17 hours ago, Matthew Hajicek - Singularity said:

That does look neat.  I'm starting to think though, that a bar-fed mill-turn would be a more stable, reliable, lower labor solution, without any accuracy problems.  Willemin-Macodel has some good looking ones.

If it can be done cheaper using subtractive machining, that is probably the best way to go.

Additive manufacturing has its place. It is not however cheap to get into and its best application is on parts that are otherwise difficult to manufacture. Ti powder to continue printing is $10k per 30kg

I can state unequivocally that parts we print could not be manufactured utilizing subtractive methods. Even if it "could" somehow, it would be cost prohibitive.  

@Matthew Hajicek - Singularity

I had this issue dropped on my desk and considering the use you have in mind, I thought this may be of interest to you

https://www.additivemanufacturing.media/articles/dmg-mori-build-plate-pucks-cut-postprocessing-time-by-80

18 hours ago, gcode said:

I'd delete the workspace file, but I don't think X4 has one.

You are correct, those versions has the .mtb file...

These old versions had all kinds of issues with .net

I can't tell you how many times the .net framework had to be completely uninstalled and reinstalled to get them running...

I might also suggest removing the config file from the folder and let X4 attempt to make a new one.

16 hours ago, Leon82 said:

What speed do you use. We want to try it on some 00-90 threads

0-80 & 1-72 both run at 800 rpms

Just me?

The tool change time "should" include your indexing time.....it's more akin to your chip to chip time

Define value...

Just the offset number or positional info?

I've seen 2 things make this happen...

1.  Make sure your feedrate is entered as IPM and FPT

or

2. In you machine def make sure your machines rapid values are set appropriately

1 minute ago, Jake L said:

Ah shoot don't know how I missed it, sorry about that. Also thank you for all the time and information you have provided.

You're welcome...I am always willing to share with those looking for honest help

17 minutes ago, Jake L said:

New discovery. My machine provider just got back to me. I can omit the Pxxxx from the M98 call line and it will search the current program for Nxxxx based on Qxxxx.

That was one of my suggestions further up 

That will allow single program now

2 minutes ago, Tim Johnson said:

What kind of fixtures are you using?

Who is that directed at Tim?

Not nearly enough information ...you'd do better sharing a file so someone can get some idea of what it is and what machine as that does not look flat and it is likely some kind of multi-axis positioning

OK, let m e see how much of this I can explain

G00G55G90X1.245Y-1.245(POSITION TO CENTER & ORIENT SPINDLE)  <-----This is the starting position
M150S3000  <------- I "think" this is the spindle clocking an orientation
(S3000, S2100, S1200, S300)
G43Z0.1H3
M184 <-------another guess this is locking the spindle
G91G99G81X.001Y-.001Z-3.65R-4.5F250.K77  <----This is stepping over in X&Y 77 times at an increment of .001" 
G00G90Z5.
G00G28G91Z0
G90
M185  <-------unlocking the spindle 
M00

Your starting position is what will need to change....whatever the distance is between the depth you currently get and the depth you want to have.

If you're going to go deeper, you'll likely want to increase the K # number repeats

If it'll be shallow, you may be able to reduce the number of repeats....

You'll then have to figure(add/subtract, the K values to make sure the distance achieved by the number of repeats gets you to your desired depth...

I keep mine very simple...

Every single program I post the subs start numbering at 40001 and just continue. Because everything is in the one file, I can use those numbers in each and every program. It makes no difference what OP....

MInd you, this is Tool #1 that works on 4 parts on 3 sides of a tombstone and has controls built in to control to choose how the program will run...that's the macro options

