Tool Change Optimization

Tool Change Optimization reduces the number of tool changes in Conversational programs. In typical Conversational program execution, each data block is completed (roughing and finishing) before the program moves to the next data block. With Tool Change Optimization, operations are completed sequentially by tool; for example, the program completes all operations that use tool 1 before moving to the operations that use tool 2, and so on.

For example:

A Mill Frame with tool 1 for roughing and tool 2 for finishing, patterned three times, with tool 1 in the spindle:

• Without Tool Change Optimization, each frame in the pattern is rough cut and finish cut before moving to the next frame in the pattern. Sequence of tool changes: 1, 2, 1, 2, 1, 2. Total number of tool changes = 5.

• With Tool Change Optimization enabled, all three frames are rough cut, then all are finish cut. Sequence of tool changes:1, 2. Total number of tool changes = 1.

More Information Online

For more information about Hurco's Tool Change Optimization option, visit the How to Use Tool Change Optimization - Hurco CNC Control Demo video demonstration on YouTube.com.

Using Tool Change Optimization

To use Tool Change Optimization, the Tool Change Optimization parameter must be set to YES (default is Yes). This parameter is found on the General 2 tab in Program Parameters:

 

In addition, the Tool Change Optimization On block must be inserted ahead of the program blocks to which it applies. Both the parameter and the data block are necessary to activate Tool Change Optimization. The Tool Change Optimization Off block is inserted after the last block in which tool optimization is to occur. This allows flexibility in using Tool Change optimization on select blocks while maintaining normal tool change sequence in other blocks of the program.

To use the Tool Change Optimization On and Off blocks:

1. From a New Block screen, select the Miscellaneous softkey.

2. Select the More softkey twice.

3. Select the Tool Optimize On softkey. The block opens:

 

4. Set the operations that will have tool changes optimized:

   1. Maintain Operation Level 1 Order—when set to Yes, all Level 1 operations (typically these are the roughing operations) are performed in block sequence, including any specified tool changes. When set to No, all Level 1 operations are performed in tool change sequence. Default is No.

   2. Maintain Operation Level 2 Order—when set to Yes, all Level 2 operations (typically these are the finishing operations) are performed in block sequence, including any specified tool changes. When set to No, all Level 2 operations are performed in tool change sequence. Default is No.

   3. Hole Operation Order—determines the order in which hole operations are performed in a program relative to all other operations in the program. Set all hole operations to be performed before or after mill finishing operations or before mill roughing operations.

5. Select the Tool Optimize Off softkey. The Tool Change Optimization Off block is used to turn off the Tool Change Optimization feature for a block or group of blocks within a program, after the Tool Change Optimization On block has been used at an earlier point in the program.

Example

In the sample screen above, tool change optimization occurs for blocks 2-6. The sequence with Tool Change Optimization parameter set to Yes and the Tool Optimization On block Maintain Operation Level 1 Order and Maintain Operation Level 2 Order set to No is shown below:

Note in the sequence that all roughing blocks that use the first roughing tool (Tool 1) are executed in block sequence, before switching to the next roughing tool (Tool 2). After all roughing operations are completed, all finishing operations that use the first finishing tool (Tool 3) are executed in block sequence, followed by the block that uses the next finishing tool (Tool 4). This requires three tool changes.

When Tool Change Optimization is not used (no Tool Optimization On block), the sequence of tool changes looks like this:

Note that tool changes occur in block order, resulting in nine tool changes.

Tool Change Review

Tool changes are reviewed on the Tool Change Review Screen, accessed with the Tool Change Review softkey in the Part Program Tool Review menu. Tools are displayed in the order they are used in the program. All tool changes in a part program are displayed, even if the Tool Change Optimization feature is not used.

 

Jump to the data block from this screen in one of the following ways:

1. Select the block in the list and press the Enter console key.

2. Select the block in the list and select the Part Programming softkey.

3. Double-click on the block in the list.

Using Tool Change Optimization with Patterns

Tool change optimization can be used along with patterns to ensure the most efficient tool changes when milling repeated features. Employed together with milled patterns, optimization can reduce the number of tool changes required: 

• Across all pattern instances, or;

• Within each individual pattern instance (if, for example, the job has multiple fixtured parts).

Depending upon job circumstances, it may be most efficient to optimize tool changes required for one pattern instance before moving on to the next. Or efficiency may be enhanced most by optimizing tool changes across all pattern instances. This is up to the professional judgment of the operator.

Once the desired level of tool change optimization is determined, the operator must use care to execute this through proper placement of the programming blocks. Whether the pattern blocks are enclosed in the tool change optimization blocks or vice versa determines how WinMax performs the optimization. See the examples below.

Example 1 — Optimization Across All Pattern Instances

In this program, patterns are used to replicate two mill features four times each: a circle and a frame. The tool optimization on/off blocks are outside the pattern blocks. This block configuration applies the optimizations globally across all instances of the pattern.

 

There are four instances of mill circle and mill frame, and a roughing tool and finishing tool are used for each. The roughing tool is applied to the first instance of the circle then the first instance of the frame. This process repeats through the remaining three instances of mill circle and frame. Then the switch is made to the finishing tool and the process is repeated for all instances of these mill features. The program execution would look as follows:

 

Tool   1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2

Mill Feature   Mill Circle 1 Mill Frame 1 Mill Circle 2 Mill Frame 2 Mill Circle 3 Mill Frame 3 Mill Circle 4 Mill Frame 4 Mill Circle 1 Mill Frame 1 Mill Circle 2 Mill Frame 2 Mill Circle 3 Mill Frame 3 Mill Circle 4 Mill Frame 4

Operation   Roughing Roughing Roughing Roughing Roughing Roughing Roughing Roughing Finishing Finishing Finishing Finishing Finishing Finishing Finishing Finishing

 

Example 2 - Optimization Within Each Individual Pattern Instance

In this variation, the tool optimization on/off blocks are inside the pattern blocks. This block configuration applies optimization to each pattern instance individually. 

This example includes the same four instances of mill circle and mill frame, with roughing and finishing tools applied for each. However here the optimization is applied at the level of each individual pattern instance. So the roughing tool finishes its operations on the first mill circle and mill frame. Following a tool change, the finishing tool is then used until its operations on the same mill circle and mill frame are complete. This cadence continues for each remaining mill feature in sequence. The program execution would look as follows:

Tool   1 1 2 2 1 1 2 2 1 1 2 2 1 1 2 2

Mill Feature   Mill Circle 1 Mill Frame 1 Mill Circle 1 Mill Frame 1 Mill Circle 2 Mill Frame 2 Mill Circle 2 Mill Frame 2 Mill Circle 3 Mill Frame 3 Mill Circle 3 Mill Frame 3 Mill Circle 4 Mill Frame 4 Mill Circle 4 Mill Frame 4

Operation   Roughing Roughing Finishing Finishing Roughing Roughing Finishing Finishing Roughing Roughing Finishing Finishing Roughing Roughing Finishing Finishing