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T O P C A M T O P T U R N T O P M I L L

M AT H E M AT I S C H T E C H N I S C H E SOFTWARE-ENTWICKLUNG GMBH

CNC Complete Machining Tu r n i n g Milling

MTS CAD-CAM solution for turning and milling For NC programming purposes, MTS is offering a programming system* and a shop-floor programming method* which can be used in conjunction with each other thanks to an identical internal structure. In addition, our shop-floor programming method includes several alternative input modes - from NC editor through to graphical geometry editor, interactive programming and teach-in operation right up to dialog programming. The operator can switch between these functions as often as he wishes while making entries. The postprocessor translates NC programs created with the TOPCAM programming system into the programming key* of the target CNC control. These can then be simulated, tested for collisions and further processed, e. g. optimized, in direct connection with the TOPTURN or TOPMILL shop-floor programming workstations which have been set to this programming key. It is this unbroken line of processes, connecting the programming system with an easy-to-use shop-floor/dialog programming method in the programming key of any desired CNC control, which is the outstanding feature of our CAD/CAM solution. This combination of the programming key and the postprocessor can then be used as a universal NC converter. *Programming system and shop-floor programming In everyday operations, we encounter both so-called computer-assisted programming, using programming systems as employed in work planning departments, as well as shop-floor programming, such as is carried out directly on the CNC control of a machine tool. In the future, this differentiation will become less and less relevant as the use of PC-based controls becomes more widespread. Programming systems normally import the workpiece geometry from CAD data and initially generate NC programs in a neutral, generic format, which is subsequently converted by postprocessors, into the programming key* of the target control system. Shop-floor programming involves creating NC programs directly in the programming key* of the CNC control on the respective control itself on the basis of a workshop drawing.

*Programming key The programming key of a CNC control system (also known as the command coding or control syntax) is defined first to be the set of programming functions according to ISO/DIN that this control system is capable of, including definition of the control-specific deviations from this standard, and second as the control-specific extensions by cycles, contour-programming etc. The term programming key is also used to describe the definition of the contents of a legible text language not based on the ISO/DIN standard.

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Management of tools, chucks, clamping devices and cutting data The MTS products TOPCAM, TOPTURN and TOPMILL utilize a uniform management system for tools, chucks, clamping devices, materials and cutting parameters/technology data. All standard tools for lathe and milling work as well as the chucks and clamping devices are recorded in parameter form, so that users can themselves define the specific tools and clamping devices to be used in their workshop. Profile turning tools can also be included using the appropriate CAD data.

The dimensions of all components are taken into account for collision tests. The chucks and clamping devices available for lathes are jaw chucks, collet chucks and centering clamps. Vises, electromagnetic plates as well as a modular clamping kit are available for milling processes.

The cutting data management is organized according to materials, tools and machining processes.

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TOPCAM Integrated NC programming and 2D CAD system for 2½D milling and for complete millturn machining with driven tools on up to 7 axes. One main feature of the TOPCAM programming system, which is embedded in a fully-functional 2D CAD front-end, is the graphical user interface linking it directly to the CAD data. In this system, the programs are generated with the aid of a simple interactive dialog, the work plan being automatically compiled as the program is created. The MTS programming key is used as an intermediate, control-independent NC data format. TOPCAM offers the following basic functions: automatic generation of work plans and set-up sheets, work plan editor with graphical display of the individual machining steps and the functions 'move', 'delete', 'insert', 'activate' and 'move to background', editing of NC programs by subsequent re-entry in the machining dialog, CAD data exchange using DXF, bidirectional DNC program transmission between programming system and CNC control • optional direct link to TOPTURN and TOPMILL.

