CNC Programming Assistant

CNC Helper V1.0

By Michael W. Hubbard

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This manual was produced using Doc-To-Help, by WexTech Systems, Inc.

WexTech Systems, Inc. 310 Madison Avenue, Suite 905 New York, NY 10017 1-800-WEXTECH (212) 949-9595 Fax: (212) 949-4007

Contents
Quick Reference 1
What Does it Do? ................................................................................................................. 1 Whats new in CNC Helper?................................................................................... 1

The Tools menu

Unit Conversions ................................................................................................................. 7 The Degrees Menu ............................................................................................................... 8 Drill Calculations ................................................................................................................. 8 Drill Point Calculations .......................................................................................... 9 Center Drill Calculations ........................................................................................ 9 The Speeds and Feeds Menu............................................................................................... 10 The Speed Calculator............................................................................................ 11 The Feed Calculator.............................................................................................. 11 The Metal Removal Rate menu............................................................................. 12 The Time in Cut Calculator................................................................................... 13 The Surface Finish menu ...................................................................................... 13 The Threads menu.............................................................................................................. 14 The Tap Drill Calculation menu............................................................................ 14 Thread Calculations.............................................................................................. 16 The Maximum Threading Speed Menu ................................................................. 17 The Triangles Menu ........................................................................................................... 19 Using the Triangle Solver ..................................................................................... 19 The Weights Menu............................................................................................................. 20

The Reference Menu

23

Useful Data at your Finger Tips.......................................................................................... 23 The Drill Chart Menu ........................................................................................... 23 The EIA and ISO Tape Format Menus .................................................................. 24 The Screw Dimensions Menu ............................................................................... 25 The Thread Data Menu ......................................................................................... 27 The Control G Code Reference Menus.................................................................. 27 The Custom Entries menu..................................................................................... 28

Glossary of Terms Index

31 33

CNC Programming Assistant

Contents i

Quick Reference

What Does it Do?

CNC Helper is a designed to assist you with the more mundane tasks of CNC programming. For example you might get a drawing that has angles in the Hour:Minute:Second format (HMS) but the machine tool control is programmed in decimal degrees. CNC Helper has several tools to help you with this type of problem. CNC Helper also has several reference tools to help you with common programming tasks. For example the Thread Reference page has all the data you need to program standard Unified threads. The Thread Reference page even has the measurement over wires for the minimum and maximum pitch diameters pre-calculated. Unlike most CNC math programs CNC Helper also has a text editor so that you can quickly edit your program. While editing you can use the Comments feature in the Edit menu to add or remove comments from your program. If you have ever wanted to experiment with a program but didnt want to delete a section of code youll know how handy this feature is.

Whats new in CNC Helper?

CNC Helper is a true 32 bit Windows program designed to run under Microsoft Windows NT, Windows 98 or Windows 95. CNC Helper uses a high performance 32 bit Microsoft Access database to store reference data and to maintain the Code Library.

CNC Helper Version 1.0 has the following features:

All standard word processor features such as Cut, Copy, Paste, Search, Select All and right mouse button support. In addition, CNC Helper includes a Code Library where you can save small sections of code. This makes it easy to reuse routines you have written. The library can be searched by Keyword or Category ID.

CNC Helper V1.0 includes the following tools:

Conversions CNC Helper has over 35 unit conversions built in. Degrees CNC Helper can convert to and from H:M:S, Decimal Degrees and Radians.

CNC Programming Assistant

Quick Reference 1

Drill Points CNC Helper can calculate the length of a drill point or tell you how deep a center drill needs to be drilled. Speeds/Feeds CNC Helper can calculate SFM or Meters per minute, feed rates in IPR, IPM, MM/Min and MM/Rev. The metal removal rate and Time of Cut for turning operations can also be calculated. Surface Finish CNC Helper can calculate the theoretical surface finish for turning given the tool nose radius and feed rate. Threads CNC Helper can calculate the tap drill diameter for inch and metric threads, best wire diameter for measurement and percent of thread for a given hole size. Finally, CNC Helper can calculate the maximum RPM and SFM for threading on a lathe. Triangles CNC Helper can solve Right triangles.

Weight CNC Helper can calculate the weight of round, square and Hex stock for a wide variety of materials.

CNC Helper V1.0 includes the following Reference Data:

Drill Chart Number, Letter, Fractional and Metric sizes from 80 to 17mm. Screw Dimensions CNC Helper includes tabulated data for standard screws from #0 to 1 diameter. Data includes Head diameter and thickness, wrench size, counter bore diameter and other data needed to design fixtures. Threads Thread data for UN, UNC, UNF and UNEF threads including Basic Pitch Diameter and Min./Max. Pitch diameter measurements over wires. EIA/ISO tape formats Graphical representation of the holes in an EIA or ISO tape. G Codes Standard G Codes for Fanuc 0M, 0T, 3M, 5M, 5T, 6M, 6T, 10M, 10T, 16M, 2000C, Haas Lathe and Mill, Mazak M32 and Okuma OSP5000. Custom Entries In addition you can add up to 25 of your own entries to the reference menu.

