Key Functions Detailed. HEIDENHAIN ND 522 - 2-2011, ND 523

I - 3 Milling Specific Operations

This section discusses operations, and soft key functions specific to milling applications only. Soft key functions that are the same, whether the ND 522/523 is configured for Mill, or Turn applications,

are detailed starting on page 17.

Key Functions Detailed

Tool Hard Key

This hard key opens the tool table, and provides access to the TOOL form for entering a tool’s parameters. The ND 522/523 can store up to

16 tools within the tool table.

Import/Export

Tool Table information can be imported, or exported over the serial port.









IMPORT, and EXPORT soft keys are available in the Tool Table screen.

Press IMPORT to download a Tool Table from a PC.

Press EXPORT to upload the Tool Table to a PC.

To exit, press the C key.

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Tool Radius Compensation feature

ND 522/523 has a tool radius compensation feature. This allows workpiece dimensions to be entered directly from the drawing. The displayed Incremental is then automatically lengthened (R+), or shortened (R–) by the value of the tool radius. (For more information

see page 39).

Tool Length

The length offset may be entered as a known value, or the

ND 522/523 may determine the offset automatically. More information is available in the following Tool Table Usage example regarding the TEACH LENGTH soft key.

The following soft keys are available while in the TOOL TABLE form, or in the individual tool data form:

Function

This key allows the operator to select which axis all the tool length offsets will effect. The tool’s diameter values will subsequently be used to offset the remaining two axes.

Soft key

Press to automatically enter the tool offset length. Only available in the LENGTH field.

This will open the TOOL TYPES form for selection. Only available in TYPE field.

Sign for the length difference

Δ

L

If the tool is longer than the reference tool:

Δ

L > 0 (+)

If the tool is shorter than the reference tool:

Δ

L < 0 (–)

The tool length is the difference in length

Δ

L between the tool, and the reference tool. The reference tool is indicated by T1.

The length difference is indicated with the “

Δ

“ symbol.

Entering tool data





Choose tool hard key

Cursor to the desired tool, and press ENTER. The TOOL

DESCRIPTION form will appear.





Enter the tool diameter.

Enter the tool length, or press TEACH LENGTH.





Enter the tool units.

Enter the tool type, and press ENTER to return to the tool table.

Press C to exit.

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I Operating Instructions

Tool Table Usage

Example: Setting a workpiece datum without using the probing function.

Tool diameter 2.00

Tool length: 20.000

Tool unit: mm

Tool type: flat end mill

It is also possible to have the ND 522/523 determine the length of an offset. See alternative example below.

Press the TOOL hard key.

The cursor will default to the TOOL TABLE form.

TOOL TABLE

TOOL DIAMETER

Enter the tool diameter (2.0mm).

Cursor down to the LENGTH field using the DOWN

ARROW key.

TOOL LENGTH

Cursor to the tool to be defined, or enter the tool number. Press Enter.

Enter the tool length (20.0mm) .

Cursor down to the UNITS field using the DOWN

ARROW key.

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- ALTERNATIVE METHOD -

It is also possible to have ND 522/523 determine an offset. This method involves touching the tip of each tool to a common reference surface. This allows

ND 522/523 to determine the difference between the length of each tool.

Move the tool until its tip is touching the reference surface.

Press the TEACH LENGTH soft key. ND 522/523 will calculate an offset relative to this surface.

Repeat the procedure for each additional tool using the same reference surface.

Only the tools set using the same reference surface may be changed without having to reset the datum.

If the tool table already contains tools in which the length has been set, the reference surface should first be established using one of them. If not,it will not be possible to switch between the new tools, and the existing tools without having to re-establish the datum. Before adding the new tools, select one of the tools from the tool table. Touch the tool to a reference surface, and set the datum to 0.

- TOOL UNIT -

Enter the TOOL UNIT (inch/mm).

Cursor down to the TOOL TYPE field.

