HEIDENHAIN 4110 User Manual
User’s Manual
MANUALplus
4110
NC Software
526 488-xx
English (en)
9/2007
MANUALplus 4110, Software and Functions
This manual describes functions that are available in
MANUALplus 4110 controls with NC software numbers
507 807-xx and 526 488-xx.
The machine manufacturer adapts the features offered by the control
to the capabilities of the specific machine tool by setting machine
parameters. Therefore, some of the functions described in this manual
may not be among the features provided by the MANUALplus on your
machine tool.
Some of the MANUALplus functions which are not available on every
machine are:
Positioning of spindle (M19) and driven tool
Machining with the C Axis
Please contact your machine manufacturer for detailed information on
the features that are supported by your machine tool.
Many machine manufacturers and HEIDENHAIN offer programming
courses for the MANUALplus controls. We recommend these courses
as an effective way of improving your programming skills and sharing
information and ideas with other MANUALplus users.
HEIDENHAIN also offers the PC software DataPilot 4110 which is
designed to simulate the functions of the MANUALplus 4110 control.
The DataPilot is suitable for both shop-floor programming as well as
off-location program creation and testing. It is also ideal for training
purposes. The DataPilot can be run on WINDOWS operating systems.
Intended place of operation
The MANUALplus 4110 complies with EN 55022, Class A, and is
intended primarily for operation in industrially zoned areas.
Contents
Introduction and Fundamentals
1
Basics of Operation
Machine Mode of Operation
Cycle Programming
ICP Programming
DIN Programming
Tool Management Mode
Organization Mode of Operation
Examples
Tables and Overviews
2
3
4
5
6
7
8
9
10
HEIDENHAIN MANUALplus 4110 3
1 Introduction and Fundamentals 19
1.1 The MANUALplus ..... 20
The C axis ..... 20
1.2 Features ..... 21
1.3 MANUALplus Design ..... 22
Lathe design ..... 22
Machine operating panel ..... 24
1.4 Axis Designations and Coordinate System ..... 25
Axis designations ..... 25
Coordinate system ..... 25
Absolute coordinates ..... 26
Incremental coordinates ..... 26
Polar coordinates ..... 26
1.5 Machine Reference Points ..... 27
Machine zero point ..... 27
Workpiece zero point ..... 27
Reference points ..... 27
1.6 Tool Dimensions ..... 28
Tool length ..... 28
Tool compensation ..... 28
Tool-tip radius compensation (TRC) ..... 28
Milling cutter radius compensation (MCRC) ..... 29
HEIDENHAIN MANUALplus 4110 5
2 Basics of Operation 31
2.1 The MANUALplus Screen ..... 32
2.2 Operation and Data Input ..... 33
Modes of operation ..... 33
Menu selection ..... 33
Soft keys ..... 33
Data input ..... 34
List operations ..... 34
Alphanumeric keyboard ..... 35
2.3 Error Messages ..... 36
Direct error messages ..... 36
Error display ..... 36
Clearing an error message ..... 37
System error, internal error ..... 37
PLC error, PLC status display ..... 37
Warnings during simulation ..... 38
2.4 Explanation of Terms ..... 39
6
3 Machine Mode of Operation 41
3.1 Machine Mode of Operation ..... 42
3.2 Switch-On / Switch-Off ..... 43
Switch-on ..... 43
Traversing the reference marks ..... 43
Monitoring EnDat encoders ..... 44
Switch-off ..... 45
3.3 Machine Data ..... 46
Input and display of machine data ..... 46
Tool call ..... 47
Tools in different quadrants ..... 48
Feed rate ..... 48
Spindle ..... 49
3.4 Machine Setup ..... 50
Defining the workpiece zero point ..... 50
Setting the protection zone ..... 51
