Mazak

The following MasterTask lesson outline indicates the tasks needed to act as a CNC Lathe and CNC Turning Center operator and set up operator on Mazak T1, T2, T3, T4, T32 and T-PlusOSP 5000 L, OSP 5000 LG and OSP 500 LG controlled machinery. Because of the performance-based approach to training utilized within MasterTask systems, the outline below indicates what a trainee will be able to DO after completing each part of a lesson. Some of these tasks require the trainee to explain how something works to insure they have the required understanding of the processes and are not simply memorizing procedures. All of the tasks listed will be a part of the Performance Test within each lesson. To learn more about these tests and the training process itself, see the Philosophy section.

Lesson 1: The Basic Mazak Lathe [ Top ]

After completing this lesson the operator will be able to:

  1. Explain how the CNC control directs the movements of the lathe.
  2. Locate and describe the basic components of a Mazak lathe and control system.
  3. Locate and describe the purpose of optional equipment and functions on a Mazak lathe
  4. Describe the EIA NC programming language and the Mazatrol programming language, and explain the differences between them.
  5. In EIA and Mazatrol part programs, identify and explain the function of Code Words, Blocks, Processes and Sequences.
  6. Explain the coordinate grid system as it applies to the lathe.
  7. Identify the axes of movement for the turret, or turrets, and indexing of the turret.
  8. Identify from a set of coordinates and their signs the location of the turret within the grid.
  9. Locate and explain the purpose of Program Zero, Reference Program Zero, Machine Zero, and the Home position.

Lesson 2: Operating Controls and Machine Startup [ Top ]

After completing this lesson the operator will be able to:

  1. Locate, identify, and explain the purpose of machine controls and components.
  2. Describe conditions when the Emergency Stop button must be used.
  3. Safely move the turret in any of the Manual Modes using the Joystick, Axis Buttons or Pulse Handle.
  4. Identify and explain the purpose of the Rapid rate of movement.
  5. Control the Rapid rate of travel using the Override buttons.
  6. Select the JOG mode and control the rate of travel with the Feed Override controls.
  7. Display the Command, or Position 1 screen, and explain the data displayed.
  8. Respond properly to a Main Power switch which is Tagged.
  9. Turn on power to the machine and to the CNC Control.
  10. Home the turret to calibrate both axes.
  11. Identify a Stroke Limit alarm condition and reestablish normal operation.
  12. Check the levels of Way Oil and Ball Screw lubricant, Spindle lubricant, and coolant.
  13. Check the coolant-to-water ratio with a refractor gauge and adjust as needed.
  14. Lubricate the grease fittings on the chuck jaws.
  15. Check Main and Chuck hydraulic pressure gauges.
  16. Manually input an active gear number, close the chuck.
  17. Identify the Message and Data Input area on the CRT.
  18. Manually set a spindle speed.
  19. Correctly interpret the Spindle Rate display when in either Auto or Manual modes.
  20. Identify the rotational direction when the Spindle Reverse button is selected.
  21. Explain the operation of the Override controls in both Manual and Auto Modes.
  22. Start the spindle for warmup.

Lesson 3: Automatic Operation and Maintaining Quality [ Top ]

After completing this lesson the operator will be able to:

  1. Properly clean and secure a workpiece into the holding devices: including chucks, tailstocks, or collets.
  2. Manually move the Tailstock and Quill using the TAIL BODY and TAIL SPINDLE controls.
  3. Verify the Program Number ("Work Number") on the COMMAND screen or T32 POSITION (1) screen.
  4. Place the machine in the AUTO mode and reset the program.
  5. Highlight the Coolant selection in the Menu to allow the coolant to be controlled by program commands.
  6. Turn down the Feed Rate Display for machining the first part of a work shift.
  7. Set the DOOR INTERLOCK switch to the correct setting for safe automatic operation.
  8. Safely machine workpieces in Automatic mode, using Feed Hold to monitor the machining cycle.
  9. Call up the TRACE screen, display the Shape and Workpiece Figure, and change the Scale to monitor the machining operation.
  10. Adjust the Feedrate Override and Spindle Speed Override to eliminate chatter during operation.
  11. Inspect workpieces to identify chatter marks, and explain how to correct the five most common causes of chatter.
  12. Explain the rough to finish pass relationship and the effect on surface finish and part dimensions.
  13. Explain how to check for improper rough to finish pass relationships.
  14. Stop the machine during a cycle and safely move the turret away from the workpiece using the TPS button, Feed Hold, the Handle Mode buttons, the Pulse Handle, and the Axis Select switch.
  15. Remove, clean and replace worn or broken inserts.
  16. Resume machining at the point where the cycle was stopped after using the TPS function.

