is passed to the Q parameter, then compensation will be in the Z direction, narrowing the wheel. If a 2 is passed to the Q parameter, then compensation will be in the X and Z directions, changing the diameter and narrowing the wheel.

Only two of the parameters I, J, K are required.

Example:

G00 G40 G54 G64 G80 G90.1 G98 G18 G20	(Safe Start Line)
T0101 									(Call wheel type)
G251 D0.0003 F10 E4 I1.0 J45.0			(Wheel Dress)
M30                                     (End program)
%                                       (EOB)
G252: Dress Taper Face 2, Right

The G252 cycle dresses a taper on the right face. It can increment in on just the X axis, just the Z axis, or on both axes.

The size of the phase height, relief height, and relief angle are all set on the Wheel Head Setup page.

Parameters:

    • D: The infeed increment to remove from the wheel on each pass.
    • E: The number of passes to make across the wheel.
    • F: The feedrate to use while dressing wheel.
    • I: The height of the taper to put on the wheel (X direction).
    • J: The angle of the taper to put on the wheel.
    • K: The length of the taper to put on the wheel (Z direction).
    • [M]: Passing in a 1 to the M parameter will force dressing. If the parameter is not given and the number of parts per dressing has not been met, then dressing will be skipped.
    • [R]: Passing in a 1 to the R parameter will skip setting tool offsets and wheel sizes.
    • [Q]: Selects the compensation direction used during the dressing cycles. By default, the compensation is only in the X direction, changing the diameter of the wheel. If a 1 is passed to the Q parameter, then compensation will be in the Z direction, narrowing the wheel. If a 2 is passed to the Q parameter, then compensation will be in the X and Z directions, changing the diameter and narrowing the wheel.

Only two of the parameters I, J, K are required.

Example:

G00 G40 G54 G64 G80 G90.1 G98 G18 G20	(Safe Start Line)
T0101 									(Call wheel type)
G252 D0.0003 F10 E4 I1.0 J45.0			(Wheel Dress)
M30                                     (End program)
%                                       (EOB)
G253: Dress Circumference and Taper Face 1, Left

The G253 cycle dresses the circumference of the wheel and puts a taper on the left face. It can increment in on just the X axis, just the Z axis, or on both axes.

The size of the phase height, relief height, and relief angle are all set on the Wheel Head Setup page.

Parameters:

    • D: The infeed increment to remove from the wheel on each pass.
    • E: The number of passes to make across the wheel.
    • F: The feedrate to use while dressing wheel.
    • I: The height of the taper to put on the wheel (X direction).
    • J: The angle of the taper to put on the wheel.
    • K: The length of the taper to put on the wheel (Z direction).
    • [M]: Passing in a 1 to the M parameter will force dressing. If the parameter is not given and the number of parts per dressing has not been met, then dressing will be skipped.
    • [R]: Passing in a 1 to the R parameter will skip setting tool offsets and wheel sizes.
    • [Q]: Selects the compensation direction used during the dressing cycles. By default, the compensation is only in the X direction, changing the diameter of the wheel. If a 1 is passed to the Q parameter, then compensation will be in the Z direction, narrowing the wheel. If a 2 is passed to the Q parameter, then compensation will be in the X and Z directions, changing the diameter and narrowing the wheel.

Only two of the parameters I, J, K are required.

Example:

G00 G40 G54 G64 G80 G90.1 G98 G18 G20	(Safe Start Line)
T0101 									(Call wheel type)
G253 D0.0003 F10 E4 I1.0 J45.0			(Wheel Dress)
M30                                     (End program)
%                                       (EOB)
G254: Dress Circumference and Taper Face 2, Right

The G254 cycle dresses the circumference of the wheel and puts a taper on the right face. It can increment in on just the X axis, just the Z axis, or on both axes.

The size of the phase height, relief height, and relief angle are all set on the Wheel Head Setup page.

Parameters:

    • D: The infeed increment to remove from the wheel on each pass.
    • E: The number of passes to make across the wheel.
    • F: The feedrate to use while dressing wheel.
    • I: The height of the taper to put on the wheel (X direction).
    • J: The angle of the taper to put on the wheel.
    • K: The length of the taper to put on the wheel (Z direction).
    • [M]: Passing in a 1 to the M parameter will force dressing. If the parameter is not given and the number of parts per dressing has not been met, then dressing will be skipped.
    • [R]: Passing in a 1 to the R parameter will skip setting tool offsets and wheel sizes.
    • [Q]: Selects the compensation direction used during the dressing cycles. By default, the compensation is only in the X direction, changing the diameter of the wheel. If a 1 is passed to the Q parameter, then compensation will be in the Z direction, narrowing the wheel. If a 2 is passed to the Q parameter, then compensation will be in the X and Z directions, changing the diameter and narrowing the wheel.

Only two of the parameters I, J, K are required.

