HEIDENHAIN TNC 406 User Manual

Download

NC Software 280 620-xx 280 621-xx 286 180-xx

User’s Manual

Conversational

Programming

English (en)

4/2001

100

F %

Controls on the visual display unit

Split screen layout Switch between machining or

programming modes Soft keys for selecting functions in screen

Switching the soft-key rows Changing the screen settings

(only BC 120)

Typewriter keyboard for entering letters and symbols

File names Comments

ISO programs

Machine operating modes

MANUAL OPERATION

INCREMENTAL JOG

POSITIONING WITH MDI

PROGRAM RUN, SINGLE BLOCK

PROGRAM RUN, FULL SEQUENCE

Programming modes

PROGRAMMING AND EDITING

TEST RUN

Program/file management, TNC functions

Delete programs and files (only TNC 406)

Activate external data transfer (only TNC 406)

Pocket calculator

Select programs and files

Moving the highlight, going directly to blocks, cycles and parameter functions

Go directly to blocks, cycles and parameter

Move highlight

functions

Override control knobs for feed rate/C axis

100

S %

Programming path movements

Straight line

Circle center/pole for polar coordinates

Circle with center

Circle with radius

Circular arc with tangential connection

Corner rounding

Electrode data

Enter and call electrode length and radius

Activate electrode radius compensation

Cycles, subprograms and program section repeats

Program stop in a program

Enter touch probe functions in a program

Define and call cycles Enter and call labels for subprogramming and

program section repeats

Coordinate axes and numbers:Entering and editing

. . .

Decimal point

Change arithmetic sign

Polar coordinates

Incremental dimensions

Q parameters

Capture actual position

Skip dialog questions, delete words

Confirm entry and resume dialog

End block Clear numerical entry or TNC error

message Abort dialog, delete program section

Select coordinate axes or enter them into the program

Numbers

TNC Models, Software and Features

This manual describes functions and features provided by the TNCs as of the following NC software numbers.

TNC Model NC Software No.

TNC 406 280 620-12

TNC 416 286 180-06

Location of use

The TNC complies with the limits for a Class A device in accordance with the specifications in EN 55022, and is intended for use primarily in industrially-zoned areas.

280 621-12 280 622-12

New features of the NC software 280 62x-xx and 280 180-xx

 Cycle 14 CONTOUR GEOMETRY (see also ”Cycle 14 CONTOUR

GEOMETRY” on page 137)

 Q parameters for the roughness (see also ”Data from the erosion

table” on page 203)

 Q parameters for the gap size (see also ”Gap size LS max when

machining which Cycle 1 GENERATOR: Q164” on page 206)

 After manual traverse, the incremental coordinates always refer to

the actual position (see also ”Resuming program run with the GOTO key” on page 226)

 Expansion of the tool table with tool pocket number, tool undersize

and radius (see also ”Entering electrode data in tables” on page 74)

 Probed values can be written to a datum table as well as to a tool

table (see also ”Writing probed values to tables” on page 28)

 Enhancement of functions FN14 and FN15 (see also ”Output of Q

Parameters and Messages” on page 197)

 M108/M109 (see Overview of Miscellaneous Functions on the

inside rear cover of this manual)

HEIDENHAIN TNC 406, TNC 416 I

Contents

Introduction

Manual Operation, Setup and Probing Functions

Positioning with manual data input (MDI)

Programming: Fundamentals, Files, Program Entry, Spark Erosion, Erosion Ta b l e s

1 2 3

Programming: Tools

Programming: Programming Contours

Programming: Miscellaneous Functions

Programming: Cycles

Programming: Subprograms and Program Section Repeats

Programming: Q Parameters

Test Run and Program Run

MOD Functions

Tables and Overviews

5 6 7 8 9

11 12 13

HEIDENHAIN TNC 406, TNC 416 III

1 Introduction ..... 1

1.1 The TNC 406, the TNC 416 ..... 2

Controls ..... 2

Visual display unit and keyboard ..... 2

Programming ..... 2

Graphics ..... 2

Compatibility ..... 2

1.2 Visual Display Unit and Keyboard ..... 3

Visual display unit ..... 3

Screen layout ..... 4

Keyboard ..... 5

1.3 Modes of Operation ..... 6

Manual Operation, Incremental Jog, and Positioning with Manual Data Input ..... 6

