CNC-Simulator Turning. Programmer's Guide

CNC-Simulator Turning with Driven Tools and Counter Spindle Programmer's Guide Version 6.07 Mathematisch Technische Software - Entwicklung GmbH Kaiserin-Augusta-Allee 101 D 10553 Berlin ( +49 / 30 / 34 99 600

Programmer's Guide CNC Simulator for Turning Version6.7 MTS Mathematisch Technische Software-Entwicklung GmbH Kaiserin-Augusta-Allee 101 D-10553 Berlin ( + 49 / 30 / 34 99 600 Fax +49 / 30 / 34 99 60 25 email: mts@mts-cnc.com WWW: http://www:mts-cnc.com Berlin, May 1995ofp, June 1998 akss, ofp, July 1998 BM; All rights reserved, including photomechanical reproduction and storage on electronic media. DIN (Deutsche Industrie Norm), is the German Standard Specification as defined by the "Deutsches Institut für Normung e. V." MS-DOS is a trademark of Microsoft Corporation PAL is short for "Prüfungs- Aufgaben und Lehrmittelentwicklungsstelle" (Institute for the Development of Examination Standards and Training Aids), a division of the "IHK Mittlerer Neckar" (Chamber of Industry and Commerce of the Middle-Neckar Region)

Contents Table of Contents 0 Introduction...9 0.1 CNC Simulator Turning with Driven Tools and Counter Spindle...10 0.2 Changes and Supplements to the Version 5.x...11 1 Basic Geometry...13 1.1 The Coordinate System...13 1.2 Reference Points...15 1.3 Absolute Dimensioning, Incremental Dimensioning...17 1.4 Tool Geometry...19 1.4.1 Compensation Value Storage...21 1.4.2 Tool Nose Compensation TNC...23 2 Introduction into NC Programming...25 2.1 Structure of an NC Block (Format)...25 2.2 Modal Commands and Non-modal Commands...26 2.3 Application and Representation of Addresses...27 3 Miscellaneous Functions (M-Functions)...28 3.1 Activate/Deactivate Spindle...28 3.2 Coolant...28 3.3 Programmed Halt...28 3.4 Program End...29 3.5 Lock / Unlock Centre Sleeve...29 3.6 Feedrate...29 3.7 Spindle Speed...29 3.8 Tool Change...30 4 Programming Commands in Compliance with DIN 66025...31 4.1 Rapid Traverse G00...33 4.2 Linear Interpolation in Slow Feed Motion G01...35 4.3 Clockwise Circular Interpolation G02...36 4.4 Circular Interpolation Counter-Clockwise G03...37 4.5 Dwell G04...38 4.6 polygonal machining G08...38 4.7 In-Position Programming (Deceleration) G09...39 4.8 Inch Data Input G20...40 4.9 Metric Data Input (mm) G21...41 MTS GmbH 1998 3

Contents 4.10 Invocation of a Subprogram G22... 43 4.11 Repeated Program Parts G23... 44 4.12 Unconditional Jump G24... 45 4.13 Move to the Reference Point G25... 46 4.14 Move to the Tool-Changing Position G26... 47 4.15 Positioning the Tailstock G28... 48 4.16 Thread Cutting G33 (Chasing Cycle)... 50 4.17 Tool Nose Compensation G41 / G42... 52 4.18 Cancel Tool Nose Compensation G40... 52 4.19 In Rapid Travel Movement to the Target Position G48... 53 4.20 Description of a Final Contour G51... 55 4.21 Define Workpiece Zero - Absolute: G54 - G56 and G58... 57 4.22 Incremental Zero Shift G59... 59 4.23 Cancel Incremental Zero Shift G53... 60 4.24 Activate Absolute Dimensions G90... 61 4.25 Activate Incremental Dimensions G91... 62 4.26 Spindle Speed Limitation G92... 63 4.27 Feedrate (Millimeters per Minute) G94... 64 4.28 Feedrate (Millimeters per Revolution) G95... 65 4.29 Constant Cutting Speed G96... 66 4.30 Cancel Constant Cutting Speed G97... 66 5 Cycles...67 5.1 Complete Table of Available Cycles... 67 5.2 Threading Cycle G31... 69 5.3 Travel Range Limitation G36 for Multipass Cycles... 72 5.4 Finishing Allowance G57... 73 5.5 Straight Roughing Cycle / Rectangular Contour G75...77 5.6 Cross Roughing Cycle / Rectangular Contour G76...79 5.7 Clearance Cutting Cycle: G78... 81 5.8 Thread Undercut G78 in Compliance with DIN 76... 85 5.9 Recessing Cycle with chamfers, roundings and bevelled sides G79... 87 5.10 Straight Roughing Cycle for any Contour G81... 88 5.11 Cross Roughing Cycle with any Contour G82... 98 5.12 Processing Cycle (Last Specified Cycle) G80... 107 5.13 Contouring Cycle/Multipass Cycle G83... 111 5.14 Travel Range Limitation for Multipass Cycles G36... 113 5.15 Deep Drilling Cycle G84... 115 5.16 Clearance Cutting Cycle G85... 117 5.17 Thread Undercut in Compliance with DIN 76... 121 5.18 Recessing Cycle for rectangular recesses G86... 123 4 Programmer's Guide for CNC Turning, Version 6.07

