Fusion 360 outputs KOSY, however this is not compatible with the WABECO CNC mils. Some simple issues like feed rates and replace M1 with M01 are easy to fix. However I keep coming against circle coding issues G2/G3 commands, The Wabeco (Max-Computer.de) software keeps reporting "Too many parameters" example is G03 X-16.21 Y0.61 Z2.19 I-1.84 J2.18 I am no expert, but seems that the Z commands may need moving to a separate program line. Below is the G02/G03 as supported on Wabeco Mills :- G02, G03 - Circle movements G02 means circle movement clockwise G03 means circle movement counter clockwise! You start from the present starting position, and give the centre of the circle in relative measure. You must indicate the rotation angle in degrees (0 to 360), e.g. circle arc clockwise in X/Y-level, rotation angle 50 degrees: G02 D50 I40 J-5 Or give the ending position instead of the rotation angle: G01 X20 Y60 ;go to starting point G02 X20 Y40 I0 J-10 ;180 degree-arc Circle, counter clockwise, in X/Z-level, rotation angle 120 degrees: G03 D120 I70 K25 Or give the ending point: G01 X10 Y80 ;go to starting point G03 X30 Y80 I10 J0 ;180 degree-arc right G02, G03 - Circles in 3 dimensions The CNC-programming allows the machining of circles in 2 1/2 D-mode. That means that circular movements can be made in the X-Y-level, the X-Z-level or the Y-Z-level. The level is indicated by the adjustment of the relative measures. The command ..... G02 D360 J10 K17 F100 ...stands, for example, for a circular movement in the Y-Z-level. The relative measures for the distance between starting point and centre of the circle are generally adjusted as follows: I to X-axis, J to Y-axis, K to Z-axis. There are a lot of Wabeco CNC mills out there, a large number of them in schools, it would be good to have a good post processor for these machines. Below is the full NC command list supported by Wabeco (basic compared to MACH3 etc) :- NC-commands After DIN/ISO 66025 Revised: June 2006 The list of CNC-commands for KOSY is ranged in the following way: 1. CNC-machining commands G.., by numbers onward. 2. Machine-controlling commands M.., by numbers onward. You also get an explanation of the NC-commands by setting the cursor on a command code in the NC-editor and then pressing the function key [F1] 1. Machining commands The commands have the following meaning: G00 - Fast mode In the fast mode a movement (without application of a tool) is made as fast as possible. Therefore you go to the indicated point in a straight line. Fast mode movements are always made in the highest possible speed. Please pay attention to the basic setting in chapter 2! Fast mode to the indicated two-dimension position: G00 X20 Z-5 Fast mode to the indicated three-dimension position: G00 X100 Y200 Z-50 G01 - Straight movement For movements where the tool goes to and into the workpiece (tool in action). When G01 is used for the first time you have to add the speed by an additional command (F). The numeric value goes from 1 (very slow) to 200 (very fast). Line movement in X-and Z-axis with speed indication: G01 X-345.02 Z-45 F30 G02, G03 - Circle movements G02 means circle movement clockwise G03 means circle movement counter clockwise! You start from the present starting position, and give the centre of the circle in relative measure. You must indicate the rotation angle in degrees (0 to 360), e.g. circle arc clockwise in X/Y-level, rotation angle 50 degrees: G02 D50 I40 J-5 Or give the ending position instead of the rotation angle: G01 X20 Y60 ;go to starting point G02 X20 Y40 I0 J-10 ;180 degree-arc Circle, counter clockwise, in X/Z-level, rotation angle 120 degrees: G03 D120 I70 K25 Or give the ending point: G01 X10 Y80 ;go to starting point G03 X30 Y80 I10 J0 ;180 degree-arc right G02, G03 - Circles in 3 dimensions The CNC-programming allows the machining of circles in 2 1/2 D-mode. That means that circular movements can be made in the X-Y-level, the X-Z-level or the Y-Z-level. The level is indicated by the adjustment of the relative measures. The command ..... G02 D360 J10 K17 F100 ...stands, for example, for a circular movement in the Y-Z-level. The relative measures for the distance between starting point and centre of the circle are generally adjusted as follows: I to X-axis, J to Y-axis, K to Z-axis. G20 - Jump to the sentence .... As a principle you jump to the program sentence with the indicated LABEL, e.g.: G20 START This command can also be used to jump over unwanted commands when testing the program and to set so-called breakpoints. G22 - Jump to sub-routine Jump to a part of the program which is needed more often and therefore is written and marked as a special program-module. You call that sub-routine, it is integrated in a program after the following pattern: G01 Z0 F75 G00 X100 Y200 G22 SUB G00 X300 Y250 G22 SUB G99 ;End main program ;------------------------------ SUB G01 X5 Y-3 G01 Y66 Z15 G01 Z44 G99 ;End sub-routine Within a sub-routine you can call up another sub-routine (box in box). This can be done up to 10 times (number of boxes = 10). G24 - Instruction for loops It is often necessary to repeat certain parts of commands or programs