Cncsetup

CNCSetup - MNMUK 设置单生成器

用途： 标准化设置文档，以缩短设置时间、防止错误并记录经验知识。

何时启用

• “为 [part/job] 创建设置单”
• “[machine name] 的设置”
• “在 NLX2500 上设置新作业”
• “[operation] 的刀具清单”
• “记录 [part number] 的设置”

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按机床类型分类的设置单模板

DMG MORI 5 轴铣床（NMV3000、DMU50、NHX500）

# SETUP SHEET - 5-AXIS MILLING

## Job Information
| Field | Value |
|-------|-------|
| Part Number | |
| Part Name | |
| Customer | |
| Operation | |
| Machine | [ ] NMV3000  [ ] DMU50  [ ] NHX500 |
| Program Number | |
| Setup By | |
| Date | |

## Workholding
| Item | Details |
|------|---------|
| Fixture ID | |
| Fixture Location | |
| Clamping Method | |
| Clamping Torque | Nm |
| Pallet Number | |
| Datum/WCS | G54 / G55 / Other: |

## Work Offset Setup
| Axis | Value | Method |
|------|-------|--------|
| X | | Probe / Edge finder / Indicator |
| Y | | Probe / Edge finder / Indicator |
| Z | | Probe / Tool setter |
| A | | |
| B/C | | |

## Tool List
| T# | Description | Diameter | Length | Offset | Notes |
|----|-------------|----------|--------|--------|-------|
| T1 | | | | H1 D1 | |
| T2 | | | | H2 D2 | |
| T3 | | | | H3 D3 | |
| T4 | | | | H4 D4 | |
| T5 | | | | H5 D5 | |

## CELOS Settings
| Parameter | Value |
|-----------|-------|
| Spindle Warm-up | [ ] Required  [ ] Not Required |
| Coolant Type | [ ] Flood  [ ] Through-spindle  [ ] Mist |
| Coolant Pressure | bar |
| Chip Conveyor | [ ] On  [ ] Off |

## Critical Dimensions (First-Off Check)
| Feature | Nominal | Tolerance | Actual | OK |
|---------|---------|-----------|--------|-----|
| | | ± | | [ ] |
| | | ± | | [ ] |
| | | ± | | [ ] |

## Safety & Notes
- [ ] Guards in place
- [ ] Correct PPE worn
- [ ] Program proven at reduced feed

### Special Instructions:


### Known Issues / Tips:

---

DMG MORI 车削中心（NLX2500、ALX2000）

# SETUP SHEET - CNC TURNING

## Job Information
| Field | Value |
|-------|-------|
| Part Number | |
| Part Name | |
| Customer | |
| Operation | OP10 / OP20 / Complete |
| Machine | [ ] NLX2500 Twin  [ ] NLX2500 Single  [ ] ALX2000 |
| Program Number | |
| Setup By | |
| Date | |

## Material & Stock
| Item | Details |
|------|---------|
| Material | |
| Stock Type | [ ] Bar  [ ] Billet  [ ] Forging  [ ] Casting |
| Stock Size | Ø x L mm |
| Bar Feeder | [ ] Yes  [ ] No |
| Bar Stop Position | mm from chuck face |

## Workholding - Main Spindle
| Item | Details |
|------|---------|
| Chuck Type | [ ] 3-jaw  [ ] Collet  [ ] Special |
| Chuck ID/Size | |
| Jaw Type | [ ] Hard  [ ] Soft  [ ] Pie jaws |
| Jaw Bore | Ø mm |
| Grip Length | mm |
| Clamping Pressure | bar |

## Workholding - Sub Spindle (if applicable)
| Item | Details |
|------|---------|
| Chuck Type | [ ] 3-jaw  [ ] Collet |
| Jaw Type | [ ] Hard  [ ] Soft |
| Grip Length | mm |
| Part-off Position | mm |
| Transfer Method | |

## Work Offset Setup
| Offset | Value | Method |
|--------|-------|--------|
| Z (Face) | | Touch-off / Probe |
| X (Diameter) | | Test cut / Probe |

## Tool List - Turret
| T# | Station | Description | Insert | Orientation | Offset | Notes |
|----|---------|-------------|--------|-------------|--------|-------|
| T1 | | | | | | |
| T2 | | | | | | |
| T3 | | | | | | |
| T4 | | | | | | |

## Live Tooling (if applicable)
| T# | Station | Description | RPM | Notes |
|----|---------|-------------|-----|-------|
| | | | | |

