ANCAcodingHelpDemo-3

Having now drilled the bearing holes we can bolt the Conrod blank to a holding fixture and proceed to mill away the side clearances on both sides using a face mill.

Fig-4 Starting the Clearance cut of the conrod.

As cut is wider than mill we do a 'U' shaped cut

Fig-5 End of the Clearance cut.

The clearance operation is done in two passes ( Top & Bottom ) using the same G-code file below,

Notice the file is made up of four basic sections,

Preamble containing set up instructions and commands
Subroutine Section
Main part of the program
Cleanup, storage of tools and moving the machine to the start position ready for the next part.

Conrod Clearance Cut G-code File Listing of the file, 'CONROD_CLEAR.ANC'

( THIS FILE MACHINES SIDE CLEARANCE INTO THE CONROD
( ORIGIN IS OVER THE SMALL END WHICH IS TO THE LEFT.
( USE 40MM CUTTER AT 1200 RPM.
( SET TO START POSITION INITIALLY USING SUBROUTINE-1.
( USE SUBROUTINE-2 TO MILL THE CLEARANCE FOR ONE SIDE, THEN TURN OVER AND CUT
( THE OTHER SIDE.
( USE 40MM CUTTER AT 1200 RPM.
( Blank is 83 * 20 * 12 thick Alluminium
(================================ Setup commands ====================================
G90 ( Absolute co-ordinates used.
G71           ( Set to Metric system (millimeters) measurement units.
G94           ( Set Feedrate to units per minute.
F100          ( Feedrate is 100 mm per minute.
T#1 40.0 0 ( Set up 40mm cutting Tool and load it.
(================================ Subroutine Section ===================================
G57R1 ( During Setup, locate cutter over little end & then move to start position 0,0
G0X20
G0Y40
G58
(
G57R2        ( Mill side clearance for one side
G1Y-40       ( Cut along the 'Y'axis 40 milli metres
G1X4.5       ( Cut along the 'X'axis 4 & 1/2 milli metres
G1Y0          ( Cut back to Y = 0.0
G0X0          ( Fast travel back to starting point.
G58
(=========================== START MAIN PROGRAM HERE ================================
(     G59R1C1 ( setup routine, comment out once setup done! Locate Spindle directly over the left bearing to begin Setup.
G59R2C1 ( Mill side clearance for one side, comment out during setup
M2

Stage-3: Machining the Outside of the Conrod blank.

Shown below is the cuting of the outside shape of the rod using a slot drill.

Fig-6 Starting to cut the outside of the conrod.

Fig-7 Conrod Outside cut Underway!

Notice again that the file is made up of the four basic sections,

Preamble containing set up instructions and commands
Subroutine Section
Main part of the program
Cleanup, storage of tools and moving the machine to the start position ready for the next part.

Outside Shape G-code File Listing of the file, 'CONROD_OUTSIDE.ANC'

( THIS FILE MACHINES THE OUTSIDE OF THE CONROD AT 63 MM BETWEEN CENTERS.
( ORIGIN IS OVER THE SMALL END WHICH IS TO THE LEFT.
( USE 12MM CUTTER AT 1200 RPM.
( SET TO START POSITION INITIALLY USING SUBROUTINE-1.
( USE SUBROUTINE-2 TO MILL THE OUTSIDE.
( Blank is 83 * 20 * 12 thick Alluminium
(================================ Setup commands ====================================
G90 ( Absolute co-ordinates used
G71 ( Set to Metric system (millimeters) measurement units
G94 ( Set Feedrate to units per minute.
F60 ( Feedrate is 60 mm per minute
T#1 12.0 0 ( Set up 12mm cutting Tool and load it
(================================ Subroutine Section ===================================
G57R1 ( During Setup, locate cutter over little end & then move to start position 0,0
G0X9
G0Y19
G58
(
G57R2 ( Cut around to create outside shape
G1Y-6
G1X46Y-5
G2X8.2Y14I8.2J-14
G1X46Y-33
G1X0Y-32
G2X-8.3Y-13I-8.3J13
G58
(============================= START MAIN PROGRAM HERE ==============================
(G59R1C1 ( Setup routine
G59R2C1 ( Cut around to create outside shape
G0Y0 ( Home tool to start position
G0X0
M2

Stage-4: Simulate Stage-2, Machining the side clearances.

