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1. 63 STARTINGEEASHGCUT CNG 4i eines Ibat PII 63 WindoWs 3 QT 3s N E EA EE EE AE E e ee e E 63 LAETI SU EE R E A R T AEE A A A A EATA 63 CONFIGURING FLASHCUT CNC ccccccccccssseseccccececaesesecccccescuassecccceeesaauseeccceeeseaaeseeccceeessuaesseecceesseaueeseeeecesseaaneees 63 LOADING G CODE BILE REI A e E E N E R E E a IR 64 VIEWING THE DOOLD PATH 5 E A AE 65 ANIMATING THE G CODE FILE cccccccsssssseccecceccesssecccccccccesessecccccecauauseeccccceesaausneeececessuaueasecccesesauuanececcessaauannes 67 BDITING A Giz CODE 3 5 rro tA ACERBA UR IRA RARIOR HARTE 68 CONNECTING THE MACHINE ONLINE 0sscccceccccesssseccccceccasesecccceeseauescecccceeecauueeeccecesseuanseeccccesssuuaeececceessauanees 70 USING THE JOG CONTROLS sssssecccccccccesseeeccccccceeseeecccccseeennsescecccseeeensescecccssuenneeececeseueansesececcesuenansessecesseeeenees 70 SETTING MACHINE ZERO 3 5 n neca D iei ia use Dy e 71 USING THE POINT MOVE econtra EE se ETE vedas ca RESTE Ee eR ENTE VR PETERE CENE OR VER 72 SETTING PROGRAM ZERO ON THE MACHINE 73 TESTING THE PROGRAM ON THE MACHINE 74 CUTTING THE PART 4i eceeuerdreeaieee ree amie peii rei PUE 75 EXITING THE PROGRAM EM RU E 75 TURNING OFF THE CONTROLLER
2. UedsvevsUedda e CEPR EVER 75 GLOSSARY 77 Section 1 FlashCut CNC Section 1 Getting Started 1 Getting Started Thank You Thank you for purchasing FlashCut CNC the affordable powerful CNC control system for Windows No other CNC system is easier to set up and use than FlashCut CNC We re sure you ll enjoy easy to use menus and real time graphics as you quickly and accurately cut parts on your machine tool We are committed to the excellence of FlashCut CNC Feel free to call us with any comments or questions Product Support We are committed to full support of FlashCut CNC products There are three support options Phone 650 853 1444 9 00 AM 5 00 PM Pac Time M F Fax 650 853 1405 24 hours a day 7 days a week E mail support flashcutcnc com 24 hours a day 7 days a week Web Site www flashcutcnc com 24 hours a day 7 days a week System Requirements IBM PC or 100 compatible with a 66MHz or faster 80486DX Pentium or higher CPU At least 8MB of RAM Hard drive with at least 20MB of space available 3 5 inch 1 44 MB floppy disk drive VGA SVGA or compatible video monitor A Microsoft compatible mouse Note that for best performance the mouse should connect directly to the bus the standard mouse plug on most systems or through
3. enne 49 G02 Clockwise Circular Cutting Move eese eene eene enne nennen enne 49 G03 Counter Clockwise Circular Cutting Move eese eene eene nennen nene neret nenee nene 51 OOE BILA CE 52 G17 G18 G19 Arc Plane 5 1 52 G20 G21 Inch Units and Metric UNnits ccccccccccccccssssssccccccccccsssecccccccccussseeccccssccuuseeeecccsssuuusseeecesssseeussesecceseseees 52 G28 Return to Reference POolht aracin ortor e e er E pe re up rede e be c ob pe herede 53 G29 Return from Reference akr esee nnne een ban ara PaRa EE EA EERS 53 G43 G44 G49 M06 Tool Change and Tool Length Compensation Commandis eese 54 G32 Local Coordinate System 3 si cse ede eee edge 58 G90 Absolute Positioning Mode eese nennen enne nnne hne enne en nete nere neret enint tenere nennen 59 G91 Incremental Positioning Mode eese 59 M00 Progam Pause oorr ob ete e br per 60 M30 End of Program eed ek ee 60 M98 M99 02 Subroutine COMMANAS cccccccccccccsessssccccccccccsssssseccccscccussseccccsssseusseescccsssucuseseecccsssseuusesescesss 60 MXX Miscellaneous 3 3 dti e i EEE EIRENE 61 F3Feedrate Command isse IEEE SERENE aM IDE EOD a 61 Progt m COMMENES ERE 61 TUTORIAL pe
4. Online Establishes communications with the Signal Generator Once communications are established FlashCut CNC places a check mark next to this menu item When the Signal Generator is online all move commands will be executed by the machine tool and the screen will update in real time Once the unit goes online a safety reminder screen appears It is imperative that you and anyone else near the machine understand agree and adhere to all of the safety guidelines If the safety guidelines are not agreed to the unit will immediately go offline Safety First FlashCut CNC is now online ALL MOVES WILL BE EXECUTED BY THE MACHINE TOOL A computer controlled machine tool is potentially dangerous You are responsible forthe safety of yourself and others during the operation of your CNC machine For safe use ofthe FlashCut CNC software and your CNC machine you must follow these safety guidelines l Never let the machine tool run unattended 2 Require any person in the same room as a running machine tool to wear safety goggles and to stay a safe distance from the machine 3 Allow only trained operators to run the machine tool Any operator must have If you do not understand and agree with all ofthe above safety guidelines please choose Go Offline below Go Offline Offline Breaks communication with the Signal Generator When the Signal Generator is offline FlashCut CNC places a check mark next to this men
5. FlashCutCNC Section4 System Programming 41 System Programming FlashCut CNC reads a subset of ANSI standard G Code to control machine tool movement This section describes how to bring a G Code file into FlashCut CNC the G Codes supported and a brief explanation of their use There are three ways you can bring G Code files into FlashCut CNC e Open an existing G Code file created by a CAM program FlashCut CNC or any other source Import a DXF file created by a CAD or drawing program e Write a G Code program directly in the FlashCut CNC editor Opening a G Code Program gt To open an existing program l Choose Open G Code from the File menu The Open G Code File dialog box appears In the List files of type pull down menu choose the type of file you are looking for Existing FlashCut CNC files will have an extension If you are unsure of the file type choose Files In the Drives pull down menu choose the drive that contains the file In the Folders list box double click the name of the folder that contains the file Continue double clicking subfolders until you open the subfolder that contains the file In the box that lists files double click the file name or click on the file name and choose OK Importing a DXF File FlashCut CNC provides a very useful 2D DXF import feature The DXF import automatically arranges all lines and circles that have common endpoints into featur
6. Cancel 2 Determine which serial port you will use to communicate with the Signal Generator Typically this can be either COMI COM 2 COM 3 or COM FlashCut CNC Section 3 Initial Setup 25 4 depending on how many serial ports and serial devices you have such as a modem Once you determine the serial port choose it from the Serial Port pull down menu The Baud Rate is the speed at which the FlashCut CNC communicates across the serial port with the Signal Generator It is measured in bits per second This is typically set at 38 400 For older PC s exhibiting serial communications problems set this to a lower speed For most applications FlashCut CNC will perform the same at baud rates of 19 200 38 400 and 57 600 If you change this setting you must reset the baud rate on the Signal Generator by going Offline and Online from the Controller menu If there are communication problems you must turn the Signal Generator off and on before going back online The Buffer Time is used to prevent system events such as screen updates from affecting motor movement on the machine tool The larger the Buffer Time the less effect system events have on motor movement The smaller the Buffer Time the more responsive the machine tool is to mouse clicks and keyboard commands In most cases the lag time between the PC and the motor movement is imperceptible The value can range from 0 01 to 1 0 seconds Slower computers may requi
7. Page Up Key Z Ctrl Page Down Key 4 Try the same for all directions on all axes making sure you have enough room in the direction of travel before you choose each Axis Jog button 5 Now select the Fast radio button and do the same exercise as you did for the Slow Jog mode The tool will move at the Fast Jog Rate defined in the Feedrate Ramping Setup dialog box 6 Position the tool so there is at least 1 of room in the positive Z direction 7 Now let s set the current position as Program Coordinates X 0 Y 0 Z 1 To do this choose the Set button next to the Program label in the Tool Position Box then choose the Zero X and Zero Y buttons and enter 1 0000 in the Z text box Choose OK to exit the dialog 8 Now let s use the Axis Jog buttons to move the tool up exactly 1 0000 It will be best to use all three jog modes to do this Fast Slow and Single Step 9 While FlashCut CNC is still in fast jog mode move the tool up until the Z axis Program coordinate is close to 2 10 Now change to slow jog mode and do the same to get even closer to 2 11 Finally change to single step jog mode This will move the tool exactly one step each time you choose one of the Axis Jog buttons Repeatedly choose either the Z or Z Axis Jog buttons until the tool is exactly at Program coordinate 2 0000 on the Z axis Depending on the resolution of your machine tool you might not be able to reach 2 0000 exactly 12 Now use the same proce
8. The Signal Generator model you have affects the way in which the limit switches should be wired Choose the appropriate model number from the pull down menu If you have Model 401A the limit switches should be 26 10 11 12 FlashCut CNC Section 3 Initial Setup wired normally closed If you have Model 401 the limit switches should be wired normally open FlashCut can be set up in either English inch or Metric mm mode Choose the appropriate system from the Display Units pull down menu The G Code File Extension text box makes opening G Code programs more convenient If you normally open files made by the FlashCut DXF import set this to FGC If you normally open files made by another CAM program type in its file extension such as NC Set the G Code Filter pull down menu to Files if you normally open files with a variety of extensions If you normally use the extension you defined above then set the G Code filter to that extension Machine Tool Settings To set the Machine Tool Settings 1 2 3 Choose Machine Tool from the Setup Menu The Machine Tool Setup dialog box will appear m Resolution Motor Res Gear Ratio Screw Tool Positioning Step Mode full steps motor revs Thread Resolution steps full step motor rev screw turn turnsfinch inches calculated XAxis fA 200 20 00000 p 0001250 Y Axis E fi 00000 20 00000 p 0001250 Z Axis 200 00
9. and so on MXX Miscellaneous Device Control Using the Output Lines Setup dialog box you can define up to 16 M codes to turn on or off different devices through the output lines M Codes can also be used for digital control of devices by turning on or off a group of output lines to be used as digital input into the control lines of the device See Output Lines Settings in the Initial Setup section for details on how to set up the M codes Popular M codes include Spindle On MOS Spindle Off M07 Mist Coolant On M08 Flood Coolant On M09 Coolant Off F Feedrate Command The F command is used to designate a feedrate The feedrate set with the F command is modal stays in effect until another F command occurs Specify the feedrate in inches minute for English units and millimeters minute for Metric units Example G01 X4 0 Y3 0 Z1 0 F7 0 Moves the tool to Program Coordinate X 4 0 Y 3 0 Z 1 0 at a feedrate of 7 0 in min Program Comments You can add comments to your program by enclosing them in parentheses FlashCut CNC ignores anything enclosed in parentheses as shown below Example 62 FlashCutCNC Section4 System Programming Move to beginning of the next feature X1 0 Y3 0 Ready to move Z axis down G00 Z 1 5 Begin next feature G01 Z 1 6 F8 G01 X3 0 Y7 5 FlashCut CNC Section5 Tutorial 63 Section 5 Tutorial Starting FlashCut CNC Windows 3 1 or 3 11 To start FlashCut CNC do
10. the program begins FlashCut CNC Section5 Tutorial 2 Choose the G Code button in the Control Box to make sure FlashCut CNC is in G Code mode 3 Select the Step radio button so the G Code Program will be executed one line at a time 4 Choose the Start button and watch the blue tool move down the Z axis scale Also note that FlashCut CNC has highlighted the next line in the Program Listing Box indicating it has fully executed the first line 5 Choose the Start button again Notice the yellow dot which represents the current position of the tool and the solid blue line which represents the cutting move just executed 6 Now select the Continuous radio button and then choose the Start button again Watch as the yellow dot moves along the tool path and as the path already cut turns blue Also notice the status of the machine tool in the message box At the end of the part program the message box will beep and tell you the file was successfully processed Editing a G Code File Now let s get familiar with using the FlashCut CNC editor 1 Choose Editor from the File menu The editor dialog box will appear FlashCut CNC Section5 Tutorial 69 Edit TUTOR FGC x File Tutorial file for FlashCut CNC GOL 2 2 25 F5 0 01 4 0 G03 Y1 0 IO 0 J0 5 GOO 20 0 GOO x0 0 YO 0 Update Tool Path Exit 2 First let s change the cutting depth to 0 25 instead of 2 25 With your mouse or your arrow keys move the cur
11. File FLASH120 STP Curr Tool No Tool Specified x Tutorial file for FlashCut CNC GOl Z 2 25 F5 G03 Yl 0 10 0 420 5 Reset CStep Continuous 600 20 0 Goo X0 0 YO 0 Start Feed Hold Any Key Faster Program Feedrate 0 0 Slower 100 19 override 0 0 Now let s get familiar with the Tool Path View Box Here are some important features Red Lines Represent the entire tool path of the part to be cut Green Dot Represents Program Zero the origin of any G Code program Light Blue Dot Represents Machine Zero also called Home Yellow Dot not shown here Represents the current XY position of the machine tool during the cutting or animating operation Blue Lines not shown here Represent the portion of the tool path already cut Dotted Lines Represent a rapid move Solid Lines Represent a feedrate move Blue Tool Represents the current Z position of the machine tool during the machining or animating operation Light Blue Lines Represent the borders of the machine tool envelope Animating the G Code File Now we are ready to animate the tool path on the screen to verify the program l Choose the Set button next to the Program label then choose Zero All in the dialog box that immediately follows FlashCut CNC sets all three program coordinates to 0 This simulates the tool being in the correct position before
12. Tool Tool Specified GOl Z 2 25 F5 0 601 X4 0 603 1 0 10 0 40 5 600 20 0 GOO X0 0 YO0 0 Faster Program Feedrate 0 0 Slower 100 v override 0 0 Reset C Step Continuous Start Feed Hold Any Key Notice how the G Code listing appeared in the Program Listing Box and a red outline of the tool path appeared in the Tool Path View Port Viewing the Tool Path There are two viewing modes for the tool path the size of the entire machine tool envelope and scale to fit Note that since the machine coordinates are not defined the window shows an area that is twice the size of the entire machine tool envelope Now let s set the machine coordinates To do this l Choose the Set button next to the Machine label in the Tool Position Box A dialog box for setting the Machine Coordinate values appears Choose the Zero button This tells Flashcut that the current tool position will be defined as Machine Zero or home FlashCut CNC Section5 Tutorial Set Machine Coordinates Ed r New Values x 0000 inches Zero X Y 0000 inches Zero Y 7 0000 inches Zero Z The coordinates previously shown as N A will now be zeroed and a light blue box will outline the entire tool envelope in the Tool Path View Port FlashCut CNC TUTOR FGC Xx File Setup Controlle
