Functions of the TNC 640 Comparison with the itnc 530

Transcription

1 Functions of the TNC 640 Comparison with the itnc 530 August 2014

2 Highlights of the TNC 640 The new 3-D simulation graphics User-friendly and practical For more than 35 years, TNC controls from HEIDENHAIN have been proving themselves in daily use on milling, drilling and boring machines, as well as machining centers. This success is due in part to their shop-oriented programmability, but also to their uniform operating concept and their compatibility with programs of the predecessor models. The great reliability of HEIDENHAIN controls has also played its part in making the name TNC a synonym for quality and performance. Now the TNC 640 is continuing to live this tradition. The TNC 640 can adapt optimally to your company s needs. Regardless of whether you write programs directly on the control or eternally with a programming system, the TNC 640 supports you in your daily work with well proven but also new functions. One of the most etensive innovations is surely the trueness to detail of its unrivaled 3-D simulation graphics, which provide you with even more capabilities in simulation. It displays the workpiece at random viewing angles and simulates both milling and turning operations in a single view. What can the new graphics do? Depict the workpiece in a high-resolution 3-D graphic simulation Display the tool path as 3-D line graphics Display a transparent tool or workpiece Color the machined surfaces differently for each tool Highlight workpiece edges Depict the point angle of the tool Simulate milling and turning operations Present a plan view with different shades of depth Define workpiece blanks as cuboids, cylinders, tubes or rotationally symmetric parts with any desired contour Display the workpiece in three projections Show real time graphics of machining progress High trueness of detail With the new 3-D graphic simulation, you can eactly evaluate the result of milling, drilling or turning processes even before actual machining. The graphic simulation is so detailed that you can detect undesired surface irregularities already in the simulation phase. However, you don't alway have to simulate your components at the highest resolution. Depending on the respective requirements you can choose from four different resolutions depending on which you value more: very high trueness to detail or fast generation. 2

3 Multifaceted display modes Color highlighting of the workpiece with another color used for each new tool helps the operator to identify individual work steps and makes it easier to assign the tools used. In addition, you can hide or show the tool or show it as solid or transparent. You can also simulate the workpiece in a transparent view. You can select simulation modes as usual between the top view, view in three planes, 3-D simulation or 3-D line graphics. Optimal control of tool paths In the 3-D simulation, you can display the programmed tool-center path as a line graphic. You can already see during the simulation which path the tool takes, including non-cutting paths such as in approach and departure movements. You should especially use this graphic mode to inspect programs created offline for irregularities before machining, in order to avoid undesirable traces of the machining process on the workpiece, e.g. when points are output incorrectly by the postprocessor. Here the 3-D line graphics are particularly helpful in order to recognize even very fine details. It enables you to detect undesired tool movements, localize danger zones and finally optimize your program. Simulating comple jobs The new 3-D simulation graphic enables you to simulated machining in the perpendicular machining position, in the tilted plane or to simulate comple simultaneous 5-ais machining. The TNC 640 is also capable of depicting the tool s point angle. Even machining operations such as chamfering, countersinking or deburring are displayed in the powerful graphics. For the user, this results in better inspection capabilities as well as improved safety and reliability Your benefits Detecting critical tool movements Have tool paths displayed to enable you to detect undesired tool movements during simulation and before actual machining Minimize scrap The detailed graphics let you recognize unwanted machining effects early on Quickly find the tool used You can see at a glance which tool performed which operation Complete simulation 5-ais milling, turning, drilling, boring, countersinking, chamfering Scalable details Simple selection between very high resolution and accuracy or fast graphic build-up 3

