Content      ..     18      19      20      21     ..

SINUMERIK 840D sl/828D. Job Planning. Programming Manual (2010-2018) - page 20

Tool offsets

7.4 Online tool offset (PUTFTOCF, FCTDEF, PUTFTOC, FTOCON, FTOCOF)

Example

Surface grinding machine with:

● Y: Infeed axis for grinding wheel

● V: Infeed axis for dressing roller

● Machining channel: Channel 1 with axes X, Z, Y

● Dressing channel: Channel 2 with axis V

After the start of grinding motion, the grinding wheel is to be dressed by an amount of 0.05 at

X100. The dressing amount is to be applied to the grinding tool with "Write online offset

continuously".

<

'UHVVLQJ UROO

'UHVVLQJ

DPRXQW

*ULQGLQJ GLVF

OHQJWK

WR EH

FRUUHFWHG

:RUNSLHFH

;

Machining program in channel 1:

Program code

Comments

…

N110 G1 G18 F10 G90

; Basic position.

N120 T1 D1

; Select current tool.

N130 S100 M3 X100

; Spindle on, traverse to starting position.

N140 INIT(2,"DRESS","S")

; Select the dressing program in channel 2.

N150 START(2)

; Start the dressing program in channel 2.

N160 X200

; Traverse to the target point.

N170 FTOCON

; Activate online offset.

N… G1 X100

; Additional machining.

N… M30

Job Planning

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

407

Tool offsets

7.5 Activate 3D tool offsets (CUT3DC..., CUT3DF...)

7.5

Activate 3D tool offsets (CUT3DC..., CUT3DF...)

7.5.1

Activating 3D tool offsets (CUT3DC, CUT3DF, CUT3DFS, CUT3DFF, ISD)

Function

Tool orientation change is taken into account in tool radius compensation for cylindrical tools.

The same programming commands apply to 3D tool radius compensation as to 2D tool

radius compensation. The left/right offset is specified in the direction of motion using G41/G42.

The approach response is always controlled with NORM. The 3D radius compensation is only

effective when 5-axis transformation is selected.

3D tool radius compensation is also called 5D tool radius compensation, because in this

case 5 degrees of freedom are available for the orientation of the tool in space.

:RUNSLHFH

FRQWRXU

3DWK RI WKH WRRO FHQWHU LQ

WKH VDPH GLVWDQFH WR WKH

FRQWRXU HTXLGLVWDQW

,6'

/

5

Difference between 2 1/2 D and 3D tool radius compensation

In 3D tool radius compensation tool orientation can be changed. With the 2 1/2D tool radius

compensation, it is assumed that only a tool with constant orientation is being used.

Job Planning

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

409

Tool offsets

7.5 Activate 3D tool offsets (CUT3DC..., CUT3DF...)

Example

Program code

Comments

N10 A0 B0 X0 Y0 Z0 F5000

N20 T1 D1

; Tool call, call tool offset values.

N30 TRAORI(1)

; Transformation selection

N40 CUT3DC

; 3D tool radius compensation selection

N50 G42 X10 Y10

; Tool radius compensation selection

N60 X60

N70 …

7.5.2

3D tool offset peripheral milling, face milling

Circumferential milling

The type of milling used here is implemented by defining a path (guide line) and the

corresponding orientation. In this type of machining, the shape of the tool on the path is not

relevant. Especially the radius at the tool intervention point is decisive.

3HULSKHUDO PLOOLQJ

$

%

=

;

<

Note

The function 3D TRC is restricted to cylindrical tools.

Job Planning

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

411

Tool offsets

7.5 Activate 3D tool offsets (CUT3DC..., CUT3DF...)

Face milling

For this type of 3D milling, you will require the line-by-line description of the 3D paths on the

workpiece surface. The tool shape and dimensions are taken into account in the calculations

- which are normally performed in CAM. The post processor writes to the part program - in

addition to NC blocks - to orientations (for active 5 axis transformation) and the G code for

the required 3D tool offset. This means that the machine operator has the possibility of using

tools that are slightly smaller - deviating from the tool used to calculate the NC paths.

Example:

NC blocks were computed using a 10 mm milling tool. In this case, a milling tool diameter of

9.9 mm can be used for machining - whereby a modified roughness profile can be

expended.

Job Planning

412

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

Tool offsets

7.5 Activate 3D tool offsets (CUT3DC..., CUT3DF...)

7.5.3

3D tool offset Tool shapes and tool data for face milling

Mill shapes, tool data

An overview of the tool shapes, which may be used for face milling operations and tool data

limit values are listed in the following. The shape of the tool shaft is not taken into account.

The effect of tool types 120 and 156 is identical.

5

5

5

5

U

U

&\OLQGULFDO

%DOO HQG

(QG PLOO

(QG PLOO ZLWK

GLH VLQNLQJ

PLOO

W\SH

FRUQHU URXQGLQJ

PLOOLQJ FXWWHU

W\SH

W\SH

W\SH

D

D

D

U

5

5

5

%HYHO FXWWHU

%HYHO FXWWHU ZLWK

7DSHUHG

W\SH

FRUQHU URXQGLQJ

GLH VLQNLQJ FXWWHU

W\SH

W\SH

If, in the NC program, a type number is specified that differs from that in the diagram, then

the system automatically uses tool type 110 (cylindrical die-sinking milling tool). An alarm is

output if the tool data limit values are violated.

Cutter type

Type No.

R

r

a

Cylindrical die-sinking milling cutter

110

> 0

-

-

Ball end mill

111

> 0

> R

-

End mill, angle head cutter

120, 130

> 0

-

-

End mill, angle head cutter with corner

121, 131

> r

> 0

-

rounding

Bevel cutter

155

> 0

-

> 0

Bevel cutter with corner rounding

156

> 0

> 0

> 0

Tapered die-sinking cutter

157

> 0

-

> 0

R

= shaft radius (tool radius)

r

= corner radius

a

= angle between the tool longitudinal axis and upper end of the torus surface

-

= is not evaluated

Job Planning

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

413

Tool offsets

7.5 Activate 3D tool offsets (CUT3DC..., CUT3DF...)

Tool data

Tool parameters

Tool dimensions

Geometry

Wear

R

$TC_DP6

$TC_DP15

r

$TC_DP7

$TC_DP16

a

$TC_DP11

$TC_DP20

Tool length offset

The tool tip is the reference point for length offset (intersection longitudinal axis/surface).

