Mts-Turning PDF

M a th e m a tis c h Te c h n is c h e
S o ftw a r e - E n tw ic k lu n g G m b H
Introduction to TopTurn
CNC Simulator turning
Version 7.1
© MTS GmbH • Kaiserin-Augusta-Allee 101 • D-10553 Berlin • Tel.: +49 / 30 / 349 960 - 0 • Fax: +49 / 30 / 349 960 - 25
MTS – Introduction to TopTurn Version 7.1
Introduction to TopTurn
Version V7.1
© MTS Mathematisch Technische Software-Entwicklung GmbH

Kaiserin-Augusta-Allee 101 • D - 10553 Berlin • Tel.: (030) 349 960 0 • Fax: 349 960 25
Berlin, 2006.
Any form of reproduction, including photo-mechanical copies and copies in electronic form, requires our prior authorization.
We are always grateful for improvement suggestions and reports on any errors detected
Seite: 2  MTS GmbH 2006

1.0. INTRODUCTION ...................................................................................................................................... 5
1.1. HOW OPERATING ELEMENTS ARE REPRESENTED IN TOPTURN .................................................. 5
1.2. STARTING OF TOPTURN ....................................................................................................................... 6
1.3. NOTES ON SETTING UP A CONFIGURATIONTYPE............................................................................ 7
2.0. TOPTURN – THE CNC SIMULATOR TURNING .................................................................................... 8
2.1. AUTOMATIC MODE ................................................................................................................................ 9
2.2. INTERACTIVE MODE ............................................................................................................................ 10
2.3. SINGLE BLOCK MODE......................................................................................................................... 11
2.4. TOOL TRACING .................................................................................................................................... 12
2.5. MEASURING AND INSPECTION.......................................................................................................... 13
2.6. 3D REPRESENTATION AND SURFACE FINISH................................................................................. 14
2.7. 2D REPRESENTATION ......................................................................................................................... 15
3.0. THE NC EDITOR.................................................................................................................................... 17
3.1. SETUP SHEET....................................................................................................................................... 18
3.2. KEYBOARD LAYOUT FOR NC EDITOR FUNCTIONS........................................................................ 19
3.3. NC DIALOG PROGRAMMING .............................................................................................................. 20
3.4. ADDITIONAL INFORMATION TO MTS NC EDITOR ........................................................................... 21
4.0 THE “TURNING” SET-UP DIALOG........................................................................................................ 22
4.1. OPEN THE DIALOG WINDOW AND ASSIGN A PROGRAM NAME .................................................... 22
4.2. SELECT THE CLAMPING DEVICE AND CLAMPING CONFIGURATION.......................................... 22
4.3. WERKSTÜCKMAßE UND NULLPUNKT DEFINIEREN ....................................................................... 23
4.4. SELECT THE MACHINING TOOL SET ................................................................................................ 24
4.5. PROGRAM FOR EXERCISES 01.DNC................................................................................................. 25
5.0. SETUP MODE OVERVIEW.................................................................................................................... 26
5.1. CLAMPING DEVICES, CLAMPING METHODS OF BLANK MATERIAL SHAPES ............................ 26
5.2. TOOL TURRETS, TOOL MOUNTINGS AND TOOLS........................................................................... 26
5.3. TOOL LIBRARY..................................................................................................................................... 27
5.4. AXIS MOTIONS IN SETUP MODE ........................................................................................................ 27
6.0. PREPARATIONS FOR PROGRAMMING ............................................................................................. 28
6.1. PRODUCTION PLANNING AND TECHNOLOGY ................................................................................ 29
 MTS GmbH 2006 Seite: 3

6.2. SETUP FORM FOR “TURNING WORKPART 1” ................................................................................. 31
6.3. PRODUCTION SHEET FOR „TURNING WORKPART 1” ................................................................... 32

Sequence of machining steps........................................................................................................................ 32
7.0. SETTING UP THE MACHINE ................................................................................................................ 33
8.0. NC PROGRAMMING IN MTS PROGRAMMING KEY .......................................................................... 43
8.1. INSIDE STRAIGHT ROUGHING CYCLE G81 ...................................................................................... 44
8.2. DRILLING CYCLE G84.......................................................................................................................... 45
8.3. OUTSIDE STRAIGHT ROUGHING CYCLE G81 .................................................................................. 46
8.4. INSIDE STRAIGHT ROUGHING CYCLE G81 ...................................................................................... 46
8.5. INSIDE FINISHING................................................................................................................................. 47
8.6. OUTSIDE FINISHING............................................................................................................................. 47
8.7. OUTSIDE THREAD-CUTTING CYCLE G31 ......................................................................................... 48
8.8. OUTSIDE GROOVE-CUTTING CYCLE G79......................................................................................... 49
8.9. INSIDE GROOVE-CUTTING.................................................................................................................. 50
9.0. QUALITY CONTROL – MEASURING OF WORKPART....................................................................... 51
10.0 APPENDICES ........................................................................................................................................ 52
10.1. NC PROGRAM %3................................................................................................................................. 53
10.2. WORKPART DRAWING ........................................................................................................................ 56
10.3. WORKING TEMPLATES ....................................................................................................................... 57

Tool data / magazine or turret positions ........................................................................................................ 57
Sequence of machining steps........................................................................................................................ 58
NC-Code ........................................................................................................................................................ 59
10.4. NOTICE FOR ADMINISTRATING AND ORGANISING OF SETUP TURNING ................................... 60
10.5. SYSTEM INFORMATION....................................................................................................................... 62

1.0. Introduction
The individual chapters of this manual explain the essential functions involved in operating and handling the
system. The functions described here are also intended to give you a general idea of the system’s capabilities
(as well as the possibilities offered for implementing dedicated training courses).
These not only include the creation of NC programs and simulating and checking their quality, but also many
other realistic ways of teaching the trainees basic CNC machine tool functions using computer support.
The examples used in the simulation are available in the programming keys of all CNC control systems supplied
by our company.
Trainees are guided through system operation step-by-step, enabling them to learn the underlying principles
and the operation of the CNC simulator in a very short time.
After some introductory explanations, we will first show you how to set up the simulator according to a work plan
and how to create a setup sheet.
1.1. How operating elements are represented in TopTurn

The operating elements and the meaning of their functions are shown by the simulator as 10 function buttons in
a menu bar at the bottom of the screen corresponding to the function keys of a PC or control keyboard.
Main menu:
To activate the desired function, either move the mouse pointer to the respective function button and click on
the leftt-hand mouse button , or press the appropriate function key … of the PC keyboard. This
enables you to adapt system operation to your preferences.
To help you follow the explanations more easily, the functions which you have to select from the menu
structures are shown in the explanatory and instruction texts with a coloured or darker background, or are
indicated by symbols representing PC keys.
To begin with, you only need to carry out the individual steps as instructed.
If the desired result is not achieved due to an input error, please observe the following notes:
• You can return to the main menu or the start-up status of the simulator at any time by pressing the or
key. Depending on how far down the menu tree you are, you may have to press the key several times.
• To select or de-select functions, use the keys … . This may pull up a new menu.
• Generally, a function is concluded or accepted by pressing . If you have navigated through several
menus in order to select a specific function, you will have to exit each menu, one at a time by pressing
or the appropriate number of times. This, too, will return you to the main menu.
Instead of using the function keys the windows toolbar can be used for operation