Defining the tool change position ..... 52
Setting C-axis values ..... 53
3.5 Setting up Tools ..... 54
Tool compensation ..... 58
Tool life monitoring ..... 59
3.6 Manual Mode ..... 60
Tool change ..... 60
Spindle ..... 60
Handwheel operation ..... 60
Jog operation (joystick) ..... 60
Cycles in Manual mode ..... 61
3.7 Teach-In Mode ..... 62
3.8 Program Run Mode ..... 63
Faulty programs ..... 63
Before executing a program ..... 63
Start block search and program execution ..... 64
Entering compensation values during program execution ..... 65
Setting compensation values with the handwheel ..... 66
Program execution in “dry run” mode ..... 67
HEIDENHAIN MANUALplus 4110 7
3.9 Graphic Simulation ..... 68
Views ..... 70
Graphic elements ..... 71
Warnings ..... 72
Magnify / Reduce ..... 73
3.10 Time Calculation ..... 74
3.11 Program Management ..... 75
Program information ..... 75
Functions for program management ..... 76
3.12 Conversion into DIN Format ..... 77
3.13 Inch Mode ..... 78
4 Cycle Programming 79
4.1 Working with Cycles ..... 80
Starting point of cycles ..... 80
Cycle transitions ..... 80
DIN macros ..... 81
Graphical test run (simulation) ..... 81
Cycle keys ..... 81
Switching functions (M functions) ..... 82
Comments ..... 82
Cycle menu ..... 83
Soft keys in cycle programming ..... 84
4.2 Workpiece Blank Cycles ..... 85
Blank—bar/tube ..... 86
ICP workpc. blank contour ..... 87
4.3 Single Cut Cycles ..... 88
Rapid traverse positioning ..... 89
Approach the tool change position ..... 90
Linear machining, longitudinal ..... 91
Linear machining, transverse ..... 92
Linear machining at angle ..... 93
Circular machining ..... 94
Chamfer ..... 95
Rounding ..... 96
M functions ..... 97
8
4.4 Roughing Cycles ..... 98
Roughing, longitudinal/transverse ..... 101
Roughing, longitudinal/transverse—Expanded ..... 103
Finishing cut, longitudinal/transverse ..... 105
Finishing cut, longitudinal/transverse—Expanded ..... 107
Plunge longitudinal/transverse ..... 109
Plunge, longitudinal/transverse—Expanded ..... 111
Finishing plunge, longitudinal/transverse ..... 113
Finishing plunge, longitudinal/transverse—Expanded ..... 115
ICP contour-parallel, longitudinal/transverse ..... 117
ICP contour-parallel finishing, longitudinal/transverse ..... 119
ICP roughing, longitudinal/transverse ..... 121
ICP finishing, longitudinal or transverse ..... 123
Examples of roughing cycles ..... 125
4.5 Recessing cycles ..... 129
Recessing, radial/axial ..... 131
Recessing, radial/axial—Expanded ..... 133
Recessing radial/axial, finishing ..... 135
Recessing radial/axial, finishing—Expanded ..... 137
ICP recessing cycles ..... 139
ICP recessing radial/axial, finishing ..... 141
Recess turning ..... 143
Recess turning, radial/axial ..... 144
Recess turning, radial/axial—Expanded ..... 146
Recess turning radial/axial, finishing ..... 148
Recess turning radial/axial, finishing—Expanded ..... 150
ICP recess turning, radial/axial ..... 152
ICP recess turning radial/axial, finishing ..... 154
Undercut type H ..... 156
Undercut type K ..... 157
Undercut type U ..... 158
Parting ..... 159
Examples of recessing cycles ..... 160
HEIDENHAIN MANUALplus 4110 9
4.6 Thread and Undercut Cycles ..... 162
Thread cycle (longitudinal) ..... 165
Thread cycle (longitudinal)—Expanded ..... 166
Tapered thread ..... 168
API thread ..... 170
Recut (longitudinal) thread ..... 172
Recut (longitudinal) thread—Expanded ..... 174
Recut tapered thread ..... 176
Recut API thread ..... 178
Undercut DIN 76 ..... 180
Undercut DIN 509 E ..... 182