Lesson 4: Reading and Understanding Part Programs [ Top ]

After completing this lesson the operator will be able to:

  1. Display the Program File screen, identify the Program Numbers, identify Mazatrol and EIA programs and determine the size of programs in memory.
  2. Explain the limits to program storage in memory, including the number of programs and the amount of available memory.
  3. Determine whether a program can be loaded or programmed based on the amount of free memory.
  4. Display a part program on the PROGRAM screen.
  5. Locate, identify, and explain the purpose of the five types of Mazatrol Processes.
  6. Identify components of Material Data, Material Shape Data and Process Data.
  7. Identify and explain the purpose of Sequences and Sequence Data.
  8. Locate and identify the eight types of Machining Processes and explain the function of each.
  9. Describe the G code programming used in Manual Machining Processes; identify and describe the purpose of the G codes which can be used in these Processes.
  10. Locate and explain the effect of absolute and incremental programming and how these modes are established.
  11. Identify when the machine may exhibit non-linear Rapid Traverse movements.
  12. Locate and explain the effect of modal and non-modal codes on programming and machine operation.
  13. Identify and describe the purpose of commonly used M codes, including program stop codes, coolant codes and Spindle control codes.

Lesson 5: Maintaining Tooling [ Top ]

After completing this lesson the operator will be able to:

  1. Identify and explain the purpose for Tool Offsets.
  2. Calculate the amount, axis, and sign of adjustments to Tool Offsets, to correct ID and OD features which are out of tolerance.
  3. Display the LAYOUT screen; identify and read the information which is shown.
  4. Determine the tool and offset to be adjusted for a given workpiece feature using either the PROGRAM screen or the LAYOUT screen.
  5. Display the Tool Set screen, and identify and explain the purpose for the Tool Set screen data.
  6. Adjust tool offsets for the correct tool number.
  7. Manually index the turret using the Tool Select button, then inspect the cutting tools; identify different types of tool wear and damage.
  8. Explain the operation of the Tool Life management function.
  9. On the Tool Data screen, identify and explain the purpose for the LIFE data and the USED data.
  10. Reset the USED TIME or USED NUMBER data for a tool to zero, after rotating or replacing an insert.
  11. Explain the operation of the SPARE TOOL function and how the Tool Life management data is used for this function.

Lesson 6: Program Editing and Management [ Top ]

After completing this lesson the operator will be able to:

  1. Make active a program stored which is stored in memory.
  2. Determine if enough free space is available for a program to be loaded.
  3. Delete unused part programs from memory.
  4. Describe the methods which can be used to load programs, including floppy disks, punched NC tape, and DNC.
  5. Connect the CMT disk drive to the CNC Control and power on the CMT unit.
  6. Load part programs into memory using the CMT floppy disk drive; use the COMPARE function to make sure the program loaded properly.
  7. Save part programs and other data from memory onto a floppy disk.
  8. On the PROGRAM screen, call up a program in the "view" mode for viewing only; place the program in the "edit" mode to enable editing of the data.
  9. Use the PROCESS NUMBER SEARCH and LAST SEARCH functions to locate Processes for editing.
  10. Perform approved edits in a part program using the Number keys and soft key editing menus.
  11. Correctly use the Edit Menu functions: Process Copy, Program Copy, Process or Sequence Insert, and Process or Sequence Erase.

Lesson 7: Work Holding Devices [ Top ]

After completion of this lesson, the Operator will be able to:

  1. Change between either ID or OD chuck operation.
  2. Remove an existing set of chuck jaws.
  3. Properly mount and position new jaws for the workpiece to be machined.
  4. Select the correct size and type of machining gauge for the diameter of the workpiece.
  5. Calculate the length of cut required for proper workpiece holding and the machining gauge.
  6. Cancel the Chuck Barrier function before machining chuck jaws.
  7. Manually start the spindle, then use the Pulse Handle to turn or bore the jaws to accommodate the machining gauge.
  8. Mount the machining gauge and turn or bore the jaw surfaces which will hold the workpiece.
  9. Make an initial setting of the Chuck Pressure adjustment based on the size and weight of the workpieces.
  10. Call up the Chuck Data display and identify the information shown on the screen.
  11. Use Chuck Data Cancel to clear existing Chuck Data; then measure the chuck dimensions and enter the Chuck Data for the new jaws.
  12. Activate the correct Chuck Data by entering the Jaw Number on the Program File screen.
  13. Remove and replace collet chuck pads or a master collet.
  14. Describe the major components and the operation of common types of tailstocks.
  15. Identify the Spindle Speed and Spindle Thrust adjustments on the tailstock and describe purpose of each.
  16. Change a live center or a dead center on the tailstock to match the requirements of a setup.

