CYCLE TIME ESTIMATOR Version 1.8 1992 Written by Greg Hoerter Cycle Time Estimator is designed to help estimate cycle times of C.N.C. machine tools. Using your speeds and feeds and machine specifications, the software will give you estimated cycle times that can be used for quoting new operations. This software will create estimates for Horizontal and Vertical Machining Centers, and all kinds of Lathes, including, 2 axis, 4 axis, live tooling, and dual spindle with one or two turrets. By simply entering speeds, feeds, length of cuts, and machine specifications the software will do the rest of the tedious tasks to give you a accurate cycle time and a printed routing to use as a programmers outline to the operation. The files needed to run Cycle Time Estimator are: CTE.EXE - the executable file CTE.OVR - the overlay file CTE.CFG - the configuration file holding your company name and comments. The files ending in MCH are the Machine files holding the specifications for each machine. The files ending in EST are the estimates created and saved. THE MAIN MENU After the opening screen the main menu will appear.  The letters inside of the quotation marks represent the keys to push to execute the command. [Create] will allow you to start fresh and create a brand new estimate. [Load] will let you pick from a list of estimates already created so that you may edit it or use as a template for a new estimate. Once the estimate is loaded you will be asked if you would like to change the date on the estimate to the current date, answer "Y" for yes or "N" for no. Then follow the instructions in "The Main Screen" and "Entering Data" described later. [Print] will allow you to print the estimate you were just working with (you must create or load an estimate before you can use this command). [Multiple Estimate Printing] allows you to choose up to 10 files to be printed, one after the other. Move the highlight bar to the first estimate you would like to print and press [ENTER], you will then be asked to select the number 2 file and so on. When you have selected all of the files you wish to print (up to 10), press [ESCAPE], and all of the files will be printed in the order you selected them. [Erase] allows you to erase an estimate or machine file. [Toggle Color On/Off] will enable you to use this software without a color monitor . [Quit] will give you the opportunity to exit the program back to dos. CREATING A NEW ESTIMATE After selecting Create from the main menu you will be asked some questions to 2 help setup the file. When you are asked any question which requires a number to be input, anywhere in the software, you may respond with an equation with one operand (+ or - or * or /). For example, 1.2+6.235 or 6.8/25.4, when you press [ENTER] the answer will be saved in its place. This can be convenient for inputting Horse Power when you are only given the Kw rating for a motor (Kw * 1.34), calculating lengths of cut from a blueprint, or converting from Metric to Inches. (This software is only designed to work in Inches) Dos filename - The filename used to store the estimate on your disk after being saved. You are allowed a maximum of 8 letters with no extension, the software automatically gives the file an EST extension. If you wish to save the file in another directory you are allowed to enter the path also (c:\estimates\acme1). You will notice under the cursor there is a ^ symbol, these symbols show you how much room you have for entering characters. If you keep typing after the second ^ symbol, only the characters between the ^ symbols are saved. These symbols will appear throughout the program for most of the questions asked of you. As with most of the questions in the software, you will notice at the end of the question there are some parenthesis (). In these parenthesis is the answer you gave last. If you would like to leave the same as before, simply press ENTER, and it will retain the answer in parenthesis. What is your Name - Type you name. Customer Name - Type in your customers name. Date for Time Estimate - Type in the date or press ENTER if the date in parenthesis is correct. Part number or Name - Type in the part number or description of the part. Part first operation description - This allows you describe the operation you will be performing. If the estimate is for a Machining Center this could be "side 1" if you will be doing 2 sides, or something like "top surface" or any other description you would like. You will be allowed to enter the Part second operation description later, in the Setup screen if you will be doing 2 separate operations. If the estimate will be for a lathe this may be just a description of the operation, like, "threaded end", or maybe "upper turret" if using a 4 axis lathe. When doing an estimate for a 4 axis lathe the first operation will be for one turret and the second operation will describe the other turrets operations. The same goes for a Dual spindle lathe, the first operation will describe what one spindle will be doing and the second operation will describe what the sub spindle is performing. Two is the maximum operations allowed in any estimate. This answer may be left blank but it helps clarify the operation when the estimate is printed. How many completed parts per cycle - This answer is usually 1 for a Lathe estimate. If you are creating an estimate for a Machining Center, this will allow you to get a cycle time per part along with a total cycle time. Fatigue factor for parts per hour - Most quotes will figure in a fatigue factor for operator fatigue or down time. If you enter anything besides 100%, the software will give you the estimated parts per hour at the given 3 percentage, along with the 100% rate. Material - Type in the material description. Turning/Boring material factor - This question will show