Contents 5.19 Recessing Cycle for any Contour G87...124 5.20 Radius/Chamfer Cycle G88...131 5.21 Straight/Plane Roughing Cycle (conical contour) G89...135 6 Segment Contour Programming...142 6.1 G-Functions for Contour String Programming...142 6.2 Additional Addresses...146 6.2.1 Circle Centres Absolute...147 6.2.2 Tangential Transitions...148 6.2.3 Selection of Solutions...151 6.3 Rounding between Two Entities...157 6.3.1 Chamfer between Two Lines...159 6.4 Two-Point String: Straight Line G71...160 6.5 Two-Point String: Arc G72/G73...162 6.6 Three-Point String: Line - Line G71G71...166 6.7 Three-Point String: Arc - Line G72G71 or G73G71...170 6.8 Three-Point String: Line - Arc G71G72 or G71G73...176 6.9 Three-Point String: Arc - Arc G72G72 or G72G73 or G73G72 or G73G73...183 6.10 Four-Point String:with Tangential Transitions...188 6.11 Open Contour Strings...194 6.12 Tangential Connection...201 7 Parameters...205 8 Programming with Special Characters...207 8.1 Comments...207 8.2 Skipping of NC blocks...207 8.3 Temporary Free Format...209 8.4 Arithmetic Operations...209 8.5 Example of Programming with Parameters and Arithmetic Operations...213 9 Setup Form...215 9.1 Preface...215 9.2 Syntax of the Setup Form...217 9.3 Setup Data: Beginning/End Indicator...218 9.4 Setup Data: Configuration Files...218 9.5 Setup Data: Blank...219 9.6 Setup Data: Prefabricated Part...221 9.7 Setup Data: Clamping Devices...222 9.8 Setup Data: Clamping Mode...223 9.9 Setup Data: Tailstock/Sleeve...224 9.10 Setup Data: Chucking Depth...224 MTS GmbH 1998 5

Contents 9.11 Setup Data: Counter Spindle... 225 9.12 Setup Data: Current Tool... 226 9.13 Setup Data: Tools in the Turret... 226 9.14 Setup Data: Driven Tools... 227 9.15 Setup Data: Compensation Values... 230 10 NC Program Analysis...231 11 3D-View...233 12 CNC-Turning with the Counter Spindle...235 12.1 Preface... 235 12.2 Configuration... 237 12.3 Programming the Counter Spindle... 238 12.3.1 Machining Transfer to the Main Spindle G29... 238 12.3.2 Work Part Transfer G30... 239 12.3.3 Incremental Shift of the Counter Spindle Reference Point (when Programming Travel Movements) G59... 240 12.3.4 Travel Movement of the Counter Spindle in Rapid Speed Movement G00... 241 12.3.5 Travel Movement of the Counter Spindle with Infeed F in mm/min G01... 242 12.3.6 Counter Spindle to the Counter Spindle Reference Point G27... 243 12.3.7 Switching on Machining on the Counter Spindle G28... 244 12.3.8 Bar feed for work parts in the main spindle G05... 246 13 CNC Turning with Driven Tools...247 13.1 Preface... 247 13.2 Configuration... 251 13.3 Turning Plane G14... 252 13.4 Standard Plane G15... 253 13.5 Free-definable Plane G16... 254 13.6 Programming the Selection of the Free-definable Plane G16... 259 13.7 Machining Cycles in the Free-definable Plane G16... 262 13.7.1 Face Milling Cycle G60... 262 13.7.2 Drilling Cycle G61... 264 13.7.3 Thread Tapping G62... 265 13.7.4 Reaming/Boring G63... 266 13.7.5 Square Pocket/Groove G64... 267 13.7.6 Circular Pocket G65... 268 13.7.7 Tapping G66... 269 13.8 Multiple Cycles in the Free-definable Plane G16... 270 13.8.1 Cycle on a Circle G67... 270 13.8.2 Cycle on a Radius G68... 271 13.8.3 Cycle at a Point G69... 272 13.9 Front Face G17... 273 13.9.1 Rapid Speed Movement in Polar Coordinates G10... 274 13.9.2 Linear Interpolation in Polar Coordinates G11... 275 13.9.3 Circle Interpolation in Polar Coordinates Clockwise G12... 276 13.9.4 Circle Interpolation in Polar Coordinates Counterclockwise G13... 277 13.10 Machining Cycles in the Front Face G17... 278 6 Programmer's Guide for CNC Turning, Version 6.07

Contents 13.10.1 Drilling Cycle G61...278 13.10.2 Thread Cutting G62...279 13.10.3 Reaming/Boring G63...280 13.10.4 Square Pocket/Groove G64...281 13.10.5 Circular Pocket G65...282 13.10.6 Tapping G66...283 13.11 Multiple Cycles in the Front Face G17...284 13.11.1 Cycle on a Circle G67...284 13.11.2 Cycle on a Radius G68...285 13.11.3 Cycle at a Point G69...286 13.12 Shell Surface - G18...287 13.12.1 Rapid Speed Movement in Cylinder Coordinates G10...289 13.12.2 Interpolation of Straight Lines in Cylinder Coordinates G11...290 13.12.3 Circle Interpolation in Cylinder Coordinates Clockwise G12...291 13.12.4 Circle Interpolation in Polar Coordinates Counterclockwise G13...292 13.13 Machining Cycles in the Shell Surface G18...293 13.13.1 Drilling cycle G61...293 13.13.2 Thread Cutting G62...294 13.13.3 Reaming/Boring G63...295 13.13.4 Square Pocket/Groove G64...296 13.13.5 Circular Pocket G65...297 13.13.6 Tapping G66...298 13.14 Multiple Cycles in the Shell Surface G18...299 13.14.1 Cycle on a Circle G67...299 13.14.2 Cycle on a Radius G68...300 13.14.3 Cycle at a Point G69...301 13.15 Chord Surface G19...302 13.16 Machining Cycles in the Chord Surface G19...304 13.16.1 Plane Milling Cycle G60...304 13.16.2 Drilling Cycle G61...306 13.16.3 Thread Cutting G62...307 13.16.4 Reaming/Boring G63...308 13.16.5 Square Pocket/Groove G64...309 13.16.6 Circular Pocket G65...310 13.16.7 Tapping G66...311 13.17 Multiple Cycles in the Chord Face...312 13.17.1 Cycle on a Circle G67...312 13.17.2 Cycle on a Radius G68...313 13.17.3 Cycle at a Point G69...314 Appendix : Table of Programmable Addresses...315 Index...318 MTS GmbH 1998 7