Programming and Editing ..... 7

Test Run ..... 7

Program Run, Full Sequence and Program Run, Single Block ..... 8

1.4 Status Display ..... 9

General status display ..... 9

Additional status displays ..... 9

1.5 Accessory: Electronic Handwheels from HEIDENHAIN ..... 13

HR electronic handwheels ..... 13

HEIDENHAIN TNC 406, TNC 416 I

2 Manual Operation, Setup and Probing Functions ..... 15

2.1 Switch-on ..... 16

Switch-on ..... 16

2.2 Moving the Machine Axes ..... 18

Note ..... 18

To traverse with the machine axis direction buttons: ..... 18

Traversing with the HR 410 electronic handwheel ..... 19

Incremental jog positioning ..... 20

Positioning with manual data input (MDI) ..... 20

Eroding a workpiece manually ..... 21

2.3 Datum Setting ..... 22

Example ..... 22

2.4 Calibration and Setup ..... 23

Using an electrode ..... 23

Select the touch probe function ..... 24

Calibrating the probing electrode ..... 25

Compensating workpiece misalignment ..... 27

2.5 Datum Setting with a Probing Electrode ..... 28

Functions for setting the datum ..... 28

Writing probed values to tables ..... 28

Datum setting in any axis ..... 29

Manual probing ..... 29

Workpiece center as datum ..... 30

Corner as datum ..... 31

Circle center as datum ..... 32

2.6 Measuring with a Probing Electrode ..... 33

Introduction ..... 33

To find the coordinate of a position on an aligned workpiece ..... 33

Finding the coordinates of a corner in the working plane ..... 33

Measuring workpiece dimensions ..... 34

Measuring angles ..... 35

2.7 Entering and Starting Miscellaneous Functions M ..... 36

Entering values ..... 36

3 Positioning with Manual Data Input (MDI) ..... 37

3.1 Positioning with Manual Data Input (MDI) ..... 38

Positioning with manual data input (MDI) ..... 38

Protecting and erasing programs in $MDI ..... 39

4 Programming: Fundamentals, Files,

Program Entry, Spark Erosion, Erosion Tables ..... 41

4.1 Fundamentals of Positioning ..... 42

Introduction ..... 42

What is NC? ..... 42

The part program ..... 42

Programming ..... 42

Position encoders and reference marks ..... 43

Reference system ..... 43

Reference system with EDMs ..... 44

Programming electrode movement ..... 44

Polar coordinates ..... 45

Absolute and incremental workpiece positions ..... 46

Setting the datum ..... 47

4.2 Files ..... 48

File directory ..... 48

Selecting, copying, deleting and protecting files ..... 50

4.3 Creating and Writing Programs ..... 51

Organization of an NC program in HEIDENHAIN conversational format. ..... 51

Defining the blank form–BLK FORM ..... 51

Creating a new part program ..... 52

Programming tool movements in conversational format ..... 54

Editing a program ..... 55

4.4 Automatic Workpiece Change with WP-Call ..... 57

Programming a workpiece change ..... 57

4.5 Fundamentals of Spark Erosion ..... 58

4.6 Erosion Tables ..... 61

Using erosion tables in a program ..... 61

Working without an erosion table ..... 61

Ready-to-use erosion tables ..... 61

HEIDENHAIN TNC 406, TNC 416 III

4.7 Parameters in the Erosion Table ..... 62

To enter erosion parameters in the erosion table ..... 63

Power stage (NR) ..... 64

Low voltage current (LV) ..... 64

High voltage current (HV) ..... 64

Gap voltage (GV) ..... 64

Pulse-on duration and pulse-off duration ..... 65

Servo sensitivity SV ..... 65

Erosion time ET, Auto jump distance AJD ..... 65

Arc sensitivity (AR) ..... 66

Electrode polarity (P) ..... 66

High voltage selector HS ..... 66

Wear rate WR ..... 67

Surface finish RA ..... 67

Stock removal SR ..... 68

Two-times gap (2G) ..... 68

Minimum undersize (UNS) ..... 69

Auxiliary parameters AUX 1, AUX 2, ... AUX 6 ..... 69

5 Programming: Tools ..... 71

5.1 Electrodes ..... 72

Electrode axis C ..... 72

Determining the electrode data ..... 72

Entering electrode data into a program ..... 73

Entering electrode data in tables ..... 74

Calling electrode data ..... 76

Following electrode ..... 77

Changing the electrode ..... 77

Electrode compensation ..... 78

5.2 Electrode Compensation Values ..... 79

Electrode length compensation ..... 79

Electrode radius compensation ..... 80

Radius compensation: Machining corners ..... 82

5.3 Entering Electrode-Related Data ..... 83

Introduction ..... 83

Feed rate F ..... 83

5.4 Actual Position Capture ..... 84

Function ..... 84

6 Programming: Programming Contours ..... 85

6.1 General Information on Programming Electrode Movements ..... 86

Path functions ..... 86

Machines with 5 axes ..... 86

Subprograms and program section repeats ..... 86

Cycles ..... 87

Parametric programming ..... 87

6.2 Contour Approach and Departure ..... 88

Starting point and end point of machining ..... 88

Tangential contour approach and departure ..... 91

6.3 Path functions ..... 92

General ..... 92

Programmed machine axis movement ..... 92

6.4 Path Contours — Cartesian Coordinates ..... 93

Overview of path functions ..... 93

Straight line L ..... 94

Inserting a chamfer CHF between two straight lines ..... 96

Corner rounding RND ..... 97

Circles and circular arcs ..... 97

Circle center CC ..... 98

Circular path C around circle center CC ..... 100

Circular path CR with defined radius ..... 101

Circular path CT with tangential connection ..... 103

6.5 Path Contours — Polar Coordinates ..... 109

Overview ..... 109

Polar coordinate origin: Pole CC ..... 109

Straight line LP ..... 110

Circular path CP around pole CC ..... 111

Circular path CTP with tangential connection ..... 112

Helical interpolation ..... 113

HEIDENHAIN TNC 406, TNC 416 V

7 Programming: Miscellaneous functions ..... 119

7.1 Entering Miscellaneous Functions M and STOP ..... 120

Fundamentals ..... 120

7.2 Miscellaneous Functions for Program Run Control, Electrode and Flushing ..... 122

Overview ..... 122

7.3 Miscellaneous Functions for Contouring Behavior and Coordinate Data ..... 123

Introduction ..... 123

Machining small contour steps: M97 ..... 123

Machining open contours: M98 ..... 124

Programming machine-referenced coordinates: M91/M92 ..... 124

Retracting electrode to block starting point at end of block: M93 ..... 125

7.4 Vacant miscellaneous functions ..... 126

8 Programming: Cycles ..... 129

8.1 General Overview of Cycles ..... 130

Prerequisites ..... 130

Start of effect ..... 130

Dimensions in the electrode axis ..... 130

OEM cycles ..... 130

Programming a cycle ..... 131

8.2 Cycle 1 GENERATOR ..... 133

Working with an erosion table ..... 133

Working without an erosion table ..... 133

To enter Cycle 1.0 GENERATOR ..... 133

Changing the power stage ..... 134

8.3 Electrode Definition ..... 135

Cycle 3 TOOL DEF ..... 135

Example NC blocks ..... 136

8.4 Erosion Cycles ..... 137

Overview ..... 137

Cycle 14 CONTOUR GEOMETRY ..... 137

Cycle 16 ORBIT ..... 139

Cycle 17 DISK ..... 142

Cycle 2 ERO.TIME LIM. ..... 145

Cycle 4 SPARK-OUT TIME ..... 146

8.5 Coordinate Transformation Cycles ..... 155

Cycles for electrode definition ..... 155

Coordinate transformation cycles ..... 155

DATUM SHIFT (Cycle 7) ..... 156

Working with datum tables ..... 157

MIRROR IMAGE (Cycle 8) ..... 158

ROTATION (Cycle 10) ..... 159

SCALING FACTOR (Cycle 11) ..... 160

WORKING PLANE (Cycle 19) ..... 161

8.6 Other Cycles ..... 171

DWELL TIME (Cycle 9) ..... 171

PGM-CALL (Cycle 12) ..... 171

HEIDENHAIN TNC 406, TNC 416 VII

9 Programming: Subprograms and Program Section Repeats ..... 173

9.1 Labeling Subprograms and Program Section Repeats ..... 174

Labels ..... 174

9.2 Subprograms ..... 175

Operating sequence ..... 175

Programming notes ..... 175

Programming a subprogram ..... 175

Calling a subprogram ..... 175

9.3 Program Section Repeats ..... 176

Label LBL ..... 176

Operating sequence ..... 176

Programming notes ..... 176

Resetting the program repeat counters after an interruption ..... 176

Programming a program section repeat ..... 176

Calling a program section repeat ..... 177

9.4 Separate Program as Subprogram ..... 178

Operating sequence ..... 178

Programming notes ..... 178

Calling any program as a subprogram ..... 178

9.5 Nesting ..... 179

Types of nesting ..... 179

Nesting depth ..... 179

Subprogram within a subprogram ..... 179

Repeating program section repeats ..... 180

Repeating a subprogram ..... 181

VIII

10 Programming: Q Parameters ..... 185

10.1 Principle and Overview ..... 186

Automatic deletion of Q parameters ..... 186

10.2 Part Families – Q Parameters in Place of Numerical Values ..... 187

Example NC blocks ..... 187

Example ..... 187

To assign numerical values to Q parameters ..... 188

10.3 Describing Contours through Mathematical Operations ..... 189

Function ..... 189

Overview ..... 189

Programming example for basic mathematical operations ..... 190

10.4 Trigonometric Functions ..... 192

Definitions ..... 192

Overview of functions ..... 193

10.5 If-Then Decisions with Q Parameters ..... 194

Function ..... 194

Unconditional jumps ..... 194

Programming If-Then decisions ..... 194

Abbreviations used: ..... 195

10.6 Checking and Changing Q Parameters ..... 196

Procedure ..... 196

10.7 Output of Q Parameters and Messages ..... 197

Output of error messages ..... 197

Output through an external data interface ..... 197

Indexed assignment ..... 198

Transferring values to/from the PLC ..... 198

10.8 Measuring with a probing electrode during program run ..... 199

Introduction ..... 199

To program the use of a probing electrode ..... 200

10.9 Q Parameters with Special Functions ..... 202

Vacant Q parameters ..... 202

Preassigned Q parameters ..... 202

Q parameters with special functions ..... 202

Preassigned Q parameters ..... 202

Q parameters with special functions ..... 206

HEIDENHAIN TNC 406, TNC 416 IX

11 Test run and Program Run ..... 215

11.1 Graphics ..... 216

Function ..... 216

Overview of display modes ..... 216

Plan view ..... 217

Projection in 3 planes ..... 217

3-D view ..... 217

Magnifying details ..... 218

Repeating graphic simulation ..... 219

11.2 Test run ..... 220

Function ..... 220

Running a program test ..... 220

Running a program test up to a certain block ..... 221

Operating time ..... 221

11.3 Program run ..... 222

Application ..... 222

Background programming ..... 222

Operating time ..... 222

Changing the erosion parameters during program run ..... 222

Running a part program ..... 223

Interrupting machining ..... 223

Mid-program startup (block scan) ..... 224

Resuming program run after an interruption ..... 225

Returning to the interruption spot ..... 226

Resuming program run with the GOTO key ..... 226

Resetting the counters ..... 227

Time capture table TIME.W ..... 227

12 MOD Functions ..... 229

12.1 MOD functions ..... 230

Selecting, Changing and Exiting the MOD Functions ..... 230

Overview of MOD functions ..... 230

Position Display Types ..... 231

Unit of measurement ..... 231

System Information ..... 232

Setting the external data interfaces ..... 232

BAUD RATE ..... 232

RS-232-C interface ..... 232

12.2 External Data Transfer ..... 233

Application examples ..... 233

LSV-2 protocol ..... 233

Protecting files ..... 233

12.3 Menu for External Data Transfer ..... 233

To select external data transfer ..... 233

Windows for external data transfer ..... 234

12.4 Selecting and Transferring Files ..... 235

Selecting the transfer function ..... 235

Selecting a file ..... 235

Transferring files ..... 235

Formatting disks ..... 236

Deleting files ..... 236

12.5 Software for Data Transfer ..... 237

Software for data transfer ..... 237

12.6 Enter Axis Traverse Limits ..... 240

Introduction ..... 240

12.7 Machine-Specific User Parameters ..... 242

Function ..... 242

12.8 Code Number ..... 243

Function ..... 243

12.9 Q Parameter Status Display ..... 244

Function ..... 244

HEIDENHAIN TNC 406, TNC 416 XI

13 Tables and Overviews ..... 245

13.1 General User Parameters ..... 246

Entering machine parameters ..... 246

Selecting the General User Parameters ..... 246

13.2 Pin Layout and Connecting Cable for the Data Interfaces ..... 254

RS-232-C/V.24 Interface HEIDENHAIN devices ..... 254

RS-422/V.11 Interface ..... 255

13.3 Preparing the Devices for Data Transfer ..... 256

HEIDENHAIN devices ..... 256

Non-HEIDENHAIN devices ..... 256

13.4 Technical Information ..... 257

13.5 TNC Error Messages ..... 259

TNC error messages during programming ..... 259

TNC error messages during test run and program run ..... 259

XII

Introduction

1.1 The TNC 406, the TNC 416

Controls

The TNC 406 and the TNC 416 are shop-floor programmable contouring controls for EDM machines with up to five axes.

Visual display unit and keyboard

The 14-inch color monitor (TNC 406) and 15-inch color monitor (TNC 416) display all information necessary for effective use of the TNC’s capabilities.

Program entry is supported by soft keys on the monitor. The keys on the operating panel are grouped according to function.

This makes it easier to create programs and use the TNC’s functions.

Programming

1.1 The TNC 406, the TNC 416

The user programs the TNC 406/TNC 416 right at the machine with interactive conversational-type guidance.

Graphics

Workpiece machining can be graphically simulated. Various display modes are available.

Compatibility

The TNC 406/TNC 416 can execute all programs whose commands belong to the command set of the TNC 406/TNC 416.

2 1 Introduction

1.2 Visual Display Unit and Keyboard

Visual display unit

The TNC 406 is delivered with the BC 110 color monitor (CRT); the TNC 416 can be delivered with the BC 120 color monitor (CRT) or the BF 120 flat-screen color monitor (TFT). The figure at top right shows the keys and controls on the BC 120, and the figure at bottom right shows those of the BF 120.

1 Header

When the TNC is on, the selected operating modes are shown in the screen header.

2 Soft keys

In the footer the TNC indicates additional functions in a soft-key row. You can select these functions by pressing the keys immediately below them. The lines immediately above the softkey row indicate the number of soft-key rows that can be called with the black arrow keys to the right and left. The line representing the active soft-key row is highlighted.

3 Soft key selector keys 4 Switching the soft-key rows 5 Setting the screen layout 6 Shift key for switchover between machining and programming

modes

1.2 Visual Display Unit and Keyboard

Keys on BC 120 only

7 Screen demagnetization; Exit main menu for screen settings 8 Select main menu for screen settings:

 In the main menu: Move highlight downward  In the submenu: Reduce value or move picture to the left or

downward

9  In the main menu: Move highlight upward

 In the submenu: Increase value or move picture to the right or

upward

10  In the main menu: Select submenu

 In the submenu: Exit submenu

Main menu dialog Function

BRIGHTNESS Adjust brightness

CONTRAST Adjust contrast

H-POSITION Adjust horizontal position

V-POSITION Adjust vertical position

V-SIZE Adjust picture height

HEIDENHAIN TNC 406, TNC 416 3

Main menu dialog Function

SIDE-PIN Correct barrel-shaped distortion

TRAPEZOID Correct trapezoidal distortion

ROTATION Correct tilting

COLOR TEMP Adjust color temperature

R-GAIN Adjust strength of red color

B-GAIN Adjust strength of blue color

RECALL No function

The BC 110 and BC 120 are sensitive to magnetic and electromagnetic noise, which can distort the position and geometry of the picture. Alternating fields can cause the picture to shift periodically or to become distorted.

Screen layout

You select the screen layout yourself: In the TEST RUN mode of operation, for example, you can have the TNC show program blocks in the left window while the right window displays programming graphics. You could also display the tool status in the right window

1.2 Visual Display Unit and Keyboard

instead, or display only program blocks in one large window. The available screen windows depend on the selected operating mode.

To change the screen layout:

Press the SPLIT SCREEN key: The soft-key row shows the available layout options (see ”Modes of Operation” on page 6).

Select the desired screen layout.

4 1 Introduction

Keyboard

The figure at right shows the keys of the keyboard grouped according to their functions:

1 Alphabetic keyboard for entering text and file names 2  File management

 MOD functions

3 Programming modes 4 Machine operating modes 5 Initiation of programming dialog 6 Arrow keys and GOTO jump command 7 Numerical input and axis selection

The functions of the individual keys are described on the inside front cover. Machine panel buttons, e.g. NC START, are described in the manual for your machine tool.

1.2 Visual Display Unit and Keyboard

HEIDENHAIN TNC 406, TNC 416 5

1.3 Modes of Operation

Manual Operation, Incremental Jog, and Positioning with Manual Data Input

The Manual Operation mode is required for setting up the machine tool. In this mode of operation, you can position the machine axes manually or by increments, set the datums, and tilt the working plane.

The Incremental Jog mode of operation allows you to move the machine axes manually with the HR electronic handwheel.

