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CNC Setups
Parts must be located precisely and held securely during the machining
process. Work holding devices are referred to as fixtures. A fixture can
be as simple as a vise with hard jaws. Very complex fixtures, like those
used in the aerospace industry, may cost many thousands of dollars and be
designed by highly experienced tooling engineers.
Devising efficient and effective fixtures is one of the most challenging
tasks of programming a CNC Mill, requiring a high level of knowledge,
skill, and ingenuity. A few of the many factors influencing work holding
include:
For example, many parts can be accurately located and held in a vise. If
the part is machined on several sides, pay careful attention to the order
each face is machined and how the part is flipped between operations.
Production quantity is an important consideration. Higher production
volumes usually justify more expensive tooling to speed production and
reduce scrap rate.
Size and type of material and cutting forces also affect fixture choice. A
foam or plastic visual prototype may be simply glued or taped down.
More substantial parts can be bolted, clamped, or held with a vacuum.
E-1
Appendix E
CNC
Setups
Vise
A basic vise setup uses a vise, step jaws, vise stop, and stock material
machined to size. The back edge of the fixed step jaw is dial indicated
parallel to the machine x-axis. The vise stop sets a limit to slide the stock
against as fresh stock material is loaded.
Vise
Stop
Back Edge of
Fixed Jaw
Parallel To
Machine X-Axis
Fixed
Jaw
Movable
Jaw
Y
X
Stock cut
To size.
Stock
Back Edge
Step Jaw
Step
Jaws
Warning
E-2
CNC Setups
The following diagram shows the layout of a typical VMC and location of
the spindle when the machine is at its Home Position.
Z
Y
Top
Iso
Front
Side
CNC programs are written in terms of the tool tip motion; not table
motion. For example, a command of X1.0 moves the tool to the right
(though on a VMC the table will move to the left).
Mastercam Handbook Volume 1
E-3
Appendix E
Fixture
Offsets
Your probably noticed that when the machine is at its home position, its
coordinate system datum is far away from the part datum. Here is why.
When you first power-up a CNC machine, it has no idea where the spindle
is located in the workspace. The machine finds its position during the
startup-home process by simply driving each machine axis towards its
(-) limit. Just before the machine hits an axis limit, it trips a micro-switch.
This signals the control that the axis is at a known location; called the
Machine Home. Home is usually defined as the center-face of the
spindle when the machine is at its (-) axes limits.
Once homed, the machine keeps track of its position by counting how far
each axis moves in reference to Home. Coordinates in reference to
Machine Home are called Machine Coordinates.
Of course, no one programs using Machine Coordinates. The Machine
Home position is far from the work piece, so programs written in Machine
Coordinates would have numbers that bear no obvious relation to
coordinates on the part.
If the fixture were removed, it would be difficult to put it back exactly
where it was, so the NC program would have to be re-written to account
for any difference. Besides, the part has its own datum, and NC programs
written in reference to the Part Datum are lot easier to understand.
E-4
Mastercam X5
CNC Setups
Any point on the part or fixture can be used to find the part datum, as long
as you can reliably measure its position.
In this example, Exercise 3-9, Fixture Plate, the material is machined to
finished size before loading it into a standard six-inch vise with step jaws.
The top of the finished material is Z-Datum.
The fixed (back) vise jaw is dial indicated parallel to the machine X-axis.
A Vise Stop, in this case an adjustable rod, allows stock material to be
loaded into the vise in the exact same position each time.
The part datum must be located precisely; typically +/- .001 or less. There
are many ways to find the part datum. In this example, the XY-Datum is
easily found using and Edge Finder to locate the back and left edges of the
part.
Vise
Stop
Back Edge of
Fixed Jaw
Parallel To
Fixed
Jaw
Movable
Jaw
Back
Edge
Stock c ut
Step
Jaws
Z
Y
E-5
Appendix E
Fixture
Offset
Registers
(G54-G59)
The coordinate system is shifted from Machine Home to the Part Datum
using a Fixture Offset. A fixture offset is simply a record machine
control keeps of the distance between the Machine Home position and the
Part Datum point. Each time the NC program commands a move, the
control checks this record, or Register, and internally adds this value to
that move.
Fixture offsets are usually assigned G-codes G54 thru G59, though some
machines allocate more. Each fixture offset has a XYZ shift value. When
a fixture offset G-code appears in the NC program, the control looks at the
register values for that offset, and adds these values to any subsequent
moves.
In this example, the G54 offset register is called on line (N2) of the NC
program. This line of code moves the center of the spindle from the
Machine Home position to directly above the Part Datum.
Mac hine
Home
Shift_X
N1
N2
Shift_Y
-7.159
12.683
N1
Part
Datum
N2
G54
Tool
Motion
Sample NC Program
N1 T1 M6
N2 G90 G54 G0 X0. Y0.
N3 S7200 M3
N4 G43 H1 Z1. M8
E-6
Mastercam X5
CNC Setups
You probably noticed that the fixture offset in this example was used only
to shift the datum in X-Y, not Z. This is because the Z shift distance
changes depending on the tool length how far the tool extends below
the center-face of the spindle. Most tools are different lengths. Length
may even change when you replace a worn or broken tool.