1.2. Starting of TopTurn

Click on the Windows START button in the task bar, select the Programs folder and then (sofar you have not
changed the folder name when installing the software) the MTS-CNC English folder to access the MTS
programs TopTurn, TopMill or TopCAM.
The respective documentation / training manuals are stored in PDF format in the Help subfolder.
If you start TOPCAM, the start-up menu will offer you the following software modules for selection:
TopCAM
A CAD system with integrated NC programming for
turning/lathe work with up to 5 axes and milling work
with 3 axes
TopTurn
NC programming module, either control-system-
specific or of neutral ISO control system type, with
simulation and collision detection; optionally available
with opposite spindle and up to 7 axes
TopMill
NC programming module, either control-system-
specific or of neutral ISO control system type, with
simulation and collision detection in 3 axes
When you start up the TURNING software for the first time, an MTS configuration group with the MTS
programming key will always be active::
MTS TM -___.___.042x0500x1000 x MTS TM CONTROL
If you have not purchased the MTS programming key, which is independent of the type of control system, but
have a turning/lathe work control system using e. g. PAL94 command codes or SINUMERIK 820T, the Start
Turning button is not active after you have installed the software. In this case, you first have to select a
corresponding configuration group. This activates the Start Turning button. This configuration group selection
is memorized for subsequent program starts.
Click left hand mouse button to select
a configuration group
Info on the machine tool axes, tailstock

in the selected configuration

1.3. Notes on setting up a configurationtype

You can skip over this chapter when first learning to operate the software.
The name of a configuration group is always related to a particular combination of machine tool and control
system configurations. These are saved and managed by the Configuration Administration. For instance, a lathe
will be configured according to the manufacturer’s instructions. The definitive properties will include the
machining space, tool travel ranges, tool magazine type and the tool positions, number of NC axes, whether a
opposite spindle, headstock or tailstock are installed etc.
The control configuration will comprise the CNC programming syntax, the allocation of the optional
postprocessor and the control settings.
A postprocessor is always needed for translating an MTS

or PAL program into a specific control system code. The
same as with the programming key, this will be activated
after the target control system has been selected.
Which of these modules are available will depend on which software level you have purchased. You can add
modules whenever required.
In the following illustration, both modules, i. e. the programming key and the postprocessor are available. The
Postprocessor and Start turning buttons are therefore enabled and activated.
Driving tool 5 axes machining (X, Z, Y, B, C) main

spindle and Counterspindel
Programming key of the control Sinumerik 810D

with 5 axes simulation
Cycle postprocessor for translating programs into
the Sinumerik 810 D NC code for 5 axes
Transfer of the NC data between the PC AND THE nc

machine tool
If you have not purchased a programming key for your postprocessor, then the button is not
enabled.
Before continuing, re-check the active configuration group.
Now start the CNC simulator by double-clicking on the <Start Turning> button. The simulator will either use the
MTS TM -___.___.042x0500x1000 x MTS TM CONTROL
configuration group as in the example bevor, or the one which you have purchased.

2.0. TopTurn – the CNC simulator turning

The CNC simulator has three different operating modes:
NC Editor
Automatic mode
Setup mode
Setup dialog
For teaching purposes, it is best to start with the <Automatic mode> . This means that the trainee will first
get familiar with the various types of simulation.
We switch the simulator to 3D
Let us start by explaining some features of the initial screen display.
The power-on state of the CNC simulator is

determined by a setup sheet. This describes a specific
simulator setup which is determined by the following
components:
• a lathe chuck with clamping jaws,
• the workpiece blank / blank material and
• tooling setup with tool positions in the tool
magazine.
The start setup sheet is stored as header in an NC
program. In each control system, it is stored under the
program administration and is named
<DLFT_MTE.DNC>. The user can adapt this setup
sheet individually or can change its name of in the
respective control system configuration.
To activate the <DLFT_MTE.DNC> program and set up

the system, select <Automatic setup> by mouse pointer
or press the key. This returns the simulator to its
original power-on state.
Header of the setup sheet as are

shown by the NC editor.
For further information on setup sheets, refer to Chapter 3.1,

2.1. Automatic mode

We want to run an NC program on a CNC machine tool. To enable this process, the program first has to be
loaded into the control system’s memory. The following description illustrates the individual steps required to
operate the MTS system in this mode.
Press key , or select the <Select program> button to open the NC Program Administration, which will
display a list of all NC programs for this control system
Double-click on the file name <%020S1__TN09-TR01-16-TM1> to load

this NC Program into the machine tool memory for further processing.
With mouse click you can activate further functions of the explorer:
e.g. copy program to diskette,
delete, rename etc..
In our example, the program <%020S1__TN09-TR01-16-TM1> has been selected. Press to confirm the
action. The system will display a new menu. This offers you four different types of simulation. We shall start
byselecting automatic mode <Automatic mode>.
Automatic mode Single block
Interactive mode Tool tracing
To start the simulation in automatic mode, press the key. The CNC program currently loaded into the
machine memory is run automatically from the first to the last block.
The right-hand pane shows important system
information on the operating state of the virtual CNC
lathe:
• current co-ordinates of the X and Z axis (as well
as of the optional additional axes),
• cutting speed, rotation speed, tool feed,
tool number,
• direction of spindle rotation, machining time,
• active G code and
• override & runtime
The lower section of the simulation window shows a
section of the program with the NC block currently
being processed by TopTurn

2.2. Interactive mode
Interactive mode, called up by pressing the key, enables the user to write, tocreate, edit and run an NC
program in dialog with the software. The CNC simulator runs the NC program block-by-block. The program can
be corrected at any time. After being executed by the simulator, any block can be rejected so that you can re-
edit it and then re-run on the simulator. During this process, the workpiece will be continuously updated, or, if
the block is rejected, the workpiece will be returned to its former condition.
Let us run the NC program <%020S2__TN09-TR01-16-TM1> in <Interactive modef> .
Initially, the program administration is opened:
Double-click left on the programm <%020S2__TN09-TR01-16-TM1> in

order to transfer it to the machine program memory.
This will get the program wunning in interactive mode. After editing and confirmation every NC block will be
simulated and this block will be represented for editing after simulation.
Execute an NC block:
Accept NC block [Y/N]
Execute an NC block
In this operating mode, the NC code can be edited

again as follows:
Reject the block by pressing the or . Using
the keyboard, edit the current block.
Instead of you may press also .

If you wish to change the speed at which the simulation is run, use the function <Override, times> . This
function is available on all modern machine tools, both during machining work and during tooling and set-up
(zero-position scratching, setting zero co-ordinates).
To access the various functions for altering the time taken to run the simulation, press the <Override,
times> button. Try using the individual options offered in the menu bar. To apply your settings, press key .
You may change the settings at any time.
Important: The override setting affects the calculated machining time. As opposed to this, the slow-motion and
test run on/off functions do not affect calculated machining times.
2.3. Single block mode

The <Single block> function is used when running in Automatic mode and requires the operator to confirm the
execution of each NC block or record individually.
The NC-Program <%020S2__TN10-TR01-16-TM1> should be executed in the operating mode <Single block>
.
Click on <Run NC block> or press the or confirm

with to run the NC block.
Note:
You can switch over between the simulation modes Automatic mode, Single block and Interactive mode
even after simulation of an NC program has been started.

2.4. Tool tracing

The function <Tool tracing> is used to display the tool travel paths described by the selected NC program e. g.
<%020S2__TN09-TR01-16-TM1>.
The program is run and the programmed 3D tool tracing of the the tool tip are displayed graphically and each
tool is shown in different colors.
Careful and precise evaluation of the programmed tool movements in rapid speed and subsequent correction of
the NC program can lead to considerable reductions in manufacturing times.
With the toolbar you can manipulate the graphic display of the tool tracing and you can also alternatively insert
the workpart.
Note:
The currently selected NC program can be run in any of the simulation modes.
<Automatic mode>
<Single block>
<Interactive mode>
<Tool tracing>
If the setup sheet interpreter is activated, every time an NC program is started the CNC simulator will be set up
according to the setup sheet in the header of the NC program. This has the advantage that the original
workpiece blank is always placed back on the machine whenever the program is restarted.

2.5. Measuring and inspection

Irrespective of the simulation mode you have selected and the NC code already processed, you can use the
<Measure/3D> button at any time to call up functions for displaying and checking the workpiece in its actual
state.
The button <Measure/3D> gives you access to simulator functions relevant to the topic of quality analysis
and checking of your own work.
The trainee is offered a comprehensive range of functions for checking the results of the work he/she has done.
The function <Entity dimensions>, or <Point dimensions> is used to make a “specifications/as is”
comparison in order to check whether the programmed workpiece contour really matches the drawing
specifications.
Now try using the various functions offered, e. g. to examine the effect of the cutting tool radius compensation
on the workpiece contours by measuring the workpiece alternately with compensation on and off.
Exit <Measuring> with .

2.6. 3D representation and surface finish
The viewing angle, viewer distance and zoom factor, To obtain a full-screen display, press + , you
as well as a cut-away section angle, can be set to suit can only switch back to the normal user interface by
your requirements. In the sections menu, you can
define the cut-away segment.. pressing the key. With the toolbar you can also
obtain a permanent 3D representation of the selected
tool
Roughness depth analyse
, calls up a function to analyse the workpiece Using the cutting tool geometry and feed, the system
contour by individual contour entities, one at a time. will calculate and display the surface and determine
the roughness depth average value. To obtain more
detailed information on the currently selected contour
entity, press keys and .