Undercut DIN 509 F ..... 184
Examples of thread and undercut cycles ..... 186
4.7 Drilling Cycles ..... 190
Drilling, axial/radial ..... 191
Deep-hole drilling, axial/radial ..... 193
Tapping, axial/radial ..... 195
Thread milling, axial ..... 197
Examples of drilling cycles ..... 199
4.8 Milling Cycles ..... 201
Rapid traverse positioning ..... 202
Slot, axial ..... 203
Figure, axial ..... 204
ICP contour, axial ..... 208
Face milling ..... 211
Slot, radial ..... 215
Figure, radial ..... 216
ICP contour, radial ..... 220
Helical-slot milling, radial ..... 223
Cutting direction for contour milling and pocket milling ..... 224
Examples of milling cycles ..... 226
4.9 Drilling/Milling Patterns ..... 227
Drilling/milling pattern linear, axial ..... 228
Drilling/milling pattern circular, axial ..... 230
Drilling/milling pattern linear, radial ..... 232
Drilling/milling pattern circular, radial ..... 234
Examples of pattern machining ..... 236
4.10 DIN Cycles ..... 239
10
5 ICP Programming 241
5.1 ICP Contours ..... 242
5.2 Editing ICP Contours ..... 243
Programming and adding to ICP contours ..... 244
Absolute or incremental dimensions ..... 244
Transitions between contour elements ..... 245
Contour graphics ..... 246
Changing the ICP contour graphics ..... 247
Selection of solutions ..... 248
Contour direction ..... 249
5.3 Importing of DXF Contours ..... 250
Fundamentals ..... 250
DXF import ..... 251
Configuring the DXF import ..... 252
5.4 Programming Changes to ICP Contours ..... 254
Editing a contour element ..... 254
Adding a contour element ..... 257
Deleting a contour element ..... 257
"Splitting" a contour ..... 258
Superimposing form elements ..... 259
5.5 ICP Contour Elements, Turning Contour ..... 260
Entering lines, turning contour ..... 260
Entering circular arcs, turning contour ..... 262
Entering form elements ..... 263
Chamfer/rounding, turning contour ..... 264
Undercuts, turning contour ..... 265
5.6 ICP Contour Elements on the Face ..... 268
Entering lines on the face ..... 269
Entering circular arcs on the face ..... 270
Entering chamfers/roundings on the face ..... 271
5.7 ICP Contour Elements on the Lateral Surface ..... 272
Entering lines on the lateral surface ..... 273
Entering circular arcs on the lateral surface ..... 274
Entering chamfers/roundings on the lateral surface ..... 275
HEIDENHAIN MANUALplus 4110 11
6 DIN Programming 277
6.1 DIN Programming ..... 278
Program and block structure ..... 279
6.2 Editing DIN Programs ..... 281
Block functions ..... 281
Word functions ..... 283
Address parameters ..... 283
Comments ..... 284
Block functions ..... 285
Menu structure ..... 286
Programming G functions ..... 287
6.3 Definition of Workpiece Blank ..... 288
Chuck part, cylinder/tube G20 ..... 288
Workpiece blank contour G21 ..... 289
6.4 Tool Positioning without Machining ..... 290
Rapid traverse G0 ..... 290
Tool change point G14 ..... 291
6.5 Simple Linear and Circular Movements ..... 292
Linear path G1 ..... 292
Circular path G2, G3—incremental center coordinates ..... 293
Circular path G12, G13—absolute center coordinates ..... 295
6.6 Feed Rate and Spindle Speed ..... 297
Speed limitation G26/G126 ..... 297
Interrupted feed G64 ..... 297
Feed per tooth G193 ..... 298
Constant feed G94 (feed per minute) ..... 298
Feed per revolution G95/G195 ..... 298
Constant cutting speed G96/G196 ..... 299
Spindle speed G97/G197 ..... 299
6.7 Tool-Tip / Milling-Cutter Radius Compensation ..... 300
Fundamentals ..... 300
G40: Switch off TRC/MCRC ..... 301
