Document Outline

• MANUALplus 4110, Software and Functions
  • Intended place of operation
• Introduction and Fundamentals
  • 1.1 The MANUALplus
    • The C axis
  • 1.2 Features
  • 1.3 MANUALplus Design
    • Lathe design
    • Machine operating panel
  • 1.4 Axis Designations and Coordinate System
    • Axis designations
    • Coordinate system
    • Absolute coordinates
    • Incremental coordinates
    • Polar coordinates
  • 1.5 Machine Reference Points
    • Machine zero point
    • Workpiece zero point
    • Reference points
  • 1.6 Tool Dimensions
    • Tool length
    • Tool compensation
    • Tool-tip radius compensation (TRC)
    • Milling cutter radius compensation (MCRC)
• Basics of Operation
  • 2.1 The MANUALplus Screen
  • 2.2 Operation and Data Input
    • Modes of operation
    • Menu selection
    • Soft keys
    • Data input
    • List operations
    • Alphanumeric keyboard
  • 2.3 Error Messages
    • Direct error messages
    • Error display
    • Clearing an error message
    • System error, internal error
    • PLC error, PLC status display
    • Warnings during simulation
  • 2.4 Explanation of Terms
• Machine Mode of Operation
  • 3.1 Machine Mode of Operation
  • 3.2 Switch-On / Switch-Off
    • Switch-on
    • Traversing the reference marks
    • Monitoring EnDat encoders
    • Switch-off
  • 3.3 Machine Data
    • Input and display of machine data
    • Tool call
    • Tools in different quadrants
    • Feed rate
    • Spindle
  • 3.4 Machine Setup
    • Defining the workpiece zero point
    • Setting the protection zone
    • Defining the tool change position
    • Setting C-axis values
  • 3.5 Setting up Tools
    • Tool compensation
    • Tool life monitoring
  • 3.6 Manual Mode
    • Tool change
    • Spindle
    • Handwheel operation
    • Jog operation (joystick)
    • Cycles in Manual mode
  • 3.7 Teach-In Mode
  • 3.8 Program Run Mode
    • Faulty programs
    • Before executing a program
    • Start block search and program execution
    • Entering compensation values during program execution
    • Setting compensation values with the handwheel
    • Program execution in “dry run” mode
  • 3.9 Graphic Simulation
    • Views
    • Graphic elements
    • Warnings
    • Magnify / Reduce
  • 3.10 Time Calculation
  • 3.11 Program Management
    • Program information
    • Functions for program management
  • 3.12 Conversion into DIN Format
  • 3.13 Inch Mode
• Cycle Programming
  • 4.1 Working with Cycles
    • Starting point of cycles
    • Cycle transitions
    • DIN macros
    • Graphical test run (simulation)
    • Cycle keys
    • Switching functions (M functions)
    • Comments
    • Cycle menu
    • Soft keys in cycle programming
  • 4.2 Workpiece Blank Cycles
    • Blank-bar/tube
    • ICP workpc. blank contour
  • 4.3 Single Cut Cycles
    • Rapid traverse positioning
    • Approach the tool change position
    • Linear machining, longitudinal
    • Linear machining, transverse
    • Linear machining at angle
    • Circular machining
    • Chamfer
    • Rounding
    • M functions
  • 4.4 Roughing Cycles
    • Roughing, longitudinal/transverse
    • Roughing, longitudinal/transverse-Expanded
    • Finishing cut, longitudinal/transverse
    • Finishing cut, longitudinal/transverse- Expanded
    • Plunge longitudinal/transverse
    • Plunge, longitudinal/transverse-Expanded
    • Finishing plunge, longitudinal/transverse
    • Finishing plunge, longitudinal/transverse-Expanded
    • ICP contour-parallel, longitudinal/transverse
    • ICP contour-parallel finishing, longitudinal/ transverse
    • ICP roughing, longitudinal/transverse
    • ICP finishing, longitudinal or transverse
    • Examples of roughing cycles
  • 4.5 Recessing cycles
    • Recessing, radial/axial
    • Recessing, radial/axial-Expanded
    • Recessing radial/axial, finishing
    • Recessing radial/axial, finishing-Expanded
    • ICP recessing cycles
    • ICP recessing radial/axial, finishing
    • Recess turning
    • Recess turning, radial/axial
    • Recess turning, radial/axial-Expanded
    • Recess turning radial/axial, finishing
    • Recess turning radial/axial, finishing-Expanded
    • ICP recess turning, radial/axial
    • ICP recess turning radial/axial, finishing
    • Undercut type H
    • Undercut type K
    • Undercut type U
    • Parting
    • Examples of recessing cycles
  • 4.6 Thread and Undercut Cycles
    • Thread cycle (longitudinal)
    • Thread cycle (longitudinal)-Expanded