Simple traverse movements can be programmed in the Positioning with Manual Data Input (MDI) mode of operation.

Soft keys for selecting the screen layout (see ”Screen layout” on page 4)

1.3 Modes of Operation

Screen windows Soft key

Positions

Left: positions. Right: status display.

6 1 Introduction

Programming and Editing

In this mode of operation you can write your part programs. The various cycles and Q parameter functions help you with programming and add necessary information.

Soft keys for selecting the screen layout

Screen windows Soft key

Top: program. Bottom: positions

Top left: program. Top right: status Bottom: positions

Test Run

In the Test Run mode of operation, the TNC checks programs and program sections for errors, such as geometrical incompatibilities, or missing or incorrect data within the program. This simulation is supported graphically in different display modes.

Soft keys for selecting the screen layout

Screen windows Soft key

Top: program. Bottom: positions

Top left: program. Top right: status Bottom: positions

Left: program. Right: status

Left: program. Right: graphics

Top left: program. Top right: graphics Bottom: positions

Graphics

1.3 Modes of Operation

HEIDENHAIN TNC 406, TNC 416 7

Program Run, Full Sequence and Program Run, Single Block

In the Program Run, Full Sequence mode of operation the TNC executes a part program continuously to its end or to a manual or programmed stop. You can resume program run after an interruption.

In the Program Run, Single Block mode of operation you execute each block separately by pressing the machine START button.

Soft keys for selecting the screen layout

Screen windows Soft key

Top: program. Bottom: positions

Top left: program. Top right: status

1.3 Modes of Operation

Bottom: positions

Top left: program. Top right: graphics Bottom: positions

8 1 Introduction

1.4 Status Display

General status display

Besides the coordinates, the status display also contains the following information:

 Type of position display (ACTL, NOML, etc.)  Axis is locked ( on the axis)

 Number of the current electrode T  Electrode axis  Feed rate F  Active miscellaneous functions M  TNC is in operation (indicated by )  Name of the selected erosion table  Permissible power stages (GENERATOR cycle)  Current power stage

Additional status displays

In all modes of operation (except PROGRAMMING AND EDITING), you can split the screen layout to display additional status information in the right screen window:

1.4 Status Display

Additional status display

Information on the current electrode

General program information

Information on the current OEM cycle

Positions and coordinates

Active coordinate transformations

Tilting the working plane

HEIDENHAIN TNC 406, TNC 416 9

Soft keys

Information on the current electrode

1 Electrode length 2 Electrode radius 3 Electrode undersize 4 Electrode axis

1.4 Status Display

General program information

1 Programs called with PGM CALL 2 Active cycle 3 Active circle center 4 Dwell time counter 5 Status for eroding with time limit 6 Operating time

1 2

3 4

10 1 Introduction

Information on the current OEM cycle

1 Active OEM cycle (number and name) 2 Number of the transfer parameters 3 Content of each transfer parameter

Positions and coordinates

1 Second position display 2 Feed rate and angular position for Cycle 17 DISK 3 Active basic rotation

1.4 Status Display

HEIDENHAIN TNC 406, TNC 416 11

Active coordinate transformations

1 Active datum table and active datum number 2 Datum shift 3 Rotation 4 Mirror image 5 Scaling factor

1.4 Status Display

Tilting the working plane

1 Active basic rotation 2 Active tilting angle

12 1 Introduction

1.5 Accessory: Electronic Handwheels from HEIDENHAIN

HR electronic handwheels

The electronic handwheels facilitate precise manual control of the axis slides. Similar to a conventional machine tool, you move the machine slide a defined distance by turning the handwheel. A wide range of traverses per revolution is available. Portable handwheels, such as the HR 410, are connected via cable to the TNC. Integral handwheels, such as the HR 130, are built into the machine control panel. Your machine manufacturer can tell you more about the handwheel configuration of your machine.

HEIDENHAIN TNC 406, TNC 416 13

1.5 Accessory: Electronic Handwheels from HEIDENHAIN

Manual Operation, Setup and Probing Functions

2.1 Switch-on

Switch-on

Switch-on and traversing the reference points can vary depending on the individual machine tool. Refer to your machine manual.

2.1 Switch-on

Switch on the power supply for control and machine. The TNC automatically initiates the following dialog

MEMORY TEST

The TNC memory is automatically checked.

POWER INTERRUPTED

TNC message that the power was interrupted — clear the message.

TRANSLATE PLC PROGRAM

The PLC program of the TNC is automatically compiled.

RELAY EXT. DC VOLTAGE MISSING

Switch on external dc voltage. The TNC checks the functioning of the EMERGENCY STOP circuit.

MANUAL OPERATION TRAVERSE REFERENCE POINTS

Cross the reference points manually in the displayed sequence: For each axis press the machine START button, or

Cross the reference points in any sequence: Press and hold the machine axis direction button for each axis until the reference point has been traversed.

16 2 Manual Operation, Setup and Probing Functions

The TNC is now ready for operation in the Manual Operation mode.

The reference points need only be traversed if the machine axes are to be moved. If you intend only to write, edit or test programs, you can select the Programming and Editing or Test Run modes of operation immediately after switching on the control voltage.

You can traverse the reference marks later by choosing the Manual mode of operation.

2.1 Switch-on

HEIDENHAIN TNC 406, TNC 416 17

2.2 Moving the Machine Axes

and

Note

The TNC shows the position of up to five machine axes. The machine manufacturer can enable the position of the

fifth axis, for example with the machine axis-direction buttons, with jog increments, with the electronic handwheel or through ”PLC positioning”.

Contact your machine manufacturer if you need to position a fifth axis.

To traverse with the machine axis direction buttons:

2.2 Moving the Machine Axes

Select the Manual Operation mode.

Press the machine axis-direction button and hold it as long as you wish the axis to move, or

Move the axis continuously: Press and hold the machine axis direction button, then press the machine START button

To stop the axis, press the machine STOP button.

18 2 Manual Operation, Setup and Probing Functions

Traversing with the HR 410 electronic

handwheel

The portable HR 410 handwheel is equipped with two permissive buttons. The permissive buttons are located below the star grip.

You can only move the machine axes when an permissive button is depressed (machine-dependent function).

The HR 410 handwheel features the following operating elements:

1 EMERGENCY STOP 2 Handwheel 3 Permissive buttons 4 Axis address keys 5 Actual-position-capture key 6 Keys for defining the feed rate (slow, medium, fast; the feed rates

are set by the machine tool builder)

7 Direction in which the TNC moves the selected axis 8 Machine function (set by the machine tool builder)

3 4

5 7

The red indicators show the axis and feed rate you have selected. It is also possible to move the machine axes with the handwheel

during a program run.

To move an axis:

Select the Jog Increment mode.

Press and hold the permissive button.

Select the axis.

Select the feed rate.

Move the active axis in the positive or negative direction.

2.2 Moving the Machine Axes

HEIDENHAIN TNC 406, TNC 416 19

If short-circuit monitoring is active: When the electrode makes sparking contact, the TNC stops positioning in the direction of the workpiece, and only permits retracting in the opposite direction. Also, the axes cannot be switched. After they have been retracted at least 10 µm, the TNC switches back to normal Handwheel operation mode. This function is not active while the reference marks are being traversed.

The axes can also be positioned with the electronic handwheel in the PROGRAMMING AND EDITING mode. You must set machine parameter MP7655=1.

Incremental jog positioning

With incremental jog positioning you can move a machine axis by a preset distance.

Incremental Jog Positioning must be enabled by the machine tool builder. Refer to your machine manual.

2.2 Moving the Machine Axes

Select the Jog Increment mode.

INTERPOLATION FACTOR =

Enter interpolation factor, i.e. 4

Go to JOG INCREMENT.

JOG INCREMENT =

Enter the jog increment in millimeters, i.e. 8 mm.

The axis moves by the jog increment every time an external axis-direction button is pressed.

Positioning with manual data input (MDI)

Positioning with manual input of the target coordinates is described in Chapter 3 (see ”Positioning with Manual Data Input (MDI)” on page

38).

8 8

816

20 2 Manual Operation, Setup and Probing Functions

Eroding a workpiece manually

The MANUAL and JOG INCREMENT modes of operation enable you to erode a workpiece manually. This function is especially useful for initial erosion and datum setting. The present gap must be taken into account when setting the datum.

Prerequisite

Cycle 1 GENERATOR must be active.

Procedure

8 Select the MANUAL or JOG INCREMENT mode of operation. 8 Switch on the generator with M36 8 Use the axis direction buttons to preposition the electrode in the

working plane. During free run of the electrode, the manual feed rate is effective.

8 Move the electrode with the axis direction button until it touches the

workpiece. Gap control becomes effective upon contact. The TNC deduces the eroding direction from the axis direction button that was last pressed.

In the MANUAL mode of operation, you can erode up to the limit switch. In the JOG INCREMENT mode of operation, the workpiece is eroded the preset distance.

During erosion you can only move the electrode in the other axes by using the handwheel.

2.2 Moving the Machine Axes

8 To end the erosion process, press the machine axis-direction button

for the opposite direction.

HEIDENHAIN TNC 406, TNC 416 21

2.3 Datum Setting

The production drawing identifies a certain form element of the workpiece (usually a corner) as the absolute datum, and usually one or more form elements as relative datums (see ”Setting the datum” on page 47). Through the datum setting process, the origin of the absolute or relative coordinate systems is set to these datums: The workpiece – aligned to the machine axes – is brought into a certain position relative to the electrode, and the display is set to zero or the appropriate position value (i.e., to account for the electrode radius).

Example

2.3 Datum Setting

Coordinates of Point 1: X = 10 mm

Y = 5 mm Z = 0 mm

The datum of the rectangular coordinate system is located negative 10 mm on the X axis and negative 5 mm on the Y axis from Point 1.

The fastest, easiest and most accurate way of setting the datum is by using the probing functions for datum determination.

22 2 Manual Operation, Setup and Probing Functions

2.4 Calibration and Setup

Using an electrode

An electrode and the probing functions of the TNC 406 can significantly reduce setup time. The TNC 406 offers the following probing functions:

 Compensation of workpiece misalignment

(Basic rotation)

 Datum setting  Measuring

- lengths and positions on the workpiece

- angles

- circle radii

- circle centers

 Measurements during program run

The TNC must be prepared by the machine tool builder before the probing functions can be used.

In probing functions, the electrode starts moving after the external START button is pressed. The machine tool builder determines the feed rate F for movement towards the workpiece.

When the probing electrode touches the workpiece,

 the TNC stores the coordinates of the probed position,  the probing electrode stops moving,

 the probing electrode returns to its starting position in rapid

traverse.