G41/G42: Switch on TRC/MCRC ..... 301
6.8 Compensation Values ..... 302
(Changing the) cutter compensation G148 ..... 302
Additive compensation G149 ..... 303
Compensation of right-hand tool nose G150
Compensation of left-hand tool nose G151 ..... 304
6.9 Zero Point Shifts ..... 305
Zero point shift G51 ..... 305
Additive zero point shift G56 ..... 306
Absolute zero point shift G59 ..... 307
12
6.10 Oversizes ..... 308
Axis-parallel oversize G57 ..... 308
Contour-parallel oversize (equidistant) G58 ..... 309
6.11 Contour-Based Turning Cycles ..... 310
Contour definition ..... 310
End of cycle G80 ..... 310
Longitudinal contour roughing G817/G818 ..... 311
Longitudinal contour roughing with recessing G819 ..... 313
Transverse contour roughing G827/G828 ..... 314
Transverse contour roughing with recessing G829 ..... 316
Contour-parallel roughing G836 ..... 317
Contour finishing G89 ..... 318
6.12 Simple Turning Cycles ..... 319
Roughing longitudinal G81 ..... 319
Roughing transverse G82 ..... 320
Simple contour repeat cycle G83 ..... 321
Line with radius G87 ..... 322
Line with chamfer G88 ..... 323
6.13 Recessing Cycles ..... 324
Contour recessing axial G861 / radial G862 ..... 324
Contour recessing cycle, finishing, axial G863 / radial G864 ..... 326
Simple recessing cycle, axial G865 / radial G866 ..... 328
Recessing finishing, axial G867 / radial G868 ..... 329
Simple recessing cycle G86 ..... 330
6.14 Recess-Turning Cycles ..... 331
Function of recess turning cycles ..... 331
Simple recess-turning cycle, longitudinal G811 / transverse G821 ..... 332
Recess-turning cycle, longitudinal G815 / transverse G825 ..... 333
6.15 Thread Cycles ..... 335
Universal thread cycle G31 ..... 335
Single thread G32 ..... 337
Thread single path G33 ..... 338
Metric ISO thread G35 ..... 339
Simple longitudinal single-start thread G350 ..... 340
Extended longitudinal multi-start thread G351 ..... 341
Tapered API thread G352 ..... 342
Tapered thread G353 ..... 343
HEIDENHAIN MANUALplus 4110 13
6.16 Undercut Cycles ..... 344
Undercut contour G25 ..... 344
Undercut cycle G85 ..... 345
Undercut according to DIN 509 E with cylinder machining G851 ..... 347
Undercut according to DIN 509 F with cylinder machining G852 ..... 348
Undercut according to DIN 76 with cylinder machining G853 ..... 349
Undercut type U G856 ..... 350
Undercut type H G857 ..... 351
Undercut type K G858 ..... 352
6.17 Parting Cycle ..... 353
Parting cycle G859 ..... 353
6.18 Drilling Cycles ..... 354
Drilling cycle G71 ..... 354
Deep-hole drilling cycle G74 ..... 355
Tapping G36 ..... 357
Thread milling, axial G799 ..... 358
6.19 C-Axis Commands ..... 359
Zero point shift, C axis G152 ..... 359
Standardize C axis G153 ..... 359
6.20 Face Machining ..... 360
Starting point of contour / rapid traverse G100 ..... 360
Linear segment, face G101 ..... 361
Circular arc, face G102/G103 ..... 362
Linear slot, face G791 ..... 363
Contour and figure milling cycle, face G793 ..... 364
Area milling, face G797 ..... 366
Figure definition: Full circle, face G304 ..... 368
Figure definition: Rectangle, face G305 ..... 369
Figure definition: Eccentric polygon, face G307 ..... 370
6.21 Lateral Surface Machining ..... 371
Reference diameter G120 ..... 371
Starting point of contour / rapid traverse G110 ..... 372
Linear segment, lateral surface G111 ..... 373
Circular arc, lateral surface G112/G113 ..... 374
Linear slot, lateral surface G792 ..... 376
Contour and figure milling cycle, lateral surface G794 ..... 377
Helical-slot milling G798 ..... 379