    • Tapered thread
    • API thread
    • Recut (longitudinal) thread
    • Recut (longitudinal) thread-Expanded
    • Recut tapered thread
    • Recut API thread
    • Undercut DIN 76
    • Undercut DIN 509 E
    • Undercut DIN 509 F
    • Examples of thread and undercut cycles
  • 4.7 Drilling Cycles
    • Drilling, axial/radial
    • Deep-hole drilling, axial/radial
    • Tapping, axial/radial
    • Thread milling, axial
    • Examples of drilling cycles
  • 4.8 Milling Cycles
    • Rapid traverse positioning
    • Slot, axial
    • Figure, axial
    • ICP contour, axial
    • Face milling
    • Slot, radial
    • Figure, radial
    • ICP contour, radial
    • Helical-slot milling, radial
    • Cutting direction for contour milling and pocket milling
    • Examples of milling cycles
  • 4.9 Drilling/Milling Patterns
    • Drilling/milling pattern linear, axial
    • Drilling/milling pattern circular, axial
    • Drilling/milling pattern linear, radial
    • Drilling/milling pattern circular, radial
    • Examples of pattern machining
  • 4.10 DIN Cycles
• ICP Programming
  • 5.1 ICP Contours
  • 5.2 Editing ICP Contours
    • Programming and adding to ICP contours
    • Absolute or incremental dimensions
    • Transitions between contour elements
    • Contour graphics
    • Changing the ICP contour graphics
    • Selection of solutions
    • Contour direction
  • 5.3 Importing of DXF Contours
    • Fundamentals
    • DXF import
    • Configuring the DXF import
  • 5.4 Programming Changes to ICP Contours
    • Editing a contour element
    • Adding a contour element
    • Deleting a contour element
    • "Splitting" a contour
    • Superimposing form elements
  • 5.5 ICP Contour Elements, Turning Contour
    • Entering lines, turning contour
    • Entering circular arcs, turning contour
    • Entering form elements
    • Chamfer/rounding, turning contour
    • Undercuts, turning contour
  • 5.6 ICP Contour Elements on the Face
    • Entering lines on the face
    • Entering circular arcs on the face
    • Entering chamfers/roundings on the face
  • 5.7 ICP Contour Elements on the Lateral Surface
    • Entering lines on the lateral surface
    • Entering circular arcs on the lateral surface
    • Entering chamfers/roundings on the lateral surface
• DIN Programming
  • 6.1 DIN Programming
    • Program and block structure
  • 6.2 Editing DIN Programs
    • Block functions
    • Word functions
    • Address parameters
    • Comments
    • Block functions
    • Menu structure
    • Programming G functions
  • 6.3 Definition of Workpiece Blank
    • Chuck part, cylinder/tube G20
    • Workpiece blank contour G21
  • 6.4 Tool Positioning without Machining
    • Rapid traverse G0
    • Tool change point G14
  • 6.5 Simple Linear and Circular Movements
    • Linear path G1
    • Circular path G2, G3-incremental center coordinates
    • Circular path G12, G13-absolute center coordinates
  • 6.6 Feed Rate and Spindle Speed
    • Speed limitation G26/G126
    • Interrupted feed G64
    • Feed per tooth G193
    • Constant feed G94 (feed per minute)
    • Feed per revolution G95/G195
    • Constant cutting speed G96/G196
    • Spindle speed G97/G197
  • 6.7 Tool-Tip / Milling-Cutter Radius Compensation
    • Fundamentals
    • G40: Switch off TRC/MCRC
    • G41/G42: Switch on TRC/MCRC
  • 6.8 Compensation Values
    • (Changing the) cutter compensation G148
    • Additive compensation G149
    • Compensation of right-hand tool nose G150 Compensation of left-hand tool nose G151
  • 6.9 Zero Point Shifts
    • Zero point shift G51
    • Additive zero point shift G56
    • Absolute zero point shift G59
  • 6.10 Oversizes
    • Axis-parallel oversize G57
    • Contour-parallel oversize (equidistant) G58
  • 6.11 Contour-Based Turning Cycles
    • Contour definition
    • End of cycle G80
    • Longitudinal contour roughing G817/G818
    • Longitudinal contour roughing with recessing G819
    • Transverse contour roughing G827/G828
    • Transverse contour roughing with recessing G829
    • Contour-parallel roughing G836
    • Contour finishing G89
  • 6.12 Simple Turning Cycles
    • Roughing longitudinal G81
    • Roughing transverse G82
    • Simple contour repeat cycle G83
    • Line with radius G87
    • Line with chamfer G88
  • 6.13 Recessing Cycles
    • Contour recessing axial G861 / radial G862
    • Contour recessing cycle, finishing, axial G863 / radial G864
    • Simple recessing cycle, axial G865 / radial G866