Example:

G00 G40 G54 G64 G80 G90.1 G98 G18 G20	(Safe Start Line)
T0101 									(Call wheel type)
G254 D0.0003 F10 E4 I1.0 J45.0			(Wheel Dress)
M30                                     (End program)
%                                       (EOB)
G255: Dress Circumference, Taper, Face 1 and Face 2

The G255 cycle dresses the circumference of the wheel and puts a taper on both faces. It can increment in on just the X axis, just the Z axis, or on both axes.

The size of the phase height, relief height, and relief angle are all set on the Wheel Head Setup page.

Parameters:

    • D: The infeed increment to remove from the wheel on each pass.
    • E: The number of passes to make across the wheel.
    • F: The feedrate to use while dressing wheel.
    • I: The height of the taper to put on the wheel (X direction).
    • J: The angle of the taper to put on the wheel.
    • K: The length of the taper to put on the wheel (Z direction).
    • [M]: Passing in a 1 to the M parameter will force dressing. If the parameter is not given and the number of parts per dressing has not been met, then dressing will be skipped.
    • [R]: Passing in a 1 to the R parameter will skip setting tool offsets and wheel sizes.
    • [Q]: Selects the compensation direction used during the dressing cycles. By default, the compensation is only in the X direction, changing the diameter of the wheel. If a 1 is passed to the Q parameter, then compensation will be in the Z direction, narrowing the wheel. If a 2 is passed to the Q parameter, then compensation will be in the X and Z directions, changing the diameter and narrowing the wheel.

Only two of the parameters I, J, K are required.

Example:

G00 G40 G54 G64 G80 G90.1 G98 G18 G20	(Safe Start Line)
T0101 									(Call wheel type)
G255 D0.0003 F10 E4 I1.0 J45.0			(Wheel Dress)
M30                                     (End program)
%                                       (EOB)
G260: Dress Circumference

The G260 cycle dresses along the circumference of the wheel, feeding in on the X axis towards the center of the wheel.

Parameters:

    • D: The infeed increment to remove from the wheel on each pass.
    • E: The number of passes to make across the wheel.
    • F: The feedrate to use while dressing wheel.
    • [M]: Passing in a 1 to the M parameter will force dressing. If the parameter is not given and the number of parts per dressing has not been met, then dressing will be skipped.
    • [R]: Passing in a 1 to the R parameter will skip setting tool offsets and wheel sizes.

Example:

G00 G40 G54 G64 G80 G90.1 G98 G18 G20	(Safe Start Line)
T0101 									(Call wheel type)
G260 D0.0003 F10 E4 					(Wheel Dress)
M30                                     (End program)
%                                       (EOB)
G261: Dress Face 1, Left

The G261 cycle dresses along the left face of the wheel, feeding in on the Z axis towards the center of the wheel.

The size of the phase height, relief height, and relief angle are all set on the Wheel Head Setup page.

Parameters:

    • D: The infeed increment to remove from the wheel on each pass.
    • E: The number of passes to make across the wheel.
    • F: The feedrate to use while dressing wheel.
    • [M]: Passing in a 1 to the M parameter will force dressing. If the parameter is not given and the number of parts per dressing has not been met, then dressing will be skipped.
    • [R]: Passing in a 1 to the R parameter will skip setting tool offsets and wheel sizes.

Example:

G00 G40 G54 G64 G80 G90.1 G98 G18 G20	(Safe Start Line)
T0101 									(Call wheel type)
G261 D0.0003 F10 E4 					(Wheel Dress)
M30                                     (End program)
%                                       (EOB)
G262: Dress Face 2, Right

The G262 cycle dresses along the right face of the wheel, feeding in on the Z axis towards the center of the wheel.

The size of the phase height, relief height, and relief angle are all set on the Wheel Head Setup page.

Parameters:

    • D: The infeed increment to remove from the wheel on each pass.
    • E: The number of passes to make across the wheel.
    • F: The feedrate to use while dressing wheel.
    • [M]: Passing in a 1 to the M parameter will force dressing. If the parameter is not given and the number of parts per dressing has not been met, then dressing will be skipped.
    • [R]: Passing in a 1 to the R parameter will skip setting tool offsets and wheel sizes.

Example:

G00 G40 G54 G64 G80 G90.1 G98 G18 G20	(Safe Start Line)
T0101 									(Call wheel type)
G262 D0.0003 F10 E4 					(Wheel Dress)
M30                                     (End program)
%                                       (EOB)
G263: Dress Circumference and Face 1, Left

The G263 dressing cycle dresses along the circumference of the wheel and the left face. It can increment in on just the X axis, just the Z axis, or on both axes.

The size of the corner radius, phase height, relief height, and relief angle are all set on the Wheel Head Setup page.

Parameters:

    • D: The infeed increment to remove from the wheel on each pass.
    • F: The feedrate to use while dressing wheel.
    • E: The number of passes to make across the wheel.
    • [M]: Passing in a 1 to the M parameter will force dressing. If the parameter is not given and the number of parts per dressing has not been met, then dressing will be skipped.
    • [R]: Passing in a 1 to the R parameter will skip setting tool offsets and wheel sizes.
    • [Q]: Selects the compensation direction used during the dressing cycles. By default, the compensation is only in the X direction, changing the diameter of the wheel. If a 1 is passed to the Q parameter, then compensation will be in the Z direction, narrowing the wheel. If a 2 is passed to the Q parameter, then compensation will be in the X and Z directions, changing the diameter and narrowing the wheel.