you a chart of material factors used to calculate horse power used. Find the material and hardness closest to your material and enter the factor for a dull or sharp tool. It is usually best to use the dull tool factor since your tool most likely will not stay sharp throughout your production run. Drilling material factor - Type in the factor from the drilling column that best describes your material and hardness. Milling material factor - Type in the factor from the milling column that best describes your material and hardness. Select Machine or Directory - This will display all of the machine files in your current directory. Move the cursor with the up and down arrows to highlight the machine you will be using or hit ESCAPE to enter in the specification for a different machine. Even if you select one of the machines listed, you will still have the opportunity to modify any of the settings and save the machine file under the same name or a new name. If you would like to get a machine file from another directory press ENTER when the cursor is highlighting the ".. " line or the directory name to display the files in that directory. ENTERING MACHINE SPECIFICATIONS Machine Make and Model - Type in the machine name and model number or any other description. Main spindle maximum RPM - Enter the maximum RPM for the spindle. Maximum Tapping RPM - Enter the maximum RPM for tapping, this is used for machines with Synchronous Tapping capabilities (Rigid Tapping). If the machine you will be using is a lathe or does not have Rigid Tapping capabilities, then just enter the maximum spindle rpm or the limit you would like for tapping. Main spindle Horse Power - Enter the maximum Horse Power capabilities for the main spindle. How may seconds to allow for a Rapid - This answer will dictate how accurate your estimate will be. Many people forget to consider acceleration and deceleration when figuring rapid times. For smaller Lathes and Machining Centers at least 1 to 2 seconds should be used. For larger and older machines a larger amount of time is needed to move from hole to hole and so on. Smaller Drilling and Tapping machines such as the Brother machines can use about .75 seconds. I've found the Brother Drilling and Tapping machines to have constant acceleration and deceleration times and are the fastest in terms of rapid times. All other machines will be at least 1 or more seconds for rapids for example... small lathes - 1.25 to 2 seconds large lathes - 2 to 3 seconds small M/C - 1.25 to 2.5 seconds large M/C - 2 to 4 seconds Chip to Chip toolchange time - Type the time it takes to go to the toolchange position, change tools, and get back to the part with the spindle running. This is usually given in the machines manual or brochure, if not you should time your machine. Lathe or Mill - Type "L" for Lathe or "M" for Machining Center. If you press "L" for a Lathe: 4 Rotary tool option - Type "Y" for yes or "N" for no if the Lathe cannot use rotating tools in the turret. Rotary tool maximum RPM - Enter the maximum RPM for the rotary tools (this question will not be asked if you entered NO for the rotary tool option question). Rotary tool Horse Power - Enter the maximum Horse Power the rotary tools are capable of delivering (this question will not be asked if you entered NO for the rotary tool option question). What kind of Lathe is it - Type the letter which describes what kind of lathe you will be using. "A" Two axis - One turret and one spindle "B" Four axis - Two turrets and one spindle "C" Twin Spindle with 1 turret - Two spindles and one turret "D" Twin Spindle with 2 turrets - Two spindles with two turrets If you answer "C" or "D", twin spindle machines you will be prompted for the maximum RPM and Horse Power for the second spindle. If you press "M" for Machining Center: Is there an Indexer on the machine - Type "Y" for Yes or type "N" for No. This also applies to Horizontal Machining Centers with a B axis (type Yes). Number of seconds for 1 index - Type the number of seconds it takes to perform an index (this question will not be asked if you entered NO for the indexer question). Do you want to add a rapid at the bottom of the hole for tapping - This question will usually be answered YES. Because the spindle must stop and reverse when reaching the bottom of the hole when tapping, time must be added to account for this. I have found, because of the Brother Drilling and Tapping machines acceleration and deceleration speeds, it is unnecessary to add time for tapping, so I suggest you answer NO if you are using a Brother Machine Tool or a self-reversing tapping head. Save these setting for future use - This will allow you to save a new machine file or update a machine file. If you answer "Y" you will be prompted for a file name of up to 8 characters. This is how you can create new machine files. This can also be done later in the Change Setup screen as described later. THE MAIN SCREEN The Main Screen is where all of your data will be entered and modified. From this screen you will be able to call up screens to view and modify the setup information that was entered when the estimate was created, display a breakdown of cycle times, and get a complete view of the information you entered for each tool and operation. If you fill up the screen with information you will be able to use the Page Up and Page Down keys on your keyboard to see all of the information. Below I have listed some of the terminology used in the software and in this manual: Tool - A group of operations performed by a single cutting tool. Operation - A single task done by a tool. Many operations can be performed by a tool. Part Operation - A process which includes 1 or more tools. There can be a maximum of 2 Part Operations in each estimate. Using Part Operations help distinguish different