Figure definition: Full circle, lateral surface G314 ..... 380
Figure definition: Rectangle, lateral surface G315 ..... 381
Figure definition: Eccentric polygon, lateral surface G317 ..... 382
14
6.22 Pattern Machining ..... 383
Linear pattern, face G743 ..... 383
Circular pattern, face G745 ..... 385
Linear pattern, lateral surface G744 ..... 387
Circular pattern, lateral surface G746 ..... 389
6.23 Other G Functions ..... 391
Period of dwell G4 ..... 391
Precision stop G9 ..... 391
Deactivate protection zone G60 ..... 391
Wait for moment G204 ..... 391
6.24 Set T, S, F ..... 392
Tool number, spindle speed /cutting speed and feed rate ..... 392
6.25 Data Input and Data Output ..... 393
INPUT ..... 393
WINDOW ..... 394
PRINT ..... 395
6.26 Programming Variables ..... 396
Fundamentals ..... 396
# variables ..... 397
V variables ..... 399
6.27 Program Branches, Program Repeats ..... 401
IF (...) (conditional program branch) ..... 401
WHILE (program repeat) ..... 402
6.28 Variables as Address Parameters ..... 403
6.29 Subprograms ..... 406
6.30 M Functions ..... 408
HEIDENHAIN MANUALplus 4110 15
7 Tool Management Mode 411
7.1 Tool Management Mode of Operation ..... 412
Tool types ..... 412
Tool life management ..... 413
7.2 Tool Organization ..... 414
7.3 Tool Texts ..... 416
7.4 Tool Data ..... 418
Tool orientation ..... 418
Reference point ..... 418
Editing tool data ..... 418
Lathe tools ..... 419
Recessing and recess-turning tools ..... 421
Thread-cutting tools ..... 422
Drilling tools ..... 423
Tapping tools ..... 424
Milling tools ..... 425
7.5 Tool Data—Supplementary Parameters ..... 426
Driven tool ..... 426
Direction of rotation ..... 426
Cutting data ..... 426
Tool life management ..... 427
16
8 Organization Mode of Operation 429
8.1 Organization Mode of Operation ..... 430
8.2 Parameters ..... 431
Current parameters ..... 432
Configuration parameters ..... 435
8.3 Transfer ..... 441
Data backup ..... 441
Data exchange with DataPilot 4110 ..... 441
Printer ..... 441
Interfaces ..... 442
Basics of data transfer ..... 442
Configuring for data transfer ..... 444
Transferring programs (files) ..... 446
8.4 Service and Diagnosis ..... 453
Access authorization ..... 453
System service ..... 455
Diagnosis ..... 455
9 Examples 457
9.1 Working with MANUALplus ..... 458
Setting up the machine ..... 459
Selecting a cycle program ..... 460
Creating a cycle program ..... 461
9.2 ICP Example "Threaded Stud" ..... 470
9.3 ICP Example "Matrix" ..... 483
9.4 ICP Example "Recessing Cycle" ..... 495
9.5 ICP Example "Milling Cycle" ..... 507
9.6 DIN Programming Example "Threaded Stud" ..... 516
9.7 DIN Programming Example "Milling Cycle" ..... 519
10 Tables and Overviews 523
10.1 Thread Pitch ..... 524
10.2 Undercut Parameters ..... 525
DIN 76—undercut parameters ..... 525
DIN 509 E, DIN 509 F—undercut parameters ..... 527
10.3 Technical Information ..... 528
10.4 Peripheral Interface ..... 532
HEIDENHAIN MANUALplus 4110 17
Introduction and Fundamentals
1.1 The MANUALplus
The MANUALplus control combines modern control
and drive technology with the functional features of a
hand-operated machine tool. You can run simple
machining operations, such as turning or facing, on
MANUALplus just like on any conventional lathe. The
axes are moved as usual by handwheel or joystick. For
machining difficult contours, such as tapers, radii,
chamfers, undercuts or threads, MANUALplus offers
fixed cycles. These cycles enable you to work faster
and produce a higher quality than on a conventional
lathe.