2.4 Calibration and Setup

Machine parameter 6100 determines whether each probing process is to be executed once or several times (maximum number of probing processes: 5). If you wish to probe several times, the TNC calculates the average of all touch points. This average value is the probing result. (See also ”Selecting the General User Parameters” on page 246)

HEIDENHAIN TNC 406, TNC 416 23

max

Select the touch probe function

Overview

The following probing functions are available in the Manual and Jog Increment modes:

Function Soft key

Measuring a basic rotation using a line

Manual probing

Set the datum in any axis

Set the datum at a workpiece center

2.4 Calibration and Setup

Set the datum at a circle center

Set the datum at a corner

Select the calibration function for the electrode length (second soft-key row)

Select the calibration function for the electrode radius (second soft-key row)

Select the touch probe function

8 Select the Manual Operation or Jog Increment mode.

8 Select the probing function by pressing the TOUCH

PROBE soft key. The TNC displays additional soft keys- see table above.

8 To select the probe cycle: press the appropriate soft

key, for example PROBING ROT, and the TNC displays the associated menu.

24 2 Manual Operation, Setup and Probing Functions

Calibrating the probing electrode

The probing electrode is to be calibrated in the following situations:

 During commissioning  When the electrode is changed  When the probing feed rate is changed  In case of irregularities, such as those arising when the machine

heats up

During calibration, the TNC finds the effective length and the effective radius of the electrode.

To calibrate the electrode, clamp a ring gauge of known height and inside diameter to the machine table.

To calibrate the effective length:

8 Set the datum in the spindle axis such that for the machine tool table

Z=0.

8 Select the calibration function for the electrode length

(second soft-key row).

8 (QWHUWKHWRROD[LVZLWKWKHD[LVNH\

8 'DWXP(QWHUWKHKHLJKWRIWKHULQJJDXJH 8 Move the probing electrode to a position just above

the ring gauge.

8 ,IQHFHVVDU\FKDQJHWKHGLUHFWLRQZLWKWKHFXUVRU

NH\V

8 The electrode probes the surface of the ring gauge:

Press the START button.

2.4 Calibration and Setup

HEIDENHAIN TNC 406, TNC 416 25

To calibrate the effective radius:

8 Position the probing electrode in the hole of the ring gauge.

8 Select the calibration function for the electrode radius

(second soft-key row).

8 Select the tool axis and enter the radius of the ring

gauge.

8 To probe the workpiece, press the machine START

button four times. The probing electrode touches the hole in each axis direction.

8 If you want to terminate the calibration function at this

point, press the END soft key.

Displaying calibration values

The effective length and radius of the probing electrode are stored in the TNC’s memory, and are taken into account when the electrode is used later.

2.4 Calibration and Setup

The stored values are displayed on the screen whenever the calibration functions are selected.

26 2 Manual Operation, Setup and Probing Functions

Compensating workpiece misalignment

The TNC electronically compensates workpiece misalignment by computing a ”basic rotation”.

For this purpose, the rotation angle is set to the desired angle with respect to the reference axis in the working plane. If the tilt working plane function is used, the TNC also takes the basic rotation into account in the tilted system.

Measuring the basic rotation

8 Select probing function BASIC ROTATION. 8 Set ROTATION ANGLE to the nominal value. 8 Move the electrode to position A near the first probe

point 1.

8 Select the probe direction perpendicular to the angle

reference axis: Select the axis by soft key.

8 To probe the workpiece, press the machine START

button.

8 Move the electrode to position B near the second

probe point 2.

8 To probe the workpiece, press the machine START

button.

A basic rotation is stored in nonvolatile memory and is effective for all subsequent program runs and graphic simulations.

2.4 Calibration and Setup

A B

Displaying a basic rotation

The angle of the basic rotation is shown after ROTATION ANGLE. The rotation angle is also shown in the additional status display window whenever a basic rotation is active.

To cancel a basic rotation:

8 Select BASIC ROTATION again. 8 Enter a rotation angle of zero and confirm with the ENT key. 8 To terminate the probe function, press the END key.

HEIDENHAIN TNC 406, TNC 416 27

2.5 Datum Setting with a Probing Electrode

Functions for setting the datum

Function Soft key

Set the datum in any axis

Manual probing

Set the datum at a workpiece center

Set the datum at a circle center

Set the datum at a corner

After probing you can set a new datum or transfer the captured values to a datum or tool table.

Writing probed values to tables

In order to write probed values to datum tables, the tables

2.5 Datum Setting with a Probing Electrode

The TNC writes the probed value to a table after the TRANSFER TO TABLE soft key is pressed. You can choose a datum table (NAME.D) as well as a tool table (NAME.T):

8 Select manual probing by pressing the TOUCH PROBE soft key. 8 Enter the name of the datum or tool table. 8 Enter the datum number or tool number. 8 Select the probing function and begin probing. 8 Press the TRANSFER TO TABLE soft key for the TNC to write the

probed value to the selected table.

Writing probed values to a table while a program is running

You can also write probed values to the TOOL table during program run. Use miscellaneous function M109 to transfer the contents of the Q parameters Q81 to Q84 into the table TOOL.T. You can also use M108 to read the tool compensation values from the TOOL table into parameters Q81 to Q84 (see also ”Q parameters for the datum table: Q81 to Q84” on page 206).

28 2 Manual Operation, Setup and Probing Functions

must be active on your TNC (bit 2 in machine parameter 7224 = 0).

Datum setting in any axis

8 Select the probing function by pressing the PROBING

POS soft key.

8 Move the touch probe to a starting position near the

touch point.

8 Select the probe axis and direction in which you wish

to set the datum, such as Z in direction Z–. Selection is made via soft keys.

8 To probe the workpiece, press the machine START

button.

8 Datum: Enter the nominal coordinate and confirm your

entry with ENT.

Manual probing

The PROBING DEPTH function enables you to probe the workpiece as often as desired in one axis. At the same time, you can move all remaining axes with the electronic handwheel. This probing function is particularly convenient for finding peaks and valleys.

In this process, the TNC always stores the last point of electrode contact with the workpiece. You can end the probing process with the CYCLE STOP button.

8 Select the probing function PROBING DEPTH. 8 Move the probing electrode to a starting position near the touch

point.

8 Set the axis traverse limit, i.e. the maximum permissible traverse of

the electrode in the probing axis, and confirm with ENT.

8 Select the probe axis and direction in which you wish to set the

datum, such as Z in direction Z–.

8 Start the probing process. The TNC moves the electrode in the

selected axis direction until it makes contact with the workpiece. This coordinate is stored in the TNC memory. The probing process is repeated until you end the probing function with CYCLE STOP.

8 Use the electronic handwheel to move the electrode in any of the

remaining axes to be scanned for peaks or valleys.

8 Enter the nominal coordinate of the datum and confirm with ENT.

2.5 Datum Setting with a Probing Electrode

HEIDENHAIN TNC 406, TNC 416 29

Workpiece center as datum

With the function PROBING CENTER, you can find the center of square or rectangular workpieces and set the datum at that point. The workpiece must be aligned paraxially to use this function.

8 Select the probing function by pressing the PROBING

CENTER soft key.

8 Move the probing electrode to a position near the first

touch point.

8 Select the probing direction via soft key, e.g. X+. 8 To probe the workpiece, press the machine START

button.

8 Move the probing electrode to a position near the

second touch point.

8 To probe the workpiece, press the machine START

button.

8 Enter the first coordinate of the datum, for example on

the X axis.

8 Repeat the process for the third and fourth touch

points on the second axis, for example on the Y axis.

8 Enter the second coordinate of the datum, for

example on the Y axis.

8 End the probing function.

2.5 Datum Setting with a Probing Electrode

30 2 Manual Operation, Setup and Probing Functions

Corner as datum

8 To select the probe function, press PROBING P. 8 Move the probing electrode to a position near the first

touch point.

8 Select the probing direction via soft key, e.g. X+. 8 To probe the workpiece, press the machine START

button.

8 Position the probing electrode near the second touch

point on the same side.

8 To probe the workpiece, press the machine START

button.

8 Probe two points on the next edge in the same

manner.

8 Datum: Enter both datum coordinates into the menu

window, and confirm your entry with the ENT key.

8 To terminate the probe function, press the END key.

Y=?

X=?

HEIDENHAIN TNC 406, TNC 416 31

2.5 Datum Setting with a Probing Electrode

Circle center as datum

With this function, you can set the datum at the center of bore holes, circular pockets, cylinders, studs, circular islands, etc.

Inside circle

The TNC automatically probes the inside wall in all four coordinate axis directions.

For incomplete circles (circular arcs) you can choose the appropriate probing direction.

8 Move the electrode to a position approximately in the center of the

circle.

8 To select the probe function, press PROBING CC. 8 To probe the workpiece, press the machine START

button four times. The touch probe touches four points on the inside of the circle.

8 Datum: Enter both circle center coordinates into the

menu window, and confirm your entry with ENT.

8 To terminate the probe function, press the END key.

Outside circle

8 To select the probe function, press PROBING CC. 8 Move the probing electrode to a position near the first

touch point outside of the circle.

8 Select the probe direction with a soft key. 8 To probe the workpiece, press the machine START

2.5 Datum Setting with a Probing Electrode

After the probing procedure is completed, the TNC displays the coordinates of the circle center and the circle radius PR on the monitor.

button.

8 Repeat the probing process for the remaining three

points. See figure at lower right.

8 Enter the coordinates of the circle center.

Y+

X+X–

Y–

X+

X–

Y+

32 2 Manual Operation, Setup and Probing Functions

2.6 Measuring with a Probing Electrode

Introduction

An electrode can be used to determine

 position coordinates, and from them,  dimensions and angles on the workpiece.

To find the coordinate of a position on an aligned workpiece

8 Select the probing function by pressing PROBING

POS.

8 Move the probing electrode to a starting position near

the touch point.

8 Select the probe direction and axis of the coordinate.

Use the corresponding soft keys for selection.

8 To probe the workpiece, press the machine START

button.

The TNC shows the coordinates of the touch point as datum.

Finding the coordinates of a corner in the working plane

Find the coordinates of the corner point as described under ”Corner as datum”.

The TNC displays the coordinates of the probed corner as datum.

2.6 Measuring with a Probing Electrode

HEIDENHAIN TNC 406, TNC 416 33

Measuring workpiece dimensions

8 Select the probing function by pressing PROBING

POS.

8 Move the probing electrode to a position near the first

touch point 1.

8 Select the probing direction with a soft key. 8 To probe the workpiece, press the machine START

button.

8 If you will need the current datum later, write down

the value that appears in the Datum display.

8 Set the datum to 0. 8 To terminate the dialog, press the END key. 8 Select the touch probe function again:

Press PROBING POS.

8 Move the probing electrode to a position near the

second touch point 2.

8 Select the probe direction with the soft keys: Same

axis but from the opposite direction.

8 To probe the workpiece, press the machine START

button.

The value displayed as DATUM is the distance between the two points on the coordinate axis.

2.6 Measuring with a Probing Electrode

To return to the datum that was active before the length measurement:

8 Select the probing function by pressing PROBING POS. 8 Probe the first touch point again. 8 Set the DATUM to the value that you wrote down previously. 8 To terminate the dialog, press the END key.

