FILOU-NC

-NC forWinPC

Introduction in FILOU-NC for WinPC-NC

FILOU Software GmbH www.filou.de

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Table of contents

Introduction in FILOU-NC for WinPC-NC

Table of contents
Reasons for using FILOU-NC if WinPC-NC is already in operation ...... 3 How does FILOU-NC operates for WinPC-NC ? ................................... 4 Support and assistance .......................................................................... 6 Three steps for creating the CNC program ............................................ 7 Step 1 Geometry ....................................................................... 7 Step 2 - CAM ............................................................................... 8 Step 3 Send to WinPC-NC ........................................................ 9 Cooperation: WinPC-NC + FILOU-NC ................................................. 10 Samples for programming .................................................................... 11 Sample: milling outside contours ......................................................... 12 Characteristics during the milling of an inside contour ....................... 15 Simulation of the created program ....................................................... 16 Appendix ............................................................................................... 18 DIN-Code or HPGL? ............................................................................. 18 DIN/ISO commands .................................................................. 20 DIN/ISO Sample of program .................................................... 22 HPGL commands ...................................................................... 22 HPGL sample ............................................................................ 22 FILOU-NC comparison of the different versions ............................... 23 Glossar ................................................................................................. 24

Additional information and online videos are available by www.filou.de

These instructions are continously completed. Please take note of the current version numbers. Version 1.01 September 2006 Copyright 2006 by FILOU Software GmbH

Reasons for using FILOU-NC if WinPC-NC is already in operation Reasons for using FILOU-NC if WinPC-NC is already in operation WinPC-NC is a CNC control system. This means that WinPC-NC is controlling a machine by a CNC program. Commands (switching on the spindle, etc.) and a description concerning milling distances are integrated in this CNC program in order to actuate the machine. By means of an editor the CNC code can be manually created. However, this requires basic knowledgement of CNC codes and mathematics. More confortable is programming by CAD + CAM programs such as FILOUNC.

The workpiece to be manufactured is defined as geometry by a CAD program. CAD drawings are generally made at a scale of 1:1 and therefore they are perfectly suitable for creating CNC programs by a CAM program. As many CAM programs provide CAD functions, the geometry can be directly carried out in the CAM system. FILOU-NC is a CAM system with this special feature. However, it is also possible to import existing CAD files, e.g. in DXF format, and to use them for creating CNC programs. Of course, this imported CAD file can be processed and optimized in FILOU-NC. The produced CAD drawing defines the workpiece to be manufactured by measurements and outlines. Parameters for the following production are not defined. Information concerning milling distances, speeds, spindle speed, etc. stated in the CNC program are not available in the CAD file. This is the reason why direct conversion of CAD geometry into CNC code

How does FILOU-NC operates for WinPC-NC ? is useless, except for some cases, as it would create an incomplete CNC program. FILOU-NC, as CAM program, carries out complex calculations and creates the complete CNC program according to specification. This procedure is executed promptly and precisely.

After completing this procedure the CNC program is simulated in FILOUNC. Errors which may occur can easily be noticed and the user saves time and money. As a result you receive a CNC code thoroughly tested. Contrary to CNC codes which are automatically created, this code provides considerably improved and optimized milling distances. Savings of time to up to 60 % are possible. How does FILOU-NC operates for WinPC-NC ? FILOU-NC for WinPC-NC means four programs which are closely associated: geometry (CAD), CAM, editor and the 3D simulation. A special feature is that any of the four programs or so-called areas are independent of each other. Areas can be changed at any time. For example if you note during programming in the CAM area that the geometry is not completed yet, it is absolu-

tely no problem to change again to the geometry area in order to complete the missing geometry. Characteristic of the four programs: In the area geometry the CAD geometry can be imported, created, pro-

How does FILOU-NC operates for WinPC-NC ? cessed, optimized and exported. The geometry is the basic element for producing CNC programs. In the CAM area milling distances are derived from the geometry. Furthermore it is possible to generate additional CNC codes by macros and cycles.