4 Highlights of the TNC 640 Milling-turning multi-operation machining in one setup Productivity in manufacturing To increase the productivity of a CNC machine, different machining methods, such as milling and turning, are often performed on the same machine. Changing spectra of parts, fleibility in machining planning and the requirement to reduce non-cutting time place great demands on the machine and the control. The TNC 640 is capable of combined milling and turning operations on the same machine. In this way you not only save space and money for another machine, but thanks to multioperation machining on a milling-turning machine it also avoids inaccuracies caused by workpiece rechucking. Simple switching between turning and milling The TNC 640 offers you powerful functions that enable you to switch the NC program as desired between turning and milling. This enables you to decide with complete freedom how and when to combine the two machining methods. And of course, the operations switch back and forth regardless of the machine and its ais configuration. During switchover, the TNC 640 assumes all necessary internal changes, such as switching to diameter display, setting the datum in the center of the rotary table, and even machine dependent functions such as clamping the tool spindle. Conveniently managing turning tools The TNC 640 s central tool management enables you to administer turning tools in a convenient, clear-cut manner. It s even more powerful with the optional epanded tool management. A tool usage list provides information as to which tools are cutting for how long. Well-designed, color coded tables show you the various tool statuses. 4

5 Well-proven range of functions The field-proven HEIDENHAIN lathe controls provide the software basis for the turning functions. Here you also have contour elements unique to turning, such as recesses or thread undercutting. Besides the standard path functions you can also use FK free contour programming to easily create contour elements. This type of programming is especially helpful when contour elements are not conventionally dimensioned for NC because even these contours can be programmed easily. If a turning contour eists in DXF format, you can easily import it with the aid of the DXF converter (option). Large selection of turning cycles HEIDENHAIN controls have always been known for their comprehensive package of cycles. Frequently recurring machining cycles that comprise several steps are saved as standard cycles. The user therefore enjoys conversational guidance to program both milled and turned contours on the TNC 640 and is supported by valuable help graphics that clearly illustrate the required input parameters. Cycles for clearing, recessing, tapping or eccentric turning are part of the TNC 640 s cycle package. Fast familiarization You can create your turning programs in the usual manner in HEIDENHAIN plainlanguage dialog. In more sophisticated contour turning cycles, the TNC 640 uses the same techniques as used for milling. TNC programmers can continue to rely on what they already know and quickly find their way into the world of turning on a milling machine. Your benefits Reduce nonmachining time Turning and milling on the same machine Avoid inaccuracy No rechucking of the workpiece on a lathe is required Easy introduction You program as usual in HEIDENHAIN plain-language dialog Efficient programming Cycles enable you to program quickly Straightforward management Convenient tool administration Application of well proven know-how Use of software basis from HEIDENHAIN lathe controls 5

6 Highlights of the TNC 640 ADP Advanced Dynamic Prediction Strengths of ADP The Advanced Dynamic Prediction feature (ADP) epands the conventional look-ahead of the permissible maimum feed rate profile and makes optimized motion control possible to produce faultless surfaces and perfect contours. ADP shows its strengths for eample during bidirectional finish milling through symmetrical feed behavior on the forward and reverse paths as well as through particularly smooth feed rate curves on parallel milling paths. Optimized user interface An insufficient quality of data in NC programs created on CAM systems frequently causes inferior surface quality of the milled workpieces. The Advanced Dynamic Prediction feature (ADP) epands the previous look-ahead of the permissible maimum feed rate profile, thereby enabling optimized motion control of the feed rate aes with 3-ais and 5-ais milling. This enables you to mill clean surfaces in short machining times even when point distribution fluctuates greatly between neighboring tool paths. Reduced feed-rate fluctuation The control dynamically calculates the contour in advance and can therefore use an acceleration-limited motion control with smoothed jerk to adapt the ais velocity at contour transitions. Reduced data resolution in NC programs or uneven point distribution no longer result in feed rate fluctuations or limit surface quality. The graphic below shows that more even feed-rate profiles are attained with ADP. Feed rate fluctuation without ADP lies in the range of between 1600 mm/min and 1800 mm/min, while feed rate fluctuation with ADP is only between appro mm/min and 1800 mm/min. The optimized feed rate profile improves surface quality the difference is detectable with the naked eye (see photo). Your benefits Higher contouring speeds Shorter machining times Optimal surface quality With ADP the tool center point (TCP) is moved more evenly and eactly. With ADP Without ADP Feed rate 6