13. Tool pull down menu on the main screen To indicate tool changes in the G Code file use the M06 command as follows FlashCutCNC Section4 System Programming 55 M06 Tn where n is the tool number in the Tooling Setup dialog box Example M06 T3 Pauses program displays dialog informing operator to change to tool number 3 Note For compatibility reasons the T command can be used on any line prior to the M06 command it does not need to be on the same line as MO6 Once the M06 command has set the current tool the G43 command applies the proper offset to account for the current tool s length as follows G43 Hn where n is the tool number for the current tool The G43 command tells FlashCut CNC to shift all subsequent Z axis moves away from the workpiece in the positive Z direction by an offset amount The offset amount is equal to the difference in lengths between the current tool when the G43 command is executed and the previous tool Flashcut CNC uses the Length Offset values in the Tooling Setup dialog box to calculate the difference in lengths between two tools Example G43 H3 Shifts all subsequent Z axis moves away from the workpiece in the positive Z direction by the difference in lengths between tool number 3 and the previous tool The G44 command is identical to the G43 command except that it shifts all Z axis moves in the direction opposite from G43 Unless you are an experienced CNC programmer and know how to use G
14. Z 4 4800 Relative se o DistToGo o X 3 7750gX 0 0118 Y 1 7704 0 0361 2 4 4800 Z 0 0000 omine Move interrupted G Code Jog Point Home Control Box le NEWSET STP Curr Tool 1 3 16 Ball End Mill 2 Flute bd Program Faster Program Feedrate 20 0 im Slower 100 Override Listing Box Sower Override 20 0 X0 7549Y 0 2900 X0 7497Y 0 3021 Reset C Step Continuous X0 7338Y 0 3384 X0 7286Y 0 3505 Start X0 7229Y 0 3626 Pull Down Menu Bar This area contains the main menu headings for many system commands File Menu FlashCut CNC No G Code Fil Setup Controller View Help Open G Code Cti 0 Close G Code Editor Ctrl E Open Setup Save Setup Save Setup As Import Ctrl Open G Code Opens an existing G Code file checks the file for errors and compatibility with FlashCut CNC draws the tool path in the Tool Path View FlashCut CNC Section 2 Main Screen Features Port and displays the program in the Program Listing Box By default the dialog box displays files with an extension Close G Code Closes the open G Code file Editor Opens the editor dialog box and displays the current G Code file Using this feature you can directly edit any G Code file without leaving FlashCut CNC Note that you can also double click the Program Listing Box to open t
15. a direct drive enter 1 in this box Screw Thread The number of turns per inch of the helical drive screw foreach axis For example a single threaded 0 05 pitch screw would have 20 turns per inch There are also general settings unique to each machine tool These are described below Once you determine the correct value for each general setting enter it in the appropriate text box Axis Length Sets the length of travel of each axis of your machine tool You may want to define the axis length slightly smaller than the values published by the machine tool manufacturer This will leave some room for error Enter these figures in the Axis Length text boxes Motor Polarity Depending on how a motor is wired the same signal from the Stepper Motor Driver can turn it clockwise or counter clockwise Use the jog buttons to make sure that a positive move in each axis on the screen corresponds to a positive move in each axis on the machine tool Note that the direction of movement is defined as the direction of the tool relative to the table For example a positive X move in the program tool movement to the right will result in table movement to the left If any direction is incorrect change the motor polarity from Positive to Negative or vice versa to reverse the correspondence between the software and machine tool Machine Envelope Home End The end of an axis at which the optional home switch is installed This determines the placement
16. a mouse bus port rather than through a serial port One available RS 232 serial port If the port has a 25 pin connector a 9 pin male to 25 pin female adapter will be required Microsoft Windows 95 98 or NT or Microsoft or PC DOS version 3 1 or later running Microsoft Windows version 3 1 or 3 11 FlashCut CNC Section 1 Getting Started Installing FlashCut CNC It s a good idea to make a working copy of the FlashCut CNC disks and put the originals away in a safe place before installing the program Then if the working copy is damaged or lost you can easily replace it If you are using Windows 3 1 or 3 11 1 2 3 Start Windows Place Disk 1 into drive A or drive B In the Windows Program Manager choose the Run command from the File menu In the Command Line text box type a setup if you are using disk drive A or b setup if you are using disk drive B Choose the OK button and follow the on screen instructions To run FlashCut CNC simply double click on the FlashCut CNC icon in the FlashCut CNC program group If you are using Windows 95 98 or NT 1 2 3 Start Windows Place Disk 1 into Drive A or Drive B From the Start menu choose the Run option In the Open text box type a setup if you are using disk drive A or b setup if you are using disk drive B Choose the OK button and follow the on screen instructions To Run FlashCut CNC choose the Programs option from the Start menu then choose the FlashCut CNC pr
17. and choose OK Some setup files are supplied for various mills and lathes If a setup file is not available for your machine select FLASHXXX STP where is the current software version eg FLASH121 STP for version 1 21 Note that FLASHXXX STP is based on the Sherline 5400 but is easily modified to accommodate any machine tool 4 Go through the Setup menus as described in Section 3 Initial Setup Enter the values that best describe your machine 5 Choose AII Coordinates from the View menu to make sure all four coordinate systems are displayed Loading a G Code File 1 Choose Open G Code from the File menu FlashCut CNC No G Code Fil Setup Controller View Help Open G Code Ctrl 0 Close G Code Editor Ctrl E Open Setup Save Setup Save Setup As Import DXF Ctrl 2 Goto the directory where FlashCut CNC is installed and double click on the file TUTOR FGC The G Code File TUTOR FGC will now be loaded into FlashCut CNC and the screen should now look like this FlashCut CNC Section5 Tutorial File Setup Controller View Help FlashCut CNC TUTOR FGC lel Es Program se o Machine s amp ol x 0 0000 lx Y 0 0000 ly N A z 0 0000 2 N A Relative Dist To Go ol x 0 0000 x 0 0000 Y 0 00007 0 0000 a 0 0000 Z 0 0000 Machine tool idle Offline Jog Boint Home Setup File FLASH120 STP Curr
18. are not lost both with and without ramping and then limiting the maximum rates for each axis to about 7096 of those values Due to variations in the drive mechanism for each axis make sure you do the following tests in all directions and at several positions along each axis gt To Set the Maximum Unramped Feedrates 1 Choose Feedrate Ramping from the Setup Menu The Feedrate Ramping setup dialog box will appear r Axis Setup Max Unramped Maximum Ramping Direction Change Feedrate Feedrate Rate Delay in min in min full steps sec sec sec X Axis 25 00 10000 p 100 Y Axis 5 00 25 00 10000 p 100 Z Axis 5 00 25 00 10000 0 100 Jog Setup Slow Jog Rate in min Fast Jog Rate 25 00 in min Arc Setup Max Arc Feedrate 25 00 in min 2 Enter 99 for the X axis Max Unramped Feedrate and 100 for the Maximum Feedrate then choose OK 3 Choose the Point button on the Control Box Select Any Point from the Name pull down menu and Incremental from the Coord pull down menu Enter 1 0 in the X text box and enter a relatively slow feedrate such as 5 Make sure you have room to move the X axis 1 inch then choose Start 4 Ifthe motor slips repeat this process with a slower feedrate If the motor doesn t slip try a faster feedrate Note that slight slippage can be detected by reading the values on the table feed hand wheel 5 Repeat this process you find the highest
19. e It s good practice to use the G43 command in the line directly following the M06 command The following example illustrates proper use of the tool change and tool length compensation commands Example The tool library is shown below r Tool Definitions Length Offset inches No Description 1 4 Ball Endmill 4 Flute 1 2 EndMill 1 8 Ball Endmill TiN coated CO FO cIojojojojojojojojojojojojojojo Cancel FlashCutCNC Section4 System Programming 57 The first tool used in the program is tool 1 so it is selected in the Current Tool pull down menu on the main screen The tool change position is defined as Machine Coordinates X22 Y 2 Z 0 Tool 1 is loaded in the machine tool Program zero has been set using tool 1 Program zero is set at Machine Coordinates X20 Y 0 Z 4 The machine tool is moved to Program Coordinates X20 Y 0 Z 1 before the G Code file is run Z 25 G01 Z 1 0 F10 G00 Z 25 G28 M06 T2 G43 H2 G29 70 25 G01 X3 Z 1 F20 G28 Z0 M06 T3 G43 H3 Move the Z axis down to Program Coordinates 0 Y 0 720 25 Machine Coordinates X20 Y 0 Z 3 75 Move the Z axis down to Program Coordinates 0 Y 0 Z 1 Machine Coordinates X 0 Y 0 Z 5 Move the Z axis up to Program Coordinates X 0 Y 0 Z 0 25 Machine Coordinates X 0 Y 0 Z 3 75 Move
20. feedrate that doesn t cause motor slippage FlashCut CNC Section 3 Initial Setup 29 Now run the entire length of the axis in both directions to make sure there is no slippage at any point on the entire axis Choose Feedrate Ramping from the Setup Menu Enter 70 of the value you found in the Max Unramped Feedrate text box for the X axis then choose OK Repeat this process for all axes To Set the Maximum Feedrates After finding the maximum unramped feedrates you re ready to find the maximum feedrates achievable with ramping 18 Choose Feedrate Ramping from the Setup Menu The Feedrate Ramping Setup dialog box will appear Enter 10 000 full steps sec sec in the Ramping Rate text box for the X axis This is an average ramping rate Leave the Max Unramped Feedrates at the values you found earlier Leave the Maximum Feedrates at the very high number 100 in min and choose OK Choose the Point button on the Control Box Select Any Point from the Name pull down menu and Incremental from the Coord pull down menu Enter 1 0 in the X text box and enter a feedrate that is about 50 higher than the Max Unramped Feedrate for the X axis Make sure you have room to move the X axis 1 inch then choose Start If the motor slips repeat this process with a slower feedrate If the motor doesn t slip try a faster feedrate Note that slight slippage can be detected by reading the values on the table feed hand wheel Repeat this
21. of program execution are called a mode group The following list shows the mode groups for G code commands supported by FlashCut CNC Move Mode G00 Rapid Tool Positioning G01 Linear Interpolated Cutting Move G02 Clockwise Circular Cutting Move G03 Counter Clockwise Circular Cutting Move Circular Interpolation G17 XY Plane Selection G18 XZ Plane Selection G19 YZ Plane Selection Units G20 Inch Units also G70 G21 Metric Units also G71 Tool Length Compensation G43 Tool Length Compensation Plus G44 Tool Length Compensation Minus G49 Cancel Tool Length Compensation Positioning Mode G90 Absolute Positioning Mode G91 Incremental Positioning Mode Miscellaneous Modes using Single Command G52 Use Local Coordinate System F Feedrate Absolute vs Incremental moves are either absolute or incremental In an absolute move the ending point is defined relative to a coordinate system origin usually Program Zero In 48 FlashCutCNC Section4 System Programming an incremental move the ending point is defined relative to the current tool location The G90 G91 commands tell the system which of these two modes to use described below While there will be cases where incremental programming is useful generally you should define your moves as absolute since it is a less error prone method of programming All of the examples in the following section use absolute positioning unless otherwise noted G and M Code Refere
22. of the origin of the Machine Tool Envelope Machine Zero once home is set Home Switch Offset The distance each axis backs away from the home switch after the switch is closed during homing Backlash Sets the amount of backlash for each axis See the Setting Backlash section below for more information Comp Tells Flashcut CNC whether or not to use backlash compensation for all direction changes Leave this checkbox unchecked for now It is discussed in the Setting Backlash section below Tool Change Position The position in Machine Coordinates where the machine will move when given the G28 command in the program When you are done entering the correct information choose the OK button 28 FlashCut CNC Section 3 Initial Setup Feedrate and Ramping Settings Every machine tool will vary as to how fast it can move each axis without losing steps Losing steps means that even though the stepper motor gets the signal to move a step it isn t able to move the step and accuracy is lost The usual cause is insufficient drive torque at a given motor RPM Since most stepper motors are open loop systems there is no way of telling when a step is lost without physically measuring the movement of the axis and comparing that to the amount it should have moved However when not over torqued a stepper motor is very reliable and accurate For that reason we highly recommend finding the maximum rates at which steps
23. process you find the highest feedrate that doesn t cause motor slippage Now run the entire length of each the X in both directions to make sure there is no slippage at any point on the entire axis Choose Feedrate Ramping from the Setup Menu Enter 70 of the highest no slip feedrate you found in the X axis Maximum Feedrate text box 10 Repeat this process for all axes To Set the Ramping Rate Ramping Rates typically range from 1000 to 100000 full steps sec sec Slower ramping rates require more time to ramp up to the maximum feedrate and to ramp down to a stop This may become a potentially dangerous situation when using the Feed Hold button or jogging since the machine will take longer to come to a complete stop The goal is to choose a fast ramping 30 FlashCut CNC Section 3 Initial Setup rate that will start and stop the tool responsively without losing steps Fast ramping rates can also allow acceleration past resonant speeds of the stepper motor 1 10 Choose Feedrate Ramping from the Setup Menu The Feedrate Ramping Setup dialog box will appear Enter 10 000 full steps sec sec in the Ramping Rate text box for the X axis This is an average ramping rate Leave the Max Unramped Feedrates and Maximum Feedrates at the values you found earlier and choose OK Choose the Point button on the Control Box Select Any Point from the Name pull down menu and Incremental from the Coord pull down menu Enter 1 0 in the X
