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
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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
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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:
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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.
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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.
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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.
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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!!