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Linea5 Training School Manual

Software Support Division

Manual Intent: This guided course aims to provide students with solid fundamental skills in
the operation of Linea5 (this includes Combi5, Cut5 and Punch5). This manual serves as an
introduction only and as such does not cover all features of software in their entirety.

Whilst making every effort to ensure data is correct Amada UK Ltd does not accept
responsibility for misuse of our software and data therein.

Written by John Wallace, Software Dept, Amada UK


Contents
Punch / Laser Program Flow ................................................................................................................... 5
Lesson 1 Introduction ............................................................................................................... 6
Overview ................................................................................................................................................. 7
Lesson 2 Guided Exercise ........................................................................................................ 12
Basic Sub Program Creation .................................................................................................................. 13
Basic Sheet Creation.............................................................................................................................. 14
Editing Sub Programs ............................................................................................................................ 17
Lesson 3 Punch Tooling & Turret Set up .................................................................................. 18
Tooling Library – Standard Tooling ....................................................................................................... 19
Tooling Library – Special Tooling .......................................................................................................... 22
Populating Turret .................................................................................................................................. 23
Lesson 4 Common Line Cutting ............................................................................................... 25
Common Line Cutting ............................................................................................................................ 26
(Laser Only) ........................................................................................................................................... 26
Common Line Cutting (Punch)............................................................................................................... 30
Lesson 5 Material Library Set up ............................................................................................. 32
Introduction........................................................................................................................................... 33
Material Library Settings....................................................................................................................... 33
Machine Material Settings .................................................................................................................... 34
Punch..................................................................................................................................................... 34
Machine Material Settings .................................................................................................................... 36
Laser ...................................................................................................................................................... 36
Standard Material Types ....................................................................................................................... 37
Fanuc Process Condition Notations....................................................................................................... 37
Laser Database...................................................................................................................................... 38
Automatic Tooling Preferences ............................................................................................................. 39
- Cutting Conditions............................................................................................................................... 39
Advanced Preferences Lead in/out (Extra) ........................................................................................... 40
Automatic Work Chute Operation (Scrap) ............................................................................................ 40
Plastic Pierce ......................................................................................................................................... 41
Colour Options ...................................................................................................................................... 42
Lesson 6 Additional Features .................................................................................................. 43
Joint Management ................................................................................................................................ 44

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Work Chute / Machine Stop Command ................................................................................................ 46
Advanced Laser Tooling ........................................................................................................................ 49
Beam Compensation ............................................................................................................................. 50
Applying Etching ................................................................................................................................... 50
Advanced Punch Tooling – Changing Tooling ....................................................................................... 50
Advanced Punch Tooling – Anchor Feature .......................................................................................... 51
Manual Punch Tooling for Profile ......................................................................................................... 52
Automatic Punch Tooling Preferences .................................................................................................. 53
Manual Nesting..................................................................................................................................... 54
Job Pack Printing ................................................................................................................................... 56
Automatic Reposition Control ............................................................................................................... 57
Backup and Restore .............................................................................................................................. 58
Saving Tooling Library ........................................................................................................................... 59
Saving Laser Database .......................................................................................................................... 59
Lesson 7 Sorting/Sequencing .................................................................................................. 60
Sorting - Manual ................................................................................................................................... 61
Sorting -Automatic ................................................................................................................................ 63
Additional Sorting Functions ................................................................................................................. 63
Shuttle Jobs – Punch Sorting ................................................................................................................. 64
Lesson 8 Advanced Operations ............................................................................................... 66
Manual Repositions .............................................................................................................................. 67
PR / Stacking ......................................................................................................................................... 68
Automatic PR Tooling............................................................................................................................ 70
Custom Stack Table Layout ................................................................................................................... 72
Adding Pallet ......................................................................................................................................... 72
Defining Table Layout ........................................................................................................................... 72
Lesson 9 Advanced Nesting Tools ............................................................................................ 74
Drag & Drop .......................................................................................................................................... 75
Work Plan Manager .............................................................................................................................. 76
Tab Overview ........................................................................................................................................ 77
Work Flow – Configuration Tab ............................................................................................................ 78
Parts Tab ............................................................................................................................................... 80
Format Tab – Method 1 ........................................................................................................................ 81
Method 2 ............................................................................................................................................... 82

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Nesting Tab ........................................................................................................................................... 83
NC Generation ....................................................................................................................................... 84

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Chapter I – Introduction

Punch /
Laser
CAD SheetWorks
Program
Flow

SDD Server
CAM

Linea5

Transmission
FMS

Machine

AMNC Machine Automated Machine or


Non-AMNC Machine

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Chapter I – Introduction

Lesson 1
Introduction

Upon successful completion of this lesson, you will be able to/be


familiar with:
 Programming theory
 Interface/available features

Please note toolbars can be customized to add or remove icons, to do this select
View – Set Tool Bar. Select Bar 1 or Bar 2 (icon destination), select icon required
from main bar and select Add. Select icon and press Left/Right to move along bar.

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Chapter I – Introduction

Overview Linea5 offers programming of multiple machines allowing full manual control of
tooling and nesting as well as automatic tooling, nesting and NC output features.

Linea5 can also be upgraded with a Multiple Nesting (formerly MasterNest)


providing greater automatic programming allowing automatically nesting of
varying parts across multiple dissimilar sheets.

Linea5 programming theory is based upon first creating a sub program for each
part then creating a sheet, which will contain multiple nested sub programs and
provide the NC code for the machine. The general programming steps for “Subs”
and “Sheets” are as follows.

Subs

 Import Geometry
 Tooling (automatic and/or manual)
 Process After e.g. joints, part picking and work chutes
 Process Sequence – part level e.g. cut order of holes/profiles

Sheets

 Importing/Nesting of Sub programs


 Process/Tooling Sequence – sheet level (inc. Simulation check)
 Part Stacking if applicable
 NC Generation

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Chapter I – Introduction

Interface Figure 1 illustrates the Linea5 main programming window, which can be split into several main areas.

Menu Bar Direct Programming Icons

Nest Display

View Manipulation/View Filters Simulation

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Chapter I – Introduction

Menu Bar Tool Assignment: Circle, Obround,


Features Rectangle/Filleted Rectangle

Tool Assignment: Notched Rectangle, Triangle

Tool Assignment: Arc, Line (useful for remnant


cuts)

Tool Assignment: Program for a Profile, various


options to tool automatically for any single
profile
Tool Assignment: Program for Single Hit (any
tool type)
Tool Assignment: Program for Pierce/Hole

Tool Assignment: Program for


Line/Rectangle/Arc/Circle/Grid of Holes

Tool Assignment: Program for


Rectangle/Triple/Oblique/Rectangular
side/Double/V- Notch side/Radius

Insert Reference Point

Add Machine Clamp

Auto Calculation of Machine Clamps

Utilities: New/Open/Save/Cut/Copy/Paste
Print Job Sheet

Undo/Re-Do

Convert Pattern of Holes into Line/Arc/Grid of


Holes (allows use of macros)
Delete (geometry and/or tooling)

Modify – allows modification of existing tooling

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Chapter I – Introduction

Modify all – allows modification of all


selected tooling (useful for etching definition)
Explode – Defined once: Breaks part/hole
grid association.
Defined twice: Breaks tooling down into
separate tooling hits.
Measure Tool

Sheet Size Definition

Insert Sub Program

Sort Block

Insert Geometry File/IGA (SDD)

Move/Mirror/Rotate/Copy of Entities (e.g.


sub programs)

NC Generation

Automatic Tooling (A.K.A. Shuttle Jobs)

Display Nesting Information (manual nesting


and automatic nesting clearance settings)

Define Internal Sub Program (used to


enter/exit sub program via sheet program)
NC Viewer/Editor

Sorting of Entities

Joint Management

Delete Double Hits/Cuts

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Chapter I – Introduction

Job View
Tool Bar View Manipulation

Draw Grid

Insert Snap

Real Job Graphics

Show Job View

Show Geometry View

Shears (Machine Option)

Show Clamps

Show Tools Filters (user defined)

Job Simulation

Show Idle Movements

Show Tool Holder

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Chapter II – Guided Exercise

Lesson 2
Guided Exercise
Upon successful completion of this lesson, you will be able to:
 Produce simple sub programs
 Produce nested sheet
 Save NC file for machine transmission

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Chapter II – Guided Exercise

Basic Sub This exercise will offer step by step instructions on the creation of a simple sub
Program program. Following the below instructions to create several basic sub programs
Creation before moving onto sheet creation.