2 Quick Reference

CNC Programming Assistant

The File Menu

The Code Library

You can use Access 97 to add data, The code library is a Microsoft Access 97 compatible database where you can store query or compact the database but often used code. We find that there are pieces of macro code that you use over and don't change the design. The database name is macro32.mdb and its located over. Rather than trying to remember what program has the code you want, opening it in the editor and then doing a cut and paste, you simply keep it in the code library. in the CNC Helper folder.

You can organize the code segments by category and then use Keywords to search the category. You can even include a searchable description of the segment.

CNC Programming Assistant

The File Menu 3

The CNC Helper Code Library

Organizing Code Segm ents

The code library uses three searchable fields to organize code segments - Category ID field, Description field and Keyword field. You should give some thought to how you're going to organize your code segments before using the library. The Category ID is a text field that can have up to 8 letters. For example, you could use category 1 for probe related code, category 2 for pallets, category 3 for alarms and so on. You could also use probe, pallets and alarms. Then you would use the Keywords to narrow the search down. For example, 15M for code specific to 15M controls, M32 for code specific to Mazak M32's or HAAS for Haas code. This way you can narrow a search very quickly. The sample database has an entry for a probe related segment for a Mazak M32. To find it you would enter Category ID PROBE, Keyword M32 and click Search. Another sample segment is a keyboard alarm macro for an Okuma OSP control. To find it enter Lathe for Category ID, Alarms for the Keyword and click search.

Adding an Entry to the Database

The first step is to open a file that has the code you want to put into the database. Highlight the code using the mouse or the keyboard. Right click the mouse and select Copy to copy the text to the clipboard.

4 The File Menu

CNC Programming Assistant

The left arrow with the line in front moves to the first record. The right arrow with the line in front moves to the last record in the database.

Click File, Code Library... or CTRL+L to open the database. Click Add to create a new record. Click Paste from Clipboard to paste the code into the database. Now enter a number in the category ID field, a description in the description field and one or more keywords in the keyword field. Finally, click Update to add the record. You could also click the single right arrow on the Record Selector to add the record. The category field can have up to 8 characters, the description field can have 250 characters and the keyword field can have up to 400 characters. A practical limit for Key words is probably closer to 50 characters or 5 words. The code segment can be up to 32k.

Searching for an Entry

To search for an entry in the database, enter values for one or all of the following in the Search Criteria frame: Cat. ID: Description: Key Word: Click on Search. A dialog will appear to notify you that the search is complete. Click OK to clear the dialog. To reset the database click Reset or do a search with no entries in the Search Criteria text boxes.

Inserting Code into CNC Helper

To insert the code segment into CNC Helper, click on Insert. The code is inserted where the cursor is located and the library is closed.

Deleting an Entry
To delete an entry, use search or the record selector to make the code segment the current record. Then click Delete to delete the entry. You will be prompted to confirm the delete. If you have changed your mind click on No and the record wont be deleted.

Code Library Setup

The most important part of the code library is the category ID. The Category ID allows you to sort your data into logical groups. For example if you have several

CNC Programming Assistant

The File Menu 5

different types of controls in your shop you might want to create categories based on control type. The following figure shows the setup dialog:

Adding a new Category

To get started, click on Setup on the Code Library form. A new dialog will open with the focus set to the New Entry text box. Type the new category into the text box and click on Add. You will then see the entry in the Current Entries list box.

Deleting a Category
To remove a category simply click on it in the Current Entries list box and then click Remove. You will notice that Remove is grayed out unless you have an entry selected.

6 The File Menu

CNC Programming Assistant

The Tools menu

Unit Conversions
CNC Helper allows you to convert to and from most commonly used units. Click on the Tools Menu (you can also use ALT+T) and select the Conversions item. A dialog box will open up ready to convert units. To change form one unit to another simply type in the known unit and the conversion will be displayed in the appropriate box. For example, to convert 1.0 inch to its equivalent in millimeters type 1 into the box labeled Inches and 25.4 will be displayed in the MM box.

The Conversion Factors Dialog

When finished click Exit or press the ESC key to close the dialog and return to CNC Helper. You can also press ALT+X to exit.