Example:

G00 G40 G54 G64 G80 G90.1 G98 G18 G20	(Safe Start Line)
T0101 									(Call wheel type)
G263 D0.0003 F10 E4 					(Wheel Dress)
M30                                     (End program)
%                                       (EOB)
G264: Dress Circumference and Face 2, Right

The G264 dressing cycle dresses along the circumference of the wheel and the right face. It can increment in on just the X axis, just the Z axis, or on both axes.

The size of the corner radius, phase height, relief height, and relief angle are all set on the Wheel Head Setup page.

Parameters:

    • D: The infeed increment to remove from the wheel on each pass.
    • E: The number of passes to make across the wheel.
    • F: The feedrate to use while dressing wheel.
    • I: The height of the taper to put on the wheel (X direction).
    • J: The angle of the taper to put on the wheel.
    • K: The length of the taper to put on the wheel (Z direction).
    • [M]: Passing in a 1 to the M parameter will force dressing. If the parameter is not given and the number of parts per dressing has not been met, then dressing will be skipped.
    • [R]: Passing in a 1 to the R parameter will skip setting tool offsets and wheel sizes.
    • [Q]: Selects the compensation direction used during the dressing cycles. By default, the compensation is only in the X direction, changing the diameter of the wheel. If a 1 is passed to the Q parameter, then compensation will be in the Z direction, narrowing the wheel. If a 2 is passed to the Q parameter, then compensation will be in the X and Z directions, changing the diameter and narrowing the wheel.

Example:

G00 G40 G54 G64 G80 G90.1 G98 G18 G20	(Safe Start Line)
T0101 									(Call wheel type)
G264 D0.0003 F10 E4 					(Wheel Dress)
M30                                     (End program)
%                                       (EOB)
G266: Roll (Crush) Dressing

The G266 roll dressing cycle brings the wheel to the start position and then increments into the diamond by set amounts. Between each infeed, there is an optional dwell time.

Parameters:

    • D: Infeed increment amount to feed into the wheel on each pass
    • E: The number of passes to make across the wheel.
    • F: The feedrate to dress at while feeding into the diamond.
    • [H]: The amount of time to dwell between each infeed, in seconds. Defaults to 0.
    • [M]: Dressing may be skipped if the number of parts made since last dress has not met the required number. In order to force dressing, pass in a 1 to the M parameter.
    • [R]: Passing in a 1 to the R parameter will stop the dressing cycle from updating offsets or wheel size during dressing.

Example:

G00 G40 G54 G64 G80 G90.1 G98 G18 G20	(Safe Start Line)
T0101 									(Call wheel type)
G266 D0.0003 F10 E2 					(Wheel Dress)
M30                                     (End program)
%                                       (EOB)
G269: Profile Dressing

The G269 profile dressing cycle runs a profile routine written by an operator. It will increment in a given number of times and repeatedly run the same profile.

Parameters:

    • D: Infeed increment amount to feed into the wheel on each pass.
    • E: The number of passes to make across the wheel.
    • F: The feedrate to dress at while feeding into the diamond.
    • P: The program number to run to cut the profile.
    • [M]: Passing in a 1 to the M parameter will force dressing. If the parameter is not given and the number of parts per dressing has not been met, then dressing will be skipped.
    • [R]: Passing in a 1 to the R parameter will skip setting tool offsets and wheel sizes.
    • [Q]: Selects the compensation direction used during the dressing cycles. By default, the compensation is only in the X direction, changing the diameter of the wheel. If a 1 is passed to the Q parameter, then compensation will be in the Z direction, narrowing the wheel. If a 2 is passed to the Q parameter, then compensation will be in the X and Z directions, changing the diameter and narrowing the wheel.

Grinding Cycles

G200: Rapid to Safety Positions

G200 commands a return to the safety positions. The safety positions are configured machine coordinates that can be set on safety page.

Parameters:

    • E: Safety position selection
      • E1: Part safety position
      • E2: Dresser safety position

Example:

G00 G40 G54 G64 G80 G90.1 G98 G18 G18 G20		(Safe Start Line)
T0101											(Call wheel type)
G200 E1											(Move to safety positions)
M3 S100                              			(Workhead on CW @ 100 RPM)
G271 X2.050 Z0.000 F10.000 H1.000				(Swing Position 1 Definition, Left)
G272 R3.000 F20.000 H2.000						(Swing Position 2 Definition, Right)
G288 											(Handwheel Infeed Cycle)
G200 E1											(Move to part safety position)
M30												(Program Rewind)
%												(EOB)
G271: Approach Swing Position 1, Left

G271 and G272 collectively define a section of the work piece for grinding. They define the swing positions, swing feedrates, and dwell times to be used for any applicable cycles that are called in the program afterwards. Both G271 and G272 must be called in the program before the following cycles can be used:

Parameters:

    • X: The starting diameter, in part coordinates, for all applicable cycles.
    • Z: The left swing position in part coordinates of the section being defined.
    • [E]: The Part Correction Offset number (0-99). Applies a correction to X and Z axes. This is used to make small corrections to the different diameters or shoulders on the part.
    • F: The feedrate used while feeding towards swing position 2 (right).
    • [H]: The time, in seconds, the machine will dwell after reaching the defined position. If unspecified, the value will default to 0.
    • [W]: Z offset

Example:

G00 G40 G54 G64 G80 G90.1 G98 G18 G18 G20		(Safe Start Line)
T0101											(Call wheel type)
G200 E1											(Move to safety positions)
M3 S100                              			(Workhead on CW @ 100 RPM)
G271 X2.050 Z0.000 F10.000 H1.000				(Swing Position 1 Definition, Left)
G272 R3.000 F20.000 H2.000						(Swing Position 2 Definition, Right)
G288 											(Handwheel Infeed Cycle)
G200 E1											(Move to safety positions)
M30												(Program Rewind)
%												(EOB)

If either G271 or G272 are not specified in the program before the applicable cycles, the machine will enter an alarm state and the program will be stopped.

G272: Approach Swing Position 2, Right

G271 and G272 collectively define a section of the work piece for grinding. They define the swing positions, swing feedrates, and dwell times to be used for any applicable cycles that are called in the program afterwards. Both G271 and G272 must be called in the program before the following cycles can be used:

Parameters:

    • R: The distance between the P1 and P2 positions. This value must be greater than the wheel width.
    • F: The feedrate used while feeding towards the defined position.
    • [H]: The time, in seconds, the machine will dwell after reaching the defined position. If unspecified, the value will default to 0.

Example:

G00 G40 G54 G64 G80 G90.1 G98 G18 G18 G20		(Safe Start Line)
T0101											(Call wheel type)
G200 E1											(Move to safety positions)
M3 S100                              			(Workhead on CW @ 100 RPM)
G271 X2.050 Z0.000 F10.000 H1.000				(Swing Position 1 Definition, Left)
G272 R3.000 F20.000 H2.000						(Swing Position 2 Definition, Right)
G288 											(Handwheel Infeed Cycle)
G200 E1											(Move to safety positions)
M30												(Program Rewind)
%												(EOB)

If either G271 or G272 are not specified in the program before the applicable cycles, the machine will enter an alarm state and the program will be stopped.

G273: Approach Oscillating Position

G273 is used in conjunction with G283 for grinding narrower features. When Invoked, the wheel will rapid to the X and Z start positions and set the oscillation stroke, which is one half the distance specified in parameter "D" in each directon.

Parameters:

  • X: X start position
  • Z: Z start position
  • D: Oscillation stroke distance
  • [E]: The Part Correction Offset number (0-99). Applies a correction to X and Z axes.  This is used to make small corrections to the different diameters or shoulders on the part.
  • [F]: Traverse feedrate
  • [H]: Number of spark passes

Example:

G00 G40 G54 G64 G80 G90.1 G98 G18 G18 G20		(Safe Start Line)
T0101											(Call wheel type)
G200 E1											(Move to safety positions)
M3 S100                              			(Workhead on CW @ 100 RPM)
G273 X2.050 Z-2.000 D1.000						(Oscillation Position Definition)
G283 X2.000 D0.005 F0.100 H1.000				(Continuous Infeed Cycle)
G200 E1											(Move to safety positions)
M30												(Program Rewind)
%												(EOB)
G274: Multiple Plunge Grind

G274 does a set of plunge grinds between the positions defined in G271 and G272, moving the wheel over by a percentage of the wheel width for each plunge. The plunge amount is the diameter defined by the finish diameter plus the allowance amount. Each plunge can have a dwell at the bottom for a specified number of seconds.

Parameters:

    • X: The final diameter to grind to in this cycle.
    • [A]: The allowance to leave on the final grind diameter. Defaults to 0.
    • [W]: The percent of wheel to step over on each plunge. Defaults to 90.
    • F: The feedrate to plunge in on the X axis.
    • [H]: The amount of time to dwell after each plunge completes. Default is 0.

Example:

G00 G40 G54 G64 G80 G90.1 G98 G18 G20	(Safe Start Line)
T0101 									(Call wheel type)
G200 E1 								(Move to safety position)
G260 D0.0003 F10 E2 					(Wheel Dress before rough grind)
M3 S100                              	(Workhead on CW @ 100 RPM)
G271 X1.010 Z0.0 F10         			(Define left start position and rapid to position)
G272 R3.5 F10                      		(Define traverse distance between left and right side of wheel)
G274 X1.0 A.001 W75 H2     				(Multi-step plunge grind. Target position X, Allowance A, Step over percent W, Dwell H)
G260 D0.0003 F10 E2            			(Wheel Dress before finish grind)
G281 X1.0 A0.0 D0.0001 H2   			(Target position X, Allowance A, Infeed D, Sparkouts H)
G280                                    (End macro)
G200 E1                                	(Move to safety position)
M30                                     (End program)
%                                       (EOB)
G276: Approach Plunge Position

G276 sets the starting position for any following G287 plunge cycles and moves into position, as Z axis then X axis.