24. set up to move to the machine coordinate 1 2 1 at a feedrate of 4 in min G Code Jog Point Home 6 Name Any Point Coord Machine in X fi 0000 Y 2 0000 Z 1 Rate Feedrate 4 00 in min f Feed Hold Any Key Now choose the Start button Notice how the machine first performed 2 Axis linear interpolation for the X and Y axis and then moved the Z axis down This sequence of movement unique to the point mode helps to avoid tool crashes From the Name pull down menu select Machine Zero Select Rapid from the Rate pull down menu The tool is set to move to Machine Coordinate 0 0 0 at the rapid feedrate FlashCut CNC Section5 Tutorial 73 G Code g Point Home oU Machine inches X i 1 0000 yf 1 0000 7 0000 Rate Rapid p 00 fin min Start Feed Hold Any Key 9 Now choose the Start button Notice how the machine first moved the Z Axis up and then performed 2 axis linear interpolation for the X and Y axes Setting Program Zero on the Machine Tool Program Zero is the origin to which all Program coordinates in the G Code file are referenced Before we cut a part Program Zero must be set to a point from which we want the G Code file to begin processing For this tutorial we will cut a file called FLASHBLT FGC 1 Choose Open G Code from the File menu and select FLASHBLT FGC then choose OK Flash
25. text box and choose the Rapid option from the Rate pull down menu Make sure you have room to move the X axis 1 inch then choose Start If the table moves at the Max Unramped Feedrate instead of the Maximum Feedrate there isn t enough room to ramp and you should increase the distance moved If the motor slips repeat this process with a lower Ramping Rate If the motor doesn t slip try a higher Ramping Rate Note that slight slippage can be detected by reading the values on the table feed hand wheel Repeat the above steps until you determine an optimal ramp rate for the X axis Choose Feedrate Ramping from the Setup Menu Enter 70 of the highest no slip ramping rate you found in the X axis Ramping Rate text box Repeat this process for all axes Note that once the optimal ramp rate is determined for each axis you may want to re test the Maximum Feedrates to see if they can be set any higher To Set the Direction Change Delay The direction change delay is a brief pause that occurs when a motor changes direction It gives the stepper motor time to settle down and come to a complete rest before moving in the opposite direction Note that the direction change delay is not used when a motor changes direction during circular interpolation l Write a G Code file that goes back and forth in a given axis at the maximum unramped feedrate For example if the maximum unramped feedrate were 8 G01 X2 F8 X0 FlashCut CNC Section
26. tool directly to the Program coordinate X 1 0 Y 3 0 Z 1 5 G90 is assumed G91 All XYZ coordinates after this command will be interpreted as incremental distances G01 X1 0 Y2 0 Z 0 5 Moves the tool a distance of 1 0 Y 2 0 Z 0 5 from the current tool location This corresponds to the Program coordinate X 2 0 Y 5 0 Z 2 0 60 FlashCutCNC Section4 System Programming G02 X1 0 Y 1 0 10 5 J 0 5 Moves the tool using counter clockwise circular interpolation to the Program coordinate X 3 0 Y 4 0 Z 2 0 with a center point at Program coordinate X 2 5 4 5 Z 2 0 G90 All XYZ coordinates after this command will be interpreted as Program coordinates G01 X1 0 Y2 0 Z 0 5 Moves the tool directly to the Program coordinate X 1 0 Y 2 0 Z 0 5 M00 Program Pause The M00 command pauses processing of the G Code program You can use this command anywhere in the program By default Flashcut CNC displays a dialog box to inform you that it has paused processing You can control whether or not this dialog box appears using the Message on Program Pause checkbox in the G M Code Setup dialog box M30 End of Program The M30 command ends processing of the G Code program and automatically resets the program to the top M98 M99 M02 Subroutine Commands Subroutines allow you to eliminate repetitive programming FlashCut CNC supports the use of subroutines with the M98 M99 and M02 or M30 commands Use of these commands
27. treats them as a single feature to machine without lifting the tool Due to rounding or drawing error two entities that are meant to be joined may not actually touch end to end The DXF import will automatically join any entities whose endpoints are less than the Join Tolerance apart Line Numbers Check this box if you want DXF import to number all of the G Code lines in the program it creates Incremental Depth of Cut The incremental depth for each milling pass For example if the final tool down is 0 2500 and the incremental depth of cut is 0 0625 then four passes would be cut on each feature to get to the final depth of cut 0 0625 0 1250 0 1875 0 2500 If the final tool down is 0 3000 and the incremental depth of cut is 0 0625 then five passes would be cut on each feature to get to the final depth of cut 0 0625 0 1250 0 1875 0 2500 0 3000 Tool Up The height program coordinates to which the tool will move before rapid moves between two features Final Tool Down Milling The final depth program coordinates to which the tool will cut each feature Final Tool Down Holes The final depth program coordinates to which the tool will cut each hole Program Zero Location X Y of Import File The X and Y location in the DXF file that FlashCut CNC will place at the program origin in the G Code file Lower Left of Toolpath Defines program zero as the lower left point of the im
28. 00 20 00000 p 0001250 r General Machine Home Switch Comp Tool Chg Axis Length Motor Envelope Offset Backlash Pos inches Polarity Home End inches inches inches X Axis 7o Negative v lt 0 1000 0000 o o000 Y Axis 4 70 Positive fv 0 1000 p 000 Z Axis Positive z 1000 fo 0000 0 0000 OK Cancel du The Tool Positioning Resolution for each axis inches of axis movement per motor step is automatically calculated for you using four factors Determine the values for each of these factors and enter them in the corresponding text box Step Mode The number of mini or micro steps between each motor step Note that this is a characteristic of the Stepper Motor Driver and cannot be changed without servicing the driver Enter 1 for full step 2 for half step 4 for quarter step and so on 10 11 12 13 14 15 FlashCut Section 3 Initial Setup 27 Motor Resolution The number of full motor steps for one revolution of the motor For example a 1 8 stepper motor will have 200 full steps per revolution a 0 9 Stepper Motor will have 400 full steps per revolution and so on This number is a characteristic of the stepper motor and is independent of the Stepper Motor Driver or the Step Mode Gear Ratio The ratio of the number of stepper motor revolutions to drive screw revolutions due to any gears or pulleys between them If it is
29. 3 Initial Setup 31 X2 X0 2 Setthe Direction Change Delay to 0 5 seconds for the given axis 3 Run the program and notice if the motor loses steps If so increase the Direction Change Delay Otherwise decrease the number 4 Repeat the above process until you reach a reasonable delay time that eliminates any motor slippage Note that this number is typically between 0 05 and 0 3 seconds If you do not see any slippage at a delay of 0 seconds it is recommended you enter at least 0 05 seconds 5 Repeat the above process for all axes To Set the Jog Rates 1 Choose Feedrate Ramping from the Setup Menu 2 in both the Slow Jog Rate and the Fast Jog Rate text boxes Choose Slow Jog Rate that will allow fine positioning of the machine tool typically about 2 5 in min Choose a Fast Jog Rate that will move the tool quickly yet allow you to remain in complete control without creating a dangerous situation Remember the CNC machine cannot jog any faster than the maximum feedrate for each axis gt Set the Maximum Arc Feedrate Due to the computations involved during circular interpolations an arc cannot be executed as fast as a line For this reason there is a user settable limitation for the maximum arc feedrate 3 Write a G Code program that cuts a circle at the maximum feedrate For example if the maximum feedrate were 25 G00 X2 Y2 G02 X2 Y2 I1 J1 F25 4 Run the program and notice if either the X or Y mot
30. 44 correctly G43 is the preferred command The G49 command cancels tool length compensation It removes any offset that Flashcut CNC has applied since the G Code program began running When using tool length compensation there are several important things to keep in mind e You must predefine all tools and tool lengths in the Tooling Setup dialog box e It s good practice to include an M06 tool change and a G43 compensation command for the first tool used near the beginning of the G Code program 56 FlashCutCNC Section4 System Programming e Flashcut CNC automatically cancels tool offset when it finishes processing a G Code file or during any operation that ends the current run of the G Code file such as resetting the program opening a new program and so on TO AVOID CRASHING THE MACHINE TOOL IT IS VERY IMPORTANT THAT YOU REMOVE THE CURRENT TOOL FROM THE SPINDLE WHENEVER FLASHCUT CNC CANCELS TOOL OFFSET The G43 G44 and G49 commands are modal so the current tool offset remains active until Flashcut CNC executes another tool offset command or until Flashcut CNC cancels tool offset as described above Note that you may only use one type of tool length compensation G43 or G44 in a G Code program e The M06 command does not move the machine tool to the Tool Change Position This is done using the G28 command described above It s good practice to place the G28 command in the line directly preceding the M06 command
31. Cut CNC File Setup Controller View Help Program zee O Machine zeo ol x 0 0000 4 0 0000 Y 0 0000 0 0000 0 0000 Z 0 0000 Relative 2 Ol DistToGo x 0 0000 x 0 0000 Y 0 0000 Y 0 0000 0 0000 Z 0 0000 Machine tool idle Offline G Code E qQ Point Home C Fast Slow Um Single Step Hold Any flashblt fqgc Made to Engrave 0 05 deep use in 1 8 or thicker plastic use 1 16 End Mill 600 X 0 0000 Y 0 1250 601 Z 0 025 2 00 Jm 2 Make sure there is enough room on all axes of the machine to run the current G Code file from the program zero point The FLASHBLT FGC program needs 42 125 inches on the X axis 1 625 inches on the Y axis and 55 inches on the Z axis 74 FlashCut CNC Section5 Tutorial Fixture a sheet of 1 8 or thicker plastic preferably machine grade or aluminum at least 2 wide and 4 long onto the XY table of the machine tool Be sure that all clamps and fixturing tools are well out of the way of the tool during all parts of the program This program will run best with a 1 16 endmill Jog the tool to the X Y corner of the workpiece using Jog mode Now carefully jog the tool down in the Z axis until it just barely touches the top of the workpiece We recommend using a feeler gage to do this and then jogging down the exact thickness of the feeler gage to touch the part To d
32. FLASHCUI CNC Computer Numerical Control for Windows Version 1 2 User s Guide FlashCut CNC GASKET6 FGC Iof x File Setup Controller View Help Program se O Machine se ol X 1 191984 1 1519 T 1 7591 1 7591 Z 0 1000 Z 3 1000 Relative Sse ol DistToGo X 5 7769 X 2 8481 Y 2 3009 Y 0 6576 2 3 3000 Z 0 0000 Processing highlighted line Offline G Code Jog Point Setup File FLASH121 STP Curr Tool Faster Program Feedrate 15 0 N520 601 Z 0 3000 F 1 00 ME N530 G02 X 4 1250 Y 3 9167 I 0 1250 J 0 0000 Sower 100 E Ovenide 15 0 N540 GOO Z 0 5000 N550 GOO X 4 0000 Y 2 4167 Reset Step Continuous 560 GOl 2 0 1000 F 1 00 N570 602 X 4 0000 Y 2 0000 N580 GOl 2 0 2000 F 1 00 1998 FlashCut CNC Inc 1263 El Camino Real Suite W Menlo Park CA 94025 Phone 650 853 1444 e Fax 650 853 1405 www flashcutcnc com Table of Contents GETTING STARTED ercesecerieeteses eost coss eeteetescessdestieieete esdesbesidebeedes quss esi eetsen ees dosi es ERR 1 THANKYOU pP 1 PRODUCT SUPPORT e reete ta RE ice Bie esta exe rege at Ae eee te e exe tese ee eL eie c exe see E 1 SYSTEM REQUIREMENTS 5 5 S 05222 oun tete Ss San ee xe EE eco e eee REL 1 INSTAELING FLASHCUT CNG d TO ND IM 2 WSING THE MOU
33. Hold Button Stops execution of the G Code file Note that once the Feed Hold button has been hit the machine tool will always ramp down to a stop if necessary to avoid loosing steps For this reason the slower the ramp rate the longer it will take from the time the Feed Hold button is hit to the time the tool comes to a complete stop You can also stop program execution by hitting any key on the keyboard except Shift or Ctrl during machine operation Jog Mode Jog mode provides controls for manually positioning the machine tool in all three axes C Fast Slow Single hi Step Hold Any Axis Jog Buttons You can move a single axis of your machine tool by pressing and holding an Axis Jog Button Ramping is used if the current jog rate is faster than the maximum unramped feedrate for a given axis Note that you can also jog the machine using the keyboard The controls are mapped as follows X Ctrl Right Arrow Key X Ctrl Left Arrow Key Y Up Arrow Key Y Ctrl Down Arrow Key Z Ctrl Page Up Key Z Ctrl Page Down Key Jog Mode Single Step Sets the mode in which the tool will move exactly one motor step each time an Axis Jog Button is chosen Slow Sets the jog rate to the slow jog rate specified in the Feedrate Ramping Setup dialog box FlashCut CNC Section 2 Main Screen Features 19 Fast Sets the jog rate to the fast jog rate specified in the Feedrate Ramping Set
34. M Codes Supported G00 G01 G02 G03 G04 G17 G18 G19 G20 G21 G28 G29 G43 G44 G49 G52 G70 G71 G90 G91 M00 M02 M06 MXX M30 M98 M99 F Rapid Tool Positioning Linear Interpolated Cutting Move Clockwise Circular Cutting Move XY Plane Counter Clockwise Circular Cutting Move XY Plane Dwell XY Plane Selection XZ Plane Selection YZ Plane Selection Inch Units same as G70 Metric Units same as G71 Return to Reference Point Return from Reference Point Tool Length Compensation Plus Tool Length Compensation Minus Cancel Tool Length Compensation Use Local Coordinate System Inch Units same as G20 Metric Units same as G21 Absolute Positioning Mode Incremental Positioning Mode Program Pause End of Program Tool Change Custom Programmable See Output Line Settings in the Software Setup section of this manual End of Program Reset Subroutine Call Return From Subroutine Feedrate Comment Key Programming Concepts There are two basic programming concepts you should understand before learning the G and M codes Mode and Absolute vs Incremental FlashCutCNC Section4 System Programming 47 Mode Most G code commands supported by FlashCut CNC are modal meaning they put the system into a particular mode of operation and need not be repeated on every program line A modal command stays in effect until another command changes the mode Related modal commands that affect one aspect