A CNC program does not merely mean milling distances. In order to choose the suitable format, there are post processors. Besides conventional edit functions the editor provides additional special NC functions such as renumber and extract tools. High efficiency of the editor is ensured by the integrated work plane that enables an immediate and simple amendment of a finished CNC program. By 3D simulation the CNC program is simulated and it does not matter whether the program has been created in FILOU-NC or whether an existing NC code has been loaded in the editor. The FILOU-NC simulation supports thereby up to three simultaneous axes.

How does FILOU-NC operates for WinPC-NC ?

Support and assistance Another tip concerning assistance. We have been thoroughly treated our assistance program. By means of various links and animated graphics it is more confortable than any printed manual. Furthermore you can use the function button F1 which can be activated at any time in the program and which displays immediately the corresponding assistance topics on the screen. A manual is not able to provide this convenience. These instructions are made for initial steps and, for further information, there are some videos in the internet under www.filou.de/nc->Support. For additional support please contact by e-mail

Step 1 Geometry

Three steps for creating the CNC program Step 1 Geometry First you have to create a CAD drawing with the geometry of the workpiece to be manufactured. Please note that the geometry defines the finished workpiece and not the milling distances to be moved. The geometry can easily be created in FILOU-NC or imported by a CAD system as AutoCAD, TurboCAD, Rhino, etc. However, it is essential that the geometry has been created at a scale of 1:1. Creating the geometry, color and layer are insignificant. There is also no requirement for closed contours or for contour elements arranged into one direction. If you want to have no gap between the elements defining a contour, you have to take care of this point. If smaller gaps should occur they can be neglected by a gap tolerance in FILOU-NC. A well-thought layer structure provides advantages with extensive drawings. In order to obtain a better view, the layers can be switched invisible by the Layer manager in FILOU-NC. If you create the geometry by a CAD program, it is recommended to export it as DXF file. FILOU-NC is equipped with a DXF import filter importing merely distances, circles, arcs and polylines. Any other parameters are ignored because they are unimportant for CNC programming. First the imported drawing is cleared up from unnecessary elements by the command clear up drawing. This automatic procedure is carried out quickly. After having prepared the geometry it should be saved as DXF with the command save drawing. Later on, respectively during the subsequent programming you still have the possibility to amend the geometry. This is possible because the NC code is derived from the geometry and geometry does not mean NC code or is connected to it.
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Step 2 - CAM

Step 2 - CAM Following statements basically apply to DIN/ISO programs, although some of the comments also refer to HPGL. At the beginning there was the zeropoint. Why ? The program zeropoint,which is identical with the workpiece zeropoint of the unmachined piece on the milling machine, should not be changed during the run of a CNC programn (with the exception of experts). The (program) zeropoint for the X and Y axes is defined in FILOU-NC. If there is an interrogation for values concerning the feed axes Z later on in the program, these values refer to the Z-zeropoint defined on the machine for the workpiece . Usually this is the upper edge of the workpiece. However, there are some users utilizing the lower edge. Generally it does not matter which edge is used, but you should be attentive to use always the same Z-zeropoint. In this way errors by incorrect entries are avoidable. Using WinPC-NC it has to be noted that the Z-axes is in reversed positon regarding the standard settings, i. e. minus is on the top and plus is at the bottom. Therefore the Z-axes in WinPC-NC firstly should be turned round (menu: parameter / data format / DIN-ISO-Z-invert axes). The next step is selecting the post processor. This means selection of the CNC format for creating the NC code. Now you have the option between HPGL or DIN/ISO. If you are unsure in selecting the suitable format, you have the possibility to obtain additional information concerning DIN/ISO (called G-code) and HPGL in the our operating instructions later on together with a comparison of both formats. Please note that WinPC-NC is able to process solely HPGL programs. Structure of the program In order to be recognized by the CNC control system the CNC programs must feature a special structure, i.e. Start of the program to End of the program. Now we select New CNC program. A small window is displayed