3D tool offset, tool change

A new tool with modified dimensions (R, r, a) or a different shaft may only be specified with

the programming of G41 or G42 (transition G40 to G41 or G42, reprogramming of G41 or G42).

This rule does not apply to any other tool data, e.g., tool lengths, so that tools can be loaded

without reprogramming G41 or G42.

Job Planning

414

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

Tool offsets

7.5 Activate 3D tool offsets (CUT3DC..., CUT3DF...)

7.5.4

3D tool offset Compensation on the path, path curvature, insertion depth

(CUT3DC, ISD)

Function

Compensation on path

With respect to face milling, it is advisable to examine what happens when the contact point

"jumps" on the tool surface as shown in the example on the right where a convex surface is

being machined with a vertically positioned tool. The application shown in the example

should be regarded as a borderline case.

6LQJXODU SRLQW

This borderline case is monitored by the control that detects abrupt changes in the

machining point on the basis of angular approach motions between the tool and normal

surface vectors. The control inserts linear blocks at these positions so that the motion can be

executed.

These linear blocks are calculated on the basis of permissible angular ranges for the side

angle stored in the machine data. The system outputs an alarm if the limit values stored in

the machine data are violated.

Path curvature

Path curvature is not monitored. In such cases, it is also advisable to use only tools of a type

that do not violate the contour.

Insertion depth (ISD)

Insertion depth ISD is only evaluated when 3D tool radius compensation is active.

Program command ISD (insertion depth) is used to program the tool insertion depth for

circumferential milling operations. This makes it possible to change the position of the

machining point on the outer surface of the tool.

Job Planning

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

415

Tool offsets

7.5 Activate 3D tool offsets (CUT3DC..., CUT3DF...)

Syntax

3D tool compensation circumference milling

CUT3DC

ISD=<value>

Significance

CUT3DC

Activate 3D tool offset for circumferential milling, e.g., for pocket milling with

oblique side walls.

ISD

The clearance (<value>) between the milling tool tip (FS) and the milling tool

construction point (FH) are specified using the command ISD.

Milling tool reference point

The milling tool reference point (FH) is obtained by projecting the programmed machining

point onto the tool axis.

)+

)6

Job Planning

416

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

Tool offsets

7.5 Activate 3D tool offsets (CUT3DC..., CUT3DF...)

Further Information

Pocket milling with inclined side walls for circumferential milling with CUT3DC

In this 3D tool radius compensation, a deviation of the mill radius is compensated by infeed

toward the normals of the surface to be machined. The plane, in which the milling tool face is

located, remains unchanged if the insertion depth ISD has remained the same. For example,

a milling tool with a smaller radius than a standard tool would not reach the pocket base,

which is also the limitation surface. For automatic tool infeed, this limitation surface must be

known to the control, see section "3D circumferential milling with limitation surfaces".

For additional information on collision monitoring, refer to:

References:

Programming Manual Basics; Chapter "Tool offsets".

7.5.5

3D tool offset Inside/outside corners and intersection procedure (G450/G451)

Function

Inside corners/outside corners

Inside and outside corners are handled separately. The terms inner corner and outer corner

are dependent on the tool orientation.

When the orientation changes at a corner, for example, the corner type may change while

machining is in progress. Whenever this occurs, the machining operation is aborted with an

error message.

0DFKLQLQJ GLUHFWLRQ

Job Planning

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

417

Tool offsets

7.5 Activate 3D tool offsets (CUT3DC..., CUT3DF...)

Significance

CUT3DCCD

Activation of the 3D tool offset for the circumferential milling with

limitation surfaces with a differential tool on the tool center point path:

Infeed to the limitation surface.

CUT3DCC

Activation of the 3D tool offset for circumferential milling with limitation

surfaces with 3D radius compensation: Contour on the machining

surface

Note

Tool radius compensation with G41, G42

If tool radius compensation with G41, G42 is programmed when CUT3DCCD or CUT3DCC is active,

the option "orientation transformation" must also be active.

Standard tools with corner rounding

Corner rounding with a standard tool is defined by the tool parameter $TC_DP7. Tool

parameter $TC_DP16 describes the deviation of the corner rounding of the real tool compared

with the standard tool.

Example

Tool dimensions of a toroidal miller with reduced radius as compared with the standard tool.

Tool type

R = shank radius

r = corner radius

Standard tool with corner rounding

R = $TC_DP6

r = $TC_DP7

Real tool with corner rounding:

R' = $TC_DP6 + $TC_DP15 + OFFN

r' = $TC_DP7 + $TC_DP16

Tool types 121 and 131 torus milling tool

(shaft milling tool)

In this example, both $TC_DP15 + OFFN and $TC_DP16 are negative.

The tool type ($TC_DP1) is evaluated.

Only cutter types with cylindrical shank

For these approved cutter types, the corner radius r is identical to the shank

(cylinder or end mill), toroidal millers (types

radius R. All other permitted tool types are interpreted as cylindrical cutters

121 and 131) and, in the limit case,

and the dimensions specified for the corner rounding are not evaluated.

cylindrical die mills (type 110) are permitted.

All tool types of the numbers 1 - 399, with the

exception of the numbers 111 and 155 to

157, are permitted.

Job Planning

420

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

Tool offsets

7.5 Activate 3D tool offsets (CUT3DC..., CUT3DF...)

Further Information

Tool center point path with infeed up to the limitation surface CUT3DCCD

If a tool with a smaller radius than the appropriate standard tool is used, machining is

continued using a milling tool, which is infed in the longitudinal direction until it reaches the

bottom (base) of the pocket. The tool removes as much material from the corner formed by

the machining surface and limitation surface. This involves a machining type combining

circumferential and face milling. Analog to a tool with lower radius, for a tool with increased

radius, the infeed is in the opposite direction.