35. R SER ETERNI nere nene nn 12 POSITION BOX sotto E EEO ntl tution tete fuste Ad sts ie tuorum 12 POSTON a e DES e UU 13 a a 13 NAA E E 13 TS ANNI GIL RR m 13 Other AA AOA EEEE t Ate PEE ELE tides 13 VIEWPORT de thc e he nat metta tet 15 SONTR OFF BORE steric dence eM ed etes 16 G COdE MOD ease DE ACS S 17 ML IEEE 18 POINTE Modes s E A ce eas De Spese UE 19 se D SUD IESUS 20 MESSAGE BOX SGU ee e die iie Wi Sa Dede TSG 21 PROGRAM LISTING BOX 4i th ete e otiosa deveddeseeucdaussevesduaeseedaetees 21 INIAC SE DUP Cac C 23 WINDOWS SETUP ne ee RR Sek RG ee EET e eee BORE Seve NU RE E RU V A SEE RR RE 23 SOETWARE SETUP de ee o e e i m t es eet dte te OREA EEN ete e te RN etudes Ete eo ve Bee 24 Ih Setup File tc t reete tet e Go tete aae ote Pod ces mta re do ede gd 24 MI VENOS EE EP 24 Machine Tool Settings e e te te o e dede e e ERE eoe ede inne 26 Feedrate and Ramping Settings eoe en oe a e e ee ee e ero e e e cere ent Ee qn 28 Setting Machine Z8t0 neen
36. SEcCu sd nicis n tec tente codeine ene deest Es 2 CHOOSING COMMANDS 2 ERR t RR DB vu tetas e M 3 Choosing a Command by Using the Mouse eese eee nennen enne nnne ener enne nenne 3 Choosing a Command by Using the nnns 3 Using Shoricut Keys a so obitu menia uiti eaultanientem utto niti esten 3 Using the TAB and ARROW Keys ciuis eunti ditam ences pim nein 3 USING STANDARD WINDOWS CONTROLS cccccccccsssssssseecccceeussecccceeecauseseeeceeeccceesaaeccccesseauusseeecceeseuaesauanscesseauaneess 3 Radio BUtt nssa eius nte nep rp ndi 3 Pull Dowmn ee m eS MA 4 Text BOXes tud cc v Gre nx E pim mnn di HIDE 4 Command D eise Mi p ES 4 SYSTEM SAFETY iiu ebseieriduedequaas einerdndeUwaebreenneenieevno euaeeo dA 5 ABOUT THIS MANUAL TA eset Pavese etiem edad tesis else 6 PROGRAM OVERVIEW dead edge telles ela esed teles 6 MAIN SCREEN EEATURES eua nope Eee cuo euo doni Cape e oes eus doni SE redes eese dens open es seen eet 7 PULE DOWNOMENU BAR ie ch D CER NR RR bee os eee AT Eee I ThE ded 7 File Menun aaa e ERRORES RC RECTE PR 7 Setup Menit ui icti di T ee te dot a Ite ee Salva Ree det Lave ead ove ede dere beh eed 8 COMPTON LEA TEE E D E 9 VAC W PATE E 12 Help Men eee ee De ERU E
37. Switches Switches placed at the end of travel of each axis When the machine tool table travels too far in either direction of any axis a limit switch is tripped which will shut down the system to prevent damage Machine Coordinates The XYZ position of the tool on the CNC Machine relative to Machine Zero Machine Origin Same as Machine Zero Machine Tool Envelope The three dimensional box defined by the maximum travel in the X Y and Z axis Once the machine tool envelope is defined the tool cannot move FlashCut CNC Section 6 Glossary outside of it The machine tool envelope can be disabled by clicking on the Clear Machine Zero button in Home mode Machine Zero The origin X Y Z 0 0 0 of useful space within the machine tool envelope Can either be defined manually or by using home switches Maximum Feedrate The maximum rate at which a motor or an axis can reliably start and stop with ramping Maximum Unramped Feedrate The maximum rate at which a motor or an axis can reliably start and stop without ramping Modal Modal commands stay in effect until another command in the same mode group is encountered Motor Polarity The association between the actual direction an axis moves and the direction FlashCut CNC thinks it s moving If they are different this value should be changed from positive to negative or vice versa Motor Resolution The number of full motor steps for one revolution of the motor For e
38. aginary box that envelopes all geometry contained in the DXF file Circles Defines diameters for circles that will be drilled at the center point instead of milled along the perimeter XY Feedrate The feedrate for all milling operations in the XY plane Plunge Feedrate The feedrate for all downward Z axis moves Choose OK The G Code will appear in the Program Listing Box and the tool path will appear in the Tool Path View Port 44 FlashCutCNC Section4 System Programming Using the Program Editor FlashCut CNC provides a handy editor for creating or modifying G Code Programs If you need a more feature rich editor for your programming you can also use your own editor such as WordPad which comes standard with Windows 95 or Microsoft Word etc If you do use a different editor make sure you save the file as Text Only and use an FGC extension on the file name To open the editor 1 Choose Editor from the File menu or double click the Program Listing Box The editor dialog box will appear Edit UNTITLED FGC x File Update Tool Path Exit 2 You can type or edit your program in the scrolling text box Refer to the and M Code Reference section below to learn more about using G Code gt To edit a new program Choose New Program from the editor s File menu FlashCutCNC Section4 System Programming 45 To open an existing program 1 Choose Open G Code from the editor s File
39. and your CNC machine the following safety guidelines must be followed Never let the machine run unattended Any person near a running machine tool must wear safety goggles Allow only trained people to operate the machine Anyone operating this machine must have Knowledge of machine tool operation Knowledge of personal computer operation Knowledge of Microsoft Windows Good common sense Place safety guards around the machine to prevent injury from flying objects FlashCut CNC highly recommends building a plexiglass safety shield around the entire tool envelope A computer controlled machine tool is potentially dangerous Unexpected machine movement can occur at any time Never place any part of your body within the tool envelope while the machine is online Be aware and on alert for computer crashes at all times Always keep the tool envelope tidy and free of any loose objects FlashCut CNC is not responsible for the safe installation and use of this product You and only you are responsible for the safety of yourself and others during the operation of your CNC machine tool FlashCut CNC supplies this product but has no control over how it is installed or used Always be careful If you do not understand and agree with all of the above safety guidelines do not use this product FlashCut CNC Section 1 Getting Started About this Manual FlashCut CNC is a unique Windows application so you ll need
40. are supplied for various mills and lathes If a setup file is not available for your machine select FLASHXXX STP where is the current software version eg FLASH121 STP for version 1 21 Note that FLASHXXX STP is based on the Sherline 5400 but is easily modified to accommodate any machine tool Once you ve opened the setup file choose Save Setup As and follow the dialog boxes to save the setup file under a new name or directory This lets you go back to the original setup file if necessary Using this method you can create a unique setup file for each of your machine tools The last setup file used will automatically be loaded the next time you run FlashCut CNC System Settings gt To set your system settings 1 Choose System Options from the Setup menu The System Options dialog box will appear r Communications r Machine Tool Serial Port COMI Type Baud Rate 38400 Iv X Axis Iv Y Axis Buffer Time 0 300 sec Iv Z Axis r G Code Display During Continuous Run r Jog Moves Show Program Listing Box Start Delay 0 100 sec Show Current G Code Line Only Coordinate Update 0 250 sec r General G Code and Point Moves Signal Generator 4014 Inputs N C 3 np Start Delay p 100 sec Display Units En lish inch glish Coordinate Update p 250 sec G Code File Extension roc G Code Filter 6 Code Files FGC
41. at can be used to maintain a repeatable location between the endmill holder and the spindle use the axial distance between the tip of the tool and the locating feature of the end mill holder as the tool length offset Note that this method assumes each tool has its own end mill holder FlashCut CNC Section 3 Initial Setup 35 Locating Surfaces on Tool Holders 9 P o m BN S a q3ueT19sgo 14 TOOL 4 Repeat the above for each tool in your library Input Line Settings FlashCut CNC can read up to 8 input lines wired to limit home switches or general safety switches such as a door switch on a safety enclosure You can use all 8 input lines however you choose but all must be wired the same either all normally open or all normally closed If the Signal Generator you are using is a model 401 then it is best if all input lines are normally open N O If your signal generator is model 401A then it is best if all input lines are normally closed N C Make sure that the signal generator model is properly selected in the System Options dialog box Please see the FlashCut CNC Hardware Guide for more hardware details including the pin layout of the input line connector When FlashCut CNC detects a tripped input line it immediately stops all tool movement without ramping The accuracy of the tool position will most likely be lost at that point If a limit switch has been tripped FlashCut CNC will only allow you t
42. ate Current Line Start Point Last Hold Point Feed Hold Any Key Coord The tool will move to the XYZ position in program coordinates machine coordinates relative coordinates or incrementally from the current position of the tool depending on the option you select in this pull down menu Rate You can set the feedrate by selecting one of the following from the pull down menu Rapid The machine tool moves at the maximum feedrate allowed by your current maximum feedrate settings in the Feedrate Ramping Setup dialog box Feedrate The machine tool moves at the feedrate you enter in the text box Home Mode Clear Machine Zero Start Feed Hold Any Key Start Finds the home switch on all three axes Homing moves each axis one at a time at a moderate feedrate to ensure that no steps are lost To save time it is recommended that you first jog each axis near the home switch before homing Once Machine Zero home is set the machine tool envelope is redefined If Machine Zero was already set before homing FlashCut CNC displays a dialog showing the discrepancy between the previous Machine Zero and the new Machine Zero just found This provides a convenient way to check that no steps were lost while cutting a part within the accuracy limits of the home switch The home switches supplied as a FlashCut accessory have a repeatability of 0 001 FlashCut CNC Section 2 Main S
43. auses the tool path of the current G Code File to expand as much as possible within the Tool Path View Port When this option is not chosen the Tool Path View Port displays the entire work envelope Program Machine Relative Distance To Go or Coordinates Allows you to choose a display mode for the Tool Position Box Choosing either Program Coordinates Machine Coordinates Relative Coordinates or Distance To Go Coordinates will expand the chosen coordinate display into the entire Tool Position Box Choosing Coordinates will display all four coordinate systems simultaneously in the Tool Position Box You can also change these view modes by choosing the expand or contract button next to any of the Coordinate System Labels Help Menu File Setup Controller View 8 5 FlashCut Help About FlashCut FlashCut Help Displays the main help screen About FlashCut Shows the version number of FlashCut CNC Tool Position Box The tool position box shows the current tool position in terms of Program Machine Relative and Distance to Go coordinates FlashCut CNC Section 2 Main Screen Features 13 Program Displays the coordinates of the current position of the tool relative to Program Zero Machine Displays the coordinates of the current position of the tool relative to Machine Zero This coordinate system is undefined if Machine Zero has not been set displays N A Relative Displays the
44. by a rapid move in the Z axis to Program Coordinate Z 2 When using G29 there are several things to keep in mind e You do not need to specify all three coordinates only the ones for which you want movement Example G29 X4 0 Y3 0 Moves the tool to Program Coordinates X 4 0 Y 3 0 leaving the Z position unchanged e The interpretation of the coordinates depends on the G90 G91 command in effect G43 G44 G49 M06 Tool Change and Tool Length Compensation Commands Flashcut CNC supports tool changes and tool length compensation Tool length compensation lets Flashcut CNC account for differences in tool lengths so the G Code program can be created without regard to specific tool lengths except for possible interference problems THESE COMMANDS ARE NOT FOR THE NOVICE CNC USER WHEN NOT PROPERLY USED TOOL LENGTH COMPENSATION CAN CRASH THE MACHINE TOOL CAUSING SERIOUS DAMAGE TO YOUR WORKPIECE OR MACHINE TOOL When applying tool length compensation Flashcut CNC uses the Length Offsets defined in the Tooling Setup dialog box See Tooling Settings in the Initial Setup section for more information on defining your tools For tool length compensation to work properly Flashcut CNC must know what tool is in use at all times including the tool that s loaded when you start running a G Code file Therefore before you run a G Code file that uses tool length compensation you must first choose your starting tool from the Current
45. creen Features 21 Clear Machine Zero Clears the current Machine Zero settings This button is useful when you set Machine Zero manually using the Zero button in the Tool Position Box and need to make a correction to the Machine Zero location Message Box Displays the current status of the Signal Generator and program When the Signal Generator is online the Message Box and the Offline Online indicator are Red Offline File successfully processed Offline Online Indicator Program Listing Box The Program Listing box displays the current part program and highlights the current line You can use the scroll bar to view the entire program GOO X0 Y 45 Program T Listing GO3 x25 YO 1 25 JO G01 X3 081 Current Line G03 X3 331 Y 25 1 0 3 25 G03 X2 903 Y2 408 25 JO Program Listing A listing of the current part program Current Line The line currently being executed or about to be executed by FlashCut CNC To improve system performance the Program Listing Box can be configured to display the current line of G Code only Choose System Options from the Setup menu to find this setting Note that you can open the Editor dialog box by double clicking the Program Listing Box FlashCut CNC Section 3 Initial Setup 23 Section 3 Initial Setup This section describes how to set up FlashCut CNC for use with your machine tool It s very important that the software and hardware are set up prope
46. current relative coordinates The relative coordinate system is general purpose and may be used for anything you choose For instance to measure the distance from any point in the program without having to use the Program or Machine coordinates just zero the relative coordinates at the point from which you want to measure Distance To Go Displays the distance to the ending position of the current move Other Features Expand Button Causes the Tool Position Box to show a large display of the chosen coordinate system 14 FlashCut CNC Section 2 Main Screen Features Program Coordinates Set tH 1 1519 5 19591 0 1000 Contract Button Causes the Tool Position Box to display all four coordinate systems simultaneously Set Button Sets the X Y and Z coordinates of the chosen coordinate system to any value When chosen the following dialog box appears Set Program Coordinates Ed New Values X 1 1519 inches Zero X Y fi 7591 inches Zero Y 7 0 1000 inches Zero Z Cancel OK Zero All gt To set new values within a coordinate system 1 Type in the X Y and Z values for each axis These coordinates will become the current position of the tool 2 Choose OK gt To zero each axis 1 Choose the Zero button for each axis you want to zero 2 Choose OK FlashCut CNC Section 2 Main Screen Features 15 gt To zero all ax
