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1 CNC & CAD/CAM initial & continuing vocational training CNC TOPTURN TOPMILL TOPCAM Complete Machining Turning Milling MATHEMATISCH TECHNISCHE SOFTWARE-ENTWICKLUNG GMBH

2 TOPTURN TOPMILL TOPCAM Software, teaching and learning aids for training in metal, plastics and woodworking For more than 20 years now, MTS has been developing software for both technical applications and special CNC shop-floor programming systems, as well as CAD/CAM and CNC simulation systems for turning and milling machining centers. The TOPTURN and TOPMILL CNC simulators and TOPCAM, the integrated CAD and NC programming system, are not only used in production, but also in initial vocational training in vocational schools and companies, adult further training and retraining in training centers of individual companies and of external training organizations serving several companies, the training of technicians and engineers of polytechnical high schools, technical colleges and technical universities. Didactic concept of the CNC simulators TOP- TURN and TOPMILL Modern CNC technologies require staff training that is innovative and in-step with current technical developments. Our simulators provide highstandard training software that encourages independent learning and work, is adaptable to different levels of learning, guarantees manufacturer-independent CNC training based on the corresponding DIN/ISO standards, taking into account knowledge on cycles and contour paths programming, offers great ease of operation corresponding, as far as possible, to operation of the machine tools and controls, constitutes a system open to integration of any CNC machine tools into the training concept, and provides possible ways of transfering and applying what has been learned to the specific environment of a particular CNC control system. Using these features, the didactic concept of MTS CNC simulators can be summarized in one simple single statement: Working with a CNC simulator should be just like working with a real machine tool. This involves integrating all preparatory and planning skills into the simulation process, as well as all set-up operations such as determining the workpiece dimensions and its clamping, setting workpiece coordinate origins, selecting tools and assembling tools and, finally, loading of tool turrets and magazines. Here priority is given to independent, activity-oriented work in all phases of the learning process. The virtual 3D reality simulation with its 3D collision determination, available as an optional software enhancement, is ideal for supporting this type of learning. 2

3 TOPTURN models a lathe which can be optionally equipped with driven tools (supplementary axes C, Y and B) and a subspindle for complete machining (supplementary axes Z2, C2). TOPMILL models a 3-axes vertical milling machining center with configurable automatic tool changer, in the variants rotational tool magazine and dual-arm gripper or pick-up-magazine. In set-up mode, the CNC simulators have to be set up just like a real machine tool. This process is assisted by tool and clamping device management modules. Moreover, the teacher can also assign complete set-up states on specific set-up sheets to particular exercises. NC programming is done in different shop-floor programming modes. It is possible to switch over from any of these modes to another while programming in order to suit the task at hand. These modes are: Interactive programming Use of an NC editor Use of a geometry editor Teach-in operation Dialog mode programming Automatic mode enables simulation of NC programs either in 2D visualization of workpiece cross-sections or, optionally, in the virtual reality provided by 3D machining area simulation and 3D material removal simulation. In the course of simulation, collision detection calculations are carried out, taking into account all components of the machining area. In addition, the tool paths can be displayed either for the entire NC program or for individual sections of this. Quality control can be integrated into the training concept by precisely measuring the dimensions of the virtual workpiece created by turning or milling simulation, We have developed the SIMSTART software module specially for vocational training school courses. This enables the students to learn the initial system skills and progress to the programming task of the respective curriculum unit quickly. When operated in a network, this software permits individual management of the trainees. 3

4 Dialog programming mode provides easy input of complex machining stages, one or several related input screens being filled in by the user with graphical assistance. The input is checked for validity of combinations, value ranges and alternatives.. Since the CNC simulator can be adapted to a wide variety of CNC controls and machine tools, this programming option is available for all CNC control systems. Consequently, our software enables an implementation of all methodical concepts for training, independent of specific CNC systems in a neutral ISO/DIN code, as well as for particular CNC systems in all control code languages (ISO/DIN dialects or legible text languages). In particular, it is possible to integrate older CNC controls (such as GE, Allan Bradley, Contur 2, Dialog 4, TNC 151/155, Sinumerik 3T, EPL 1 / 2 and TX8) into the training courses. Postprocessors convert the NC programms generated by TOPCAM in a neutral ISO format into the NC code format of the target CNC control. There are two different versions of the TOPCAM postprocessor: configurable ISO command set postprocessor for 2-axes turning and 3-axes milling, and cycle postprocessor that can be adapted to any type of CNC control generating the cycles of the target CNC control. From the drawing to the finished workpart: TOPCAM - CAD/CAM system for training and production TOPCAM, the integrated CAD and NC programming system, combines the functions of a fully-fledged 2D CAD system with a comfortable NC programming system for 2½D milling and complete mill-turn machining with driven tools. The CAD system provides powerful functions for creating, editing and documenting technical drawings. For transfering geometry data to and from other CAD systems, DXF standard format is supported. The NC programming system enables automatic generation of NC programs using contour strings and all common machining cycles. An easy-to-use interactive graphic dialog permits automatic generation of NC programs, not only for conventional machining processes, but also for mill-turn processes using driven tools and sub-spindles (with 5 axes each for main spindle and sub-spindle machining). For woodworking special functions such as progressive tool lowering are also provided. 4

