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HEIDENHAIN MANUALPLUS 4110, Manual

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HEIDENHAIN MANUALPLUS 4110 Manual Download Page 103

HEIDENHAIN MANUALplus 4110 Surface Machining Example

8.1

Create the “Matrix” cycle program

“Matrix” example program

This example illustrates transverse machining. (It is assumed that the reader is familiar with steps 
explained in the previous example.)

Prerequisites:

„

The workpiece blank is clamped

„

The roughing tool T1 is clamped

„

The roughing tool T1 and finishing tool T6 is defined and measured

„

The workpiece datum is defined

„

The tool change point is defined

„

The protection is defined and activated

„

The maximum shaft speed is defined

Summary of Contents for MANUALPLUS 4110

Page 1: ...MANUALplus 4110 NC Software 507 807 xx 9 2004 User Training ...

Page 2: ...ey may only be copied and printed for private scientific and non commercial informative purposes and only if they include this copyright notice Dr JOHANNES HEIDENHAIN GmbH reserves the right to revoke this permission at any time Without obtaining written permission in advance from Dr JOHANNES HEIDENHAIN GmbH the texts pictures and graphics may not be duplicated archived stored on a server included...

Page 3: ...User Components 2 System Operation 3 Tool Management Setup 4 Tool Measurement 5 Machine Setup 6 Longitudinal Machining Example Programming 7 Surface Machining Example 8 Recess Machining Example 9 Simulation 10 Program Execution 11 12 ...

Page 4: ......

Page 5: ...s the Z axis Traverse motions Program a positive value to depart the workpiece Program a negative value to approach the workpiece Reference points The machine datum M is the origin of the machine coordinate system As a rule the machine datum is at the intersection of the Z axis with the spindle surface The workpiece datum W is the origin of the workpiece coordinate system As a rule the workpiece d...

Page 6: ... either in front of or behind the workpiece The MANUALplus 4110 detects the design of your machine and takes the position of the X axis into account for the graphic support the simulation and the machining of the workpiece Tool in front of the workpiece Tool behind the workpiece This documentation assumes a lathe with tools in front of the workpiece ...

Page 7: ...tool tip is clearly defined by its X and Z coordinates in a two dimensional coordinate system The MANUALplus 4110 recognizes linear and circular contour elements A workpiece contour is programmed by entering the coordinates for a succession of points and connecting them with linear or circular contour elements The coordinates entered for the axes X and Z are referenced to the workpiece datum Angle...

Page 8: ...erse are referenced to the theoretical tool tip S The radius of the tool tip on lathe tools causes inaccuracies when machining tapers chamfers and radii These inaccuracies are removed with the cutter radius compensation A new path of traverse the equidistant line is calculated to compensate for this error ...

Page 9: ...dle speed is independent of the diameter the tool is working on Constant cutting speed You program the spindle speed indirectly The MANUALplus 4110 changes the spindle speed depending on the diameter momentarily being worked on by the tool This results in a constant cutting speed Example Constant spindle speed Sections 1 to 3 identical spindle speeds Constant cutting speed Section 1 High spindle s...

Page 10: ...HEIDENHAIN MANUALplus 4110 Basic Knowledge 1 6 ...

Page 11: ...s of operation Process key Selects a mode of operation Prerequisite the MANUALplus 4110 must be in the main menu Backspace key Deletes the character to the left of the cursor Deletes the most recent error message Switching key Toggles the support graphics between internal and external machining Clear key Deletes all error messages ...

Page 12: ... algebraic sign Enter key Confirms the entered value Store key Concludes data input and stores values Arrow keys Moves the cursor in the indicated direction by one position character field line etc Page forward Page back Shows the information on the previous or next screen page Switches between two input windows Info key Calls the error information or PLC status display ...

Page 13: ...osition on the control s numerical keypad The meaning of the symbol menu item is also described in the footer Example The 4 key calls the Roughing cycles longitudinal transverse submenu Soft keys A bar at the bottom of the screen shows you the meaning of the soft keys Press the corresponding key to call the function Soft keys as toggle switches Some soft keys work like toggle switches The status t...

Page 14: ...ce to go is not displayed Axes are traversed with the jog keys with protection zone monitoring active The distance to go for the Z axis refers to the protection zone position Axes are traversed with the jog keys with protection zone monitoring not active The distance to go refers to the software limit switches The machine data display is configurable The display on your screen may therefore deviat...

Page 15: ... Feed rate display element Top line Programmed feed rate Bottom line Current feed rate override Actual feed rate taking the feed rate override into account Units type of feed rate mm r Feed rate per revolution mm min Feed rate per minute Cycle ON Cycle or program is being performed Cycle STOP Rapid traverse paths The feed rate is displayed as feed rate per minute Set the feed rate per revolution f...

Page 16: ...its Cutting speed m min Spindle speed r min Spindle rotates counterclockwise M3 Spindle rotates clockwise M4 Spindle stop Display for positioning of spindle M19 Top line Target position Bottom line Current position Driven tool Identification The S is highlighted The display refers to the driven tool Set a constant cutting speed the constant spindle speed is deactivated Set a constant spindle speed...

Page 17: ...nt The last two digits Rotated position of the turret Tool display element Identification letter T Depending on the tool carrier either a 2 or 4 digit number follows without leading zeros Fields dx dz Current tool compensation Example T1 T1 from the tool manager is activated Example T28 T28 from the tool manager is activated Example T101 T1 from the tool manager is activated Rotated turret positio...

Page 18: ...locked for the axes to be enabled Colors of the identification letters White identification letters Axes are not enabled Black identification letters Axes are enabled Main switch on In the screen dialog line the MANUALplus 4110 shows you step by step how to proceed when starting the system Symbol indicating the existence of current PLC status information Call the PLC status display Press the Info ...

Page 19: ...ines with EnDat encoders Sequence for reference run On standard encoders A fixed reference mark is traversed This direction of approach must be considered For distance coded encoders The MANUALplus 4110 finds the position after a brief reference run There are reference marks every 20 to 80 mm Traversing the reference marks Pre position the axes with handwheels or jog keys Press the X Reference sof...