Step 3 - Send to WinPC-NC where you can enter a certain program number and a comment (e.g. description of the program). By this procedure the beginning of the program has already been effected and a look into the editor supplies the corresponding confirmation. The next step is launching the tool. This can be made either by activating the tool manager or by one of the operating functions (contour, pockets, etc.) Now the geometry is gradually processed by the operating functions and thereby the CNC code is automatically created in the editor. Finally the End of the program is inserted. The procedure is completed and the program can be inspected in the editor. Editor and work plane Working in the CAM area FILOU-NC registers each process in the editor together with a corresponding comment. These comments are automatically extracted in the work plane and constitute the working scheme. It is possible to give these entries predicative names, to move or delete them. If the comments are not required they can be automatically deleted by saving. 3D simulation The CNC program which is registered in the editor can be simulated at any time, regardless whether it has been created in FILOU-NC or whether an existing NC code has been loaded in the editor. First of all the NC code is analyzed, measurements of unmachined pieces are entered and tools are accordingly assigned. After this procedure operation can be simulated. Step 3 Send to WinPC-NC After the NC code has been completed with satisfying result, the project can be saved and the CNC program can directly be transmitted to WinPC-NC.

Cooperation: WinPC-NC + FILOU-NC

Cooperation: WinPC-NC + FILOU-NC Z-axes The standard setting of the Z-axes in WinPC-NC is in reversed position, i.e. minus is top and plus is at bottom. Therefore the Z-axes has to be turned round in WinPC-NC (menu: parameter / data format / DIN-ISO-Z-invert axes). Tool numbers Please note that WinPC-NC accepts only tool numbers from 0 9 when they are set up in FILOU-NC for the first time. Other settings in the WinPC-NC menu parameter / data format should remain deactivated. DIN-ISO and WinPC-NC Light Attention: Only HPGL programs can be processed by WinPC-NC Light. Prior to programming please select a HPGL post processor. Feed and rotational speed with DIN-ISO code Using the calculation of cutting data in the FILOU-NC tool data bank, the rotational speed is indicated per minute and the feed rate in mm/min. The units in mm + mm/min. have to be set up in WinPC-NC accordingly (menu: parameter / coordinates /measuring unit + units). Measuring unit As measuring unit 1/1000 mm has to be adjusted in the DIN/ISO code (menu: parameter / coordinates / measuring unit + units).

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Sample: importing and preparing geometry

Samples for programming Samples presented now require knowledge of the preceding basic elements. Please study the previous chapters. Importing and preparing geometry 1. Loading the drawing Select the desired format from the file samples, in our sample it is the file SAMPLE.DXF.

2. Clean up drawing This step should be carried out generally during the import of drawings. This function is responsible for the execution of four special tasks: Remove identical elements Deletes elements of the same size. Such errors may occour during copying. Remove overlaying elements Elements next to each other or overlapping are reduced to one element. This is often the case with drawings deriving from 3D. Full circle arcs to circles Circles are produced by arcs with an opening angle of 360 . Deleting small elements Elements which are below a minimum length are deleted from the drawing. This is often the case with drawings deriving from 3D. 3. Filling a gap Extensive gaps in the contour can be filled by the trim function.

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Sample: milling outside contours Sample: milling outside contours 1. Loading and preparing the drawing See sample: importing and optimizing geometry Change to the area CAM 2. Selecting post processor First you have to select the desired CNC format DIN/ISO or HPGL. In our sample decision was made for DIN/ISO. 3. Creating new program Please insert a program number as well as a brief description of the program. By clicking OK the program start and the corresponding indications are registered in the editor. 4. Determination of the zero point Now you have to determine the zero point for the X and Y axes by activating the necessary option and catch the desired point.12 5. Selecting tool Call up the tool data bank and select the required milling cutter. After definiton of the corresponding materials you can immediately effect calculation of feed rates and spindle speeds. Using a tool changer you have the option for changing the milling cutter later on or with the specific function. 6. Routing contours Routing contours, the milling distance is derived from the CNC contour of the geometry. FILOU-NC automatically searches for possible contours. Please observe messages at the lefthand bottom in the status bar. Attention: The contour lining is able to process open and closed contours. Contour processing starts always at one end of an element, i.e. at the end of a distance or an arc. From this position FILOU-NC moves to the oter end of