TOOL TYPE

Press TOOL TYPES soft key. Select from list of tools, and press Enter

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I Operating Instructions

Calling the Tool Table

Before machining starts, select the tool to be used from the tool table.

ND 522/523 then takes into account the stored tool data when working with tool compensation.

Tool call

Press the TOOL hard key.

TOOL NUMBER

Use the UP/DOWN ARROW keys to cursor through the selection of tools (1-16). Highlight the tool to be used.

Verify the proper tool has been called, and press the

C key to exit.

Datum Hard key

Datum settings define the relationships between the axis positions, and the display values.

The easiest way to set datum points is to use the ND 522/523's probing function when probing the workpiece with an edge of a tool.

Datum points can also be set in the by touching the edges of the workpiece, one after the other with a tool, and manually entering the tool positions as datum points (see examples following this page).

The datum table can hold up to 10 datum points. In most cases this will eliminate from having to calculate the axis travel when working with complicated workpiece drawings containing several datums.

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Example: Setting a workpiece datum without using the probing function.

Tool diameter: D = 3 mm

Axis sequence in this example: X - Y - Z

Preparation: Set the active tool to the tool that will be used to set the datum

Press the DATUM hard key.

Cursor will be in the DATUM NUMBER field.

Enter the datum number, and press the DOWN

ARROW key to go to the X axis field.

Touch the workpiece at edge

1

.

DATUM SETTING X

Enter the position of the tool center (X = – 1.5 mm) and press the DOWN ARROW key to advance to the Yaxis.

Touch the workpiece at edge

2

.

DATUM SETTING Y

Enter the position of the tool center (Y = – 1.5 mm).

Press the DOWN ARROW key.

Touch the workpiece surface.

DATUM SETTING Z = + 0

Enter the position of the tool tip (Z = 0 mm) for the Zcoordinate of the datum. Press Enter.

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I Operating Instructions

Probing with a Tool

Using a tool to set datum points using the ND 522/523's probing functions.

Preparation: Set the active tool to the tool that will be used to set the datum.

Example: Probe workpiece edge, and set edge as datum

Datum axis: X =0 mm

Tool diameter D = 3 mm

Press DATUM.

Press the DOWN ARROW key until the X AXIS field is highlighted.

Press PROBE soft key.

Press EDGE soft key.

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PROBE IN X

Touch workpiece edge.

Store the position of the edge by pressing the NOTE soft key.The NOTE soft key is useful when determining tool data by touching the workpiece in the absence of an edge finder with feedback. To avoid losing the position value when the tool is retracted, press the NOTE soft key to store the value while it is in contact with the workpiece edge. The location for the touched edge will take into account the diameter of the tool in use (T:1, 2...), and the last direction the

tool was moved

prior to pressing the NOTE soft key.

Retract the tool from the workpiece.

ENTER VALUE FOR X

Enter coordinate of the edge and press Enter.

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I Operating Instructions

Presetting

The Preset function allows the operator to indicate the nominal (target) position for the next move. Once the new nominal position information is entered the display will switch to Incremental mode, and show the distance between the current position, and the nominal position. The operator now only needs to move the table until the display is zero, and he will be at the required nominal position. The information for the location of the nominal position can be entered as an absolute move from the current datum zero, or as an incremental move from the current nominal position.

Presetting also allows the operator to indicate which side of the tool will be doing the machining at the nominal position. The R+/- soft key in the Preset form defines the offset that will be in effect during the move. R+ indicates that the center line of the current tool is in a more positive direction than the edge of the tool. R- indicates that the center line is in a more negative direction than the edge of the current tool.

Using R+/- offsets automatically adjusts the incremental value to account for the diameter of the tool.

Absolute Distance Preset

Example: Milling a shoulder by traversing to display value zero using absolute position

The coordinates are entered as absolute dimensions; the datum is the workpiece zero.