2.7. 2D representation
The functions accessed by the <Grafic display> or key allow you to modify the on-screen display mode in
three ways:
• Workpiece views
• Zoom functions
• NC code line display
To apply the setting changes made in the <Grafic display> , press the key; to reject them, press .
A rectangular zoom section will be defined by the two You can always switch back instantly to the overall
points of a section diagonal.To define a zoom section, view of the machining space or to a standard display
related to the workpiece blank.
click with the left-hand mouse button on one edge
of the rectangle and drag the mouse pointer to the
diagonally opposite corner of the rectangle..
After selecting the new display mode, exit the menu by clicking on the <Quit> button or by pressing . The
selected view mode will remain in force until it is changed again. (Except when the NC program itself calls up a
window setting). The simulator will return to the function which was selected at the time you called up the
<Graphic display> functions.

The following workpiece geometry views can be selected: outside view, half-section (top or bottom half) and full
longitudinal section.
Outside view display Display showing bottom half-section
Display showing full section The <Display NC-file> button or key calls up a
function which you can use to define the number of
lines of NC code to be displayed in automatic mode.

3.0. The NC Editor

The initial menu of the NC editor provides access to the following functions:
• Edit the current NC program

• not assigned
• Select an NC program from the Administration in order to edit it, or to create a new program
• not assigned
• Print the NC program
• Transfer the NC program to the machine tool in DNC mode
• Return to setup mode
• Return to automatic mode
•
As you already learned in the section on <Automatic mode>, you can select a program or create a new
program using the file selection dialog.
This offers various ways of opening or creating a program. Press or click on <Edit program>, and enter
a program name.
If a program with this name already exists, it will be opened for editing, if not, you will be shown a message:
“Program does not exist! Create program [Y/N]?”. In the latter case, press the [Y] key to create a new
program and [N] [to abort.
You can also select a program by clicking <Select program> or pressing . The selected name is then
copied into the simulator’s status bar when the dialog window is closed. You can subsequently open it with
or by using other functions.
The NC program <%010S1__TN07-TR01-16- After you have marked the NC program with a single
TM1.dnc> is to be opened for viewing. It contains all
left mouse click , you can click on the right-hand
required information, from the setup data for simulation
right down to the NC code of the program. mouse button to call up further supplementary
functions.

3.1. Setup sheet

A setup sheet stored as header of an NC program always has the same structure. It comprises the following
groups:
• Machine tool and control system configuration names,

• Workpiece blank and geometry
• Clamping devices and their positioning
• Active tool in the machining position
• Tools in the tool magazine, tool positions including tool correction values
In the main menu, click on <Setup form > or press in order to access the setup form menu.
After the simulator was set-up in setup mode you can save this setup in a respective setup sheet:
Press and enter a program name.
Setup sheet information
• () Beginning and end marks for the setup sheet interpreter

• ( Setup sheet line which is to be processed by the interpreter
• (( Comments, these are not to be processed by the interpreter
When you create a new setup sheet, the command <M30> (meaning “end of program”) will be the only NC line
to be added to the setup sheet. Without <M30> the error message “unanticipated end of program” will be
displayed when you are working in automatic mode or when the setup sheet is being used as a startup setup
sheet.

3.2. Keyboard layout for NC editor functions

The section of the program that can currently be edited is always shown between two horizontal rules. To select
a word, use the cursor key . You can change, delete or write new code as you wish.
Confirm and conclude your entries by pressing the key.
Browse a page at a time or
Browse block by block or
Insert a line: +
Delete a line: +
Inset a word:
Delete a word:
• Link programs
• Group operation
• Renumber the NC program
To insert another NC program in front of the currently selected line, call up the appropriate function by pressing
the key or clicking on on <Link programs>. This is an important function that is needed for creating
modification copies, for instance.
The group operation function, called up by pressing the key, enables you to mark a block of multiple
complete lines, including the beginning and end marks, and then carry out operations such as shift, copy or
delete block.
The Renumber functions called up by pressing enable you to renumber the NC program from a first
program number up to another program number by specifying a start number and a numbering increment.

3.3. NC dialog programming
To enter dialog programming mode, press the key or click on <Dialog program>. This is a universal MTS
software function which can be adapted to all types of NC controls. When you press the key, the current
work line is analyzed to locate commands for which a dialog screen is available. If a fitting dialog screen is
found, it will be displayed and the respective input parameter values shown in the dialog screen.
Dialog screen List of contentc
In the above example, this is an MTS straight roughing machining cycle call G81 with three addresses: X, Z and
I, as well as supplementary parameters which have not yet been assigned values in the example. You can
change the address values and also add values from the dialog screen. To enter all values into the actual NC
program, click on the button.
If no key word is found, the dialog programming module will call up the list of contents showing all available
commands, allowing you to select one of these by clicking on “Parameter” . The corresponding dialog
screen is then opened so that you can enter the desired values. Click on to confirm your input. The
corresponding new NC code line will replace the line originally selected. If you have accessed the end of the NC
program, a new line will be appended to the existing NC program. (This operation also applies to multiple-line
NC programming commands, provided that the selected NC control system supports these).
You can either enter a numerical value, or in the case of switch functions, select the respective function setting.
In this procedure, the permissible value ranges are checked and a distinction is made between mandatory
addresses and optional addresses. You also have the option of using an alternative address combination, e. g.
defining an arc by I and K instead of by the radius.
In dialog programming of more complex cycles, you

can also call up the corresponding Windows help
screens if available for this specific control..

3.4. Additional information to MTS NC editor
The function key Dialog/Help can also be activated by pressing the key combination + , or by clicking
on with the right mouse button , to get into a help box for tool magazine informations.
Enter T in the input field and confirm with , then you will get the information display of the actual tool
magazine equipment of the CNC simulator.
Here you can get additional informations about the

marked tool.
Note:
The modification of the tool equipment is not possible
in this helpscreen.
Press to leave this tool magazine information.

4.0 The “turning” set-up dialog
Four simple steps to create a setup sheet
The set-up dialog assists you to create a setup sheet for a new programming task quickly. First, the clamping
device - e.g a chuck and jaws - is selected. Then the workpiece - a cylinder or a pipe - is defined, the workpiece
origin is specified and the new program is completed by adding a suitable set of tools. After the procedure is
finished, the controls read in the setup sheet in the form of a program header, and the user can immediately
start to key in the new program.
4.1. Open the dialog window and assign a program name
To open the set-up dialog, press key . Enter a

new name for the CNC program you wish to create,
e. g. "Exercise 01" and then open the program
4.2. Select the clamping device and clamping configuration
Select the clamping device.
Explanation:
7 different clamping devices are offered for selection. A clamping depth definition is not necessary in case of
peak clamping. In this case the workpart must have a centering. Is the workpart a pipe, an external and internal
diameter must be entered.

Select the clamping device

KFD-HS 130 min.46 max.118 Et=18
Determine the clamping depth of the workpart

Input: 18 mm
Next open the tab:

Blank/Zero point
Explanation:
Observe the range of values in the display field. If a value cannot be evaluated, then it is shown in red in the
input field and is not processed.
Selection of the vise corresponds to the standard in the „Turning“ clamping device library.
KFD-HS 130 min.46 max.118 Et=18
KFD-HS 130 describes the lathe chuck, min. 46 til max. 118 mm describes the opening range of the respective
jaw and Et=18 mm is the maximum clamping depth possible for a workpart.
4.3. Werkstückmaße und Nullpunkt definieren
Specify the workpart dimensions:

Input length = 120 mm,
Input width = 60 mm
and enter a zero point shift from front side into the
material.
Input Z= -2 mm
Next open the tab:

Tools
Explanation:
The position of the workpiece origin can be specified by selecting a value in the center input field of this tab.
A total of 2 possible workpart origins are offered for selection: right or left from the workpart.
Additionally this point can be moved incrementally in Z ± direction from the selected point.

4.4. Select the machining tool set
Select the tool set e.g. 94-03 and inform about the
tooling of the turret magazine.
Next open the tab:

Compensation value
Explanation:
The tool set determines which tools are to be made available on the setup sheet.
You find here a list of compensation values.
Explanation:
Select the compensation values tab in order to obtain
more detailed tool information.
Confirm your input by clicking on the button to

create the new setup sheet. This is then read in by the
CNC machine tool in Automatic mode – Interactive
programming – and you can then start programming
the machine.
The CNC program can be created immediately.