47. e running the G code file FlashCut CNC automatically cancels the local coordinate system when it completes execution of a G code file FlashCutCNC Section4 System Programming 59 Example G01 X1 0 Y3 0 Z 1 5 F12 Moves the tool directly to the Program coordinate X 1 0 Y 3 0 Z 1 5 G52 X3 Y 7 ZO Activates a local coordinate system with origin at X 3 Y 7 Z 0 relative to Program Zero The machine tool does not move G01 X1 0 Y10 0 Z2 0 Moves the tool directly to the point X 1 0 Y 10 0 Z 2 0 relative to the local coordinate system as defined by the G52 command above G52 X0 YO ZO Cancels use of the local coordinate system All absolute moves are again relative to Program Zero as you set it before running the program G90 Absolute Positioning Mode The G90 command puts the system into absolute positioning mode All XYZ coordinates are treated as points relative to Program Zero or a local coordinate system set by the G52 command This command stays in effect until a G91 command occurs Note that absolute positioning is the default positioning mode for FlashCut CNC It is not necessary to include this command in your G code file if all your moves are absolute G91 Incremental Positioning Mode The G91 command puts the system into incremental positioning mode All XYZ coordinates are treated as incremental move distances This command stays in effect until a G90 command occurs Example G01 X1 0 Y3 0 Z 1 5 F12 Moves the
48. e Coordinate X 1 Y 1 Z 1 G01 5 Y2 5 Z 3 F10 Linear move to the Program Coordinate X 1 5 Y 2 5 Z 3 G28 70 Rapid move in the Z axis only to Machine Coordinate Z 1 G01 5 Y2 5 Z 3 F10 Linear move to the Program Coordinate X 1 5 Y 2 5 Z 3 G28 Rapid move in the Z axis to Machine Coordinate Z 1 followed by a rapid move in the XY plane to Machine Coordinate X 1 Y 1 G01 5 Y2 5 Z 3 F10 Linear move to the Program Coordinate X 1 5 Y 2 5 72 3 G28 X0 YO ZO Rapid move in the Z axis to Machine Coordinate Z 1 followed by a rapid move in the XY plane to Machine Coordinate X 1 Y 1 identical to the G28 command with no parameters specified G29 Return from Reference Point The G29 command moves the tool to the designated XYZ coordinate at the rapid rate If the move contains positive Z movement the machine first moves up in the Z axis and then moves across in the XY plane If the move contains negative Z movement the machine first moves across in the XY plane and then moves down in the Z axis Example FlashCutCNC Section4 System Programming The Tool Change Position is defined as Machine Coordinate X 1 Y 1 Z 1 G01 X1 5 Y2 5 Z 3 F10 Linear move to the program coordinate X 1 5 Yz2 5 Z 3 G28 Rapid move in the Z axis to Machine Coordinate Z 1 followed by a rapid move in the XY plane to Machine Coordinate X 1 Y 1 G29 X2 Z 2 Rapid move in the XY plane to Program Coordinate X 2 Y 3 followed
49. e Set Machine Coordinates dialog box If Machine Zero was already set FlashCut CNC displays a dialog showing the discrepancy between the previous Machine Zero and the new Machine Zero just set Choose Yes if you want to use the new Machine Zero just set or No if you want to keep the existing Machine Zero If you chose Yes the Machine Coordinates will automatically zero The Machine Tool Envelope will appear in the Tool Path View Port Setting Backlash If you do not have ball screws or any other zero backlash scheme on your machine the software can compensate for the backlash Of course you are always best off removing as much backlash from the mechanical system as possible in addition to using the software backlash compensation ToSet Backlash 1 Choose Machine Tool from the Setup Menu The Machine Tool Setup screen will appear Make sure the Comp checkbox is unchecked then choose OK Choose the Jog button on the Control Box Drive the X axis in one direction at least 0 25 this will take out any backlash in that direction Zero the Relative Coordinates by choosing the Set button next to the Relative label then Zero Choose the Single Step radio button Jog the axis step by step in the opposite direction until you detect table movement using a dial indicator The Relative Coordinate X axis value is the amount of X axis backlash on your machine tool Write down this number and repeat the above p
50. efine this point as Program Zero choose the Set button next to the Program label then choose Zero All in the dialog that immediately follows Using either Jog mode or Point Mode bring the tool up in the Z axis exactly 1 0 and again define this point as Program Zero by choosing the Set button next to the Program label and Zero All in the dialog that follows Note that this point is exactly 1 above where it needs to be to actually cut the workpiece The machine is now ready to do a dry run without cutting the workpiece Testing the Program on the Machine Tool It is always a good idea to do a dry run of the G Code file both in offline and online modes before cutting a part This way you can make sure the tool behaves as intended before cutting the part 1 Put FlashCut CNC into G Code mode by choosing the G Code button in the Control Box Make sure the G Code program is reset by choosing the Reset button on the Control Box then OK in the confirmation dialog Take the Signal Generator offline by choosing Offline from the Controller menu Go into step mode by choosing the Step radio button in the Control Box Repeatedly choose the Start button watching the screen to make sure the tool behaves properly Once you are satisfied the program will behave properly re establish communications with the Signal Generator by choosing Online from the Controller menu A dialog will ask you if you want to revert to the coordina
51. es 1 Choose the Zero All button to zero all of the coordinates simultaneously Tool Path View Port The figure below shows the Tool Path View Port The XY Grid represents an aerial view of the tool envelope The Z Scale represents the height of the tool during machining Green and light blue dots are used to represent the origins of the Program and Machine if used coordinate systems respectively The Machine Envelope is shown as the light blue box on the XY Grid and by the light blue bar on the Z Scale Machine Zero Machine Envelope The figure below shows the Tool Path View Port during the machining process The bottom of the blue tool icon adjacent to the Z scale represents the current Z position of the tool The yellow dot on the XY grid represents the current position of the tool The red outline in the XY Grid represents the tool path of the entire G code program The red bar along the Z Scale represents the total Z travel Blue represents the portion of the tool path that has already been cut Solid lines depict feedrate moves while dashed lines represent rapid moves FlashCut CNC Section 2 Main Screen Features Total Z Travel Current Z Height Program Tool Path Red Control Box The Control Box shown below contains all of the controls to move the machine tool Code Jog Point Home Setup File SHER5400 STP Curr Tool n 3 16 Ball End Mill 2 Flute Fas
52. es The entire toolpath is then optimized to reduce total machining time for the part The DXF import assumes the part surface is at a Z program height of 0 0 and all geometry is to be treated as either holes or cutter paths with no offsets gt To import a DXF file 1 Choose Import DXF from the File menu The Import DXF File dialog box appears In the List files of type pull down menu choose the type of file you are looking for A DXF file should have a DXF extension 42 FlashCut CNC contains the file name and choose OK Section 4 System Programming In the Drives pull down menu choose the drive that contains the file In Folders list box double click the name of the folder that contains the file Continue double clicking subfolders until you open the subfolder that In the box that lists files double click the file name or click on the file The Save G Code File dialog box appears asking you the name of the new G Code file created by the DXF import By default it will use the DXF file name with an FGC extension in the same drive and folder in which the DXF file resides If this is acceptable choose OK To choose a different file name or folder 1 Choose the drive you want from the Drives pull down menu 2 Click on the folder you want in the Folder box 3 Type the file name in the File name box or type the entire path in the File name box 4 Choose OK 5 The Import Setup dialog box wi
53. es all distances are in millimeters and all feedrates are in millimeters minute For compatibility reasons Flashcut CNC accepts G71 as equivalent to G21 When using G20 or G21 there are several things to keep in mind e If you don t use either command FlashCut CNC assumes all program values are consistent with the Display Units setting in the System Options dialog box e You may only use one of these two commands in any G Code program so all values in a G Code file must use the same unit system FlashCutCNC Section4 System Programming 53 G28 Return to Reference Point The G28 command moves the tool at the rapid rate to the Tool Change Position defined in the Machine Tool Setup dialog box This position is defined in Machine Coordinates so Machine Zero must be set for this command to be used If the move contains positive Z movement the machine first moves up in the Z axis and then moves across in the XY plane If the move contains negative Z movement the machine first moves across in the XY plane and then moves down in the Z axis If you want the G28 command to move only one or two axes you can limit the movement to those axes by adding the parameters X0 YO or ZO after the G28 command Then Flashcut CNC moves only the indicated axes to their Tool Change Position coordinates A typical use is to only raise the Z axis fora manual tool change G28 Z0 Example The Tool Change Position is defined as Machin
54. feedrate of 3 0 in min G02 X3 0 Y3 0 11 0 J1 0 Moves the tool using clockwise circular interpolation to the Program Coordinates X 3 0 Y 3 0 with a center point of X 2 0 Y 2 0 at a feedrate of 3 0 in min 2 2 Center 1 1 Start When using G02 there are several things to keep in mind The command is modal i e G02 is in effect until another move command occurs G00 G01 or G03 The interpretation of the X Y and Z coordinates depends on the G90 G91 command in effect The I J and K values are unaffected by G90 G91 The tool will move at the current feedrate set by the last F command Only XY arcs can be cut when G17 is active only XZ arcs can be cut when G18 is active and only YZ arcs can be cut when G19 is active The clockwise direction of rotation is as viewed from the positive end of the unused axis the axis not in the plane of motion For example a G02 arc move in the XY plane is clockwise as viewed from the positive end of the Z axis ie from above The following diagram illustrates this behavior FlashCutCNC Section 4 System Programming 51 G02 Clockwise G02 Clockwise G02 Clockwise G03 Counter Clockwise Circular Cutting Move The G03 command is identical to the GO2 command but it moves the tool in a counter clockwise arc instead of a clockwise arc Example G01 X2 0 Y1 0 F8 0 Moves the tool directly to the Program Coordinates X 2 0 Y 1 0 at a feedrate of 8 0 i
55. for a machine tool These files have a STP extension by default Step Mode The number of mini or micro steps between each full motor step The default step mode in FlashCut CNC is Quarter Step or four micro steps between each full motor step Stepper Motor A motor that moves a precise amount when given an electrical pulse Stepper motors typically have 200 full steps per revolution or 1 8 per full step Other popular stepper motors have 0 9 and 7 5 per step Text Boxes Areas in which you type either a name or a value Tool Path The path that a machine tool moves as a G Code program is executed Tool Path View Port The area of the main screen that graphically displays the tool path in real time Tool Position Box The area of the main screen that shows the current coordinates of the tool on the machine tool You can display any one or all of the four coordinate systems in this box Tool Positioning Resolution The amount of machine tool movement on a given axis that corresponds to one step of the stepper motor Note that one step is either one Full Step one Half Step or one Quarter Step depending on the step mode of the Stepper Motor Driver Tool Positioning Resolution TPR depends on 4 factors Step Mode SM Gear Ratio GR Motor Resolution MR and Screw Thread ST where TPR 1 SM GR MR ST
56. g the Continuous radio button 7 Turn the machine tool spindle on and make sure everything is ready on the CNC Machine 8 Choose the Start button and the CNC Machine will begin to cut out your first part Always be on alert to choose the Feed Hold button or hit any key in case of emergency 9 Congratulations you ve successfully cut your first part using FlashCut CNC Exiting the Program To exit FlashCut CNC choose Exit from the File menu This will close communications with the Signal Generator and return you back to Windows Turning off the Controller Always turn off the Signal Generator and Stepper Motor Driver when they are not in use FlashCut CNC Section 6 Glossary 77 Section 6 Glossary Backlash The amount of motor movement that occurs without table movement when changing directions This is usually due to the amount of slop between the nut and the screw in the drive system Baud Rate The speed at which Flashcut CNC communicates across the serial port with the Signal Generator It is measured in bits per second and is typically set at 38 400 Buffer Time The Buffer Time is used to prevent system events from affecting motor movement The larger the Buffer Time the less effect system events have on motor movement The smaller the Buffer Time the more responsive the machine tool is to mouse clicks Stepper Motor Driver The electronic box that converts step and direction signals from the Signal Generato
57. green dot in the Tool Path View Port Pull Down Menu A standard Windows control that lets you select a single item from a list Quarter Step Step mode where four steps from the controller correspond to one full step of the motor Radio Buttons A group of options requiring a single selection like the channel buttons on your car radio Ramping Method of accelerating a motor at increasingly faster step rates in order to reach high feedrates Ramp rates are measured in full steps sec sec When ramping is used a motor will accelerate and decelerate at the same ramping rate FlashCut CNC Section 6 Glossary 79 Relative Coordinates The XYZ position of the tool on the CNC machine relative to the point at which the Relative Coordinates were zeroed The relative coordinate system is general purpose and may be used for anything you choose Resonant Speeds Rotational speeds at which a stepper motor will vibrate excessively Quite often the motor will stall if run at these speeds This is dependent on the size of the motor the size of the load it is driving and the power of the controller Typically increasing loads and reducing controller current will reduce resonance Screw Thread The number of turns per inch of travel of the helical drive screw for each axis Serial Port A communications port on both the PC and the Signal Generator used to exchange commands and information Setup File A file containing the CNC Setup Parameters