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Sample: Milling outside contours the element and checks whether there is another element with its starting point. If this is the case, the element is automatically adopted, etc. If FILOU-NC discovers serveral elements at the same time, a message with the information Click on following element is displayed in the status bar. Clicking to the correct element, the contour lining continues running as long as possible. The contour lining always wants to route all elements of a contour. This means that there are two reasons why the contour cannot be processed: 1. If the milling cutter is greater or of the same size as the circle arc in this contour 2. If an element cannot be machined due to the tool size An error message is displayed with the information contour lining interrupted. In order to eliminate this error please select a smaller milling cutter or change the contour. Attention: Gaps in the contour Tolerance of sequential elements can be determined in the parameter settings. In order to find subsequent elements, the corresponding ends have to positioned side by side. A slight deviation is permissible which is called tolerance of sequential elements. Additional settings for contour lining are as follows: Confirm adoption If this option is activated, as it is recommended, you have to confirm the contour prior to the editor registration of the NC code. Automatic releasement of used elements Used elements are blocked during contour lining. These elements are dispayled in green color and invisible for further functions. If the parameter Automatic releasement of used elements is activated, these elements are immediately released again. Offset correction In order to obtain a workpiece corresponding exactly to the size of the drawing, the milling cutter has to rout beside the contour. This procedure is called offset correction. There are three possibilities in FILOU-NC: - to the left of the contour - onto the contour (without) - to the right of the contour
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Sample: Milling outside contours Right and left is referring to the milling direction which is defined by the starting point of the contour as it has already been explained. Move the cursor over the geometry. FILOU-NC displays the current path correction. A click with the left mouse button confirms your selection. Once more we want to remind you of the program assistance which can be activated by pressing button F1 and provides you with direct support. Even the graphical display above is derived from this support. Additional parameters are described in the program assistance by pressing the button F1. Before starting the contour lining all settings can be changed. After completion of all settings, click to the contour start by the left mouse button and proceed according to prior descriptions. Subsequent proceedings are possible. After finishing the process call up CNC end of program.

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Characteristics during the milling of an inside contour Characteristics during the milling of an inside contour

contour violations

As contour lining always starts at one end of the element and all elements are to be routed, some contour violations may arise concerning the inside contours.

Remedy is made by dividing or cutting the element. In this way new starting points are produced and the contour can be routed without any problems.

Circles are automatically sliced at one of the quadrant points.

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he created program Simulation of the created program Simulation of the created program The simulation analyzes the NC code in the editor and processing is visibly displayed.

First step: Analysis of the NC program

After clicking Analyze NC program, FILOU-NC displays the milling distances. In the right section you can enter measurements of the unmachined piece. FILOU-NC starts automatically with the largest milling distances as basis for the size of the unmachined piece. The coordinates refer to the zero point. For this purpose FILOU-NC extracts the tools available in the program. By drag and drop you have to assign an element of the tool store to the tools.

If all settings are finished you have to select simulation.

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Simulation of the created program

In the simulation window you select adopt analysis. Press button F1 for description of functions.

The time required for calculating 3D simulation depends on the size of the workpiece and the adjusted precision. The smaller the workpiece, the better the adjusted precision. Attention: Existing CNC programs can also be simulated. Therefore the program has to be loaded in the editor following by executing the steps described here. It is possible to simulate CNC prorgrams with max. three simultaneous axis.

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Appendix: DIN code or HPGL?

Appendix DIN-Code or HPGL? Often we have to answer questions concerning the difference between both languages for CNC programming. Some general and subjective information below: HPGL DIN code Upshot FILOU-NC and WinPC-NC FILOU-NC and HPGL As already expressed by the term HPGL itself, HPGL (Hewlett-PackardGraphic-Language) is actually a graphical language for (pin) plotter controllers. This means a 2D geometry description with the options pin down or pin up. Arcs and circles are resolved in many small paths. The plotter is drawing with a special kind of pin depending on the color. Later on HPGL2 was presented as a further development. It provided a userfriendly language but in principle, there have been no considerable changes. As the plotter pins are directly moving over the geomery, there is no requirement for path or tool correction. However, one characteristic is worth mentioning: The smallest resolution is 1/40 mm respectively 0,025 mm. Some singular programs or machines provide / require a HPGL file with the smallest possible resolution of 0,0254 mm which corresponds to a thousandth inch (25,4 mm). Simple creation of the HPGL format is a great advantage. It can be produced by nearly all available graphic programs supporting a (HPGL) plotter.A disadvantage is the restriction to true 2D procedures. Generally drilling is not possible with a true HPGL code. There are some restrictions when using HPGL: Relatively rough resolution, working in only one level, missing correction of milling radius and sometimes the quite irregular moving of the contours