7 Programming Optimized editor for clear and simple operation Simplified handling The TNC 640 also offers a number of features that make working with the control even easier and user-friendlier than ever. NC programs can be created more easily, the editor is even more powerful, the handling of DXF files was simplified, PDF files can be displayed directly on the control these are just some of the TNC 640 s new functions. The TNC 640 s user interface not also features a more modern appearance with slightly rounded forms, color gradients and a font with uniform appearance. Contet-sensitive cutting data calculator The input and calculation of technology data is a fied part of program creation. With the contet-sensitive cutting data calculator, operators can calculate spindle speed and feed rate for the specific machining process and adopt these values directly into the open feed rate or speed dialog. The cutting-data calculator recognizes the respective contet and automatically queries the required input data. Practical selection of functions with smartselect With smartselect you enjoy dialog guidance for selecting functions quickly and easily that up to now were accessible only through the soft-key structure. Moreover, in the right part of the smartselect window, the TNC displays the integrated help. Your benefits Better readability of NC programs Clear-cut, user-friendly user-interface, modern appearance and color combinations User-friendly selection of functions Orientation aid for the selection of functions is provided by smartselect Calculate technology data quickly and easily Contet-sensitive cutting data calculator supports the user 7

8 Programming Improved functions and cycles make programming even easier The new face milling cycle Face milling cycles have long been a feature of HEIDENHAIN TNC controls. But the new face milling cycle 233 can do far more than only machine a plane surface in multiple infeeds. In Cycle 233 you can define up to three side surfaces that then limit the machining of the face. You can define a corner radius for corners created by adjacent sides. Moreover, various machining strategies are available, e.g. spiral clearing of the face or multipass milling in parallel lines with or without overlap. You can also select the machining direction. This can be helpful when you want to direct the cutting pressure against the fied vice jaw. Parallel-ais functions If your machine is equipped with secondary aes, the TNC 640 supports you with several well-proven parallel-ais functions: The traverse of a secondary ais (U, V, W) is compensated by the traverse of the associated principal ais (X, Y, Z) Traverse movements of parallel aes are calculated into the position display of the associated principal ais (sum display) Program the workpiece as usual with the coordinate entries of the principal aes and then specify the aes with which the workpiece is to be machined, e.g. the X, Y and W ais Cylinder surface machining With the TNC 640 it is quite easy to program contours on cylindrical surfaces: You simply program the contour in a plane as if the cylinder surface were unrolled. The TNC 640 then machines the corresponding cylindrical contour. So with the TNC 640 you can program cylinder-surface contours independently of your machine configuration. The machine on which you later run the program plays no role for programming. The TNC 640 features three cycles for cylindrical surface machining: Slot milling (the slot width is the same as the tool diameter) Guide-groove milling (the slot width is greater than the tool diameter) Ridge milling Your benefits More effective face milling The new Cycle 233 offers the right machining strategy for any requirement Fleibility in machine planning Program cylinder-surface contours regardless of the machine configuration Simple handling of parallel aes Program the part in X, Y, Z, for eample, and have it machined in U, V, W 8

9 Setting up the machine Application-oriented probing functions Calibration cycles guarantee high process reliability Before you use a touch probe, you have to ascertain the eact dimensions and the center offset. The TNC 640 offers several calibration cycles that allow you to find these values simply and at the same time precisely. This enables you to calibrate the effective touch-probe length, the ball radius and the center offset fully automatically. You decide for yourself whether to use a calibrating mandrel, a calibration ring or a calibration sphere. Manual probing cycles The manual scanning cycles have been epanded by several new functions that make machine setup even easier. On a machine with a rotary table, for eample, you can now correct the misalignment of a workpiece by turning the table. Moreover, all manual probing cycles also provide automatic probing routines for holes and circular studs. For circle calculation, the TNC uses special algorithms that ensure highly accurate measuring results. The TNC 640 is capable of probing a circle with up to eight touch points. Clearly structured touch probe table When you are using a touch probe, several settings are required that influence the probing behavior. The TNC 640 manages these settings centrally and straightforwardly in a touch probe table. Here you can easily access all important settings such as touch probe type, feed rate, safety clearance and probing path and have all necessary data in view. Of course you can also manage several data records per touch probe in the touch probe table, for eample to use a touch probe with various probing feed rates Your benefits Calibration made easy Fully automatic calibration of the touch probe Convenient setup Alignment of clamped workpieces with a probing cycle and automatic probing routine for holes and circular studs Managing multiple touch probe files Straightforward central management of touch probe files 9