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Complete mill-turn machining with driven tools on up to 5 configurable axes (X, Z, C, Y, B) and with sub-spindle (Z2, C2), including all machining cycles, in particular radial and axial recess cycles with selectable recessing or roughing machining, elimination of unnecessary cutting paths, macros for workpart takeover to sub-spindle, automatic insertion of diameter tolerances, fits, allowances, undercuts and relief grooves form E/F according to DIN/ISO, radii and chamfers, 2½D milling with driven tools on the planes: front face, chords and slanted chord surfaces as well as circumferential surfaces with using the machining cycles: pocket-milling, drilling, reaming, boring, thread-cutting and hole patterns with user macros for sequences of operations with different tools.

2½D programming system for milling using all common machining methods such as drilling, reaming, boring, threading cycles, circular and rectangular pockets and pins, as well as, in particular, contour parallel or meandering milling of pockets with any type of edges and islands, holes and finishing allowances and also with creation of radial and linear hole patterns, approach and withdrawal macros for contour milling and engraving of groups of entities with optimization of the tool path.

Postprocessors

There are two different versions of the TOPCAM postprocessor: • configurable ISO command

set postprocessor for 2-axes turning and 3-axes milling, and • cycle postprocessor that can • be adapted to any type of • CNC control generating the cycles of the target CNC control.

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Shop-floor programming and CNC simulation with TOPTURN and TOPMILL The CNC simulators TOPTURN (for lathe and turnmill operations) and TOPMILL (for milling) have a dual function within the MTS CAD/CAM solution: 1. Shop-floor programming in the programming key* of any desired CNC control, with a uniform user interface and direct linking to the machine tool.

2. CNC simulation, as an optional TOPCAM software enhancement, for testing the programs generated by TOPCAM in the machine-independent, neutral MTS programming key, or for testing the neutral NC programs converted by the postprocessor into the programming key of the specific target CNC control (CNC simulation after postprocessing).

TOPTURN models a lathe which can be optionally equipped with driven tools (supplementary axes C, Y and B) and a sub-spindle for complete machining (supplementary axes Z2, C2). TOPMILL models a 3-axes vertical milling machining center with configurable automatic tool changer, in the variants rotational tool magazine and dual-arm gripper or pick-upmagazine. A mathematically exact 3D model of the workpart is computed in parallel during machining, and precise collision tests are carried out, taking into consideration all components of the workspace within the framework of the 2D and 3D machine tool models. Configuration The wide range of practical utilization options which TOPTURN and TOPMILL offer for shop-floor programming and CNC simulation is based on the comprehensive configuration possibilities provided by their 2D and 3D machine tool models, which permit the user to adapt these to the existing machine tools and CNC controls. In addition to being able to define the dimensions of the workspace or the machine table, the user can also define the strokes of the NC-axes and the position of machine zero coordinates and reference points. The tooling systems are also configurable, as turret systems or tool magazines.

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Programming key* and NC compiler

Milling

Turning

A. Bradley CNC 8400LM

Acramatic 900TC

Anton CNC 3300

A. Bradley CNC 8400LP

Bosch CC 100 M/200M

Anton CNC 3300

Bosch CC 300 M

Bosch CC 200 T

DMG MILL PLUS

Bosch CNC Alpha 2

Deckel Contour 2

Emcotronic T1/T1

Deckel Contour 3/Dialog 4

Engelhardt CNC 3300

Deckel Dialog 11/12

Fagor CNC 8020

Emcotronic M1/M2

Fanuc Series 0T/18T/21T

Engelhardt CNC 3300

Fanuc Series 6T/10T/15T

Fanuc Series 0-MB/MC Fanuc Series 6M/11M/16M Fagor 8050M FC 16 CNC H & K CNC 781M/783M Heidenhain TNC: - 151/155/355/360 (ISO) - 407/415/425 (ISO) - 410/426/430/310 (ISO) - 150/155/355/360 (cleart.) - 407/415/425 (cleart.) - 410/426/430/310 (cleart.) Maho CNC 232 (cleart.) Maho CNC 432/532 Maztrol M32/M+(EIA/ISO) Mitsubishi M50 NUM 720F/750/760 Pronumerik CNC 640 Okuma OSP 5020M Sanying Sinumerik 3M/6M/7M Sinumerik 810M/820M Sinumerik 850M/880M Sinumerik 802SD Sinumerik 810D/840D Traub MX8