Lesson 8: Installing Tools and Entering Tool Data [ Top ]

After completing this lesson the operator will be able to:

  1. Identify where and how turning tools are to be installed from the setup documentation.
  2. Identify where and how drills are to be installed from the setup documentation.
  3. Remove tools and correctly clean tools and tool pockets.
  4. Correctly identify the "hand" (right, left or neutral) of turning tools.
  5. Determine the correct position for the Clamping Block in the tool holder, based on the hand of the tool and the types of machining operations; remove and reposition the Clamping Block.
  6. Correctly install ID tools in the appropriate tool holders before installation on the turret.
  7. Install all OD and ID tools for a setup.
  8. Select and install shims as needed to bring tools on center.
  9. Explain the purpose of information on the Tool File screen and the Tool Data screen (T1-T4).
  10. Clear the Tool File data for a single tool using TOOL FILE CANCEL; clear all Tool File data using ALL ERASE.
  11. Enter the Tool File information for newly installed tools.
  12. Enter the Tool Data for newly installed tools.
  13. Copy the Tool Data from one tool to another using TOOL DATA MOVE; clear the Tool Data for a single tool using TOOL DATA CANCEL; clear all Tool Data using ALL ERASE.
  14. Explain the different information found on the T32 Tool Data screens, including Group Numbers, additional tool types, Tool Names and ID Numbers, and Tool Eye Compensation.

Lesson 9: Program Zero, Tool Set and the Barriers [ Top ]

After completing this lesson the operator will be able to:

  1. Safely lower and raise the Tool Eye.
  2. Touch off tools using the Tool Eye and input the Tool Set values.
  3. Manually machine, then measure a workpiece; touch off tools on the workpiece and input the Tool Set values.
  4. Explain the method of establishing the location of Program Zero.
  5. Locate and display the Z Offset data on the Program File screen.
  6. Measure a machined workpiece, touch off a tool on it, then establish Program Zero for the Z axis using the Z OFFSET TEACH function.
  7. Shift Program Zero for a family of parts.
  8. Position a tool near the chuck and input the Chuck Barrier data using C-BARRIER TEACH.
  9. Turn on or off the use of the Chuck Barrier on the T32 SETUP screen, and enter the additional tailstock information on that screen.
  10. Enter the Tailstock data.
  11. Set the Tailstock Barrier using the REFERENCE TO TAILSTOCK CENTER - TEACH function.

Lesson 10: Machining the First Workpiece [ Top ]

After completing this lesson the operator will be able to:

  1. Run the CHECK, FIGURE CHECK and SIMULATION functions to detect any positioning or machining errors.
  2. Locate and explain the use of the Optional Stop control code (M Code).
  3. Enable the Optional Stop menu control for the trial run.
  4. Properly adjust the coolant nozzles.
  5. Enter trial X axis offsets to reduce the chance of overcutting on the first workpiece.
  6. Safely trial run using Single Step.
  7. At the end of each tool path, measure workpiece features and determine if adjusting offsets or coordinates is required.
  8. Perform a Restart operation to remachine features to bring them to nominal size.
  9. After completing the trial run, determine whether Tool Offsets or Coordinates must be adjusted to bring other features to size.
  10. Troubleshoot drilled, center drilled, tapped and threaded features and adjust as needed.
  11. Alter programmed feeds and speeds using the VFC button.
  12. Determine the adjustment data and sign of changes to coordinates.
  13. Prepare the machine for the production run after successfully completing the trial run.