10 Eecution of NC programs Precise and straightforward manufacturing of parts Higher input resolutions The display step option enables you to increase the resolution of the input coordinates in the NC program. That makes it possible now to epand the input range to 0.01 µm or This enables the programmer to more precisely define the tool path, especially for machining very small steps on lightly curved free-form surfaces. It also permits the control to plan the feed rate profile more eactly and, in particular, to optimize the cutter behavior with angle data. Permanent display of process-relevant Q parameters The TNC 640 can display an additional status window in Manual Operation, Program Run and Test Run. Process-relevant Q parameters can be shown in this window either permanently or only when desired. Depending on the respective requirements, you can select as desired which Q, QS, QL, and QR parameters are shown in the status window. Observing the program progress on the screen The direct observation of the milling process is often only partially possible due to the coolant and the safety enclosure The TNC 640 therefore shows a real-time graphic of the machining progress. You can use free moments to take a glance at a keystroke at the progress of workpiece machining. You can choose as usual between plan view, projection in three planes, 3-D view, 3-D line graphics and section detail enlargement. Your benefits Optimized milling behavior Increase input resolution for an even more precisely defined cutter path Best possible orientation Show process-relevant Q parameters a separate window Machining always in view The current machining situation is depicted in the graphic 10

11 Optimizing productivity Dynamic Efficiency efficient roughing Dynamic Precision eact finishing Dynamic Efficiency Dynamic Efficiency makes heavy machining and roughing more efficient while also enhancing process reliability. Higher metal removal rates and increased productivity along with the avoidance of tool overload are achieved thanks to the following functions: Active Chatter Control (ACC) This option reduces chatter tendencies and permits greater infeeds Adaptive Feed Control (AFC) Automatic feed-rate adjustment depending on the spindle power Trochoidal milling Roughing of slots and pockets in a manner that eases the load on the tool and the machine Dynamic Precision Dynamic Precision combines the competing demands for accuracy, high surface quality and short machining times. The effects of compliance and vibration are countered with intelligent control technology. CTC Compensation of accelerationdependent position errors AVD Active Vibration Damping PAC Position-dependent adaptation of controller parameters LAC Load-dependent adaptation of control parameters MAC Motion-dependent adaptation of control parameters Functions are perfectly matched Dynamic Efficiency and Dynamic Precision can achieve dramatic successes: not only is the metal removal rate increased by 20 to 25 percent in practice (Dynamic Efficiency), dimensional accuracy and surface definition are also improved (Dynamic Precision). For the user, this is a decisive improvement of the machining process: it eploits the full potential of the machine and tool while at the same time reducing the mechanical load on the machine. Your benefits Increased metal removal rate Dynamic Efficiency Improved surface definition Dynamic Precision Increased accuracy Dynamic Precision Without CTC: Contour damage through position error With CTC: Precise tool movements yield an eact contour 11