processes on the machine. For example, on a Machining Center, Part Operation 1 may be a vise on one side of the table and Part Operation 2 being another vise on the table, each doing different operations or parts. Using Part Operations on a Machining Center is available for your convenience to help break down the cycle times, it is optional and only used when you see fit. On a twin turret or twin spindle Lathe, each Part Operation will be used to separate each turret or spindle. The upper two lines of the Main Screen are used for Titles and Column numbers. The top row shows you all of the column numbers used when Altering data. At the upper right corner you are told which Part Operation you are presently working with, this display will change as you toggle back and forth between Part Operation 1 and 2. The second row of information are the titles for the columns of data. Below are the descriptions of each column: Tool - Tool number. As you enter data, a tool number will automatically be assigned to this column in numerical order. A tool number will only be displayed in the row of the first operation for each tool. These numbers cannot be modified and are only to help separate the tools from one another and for copying/moving data. Oper - Operation number. Like the Tool numbers, these are assigned automatically and cannot be modified. They will be assigned in numerical order and are also used designate operations when copying and moving data. Diam - Diameter of tool or Cutting diameter. Descrptn - A description of the process performed in that operation. Only 8 letters are shown on this screen, but a maximum of 12 letters can be used for the description. Only the first 8 letters are displayed to save space. SFM - Surface Feet Per Minute. Most tooling guidelines for cutting speeds are given in Surface Feet Per Minute. FPR - Feed Per Revolution. The distance, in inches, a tool will feed for each revolution of the spindle. This is also a typical guideline for feedrates. # - Number of Cuts or Passes. This column may show you number of holes, milling passes, turning passes, etc.. LOC - Length of Cut. The distance, in inches, a tool will travel while cutting. 5 DOC - Depth of Cut. Used for calculating Horse Power consumption when milling and turning. Idx - Number of Indexes. Only used on estimates for Machining Centers with indexers to show how many indexes were performed in each operation. RPM - Rotations Per Minute. The number of rotations the spindle will perform each minute. IPM - Inches Per Minute. This is for your reference only, showing you how many inches the tool will travel in one minute (RPM * IPR). (This is not displayed when working with 4 axis (twin turret) Lathes) COMB/W - Tools Combined With. On an estimate for 4 axis Lathes, this column will show you which tool(s) from the opposite turret (part operation) it is being combined with. Combining tools will be discussed in detail later in the 4 axis section. (This is only displayed in estimates for 4 axis Lathes) Secs - Seconds. The number of seconds to perform each operation. This number is rounded to the nearest whole number. HP - Horse Power used. The amount of Horse Power consumed for each operation. The bottom 2 lines are the commands you may execute while on the Main Screen. The letters highlighted in reverse video are the keys to push to execute each of the commands. Once you start entering data, 2 lines above the bottom command lines will display the Total Time in minutes and seconds for each Part Operation. This is only for your convenience and reference. ENTERING DATA Next we will go through each of the commands on the bottom command line in detail. Next Tool - This is the first command you will execute when starting a new estimate. This command is like calling up a tool from the tool changer and putting it in the spindle or indexing the turret on a Lathe. The software will automatically add the time it takes to execute a tool change to your estimate (unless the estimate consists of only one tool). When you execute this command a new screen will pop up to show the process choices available for the machine you selected (Lathe or Mill). For a Lathe estimate: Select the type of operation the tool will be performing. Turn - Straight or angled turning. You will first be asked to enter a description of the tool you will be using, you are allowed up to 12 letters. Next enter a description of the operation you want to perform (turn boss, etc.). These two questions will be asked after selecting any of the process choices. You will then be asked if it is a Straight Turn, Angle Turn, or 45 degree Angle Turn. Straight Turn - For turning straight across the Z axis at one diameter. You will be asked the diameter of the turn. or, Angle Turn - For turning a taper at a known angle. You will be asked to give an angle from the Z axis and a length along the Z axis so that the software can calculate the length of cut and average cutting diameter for you. or, 45 degree Angle Turn - For turning a chamfer or taper at 45 degrees. You will be asked for the length in the Z axis and the ending diameter of the cut so that the software can calculate the length of cut and average cutting diameter for you. SFM - Type in the Surface Feet Per Minute. If you would rather just type in the RPM then enter 0 (zero) and you will be asked what RPM the part will be spinning at and the software will calculate the SFM. Feed Per Rev - Type in the inches per revolution the tool will feed at. Number of Cuts - Type in the number of cuts or passes the tool will execute for this operation. Length of Cut - Type in the distance the tool will travel for each cut, if you enter more than 1 for the number of cuts, the software will calculate the total length of all cuts and figure the time needed to execute accordingly. Depth