6WDQGDUG WRRO

7RRO ZLWK VPDOOHU UDGLXV

IHHG WR WKH OLPLWLQJ VXUIDFH

/LPLWLQJ VXUIDFH

Contrary to all other tool offsets of G code group 22, tool parameter $TC_DP6 specified for

CUT3DCCD does not influence the tool radius and the resulting compensation.

The compensation offset is the sum of:

● The wear value of the tool radius (tool parameter $TC_DP15)

● and a tool offset OFFN programmed to calculate the perpendicular offset to the limitation

surface.

The generated part program does not specify whether the surface to be machined is to the

right or left of the path. It is therefore assumed that the radius is a positive value and the

wear value of the original tool is a negative value. A negative wear value always describes a

tool with a lower diameter.

Using cylindrical tools

When cylindrical tools are used, infeed is only necessary if the machining surface and the

surface of limitation form an acute angle (less than 90 degrees). If a torus milling tool

(cylinder with rounded corners) is used, tool infeed in the longitudinal direction is required for

both acute and obtuse angles.

Job Planning

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

421

Tool offsets

7.5 Activate 3D tool offsets (CUT3DC..., CUT3DF...)

3D radius compensation with CUT3DCC, contour on the machining surface

If CUT3DCC is active with a torus milling tool, the programmed path refers to a fictitious

cylindrical milling tool having the same diameter. The resulting path reference point is shown

in the following diagram for a torus milling tool.

3DWK UHIHUHQFH SRLQW

5

/LPLWLQJ VXUIDFH

The angle between the machining and limitation surfaces may change from an acute to an

obtuse angle and vice versa even within the same block.

The tool actually being used may either be larger or smaller than the standard tool. However,

the resulting corner radius must not be negative and the sign of the resulting tool radius must

be kept.

For CUT3DCC, the NC part program refers to contour on the machining surface. As for

conventional tool radius compensation, the total tool radius is used that comprises the sum

of:

● Tool radius (tool parameter $TC_DP6)

● Wear value (tool parameter $TC_DP15)

● and a tool offset OFFN programmed to calculate the perpendicular offset to the limitation

surface.

The position of the limitation surface is determined from the difference between these two

values:

● Dimensions of the standard tool

● Tool radius (tool parameter $TC_DP6)

Job Planning

422

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

Tool offsets

7.6 Tool orientation (ORIC, ORID, OSOF, OSC, OSS, OSSE, ORIS, OSD, OST)

7.6

Tool orientation (ORIC, ORID, OSOF, OSC, OSS, OSSE, ORIS,

OSD, OST)

Function

The term tool orientation describes the geometric alignment of the tool in space. The tool

orientation on a 5-axis machine tool can be set by means of program commands.

=

'LUHFWLRQ YHFWRU

;

<

Orientation rounding movements activated with OSD and OST are formed differently depending

on the type of interpolation for tool orientation.

If vector interpolation is active, the smoothed orientation characteristic is also interpolated

using vector interpolation. On the other hand, if rotary axis interpolation is active, the

orientation is smoothed directly using rotary axis movements.

Programming

Programming a orientation change:

A change in tool orientation can be programmed by:

● Direct programming of rotary axes A, B, C (rotary axis interpolation)

● Euler or RPY angle

● Direction vector (vector interpolation by specifying A3 or B3 or C3)

● LEAD/TILT (face milling)

The reference coordinate system is either the machine coordinate system (ORIMKS) or the

current workpiece coordinate system (ORIWKS).

Job Planning

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

423

Tool offsets

7.6 Tool orientation (ORIC, ORID, OSOF, OSC, OSS, OSSE, ORIS, OSD, OST)

2ULHQWDWLRQ

FKDQJH

Programming tool orientation:

Command Significance

ORIC:

Orientation and path movement in parallel

ORID:

Orientation and path movement consecutively

OSOF:

No orientation smoothing

OSC:

Orientation constantly

OSS:

Orientation smoothing only at beginning of block

OSSE:

Orientation smoothing at beginning and end of block

ORIS:

Velocity of the orientation change with orientation smoothing activated in

degrees per mm (valid for OSS and OSSE)

OSD:

Smoothing of orientation by specifying smoothing distance with setting data:

SD42674 $SC_ORI_SMOOTH_DIST

OST:

Smoothing of orientation by specifying angular tolerance in degrees for

vector interpolation with setting data:

SD42676 $SC_ORI_SMOOTH_TOL

With rotary axis interpolation, the specified tolerance is assumed to be the

maximum variance of the orientation axes.

Note

All commands for smoothing the tool orientation (OSOF, OSC, OSS, OSSE, OSD, and OST) are

summarized in G function group 34. They are modal; in other words, only one of these

commands can ever be effective at the same time.

Job Planning

424

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

Tool offsets

7.6 Tool orientation (ORIC, ORID, OSOF, OSC, OSS, OSSE, ORIS, OSD, OST)

Examples

Example 1: ORIC

If ORIC is active and there are two or more blocks with changes in orientation (e.g.A2=...

B2=... C2=...) programmed between traversing blocks N10 andN20, then the inserted circle

block is distributed among these intermediate blocks according to the absolute changes in

angle.

1

1

1

1

Program code

Comments

ORIC

N8 A2=… B2=… C2=…

N10 X… Y… Z…

N12 C2=… B2=…

; The circle block inserted at the external corner is

distributed between N12 and N14, corresponding to

N14 C2=… B2=…

the change in orientation. The circular motion and

the orientation change are executed in parallel.

N20 X =…Y=… Z=… G1 F200

Job Planning

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

425

Tool offsets

7.6 Tool orientation (ORIC, ORID, OSOF, OSC, OSS, OSSE, ORIS, OSD, OST)

Example 2: ORID

If ORID is active, then all blocks between the two traversing blocks are executed at the end of

the first traversing block. The circle block with constant orientation is executed immediately

before the second traversing block.