1. Open DB Server then Linea5 (DB Server is often set to run automatically)

2. Import Geometry. Left hand icon (Geometry) will open a


windows explorer window allowing selection of .DXF,
.WKF or .E2 files. Right hand icon (IGA) will open a SDD
window allowing selection of AP100 CAD data.

If using Import Geometry a layer selection filter will also open this allows selection
of all or selected layers. This can be useful to omit layers that do not contain cut
data e.g. dimensions.

3. Square Sheet. Select icon shown and press Square. This will
adjust work area to the envelope dimensions of the part.

Tick Movement and Geometry under the Include section, this will ensure
geometry is snapped to 0, 0 resulting in the smallest possible sub sheet size.

4. Automatic Tooling. Drag a box around geometry (hold left


mouse button) and select icon shown. Press OK.

Ensure all geometry types expect Bend Lines are ticked under Machine
Automatically.

Note: under Advanced, a feature for Machine Edge is available this can be helpful
when using cut to size blanks. Un-ticking this box will not apply any tooling to the
external profile.

5. Save. Select File – Save As. Select save destination and enter file
name as needed. Tick Save Graphics, this allows a useful preview to
be shown when opening the program.

For the purposes of this training school, please create a folder on the desktop in
which to save all Subs, Sheets and NC files.

The above instructions include the minimum number of operations required for
sub program creation. The following additional steps may also be required for
more advanced jobs.

 Turret Tool Check (good practice)


 Manual Tooling (application or modification)
 Process After – Joints, Work Chute, Machine Stop, Part Picking.
 (Manual Sequence (part level)

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Chapter II – Guided Exercise

Basic Sheet 1. Select File – New. Material input window opens automatically.
Creation
2. Sheet Selection. Select Material Type from the Material Library drop
down menu, select Machine Material (Drives M102/G06) e.g. SPC, AL
or SUS for punch and assist gas/lens selection for laser. Select
Thickness (type in Thickness for Punch) and type in sheet size in the
Length/Width fields.

Figure 1

3. Insert Sub-Program. Select icon shown, locate sub program and


select Insert. Within the Insert Program dialogue it is possible
to automatically position the part (bottom left corner) by
inputting values into the X Pos/ Y Pos fields.

4. (If required) Move Sub-Program to provide material border. Sub


program can be moved by dragging (hold left mouse button

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Chapter II – Guided Exercise

when hand icon shows) or selecting Display Nesting Information


(icon shown) and typing X/Y location (bottom left corner).

5. (Laser only) Clearance Settings. Select Display Nesting Information


and enter part spacing in the CL field. This will be the distance between
nested parts.

6. Nest Sub Programs. Drag box (left mouse button) around sub
program and select icon shown. Select Auto, (Punch only) Enter
part clearance values in Vertical and Horizontal Frame, tick See and
select OK.

Figure 2

To edit a grid of parts, double click on any one of the child parts and the copy
window shown in Figure 2 will open and allow editing.

7. (Laser only) Sequencing. Select Sorting of Entities, Select


Automatic tab, specify Start Position, Horizontal or
Vertical Grid (alter strip is require) and select Sort
Automatically (icon shown). Further detail is found in
Chapter 7 – Automatic Sorting.

8. (Punch only) Turret Check. Select Set – Tools – Turret. Select


Check, load in displayed tools by selecting free station in turret window
and selecting Add.

9. Generate NC. Select icon shown, select OK.

(Punch only) Select Simple Sorting or Exploding Path All under


Job Sorting before selecting OK.

Within Post Processor select NC style required Macro, Sub


programs (old machines) or Single Elements.
(Laser Only) Tick Use Shape.

(Optional) Tick Job List – this outputs useful reference information at the
top of the NC code in brackets. This includes tooling and material used.

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Chapter II – Guided Exercise

(Laser Only)

Single Elements: Uncondensed full length standard NC code.

Macro: NC code is greatly condensed using G93/98 part macros in which a code
for one part is output with a G93/98 code (plus a repeat command line) stating
amount and positions of child parts.

Sub Programs: the sheet NC will reference separate NC files for each part used
on old Fanuc machines.

Use Shape: Enables Shape Macros, condenses NC code by replacing programs


for lines and arcs that make up holes into single lines e.g. G111 will specify the
size/angle of a square/rectangle.

10. Simulation. Press F4, a simulation window opens. Select icon


shown from the view toolbar. Set playback Speed % and press
Play.

It is good practice to access simulation via Reverse Post Processor (Pressing


F4). This reads the NC code directly giving a more reliable simulation, this mode
also allows the NC code to be played alongside simulation with Associated NC
(useful for trouble shooting).

11. Save. Select File – Save As. Again select save destination and enter file
name as needed. This will save the NC file generated as well as the
Linea5 program for the sheet.

It may be useful to add sheet size to the end of your sheet program file names to
quickly differentiate between sheet and sub linea5 files (.PAR).

To save the NC file only instead select File – Save NC.

Congratulations you have completed your first Sheet program with Linea5.
Please create several sheets first with a single sub program per sheet and then
with multiple sub programs per sheet before continuing.

As before The above instructions include the minimum number of operations


required for sheet creation. The following additional steps may also be required
for more advanced jobs.

 Manual Sequencing (Important for laser programs)


 Stack Table for unload

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Chapter III – Punch Tooling and Turret Set up

Editing Sub If you wish to modify a sub programs this is possible directly through the
Programs sheet program. To enter the sub program double click on the sub
program. The shown icon will then depress, once changes have been made to
the sub program select the icon shown to return to the sheet either updating
with changes or discarding changes.

If changes have been it is necessary to re-run and save the NC code (Step 7
onwards above).

If this feature does not work the association to the sub program has been broken,
this will have been caused by exploding sub programs and to resolve the sheet will
need recreating.

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Chapter III – Punch Tooling and Turret Set up

Lesson 3
Punch Tooling & Turret Set up
Upon successful completion of this lesson, you will be able to:
 Add standard tooling to library
 Add special/forming tooling to library
 Populate and manage turret

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Chapter III – Punch Tooling and Turret Set up

Tooling To compile a tooling library with standard tools follow the below steps. Please
Library – create several standard different tools as practice.
Standard
Tooling
1. Select Set – Tools – Library (from top menu bar). The window
shown in Figure 3 will display.

Figure 3

2. Select Add. The window shown in Figure 4 will display

Figure 4

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Chapter III – Punch Tooling and Turret Set up

3. Type. Select the Tool Type required.

4. Dimensions. Enter as required in Dim fields.

5. Size. Select tool station size as needed in Guide drop down.

Station Size Range


A 1.6 - 12.7
B 12.8 – 31.7
C 31.8 – 50.8
D 50.9 – 88.9
E 89 – 114.3
Table 1

Auto Index notations: G – B Station H – C Station

6. M-Code. Enter Postprocessor Code, default M500.

Mode M-Code
Standard 500
Roofline 501
510-517, 568-569,
Forming
800-999
Marking 560-567, 574-575
Knockout 502-505, 570-573
Slitting 506-509
Nibbling 12
NEX 696
Table 2

Note: For slitting most customers will use M500 or M501 only.

7. Quantity. Enter number of tools owned in Quantity field.

8. (Optional) Advanced Tool Type. Allows selection of special tool type e.g.
Hemming, P&F (up-form ram), Slotting. This feature adds additional NC
codes such as M08 for forming, this code causes the tool hover height to
increase reducing chance of sheet wraps, but increasing process time.

9. (Optional) Forming Tool. Check for forming tool simply providing a quick
user reference.

10. (Optional) Lubricated Tool. Checking this box enables air blow to be
outputted either side of the tool within the NC (M690/691).

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Chapter III – Punch Tooling and Turret Set up

11. (Optional) Multi-tool. Allows use in tool adapter. The item is an adapter
for large tooling stations allowing several small station tools to be fitted
within one large station.

12. (Optional) Technology. This Technology tab contains several settings


including max nibbling pitch and maximum sheet thickness. Holding time
can also be used to apply M08/M09 commands for forming/tapping
tools.

13. (Optional) Sorting. The Sorting tab allows a tool specific process
direction, this can be useful for louvers to constrain sorting to one
direction only to prevent sheet wraps.

LDP, UDP and Priority are not relevant to Amada machines.

