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Process setting

The controls in the process setting layer of the Productive Process Pyramid™ establish the relationships between the machine, the part and the tools before cutting starts. These automated, predictive controls ensure that the first cuts are correct.

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Ensure that first cuts are accurate

The Productive Process Pyramid™ - Process setting The process setting layer of the Pyramid deals with sources of variation such as the location of the part, the size of tools, and offsets on the machine, aligning the machining activities to the actual location of the part.

These are predictive controls applied just before metal cutting starts.

Tool setting establishes …

length from the spindle gauge-line to establish a height offset, and to check that length is within the specified tolerance
diameter when spinning to establish a tool size offset

Part setting establishes …

component identification to select the correct NC program
position of a datum feature to establish a work co-ordinate system (WCS)
billet/component size to determine stock condition and roughing cut sequence
orientation of a component (relative to machine axes) to establish the co-ordinate rotation

Machine setting establishes …

alignment of a rotary axis, indexer or fixturing elements required to position and hold components
position of an indexer's centre of rotation and/or reference points on fixture elements

Predictive controls

Automated setting using probing can be up to 10 times quicker than manual methods, freeing up more time for cutting metal.

Probing is also predictable – you'll know how long setting will take and can plan accordingly.

Setting processes that use on-machine probing can be fully program controlled, so that skilled operators are no longer needed to take measurements, make calculations and input offset changes.

Renishaw's workpiece inspection probes, tool setters and Productivity+™ software are essential tools for fast, automatic and repeatable set-up of metal cutting operations.

Workpiece inspection probes		Tool setters		Productivity+™
Workpiece inspection probes for automated measurement of component position and alignment.		Tool setters enable dynamic setting of cutting tools on the machine tool.		Productivity+™ enables tool and part setting to be seamlessly integrated with metal cutting.

Documents

[4.7MB] Metrology solutions for productive process control brochure
Transform your manufacturing performance with help from the process control experts
[1.5MB] Survival of the fittest - the process control imperative
In tough times, manufacturers focus on reducing their operating costs, but may not be able to afford to spend their way out by buying more productive machinery. With that pathway closed, what are the opportunities for radically reducing costs without replacing existing machines? This paper explores four areas where substantial savings can be found if firms are prepared to change the way they control their machining processes.

Productive Process Patterns

[400kB] (AP200) Part identification
Productive Process Pattern™ from the process setting layer of the Productive Process Pyramid™. Use a workpiece inspection probe to take measurements on the raw material (or previously machined features) to determine the identity of the component, the component alignment on the machine tool, and/or to check for non-conforming material.
[274kB] (AP201) Intelligent program selection
Productive Process Pattern™ from the process setting layer of the Productive Process Pyramid™. Use a workpiece inspection probe to determine whether the component blank loaded in the machine tool is the correct one for the machining program. Where a unique, identifiable feature exists on the component (or one can be added) a probe may be used to make a logical decision about which of the available cutting programs should be used.
[383kB] (AP202) Part presence check
Productive Process Pattern™ from the process setting layer of the Productive Process Pyramid™. Use a workpiece inspection probe to identify which components are actually present and should be machined. The probing results can be used to control program logic that determines whether to machine a component or to skip machining if no part is present.
[393kB] (AP203) Job set-up
Productive Process Pattern™ from the process setting layer of the Productive Process Pyramid™. Use a workpiece inspection probe to automatically measure the location of the component and update the relevant offset. Where appropriate, also use the probe to update the orientation of the component using a controller function or a rotary axis.
[654kB] (AP204) Tool setting
Productive Process Pattern™ from the process setting layer of the Productive Process Pyramid™. Use a tool setting probe mounted within the machine tool to automatically set the length and diameter of each tool before machining begins.
[1.2MB] (AP205) Tool identification
Productive Process Pattern™ from the process setting layer of the Productive Process Pyramid™. An on-machine tool setting system is used to establish tool length and diameter offsets when replacing tools. As a safety check, the measured values are compared against reference dimensions with a tolerance applied: if the tool length or diameter deviation is greater than the allowed tolerance, the process will stop safely before any machining takes place or any damage can occur.
[229kB] (AP206) Machine capability check
Productive Process Pattern™ from the process setting layer of the Productive Process Pyramid™. Use a workpiece inspection probe to perform a machine capability test before machining. Commence machining only if the machine is within the capability limits defined for the component. Measuring known reference features shows the machine is capable of positioning itself accurately and repeatably, or if there is a capability problem.
[221kB] (AP207) Clearance check
Productive Process Pattern™ from the process setting layer of the Productive Process Pyramid™. Use a workpiece inspection probe to test critical sections of a toolpath where interference is possible. The probe will stop when a collision is detected making it safe to perform this check: a cutting tool is not able to provide this feedback. Proceed with the machining process only after all potentially hazardous areas have been tested and probe results indicate that no obstacles exist within the tool path.
[414kB] (AP208) Parametric programming
Productive Process Pattern™ from the process setting layer of the Productive Process Pyramid™. Use a workpiece inspection probe to measure features which vary between parts within a given family and allocate macro variables for those feature measurements. Different parts can be produced by a family-specific rather than a part-specific program by controlling features that vary between parts using logic based on probe measurement results.
[345kB] (AP209) Path optimisation
Productive Process Pattern™ from the process setting layer of the Productive Process Pyramid™. Use a workpiece inspection probe to measure workpiece condition. Apply logic based on the measured stock size to control the cutting path so that air cutting is eliminated and machining moves always cut metal.

Next steps

Contact us online if you require more information or you have a pricing query, or alternatively you may like to speak directly to your local Renishaw office.