Introduction 0 Introduction Dear user of the MTS CNC Simulator Turning 6, To make CNC Software for training and production means for us to follow carefully the development of CNC machines and controls all the time. With the target to give you an up-to-date product for the CNC programming of machining processes with five controllable NC axes, driven tools and counter spindle the MTS CNC Simulator is being constantly further developed and updated. These further developments are released as a new software version with corresponding modifications of operating and programming manuals. MTS Mathematisch Technische Software-Entwicklung GmbH Regarding this edition This Programmer's Guide explains all available NC commands of the MTS Programming Code. In addition to the DIN 66025 commands, the programming of machining cycles and segment contour programming are explained. The MTS Programming Code is non-proprietary, i.e. not any specific to any one manufacturer's CNC control system. The Programmer's Guide is structured as follows: This Programmer's Guide explains all available NC commands of the MTS Programming Code. In addition to the DIN 66025 commands, the programming of machining cycles, segment contour programming, the programming of the counter spindle and driven tools are explained. The MTS Programming Code is non-proprietary, i.e. not any specific to any one manufacturer's CNC control system. The Programmer's Guide is structured as follows: Part One presents and explains the basic techniques of NC programming. Part Two, which is far more extensive, explains all commands which are part of the MTS programming code. For reasons of clarity these have been arranged in three main sections: - DIN Commands - Machining Cycles - Segment Contour Programming (Contour Strings) - Counter Spindle - Driven Tools This structure is intended to provide an easy introduction to NC programming even for the unskilled user. The expert programmer may use the clearly structured listing of commands as a quick-reference manual when confronted with complicated tasks. The general idea of the Programmer's Guide is to provide the user with explanations and support as he becomes familiar with manual programming. All mandatory and optional parameters are explained using NC Blocks and graphically represented. MTS GmbH 1998 9

Introduction 0.1 CNC Simulator Turning with Driven Tools and Counter Spindle Complete Machining The re-developed version 6 of the CNC system turning expands the performance of the MTS CNC Simulator. In addition to improved programming of rotation symmetrical machining it is possible to create and simulate easily NC programs for complete machining with driven tools and a counter spindle. Both of the new modules are optionally available to the new basic version of CNC Turning 6. 5 Controllable NC Axis: X, Z, C, Y, B Counter Spindle 2D- and 3D-Representation in Multiple Windows Technique For the realization of complex machining tasks 5 controllable NC axes and driven tools are available. It is possible to position the C axis exactly and to interpolate it, for instance, to generate geometries by overlaying tool movements. The turret can additionally be moved in the Y axis and rotated in the B axis. To support rear side machining a special free-configurable counter spindle has been realized on a track of its own for the work part take-over. Counter spindle and turret can be configured alternatively. For machining on counter spindle a complete programming code including the application of driven tools is available. The dynamic simulation of machining with driven tools is carried out in the CNC Simulator Turning in multiple windows technique enabling both 2D as well as 3D representations of the machining process. Hereby the contour of the work part being machined is being constantly updated. Screen Layout in CNC Simulator 6 Turning during Machining with Driven Tools When machining with driven tools the following four windows are represented on the screen: 1 3 2 4 1 Longitudinal section as a full section on X, Z plane based on the current C axis (so-called C cut). The view can be shifted and zoomed as desired. The window 2 is always represented in the same scale as the window 1. 2 Section cut as a full section on X, Y plane. The Z coordinate of the section can be selected in window 1. 3 Free-definable view of a work part or of the whole work space of the CNC turning machine corresponding to window 1. 4 3D machining view. Distance and viewing angle in relation to the work space can be changed as desired. 10 Programmer's Guide for CNC Turning, Version 6.07

Introduction 3D-Collision Monitoring NC Data Analysis During machining processes with driven tools collision monitoring is carried out in 3D window. It considers the clamping device, the non-cutting parts of the tool (shaft, take-over, turret) as well as the cutting part of the tool during rapid speed movement of the tool. The CNC Simulator Turning 6 offers as an effective function the possibility to acquire production-relevant technology information during the simulation of an NC program. In the programming analysis of rotation-symmetrical machining the work phases are represented as machining paths for each tool and the corresponding technology data is acquired. After the analysis the following data referring to the work phases is available as a table: machining diameter area, RPM, cutting speed, feed-in, path, feed-in rate, rapid transfer speed, tool change time, cut volume, cut mass. The analyzed data can be stored in the current NC program where it is correspondingly available for further evaluation. 0.2 Changes and Supplements to the Version 5.x Change of Address Letter Due to the application of the address letter C for the programming of the C axis it was necessary to change the address letters. Old: C (Chamfer, Radius) R (Parameter identification letter) P (Block number, alternative) ð ð ð New: R Address letter for programming of chamfers and radii P Address letter for programming of parameters O Address letter for programming of block numbers and choice of alternatives C Y B Positionable turning axis Additional feed axis for the turret Additional swivel rotation axis for the turret (depending on machine configuration and of the current machining plane) Exception: During contour programming of G72/G73 B remains circle radius. Summary of some G-commands When uniforming MTS syntax some of the commands were put together: The previous cycles G87 (radius) and G88 (chamfer) were put together to G88. This cycle can generate both radii and chamfers. The previous cycles G65 (straight roughing cycle, conical contour) and G66 (plane roughing cycle, conical contour) are replaced by the cycle G89. Some new G commands as syntax extension To extend the performance of MTS syntax for the NC programming of rotationsymmetrical machining additional addresses were included in some G commands. The parameters of the cycles G81 (straight roughing cycle of any contour) and G82 (plane roughing cycle of any contour) were extended. The parameters E, A, O and Q have been added. MTS GmbH 1998 11

1. Basic Geometry Examples P : X= 20, Y= 30 P : X=-20, Y= 15 P : X= 40, Y=-25 Diagram 1.1 : Cartesian Coordinate System Angles of holes on a divided circle Determination of a point by the length L and the angle A Diagram 1.2 Diagram 1.3 Two-dimensional coordinate system for NC programming for turning Diagram 1.4 12 Programmer's Guide for CNC Turning, Version 6.07