CNC Programming Assistant

The Tools menu 7

The Degrees Menu

To open the Degrees dialog click Tools, Degrees or press ALT+T, G from the keyboard. CNC Helper makes it easy to work with prints that are dimensioned using the older Degrees, Minutes, Seconds (DMS) format. First a quick review of the two formats. Remember that in the DMS format there are 60 minutes in a degree and 60 seconds in a minute. For example 45 degrees, 30 minutes is equal to 45.50 degrees in the decimal format. Thats because 30 minutes is equal to 30/60 or .5 degrees. Now what if the drawing called for 45 degrees, 30 minutes and 30 seconds? In decimal format that would be 45.5083. Why the 83? Dont forget that there are 60 minutes in a degree and 60 seconds in a minute but there are 3600 seconds in a degree. Thats equal to 60 x 60! So in this example you have 30/3600 or .0083 in decimal format. CNC Helper can also convert from Decimal or DMS units to Radians. Radians arent used much in CNC Programming but are included here in case you are machining an involute or some other higher order curve.

Degree Conversion Dialog

Now, to do a conversion from DMS to decimal degrees simply enter the Degrees, Minutes and seconds in the appropriate boxes. The decimal and radian formats will be automatically calculated and displayed. To convert from decimal format to DMS simply enter the decimal format in the Decimal: box and the DMS boxes will be filled in and the Radians box will be updated. When finished click Exit or press the ESC key to close the dialog and return to CNC Helper. You can also press ALT+X to exit.

Drill Calculations
This menu has two sub menus Drill Point and Center Drills. The first sub menu, Drill Point is used to calculate the length of a drill point given the diameter and included angle of the drill. The second menu, Center Drills, calculates the depth to drill given the center diameter.

The Drill Point Menu

8 The Tools menu

CNC Programming Assistant

Drill Point Calculations

To open the drill point dialog click on Tools, Drill Calculations, Drill Point. You can also use ALT+T, U, P from the keyboard if you prefer keystrokes to mouse clicks. To calculate a drill point length, enter the drill diameter and point angle. The point length will be displayed in the Drill Point Length box. You can then change either the angle or the diameter to calculate a new length.

The Drill Point Dialog

Center Drill Calculations

The Center Drills menu allows you to quickly determine the drill depth for a required center diameter. In addition, every center drill that can be used will be displayed. This is convenient because you dont have to spend time looking up a drill with the correct tip diameter or body diameter, CNC Helper does it for you. Finally, if you hover the mouse over one of the center drill labels a Tool Tip will appear with the centers Tip Diameter, Tip Length and body diameter. See the following figure.

The Center Drill Dialog

How to Calculate the Depth

If you would like to calculate the depth manually the following figure will show you how.

CNC Programming Assistant

The Tools menu 9

Center Drill Calculations

In the figure D2 is the diameter that we are drilling. To calculate the depth that corresponds to D2 we need to find L1, L2 and L3. L1 is the tip length and is looked up in a table. L2 is equal to the (tip diameter/2)/TAN(60). L3 is equal to (D2 the tip diameter)/2 x TAN(60) Finally, the depth to drill is L1+L2+L3. For example to drill a .190 diameter center with a #3 Center Drill: L1 is .109 L2 = (.109/2)/TAN(60) or .0545/1.7321 L2 = .0315 L3 = (.190 - .109)/2 x 1.7321 L3 = .0701 Depth = .109 + .0315 + .0701 Depth = .2106 When finished click Exit or press the ESC key to close the dialog and return to CNC Helper. You can also press ALT+X to exit.

The Speeds and Feeds Menu

The Feeds & Speeds menu has three sub menus Speed/Feed Calculator, Metal Removal Rate and Surface Finish. To open the Speed/Feed Calculator click on Tools, Feeds & Speeds, Speed/Feed Calculator. You can also press ALT+T, F, l from the Keyboard to open the dialog.

The Speed/Feed Menu

10 The Tools menu

CNC Programming Assistant

The Speed Calculator

The Speed calculator is designed to make it easy to determine the correct RPM for a tool or part. The tool or part diameter can be metric or English. There are two ways to use the Speed Calculator. First, you can enter a diameter and RPM and the calculator will display the Surface Feet Per Minute in the Surface Ft./Min. box. Second, you can enter a diameter and Surface Speed and the calculator will display the correct RPM needed. Again, you can enter the diameter or Surface Speed in metric or English units. In the figure a 1.0 diameter is entered with 500 RPM. The SFM displayed is 130.9 Ft./Min. At the same time the 1.0 diameter is converted to 25.4 mm and 25.4 is displayed in the mm box. 130.9 Surface Feet/Min is converted to 39.88 Meters/Min and is displayed in the Surface M/Min box.

Calculating Surface feet per Minute

The Feed Calculator

The feed calculator makes it easy to convert from feed rates in Inches or millimeters per minute to Inches per revolution or millimeters per revolution. In the Figure, a 2.0 Inch per Minute feed rate is converted to .004 per revolution at 500 RPM.