Fanuc Series 150-TA

The NC syntax of the CNC simulator is determined by the currently activated programming key. This correlates all NC blocks to the MTS programming key which is used as an internal universal programming key. MTS programming key includes all commands defined in ISO/DIN 66025, parameter programming, comprehensive extensions with canned cycles and geometric tool path commands in the form of contour strings. The target program code in an activated programming key is translated with the aid of a universal preprocessor which can convert the CNC control specific program code into MTS programming key code. This is normally possible owing to the wide range of MTS programming key features. However, if the preprocessor is not able to model a particular control cycle, this cycle cannot be used in the simulation either. Thus, NC programs originally written externally in a specific control code can be simulated as long as all NC commands used in the program are available in the activated programming key, i. e. can be translated into the MTS programming key by the preprocessor. The combination of preprocessor and postprocessor enabled in this way forms the NC compiler, which can translate NC programs from one control-specific key into another programming key. It is always possible to transfer an NC program from MTS shop-floor programming systems to a specific CNC control and vice-versa as long as the program does not contain any commands which are not available in the target programming key set.

Gildemeister EPL1 Gildemeister EPL2 Lux-Turn Maho 432T Mazatrol T32 (EIA/ISO) Mazatrol TPLUS(ISO) Mitsubishi Meldas 310L Mori Seiki MF-T4/T6 MANUAL PLUS NCT 90T NUM 720T/750T/760T Okuma OSP500L Sinumerik 3T Sinumerik 8T Sinumerik 802SD Sinumerik 805T Sinumerik 810T/820T/ Sinumerik 850T/880T Sinumerik 810D/840D Sinumerik 840C SMT CC4200T SUF 16 CNC Traub TX8 Traub TX8D/TX8F

Here, we would like to refer to our extensive range of programming key examples provided in the control cycles of the demonstration version which you can download from our web site. http://www.mts-cnc.com

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Set-Up - Programming - Automatic Mode The shop-floor programming stations TOPTURN and TOPMILL offer three distinct operating modes: • set up • programming • automatic mode

completed by the quality assurance functions: • workpiece measurement at cross-sections • 3D workpiece display.

For graphical representation of the machine

tool operating modes, an optional software enhancement: 3D machine-tool space with 3D material removal simulation and 3D collision detection is available in addition to the various standard schematic 2D representations of longitudinal sections or top views with longitudinal and transversal cross-sections.

With the conventional navigation functions

(zoom, rotate, shift etc.), the 3D graphical displays can be modified, parts of the machine tool can be blanked out and parts of the workpiece can be cut away to enable viewing of internal machining processes.

Set-up and tooling

As on a real machine tool, tools are selected using the tool

management and are installed in the tooling system, compensation values are set, material blanks are defined and clamped, and the workpiece coordinate origin is set in the same way as on a real machine tool. The CNC simulator motions can be controlled manually, machining the virtual workpiece in the process, e. g. in order to determine the workpart zero point or tool offsets by teachin. Of course, the CNC simulators can also be set up automatically using a set-up sheet included in the header of the NC program. Conversely, it is possible to save the actual set-up state in a set-up sheet.

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Programming TOPTURN and TOPMILL offer different shop-floor programming modes. It is possible to switch over from any of these modes to another while programming in order to suit the task at hand. These modes are: • Interactive programming • Use of an NC editor • Use of a geometrie editor • Teach-in operation • Dialog mode programming

