Okuma

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 OSP 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 Okuma 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 name the basic components of an Okuma lathe and control system.
  3. Explain the coordinate grid system as it applies to the lathe.
  4. Identify the axes of movement for the turret or turrets.
  5. Identify from a coordinate and it's signs the location of the turret within the grid.
  6. Identify where program zero is located based on the signs of coordinate values.

Lesson 2: Main 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 on both G and non-G version controls:
  2. Turn on main power, activate power to control and machine.
  3. Check all lubrication and coolant system levels.
  4. Check hydraulic pressure gauges.

Lesson 3: Maintaining Control Over Machining Quality [ Top ]

After completing this lesson the operator will be able to:

  1. Explain the Work Coordinate Grid system.
  2. Explain the Machine Coordinate Grid system.
  3. Display the Actual Position and Actual Position and Remaining Distance screens and explain the data shown for single or two turret models.
  4. Locate, identify, and explain the purpose for chucks, tailstocks, and collets.
  5. Properly locate and secure a workpiece into the holding devices including chucks, tailstocks, or collets.
  6. Place the machine in the AUTO mode and reset the program in preparation for automatic machining.
  7. Verify the part program number and file name on the CRT display.
  8. Use the Feedrate Override and Slide Hold controls to safely machine workpieces.
  9. Inspect workpieces to identify chatter marks and explain how to correct the five most common causes of chatter.
  10. Explain the rough to finish pass relationship and the effect on surface finish and part dimensions.
  11. Explain how to check for improper rough to finish pass relationships.
  12. Select the Mid-Auto Manual mode to replace worn or broken inserts using the Pulse Handle, Axis Select switch and Slide Jog buttons.
  13. Index the turret then remove, clean and replace worn or broken inserts.
  14. Restart the Spindle manually and continue machining by performing a Sequence Restart operation.

Lesson 4: Reading and Understanding Part Programs [ Top ]

After completing this lesson the operator will be able to:

  1. Display part program screens and identify the program numbers.
  2. Display and identify data contained on the Program Directory screen.
  3. Display and identify the data on the Free Memory page.
  4. Identify and explain how to enter and use legal file and program names and their common extensions.
  5. Locate and identify program blocks and sequence numbers.
  6. Locate and explain the purpose of various G, M, T, F, and S codes within a part program.
  7. Locate and explain the effect of absolute and incremental programming and how these modes are established.
  8. Explain the use of the P address word in two-turret four-axis machining operations.
  9. Identify and explain the data within a tool path and describe the tool's movements.
  10. Identify when the machine may exhibit linear or non-linear G00 path movements.
  11. Locate and identify the codes which control feedrate execution G94 and G95.
  12. Locate and explain the effect of various modal and non-modal codes on programming and machine operation.

Lesson 5: Loading and Editing Programs and Using Tool Offsets [ Top ]

After completing this lesson the operator will be able to:

  1. Identify and explain the purpose for Tool Offsets and Tool Nose Radius offsets.
  2. Calculate and determine the amount, axis, and sign of corrections to Tool Offsets to correct out of tolerance ID and OD features.
  3. Display the Tool Offset table and identify the data displayed.
  4. Enter Tool offsets for the correct tool number using either the ADD or SET function.
  5. Locate and identify different types of tool wear and damage.
  6. Select the Manual mode and jog the turret to inspect the inserts.
  7. Replace tool inserts, remachine workpieces and adjust Tool offsets accordingly.
  8. Make active the correct program stored in memory.
  9. Determine if enough free space is available for the program to be loaded.
  10. Delete some or all unused part programs from memory.
  11. Load part programs into memory from a punched tape using a tape reader.
  12. Transfer a program into the edit memory of the control.
  13. Use the FIND function to locate data.
  14. Perform approved edits in a part program using Line Delete, Character Delete, Line Insert, and Character Insert functions.

Lesson 6: Work Holding Devices [ Top ]

After completing this lesson the operator will be able to:

  1. Select between ID and 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 diameter of the workpiece.
  5. Calculate the length of cut required for proper workpiece holding and the machining gauge.
  6. Control the Z axis depth of cut by setting the Variable Limits position.
  7. Using the MDI mode, manually start the spindle, ink jaws, then use the Handle and Jog controls to turn the surface which will hold the machining gauge.
  8. Mount the machining gauge and turn the jaw surfaces which will hold the workpiece.
  9. Adjust the Chuck-Unclamp Alarm switches to detect problem conditions.
  10. Remove and replace collet chuck pads or a master collet.
  11. Change a center, and position the tailstock and identify tailstock commands.

Lesson 7: Tool Installation and Tool Nose Radius Compensation [ Top ]

After completion of 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. Install all OD and ID tools for a setup using the Tool Setting Caliper.
  5. Locate and identify the eccentric cam and adjust an ID tool block on center.
  6. Locate and explain the function of tool nose radius compensation commands in a part program.
  7. Clear unnecessary tool offsets and enter tool tip and tool nose radius compensation values required for the setup.
  8. Locate and identify a P value for a tool from charts provided in the Operator's Manual.
  9. Identify the signs of Nose Radius offset values when P values are not used.