3HUIRUP 1

DQG 1

1

1

Program code

Comments

ORID

N8 A2=… B2=… C2=…

N10 X… Y… Z…

N12 A2=… B2=… C2=…

; The N12 and N14 blocks are executed at the end of N10.

The circle block is then executed with the actual

orientation.

N14 M20

; Help functions, etc.

N20 X… Y… Z…

Note

The method which is used to change orientation at an outer contour is determined using the

program command that is active in the first traversing block of an outer corner.

Without change in orientation:If the orientation is not changed at the block boundary, the

cross-section of the tool is a circle, which touches both of the contours.

Job Planning

426

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

Tool offsets

7.6 Tool orientation (ORIC, ORID, OSOF, OSC, OSS, OSSE, ORIS, OSD, OST)

Example 3: Changing the orientation at an inner corner

1

1

1

:5.

Program code

ORIC

N10 X …Y… Z… G1 F500

N12 X …Y… Z… A2=… B2=… C2=…

N15 X …Y… Z… A2=… B2=… C2=…

Further Information

Behavior at outer corners

A circle block with the radius of the cutter is always inserted at an outside corner.

The ORIC and ORID program commands are used to determine whether changes in

orientation programmed between block N1 and N2 are executed before the inserted circle

block is processed or at the same time.

Job Planning

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

427

Tool offsets

7.6 Tool orientation (ORIC, ORID, OSOF, OSC, OSS, OSSE, ORIS, OSD, OST)

$ FLUFXODU EORFN ZLOO EH DGGHG

EHWZHHQ EORFN 1 DQG 1

1

1

5

If an orientation change is required at outside corners, this can be performed either at the

same time as interpolation or separately together with the path movement.

When ORID is programmed, the inserted blocks are executed first without path motion. The

circle block generating the corner is inserted immediately before the second of the two

traversing blocks.

If several orientation blocks are inserted at an external corner and ORIC is selected, the

circular motion is distributed among the individual inserted blocks according to the absolute

values of the orientation changes.

Smoothing orientation with OSD or OST

When blending with G642, the maximum variance for the contour axes and orientation axes

cannot vary greatly. The smaller tolerance of the two determines the type of smoothing

motion and/or angular tolerance to smooth the orientation characteristic relatively strongly

without having to accept higher contour deviations.

OSD and OST can be activated to "generously" smooth very slight deviations from the

orientation characteristics with a specified smoothing distance and angular tolerance without

serious contour deviations.

Note

Unlike the process of rounding the contour (and orientation characteristics) with G642, when

rounding the orientation with OSD and/or OST, a separate block is not formed, instead the

rounding movement is added directly to the programmed original blocks.

With OSD and/or OST, block transitions cannot be rounded if there is a change in the type of

interpolation for tool orientation (vector → rotary axis, rotary axis → vector). These block

transitions can if necessary be rounded with the standard rounding functions G641, G642 and

G643.

Job Planning

428

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

Tool offsets

7.8 Tool holder kinematics

7.8

Tool holder kinematics

Prerequisites

A toolholder can only orientate a tool in all possible directions in space if

● two rotary axes V1 and V2 are present.

● the rotary axes are mutually orthogonal.

● the tool longitudinal axis is perpendicular to the second rotary axis V2.

In addition, the following requirement is applicable to machines for which all possible

orientations have to be settable:

● the tool longitudinal axis must be perpendicular to the first rotary axis V1.

Function

The toolholder kinematics with a maximum of two rotary axes v1 or v2 are defined using the

17 system variables $TC_CARR1[m] to $TC_CARR17[m]. The description of the toolholder

consists of:

● the vectoral distance from the first rotary axis of the toolholder I1, the vectoral distance

from the first rotary axis to the second rotary axis I2, the vectoral distance from the

second rotary axis to the reference point of the tool I3.

● the direction vectors of both rotary axes V1, V2.

● the rotational angles α1, α2 at the two axes. The rotation angles are counted in viewing

direction of the rotary axis vectors, positive, in clockwise direction of rotation.

O

9

˞

O

O

˞

9

For machines with resolved kinematics (both the tool and the part can rotate), the system

variables have been extended with the entries

● $TC_CARR18[m] to $TC_CARR23[m].

Job Planning

434

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

Tool offsets

7.8 Tool holder kinematics

Parameters

Function of the system variables for orientable toolholders

Designation

x component

y component

y component

l1 offset vector

$TC_CARR1[m]

$TC_CARR2[m]

$TC_CARR3[m]

l2 offset vector

$TC_CARR4[m]

$TC_CARR5[m]

$TC_CARR6[m]

v1 rotary axis

$TC_CARR7[m]

$TC_CARR8[m]

$TC_CARR9[m]

v2 rotary axis

$TC_CARR10[m]

$TC_CARR11[m]

$TC_CARR12[m]

α1 angle of

$TC_CARR13[m]

rotation

$TC_CARR14[m]

α2 angle of

rotation

l3 offset vector

$TC_CARR15[m]

$TC_CARR16[m]

$TC_CARR17[m]

Extensions of the system variables for orientable toolholders

Name

x component

y component

z component

l4 offset vector

$TC_CARR18[m]

$TC_CARR19[m]

$TC_CARR20[m]

Axis identifier

Axis identifier of the rotary axes v1 and v2 (initialized with zero)

rotary axis v1

$TC_CARR21[m]

rotary axis v2

$TC_CARR22[m]

Kinematic type

$TC_CARR23[m]

Tool

Kinematics type T ->

Kinematics type P ->

Kinematics type M

Part

Only the tool can rotate

Only the part can rotate

Part and tool can rotate

Mixed mode

(default).

