Ok so let's take one issue at a time.
1) This one is easy to replicate as it happens EVERY time
After a drilling operation all following features lack a RAPID Z move and basically from the Tool change on will move the Z Axis at regular feed speeds down to the the work piece (which of course takes forever).
Here is the code for the end of the drilling cycle then a tool call for the pocket cycle.
Code:
N0088 G00 Z2.54
N0089 M09
N0090 M05
(JOB 3 PROFILE)
(FEATURE PROFILE)
N0091 ( TOOL CHANGE )
N0092 M05
N0093 G74 Z X
N0094 T00.12 M06
N0095G43
N0096 S6000 M03
N0097 G54
N0098 G90
N0099 X-3.08 Y112.671
N0100 M08
N0101 G00
N0102 G01 Z-7. F 95. <<<<<<<<<<<<<<<<<
Here is the same code with the post processor debug on:
Code:
N0088 G00 Z2.54
************* 40 - Operations//Start of operation **********
************* 3 - Tool Change//Move to next cut change tool **********
N0089 M09
N0090 M05
(JOB 3 PROFILE)
(FEATURE PROFILE)
N0091 ( TOOL CHANGE )
N0092 M05
N0093 G74 Z X
N0094 T00.12 M06
N0095G43
N0096 S6000 M03
N0097 G54
N0098 G90
N0099 X-3.08 Y112.671
N0100 M08
************* 40 - Operations//Start of operation **********
************* 27 - Rapid moves//First rapid move Z **********
N0101 G00
************* 51 - Feed moves//Feed move Z **********
N0102 G01 Z-7. F 95.
So the feed problem that is concurring, after a tool change is happening in your post block 3, So let's look at the code from the post.
Code:
3. Tool change
n,coolant_off
n,spindle_off
system_comment
feature_name_comment
n,"( TOOL CHANGE )"
n,spindle_off
n,coolant_off
n,"G74 Z X"
n_forced,"T00.",list_tool_number,"M06"
n,output_rotary_angle
n,output_second_rotary_angle
n,length_offset
n,s,spindle_on
n,work_coord
n,rapid_move,absolute_coord
n,force_x,xr,force_y,yr,p_rot,s_rot,
n,coolant_on
output_rotary_angle
In this block of code you can see after the work cord and the force XY move you do not see anything for Z. So what is happening is the software still thinks it's at it's last Z move which is N0088 G00 Z2.54 and because there is nothing in the code to tell the tool to come down to Z after the tool change. The fist Z move is a feed move. So the tool is feeding from the Z tool change location.
The good thing about this issue is it's easy to fix and also will not create scrap, it just extends the run time.
You should be thinking why isn't a Z move posted on N0101 G00 This is because your code is model and the last Z move was at G00 Z2.54 so it doesn't post this location again because there was no change.
What we need to do to fix this is force a Z move in the tool change block to bring the tool back down to clearance as a rapid move.
Code:
3. Tool change
n,coolant_off
n,spindle_off
system_comment
feature_name_comment
n,"( TOOL CHANGE )"
n,spindle_off
n,coolant_off
n,"G74 Z X"
n_forced,"T00.",list_tool_number,"M06"
n,output_rotary_angle
n,output_second_rotary_angle
n,length_offset
n,s,spindle_on
n,work_coord
n,rapid_move,absolute_coord
n,force_x,xr,force_y,yr,p_rot,s_rot,
n,coolant_on
n,force_z,zr <<<<<<<<<<<<<<<<<<<<<<<
output_rotary_angle
Adding the force_z,zr will force a Z move and bring the tool down to the clearance plane after the tool had moved to it's next XY location.
Now that I've made this change to the post this is what the code looks like:
Code with debug on:
Code:
N0088 G00 Z2.54
************* 40 - Operations//Start of operation **********
************* 3 - Tool Change//Move to next cut change tool **********
N0089 M09
N0090 M05
(JOB 3 PROFILE)
(FEATURE PROFILE)
N0091 ( TOOL CHANGE )
N0092 M05
N0093 G74 Z X
N0094 T00.12 M06
N0095G43
N0096 S6000 M03
N0097 G54
N0098 G90
N0099 X-3.08 Y112.671
N0100 M08
N0101 Z2.54
************* 40 - Operations//Start of operation **********
************* 27 - Rapid moves//First rapid move Z **********
N0102 G00
************* 51 - Feed moves//Feed move Z **********
N0103 G01 Z-7. F 95.
Code with debug off:
Code:
N0088 G00 Z2.54
N0089 M09
N0090 M05
(JOB 3 PROFILE)
(FEATURE PROFILE)
N0091 ( TOOL CHANGE )
N0092 M05
N0093 G74 Z X
N0094 T00.12 M06
N0095G43
N0096 S6000 M03
N0097 G54
N0098 G90
N0099 X-3.08 Y112.671
N0100 M08
N0101 Z2.54
N0102 G00
N0103 G01 Z-7. F 95.
So that was a simple fix....
The other thing I noticed is on your posting block #2 that you work cord reference moves looks like this.
n,rapid_move,absolute_coord,force_x,xr,force_y,yr, zr,p_rot,s_rot
This will create a ramp move to your start location. I personally do not like this even if it's faster... I would prefer to have the XY move at tool change Z and once in location have the tool come down.
So I would change the post block to :
n,rapid_move,absolute_coord,force_x,xr,force_y,yr, p_rot,s_rot
n,rapid_move, force_z,zr