of Cut - Type in the amount of stock the tool will remove radially (per side), this is needed for Horse Power calculations only. Once you enter all of the data the command lines will re-appear and the cycle times and data will appear above. Rough Turn/Bore (multiple cuts) - This command comes in handy when you need to take multiple cuts and different diameters with the same length of cut. You will be asked for a tool description and operation description just like the rest of the commands and then you will be asked for a Starting Diameter which is the diameter of your part before you start turning or boring (O.D. for turning, and I.D. for boring). You will then be asked for the Ending Diameter, which is the diameter of the last pass or cut. You will then be asked for the usual information for SFM, FPR, Length of Cut, and the Depth of Cut (See above). After all of the data is entered the software will calculate the average cutting diameter and the number of cuts for you, based on your depth of cut, starting dia., and ending dia.. Face - For facing, you will be asked for the usual information (see Turn above), except by entering the starting and ending diameter the average cutting diameter and length of cut will be calculated for you. Bore/Ream - You will be asked the same questions as Turning (above), but remember if you choose angle bore or 45 degree angle bore that you will be starting at a larger diameter than you will end at. 6 OD/ID Groove - You will answer the usual questions as above but you must enter the Starting Diameter and the Ending Diameter so that the software can calculate the average cutting diameter and the length of cut. You will also be asked the Width of cut rather than Depth of Cut, just enter the width of the tool for Horse Power calculations. Face Groove - The only question for Face Grooving that is different than Turning is you will be asked for a Width of Cut rather than Depth of Cut. Enter in the width of the tool for Horse Power calculations. Thread - Threading operations are the same as Turning except you will be able to enter the Threads Per Inch to make it easier for you, or just enter 0 (zero) to be prompted for the FPR. The depth of cut is not needed here. Drill - Besides the usual questions you will be asked for a Drill Point Angle, this is the included angle at the end of the drill (118 degrees for a standard HSS drill, 180 deg. for a indexable insert drill). The default is 118 degrees (just hit [ENTER]). This is used to calculate how much extra distance the drill will travel to drill to full diameter, so just enter the depth you need and the amount of clearance in front of the part for the approach when asked for the depth of the hole. PeckDrill - This is the same as Drill above but you will also be asked to give the distance the drill will cut before pecking for the first time. This is used as a drilling cycle that will retract out of the hole for each peck for deep hole drilling. The software will determine how many pecks will be required to complete the hole and add some extra time to allow for pecking. (Number of Cuts is asking for the number of holes and does not have anything to do with the number of pecks) Tap - This function is just like Threading because it allows you to enter Threads per Inch instead of FPR, except, when you answer the Depth of Hole (length of cut), the software will double your answer to account for the time to feed back out of the hole. This function is used to tap holes in the center of the part as well as for a Lathe equipped with rotary tools. Mill - This is used for Lathes equipped with rotary tools on the turret. Enter the usual information including Depth of Cut and Width of Cut (Width of cutter in contact with the part) for Horse Power calculations. CutOff - The questions for CutOff are the same as OD/ID Grooving (above) and will calculate the average cutting diameter and the length of cut. Allow Time or Message - This is used to add time to your estimate for functions not shown above, like, changing the part, or blowing off the part. Just type in a description of the process and number of seconds you think it will take to perform. It can also be used to add messages to your estimate between operations or tools (enter 0 for seconds or just hit [ENTER]). This function is only available when inputting the first operation of the first tool of a Part Operation or when adding operations to a tool. Next Operation/Allow Time - This command is exactly like Next Tool with the exception of adding a tool change to your cycle time. You will use this command to add more processes that will be performed with the last tool. You will have the opportunity to use the Allow Time or Message command when adding operations to a tool. You will also notice that when you are asked most of the questions, the last answer entered will appear at the end of the line in parenthesis (), by just hitting [ENTER] you will save the same data as the last operation so you will not have to re-type the same data. If you want to change the data just type the new information and it will be saved instead. For a Machining Center (mill) estimate: Select the type of operation the tool will be performing. Mill Straight Line - Milling a straight line or a known distance. You will first be asked to describe the tool you will be using, using up to 12 letters. Then you will be asked to describe the operation it will be performing (mill top, etc.), up to 12 letters can be used. These two questions will be asked after selecting any of the process choices. Mill Diameter - Enter the diameter of the milling tool. SFM - Type in the Surface Feet Per Minute. If you would rather just type in the RPM then enter 0 (zero) and you will be asked what RPM the tool will be spinning at and the software will calculate the