1.1 Coordinate System 1 Basic Geometry In this chapter we outline the basic mathematical and technical knowledge, as required for NC programming. 1.1 The Coordinate System An important part of an NC program is the description of tool motions (distances) and their target points. To ensure correct execution of such commands, the appropriate geometric dimensions must be precisely defined, so as to effect the corresponding tool movement on the machine tool. It follows that a reference system must be determined, within which the position of each desired point can be specified. This is called a coordinate system. Origin of the Coordinate System The coordinate system is composed of two axes at a right angle; each axis is scaled, so that numeral values can be marked off on it. The intersection point of the two axes is the origin (or zero point) of the coordinate system. As a rule the horizontal axis is designated as the X axis, the vertical axis as the Y axis. The coordinate system used for turning is different in that the horizontal axis is designated as Z and the vertical axis is designated as X. A plane coordinate system of this type is called a cartesian coordinate system. Coordinates Example: (see Diagram 1.1) A coordinate system serves to definitely locate each point, by specifying its coordinates (in numeral values) on the X and Y axes. The coordinates of point P 1 are: X = 20 and Y = 30, i.e. the location of the point is defined by marking off (from the origin) the value 20 in the positive direction X and the value 30 in the positive direction Y. Accordingly the coordinates of points P 2 and P 3 are as follows: P 2 : X=-20, Y=15 P 3 : X=40, Y=-25 Polar Coordinate System In addition to the cartesian system, polar coordinates are used, e.g. in cases where a large number of angle dimensions must be programmed. Example:Pattern of drilled holes on a circle (see Diagram 1.2) Polar coordinates are used to define the points on a plane by specifying: the length L and the angle A Coordinate System for CNC Turning A two-dimensional coordinate system is used for turning. The Z-coordinate is marked off on the horizontal axis, the diameter X is set on the vertical (half) axis (see Diagram 1.4). MTS GmbH 1998 13

1. Basic Geometry Diagram 1.5 : Position and graphic symbols denoting the reference points of a CNC lathe Diagram 1.6 : The dimensioning is dependent on the location of the workpiece zero. Postaxial machining Preaxial machining Diagram 1.7 : The coordinate system is dependent on the tool position 14 Programmer's Guide for CNC Turning, Version 6.07

1.2 Reference Points 1.2 Reference Points To ensure that the control system of the machine will read the specified coordinates correctly and effect the corresponding movements of the tool slide, the machine tool has its own "coordinate system", which is called a "reference system". The following reference points are part of this system (see Diagram 1.5): Machine Zero Reference Point Tool Reference Point Workpiece Zero The origin of the reference system is called the machine zero (or datum). It is defined by the manufacturer and cannot be modified. A point within the travel range of the turret reference point is determined as the reference point to which the coordinate systems of the slide axes relate. With lathes using an incremental system of coordinates, the tool must be moved to the reference point after each startup of the machine. When absolute measuring systems are employed, it is not necessary to move it to the reference point. The appropriate type of machine can be determined in the configuration program (cf. Configuration Manual). All tool slide movements executed by the control system, according to the specified coordinates, will relate to the tool reference point, which is situated on the front face of the tool mounting. To compute the target position of the tool tip, the control system needs to be informed of the tool compensation value, denoting the distance between the tool reference point and the tool nose. From these differential values the system will compute the distances to the target point. (cf. Section 1.4: Tool Geometry - Compensation Values). The workpiece zero, as related to the machine zero, can be determined at will. It is advisable, however, to define the workpiece zero as identical to the origin (zero point of the coordinate system) of the workpiece design drawing - in this way the dimensions can be read in directly from the drawing. FIf the workpiece zero is located on the right front face of the workpiece (see Diagram 1.6), the Z coordinates must be programmed with a negative sign. Tool Position Note: the coordinate system is also dependent on the position of the tool slide, which may be either "in front of" or behind" the centre line as viewed from a position in front of the machine tool (i.e. to the right or the left of the rotational axis of the workpiece, as seen from the drive / clamped side), depending on the make of the lathe (see Diagram 1.7). In this manual the corresponding differentiation of tools and their position are be denoted by the terms "preaxial / postaxial". MTS GmbH 1998 15

1. Basic Geometry Absolute Dimensioning : All specified dimensions are related to the same point, which is the dimensioning reference point Incremental Dimensioning: Starting from the origin of the coordinate system, the distance between the current point and the preceding point is measured. Diagram 1.8 Tool motions according to the absolute dimensioning system: The tool moves to Z 50. Tool motions according to the incremental dimensioning system: The tool moves by the value 30 in the negative direction Z. Diagram 1.9 16 Programmer's Guide for CNC Turning, Version 6.07

1.3 Absolute / Incremental Dimensioning 1.3 Absolute Dimensioning, Incremental Dimensioning (Relative Dimensioning) The following dimensioning systems are commonly used with design drawings (see Diagram 1.8): Absolute Dimensioning In the absolute system all dimensions relate to the origin (zero point) of the (Fixed Zero System) coordinate system, which is also called the dimensioning reference point. Incremental Dimensioning Contrary to the absolute system, the incremental dimensioning system is based on the specification of the distance between a current point and its preceding point on an axis. Because in this system a sequence of additive dimensions is produced, it is called incremental. Depending on the type of dimensioning used in the drawing, the tool motions of an NC program can be programmed either in the absolute or in the incremental system of coordinates. (see Diagram 1.9). MTS GmbH 1998 17

1. Basic Geometry Cross turning and roughing tool Diagram 1.10 Finishing tool Diagram 1.11 The angular position of the reversible tip is greater than the infeed angle The angular position of the reversible tip is less than the infeed angle Diagram 1.12 18 Programmer's Guide for CNC Turning, Version 6.07

