Help figuring out macro variables for cam grinding

Hi all,
Long story short, the machinist who used to make these cams no longer works at my company. Unfortunately, he was the type of guy who refused to teach anyone.
Specifics, Fadal VMC4020 with 5th axis.
Tools :
#1 c'drill
.500 roughing cutter
.500 finish cutter
1.625 grinding wheel

The part runs with the B axis pointing straight up.
The set-up sheet tells nothing beyond rotary set up and the programmed radius for the grinding wheel.

What I cant figure out, is how to figure the data for the F & R & V.
I have never had any experience with macros, and I'm at a total loss.
I've at least found the variable table in offsets.
I'll get some photos posted tonight, I realize its hard to visualize.
The cam is small, approx. 1" diameter.

This is what the program looks like:

O1111( CAM, +-.040 TRAVEL)
(05-12)
(ALL PART CAME OUT PERFECT AT +.003 OVER)
(DIM. 542 AT 270. DEG. SHOULD BE .545)
N1 L100
N2 G1 X0 F+R1
N3 G91 A-90. Y-0.084 F+R2
N4 A-270. Y0.084
N5 Y-0.05 F+R1
N6 X-0.5
N7 G90
N8 M17
N9 M30
N10 M0 (UPDATE 'LETTER' FOR PART #)
(ENGRAVE DATE AS MONTH-YEAR 'LETTER')
(LETTER A FOR THE 1ST PART)
(THEN B FOR 2ND AND SO ON)
N11 G0 G90 G49 Z0 H0
N12 G54 X-10. Y0
N13 M6 T1(#1 C'DRILL)
N14 Z4. H0
N15 G0 G90 G57 A135. B-270. X0.05 Y0
N16 M62
N17 M3 S2000
N18 G43 Z0.1 H1 M8 D1
N19 G1 Z-0.005 F1.
N20 X0.59
N21 G0 Z0.1
N22 X-0.25 Y-0.32 A180.
N23 L9201 R+0.05 R1+0 R2+0.1 R3+0 Z-0.005 F1.(05-06 A
N24 G0 Z0.1 M5 M9
N25 Z4. H0
N26 G54 Y0 X-10.
N27 M1
N28 M6 T8(.500 ROUGH)
N29 Z4. H0
N30 R1+3.(TABLE FEED )
N31 R2+100.(ROTAR Y FEED)
N32 G0 G90 G57 A-270. B-270. X-0.5 Y-0.72
N33 M62
N34 M3 S600
N35 G43 Z0.1 H8 M8
N36 G1 Z-0.25 F40.
N37 L101
N38 G0 Z0.1 M5 M9
N39 Z4. H0
N40 G54 X-10. Y0
N41 M1
N42 M6 T9(.500 FINISH)
N43 Z4. H0
N44 R1+3.(TABLE FEED )
N45 R2+100.(ROTAR Y FEED)
N46 G0 G90 G57 A-270. B-270. X-0.5 Y-0.72
N47 M62
N48 M3 S700
N49 G43 Z0.1 H9 M8
N50 G1 Z-0.25 F40.
(ADD .001 TO Y-.71)
N51 Y-0.711
N52 L101
N53 G0 Z0.1 M5 M9
N54 Z4. H0
N55 G54 X-10. Y0
N56 M1
N57 M6 T10(1.625 DIA. GRINDING TOOL)
(PART SHOULD FINISHED AT +.003 OVER AS REQUIRE)
N58 Z4. H0
N59 R1+2.
N60 R2+100.
N61 # V1=1.2715
(R+.458+.001 FOR 3 CUTS)
N62 G0 G90 G57 A-270. B-270. X-0.5 Y-1.5
N63 M3 S6000
N64 G43 Z1. H10 M8 D10
N65 G1 Z-0.65 F30.
N66 # V2= V1+(D10/2)
N67 # R3= V2
N68 Y- R3 F+R1
N69 L101
N70 Y-1.5
N71 X-0.5
N72 # V1= V1-.0005
(FIRST CUT)
N73 # V2= V1+(D10/2)
N74 # R3= V2
N75 Y- R3 F+R1
N76 L101
N77 Y-1.5
N78 X-0.5
N79 # V1= V1-.0002
(SECOND CUT)
N80 # V2= V1+(D10/2)
N81 # R3= V2
N82 Y- R3 F+R1
N83 L101
N84 Y-1.5
N85 X-0.5
N86 # V1= V1-.0002
(FINISH CUT)
N87 # V2= V1+(D10/2)
N88 # R3= V2
N89 Y- R3 F+R1
N90 L101
N91 Y-1.5
N92 X-0.5
N93 # V1= V1-.0001
(FINISH CUT)
N94 # V2= V1+(D10/2)
N95 # R3= V2
N96 Y- R3 F+R1
N97 L101
N98 Y-1.5
N99 X-0.5
N100 G0 G90 Z1. M5 M9
N101 Z4. H0
N102 G54 X-10. Y0
N103 A0 B0
N104 M2
%

Here is the setup. The way its supposed to run is by infeeding, then outfeeding with one axis while the A axis rotates.