CNC Programming Assistant

The Tools menu 11

Calculating In/Rev from In/Min

Keep in mind that the feed rate in Inches per Minute is dependent on the RPM and the feed rate in Inches per Minute. The conversion is feed in IPR x RPM. In the example .004 per rev. x 500 rev. per min. = 2.0 Inches per Minute. For example, if you had a 3/8-16 Tap running at 1000 RPM the feed rate would be 1/16 or .0625 in IPR or 31.250 IPM. When finished click Exit or press the ESC key to close the dialog and return to CNC Helper. You can also press ALT+X to exit.

The Metal Removal Rate menu

To open the Metal Removal Rate dialog click on Tools, Feeds & Speeds, Metal Removal Rate.

The Metal Removal Rate Menu

The Metal Removal Rate Calculator

The metal removal rate dialog allows you to calculate the metal removal rate of turning operations. This is convenient when you want to compare one insert to another. For example lets say youre running your favorite insert at 500 SFM, .200 depth of cut and .012 IPR. Now your cutting tool salesman comes in and says he has a great new insert that can run at 600 SFM and .200 depth of cut but youll have to drop the feed rate to .01 IPR. If both inserts give you the same amount of tool life in minutes which one is best? CNC Helper makes it easy to figure this out. First, open the metal removal rate dialog. Enter 500 in the SFM box, .012 in the Feed Rate box and .200 in the Depth of Cut box. 14.40 Cubic Inches per minute is displayed in the Removal Rate box. Now enter 600, .01 and youll see that the rate remains the same. How can this be? The equation for metal removal rate in a turning operation is Rate = SFM x Depth of Cut x Feed Rate x 12. As you can see all the terms are linear so increasing the SFM by 20% (500 to 600) and reducing the feed rate by 20% results

12 The Tools menu

CNC Programming Assistant

in the same removal rate. In this case the new insert doesnt removal metal any faster even though it can run at a higher speed. Use CNC Helper to find the most efficient parameters for your application and maximize your profit. Remember, a larger depth of cut or feed rate usually doesnt effect tool life much but a higher speed will.

The Metal Removal Dialog

The Time in Cut Calculator

To calculate the time needed for a cut use the Time in Cut calculator. This dialog takes the RPM, Feed rate and Length of cut and calculates the time needed in minutes and seconds. In the above figure, 500 RPM, .012 IPR and a 3.0 length of cut require .50 minutes or 30 seconds. When finished click Exit or press the ESC key to close the dialog and return to CNC Helper. You can also press ALT+X to exit.

The Surface Finish menu

To open the Surface Finish dialog click on Tools, Feeds & Speeds, Surface Finish. You can also press ALT+T, F, S from the Keyboard to open the dialog.

The Surface Finish menu

The surface finish dialog allows you to estimate the surface finish that a given combination of insert radius and feed rate will produce. This is the best theoretical finish possible. The actual surface finish may be rougher.

CNC Programming Assistant

The Tools menu 13

The Surface Finish Dialog

In the above figure, a tool nose radius of .0156 (1/64) and a feed rate of .003 IPR will give a theoretical finish of 72 microinches or an RMS of 32. This is a very good finish and the low feed rate will increase cycle time. If the print doesnt call for such good finish a higher feed rate will result in a lower cost. When finished click Exit or press the ESC key to close the dialog and return to CNC Helper. You can also press ALT+X to exit.

The Threads menu

The Threads menu has three sub menus Tap Drill Calculations, Thread Calculation and Max. Thread Speed. The tools in this menu allow you to calculate the correct drill size for a given tap, calculate various thread parameters or calculate the maximum speed that your lathe can thread at.

The Threads menu

The Tap Drill Calculation menu

To open the Tap Drill Calculation menu click on Tools, Threads, Tap Drill Calculation. You can also press ALT+T, H, P from the Keyboard to open the dialog.

The Tap Drill Calculation menu

The tap drill calculation dialog allows you to enter the nominal tap diameter and the number of threads per inch and get the size drill needed for the thread. The default percentage of is 75%. This is a standard percentage of thread is used by most tap drill charts. The following figure shows the dialog for a -20 tap.

14 The Tools menu

CNC Programming Assistant

The Tap Drill Calculator dialog for a -20 Tap

The dialog has another feature that is very useful in the shop. Next to the calculated drill size are four boxes. These boxes list the drill sizes close to the calculated drill size. These are based on a drill chart and you can click the arrows to view drills that are larger or smaller than the calculated size. The following figure shows the Closest Drill sizes for the -20 tap.