12 Functions of the TNC 640 New functions New functions of the TNC 640 Highlights High resolution 3-D simulation graphics Transparent depiction of the workpiece and tool Tool-specific coloring of the workpiece The point angle of the tool is considered in the 3-D simulation graphics Milling and turning operations can be simulated Workpiece blank definition: cuboids, cylinders, tubes or rotationally symmetric parts with any desired contour Functions for turning Integrated in HEIDENHAIN plain language Constant surface speed Tool-tip radius compensation Comprehensive package of cycles: stock removal, recessing, tapping, eccentric turning Updating of the workpiece blank during contour cycles Path functions for recesses and undercuts Management of various lathe tool types Simple programming of turning operations with inclined tool Programming Optimized functions in the editor Synta highlighting Rapid selection of functions and cycles with smartselect Scrollbar in the program window Contet-sensitive cutting data calculator Calculate spindle speed and feed rate for the specific machining process Load value directly into the open feed rate or spindle speed dialog bo Functions in Cycle 233, face milling Selectable machining direction Spiral face milling is possible Up to 3 limit walls (e.g. for an open rectangular pocket) Corner rounding of limit walls Finishing the limit walls Parallel-ais functions FUNCTION PARAXMODE Select machine aes for machining Machine-independent programming in the coordinate input system (X, Y, Z) FUNCTION PARAXCOMP Inclusion of movements of parallel aes Cylinder surface machining Programming of cylindrical surfaces independently of machine configuration Setup Program run Calibrating the touch probe Calibration with calibration mandrel, ring or sphere Touch-probe table Management of multiple data records per touch probe ADP Dynamically calculates the contour in advance. Optimized motion control of the feed aes More even velocity profiles Higher contour speed and shorter machining times Superior surface quality 12

13 Improved functions Scope of application Standard function of the itnc 530 Improved function of the TNC 640 Drilling Cycle 241: Single-lip deep-hole drilling Cycle 241: Chip breaking and feed-rate reduction possible for through-drilling Pocket milling Cycles 251 and 252: Pocket milling Cycles 251 and 252: Monitoring of overlap during helical plunging in pocket cycles Slot milling Cycle 275: Trochoidal milling of slots Cycle 275: Closed contours also permitted Calibrating the touch probe Automatic calibration of the workpiece touch probe with Cycles 2 and 9 Automatic calibration of the workpiece touch probe with Cycles 461 to 463; calibration is now also possible with calibration mandrel, ring or sphere Manual probing cycles Automatic probing routines for holes are available only in some manual probing cycles (intersection of 4 holes, circle center of 3 holes) All manual probing cycles also provide automatic probing routines for holes and circular studs Working with parallel aes Hole and stud can be probed with four touch points Selection of parallel ais in TOOL CALL or through pre-positioning. No compensating movement or offset possible in the position display Hole and stud can now be probed with up to eight touch points Definition of the parallel ais through FUNCTION PARAXMODE, compensating movement or offset in the position display 13

14 Functions of the TNC 640 Differences in function Scope of application Function of the itnc 530 Operation in the TNC 640 MDI Program Run, Full Sequence/Single Block Manual operation Eecution of connected program sequences is possible Distance-to-go display in the tilted workpiece coordinate system The actual position is shown with respect to the tilted workpiece coordinate system Program information is considered only block by block. Functions such as radius compensation, labels for subprograms and program section repeats are not included Distance-to-go display in input coordinate system The actual position is shown with respect to the input coordinate system (all transformations are calculated into the display value) Simulation At START the machining time begins with 0 At START the machining time begins is added Programming FN 16: F-PRINT Differences in functional details FN 18: SYSREAD Pole transfer through CC without entering the plane The TNC issues an error message. Additional input is required because otherwise the interpretation Incrementally programmed arc with polar can be ambiguous. coordinates smart.nc Cutting data table for automatic calculation of spindle speed and feed rate smart.nc: Fillable-form-based programming in working steps Automatic calculation of spindle speed and feed rate with contet-sensitive cutting data calculator possible Eecution of smart.nc programs is supported Cycle Editor for point patterns in HP format No editor for point pattern in HP format. Eecution of HP files is supported. M function M124 point filter Function is configurable by machine parameter (CfgStretchFilter) Soft-key row Binary search Management Display of the soft-key row SPEC FUNCT: Soft-key row is appended Soft-key rows CYCL DEF and TCH PROBE are not retained after programming a cycle Binary search without limit to program length (binary search = jump to same elements in the NC program, starting from the active input element) Tool carrier management (e.g. angle head) in the tool table. The TOOL CALL considers the kinematics Pallet datums can be set Display of the soft-key row SPEC FUNCT: Soft-key row is not appended (menu has to be eited first to switch the soft-key row) Behavior is configurable (togglecycldef) Limit to program length for the binary search is adjustable by parameter (malinecommandsrch). Tool carrier can be activated through subkinematics Pallet datums can be set by entry in the subkinematics 14