Corner 1: X = 0 mm / Y = 20 mm

Corner 2: X = 30 mm / Y = 20 mm

Corner 3: X = 30 mm / Y = 50 mm

Corner 4: X = 60 mm / Y = 50 mm

To recall the last entered preset for a particular axis, press the axis key.

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Preparation:





Select the tool with the appropriate tool data.

Pre-position the tool to an appropriate location (such as X = Y =

-20 mm).



Move the tool to milling depth.

Press the SET/ZERO soft key to be in the Set mode.

Press the Y axis key

NOMINAL POSITION VALUE

Enter nominal position value for corner point

1

:

Y = 20 mm, and select tool radius compensation R + with R+/- soft key. Press until R+ is shown next to axis form.

Press Enter.

Traverse the Y axis until the display value is zero. The square in the graphic positioning aid is now centered between the two triangular marks.

Press the X axis key

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I Operating Instructions

NOMINAL POSITION VALUE

Enter nominal position value for corner point

2

:

X = +30 mm, select tool radius compensation R – with R+/- soft key. Press twice until R+ is shown next to axis form.

Press Enter.

Traverse the X axis until the display value is zero. The square in the graphic positioning aid is now centered between the two triangular marks.

Press the Y axis key

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NOMINAL POSITION VALUE

Enter nominal position value for corner point

3

:

Y = +50 mm, select tool radius compensation R + with R+/- soft key, and press until R+ is shown next to axis form.

Press Enter.

Traverse the Y axis until the display value is zero. The square in the graphic positioning aid is now centered between the two triangular marks.

Press the X axis key

NOMINAL POSITION VALUE

Enter nominal position value for corner point

4

:

X = +60 mm, select tool radius compensation R +, and press

Enter

.

Traverse the X axis until the display value is zero. The square in the graphic positioning aid is now centered between the two triangular marks.

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I Operating Instructions

Incremental Distance Preset

Example: Drilling by traversing to display value zero with incremental positioning

Enter the coordinates in incremental dimensions. These are indicated in the following (and on the screen) with a preceding I. The datum is the workpiece zero.

Hole

1

at: X = 20 mm / Y = 20 mm

Distance from hole

2

to hole

1

: XI = 30 mm / YI = 30 mm

Hole depth: Z = –12 mm

Operating mode: INCREMENTAL

Press the SET/ZERO soft key to be in the Set mode.

Press the X axis key.

- NOMINAL POSITION VALUE -

Enter nominal position value for hole 1: X = 20 mm, and ensure no tool radius compensation is active.

Press the DOWN ARROW key.

NOMINAL POSITION VALUE

Enter nominal position value for hole 1: Y = 20 mm.

Ensure no tool radius compensation is showing.

Press the DOWN ARROW key.

NOMINAL POSITION VALUE

Enter the nominal position value for the hole depth:

Z = –12 mm. Press Enter.

Drill hole

1

: Traverse the X, Y, and Z axis until the display value is zero. The square in the graphic positioning aid is now centered between the two triangular marks.

Retract the drill.

Press the X axis key

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NOMINAL POSITION VALUE

Enter nominal position value for hole

2

: X = 30 mm, mark the input as an incremental dimension, press I soft key.

Press Enter.

Press the Y axis key.

NOMINAL POSITION VALUE

Enter nominal position value for hole

2

: Y = 30 mm, mark the input as an incremental dimension, press I soft key.

Press Enter.

Traverse the X, and Y axes until the display value is zero. The square in the graphic positioning aid is now centered between the two triangular marks.

Press the Z axis key.

NOMINAL POSITION VALUE

Press Enter (uses last entered preset).

Drill hole

2

: Traverse Z axis until the display value is zero. The square in the graphic positioning aid is now centered between the two triangular marks. Retract the drill.

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I Operating Instructions

RPM Calculator

The RPM calculator is used to determine the RPM (or surface cutting speed) based on a specified tool (part, for turning applications) diameter. The values shown in this Figure are only an example.

Consult the tool manufacturer’s manual to verify spindle speed ranges per tool.