## Cutting Parameters Reference
| Operation | Speed (m/min) | Feed (mm/rev) | DOC (mm) |
|-----------|---------------|---------------|----------|
| Rough OD | | | |
| Finish OD | | | |
| Rough ID | | | |
| Finish ID | | | |
| Thread | | | |
| Part-off | | | |

## Coolant Settings
| Parameter | Value |
|-----------|-------|
| Coolant Type | [ ] Flood  [ ] High-pressure |
| HP Coolant Pressure | bar |
| Chip Conveyor | [ ] On  Direction: |

## Critical Dimensions (First-Off)
| Feature | Nominal | Tolerance | Actual | OK |
|---------|---------|-----------|--------|-----|
| OD 1 | Ø | ± | | [ ] |
| OD 2 | Ø | ± | | [ ] |
| Length | | ± | | [ ] |
| Thread | | Class | | [ ] |

## Cycle Time
| Phase | Time |
|-------|------|
| Load | sec |
| Cut Cycle | sec |
| Unload | sec |
| **Total** | sec |

### Special Instructions:


### Known Issues / Tips:

---

HARDINGE 双主轴车床

# SETUP SHEET - HARDINGE TURNING

## Job Information
| Field | Value |
|-------|-------|
| Part Number | |
| Part Name | |
| Operation | |
| Program Number | |
| Setup By | |
| Date | |

## Stock
| Item | Details |
|------|---------|
| Material | |
| Stock Size | Ø x L mm |
| Bar Feed | [ ] Yes  [ ] No |

## Workholding
| Spindle | Chuck | Collet/Jaw | Grip | Pressure |
|---------|-------|------------|------|----------|
| Main | | | mm | bar |
| Sub | | | mm | bar |

## Precision Notes (±0.003mm capability)
| Parameter | Setting |
|-----------|---------|
| Warm-up Cycle | [ ] Required - Run time: min |
| Temperature Stability | [ ] Verified |
| Probe Calibration | [ ] Verified |

## Tool List
| T# | Description | Insert | Offset | Notes |
|----|-------------|--------|--------|-------|
| | | | | |

## Critical Dimensions
| Feature | Nominal | Tol | Gage | Method |
|---------|---------|-----|------|--------|
| | | ±0.003 | | |

### Precision Tips:
- Allow 20-min spindle warm-up for best tolerance
- Verify coolant temperature stable
- Use in-process gauging for critical features

---

CITIZEN 瑞士型机床（走心式）

# SETUP SHEET - CITIZEN SWISS

## Job Information
| Field | Value |
|-------|-------|
| Part Number | |
| Part Name | |
| Machine | [ ] Citizen Laser Head  [ ] Citizen LFV |
| Program Number | |
| Setup By | |
| Date | |

## Material & Bar Stock
| Item | Details |
|------|---------|
| Material | |
| Bar Diameter | Ø mm (max Ø38.1mm) |
| Bar Length | mm |
| Bar Supplier/Heat | |

## Guide Bushing Setup
| Parameter | Value |
|-----------|-------|
| Guide Bushing Size | Ø mm |
| Bushing Type | [ ] Rotating  [ ] Fixed |
| Bushing Material | [ ] Carbide  [ ] Bronze |
| Z-axis Reference | mm |

## Main Spindle Collet
| Parameter | Value |
|-----------|-------|
| Collet Size | Ø mm |
| Clamping Pressure | bar |
| Stock Stick-out | mm |

## Sub Spindle Setup
| Parameter | Value |
|-----------|-------|
| Collet Size | Ø mm |
| Pickup Position | Z = mm |
| Grip Length | mm |

## Tool List - Gang Slide
| Position | Tool | Insert/Size | Offset | Notes |
|----------|------|-------------|--------|-------|
| | | | | |
| | | | | |
| | | | | |

## Tool List - Back Working
| Position | Tool | Insert/Size | Notes |
|----------|------|-------------|-------|
| | | | |
| | | | |

## LFV Settings (if LFV machine)
| Parameter | Value |
|-----------|-------|
| LFV Mode | [ ] On  [ ] Off |
| Oscillation Frequency | Hz |
| Amplitude | mm |
| Applied To | [ ] OD  [ ] ID  [ ] Drilling |

## Laser Head Settings (if Laser machine)
| Parameter | Value |
|-----------|-------|
| Laser Operation | [ ] Marking  [ ] Cutting  [ ] N/A |
| Power | W |
| Program | |

## Coolant
| Type | Setting |
|------|---------|
| Oil Type | |
| Pressure | bar |
| Mist | [ ] On  [ ] Off |

## Critical Dimensions (±0.003mm capability)
| Feature | Nominal | Tol | Method |
|---------|---------|-----|--------|
| | | ± | |
| | | ± | |