    • Recessing finishing, axial G867 / radial G868
    • Simple recessing cycle G86
  • 6.14 Recess-Turning Cycles
    • Function of recess turning cycles
    • Simple recess-turning cycle, longitudinal G811 / transverse G821
    • Recess-turning cycle, longitudinal G815 / transverse G825
  • 6.15 Thread Cycles
    • Universal thread cycle G31
    • Single thread G32
    • Thread single path G33
    • Metric ISO thread G35
    • Simple longitudinal single-start thread G350
    • Extended longitudinal multi-start thread G351
    • Tapered API thread G352
    • Tapered thread G353
  • 6.16 Undercut Cycles
    • Undercut contour G25
    • Undercut cycle G85
    • Undercut according to DIN 509 E with cylinder machining G851
    • Undercut according to DIN 509 F with cylinder machining G852
    • Undercut according to DIN 76 with cylinder machining G853
    • Undercut type U G856
    • Undercut type H G857
    • Undercut type K G858
  • 6.17 Parting Cycle
    • Parting cycle G859
  • 6.18 Drilling Cycles
    • Drilling cycle G71
    • Deep-hole drilling cycle G74
    • Tapping G36
    • Thread milling, axial G799
  • 6.19 C-Axis Commands
    • Zero point shift, C axis G152
    • Standardize C axis G153
  • 6.20 Face Machining
    • Starting point of contour / rapid traverse G100
    • Linear segment, face G101
    • Circular arc, face G102/G103
    • Linear slot, face G791
    • Contour and figure milling cycle, face G793
    • Area milling, face G797
    • Figure definition: Full circle, face G304
    • Figure definition: Rectangle, face G305
    • Figure definition: Eccentric polygon, face G307
  • 6.21 Lateral Surface Machining
    • Reference diameter G120
    • Starting point of contour / rapid traverse G110
    • Linear segment, lateral surface G111
    • Circular arc, lateral surface G112/G113
    • Linear slot, lateral surface G792
    • Contour and figure milling cycle, lateral surface G794
    • Helical-slot milling G798
    • Figure definition: Full circle, lateral surface G314
    • Figure definition: Rectangle, lateral surface G315
    • Figure definition: Eccentric polygon, lateral surface G317
  • 6.22 Pattern Machining
    • Linear pattern, face G743
    • Circular pattern, face G745
    • Linear pattern, lateral surface G744
    • Circular pattern, lateral surface G746
  • 6.23 Other G Functions
    • Period of dwell G4
    • Precision stop G9
    • Deactivate protection zone G60
    • Wait for moment G204
  • 6.24 Set T, S, F
    • Tool number, spindle speed /cutting speed and feed rate
  • 6.25 Data Input and Data Output
    • INPUT
    • WINDOW
    • PRINT
  • 6.26 Programming Variables
    • Fundamentals
    • # variables
    • V variables
  • 6.27 Program Branches, Program Repeats
    • IF (...) (conditional program branch)
    • WHILE (program repeat)
  • 6.28 Variables as Address Parameters
  • 6.29 Subprograms
  • 6.30 M Functions
• Tool Management Mode
  • 7.1 Tool Management Mode of Operation
    • Tool types
    • Tool life management
  • 7.2 Tool Organization
  • 7.3 Tool Texts
  • 7.4 Tool Data
    • Tool orientation
    • Reference point
    • Editing tool data
    • Lathe tools
    • Recessing and recess-turning tools
    • Thread-cutting tools
    • Drilling tools
    • Tapping tools
    • Milling tools
  • 7.5 Tool Data- Supplementary Parameters
    • Driven tool
    • Direction of rotation
    • Cutting data
    • Tool life management
• Organization Mode of Operation
  • 8.1 Organization Mode of Operation
  • 8.2 Parameters
    • Current parameters
    • Configuration parameters
  • 8.3 Transfer
    • Data backup
    • Data exchange with DataPilot 4110
    • Printer
    • Interfaces
    • Basics of data transfer
    • Configuring for data transfer
    • Transferring programs (files)
  • 8.4 Service and Diagnosis
    • Access authorization
    • System service
    • Diagnosis
• Examples
  • 9.1 Working with MANUALplus
    • Setting up the machine
    • Selecting a cycle program
    • Creating a cycle program
  • 9.2 ICP Example "Threaded Stud"
  • 9.3 ICP Example "Matrix"
  • 9.4 ICP Example "Recessing Cycle"
  • 9.5 ICP Example "Milling Cycle"
  • 9.6 DIN Programming Example "Threaded Stud"
  • 9.7 DIN Programming Example "Milling Cycle"
• Tables and Overviews
  • 10.1 Thread Pitch
  • 10.2 Undercut Parameters
    • DIN 76-undercut parameters
    • DIN 509 E, DIN 509 F-undercut parameters
  • 10.3 Technical Information
  • 10.4 Peripheral Interface
• Index
• Overview of G functions
• Overview of Cycles