Tool
Length
Offsets
(H)
Mac hine
Home
N2
N4
Part
Datum
N5
Shift_Z
Tool
Length
Home Z-Datum
To
Part Z-Datum
Sample NC Program
N1 T1 M6
N2 G90 G54 G0 X0. Y0.
N3 S7200 M3
N4 G43 H1 Z1. M8
N5 Z0. F3.
Shift_Z
(-11.913)
N4
N5
E-7
Appendix E
The previous illustration shows the simplest way to use tool length offsets.
This method is widely used in prototype and short production work.
The tool is jogged to the Part Z-Datum (in this case, the top of the
part).
The incremental distance moved in Z from the home position to
the top of the part is recorded and entered in the appropriate Tool
Length Register.
This value represents the shift in Z from the machine home to the
Z-Datum of the part.
The value is usually negative; the machine subtracts this value
from the Z-position of the spindle, shifting the tool down towards
the part.
Another method uses what is called preset tooling. This is used more
often in larger companies and long production run work:
The tool length (distance from the center-face of the spindle to the
tip of the tool) is accurately measured in the tool room.
This gage length is entered in the tool-offset register as a positive
value.
The fixture offset Z-value represents the distance from the centerface of the spindle to the part Z-datum.
Internally, the control first subtracts the fixture offset from a
command move. It then adds the tool gage length to the move.
Some machines have automatic tool probes which measure the length
automatically. Follow the instructions in the machine operator manual
for use of tool and fixture offsets with a probe.
There are other ways to use fixture and tool offsets. They all work, and
companies have good reasons to adopt a particular method. But, once
you understand how fixture and tool offsets work, will easily adapt to
whatever method your company or school uses.
E-8
Mastercam X5
CNC Setups
CNC
Setups
The purpose of the fixture plate is to accurately locate the stock material
and then keep the part from moving during machining.
The illustration below shows a typical fixture plate. The fixture base is
machined flat, square, and parallel. Notice the plate is engraved with the
part name and coordinates of the part datum in reference to the upper-left
corner. This makes it easier to reuse the fixture plate.
A) Fixture Base
B) Clamp (2X)
C) Dowel Pin (3X)
D) Washer (2X)
E) Bolt (4X)
E-9
Appendix E
Example
Fixture
Plate
The fixture plate below shows the setup just before the first machining
operation. After the holes are drilled and bolts inserted through the part,
the dowel pins and clamps should be removed if there is any possibility of
a collision with the tool or holder.
Stock Material
Aluminum Sheet
5.0 x 2.5 x .063
Aluminum Base
6.0 x 5.0 x .625
Clamp
.5 x 1 x .25
Dowel Pin
.250 x .625
Bolt
1/4-20 x .75
E-10
Reamed Hole
.251 x .375 Deep
Vent Hole
.093 Thru
Mastercam X5
CNC Setups
Component
Fixture
Plate
Stock
Description
This is the base on which the fixture is built. For short
production and prototype parts, an aluminum plate is
commonly used. It is machined flat, square and parallel.
Fixture
Plate
Components
De-burr all sharp edges and holes so the stock lies flat on
the surface and is not scratched.
Sheet aluminum stock that is within specification in
thickness.
Since a OD contour cut is made all around the part, stock
can be sheared or saw cut to approximate size.
Dowel Pins
Washers
Cap
Screws
Clamps
E-11
Appendix E
Components
Specifications
Component
Fixture
Plate
Stock
Dowel Pins
Specification
6061-T6 Aluminum
Width: 6.00
Height: 4.25
Thickness: .625 (5/8)
6061-T6 Sheet Aluminum
Width: 6.00
Height: 4.25
Thickness: .063
Ground Steel
Diameter: .250
Height: .625 (5/8)
Install: .375 Deep
McMaster-Carr p/n:
Washers
Cap
Screws
Aluminum
ID:.266
OD:.50
Thickness: .064
-20 Socket Head
OD: .250 Thread
Head Dia: .375
Grip Length: .75
McMaster-Carr p/n:
Clamps
E-12
6061-T6 Aluminum
Width: .5
Height: 1.0
Thickness: .25
Step: .063
D-Hole: .26 WD x .50 HT
Shop Made
Mastercam X5
CNC Setups
The following steps show how a simple fixture plate may be setup and
used on a vertical machining center.
Process
Overview
Setup
1) Fixture can be clamped to
machine table or clamped in a
vise.
2) Vise fixed jaw is aligned with
machine X-axis.
3) Left-Back edge of fixture can
be located as a reference point.
Warning
E-13
Appendix E
Step 4: Contour OD
1) Machine OD with 3/16 End
Mill.
2) Provide sufficient lead-in to
Clear stock.
E-14
Exercise care when handling parts, and keep a clean work area.
Strive to deliver quality in everything you do. Parts that are
properly de-burred and are not marred in any way by mishandling
are the mark of a professional machinist.
Mastercam X5
CNC Setups
In cases where you need to position a plate with existing holes, never rely
on threaded holes to locate the part. Instead us Shoulder Bolts (aka
Stripper Bolts).
Shoulder
Bolts
Counterbore a hole in the fixture plate the diameter of the bolt shank.
Drill and tap a hole in the bottom of this counterbore to screw in the
shoulder bolt.
Shoulder Bolt
Ground Shank
Located in Counterbore Hole
E-15
Appendix E
Notes:
E-16
Mastercam X5