4110 Operator Manual

User Training
MANUALplus
4110
NC Software
507 807-xx
9/2004
This manual is intended to improve your operation and programming of the MANUALplus 4110.
By way of examples, the setup of the lathe, the description and measurement of tools, and the
creation of cycle programs and ICP contours are explained step by step.
These examples were created with NC software 507 807-xx.
2004 Dr. JOHANNES HEIDENHAIN GmbH

All texts, pictures and graphics, as well as any parts thereof, are copyrighted material. They may
only be copied and printed for private, scientific and non-commercial informative purposes,
and only if they include this copyright notice. Dr. JOHANNES HEIDENHAIN GmbH reserves the
right to revoke this permission at any time. Without obtaining written permission in advance from
Dr. JOHANNES HEIDENHAIN GmbH, the texts, pictures and graphics may not be duplicated,
archived, stored on a server, included in newsgroups, used in online services, saved on
CD-ROMs or printed in publications. The unlawful duplication and/or dissemination of the
copyrighted texts, pictures and graphics will be prosecuted according to civil and criminal law.
User Components
System Operation
Tool Management
Tool Measurement
Machine Setup
Longitudinal Machining Example
Surface Machining Example
Recess Machining Example
10
Simulation
11
Program Execution
12
Fundamentals
Setup
Basic Knowledge
Programming
Axis directions and reference points
Axis directions
X axis: the cross slide is referred to as

the X axis. All X-axis values that are
displayed or entered are regarded as
diameters.
Z axis: the saddle is referred to as the

Z axis.
Traverse motions:
Program a positive value to depart

the workpiece.
Program a negative value to

approach the workpiece.
Reference points
The machine datum (M) is the origin

of the machine coordinate system. As
a rule, the machine datum is at the
intersection of the Z axis with the
spindle surface.
The workpiece datum (W) is the

origin of the workpiece coordinate
system. As a rule, the workpiece
datum is at the intersection of the Z
axis with the end surface.
HEIDENHAIN MANUALplus 4110 Basic Knowledge
1.1
Lathe design
Tool in front of or behind the workpiece

Depending on the design of the lathe, the tool is either in front of or behind the workpiece. The
MANUALplus 4110 detects the design of your machine, and takes the position of the X axis into
account for the graphic support, the simulation and the machining of the workpiece.
Tool in front of the workpiece
Tool behind the workpiece
This documentation assumes a lathe with tools in front of the workpiece.
1.2
The coordinate system
Two-dimensional coordinate system
The position of the tool tip is clearly

defined by its X and Z coordinates in a
two-dimensional coordinate system.
The MANUALplus 4110 recognizes

linear and circular contour
elements. A workpiece contour is
programmed by entering the
coordinates for a succession of points
and connecting them with linear or
circular contour elements.
The coordinates entered for the axes X

and Z are referenced to the
workpiece datum.
C axis
Angles entered for the C axis are

referenced to the datum of the C axis.
Accuracy
Positions can be programmed to an accuracy of 1 m (0.001 mm) or 0.001. This is also the
accuracy with which they are displayed.
1.3
Tool-tip radius compensation (TRC)
Programmed paths of traverse are

referenced to the theoretical tool tip
S. The radius of the tool tip on lathe
tools causes inaccuracies when
machining tapers, chamfers and radii.
These inaccuracies are removed with

the cutter radius compensation. A
new path of traverse (the equidistant
line) is calculated to compensate for
this error.
1.4
Feed rate and spindle speed
Feed rate
You select from the following methods:
Feed rate per revolution in mm/rev

The feed rate depends on the spindle speed. The tool is moved at the programmed value for
each spindle revolution.
Feed per minute in mm/min.

The feed rate is independent of the spindle speed. The tool constantly moves at the
programmed value.
Spindle speed
You select from the following methods:
Constant spindle speed

You program the spindle speed directly. The spindle speed is independent of the diameter the
tool is working on.
Constant cutting speed

You program the spindle speed indirectly. The MANUALplus 4110 changes the spindle speed
depending on the diameter momentarily being worked on by the tool. This results in a constant
cutting speed.
Example:
Constant spindle speed:

Sections 1 to 3: identical spindle
speeds
Constant cutting speed:

Section 1: High spindle speed
Section 2: Constantly decreasing
spindle speed
Section 3: Low spindle speed
Maximum speed (speed limitation):
If the constant spindle speed that you program is greater than the specified maximum
spindle speed, the maximum speed is valid.
For constant cutting speed the speed is limited by the defined maximum spindle
speed.
1.5
1.6
Data input keypad
Menu key
Calls the main menu in the Machine and

Organization modes of operation
Process key
Selects a mode of operation.