Within the Virtual Tool Library tools can be displayed in groups according to
size, type etc by selecting the column heading. Columns can be customized using
the Settings button.

Simple Edit and Remove options enable the library to be easily updated.

Load/Save within the Tool Library creates an individual tooling library backup to
be created rather than having to restore globally using a .CCF file.

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Chapter III – Punch Tooling and Turret Set up

Tooling To add special and forming tool first either use AP100 to register the tools
Library – geometry as explained in the AP100 Training School Manual or prepare a
Special .DXF/.WKF of tooling geometry including tool center point. If registered with
Tooling AP100, the geometry must be registered as a special (SP) to the SDD not a
forming (FM) for linea5 to recognize.

Differences with adding special tools include are listed below

1. Select Tool Type as Special Tool (magenta triangle symbol)


2. Select SDD under Logical Name and select geometry from SDD special
tooling library.

Alternatively select Browse (… icon) under File and a .DXF or .WKF can be used.

3. Ensure Postprocessor Code is changed unless tool is standard M500


hit.

4. (Optional) If tool is symmetrical tick Mirror (Technology tab) enter 90,


180, 270 to prevent unneeded auto index rotation and potential ‘tooling
not found’ errors, when tool is in standard keyed station.

Figure 5

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Chapter III – Punch Tooling and Turret Set up

Populating Once tooling has been created a standard turret should ideally then be created.
Turret This turret will contain commonly used tools fixed to a particular station and have
a small bank of free stations for additional tools to be added as required. Linea5
can automatically add tooling to turret; however it is better practice to control
this manually with help from the Check and Lock features.

The Check feature within the turret window will display a list of tools not added
to the current turret layout allowing these tools to then be added to preferred
station. This must be done prior to NC Generation for every sheet to ensure
the correct station numbers are output. It is also good practice to run the Check
tool in sub program, this can help to prevent potential problems on the sheet
stage with lack of free stations (particularly auto index).

The Lock feature allows stations to be fixed preventing Linea5 automatically


swapping the tool, this enables a standard turret layout to be easily maintained.

Once created turret layouts can be saved and loaded (Save and Load), this can
be very useful as either back up or switching between multiple common layouts
used. Both options use the standard intuitive windows explorer to create/access
the .TRF file.

To add punch tooling to turret

1. Select Set – Tools – Turret, the window shown in Figure 6 will open.

Figure 6

2. Select Station either via Tool Turret table or Turret image (on right
hand side).

3. Select Add. All in stock tooling present of that station size will display in
a new window.

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Chapter III – Punch Tooling and Turret Set up

4. Type in Loading Angle and select Load.

5. (Optional) If the station is part of standard turret layout with the tool still
highlighted select Lock.

6. (Optional) Once a standard turret has been created, save for records by
selecting Save and providing File Name and save destination.

Remove – removes selected tool from turret only (holding Ctrl allows multiple
selection).

Clear – empties entire turret, a confirmation message will appear before clearing
turret.

The following colours are used in the turret window to display station status

Red – In use in program

Yellow – Station occupied

Green – Free Station

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Chapter IV – Common Line Cutting

Lesson 4
Common Line Cutting
Upon successful completion of this lesson, you will be able to:
 Produce a common line program
 Save NC file for machine transmission

Common line cutting allows maximum sheet utilisation and shorter process time
due to sharing cuts between parts. It is important to realise this technique results
in cutting over cut parts and leaves a weak sheet skeleton. So a degree of risk
exists e.g. laser head collisions, sheet wrap ups and scrap. Therefore this
programming style will be your own risk.

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Chapter IV – Common Line Cutting

Common The procedure for common line cutting is different to standard nesting in that we
Line Cutting do not have a sub program level and nested geometry is tooled on mass due to
(Laser Only) shared tooling between parts.

1. Select File – New. Material input window opens automatically.

2. Sheet Selection. Select Material Type from the Material Library drop
down menu, select Machine Material (Drives M102) e.g. assist gas
selection for laser. Select Thickness and type in sheet size in the
Length/Width fields.

3. Import CAD Geometry. Left hand icon (Geometry) will


open a windows explorer window allowing selection of
.DXF, .WKF or .E2 files. Right hand icon (IGA) will open a
SDD window allowing selection of AP100 CAD data.

4. (If required) Move Geometry to provide material border. Sub


program can be moved by dragging (hold left mouse button) or
selecting Display Nesting Information (icon shown) and typing X/Y
location (bottom left corner).

5. Clearance Setting. Draw window around geometry (turns green)


and Select Display Nesting Information and (laser) press
icon shown. This will set the distance between nested parts to
laser beam width (0.20mm).

6. Nest geometry. Drag box (left mouse button) around geometry


program and select icon shown. Select Auto, tick See and
select OK.

To add joints to a laser common line program an internal sub program is required.
Double click on a part and the icon shown becomes highlighted, add
joints as required (see Lesson 6) then press the icon shown to return to
sheet.

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Chapter IV – Common Line Cutting

For common line application it is recommended to common line cut in one


direction only, then leaving reasonable spacing between banks of parts, this helps
provide increased sheet strength reducing machine risk associated with common
line cutting particularly for machines with moving bed.

Figure 7

7. Automatic Tooling. Drag a box around all geometry (hold left


mouse button) and select icon shown. Tick Laser Common
Cuts, Press OK.

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Chapter IV – Common Line Cutting

We can control advanced options specific to laser common line cutting via
selecting Settings – Common Cut Parameters (tab) under the Shuttle Jobs
(Automatic Tooling). Options are outlined below.

Figure 8

Path Direction- Direction of the tool path

Start - The corner of the sheet from which common cuts (or skeleton cuts) are
started

Direction - Cutting direction order

Pre-Cutting - Size of the preliminary cuts required to cut common edges or the
skeleton

Start Again - The length by which common or skeleton cuts overlap preliminary
cuts

Skeleton Cut Exit - Over-cut of lead-outs during skeleton cutting

Lead In on Overlap - Creates a new lead-in when common cuts must overlap
previous

Internal Cuts First - Internal profiles are cut before common edges, if any

Switch Beam Off for Pre-Cutting - Switches off the laser, when passing over
preliminary cuts (rapid move). Deselect the option if you wish to keep the beam on
and machine will move at standard speed

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Chapter IV – Common Line Cutting

8. Generate NC. Select icon shown, select OK.

Within Post Processor select NC style required Macro or Single


Elements and Tick Use Shape.

9. Simulation. Press F4, a simulation window opens. Select icon


shown from the view toolbar. Set playback Speed % and press
Play.

10. Save. Select File – Save As. Select save destination and enter file
name as needed. This will save the NC file generated as well as the
Linea5 program for the sheet.

Congratulations you have completed your common line program with Linea5.

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Chapter IV – Common Line Cutting

Common To produce a common line punch program follow the below procedure. Note:
Line Cutting Punch common line cutting programs do require a sub program.
(Punch)
1. Select File – New. Material input window opens automatically.

2. Sheet Selection. Select Material Type from the Material Library drop
down menu, select Machine Material (Drives G06) e.g. SPC, AL or SUS
for punch. Type in Thickness and type in sheet size in the
Length/Width fields.

12. Insert Completed Sub-Program. Select icon shown, locate sub


program and select Insert. Within the Insert Program dialogue
it is possible to automatically position the part (bottom left
corner) by inputting values into the X Pos/ Y Pos fields.

3. (If required) Move Sub-Program to provide material border. Sub


program can be moved by dragging (hold left mouse button) or selecting
Display Nesting Information (icon shown) and typing X/Y location
(bottom left corner).

4. Nest Sub Program. Drag box (left mouse button) around


geometry program and select icon shown. Select Auto, tick See
the window shown in Figure 9 will display.

Figure 9

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Chapter IV – Common Line Cutting

It is recommended for apply common line cutting in one direction only, then
leaving reasonable spacing between banks of parts (see

Figure 7) , this helps provide increased sheet strength reducing machine risk
associated with common line cutting particularly for machines with moving
bed.

5. Set Common Line Tooling. In window shown in Figure 10 tick whether


common line cutting in vertical and/or horizontal direction.

6. Generate NC. Select icon shown, select OK.

(Punch only) Select Exploding Path All under Job Sorting before
selecting OK.

11. Simulation. Press F4, a simulation window opens. Select icon


shown from the view toolbar. Set playback Speed % and press
Play.