58. hCut CNC TUTOR FGC File Setup EMLOS View T v Offline Input Status Dutput Control Using the Jog Controls The jog controls let you manually position the tool to any position within the machine tool envelope 1 Choose Jog button in the Control Box This will put FlashCut into Jog mode Select the Slow radio button In this mode the machine tool will move at the Slow Jog Rate defined in the Feedrate Ramping Setup dialog box If you are offline the jog rate on the screen is determined by the speed of your CPU Look at the machine tool envelope to make sure there is enough room to move the tool in the Z direction If there is enough room click down hold and release the Z Axis Jog button Notice how the tool moved up and the Z program and relative coordinates changed Also notice how the machine moved until you released the button If the tool went down instead of up change the motor polarity for the Z axis in the Machine Tool Setup menu as described in Section 1 Initial Setup Note that if Machine coordinates are properly set described in the next section Setting Machine Zero FlashCut CNC will not let you move beyond the machine tool envelope Note that you can also jog the machine using the keyboard The controls are mapped as follows FlashCut CNC Section5 Tutorial 71 X Right Arrow Key X Ctrl Left Arrow Key Y Ctrl Up Arrow Key Y Ctrl Down Arrow Key Z Ctrl
59. he editor Open Setup Opens a file containing all CNC Setup Parameters for your machine tool You can set these parameters using commands in the Setup and View menus described below Setup file names have a STP extension by default Save Setup Saves the current CNC setup parameters under any file name in any directory Save Setup As Prompts you for a file name in which to save the current CNC Setup Parameters Import DXF Directly translates a 2 dimensional DXF file into G Code for use in FlashCut CNC Exit Closes the communications port to the controller then exits the program This does not automatically turn off the controller You must turn off the controller separately Setup Menu FlashCut CNC No G Code File Open Controller View Help Machine Tool Feedrate Ramping Tooling Input Lines Dutput Lines Motor Signals G M Codes Import System Options Machine Tool Feedrate Ramping Tooling Input Lines Output Lines Motor Signals G M Codes Import System Options Open dialog boxes where you ll enter your CNC setup parameters such as the size of your machine tool envelope or the configuration of your Signal Generator These parameters are described in detail later in the manual FlashCut CNC Section 2 Main Screen Features Controller Menu FlashCut CNC No G Code File Open File Setup Online v Offline Input Status Output Control
60. is best explained through a simple example The following G code program uses one subroutine called mysub Example G01 X1 Y1 F10 First line of main program M98 Pmysub Jump to subroutine mysub G01 X0 YO Continued execution after mysub ends M02 End of main program Omysub First line of the subroutine called mysub G01 X2 Y2 Continued execution within the subroutine M99 End of subroutine mysub In the main program the M98 command causes program execution to jump to the first line of the subroutine named mysub Notice that the letter P must immediately precede the name of the subroutine with no spaces FlashCutCNC Section 4 System Programming 61 The subroutine definition begins with the letter O followed immediately by the subroutine name with no spaces The subroutine must end with the M99 command as shown M99 causes program execution to jump back to the main program continuing with the line immediately following the M98 line G01 YO above The main program must end with M02 the End of Program command M02 is not required in a G code program unless there are subroutines defined below the main program Subroutine names may include up to 10 alpha numeric characters You may use as many subroutines as you like but each must have a unique name within the program file If necessary you can nest subroutines meaning one subroutine may call another subroutine which in turn may call another subroutine
61. ll appear r General r Feedrates Scale 1 0000 Decimals 4 XY Feedrate 15 00 in min Join Tol D D0100 inches Iv Line Numbers Plunge Feedrate 1 00 in min mZ Axis Coordinates m Circles Tool Up 0 2500 inches Incremental Depth of Cut 1000 inches Final Tool Down Milling 0 2000 inches Final Tool Down Holes 0 1000 inches amp Mill All Circles C Drill Circles of Diameter Less Than fo 0000 inches C Drill Circles of Diameter fo 0000 inches fo 0000 inches fo 0000 inches o 0000 inches Program Zero Location C X Y of Import File X 0 0000 inches Y 10 0000 inches Lower Left of Toolpath Fill in the values for each of the following fields Scale A multiplication factor for the toolpath in the XY plane only For example if you enter a 2 here the toolpath generated will be double the 10 11 12 13 14 15 16 17 18 19 20 PAM 22 FlashCutCNC Section4 System Programming 43 size of the original geometry defined in the DXF file Note that the values you enter for positioning the Z axis are unaffected by the scale factor Decimals The number of decimal places to use for all coordinates A higher number can help eliminate extra backlash compensation moves caused by rounding error Join Tolerance If two drawing entities such as two lines are touching end to end Flashcut CNC
62. menu The Open G Code File dialog box appears 2 In the List files of type pull down menu choose the type of file you are looking for Existing FlashCut CNC files will have an FGC extension If you are unsure of the file type choose Files 3 In the Drives pull down menu choose the drive that contains the file 4 In Folders list box double click the name of the folder that contains the file Continue double clicking subfolders until you open the subfolder that contains the file 5 In the box that lists files double click the file name or click on the file name and choose OK To see your new tool path updated in the Tool Path View Port without leaving the editor 1 Choose Update Tool Path To save your program using the same file name Choose Save G Code from the editor s File menu 2 If you re saving a new file a Save G Code File dialog box will appear Follow the directions save a new program below starting with step 2 To save a new program created by the editor or to save an edited file under a different file name 1 Choose Save G Code As from the editor s File menu 2 Choose the drive you want from the Drives pull down menu 3 Click on the folder you want in the Folder box 4 Type the file name in the File name box or type the entire path in the File name box 5 Choose OK To close the editor 1 Choose Exit 46 FlashCutCNC Section4 System Programming G and
63. n min G03 X0 0 Y3 01 1 0J1 0 Moves the tool using counter clockwise circular interpolation to the Program Coordinates X 0 0 Y 3 0 with a center point of X 1 0 Y 2 0 at a feedrate of 8 0 in min 1 2 Center 2 1 Start 52 FlashCutCNC Section4 System Programming G04 Dwell The G04 command causes the program to dwell or wait for a specified amount of time The time to wait is specified by the letter X immediately followed by the number of seconds For safety reasons there is a maximum time allowed for each dwell command Example G04 X1 5 The program pauses for 1 5 seconds before moving on to the next line of G Code G17 G18 G19 Arc Plane Selection These commands specify the plane used for circular interpolation as follows G17 XY plane G18 XZ plane G19 YZ plane When using G17 G19 there are several things to keep in mind e Unless you explicitly use the G18 or G19 command Flashcut CNC assumes G17 as the default e The three commands are modal i e one command remains in effect until another in the set is used G20 G21 Inch Units and Metric Units The G20 command indicates that all G Code commands are in inch units Flashcut CNC then assumes all distances are in inches and all feedrates are in inches minute For compatibility reasons Flashcut CNC accepts G70 as equivalent to G20 The G21 command indicates that all G Code commands are in metric units Flashcut CNC then assum
64. n the command name To close a menu without choosing a command press ESC Using Shortcut Keys Some of the FlashCut CNC commands have shortcut keys associated with them You can choose these commands by pressing the shortcut keys listed on the menu to the right of the command Using the TAB and ARROW Keys The TAB key and ARROW keys can be used to navigate through the currently active screen selections Once the selection that you want is highlighted use the RETURN key to select it Using Standard Windows Controls FlashCut CNC uses several standard Windows controls radio buttons pull down menus text boxes and command buttons Radio Buttons Radio buttons represent a group of options of which only one can be selected at a time just like the channel buttons on your car radio FlashCut CNC Section 1 Getting Started Pull Down Menus A pull down menu is a list of commands which appear when you select either a menu or a down arrow icon Text Boxes Text boxes are areas in which you type either a name or a value Command Buttons Command buttons perform a specific task when selected G Code Jog Point Any Point Coord Incremental in Start Feed Hold Any Key FlashCut CNC Section 1 Getting Started 5 System Safety When running any machining operation safety is of utmost importance For proper and safe use of the FlashCut CNC program
65. nce G00 Rapid Tool Positioning The G00 command moves the tool to the designated XYZ coordinate at the rapid rate using 3 Axis linear interpolation The rapid rate is calculated from the Maximum Feedrates defined in the Feedrate Ramping Setup dialog box Example G00 X1 0 Y2 0 Z1 5 Moves the tool directly to the Program Coordinate X 1 0 Y 2 0 Z 1 5 at the rapid rate assuming G90 is active If G91 is active then it moves the tool a distance 1 2 1 5 from the current location When using 00 there are several things to keep in mind e You do not need to specify all three coordinates only the ones for which you want movement Example G00 X4 0 Y3 0 Moves the tool to Program coordinate X 4 0 Y 3 0 leaving the Z position unchanged e This is a modal command meaning that all successive moves will be treated as rapid moves until another modal move command G01 G02 or G03 occurs Example G00 X1 0 Y2 0 Z1 5 Rapid Move X4 0 Y6 5 Z1 0 Rapid Move G01 X3 0 Y3 0 71 4 Feedrate Move X2 8 Y1 4 ZO Feedrate Move e The interpretation of the coordinates depends on the G90 G91 command in effect FlashCutCNC Section4 System Programming 49 G01 Linear Interpolated Cutting Move The G01 command moves the tool to the designated XYZ Program coordinate at the designated feedrate using 3 Axis linear interpolation Example G01 X2 0 Y1 0 Z 1 5 F2 0 Moves the tool directly to the Program coordinate X 2 0 Yz1 0 Z 1 5 ata feed
66. o jog away from the switch that was tripped Once you move the table off the limit switch normal operation will resume If a safety switch is tripped FlashCut CNC will not allow any machine movement until you clear the switch gt To Configure the Input Lines 1 Choose Input Lines from the Setup menu The Input Lines Setup dialog box will appear 36 FlashCut CNC Section 3 Initial Setup Input Lines Setup x mInput Lines Switch Line Function Description M 2 ili ll P4 4 Safety Unused Unused 2 Forinput line 1 choose the appropriate option from the Switch Function pull down menu For example if the line is wired to a limit switch on the negative end of the X axis choose X If the line is wired to a general purpose safety switch choose Safety and enter a Description If the line is unused choose Unused Note The Control option is not used by the current version of FlashCut CNC 3 Repeat for all 8 input lines Output Line Settings FlashCut CNC can control up to 8 output lines to activate devices such as the spindle or coolant pump You can manipulate any or all of the output lines with user defined M codes Please see the FlashCut CNC Hardware Guide for more hardware details including the pin layout of the output line connector gt To Configure the Output Lines 1 Choose Output Lines from the Setup menu The Output Lines Setup dialog box will appea
67. ocess for any reason choose the Feed Hold button or hit any key on the keyboard besides Ctrl or Shift If Machine Zero was already set before homing FlashCut CNC displays a dialog showing the discrepancy between the previous Machine Zero and the new Machine Zero just found Choose Yes if you want to use the new Machine Zero just found or No if you want to keep the existing Machine Zero If you chose Yes the Machine Coordinates will automatically zero The Machine Tool Envelope will appear in the Tool Path View Port To Set Machine Zero Without Using Home Switches l Choose Machine Tool from the Setup Menu The Machine Tool Setup screen will appear Make sure you ve entered correctly the home switch setup parameters as described in the Machine Tool Settings section of this manual Choose OK Choose the Jog button on the Control Box FlashCut CNC Section 3 Initial Setup 33 Jog the tool to the home end of each axis as defined in the Machine Envelope Home End column in the Machine Tool Setup screen Move each axis to within a short distance of its physical limit If this is the first time you re setting Machine Zero it might be helpful to scratch a reference line or affix a vernier scale between the two relative moving parts on each axis This will help you eye ball the same home position again Choose the Set button next to the Machine label in the Tool Position Box Then choose the Zero button in th
68. ogram group then choose the FlashCut CNC program icon Using the Mouse Most mice have two buttons When using FlashCut CNC always use the left mouse button unless specifically instructed otherwise The following table explains basic terms associated with using the mouse To Point Click Do this Position the pointer arrow on an item Point to an item and then quickly press and release the mouse button Double click Point to an item and then quickly press and release the mouse Drag Hold button twice Point to an item press and hold the mouse button as you move the mouse to a new location Then release the mouse button Point to an item press and hold the mouse button FlashCut CNC Section 1 Getting Started 3 Choosing Commands A command is an instruction that tells FlashCut CNC to perform a task You can choose a command by 1 Choosing a command from a menu with your mouse 2 Choosing a command from a menu with your keyboard 3 Using shortcut keys 4 Using the TAB and ARROW keys Choosing a Command by Using the Mouse Click the name of a menu item on the menu bar then click the command name To close the menu without choosing a command click outside the menu Choosing a Command by Using the Keyboard Press ALT or F10 to make the menu bar active and then press the key corresponding to underlined letter in the menu name To choose a command press the key corresponding to the underlined letter i