And this is the what a finished part looks like.

Looks like this has "man readable" shorthand that needs to get translated before it can be run. Do you have an example on a control that's been run?

Looks to me like "F" should be the radius of the grinding wheel, "R1" and "R2" should be the two radii of the cam?

I'm thinking "#V1" needs to be replaced with an open variable, such as "#101".

Line N61 tell me that V1=1.2715
Line 66 tells me that V2=V1+(D10/2)On the Fadal control it uses the actual diameter for cutter comp.
So, if I take the programmed radius, minus the actual radius if the grinding wheel, which in this case would be 1.2715+(-.388/2)=1.0775 ~this shows the difference between programed supposed cutter size,1.625 and the actual cutter size, 1.237~
(I know the values in the photo are off, they were left over from the last time this job was run)
That part make sense.

mhajicek said:

Looks like this has "man readable" shorthand that needs to get translated before it can be run. Do you have an example on a control that's been run?

Looks to me like "F" should be the radius of the grinding wheel, "R1" and "R2" should be the two radii of the cam?

I'm thinking "#V1" needs to be replaced with an open variable, such as "#101".

Click to expand...

Unfortunately, the the other guy left, he wiped all programs out of the machine control, as well as all programs off of his computer.
You could say he was pretty much a dick.

I just can't see why the program would require you to edit in values for F & R into the actual program by hand so many times.
Seems high likelyhood for errors.

Greg B said:

Unfortunately, the the other guy left, he wiped all programs out of the machine control, as well as all programs off of his computer.
You could say he was pretty much a dick.

I just can't see why the program would require you to edit in values for F & R into the actual program by hand so many times.
Seems high likelyhood for errors.

Click to expand...

If anyone did this here they would have a big lawsuit on there ass.

What kind of idiot does this ?

Sendt fra min EML-L29 med Tapatalk

Greg B said:

Unfortunately, the the other guy left, he wiped all programs out of the machine control, as well as all programs off of his computer.
You could say he was pretty much a dick.

I just can't see why the program would require you to edit in values for F & R into the actual program by hand so many times.
Seems high likelyhood for errors.

Click to expand...

I haven't looked at this super closely nor pulled your code apart but presumably there is the need to dress the wheel from time to time ? [Hence progressive change in radius versus regular tool wear / comps ?.]

So for every dressing cycle someone has to gauge the grinding wheel ? Enter values in manually ?

Without seeing a video of the kinds of passes the wheel makes (for me) not easy to see the absolute logic of your former employee.

Did your employee also walk off with the diamond dressing tool that would have been bolted somewhere on your machine table ?

How is the wheel dressed in this case ?

I've figured some things out.
The F+R1 & F+R2 are called after each tool change, so there is that data.
It now seems to me, the program reads the L101, and is supposed jump the the L100 subroutine at the beginning of the program. But it doesn't.
Ugh. Hope it isn't a control issue.
More sleuthing is required.

If all he did was delete the files and not any sort of wipe you may be able to get the programs back.
find an undelete program you can run from a pen/usb drive (minimize the chance of over writing the disk space)
and see if you can bring them back.

cameraman said:

I haven't looked at this super closely nor pulled your code apart but presumably there is the need to dress the wheel from time to time ? [Hence progressive change in radius versus regular tool wear / comps ?.]

So for every dressing cycle someone has to gauge the grinding wheel ? Enter values in manually ?

Without seeing a video of the kinds of passes the wheel makes (for me) not easy to see the absolute logic of your former employee.

Did your employee also walk off with the diamond dressing tool that would have been bolted somewhere on your machine table ?

How is the wheel dressed in this case ?

Click to expand...

I have a diamond dresser bolted to the table way off in the corner.
My intent was to dress the wheel, and enter the difference in diameter in D10 of the diameter offset for tool 10.
Which is how I think it is supposed to be done.

Oh, and not my employee, co-worker. I'm just the last machinist in the shop. But it all falls to me now. At least for the time being.