Parameters:

    • X: Defines the starting X diameter for subsequent plunge cycles
    • Z: Defines the starting Z position for subsequent plunge cycles

Example:

G00 G40 G54 G64 G80 G90.1 G98 G18 G20	(Safe Start Line)
T0101 									(Call wheel type)
G200 E1 								(Move to safety position)
G260 D0.0003 F10 E2 					(Wheel Dress before rough grind)
M3 S100                              	(Workhead on CW @ 100 RPM)
G276 X1.010 Z0.0	         			(Define plunge grind start position and rapid to position)
G287 X1.0 Z-0.02 F0.001 H2   			(Target position X, Target position Z, Feedrate F, Sparkout time H)
G280                                    (End macro)
G200 E1                                	(Move to safety position)
M30                                     (End program)
%                                       (EOB)
G280: End of Grind Cycle

G280 will reset the dressing flag and clears grinding data.

G281: Traverse Grind with Infeed at Swing Position 1, Left

G281 does a traverse grind between the positions defined in G271 and G272 while infeeding the wheel incrementally by a defined infeed amount each time the wheel reaches swing position 1 (left), until the diameter defined by the finish diameter plus allowance amount has been reached, at which point a specified number of spark passes will happen.

Parameters:

    • D: The infeed increment that X axis feeds in by each time the Z axis reaches swing position 1, left
    • X: The final diameter to grind to during this cycle
    • F: The feedrate to feed in at the X axis
    • [A]: The allowance to leave on the final grind diameter. Defaults to 0.
    • [H]: The number of spark passes to do after the grind completes. Default is 0.

Example:

G00 G40 G54 G64 G80 G90.1 G98 G18 G20	(Safe Start Line)
T0101 									(Call wheel type)
G200 E1 								(Move to safety position)
G260 D0.0003 F10 E2 					(Wheel Dress before rough grind)
M3 S100                              	(Workhead on CW @ 100 RPM)
G271 X 1.010 Z0.0 F10         			(Define left start position and rapid to position)
G272 R3.5 F10                      		(Define traverse distance between left and right side of wheel)
G274 X1.0 A.001 W75 H2     				(Multi-step plunge grind. Target position X, Allowance A, Step over percent W, Dwell H)
G260 D0.0003 F10 E2            			(Wheel Dress before finish grind)
G281 X1.0 A0.0 D0.0001 H2  				(Target position X, Allowance A, Infeed D, Sparkouts H)
G280                                    (End macro)
G200 E1                                	(Move to safety position)
M30                                     (End program)
%                                       (EOB)
G282: Traverse Grind with Infeed at Swing Position 2, Right

G282 does a traverse grind between the positions defined in G271 and G272 while infeeding the wheel incrementally by a defined infeed amount each time the wheel reaches swing position 2 (right), until the diameter defined by the finish diameter plus allowance amount has been reached, at which point a specified number of spark passes will happen.

Parameters:

    • D: The infeed increment that X axis feeds in by each time the Z axis reaches swing position 2, right
    • X: The final diameter to grind to during this cycle
    • F: The feedrate to feed in at the X axis
    • [A]: The allowance to leave on the final grind diameter. Defaults to 0.
    • [H]: The number of spark passes to do after the grind completes. Default is 0.

Example:

G00 G40 G54 G64 G80 G90.1 G98 G18 G20	(Safe Start Line)
T0101 									(Call wheel type)
G200 E1 								(Move to safety position)
G260 D0.0003 F10 E2 					(Wheel Dress before rough grind)
M3 S100                              	(Workhead on CW @ 100 RPM)
G271 X 1.010 Z0.0 F10         			(Define left start position and rapid to position)
G272 R3.5 F10                      		(Define traverse distance between left and right side of wheel)
G274 X1.0 A.001 W75 H2     				(Multi-step plunge grind. Target position X, Allowance A, Step over percent W, Dwell H)
G260 D0.0003 F10 E2            			(Wheel Dress before finish grind)
G282 X1.0 A0.0 D0.0001 H2   			(Target position X, Allowance A, Infeed D, Sparkouts H)
G280                                    (End macro)
G200 E1                                	(Move to safety position)
M30                                     (End program)
%                                       (EOB)
G283: Continuous Infeed Grind

G283 is used in conjunction with G273 for grinding narrower features. When invoked, the wheel will rapid to the X and Z start positions and set the oscillation stroke defined with G273. The wheel will then feed in the specified "D" distance in X while traversing in each Z direction.

Parameters:

    • X: The final diameter to grind to during this cycle
    • D: The infeed increment that X axis feeds in by on each pass
    • [A]: The allowance to leave on the final grind diameter. Defaults to 0.
    • F: The feedrate to move at during this cycle
    • [H]: The number of spark passes to do after the grind completes. Default is 0.