The first two programming modes involve the input of NC blocks by the programmer; in the others, the NC blocks are generated automatically. In interactive programming, NC editing and automatic mode are used in combination. Once an NC block or cycle has been programmed, the corresponding machining procedure is simulated, thus allowing immediate testing of an NC block by simulation at the input stage. After each block the programmer can decide if he wants to accept or modify the block. A special NC editor is provided to assist manual NC programming, giving the possibilities to detect and display syntax errors or out-of-range motions at the input stage already. In teach-in mode, the workpiece can be machined under manual control. The resulting tool paths are translated into ISO/DIN commands (G00 and G01) and then inserted into the NC program. The Geometry editor (WOP workshop-orientated programming) makes programming of even the most complex contours easy and requires no separate calculations. The dimensions taken from the drawings are entered in the dialog and are then converted to contour path commands (extensions to the standard ISO/DIN command set). The transition points, circle centers, roundings and chamfers are calculated automatically during this procedure. Collisions will be immediately detected during simulation. 9

Dialog programming mode Dialog programming mode provides easy input of complex machining stages, one or several related input screens being filled in by

the user with graphical assistance. The input is checked for validity of combinations, value ranges and alternatives with logical combination functions. Dialog programming can be used to create and edit NC programs in the respective programming key without having to resort to explicit editing of NC blocks. Dialog steps are selected individually, starting from the overview of the machining functions arranged in a tree structure. The most efficient method of creating a program is to combine dialog programming with the geometry editor and interactive programming, whereby the NC editor can be used to display the resulting NC program at any time.

The user can customize the form, contents and functions of a dialog input. He can also add new input screens, e. g. to complete userspecific machining cycles.

At this point it must be stressed that shop-floor programming can be extended by an adapted, graphicssupported dialog programming mode for every TOPTURN or TOPMILL programming key. Since it is possible to create a corresponding MTS-CNC simulation programming key for any given CNC control, one specific application is to use the combination of these capabilities as a modern, easy-to-use dialog for programming elderly CNC controls.

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Automatic mode In automatic mode, NC programs can be simulated in continuous sequence or block by block in real time with override function, or in an accelerated test run. Dynamic simulation is displayed graphically in two dimensional or optionally three dimensional views. The manufacturing, feed and tool usage times as well as the volume of workpiece material removed by machining are calculated concurrently. The comprehensive collision detection calculations support the run-in of NC programs, especially in tight workspaces, complicated clamping situations or critical tool location combinations (danger of collision with neighbour tools). Quality and dimensional accuracy of the workpiece being machined can be monitored at any time in the course of the simulation using the 'measure' and 3D workpiece display functions. A tool path display is provided to allow analysis of the tool movements.

System requirements

The software can be run on WIN-

DOWS 95/98/ME/NT/2000/XP operating systems, either as a stand-alone or as a network version.

64 MB of main memory are adequate for 2D CNC simulation.

For optional 3D simulation, 128 MB main memory, a powerful processor and a high-performance graphics card are recommended.

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About MTS MTS was founded in Berlin in 1980 by Dr. Hans-Joachim Pfeiffer. Its corporate mission is to develop software for technical applications, using mathematical methods.

http://www.mts-cnc.com email: [email protected] Tel.: +49-30-349 96 00

Fax: +49-30-349 96 025

We have been specializing in the development of CAD/CAM and CNC software for more than 20 years. Our activities focus firstly on the software packages presented here: TOPCAM, TOPTURN and TOPMILL, representing the results of 20 years continued further development, and secondly, on projectoriented development work on contract for third parties. The latter mainly involves extensive adaptations of our standard software for major manufacturers of CNC controls and machine tools, e.g. in the projects: • CNC simulation of complete machining on lathes and mill-turn centers (7 axes) • CNC simulation of Swiss type CNC lathes (10 axes) • Programming and simulation of multi-spindle CNC machine tools (24 or more axes)

Another important sphere of our activities involves softwarerelated training of our clients' staff. We hold regular training courses on our standard software and also provide a telephone hotline service.

You can also order our software in the following

languages: Chinese (simplex & traditional), Czech, English, French, German, Hungarian, Italian, Polish, Portuguese, Russian, Slovakian, Spanish, Swedish, Thai, Turkish and Vietnamese.

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