Offset of the

Angle in degrees of the rotary axes v1 and v2 on assuming the initial setting

rotary axis v1

$TC_CARR24[m]

rotary axis v2

$TC_CARR25[m]

Angle offset of

Offset of the Hirth tooth system in degrees for rotary axes v1 and v2

the rotary axis v1

$TC_CARR26[m]

rotary axis v2

$TC_CARR27[m]

Angle increment

Offset of the Hirth tooth system in degrees for rotary axes v1 and v2

v1 rotary axis

$TC_CARR28[m]

v2 rotary axis

$TC_CARR29[m]

Min. position

Software limit for the minimum position of the rotary axes v1 and v2

rotary axis v1

$TC_CARR30[m]

rotary axis v2

$TC_CARR31[m]

Max. position

Software limits for the maximum position of the rotary axes v1 and v2

rotary axis v1

$TC_CARR32[m]

rotary axis v2

$TC_CARR33[m]

Toolholder name

A toolholder can be given a name instead of a number. $TC_CARR34[m]

User:

Intended use in user measuring cycles $TC_CARR35[m]

Axis name 1

$TC_CARR36[m]

Axis name 2

$TC_CARR37[m]

Identifier

$TC_CARR38[m]

$TC_CARR39[m]

$TC_CARR40[m]

Position

Job Planning

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

435

Tool offsets

7.8 Tool holder kinematics

Extensions of the system variables for orientable toolholders

Fine

Parameters that can be added to the values

offset

in the basic parameters.

l1 Offset vector

$TC_CARR41[m]

$TC_CARR42[m]

$TC_CARR43[m]

l2 Offset vector

$TC_CARR44[m]

$TC_CARR45[m]

$TC_CARR46[m]

l3 Offset vector

$TC_CARR55[m]

$TC_CARR56[m]

$TC_CARR57[m]

l4 Offset vector

$TC_CARR58[m]

$TC_CARR59[m]

$TC_CARR60[m]

v1 rotary axis

$TC_CARR64[m]

v2 rotary axis

$TC_CARR65[m]

Note

Explanations of parameters

"m" specifies the number of the toolholder to be programmed.

$TC_CARR47 to $TC_CARR54 and $TC_CARR61 to $TC_CARR63 are not defined and produce an

alarm if read or write access is attempted.

The start/endpoints of the distance vectors on the axes can be freely selected. The rotation

angles α1, α2 about the two axes are defined in the initial state of the toolholder by 0°. In this

way, the kinematics of a toolholder can be programmed for any number of possibilities.

Toolholders with only one or no rotary axis at all can be described by setting the direction

vectors of one or both rotary axes to zero.

With a toolholder without rotary axis the distance vectors act as additional tool

compensations whose components cannot be affected by a change of machining plane (G17

to G19).

Parameter extensions

Parameters of the rotary axes

The system variables have been extended by the entries $TC_CARR24[m] to

$TC_CARR33[m] and described as follows:

Offset of rotary axes

Changing the position of the rotary axis v1 or v2 for the initial setting of the

v1, v2

oriented toolholder.

The angle

The offset or the angle increment of the Hirth tooth system of the rotary axes

offset/angle

v1 and v2. Programmed or calculated angle is rounded up to the next value

increment of the

that results from phi = s + n * d when n is an integer.

rotary axes v1, v2

The minimum and

The minimum and maximum position of the rotary axis limit angle (software

maximum position of

limit) of the rotary axes v1 and v2.

the rotary axes v1, v2

Parameters for the user

$TC_CARR34 to $TC_CARR40 contain parameters that are freely available to users and up

to SW 6.4 were as standard, not further evaluated within the NCK or had no significance.

Job Planning

436

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

Tool offsets

7.8 Tool holder kinematics

Fine offset parameters

$TC_CARR41 to $TC_CARR65 include fine offset parameters that can be added to the

values in the basis parameters. The fine offset value assigned to a basic parameter is

obtained when the value 40 is added to the parameter number.

Example

The toolholder used in the following example can be fully described by a rotation around the

Y axis.

]

]

=

<

<

=

;

<

;

;

;

Program code

Comments

N10 $TC_CARR8[1]=1

; Definition of the Y component of

the first rotary axis of

toolholder 1.

N20 $TC_DP1[1,1] = 120

; Definition of a shaft miller.

N30 $TC_DP3[1,1]=20

; Definition of a shaft miller, 20

mm long.

N40 $TC_DP6[1,1]=5

; Definition of a shaft miller with

5 mm radius.

N50 ROT Y37

; Frame definition with 37° rotation

around the Y axis.

N60 X0 Y0 Z0 F10000

; Approach starting position.

N70 G42 CUT2DF TCOFR TCARR=1 T1 D1 X10

; Set radius compensation, tool

length compensation in rotated

frame, select toolholder 1, tool

1.

Job Planning

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

437

Tool offsets

7.9 Tool length compensation for orientable toolholders (TCARR, TCOABS, TCOFR, TCOFRX, TCOFRY, TCOFRZ)

7.9

Tool length compensation for orientable toolholders (TCARR,

TCOABS, TCOFR, TCOFRX, TCOFRY, TCOFRZ)

Function

When the spatial orientation of the tool changes, its tool length components also change.

=

=

,

,

,

;

;

After a reset, e.g., through manual setting or change of the toolholder with a fixed spatial

orientation, the tool length components also have to be determined again. This is performed

using the TCOABS and TCOFR path commands.

For a toolholder of an active frame that can be orientated, when selecting the tool with

TCOFRZ, TCOFRY and TCOFRX, it is possible to define the direction in which the tool should point.

Syntax

TCARR=[<m>]

TCOABS

TCOFR

TCOFRZ

TCOFRY

TCOFRX

Job Planning

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

439

Tool offsets

7.11 Cutting data modification for tools that can be rotated (CUTMOD)

7.11

Cutting data modification for tools that can be rotated (CUTMOD)

Function

Using the function "cutting data modification for rotatable tools", the changed geometrical

relationships, that are obtained relative to the workpiece being machined when rotating tools

(predominantly turning tools, but also drilling and milling tools) can be taken into account with

the tool compensation.

7RRO VSLQGOH

% D[LV

0DLQ VSLQGOH

&

&

%

&RXQWHUVSLQGOH

&

;

<

=

=

Figure 7-1

Rotatable tool for a lathe

The actual tool rotation is always determined from a currently active toolholder that can be

orientated (refer to " Tool length compensation for toolholders that can be orientated

(Page 439)").

The function is activated using the command CUTMOD.