## Cycle Time Target
| | Time |
|--|------|
| Cycle | sec |
| Parts/Hour | |

### Swiss-Specific Tips:
- Verify guide bushing alignment before production
- Check oil level and filtration
- LFV excellent for 316SS and titanium chip breaking
- Monitor bar remnant length

---

MITSUBISHI EDM（线切割与火花放电）

# SETUP SHEET - EDM

## Job Information
| Field | Value |
|-------|-------|
| Part Number | |
| Part Name | |
| Machine | [ ] Wire EDM  [ ] Spark EDM |
| Program Number | |
| Setup By | |
| Date | |

## Workpiece
| Item | Details |
|------|---------|
| Material | |
| Hardness | HRC |
| Dimensions | L x W x H mm |
| Weight | kg |

---

## WIRE EDM SETUP

### Wire Settings
| Parameter | Value |
|-----------|-------|
| Wire Type | [ ] Brass  [ ] Coated  [ ] Other: |
| Wire Diameter | mm |
| Wire Tension | g |
| Wire Speed | m/min |

### Workholding
| Item | Details |
|------|---------|
| Fixture Type | |
| Leveling | [ ] Verified |
| Start Hole | X: Y: (if applicable) |

### Cutting Parameters
| Pass | Power | On-Time | Off-Time | Wire Speed | Offset |
|------|-------|---------|----------|------------|--------|
| Rough | | μs | μs | m/min | mm |
| Semi | | μs | μs | m/min | mm |
| Finish | | μs | μs | m/min | mm |
| Skim | | μs | μs | m/min | mm |

### Flushing
| Parameter | Value |
|-----------|-------|
| Upper Nozzle | mm gap |
| Lower Nozzle | mm gap |
| Flushing Pressure | bar |
| Submerged | [ ] Yes  [ ] No |

---

## SPARK EDM (SINKER) SETUP

### Electrode
| Parameter | Value |
|-----------|-------|
| Electrode Material | [ ] Copper  [ ] Graphite |
| Electrode ID | |
| Undersize | mm |
| Polarity | [ ] +  [ ] - |

### Cutting Parameters
| Phase | Current | On-Time | Off-Time | Depth |
|-------|---------|---------|----------|-------|
| Rough | A | μs | μs | mm |
| Semi | A | μs | μs | mm |
| Finish | A | μs | μs | mm |

### Flushing
| Method | Setting |
|--------|---------|
| Type | [ ] Jet  [ ] Suction  [ ] Orbital |
| Pressure | bar |
| Retract Height | mm |
| Jump Frequency | |

---

## Dielectric
| Parameter | Value |
|-----------|-------|
| Type | |
| Level | [ ] Verified |
| Filter Status | [ ] OK |
| Conductivity | μS |

## Critical Dimensions (Wire: ±0.004mm, Spark: ±0.050mm)
| Feature | Nominal | Tol | Actual | OK |
|---------|---------|-----|--------|-----|
| | | ± | | [ ] |

### EDM Tips:
- Wire: Check wire path and guides before start
- Spark: Verify electrode alignment with workpiece
- Monitor dielectric condition
- Log electrode wear for repeat jobs

---

HAAS 快速响应单元（Mini Mill 和 Tool Room Lathe）

# SETUP SHEET - HAAS FAST RESPONSE

## Job Information
| Field | Value |
|-------|-------|
| Part Number | |
| Part Name | |
| Machine | [ ] Mini Mill  [ ] Tool Room Lathe |
| Program Number | |
| Setup By | |
| Date | |
| Priority | [ ] Urgent  [ ] Standard |

## Purpose
[ ] Prototype  [ ] First Article  [ ] Repair  [ ] One-off  [ ] Prove-out

---

## MINI MILL SETUP

### Workholding
| Item | Details |
|------|---------|
| Vice/Fixture | |
| Parallels | Height: mm |
| Stop Position | |
| WCS | G54 |

### Tool List
| T# | Description | Diameter | Length | Notes |
|----|-------------|----------|--------|-------|
| T1 | | | | |
| T2 | | | | |
| T3 | | | | |

### Work Offsets
| Axis | Value | Method |
|------|-------|--------|
| X | | Edge finder |
| Y | | Edge finder |
| Z | | Tool touch |

---

## TOOL ROOM LATHE SETUP

### Workholding
| Item | Details |
|------|---------|
| Chuck | [ ] 3-jaw  [ ] Collet  [ ] Other |
| Stock | Ø x L mm |
| Stick-out | mm |

### Tool List
| T# | Description | Offset | Notes |
|----|-------------|--------|-------|
| T1 | | | |
| T2 | | | |
| T3 | | | |