5 ISO control system for trainee examinations In the Federal Republic of Germany, the topic generating an NC program" in vocational examinations for chip-cutting machine tool operators is handled using a test ISO control system with the enter the missing text" or cloze test" method, the assignments being formulated in a manufacturer-independent ISO programming key, named PAL. MTS CNC simulators can be configured to this simple programming key, thus also offering supplementary functions such as workpiece dimension measuring, collision checks and 3D visualization. In the training phase, all programming methods, in particular interactive programming and ISO programming in dialog mode, can be used to supplement the courses. A teacher's program module allows instructors to create their own cloze test" or missing-text" assignment programs. Instructors can refer to a comprehensive collection of exercises. An NC program column editor and a corresponding postprocessor has been developed for entering missing text" in ISO column format. The postprocessor converts the NC programs written in ISO command code into the programming key of any desired target CNC control. Cycle commands are converted into the target CNC control's cycles - if available. In this way, you are able to run the ISO exercise programs on any CNC lathe or milling machine. TOPMILL for machining wood and plastic Special technologies for CNC wood machining are supported. For instance, the tool management modules permit the use of other tool group designations, as well as providing additional concave and boxhandhole milling tools. Vacuum tables are used instead of magnetic clamping plates. The MTS transfer program can be used for quick and easy transfer of the specific control programs created with the CNC simulators or TOPCAM postprocessors to any desired CNC control. * PAL Prüfungsaufgaben- und Lehrmittelentwicklungsstelle IHK Mittlerer Neckar, Stuttgart *Programming key The programming key of a CNC control system (also known as the command coding or control syntax) is defined first to be the set of programming functions according to ISO/DIN that this control system is capable of, including definition of the control-specific deviations from this standard, and second as the control-specific extensions by cycles, contour-programming etc. The term programming key is also used to describe the definition of the contents of a legible text language not based on the ISO/DIN standard. 5

6 MTS has been specializing in developing CAD/CAM and CNC software for production and training for more than 20 years. Tel.: Fax: Our customer portfolio in the production sector includes many renowned CNC control and machine tool manufacturers. Working in close co-operation with the German Federal Institute for Vocational Training (Bundesinsitut für Berufsbildung - BIBB) in the 1980's, we developed the future-oriented didactic concepts of the TOPTURN and TOPMILL shop-floor programming workstations for the vocational training sector, and these still represent the state-of-the-art up to this day. Since then, the systems have been enhanced with regard to their graphical user interfaces and user dialogs, thanks to the enormous increases in performance achieved by PC technology. Since the early '90s, we have also been offering training material, software primers and training exercise assignments in addition to the software documentation, as well as carrying out teachers' training courses for our customers. Our training center in Berlin offers one-week seminars at regular intervals on the following topics: Introduction to CNC programming Introduction to CNC turning and milling with TOPTURN and TOPMILL Advanced seminar CNC turning Advanced seminar CNC turning complete mill-turn machining with driven tools Advanced seminar CNC milling Advanced seminar parameter programming Introduction to CAD/CAM using TOPCAM Advanced seminar CAD/CAM complete mill-turn machining Development and preparation of curricula, teaching and learning materials Introductory and advanced seminars at customers' premises Hotline and service Software updates and software maintenance You can also order our software in the following languages: Chinese (simplex & traditional), Czech, English, French, German, Hungarian, Italian, Polish, Portuguese, Russian, Slovakian, Spanish, Swedish, Thai, Turkish and Vietnamese. System requirements The software can be run on WINDOWS 95/98/ME/NT/2000/XP operating systems, either as a stand-alone or as a network version. 64 MB of main memory are adequate for 2D CNC simulation. For optional 3D simulation, 128 MB main memory, a powerful processor and a high-performance graphics card are recommended. 6

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