Press CALC.

Press the RPM soft key to open the RPM CALCULATOR form.

The RPM calculator requires a tool diameter. Use the numeric hard keys to enter a diameter value. The diameter value will default to the current tool’s diameter. If there is no last value entered in this power cycle, the default value is 0.

If a surface speed value is required, enter the value using the numeric hard keys. When a surface speed value is entered, the associated RPM value will be calculated.

When in the Surface Speed field, a soft key is available for opening online help. The table may be consulted for a recommended range of surface speeds for the material being machined.





Press the UNITS soft key to show the units as inch, or millimeter.

The RPM CALCULATOR form is closed by pressing the C key.

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Circle, and linear Patterns (Milling)

This section describes the hole pattern functions for Circle, and Linear patterns.

Press the circle pattern, or linear pattern hard keys to select the desired hole pattern function, and enter the required data. This data can usually be taken from the workpiece drawing (e.g. hole depth, number of holes, etc.).

With hole patterns, the ND 522/523 then calculates the positions of all the holes, and displays the pattern graphically on the screen.

The View Graphic enables verification of the hole pattern before machining starts. It is also useful when: selecting holes directly, executing holes separately, and skipping holes.

Functions for milling patterns

Function

Press this to see the layout of the current pattern.

Soft key

Press to go to previous hole.

Press to manually advance to the next hole.

Press this to use the existing position.

Press to end drilling.

Circle Pattern

Information required:



Pattern type (full, or segment)



Holes (number of)



Center (center of circle pattern in pattern plane)



Radius (defines radius of the circle pattern)



Start angle (angle of 1st hole in the pattern) - The start angle is between the zero angle reference axis, and the first hole ( for added

information see page 14).



Step angle (optional: this only applies if creating a circle segment.) - The step angle is the angle between holes.



Depth (the target depth for drilling in the tool axis)

ND 522/523 calculates the coordinates of the holes which the tool can then be moved to by traversing to display value zero.

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I Operating Instructions

Example: Enter data, and execute a circle pattern.

Holes (no. of): 4

Coordinates of center: X = 10 mm / Y = 15 mm

Bolt circle radius: 5 mm

Start angle: (Angle between X axis, and 1st hole): 25°

Hole depth: Z = -5mm

1st step: Enter data

Press CIRCLE PATTERN hard key.

PATTERN TYPE

Enter the type of circle pattern (full). Cursor to the next field.

HOLES

Enter the number of holes (4).

CIRCLE CENTER

Enter the X, and Y coordinates of the circle center

Example: (X = 10), (Y = 15), or press NOTE to set the coordinate to the current position. Cursor to the next field.

RADIUS

START ANGLE

Enter the radius of the circle pattern (5).

Enter the start angle (25°).

STEP ANGLE

Enter the step angle (90°) (this can only be changed if entering a “segment”).

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DEPTH

Enter the depth when needed. The depth of the hole is optional, and may be left blank.

Press Enter.

Pressing the VIEW soft key will toggle between the three views of the pattern (the Graphic, DTG, and

Absolute).

2nd step: Drill

Move to hole:

Traverse the X, and Y axes until display value zero.

Drill:

Traverse to display value zero in the tool axis.

After drilling, retract the drill in tool axis.

Press the NEXT HOLE soft key.

Continue to drill the remaining holes in the same way.

When pattern is complete, press the END soft key.

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I Operating Instructions

Linear Pattern

Information required:

 Linear pattern type (array, or frame)

 First hole (1st hole of the pattern)

 Holes per row (number of holes in each row of pattern)

 Hole spacing (the spacing, or offset between each hole in the row)

 Angle (the angle, or rotation of the pattern)

 Depth (the target depth for drilling in the tool axis)

 Number of rows (number of rows in the pattern)

 Row spacing (the spacing between each row of the pattern)

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Example: Enter data, and execute a linear pattern.