12. Save. Select File – Save As. Select save destination and enter file
name as needed. This will save the NC file generated as well as the
Linea5 program for the sheet.

Congratulations you have completed your first common line punch program with
Linea5.

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Chapter V – Material Library Set Up

Lesson 5
Material Library Set up
Upon successful completion of this lesson, you will be able to
manage:
 Material Library
 Machine Material Library
 Laser Database (Laser/Combination only)

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Chapter V – Material Library Set Up

Introduction Linea5 uses two material related libraries for punch and three for laser/
combination machines, each is explained below. All libraries are located in the
Set menu.

Upon installation your software will be loaded with appropriate materials and
processing information (imported from machine for lasers). However it is
important to be aware of these libraries enabling settings to be added, edited or
removed to suit needs.

Material This library (shown in Figure 10) contains basic material types, which can be later
Library linked to machine process settings within the Machine Material Settings and
Settings Laser Database.

Figure 10

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Chapter V – Material Library Set Up

The library is intuitive to use, simply select Add to create new material types or
Edit to modify. Either option will open the window shown in Figure 11 . The
only field required is Material Code; other fields can be used for the users
reference or if scrap calculation values are to used.

Figure 11

Machine This library links the Material Library to the punches machines material
Material address line (G06). For each instance in the Material Library a Machine
Settings Material instance must be created.
Punch

Figure 12

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Chapter V – Material Library Set Up

Again simply select Add to create new material types or Edit to modify. Either
option will open the window shown in Figure 13.

Figure 13

To add a new machine material

1. Select Add
2. Select the Material Code (this links from the Material Library)
3. Type a Material Name (usually a duplicate of code unless combi)
4. Enter Postprocessor Code this will output the G06 B value at the top
of the NC code. This should be set as shown in Table 3.

Machine G06 B
Material
SPC 0
SUS 1
AL 2
Table 3

5. (Optional) Enter Critical Thickness (default 0mm).

Critical Thickness: When this threshold value (of sheet thickness) is exceeded M08
codes are applied to all tooling lines. This code reduces the machines strike rate
and slows the acceleration of the ram. If this is not wanted set critical thickness
to 0mm.

Punch machines (excluding combination machines) only need Material Library


and Machine Material Settings, the remainder of this lesson can be ignored.

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Chapter V – Material Library Set Up

Machine This library links the Material Library to the machines material address line
Material (M102). For each instance in the Material Library a Machine Material
Settings instance must be created. For laser machines only steps 1-3 (Machine Material
Laser Library - Punch) are required, for combination machines all five steps are still
required. When importing cut conditions from the laser machine, machine
materials will be automatically created if not present.

The difference at this point for laser/combination machines will be the Material
Name, for every cut condition related to each material code a Material Name
will be added. For example for SUS (stainless steel) a Material Name instance
should be create for at least Compressed Air and Nitrogen (clean cut). A simple
example of a completed laser Machine Material Library is shown in Figure
14.

This library may also contain an option for lens size, WACS and eco cut nozzle
depending on machine and nature of work i.e. amount of laser cut conditions
used. A table of material type and cut condition acronyms follows.

Figure 14

For combination machines information must be added for laser and punch
material address lines. The Machine Material library should be the same as for
standalone lasers, but with Post Processor (and Critical Thickness if wanted)
entered for the punch.

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Chapter V – Material Library Set Up

Standard
Material
Types Abbreviation Description

A1050 Aluminium - 1000 series

A5052 Aluminium - 5000 series

SECC Mild Steel - Zintec

SPC Mild Steel - Cold Rolled

SGC Mild Steel - Galvanised

SPH Mild Steel - Hot Rolled

SS400 Mild Steel - Plate

SUS Stainless Steel

SUS316 Stainless Steel Grade 316

Table 4

Fanuc
Process Abbreviation Description M102 Example
Condition
Notations A Air Cut A-SUS1.0

C Clean Cut (Nitrogen) C-SPC1.0

Easy Cut
E E-SPC1.0
(Machine Option)

Oxygen SPC1.0

High Pressure Assist


H C-SPC1.0H
Gas (>1.0MPa)

5” Lens C-SPC1.0

S 7.5” Lens SPC1.0S

T 10” SS40022T

W WACS SS40015.0SW

E Eco Nozzle (1.2mm) SPC1.0E

Table 5

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Chapter V – Material Library Set Up

Laser Contained within Set – Database Laser, this library includes all cut conditions
Database (imported from the machine) and settings to control the automatic tooling of
laser profiles (Shuttle Jobs preferences) and advanced machine functions such as
film pierce.

Note: Values displayed within software do not control the physical cutting on the
machine; the software only outputs the M102, which is looked up under the Cond.
shield on the machine itself.

Figure 15

Within the JKF tab (see Figure 15) imported cut data is shown, this can be useful
for reference providing this has not been altered on the machine.

The top table shown is cut data; this consists of 10 cut lines (e-lines). E01-E04 are
default cut lines with E04 being quickest (see Feed column, units mm/min). E05-
E09 are reference lines useful for testing and E10 is used for etching. The lower
tables are pierce data and edge/approach data.

To add a new cut condition you can either import all cut conditions via Open or
add a new cut condition without actual machine data via Add, with this option
you must select Material from a drop down of Machine Materials and type a
Thickness. With either option you must ensure the M102 field (highlighted in
Figure 15) is completed as required. The contents of this field will be outputted
into the NC code.

An Amada engineer will set important values as a base for the following settings.
However it is useful to be capable of updating as required. This data will also be
recorded when creating Linea5 backup files (.ccf).

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Automatic The Cutting Conditions tab is very important to ensure laser paths are output
Tooling on the correct cut line (e-line). By default Linea5 will output all data on line E01
Preferences resulting in an unnecessarily slow program if not changed. Within this feature
- Cutting size limits can be set for each cut line as shown in Figure 16, this can be further
Conditions defined for profile type e.g. rectangle, circles etc. As shown in Figure 16 9999 is
set for E04, this will ensure all geometry above 50mm (E03 setting) will be
outputted on maximum cut speed.

Figure 16

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Chapter V – Material Library Set Up

Advanced Within the Extra tab it is also possible to control useful data relating to lead ins
Preferences and lead outs, such as length, angle and style.
Lead in/out
(Extra)

Figure 17

Automatic The Scrap tab enables automatic work chute set up. This is activated by
Work Chute entering min/max X/Y sizes for scrap. When a hole is within these limits a work
Operation chute command will be outputted (M180). It is important to ensure Head Up is
(Scrap) selected (prevents head collisions).

Under NC Workchute it is also possible to deselect M180 (machine work chute


macro) and instead output a manual M80 G04 M81 (Open, Dwell in seconds,
Close). Please note laser machines include a drop sensor, so M180 are usually
output for a more efficient program.

Automatic Also within the Scrap tab an automatic setting for machine stop (M00) based on
Machine size is available. By default this setting is active for all geometry, therefore it is
Stop (Scrap) necessary to alter Scrap Dimensions for Machine Stop to zero (unless wanted).

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Chapter V – Material Library Set Up

Plastic Plastic pierce is used to blow a hole in protective plastic film either at pierce
Pierce locations only or pierce locations and full cut profiles. This increases process time
(Non-AMNC but reduces chance of plastic film either peeling away at edges or melting
machines) (becoming harder to remove). With newer machines particularly when using
laser film it is generally not necessary to perform this additional process. For
AMNC machines this method is not used, the program is output as normal and on
the machine a M135 pierce is applied to the program.

To use this feature first tick Film Piercing within Extra tab shown in Figure 17
and type in the program loaded into the machine (usually O6999). This program
must first be set up under instruction from the machine hotline.

Figure 18

Once set up within Laser Database, the option can be activated when
generating the NC code (Job Sorting and NC Generation) by ticking
Piercing or Cut under Film as shown in Figure 19.

Figure 19

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Chapter V – Material Library Set Up

Colour The final tab within Laser Database that is frequently used is Colours; this
Options changes graphics according to cut line assignment. It is useful to customize these
settings in order to have a quick visual cue to provide reference to the machines
settings over varying geometry.

Figure 20

Copy Option Once a cut condition has been fully set up across these tabs (Cutting Conditions,
Scrap, Colours etc) it is possible to copy these settings to another cut condition.
To do select the completed cut condition, select Copy, then select cut condition
to copy to. This can save a great deal of time if many changes are required.