34 2 Manual Operation, Setup and Probing Functions

Measuring angles

You can also use the probing electrode to measure angles in the working plane. You can measure

 the angle between the angle reference axis and a workpiece side, or  the angle between two sides.

The measured angle is displayed as a value of maximum 90°.

To find the angle between the angle reference axis and a side of the workpiece

8 Select the probing function by pressing the PROBING

ROT soft key.

8 Rotation angle: If you will need the current basic

rotation later, write down the value that appears under Rotation angle.

8 Make a basic rotation with the side of the workpiece

(see ”Compensating workpiece misalignment” on page 27).

8 Press the PROBING ROT soft key to display the angle

between the angle reference axis and the edge of the workpiece as the rotation angle.

8 Cancel the basic rotation, or restore the previous basic

rotation by setting the Rotation angle to the value that you wrote down previously.

To measure the angle between two workpiece sides:

8 Select the probing function by pressing the PROBING ROT soft key. 8 Rotation angle: If you will need the current basic rotation later, write

down the value that appears under Rotation angle.

8 Make a basic rotation with the side of the workpiece (see

”Compensating workpiece misalignment” on page 27).

8 Probe the second side as for a basic rotation, but do not set the

Rotation angle to zero!

8 Press the PROBING ROT soft key to display the angle PA between

the two sides as the Rotation angle.

8 Cancel the basic rotation, or restore the previous basic rotation by

setting the Rotation angle to the value that you wrote down previously.

100

–10

2.6 Measuring with a Probing Electrode

α?

100

HEIDENHAIN TNC 406, TNC 416 35

2.7 Entering and Starting Miscellaneous Functions M

Entering values

Miscellaneous function M

To enter the miscellaneous function, press the M soft key.

MISCELLANEOUS FUNCTION M =

The machine tool builder determines which miscellaneous functions M are available on your TNC and what function they have. Refer to your machine manual.

2.7 Entering and Starting Miscellaneous Functions M

Enter a miscellaneous function, e.g. M6.

Start the miscellaneous function.

36 2 Manual Operation, Setup and Probing Functions

Positioning with Manual Data Input (MDI)

3.1 Positioning with Manual Data Input (MDI)

The POSITIONING WITH MANUAL DATA INPUT mode of operation is particularly convenient for simple machining operations or exact prepositioning of the electrode. You can write a program in conversational programming and execute it immediately. You can also define and call TNC cycles. The program is stored in the file $MDI.

 PGM CALL can not be used to call a program.  LBL CALL can not be used for calling sub-routines or

repeating sections of programs.

 For a TOOL CALL block to processed, the

corresponding TOOL DEF tool definition must be programmed within the $MDI file.

 Incremental positionings always refers to the present

electrode position.

 Programming a radius compensation (RL/RR) is not

permitted.

Positioning with manual data input (MDI)

Select the Positioning with MDI mode of operation. Program the file $MDI as you wish.

3.1 Positioning with Manual Data Input (MDI)

Example: Programming and processing a line

38 3 Positioning with Manual Data Input (MDI)

To start program run, press the machine START button.

Select operating mode: Positioning with MDI.

Select the axis, and enter the end-point coordinates of the line and the feed rate, i.e.: L X+125 R F100 M

Conclude entry.

Start positioning block.

Protecting and erasing programs in $MDI

74523

The $MDI file is generally intended for short programs that are only needed temporarily. Nevertheless, you can store a program, if necessary, by proceeding as described below:

Select the Programming and Editing mode of operation.

To call the file manager, press the PGM MGT key (program management).

Move the highlight to the $MDI file.

To select the file copying function, press the COPY soft key.

TARGET FILE =

Enter the name under which you want to save the current contents of the $MDI file.

End the copying process with the ENT key.

Erasing the contents of the $MDI file is done in a similar way: Instead of copying the contents, however, you erase them with the DELETE soft key. The next time you select the operating mode Positioning with MDI, the TNC will display an empty $MDI file.

If you wish to delete $MDI, then

 you must not have selected the Positioning with MDI

mode.

 you must not have selected the $MDI file in the

Programming and Editing mode.

HEIDENHAIN TNC 406, TNC 416 39

3.1 Positioning with Manual Data Input (MDI)

Programming: Fundamentals, Files, Program Entry, Spark Erosion, Erosion Tables

4.1 Fundamentals of Positioning

Introduction

This chapter covers the following topics:

 What is NC?  The part program  Programming  Position encoders and reference marks  Reference system  Reference system with electrical discharge machines (EDM)  Programming electrode movement  Polar coordinates  Absolute and incremental workpiece positions  Setting the datum

What is NC?

NC stands for Numerical Control, that is, the operation of a machine

4.1 Fundamentals of Positioning

tool by a series of coded instructions comprised of numbers. Modern controls such as TNCs have a built-in computer for this

purpose and are therefore called CNC (Computerized Numerical Control).

The part program

The part program is a complete list of instructions for machining a part. It contains such information as the target position of an electrode movement, the path function (how the electrode should move toward the target position) and the feed rate. Information on the radius and length of the electrode and the electrode axis must also be included in the program.

Programming

Conversational programming is a particularly easy method of writing and editing part programs. HEIDENHAIN NCs were developed specifically for the machine operator who keys in programs right at the machine. This is why they are called TNC (Touch Numerical Control). You begin each machining step by pressing a key. The TNC then asks you for all the information it needs to execute the step.

42 4 Programming: Fundamentals, Files, Program Entry, Spark Erosion, Erosion Tables

Position encoders and reference marks

The machine axes are equipped with position encoders that register the positions of the machine table or tool. When a machine axis moves, the corresponding position encoder generates an electrical signal. The TNC evaluates this signal and calculates the precise actual position of the machine axis.

If there is an interruption of power, the calculated position will no longer correspond to the actual position of the machine slide. The TNC can re-establish this relationship with the aid of reference marks when power is returned. The scales of the position encoders contain one or more reference marks that transmit a signal to the TNC when they are crossed over. From the signal the TNC identifies that position as the machine-axis reference point and can re-establish the assignment of displayed positions to machine axis positions.

Linear encoders are generally used for linear axes. Rotary tables and tilt axes have angle encoders. If the position encoders feature distance-coded reference marks, you only need to move each axis a maximum of 20 mm (0.8 in.) for linear encoders, and 20° for angle encoders, to re-establish the assignment of the displayed positions to machine axis positions.

X (Z,Y)

Reference system

A reference system is required to define positions in a plane or in space. The position data are always referenced to a predetermined point and are described through coordinates.

The Cartesian coordinate system (a rectangular coordinate system) is based on the three coordinate axes X, Y and Z. The axes are mutually perpendicular and intersect at one point called the datum. A coordinate identifies the distance from the datum in one of these directions. A position in a plane is thus described through two coordinates, and a position in space through three coordinates.

Coordinates that are referenced to the datum are referred to as absolute coordinates. Relative coordinates are referenced to any other known position (datum) you define within the coordinate system. Relative coordinate values are also referred to as incremental coordinate values.

4.1 Fundamentals of Positioning

HEIDENHAIN TNC 406, TNC 416 43

Reference system with EDMs

When using an EDM, you orient tool movements to the Cartesian coordinate system. The illustrations at right show how the Cartesian coordinate system describes the machine axes. The figure at center right illustrates the ”right-hand rule” for remembering the three axis directions: the middle finger is pointing in the positive direction of the tool axis from the workpiece toward the tool (the Z axis), the thumb is pointing in the positive X direction, and the index finger in the positive Y direction.

The TNC 406/TNC 416 can control up to 5 axes. The axes U, V and W are secondary linear axes parallel to the main axes X, Y and Z, respectively. Rotary axes are designated as A, B and C. The illustration at lower right shows the assignment of secondary axes and rotary axes to the main axes.

Programming electrode movement

Depending on the machine tool, either the machine table with the workpiece moves or the electrode moves.

You always program as if the electrode moves and the

4.1 Fundamentals of Positioning

If the machine table moves, the corresponding axes are identified on the machine operating panel with a prime mark (e.g., X’, Y’). The programmed direction of such axis movement always corresponds to the direction of electrode movement relative to the workpiece but in the opposite direction.

workpiece remains stationary, no matter the type of machine.

W+

C+

B+

V+

A+

U+

44 4 Programming: Fundamentals, Files, Program Entry, Spark Erosion, Erosion Tables

Polar coordinates

If the production drawing is dimensioned in Cartesian coordinates, you also write the part program using Cartesian coordinates. For parts containing circular arcs or angles it is often simpler to give the dimensions in polar coordinates (see „Path Contours — Polar Coordinates” on page 109).

While the Cartesian coordinates X, Y and Z are three-dimensional and can describe points in space, polar coordinates are two-dimensional and describe points in a plane. Polar coordinates have their datum at a circle center (CC), or pole. A position in a plane can be clearly defined by the:

 Polar Radius, the distance from the circle center CC to the position,

and the

 Polar Angle, the size of the angle between the reference axis and

the line that connects the circle center CC with the position.

See figure at upper right.

Definition of pole and angle reference axis

The pole is set by entering two Cartesian coordinates in one of the three planes. These coordinates also set the reference axis for the polar angle PA.

Coordinates of the pole (plane) Reference axis of the angle

X/Y +X

0°

4.1 Fundamentals of Positioning

Y/Z +Y

Z/X +Z

HEIDENHAIN TNC 406, TNC 416 45

Absolute and incremental workpiece positions

Absolute workpiece positions

Absolute coordinates are position coordinates that are referenced to the datum of the coordinate system (origin). Each position on the workpiece is uniquely defined by its absolute coordinates.

Example 1: Holes dimensioned in absolute coordinates

Hole 1 Hole 2 Hole 3 X = 10 mm X = 30 mm X = 50 mm Y = 10 mm Y = 20 mm Y = 30 mm

Incremental workpiece positions

Incremental coordinates are referenced to the last programmed nominal position of the tool, which serves as the relative (imaginary) datum. When you write a part program in incremental coordinates, you thus program the tool to move by the distance between the previous and the subsequent nominal positions. Incremental coordinates are therefore also referred to as chain dimensions.

To program a position in incremental coordinates, enter the prefix "I" before the axis.

4.1 Fundamentals of Positioning

Example 2: Holes dimensioned in incremental coordinates Absolute coordinates of hole 4 X = 10 mm

Y = 10 mm Hole 5, referenced to 4 Hole 6, referenced to 5

X = 20 mm X = 20 mm Y = 10 mm Y = 10 mm

Absolute and incremental polar coordinates

Absolute polar coordinates always refer to the pole and the reference axis.

Incremental polar coordinates always refer to the last programmed nominal position of the tool.

10 10

3010

+IPR

+IPA

0°

46 4 Programming: Fundamentals, Files, Program Entry, Spark Erosion, Erosion Tables

Setting the datum

The production drawing identifies a certain form element of the workpiece (usually a corner) as the absolute datum, and usually one or more form elements as relative datums. Through the datum setting process, the origin of the absolute or relative coordinate systems is set to these datums: The workpiece – aligned to the machine axes – is brought into a certain position relative to the electrode, and the display is set to zero or the appropriate position value (i.e., to account for the electrode radius) (see „Datum Setting” on page 22).