Example:

G00 G40 G54 G64 G80 G90.1 G98 G18 G18 G20		(Safe Start Line)
T0101											(Call wheel type)
G200 E1											(Move to safety positions)
M3 S100                              			(Workhead on CW @ 100 RPM)
G273 X2.050 Z-2.000 D1.000 F10.000 H1.000		(Oscillation Position Definition, Left)
G283 X2.000 D0.005 F0.100						(Continuous Infeed Cycle)
G200 E1											(Move to safety positions)
M30												(Program Rewind)
%												(EOB)
G284: Traverse Grind with Infeed at Both Swing Positions

G284 does a traverse grind between the positions defined in G271 and G272 while infeeding the wheel incrementally by a defined infeed amount at each swing position, until the diameter defined by the finish diameter plus allowance amount has been reached, at which point a specified number of spark passes will happen.

Parameters:

    • D: The infeed increment that X axis feeds in by each time the Z axis reaches a swing position
    • X: The final diameter to grind to during this cycle
    • F: The feedrate to feed in at the X axis
    • [A]: The allowance to leave on the final grind diameter. Defaults to 0.
    • [H]: The number of spark passes to do after the grind completes. Default is 0.

Example:

G00 G40 G54 G64 G80 G90.1 G98 G18 G20	(Safe Start Line)
T0101 									(Call wheel type)
G200 E1 								(Move to safety position)
G260 D0.0003 F10 E2 					(Wheel Dress before rough grind)
M3 S100                              	(Workhead on CW @ 100 RPM)
G271 X 1.010 Z0.0 F10         			(Define left start position and rapid to position)
G272 R3.5 F10                      		(Define traverse distance between left and right side of wheel)
G274 X1.0 A0.001 W75 H2    				(Multi-step plunge grind. Target position X, Allowance A, Step over percent W, Dwell H)
G260 D0.0003 F10 E2            			(Wheel Dress before finish grind)
G284 X1.0 A0.0 D0.0001 H2   			(Target position X, Allowance A, Infeed D, Sparkouts H)
G280                                    (End macro)
G200 E1                                	(Move to safety position)
M30                                     (End program)
%                                       (EOB)
G285: Shoulder Grind at Swing Position 1, Left

G285 works with G271 and G272 or G273. G285 does a shoulder grind in the negative Z direction, starting from swing position 1, left. This means it will move outside of the area defined by G271 and G272. G285 will grind to a defined Z position, leaving space for an optional stock allowance.

Parameters:

    • Z: The Z target position to grind to.
    • [X]: The diameter to rapid X to before grinding in the Z direction.
    • D: Feedrate to move the Z axis at.
    • [A]: The allowance to leave on the final grind position. Defaults to 0.
    • [H]: The amount of spark out time once final grind position is reached. Defaults to 0.

Example:

G00 G40 G54 G64 G80 G90.1 G98 G18 G18 G20		(Safe Start Line)
T0101											(Call wheel type)
G200 E1											(Move to safety positions)
M3 S100                              			(Workhead on CW @ 100 RPM)
G271 X2.050 Z0.000 F10.000 H1.000				(Swing Position 1 Definition, Left)
G272 R3.000 F20.000 H2.000						(Swing Position 2 Definition, Right)
G285 Z-1.000 D0.005								(Left Shoulder Grind Cycle)
G200 E1											(Move to safety positions)
M30												(Program Rewind)
%												(EOB)
G286: Shoulder Grind at Swing Position 2, Right

G286 works with G271 and G272 or G273. G286 does a shoulder grind in the positive Z direction, starting from swing position 2, right. This means it will move outside of the area defined by G271 and G272. G286 will grind to a defined Z position, leaving space for an optional stock allowance.

Parameters:

    • Z: The Z target position to grind to.
    • [X]: The diameter to rapid X to before grinding in the Z direction.
    • D: Feedrate to move the Z axis at.
    • [A]: The allowance to leave on the final grind position. Defaults to 0.
    • [H]: The amount of spark out time once final grind position is reached. Defaults to 0.

Example:

G00 G40 G54 G64 G80 G90.1 G98 G18 G18 G20		(Safe Start Line)
T0101											(Call wheel type)
G200 E1											(Move to safety positions)
M3 S100                              			(Workhead on CW @ 100 RPM)
G271 X2.050 Z0.000 F10.000 H1.000				(Swing Position 1 Definition, Left)
G272 R3.000 F20.000 H2.000						(Swing Position 2 Definition, Right)
G286 Z4.000 D0.005								(Right Shoulder Grind Cycle)
G200 E1											(Move to safety positions)
M30												(Program Rewind)
%												(EOB)
G287: Plunge Infeed Grind

G287 is used in conjunction with G276 for two axis plunge grinding. G276 defines the start point of the grind and G287 defines the ending position of the plunge grind.

Parameters:

    • [X]: The final X diameter to plunge to
    • [Z]: The final Z position to plunge to
    • [A]: The allowance to leave on final grind position in both X and Z axes. Default is 0.
    • F: The feedrate to plunge grind at.
    • [H]: The amount of time to dwell after reaching plunge depth. Defaults to 0.