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Chapter VI – Additional Functions

Lesson 6
Additional Features
Upon successful completion of this lesson, you will be able to
manage/use:
 Joint Management
 Work Chute/Machine Stop Definition
 Advanced Laser Tooling including etch assignment
 Advanced Punch Tooling (Anchor Feature)
 Automatic Tool Preferences – Punch
 Manual Nesting
 Automatic Reposition Control
 Job Print out
 Backup/Restore Features
 Automatic E-mail Notification

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Chapter VI – Additional Functions

Joint Wire joints (applied to line) and micro joints (applied to corner) can be
Management added via the Joint Management tool (icon shown). By ticking
(V14 onwards) Insert Micro Joints and entering a joint size (Microjoint
Thickness), joints can be added by directly simply by left clicking on required
position along path.

Figure 21

Two graphical symbols are used to denote whether a wire joint or micro joint
(corner joint) are added. Both symbols appear automatically when moving the
mouse over a corner or line/arc, see Figure 22.

Figure 22

Joints must be added to Sub Programs rather than at Sheet level. If applying to a
laser common line cutting program, double click on the bank of parts and an
internal sub program will be created/open. Apply joints as needed and
then return to sheet with icon shown.

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Chapter VI – Additional Functions

To prevent an additional laser pierce it is possible to use the existing pierce/lead


in of the path. To apply left click on the existing lead in and a joint will be added
to the end of the path. It is also possible to change the lead in position at the
same time as applying joint by ticking Move Lead In and again left clicking in
desired location, the lead in will move with a joint affixed.

To delete a laser joint holding Shift hover over the joint (the joint icon will change
to include a circle around the symbol) left click and the joint will be removed. It
is then possible to simply reapply in new position if required.

To delete punch joints to remove joint Undo can be used or tooling can be
manually adjusted.

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Chapter VI – Additional Functions

Work Chute / Work chute/machine stop commands can be applied to parts or large holes to
Machine Stop
prevent the need for applying joints/tags.
Command
To apply double click on tooling which requires work chute or machine stop; the
Technology window shown in Figure 23 will open, the Stop field (highlighted)
contains three icons, the left hand icon activates Work Chute, the central icon
inputs a Machine Stop line and the right hand icon takes No Action.
Select the required option and additional NC lines will be added after
cutting/punching e.g. M00 for machine stop or M180 for work chute. Once the
Work Chute icon has been selected it is also necessary to select the Chutes
button (at base of window) and adjust position of part as required Manual
Nesting.

Figure 23

If using the Work Chute option with laser machine it is important to ensure the
start/end point is on the correct side of work chute to ensure the majority of the
part (and its cog) is over the work chute, this ensures the part will fall down the
chute. To ensure this practice, it becomes necessary to create separate sub
programs for the same part if used at different orientation with the difference
being the start/end point.

As shown in Figure 24, (for laser) the start/end point should be on the right hand
side of the part. This is due to the work chute be situated on the right hand side
of the machine bed graphic shown on Linea5 and the work chute hinging on the
right hand side.

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Chapter VI – Additional Functions

Figure 24

To change the start point within the sub program, select Sorting of
Entities (icon shown); then select Change Start Point. Next left click
on path at location required.

Figure 25

For punch application it is important to also ensure process order of tooling hits
to allow parts to fall down the work chute safely i.e. the final hits being on the
right hand side of the part, so the majority of the part is over the work chute.
This can be achieved via sorting in several ways using automatic settings with
relevant start point, using priorities, manually sorting or using sort blocks (topics
all covered in Lesson 7).
The final step is to position the part over the work chute. After selecting the
chute icon, select Chute (at base of Technology window) and drag the chute
so the part is within the work chute represented by a red square or rectangle and
press OK, see Figure 26.

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Chapter VI – Additional Functions

Figure 26

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Chapter VI – Additional Functions

Advanced After tooling automatically it is possible to then adjust tooling manually e.g.
Laser changing E-line, lead in size etc. If this method is being used regularly it may be
Tooling helpful to simply update the Extra tab within Laser Database to adjust
automatic tooling preferences.

To edit a single profile as with Work Chute/Machine Stop definition double click
the laser path to open the Technology window shown in Figure 16 and select
Menu Cut, this will open the window shown in Figure 27. Options within this
field are explained below.

Figure 27

 Head Control – set whether laser head stays down (at nozzle gap
height) or returns to machines hover height (the Z height is set within the
Scrap tab in the Laser Database under Gap between Idle Field).
Linea5 defaults to head up as this is a safer, more reliable setting
although slower. NC can be output with head up and managed on
machine to head up, partial retract, ping pong (stand alone lasers).

 Lead in Point - alters between lead in applied to corner or along line.


If corner is used lead in angle defaults to 180°. Fraction of tract is
distance from line/arc start point.

 Lead in – allows lead in style, length, angle and radius (if applicable) to
be adjusted.

 Corner Type – corner loops or radiused corners can be automatically


applied to corners above threshold angle. Corner loops can also be
added manually via Sorting of Entities (Lesson 7) this method is more
reliable and provides greater control.

Figure 28

 Exit – adds a lead out of specified type, size and angle.

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Chapter VI – Additional Functions

 Film Cutting – Applies film cutting, if used in conjunction with film


cutting options in NC Generation (and set up within laser database).
 Pierce – Alter pierce type used, default M103. Pierces can be globally
managed on the machine, although it may be useful to manage individual
pierces via software.
 Lead in E Value – allows differed E line for lead in, defaults on Auto.
 Cut E Value – changes cutting E line e.g. E01-E10.

Beam Beam compensation can be altered within the Technology window


Compensati- shown in Figure 23 under Compensation (shown icons). These
on options allow the laser beam to offset to ensure inner and outer profiles are to
size. The central option turns off compensation, if used parts will be around
0.20mm under sized and no G41/42 NC lines will be present. The larger Profile
window which accompanies the Technology window allows the cutting
direction to be seen or edited.

Applying To define etching the Cut E Value must be changed via the Laser
Etching Technology window explained above. However to ensure an efficient
procedure multiple entities laser technology can be edited on mass.

This is possible by first dragging a box around the incorrectly tooled


geometry to select. Next select the icon shown and change as normal,
select Menu Cut, change Cut E Value to 10 and press OK twice to
return to nest screen. The graphics should update in accordance with colours set
for E10 within Laser Database – Colours.

Advanced To change punch tooling (within sub program) follow the below procedure
Punch
Tooling – 1. Double click tooling to open the Technology window
Changing 2. Select Tooling Library (Libr.) or Turret under Tools.
Tooling 3. Select Available Tools (icon shown), tools available in of
tool type selected will display
4. Select tool to be used and press OK
5. Press OK on larger Cut window

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Chapter VI – Additional Functions

Advanced The below procedure demonstrates manual punch tool assignment using the
Punch Anchor Function, this allows geometry to be snapped to rather than inputting X/Y
Tooling – Co-ordinates. A standard round is used in this example.
Anchor
Feature When you are manually tooling a part, you can use the anchor function to locate
a tool exactly into a corner, onto a hole, along the length of a part, etc.

1. Press Program for a Hole, icon shown

2. Double click tooling (whilst hand icon displays) to open Technology


menu.

3. Select the tool required from your turret or library to do this


select Available Tools, icon shown. The tool will appear at
coordinates specified (tool will show with a yellow centre cross), zoom out
to ensure tool is visible to allow selection.

4. Press the Anchor icon shown.

5. Select the tooling hit (a cross hair symbol displays)

6. Select the geometry to snap to (a paper clip symbol displays), the tool hit
will snap to selected geometry (X, Y field will also update).

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Chapter VI – Additional Functions

Manual To apply tooling to a complete or partial profile e.g. nibbling/slitting follow the
Punch below procedure.
Tooling for
Profile 1. Press Program for a Profile, icon shown

2. Double click tooling (whilst hand icon displays) to open Technology


menu.

3. Select the tool required from your turret or library to do this


select Available Tools, icon shown. The tool will appear at
coordinates specified (tool will show with a yellow centre cross), zoom out
to ensure tool is visible to allow selection.

4. Select Punch for Slitting (automatic pitch control) or Nibbling for


nibbling (manual pitch control).

5. Select Profile option require from


Profile window (icons shown).

Options from left to right: Complete Profile, Partial Profile – Edge


Selection, Partial Profile – Start/Finish Point, Partial Profile – Start/Finish
Point Adv (including option to overlap breaks along profile).