69. on eptenniteieani eite nip eec nimios 31 Setting pecie eiut 33 Tooling SCHINGS cuis ssepe on a e 34 Input Eine Settings teo epp on uiteniauserie eene 35 Output Line Settings iu esee eoe Ote ate nne 36 Motor Signal Settings iau 38 Gand M Code Settings i utente 39 SYSTEM PROGRAMM ING soe po o coa eeu eee aorta ned aee akon eaae eese osa coe osea deu aeneus aseo eue 41 OPENING A GiCODE PROGRAM tere eset Peoria eim a 41 IMPORTING A DXE BIEE 5 2 ERE nete tta teet eter dt ania e e 41 USING THE PROGRAM EDITOR 2 5 5 ns RETE Desde he ER OI RI ET EEE ERE 44 GAND M CODES SUPPORTED et Cree taxe ER Eee e aa tee Renee Ure ere REN 46 KEY PROGRAMMING CONCEPTS cccccccsssssssecceecccceecueecccceeceusnseeeccceeeceeeeaaaecceeesauueeseccesesssuansaansecessaaaeeeececesseaannses 46 MOUe 0 2 Sole ee 47 Absolute VS Incrementidls 47 AND M CODE REFERENCE 5 PAETE ESES 48 GOO Rapid Tool Positioning esie ite pibe Bite el ou atte ebrei ined 48 GOI Linear Interpolated Cutting Move eese eene
70. ors lose steps If so decrease the feedrate in the program 5 Repeat the above process until neither motor loses any steps When you are done enter the final feedrate from the program into the Maximum Arc Feedrate text box If there was no loss of steps when the Maximum Feedrate was used enter the Maximum Feedrate into the text box Setting Machine Zero Setting Machine Zero using home switches not only sets up the machine tool envelope but also allows you to re position a tool to a precise physical location even after the controller has been turned off or has lost power 32 FlashCut CNC Section 3 Initial Setup Setting Machine Zero without home switches won t help you reposition a tool after losing power but it will set the machine tool envelope This is very useful because the software will always ramp down the machine to a complete stop at the defined limits of the machine tool envelope gt To Set Machine Zero Using Home Switches 15 Choose Machine Tool from the Setup Menu The Machine Tool Setup dialog box will appear Make sure you ve entered correctly the home switch setup parameters as described in the Machine Tool Settings section of this manual Choose OK Choose the Home button on the Control Box G Code Jog Point Clear Machine Zero Start Feed Hold Any Key Choose the Start button The machine will now move each axis until it finds the home switch If you need to stop the pr
71. r FlashCut CNC Section 3 Initial Setup 37 Output Lines Setup x r Output Lines Line Description Line Description 1 Spindle 5 2 Mist Coolant 6 3 Flood Coolant 7 Cancel 4 8 M Codes Before After Delay Move sec Output Line Action M Code Description 4 5 6 7 8 Spindle On Spindle Off Mist Coolant On Flood Coolant On Coolant Off Change 2 In the Description text boxes type descriptions for each device connected to the output lines To define an M code to control output lines 1 In the M Code text box type the number for the M code that you want to define 2 In the Description text box type a phrase which best describes the action taken when this M code is executed 3 In the Output Line Action pull down menus choose the action for each line upon execution of the M code The choices are On Off or where the indicates that the state of the line remains unchanged 4 Choose Before or After from the Before After Move pull down menu If you choose Before and there is a machine tool move command on the same program line as the M Code the M code will be executed before the move If you chose After the M code will be executed after the move 5 In the Delay text box enter the amount of delay between execution of the M Code and execution of the next G Code command Fo
72. r View Help Program s Machine x amp ol x 0 0000 X 0 0000 Y 0 0000 0 0000 2 0 0000 Z 0 0000 Relative se o DistToGo oF 0 0000 X 0 0000 Y 0 0000 0 0000 2 0 0000 Z 0 0000 Machinetooide Offline G Code Jog Point Home Setup File FLASH120 5TP Curr Tool No Tool Specified x Faster Program Feedrate 0 0 GOl 7 2 25 F5 0 swe 100 override 0 0 601 X4 0 G03 Yl 0 I0 0 J0 5 Reset CStep Continuous 600 20 0 Start Feed Hold Any Key Goo X0 0 Y0 0 To view in scale to fit mode choose Scale to Fit from the View menu The tool path will now expand to the largest size possible in the Tool Path View Box Now choose the View menu again and notice the check mark in front of the Scale to Fit menu item This means that the Tool Path View Box is currently in scale to fit mode If you wanted to view the entire machine tool envelope you would choose Scale to Fit again but for now let s keep the screen in scale to fit mode so hit the escape key on your keyboard FlashCut CNC Section5 Tutorial 67 FlashCut CNC TUTOR FGC OF x File Setup Controller View Help Program _se ol Machine ku ol x 0 0000 0 0000 Y 0 0000 fy 0 0000 Z 0 000042 0 0000 Relative se Gi DistToGo x 0 0000 JX 0 0000 Y 0 0000 0 0000 Z 0 000044 0 0000 amp Code Home Setup
73. r example if your spindle motor takes about 3 seconds to get to full speed this value should be at least 3 For safety reasons the maximum value for this delay is 5 seconds 38 FlashCut CNC Section 3 Initial Setup Motor Signal Settings FlashCut CNC provides four signals for stepper motor drivers step direction park and enable Different manufacturers have different requirements for the polarity and timing of these signals FlashCut CNC provides the flexibility to tailor the motor signals to run most drivers To Configure the Motor Signal Lines 1 Choose Motor Signals from the Setup menu The Motor Signals Setup dialog box will appear Motor Signal Setup Ed Motor Signals Step Pulse Step Pulse Width usec Enable Signal Low Park Signal High 2 From the Step Pulse pull down menu choose either High or Low depending on the polarity of the step pulse See the diagram below 5 V ml OV Low Step Pulse h Step Pul gh Step Pulse 45 OV sep Pulse Width 3 In the Step Pulse Width text box type the duration of the step pulse in microseconds 4 From the Enable Signal pull down menu choose High if the driver is enabled by a high signal or Low if the driver is enabled by a low signal 5 From the Park Signal pull down menu choose High if a high signal to the park low power line puts the driver into a reduced power mode Choose Low if the opposite is t
74. r into a sequence of amplified signals to drive a stepper motor Signal Generator The electronic box that converts computer commands into step and direction signals for input into a Stepper Motor Driver It also interprets input signals and creates output signals to control various peripheral devices CNC Setup Parameters FlashCut CNC settings that are unique to each machine tool You can set these settings in the Machine Tool Setup Feedrate Ramping Setup System Options and Import Setup dialog boxes The coordinate display mode is also a CNC Setup Parameter All of these settings are saved in a setup file Command Buttons Buttons which perform a certain task when chosen DXF Document Exchange Format Defined by AutoDesk Inc as a way to exchange CAD files between different CAD CAM or CAE programs Feedrate The linear speed of the cutting tool relative to the workpiece Defined in G Code by the F parameter in inches minute Full Step Step mode where one step from the controller corresponds to one full step of the motor G Code Standard programming language used to control a CNC machine Gear Ratio The ratio of the number of stepper motor revolutions to drive screw revolutions due to any gears or pulleys between them Half Step Step mode where two steps from the controller correspond to one full step of the motor Jog Method of manually controlling the motors of the machine tool on any axis in any direction Limit
75. rate of 2 0 in min You do not need to specify all three coordinates only the ones for which you want movement Example G01 X4 0 Y3 0 Moves the tool to Program coordinate X 4 0 Y 3 0 leaving the Z position unchanged When using G01 there are several things to keep in mind e As explained for the GOO Command X Y and Z are not required e The command is modal i e GO1 is in effect until another move command occurs G00 G02 or G03 e The interpretation of the coordinates depends on the G90 G91 command in effect e The F command is used to designate a feedrate The feedrate set with the F command is modal stays in effect until another F command occurs Example G01 X4 0 Y3 0 Z1 0 F7 0 Moves the tool to Program coordinate X 4 0 Y 3 0 Z 1 0 at a feedrate of 7 0 in min X2 0 Y2 5 Moves the tool to Program Coordinate X 2 0 Y 2 5 leaving the Z axis unchanged at Z 1 0 The feedrate remains 7 0 in min G02 Clockwise Circular Cutting Move The G02 command moves the tool in a clockwise path from the starting point the current tool position to the designated ending point in the currently selected plane see G17 G19 The I J and parameters represent the relative X Y and Z distances respectively from the starting point of the arc to the center point of the arc Example 50 FlashCutCNC Section 4 System Programming 1 X1 0 Y1 0 F3 0 Moves the tool directly to the Program Coordinates X 1 0 Y 1 0 at a
76. re a higher value If you want to change this setting enter a new value in the Buffer Time text box The Start Delay allows the screen to fully update after the Start button or Jog button is selected and before your machine tool begins moving There are separate values for Jog moves and G Code or Point moves Slower computers may require a higher value If you want to change these settings enter a new value in the appropriate text box The Coordinate Update value determines how often the coordinates are updated in the Tool Position Box while the tool is moving There are separate values for Jog moves and G Code or Point moves Higher values may increase performance on slower computers If you want to change these settings enter a new value in the text box Note that coordinates are always updated at the end of every move The size of the Program Listing Box affects system performance during a continuous run To see the entire Program Listing Box during a continuous run select the Show Program Listing Box radio button For better performance select the Show Current G Code Line Only radio button This is especially important when you re running programs with a large number of very short moves FlashCut can easily be configured for the type of machine that you are running Choose either Mill or Lathe from the Type pull down menu If you are using a machine with CNC control on the X and Y axes only remove the check from the Z Axis check box
77. rly before you attempt to operate the machine tool Otherwise the machine may behave in a potentially dangerous manner Please read through this section carefully to get a good understanding of how FlashCut CNC controls your machine Windows Setup Since FlashCut CNC is a real time control program it must have full control of the operating system while running It is very important that you do the following before running Flashcut CNC Disable all screen savers and power management programs Make sure there are no background programs running such as back up software and calendar reminders Make sure no other programs are open To Disable the Screen Saver Windows 95 98 or NT 1 Choose Settings then Control Panel from the Start Menu 2 Double click the Display icon 3 Select the Screen Saver tab 4 Select None from the Screen Saver pull down menu 5 Choose the Apply button 6 Choose OK to exit Windows 3 1 1 Double click the Control Panel icon in the Main program group 2 Double click the Desktop icon 3 Select None from the Screen Saver Name pull down menu 4 Choose OK to exit FlashCut CNC Section 3 Initial Setup Software Setup The Setup File software settings are stored in a setup file which by default has a STP extension Before you start you ll need to open the appropriate setup file Choose Open Setup from the File menu and select the appropriate setup file Some setup files
78. rocess at different places along the X axis Choose Machine Tool from the Setup menu The Machine Tool Setup dialog box will appear 34 FlashCut CNC Section 3 Initial Setup 10 Record the average of all backlash values in the X axis Backlash text box If you have no backlash on an axis or if you don t want backlash compensation on an axis just enter zero 11 Repeat the above steps for each axis When you re finished choose the Comp checkbox and make sure there is a check in it Tooling Settings FlashCut CNC provides for a tool library of up to 100 tools Each tool has an associated tool number description and length offset The length offset is used when tool length compensation G43 or G44 is used in a G Code program gt To Set Up the Tool Library 1 Choose Tooling from the Setup menu The Tooling Setup dialog box will appear Tool Definitions Length Offset Description inches 1 4 Ball Endmill 4 Flute 1 2 EndMill no e e eiojoiojoeijejeiejeiejeiejeiejeilojio ejiejieleilelelpelielelaelilejlelelaelejloeljao c OOOO OO OO oo oo oo oo aoa 2 Enter the tool description for each tool next to the appropriate tool number This description will be used by the program when referring to a given tool 3 Enter the length of the tool relative to a common reference point For example if there is a locating feature on an endmill holder th
79. rue Note that most motor drivers do not have a FlashCut CNC Section 3 Initial Setup 39 separate line to control the power level In this case the setting for this line will not be applicable 6 Note that the direction polarity is set by the Motor Polarity field in the Machine Tool Setup dialog box Recommended Settings for Various Stepper Motor Driver Boxes FlashCut CNC Stepper 3020 3035 3070 2070 Motor Driver Models 2020 2035 1120 Enable Signal Park Signal Not Used Not Used Low or High Low or High G and M Code Settings FlashCut CNC lets you customize handling of some G and M codes gt To Configure G and M Code Handling 1 Choose G M Codes from the Setup menu The G M Code Setup dialog box will appear G M Code Setup x G M Code Options Message On 00 Program Pause 2 Check the Ignore G54 checkbox if you want Flashcut CNC to ignore this command in a G Code program Flashcut CNC does not currently support G54 If you choose to ignore G54 make certain any G Code program you run does not rely on G54 to position the machine tool 3 Check the Message on MOO Program Pause checkbox if you want Flashcut CNC to display a message dialog whenever it encounters an command in a G Code program If you uncheck this option Flashcut 40 FlashCut CNC Section 3 Initial Setup CNC will pause processing of the G Code program without displaying a message Section 4
80. some instruction to get started Since automated machining is potentially dangerous please take the time to completely read through this manual to understand the operation of the software and machine before cutting a part Please note that all FlashCut CNC terminology appears in boldface upon first occurrence and is defined in the glossary It is assumed that you already have a working knowledge of the PC and Windows If you are not familiar with either of these please review your PC or Windows user s guides before you use FlashCut Program Overview FlashCut CNC is a Windows based program that gives you direct control of your machine tool while displaying real time graphics With FlashCut CNC you can e Visualize and verify the tool path generated from a G Code file e Watch the current position of the machine tool as it moves e See the current position of the machine tool in either Machine Program Relative or Distance To Go coordinates e Create edit and display a G Code program e Move the machine tool in any of four different modes Jog Point G Code or Home Import DXF files FlashCut CNC Section 2 Main Screen Features 7 Section 2 Main Screen Features The main screen is shown below An explanation of each area of the screen follows FlashCut CNC SHOW2 FGC lolx File Setup Controller View Help Test Program s amp Machine s ol X 0 7750 X 3 7750 Y 0 2296 Y 1 7704 2 4800