1.4 Tool Geometry 1.4 Tool Geometry The applications of a turning tool are determined by its geometry: the tool nose angles of a corner tool for cross turning or roughing, for instance, should be smaller than those of a finishing tool (see. Diagram 1.10). Important parameters of the tool geometry are (see Diagram 1.11) : - Tool nose angles - Angle of the reversible tip - Length / Width of the tool nose - Tool nose radius Further important parameters are (with internal tools): - length and diameter of the shank - minimum diameter and (with twist drills): - diameter - maximum drilling depth Angular Position of the Reversible Tip The angular position of the reversible tip is of critical importance especially with the generation of falling contours, because it determines the maximum possible angle at which the tool feeds down towards the interior of the workpiece (infeed angle). If the angle is less than the angle of the contour to be cut, the contour will be gouged or the tool holder will collide with the workpiece contour. (see Diagram 1.12). FThe maximum angle at which the tool feeds down into the workpiece should be determined to be, as a rule, 2-3 smaller than the adjustable angular position of the reversible tip. Minimum Diameter The minimum diameter of a drilled hole allowing the insertion of a tool (e.g. internal recessing tool) without touching the surface of the workpiece. MTS GmbH 1998 19

1. Basic Geometry The tool compensation value in Z is determined by the distance on the Z-axis between the cutting point and the tool reference point. Diagram 1.13 : Tool compensation The tool compensation values in X and Z are determined by the distances between the tool nose and the tool reference point in the direction of the X and Z axes. Example: Radius 0,4 X=-0,400 Y=-0,400 Diagram 1.14 : Example: Radius 0,4 X=-0,231 Y=-0,400 The compensation vector determines the position of the tool nose Diagram 1.15 : A comparison of tooling quadrants and TNC vectors (CNC lathe for tooling behind centre) 20 Programmer's Guide for CNC Turning, Version 6.07

1.4.1 Compensation Value Storage 1.4.1 Compensation Value Storage In computing the tool motions the control system relates all programmed coordinates to the tool reference point which is situated at the stop face of the tool mounting. Given the various tool geometries, the distance between the tool nose and the reference point will of course vary from tool to tool. It follows that the distance between the theoretical cutting point of the tool nose and the tool reference point must be determined for every tool, so that the actual tool path can be computed. Each of these differential values is stored as a tool compensation value in a corresponding compensation value storage. When a programmed tool change is to be executed in the course of an NC program, the system will read in the applicable compensation value storage, to account for the tool geometry in computing the tool path. Tool nose geometry data are the following: - distance in X from the tool reference point - distance in Z from the tool reference point - radius of the tool nose - tooling quadrant or compensation vector Compensation Values The control system must be informed of the distances in the directions X and Z between the theoretical cutting point of the tool nose and the tool reference point for each tool to be used (see Diagram 1.13). These differential values are stored in corresponding compensation value storages. In computing the feed motion of a selected tool, the control system accounts for the applicable compensation values, to the effect that the tool nose (i.e. the theoretical cutting point) feeds precisely to the programmed target position. Tool Nose Compensation Vector In computing the cutter path, the control system assumes a theoretical cutting point. The actual cutting edge of the tool nose however is rounded, with a radius ranging from some tenths of a millimeter to a circular tip. With each tool the theoretical cutting point of the tool nose must be defined by the tool nose compensation vector (TNC vector) to make sure that the control system can compute the path of the actual cutting point in the execution of a cycle. The TNC vector defines the theoretical position of the tool nose (in the directions X and Z) relative to its centre (see Diagram 1.14). The tool management predefines a TNC vector for every tool available in the Simulator system. Quadrants Alternatively the TNC vector can be determined by eight tooling quadrants (as shown in Diagram 1.15 ). This is common practice and applicable to standard cases. cannot, however, be applied in all cases. MTS GmbH 1998 21

1. Basic Geometry P M Theoretical tool nose (cutting point) Tool nose Centre The actual cutting point of the reversible tip is dependent on the direction of cut. Diagram 1.16 : If tool nose compensation is not selected, the actual machining will deviate from the programmed contour on the rising and falling segments of a contour, due to the radius of the tip of the tool. Diagram 1.17 : - - - Offset Path M Tool Nose Centre If the tool nose compensation (TNC) is selected the system computes the motion of the tool nose centre on an offset path equidistant to the contour, i.e. the actual cutting point will move exactly along the programmed contour of the workpiece. Diagram 1.18 : 22 Programmer's Guide for CNC Turning, Version 6.07

1.4.2 Tool Nose Compensation (TNC) 1.4.2 Tool Nose Compensation TNC The actual cutting point of the reversible tip will change in the course of machining, according to the direction of motion of the tool. (see Diagram 1.16). In computing the tool motion the control system assumes the movement of the theoretical cutting point of the tool nose along the programmed contour. Every time the tool executes a programmed movement not parallel to either the X- or Z-axis, however, deviations from the desired contour and the corresponding dimensions will occur, due to the radius of the tip of the tool employed (see Diagram 1.17). When tool nose compensation is activated, the control system will compute the path of the centre of the tool nose, equidistant to the contour, accounting for the radius. Taking account of either the tooling quadrant or the TNC vector, the theoretical cutting point is shifted to the centre of the tool nose radius, which will then be computed to move on the path accordingly offset from the programmed contour (see Diagram 1.18). MTS GmbH 1998 23

2. Introduction into NC Programming N G Block Number G- Command X ³ ÃÄ Z ³ F S T Coordinates of the Target Position Feed Speed Tool Number/Turret Position M Switches and Machine Functions (Spindle, Coolant...) Diagram 2.1 : Sequence of Words within an NC Block 24 Programmer's Guide for CNC Turning, Version 6.07