At least one of X or Z must be called in the cycle, if not both axes.

Example:

G00 G40 G54 G64 G80 G90.1 G98 G18 G20	(Safe Start Line)
T0101 									(Call wheel type)
G200 E1 								(Move to safety position)
G260 D0.0003 F10 E2 					(Wheel Dress before rough grind)
M3 S100                              	(Workhead on CW @ 100 RPM)
G276 X1.010 Z0.0	         			(Define plunge grind start position and rapid to position)
G287 X1.0 Z-0.02 F0.001 H2   			(Target position X, Target position Z, Feedrate F, Sparkout time H)
G280                                    (End macro)
G200 E1                                	(Move to safety position)
M30                                     (End program)
%                                       (EOB)
G288: Handwheel Infeed Cycle

This cycle allows the operator to manually jog the X axis with the MPG handwheel or operator panel while the Z axis maintains the motion defined by G271 and G272. The cycle will continue until the operator presses Cycle Start or stops the program. Jogging on all axes other than X will be disabled during this cycle. There are no parameters for this cycle.

Upon pressing Cycle Start, the operator will be presented with a confirmation dialog on the control screen that they wish to end the handwheel infeed cycle. If they select 'No', the cycle will continue until they choose to end it again. If they select 'Yes', then the Z axis will continue its cycling until it reaches swing position 1, defined by G271, and then the main program will continue. While the axis is returning to swing position 1, a progress dialog will be displayed on the control screen.

If the operator presses Feedhold during the handwheel cycle, the Z axis will continue until it reaches the next swing position, and then stop there until Cycle Start is pressed or the program is stopped.

If the operator presses Cycle Stop while this cycle is running, the Z axis will stop without returning to either swing position. To control the distance that the axis takes to stop, set the parameter in MachMotion Configuration for Reciprocating Axis - Z Axis - Cycle Stop Distance.

Example:

G00 G40 G54 G64 G80 G90.1 G98 G18 G18 G20		(Safe Start Line)
T0101											(Call wheel type)
G200 E1											(Move to safety positions)
M3 S100                              			(Workhead on CW @ 100 RPM)
G271 X2.050 Z0.000 F10.000 H1.000				(Swing Position 1 Definition, Left)
G272 R3.000 F20.000 H2.000						(Swing Position 2 Definition, Right)
G288 											(Handwheel Infeed Cycle)
G200 E1											(Move to safety positions)
M30												(Program Rewind)
%												(EOB)
G289: Relieve

G289 performs a retract in X and Z axes. The cycle preceding G289 determines which axis and the direction of the retract. If G289 follows G281, G282, G283, G284, or G288, then the retract will be a positive X axis move. If G289 follows G285, then the retract will be a positive Z axis move. If G289 follows G286, then the retract will be a negative X axis move.

Parameters:

    • [W]: Relieve amount
    • [F]: Feedrate

Example:

G00 G40 G54 G64 G80 G90.1 G98 G18 G18 G20		(Safe Start Line)
T0101											(Call wheel type)
G200 E1											(Move to safety positions)
M3 S100                              			(Workhead on CW @ 100 RPM)
G271 X2.050 Z0.000 F10.000 H1.000				(Swing Position 1 Definition, Left)
G272 R3.000 F20.000 H2.000						(Swing Position 2 Definition, Right)
G288 											(Handwheel Infeed Cycle)
G289											(Retract)
M30												(Program Rewind)
%												(EOB)

Measuring Cycles

G230: Active Flagging with Probe

Flagging is used to find a shoulder on the part.  When G230 is called the X axis will move to the X swivel position followed by the Z axis.  The flagging slide will extend and then the Z axis will move to the Z start position followed by the X axis. The probing cycle will start with the Z axis moving at the calibrated fast feedrate. When the shoulder is detected, the probe will back off and probe again at the calibrated slow feedrate.  The K parameter will be written to the current fixture offset (which defaults to G54) and the fixture table will be saved. The probe will move back to the start position, then back to the swivel position, and then retract.

Parameters:

    • X: The start position X will rapid to before starting the flagging routine, after flag is extended.
    • Z: The start position Z will rapid to before starting the flagging routine, after flag is extended.
    • W: The distance Z will move searching for a shoulder, which can be positive or negative to indicate direction of travel.
    • [E]: Selects between flagging the part and calibrating the probe. E1 will calibrate the probe. Defaults to 0 for normal flagging.
    • [K]: The Z position used to calibrate the shoulder. Default is 0.
    • [R]: Indicates if to retract the probe at the end of cycle. A value of 1 will leave the probe extended at the end of the cycle. Default is 0 to retract the probe.

Example:

G00 G40 G54 G64 G80 G90.1 G98 G18 G18 G20		(Safe Start Line)
T0101											(Call wheel type)
M5		                             			(Workhead off)
G230 X2.0 Z0.2 W-1.0 K0.0						(Active Flagging Cycle)
M30												(Program Rewind)
%												(EOB)

When the flagging device is extended the X and Z axis reference switches from the wheel to the probe tip.