G20
G0G17G40G49G80G90
G0G28G91Z0.
M00
()
IF[#925EQ3]GOTO88001
()
(1/2 3FL ENDMILL TOOL - 11010500 DIA. OFF. - 51999 LEN. - 51999 TOOL DIA. - .5)
(1/2 ENDMILL / R-F-MILL SIDE STEPS MILL .650 WIDE  / Z-.080)
(MAX Z DEPTH - Z1.)
(MIN Z DEPTH - Z-.862)
(OPERATION #1)
N1000
T11010500M6
IF[#925NE0]GOTO80001
T11010188
N80001
G90G10L10P#51999R0
G90G10L12P#51999R0
S18000M3
M8
()
IF[#925EQ1]GOTO10101
IF[#925EQ2]GOTO10108
IF[#925EQ4]GOTO10117
IF[#900EQ1]GOTO10101
IF[#900EQ0]GOTO30101
N10101
()
G0G90B0.
G0G90G54.1P101X-2.315Y1.2448
G43H#51999Z1.
M98H40001
(1/2 ENDMILL / R-F-MILL SIDE STEPS MILL .650 WIDE  / Z-.080)
G0G90Z12.
()
IF[#925EQ1]GOTO30100
()
N30101
IF[#901EQ1]GOTO10102
IF[#901EQ0]GOTO30102
N10102
()
G0G90B0.
G54.1P102X-2.315Y1.2448
G43H#51999Z1.
M98H40001
(1/2 ENDMILL / R-F-MILL SIDE STEPS MILL .650 WIDE  / Z-.080)
G0G90Z12.
()
N30102
IF[#902EQ1]GOTO10103
IF[#902EQ0]GOTO30103
N10103
()
G0G90B0.
G54.1P103X-2.315Y1.2448
G43H#51999Z1.
M98H40001
(1/2 ENDMILL / R-F-MILL SIDE STEPS MILL .650 WIDE  / Z-.080)
G0G90Z12.
()
N30103
IF[#903EQ1]GOTO10104
IF[#903EQ0]GOTO30104
N10104
()
G0G90B0.
G54.1P104X-2.315Y1.2448
G43H#51999Z1.
M98H40001
(1/2 R-MILL / R-MILL OUTSIDE PROFILE / Z-.74)
(OPERATION #3)
N1001
G0G90Z12.
()
N30104
IF[#903EQ1]GOTO10105
IF[#903EQ0]GOTO30105
N10105
()
G0G90B90.
G54.1P10X-1.5185Y-2.2413
Z1.
M98H40002
(1/2 R-MILL / R-MILL OUTSIDE PROFILE / Z-.74)
(OPERATION #3)
N1016
G0G90Z12.
()
N30105
IF[#902EQ1]GOTO10106
IF[#902EQ0]GOTO30106
N10106
()
G0G90B90.
G54.1P7X-1.5185Y-2.2413
Z1.
M98H40002
(1/2 R-MILL / R-MILL OUTSIDE PROFILE / Z-.74)
(OPERATION #3)
N1031
G0G90Z12.
()
N30106
IF[#901EQ1]GOTO10107
IF[#901EQ0]GOTO30107
N10107
()
G0G90B90.
G54.1P4X-1.5185Y-2.2413
Z1.
M98H40002
(1/2 R-MILL / R-MILL OUTSIDE PROFILE / Z-.74)
(OPERATION #3)
N1046
G0G90Z12.
()
N30107
IF[#900EQ1]GOTO10108
IF[#900EQ0]GOTO30108
N10108
()
G0G90B90.
G54.1P1X-1.5185Y-2.2413
G43H#51999Z1.
M98H40002
(1/2 R-MILL / R-MILL SIDE RECESS / Z-.390)
(OPERATION #19)
N1061
G0G90Z12.
()
IF[#925EQ2]GOTO10109
()
N30108
IF[#900EQ1]GOTO10109
IF[#900EQ0]GOTO30109
N10109
()
G0G90B0.
G54.1P2X.3978Y.7071
Z1.
M98H40003
(1/2 R-MILL / R-MILL SIDE RECESS / Z-.390)
(OPERATION #19)
N1063
G0G90Z12.
()
IF[#925EQ2]GOTO10116
()
N30109
IF[#901EQ1]GOTO10110
IF[#901EQ0]GOTO30110
N10110
()
G0G90B0.
G54.1P5X.3978Y.7071
Z1.
M98H40003
(1/2 R-MILL / R-MILL SIDE RECESS / Z-.390)
(OPERATION #19)
N1065
G0G90Z12.
()
N30110
IF[#902EQ1]GOTO10111
IF[#902EQ0]GOTO30111
N10111
()
G0G90B0.
G54.1P8X.3978Y.7071
Z1.
M98H40003
(1/2 R-MILL / R-MILL SIDE RECESS / Z-.390)
(OPERATION #19)
N1067
G0G90Z12.
()
N30111
IF[#903EQ1]GOTO10112
IF[#903EQ0]GOTO30112
N10112
()
G0G90B0.
G54.1P11X.3978Y.7071
Z1.
M98H40003
(1/2 R-MILL / R-MILL SIDE RECESS / Z-.280)
(OPERATION #22)
N1069
G0G90Z12.
()
N30112
IF[#903EQ1]GOTO10113
IF[#903EQ0]GOTO30113
N10113
()
G0G90B180.
G54.1P12X-.0328Y-1.3437
Z1.
M98H40004
(1/2 R-MILL / R-MILL SIDE RECESS / Z-.280)
G0G90Z12.
()
N30113
IF[#902EQ1]GOTO10114
IF[#902EQ0]GOTO30114
N10114
()
G0G90B180.
G54.1P9X-.0328Y-1.3437
Z1.
M98H40004
(1/2 R-MILL / R-MILL SIDE RECESS / Z-.280)
G0G90Z12.
()
N30114
IF[#901EQ1]GOTO10115
IF[#901EQ0]GOTO30115
N10115
()
G0G90B180.
G54.1P6X-.0328Y-1.3437
Z1.
M98H40004
(1/2 R-MILL / R-MILL SIDE RECESS / Z-.280)
G0G90Z12.
()
N30115
IF[#900EQ1]GOTO10116
IF[#900EQ0]GOTO30116
N10116
()
G0G90B180.
G54.1P3X-.0328Y-1.3437
Z1.
M98H40004
(1/2 R-MILL / R-MILL EXCESS STOCK / Z+.010)
(OPERATION #24)
N1070
G0G90Z12.
()
IF[#925EQ2]GOTO30100
()
N30116
IF[#900EQ1]GOTO10117
IF[#900EQ0]GOTO30117
N10117
()
G0G90B270.
G54.1P17X-1.3827Y-2.1882
G43H#51999Z1.
M98H40005
(1/2 R-MILL / R-MILL EXCESS STOCK / Z+.010)
G0G90Z12.
()
IF[#925EQ4]GOTO30100
()
N30117
IF[#901EQ1]GOTO10118
IF[#901EQ0]GOTO30118
N10118
()
G0G90B270.
G54.1P18X-1.3827Y-2.1882
Z1.
M98H40005
(1/2 R-MILL / R-MILL EXCESS STOCK / Z+.010)
G0G90Z12.
()
N30118
IF[#902EQ1]GOTO10119
IF[#902EQ0]GOTO30119
N10119
()
G0G90B270.
G54.1P19X-1.3827Y-2.1882
Z1.
M98H40005
(1/2 R-MILL / R-MILL EXCESS STOCK / Z+.010)
G0G90Z12.
()
N30119
IF[#903EQ1]GOTO10120
IF[#903EQ0]GOTO30100
N10120
()
G0G90B270.
G54.1P20X-1.3827Y-2.1882
Z1.
M98H40005
()
N30100
()
M9
M5
G0G28G91Z0.
G90G10L10P#51999R0
G90G10L12P#51999R0
M01