2.1 NC Block Format 2 Introduction into NC Programming A distinct program structure is essential for the generation of NC programs. Most importantly, the process of detecting eventual program errors will be much facilitated by a clear structure - especially if this task is carried out by a different programmer. 2.1 Structure of an NC Block (Format) Unlike the conventional lathe, a modern machine tool will be equipped with a numerical control system. The machining of a workpiece can be executed automatically, provided that each operational step has been described in a "language" (code) which can be read by the control system. The collection of coded descriptions referring to a workpiece is called an NC program. Blocks Words Address, Value Each NC program comprises a number of so-called blocks, which contain the commands to be executed. These blocks are consecutively numbered; each block number consisting of the letter "N" plus a (e.g. three-digit) numeral. Block numbers appear at the beginning of each program line. As a rule an NC block is comprised of several words. Each word consists of an address (letter) and a value or code (numerals). Example N110 G01 X+60 M03 Block No. Word Word Word A numeral may either denote a code (e.g. G01: Linear Feed Motion ) or a value (e.g. X+60 : Approaching the Target Coordinate X=60). Word Word Word G 01 Address Code X 60 Address Value F 0.07 Address Value MTS GmbH 1998 25

2. Introduction into NC Programming 2.2 Modal Commands and Non-modal Commands Modal commands are self-retentive, i.e. they will take effect in consecutive NC blocks, until they are deleted or overwritten by a command at the same address. Non-modal commands instead are "block-oriented", they will be active only in the block in which they are programmed. Examples of modal commands are: spindle speed, feedrate, sense of rotation, tool selection etc. Once entered, these commands will remain active also with the subsequently programmed blocks. Example: N115 F0.07 S1800 M03 N120 G01 Z-60 N125 X+70 N130 Z-85 Explanation: (see Diagram 2.2) Block No. N115 A feedrate of 0,07 mm/rev and a spindle speed of 1800 r.p.m., with clockwise spindle rotation, is programmed. This technology data is automatically retained to take effect through NC blocks N120 to N130. N120 The tool moves on a straight line (G01) from its current position to the target position Z=-60. N125 Because G01 is a modal command, the tool moves once again on a (vertical) straight line upwards to X=70. N130 The tool moves horizontal to Z=-85 Diagram 2.2 : Tool motions effected by modal commands (G01) for roughing 26 Programmer's Guide for CNC Turning, Version 6.07

2.3 Application and Representation of Addresses 2.3 Application and Representation of Addresses Example G96 S... As a rule, an NC command contains several addresses. These addresses must be discriminated as mandatory addresses (which must be programmed) and optional addresses (which may be programmed). In addition to this there are certain addresses which must always be programmed together (combined addresses) as well as others which cannot be programmed together (alternative addresses). To distinguish between the mandatory and optional addresses, as well as the combined and alternative addresses, in this guide the following mode of representation is applied: Addresses that must be programmed with a specific NC command ("mandatory addresses") appear in a separate NC block, without any additional program information. When the G96 command (constant cutting speed) is programmed, the address S, followed by the desired value, is a mandatory entry to this block. Addresses which are not mandatory but may instead be programmed with a specific command ("Optional Addresses") appear in brackets in the applicable program line. Example G78 X... Z... L... O... [D...] [I...] In this example of an NC block, the addresses X, Z, L and O must be programmed. Only the programming of the addresses D and I is optional. When one of the given addresses must or may be programmed, they appear together, separated by a slash. Example G75 X... Z... S.../D... In this case one of the addresses S and D must be programmed, i.e. either S or D. Addresses that must always be programmed together (combined addresses) are written together, without any separating sign. Example G82 K... [X... Z...] [R... V...] [H... W...] [L...] [E...] [A...] [O...] [Q...] If X is programmed, Z must be programmed as well. If R is programmed, V must be programmed as well just so if H is programmed, W must be programmed as well (and vice versa). MTS GmbH 1998 27

3. Miscellaneous Functions 3 Miscellaneous Functions (M-Functions) With each NC block a number of additional functions (commonly referred to as miscellaneous functions or M-Functions) can be programmed. These are often machine functions and switches, e.g. to specify the feedrate, the spindle speed and the tool change. 3.1 Activate/Deactivate Spindle M03 M04 M05 Activate Spindle - Right-Hand Rotation (Clockwise) Activate Spindle - Left-Hand Rotation (Counter-Clockwise) De-Activate Spindle M04: Spindle rotation counter-clockwise The sense of rotation is determined as seen from the drive, i.e. in the line of view of the positive Z-axis. 3.2 Coolant M07 Activate pump - Coolant 1 M08 Activate pump - Coolant 2 M09 De-activate coolant pump 3.3 Programmed Halt M00 After the execution of a block which contains the command M00, the program execution will be halted, to allow gauging of the workpiece. 28 Programmer's Guide for CNC Turning, Version 6.07

3.4 Program End 3.4 Program End M30 M02 M99 This command serves to terminate the program. The spindle rotation and the coolant pump will be deactivated and the automatic program run is terminated. All incremental or rotary zero shifts (G59) are undone (with older types of NC lathes the punched tape will be rewound). The system quits the automatic mode after execution of that NC block in which M02 has been programmed ( with older types of NC lathes the punched tape will not be rewound). This command terminates a subprogram. The control system will return to the main program and continue the program run from the command in the respective program line which is subsequent to the subprogram invocation. 3.5 Lock / Unlock Centre Sleeve M20 M21 If the tailstock has been selected, the M20 command serves to lock the centre sleeve. The M21 command unlocks the sleeve. 3.6 Feedrate F... The feedrate is programmed in millimeters per revolution (mm/rev). Example: F000.200 Here the programmed feedrate is 0,2 millimeters per revolution. FAlternatively the feedrate may be programmed in millimeters per minute (see G94 and G95). 3.7 Spindle Speed S... The spindle speed is programmed in revolutions per minute (RPM). Example: S1800 Here the programmed spindle speed is 1800 revolutions per minute. MTS GmbH 1998 29