Type of pattern: Array

First X coordinate of hole: X = 20 mm

First Y coordinate of hole: Y = 15 mm

Number of holes per row: 4

Hole spacing: 10 mm

Tilt angle: 18°

Hole depth: -2

Number of rows: 3

Row spacing: 12 mm

1st step: Enter data

Press LINEAR PATTERN hard key.

PATTERN TYPE

Enter the type of pattern (Array). Cursor to the next field.

FIRST HOLE X, AND Y

Enter the X, and Y coordinates (X = 20), (Y = 15).

Cursor to the next field.

HOLES PER ROW

HOLE SPACING

Enter the number of holes per row (4).Cursor to the next field.

Enter the hole spacing (10).

ANGLE

Enter the tilt angle (18°).

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I Operating Instructions

DEPTH

Enter the depth when needed (-2). The depth of the hole is optional, and may be left blank.

NUMBER OF ROWS

Enter the number of rows (3).

ROW SPACING

Enter the spacing between rows, press Enter.

Pressing the VIEW soft key to see the graphic.

2nd step: Drill

Move to hole:

Traverse the X, and Y axes until display value zero.

Drill:

Traverse to display value zero in the tool axis.

After drilling, retract the drill in tool axis.

Press the NEXT HOLE soft key.

Continue to drill the remaining holes in the same way.

When pattern is complete, press the END soft key.

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Incline & Arc Milling

This section describes the functions for Incline, and Arc milling features.

By pressing either the Incline milling hard key, or the Arc milling hard key, will open the associated Entry Form. These features provide ways to machine a flat diagonal surface (incline milling), or a rounded surface (arc milling) using a manual machine.

Functions for Incline, and Arc Milling.

Function

Press this to select a plane.

Soft key

Press this to use the existing position.

Press to return to the previous step.

Press to advance to the next step.

Incline Milling

Entry Form:



The Incline Milling form is used to specify the flat surface to be milled. Press the INCLINE MILLING hard key to open the form



Plane - Select the plane by pressing the PLANE soft key. The current selection is shown on the soft key, and in the plane field. The graphic in the message box aids in selecting the correct plane.



Start Point: Enter the coordinates of the start point, or press NOTE to set the coordinate to the current position.



End Point: Enter the coordinates of the end point, or press NOTE to set the coordinate to current position.



Step: Enter the step size. When milling, this is the distance between each pass, or each step along the line.

The Step size is optional. If the value is zero, the operator decides at run-time how far to move between each step.

Press Enter to execute the surface milling operation. Press C to exit the form without executing. Settings are retained until power is turned off.

52

I Operating Instructions

Execution

 Execute the milling operation by opening the incline milling form, and pressing the Enter key. The screen switches to the incremental

DRO view.

 Initially, the DRO shows the current incremental moving distance from the start point. Move to the start point, and make a plunge cut, or the first pass across the surface. Press the Next pass soft key to continue with the next step along the contour.

 After pressing NEXT PASS, the incremental display shows the distance from the next step along the line’s contour.

 If no step size was specified, the incremental display always shows the distance from the closest point on the line. To follow the contour, move the two axes in small steps, keeping the (X, Y) positions as close to 0 as possible.

 When executing a surface milling operation, three views are available: incremental DRO, contour, and absolute DRO. Press the

VIEW soft key to toggle through the available screens.

 The contour view shows the position of the tool relative to the milling surface. When the crosshair representing the tool is on the line representing the surface, the tool is in position. The tool crosshair remains fixed in the center of the graph. As the table is moved, the surface line moves.

 Press the END soft key to exit the milling operation.

Tool radius compensation is applied based on the radius of the current tool. If the plane selection involves the tool axis, the tool tip is assumed to have a ball end.

The tool offset direction (R+, or R-) is applied based on the tool position. The operator must approach the contour surface from the appropriate direction for tool compensation to be correct.

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Example: Press the Incline Milling hard key to open the Form:

Plane: XY (3 choices are available- XY, YZ, & XZ) Select appropriate plane.