(Prerequisite: the MANUALplus 4110 must be in the
main menu)
Backspace key
Deletes the character to the left of the cursor

Deletes the most recent error message
Switching key
Toggles the support graphics between internal and

external machining
Clear key
Deletes all error messages
HEIDENHAIN MANUALplus 4110 User Components
2.1
Data input keypad
Numbers (0 to 9)
For value entry
Decimal point key
For entering the decimal point
Minus key
For entering the algebraic sign
Enter key
Confirms the entered value
Store key
Concludes data input and stores values
Arrow keys
Moves the cursor in the indicated

direction by one position (character, field,
line, etc.)
Page forward/
Page back
Shows the information on the

previous or next screen page
Switches between two input windows

Info key
HEIDENHAIN MANUALplus 4110 User Components
Calls the error information or PLC status

display
2.2
Menu selection, soft keys
Menu selection (9-field box)

The MANUALplus 4110 presents cycles, tools and functions in the Machine and Tool
Management modes as a 9-field box. Each field of this symbol corresponds to the numerical key
that is located at the same position on the controls numerical keypad.
The meaning of the symbol / menu item is also described in the footer.
Example: The 4 key calls the Roughing cycles, longitudinal/transverse submenu.
Soft keys
A bar at the bottom of the screen shows you the meaning of the soft keys. Press the
corresponding key to call the function.
Soft keys as toggle switches:
Mode activated (blue background)
Some soft keys work like toggle

switches. The status that they activate
remains until it is switched off again.
Mode deactivated
HEIDENHAIN MANUALplus 4110 System Operation
3.1
Machine data display
The machine data display is configurable. The display on your screen may therefore
deviate from the example shown.
Position display
Display of X and Z position:

Momentary distance from the tool tip
to the workpiece datum. The unit of
measurement is mm or inch,
depending on the setting.
Display of C position:
Momentary spindle position in
degrees ()
Meaning of the color of the axis letter:
Black: axis is active

White: axis is not activate
Distance-to-go display
Elements of the distance-to-go display
Distance-to-go display for cycle and program execution: The distance remaining is calculated
from the current position and the target position of the active traversing command, and displayed.
Distance-to-go display in Manual mode
Axes are traversed with the handwheels: The distance-to-go is not displayed
Axes are traversed with the jog keys with protection zone monitoring active: The distance-togo for the Z axis refers to the protection zone position
Axes are traversed with the jog keys with protection zone monitoring not active: The distanceto-go refers to the software limit switches
3.2
Protection zone status

The following symbols indicate the
protection zone status:
Protective zone monitoring activated

Protective zone monitoring deactivated
Feed rate display

Feed rate display element:
Top line: Programmed feed rate

Bottom line:
Current feed-rate override
Actual feed rate (taking the feedrate override into account)
Cycle ON:
Cycle or program is being performed
Cycle STOP
Units / type of feed rate
mm/r: Feed rate per revolution

mm/min: Feed rate per minute
Rapid traverse paths: The feed rate is
displayed as feed rate per minute
Set the feed rate
Set the feed rate per revolution (feed rate per minute is deactivated)
Set the feed rate per minute
3.3
Spindle display
Spindle display element:
Top line: Programmed cutting speed

or spindle speed
Bottom line:
Current speed override
Actual spindle speed (taking the
Spindle rotates counterclockwise (M3)

Spindle rotates clockwise (M4)
speed override into account)
Little number beside the S: Gear range
Spindle stop
Units:
Cutting speed: m/min

Spindle speed: r/min
Display for positioning of spindle
(M19):
Top line: Target position

Bottom line: Current position
Driven tool:
Identification: The S is highlighted

The display refers to the driven tool
Setting the cutting speed or spindle speed:
Set a constant cutting speed (the constant spindle speed is deactivated)
Set a constant spindle speed
Spindle utilization
Spindle utilization display element:
Current performance of the spindle

motor relative to the rated motor
performance
Bottom line: Maximum speed (speed

limitation)
3.4
Tool display
Tool display element:
Identification letter: T
Depending on the tool carrier, either a
2- or 4-digit number follows (without
leading zeros)
Fields dx, dz: Current tool

compensation
One tool holder (two-digit T display)