Lesson 8: Establishing Program Zero, Entering Tool Offsets and Setting Safe Index [ Top ]

After completing this lesson the operator will be able to:

  1. Explain the method of establishing the location of Program Zero as referenced from Machine Zero.
  2. Locate and display the Zero Offset register.
  3. Select a reference tool for manual machining.
  4. Manually start spindle rotation and index the reference tool into position for machining.
  5. Manually machine a workpiece, measure, and establish Program Zero for the Z axis.
  6. If necessary, manually machine the OD to establish the location of Program Zero in X.
  7. Enter a previously established Zero Offset value for X using the SET function.
  8. Modify an existing set of Zero Offset values by using the ADD function.
  9. For preset tooling, enter the Tool Offset values provided into the offset table.
  10. For non-preset tooling, touch off all tools to establish X and Z axis tool offset values using the Calculate function.
  11. Explain the purpose of the three sets of turret movement limits within the machining area.
  12. Establish the safe index point for the tooling mounted in the turret(s).
  13. Display and explain the purpose of the User Parameter screen.
  14. Enter the Variable Limits coordinates for the plus and minus directions of each axis to establish the safe index point.
  15. Locate and explain the purpose of the Machine Lock function.
  16. Complete a program verification using Machine Lock and Dry Run functions.
  17. Locate coordinates which place the turrets beyond the Variable Limits and edit the Limit coordinates as required.
  18. Clear any alarm conditions created by the program verification process.

Lesson 9: Machining the First Workpiece [ Top ]

After completing this lesson the operator will be able to:

  1. If appropriate to shop practice, safely Dry Run the program to detect problems.
  2. Use the Zero Shift function to position dry run away from spindle.
  3. Locate and explain the Block Delete codes and switch.
  4. Locate and explain the use of the Optional Stop switch and control code.
  5. Locate and explain the use of the Interlock control on G version controls.
  6. Locate and explain the purpose for the Turret Control Switches for individual and simultaneous operation.
  7. Properly set the coolant control and adjust coolant nozzles.
  8. Safely trial run in single block mode.
  9. At the end of each tool path, measure workpiece features and determine if adjusting offsets or coordinates is required.
  10. Complete a Sequence Restart operation to remachine features to bring them to nominal size.
  11. Complete a Sequence Restart operation using the Block Counter method.
  12. After completing the trial run, determine whether Tool Offsets or Coordinates must be adjusted to bring other features to size.
  13. Trial cut OD grooves to adjust Z axis offsets.
  14. Troubleshoot drilled and tapped features and adjust accordingly.
  15. Calculate a new feedrate or spindle speed from the percentage of override required to correct the problem.
  16. Determine the adjustment data and sign of changes to coordinates.
  17. Locate and explain the use of dwell commands.

Lesson 10: Arc, Threading and Compound Cycles [ Top ]

After completing this lesson the operator will be able to:

  1. Locate and explain the programming associated with circular interpolation including direction of cut, start point, end point, center point or radius.
  2. Explain the data information needed to produce various arcs and radii with both G02 and G03 commands.
  3. Identify and explain the use of I, J, and K coordinate programming for center points.
  4. Identify and explain the use of L address radius programming.
  5. Identify and explain the use of the CALRG command word.
  6. Explain the effect of editing various coordinate values on arc location and size.
  7. Identify and explain the use of G31 through G35 threading commands.
  8. Identify and explain the use of G71 and G729. Identify and explain the use of M22 and M23 automatic chamfering commands.
  9. Identify and explain the use of A and I address words used for tapered thread cutting.
  10. Identify and explain the use of E address words for variable-lead thread cutting.
  11. Identify and explain the use of K address words for multi-start thread cutting.
  12. Identify and explain the use of J address words for thread cutting.
  13. Identify and explain the use of M26 and M27 to establish thread lead axis.
  14. Identify and explain the use of B, D, U, & H addresses in G71 compound cycles.
  15. Measure thread dimensions with a pitch micrometer and calculate adjustment values.
  16. In G73 and G74 drilling and grooving cycles, locate and explain programming associated with the initial point, rate of tool movement, depth of hole, and dwell.

Lesson 11: Lathe Auto-Programming [ Top ]

After completing this lesson the operator will be able to:

  1. Identify and explain the contour definition blocks within an auto programming sequence.
  2. Identify and explain the G81 longitudinal definition and G82 transverse definition blocks.
  3. Identify and explain the G80 end-of-contour definition block.
  4. Identify and explain the parameter codes within the call block.
  5. Identify and explain the three cutting modes available.
  6. Identify and explain the G85 bar stock programming code.
  7. Identify and explain the D, F, U, and W cutting parameters.
  8. Identify and explain the G84 cutting change command and the XA, ZA DA, and FA parameters.
  9. Identify and explain the use of the dollar sign for splitting long blocks.
  10. Identify and explain the G87 finish cut cycle command block.
  11. Identify and explain the G86 copy turning sequence and the D, F, U, and W parameters.
  12. Identify and explain the G88 continuous thread cutting command and D, U, W and B parameter.