Syntax

CUTMOD=<value>

Job Planning

446

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

Tool offsets

7.11 Cutting data modification for tools that can be rotated (CUTMOD)

System variables

The following system variables are available:

System variables

Significance

$P_CUTMOD_ANG /

Supplies the (non-rounded) angle in the active machining plane, that was

$AC_CUTMOD_ANG

used as basis for the modification of the cutting data (tool nose position,

cut direction, clearance angle and holder angle) for the functions

activated using CUTMOD and/or $SC_CUTDIRMOD.

$P_CUTMOD_ANG refers to the actual state in the preprocessing,

$AC_CUTMOD_ANG to the actual main run block.

$P_CUTMOD /

Reads the currently valid value that was last programmed using the

$AC_CUTMOD

command CUTMOD (number of the toolholder that should be activated for

the cutting data modification).

If the last programmed CUTMOD value = -2 (activation with the currently

active toolholder that can be orientated), then the value -2 is not returned

in $P_CUTMOD, but the number of the active toolholder that can be

orientated at the time of programming.

$P_CUTMOD refers to the actual state in the preprocessing,

$AC_CUTMOD to the actual main run block.

$P_CUT_INV /

Supplies the value TRUE if the tool is rotated so that the spindle direction

$AC_CUT_INV

of rotation must be inverted. To do this, the following four conditions must

be fulfilled in the block to which the read operations refer:

1. If a turning or grinding tool is active

(tool types 400 to 599 and / or

SD42950 $SC_TOOL_LENGTH_TYPE = 2).

2. The cutting influence was activated using the language command

CUTMOD.

3. A toolholder that can be orientated is active, which was designated

using the numerical value of CUTMOD.

4. The toolholder that can be orientated rotates the tool around an axis

in the machining plane (this is typically the C axis) so that the

resulting perpendicular of the tool cutting edge is rotated with respect

to the initial position by more than 90° (typically 180°).

The contents of the variable is FALSE if at least one of the specified four

conditions is not fulfilled. For tools whose tool nose position is not

defined, the value of the variable is always FALSE.

$P_CUT_INV refers to the actual state in the preprocessing and

$AC_CUT_INV to the actual main run block.

All main run variables ($AC_CUTMOD_ANG, $AC_CUTMOD and $AC_CUT_INV) can be

read in synchronized actions. A read access operation from the preprocessing generates a

preprocessing stop.

Job Planning

450

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

Tool offsets

7.11 Cutting data modification for tools that can be rotated (CUTMOD)

Modified cutting data:

If a tool rotation is active, the modified data are made available in the following system

variables:

System variable

Significance

$P_AD[2]

Tool nose position

$P_AD[10]

Holder angle

$P_AD[11]

Cut direction

$P_AD[24]

Clearance angle

Note

The data are always modified with respect to the corresponding tool parameters

($TC_DP2[..., ...] etc.) if the function "cutting data modification for rotatable tools" was

activated using the command CUTMOD and a toolholder that can be orientated, which causes a

rotation, is activated.

References

For additional information on the function "cutting data modification for rotatable tools", refer

to:

Function Manual Basic Functions; Tool Offset (W1)

Job Planning

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

451

Path traversing behavior

8

8.1

Tangential control (TANG, TANGON, TANGOF, TLIFT, TANGDEL)

Function

The following axis follows the path of the leading axis along the tangent. This allows

alignment of the tool parallel to the contour. Using the angle programmed in the

TANGONinstruction, the tool can be positioned relative to the tangent.

<

;

Application

Tangential control can e.g. be used in the applications:

● Tangential positioning of a rotatable tool during nibbling

● Tracking the workpiece alignment for a bandsaw (see the following diagram).

● Positioning of a dressing tool on a grinding wheel

● Positioning of a cutting wheel for glass or paper working

● Tangential feed of a wire for 5-axis welding.

Job Planning

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

453

Path traversing behavior

8.1 Tangential control (TANG, TANGON, TANGOF, TLIFT, TANGDEL)

<

:RUNSLHFH

6DZ EDQG

;

Syntax

Defining tangential tracking:

TANG(<Faxis>,<Laxis1>,<Laxis2>,<coupling factor>,<KS>,<Opt>)

Activating tangential control:

TANGON(<Faxis>,<angle>,<Dist>,<angular tolerance>)

Deactivating tangential control:

TANGOF (<Faxis>)

Activating the "Insert intermediate block at contour corners" function:

TLIFT(<Faxis>)

The TLIFT operation is specified after the axis assignment with TANG(...).

Deactivating the "Inserting intermediate block at contour corners" function:

Repeat the TANG(...) operation without a following TLIFT(<Faxis>).

Deleting definition of tangential tracking:

TANGDEL(<Faxis>)

An existing user-defined tangential tracking must be deleted if a new tangential tracking with

the same following axis is defined in the preparation call TANG. Deletion is only possible if the

coupling with TANGOF(<Faxis>) is deactivated.

Meaning

TANG:

Preparatory operation for the definition of tangential tracking

TANGON:

Activate tangential control for the specified following axis

Job Planning

454

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

Path traversing behavior

8.1 Tangential control (TANG, TANGON, TANGOF, TLIFT, TANGDEL)

Further information

Defining following axis and leading axis

TANG is used to define the following and leading axes.

A coupling factor specifies the relationship between an angle change on the tangent and the

following axis. Its value is generally 1 (default).

Limit angle using the working area limitation

For path movements, which oscillate back and forth, the tangent jumps through 180° at the

turning point on the path and the orientation of the following axis changes accordingly. This

behavior is generally inappropriate: The return movement should be traversed at the same

negative offset angle as the approach movement:

<

˞

˞

˞

8QZDQWHG UHYHUVH

PRWLRQ

;

<

˞

'HVLUDEOH UHYHUVH

PRWLRQ

;

To do this, limit the working area of the following axis (G25, G26). The working area limit must

be active at the instant of path reversal (WALIMON). If the offset angle lies outside the working

area limit, an attempt is made to return to the permissible working area with the negative

offset angle.