81. sor to the first line of G Code that reads G01 Z 2 25 F5 0 Change it to read GO1 Z 0 25 F5 0 then choose Update Tool Path on the bottom of the editor screen Notice how the red line along the Z axis which shows the total length of Z travel shrinks down to 0 25 3 Now let s change the diameter of the arc we are cutting Move the cursor to the line of G Code that reads G03 Y1 0 10 0 JO 5 Change it to read G03 Y2 0 10 0 J1 0 4 To save your changes 1 Choose Save G Code As from the editor s File menu 2 Choose the drive you want from the Drives pull down menu 3 Click on the folder you want in the Folder box 4 Type tutor2 fgc in the File name box 5 Choose OK 5 Toclose the editor choose Exit 70 FlashCut CNC Section5 Tutorial Connecting the Machine Online Now you are ready to communicate with the Signal Generator In this step we will put FlashCut CNC into online mode Note that when in online mode all moves will be performed by the machine tool If you are running the Demo version of FlashCut CNC or do not have the means to go online at this time ignore this section and continue with Using the Jog Controls below l Make sure that the machine tool and Signal Generator are connected properly as described in Section 1 Initial Setup Turn on the Signal Generator Choose Online from the Controller menu After a short wait a dialog box should inform you that the controller is now online Flas
82. ss to move the tool exactly 0 5000 inches in the X direction and 0 2500 inches in the direction The Program coordinates should now read X 0 5000 Y 0 2500 Z 2 0000 Setting Machine Zero You can set Machine zero by either jogging the tool to the corner of the machine tool envelope or by going into home mode and finding home for all 3 axes In this tutorial we will jog to a point and define it as Machine Zero 1 Choose the Home button in the Control Box This will put FlashCut CNC into Home mode 72 s he do um FlashCut CNC Section5 Tutorial Choose the Clear Machine Zero button This will clear the machine coordinates and remove the light blue Machine Tool Envelope Choose the Jog button in the Control Box This will put FlashCut CNC into jog mode Jog the tool to 1 10 from the top of the Z axis Jog the table in the X direction to about 1 10 from the end of travel Jog the table in the Y direction to about 1 10 from the end of travel Choose Set next to the Machine label Choose Zero All in the dialog box Using the Point Move There is an even easier way to move the tool to an exact position using the point mode of the Control Box l Choose the Point button in the Control Box From the Name pull down menu select Any Point From the Coord pull down menu select Machine 2 3 4 5 Fill in the X Y and Z point coordinates to read 1 2 1 Enter 4 in the Feedrate box The machine is now
83. ter Program Feedrate 20 0 Slower 100 override 20 0 Reset CStep Continuous Start Feed Hold Any Key There are four modes G Code Moves the tool along the tool path specified by a G Code program Jog Provides means to manually move the tool in all three axes Point Moves the tool to any point you specify Home Seeks the home switches for all three axes To change modes simply click on the appropriate mode button The operation of each mode is described below FlashCut CNC Section 2 Main Screen Features 17 G Code Mode G Code mode provides controls to move the tool as directed by the current G Code program Curr Tool 1 3 16 Bal Faster Program Feedrate 20 0 Override 20 0 Reset CStep Continuous Feed Hold Any Key Start Button Current Tool Displays the current tool loaded in the machine tool Note that FlashCut CNC uses this setting for tool length compensation see System Programming for more information Feedrate Override Buttons Increases or decreases the feedrate on the machine as a percent of the programmed feedrate During linear interpolation moves G01 you can gradually change the feedrate using the Faster or Slower buttons The Faster and Slower buttons are disabled during circular interpolation and rapid moves When the machine is stopped you can en
84. ter an exact percentage by either typing a value in the percentage text box or by choosing a value from the pull down menu in the percentage text box Both the programmed feedrate and the override feedrate are displayed in the text boxes to the right Rapid moves are not affected by the feedrate override You can use the keyboard instead of the Faster Slower buttons as follows Faster Ctrl Up Arrow Key Slower Ctrl Down Arrow Key Reset Button Resets the current G Code file to the first executable line and refreshes the Tool Path View Port Continuous Step Radio Buttons You can run the G Code file in either Continuous or Step mode by selecting one of these two radio buttons In Continuous mode the G Code program runs non stop In Step mode the G Code Program only executes one line at a time You can switch between step and continuous modes while the machine is moving Start Button Begins execution of the current line of the G Code file When in Step mode execution will stop automatically at the end of the current line or when the Feed Hold button is hit When in Continuous mode execution continues until the end of the program or until the Feed Hold button is hit If the 18 FlashCut CNC Section 2 Main Screen Features program had been stopped in the middle of a G Code line choosing the Start button will begin execution exactly where the program stopped Note that all moves begin with ramping when necessary Feed
85. tes used before going offline Choose OK Go into step mode by choosing the Step radio button in the Control Box Choose the Start button The machine should move in the X and Y axes and then stop Note that everything else is identical to offline mode Step through the entire program by choosing the Start button for every line of G Code If you have to stop the tool at any time you can either choose the Feed Hold button with your mouse or hit any key on your keyboard If you FlashCut CNC Section5 Tutorial 75 stop the tool in the middle of the program you can start exactly where you left off by choosing the Start button You may want to try this for practice Cutting the Part Assuming everything was fine in the previous step we are ready to cut an actual part 1 Check to make sure the Program Coordinates are at 0 0 0 If not go through the Setting Program Zero on the Machine Tool section above 2 Now go into jog mode and carefully move the tool down in the Z direction to the part surface This should be at the program coordinate 0 0 1 3 Set this point as Program Zero by choosing the Set button next to the Program label and Choosing Zero in the following dialog 4 Now jog the tool 0 5 UP in the 7 direction This places the tool in the correct starting position to begin cutting the workpiece 5 Go back into G Code mode by choosing the G Code button in the Control box 6 Go into continuous mode by choosin
86. the Z axis up and the X and Y axes across to the Tool Change Position Program Coordinates 2 Y 2 Z 4 Machine Coordinates X 2 Y 2 Z 0 Change the tool to Tool 2 All coordinates remain unchanged Apply the tool length compensation for tool 2 The offset amount is 0 750 2 250 1 500 The tool does not move However the Program Coordinates change to X 2 Y 2 Z 3 25 The Machine Coordinates remain unchanged at X 2 Y 2 Z 0 Move the X and Y axes across and the Z axis down to Program Coordinates X 1 Y 1 Z 0 25 Machine Coordinates X 1 Y 1 Z 3 0 Linear interpolation to Program Coordinates X 3 Y 3 Z 1 Machine Coordinates X 3 Y 3 Z 4 25 Rapid move in the Z axis only to Program Coordinates X 3 Y 3 Z 3 25 Machine Coordinates X 3 Y 3 Z 0 Change the tool to tool 3 All coordinates remain unchanged Apply the tool length compensation for tool 3 The offset amount is 1 250 1 000 2 250 The tool does not move However the Program Coordinates change to X 3 58 FlashCutCNC Section4 System Programming Y 3 Z 4 5 The Machine Coordinates remain unchanged at 3 Y 3 Z 0 G29 X4 Y4 ZO Move the X and Y axes across and the Z axis down to Program Coordinates X 4 Y 4 Z 0 Machine Coordinates X 4 Y 4 Z 4 5 G01 X5 7 1 Linear interpolation to Program Coordinates X 5 Y 4 Z 1 Machine Coordinates X 5 Y 4 Z 5 5 G28 Move the Z axis up and the X and Y axes across to the Tool Change Posi
87. tion Program Coordinates X 2 Y 2 Z 4 5 Machine Coordinates X 2 Y 2 Z 0 G49 Cancel Tool Length Compensation The Z axis Program Coordinate changes by 0 500 the difference in Length Offset between the current tool 3 1 000 and the tool displayed in the Current Tool pull down menu when the program first began 1 1 500 The new Program Coordinates are X 2 Y 2 Z 4 The Machine Coordinates remain unchanged at X22 Y 2 Z 0 At this point the current tool should be removed from the spindle G52 Local Coordinate System The G52 command defines and activates a local coordinate system that FlashCut CNC uses in place of your original Program Coordinates for all absolute positioning moves The X Y and Z parameters indicate the offset from your original Program Zero location to the origin for the local coordinate system For example G52 X1 Y2 Z 4 would activate a local coordinate system whose origin is at a distance of 1 2 4 from the original Program Zero absolute moves are made relative to the new local coordinate system To cancel use of the local coordinate system in the middle of a G code file use the command G52 X0 YO 70 When FlashCut CNC reads a G52 command it displays a magenta dot in the Tool Path View Port showing the origin of the local coordinate system Note that the local coordinate system only applies to the G code file being executed The G52 command has no effect on the Program Zero you set befor
88. u item In this mode the screen will update but the machine tool will not move This option lets you animate a G Code file which is useful for debugging before cutting a part 9 10 FlashCut CNC Section 2 Main Screen Features Input Status Shows the current status of the input lines The following dialog box is displayed Input Status d all Reset eset FlashCut CNC Section 2 Main Screen Features 11 Output Control Allows you to change the state of any output line The following dialog box is displayed Output Control Ed Output Lines Line Description Status 1 Spindle 2 Mist Coolant 3 Flood Coolant c eo gt To change the state of an output line 1 Choose On or Off from the Status pull down menu for a given output line A dialog box will ask if you re sure you want to turn on or off the associated device FlashCut CNC Ea N FlashCut CNC is about to set the SPINDLE line ON Are you sure it s safe to proceed E Cancel 2 Choose OK to proceed or Cancel Note that the device will turn on or off immediately after you choose OK 12 FlashCut CNC Section 2 Main Screen Features View Menu File Setup Controller MIN Help Scale to Fit Ctrl F Program Coordinates Machine Coordinates Relative Coordinates Distance To Go Coordinates v All Coordinates Scale to Fit C
89. uble click on the FlashCut CNC icon in the FlashCut CNC Program Group A dialog will appear asking you if you want to start with the Signal Generator online or offline At this point choose the No Start Offline button If you are running the Demo version choose Continue Windows 95 98 or NT To start FlashCut CNC click on the Start button select Programs select FlashCut CNC and then select the FlashCut CNC icon A dialog will appear asking you if you want to start with the Signal Generator Online At this point choose the No Start Offline button If you are running the Demo version choose Continue FLASHCUT CNC lj Version 1 21 Should FlashCut CNC establish a connection to the Signal Generator now No Start Offline Copyright 1997 1998 Inc All rights reserved Configuring FlashCut CNC 1 Refer to Section 2 Initial Setup to properly configure FlashCut CNC your Signal Generator your Stepper Motor Driver and your machine tool If you have already made a setup file or want to use a predefined setup file do the following 2 Choose Open Setup from the File menu FlashCut CNC Section5 Tutorial FlashCut CNC No G Code F Setup Controller View Open G Code Ctrl 0 Close G Code Editor Ctrl E Open Setup Save Setup Save Setup As Import DXF Ctrl 3 Select the drive and directory where the setup file is located then select the file
90. up dialog box Point Mode Point mode provides controls for moving the tool to the XYZ position you enter at the feedrate you specify In order to avoid tool crashes all moves with a positive Z axis element will first move up to the desired Z coordinate and then move to the desired XY position All moves with a negative Z axis element will first move to the desired XY position and then move down to the desired Z position G Code Jog Point Home FXPTZCTNIENIN Coord Incremental in X p 0000 Y 0 0000 0 0000 Rate Feedrate 0 00 in min Start Feed Hold Any Key Name Provides a list of options for where to move Any Point Moves to any XYZ point you enter Program Zero Moves to Program Zero Machine Zero Moves to Machine Zero if defined Tool Change Position Moves to the Tool Change Position defined in Machine Coordinates in the Machine Tool Setup dialog box Program Start Point Moves to where the tool was located when the current G Code program was started Current Line Start Point Moves to where the tool was located when the current G Code line began execution Last Hold Point Moves to where the tool was located when you stopped G Code execution using the Feed Hold button FlashCut CNC Section 2 Main Screen Features G Code Jog Point Home Name Any Point Coord Program Zero Machine Zero X Tool Change Position Program Start Point R
91. xample a 1 8 Stepper motor will have 200 full steps per revolution a 0 9 Stepper Motor will have 400 full steps per revolution and so on Motor Step The amount of movement associated with one electric pulse to the stepper motor This will vary depending on the step mode and the steps per motor revolution Offline Mode in which FlashCut CNC does not communicate with the Signal Generator also called animation mode All G Code Jog and Point moves appear on the screen but the machine tool will not move Online Mode in which FlashCut CNC directly communicates with the Signal Generator In this mode all G Code Jog and Point moves are executed by the machine tool Open Loop A control system in which a device receives a command and executes the command without communicating back that the command was completed successfully Most stepper motor systems are open loop due to there high reliability in performing step commands when used within their torque limits for a given RPM Part Program Program used to control the movement of the machine tool G Code is a part programming language Program Coordinates The XYZ position of the tool on the CNC machine relative to Program Zero Program Listing Box The area of the main screen that shows a listing of the part program currently loaded in FlashCut CNC Program Zero The zero point or origin to which all absolute coordinates in the G Code file are referenced It is depicted as a

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