The machine origin (zero point) specified in the dilaog
is entered at the bottom of the setup sheet and can
then be activated with the assigned command, e.g.
G54.
Below is an excerpt from the setup sheet:
(
( WORKPART ZERO-POINT
( G54 X200.000 Y+150.000 Z+105.000

4.5. Program for exercises 01.dnc

()
(( 06.04.2006 16:57
(
( CONFIGURATION
( MACHINE MTS01 TM-016_-R1_-060x0646x0920
( CONTROL MTS TM01
(
( PART
( CYLINDER D+060.000 L+120.000
(
( MAIN SPINDLE WITH WORKPART
( CHUCK KFD-HS 130
( STEP JAW HM-110_130-02.001
( TYPE OF CHUCK EXTERNAL CHUCK OUTSIDE STEP JAW
( CHUCKING DEPTH E18.000
(( Right side of the part: Z+230.000
(
( TOOLS
( T01 "DIN69880 V 30\Left corner tool\CL-SCLCL-2020 L 1208 ISO30"
( T02 "DIN69880 V 30\Left corner tool\CL-SVACL-2020 L 1604 ISO30"
( T03 "DIN69880 V 30\Left corner tool\CL-MTJNL-2020 L 1608 ISO30"
( T04 "DIN69880 V 30\Round horizontal\CT-SRDCN-2016 L 0603 ISO30"
( T05 "DIN69880 V 30\Left corner tool\CL-SDJCL-2020 L 1208 ISO30"
( T06 "DIN69880 V 30\Recessing tool\EA-SGTFL-2012 L 02.5-0 ISO30"
( T07 "DIN69880 V 30\Left threading tool\TL-LHTR-2020 R 60 1.50 ISO30"
( T09 "DIN69880 V 30\Left corner tool\CL-SVJCL-2020 L 1604 ISO30"
( T10 "DIN69880 V 30\Twist drill\DR-18.00 130 R HSS ISO30"
( T11 EMPTY
( T12 EMPTY
( T14 "DIN69880 V 30\Recessing tool\ER-SGTFL-1212 L 01.6-0 ISO30"
(
( TOOL COMPENSATION
( D01 T01 Q3 R0.800 X+070.0 Z+045.000 G000.000 E005.005 I-0.800 K-000.800 A+004.375 L011.855 N01
( D02 T02 Q3 R0.400 X+070.0 Z+045.000 G000.000 E052.393 I-0.400 K-000.400 A+002.372 L016.178 N01
( D03 T03 Q3 R0.800 X+070.0 Z+045.000 G000.000 E027.130 I-0.800 K-000.800 A+002.372 L015.678 N01
( D04 T04 Q8 R3.000 X+070.0 Z+034.000 G006.000 E090.000 I-3.000 K+000.000 A+000.000 L003.000 N01
( D05 T05 Q3 R0.800 X+070.0 Z+045.000 G000.000 E032.178 I-0.800 K-000.800 A+002.372 L010.785 N01
( D06 T06 Q3 R0.160 X+060.0 Z+041.250 G002.500 E000.000 I-0.160 K-000.160 A+000.000 L012.000 N01
( D07 T07 Q8 R0.217 X+070.0 Z+042.699 G000.000 E000.000 I-0.217 K+000.000 A+000.000 L000.000 N01
( D08 T08 Q8 R0.288 X+070.0 Z+042.699 G000.000 E000.000 I-0.288 K+000.000 A+000.000 L000.000 N01
( D09 T09 Q3 R0.400 X+070.0 Z+045.000 G000.000 E052.393 I-0.400 K-000.400 A+002.372 L016.178 N01
( D10 T10 Q7 R0.000 X+000.0 Z+204.000 G018.000 E059.000 I+0.000 K+000.000 A+000.000 L000.000 N01
( D11 T11 Q0 R0.000 X+000.0 Z+000.000 G000.000 E000.000 I+0.000 K+000.000 A+000.000 L000.000 N01
( D12 T12 Q0 R0.000 X+000.0 Z+000.000 G000.000 E000.000 I+0.000 K+000.000 A+000.000 L000.000 N01
( D13 T13 Q8 R0.217 X+070.0 Z+042.699 G000.000 E000.000 I-0.217 K+000.000 A+000.000 L000.000 N01
( D14 T14 Q3 R0.160 X+060.0 Z+041.300 G001.600 E000.000 I-0.160 K-000.160 A+000.000 L008.000 N01
(
( WORKPART ZEROPOINTS
( G54 X000.000 Z+228.000
(
()
N0010 G54

5.0. Setup mode overview

The setup mode integrated into the TopTurn has a very wide function range. The following chapters provide a
brief synopsis of the various options offered.
5.1. Clamping devices, clamping methods of blank material shapes
5.2. Tool turrets, tool mountings and tools
Tool length compensation
1.Ouadrant: K= R I= R
2.Ouadrant: K=-R I= R
3.Ouadrant: K=-R I=-R
4.Ouadrant: K= R I=-R
5.Ouadrant: K= R I= 0
6.Ouadrant: K= 0 I= R
7.Ouadrant: K=-R I= 0
8.Ouadrant: K= 0 I=-R
P = Tool holder reference point

B1 = Length compensation in X
A1 = Length compensation in Z
F1 = Cutting radius F1 gives the values for I and K
E1 = Value for I
D1 = Value for K

5.3. Tool library
Currently, the software handles about 700 turning tools in 20 tool types (extendable by the user).
5.4. Axis motions in setup mode
Motion control keys:
or move along Z axis in feedrate

or move along X axis in feedrate
+ or move along Z axis in rapid speed

+ or move along X axis in rapid speed
To move the tool turret around in the machining space, press the respective motion control keys just as on a
real machine tool. The workpiece coordinate origin can also be determined by zero-point scratching.
With the technology menu, or the direct hot-keys:
switch spindle 3, 4 or 5, lubricant 7, 8 or 9

rotation speed 1000
feed rate 0.220
turret tool position 0202
you can set the correct speed, feed, tool, spindle and machining lubricant by numerical input
6.0. Preparations for programming
Before starting to write an NC program, you must study the drawings and production specifications carefully. As
soon as all the information required for creating a program is available, you can start planning the individual
machining steps. It is important to take into consideration which machine tool the respective workpiece is to be
produced on and which tools and clamping devices are available on that machine tool.
Appendix 1 contains a complete drawing of the part (“Drehteil 1”, page ) used in our example.
• Analyze the workshop drawing

• Fixing the work plan
• Select the clamping devices and the required tools (setup sheet)
• Write the NC program
study study
work order workshop drawing
tools programmer clamping

devices
work plan set-up form
program sheet
Typical work preparation and planning forms

6.1. Production planning and technology
Machining step Type of tool, position in turret Machining step diagram

cutting data
1 Determine Calinder D: 80 mm L: 122 mm
Blank Material: AlMg1
dimensions Chuck: KFD-HS 130
Clamp blank Chuck jaws: HM-110_130-02.001

2 Determine
origin of Clamping depth: 18.0 mm
workpiece
coordinates
3
4 Facing LEFT HANDED CORNER CUTTER
CL-SCLCL-2020/L/1208 ISO30
T0101 G96 S260 M04

G95 F0.250 M08
5 Straight LEFT HANDED CORNER CUTTER

roughing
CL-SCLCL-2020/L/1208 ISO30
external profile
T0101 G96 S260 M04

G95 F0.350 M08
6 Drilling TWIST DRILL

DR-18.00/130/R/HSS ISO30
T0606 G97 S1200 M03

G95 F0.220 M08
7 Straight BORING TOOL (POSTAXIAL)

roughing
BI-SCAAL-1010/L/0604 ISO30
internal profile
T0808 G96 S220 M04

G95 F0.250 M08

Production planning (continued)
Machining step Type of tool, position in turret Machining step diagram

cutting data
6 Finishing BORING TOOL (POSTAXIAL)
internal profile
BI-SCAAL-1010/L/0604 ISO30
T1010 G96 S300 M04

G95 F0.100 M08
7 Finishing LEFT HANDED CORNER CUTTER

external profile
CL-SVJCL-2020/L/1604 ISO30
T0202 G96 S360 M04

G95 F0.100 M08
8 External LEFT HANDED THREADING TOOL

Threading TL-LHTR-2020/R/60/1.50 ISO30
T0303 G97 S1000 M03

G95 F1.5 M08
9 Cutting three EXTERNAL RECESSING TOOL7

external RI-GHILL-1013/L/01.10 ISO30
grooves
T0404 G97 S1000 M04

G95 F0.150 M08
10 Cutting internal INSIDE RECESSING TOOL (POSTAXIAL)

groove
RI-GHILL-1013/L/01.10 ISO30
T1212 G97 S01000 M04

G95 F000.150 M08
The setup sheet is to be compiled on the basis of this work plan.