The closest drills for a -20 tap

The calculated drill size for a -20 tap with 75% thread is .2013. This isnt a standard drill size but CNC Helper makes it easy to find a standard drill. Simply look at the Closest Drill Sizes part of the dialog. The boxes on the left show the standard drill that is smaller than the calculated and the boxes on the left show the next drill larger. The first box shows the decimal size and the second shows the letter, number or fractional designation. You can click on the arrows to move down or up the drill chart range to find a different drill if the size shown doesnt fit you need.

Selector Arrows

For example, you may want to use the largest drill size possible to minimize the chance of breaking the tap. In this case you could click the up arrow on the Larger side dialog to find another drill. For a -20 thread the next few drills are .204, 6 and .2055, 5. If you want to know what percentage thread these drills will produce you can enter the decimal size into the Tap Drill Dia. Box and the calculator will show the new percentage of thread.

CNC Programming Assistant

The Tools menu 15

Finding a Percentage of thread

This can also be useful if you have accidentally drilled a hole too large and are trying to get the engineering department to buy off on it. Instead of just begging forgiveness you can quickly calculate the percentage of thread and plead your case with the facts!

The Tap Drill Calculator can also calculate the percentage of thread based on a drill diameter if you enter the decimal size into the Tap Drill Diameter Box. For example, if you entered .25 for the Tap Diameter, 20 for the Threads per Inch and .2055 for the drill diameter you will see 68.5 for the percentage of thread.

Number Taps
The Tap Drill Calculator works with number size taps. To calculate the tap drill size for a number tap, click the Number Tap option button. A new box, Inch, will appear. When you enter the number for the tap in the Tap Number box, the corresponding decimal diameter will be displayed in the Inch box. See the following figure.

A 10-32 Tap

Metric Taps
The Tap Drill Calculator also works with metric taps. To calculate the tap drill size for a metric tap click on the option button Metric Tap. When the metric tap option button is selected the label for tap size changes to read Tap Diameter in MM and the threads per inch box changes to Pitch of Thread in MM. In the next figure a 5mm x .8 tap has been entered.

A 5mm x .8 Tap

The diameter has been converted to English and the Threads per Inch are displayed. The threads per inch box doesnt actually make sense for a metric tap and is only included for educational purposes. In other words you can start to get a feeling for how fine a .8mm pitch thread is by seeing that it is equivalent to 31.75 TPI.

Thread Calculations
This menu choice is different from the Tap Drill Calculator because it calculates several parameters needed to program external threads on a lathe. If you hold the mouse over each of the calculated dimensions a Tool Tip will appear showing the calculation used. In the next figure a -20 thread has been entered. The best wire size is calculated as .0289, the Pitch is .0500 and the depth of the external thread is .0325. Since a standard thread wire set doesnt include a .0289 diameter wire you can click into the

16 The Tools menu

CNC Programming Assistant

Wire Diameter for Measurement box and change it to .029, which is a standard thread wire. The Measurement over wires box will change to reflect the new wire size.

The Thread Calculator Dialog

The Maximum Threading Speed Menu

To open the Maximum Threading Speed menu click on Tools, Threads, Max Threading Speed. You can also press ALT+T, H, X from the Keyboard to open the dialog.

When cutting threads on a lathe the maximum traverse feed of the lathe in IPM limits the spindle speed that can be used. The limit comes from the fact that threads required higher feed rates than standard turning operations and the feed must be synchronized to spindle. For example, a 3.000-4UNC thread has a pitch of .25 which means you have to program a threading feed rate of .25 IPR. Compare this to most turning operations where you would use .02 IPR or less. In this example suppose you are threading an Aluminum part and the carbide insert youre using could run at 1000 SFM. If the lathe youre programming has a maximum Z axis feed of 150 IPM can you run the thread at 1000 SFM? CNC Helper makes it easy to figure this out. To find out open the Maximum Threading Speed dialog. Enter 4.0 in the Threads per Inch box, 3.0 in the Thread Diameter box and click on Haas in the Select a Machine Type list box. See the following figure.

CNC Programming Assistant

The Tools menu 17

The Maximum Threading Speed dialog for a 3.0004UNC thread

As you can see the maximum SFM that can be attained is 471. Thats because the combination of 150 IPM maximum feed and a pitch of .25 limits the RPM to 600. The equation for the maximum SFM is Diameter x PI x TPI x Max. IPM/12. This equation gives you the maximum SFM but dont forget, you always program threading operations in RPM. This is because the feed must be synchronized to the spindle and programming SFM causes the spindle RPM to change as the diameter changes. This makes it difficult for the control to keep the start point synchronized and usually results in a poor quality thread.

Selecting a Machine
CNC Helper comes with several machines built in. To select a machine simply click on it in the Select a Machine list box. The SFM and RPM fields will be recalculated based on the machines capability. See the next figure.

