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Process setting

Automated setting using probing can be up to 10 times quicker than manual methods.

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.

Ensure that first cuts are accurate

The Productive Process Pyramid™ - Process settingThe 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 …

  • OTS on machinelength 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 …

  • RLP40 touch probecomponent 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 …

  • AxiSet Check-Up sphere on 5-axis tablealignment 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.

 

Productive Process Patterns

  • (AP200) Productive Process Pattern: Part identification (AP200) Productive Process Pattern: 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.

  • (AP201) Productive Process Pattern: Intelligent program selection (AP201) Productive Process Pattern: 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.

  • (AP202) Productive Process Pattern: Part presence check (AP202) Productive Process Pattern: 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.

  • (AP203) Productive Process Pattern: Job set-up (AP203) Productive Process Pattern: 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.

  • (AP204) Productive Process Pattern: Tool setting (AP204) Productive Process Pattern: 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.

  • (AP205) Productive Process Pattern: Tool identification (AP205) Productive Process Pattern: 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.

  • (AP206) Productive Process Pattern: Machine capability check (AP206) Productive Process Pattern: 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.

  • (AP207) Productive Process Pattern: Clearance check (AP207) Productive Process Pattern: 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.

  • (AP208) Productive Process Pattern: Parametric programming (AP208) Productive Process Pattern: 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.

  • (AP209) Productive Process Pattern: Path optimisation (AP209) Productive Process Pattern: 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.

  • (AP210) Productive Process Pattern: Adaptive machining (AP210) Productive Process Pattern: Adaptive machining

    A manufacturing process may dictate that the form of a finished component is dependent on the form of the input material for that process. In these circumstances, it is necessary to measure the form of the input component and use the measurement to produce a customised cutting program which is unique to that component.

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