6.2. Setup form for “Turning workpart 1”
CNC
Turning
Setup Sheet
Mathematisch Technische Software-Entwicklung GmbH Datum :
Program No. Turning workpart 1 Clamping mode: Inside

Programmer MTS Clamping device: Chuck
Drawings No. 2704 Clamping depth back stop 18 mm
Designation Turning workpart 1 Tailstock position: 800
Material: AlMg1
Raw part/blank 80 x 122
Other info: MTS TM
Tool data / magazine or turret positions

Station Tool designation Tool File No. Compensation data Ag.
01 LEFT HANDED CORNER CL-SCLCL-2020/L/1208 ISO30 X 60,0 R 0,8 01

CUTTER Z 43,0 Quadr. 7 02
06 TWIST DRILL DR-18.00/130/R/HSS ISO30 X 0,0 R 0,0 03
Z 210,0 Quadr. 7
08 BORING TOOL (POSTAXIAL) BI-SCAAL-1010/L/0604 ISO30 X –6,77 R 0,4 04
Z 160,0 Quadr. 2
10 BORING TOOL (POSTAXIAL) BI-SCAAL-1010/L/0604 ISO30 X –6,77 R 0,4 05
Z 160,0 Quadr. 2
02 LEFT HANDED CORNER CL-SVJCL-2020/L/1604 ISO30 X 70,0 R 0,4 06
CUTTER Z 43,0 Quadr. 3
03 LEFT HANDED THREADING TL-LHTR-2020/R/60/1.50 ISO30 X 70,0 R 0,217 07
TOOL Z 38,783 Quadr. 8
04 EXTERNAL RECESSING ER-SGTFL-1212/L/01.8-0 ISO30 X 60,0 R 0,160 08
TOOL Z 40,2 Quadr. 3
12 INSIDE RECESSING TOOL RI-GHILL-1013/L/01.10 ISO30 X –11,5 R 0,1 09
(POSTAXIAL) Z 125,9 Quadr. 2
X R
Z Quadr.
X R
Z Quadr.
X R
Z Quadr.
X R
Z Quadr.
X R
Z Quadr.
X R
Z Quadr.
X R
Z Quadr.
X R
Z Quadr.

6.3. Production sheet for „Turning workpart 1”
CNC
Turning Production Sheet
Program No . Turning workpart 1

Programmer MTS
Drawings No. 2704
Designation Turning workpart
Material AlMg1
Raw part/blank 80 x 122
Steuerung MTS TM
Sequence of machining steps

Nr. Machining step NC programming code Tool Cutting data
position
01 Facing G01 T01 F 0,25 N
Vc 260
02 Straight roughing external profile G81 Straight roughing cycle T01 F 0,35 N
Vc 260
03 Drilling G84 Drilling cycle T06 F 0,22 N 1200
Vc
04 Straight roughing internal profile G81 Straight roughing cycle T08 F 0,25 N
Vc 220
05 Finishing internal profile G41 G01 G02 G03 T10 F 0,10 N
G23 Vc 300
06 Finishing external profile G42 G01 G02 G03 G85 T02 F 0,10 N
G23 Vc 300
07 External threading G31 threading cycle T03 F 1,5 N1000
Vc
08 Cutting three external grooves G79 grooving cycle T04 F 0,15 N1000
Vc
09 Cutting internal groove G01 T12 F 0,10 N1000
Vc
10 F N
Vc
11
12 F N
Vc
13 F N
Vc
14 F N
Vc
15 F N
Vc
16 F n
Vc
17 F n
Vc
18 F n
Vc

7.0. Setting up the machine

This chapter explains how to set up the CNC simulator for an exercise. This involves the following steps:
• Selecting a blank, blank material, the clamping device and clamping method, clamping device changes
• Assigning tools to tool turret positions and creating new tool data
• Generating the setup sheet
Exercise:
A cylindrical aluminium alloy (AlMg1) blank, 80 x 122 mm is to be clamped against a back stop (18 mm) in a jaw
chuck. In the setup mode menu, click on <Part / Chuck> or press to select the workpiece/clamping menu.
First select the desired material from the material table by pressing , then enter the blank geometry – a
cylinder in our example. (However, material selection is not mandatory on the CNC simulator).
Select the material group

Select the material and press to confirm.
Enter the dimensions of the blank in the top right-hand
input fields:
• Enter the cylinder geometry data:
In filed D: enter : 80
im field L: enter : 122
To confirm your entries for the workpiece blank and

register, press
Information to the material AlMg1

You have now defined the blank, the next step is to
clamp it on the machine tool.

The last set-up to be used determines the currently

To change clamping mode, press or click left
suggested clamping method. As the current jaws only
The coloured frame marks the currently selected type.
permit a maximum clamping depth of 15…16 mm, a
To confirm your selection, press .. new chuck combination must be set up on the
machine.
To access the chuck menu, press .
Here again, you may change the clamping method for your workpiece. In our example, this is not necessary
To accept the selected clamping method, press to First select a suitable lathe chuck.
call up the chuck device library. Open the lathe chuck library.
Clamping and chuck devices are stored, by name, in a special library. You can modify these in order to comply
with the tooling available in the respective workshop.

Next, you must select suitable stepped jaws.

Click on to select the required item in the library
KFD-HS 130, then press to confirm.
Chuck jaw selection, explanation of designations inside With this, you have equipped your machine tool with a
the name: new chuck with stepped jaws.
HM (hard alloy) You can still make changes at any time. The other
110_130 (suitatble clamping devices are released in relation to the
for the chuck and blank diameter) method of clamping selected before.
-02 (number of Steps in the jaw) Press in order to install the combination on the
-001 (serial number) simulator.
Press in order to select type HM-110_130-02.001
Of course, you can also define other chucks and stepped jaws as you wish.

Now the workpiece blank has to be clamped in the Now clamp the workpiece
chuck. Press several times to move the workpiece into
Press in order to select the main spindle for the chuck area.
clamping the workpiece. Press to close the chuck.
Press several times to move the workpiece until it
rests against the jaw stop.
Press to conclude and accept the clamping set-
up.
Note:
The clamping device combination of chuck <KFD-HS 130> and jaw type <HM 110_130-02-002> can clamp
workpieces with a diameter of 50 mm up to 116 mm and can grip these up to a length of 18 mm to the jaw stop.
When creating a setup sheet, this informations will be saved as header in an NC program. Open this program in
the NC editor and you will see the following entry:
( ZYLINDER D080.000 L122.000.
If you use the editor to change the dimension entries e. g. to D060.000 L050.000, a blank with these dimensions
will be used in the simulator the next time the program is started. If you have chosen a blank diameter which is
too small or too big for the combination of chuck and jaws, e. g. D040, an error message will be generated.

Assigning tools to tool stations on the turret
The tool turret currently installed has 16 tool positions (“stations”). (You can change this in the configuration
settings). Use the mouse pointer to select the turret position. The associated tool in this position is shown more
largely on the screen.
You will have to mount the tools on the turret to comply with your production sheet.
T01 LEFT HANDED CORNER CUTTER CL-SCLCL-2020/L/1208 ISO30
Select position T01 and with double click open the Press to select the tool type library.
tool library.
Select tool type <Left handed corner cutter>

Use the mouse to locate the tool called
<CL-SCLCL-2020/L/1208 ISO30> and select it with
. This tool is then mounted on turret position T01.
In the two preceding steps, you have replaced a tool in the tool turret. To locate this tool, you have searched
through a tool type for a tool with a specific name.
The tool T02 < CL-SVJCL-2020/L/1604 ISO30> ist suitable for tooling.

We will now show you an alternative method, using the tool set-up for position T03 as an example. We need a
thread-cutting tool for cutting an external thread with a pitch of 1.5 mm.
Thus, the first step is to search for all tools suitable for cutting threads with a 1.5 mm pitch.
Select position T03 and then press with double click

Press to select the tool type library.
to open the tool library.
Select tool type <Left handed thread cutting tool>

With mouse click we select in the list field
. All left handed thread cutting tools are then
ordered in the pitch parameter Pmin.