Example

The workpiece drawing at right shows holes (1 to 4) whose dimensions are shown with respect to an absolute datum with the coordinates X=0, Y=0. The holes (5 to 7) are dimensioned with respect to a relative datum with the absolute coordinates X=450, Y=750. With the DATUM SHIFT cycle you can temporarily set the datum to the position X=450, Y=750, to be able to program the holes (5 to 7) without further calculations.

MAX

MIN

750

320

4.1 Fundamentals of Positioning

150

-150

0,1 ±

300

325

450 900

950

HEIDENHAIN TNC 406, TNC 416 47

4.2 Files

The TNC 416 saves programs and tables as files. The TNC can store up to 100 files. A file is identified by its file name and file extension.

4.2 Files

The file name is entered when a new file is created. The file extension is separated from the file name by a period, and

indicates what type of file it is.

Files in the TNC Ty p e Programs

In HEIDENHAIN format .H

Tables for

Erosion Datum Tools Time capture

The tool table TOOL.T is only active if bit 2 of MP7224 is set to 0.

File directory

You call the file directory with the PGM NAME key (TNC 406) or the PGM MGT key (TNC 416).

To delete files from the TNC, use CL PGM on the TNC 406 to call up the directory.

Overview of the file management functions:

.E .D .T Time.W

File

... Create or

... Edit or

... Delete or

... Test or

... Run or

48 4 Programming: Fundamentals, Files, Program Entry, Spark Erosion, Erosion Tables

Operating mode

Call file directory with

The file directory contains the following information:

Display Meaning FILE NAME Name (up to 8 characters plus file extension)

BYTE File size in bytes

STATUS

R E P I

STORAGE AREA AND NUMBER

INTERNAL FILES

EXTERNAL FILES

Files in ROM

Pressing the ROM soft key displays files that the machine tool builder wrote and stored in ROM, such as erosion tables. These files can be edited.

Identification of protected files

The TNC inserts a ”P” in the first and last lines of write- and eraseprotected files. The file directory also shows a ”P” next to the file name.

Properties of the file: File is active for Program Run/Program Test. File is active for Programming and Editing. File is protected against editing and erasure. Dimensions are given in inches.

Files in the TNC memory

Files, e.g., on a PC 401

4.2 Files

HEIDENHAIN TNC 406, TNC 416 49

Selecting, copying, deleting and protecting files

Activate the file directory

8 Use the PGM MGT key with the TNC 416, and the PGN NAME key

with the TNC 406. If you want to delete files with the TNC 406, you

4.2 Files

must call the file directory with the CL PGM key.

Select the file

8 Enter the file name (not for CL PGM) or move the highlight with the

cursor keys to the desired file.

Function Soft key

Go to the next page

Go to the previous page

Display files in ROM

Select file (such as for a test run)

Copy file: Enter the name of the target file

File protection

Cancel file protection

Deleting a file

Close the file directory

50 4 Programming: Fundamentals, Files, Program Entry, Spark Erosion, Erosion Tables

4.3 Creating and Writing Programs

Organization of an NC program in HEIDENHAIN conversational format.

A part program consists of a series of program blocks. The figure at right illustrates the elements of a block.

The TNC numbers the blocks in ascending sequence. The first block of a program is identified by BEGIN PGM, the program

name and the active unit of measure. The subsequent blocks contain information on:

 The workpiece blank  Tool definitions, tool calls  Feed rates and spindle speeds, as well as  Path contours, cycles and other functions

The last block of a program is identified by END PGM, the program name and the active unit of measure.

Defining the blank form–BLK FORM

Immediately after initiating a new program, you define a cuboid workpiece blank. If you wish to define the blank at a later stage, press the BLK FORM soft key. This definition is needed for the TNC’s graphic simulation feature. The sides of the workpiece blank lie parallel to the X, Y and Z axes and can be up to 30 000 mm long. The blank form is defined by two of its corner points:

 MIN point: the smallest X, Y and Z coordinates of the blank form,

entered as absolute values.

 MAX point: the largest X, Y and Z coordinates of the blank form,

entered as absolute or incremental values.

Blocks

10 L X+10 Y+5 R0 F100 M3

Path function

Block number

MAX

Words

4.3 Creating and Writing Programs

You only need to define the blank form if you wish to run a graphic test for the program!

MIN

HEIDENHAIN TNC 406, TNC 416 51

Creating a new part program

You always enter a part program in the Programming and Editing mode of operation. Program initiation in an example:

Select the Programming and Editing mode of operation.

Press the key to call the file directory.

FILE NAME = 7432

Enter the new program name and confirm your entry with the ENT key.

Choose the type of file: Press the .H, .E or .D soft key. The TNC changes to the program window.

4.3 Creating and Writing Programs

WORKING SPINDLE AXIS X/Y/Z ?

DEF BLK FORM: MIN-CORNER ?

-40

DEF BLK FORM: MAX-CORNER ?

100

To define the BLK-FORM, press the BLK-FORM soft key. The TNC opens a dialog for defining the

BLK FORM.

Enter the spindle axis.

Enter in sequence the X, Y and Z coordinates of the MIN point.

Enter in sequence the X, Y and Z coordinates of the MAX point.

52 4 Programming: Fundamentals, Files, Program Entry, Spark Erosion, Erosion Tables

Example: Display the BLK form in the NC program.

0 BEGIN PGM NEW MM 1 BLK FORM 0.1 Z X+0 Y+0 Z-40 2 BLK FORM 0.2 X+100 Y+100 Z+0 3 END PGM NEW MM

The TNC automatically generates the block numbers as well as the BEGIN and END blocks.

If you do not wish to define a blank form, cancel the dialog at Working spindle axis X/Y/Z by pressing the DEL key!

The TNC can display the graphic only if the ratio of the short side to the long sides of the BLK FORM is greater than 1:64!

Program begin, name, unit of measure Spindle axis, MIN point coordinates MAX point coordinates Program end, name, unit of measure

4.3 Creating and Writing Programs

HEIDENHAIN TNC 406, TNC 416 53

Programming tool movements in conversational

format

To program a block, initiate the dialog by pressing a function key. In the screen headline, the TNC then asks you for all the information necessary to program the desired function.

Example of a dialog

Dialog initiation

COORDINATES ?

RADIUS COMP. RL/RR/NO COMP. ?

4.3 Creating and Writing Programs

FEED RATE ? F= / F MAX = ENT

100

MISCELLANEOUS FUNCTION M ?

The program blocks window will display the following line:

3 L X+10 Y+20 R0 F100 M36

Enter the target coordinate for the X axis.

Enter the target coordinate for the Y axis, and go to the next question with ENT.

Enter ”No radius compensation” and go to the next question with ENT.

Enter a feed rate of 100 mm/min for this path contour; go to the next question with ENT.

Enter the miscellaneous function M36 ”eroding ON”; pressing the ENT key terminates this dialog.

54 4 Programming: Fundamentals, Files, Program Entry, Spark Erosion, Erosion Tables

Function Key

Continue the dialog

Ignore the dialog question

End the dialog immediately

Abort the dialog and erase the block

Editing a program

While you are creating or editing a part program, you can select any desired line in the program or individual words in a block with the arrow keys or the soft keys:

Function Soft keys/keys

Go to the previous page

Go to the next page

Move from one block to the next

Select individual words in a block

Function Key

Set the selected word to zero

Erase an incorrect number

Clear a (non-blinking) error message

Delete the selected word

Delete the selected block

Erase cycles and program sections: First select the last block of the cycle or program section to be erased, then erase with the DEL key.

4.3 Creating and Writing Programs

HEIDENHAIN TNC 406, TNC 416 55

Inserting blocks at any desired location

8 Select the block after which you want to insert a new block and

initiate the dialog.

Editing and inserting words

8 Select a word in a block and overwrite it with the new one. The plain-

language dialog is available while the word is highlighted.

8 To accept the change, press the END key.

If you want to insert a word, press the horizontal arrow key repeatedly until the desired dialog appears. You can then enter the desired value.

Looking for the same words in different blocks

To select a word in a block, press the arrow keys repeatedly until the highlight is on the desired word.

Select a block with the arrow keys.

Select a block directly.

4.3 Creating and Writing Programs

The word that is highlighted in the new block is the same as the one you selected previously.

56 4 Programming: Fundamentals, Files, Program Entry, Spark Erosion, Erosion Tables

4.4 Automatic Workpiece Change with WP-Call

If your machine features an automatic handling system, you can program an automatic workpiece change with the WP-CALL function. WP-CALL resets an active rotation, and can be programmed to subsequently execute a datum shift and activate the rotation again, if desired. The values for datum shift and rotation are transferred by the PLC.

The function for automatic workpiece change is adapted to the TNC by the machine tool builder. Refer to your machine tool manual.

Programming a workpiece change

8 Select the Programming and Editing mode of operation.

8 Press the WP-CALL soft key. 8 Workpiece name: Enter the name of the pallet

(for example, 1). You can enter up to 16 characters (letters and numbers).

8 Number of tilts: Enter the number of tilts (maximum

input value: 9).

Example NC block

7 WP–CALL 1 / 1

HEIDENHAIN TNC 406, TNC 416 57

4.4 Automatic Workpiece Change with WP-Call

4.5 Fundamentals of Spark Erosion

Electrical discharge machining is an electrothermal process which uses a spark to remove metal by melting and vaporizing (”eroding”) the workpiece surface. In contrast, cutting machine tools such as milling machines remove metal by direct abrasive action. The spark erosion process is described on the following pages.

The electrode (e) and the workpiece (w) are submerged in a dielectric fluid (d). A generator applies a voltage to the electrode and the workpiece (both the electrode and the workpiece are then electrodes).

An electric field is then created in the gap between the electrode and the workpiece. The electric field is strongest where the gap is the smallest. The electrically conductive particles in the dielectric fluid are concentrated at this point.

4.5 Fundamentals of Spark Erosion





A bridge of electrically conductive particles forms between the electrode and the workpiece.



58 4 Programming: Fundamentals, Files, Program Entry, Spark Erosion, Erosion Tables

After a certain length of time (the ignition delay time), a discharge channel suddenly forms across the bridge of particles, and current starts to flow between the electrode and the workpiece. The current flow increases the temperature in the discharge channel, and further electrically charged particles are created (ions). The current increases.

The temperature in the discharge channel becomes so great that the dielectric fluid there vaporizes.



4.5 Fundamentals of Spark Erosion



The discharge channel expands in the middle while at the electrode and workpiece it becomes narrower. The temperature increases to a point where the surfaces of the electrode and workpiece melt. Part of the molten metal vaporizes.



HEIDENHAIN TNC 406, TNC 416 59

When the voltage is removed, the discharge channel collapses (implodes).