3. Miscellaneous Functions 3.8 Tool Change T... A tool change is programmed by a four-digit number at the address T. The first two digits designate the tool position in the turret, the last two digits indicate the tool compensation storage. Example: T0808 Programming of this number effects the insertion of the correct tool at the turret position 8 as well as the concurrent loading of tool compensation storage No. 8. In the CNC Simulator there is a maximum of 16 turret positions available, as well as 99 compensation value storage registers. This provides the opportunity, for example, to assign the compensation value storage No. 36 to the tool in the turret position No. 12, if this seems applicable. The corresponding NC command would then be: T1236 FIf you decide to program an NC block containing one or several M - functions together with a G-command, please take care to observe the proper sequence of command execution, as listed in the following table: To be executed prior to the G-command: To be executed after the G-command M03/M04Activate spindle M00 Programmed halt M07/M08Activate coolant M02 Program end without backspacing M20/M21Lock/Unlock Sleeve M05 De-activate spindle F Feedrate M09 De-activate coolant S Speed M30 Program end and backspacing T Tool change M99 Subprogram end An NC block may contain a maximum of three M-commands. 30 Programmer's Guide for CNC Turning, Version 6.07

Rapid Traverse G00 4 Programming Commands in Compliance with DIN 66025 Table of available DIN commands: G00 G01 G02 G03 G04 G09 G20 G21 G22 G23 G24 G25 G26 G28 G33 G40 G41/G42 G51 G53 G54 - G56, G58 G59 G90 G91 G92 G94 G95 G96 G97 Rapid Traverse Linear Interpolation in Slow Feed Motion Circular Interpolation Clockwise Circular Interpolation Counter-clockwise Dwell In-Position Programming (Deceleration) Unit of Measurement: (Inch) Unit of Measurement: (mm) Subprogram Invocation Repeated Program Part (Routine) Unconditional Jump Instruction Move to the Reference Point Move to the Tool Changing Position Positioning of the Tailstock Threading Cancel Tool Nose Compensation Tool Nose Compensation to the left/right of the Contour Programmed Contour Cancel Incremental Zero Shift Set Absolute Zero Incremental Zero Shift Activate Absolute Dimensioning Activate Incremental Dimensioning Speed Limitation Feedrate (mm/min) Feedrate (mm/rev) Constant Cutting Speed Cancel Constant Cutting Speed MTS GmbH 1998 31

G00 Rapid Traverse Programming Absolute Dimensions: N... G90 N... ò N... N115 G00 X+30 Z+5 Diagram G00.1 : Programming absolute dimensions - the tool moves to the point X=30/Z=5. In this example the X-coordinate is programmed relative to the diameter. Programming Incremental Dimensions: N... G91 N... ò N... N115 G00 X-12,5 Z-35 Diagram G00.2 : Programming incremental dimensions - the tool moves in the direction X by the value 12.5 and in the direction Z by the value -35. Positioning the tool at X+30 / Z+5 will be possible only if the tool has been positioned at X+55, Z+40 (start position) in the preceding block. In this example the X-coordinate is programmed relative to the radius. 32 Programmer's Guide for CNC Turning, Version 6.07

Rapid Traverse G00 4.1 Rapid Traverse G00 Function The tool moves at the maximum possible speed to the target position as programmed by the X- and Z- coordinates. These coordinates may either be programmed in the absolute system (G90) or in the incremental system (G91). NC Block G00 [X...] 1) [Z...] 1) [F...] [S...] [T...] [M...] Optional Addresses X X-Coordinate of the Target Point Z Z-Coordinate of the Target Point 1) If a tool movement parallel to an axis is desired, the respective target coordinate will be identical with that of the current tool position. It does not have to be programmed separately, as the coordinate address is self-retentive. If none of the coordinates in X and Z has been programmed, only the rapid traverse function will be retained. F S T M Feedrate (mm/rev) Speed (RPM) Tool Change Additional Function Programming Hints If a tool change, a change of the feedrate and/or a change of spindle speed is programmed within the same NC block, the tool change will be executed first; the change of speed is effected at the beginning of the tool movement, while at the same time the feedrate value is entered to the register. A maximum of three M-commands may be programmed; their respective order of execution is described in Section 3 ("Miscellaneous Functions"). FWhen absolute dimensioning (G90) is operative, the X-coordinate is programmed relative to the diameter of the workpiece. When incremental dimensioning (G91) is operative, the X-coordinate is programmed relative to the radius of the workpiece. MTS GmbH 1998 33

G01 Linear Interpolation in Slow Feed Motion Example for Programming Absolute Dimensions: N... G90 N... ò N... N115 G01 X+140 Z-90 Diagram G01.1 : Programming absolute dimensions - the tool moves to the point X=140, Z=-90. The X-coordinate is programmed relative to the diameter. Example for Programming Incremental Dimensions N... G91 N... ò N... N115 G01 X+20 Z-60 Diagram G01.2 : Programming incremental dimensions - the tool moves in the direction X by the value 20 and in the direction Z by the value-60. Positioning the tool at X+140, Z-90 will be possible only if the tool has been positioned at X+100, Z-30 (start position) in the previous block. The X-coordinate is programmed relative to the radius. 34 Programmer's Guide for CNC Turning, Version 6.07

Linear Interpolation in Slow Feed Motion G01 4.2 Linear Interpolation in Slow Feed Motion G01 Function The tool moves at the programmed feedrate to the target position as determined by the X- and Z- coordinates. These coordinates may either be programmed in the absolute system (G90) or in the incremental system (G91). NC Block G01 [X...] 1) [Z...] 1) [F...] [S...] [T...] [M...] Optional Addresses X X-Coordinate of the Target Point Z Z-Coordinate of the Target Point 1) If a tool movement parallel to an axis is desired, the respective target coordinate will be identical with that of the current tool position. It does not have to be programmed separately, as the coordinate address is self-retentive. If none of the coordinates in X and Z has been programmed, only the slow feed function will be retained. F S T M Feedrate (mm/rev) Speed (RPM) Tool Change Additional Function Programming Hints If a tool change, a change of the feedrate and/or a change of speed has been programmed within the same NC block, these functions will be executed before the tool is moved to the target position. A maximum of three M-commands may be programmed; their respective order of execution is described in Section 3 ("Miscellaneous Functions"). FWhen absolute dimensioning (G90) is operative, the X-coordinate is programmed relative to the diameter of the workpiece. When incremental dimensioning (G90) is operative, the X-coordinate is programmed relative to the radius of the workpiece. MTS GmbH 1998 35