Now scroll all left handed thread cutting tools suitable

Press to select and confirm the tool with the
for cutting threads with a 1.5 mm pitch. Select one of
designation <TL-LHTR-2020/R/60/1.50 ISO30>. Now
the two availabel tools. this tool has been mounted in position T03.
We have now shown you two different ways of selecting tools and mounting them on the turret. You can now
mount the other tools of your setup sheet on your own.
You can press the tool bar button to remove an unnecessary marked tool from the turret.
Tool table synopsis:
T01 LEFT HANDED CORNER CUTTER CL-SCLCL-2020 L 1208 ISO30

T02 LEFT HANDED CORNER CUTTER CL-SVJCL-2020 L 1604 ISO30
T03 LEFT HANDED THREADING TOOL TL-LHTR-2020 R 60 1.50 ISO30
T04 EXTERNAL RECESSING TOOL ER-SGTFL-1212 L 01.8-0 ISO30
T05 TWIST DRILL DR-18.00 130 R HSS ISO30
T08 BORING TOOL (POSTAXIAL) BI-SCAAL-1010 L 0604 ISO30
T10 BORING TOOL (POSTAXIAL) BI-SCAAL-1010 L 0604 ISO30
T12 INSIDE RECESSING TOOL (POSTAXIAL) RI-GHILL-1013 L 01.10 ISO30

The tool for position T12 of type inside recessing tool RI-GHILL-1013 L 01.10 ISO30, is currently not available in
the library.
Using the tool <Management> function we will enter the respective tool data and create a new tool.
The tool management enables you to create new tool data in the individual tool types as well as to edit or delete
existing tool data.
We select position T12 and select the tool

Press to open the tool type library.
management.
Since a large amount of data is required, it is helpful to The selected tool is read in as a copy.
select an existing, similar tool to use as a template. Next, select a new name for the the tolol and write the
Mark the selected tool < RI-GHILL-1013 L/01.30 selected tool name in the entry field.
RI-GHILL-1013 L/01.10 ISO30
ISO30> to be processed per mouse click . Open
with mouse click a context menu and select
function “create”.

We select with mouse click tool parameter set

cutting plate.
The new tool data can be edited in the respective
parameters
You can now select with the input field.
Write the following values and enter the required data:
Broad, upper: 2.9

Broad, bottom: 3.2
After you have modified all required data you can now
genererate the tool.
Confirm by pressing . The new tool is stored
under the tool type <inside recessing tool> in the tool
management. You come back to the tool type list view
of the tool management.
Exit tool management with . When all tools are selected for tooling, leave the tool
Now the new tool has to be assigned to position T12 magazine with
on the tool turret.
We move the tool into position 12 as before
Now tooling is completed. Our next step is to generate a setup sheet.

In the main menu press to call up the setup form menu.
Press to generate a new setup sheet. Enter a program name e.g. <%3>.
Save with or or press to quit. The setup Call up the NC Editor and open the new NC
sheet has been created as header for the NC program. program.
If you wish you can exit the NC editor by pressing
The next chapter will outline one of the methods for

creating NC programs.

8.0. NC programming in MTS programming key

This chapter describes how the editor can be used in combination with interactive programming and dialog
programming as an NC programming method.
Using the NC editor, delete the “M30” command at the The beginning of the NC program will be written block
end of the setup form section by positioning the cursor by block. Exit the editor after block N40 and change
on [M] and pressing . over to interactive programming mode, a second
optional method of generating NC programs with
TopTurn.
Each NC command block is run individually.
N0010 G90
N0015 G54
N0020 G00 X+100.000 Z+0150.000
N0025 G92 S4000
N0030 G96 F0000.250 S0260
N0035 T0101 M04
N0040 G00 X+082.000 Z+0000.000
N0045 G01 X-001.600
N0050 G00 X+082.000 Z+0002.000
N0055 G57 X+000.500 Z+0000.200
After the facing, a straight roughing turning cycle follows, as mentioned in the production sheet..

8.1. Inside straight roughing cycle G81
We shall enter the canned cycle call in dialog programming mode by pressing .
G81 Straight roughing cycle will be selected.
In the command overview you select the cycle with Enter the cycle parameter values into the respective
mouse click and press on to confirm fields in the form screen, then click on to save
them to the program.
N0060 G81 X+033.000 Z+002.000 I+003.000
Now enter the contour description in interactive mode:
N0065 G01 Z+0000.000

N0070 X+036.000 Z-0001.500
N0075 Z-0030.000
N0080 X+040.000
N0085 X+060.000 Z-0050.000
N0090 Z-0095.000
N0095 X+074.000
N0100 X+084.000 Z-0100.000
N0105 G80
Once the cycle call G80 is entered, the NC program will

be run.
Note: In interactive mode the programmed contour will be shown graphically.

8.2. Drilling cycle G84

Technology and tool change
for drilling cycle programing.
N0110 G00 X+150.000 Z+0100.000

N0115 G97 S1200 M08 F0000.150
N0120 T0505 M03
N0125 G00 Z+0002.000
N0130 G00 X+000.000
Call up dialog programming mode in order to program the drilling cycle.
In the command overview you select the cycle with Enter the cycle parameter values into the input
mouse click and press on to confirm. screen, then click on to save them to the
program.
The NC command line thus created reads:
Drilling cycle
N0135 G84 Z-0095.326 A+000.200 B+000.200

D+010.000 K+020.000

8.3. Outside straight roughing cycle G81
N0140 G00 X+150.000 Z+0150.000

N0145 G92 S4000
N0150 G96 F0000.250 S0220
N0155 T0808 M04
N0160 G00 X+015.000 Z+0001.500
N0165 G57 X-001.000 Z-0000.100
8.4. Inside straight roughing cycle G81

Inside straight roughing cycle and contour description
N0170 G81 X+021.000 Z+0001.000 I+002.000

N0175 G01 X+020.000 Z-0000.500
N0180 Z-0035.000
N0185 G01 X+024.000 Z-0038.464
N0190 Z-0076.536
N0195 X+020.000 Z-0080.000
N0200 Z-0091.000
N0205 X+013.000
N0210 G80

8.5. Inside finishing
Technology and tool change, finishing with repeated program sections.
N0215 G00 X+100.000 Z+0150.000

N0220 G92 S4000
N0225 G96 F0000.100 S0300
N0230 T1010 M04
N0235 G57 X+000.000 Z+0000.000
N0240 G41 G00 X+021.000 Z+0001.500
N0245 G01 X+021.000 Z+0000.000
N0250 G23 O0175 Q0205
N0255 G40
N0260 G00 Z+0002.000
8.6. Outside finishing

Technology and tool change, finishing with repeated
program sections.
N0265 G00 X+100.000 Z+0150.000

N0270 G92 S4500
N0275 G96 F0000.100 S0360
N0280 T0202 M04
N0285 G42 G00 X+033.000 Z+0001.500
N0290 G01 Z+0000.000
N0295 G01 X+036.000 Z-0001.500
N0300 G85 X+036.000 Z-0030.000 I+001.100
K+005.300
N0305 G23 O0080 Q0100
N0310 G40

8.7. Outside thread-cutting cycle G31
Technology and tool change for calling up thread-cutting

cycle.
N0315 G00 X+100.000 Z+0150.000

N0320 G97 F001.500 S1000
N0325 T0303 M03
N0330 G00 X+038.000 Z+0004.000
Dialog programming the threadding cycle
program.
The NC command line thus created:
N0340 G31 X+036.000 Z-0027.600 F0001.500

D+000.920 S0006 F0001*
N0345 M05

8.8. Outside groove-cutting cycle G79

N0350 G00 X+100.000 Z+0150.000

N0355 G92 S4000
N0360 G96 F0000.150 S0260
N0365 T0404 M04
N0370 G00 X+062.000 Z-0063.500
Dialog programming the groove-cutting cycle G79
program.
Cutting three external grooves
N0380 G79 X+054.000 Z-0064.500 I+000.300

K+000.300 J+002.000 A+000.200 D-002.600
W+000.300 O0005 Q0005
N0380 G79 X+054.000 Z-0072.500 I+000.300
K+000.300 J+002.000 A+000.200 D-002.600
W+000.300 O0005 Q0005
N0380 G79 X+054.000 Z-0080.500 I+000.300
K+000.300 J+002.000 A+000.200 D-002.600
W+000.300 O0005 Q0005

8.9. Inside groove-cutting

Technology and tool change and inside groove-cutting
N0390 G00 X+100.000 Z+0150.000

N0395 G97 F0000.100 S1000
N0400 T1212 M04
N0405 G00 X+018.000 Z+0002.000
N0410 Z-0002.600
N0415 G01 X+021.000
N0420 X+018.000
N0425 G00 Z-0023.700
N0430 G01 X+021.000
N0435 X+018.000
N0440 G00 Z+0002.000
N0445 G00 X+100.000 Z+0150.000
N0450 M30
3D representation of the workpart created by the entered program

9.0. Quality control – Measuring of workpart

10.0 Appendices
Sample NC program
Drawing Turning workpart1
Template setup form (setup sheet)
Template work plan
Template NC programming sheet
Information hardlock