---

## Notes (±0.050mm typical tolerance)

### Special Instructions:


### For Production Transfer:
Machine recommended:
Key learnings from prototype:

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设置单最佳实践

设置前

1. 查看图纸和之前的设置单
2. 准备好所有刀具、夹具和量具
3. 确认程序版本与图纸一致
4. 检查原材料是否符合规格

设置期间

1. 按步骤遵循设置单
2. 记录任何偏差
3. 确认刀具长度和偏置
4. 以降低后的进给率（50%）加工首件

设置后

1. 首件检验——使用适当的测量设备检查所有关键尺寸：
   • 卡尺（数显游标卡尺）：用于一般尺寸
   • 千分尺（外径／内径）：用于严格公差
   • CMM：用于复杂几何形状或 GD&T 特征
   • 螺纹规（通止规）：用于螺纹特征
   • 内径量表：用于内径
   • 高度规：用于长度／台阶特征
2. 根据任何变更更新设置单
3. 记录实际循环时间
4. 记录任何问题或改进之处

持续改进

• 添加经验丰富的操作员提供的“技巧”
• 根据结果更新刀具建议
• 为复杂作业的关键设置步骤拍照
• 跟踪设置时间以进行基准比较

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输出格式

生成设置单时，我将：

1. 如果未指定机床／作业，询问具体信息
2. 生成适用的模板
3. 预填已知信息
4. 突出显示需要操作员填写的字段
5. 添加相关经验知识中的技巧

关键输出规则：

• 始终输出完整的刀具清单表——不得截断或在行中间结束。每条刀具记录都必须完整填写 T#、描述、直径／尺寸、偏置参考和备注列，或标记为空（例如“-”）。
• 每张刀具清单表至少显示 5 行刀具记录，即使其中某些行是空白占位行。
• 始终输出完整的工件装夹／夹具部分，包括类型、方向、夹紧方式以及扭矩／压力字段。
• 不得缩写或概述任何表格——须完整输出所有行和列。
• 如果设置单较长，继续输出直至每个部分都完整。不得提前结束。

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工作流路由

输入	工作流	输出
“NLX2500 的设置单”	DMG MORI 车削模板	完整车削设置单，包含刀塔布局、工件装夹和偏置
“为 NMV3000 创建设置”	DMG MORI 5 轴铣床模板	完整 5 轴设置单，包含 CELOS 设置、刀具清单和基准
“Citizen Swiss 的设置”	CITIZEN 瑞士型模板	瑞士型机床设置，包含导套、LFV 设置和排刀布局
“工具钢的 EDM 设置”	MITSUBISHI EDM 模板	线切割或火花放电 EDM 设置，包含切削参数和介电液设置
“快速 Haas 设置”	HAAS 快速响应模板	简化刀具清单的原型／工具间设置单
“夹具设置／工件装夹”	任何适用模板	预填相关夹具详情的工件装夹部分

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示例

示例 1 — 车削中心设置：

"为 NLX2500 Twin 上的 OP10 创建一份设置表，加工 Ø38mm 的 316SS 棒料"

生成一份完整的 CNC 车削设置表，其中预填内容包括：机床 = NLX2500 Twin、OP10、Ø38mm 的 316SS 棒料、主轴/副主轴夹持部分、带有推荐车端面/粗加工/精加工位置的刀塔刀具列表、已启用高压冷却液、首件关键尺寸表。

示例 2 — 五轴铣削设置：

"为 DMU50 创建设置表，零件号 MNM-4521，Op20 使用托盘 B 上的夹具"

生成一份五轴铣削设置表，其中包括：零件号 MNM-4521、机床 = DMU50、Op20、夹持部分注明托盘 B、G54/G55 工件坐标系选择、完整的刀具列表（至少 T1–T5）、CELOS 主轴预热和冷却液字段、首件尺寸表。

示例 3 — Citizen Swiss 新任务：

"为 Citizen LFV 上的 Ø12mm 钛合金螺钉创建新任务设置，要求完全加工"

生成一份 CITIZEN Swiss 设置表，其中包括：机床 = Citizen LFV、棒料直径 Ø12mm、材料 = 钛合金、LFV 模式已开启（推荐用于钛合金断屑）、导套尺寸、主加工和背面加工刀具列表、目标循环时间字段。还包括 Swiss 专用提示：检查导套对齐情况和油液。

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与其他技能集成

• PlantCapability：在设置前验证机床选择
• AutomotiveManufacturing：将设置表关联到作业指导书
• TribalKnowledge：将技巧和已知问题加入设置表