Fanuc Zero Series

The following MasterTask lesson outline indicates the tasks needed to act as a CNC Machining Center and CNC Mill operator and set up operator on Fanuc 0M 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 Computer Controlled Machine Tool [ Top ]

After completing this lesson the operator will be able to:

  1. Locate, identify, and explain the purpose of the basic components of a CNC machining center.
  2. Explain the coordinate grid system and how it relates to the machine movements.
  3. Explain Absolute Programming and the use of coordinates.
  4. Explain Incremental Programming and the use of signed incremental distances.
  5. Locate, identify, and explain Machine Zero.
  6. Locate and explain the machine axes and the signs of coordinates on the machine bed from an assumed program zero point.
  7. Perform basic operations using the soft keys to display various CRT screens.
  8. Display the active part program and move the cursor throughout the program.

Lesson 2: Basic Control and Normal Machine Operation [ Top ]

After completing this lesson the operator will be able to:

  1. Locate, identify, and explain the use of the basic operating controls on the Operator Control Panel.
  2. Identify and explain the use of various operating modes including Memory, Edit, MDI, Tape, Handle, Jog, Rapid, and Zero Return.
  3. Locate and explain the use of Cycle Start, Spindle Speed Override, Feedrate Override, Rapid Override, and Emergency Stop.
  4. Reset an after an Emergency Stop condition and perform a Manual Reference Point Return operation.
  5. Manually restart the spindle and the coolant.
  6. Identify and explain the function of Machine Zero and the Machine Coordinate Grid.
  7. Unload a finished part and clean the fixture mounting surfaces.
  8. Clean, deburr, load, align, and clamp a new workpiece on a fixture.
  9. Reset and start automatic operation of the active program and use Override and Feed Hold controls as required.
  10. Display and use the Program Text and Program Check Screens to monitor program execution.

Lesson 3: Understanding Part Programs [ Top ]

After completing this lesson the operator will be able to:

  1. Display the active part program and identify and explain the components which make it up.
  2. Locate, identify, and explain sequence blocks, block numbers and their numbering method.
  3. Locate, identify, and explain addresses, command codes, coordinates, and end-of-block codes.
  4. Locate, identify, and explain tool paths and tool change commands within a program.
  5. Identify and explain the function of codes: G20, G21, G90, G91, G17, G18, G19, G00, G01, G02, G03, G43, G44, G49, and G40.
  6. Locate, identify, and explain the function of M codes: M06, M00, M03, M04, M07, M08, M09, M05, M06, M01, M02, and M30.
  7. Locate, identify, and explain X, Y, Z, and B axis address words.
  8. Locate, identify, and explain F (Feed Rate), S (Spindle Speed), P (Dwell), and T (Tool) commands.
  9. Locate, identify, and explain Modal and Non-Modal groups of command words.

Lesson 4: Deleting and Loading Part Programs, and Installing Fixtures [ Top ]

After completing this lesson the operator will be able to:

  1. Locate and identify the program name and number from setup documentation and from a punched tape.
  2. Display the Library screen and identify and explain the available program numbers and pages of program memory.
  3. Using the search functions, locate and make active a part program stored in memory.
  4. Calculate the amount of memory needed for specific length punched tapes.
  5. Delete unused programs from the control memory.
  6. Setup a tape reader and load a program into memory from a punched tape.
  7. Identify and explain the use of the G28 and G30 commands to return the machine to Reference Point.
  8. Select the Jog Mode and safely jog the machine using the JOG buttons and Hand Wheel in all axes.
  9. Reset the machine after an overtravel condition.
  10. Remove, clean, and store an existing fixture.
  11. Clean, deburr, align, and install a new fixture or fixtures on the machine bed according to setup documentation.

Lesson 5: Loading Tools and Setting Program Zero [ Top ]

After completing this lesson the operator will be able to:

  1. Using the setup documentation, locate and identify the correct tooling for the job.
  2. Sequence a tool magazine and safely remove tool carriers from the magazine.
  3. Clean, orient, and load the correct tool carriers into the correct position in the magazine.
  4. Stop machine operation, spindle rotation, and coolant flow and remove a damaged tool from the spindle.
  5. Explain the relationship between Machine Zero and Program Zero, and the function of G92 commands within a program.
  6. Establish Program Zero by dialing in a set point and editing the coordinates into a G92 block.
  7. Establish the Program Zero location with the use of G54 through G59 Work Coordinate Shift commands and input those values.
  8. Explain how the G10 command may be used to establish Work Coordinate Shift values.