6. Select profile/line required when cross hair cursor appears. Selecting the
inside of the profile places tools inside profile (holes), selecting outside
places tooling on outside (part outer profiles).

7. Press OK within Profile window.

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Chapter VI – Additional Functions

Automatic Found within the Settings button at the bottom of Shuttle Jobs (Automatic
Punch Tooling) punch tooling preferences can be set in the same way as laser tooling
Tooling preferences are controlled within the Laser Database (as already covered).
Preferences These settings are usually left as default values, although there are several
potentially useful settings present.

Identification of tolerance for single allows a global tooling tolerance


(single hit), this can be useful if quality is not critical and tooling for example
which may be 0.1mm larger than geometry will automatically be used rather than
a slow nibbling process.

Scrap destroy options can be used to automatically destroy the centres of large
holes (up to Max Size set) rather than nibbling around the profile and leaving a
large floating piece of scrap, which would require tagging.

Within the Profile Settings tab master on/offs for the automated tooling of
crucifix and triangular tooling are present, so if these special tools are used for
automatic tooling to apply, these settings must be activated.

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Chapter VI – Additional Functions

Manual Display Nesting Information (icon shown) can be used to manually


Nesting move and rotate parts manually. This window also contains several
manual nesting features. Features are explained below

Figure 29

X/Y: Coordinates of chosen element, this field enables new coordinates to be


entered to move parts/tooling/clamps.

Ang: Angle of chosen element, this field enables a new angle to be entered to
move parts/tooling. Alternatively the second row of icons contains four arrows
to rotate at 45°, 90° or 180°, CW or CCW.

Step: Entering a fixed value e.g. 5mm in this field enables parts to be moved by
5mm steps using the 4 arrow buttons at the bottom of the window.

CL: Clearance value used to separate nested parts, when using Copy Selected
Entities or Checker tools.

Part Interference Checker: If parts are moved to an overlapping


position parts will snap to the clearance amount set in CL.

Sheet Position Checker: Prevents parts being moved outside of


sheet area, parts snap to clearance amount set in CL.

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Chapter VI – Additional Functions

Clamp Position Checker: Checks clamp interference, parts snap to


clearance amount set in CL.

Automatic Clearance from Database : Sets clearance value to laser


beam width for common line cutting (e.g. 0.20mm).

Mirror along X/Y Plane: Mirrors entities about X or Y plane.

Disable X/Y Movements: Disables X/Y movements, useful


when freely dragging parts.

Connect Job to an Entity: Allows parts/entities to be moved together


according to their clearance value.

Define Sheet Edges: Allows a nesting border to be added around


sheet (Left, Right, Top and Bottom).

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Chapter VI – Additional Functions

Job Pack Linea5 produces a customizable job print out allowing information such a
Printing material used, tooling used, nesting layout, lists of parts and so on. This can be
executed via File – Print, this opens the window shown in Figure 30 where
items to be included can be checked. Upon initial use Print Preview can be
helpful to set up items desired.

To change from Windows default printer, select Print Setup this will open
Windows print manager allowing printer selection and set up.

Figure 30

To backup print out options select Save cfg. and provide file name and location,
Load cfg. can be used to restore these settings. These settings are not saved
within the system backup .ccf file.

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Chapter VI – Additional Functions

Automatic If applicable to machine used, when a nest exceeds machine work area a
Reposition reposition will automatically occur. Settings controlling the automatic reposition
Control are found within NC Generation – Features (Sort must be ticked). Within
the First Field group it is possible to change the reposition X value from
Maximum. To do this select the Minimum radio button and type in the
reposition value required.

The minimum value entered will form work area one, this area will be machined,
the machine will then reposition, remaining work area will then be machined and
finally the machine will return to home for unloading.

Figure 31

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Chapter VI – Additional Functions

Backup and Linea5 includes a very useful backup and restore feature, backups can be created
Restore to save all settings as well as the current work plan. This includes tooling and
material libraries, but excludes Laser Database.

To create a back up from the top menu bar select Set – Save Settings, this
opens the window shown in Figure 32. Select save destination and enter File
name.

At the base of the window Include Current Program into Configuration File if
ticked allows the current work plan to be saved, this can be useful for sharing
with Amada Support for offline trouble shooting assistance.

It is good practice to routinely create a backup of settings to a mapped network


drive (safer in case of local computer hardware failure). Created .CCF files are
heavily compressed to around 100kb, so can be easily managed.

Figure 32

To restore from a backup select Set – Load Settings, locate file and press
Open. At the base of the window options to load included program and to
overwrite configuration settings are available.

The backup feature, backups the selected machine only not all machines present
on install. Therefore it is necessary to maintain backups for each machine
separately.

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Chapter VI – Additional Functions

Saving It is also recommended to save the punch tooling library in case of potential
Tooling corruption to backup files and to allow independent reloading of the tooling
Library library. To do this select Save button shown Figure 3 (Set – Tooling – Save),
enter file name and save destination.

Saving Laser As stated already the Laser Database is not included in the backup .CCF file, to
Database save the Laser Database select Save within Set – Database Laser, enter file
name and save location.

Automatic A new version 15 feature allows a system backup to be created and emailed to
E-mail
Amada with manually enter email explanation. These can help save time with
Notification
creating an email and manually created a system backup, as well as providing
additional information to Amada Support.

To set up select Help – Notify Errors, this will open the below window. Enter
company name, software@amada.co.uk within the To field and tick Current
Settings option.

To use open the part or nest which has the problem, then select Help – Notify
errors, enter a subject and explanation of the problem on the bottom field then
press Send. Linea5 will then access your mail client e.g. Microsoft Outlook to
send the email, a permission window may appear ensure Allow is selected.

Figure 33

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Chapter VII – Sorting / Sequencing

Lesson 7
Sorting/Sequencing
Upon successful completion of this lesson, you will be able to
assign/edit:
 Manual/Automatic Sequencing Assignment (Sorting)
 Priority Setting
 Punch Sequencing Options (Shuttle Jobs)

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Chapter VII – Sorting / Sequencing

Sorting - Automatic and manual sorting tools can be found within Sorting of
Manual Entities (icon shown).

Manual Sorting (icon shown) can allow a custom process sequence to be assign
either on the sub program at a part level or on the sheet.

Figure 34

Within the Manual Sorting tab there is two sorting options Magic Tool and
Mouse Click. When one of these is ticked the nest display will include red
process order labels on each path/tool (sub program) or each part (sheet).

With Mouse Click select each profile in turn in the order you wish to process,
numbers will update instantly.

Magic Tool can be a quicker tool to use, hold the left mouse button and drag
the magic tool box through each part/profile. To suit the job the magic tool
selection box can be made smaller or larger to allow easy use.

Sorting Order (see top left of Figure 34) changes the first process order
instance to be changed for example if tooling 1-20 are already correct and only
21-30 need altering, change this value to 21 and only select only 21-30. This can
also be helpful if a mistake is made.

Priorities can be a quick and easy way to sort an entire block of tooling or
perhaps one particular tool, by increasing the priority of certain tooling. The
Offset/Layers window will open whenever tooling is selected (left mouse
button), decrease the value in Priority to process sooner. This method can be
helpful for managing work areas and manual sheet cut offs.

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Figure 35

Sort Block (icon shown) allows grouping of a custom defined group of


tooling. First select tooling, select Sort Blocks icon and enter a name
this creates the sort block. Next double click on the group an internal
will open this group can then be sorted easily, once complete return to
the sheet saving changes.

This method is not often used, but can be helpful for punch part picking machines
to increase the length of last hit lines.

It is important to note, if a custom sequence is defined for a punch operations,


ensure the correct Job Sorting option is used, when generating the NC code,
see Shuttle Jobs – Punch Sorting.

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Chapter VII – Sorting / Sequencing

Sorting - To use automatic settings select a Start Point (clamp machines usually work
Automatic towards clamps for sheet strength), select a sort method either a
process direction or nearest job, alter Strip value to sort and finally
press the Sort Automatically icon shown. By altering strip value and again
selecting Sort Automatically icon numbers the sequence can easily be
recalculated.

Figure 36

Within the Sorting window you can also access Change Technology features
Additional
Sorting already explained such as corner types, lead ins/out etc. There are also tick boxes
Functions on the Manual tab these include Change Start Point, Lead in at Mouse
Position and Skip Rips/Idle Runs (for manual idle movement control). As
well as these duplicate controls for Head Control, Priorities and Reverse
Path.

