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O1
;(FLASHLIGHT BODY--FOR BODY DRW_REV#10)
;(ANDREW HELLIE, WES BROWN, ANDY WOOLEY, GREG PETERSON)
;(STOCK: ALUM 38.1MM DIAMETER X #501 + 10MM)
;(14:00 APRIL 26, 2011)
;
; (TOOLS)
; (T0101 - 80DEG DIAMOND CNMG)
; (T0202)
; (T0303 - OD THREADING)
; (T0404)
; (T0505 - CENTER DRILL)
; (T0606)
; (T0707 - 19MM END MILL)
; (T0808 - INT THREADING TOOL)
; (T0909 - 14.4MM MIN DIAM BORING BAR)
; (T1010 - CUTOFF)
; (T1111)
; (T1212 - 0.5IN DRILL)
;
;(VARIABLES)
#1=1.0     				(THREAD PITCH - MM)
#2=#1 * 0.5/TAN[30.0]   (THREAD HEIGHT)
#3=#2 * 5.0 / 8.0     	(THREAD DEPTH - INT)
#4=3.0      			(NUMBER OF STARTS)
#5=0      				(START NUMBER)
;
#500=38.1 		(STOCK DIAMETER)
#501=73.7  		(STOCK LENGTH)
#502=75.0 		(ROUGING SURFACE SPEED M/MIN)
#503=0.2 		(ROUGHING FEED: MM/REV)
#504=0.05		(FINISHING FEED MM/REV)
#505=32.75		(THREAD MAJOR DIAMETER)
#506=8.45		(THREAD LENGTH)
#507=1500 		(FINISHING SURFACE SPEED M/MIN)
;
;(INTIAL PARAMETERS)
G54			(WORK OFFSET)
G21			(METRIC UNITS)
G50 S2000	(LIMIT SPEED)
G96 S#502	(CONSTANT SURFACE SPEED)
G99			(FEED PER REVOLUTION)
;
;(FACING)
N1
G28 U0 W0
G00 T0101				(80 DEGREE DIAMOND TOOL)
M03						(SPINDLE ON, NORMAL)
G00 X[#500+1.0] Z#501
M08						(COOLANT ON)
G01 X-0.1 F#504 		(FACE FROM OUTSIDE DOWN TO -0.1)
G01 Z[#501+1.0] F1.0 	(MOVE OFF FROM FACE)
M09 					(COOLANT OFF)
M05 					(SPINDLE OFF)
G28 U0 W0 				(GO HOME)
M01 					(OPTIONAL STOP)
;
;
;(ROUGH OD TO +0.5MM)
;(USE 2.0 MM DOC-> xx PASSES)
N2
G00 T0101 (80DEG DIAMOND TOOL, TOOL 1)
G50 S2000 (CLAMP SPEED AT 2000)
G96 S#502 (CONST SURF SPEED)
G99 (FEED PER REV) (RETURN TO R LEVEL IN A FIXED CYCLE)
M03 (SPINDLE ON)
M08 (COOLANT ON)
G00 X[#500 + 0.5] Z#501 (INITIAL POINT FOR ROUGHING)
;
G00 X37.5 Z#501
;
G01 X37.5 Z-3.0 F#503 (FIRST PASS)
G01 X[#500 +0.5] F#503 (RETRACT X)
G00 Z#501 (RETRACT Z)
;
M09 (COOLANT OFF)
M05 (SPINDLE OFF)
G28 U0 W0 (GO HOME)
M01 (OPTIONAL STOP)
;
;
;(FINISH OD TO +0.0MM)
N3
;
G00 T0202 (30DEG DIAMOND TOOL, TOOL 2)
G50 S2000 (CLAMP SPEED AT 2000)
G96 S#507 (CONST SURF SPEED)
G99 (FEED PER REV)
M03 (SPINDLE ON)
M08 (COOLANT ON)
;
G00 X36.0 Z[#501+0.5] 
G01 X36.0 Z#501 F#504
G01 X37.0 Z73.2 F#504
G01 X37.0 Z0.5 F#504
G01 X36.0 Z0.0 F#504
G01 X36.0 Z-1.0 F#504
