Back End Parametric Programming for Tool Life Monitoring and Accident Prevention in CNC Machining Centres

This study addresses the critical role of Human-Computer Interaction in minimising human error within computer-controlled manufacturing. Back-End Parametric Programming (BEPP) was developed to enhance operational safety and reduce costs on transfer lines. The BEPP system automatically tracks tool life and table position. It immediately stops the machine to prevent accidents and excessive tool wear. The BEPP programs were installed and run along with the main part programs. The rotary table positions are predefined in BEPP and continuously monitored by the programs. Implementation began on one machine and was phased to all other machines. Evaluation of the same was done by observing machine downtime, tool life, machining quality by inspection of parts and the number of accidents due to incorrect table positioning. Implementation of this programming on MY 40H machines yielded significant results over nine months. The average number of accidents caused by incorrect table positions was reduced from 3.5 to zero per month. Machine downtime for tool checks and changes was cut from 137 minutes to just 28 minutes per machine per month. This original coding work demonstrates that BEPP can deliver substantial savings in tooling costs and drastically improve machine safety and productivity.