Page 20: ...nce marks Confirm tool The MANUALplus 4110 assumes that the most recently active tool is still in the tool holder Confirm the tool with the Tool change button The tool and feed rate are enabled On some machines such as those with automatic tool changer the acknowledgment is automatic ...

Page 21: ...urrent operating mode Press the Menu key Select the operating mode line Press the Process key Mark the desired operating mode Press the arrow key Activate the marked operating mode Press the Process key again The active operating mode is marked in the tab of the uppermost screen line The operating modes are changed from the main menu ...

Page 22: ...y To close the error window without deleting the error messages Press the Back soft key Processing PLC status displays Remove the cause of the message then the message is deleted and the window closed Switching between the error window and the PLC status display Call the PLC status display Press the PLC diagnosis soft key Call the error window Press the CNC diagnosis soft key Open the error window...

Page 23: ...he control If this is not done appropriately loss of data and functional problems can occur Call the main menu of the Machine operating mode Press the Menu key Press the Switch off soft key Confirm the confirmation request Press the Enter key When the picture of the main switch in the power off position appears Switch the machine off with the main switch ...

Page 24: ...HEIDENHAIN MANUALplus 4110 System Operation 3 12 ...

Page 25: ... and the setup functions For better identification of the tools the tool text is added as a description The first tool serves as a reference tool The setting dimensions are measured and entered The setting dimensions of the other tools are not yet relevant They will be measured later Tool measurement Roughing tool T1 Cutting radius 0 8 mm Tool angle 93 Point angle 80 Setup dimension X 92 mm Setup ...

Page 26: ...d a new tool Press the Insert soft key The cursor is on the position T 1 Select the tool type Press the Lathe tool menu key Setup dimension X in X 92 mm Setup dimension Z in Z 62 mm Cutting radius R 0 8 mm Tool orientation WO 1 outside tool machining direction toward the chuck Tool angle A 93 Tip angle B 80 Wear compensation DX in X 0 mm Wear compensation DZ in Z 0 mm ...

Page 27: ... key The cursor is on the position Q 1 Enter text Press the Change text soft key Enter Roughing tool Outside Select each letter with the arrow keys and confirm them with the Enter key Save the entered text Press the Save soft key Save the text number to the parameter Tool text Q Press the Take over text no soft key ...

Page 28: ...eed TS 200 m min Feed rate TF 0 4 mm rev Quantity PZ No entry Save the tool data Press the Save soft key Setup dimension X in X 92 mm Setup dimension Z in Z 62 mm Cutting radius R 0 8 mm Tool orientation WO 1 Tool angle A 93 Tip angle B 80 Wear compensation DX in X 0 mm Wear compensation DZ in Z 0 mm Tool text Q 1 Machining direction MD M3 3 M4 4 3 Cutting speed TS 200 m min Feed rate TF 0 4 mm re...

Page 29: ...he setting dimensions are assumed at first and will be determined exactly later Assume tool data and specify the position in the tool manager Roughing tool T2 Cutting radius 0 8 mm Tool angle 93 Tip angle 55 Load the tool data T1 into the intermediate memory Press the Copy soft key Place the cursor on position T2 Press the arrow key Insert the tool data from the intermediate memory to position T2 ...

Page 30: ...rrow key repeatedly Tip angle B 55 Save the tool data T2 Press the Save soft key Setup dimension X in X 92 mm Setup dimension Z in Z 62 mm Cutting radius R 0 8 mm Tool orientation WO 1 Tool angle A 93 Tip angle B 55 Wear compensation DX in X 0 mm Wear compensation DZ in Z 0 mm Tool text Q 1 Machining direction MD M3 3 M4 4 3 Cutting speed TS 200 m min Feed rate TF 0 4 mm rev Lifetime PT Quantity P...

Page 31: ...ns are assumed at first and will be determined exactly later Finishing tool T6 Cutting radius 0 4 mm Tool angle 93 Tip angle 55 Load the tool data T2 into the intermediate memory Press the Copy soft key Place the cursor on position T6 Press the arrow key repeatedly Insert the tool data from the intermediate memory to position T6 Press the Insert soft key ...

Page 32: ...the input field Cutting radius R Press the arrow key repeatedly Cutting radius R 0 4 mm Press the Tool text soft key Place the cursor on position Q 2 Press the arrow key Press the Change text soft key Enterthetext Finishingtool Outside with the on screen keyboard Press the Save soft key Save the text number to the parameter Tool text Q Press the Take over text no soft key ...

Page 33: ... rate TF 0 25 mm rev Save the tool data Press the Save soft key Setup dimension X in X 92 mm Setup dimension Z in Z 62 mm Cutting radius R 0 4 mm Tool orientation WO 1 Tool angle A 93 Tip angle B 55 Wear compensation DX in X 0 mm Wear compensation DZ in Z 0 mm Tool text Q 2 Machining direction MD M3 3 M4 4 3 Cutting speed TS 220 m min Feed rate TF 0 25 mm rev Lifetime PT Quantity PZ ...

Page 34: ...are preliminarily entered as 0 Place the cursor on position T8 Press the arrow key repeatedly Add a new tool Press the Add soft key Select the tool type Press the Threading tool menu key Setup dimension X in X 0 mm Setup dimension Z in Z 0 mm Tool orientation WO 1 outside tool machining direction toward the chuck Wear compensation DX in X 0 mm Wear compensation DZ in Z 0 mm ...

Page 35: ...ition Q 3 Press the arrow key Enter text Press the Change text soft key Enter the text Thread cut tool Outside with the on screen keyboard Press the Save soft key Save the text number to the parameter Tool text Q Press the Take over text no soft key Press the Page forward key Machining direction MD M3 3 M4 4 3 3 Machining direction to the right Shaft speed TS 600 rev min ...

Page 36: ...a T8 Save the tool data Press the Save soft key Setup dimension X in X 0 mm Setup dimension Z in Z 0 mm Tool orientation WO 1 Wear compensation DX in X 0 mm Wear compensation DZ in Z 0 mm Tool text Q 3 Machining direction MD M3 3 M4 4 3 Shaft speed TS 600 rev min Lifetime PT Quantity PZ ...