I have NO idea what this is even doing...it's a bunch of G81 cycles with no way to relate what it's doing besides punching into a position

That'll make file management a WHOLE lot easier!

Try

M98Q40001

N40001

@cncappsjames

ANy chance you're aware of the setup for using internal subs on the above referenced control

What control?

I know for our Mazaks the internal calls work as such

M98H40001

that calls 

N40001

at the bottom..

You might look through the controls book and see if it calls internal subs using different headers

I remember back in the day on some older Fanucs...I would have them all after the M30....

I would make sure there was no % as that signals the end of the program, after the M30. I would edit the M30 to M99 for loading, then change it back after loading it..

The larger answer to separate subs is using the subout command....though I would have to mess with it to figure it out, perhaps someone has a concise answer

3 minutes ago, Jake L said:

looking to have subprograms output as individual files

I am curious as to why you would want them as separate files as opposed to in the same file?

In my own head it seems they would be easier to manage all in a single file..

Unless something has changed over the years, not that I am aware...

Yes, when you save a new tool to your library, save it as the tool number that you want it to have...

When you're programming, make sure you uncheck the option to Assign tool numbers sequentiallyo 

about 45, 27 HMC's, 10 VMC's, 5 MIll-Turns, 3-5AX's plus additive machine,. plus mold shop and tool room programming support

We're a crew of 3

11 minutes ago, mcpgmr said:

To anyone interested. The solution we came up with is just simply updating WCS for each feature on the part. I reset all WCS's that were updated and all of the extended work offsets back to match G54  values at the end of the program using a sub call. G54 on these machine never changes since it's at the trunnion rotation point. Productivity + is pretty cool and powerful if used properly.

 

O7200 (RESET WCS VALUES TO MATCH G54)
G00 G90 G54
G10 L2 P1 X-12.4016Y-23.6221Z-25.5905A0.C0.
G10 L2 P2 X-12.4016Y-23.6221Z-25.5905A0.C0.
G10 L2 P3 X-12.4016Y-23.6221Z-25.5905A0.C0.
G10 L2 P4 X-12.4016Y-23.6221Z-25.5905A0.C0.
G10 L2 P5 X-12.4016Y-23.6221Z-25.5905A0.C0.
G10 L2 P6 X-12.4016Y-23.6221Z-25.5905A0.C0.
G10 L20 P1 X-12.4016Y-23.6221Z-25.5905A0.C0.
G10 L20 P2 X-12.4016Y-23.6221Z-25.5905A0.C0.
G10 L20 P3 X-12.4016Y-23.6221Z-25.5905A0.C0.
G10 L20 P4 X-12.4016Y-23.6221Z-25.5905A0.C0.
M99

 

Something to think on...

Instead of setting the hard values, I would lean towards pulling the values via variables...the "if" the G54 should need to change for some reason, they all update...

In the case of our Mazaks...they would be as such

G10 L2 P1 X-12.4016Y-23.6221Z-25.5905A0.C0.
G10 L2 P2 X#5221Y#5222Z#5223A#5224C#5226
G10 L2 P3 X#5221Y#5222Z#5223A#5224C#5226
G10 L2 P4 X#5221Y#5222Z#5223A#5224C#5226
G10 L2 P5 X#5221Y#5222Z#5223A#5224C#5226
G10 L2 P6 X#5221Y#5222Z#5223A#5224C#5226
G10 L20 P1 X#70001Y#70002Z#70003A#70004C#70006
G10 L20 P2 X#70001Y#70002Z#70003A#70004C#70006
G10 L20 P3 X#70001Y#70002Z#70003A#70004C#70006
G10 L20 P4 X#70001Y#70002Z#70003A#70004C#70006
M99