15 Provided functions Function of the itnc 530 Provided for SW Remark regarding TNC Later Test Run: Coordinate display with sectional display mode Depth display for plan view Stop at block number (N) Structure view Dynamic collision monitoring Cycle 290: Interpolation turning of a shoulder Cycle 484: TT calibration Stop before eecution of the cycle Outputting tet or Q parameters with FN 15: PRINT F print is alternatively possible with FN 16 Conversion of FK blocks Continue program after ending an NC block. User can then use GOTO to jump to any location in the NC program. First an internal stop before user can select GOTO to continue machining at another location. Modal program information is not loaded KinematicsComp (option 52) Support of KinematicsComp (option 52) by KinematicsOpt Manual limitation of the traverse range in MOD menu Global program settings (option 44) Handwheel superimposition with M118 in in the virtual tool ais Chuck monitoring with Dynamic Collision Monitoring (DCM) The machine tool builder can predefine chucking devices 3-D radius compensation with 3D ToolComp (option 92) 3-D radius compensation now through normal vectors Activate tool-carrier kinematics by tool call Cycle 22 Contour pocket rough-out Q401: Feed rate factor with tool circumference engagement of 180 Q404: Definition of the fine-roughing strategy Cycle 39: Cylinder surface outside contour Cycle 253: Slot and Cycle 254: Rounded slot Q439: Feed-rate interpolation Cycle 22 now available without Q401 and Q404 Cycles 253 and 254 presently available without Q439 Cycle 25: Contour train residual material machining Cycle 25 presently without residual material machining Cycle 276: 3-D contour train Presently only 2-D contour train available Cycle 270: Contour train data Tool-oriented machining across several workpiece programs Mid-program startup: Graphically supported mid-program startup of point patterns Mid-program startup in one subprogram, started from the main program Continuation of a mid-program startup 15

16 Functions of the TNC 640 Technologically obsolete functions Why doesn t the TNC 640 support certain functions anymore? HEIDENHAIN controls are known for their simple and user-friendly programming, and at the same time they ensure considerable downward compatibility. The TNC 640, too, is downward compatible to a high degree with certain eceptions, however. Now the TNC 640 has replaced certain functions, some of which were developed more that 35 years ago. Obsolete functions have been superseded by new ones. The following list shows the functions of the itnc 530 that the TNC 640 no longer supports and alternatives it offers instead. Functions of the itnc 530 Remark regarding TNC 640 SL1 cycle: Pocket rough-out Cycle 440: Measure ais drift using a TT Cycle 441: Fast probing M90: Smoothing corners M112: Insert rounding radius M132: Filter sequence M114 / M115: Compensation of machine geometry Replaced by SL2 cycles (larger performance range and more effective roughing strategy) Ais shift can be measured with the TS Fast probing possible through configuration of the touch probe in the touch probe table Replace by Cycle 32 TOLERANCE Replaced by TCPM functions M144 and M128 M104: Activate last manually set datum Replaced through Cycle 247 or calling datum table pocket 0 M105 / M106: Activate/deactivate 2nd set of kv factors M134 / M135: Activate/reset precision stop of rotary aes Implementation through MP subfiles Implementation through FN functions M142: Delete modal program information Not realized due to lack of demand M150: Suppress limit switch message Implementation through FN functions FN25: Set datum manually Feed rate in time (FT and FMAXT) Manual datum is set in Manual mode Alternative programming capabilities, e.g. dwell time More information: DR. JOHANNES HEIDENHAIN GmbH Dr.-Johannes-Heidenhain-Straße Traunreut, Germany { info@heidenhain.de Catalog: TNC 640 Technical Information: Dynamic Efficiency Technical Information: Dynamic Precision Catalog: Options and Accessories /2014 H Printed in Germany *I_ *