Lesson 6: Tool Length Offsets [ Top ]

After completing this lesson the operator will be able to:

  1. Explain tool length offsets and why and how they are applied.
  2. Display the Tool Offset Table and explain the data stored within the table.
  3. Locate H address words within the part program and explain their purpose and the tools to which they apply.
  4. Explain how G43, G44 and G49 codes affect tool offset values.
  5. Clear all or some offset values from the Offset Table.
  6. Manually command a tool change operation to place a specific tool into the spindle.
  7. Using the setup documentation and part program, establish H and T codes, touch off tooling to correct gauge points, and input the correct Z axis tool offset for STANDARD tooling.
  8. Using the setup documentation and part program, establish H and T codes, touch off tooling to correct gauge points, and input the correct Z axis tool offset for PRESET tooling when G54 through G59 are applied.
  9. Using the setup documentation and part program, establish H and T codes, touch off tooling to correct gauge points, and input the correct Z axis tool offset for STANDARD tooling when G54 through G59 are applied.

Lesson 7: Cutter Radius Compensation [ Top ]

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

  1. Explain cutter radius compensation and when and why it is applied.
  2. Explain the use of G41, G42, and G40 codes and H address words within a part program.
  3. Explain how compensation offset values are applied to the tool path during operation.
  4. Explain how the G17, G18 and G19 plane select commands affect cutter radius compensation commands.
  5. Use the Program Check Screen to determine currently active plane select and other codes.
  6. Input cutter radius compensation for preset tooling when supplied in setup documentation.
  7. Measure and calculate the correct value of cutter radius compensation for tools under various part programming methods.
  8. Correct workpiece dimensions using cutter radius compensation under various part programming conditions.

Lesson 8: Machining the First Workpiece [ Top ]

After completing this lesson the operator will be able to:

  1. Explain the purpose for Insert, Alter, and Delete editing functions.
  2. Use the search functions to locate data for editing purposes.
  3. Insert approved words into the correct location within the program and log the change.
  4. Insert approved blocks into the correct location with the correct sequence number, and log the change.
  5. Correctly Alter an approved word within the part program and log the change.
  6. Correctly Delete approved words or blocks, or groups of words or blocks, within a part program and log the change.
  7. Prepare the control, start, and complete the trial run of a new job using Cycle Start, Single Block, Overrides and Feed Hold Controls.
  8. After trial machining, measure workpiece features and calculate corrections to coordinates or offset values to correct tool paths.

Lesson 9: Identifying Machining Problems and Rerunning Blocks [ Top ]

After completing this lesson the operator will be able to:

  1. Identify workpiece quality problems and the likely tool conditions which caused them.
  2. Check tooling for problem conditions and correctly select a replacement cutter when required.
  3. State the most common causes of chatter and the corrective action for each.
  4. Calculate new speeds and feeds based on programmed rates and override percentages required to correct problems.
  5. Stop and restart the program and re-establish the correct modal G and M codes.
  6. Reposition the tool manually, or through MDI, to the correct restart point.
  7. Remachine all or part of a tool path by rerunning blocks.

Lesson 10: Circular Cut Commands [ Top ]

After completing this lesson the operator will be able to:

  1. Define the basic information needed within the part program to produce arcs and complete circles.
  2. Explain the two methods of programming the center point of circular cut data blocks.
  3. Locate and explain the use of plane select codes within circular cut programming.
  4. Explain the start point and end point of G02 and G03 programmed cuts.
  5. Explain how circular cut programming changes when G90 or G91 are active.
  6. Explain the use of I, J and K addresses.
  7. Explain editing techniques to correct oversize, undersize, and mis-located circular cuts.
  8. Correctly edit a complete circle programming to bring the feature into proper location and size.

Lesson 11: Canned Cycles [ Top ]

After completing this lesson the operator will be able to:

  1. Explain the basic operation and format of canned cycle programming including; G98, G99, Initial level, R plane, L addresses, P addresses, Q addresses, and I, J, and K addresses.
  2. Explain the drilling and reaming canned cycles G81, G82, G83, and G73.
  3. Explain the tapping cycles G84 and G74.
  4. Explain the boring canned cycles G76, G85, G86, G87, G88, and G89.
  5. Explain the use and response of various controls during canned cycle operations and edit a canned cycle to correct errors or to make it more efficient.