X/C posts in MM min, not degrees - Tool Breakage

[ManfluIsSerious]

Hi All,

I hope everyone is safe and well.

With the exception of a HAAS post, I would be having tool breakage issues with both Doosan and Mazak Mill/Turn Posts. They are posting X/C milling feed rates in MM/Min, rather Than Degrees Per Minute, which depending what diameter we care cutting at can overload the tool.

The HAAS post seems to vary the feed to allow for the DPM about the profile.

Does anyone have any Idea what I am doing wrong when using the Doosan/Mazak posts; I feel I'm missing something.

I've attached a photo of the code samples, both tools are programmed at the same cutting data for the tool, Which is a Cutting feed rate of 1909.86 mm/min, inside Fusion.

Thanks for reading, take care and stay safe.

[bob.schultz]

The Haas post actually outputs adjusted feed rates based on the diameter defined in the Feed rate calculation diameter post property while in XZC-mode, where the post calculates the XC positions to simulate the X and Y-axes.

In the Mazak (and Doosan) posts, axial milling is output in G12.1 Polar Interpolation mode, where the control will convert the XY positions to XC positions.  When in polar mode the Y-axis position is actually output as Cxxxx, though it is still the linear Y-axis position.

When the machine control is in polar mode the feed rates are in FPM (MMPM) and the control will/should calculate the speed of the X and C-axes to maintain this linear feed on the part.  This is standard with controls that support polar interpolation.

It may have something to do with the way the machine controls the feed rates when in polar mode, but it looks like you will need to slow down the feed rates.  If you want DPM feed rates output you will need to force XZC-mode in the Mazak post, but this will generate a lot more output since the post has to linearize the XC moves to maintain a straight line (see the size difference between the Haas and Mazak outputs).

[ManfluIsSerious]

Hi, Sorry for the delay,

I have been dealing with this via a help ticket only to find that they have told me to reply here.

Please see my response, 

Hi Srinivasa

Unfortunately I am working on a site where mobile phones are to be left at security.

However, I have noted the comments made in the forum and find;

The feed rate should not be reduced. Should I run less feed per tooth at this radial engagement I will loose the required chip thickness and therefore burn out the tooling (I am currently down to a 0.08mm chip and therefore this is none viable)

Also, some machines accept the mentioned G-Code and others have ignored it. It seems to be something with the way a control is setup from Mazak. This had affected 1 machine with Matrix and 1 machine with Smooth – however, similar machines with the controls do indeed accept the poplar codes.

Also in the forum reference is made to been able to force the DPM within the post, however, I cannot see an option for this from within the fusion post menu.

[bob.schultz]

Hello @ManfluIsSerious,

If the control does not properly handle the feed rates in polar mode, then you can use XZC-mode in the post processor which will output the feed rate in DPM mode.  You need to change the following assignment to 'false' in the post to get XZC-mode output.  Make sure you change this line under the correct machine model (QUICK TURN 100-M, QUICK TURN 100-MS, etc.).

gotPolarInterpolation = false; // specifies if the machine has XY polar interpolation capabilities

If the feed rates are too slow, then you also need to change the following value to 1.0.

var dpmBPW = 1.0; // ratio of rotary accuracy to linear accuracy for DPM calculations