Insert intermediate block at contour corners (TLIFT)

At one corner of the contour the tangent changes and thus the setpoint position of the

following axis. The axis normally tries to compensate this step change at its maximum

possible velocity. However, this causes a deviation from the desired tangential position over

a certain distance on the contour after the corner. If such a deviation is unacceptable for

technological reasons, the instruction TLIFT can be used to force the control to stop at the

corner and to rotate the following axis to the new tangent direction in an automatically

generated intermediate block.

The path axis is used for turning if the following axis has been used once as the path axis. A

maximum axis velocity of the following axis can be achieved with function

TFGREF[<axis>]=0.001.

If the follow-up axis was not previously traversed as a path axis it is now traversed as a

positioning axis. The velocity is then dependent on the positioning velocity in the machine

data.

Job Planning

458

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

Path traversing behavior

8.1 Tangential control (TANG, TANGON, TANGOF, TLIFT, TANGDEL)

The axis is rotated at its maximum possible velocity.

Optimization possibility

If the automatic optimization is selected (<Opt>="P") and if the parameter smoothing distance

(<Dist>) and angular tolerance (<angular tolerance>) are specified for the following axis,

then for tangential tracking, velocity steps of the slave axis as a result of steps in the leading

axis contour are smoothed. In this case, the following axis is controlled with look ahead (refer

to the diagram) in order to keep the deviation as small as possible.

YF

6HWSRLQW YHORFLW\ SURILOH RI

WUDFNHG D[LV &

6PRRWKHG YHORFLW\ SURILOH

W V

'LVW

1

1

1

1

1

Defining the angle change

The angular change limit at which an intermediate block is automatically inserted is defined

using the following machine data:

MD37400 $MA_EPS_TLIFT_TANG_STEP (Tangent angle for corner recognition)

Effect on transformations

The position of the rotary axis to which follow-up control is applied can act as the input value

for a transformation.

Explicit positioning of the following axis

If an axis, which is following your lead axes, is positioned explicitly the position is added to

the programmed offset angle.

All distance data are permissible (path and positioning axis motion).

Status of coupling

The status of the coupling can be interrogated in the NC part program using the system

variable $AA_COUP_ACT[<axis>]:

Value

Meaning

0

No coupling active

1,2,3

Tangential follow-up active

Job Planning

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

459

Path traversing behavior

8.2 Feedrate response (FNORM, FLIN, FCUB, FPO)

Example: Various feed profiles

This example shows you the programming and graphic representation of various feed

profiles.

)HHG

3DWK

1

1

1

1 1

1

1 1

1

1

1

1

1 1 1

Program code

Comments

N1 F1000 FNORM G1 X8 G91 G64

; Constant feedrate profile, incremental

dimension data

N2 F2000 X7

; Setpoint velocity step change

N3 F=FPO(4000, 6000, -4000)

; Feed profile via polynomial with feed 4000

at the end of the block

N4 X6

; Polynomial feedrate 4000 is valid as modal

value

N5 F3000 FLIN X5

; Linear feedrate profile

N6 F2000 X8

; Linear feedrate profile

N7 X5

Linear feedrate is valid as modal value

N8 F1000 FNORM X5

; Constant feedrate profile with acceleration

step change

N9 F1400 FCUB X8

; All of the following F values programmed in

blocks are connected with splines

N10 F2200 X6

N11 F3900 X7

N12 F4600 X7

N13 F4900 X5

; Switch-out spline profile

N14 FNORM X5

N15 X20

Job Planning

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

461

Path traversing behavior

8.2 Feedrate response (FNORM, FLIN, FCUB, FPO)

FNORM

The feed address F defines the path feed as a constant value according to DIN 66025.

Please refer to Programming Manual "Fundamentals" for more detailed information on this

subject.

)HHG

3DWK

FLIN

The feed characteristic is approached linearly from the current feed value to the programmed

F value until the end of the block.

Example:

N30 F1400 FLIN X50

)HHG

3DWK

Job Planning

462

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

Path traversing behavior

8.2 Feedrate response (FNORM, FLIN, FCUB, FPO)

FCUB

The feed is approached according to a cubic characteristic from the current feed value to the

programmed F value until the end of the block. The control uses splines to connect all the

feed values programmed non-modally that have an active FCUB. The feed values act here

as interpolation points for calculation of the spline interpolation.

Example:

N50 F1400 FCUB X50

N60 F2000 X47

N70 F3800 X52

)HHG

3DWK

F=FPO(…,…,…)

The feed characteristic is programmed directly via a polynomial. The polynomial coefficients

are specified according to the same method used for polynomial interpolation.

Example:

F=FPO(endfeed, quadf, cubf)

endfeed, quadf and cubf are previously defined variables.

endfeed:

Feed at block end

quadf:

Quadratic polynomial coefficient

cubf:

Cubic polynomial coefficient

With an active FCUB, the spline is linked tangentially to the characteristic defined via FPO at the

block beginning and block end.

Job Planning

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

463

Path traversing behavior

8.2 Feedrate response (FNORM, FLIN, FCUB, FPO)

)HHG

3DWK

Restrictions

The functions for programming the path traversing characteristics apply regardless of the

programmed feed characteristic.

The programmed feed characteristic is always absolute regardless of G90 or G91.

Feed response FLIN and FCUB are active with

G93 and G94.

FLIN and FCUB is not active with

G95, G96/G961 and G97/G971.

Active compressor COMPON

With an active compressor COMPON the following applies when several blocks are joined to

form a spline segment:

FNORM:

The F word of the last block in the group applies to the spline segment.

FLIN:

The F word of the last block in the group applies to the spline segment.

The programmed F value applies until the end of the segment and is then approached

linearly.

FCUB:

The generated feed spline deviates from the programmed end points by an amount not

exceeding the value set in machine data $MC_COMPESS_VELO_TOL.

F=FPO(…,…,…)

These blocks are not compressed.