SFM. Feed Per Rev - Type in the inches per rev. the tool will feed at. Number of Cuts - Type in the number of cuts or passes the tool will execute for this operation. Length of Cut - Type in the distance the tool will travel for each cut, if you enter more than 1 for the number of cuts, the software will calculate the total length of all cuts and figure the time needed to execute accordingly. Depth of Cut - Type in how deep, in inches, the tool will be engaged into the part, this is needed for Horse Power calculations only. Width of Cut - Type in how much of the cutter, in inches, will be cutting, for Horse Power calculations. Number of Indexes - This question will only be asked if you answered yes to the question of whether the machine has an indexer installed or not. You may enter a number of times the indexer or table will index here so that the software can add the time it takes to the cycle time, you may enter 0 (zero) if you are not indexing during this particular operation. Description of Index(s) - This is again only asked if you specified that an indexer was installed and you answered 1 or more to the Number of Indexes question. This question is only for your own reference and may be left black if you wish. It can be useful for specifying the side of the fixture you are working on (90 degrees, back side, etc.). Once you enter all of the data the command lines will re-appear and the cycle times and data will appear above. Milling Inside Circle/Radius - For milling arcs or circles. This function is the same as milling straight lines except by answering the radius and degrees of a circle, the software will calculate the actual length of cut for you. You will be asked the usual questions in addition to the Radius of the cutting path. This answer must not include any compensation for the cutter diameter, you may enter the radius right from the blueprint, by selecting 'Inside' Circle/Radius, the software will be able to calculate the actual cutting radius at the center of the tool. You must then enter the Angle of the Radius, it is asking if you are doing a complete circle (360 degrees), or a portion of a circle (90 deg, 180 deg, etc.) for cutting an arc. You will then be asked for the Distance to Feed Into the Cut and the Distance to Feed Out of the Cut, these questions are optional (you may enter 0 if either one is not needed). After entering all of the data the software will be able to calculate the length of cut for you. Milling Outside Circle/Radius - Same as above except the software will calculate the length of cut with the tool traveling outside of the radius you input. Drill - Besides the usual questions you will be asked for a Drill Point Angle, this is the included angle at the end of the drill (118 degrees for a standard HSS drill, 180 deg. for a indexable insert drill). The default is 118 degrees (just hit [ENTER]). This is used to calculate how much extra distance the drill will travel to drill to full diameter, so just enter the depth you need and the amount of clearance at the top of the part for the approach when asked for the depth of the hole. PeckDrill - This is the same as Drill above but you will also be asked to give the distance the drill will cut before pecking for the first time. This is used as a drilling cycle that will retract out of the hole for each peck for deep hole drilling. The software will determine how many pecks will be required to complete the hole and add some extra time to allow for pecking. (Number of Cuts is asking for the number of holes and does not have anything to do with the number of pecks) Tap - This function is just like Drilling except it allows you to enter Threads per Inch instead of FPR, or enter 0 (zero) if you would like to enter the FPR, and when you answer the Depth of Hole (length of cut), the software will double your answer to account for the time to feed back out of the hole. 7 Bore/Ream - This is the same as the Drilling function without the question for Drill Point Angle except it will also ask for a Depth of Cut (radially) to calculate the Horse Power required. Spotface - This is the same as the Drilling function without the question for Drill Point Angle. No Horse Power calculations are made for this function. Couterbore - This is the same as the Drilling function without the question for Drill Point Angle. No Horse Power calculations are made for this function. Allow Time or Message - This is used to add time to your estimate for functions not shown above, like, changing the part, or pallet changing. Just type in a description of the process and number of seconds you think it will take to perform. It can also be used to add messages to your estimate between operations or tools (enter 0 for seconds or just hit [ENTER]). This function is only available when inputting the first operation of the first tool of a Part Operation or when adding operations to a tool. Next Operation/Allow Time - This command is exactly like Next Tool with the exception of adding a tool change to your cycle time. You will use this command to add more processes that will be performed with the last tool. You will have the opportunity to use the Allow Time or Message command when adding operations to a tool. You will also notice that when you are asked most of the questions, the last answer entered will appear at the end of the line in parenthesis (), by just hitting [ENTER] you will save the same data as the last operation so you will not have to re-type the same data. If you want to change the data just type the new information and it will be saved instead. SWITCHING PART OPERATIONS Part Operation - A process which includes 1 or more tools. There can be a maximum of 2 Part Operations in each estimate. Using Part Operations help distinguish different processes on the machine. For example, on a