Page 37: ...mensions are preliminarily entered as 0 Place the cursor on position T10 Press the arrow key repeatedly Add a new tool Press the Add soft key Select the tool type Press the Recessing tool menu key Setup dimension X in X 0 mm Setup dimension Z in Z 0 mm Cutting radius R 0 2 mm Tool orientation WO 1 Cutting width K 5 mm Wear compensation DX in X 0 mm Wear compensation DZ in Z 0 mm Special compensati...

Page 38: ...row key Enter text Press the Change text soft key Enter the text Recessing tool Outside with the on screen keyboard Press the Save soft key Save the text number to the parameter Tool text Q Press the Take over text no soft key Press the Page forward key Machining direction MD M3 3 M4 4 3 3 Machining direction to the right Cutting speed TS 120 m min Feed rate TF 0 2 mm rev Quantity PZ No entry ...

Page 39: ...Setup dimension X in X 0 mm Setup dimension Z in Z 0 mm Cutting radius R 0 2 mm Tool orientation WO 1 Cutting width K 5 mm Wear compensation DX in X 0 mm Wear compensation DZ in Z 0 mm Special compensation DS 0 mm Tool text Q 4 Machining direction MD M3 3 M4 4 3 Cutting speed TS 120 m min Feed rate TF 0 2 mm rev Lifetime PT Quantity PZ ...

Page 40: ...HEIDENHAIN MANUALplus 4110 Tool Management 4 16 ...

Page 41: ... the measured tool T1 First step Determine the workpiece datum to set a measuring diameter Further steps Determine the setting dimensions of the tools by touching the workpiece Prepare the machine Entering the machine data Clamp a workpiece Clamp tool T1 Call the main menu Press the Menu key Select machine data entry Press the Set S F and T menu key ...

Page 42: ... tool soft key Assume the cutting speed and feed rate from the tool file Press the S F from tool soft key Entered and assumed machine data Tool number T 1 Cutting speed S 200 m min Feed rate per revolution F 0 4 mm rev Maximum shaft speed D 2000 rev min Stopping angle A No entry Activate machine data Press the Save soft key The maximum speed depends on the machine and the clamped workpiece ...

Page 43: ...atum Confirm T1 with the tool change key Return to the main menu Press the Back soft key Switch the spindle on Position the tool to the workpiece with the handwheels Call the main menu Press the Menu key Call the setup functions Press the Setup menu key Call Set datum Press the Set axis values menu key ...

Page 44: ...ace turning Machine in X direction with the handwheel Retract the tool in X direction Define the faced surface as workpiece datum Press the Z 0 soft key Display The actual value display now shows 0 for the Z axis Return to the setup menu Press the Back soft key Return to the main menu Press the Back soft key ...

Page 45: ...he precise setting dimensions as follows Setting dimension X Turn and measure the measuring diameter Setting dimension Z Is already specified with the definition of the workpiece datum Call the Measure tool function Call the main menu Press the Menu key Select machine data entry Press the Set S F and T menu key Tool T1 is already activated Select Measure tool Press the Measure tool soft key ...

Page 46: ...ss the Tale over X soft key The MANUALplus 4110 calculates the setting dimension X and enters it in the tool file Display The actual value display now shows the value entered for the X axis Conclude measurement of tool T1 Press the Back soft key Notes on the setting dimension in Z The position of the tool tip relative to the workpiece datum is definitive for the programming and display Small devia...

Page 47: ...he precise setting dimensions as follows Setting dimension X Touch measuring diameter Setting dimension Z Touch the end face workpiece datum Activate tool T2 Situation after measurement of tool T1 Open the tool file Press the Tool list soft key Place the cursor on position T2 Press the arrow key Press the Take over tool soft key ...

Page 48: ...ies and assumed machine data Tool number T 2 Cutting speed S 200 m min Feed rate per revolution F 0 4 mm rev Maximum shaft speed D 2000 rev min Stopping angle A No entry Activate the tool Press the Save soft key Insert tool T2 Confirm T2 with the tool change key Select the Measure tool function Press the Measure tool soft key ...

Page 49: ...ameter with the tool Retract the tool in Z direction Enter the touched measuring diameter in Measuring point coordinate X Press the Take over X soft key Touch the end face with the tool Retract the tool in X direction Enter the value 0 position of workpiece datum for the measuring point coordinate Z Press the Take over Z soft key Conclude measurement of tool T2 Press the Back soft key ...

Page 50: ...ecise setting dimensions as follows Setting dimension X Touch measuring diameter Setting dimension Z Touch the end face workpiece datum Activate tool T6 Situation after measurement of tool T2 Open the tool file Press the Tool list soft key Place the cursor on position T6 Press the arrow key repeatedly Press the Take over tool soft key ...

Page 51: ... min Feed rate per revolution F 0 25 mm rev Maximum shaft speed D 2000 rev min Stopping angle A No entry Activate the tool Press the Save soft key Insert tool T6 Confirm T6 with the tool change key Select the Measure tool function Press the Measure tool soft key Touch the measuring diameter with the tool Retract the tool in Z direction Enter the touched measuring diameter in Measuring point coordi...

Page 52: ...ions for T6 Touch the end face with the tool Touch the end face with the tool Retract the tool in X direction Enter the value 0 position of workpiece datum for the measuring point coordinate Z Press the Take over Z soft key Conclude measurement of tool T6 Press the Back soft key ...

Page 53: ...ecise setting dimensions as follows Setting dimension X Touch measuring diameter Setting dimension Z Touch the end face workpiece datum Activate tool T8 Situation after measurement of tool T6 Open the tool file Press the Tool list soft key Place the cursor on position T8 Press the arrow key repeatedly Press the Take over tool soft key ...

Page 54: ...ol number T 8 Shaft speed S 600 rev min Feed per revolution F Maximum shaft speed D 2000 rev min Stopping angle A No entry Activate the tool Press the Save soft key The parameter Feed rate per revolution F is not evaluated for threading tools Insert tool T8 Confirm T8 with the tool change key Select the Measure tool function Press the Measure tool soft key ...

Page 55: ...iameter with the tool Retract the tool in Z direction Enter the touched measuring diameter in Measuring point coordinate X Press the Take over X soft key Touch the end face with the tool Retract the tool in X direction Enter the value 0 position of workpiece datum for the measuring point coordinate Z Press the Take over Z soft key Conclude measurement of tool T8 Press the Back soft key ...