Job Planning

464

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

Path traversing behavior

8.3 Program sequence with preprocessing memory (STOPFIFO, STARTFIFO, FIFOCTRL, STOPRE)

8.3

Program sequence with preprocessing memory (STOPFIFO,

STARTFIFO, FIFOCTRL, STOPRE)

Function

Depending on its expansion level, the control system has a certain quantity of so-called

preprocessing memory in which prepared blocks are stored prior to program execution and

then output as high-speed block sequences while machining is in progress. These

sequences allow short paths to be traversed at a high velocity. Provided that there is

sufficient residual control time available, the preprocessing memory is always filled.

3UHSUR

1& SURJUDP

FHVVLQJ

PHPRU\

3URGXFWLRQ SURFHGXUH IDVW EORFN VHTXHQFH

Designate machining step

The beginning and end of the machining step to be buffered in the preprocessing memory

are identified in the part program with STOPFIFO and STARTFIFO respectively. The processing

of the preprocessed and buffered blocks starts only after the STARTFIFO command or if the

preprocessing memory is full.

Automatic preprocessing memory control

Automatic preprocessing memory control is called with the FIFOCTRL command. FIFOCTRL

initially works just like STOPFIFO. Whatever the programming, processing will not start until the

preprocessing memory is full. However, the response to the emptying of the preprocessing

memory does differ: With FIFOCTRL, the path velocity is reduced increasingly once the fill

level reaches 2/3 in order to prevent complete emptying and deceleration to standstill.

Preprocessing stop

Programming the STOPRE command in a block will stop block preprocessing and buffering.

The following block is not executed until all preprocessed and saved blocks have been

executed in full. The preceding block is halted in exact stop (as with G9).

Job Planning

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

465

Path traversing behavior

8.3 Program sequence with preprocessing memory (STOPFIFO, STARTFIFO, FIFOCTRL, STOPRE)

Note

The preprocessing memory is not filled or filling is interrupted if the machining step contains

commands that require unbuffered operation (search for reference, measuring functions,

etc.).

Note

The control generates an internal preprocessing stop in the event of access to status data

($SA...).

CAUTION

If tool offset or spline interpolations are active, a STOPRE command should not be

programmed, as this will lead to contiguous block sequences being interrupted.

Example: Stop preprocessing

Program code

Comment

N30 MEAW=1 G1 F1000 X100 Y100 Z50

; Measurement block with probe at first

measuring input and linear

interpolation.

N40 STOPRE

; Preprocessing stop.

Job Planning

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

467

Path traversing behavior

8.4 Conditionally interruptible program sections (DELAYFSTON, DELAYFSTOF)

Selection of a number of stop events, which induce at least short stopping:

Event name

Response

interruption parameters

RESET

immediate

IS: DB21,… DBX7.7 and DB11, … DBX20.7

PROG_END

Alarm 16954

NC prog.: M30

INTERRUPT

delayed

IS: FC-9 and ASUP DB10, ... DBB1

SINGLEBLOCKSTOP

delayed

Single block mode in the stop delay section is activated:

NC stops at the end of the first block outside the stop delay

section.

Single block already selected before the stop delay

section:

NST: "NC Stop at block limit" DB21, ... DBX7.2

STOPPROG

delayed

IS: DB21,… DBX7.3 and DB11, … DBX20.5

PROG_STOP

Alarm 16954

NC prog.: M0 and M1

WAITM

Alarm 16954

NC prog.: WAITM

WAITE

Alarm 16954

NC prog.: WAITE

STOP_ALARM

immediate

Alarm: Alarm configuration STOPBYALARM

RETREAT_MOVE_THREAD

Alarm 16954

NC prog.: Alarm 16954 with LFON

(stop and fastlift in G33 not possible)

WAITMC

Alarm 16954

NC prog.: WAITMC

NEWCONF_PREP_STOP

Alarm 16954

NC prog.: NEWCONF

SYSTEM_SHUTDOWN

immediate

System shutdown with 840Di

ESR

delayed

Extended stop and retract

EXT_ZERO_POINT

delayed

External zero offset

STOPRUN

Alarm 16955

OPI: PI "_N_FINDST" STOPRUN

Explanation of the responses

immediate ("hard" stop event)

Stops immediately even in stop delay

section.

delayed ("soft" stop event)

Does not stop (even short-term) until after

stop delay section.

Alarm 16954

Program is aborted because illegal program

commands have been used in stop delay

section.

Alarm 16955

Program is continued, an illegal action has

taken place in the stop delay section.

Alarm 16957

The program section (stop delay section)

enclosed by DELAYFSTON and

DELAYFSTOF could not be activated.

Every stop will take effect immediately in

the section and is not subject to a delay.

For a list of other responses to stop events, see:

References:

Function Manual Basic Functions; Mode Group, Channel, Program Operation, (K1),

"Influencing and Impact on Stop Events"

Job Planning

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

469

Path traversing behavior

8.4 Conditionally interruptible program sections (DELAYFSTON, DELAYFSTOF)

Example: Nesting stop delay sections in two program levels

Program code

Comments

N10010 DELAYFSTON()

; Blocks with N10xxx program level 1.

N10020 R1 = R1 + 1

N10030 G4 F1

; Stop delay section starts.

N10040 subprogram2

; Interpretation of subprogram 2

N20010 DELAYFSTON()

; Ineffective, repeated start, 2nd level.

N20020 DELAYFSTOF()

; Ineffective, end at another level.

N20030 RET

N10050 DELAYFSTOF()

; Stop delay section end at the same level.

N10060 R2 = R2 + 2

N10070 G4 F1

; Stop delay section ends. From now, stops act

immediately.

Example: Program excerpt

The following program block is repeated in a loop:

1& VWRSV

1

* =

1

* ;

1

* ; =

1

*

=

;

1

*

=

;

6WRS NH\

6WRS NH\ GXULQJ *

PDFKLQLQJ

=

As shown in the diagram, the user presses "Stop" in the stop delay section and the NC starts

deceleration outside the stop delay section, i.e., in block N100. That causes the NC to stop at

the beginning of N100.

Job Planning

470

Programming Manual, 03/2010, 6FC5398-2BP20-1BA0

Content      ..     18      19      20      21     ..