Select a Machine Dialog

Adding Your Own Machines

You can easily add your lathes to the dialog. First look up the maximum Z-axis feed rate in IPM in the machine manual. You may have to call the machine tool builder if you cant find it in the manual. When you have the correct value, click on the Add a Machine button or press ALT+M to open the Add a Machine Dialog.

18 The Tools menu

CNC Programming Assistant

Enter the maximum feed rate, the letters IPM and a description of the machine. The following figure shows the Machine File Update Dialog adding the Super High Speed lathe.

The Machine File Update dialog adding the Super High Speed Lathe

When finished click Exit or press the ESC key to close the dialog and return to CNC Helper. You can also press ALT+X to exit.

The Triangles Menu

The Triangles solver allows you to easily solve right triangle problems. To open the Triangles dialog click on Tools, Triangles. You can also use ALT+T, A from the keyboard if you prefer keystrokes to mouse clicks.

Using the Triangle Solver

To solve a triangle problem simply enter the known data into the appropriate text box and the triangle solver will automatically solve for the unknowns. In the following figure, 6.000 was entered for the base and the height. The solver then filled in the Hypotenuse and angles.

CNC Programming Assistant

The Tools menu 19

The Triangle Solver Dialog

Just as easily you could enter a hypotenuse and base or hypotenuse and one of the angles. For example, if you clicked in the Height box and entered 5.0 and then clicked in the box labeled A2 and entered 50.000 the hypotenuse would change to 7.7786, the base to 5.9587 and A1 to 40. Notice that the height didnt change. The first box you click in will remain constant. When finished click Exit or press the ESC key to close the dialog and return to CNC Helper. You can also press ALT+X to exit.

The Weights Menu

The Weights dialog allows you to easily determine the weight of a part or piece of stock. To open the Weights dialog click on Tools, Weights. You can also use ALT+T, W from the keyboard if you prefer keystrokes to mouse clicks.

The Weights Menu

With the Weight calculator you can quickly determine the weight of round, plate or hexagon stock. You can use the plate fields to calculate the weight of square stock also. Simply enter the same value for length and width. Enter the length of the stock in the width field. For example, to find the weight of a 2 square bar of 316SS that is

20 The Tools menu

CNC Programming Assistant

144 long enter 2 for the length, 2 for the width and 144 for the thickness. The following figure shows the weight calculator solving for this piece of stock:

The Weight Calculator solving for a 2 square bar 144 long.

CNC Programming Assistant

The Tools menu 21

The Reference Menu

Useful Data at your Finger Tips

The items in the reference menu are slightly different than those in the Tools menus. The entries in the Reference menu are data items that can be looked up in a chart or book. CNC Helper removes the need to have so many books or charts lying around.

The Drill Chart Menu

This is one of the handiest features of CNC Helper. Instead of having to keep drill charts on the wall or taped to the monitor you can click on this menu and look up the data you need! To open the Drill Chart dialog click on Reference, Drill Chart. You can also use ALT+R, D from the keyboard if you prefer keystrokes to mouse clicks. The drill chart is very easy to use and has all drill sizes from #80 to 1.000 including metrics. If you would like to add more sizes to the drill chart its very easy. Click on File, Open in CNC Helper, then click on Files of type and select All Files. Now double click on the Data folder. You will see an entry for drilchrt. See the next figure:

The File Open dialog showing the Drilchrt file

CNC Programming Assistant

The Reference Menu 23

Click Open to open the file in CNC Helper. When the file opens you will recognize the entries from the drill chart. Scroll down to where you want to add an entry. Press Enter to add a new line and then type the diameter of the drill. Press the space bar and then the TAB key. Now enter the name for the drill. If you make a mistake you can use the standard editing keys to fix it. If you get completely mixed up simply close the file without saving it. You probably wont need to add any entries because CNC Helper already has a complete set of drill sizes. The following figure shows the drill chart:

CNC Helpers Drill Chart

If you would like to insert the diameter of the drill into your program you can click the Insert button. One nice feature of CNC Helpers reference dialogs is that they remember where you placed them and how you sized them. For example you might decide to make the dialog long and narrow and place it on the right side of the screen. When you close it the current size and position are stored in a file. The next time you open a dialog it remembers it size and location.

The EIA and ISO Tape Format Menus

Paper tape or Mylar tape is fairly rare now but sometimes you still run into it. This reference shows both EIA and ISO tape codes in a graphical layout. To open the Tape Format dialog click on Reference, EIA Tape Format or Reference, ISO Tape format. You can also use ALT+R, I from the keyboard if you prefer keystrokes to mouse clicks to open the ISO tape format dialog.