G02 Clockwise Circular Interpolation 4.3 Clockwise Circular Interpolation G02 Function NC Block The tool will move at the programmed feedrate clockwise on a circular arc to the target position as defined by the coordinates in X and Z. G02 [X...] 1) [Z...] 1) [I...] 2) [K...] 2) [F...] [S...] [T...] [M...] Optional Addresses X X-Coordinate of the target point When absolute dimensions are programmed (G91), X relates to the workpiece diameter. When incremental dimensions are programmed (G91), X relates to the workpiece radius. Z Z-Coordinate of the target point 1) If a target coordinate is identical to the corresponding coordinate of the current tool position, it does not have to be programmed, as the coordinate address is selfretentive. I K Circle Centre Incremental (distance between the starting position and the circle centre in the direction X, relative to the radius). Circle Centre Incremental (distance between the starting position and the circle centre in the direction Z). 2) When I or K (as described above) are not programmed, the respective centre coordinate is set to zero. F S T M Feedrate (mm/rev) Spindle Speed (RPM) Tool Change Additional Function Programming Example: N110 G01 X+80 Z-40 N115 G02 X+140 Z-106 I+45 K-20 Programming Hints The coordinates X and Z may either be programmed in the absolute system (G90) or in the incremental system (G91). The default mode for definition of centre coordinates I and K is incremental (relative to the starting point). In the configuration program for the control system for turning the centre dimensioning can be set to the absolute system (see Configuration Manual). If a tool change, a change of the feedrate and/or a change of speed has been programmed within the same NC block, these commands will be executed before the tool is moved to the target position. 36 Programmer's Guide for CNC Turning, Version 6.07

Counter-Clockwise Circular Interpolation G03 4.4 Circular Interpolation Counter-Clockwise G03 Function NC Block The tool will move at the programmed feedrate counter-clockwise on a circular arc to the target position as defined by the coordinates in X and Z. G03 [X...] 1) [Z...] 1) [I...] 2) [K...] 2) [F...] [S...] [T...] [M...] Optional Addresses X X-Coordinate of the target point When absolute dimensions are programmed (G91), X is related to the workpiece diameter. When incremental dimensions are programmed (G91), X is related to the radius of the workpiece. Z Z-Coordinate of the target point 1) If a target coordinate is identical to the corresponding coordinate of the current tool position, it does not have to be programmed, as the coordinate address is selfretentive. I K Circle Centre Incremental (distance between the starting position and the centre of the circle in the direction X, relative to the radius). Circle Centre Incremental (distance between the starting position and the centre of the circle in the direction Z). 2) When I or K (as described above) are not programmed, the respective centre coordinate is set to zero. F Feedrate (mm/rev) S Spindle Speed (RPM) T Tool Change M Additional Function Programming Example: N110 G01 X+80 Z-50 N115 G03 X+140 Z-80 I-15 K-45 Programming Hints The coordinates X and Z may either be programmed in the absolute system (G90) or in the incremental system (G91). The default mode for definition of centre coordinates I and K is incremental (relative to the starting point). In the configuration program for the control system for turning, the centre dimensioning can be set to the absolute system (see Configuration Manual). If a tool change, a change of the feedrate and/or a change of speed has been programmed within the same NC block, these commands will be executed before the tool is moved to the target position. MTS GmbH 1998 37

G04 Dwell 4.5 Dwell G04 Function The tool movement is halted for the specified dwell time. NC Block G04 X... Addresses X Dwell time in seconds Programming example N120 G04 X2 Programming Hints The dwell time must be specified in seconds, at the address X. The G04 command must be programmed in a separate NC block. 4.6 polygonal machining G08 Function The function G08 serves to machine an N polygon. Condition The selected machining plane is the turning plane G14! NC Block G08 O... V... W... [C...] Optional Addresses O Number of corners of the N-polygon V Length of the N-polygon V is positive: the length is from the actual postion incremental in positive Z direction V is negative: the length is from the actual postion incremental in negative Z direction W Width of the N-polygon N is an even number: the width of each polygon side D corresponds to the distance of two opposite areas. N is an uneven number: the width of each polygon side D corresponds to the distance of one side to the opposite area. C rotary angle of the N-polygon Programming example N50 G08 O006 V-072.000 W+040.00 3D view of an hexagon 38 Programmer's Guide for CNC Turning, Version 6.07

In-Position Programming (Deceleration) G09 4.7 In-Position Programming (Deceleration) G09 Function When G09 is programmed as part of an NC block, the feedrate will be decelerated to zero as the programmed contour point is approached. After the standstill at precisely the programmed position, the tool motion is resumed and the the next contour point, as programmed in the subsequent NC block, is approached. NC Block G01 [X...] 1) [Z...] 1) G09 or [X...] 1) [Z...] 1) G09 1) If a tool movement parallel to an axis is desired, the respective target coordinate is identical to that of the current tool position. It does not have to be programmed, as the coordinate address is self-retentive. Explanation: As NC programs are executed continuously, i.e. without interruption of the feed motion, position errors such as lags or overshots may occur. To move the tool precisely to the programmed coordinates, the G09 command must be programmed. Programming Example: N110 G00 X+40 Z-20 N115 G01 X+100 Z-35 G09 N120 G01 X+130 Z-60 G09 N125 G01 X+140 Z-95 Programming Hints The G09 command must be programmed at the end of the NC block. MTS GmbH 1998 39