Page 56: ...ecise setting dimensions as follows Setting dimension X Touch measuring diameter Setting dimension Z Touch the end face workpiece datum Activate tool T10 Situation after measurement of tool T8 Open the tool file Press the Tool list soft key Place the cursor on position T10 Press the arrow key repeatedly Press the Take over tool soft key ...

Page 57: ... min Feed rate per revolution F 0 2 mm rev Maximum shaft speed D 2000 rev min Stopping angle A No entry Activate the tool Press the Save soft key Insert tool T10 Confirm T10 with the tool change key Select the Measure tool function Press the Measure tool soft key Touch the measuring diameter with the tool Retract the tool in Z direction Enter the touched measuring diameter in Measuring point coord...

Page 58: ...d face with the tool Touch the end face with the tool Retract the tool in X direction Enter the value 0 position of workpiece datum for the measuring point coordinate Z Press the Take over Z soft key Conclude measurement of tool T10 Press the Back soft key Return to the main menu Press the Back soft key ...

Page 59: ...ating a tool Entering technology data shaft speed cutting speed feed rate maximum speed Setting the workpiece zero point Defining the protection zone Defining the tool change point Prepare the machine Entering the machine data Clamp a workpiece Clamp tool T1 Call the main menu Press the Menu key Select machine data entry Press the Set S F and T menu key ...

Page 60: ...tool soft key Press the S F from tool soft key Entered and assumed machine data Tool number T 1 Cutting speed S 200 m min Feed rate per revolution F 0 4 mm rev Maximum shaft speed D 2000 rev min Stopping angle A No entry Activate machine data Press the Save soft key The maximum speed depends on the machine and the clamped workpiece Confirm T1 with the tool change key Return to the main menu Press ...

Page 61: ...ENHAIN MANUALplus 4110 Machine Setup 6 3 Specify the workpiece datum Set the workpiece datum Call the main menu Press the Menu key Press the Setup menu key Call Set datum Press the Set axis values menu key ...

Page 62: ...datum Press the Z 0 soft key Displays Actual value display for Z axis 0 The field highlighted in blue in the support graphics shows the datum offset distance between machine datum and workpiece datum Return to the setup menu Press the Back soft key Return to the main menu Press the Back soft key The tool may not be moved in Z direction after the face turning Only after the faced surface has been d...

Page 63: ...ne Setup 6 5 Defining the protection zone Setting the protection zone Call the main menu Press the Menu key Press the Setup menu key Call Protection zone Press the Set protection zone menu key Protective zone monitoring is deactivated ...

Page 64: ...e parameter Press the Take over position soft key Display The field highlighted in blue shows the distance from the machine datum to the protection zone position Return to the setup menu Press the Back soft key Protective zone monitoring is activated Return to the main menu Press the Back soft key Symbols for protection zone monitoring Protective zone monitoring not activated Protective zone monit...

Page 65: ...etup 6 7 Defining the tool change point Defining the tool change position Call the main menu Press the Menu key Call the setup functions Press the Setup menu key Call Defining the tool change point Press the Set tool change point menu key ...

Page 66: ...lways program the tool change point far away enough from the workpiece to avoid damage during a tool change Define the tool change point Press the Take over position soft key Display The fields highlighted in blue show the distance from the machine datum to the tool change point Return to the setup menu Press the Back soft key Return to the main menu Press the Back soft key ...

Page 67: ...ual working steps for machining the ICP contour and integrating the contour into ICP cycles are based on the workpiece drawing Prerequisites The workpiece blank is clamped The roughing tool T1 is clamped The tools to be used is defined and measured The workpiece datum is defined The tool change point is defined The protection is defined and activated The maximum shaft speed is defined All values a...

Page 68: ...reate the Threaded stud cycle program Creating a cycle program Activate the teach in mode Press the Teach in soft key Call the program list Press the Program list soft key Enter program number 1 for Cycle program Call cycle program 1 Press the Select soft key ...

Page 69: ... cycle program Program the cycle Blank bar tube Enter the program name Press the Change text soft key Enter the text Threaded stud with the on screen keyboard Save the entered text Press the Save soft key Add a new cycle Press the Add cycle soft key Press the Define blank menu key ...

Page 70: ...Bar Tube menu key Enter the cycle parameters Outside diameter X 60 mm Length Z 100 mm Inside diameter I No entry Right edge K 1 mm face oversize Clamping range B 20 mm Clamp type J 1 Conclude entry Press the Input finished soft key Test the cycle Press the Graphics soft key Conclude entry Press the Save soft key ...

Page 71: ...ycle parameters Starting point X in X direction 60 mm Starting point Z in Z direction 4 mm Infeed depth P 4 mm I oversize X 0 3 mm K oversize Z 0 1 mm ICP contour number N 1 specify the ICP contour number Tool number T 1 Cutting speed S 200 m min Feed rate per revolution F 0 4 mm rev Assume the tool number and technology data from the tool file see following steps Create the ICP contour threaded s...

Page 72: ...d stud cycle program Assume the tool and technology data from the tool file Open the tool file Press the Tool list soft key Assume the tool cursor is on the position T 1 Press the Take over tool soft key Assume the cutting speed and feed rate Press the S F from tool soft key ...

Page 73: ...ed stud ICP contour Threaded stud The contour is described in the machining direction The contour is described completely including form elements Call the ICP editor Contour element 1 chamfer Press the Edit ICP soft key Press the Insert element soft key Press the Form elements menu key ...

Page 74: ...t Press the Chamfer menu key Describe the contour element Starting point XS in X 16 mm Starting point ZS in Z 0 mm Chamfer width B 1 5 mm Element position J 1 Special feed rate F No entry Conclude entry Press the Save soft key Unresolved elements are shown as symbols below the graphics window Press the Form elements menu key ...

Page 75: ...th No entry W undercut angle No entry R undercut radius No entry Element position J No entry Special feed rate F No entry The MANUALplus 4110 determines the undercut parameters from the thread pitch Conclude entry Press the Save soft key The part of the contour you have entered up to now is clearly defined and is displayed Press the Line menu key Describe the contour element Target point X in X 40...