In addition, you can teach in a machining sequence
1.1 The MANUALplus
and then have MANUALplus rerun the machining
operation automatically as often as desired. Each
additional part machined saves you time.
MANUALplus offers a wide range of capabilities:
From performing simple lathe jobs through to
complex workpiece contours, including drilling and
milling operations on the face and lateral surface.
MANUALplus lets you choose between manual,
semi-automatic and automatic operation. Regardless
of whether you are machining a single part, producing
a whole batch or repairing a workpiece, MANUALplus
always gives you optimum support.
The C axis
With a C axis you can drill and mill a workpiece on its
front, back and lateral surfaces.
During use of the C axis, one axis interpolates linearly
or circularly with the spindle in the given working
plane, while the third axis interpolates linearly.
MANUALplus supports cycle and DIN programming
with the C axis.
20 1 Introduction and Fundamentals
1.2 Features
The functions of the MANUALplus are grouped into operating modes:
Machine mode of operation
This operating mode includes all functions for machine setup,
workpiece machining, and cycle and DIN program definition.
The cycle programming functions are available in both manual
and automatic modes. You can program cycles for roughing,
recessing, thread-cutting and drilling operations.
ICP programming (Interactive Contour Programming) enables
you to describe complex and even incomplete contours. You need
to enter the values for the known elements, MANUALplus then
automatically calculates the transitions, intersections, and any
other missing data. MANUALplus graphically displays the contour
sections entered and calculated. You can usually program a
contour with the dimensions given in the workpiece drawing. ICP
contour descriptions are included in the machining cycles.
The DIN programming feature (NC programming in DIN format
according to DIN 66025 (ISO 6983)) enables you to run highly
complex, technologically sophisticated machining operations.
Apart from pure traversing commands, DIN cycles also provide
functions for roughing, drilling and milling, for programming
schematic contour geometry to calculate missing data, and for
programming variables. You can even write separate DIN
programs or integrate DIN macros in cycles.
Before executing a part program, you can run a graphic
simulation of all machining operations that were programmed
with cycles, cycle programs, or DIN programs.
Tool management mode
MANUALplus stores and manages up to 99 tool definitions.
MANUALplus stores all of the tool data required for calculating
cutting radius compensation, proportioning of cuts, plunging angle,
etc.
1.2 Features
With the tool data, MANUALplus also manages the data for tool life
monitoring as well as the cutting data, feed rate and spindle speed.
Organization mode of operation
The behavior of the MANUALplus system is controlled by
parameters. In the Organization mode, you set the parameters to
adapt the MANUALplus to your situation.
Furthermore, you can exchange and save cycles and DIN programs
with other systems over a serial data line (PC, host computer, etc).
This operating mode also provides diagnostic functions for
commissioning and checking the system.
HEIDENHAIN MANUALplus 4110 21
1.3 MANUALplus Design
The dialog between machinist and control takes place via:
Screen
Soft keys
Data input keypad
Machine operating panel
The entered data can be displayed and checked on the screen. With
the function keys directly below the screen, you can select functions,
capture position values, confirm entries, and a lot more.
With the information key (also found beneath the screen), you can
call error and PLC information and activate the PLC diagnostic
function.
The data input keyboard (operating panel) serves for the input of
1.3 MANUALplus Design
machine data, positioning data, etc. The MANUALplus does not need
an alphanumeric keyboard. Tool descriptions, program descriptions or
comments in a DIN program are entered with an on-screen
alphanumeric keyboard.