Machining Center, Part Operation 1 may be a vise on one side of the table and Part Operation 2 being another vise on the table, each doing different operations or parts. Using Part Operations on a Machining Center is available for your convenience to help break down the cycle times, it is optional and only used when you see fit. On a twin turret or twin spindle Lathe, each Part Operation will be used to separate each turret or spindle. To switch Part Operations, simply press "P" shown on the bottom command line. You may do 3 different functions on this screen, enter or change the name of the Second Part Operation (this question was not asked when you created the estimate), you may Erase the Second Part Operation (enter 99), or you may just toggle back and forth between First and Second Part Operations (press [ENTER]). The first line on this screen asks you to enter the description of the Second Part Operation, and shows you the current setting in parenthesis. The second line gives you some examples of Part Operation descriptions. The third line reminds you than the maximum number of Part Operations per estimate is two. The last 3 lines on the screen give you your options. Enter to leave the same - Press [ENTER] to leave the Second Part Operation description the same and toggle to the other Part Operation. 0 to Cancel - Enter 0 (zero) to cancel the command and keep entering data to the same Part Operation. 99 to Erase 2nd Op. - Enter 99 to erase all of the data entered in the Second Part Operation. If you decide you do not want a Second Part Operation in your estimate after entering data to the 2nd part op., you must use this command to clear all data. The bottom line is used to enter your response, if you type in anything besides just 0 or 99, the software will save your response as the new description of the Second Part Operation and toggle to the other Operation. You may also change the Second Operation description in the "Change Setup" screen which will be discussed later. When you press [ENTER] or type in a new description, you will be brought back to the main screen to enter more data for the other Part Operation. You will notice in the upper right hand corner of the screen, the Part Operation you are working with is displayed. You may now start entering data to the Part Operation with the Next Tool and Next Operation commands. CHANGING THE SETUP On the bottom command line of the main screen you can press "S" to select Change Setup. This screen will allow you to change any of the information you entered when you created the estimate, and a few other pieces of information. Just press the letter on the left side of the data you would like to change and you will be prompted to type in the new value or press enter to leave the it as is (the current setting will be in parenthesis). You will also have the opportunity to change some other information such as: Second Operation Description - You may enter the description here instead of entering it when you select "Switch Part Ops" from the main screen. You may have notices this question was not asked when you created you estimate, so if you will be using 2 Part Operations, you must enter the data here or when you switch Part Operations from the main screen. Part per Setup - This question was asked when you created your estimate, but you may modify it here and also change the estimate accordingly. After you type in the number of completed parts per cycle, you will be asked if you want the software to change the Number of Cuts accordingly. If you type "Y" for yes, the number of cuts for all of the tools and operations will be changed to reflect the change of parts completed. For example if the value was 2 and the new value you enter is 4, all of the Number of Cuts in your estimate will be doubled to reflect 4 parts on the table instead of 2, and your cycle time will show the total time of the cycle. If you answer "N" for no, your Number of cuts will not be modified. Machine type/accessories - You may change the Machine specifications here, just as you did when you created the estimate. You will first be shown a list of machine files available to choose from, you may select one or press [ESC] to modify the values you already are using. Answer all of the question as described above in "Entering Machine Specifications". When you are finished entering the settings, you will be asked if you would like to save the settings for later use, if you reply "Y" for yes, you will be asked for a filename to save the settings as. This will be the best was to create new Machine Files, after you save the settings you may start again and enter the settings for a new machine and save another file. You may repeat these steps to create as many machine files for later use as you like. Be careful, you may notice some of the most often changed machine settings are shown above in the change setup screen (RPM's, Horse Power's, Rapid, and Toolchange times), if you are creating machine files make sure to change all of the machine settings before saving the machine file. Company Name/Message - These settings are saved in a file called CTE.CFG, this file must be in the same directory as the other CTE files. By selecting, you may enter your company name and two lines of information that will be printed at the end of each estimate. You will first be asked to enter your company name or press enter to leave the same. Next you will be shown the messages that are saved for the two lines available, press "Y" to change the information or [ENTER] to leave it alone. If you press "Y", type in the message for the first line and press [ENTER]. Then type in the message for the second line and press [ENTER]. You will then be shown the information you entered and asked if you would like to save these settings as the default so that next time you run Cycle Time Estimator, it will use these same settings. If you press any other key besides "Y", the settings will be used until you exit the program, so you should print the estimates you would like before exiting. These settings are not saved with the estimate. When finished press "Q" to get back to the main screen. It is not recommended to change the machine files from Lathe to Mill, or vice versa, when you have data entered in the main screen. If you are starting a new estimate, it is best to save the estimate, erase all data and start new, or just Quit back to the Main Menu and Create a new estimate. DISPLAY CYCLE TIMES By pressing Disp. Times on the bottom command line of the main screen you will be shown a breakdown of the cycle times.  