Page 76: ...ed stud Contour element 4 horizontal line Conclude entry Press the Save soft key Contour element 4 horizontal line Press the Line menu key Describe the contour element Target point Z in Z 55 mm Length of line L No entry Special feed rate F No entry Conclude entry Press the Save soft key ...

Page 77: ...ent 6 vertical line Press the Form elements menu key Press the Rounding menu key Describe the contour element Rounding radius B 4 mm Special feed rate F No entry Conclude entry Press the Save soft key Press the Line menu key Describe the contour element Target point X in X 55 mm Length of line L No entry Special feed rate F No entry ...

Page 78: ... ICP contour Threaded stud Contour element 7 chamfer Conclude entry Press the Save soft key Press the Form elements menu key Press the Chamfer menu key Describe the contour element Chamfer width B 2 mm Special feed rate F No entry Conclude entry Press the Save soft key ...

Page 79: ...our element 9 vertical line Press the Line menu key Describe the contour element Target point Z in Z 70 mm Length of line L No entry Special feed rate F No entry Conclude entry Press the Save soft key Press the Line menu key Describe the contour element Target point X in X 60 mm Length of line L No entry Special feed rate F No entry ...

Page 80: ...ntour Threaded stud Enter the contour name Conclude entry Press the Save soft key The threaded stud contour is completely described Exit the input mode Press the Back soft key Press the Contour list soft key Press the Change text soft key Enter the contour name Threaded stud ...

Page 81: ...4110 Linear Machining Example 7 15 Create the ICP contour Threaded stud Press the Take over text soft key Exit the contour list Press the Back soft key Exit the ICP editor return to cycle programming Press the Back soft key ...

Page 82: ... residual material remains in this example This leads to a warning see the soft key Warning no 1 Check if any changes to the program are necessary In this example the residual material is carried off in the finishing cycle No changes to the program are necessary Conclude input of the roughing cycle Press the Input finished soft key Test the cycle Press the Graphics soft key Call the warning Press ...

Page 83: ...s a precaution switch to Single Block mode Press the Single Block soft key Set the feed rate override feed rate override to 0 Activate Cycle Start Slowly increase the feed rate override The roughing cycle is performed Run each block by pressing Cycle Start single block mode Save the cycle Press the Save soft key ...

Page 84: ...e position cycle Press the Add cycle soft key Press the Single cuts menu key Press the Rapid traverse positioning menu key Press the T Change approach soft key Enter the cycle parameters Sequence Q 0 approach the tool change position on a diagonal path Tool number T 1 maintain T1 Conclude entry Press the Input finished soft key ...

Page 85: ...le Test the cycle Press the Graphics soft key The bright dot is at the tool change position Set the feed rate override feed rate override to 0 Activate Cycle Start Slowly increase the feed rate override The tool moves to the tool change position Insert finishing tool T6 Save the cycle Press the Save soft key ...

Page 86: ...inishing longitudinal cycle by copying Place the cursor on the ICP cutting longitudinal cycle Press the arrow key Press the Copy cycle soft key Place the cursor in front of the insert position Press the arrow key Press the Add cycle soft key The new cycle and all parameters are inserted below the cursor position ...

Page 87: ... mm Starting point Z 4 mm ICP contour number N 1 Tool number T 6 Cutting speed S 220 m min Feed rate per revolution F 0 25 mm rev Assume the tool number and technology data from the tool file see following steps Call the tool list Press the Tool list soft key Position the cursor on T6 Press the arrow key repeatedly Assume the tool Press the Take over tool soft key Assume the cutting speed and feed...

Page 88: ...l path simulation accounts for the exact geometry of the tool tip Therefore this simulation is recommended for the finishing process Conclude input Press the Input finished soft key Press the Graphics soft key Call the additional functions of the simulation Press the Extra functions soft key Press the Track soft key Press the Slide soft key ...

Page 89: ...h new settings Press the Graphics soft key Set the feed rate override feed rate override to 0 Activate Cycle Start The finishing tool is not yet confirmed Confirm tool T6 with the Tool change key Activate Cycle Start again Slowly increase the feed rate override The finishing cycle is performed Measure the created diameter and correct the tool if necessary Retract with the handwheel Measure the dia...

Page 90: ...ess the Tool offset soft key Press the X offset for tool soft key Set the handwheel resolution for compensation Set tool compensation with the X handwheel The compensation set via handwheel is shown in the Delta X field example 0 04 mm Assume the compensation Press the Save soft key The saved compensation value is shown in the T6 dx field example 0 04 mm Conclude compensation Press the Back soft k...

Page 91: ...shing longitudinal cycle Program the Approach tool change position cycle Activate Cycle Start Save the cycle Press the Overwrite soft key The tool compensation and finishing cycle can be repeated as often as necessary until the correct dimension is reached Press the Add cycle soft key Press the Single cuts menu key ...

Page 92: ...ycle parameters Sequence Q 0 approach the tool change position on a diagonal path Tool number T 6 maintain T6 Press the Input finished soft key Test the cycle Press the Graphics soft key Set the feed rate override feed rate override to 0 Activate Cycle Start Slowly increase the feed rate override The tool moves to the tool change position Use the threading tool T8 Save the cycle Press the Save sof...

Page 93: ...cycle Press the Thread cutting menu key Press the Threading cycle menu key Enter the cycle parameters Starting point X 16 mm Starting point Z 4 mm End point of thread Z2 29 mm Thread pitch F1 1 5 mm Thread depth U No entry First cutting depth I No entry Tool number T 8 Shaft speed S 600 m min Assume the tool number and technology data from the tool file see following steps ...

Page 94: ...ud cycle program Call the tool list Press the Tool list soft key Position the cursor on T8 Press the arrow key repeatedly Assume the tool Press the Take over tool soft key Assume the shaft speed from the tool file Press the S F from tool soft key Press the Input finished soft key ...

Page 95: ...r Warnings If Contour view is selected the MANUALplus 4110 checks all previous machining procedures In this example the already known warning from the roughing cycle is output Test the cycle Press the Graphics soft key Press the Extra functions soft key Switch to Wire frame graphics Press the Track soft key deactivate Show all contours defined until now Press the Contour view soft key Check and co...