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Appendix: DIN Code or HPGL ? when pin change is carried out frequently. Therefore it makes sense to optimize the HPGL code by FILOU-NC. Some manufacturers of control systems have modified HPGL in the way that 3D can be used. However this process is very specific to controlling and cannot be produced by CAD or graphic programs. The values in HPGL range from plus/minus 32768 (16 bit) and results in a max. length of distances of: 2 x 32768 / 40 = 1638,4 mm per axes. This should cause no problems, as acutually there are a lot of control systems accepting wider value ranges. The DIN code, called G-Code, is defined according to DIN 66025 and is considered as standard in acutal professional NC programming. Many industrial control systems apply DIN programming or elements of it as basis, completed by individual functions. There are so-called M commands concerning switching on/off the cooling water or the G functions, e.g. for distances, cycles, selection of the level, path correction, etc. The supply is completed by technical sub-routines and 3D processes. Generally programming is effected by a resolution of 0,001 mm. DIN code offers a wider range of possibilities than HPGL Finally it can be stated, that the DIN code provides much more possibilities than the relatively simple HPGL format and does not cause disadvantages like HPGL. However, creating NC code in the DIN format requires basic knowledge of the language. The DIN format is clearly structured and easy to master. Upshot HPGL is effective for simple 2D moving of 2D contours. Requiring a wider range of possibilities or absolute accuracy, the application of DIN programming is recommended. FILOU-NC and WinPC-NC

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Appendix: DIN/ISO commands By special post processors FILOU-NC, as a steppermotor controller, matches with WinPC-NC. This applies for the HPGL format as well as the DIN code. FILOU-NC creates a NC code which can be read and processed by WinPC-NC. In order to be processed by PC-NC, FILOU-NC is equipped with the corresponding functional range. FILOU-NC and HPGL By means of FILOU-NC an optimized HPGL code can be created. It is possible to move contours, completely or partly, in a defined direction. On request the tool path with corresponding path correction can be immediately created for the selected tool. By contour lining the contours are automatically combined and unproductive distances are minimized. In this way all contours for a individual tool can be machined. Afterwards all contours for another tool can be created. DIN/ISO commands Following DIN/ISO commands are supported by WinPC-NC: G-commands G00 Linear interpolation with rapid speed G01 Processing, linear interpolation G02 Clockwise circle movement G03 Counter-clockwise circle movement G04 Dwell time, time with F-command G17 Level XY G18 Level XZ G19 Level YZ G70 Measurements in inch G71 Measurements in mm G90 Absolute position information G91 Relative position information G98 Define subroutine M-commands M00 Program halt M02 End of program M03 Spindle on, clockwise rotation

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Appendix: DIN/ISO Sample of program M04 M05 M06 M07 M08 M09 M16 M30 M66 M70 M71 M72 M73 M74 M75 M76 M77 Others N Record number Spindle on, counter-clockwise rotation Spindle off Change tool Coolant on Coolant on Coolant off Wait for input, input number in F End of program Change tool, same as M06 Set output 100 to HIGH Set output 101 to HIGH Set output 102 to HIGH Set output 103 to HIGH Set output 104 to HIGH Set output 105 to HIGH Set output 106 to HIGH Set output 107 to HIGH

Commands S F F F Spindle speed Input number (with M16 command) Dwell time (with G04 command) Feed (without M16 and G04 command) Speed in set unit of measurement (mm/s or mm/min. or inch/min.) Circle parameters Select tool Coordinates Coordinates for 4th axis, if activated Coordinates for 4th axis, if activated Radius of arcs Call subroutines (1...20)