;
G01 X[#500+1.0] F#504 (RETRACT X)
G00 Z#501 (RETRACT Z)
M09
M05
G28 U0 W0
M01 		(OPTIONAL STOP)
;
;
;(CENTER DRILL)
N4
G00 T0505          	(CENTER DRILL)
G97 S1000	        (CONSTANT SPINDLE SPEED 1000RPM)
G99					(FEED PER REVOLUTION)
M03					(SPINDLE ON, NORMAL)
M08					(COOLANT ON)
G00 X0.0 Z[#501 + 2.0]
G01 X0.0 Z[#501 - 2.0] F0.5
G01 X0.0 Z[#501 + 2.0] F2.0
M09					(COOLANT OFF)
M05					(SPINDLE OFF)
G28 U0 W0
M01
;
;
;(DRILLING)
N5
G00 T1212			(1/2" DRILL)
G97 S1000          	(CONSTANT SPINDLE SPEED 1000RPM)
G99					(FEED PER REVOLUTION)
M03					(SPINDLE ON, NORMAL)
M08					(COOLANT ON)
G00 X0.0 Z[#501 + 5.0]
G83 Z2.0 Q10000 F0.2 
G01 Z[#501+5.0] F2.0
M09					(COOLANT OFF)
M05					(SPINDLE OFF)
G28 U0 W0
M01
;
;
;(BODY ROUGH BORE)
N6
IF [#505 + 2*#3 + 0.1 GE 19.0] GOTO 66
M01  			(ERROR - BORE SMALLER THAN TOOL)
N66
G00 T0707 	        (19MM END MILL)
G96 S#502         	(CONSTANT SURFACE SPEED)
G99					(FEED PER REVOLUTION)
M03					(SPINDLE ON, NORMAL)
M08					(COOLANT ON)
G00 X19.0 Z[#501 + 2.0] (START POINT)
G71 U2.0 R0.5     	(2MM DEPTH OF CUT, 0.5MM RETRACT)
G71 P20 Q25 U-0.7 W0.0 F#503
N20 G00 X[32.67] Z[#501 + 2.0]
    G01 X[32.67] Z[#501] F#504
	G01 X[31.67] Z[71.7] F#504
	G01 X[31.67] Z[63.75] F#504
	G01 X[28.0]  Z[63.75] F#504
	G01 X[27.0]  Z[63.25] F#504
	G01 X[27.0]  Z[2.0]  F#504
N25 G00 U-0.4
M09			(COOLANT OFF)
M05			(SPINDLE OFF)
G28 U0 W0
M01
;
;
;(BODY FINISH BORE)
N7
G00 T0909          (14.4MM MIN DIAM BORING BAR)
G96 S#502
G99
M03			(SPINDLE ON, NORMAL)
M08			(COOLANT ON)
G00 X27.0 Z[#501 + 2.0]
G70 P20 Q25
G00 Z[#501 + 2.0]
M09			(COOLANT OFF)
M05			(SPINDLE OFF)
G28 U0 W0
M01
;
;
;(INTERNAL THREAD)
N8
;
G00 T0808          (INT THREADING TOOL)
G00 X31.67 Z[#501 + 3 * #1 * #4]  (START 3x LEAD AWAY)
G97 S800           (FIXED 800RPM SPEED)
G99                (FEED PER REV)
M03
M08
WHILE [#5 LT #4] DO 1
   G00 X[#505 - #2 * 2] Z[#501 + #1 * #5 + 3 * #1 * #4]
   G76 P040060 Q005 R0.1
   G76 X[#505 + #3/2.0] Z[#501-#506] P[FIX[#3*1000]] Q0200 F[#1 * #4]
   #5 = #5 + 1
END 1
G00 Z[#501+2.0]
M09
M05
G28 U0 W0
M01
;
;(CUTOFF)
N9
G00 T1010
M03
M08
G50 S1000
G96 S#502
G00 X[#500+2.0]
G00 Z-2.4
G01 X0.0 Z-2.4 F#504
M09
M05
G28 U0 W0
M30
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