Page 96: ...not yet confirmed Confirm tool T8 with the Tool change key Activate Cycle Start again Slowly increase the feed rate override The threading cycle is performed Check the thread and correct the tool if necessary The threading cycle is finished Retract with the handwheel Measure the thread Thread paths are always machined at the programmed feed rate thread pitch regardless of the current feed rate ove...

Page 97: ...ress the Tool offset soft key Press the X offset for tool soft key Set the handwheel resolution for compensation Set tool compensation with the X handwheel The compensation set via handwheel is shown in the Delta X field example 0 04 mm Assume the compensation Press the Save soft key The saved compensation value is shown in the T8 dx field example 0 04 mm Conclude compensation Press the Back soft ...

Page 98: ...hreaded stud cycle program Repeat the last thread cut with the corrected tool Press the Last cut soft key Activate Cycle Start Save the cycle Press the Save soft key The tool compensation and the last cut can be repeated as often as necessary until the thread is correct ...

Page 99: ...le Press the Add cycle soft key Press the Single cuts menu key Press the Rapid traverse positioning menu key Press the T Change approach soft key Enter the cycle parameters Sequence Q 0 approach the tool change position on a diagonal path Tool number T 8 maintain T8 Press the Input finished soft key Test the cycle Press the Graphics soft key ...

Page 100: ...ate the Threaded stud cycle program Run the cycle Set the feed rate override to 0 Activate Cycle Start Slowly increase the feed rate override The tool moves to the tool change position Save the cycle Press the Save soft key Exit Teach in Press the Back soft key ...

Page 101: ...HEIDENHAIN MANUALplus 4110 Linear Machining Example 7 35 Create the Threaded stud cycle program Results The workpiece The cycle program Threaded stud The ICP contour Threaded stud ...

Page 102: ...HEIDENHAIN MANUALplus 4110 Linear Machining Example 7 36 ...

Page 103: ... assumed that the reader is familiar with steps explained in the previous example Prerequisites The workpiece blank is clamped The roughing tool T1 is clamped The roughing tool T1 and finishing tool T6 is defined and measured The workpiece datum is defined The tool change point is defined The protection is defined and activated The maximum shaft speed is defined ...

Page 104: ...in Enter the program number and name Press the Add cycle soft key Press the Define blank menu key Press the Blank Bar Tube menu key Enter the cycle parameters Outside diameter X 95 mm Length Z 50 mm Inside diameter I No entry Right edge K 1 mm Clamping range B 20 mm Type of clamping J 1 Press the Input finished soft key Test the cycle Press the Graphics soft key ...

Page 105: ...l transverse menu key Press the ICP cut transverse menu key Enter the cycle parameters Starting point X 95 mm Starting point Z 4 mm Infeed depth P 4 mm I oversize X 0 3 mm K oversize Z 0 1 mm ICP contour number N 2 For programming of the ICP contour see Page 11 Tool number T 1 Cutting speed S 200 m min Feed rate per revolution F 0 4 mm rev Assume the tool number and technology data from the tool f...

Page 106: ...rogram Run a graphic simulation of the cycle Run the cycle Test the cycle Press the Graphics soft key Set the feed rate override feed rate override to 0 Activate Cycle Start Slowly increase the feed rate override The roughing cycle is performed Save the cycle Press the Save soft key ...

Page 107: ... tool change position Press the T Change approach soft key Enter the cycle parameters Sequence Q 0 approach the tool change position on a diagonal path Tool number T 1 maintain T1 Press the Input finished soft key Test the cycle Press the Graphics soft key Set the feed rate override feed rate override to 0 Activate Cycle Start Slowly increase the feed rate override The tool moves to the tool chang...

Page 108: ... the Save soft key Press the Add cycle soft key Press the Roughing cycles longitudinal transverse menu key Press the ICP cutting longitudinal menu key Switch to Finishing cycle Press the Finishing run soft key Enter the cycle parameters Starting point X 95 mm Starting point Z 4 mm ICP contour number N 21 For programming of the ICP contour see Page 20 Tool number T 6 Cutting speed S 220 m min Feed ...

Page 109: ... simulation is recommended for the finishing process Test the cycle Press the Graphics soft key Switch from path display to display of the cutter Call the additional functions of the simulation Press the Extra functions soft key Press the Track soft key Press the Slide soft key Conclude setting of the additional functions Press the Back soft key Repeat the simulation with new settings Press the Gr...

Page 110: ...oach tool change position cycle Set the feed rate override feed rate override to 0 Activate Cycle Start Slowly increase the feed rate override The finishing cycle is performed Save the cycle Press the Save soft key Press the Add cycle soft key Press the Single cuts menu key Press the Rapid traverse positioning menu key ...

Page 111: ...r the cycle parameters Sequence Q 0 approach the tool change position on a diagonal path Tool number T 6 maintain T6 Press the Input finished soft key Test the cycle Press the Graphics soft key Set the feed rate override feed rate override to 0 Activate Cycle Start Slowly increase the feed rate override The tool moves to the tool change position Save the cycle Press the Save soft key ...

Page 112: ...UALplus 4110 Surface Machining Example 8 10 Create the Matrix cycle program Results The workpiece The Matrix cycle program The Matrix ICP contour for roughing machining The Matrix ICP contour for finishing machining ...

Page 113: ... described in the machining direction First step Input of the contour without form elements rough contour Second step Superimposition of the form elements roundings Create an ICP contour Call the ICP editor Press the Edit ICP soft key Press the Contour list soft key ICP Contour 2 Enter the ICP contour number Press the Select soft key ...

Page 114: ...Insert element soft key Press the Line menu key Describe the contour element Starting point XS in X 95 mm Starting point ZS in Z 26 mm Target point X in X 90 mm Length of line L No entry Special feed rate F No entry Conclude entry Press the Save soft key Press the Line menu key Describe the contour element Target point Z in Z 17 mm Length of line L No entry Special feed rate F No entry ...

Page 115: ...ment 3 oblique cut Conclude entry Press the Save soft key Press the Line menu key Describe the contour element Target point X in X No entry Target point Z in Z No entry Angle A to Z axis 81 5 Length of line L No entry Special feed rate F No entry Conclude entry Press the Save soft key The oblique cut is an unresolved element ...