The next figure shows the ISO tape format dialog:

24 The Reference Menu

CNC Programming Assistant

The ISO Tape Format dialog

The Screw Dimensions Menu

This feature is very convenient when designing a fixture or piece of tooling. The key data for most types of screws including shoulder screws is available for sizes from #1 to 1.00. To open the Screw Dimension dialog click on Reference, Screw Dimensions. You can also use ALT+R, S from the keyboard if you prefer keystrokes to mouse clicks. This dialog is fairly self-explanatory. To select a screw size click on the right or left arrow on the Screw Size Selector control. Clicking on the button with the arrow and bar takes you to the beginning or end of the database. The current screw size is show in the box titled Screw Size. The following figure shows the screw size box with the database control:

The Screw Size control

Set Screws
The database contains dimensions for the following types of set screws: Oval Point Oval radius Dog Pont Dog diameter, Dog Length Cup & Flat point Cup or Flat diameter

The following figure shows the data for set screws:

CNC Programming Assistant

The Reference Menu 25

Set Screw Data

Miscellaneous Screws
Each screw type has at least two entries: Head Diameter The diameter of the head on the screw. Head Height The height of the head on the screw.

Additional entries include: Wrench Size The Hex Wrench needed for the screw. Distance Across Flats This is the wrench needed for Hex Head screws. Maximum Cross Hole Diameter for Wire This is the largest Hole that should be drilled through the screw for safety wire.

Hex Nuts
There are two entries for Hex Nuts: Distance Across Flats This is the wrench size needed for the nut. Distance Across Points This is the distance measured across the points on the nut.

Socket Head Cap Screws

There are four entries for socket head cap screws (SHCS): Wrench Size The Hex Wrench needed for this SHCS Head Diameter The Diameter of the head on the SHCS Head Height The height of the head on the SHCS Counter Bore Diameter The standard counter bore diameter to use.

Shoulder Screws
There are six entries for shoulder screws: Wrench Size The Hex Wrench needed for this SHCS Head Diameter The Diameter of the head on the SHCS Head Height The height of the head on the SHCS Body Diameter The diameter of the screw body. Thread Length The length of thread on the screw. Thread Size The diameter of the threads on the screw.

When finished looking up screw dimensions click on Exit to close the dialog and return to you program.

26 The Reference Menu

CNC Programming Assistant

The Thread Data Menu

This dialog contains all the data you will need to program a thread on a lathe. Included in the dialog are the minimum major diameter, the minimum and maximum pitch diameter, the pitch and the lead angle at the basic diameter. In addition to the standard thread data, CNC Helper shows you the standard wire size needed to measure the thread. This is slightly different than the best wire size because a standard wire set doesnt included every possible wire size. In addition, the minimum and maximum pitch diameter measured over wires is included. This allows you to quickly determine if the pitch diameter is within spec without having to do any calculations. The first thing you do after opening the dialog is select a family of threads. CNC Helper has the following thread families: UNC Unified National Coarse. These are the standard coarse threads. UNF Unified National Fine. These are the standard fine threads. UNEF Unified National Extra Fine. These are extra fine threads. UN Unified National threads. All Click this button to view all thread types.

The thread selection controls look like this:

The Thread Selection controls

To view by a family of threads click on the button with the family name. For example, to view only UNC threads click on the button marked UNC. To select a thread size after sorting click on the up or down arrow on the Thread Size list box.

The Control G Code Reference Menus

CNC Helper comes with G codes for most common CNC Controls but as youll see in the next section you can add your own. You can also edit the existing files if you want to. Each menu loads a file from the CNC Helper\data folder. Its fairly obvious what control each file belongs to. For example, F16MG is a Fanuc 16M. If you would like to edit one of the files its very easy. Click on File, Open in CNC Helper, then click on Files of type and select All Files. Now double click on the Data folder. You will see all of the files. Click on the one you want to open. In the next figure the Fanuc 10M is selected:

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The Reference Menu 27

Open a Menu file for editing

Click Open to open the file in CNC Helper. When the file opens you will recognize the entries. Scroll to where you want to add or edit an entry. To add an entry, press Enter to add a new line and then type the new data. Do not use a comma in the line. If you do the comma will be interpreted as a separator and the line will be broken. Press the space bar and then the TAB key. If you make a mistake you can use the standard editing keys to fix it. If you get completely mixed up simply close the file without saving it. You probably wont need to add any entries because CNC Helper already has a complete set of G codes but at least you have the option.