Path to swivel position and extend flagging probe:

Path to part from swivel position:

Flagging move from X and Z start position:

Appendix

Cycle States

0 Idle
1 Positioning
2 Spark-out
3 Finished
4 Free Pass
100 Grinding
101 Positioning
102 Spark-out
103 Finished
104 Free Pass
105 Moving to Grind Position
106 Gap Control Grinding
200 Dressing
201 Positioning
202 Spark-out
203 Finished
204 Free Pass
205 Moving to Dress Position
206 Returning from Dress Position
207 Gap Control Dressing

 

Cycle Types

251 Dress Taper Face 1
252 Dress Taper Face 2
253 Dress CIRCUM and Taper Face 1
254 Dress CIRCUM and Taper Face 2
255 Dress CIRCUM, Taper and Faces
260 Dress Circumference
261 Dress Face 1
262 Dress Face 2
263 Dress Circumference and Face 1
264 Dress Circumference and Face 2
265 Dress Circumference and Both Faces
268 Roll Dress
269 Profile Dress
296 Dress for Taper Grind
271 Approach Swing Position 1
272 Approach Swing Position 2
273 Approach Oscillating Position
274 Multiple Plunge Grind
275 Profile Grind
276 Approach Plunge Position
280 End of Grind Cycle
281 Infeed in the Swing Position 1
282 Infeed in the Swing Position 2
283 Oscillation Infeed
284 Infeeds in both Swing Positions
285 Shoulder Grind in Swing Position 1
286 Shoulder Grind in Swing Position 2
287 Plunge Infeed Grind
288 Handwheel Infeed
289 Relieve
295 Shoulder Plunge Grind
297 Taper Grind

 

Wheel Head Memory

Pound Variable Description
#9000 Diameter
#9001 Effective Width
#9002 Overhang
#9003 Minimum Diameter
#9004 Minimum Width
#9005 Working Angle
#9006 Corner Radius Left
#9007 Relief Angle Left
#9008 Relief Height Left
#9009 Corner Radius Right
#9010 Relief Angle Right
#9011 Relief Height Right
#9012 Phase Height Left
#9013 Phase Height Right
#9014 Max Wheel RPM
#9015 Wheel SFM
#9016 Wheel RPM
#9017 Dresser Diamond Type
#9018 X Position Diamond 1
#9019 Z Position Diamond 1
#9020 X Position Diamond 2
#9021 Z Position Diamond 2
#9022 X Position Diamond 3
#9023 Z Position Diamond 3
#9024 Tip Radius Diamond 1
#9025 Tip Radius Diamond 2
#9026 Tip Radius Diamond 3
#9027 Infeed Angle
#9028 Feed Factor 1
#9029 Feed Factor 2
#9030 Xsw Safety Position
#9031 Zs Safety Position
#9032 Xsd Safety Position
#9033 Deta X Safety Clearance
#9034 Deta ZL Safety Clearance
#9035 Deta ZR Safety Clearance
#9036 X Return Clearance
#9037 Z Return Clearance
#9040 Current Commanded RPM
#9041 Wheel Dressing SFM
#9042 Rotary Dresser Roll Diameter
#9043 Rotary Dresser SFM
#9044 Rotary Dresser RPM
#9045 Current Rotary Dresser Rpm
#9046 X Dresser Offset (Optional)
#9047 Rotary Dresser Maximum RPM
#9048 Wheel Speed Mode
#9049 Rotary Dresser Surface Feet Per Min Mode
#9050 Rotary Dresser Direction (0 = FWD,1 = REV)
#9051 Teach New Wheel Dresser Offset 1
#9052 Teach New Wheel Dresser Offset 2
#9060 Wheel Type
#9080 Current Cycle State
#9081 Current Cycle Type
#9082 Current Cycle Passes Remaining
#9083 Parts Per Dress Cycle
#9084 Parts Since Last Dress Cycle
#9085 Part Count On Last Dress Cycle
#9086 Parts Per Dress Cycle Enabled
#9100 Work Head Diameter

Active Flagging Memory

#9230

Active Flag X Swivel Position (Machine Zero)
#9231 Active Flag Z Swivel Position (Machine Zero)

#9232

Active Flag Tip Diameter
#9233 Active Flag Fast Feedrate
#9234 Active Flag Slow Feedrate
#9235 Active Flag Back-Off Distance
   
   
#9238 Active Flag X Measured Position
#9239 Active Flag Z Measured Position

Global Memory

#9250

Angle of last grind cycle
   
   
   
   
   
   
   
   
   

GCode Parameters

1900

Gap Control
1910 Wheel Diameter Lock (1 = Lock, 0 = Unlock)

1911

Wheel Width Lock (1 = Lock, 0 = Unlock)
   
   
   
   
   
   
   

Warranty Information

MachMotion warranty policy is subject to change. Updated information is available at our website:
https://machmotion.com/warranty

 

The MachMotion Team
http://www.machmotion.com
14518 County Road 7240, Newburg, MO 65550
(573) 368-7399 • Fax (573) 341-2672

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