8 If you have 2 Part Operations in your estimate they will both be shown with their descriptions on the first line, if not, only one will be shown. If you said there is more than one part per cycle, a total cycle time will be displayed along with the cycle time per part (total / parts). The parts per hour will be displayed at 100% efficiency, and the parts per hour at the fatigue factor is one was entered other than 100%. TOOL DISPLAY By selecting TooL Display, you be asked to highlight the tool and operation you would like displayed. Use the Up and Down arrow keys and the Page Up and Page Down keys if needed, and press[ENTER] when the operation you like is highlighted. A screen with all of the detailed information you entered for that operation will be displayed, this screen is for your convenience and is easier to read than the condensed version on the main screen. You can use the Up and Down arrow keys to look at all of the operations in your estimate, in order, any other key will return you to the main screen. SAVING ESTIMATES By selecting SaVe you will be prompted whether to save the estimate with the current filename, and the opportunity to change the filename. If the file already exists on the disk, you will be asked if you would like to overwrite it. If you reply "N" for no, you can enter a different filename to save the estimate as. When you are finished you will be returned to the main screen. QUIT By selecting Quit from the bottom command line, you will be asked whether you would like to save the estimate first. If you reply "Y", you will follow the same procedures as above, if you reply "N", the Main Menu will appear. MODIFYING DATA ON THE MAIN SCREEN Alter - You may alter any data in any operation with the Alter command. When selected, move the highlight bar to the operation you would like to change by using the Up and Down arrow keys, or the Page Up and Page Down keys if needed, and pressing [ENTER]. After selecting the operation you will be asked for a column number (1-9 on the top line of the screen), or to enter 0 (zero) to change all of the data in the operation. If the operation you selected is the first of more than one for the tool (the line with the tool number at the left), you may be asked, depending on the column you selected, if you would like to change that column for all of the operations for that tool. For example, if you selected column 2 and you answered "Y", the SFM you enter will be changed for all of the operations for that tool. You will then be asked to type in the new value, in most cases the old value will also be shown, so just press [ENTER] to retain it. If you select 0 (zero) instead of a column number, you will have to answer all of the questions as you did when you entered the operation. It is recommended not to try to change the "operation type" (drill, mill, etc.) to change to another type of process. It is best to erase the operation and insert a new one with the new type of process. Copy - This is used to copy a operation or whole tool to another part of your estimate. When you press"C" for copy, you must select the tool or operation you would like to copy as explained above. If you would like to copy all of the operations with the tool you should select the first operation for the tool (the line with the tool number at the left). If you do select the first operation, you will be asked one of two questions, if the tool only has one operation you will be asked "Do you want to copy as a New tool?", if you enter "Y", it will be inserted elsewhere as a new tool, if you say "N", the operation will be added to another tool. If the tool has more than one operation, you will be asked "Do you want to copy all of the operations with the tool?, If you reply "Y", the entire tool with all of its operations will be inserted elsewhere in the estimate, if you enter "N", only the first operation will be copied to another tool. If you are working with 2 Part Operations, you will then be asked if you want to copy the tool or operation to Part Operation 1 or Part Operation 2, enter 1 or 2. You will then be asked for the New Tool Number. Copying a Tool - Example: If you currently have 6 tools and you would like this tool to be the last one, enter 7. If you press 4, the current tools 4 5 and 6 will then become 5 6 and 7. Copying an Operation - Just type the number of the tool you would like to copy the operation too. You will then be asked for the New Operation Number. Example: If the tool has 3 operations and you want the copied operation to be the first, type 1, and 1 2 and 3 will become 2 3 and 4. If you would like the operation to be the last operation of that tool, just type 4. Move - The Move command is the same as Copy, except the tool or operation selected will be removed from it's original location. When you are asked for the New Tool or Operation number, use the numbers as they are before the move is complete. Erase - Erase is used to remove a complete tool or an operation. After pressing "E" for erase, you will have to move the highlight bar to