several times. The NC-command G24 allows repeating in the following way: G01 .... . G24 N5 ;start of the loop G00.. G00 .. G98 ;End of the loop G00... . G01 .... G24 N5 ;start of the loop G00 .. The commands in between are repeated 5 times. G00 .. G98 ;end of the loop G00 .... We advise you to build up a clear structure of the program by making useful indentations, as shown in the example. See also the example program G24-G79-DEMO. G54 - Set workpiece-zeropoint In the program a new workpiece zeropoint (WZP)is set at the given coordinates, e.g.: G54 X100 Y200 Z50 If no coordinates are given in the program sentence the current position is taken as WZP, e.g.: G54 This command can also be used to correct tool length or tool diameter. You only have to change the WZP in the Z-level, e.g.: G54 Z-15 ;new tool 15mm shorter G54 Z6 ;new tool 6mm longer G60 - Set engraving parameters The files xxx.QFN contain engraving fonts. For engraving you have first to go to the starting position of the characters, - and to enter the parameters. Besides that, the WZP has to be set in a way that its Z-coordinate touches the surface of the workpiece. The measures for B (clearing distance) and Z (diving-in-depth) refer to that. E.g.:G00 X10 Y20 G60 H5 B2 Z1 D90 S2 F100 F = feed (depending on material) Z = diving-in depth in Z-direction as positive number B = clearing distance in Z H = height of the characters in mm D = rotation angle of the characters (e.g. D90 = upwards) S = fonts (fonts file, 1...4, as set). Please notice that the width of the characters depend on the diving-in depth and the top angle of the engraving tool. Make the two determinations of H (height of characters) and Z (dive-in depth) in accordance to it. G61 - Give in the text to engrave The command word G61 and a blank is followed by the text to engrave with a maximum of 76 characters. Blanks at the end of the text are not counted. Please pay attention that all enterings (WZP, starting position and parameters with G60) have been made, e.g..: G00 X10 Y20 G60 B3 H10 Z1.5 D45 F100 G61 KOSY-Engraving test G74 - Go to workpiece zeropoint The current workpiece zero point is gone to in fast mode G74 G76 - Go to HOME-position The HOME-position is gone to in a start/stop speed, that means, go to the final switches,then backwards for 1mm. G76 G77 - Go to Workpiece-changing position The Workpiece-changing position is gone to in fast mode (Y-table right in front; X-table quite left, Z-table quite top). G77 G79 - Call up a cycle A pre-defined drilling- or milling-cycle is positioned and called up. You can repeat the calling up as often as you like, it refers always to the cycle that was defined last , e.g..: G81 Z5 B3 F100 ;drilling depth 5mm, clearing distance 3mm, feed. 100 G79 X10 Y20 Z0 ;at the first G79-calling up you must give Z-Position G79 X20 Z15 ;same driling cycle, new X- and Z-position G81 - Set a drilling cycle Set a drilling cycle with diving-in depth Z (positive number), clearing distance B and feed F, e.g.: G81 Z5 B2 F48 G79 X60 Y10 Z10 ;drill with the setting made in G81 before .... G79 X90 Z15 With the drilling cycle and the subsequent calling up of the cycle the following works are automated : 1.) go to Z-Position + B (fast mode) 2.) go to X-Y-Position (fast mode) 3.) go down to B/4 (fast mode) 4.) dive in according to dive-in depth Z (feed. F) 5.) working in B/4 (Feed F) 6.) go back to clearing distance B (fast mode) See also the demonstration program G24-G79-DEMO. G87 - Set a rectangle pocket hole Set a milling cycle for a rectangle pocket hole, e.g.: G87 X30 Y20 Z1 B2 J0 K0.7 T2 F48 Then mill with the setting given before in G87 at different X,Y,Z-positions in the middle of the pocket hole, e.g.: G79 X60 Y10 Z10 G79 X90 Y20 Z15 D45 X = width of the pocket hole parallel to X-axis !!! X must be bigger than Y !!! Y = height of the pocket hole parallel to Y-axis Z = entire depth of the pocket hole B = clearing distance J = direction of milling (0=counter clockwise, 1=clockwise) K = depth per steps T = tool diameter F = feed D = rotation angle of the pocket hole (is given with the calling up of the cycle G79 ) G88 - Set oblong pocket hole Set a milling cycle for an oval pocket hole, e.g.: G88 X40 Y20 Z2 B1 J0 K0.8 T3 F40 Then mill with the setting given before in G88 at different X,Y,Z-positions of the diving-in point: G79 X60 Y10 Z10 G79 X90 Y20 Z15 D60 X = width of the pocket hole parallel to X-axis !!! X must be bigger than Y !!! Y = height of the pocket hole parallelto the Y-axis Z = entire depth of the pocket hole B = clearing distance J = direction of milling(0=counter clockwise, 1=clockwise) K = depth per steps T = tool diameter F = feed D = rotation angle of the pocket hole (is given with the calling up of the cycle G79 ) G89 - Set a circular pocket hole Set a milling cycle for a circular pocket hole e.g.: G89 Z2 B2 R25 J0 K0.9 T2.5 F40 Then mill with the setting given before in G88 at different X,Y,Z-positions of the circle centre: G79 X60 Y10 Z10 G79 X90 Y20 Z15 Z = entire depth of the pocket hole B = clearing distance R = radius of the pocket hole J = direction of milling (0=counter clockwise, 1=clockwise) K = depth per steps