Page 116: ...us Press the Arc with Mp R menu key Describe the contour element Target point X in X No entry Target point Z in Z No entry Center point I in X 0 mm Center point K in Z 11 6 mm Radius R 7 5 mm Special feed rate F No entry Conclude entry Press the Save soft key There are two solutions Display next solution Press the Next solution soft key desired solution Press the Select solution soft key ...

Page 117: ...oft key Press the Line menu key Describe the contour element Target point X in X 4 mm Target point Z in Z 0 mm Angle A to Z axis 5 5 Length of line L No entry Special feed rate F No entry Conclude entry Press the Save soft key There are two solutions Display next solution Press the Next solution soft key desired solution Press the Select solution soft key ...

Page 118: ...contour input Press the Back soft key Press the Superimpose form elements soft key Position for superimposing is shown with a red square Press the Rounding menu key Describe the superimposed element Rounding radius B 1 mm Special feed rate F No entry Insert rounding Press the Save soft key Next position for superimposing is shown ...

Page 119: ...d element Rounding radius B 2 5 mm Special feed rate F No entry Insert rounding Press the Save soft key Next position for superimposing is shown Press the Rounding menu key Describe the superimposed element Rounding radius B 3 5 mm Special feed rate F No entry Insert rounding Press the Save soft key Next position for superimposing is shown ...

Page 120: ...18 Create the Matrix ICP contour All contour transitions are imposed The Matrix ICP contour is complete Press the Rounding menu key Describe the superimposed element Rounding radius B 1 mm Special feed rate F No entry Insert rounding Press the Save soft key ...

Page 121: ...e the Matrix ICP contour Enter the contour name Press the Contour list soft key Press the Change text soft key Enter the contour name Matrix Press the Take over text soft key Exit the contour list Press the Back soft key Exit the ICP editor Press the Back soft key ...

Page 122: ...ith the contour direction from inside to outside is created Copy ICP contour Call the ICP editor Press the Edit ICP soft key Press the Contour list soft key Position the cursor on the 2 Matrix ICP contour Press the arrow key Prepare for copying Press the Copy soft key Enter the new ICP contour number 21 in the to field Perform copying Press the Copy Yes soft key Change the contour name Press the C...

Page 123: ...for finishing machining Press the Take over text soft key Load ICP contour Press the Select soft key Reverse the direction of the ICP contour description Press the Turn contour soft key The small yellow rectangle indicates the end of the contour Exit the ICP editor Press the Back soft key ...

Page 124: ...HEIDENHAIN MANUALplus 4110 Surface Machining Example 8 22 ...

Page 125: ...cessing machining It is assumed that the reader is familiar with steps explained in the previous examples Prerequisites The workpiece blank is clamped The recessing tool T10 is defined measured and inserted The workpiece datum is defined The tool change point is defined The protection is defined and activated The maximum shaft speed is defined ...

Page 126: ... in Enter the program number and name Press the Add cycle soft key Press the Define blank menu key Press the Blank Bar Tube menu key Enter the cycle parameters Outside diameter X 60 mm Length Z 75 mm Inside diameter I No entry Right edge K 1 mm Clamping range B 20 mm Type of clamping J 1 Press the Input finished soft key Test the cycle Press the Graphics soft key ...

Page 127: ...NUALplus 4110 Recess Machining Example 9 3 Create the Form roll cycle program Program the ICP cut radial cycle Conclude entry Press the Save soft key Press the Add cycle soft key Press the Recessing cycles menu key ...

Page 128: ... Starting point Z 2 mm Recessing width P No entry The recessing width is derived from the cutting width tool parameter I oversize X 0 2 mm K oversize Z 0 2 mm ICP contour number N 3 For programming of the ICP contour see Page 11 Distance DX to the subsequent recess No entry Distance DZ to the subsequent recess No entry Q number of recess cycles 1 Tool number T 10 Cutting speed S 120 m min Feed rat...

Page 129: ... the Extra functions soft key Press the Track soft key Press the Slide soft key Conclude entry of the additional functions Press the Back soft key Stop the simulation after every traverse path Press the Single block soft key Test the cycle Press the Graphics soft key Displaysubsequenttraverse paths Press the Graphic Continue soft key repeatedly ...

Page 130: ...cle program Run the cycle Switch single block mode off Press the Single block soft key deactivate Set the feed rate override feed rate override to 0 Activate Cycle Start Slowly increase the feed rate override The recessing cycle is performed Save the cycle Press the Save soft key ...

Page 131: ...ess the Edit cycle soft key Switch to Finishing cycle Press the Finishing run soft key Check the cycle parameters Starting point X 62 mm Starting point Z 2 mm ICP contour number N 3 Same ICP contour as for roughing Distance DX to the subsequent recess No entry Distance DZ to the subsequent recess No entry Q number of recess cycles 1 Tool number T 10 Cutting speed S 120 m min Feed rate per revoluti...

Page 132: ...Run the cycle Test the cycle Press the Graphics soft key Displaysubsequenttraverse paths Press the Graphic Continue soft key repeatedly Set the feed rate override feed rate override to 0 Activate Cycle Start Slowly increase the feed rate override The recess finishing cycle is performed Save the cycle Press the Overwrite soft key ...

Page 133: ...ch to Approach tool change position Press the T Change approach soft key Enter the cycle parameters Sequence Q 0 approach the tool change position on a diagonal path Tool number T 10 maintain T10 Press the Input finished soft key Test the cycle Press the Graphics soft key Set the feed rate override feed rate override to 0 Activate Cycle Start Slowly increase the feed rate override The tool moves t...

Page 134: ...HEIDENHAIN MANUALplus 4110 Recess Machining Example 9 10 Create the Form roll cycle program Results The workpiece The Form roll cycle program The Form roll ICP contour ...

Page 135: ...contour Contour element 1 horizontal line Call the ICP editor Press the Edit ICP soft key Press the Contour list soft key ICP Contour 3 Specify the ICP contour number Press the Select soft key Call the element input Press the Insert element soft key Press the Line menu key Describe the contour element Starting point XS in X 60 mm Starting point ZS in Z 0 mm Target point Z in Z 5 mm Length of line ...