the tool or operation you would like to erase, and press [ENTER], just as explained above for the Copy command. If you select the first operation of the tool you will be asked if you would like to erase the "Tool or Operation?" (if the tool has only one operation it will be erased immediately). Press T to erase the entire tool, or O to erase the first operation only. If you just move the highlight bat to an operation it will be removed as soon as you press [ENTER]. Insert - If you would like to add an operation or a tool in the middle of your estimate, you can use the Insert command. If you have 2 Part Operations in your estimate you will be asked if you want to insert the tool or operation to Part Operation 1 or Part Operation 2, enter 1 or 2. You will then be asked "Tool or Operation", enter T to add a new tool, or O to add an operation to any tool. Inserting a Tool - Example: If you currently have 6 tools and you would like this tool to be the last one, enter 7. If you press 4, the current tools 4 5 and 6 will then become 5 6 and 7. You will then have to answer all of the questions just as if you selected Next Tool from the command line. Inserting an Operation - Just type the number of the tool you would like to insert the operation too. You will then be asked for the New Operation Number. Example: If the tool has 3 operations and you want the new operation to be the first, type 1, and 1 2 and 3 will become 2 3 and 4. If you would like the operation to be the last operation of that tool, just type 4. You will then have to answer all of the questions just as if you selected Next Oper from the command line. ESTIMATES FOR A TWIN SPINDLE LATHE When creating an estimate for a twin spindle Lathe, you will have to use Part Operation 1 to enter the process for the main spindle, and Part Operation 2 for the sub spindle or opposed spindle. If the Lathe has two turrets, when you display the cycle times, the Part Operation with the longest cycle time will be used to figure out the actual cycle time and the parts per hour. I would suggest you enter all of the data for both spindles first, including barfeed or part loading. Then you can add the transfer time to the cycle with the longest times. This will give you an accurate cycle time because a Lathe with 2 spindles and 2 turrets will have one spindle and turret working internal to the other spindle's cycle time. ESTIMATES FOR A TWIN TURRET LATHE WITH ONE SPINDLE If you are entering an estimate for a 4 axis (twin turret) Lathe, the machine has the capability to perform one process while the other turret is performing another process. In this case I suggest you use Part Operation 1 to describe the Upper Turret's operations, and Part Operation 2 for the Lower Turret's operations. Enter all of the data for each turret before you combine any of the tools. An accurate cycle time estimate is not easy for a 4 axis Lathe, if you have 2 tools working at the same time, the spindle must be running at the same RPM, and you must keep an eye on the Horse Power used for each tool that is working together so that the combined Horse Power does not exceed the maximum spindle horse power. After you enter all of your data you can begin Combining Tools. ComIne - This command is used to tell the software which tools will be working simultaneously. When you select Combine, you will be able to combine tools, un-combine tools, or cancel the command. Combine will only be available if you selected a 4 axis Lathe when entering the Machine settings. You will only be able to combine tools when you have entered data in both Part Operation 1 and Part Operation 2. It is only possible to combine Tools and not individual Operations. Combining Tools - Select "1" from the combine menu. You will then be asked to select a tool number from the Top Turret, and then from the Bottom Turret. When you press [ENTER], the slowest of the two tools (including all operations) will show "INT' in the seconds column. This means the INTERNAL tool will finish before the other tool in the other turret, so it's cycle time does not apply to the total cycle time. If by chance, the cycle times of both tools are exactly the same, you will notice that neither of the tools is INTERNAL, so you will have to Alter one of them slightly to make one of them slower or faster (adding or subtracting .4 SFM sometimes works). You will also notice that the column that usually is for IPM, is now labeled COMB/W. This column will show you which tool(s) in the opposite turret it is combined with. You may however, combine more than 2 tools. For example, if you have 3 tools in each turret and you can perform the operations of 2 tools in the lower turret while the first tool is operating in the upper turret. First combine tool 1 and tool 1, then select combine again and combine upper tool 1 with lower tool 2. This will show that tools 1 and 2 in the lower turret are INTERNAL to tool 1 in the upper turret. You may a tool with as many tools in the other turret as you like. Again, make sure the spindle RPM's are relatively close for each of the tools that are combined together, this is important for accurate estimates. Once all of your tools that will work simultaneously are combined, the total cycle time will reflect the actual time to complete a part. Un-Combining Tools - If you decide to Copy or Move any of the process' around, I strongly suggest you Un-Combine the tools first, or your cycle times may not be correct. To Un-Combine a tool, press "2" from the Combine menu and enter the tool number from the top turret and the lower turret as you did when you Combined them. The COMB/W column will help you remember which tools were combined together. Repeat this until the COMB/W column is completely blank and the Secs column has no INT's displayed. GOOD LUCK AND HAPPY ESTIMATING!!