I,J,K T X,Y,Z U,V,W A,B,C R L

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Appendix: HPGL commands DIN/ISO Sample of program % name N001 G90 N002 G71 T1 M6 N003 G00 X110 Y100 Z10 N004 G01 Z11 N005 G01 X190 N006 G03 X200 Y110 J10 N007 G01 Y190 N008 G03 X190 Y200 I-10 N009 G01 X110 N010 G03 X100 Y190 J-10 N011 G01 Y110 N012 G03 X110 Y100 110 N013 G01 Z10 N014 G00 X0 Y0 Z0 N015 M30 HPGL commands PA [x,y[,x,y]]; PR [x,y[,x,y]]; PU [x,y[,x,y]]; PD [x,y[,x,y]]; SP x; CI r [,a]; AA x,y,a[,c]; AR x,y,a[,c]; HPGL sample PU; PA1000,1000; SP1; PD; PA1000,2000; PA2000,2000; PA2000,1000; PA1000,1000; PU;

Program start Absolute coordinates Rapid speed to first position Plunge movement with Z Feed movement in straight line Arc about center point etc.

Rapid speed to zero point End of program

Move to absolute position(s) Move to relative position(s) Lift and move tool Lower and move tool Select tool Draw complete circle Absolute arc Relative arc

Start by lifting tool Then move to 1000/1000 Select tool 1 Lower tool Outline square

Lift tool
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FILOU-NC comparison of the different versions FILOU-NC comparison of the different versions
FILOU-NC Operations Geometry CAM Editor 3D-Simulation CNC-Backplot V24-Transfer*** Individual post processors (optional or selfmade) Macroprogramming Standard post processors (extent of delivery) + + + + + + + FILOU-NC / SE Milling + Drilling + + + + + FILOU-NC for WinPC-NC + + + + -

Output

Contour 2 / 3 PCNC (DIN/ISO) Dialog 4 / 11 / 12 HPGL (distances) Fanuc HPGL DIN/ISO (distances + arcs) HPGL (distances) HPGL (distances + arcs) ISEL (NCP) MACH 2 / 3 Mitsubishi PC-NC (DIN/ISO) Sinumerik 810-840 Heidenhain TNC 135-155 Heidenhain TNC 355 Heidenhain TNC 426-430 can be extended cannot be extended As file and/or byV24 File Directly to to the CNC WinPC-NC 1295,-***EUR 595,-***EUR + -> Mill 300,-***EUR + -> Mill or SE

Price Upgrades are possible

+ = available, - = not available, ** = for steppermotor controllers not suitable *** = V.A.T. not included

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Appendix: Glossary Glossar CAD Construction supported by computer or Computer Aided Design (CAD) CAD 2D 2D CAD sytems are vector orientated drawing programs. Drawing elements are points, lines, polylines (line drawings), circle arcs, splines and operation corresponds to the conventional working by drawing board. FILOU-NC imports 2D DXF files and creates 2D geometry. CAD 21/2D This is no real 3 D and is also called wiry model with spatial arranged vectors, e.g. a 3D polyline. FILOU-NC imports 3D polylines in DXF files. CAD 3D Defines the 3D model by lines or sizes. CAM Computer Aided Manufacturing (CAM) means fabrication supported by computer. CAM is a program which makes it possible to create a NC code out of CAD geometry in order to actuate machines. Therefore the NC code is derived from the CAD geometry. FILOU-NC is a CAM program. CAM 21/2D 21/2D CAM programs are calculating the tool distance parallel to the geometrical 2D contour of the CAD geometry The tool is working in the direction of the Z-axis (by a predefined height two axes are simultaneously machined). The Z-height is defined by the user. FILOU-NC provides 2D milling routines. CAM 3, 4 or 5 axis simultaneously In order to rout (free-shape) surfaces a CAM software is required which is able to create the CNC code for three, four or five simultaneous axis. For this purpose we can offer DeskProto and Mayka.

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Appendix: Glossary CNC A Computerized Numerical Control (CNC) means electronic and/or software for controlling machines. CNC resulted from NC. Today both terms, CNC and NC, are equally used. CNC controllers are differentiated by the number of simultaneously movable axis and by controlling points, distances and paths. NC A Numerical Control (NC), also called numerical controller, means electronic with additional software for controlling machines. All information of NC is read in from a punched tape in records. Post processor The postprocessor is responsible for creating the correct CNC code. In FILOU-NC for WinPC-NC the post processor is selected in order to create a CNC program either in DIN/ISO or HPGL format. In FILOU-NC the post processor is selected at the start of the CNC programming.

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