Start Point: Enter data, or press Note soft key

1st step: Enter data

Press PLANE soft key to select the milling plane.

Press DOWN ARROW hard key.

START POINT

Enter the coordinates of the first axis start point, or press note to set the coordinate to current position.

Press DOWN ARROW hard key

Enter the coordinates of the second axis start point, or press note to set the coordinate to current position

NEXT DATA ENTRY

Press DOWN ARROW hard key

END POINT

Enter the coordinates of the first axis end point, or press note to set the coordinate to current position.

Press DOWN ARROW hard key

Enter the coordinates of the second axis end point, or press note to set the coordinate to current position

NEXT DATA ENTRY

Press DOWN ARROW hard key

STEP SIZE

Enter the step size. The Step size is optional. If the value is zero, the operator decides at run-time how far to move between each pass.

press Enter to run the program, or the end soft key to exit.

54

I Operating Instructions

Arc Milling

The Arc Milling form is used to specify a curved surface to be milled.

Press the ARC milling hard key to open the form.



Plane Selection

: Select the plane by pressing the PLANE soft key.

The current selection is shown on the soft key, and in the plane field.

The graphic in the message box aids in selecting the correct plane.



Center Point

: Enter the coordinates of the arc’s center point.



Start Point

: Enter the coordinates of the start point.



End Point

: Enter the coordinates of the end point



Step

: Enter the step size. When milling, this is the distance along the circumference of the arc between each pass, or step along the arc’s contour.

The Step size is optional. If the value is zero, the operator decides at run-time how far to move between each step.

Press Enter or RUN to execute the milling operation. Press C to exit the form without executing. Settings are retained until power is turned off.

Execution

 Execute the milling operation by opening the entry form, and pressing the RUN soft key, or Enter key. The screen switches to the incremental DRO view.

 Initially, the DRO shows the current incremental distance from the start point. Move to the start point, and make a plunge cut, or the first pass across the surface. Press the NEXT PASS soft key to continue with the next step along the contour.

 After pressing NEXT PASS, the incremental display shows the distance from the next step along the arc’s contour.

 If no step size was specified, the incremental display always shows the distance from the closest point on the arc. To follow the contour, move the two axes in small steps, keeping the (X, Y) positions as close to 0 as possible.

 When executing a surface milling operation, three views are available: incremental DRO, contour, and absolute DRO. Press the

VIEW soft key to toggle through the available screens.

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 The contour view show the position of the tool relative to the milling surface. When the crosshair representing the tool is on the line representing the surface, the tool is in position. The tool crosshair remains fixed in the center of the graph. As the table is moved, the surface line moves.

 Press the END soft key to exit the milling operation.

Tool radius compensation is applied based on the radius of the current tool. If the plane selection involves the tool axis, the too tip is assumed to have a ball end.

The tool offset direction (R+, or R-) is applied based on the tool position. The operator must approach the contour surface from the appropriate direction for tool compensation to be correct.

56

I Operating Instructions

Example: Press the Arc Milling hard key to open the Entry Form:

Plane: XY (3 choices are available- XY, YZ, & XZ) Select appropriate plane.

Center Point: Enter data, or press Note soft key

1st step: Enter data

Press PLANE soft key to select the milling plane.

Press DOWN ARROW hard key.

CENTER POINT

Enter the coordinates of the center point, or press

NOTE to set the coordinate to current position.

Press DOWN ARROW hard key

NEXT DATA ENTRY

Press DOWN ARROW hard key

START, AND END POINT

Enter the XY coordinates of the axis start point, or press NOTE to set the coordinate to current position.

Enter the coordinates of the axis end point, or press

NOTE.

Press DOWN ARROW hard key

NEXT DATA ENTRY

Press DOWN ARROW hard key

STEP SIZE

Enter the step size. The Step size is optional. If the value is zero, the operator decides at run-time how far to move between each pass.

press Enter to run the program, or the END soft key to exit.

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