10.1. NC Program %3
()
(( 12.4.2006 10:09
(
( CONFIGURATION
( MACHINE MTS01 TM-016_-R1_-060x0646x0920
( CONTROL MTS TM01
(
( FINISHED PART %040____TN08-TR01-16-TM1
(
( PART
( CYLINDER D080.000 L122.000
( MATERIAL "N\Aluminium\AlMgSi0.5"
( DENSITY 002.70
(
( MAIN SPINDLE WITH WORKPART
( CHUCK "Chuck Turning\Jaw chuck\KFD-HS 130"
( STEP JAW "Jaw\Step jaw\HM-110_130-02.001"
( TYPE OF CHUCK EXTERNAL CHUCK OUTSIDE STEP JAW
( CHUCKING DEPTH E18.000
(
(
( TAILSTOCK
( TAILSTOCK POSITION Z+1095.000
(
( CURRENT TOOL T01
( TOOLS
( T01 "DIN69880 V 30\Left corner tool\CL-SCLCL-2020 L 1208 ISO30"
( T02 "DIN69880 V 30\Left corner tool\CL-SVJCL-2020 L 1604 ISO30"
( T04 "DIN69880 V 30\Recessing tool\ER-SGTFL-1212 L 01.8-0 ISO30"
( T05 "DIN69880 V 30\Twist drill\DR-18.00 130 R HSS ISO30"
( T06 EMPTY
( T07 EMPTY
( T08 "DIN69880 V 30\Inside turning tool postaxial\BI-SCAAL-1010 L 0604 ISO30"
( T09 EMPTY
( T10 "DIN69880 V 30\Inside turning tool postaxial\BI-SCAAL-1010 L 0604 ISO30"
( T11 EMPTY
( T12 "DIN69880 V 30\Inside recessing tool postaxial\RI-GHILL-1013 L 01.10 ISO30"
( T13 EMPTY
( T14 EMPTY
( T15 EMPTY
( T16 EMPTY
(
( TOOL COMPENSATION
( D01 T01 Q3 R000.800 X+070.000 Z+0045.000 G000.000 E005.005 I-000.800 K-000.800 A+004.375 L011.855 N01
( D02 T02 Q3 R000.400 X+070.000 Z+0045.000 G000.000 E052.393 I-000.400 K-000.400 A+002.372 L016.178 N01
( D03 T03 Q8 R000.217 X+070.000 Z+0042.699 G000.000 E000.000 I-000.217 K+000.000 A+000.000 L000.000 N01
( D04 T04 Q3 R000.160 X+060.000 Z+0041.200 G001.800 E000.000 I-000.160 K-000.160 A+000.000 L008.000 N01
( D05 T05 Q7 R000.000 X+000.000 Z+0204.000 G018.000 E059.000 I+000.000 K+000.000 A+000.000 L000.000 N01
( D08 T08 Q2 R000.400 X-008.238 Z+0170.000 G000.000 E032.079 I+000.400 K-000.400 A+002.721 L005.992 N01
( D10 T10 Q2 R000.400 X-008.238 Z+0170.000 G000.000 E032.079 I+000.400 K-000.400 A+002.721 L005.992 N01
( D12 T12 Q2 R000.100 X-011.500 Z+0125.000 G001.100 E000.000 I+000.100 K-000.099 A+000.000 L004.000 N01
(
( WORKPART ZEROPOINTS
( G54 X+000.000 Z+0231.000
(
()
N0010 G90
N0015 G54
N0020 G00 X+100.000 Z+0150.000
N0025 G92 S4000
N0030 G96 F0000.250 S0260
N0035 T0101 M04
N0040 G00 X+082.000 Z+0000.000
N0045 G01 X-001.600
N0050 G00 X+082.000 Z+0002.000
N0055 G57 X+000.500 Z+0000.200
N0060 G81 X+033.000 Z+0002.000 I+003.000
N0065 G01 Z+0000.000
N0070 X+036.000 Z-0001.500
N0075 Z-0030.000
N0080 X+040.000
N0085 X+060.000 Z-0050.000
N0090 Z-0095.000
N0095 X+074.000
N0100 X+084.000 Z-0100.000
N0105 G80
N0110 G00 X+150.000 Z+0100.000
N0115 G97 S1200 M08 F0000.150
N0120 T0505 M03
N0125 G00 Z+0002.000
N0130 G00 X+000.000
N0135 G84 Z-0095.326 A+000.200 B+000.200 D+010.000 K+020.000
N0140 G00 X+150.000 Z+0150.000
N0145 G92 S4000
N0150 G96 F0000.250 S0220
N0155 T0808 M04
N0160 G00 X+015.000 Z+0001.500
N0165 G57 X-001.000 Z-0000.100
N0170 G81 X+021.000 Z+0001.000 I+002.000
N0175 G01 X+020.000 Z-0000.500
N0180 Z-0035.000
N0185 G01 X+024.000 Z-0038.464
N0190 Z-0076.536
N0195 X+020.000 Z-0080.000
N0200 Z-0091.000
N0205 X+013.000
N0210 G80
N0215 G00 X+100.000 Z+0150.000
N0220 G92 S4000
N0225 G96 F0000.100 S0300
N0230 T1010 M04
N0235 G57 X+000.000 Z+0000.000
N0240 G41 G00 X+021.000 Z+0001.500
N0245 G01 X+021.000 Z+0000.000
N0250 G23 O0175 Q0205
N0255 G40
N0260 G00 Z+0002.000
N0265 G00 X+100.000 Z+0150.000
N0270 G92 S4500
N0275 G96 F0000.100 S0360
N0280 T0202 M04
N0285 G42 G00 X+033.000 Z+0001.500
N0290 G01 Z+0000.000
N0295 G01 X+036.000 Z-0001.500
N0300 G85 X+036.000 Z-0030.000 I+001.100 K+005.300
N0305 G23 O0080 Q0100
N0310 G40
N0315 G00 X+100.000 Z+0150.000
N0320 G00 X+100.000 Z+0150.000
N0325 G97 F0001.500 S1000
N0330 T0303 M03
N0335 G00 X+038.000 Z+0004.000
N0340 G31 X+036.000 Z-0027.600 F0001.500 D+000.920 S0006 F0001*
N0345 M05
N0350 G00 X+100.000 Z+0150.000
N0355 G92 S4000
N0360 G96 F0000.150 S0260
N0365 T0404 M04
N0370 G00 X+062.000 Z-0063.500
N0380 G79 X+054.000 Z-0064.500 I+000.300 K+000.300 J+002.000 A+000.200 D-002.600 W+000.300 O0005 Q0005
N0380 G79 X+054.000 Z-0072.500 I+000.300 K+000.300 J+002.000 A+000.200 D-002.600 W+000.300 O0005 Q0005
N0380 G79 X+054.000 Z-0080.500 I+000.300 K+000.300 J+002.000 A+000.200 D-002.600 W+000.300 O0005 Q0005
N0390 G00 X+100.000 Z+0150.000
N0395 G97 F0000.100 S1000
N0400 T1212 M04
N0405 G00 X+018.000 Z+0002.000

N0410 Z-0002.600
N0415 G01 X+021.000
N0420 X+018.000
N0425 G00 Z-0023.700
N0430 G01 X+021.000
N0435 X+018.000
N0440 G00 Z+0002.000
N0445 G00 X+100.000 Z+0150.000
N0450 M30

10.2. Workpart drawing

10.3. Working templates
CNC
Turning
Setup Sheet
Program No. Clamping mode

Programmer Clamping device
Drawing No. Clamping depth
Designation Tailstock/vise position
Material:
Raw part/blank :
CNC control
Tool data / magazine or turret positions

Station Tool designation Tool file No. Compensation data Ag.
X R
Z0 Quadr.
X R
Z Quadr.
X R
Z Quadr.
X R
Z Quadr.
X R
Z Quadr.
X R
Z Quadr.
X R
Z Quadr.
X R
Z Quadr.
X R
Z Quadr.
X R
Z Quadr.
X R
Z Quadr.
X R
Z Quadr.
X R
Z Quadr.
X R
Z Quadr.
X R
Z Quadr.
X R
Z Quadr.