The machine operating panel contains all necessary controls for
manual operation of the lathe.
The actual control is not accessible to the machinist. You should know,
however, that your MANUALplus has an integrated hard disk on which
all cycle programs, ICP contours and DIN programs that you enter are
stored. This allows you to save a vast number of programs.
For data exchange and data backup, you can use the serial data
interface (RS-232-C) or the Ethernet interface.
Lathe design
MANUALplus is configured by the machine manufacturer as a vertical
boring and turning mill or to machine with tools "in front of" or "behind"
the workpiece—depending on the design of the lathe or the position
of the tool carrier. The menu symbols, the graphic support windows
as well as the graphic representation during ICP and graphic
simulation all reflect the configuration of the lathe.
The representations in this User's Manual assume a lathe with tool
carrier in front of the workpiece.
22 1 Introduction and Fundamentals
Data input keypad Symbol
Menu
Call the main menu.
Data input keypad Symbol
ENTER
Confirm the entered value.
Process
Select a new mode of operation.
Backspace
Delete the character to the left of the
cursor.
Switching key
Switch between help graphics for
internal/external machining.
Clear
Delete error messages.
Numbers (0 to 9)
For entering values and selecting soft
keys.
Decimal point
Minus
Enter the algebraic sign.
Store
Conclude data input and transfer values.
Arrow keys
Move the cursor in the indicated
direction by one position (character,
field, line, etc.).
Page up, Page down (PgUp/PgDn)
Show the information of the previous/
next screen page; toggle between two
input windows.
Info
Call the error information or PLC status
display.
1.3 MANUALplus Design
HEIDENHAIN MANUALplus 4110 23
Machine operating panel
The machine operating panel is interfaced to the lathe by the
machine tool builder. The controls on your machine may
deviate slightly from those shown in the illustration. Your
machine documentation provides more detailed information.
Controls and displays
1 Handwheel resolution
Set the handwheel resolution to 1/10 mm, 1/100 mm or 1/
1000 mm per graduation mark—or to other resolutions
defined by the machine tool builder.
2 Handwheel superposition in thread cycles
Set the handwheel to "superposition for thread cycles."
3 X handwheel
Position the cross slide (cross slide axis = X axis).
4 Feed-rate override
1.3 MANUALplus Design
Change the programmed feed rate.
5 Speed override
Change the preset speed.
6 EMERGENCY STOP button
7Z handwheel
Position the saddle (saddle axis = Z axis).
8Tool change
Confirm a tool change.
9 Coolant ON/OFF
Enable/disable coolant supply.
10 Joystick
Move the slide on a linear path at feed rate or rapid
traverse; with a built-in switch for enabling rapid traverse.
11 Spindle switch
Switch spindle to clockwise rotation (cw),
counterclockwise rotation (ccw), or spindle stop (M05).
12 Cycle STOP
Stop traverse and cycle execution (the spindle remains
ON).
13 Cycle START
Start a cycle, cycle program or NC program.
14 Spindle jog cw
Slowly rotate the spindle clockwise (cw).
15 Spindle jog ccw
Slowly rotate the spindle counter-clockwise (ccw).
24 1 Introduction and Fundamentals
1.4 Axis Designations and
Coordinate System
Axis designations
The cross slide is referred to as the X axis and the saddle as the Z axis
(see figure at top right).
All X-axis values that are displayed or entered are regarded as
diameters.
When programming paths of traverse, remember to:
Program a positive value to depart the workpiece.
Program a negative value to approach the workpiece.
Coordinate system
The axis designations X and Z describe positions in a two-dimensional
coordinate system. As you can see from the figure to the center right,
the position of the tool tip is clearly defined by its X and Z coordinates.
MANUALplus can connect points by linear and circular paths of
traverse (interpolations). Workpiece machining is programmed by
entering the coordinates for a succession of points and connecting the
points by linear or circular paths of traverse.