Lesson 11: Process Planning [ Top ]

After completing this lesson the operator will be able to:

  1. Read the print to locate and understand the workpiece material requirements for bar, cast or forged pieces.
  2. Identify those dimensions required for later processes such as grinding.
  3. Select a Program Zero location and recalculate feature dimensions from this location as necessary.
  4. Calculate all undimensioned features from the chosen Program Zero location.
  5. Calculate the size of rough stock required based on final part dimensions.
  6. Select work holding devices including chucks, collets, and tailstocks, based on the workpiece size, weight, and shape.
  7. Identify quality and safety problems that can arise from incorrect workpiece holding.
  8. Plan an efficient order of machining operations for a selected workpiece.
  9. Determine whether a workpiece must be double chucked to complete all features.
  10. Select the correct machining Processes based on feature requirements.
  11. Determine the correct order for the machining processes selected.
  12. Determine which of the existing tools can be used for the new job.
  13. Select the new tools, inserts, and holders based on the machining Processes and workpiece material requirements.
  14. Establish location of tools in the turret based on tool and chuck clearance considerations.

Lesson 12: Writing Mazatrol Programs [ Top ]

After completing this lesson the operator will be able to:

  1. Determine if enough memory space is available for the new program.
  2. Establish an appropriate workpiece number and begin a Mazatrol program.
  3. Identify, explain, and enter the correct Common Data for a new job.
  4. Explain how to avoid Out-of-Shape alarms.
  5. Enter Material Shape Data to match contoured workpiece features for either T32 or T1-T4 controls.
  6. Explain how Linear lines are specified without start point coordinates.
  7. Explain how Tapered lines are specified and the use of the Continue function.
  8. Explain how Concave and Convex features are entered and the use of the Automatic Intersecting Point Calculation feature.
  9. Enter an M code process to avoid Chuck Unclamped alarms.
  10. Explain the programming of and enter an EDGE process to face the workpiece.
  11. Explain the use of separate rough and finish pass programming to reduce cycle time.
  12. Jog an appropriate tool near a contoured workpiece to locate a Start Point coordinate.
  13. Use the Surface Finish Job Aid provided to determine the required finish.
  14. Use the Figure Check function to validate the programming entered at each step.
  15. Select and enter the correct BAR process data to produce accurate workpiece features for OUT, IN, FACE, and BACK.
  16. Explain the use of Cutting Pattern for both ID and OD selections on T 32 controls.
  17. Explain and enter BAR sequence data using all four Shape Pattern selections to produce accurate workpiece features.
  18. Explain and enter an END process data using counters, continue, shift-amount, and return-position functions.

Lesson 13: Additional Processes, Setting Cutting Conditions, and Using the Layout Function [ Top ]

After completing this lesson the operator will be able to:

  1. Be able to explain and enter the data necessary to program Copy Turning processes.
  2. Be able to explain and enter the data necessary to program Corner turning processes.
  3. Be able to explain and enter the data necessary to program Grooving processes, including the variations found on T32 controls.
  4. Be able to explain and enter the data necessary to program Threading processes, including the variations found on T32 controls.
  5. Be able to explain and enter the data necessary to program Threading processes, including the variations found on T32 controls.
  6. Be able to explain and enter the data necessary to program Tapping processes, including the variations found on T32 controls.
  7. Be able to explain and enter Cutting Conditions data.
  8. Be able to explain and enter new Workpiece Material data.
  9. Be able to explain and reorder machining processes using the Layout Page.
  10. Determine total cycle time and individual process time.

Lesson 14: MNP Proceses, Tailstock Programming, and TPC Functions [ Top ]

After completing this lesson the operator will be able to:

  1. Explain the difference in the signs of Z axis coordinates found in Manual Processes.
  2. Identify and explain the purpose of data in the Process and Sequence lines of Manual Programming on T1 through T4 controls.
  3. Identify and explain the purpose of data in the Process and Sequence lines of Manual Programming on T32 controls.
  4. Explain the tool path of G00 commands and their potential for causing collisions.
  5. Program linear cuts, tapered cuts, arcs, or threads in a Manual Process on T1 through T4 controls.
  6. Program linear cuts, tapered cuts, arcs, or threads in a Manual Process on T32 controls.
  7. Identify and explain the operation of the Limit Switch, Trip Dog, and Latching style Tailstocks.
  8. Complete a Manual Program Process for a Limit-Switch or Trip-Dog style tailstock.
  9. Complete the Manual Program Processes necessary to bring a Latching style tailstock forward and back at the correct cycle time.
  10. Locate, identify, and explain a TPC data screen.
  11. Explain and enter Contour Clearance data.
  12. Explain and enter Relay Point data.
  13. Explain and enter Wall Relief data.
  14. Explain and enter data in the Rough or Finish Cutting data lines.