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Chapter VII – Sorting / Sequencing

Shuttle Jobs For punch/combinations machines Shuttle Jobs (a.k.a. NC Generation) also
– Punch contains options that greatly effects sequence order under the Job Sorting group.
Sorting

Figure 37

The Tools button shows a table of all tools used within the program the top of
this table is the first tool to be used. It is possible to move tooling up and down
and also constrain start point and direction (this can be especially useful with
forming tools). If All Fields is checked, each angle of auto index tools will be listed
allowing for sequencing by angle.

Job Sorting options are as follows.

No Sorting – maintains manual sequencing fully and provides no optimisation.

From Configuration File – Not used.

Simple Sorting – basic option maintains manual tooling but ignores sort
blocks.

Simple Sorting with Path Optimisation – this method includes further


optimisation to reduce idle movements.

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Chapter VII – Sorting / Sequencing

Zigzag Path Keeping Sub – keeps sub level sorting and includes process
direction preference.

Zigzag Path Exploding All – explodes all tooling to individual hits before
sorting, this method should provide the most efficient punch processing, but
loses all manual sequencing. Also includes direction preference.

For combination machines, it is also important to note within the Features


button, Skip Laser Jobs when Sorting can be helpful. If checked this allows
laser to be processed as defined manually, whilst punching is considering using
the above listed Job Sorting options.

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Chapter VIII – Advanced Operations

Lesson 8
Advanced Operations
Upon successful completion of this lesson, you will be able to
assign/edit:
 Manual Repositions
 Part Picking/Stacking

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Chapter VIII – Advanced Operations

Manual For advanced jobs it is sometimes necessary to manually add or edit repositions,
Repositions Linea5 allows for this within the Work Areas tab in Sorting. If repositions are
already set these will be listed in the table with X reposition value(s) and blank
holder X/Y values (these are the reposition arms fitted either side of machine
turret). To access Work Areas tab, Ignore Work Areas must be un-ticked
within the Manual tab.

Figure 38

To add a manual reposition complete the following steps

1. Enter Reposition Distance


2. Enter Blank Holder X Dimension, red graphics of holder will show
ensure holders are not over large holes.
3. Enter Blank Holder Y Dimension.
4. Select the Reposition icon shown.
5. (Optional) Set two priorities for each full work area to assign
process order (See Lesson 6).

A new row will be added to the Work Area Management table, clicking on the
new row will display the clamp and work holder positions visually. If either values
are modified, first select the relevant row, make requires changes, then
select Modify Work Area (icon shown).

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Chapter VIII – Advanced Operations

PR / Once your subprogram has been tooled, follow these steps to create a part ready
Stacking for a PR machine.

1. Select last line of slitting (double click, this is generally the lower left of
the part).

2. Within Technology Select the PR icon shown and


select Unload (base of window).

Figure 39

3. Position to ensure adequate suction and balance, using X/Y function or


Arm to move one arm independently.

Ensure arm opening distance (O) is a minimum of 200mm for punch PR or 210mm
for laser/combination PR. It should not be possible to move arms closing together
than these values; you should also notice the arms will snap to a minimum
clearance distance from final tooling line and adjacent part edge.

4. Either select All Cups or manually click on each suction cup to turn on
or off. Green denotes a good connection with the part, yellow illustrates
a potential problem e.g. cup over hole as seen in Figure 39.

5. (Optional) Select Movement Speed and check Lower before


Stacking.

6. (Small parts <400mm) Select Alternative from Pick From, this resets
the part pick window for setting of an alternative picking location. This is
used as an arm B (top arm) layout if location of part on sheet causes over
travel of PR.

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7. Press OK.

8. Save sub program.

9. Within Sheet, select Unloading Device – Unloading (top menu),


window shown in Figure 40 will display.

Figure 40

Stack Window: White recetangle – Table; Blue rectangle – Arm stacking range
(this can vary with part and arm(s) used).

10. Drag parts to stack positions required, selecting Stack Similar Parts
will stack all similar parts. To instead group similar parts into more than
one stack, whilst holding down Ctrl select the amount of stacks required
e.g. 2 then select Stack Similar Parts, similar parts will then be split
between 2 stacks of parts.

11. Press OK.

12. Generate NC code, within Post Processor (second window of NC


Generation) check Use Loading/Unloading and also check Loading
Device on final screen of NC Generation.

It is important to ensure sensor cups of PR have a good suction to prevent


machine alarms, therefore do not place over holes or off the edge of the part.
Your Amada engineer can provide a PR sensor cup layout drawing to suit PR
model.

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Note: Linea5 will add a small red square to the last cut line allowing instant user
recognition of PR defined sub programs.

Figure 41

Automatic Linea5 can automatically tool a part at multiple angles for PR application. This
PR Tooling
technique is used on lasers PR machines.

1. Tool job as normal (Shuttle Jobs). Tick Creating Sub Routines


(under Nesting/Unloading). Select Settings.

Figure 42

2. From Unload Angles, Select 0 from the drop down menu. Select Add.

3. Repeat for 90. Press OK.

4. Set both Inside columns to No Unload, set both Outside columns to


Unloading.

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5. Select the icon shown will display. This will be on the top right of
the nesting display.

6. Check PR positions as normal (Technology) and save sub program.

When importing sub program, it is now possible to select orientation required


using Angle drop down. Each will have defined independent set PR positions.

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Custom Custom stack tables can be easily created and saved allow accurate stacking
Stack Table across varying stack table layouts e.g. 3 side by side Euro pallet layout. To set up
Layout
and apply a custom table layout use the following procedure.

Adding 1. Select Unloading Device – Pallet Type, window shown in Figure 43


Pallet displays.

Figure 43

2. Select Add (top left icon) and enter data as require, see Figure 43.

Version 15 users can alternatively add a CAD .DXF file of exact size/form of pallets
used by select Browse (...) under Shape.

3. Click OK (green tick).


Defining 4. Select Unloading Device – Pallet Diagrams
Table Layout
5. Select Add (top left icon), opens Set Diagram window
6. Select Add (top left icon) again, opens Carrier Position see Figure 44.

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Figure 44

7. In Equipment select Pallet Type e.g. pallet created in step 2.


8. Enter X, Y position on table.
9. Press OK.
10. Repeat steps 6 to 9 to add amount of pallets require.

11. To use new layout when within the stack window (Unloading Device –
Unloading), select Change beneath Pallet Diagram, Select layout
from list and press OK (green tick).

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Chapter VIIII – Advanced Nesting

Lesson 9
Advanced Nesting Tools
Upon successful completion of this lesson, you will be able to
assign/edit:
 Drag & Drop
 Work Plan Manager

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Drag & Drop If a sheet contains several sub programs Drag & Drop can be a helpful
productivity tool. Select Nesting – Drag & Drop for the window shown in
Figure 45 to appear.

Figure 45

The five icons along the left of the window allow sub programs to be added and
removed, the second icon allow multiple sub programs to be added at once to
the Drag & Drop window.

Once sub programs have been added it is possible to drag the preview frames
within the drag & drop window straight onto the sheet.

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Work Plan Work plan manager is a powerful add-in module to the Linea5 package which
Manager automatically created nested sheets.

The following two software variants are available

1. Single Sheet Nesting (basic package: included in standard Linea5


package – may not be included if only upgrading old license)

This nesting package allows sub programs to be nesting automatically across a


single sheet of user defined type, thickness and size

2. Multiple Sheet Nesting (software option: requires additional license)

This package enables a full schedule of sub programs to be automatically


produced across numerous sheets over dissimilar material type/thickness and
sheet size.

To start the Work Plan Manager, select Libraries – Work Plans from the
Linea5 menu bar. It is also possible to create a separate Desktop icon for the
module.

Figure 46

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Tab The software opens in a separate window (see Figure 46) and contains six areas,
Overview which intuitively become accessible as work is completed.

1. Work Plan Manager – allows Work Plan Manager programmes to be


managed or a new program created.

2. Configuration – contains program name field, machine selection


option and various nesting options such as part in part nesting and
common line cutting.

3. Parts – used to import sub programs and assign nesting quantities for
each.

4. Formats – manages assigned sheet sizes/quantities.

5. Nesting – Prior to nesting contains execution of nesting controls


(Single Sheet and Multiple Nesting), post nesting contains all nests
created allowing nests to be viewed/edited.