The Custom Entries menu

The Custom Entries menu allows you to add up to 25 of your own reference tables to CNC Helper. To add your own entry simply create a standard text file (ASCII File) using CNC Helper or any word processor that can save a file as an ASCII file. The same dialog that is used with the other reference data is used with the custom entries. Each line in the file will be displayed on a separate line in the list box. Do not use a comma in the line. If you do the comma will be interpreted as a separator and the line will be broken. If you want to be able to click Insert and have the first word on the line inserted into your program you must have a space between the first word and the second. You can use a TAB after the space. When you are finished adding data to the file save it the CNC Helper\data folder. The file name will become the title for the menu so choose the filename carefully. You must use a TXT file extension when you save the file. For example a good file name for the M codes for an Okuma LC20 might be Lc20m. Here is what the menu would look like if you saved Lc20m.txt to the CNC Helper\data folder:

Custom Menu

28 The Reference Menu

CNC Programming Assistant

CNC Programming Assistant

The Reference Menu 29

Glossary of Terms

RPM
Revolutions per Minute. This is how fast the part or cutter is revolving in the machine. Most cutting tools are rated in Surface Feet per Minute instead of RPM. You will need to convert RPMs into Surface feet per Minute to program the tool.

Surface Feet Per Minute

Surface Feet Per Minute is equal the circumference of the part or cutter in feet multiplied by the RPM. The circumference is equal to PI x the diameter. For example a 3.82" part rotating at 100 RPM would be 3.82 x PI x 100/12 or 100 SFM. The division by 12 converts inches into feet.

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Glossary of Terms 31

E
external threads 16

Index

G
G codes 2, 2728, 27

H
Hex Nuts Distance Across Flats 26 Distance Across Points 26

I B
best wire size 16, 27 IPM 2, 12, 1718, 1719, 1718

K
keyword 4 Keywords 34

C
calculated drill size 15 category 34, 34, 3, 4 Category ID 1, 4, 5 code library 1, 35 Code Library category 34, 34, 3, 4 Category ID 1, 4, 5 description 34, 34 Description Field 4 keyword 4 record selector 45, 45, 4, 5 Counter Bore Diameter 2, 26 Cup & Flat point 25

M
machines capability 18 Measurement over wires 1, 17 metal removal rate 2, 10, 12 Metal Removal Rate Cubic Inches per minute 12 Time in Cut 13 metric taps 16 Mylar Tape 2, 2425

N
number size taps 16

D
Degrees DMS format 8 involute 8 Radians 1, 8 Degress Degrees, Minutes, Seconds 8 delete 5 description 34, 34 Description field 4 Description Field 4 Dog Pont 25 Drill Calculations body diameter 9, 26 Center Drills 89, 89 Drill Point 2, 8 Tip Diameter 910, 910, 910 Tip Length 910, 910, 910 To calculate the depth 9

O
Oval Point 25

P
Paper Tape 2, 2425 percentage of thread 1415, 1415, 1416 Pitch 12, 12, 1618, 1618, 1618, 27 pitch diameter 2, 27

R
record selector 45, 45, 4, 5

S
select a machine 1718, 1718, 1718 Set Screws

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Index 33

Cup Point 25 Dog Point 25 Oval Point 25 SHCS Couter Bore Diameter 2, 26 Speeds & Feeds diameter 2, 811, 811, 811, 14, 811, 14, 1618, 1618, 2426, 2427 Inches per revolution 11 millimeters per revolution 11 RPM 2, 1113, 1113, 18 Speed calculator 11 Surface Feet Per Minute 11 spindle speed 17 surface finish 2, 10, 1314, 1314 synchronized 1718, 1718, 1718

Unified National Extra Fine 27 Unified National Fine 27 Unified National threads 27 Unit Conversion 78, 78, 78, 12 Inches 7, 1112, 1112, 1112 millimeters 7, 11

W
Wire Diameter 2, 17 best wire size 16, 27 Wrench Size 2, 26 SHCS 2, 26 Shoulder Screws 2, 26

T
tap diameter 1416, 14, 16 tap drill 2, 1416, 1416, 1416 Tap Drill Calculations calculated drill size 15 metric taps 16 number size taps 16 percentage of thread 1415, 1415, 1416 tap diameter 1416, 14, 16 tap drill 2, 1416, 1416, 1416 threads per inch 1417, 1417, 14, 1617 tape 2, 2425 Thread Calculations best wire size 16, 27 external threads 16 measurement over wires 1, 17 pitch 12, 12, 1618, 1618, 1618, 27 wire diameter 2, 17 Thread Data pitch diameter 2, 27 threading operations 18 Threading Speed IPM 2, 12, 1718, 1719, 1718 machine capability 18 select a machine 1718, 1718, 1718 spindle speed 17 synchronized 1718, 1718, 1718 threading operations 18 Threads Unified National Coarse 27 Unified National Extra Fine 27 Unified National Fine 27 Unified National threads 27 threads per inch 1417, 1417, 14, 1617

U
Unified National Coarse 27

34 Index

CNC Programming Assistant