CNC
Turning
Production Sheet
Program No.
Programmer
Drawing No.
Designation
Material
Raw part/blank
CNC control
Sequence of machining steps

Nr. Maching step NC programming code Tool Cutting data
position
01 F N
Vc
02 F N
Vc
03 F N
Vc
04 F N
Vc
05 F N
Vc
06 F N
Vc
07 F N
Vc
08 F N
Vc
09 F N
Vc
10 F N
Vc
11 F N
Vc
12 F N
Vc
13 F N
Vc
14 F N
Vc
15 F N
Vc
16 F n
Vc
17 F n
Vc
18 F n
Vc
19 F n
Vc

CNC
Turning
Programming Sheet
Program No. Designation

Programmer Material
Drawing No. Raw part/blank
NC-Code
N G X Z I K F M T
05
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
110
115

10.4. Notice for administrating and organising of setup turning

The data available in the setup dialogue are read from already existing setup sheets. Those sheets can be
found in the file:
.\MTS-CNC Deutsch\Setup_T\
mtssetup.sct
The data mtssetup.sct .(Turning) contains the corresponding informations on the setup dialog. They can be at
any time edited and extended for new clamping devices.
Excerpt Source File mtssetup.scm Meaning
[HAUPTSPINDEL] = Keyword
INFO=KFD-HS 130 min.42 max.118 Et=30 = Name Clamping device
DATEI=KFD-HS 130-42-118-E30-A.dnc = Setup sheet with clamping device
LMIN=10 = min. workpart size
LMAX=300 = max. workpart size
DMIN=42 = min. outside diameter
DMAX=118 = max. outside diameter
IMIN=30 = min. inside diameter
IMAX=80 = max. inside diameter
EMIN=5 = min. clamping depth
EMAX=30 = max. clamping depth
CMIN=1 = min. center diameter
CMAX=6 = max. center diameter
New tool set:
During setup assign the tools from the tool administration to the corresponding tool positions. Leave the
magazine with exact correction values and create a new setup sheet. Tool set 05.dnc.
Consider, that every tool correction values must be listed, otherwise the new workpart set will not be shown in
the setup dialog.
Copy the setup sheet Tool set 05.dnc into .\MTS-CNC Deutsch\Setup_T\.
The new tool set is automatically shown in the list field and is available for new setup.

Clamping device overview
CNC-Programm INFO für clamping device Clamping

picture
KFD-HS 130-42-118-E30-A.dnc KFD-HS 130 min.42 max.118 Et=30


KFD-HS 130-46-118-E10.dnc KFD-HS 130 min.46 max.118 Et=10


KFD-HS 130-48-114-E10-I.dnc KFD-HS 130 min.48 max.114 Et=10



KFD-HS 160-114-193-E425-I.dnc KFD-HS 160 min.114 max.193 Et=42.5
KFD-HS 160-114-196-E44-I.dnc KFD-HS 160 min.114 max.196 Et=44.0
KFD-HS 130-46-118-E30-A-RS-02MT2.dnc KFD-HS 130 min.46 max.118 Et=30 RS 02-MT2


KFD-HS 130-42-118-E15-RS-02MT2.dnc KFD-HS 130 min.46 max.118 Et=10 RS 02-MT2


FDSC 046-60-100-02-MT2.dnc FDSC 046 min.060 max.100 02-MT2

FDSC 070-90-200-04-MT3.dnc FDSC 070 min.090 max.200 04-MT3

10.5. System Information
* Windows NT 2000 or XP:

Administrator right must be available in order to install the software. The software must have read and write
rights in the installation folder.
* Windows NT:
The dialog programming of the simulator requires the Internet Explorer 4.01 SP2 (or higher).
If for technical reasons once is not activ, the system must be checked.
With right mouse click on you open a meu.
Under Info for TopMill the number of the hardlock is shown.
Compare it with the number of the software licence you have purchased.
If hardlock number 0 is shown, there is a mistake in the system or in the software installation.
• Search in Windows functions for a file name:

• Hardlock.sys (WINNT-2000 XP).
• Examine the attachment of the hardlock on the LPT-Port.

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M a th e m a tis c h Te c h n is c h e

© MTS Mathematisch Technische Software-Entwicklung GmbH

Seite: 2  MTS GmbH 2006

1.0. INTRODUCTION ...................................................................................................................................... 5

1.1. HOW OPERATING ELEMENTS ARE REPRESENTED IN TOPTURN .................................................. 5

1.2. STARTING OF TOPTURN ....................................................................................................................... 6

1.3. NOTES ON SETTING UP A CONFIGURATIONTYPE............................................................................ 7

2.0. TOPTURN – THE CNC SIMULATOR TURNING .................................................................................... 8

2.1. AUTOMATIC MODE ................................................................................................................................ 9

2.2. INTERACTIVE MODE ............................................................................................................................ 10

2.3. SINGLE BLOCK MODE......................................................................................................................... 11

2.4. TOOL TRACING .................................................................................................................................... 12

2.5. MEASURING AND INSPECTION.......................................................................................................... 13

2.6. 3D REPRESENTATION AND SURFACE FINISH................................................................................. 14

2.7. 2D REPRESENTATION ......................................................................................................................... 15

3.0. THE NC EDITOR.................................................................................................................................... 17

3.1. SETUP SHEET....................................................................................................................................... 18

3.2. KEYBOARD LAYOUT FOR NC EDITOR FUNCTIONS........................................................................ 19

3.3. NC DIALOG PROGRAMMING .............................................................................................................. 20

3.4. ADDITIONAL INFORMATION TO MTS NC EDITOR ........................................................................... 21

4.0 THE “TURNING” SET-UP DIALOG........................................................................................................ 22

4.2. SELECT THE CLAMPING DEVICE AND CLAMPING CONFIGURATION.......................................... 22

4.3. WERKSTÜCKMAßE UND NULLPUNKT DEFINIEREN ....................................................................... 23

4.4. SELECT THE MACHINING TOOL SET ................................................................................................ 24

4.5. PROGRAM FOR EXERCISES 01.DNC................................................................................................. 25

5.0. SETUP MODE OVERVIEW.................................................................................................................... 26

5.1. CLAMPING DEVICES, CLAMPING METHODS OF BLANK MATERIAL SHAPES ............................ 26

5.2. TOOL TURRETS, TOOL MOUNTINGS AND TOOLS........................................................................... 26

5.3. TOOL LIBRARY..................................................................................................................................... 27

5.4. AXIS MOTIONS IN SETUP MODE ........................................................................................................ 27

6.0. PREPARATIONS FOR PROGRAMMING ............................................................................................. 28

6.1. PRODUCTION PLANNING AND TECHNOLOGY ................................................................................ 29

 MTS GmbH 2006 Seite: 3

6.2. SETUP FORM FOR “TURNING WORKPART 1” ................................................................................. 31

6.3. PRODUCTION SHEET FOR „TURNING WORKPART 1” ................................................................... 32

8.0. NC PROGRAMMING IN MTS PROGRAMMING KEY .......................................................................... 43

8.1. INSIDE STRAIGHT ROUGHING CYCLE G81 ...................................................................................... 44

8.2. DRILLING CYCLE G84.......................................................................................................................... 45

8.3. OUTSIDE STRAIGHT ROUGHING CYCLE G81 .................................................................................. 46

8.4. INSIDE STRAIGHT ROUGHING CYCLE G81 ...................................................................................... 46

8.5. INSIDE FINISHING................................................................................................................................. 47

8.6. OUTSIDE FINISHING............................................................................................................................. 47

8.7. OUTSIDE THREAD-CUTTING CYCLE G31 ......................................................................................... 48

8.8. OUTSIDE GROOVE-CUTTING CYCLE G79......................................................................................... 49

8.9. INSIDE GROOVE-CUTTING.................................................................................................................. 50

9.0. QUALITY CONTROL – MEASURING OF WORKPART....................................................................... 51

10.0 APPENDICES ........................................................................................................................................ 52

10.1. NC PROGRAM %3................................................................................................................................. 53

10.2. WORKPART DRAWING ........................................................................................................................ 56

10.3. WORKING TEMPLATES ....................................................................................................................... 57

10.5. SYSTEM INFORMATION....................................................................................................................... 62

Seite: 4  MTS GmbH 2006

1.1. How operating elements are represented in TopTurn

 MTS GmbH 2006 Seite: 5

1.2. Starting of TopTurn

MTS TM -___.___.042x0500x1000 x MTS TM CONTROL

Info on the machine tool axes, tailstock

Seite: 6  MTS GmbH 2006

1.3. Notes on setting up a configurationtype

A postprocessor is always needed for translating an MTS

Driving tool 5 axes machining (X, Z, Y, B, C) main

Programming key of the control Sinumerik 810D

Transfer of the NC data between the PC AND THE nc

MTS TM -_._.042x0500x1000 x MTS TM CONTROL