6. Parts/Format Usage – this tab opens automatically after nesting and


provides report of nesting operation including achieved part quantities
and sheet usage percentage. Also includes print option.

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Work Flow – To produce a Work Plan Manager program follow the below instructions
Configuration
Tab Work Plan Manager/Configuration Tab
1. Select New (Configuration tab automatically opens)
2. Enter program name in Description
3. Select Machine from drop down (for purposes of this training exercise
ensure several sub programs are previously created for machine selected)

Additional options – Configuration Tab

Part Program – options relating to save location, name and file type.

Nesting parameters

Clearance: Distance set between parts

Part in parts: Allows smaller parts to be nested within sufficiently sized inner
profiles

Common Cut: Includes options for standard nesting, common line both
directions and common line horizontal or vertical only.

Last Sheet: Fill allows max quantities to be used (see Parts Tab), Flat End aims
to process a nest which maximises size of a rectangular sheet cut off (applied in
Linea5 or NC Generation), Save Scrap saves the skeleton sheet to the material
format library.

Extract sub copies: copies subroutines within the current job, which is
particularly useful when parts are laid out in a grid (part programs only).

Automatic Nesting Direction: automatically selects the best possible


direction for nesting the current sheet. Enabling this option, MasterNEST
algorithm automatically selects the best nesting path in order to maximize
material yield, ignoring the direction you specified within sheet format.

Repeat: Allows searching for repeatable layouts of parts to improve sheet


utilization. This option is particularly useful to reduce the number of output files
i.e. a 10 sheet job could be 10 different sheet layouts or one common layout.
Two different types of repeats are available: Multiple searches for more layouts
that can be repeated many times to obtain the required number of parts
guaranteeing best sheet utilization. Single searches for a single part layout, which
can be repeated as many times as required. This option is more restrictive and
might make nesting impossible (an error will display).

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Nesting Mode: This setting adjusts the sheet selection decision

Standard selects the first selected format until stock quantity is exhausted before
moving to next format.

Find Best Format Work Plan finds the best sheet size for the overall schedule i.e.
only one sheet size will be used to reduce material handling.

Find Best Formats aims to maximise sheet utilisation producing least scrap but
increases material handling, this option also allows a maximum number of
different sheet sizes allowable.

All Formats: This option will remove the user controlled sheet selection settings.

Tool Check: This option checks if required tools are available in turret layout
loaded. The software will automatically run this command both when
activating/opening an existing work plan and when running the nest. If additional
tools are required revisiting the Tool Check icon will show additional turret layouts
required for the work plan. Please note, this option will increase processing time.

Optimizer: Recommended only for non urgent jobs due to increased processing
time. This tool allows nesting results to be optimised by retrying the operation
several times with different arrangements. These trials are run repeatedly until
all the optimising algorithms have been used. To prevent time-consuming trials,
you can specify the maximum time allowed (seconds) or the acceptable sheet
utilization percentage. When the specified percentage is met, the process is
automatically stopped. The default values should be lowered to improve process
time.

It is possible to request the module to generate grids instead of clusters of parts or


vice versa. Back Tracking allows a greater number of different nesting layouts
to be calculated. This new approach can greatly increase nesting time.

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Parts Tab 1. Select Browse (...) button within File System, locate folder
containing required sub programs. All available sub programs will display
within in the lower window (various filters are present within the tab
which can be used to easily locate sub programs).
2. Double click on each sub program to be nested, the part will appear in
the top table (Assigned Parts)
3. Next left click on the Quantities column and enter require quantities for
each part. Double clicking Quantities column allows all cells to be
entered at once.
4. (Optional) If Fill is selected under the Configuration tab, Max Quantity
can be entered. The last sheet will be automatically filled with additional
parts up to this quantity; a new sheet will not be started if standard
quantities are satisfied.

Figure 47

Trouble Shooting: Parts should be filled with colour as shown in Figure 46 this
shows the software has identified the boundary of the outer profile allowing
correct nesting. It is important to note that sub program containing multiple
outer profiles or containing no geometry will not nest correctly.

If no parts are found within specified folder Linea5 parameter 462 may activating,
this can be done by opening Linea5 then selecting Set – General – Find – 462 and
changing setting to 1. Required sub programs will then require resaving although
no changes are actually required simply open the part and press save.

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Additional options – Parts Tab

Double clicking on each part provides further settings specific to selected part.
This includes allowable rotation (including grain direction) and an important
option for additional sub programs based on rotation angle. To use this option
double click on the Part Program cell and locate sub program required.

To return to the Parts tab select Edit from the ribbon bar.

Format Tab 1. Select New (ribbon bar)


– Method 1 2. Double click on newly created table row
(manual input) 3. Enter Description (Sheet Name), Material Type and Thickness
4. Enter Quantity of sheets available for use (important for multiple sheet
nesting)
5. Under Drawing, tick Rectangular Sheet and enter X Y size
6. Select Start point e.g. top left for clamp machine.
7. Enter desired material border settings under Edge Trim
8. Right click on Clamps window and select Add and enter clamp positions
(pressing enter will add additional clamp)
9. Select Edit (ribbon bar), this will return to the format tab with newly
created sheet present

Figure 48

If border settings are not entered the software will default to current clearance
(CL) value set in Linea5 Display Nesting Information. Therefore it can be faster to
enter only a bottom value for clamp machines.

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Method 2 An alternative method of sheet creation and allocation is to use the Linea5
(automatic Formats Library. This technique adds sheets which can later be automatically
Input) added to future programs so eliminating the need to add sheets manually for
each programme. The below procedure can be followed to use this feature.

Work Plan Manager must be closed to access Formats Library, if a work plan
is in progress select Save when prompted after closing Work Plan Manager.

1. (Linea5) Select Libraries – Formats from the menu bar


2. Select New (ribbon bar)
3. Enter Description (Sheet Name), Material Type and Thickness
4. Enter Quantity of sheets available for use (important for multiple sheet
nesting)
5. Under Dimensions enter X Y size
6. Select Start point e.g. top left for clamp machine
7. Enter desired material border settings under Edge Trim
8. Right click on Clamps window and select Add and enter clamp positions
(pressing enter will add additional clamp)
9. Select Save and Exit from the Amada button (top left), this will return
to the format library tab with newly created sheet present.
10. Repeat steps for each sheet required e.g. material type, thickness and
sheet
11. Close Format Library window
12. (Linea5) Select Libraries – Work Plans from the menu bar

Figure 49

13. Double click on saved work plan from the Work Plan Manager Tab
14. Select Formats tab
15. Select Run, the newly added format will now appear in Available
Formats table
16. Double click sheet to transfer to Assigned Formats (it may be
necessary to alter sheet quantity column)

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Nesting Tab Select either Single Sheet or Multiple Nesting (depending on product
purchased) and then confirm completion message.

Parts/Format Usage tab will automatically open and provide information on


nested quantities, sheets used and sheet utilisation (%). Any parts which have
either not been nested or only partially placed will display as orange and yellow
rows respectively.

From this screen it is possible to use the Print option; this provides a list of
information to be outputted and opens windows print manager to allow printer
selection.

Figure 50

After nesting it is possible to use the Single Sheet Nesting to add additional sheets
to the nesting plan. To do use adjust parts/part quantities if needed and select
Single Sheet Nesting again the below window will open. Add will add an
additional sheet to the nesting plan, re-nest will re-run losing current sheet and
New adds a new sheet to be selected for nesting.

Figure 51

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Figure 52

Final steps to complete full programming procedure

NC 1. Select sheet from left of Nesting tab


Generation 2. Select Edit (Linea5 will now automatically open)
3. Select NC Generation and relating options desired
4. To return to Work Plan Manager, hover cursor over the left of the Linea5
window and select Save and Exit (green floppy disc icon)

It is possible to also complete any Linea5 operations during this time, as well as
further nesting using drop and drag feature automatically enabled.

5. Repeat step 1 to 4 for each sheet in turn


6. Finally to return to the Work Plan Manager tab and exit the current job,
select the Amada icon and select Save and Exit.

Figure 53

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Further Nesting tab options

Manual – this option will enter into Linea5 with a un-nested sheet with drop and
drag enabled on the left of the screen containing parts assigned to Parts tab.

Delete – removes sheet from job

Lock – Disables edit and delete options for selected sheet

Repeats – enables sheet quantity to be changed

Export to CSV – Created a .csv file for use with manufacturing logistics systems

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