When the discharge channel collapses, the implosion thrusts the molten metal into the dielectric fluid.

4.5 Fundamentals of Spark Erosion



A small crater remains on the electrode and the workpiece. The debris of melted electrode or workpiece material remains suspended in the dielectric fluid.



60 4 Programming: Fundamentals, Files, Program Entry, Spark Erosion, Erosion Tables

4.6 Erosion Tables

The machine tool builder can define the erosion tables as required. He may also define additional parameters that are not mentioned in your TNC manual. Refer to your machine tool manual.

The spark erosion process is influenced by process variables called erosion parameters. You can enter the erosion parameters for a machining sequence in erosion tables for the TNC 406/416. For example, you can create a separate erosion table for each combination of electrode and workpiece material. All parameters are then clearly grouped in this table. The TNC can access the parameters for a particular machining sequence.

Using erosion tables in a program

If you want to work with erosion tables in a program, you must copy Cycle 1 (GENERATOR) into the program (see „Cycle 1 GENERATOR” on page 133). In this cycle you declare what erosion table you are working with.

Working without an erosion table

It is also possible to work without an erosion table. In this case the TNC stores the erosion parameters in the Q parameters Q90 to Q99 (see „Preassigned Q parameters” on page 202). Your machine manual provides more information on these Q parameters.

4.6 Erosion Tables

Ready-to-use erosion tables

The machine builder can prepare erosion tables and store them in the TNC’s ROM. Proceed as follows if you want to work with these erosion tables:

8 Press the PGM NAME key in the PROGRAMMING AND EDITING

mode of operation.

8 Press the ROM soft key.

The machine tool builder can give you additional information on these erosion tables.

HEIDENHAIN TNC 406, TNC 416 61

4.7 Parameters in the Erosion Table

You can enter the following erosion parameters in one erosion table:

Meaning Range

Power stage (NR) 25 to 1

Low voltage current (LV) 0 to 99

High voltage current (HV) 0 to 9

Gap voltage (GV) 0 to 99

Pulse-on duration (TON) 0 to 999

Pulse-off duration (TOFF) 0 to 255

Servo sensitivity (SV) 0 to 99 %

Auto jump distance (AJD) 0 to 99.9 mm

Erosion time (ET) 0 to 999 s

Arc sensitivity (AR) 0 to 99

Electrode polarity (P) 0 or 1

4.7 Parameters in the Erosion Table

High voltage selector (HS) 0 to 99

Wear rate (WR) 0 to 99 %

Surface finish (RA) 0 to 99.9 µm

Stock removal (SR) 0 to 999.999 ccm/min

Two-times gap (2G) 0 to 9.999 mm

Minimum undersize (UNS) 0 to 9.999 mm

Auxiliary parameters (AUX 1 to AUX 6)

62 4 Programming: Fundamentals, Files, Program Entry, Spark Erosion, Erosion Tables

To enter erosion parameters in the erosion table

Activate file management.

FILE NAME ?

Select a file with the arrow keys.

PROGRAM SELECTION

POWER STAGE NUMBER

The TNC then asks for all further erosion parameters described in this chapter.

To enter erosion parameters for additional power stages

Enter the file name directly, e.g. 15. For a new erosion table you must enter the name.

Open the selected erosion table.

Select program type .E (erosion table).

Enter the number of the power stage for the following data. Confirm with ENT.

With INSERT, erosion parameters for up to 25 power stages can be entered.

4.7 Parameters in the Erosion Table

To conclude entry

Return to program management with PGM NAME.

To go to a certain power stage

Use GOTO to directly access a certain power stage number in the erosion table (do not enter the table row number).

Unit of measurement in the table

With the TAB soft key you can change the name of the table and the unit of measurement. The same unit (millimeters or inches) should be used in the erosion tables as in the NC program.

HEIDENHAIN TNC 406, TNC 416 63

Power stage (NR)

The power stages determine the type of machining (roughing, finishing or polishing).

Recommended input

 Roughing NR = 15 to 10  Finishing NR = 10 to 6  Fine finishing NR = 6 to 1  Polishing NR = 5

Input range

15 (25) to 1 in decreasing order.

To change the power stage in the program

The current power stage is given by Q parameter Q99. If you change Q99, you also change the power stage.

Low voltage current (LV)

The machine tool builder can give you information on this

4.7 Parameters in the Erosion Table

Input range

0 to 99 in up to 100 increments.

erosion parameter. Refer to your machine tool manual.

High voltage current (HV)

The machine tool builder can give you information on this erosion parameter. Refer to your machine tool manual.

Input range

0 to 9 in up to 10 increments.

Gap voltage (GV)

The TNC adjusts the width of the gap between the electrode and the workpiece by controlling the gap voltage. The nominal gap voltage GV should be chosen with care.

Setting

 If the gap voltage is too high, the rate of stock removal will be too

low.

 If the gap voltage is too low, irregularities will occur (arcing, short

circuiting).

64 4 Programming: Fundamentals, Files, Program Entry, Spark Erosion, Erosion Tables

Pulse-on duration and pulse-off duration

The pulse-on duration (TON) is the time in which the generator applies a voltage to the electrode and workpiece. Ignition and subsequent discharge take place during this time.

The pulse-off duration (TOF) is the time in which no voltage is generated. During this time the gap is flushed and deionized.

Select the TON/TOF ratio according to the type of machining:

Setting

 Roughing: Long pulse-on duration, short pulse-off duration  Finishing and polishing: Short pulse-on duration, long pulse-off

duration

Servo sensitivity SV

The machine tool builder specifies a characteristic curve for servo sensitivity (see figure center right). Refer to your machine tool manual.

The servo sensitivity influences the reaction speed of the gap control.

Setting

 High servo sensitivity: fast gap control  Low servo sensitivity: slow gap control

T- ON TF

SV= 99

SV= 60

U gap

4.7 Parameters in the Erosion Table

Input range

0 to 99 %

Erosion time ET, Auto jump distance AJD

The erosion time determines how long an erosion step lasts. When the programmed erosion time has run out, the electrode retracts by the auto jump distance and subsequently returns to the position given in machine parameter MP2051.

Intermittent flushing

To improve deionization of the gap and flush away debris, you can activate miscellaneous function M8 (intermittent flushing ON).

HEIDENHAIN TNC 406, TNC 416 65

AJD

MP 2051

Arc sensitivity (AR)

The arc sensitivity setting influences the gap signal that the generator sends to the TNC. The characteristic curve shows the nominal speed value plotted against the gap voltage.

The machine tool builder can give you information on this erosion parameter. Refer to your machine tool manual.

Electrode polarity (P)

To minimize wear on the electrode and ensure a high rate of stock removal, you must set the correct electrode polarity.

Input value

 Positive electrode: 0  Negative electrode: 1

If you mount the electrode on the machine table, you must change the electrode polarity defined in the machine table. The TNC does not reverse the polarity automatically.

4.7 Parameters in the Erosion Table

High voltage selector HS

The high voltage is the voltage that the generator applies to the electrode and workpiece.

Setting

 High value for HS:

For large gaps and for high rate of stock removal.

 Low value for HS (with ignition pulse):

For small gaps and for low rate of stock removal.

 Low value for HS (without ignition pulse):

For a few specific hard metals and very small electrodes.

T- ON

66 4 Programming: Fundamentals, Files, Program Entry, Spark Erosion, Erosion Tables

Wear rate WR

The wear rate is the ratio between the volume of material removed from an electrode (Ve) and the volume of material removed from the workpiece (Vw).

WR = Ve / Vw • 100 % For the wear rate on the electrode for your particular machining task

and combination of materials, refer to the electrode table.

Surface finish RA

Surface finish is a measure of machining quality. A machined surface is never absolutely smooth, but consists of a series of peaks and valleys.

4.7 Parameters in the Erosion Table

Maximum surface roughness R

max

The maximum surface roughness Rmax is the difference in height between the highest peak and the lowest valley. The maximum surface roughness Rmax is also calculated from the width of the two-times gap 2G and the minimum undersize UNS as follows:

= 0.5 • ( UNS – 2G )

max

Determining surface finish RA according to VDI 3400 1 Determine the centerline of R

max

2 Measure all peaks and valleys from the centerline 3 Add the measured values together and divide by the number of

measured values. The result is the surface finish RA in [µm]

max

R2 R3 R4

max

min

HEIDENHAIN TNC 406, TNC 416 67

Stock removal SR

The stock removal is the volume of removed workpiece material (Vw) per unit of time. Stock removal is measured in ccm/minute.

Two-times gap (2G)

During the erosion process, a minimum gap G must be maintained between the electrode and the workpiece. The higher the current, the larger the gap (G = radial gap) can (and should) be.

4.7 Parameters in the Erosion Table

Minimum for the two-times gap

The two-times gap 2G is the minimum total gap (2 x G in millimeters) that must be maintained in the cavity between the electrode and the workpiece (2G = diametrical gap).

max

68 4 Programming: Fundamentals, Files, Program Entry, Spark Erosion, Erosion Tables

Minimum undersize (UNS)

The electrode diameter (Re) must be smaller than the cavity diameter by at least the value of the minimum undersize UNS.

 Roughing

For roughing, the minimum undersize UNS is calculated from the two-times gap 2G and the maximum surface roughness R

 Finishing and polishing

For finishing and polishing, the minimum undersize UNS is equal to the two-times gap 2G. (The maximum surface roughness R be disregarded.)

max

can

max

UNS

Selecting the actual undersize UM

 For a simple cavity (movement only in the electrode axis):

UNS = UM

 For contour eroding and eroding with DISC cycle

(movement of the electrode in all axes): UM ≥ UNS

Auxiliary parameters AUX 1, AUX 2, ... AUX 6

The machine tool builder can assign functions to up to six auxiliary parameters. Refer to your machine tool manual.

4.7 Parameters in the Erosion Table

HEIDENHAIN TNC 406, TNC 416 69

Programming: Tools

5.1 Electrodes

Each electrode is identified by a number. The electrode data, consisting of the

 Length L  Radius R

are assigned to the electrode number.

5.1 Electrodes

The electrode data are entered into the program with the TOOL DEF command. The TNC takes the electrode length and radius into account when the electrode is called by its number.

If you are working with standard electrodes you can also define all the electrode data in a separate program. In the part program you then call the program containing the electrode definitions with the PGM CALL command.

Electrode axis C

You can define the C axis as the electrode axis. The TNC then operates as if the Z axis were the electrode axis. This also holds for radius compensation and for the ROTATION cycle.

Determining the electrode data

Electrode number

Each electrode is assigned a number from 0 to 99 999 999. Electrode number 0 is defined as having length L = 0 and radius R = 0

when the electrode data are entered into the program.

Electrode radius R

The radius of the electrode is entered directly.

Electrode length L

The compensation value for the electrode length is defined

 as a length difference between the electrode and a zero electrode,

 with a tool presetter.