Page 136: ...rc Conclude entry Press the Save soft key Only the radius is known for the arc Press the Arc with R menu key Describe the contour element Target point X in X No entry Target point Z in Z No entry Radius B 5 mm Special feed rate F No entry Conclude entry Press the Save soft key The arc is an unresolved element ...

Page 137: ... Press the Line soft key Press the Line menu key Describe the contour element Target point X in X 49 5 mm Target point Z in Z 32 mm Angle A to Z axis 6 Length of line L No entry Special feed rate F No entry Conclude entry Press the Save soft key There are two solutions Display next solution Press the Next solution soft key desired solution ...

Page 138: ... element 4 oblique cut Conclude entry Press the Select solution soft key Press the Line menu key Describe the contour element Target point X in X 35 mm Target point Z in Z 34 mm Angle A to Z axis No entry Length of line L No entry Special feed rate F No entry Conclude entry Press the Save soft key ...

Page 139: ...ey Describe the contour element Target point Z in Z 45 mm Length of line L No entry Special feed rate F No entry Conclude entry Press the Save soft key Press the Line menu key Describe the contour element Target point X in X 60 mm Target point Z in Z 49 mm Angle A to Z axis No entry Length of line L No entry Special feed rate F No entry Conclude entry Press the Save soft key ...

Page 140: ...our Form roll Contour element 7 horizontal line Press the Line menu key Describe the contour element Target point Z in Z 51 mm Length of line L No entry Special feed rate F No entry Conclude entry Press the Save soft key Conclude the rough contour input Press the Back soft key ...

Page 141: ...e roundings Press the Superimpose form elements soft key Position for superimposing is shown with a red square Press the Rounding menu key Describe the contour element Rounding radius B 1 5 mm Special feed rate F No entry Insert rounding Press the Save soft key Next position for superimposing is shown ...

Page 142: ...ed element Rounding radius B 1 5 mm Special feed rate F No entry Insert rounding Press the Save soft key Next position for superimposing is shown Press the Rounding menu key Describe the superimposed element Rounding radius B 1 5 mm Special feed rate F No entry Insert rounding Press the Save soft key Next position for superimposing is shown ...

Page 143: ...mplete Press the Rounding menu key Describe the superimposed element Rounding radius B 1 5 mm Special feed rate F No entry Insert rounding Press the Save soft key Next position for superimposing is shown Press the Rounding menu key Describe the superimposed element Rounding radius R 1 5 mm Special feed rate F No entry Insert rounding Press the Save soft key ...

Page 144: ...he ICP contour Form roll Enter the contour name Press the Contour list soft key Press the Change text soft key Enter the contour name Form roll Press the Take over text soft key Exit the contour list Press the Back soft key Exit the ICP editor Press the Back soft key ...

Page 145: ...p is the reference point This view is well suited for showing machining passes Cutting path graphics In this view the cutter geometry of the tool is taken into consideration Here you can check if material remains or if the contour is damaged Machining simulation The blank is displayed as a white surface which is machined during the simulation erasing graphics Tool tip For the wire frame and cuttin...

Page 146: ... key Activate the cutting path graphics Press the Track soft key Activate the cutter graphics Press the Slide soft key Conclude setting of the additional functions Press the Back soft key Repeat the simulation with new settings Press the Graphics soft key Set the machining simulation Press the Machining simulation soft key Start the simulation Press the Graphic Continue soft key ...

Page 147: ...splayed graphics Change the image section Initial situation Call the zoom functions Press the Zoom soft key The red rectangle indicates the selected section Reduce the section Press the Page forward key Increase the section Press the Page back key Move the section Press the arrow keys Assume the selected section Press the Take over soft key Start the simulation Press the Graphic Continue soft key ...

Page 148: ... 4110 Graphic Simulation 10 4 Enlarging reducing selecting a section for enlargement Extend the view Extending the view decreases the size of the workpiece You then select the section desired Press the Extend view soft key ...

Page 149: ...ution Actions before executing a program Load the cycle program Check the cycle program Run a graphic simulation of the cycle program Activate program run Call the main menu Press the Menu key Press the Program run soft key The program edited or used most recently is loaded ...

Page 150: ...us 4110 checks the program when it loads it The error symbol appears if there are errors or warnings Press the Program list soft key Place the cursor on the program to be loaded Press the arrow keys Press the Select soft key Display warning Press the Info key Clear the warning and close the error window Press the Clear key ...

Page 151: ...ce the cursor on the cycle Check the program before running it Run a graphic simulation of the program Place the cursor at the beginning of the program Press the Program start soft key Place the cursor on the cycle Press the arrow key Place the cursor at the beginning of the program Press the Program start soft key Press the Graphics soft key ...

Page 152: ...The cycle program has been checked Run cycles individually If Continuous run is disabled the MANUALplus 4110 stops after each cycle Run the cycle program for each cycle Place the cursor at the beginning of the program Press the Program start soft key To deactivate the Continuous run mode Press the Continuous run soft key Press Cycle Start The cycle is started At a tool change Change the tool Confi...

Page 153: ...ded to the existing values and is effective immediately In the following example of a threaded stud program run is stopped after the finishing cycle The workpiece is measured in the machine The tool compensation is then entered and the finishing cycle is repeated Interrupt the program run Initial situation Several workpieces have already been produced The finishing tool is worn Deactivate the Cont...

Page 154: ...cles N1 to N5 Stop the spindle Measure the workpiece Example The diameter of the finishing allowance is 0 2 mm too large Select tool compensation Press the Tool Add correct soft key Tool correct is already active No compensation values have been entered yet DX und DZ have the value 0 Enterthecompensationvalue 0 2 mm in the DX field ...

Page 155: ... T6 dx field and in the DX field of the dialog box Exit the Tool correct function Press the Back soft key Return to program run Press the Back soft key Position the cursor on the finishing cycle again Press the arrow key Activate the Continuous run mode Press the Continuous run soft key Cycles are run continuously without interruption up to the next tool change Repeat the finishing cycle then run ...

Page 156: ...HEIDENHAIN MANUALplus 4110 Executing Programs 11 8 ...

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