Like the paths of traverse, you can also describe the complete contour
of a workpiece by defining single points through their coordinates and
connecting them by linear or circular paths of traverse.
The coordinates entered for the X axis and Z axis are referenced to
the workpiece zero point.
Angles entered for the C axis are referenced to the zero point of the
C axis (see bottom-right figure).
Positions can be programmed to an accuracy of 1 µm (0.001 mm). This
is also the accuracy with which they are displayed.
1.4 Axis Designations and Coordinate System
HEIDENHAIN MANUALplus 4110 25
Absolute coordinates
If the coordinates of a position are referenced to the workpiece zero
point, they are referred to as absolute coordinates. Each position on a
workpiece is clearly defined by its absolute coordinates (see figure at
upper right).
Incremental coordinates
Incremental coordinates are always referenced to the last
programmed position. They specify the distance from the last active
position and the subsequent position. Each position on a workpiece is
clearly defined by its incremental coordinates (see figure at center
right).
Polar coordinates
Positions located on the face or lateral surface can either be entered
in Cartesian coordinates or polar coordinates.
When programming with polar coordinates, a position on the
workpiece is clearly defined by the entries for diameter and angle (see
figure at bottom right).
1.4 Axis Designations and Coordinate System
26 1 Introduction and Fundamentals
1.5 Machine Reference Points
Machine zero point
The point of intersection of the X and Z axes is called the "machine
zero point." On a lathe, the machine zero point is usually the point of
intersection of the spindle axis and the spindle surface. The machine
zero point is designated with the letter "M" (see figure at upper right).
Workpiece zero point
For machining a workpiece, it is easier to reference all input data to a
zero point located on the workpiece. By programming the zero point
used in the workpiece drawing, you can take the dimensions directly
from the drawing, without further calculation. This point is the
"workpiece zero point." The workpiece zero point is designated with
the letter "W" (see figure at center right).
Reference points
Whether the control "forgets" the positions of the machine axes when
it is switched off depends on the position encoders used. If the
positions are lost, you must pass over the fixed reference points after
switching on the MANUALplus. The control knows the exact distance
between these reference marks and the machine zero point (see
figure at lower right).
1.5 Machine Reference Points
HEIDENHAIN MANUALplus 4110 27
1.6 Tool Dimensions
MANUALplus requires data on the specific tools for a variety of tasks,
such as positioning the axes, calculating cutting radius compensation
or proportioning of cuts.
Tool length
All position values that are programmed and displayed are referenced
to the distance between the tool tip and workpiece zero point. Since
the control only knows the absolute position of the tool carrier (slide),
it needs the dimensions XWz and ZWz to calculate and display the
position of the tool tip (see figure at upper right).
1.6 Tool Dimensions
Tool compensation
The tool tip is subjected to wear during machining processes. To
compensate for this wear, MANUALplus uses compensation values
which are managed independent of the values for length. The system
automatically adds the compensation values to the values for length.
Tool-tip radius compensation (TRC)
The tip of a lathe tool has a certain radius. When machining tapers,
chamfers and radii, this results in inaccuracies which MANUALplus
compensates with its cutting radius compensation function.
Programmed paths of traverse are referenced to the theoretical tool
tip S (see figure at center right). With non-paraxial contours, this will
lead to inaccuracies during machining.
The TRC function compensates this error by calculating a new path of
traverse, the equidistant line (see figure at bottom right).
MANUALplus calculates the TRC for cycle programming. The DIN
programming feature also takes the TRC for clearance cycles into
account. During DIN programming with single paths, you can also
enable/disable TRC.
28 1 Introduction and Fundamentals
Milling cutter radius compensation (MCRC)
In milling operations, the outside diameter of the milling cutter
determines the contour. When the MCRC function is not active, the
system defines the center of the cutter as reference point. The MCRC
function compensates for this error by calculating a new path of
traverse, the equidistant line.
1.6 Tool Dimensions
HEIDENHAIN MANUALplus 4110 29
Loading...