Feed Ramp UP – CNC Program

So I work in a high production environment where every 10th-seconds matters when it comes to cycle time on our CNC machine.

We’ve been having an issue with early failures on some of our PCD diamond custom tools. See I have to feed them very fast to make cycle time and the issue is they are so sharp sometimes they just fracture with maybe in the first several operations or hundreds of parts. Normally they would run 20,000 pieces before they would need be sent out for rework.

One way that I found that would prevent the tools from breaking early on was to manually slow feed rate down and then slowly bring it up to 100%. I did this by listening to the tool cutting and used my best judgment of one to increase the feed. I can’t be there all the time to do that and other machinists in the five production environment don’t have the time to stand there to monitor just one machine. So I have come up with a program that would just slowly ramp rate up to 100% over 100 parts spam.

So you change a tool and you reset the counter(R900) to zero and that will activate the sub-program that will run 30 parts at 20%, 30 parts at 40%, 30 parts at 60% and 30 parts at 80%, then at 101 parts it is running at a full feed rate 100% of the program.


GOTOF END_OF_INFO
;------------------------------------
;	VERSION:	1.1
;	DATE:		JULY 8, 2019
;	PROGRAMMER:	MARK VANDERBERG
;	PROGRAM:	FEED_RAMP_UP.SPF
;	COMMENT:	 FEED RAMP UP
;------------------------------------

;*************************************
;--- SIEMENS 840D ----- Chiron ------ 
;   Twin Spindle Vertical Mill  
;	MACHINE  :Chiron DZ12W
;	DRAWING NUMBER:  
;	MATERIAL:	ALUMINUM     
;*************************************

END_OF_INFO:

R900=R900+1 ;COUNTER: RESET R900 BACK TO ZERO MANUALLY AFTER REPLACING TOOL

;COUNT CYCLES
R901=30
R902=60
R903=80
R904=100

;READ IN FEED RATES
R910=2000
R911=2400
R912=2500
R913=3000
R914=3600
R915=4000
R916=4500
R917=5000

;20 PERCENT
IF R900 <= R901
MSG ("RUNNING @ 20 PERCENT")
R950=R910*.2
R951=R911*.2
R952=R912*.2
R953=R913*.2
R954=R914*.2
R955=R915*.2
R956=R916*.2
R957=R917*.2
ENDIF

;40 PERCENT
IF (R900 >= R901) AND (R900 <= R902)
MSG ("RUNNING @ 40 PERCENT")
R950=R910*.4
R951=R911*.4
R952=R912*.4
R953=R913*.4
R954=R914*.4
R955=R915*.4
R956=R916*.4
R957=R917*.4
ENDIF

;60 PERCENT
IF (R900 >= R902) AND (R900 <= R903)
MSG ("RUNNING @ 60 PERCENT")
R950=R910*.6
R951=R911*.6
R952=R912*.6
R953=R913*.6
R954=R914*.6
R955=R915*.6
R956=R916*.6
R957=R917*.6
ENDIF

;80 PERCENT
IF (R900 >= R903) AND (R900 <= R904)
MSG ("RUNNING @ 80 PERCENT")
R950=R910*.8
R951=R911*.8
R952=R912*.8
R953=R913*.8
R954=R914*.8
R955=R915*.8
R956=R916*.8
R957=R917*.8
ENDIF

;100 PERCENT
IF R900 > R904
MSG ("RUNNING @ 100 PERCENT")
R950=R910
R951=R911
R952=R912
R953=R913
R954=R914
R955=R915
R956=R916
R957=R917
ENDIF

NN9999: M17
____

If you would handle this problem in a different way please leave a comment.

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