Simulation: Machining the side Clearance of the Conrod blank.

Fig-8 Conrod CLEARANCE
Overlay Image taken from Bmach2d.

Fig-9 Image taken from
Bmach2d after clearance cut simulation.

Here we are looking at Figure-8 and Figure-9 which shows the simulation of a 40mm cutter which is machining one side of the conrod for crankshaft clearance. Not shown is the same operation on the back to clear other parts of the engine at bottom dead center.

Open 'side4linux' and click on 'Project>Open Project' in the Main menu. double click on the 'DEMOS' Product Area,
Double click on the 'SIDEdemos' Product,
In the file dialog double click the 'ANCA' folder, this takes you to where ANCA style G-code projects are kept for this Product.
Double click on 'Conrod', this opens the 'Conrod' project folder.
Notice that project names are set to be an upper case letter followed by lower case letters (easier on the IDE's Project routines).
Double click on 'conrod.prf', this opens the 'Conrod' project file.
Notice that the left bottom status bar window says 'Project: Conrod' which is the Project Name
Notice that the next window says 'Ptype: ANCA' which is the Project Type.
Try clicking on 'Project' on the Main menu, you will notice that 'Close Project' is now active.
Click on the 'Open' toolbar button, observe the files 'CONROD_CLEAR.ANC', 'CONROD_OUTSIDE.ANC' and their 'OVL' overlay files,
and double click on 'CONROD_CLEAR.ANC'. This opens the sample G-code file we need to compile.
To compile the file click on the 'Build' Toolbar Button.
NOTE: You need to have an 'ANC' file in the current page of the Notebook to tell the compiler which file to compile.
Notice after about a minute the result in the 'Output' window below.
Notice in the status bar below that the message 'PBuild: Success!'.
Now open the 2d simulator Bdmach2d with 'Tools/ANCA/Bmach2d'.
Click on 'Settings/Gridsize/Gridsize 2mm' to set the display to 2mm per grid square.
Load the Overlay file for this operation by clicking on 'File>Load Overlay File' and select 'CONROD_CLEAR.OVL'.
Now run the Overlay 'File>Run Overlay File' to produce Figure-8 above.
And you can run the simulation with 'File>Run CMD' to produce Figure-9 above.
Close down Bmach2d with 'File>Quit'.
Notice that you need to have the 'ANC' file you wish to compile in the Notebook and it must be currently active,
Click the file's Notebook tab if the file is not current and left click in the file space before the click on 'Build',
this tells the 'Compiler' which file to compile..

Stage-5: Simulate Stage-3, Machining the outside of the blank.

Simulation: Machining the Outside of the Conrod blank.

Fig-10 Conrod OUTSIDE Overlay
Image taken from Bmach2d.

Fig-11 Conrod OUTSIDE Cut.
Image taken from Bmach2d.

Continuing on from Stage-4 above...

Click on the 'Open' toolbar button, observe the files 'CONROD_CLEAR.ANC', 'CONROD_OUTSIDE.ANC' and their 'OVL' overlay files,

and double click on 'CONROD_OUTSIDE.ANC'.

This opens the sample G-code file we need to compile to simulate cutting the outside of the Conrod blank.

To compile the file click on the 'Build' Toolbar Button.

NOTE: You need to have an 'ANC' file in the current page of the Notebook to tell the compiler which file to compile.

Notice after about a minute the result in the 'Output' window below.

Notice in the status bar below that the message 'PBuild: Success!'.

Now open the 2d simulator Bdmach2d with 'Tools/ANCA/Bmach2d'.

Click on 'Settings/Gridsize/Gridsize 2mm' to set the display to 2mm per grid square.

Load the Overlay file for this operation by clicking on 'File>Load Overlay File' and select 'CONROD_OUTSIDE.OVL'.

Now run the Overlay 'File>Run Overlay File' to produce Figure-10 above.

And you can run the simulation with 'File>Run CMD' to produce Figure-11 above.

Close down Bmach2d with 'File>Quit'.

Click on 'Project>Close Project' to end Demo-3.


Fig-3a Drill Jig with unmachined Blank on the left and Finished Conrod on the right.	Fig-3b Blank in lower half of Drill Jig	Fig-3c Drill Jig ready to use, notice the adjustable bushing!	Fig-3d Drill Jig on drill press about to drill the first hole.