T = tool diameter F = feed G90 - Absolute measures Set all measurements or movements in reference to an absolute point. All distances are measured from this point. G90 ;first setting to absolute measures G01 X30 G01 Y10 G01 X50 G01 Y35 G01 X0 G01 Y0 Program example for one shape, positions in absolute measures. G91 - Relative measures All measurements refer to movement distances and are taken from the current position. G91 ;first setting to relative measures G01 X30 G01 Y10 G01 X20 G01 Y25 G01 X-50 G01 Y-35 Program example for the same shape as in G90, positions in relative measures though. G98 - End of loop The end of a repeating loop is marked with G98 , see also G24 . G99 - End of a program-module The end of a program-module (main program or sub program) has to be marked with G99 ,in order to guarantee a perfect run of the program. E.G..: START G00 .... ;main program-start G22 SUB G99 ;main program-end ;----------------------------------- SUB G00 ... ;sub program-start .... G99 ;sub program-end See also the programs TOOL and AUTOMAT1 2. Machine-controlling commands The commands have the following meaning: M01 - Interruption The NC-program is interrupted and is only continued when you press RETURN. By this you can instal breakpoints in the program,for instance in order to change tools. When you have finished, you press RETURN and the program goes on, e.g.: G00 X200 Y100 Z30 G01 Z-50 G00 Z50 M01 G00 Y200 G01 Z-50 M02 - Switch off U/C-Axis The additional axis U or C is switched off. Without mentioning the axis, this commands relates to the U-Axis, e.g.: M02 When you mention the axis this command relates to the U- or C-Axis, e.g.: M02 U0 M02 C0 M03 - Switch on U/C-Axis, clockwise The additional axis U or C is switched on in clockwise direction. Without mentioning the axis, this command relates to the U-Axis, e.g.: M03 S100 When you mention the axis this command relates to the U- or C-Axis, e.g.: M03 U0 S200 M03 C0 S500 S defines the speed. The minimum and maximum values for S are product specific and can be taken from the data sheet. M04 - Switch on U/C-Axis, counter clockwise The additional axis U or C is switched on in counter clockwise direction. Without mentioning the axis, this command relates to the U-Axis, e.g.: M04 S100 When you mention the axis this command relates to the U- or C-Axis, e.g.: M04 U0 S200 M04 C0 S500 S defines the speed. The minimum and maximum values for S are product specific and can be taken from the data sheet. M05 - Set a new WZP You leave the NC-program, the system changes automatically to manual operation. You can go to the new workpiece-zero point. By pressing Ctrl+End the display of all three axes is set to 0. If you want to move only one axis, you go to the current position and take the given position values into the G54-command, e.g.: G54 Z-3.76 Wth Ctrl+F you go back to the program, it will be continued, an example: G00 X100 Y200 G01 Z50 G01 Z100 M05 G01 Z50 M10 - Relay-controlling The available relays can be switched on/off. The data for the particular relays are given as follows: M10 O3.1 ;Relay 3 ON M10 O5.0 ;Relay 5 OFF The letter" O " stands for OUTPUT, it is followed by a number: the number before the decimal point gives the number of the relay, the number after the point is either ... 0 (switch off) or 1 (switch on). How the relays are connected and assigned see appendix C-1 M15 - Switch query The program is interrupted until the concerning digital input has got the wanted state (0 for switch closed or 1 for switch opened ), e.g.: G00 X100 Y200 M15 I3.0 ;Wait, until switch 3 closed G01 Z-30 M15 I2.1 ;Wait, until switch 2 opened G01 Z50 How to connect the switch inputs see appendix C-1 ! M20 - Switch off all relays All existing relays are switched off, e.g.: M20 M25 - Adjustable auxiliary voltage Between Pin 1 (+ pole) and Pin 14 (- pole) of the 25-pole SUB-D-connector "Zusatzfunktionen" ("additional-functions") at the back of the CNC-machine the voltage is indicated. At first you have to switch on relay 1 with the NC-command M10 O1.1 .The voltage can be adjusted from about 1 to 24 Volt - and can carry a maximum of 1 ampere. The current voltage at the connector is measured and indicated on the screen in the field "position" under Ust. Example: M10 O1.1 ;Relay 1 on M25 U12.5 ; give 12.5 Volt ...... M30 - Waiting time The NC-program is interrupted for a indicated break time, afterwards it will continue automatically with the next program sentence, e.g.: G01 X200 M30 P10 ;10 * 1/18 second =0.55 seconds break G01 Y200 G00 Z30 The PC has an interruption function, which is activated every 1/18 seconds. It is used here. By this it is possible to program waiting times in intervals of 0,05555 seconds. To get a waiting ime of 1 second for instance, the command must be M30 P18. The highest possible number as parameter for the waiting time is 999. M35 - Wait until the given time, set on the clock The program is continued only when the given time is reached. By this you get the function of a timer. E.G.: G00 X100 M35 W13.15 ;Wait until 1.15 p.m. G01 Z-5 The current time is shown in the windows status bar.
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