Tool Programmers, Numerical Control
Nature of the Work
Aircraft, industrial machinery, medical and scientific instruments, and many other
durable goods require precision-machined metal parts. Most of parts are made with
machine tools--drill presses, lathes, milling machines, and others. A growing number of
machine tools are numerically controlled. These have two components: An electronic
controller and the machine tool itself. The controller "reads" a program--a coded list of the
steps necessary to perform a specific machining job--and runs the machine tool's
mechanisms through the steps. The efficient operation of these machine tools depends,
in large part, on the skill of tool programmers, who write the programs.
Tool programmers must have a broad knowledge of machining operations,
mathematics, and blueprint reading. They must know how various machine tools operate
and the working properties of the metals and plastics used to make parts. Because the
various brands and models of numerically controlled machine tools use different
programming languages, tool programmers must know the languages for each of the
machines they work with.
Programmers begin the task of writing a program by analyzing the blueprints of the
item to be made by the machine. They then determine the sequence of machine operations
and select the proper cutting tools needed to machine the workpiece into the desired shape.
For simple jobs, they manually compute the size and position of the cuts that must be made
on the workpiece, and also calculate the machine speed and feed rate needed for the type
of material being machined. They then write the program in the language of the machine's
controller and put it on a storage medium such as punch tape, magnetic tape, or disc.
For most jobs, programmers use computers to write the program for the machine
controller. Using computer languages called general processors, programmers can write
the program for a controller as a series of simple commands. The computer does the
mathematics and uses programs called post processors to translate the general processor
program into the language of the controller and store it on tape or disc.
A growing number
of firms have computer-aided design (CAD) systems that programmers can use to write the
program for the controller. When a part is designed using a CAD system, data about its
dimensions are calculated. In a CAD system with the proper software, the tool programmer
can use these data to develop the controller's program. Tool programmers do not write or
maintain the general or post processors and CAD software; they only use them as aids in
their work.
Programmers also write an instruction list to help the machine operator set up and
tend the machine. Finally, programmers may watch the operation of a trial run of the
machine to insure that it is functioning properly and check the output to be sure the
specifications are met. Computer simulations may be used instead of a trial run to check
the program.
Working Conditions
Tool programmers work in comfortable surroundings. The rooms in which they work
generally are separated from the areas where the machine tools are in use. Their work
generally is not as active as that of the workers who operate the machine tools.
Employment
Tool programmers held about 8,100 jobs in 1990. Almost all work for manufacturing
firms or small machining shops that produce durable goods such as aircraft, industrial
machinery, and instruments. Most jobs for tool programmers are in large metropolitan
areas where most factories and machine shops are located.
Training, Other Qualifications, and Advancement
Tool programmers learn their jobs through a combination of work experience and
vocational study. Employers prefer to promote or hire skilled machinists or machine
operators for programmer jobs. To learn programming, these experienced workers take
courses at vocational schools or junior colleges; employers may pay for these courses.
Because programming methods differ among the brands of numerically controlled machine
tools, manufacturers usually provide training in programming for employees of firms that
purchase their machines.
Although this is not generally considered an entry level job, some
employers will hire people without machining experience if they have completed vocational
school or junior college courses in tool programming and demonstrate the ability to learn
machine operations. Those who have completed high school courses and have displayed
ability in mathematics, blueprint reading, metalworking, data processing, physics, and
drafting will have the best chance of landing a job.
Tool programmers can advance to supervisory jobs or transfer to skilled machining
jobs such as tool designer.
Job Outlook
Employment of tool programmers is expected to increase much faster than the
average for all occupations through the year 2000. Besides openings arising from growth
in demand for these workers, many openings are expected to occur each year as
programmers transfer to other fields of work, retire, or die. However, since this is a
relatively small occupation, the total number of job openings will be much smaller than in
other machining occupations such as metalworking machine operator, machinist, and tool-
and-die maker.
As the economy grows,the demand for industrial machinery, aircraft, motor vehicles,
and other products that use machined parts or tooling for molded parts will increase. In
order to compete with foreign manufacturers of these goods, American firms are expected
to increase sharply their use of numerical control and other types of automated machining
equipment. This equipment will enable these firms to better control their costs and to
machine parts and tooling to more exact specifications. As more firms install numerically
controlled machine tools, the demand for tool programmers also will rise. However, this
increase in demand will be limited by advances in the software used in tool programming.
The link between computer-assisted design systems and machine controllers, for example,
is expected to improve--making the writing of programs easier and quicker.
Earnings
In 1990, tool programmers earned about $14.56 an hour, according to limited data
available. In comparison, the hourly rate for all production workers in private industry,
except farming, was $9.66. Tool programers generally work a 40-hour week; however,
overtime is common during periods of high manufacturing activity.
Related Occupations
Tool programmers apply their knowledge of machining operations, blueprints, and
machine programming to write programs that run machine tools. Other highly skilled
workers involved in metal machining work are: Tool-and-die designers, tool planners, tool-
and-die makers, and machinists.
Sources of Additional Information
For more information about this occupation, contact:
The National Machine Tool Builders, 7901 Westpark Dr., McLean, Va. 22102.
The National Tooling and Machining Association, 9300 Livingston Rd., Ft.
Washington, MD. 20744.
The National Screw Machine Products Association, 6700 W. Snowville Rd.,
Breckville, Ohio 44141.
The Tool and Die Institute, 777 Busse Highway, Park Ridge, Ill. 60068.
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