If electrode lengths are determined with a tool presetter they should be entered directly into the electrode definition (TOOL DEF block) without further conversions.

72 5 Programming: Tools

Determining the electrode length with a zero electrode

Sign of the electrode length L: L>L0: The tool is longer than the zero tool

L<L0: The tool is shorter than the zero tool

To determine the length:

8 Move zero electrode to the reference position in electrode axis

(such as workpiece surface with Z = 0).

8 If necessary, set datum in electrode axis to zero. 8 Insert electrode. 8 Move electrode to the same reference position as zero electrode. 8 The compensation value for length L of the electrode is displayed. 8 Write down the value and enter it later, or transfer the value with the

actual position capture function.

Entering electrode data into a program

For each electrode the electrode data can be entered once in the part program:

 Electrode number  Electrode length compensation value L  Electrode radius R

To enter the electrode data into a program block

The number, length and radius of a specific electrode is defined in the TOOL DEF block of the part program.

8 To select tool definition, press the TOOL DEF key.

8 Tool number : Assign a number to the electrode 8 Tool length : Compensation value for the tool length 8 Tool radius : Compensation value for the tool radius

5.1 Electrodes

Z = 0 L = 0

L 

L +

 The electrode length L can be transferred directly into

the electrode definition with the actual position capture function (see ”Actual Position Capture” on page 84).

 Cycle 3 TOOL DEF (see ”Cycle 3 TOOL DEF” on page

135) deletes the tool length from the TOOL DEF(inition)!

Example

4 TOOL DEF 5 L+10 R+5

HEIDENHAIN TNC 406, TNC 416 73

Entering electrode data in tables

You can define and store up to 999 tools and their tool data in a tool table. You can assign a pocket number in the tool magazine to the tools.

With MP7261 you can limit the number of pockets in the tool magazine. There is no limiting if MP7261=0. Setting MP7265=1 prevents multiple assignment of a

5.1 Electrodes

Tool table: Standard tool data

Abbr. Input Dialog

NR Number by which the tool is called in the program (e.g. 5) Tool number ?

PT Pocket number in the tool magazine Pocket number?

U Tool undersize (diametrical) Tool undersize? (diametrical)

X Tool compensation value for the X axis Tool compensation?

Y Tool compensation value for the Y axis Tool compensation?

Z Tool compensation value for the Z axis Tool compensation?

C Tool compensation value for the C axis Tool compensation?

R Compensation value for the tool radius R Tool radius R?

pocket number.

Tool undersize from the table is only active if you do not define it again during TOOL CALL.

Editing tool tables

The tool table that is active during execution of the part program is designated TOOL.T. It can only be edited in the Programming and Editing mode. Other tool tables that are used for archiving or test runs are given different file names with the extension .T .

To open any other tool table:

8 Select the Programming and Editing mode of operation.

8 Call the program directory. 8 Choose the desired TOOL table, and confirm your

choice with the ENT key or with the SELECT soft key.

When you have opened the tool table, you can edit the tool data by moving the cursor to the desired position in the table with the arrow keys or the soft keys. You can overwrite the stored values, or enter new values at any position. The available editing functions are illustrated in the table below.

74 5 Programming: Tools

If the TNC cannot show all positions in the tool table in one screen page, the highlight bar at the top of the table will display the symbol ”>>” or ”<<”.

Exiting the tool table

8 Call the file manager and select a file of a different type, e.g. a part

program.

Editing functions for tool tables Soft key

Insert new line above the highlighted field

Delete line

Create new TOOL table by entering a new name

5.1 Electrodes

HEIDENHAIN TNC 406, TNC 416 75

Calling electrode data

Electrode data are called into the part program with TOOL CALL. TOOL CALL is programmed with

 Tool number  Spindle axis  Undersize  Code indicating whether the electrode is a following electrode

5.1 Electrodes

You can skip individual entries with NO ENT, for example to enter only one (new) undersize.

Calling electrode data

8 Select the tool call function with the TOOL CALL key. 8 Tool number: Enter the number of the electrode as

defined in TOOL DEF block. Confirm your entry with the ENT key.

8 Working tool axis X/Y/Z/4: Enter the tool axis, e.g.

8 Tool undersize (diameter): Enter the electrode

undersize (diameter), e.g. 0.5. Confirm with the ENT key or skip the entry with the NOENT key.

8 Folw. electrode YES=ENT/NO=NOENT: e.g., to identify

the electrode as a following electrode.

If you define a value for the tool undersize in the TOOL CALL, the value from the TOOL table is ignored. Otherwise the undersize from the TOOL table is valid.

Example: Electrode call Call electrode number 5 in the tool axis Z.

The diametrical electrode undersize is + 0.5 mm.

20 TOOL CALL 5 Z U+0.5 F

76 5 Programming: Tools

Following electrode

Answering ”YES” to FOLW. ELECTRODE prevents the workpiece from being damaged by too large an amount of taper (caused by insufficient flushing or deep mold cavities) during roughing operations at high current. For the gap between the electrode and the workpiece the TNC multiplies the minimum gap by the value in Q157. The value in Q157 is determined by your answer to FOLW. ELECTRODE.

Call with following electrode: finishing, small undersize (narrow gap): Q157 = 1

Call without following electrode: roughing, large undersize (wide gap): 1< Q157 < 2.5

Changing the electrode

The electrode can be changed automatically or manually.

Automatic electrode change with EL-CALL

The function for automatic electrode change is adapted to the TNC by the machine tool builder. Refer to your machine tool manual.

If your machine features an automatic handling system, you can program an automatic electrode change with the EL-CALL function. EL-CALL combines the functions TOOL DEF and TOOL CALL.

8 Select the Programming and Editing mode of operation.

8 Select the EL-CALL function with the EL-CALL soft

key.

8 Electrode name: Enter the name of the electrode, e.g.

1. You can enter up to 16 characters (letters and numbers). Confirm your entry with the ENT key.

8 Working tool axis X/Y/Z/4: Enter the tool axis.

8 Folw. electrode YES=ENT/NO=NOENT:

e.g., to identify the electrode as a following electrode.

Example

5.1 Electrodes

4 EL-CALL 1 /ZF

To ensure that the TNC shifts the electrode correctly to the programmed position, you must enter the correct C axis coordinates in a traversing block with L, programmed directly after the EL-CALL block.

HEIDENHAIN TNC 406, TNC 416 77

Manual electrode change

Before a manual electrode change, you must move the electrode to a changing position. Course of actions:

 Interrupt program run (see ”Interrupting machining” on page 223)  Move the electrode to the change position (can be programmed)  Change electrode  Resume the program run (see ”Resuming program run after an

interruption” on page 225)

5.1 Electrodes

Electrode change position

The electrode change position must be capable of being approached without collision next to or over the workpiece. The coordinates of the change position can also be entered as machine-based coordinates with miscellaneous functions M91 and M92. If TOOL CALL 0 is programmed before the first electrode call, the TNC moves the clamping shaft in the spindle axis to a position that is independent of the electrode length.

Electrode compensation

You can compensate the electrode length and radius in a separate program block.

8 Select the Programming and Editing mode of operation.

8 Select the EL-CORR function with the EL-CORR soft

key.

8 Undersize comp: Enter the undersize compensation.

Confirm your entry with the ENT key.

8 Electrode length comp:

Enter the electrode length compensation value. Confirm your entry with the ENT key. If no electrode length compensation: Press the NO ENT key.

8 Electrode radius comp:

Enter the electrode radius compensation value. Confirm your entry with the ENT key. If no electrode radius compensation: Press the NO ENT key.

Example

4 EL-CORR U+1 L R+0.5

Effect on Q parameters

The EL CORR block influences the pre-assigned Q parameters Q108, Q158 and Q159 (see also ”Electrode data: Q108, Q158 to Q160” on page 203).

78 5 Programming: Tools

5.2 Electrode Compensation Values

For each electrode, the TNC takes the compensation value for the electrode length into account for the electrode axis. In the working plane, it compensates the electrode radius.

Electrode length compensation

The compensation value for the electrode length goes into effect automatically as soon as an electrode is called and the spindle axis is moved. The compensation value for the electrode length is cancelled by calling an electrode with length L = 0.

If a positive length compensation was active before TOOL CALL 0, the distance to the workpiece will be reduced. If the electrode axis is positioned incrementally immediately following a TOOL CALL, then in addition to the programmed value the length difference between the old and new electrodes will also be traversed.

5.2 Electrode Compensation Values

HEIDENHAIN TNC 406, TNC 416 79

HEIDENHAIN TNC 406 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

TNC Models, Software and Features

New features of the NC software 280 62x-xx and 280 180-xx

1 Introduction ..... 1

2 Manual Operation, Setup and Probing Functions ..... 15

3 Positioning with Manual Data Input (MDI) ..... 37

5 Programming: Tools ..... 71

6 Programming: Programming Contours ..... 85

7 Programming: Miscellaneous functions ..... 119

8 Programming: Cycles ..... 129

9 Programming: Subprograms and Program Section Repeats ..... 173

10 Programming: Q Parameters ..... 185

11 Test run and Program Run ..... 215

12 MOD Functions ..... 229

13 Tables and Overviews ..... 245

Introduction

Controls

Visual display unit and keyboard

Programming

1.1 The TNC 406, the TNC 416

Graphics

Compatibility

Visual display unit

1.2 Visual Display Unit and Keyboard

Screen layout

Keyboard

Manual Operation, Incremental Jog, and Positioning with Manual Data Input

1.3 Modes of Operation

Programming and Editing

Test Run

Program Run, Full Sequence and Program Run, Single Block

General status display

Additional status displays

1.4 Status Display

HR electronic handwheels

1.5 Accessory: Electronic Handwheels from HEIDENHAIN

Manual Operation, Setup and Probing Functions

Switch-on

2.1 Switch-on

Note

To traverse with the machine axis direction buttons:

2.2 Moving the Machine Axes

Incremental jog positioning

Positioning with manual data input (MDI)

Eroding a workpiece manually

Example

2.3 Datum Setting

Using an electrode

2.4 Calibration and Setup

Select the touch probe function

Calibrating the probing electrode

Compensating workpiece misalignment

Functions for setting the datum

Writing probed values to tables

2.5 Datum Setting with a Probing Electrode

Datum setting in any axis

Manual probing

Workpiece center as datum

Corner as datum

Circle center as datum

Introduction

To find the coordinate of a position on an aligned workpiece

Finding the coordinates of a corner in the working plane

2.6 Measuring with a Probing Electrode

Measuring workpiece dimensions

Measuring angles

Entering values

2.7 Entering and Starting Miscellaneous Functions M

Positioning with Manual Data Input (MDI)

Positioning with manual data input (MDI)

3.1 Positioning with Manual Data Input (MDI)

Protecting and erasing programs in $MDI

Programming: Fundamentals, Files, Program Entry, Spark Erosion, Erosion Tables

Introduction

What is NC?

4.1 Fundamentals of Positioning

The part program