The T number indicates the position in the tool management.
Example T1
T1 from the tool manager is activated.
Example T28
Turret or automatic tool changer (four-digit T display)

The first two digits: Position in the tool management
The last two digits: Rotated position of the turret

Example T101:

Rotated turret position: 1
Example T2908:
T29 from the tool manager is

activated.
Rotated turret position: 8
3.5
Switch-on and traversing the reference marks
Switching on the machine
Main switch on
In the screen dialog line, the
MANUALplus 4110 shows you step by
step how to proceed when starting the
system.
Symbol indicating the existence of current

PLC status information
Call the PLC status display:

Press the Info key
(On some machines the PLC status

display is called automatically.)
Switch the drive on

(the PLC status display closes
automatically)
Axis and spindle enabling

The axes are enabled after the drives are switched on. You can traverse the axes per handwheel
or with the axis direction keys. (On some machines protective covers and guard doors must be
locked for the axes to be enabled.)
Colors of the identification letters:
White identification letters: Axes are not enabled

Black identification letters: Axes are enabled
3.6
Traversing the reference marks

For machines with standard encoders or distance-coded encoders a reference run must be made.
Reference runs are not necessary on machines with EnDat encoders.
Sequence for reference run:
On standard encoders: A fixed reference mark is traversed. This direction of approach must be
considered.
For distance-coded encoders: The MANUALplus 4110 finds the position after a brief reference
run. (There are reference marks every 20 to 80 mm.)
Traversing the reference marks:
Pre-position the axes with

handwheels or jog keys
Press the X Reference soft

key
Press the Z Reference soft

key
Activate Cycle Start
3.7
Confirm tool
The MANUALplus 4110 assumes that
the most recently active tool is still in the
tool holder.
Confirm the tool with the Tool change

button
(The tool and feed rate are enabled.)
On some machines (such as those with automatic tool changer) the acknowledgment
is automatic.
3.8
Switching the operating modes
Switching the operating mode
Call the main menu of the

current operating mode:
Press the Menu key
Select the operating mode

line:
Press the Process key
Mark the desired operating

mode:
Press the arrow key
Activate the marked

operating mode:
Press the Process key again
The active operating mode is marked in the tab of the uppermost screen line.
The operating modes are changed from the main menu.
3.9
Error messages and PLC status information
The symbol in the upper left corner signalizes error messages or PLC status information.
Open the error window or

PLC status display:
Press the Info key
Red symbol for error messages

Green symbol for PLC status information
Processing error messages:

To
delete the error marked by the cursor: Press the Backspace key
To
delete all errors: Press the Clear key
To
close the error window without deleting the error messages:

Press the Back soft key
Processing PLC status displays:

Remove the cause of the message, then the message is deleted and the window closed.
Switching between the error window and the PLC status display:
Call the PLC status display: Press the PLC diagnosis soft key
Call
the error window: Press the CNC diagnosis soft key
3.10
Switching the MANUALplus 4110 off
Correct shutdown is necessary to ensure the functional reliability of the control. If this is not done
appropriately, loss of data and functional problems can occur.
Call the main menu of the

Machine operating mode:
Press the Menu key
Press the Switch off soft

key
Confirm the confirmation

request:
Press the Enter key
When the picture of the main switch in

the power off position appears:
Switch the machine off with the main

switch
3.11
3.12
Creating tool T1
Tool data
The tool description contains the geometric data and cutting values. The cutting values from the
tool file are then used for cycle programming and the setup functions.
For better identification of the tools, the tool text is added as a description.
The first tool serves as a reference tool. The setting dimensions are measured and entered. The
setting dimensions of the other tools are not yet relevant. They will be measured later.
Roughing tool T1
Cutting radius: 0.8 mm

Tool angle: 93
Point angle: 80
Tool measurement:
Setup dimension X: 92 mm
Setup dimension Z: 62 mm
HEIDENHAIN MANUALplus 4110 Tool Management
4.1
Creating tool T1
Specify the position in the tool manager
Activate the Tool Management mode
Add a new tool:

Press the Insert soft key
(The cursor is on the
position T 1)
Select the tool type:

Press the Lathe tool menu
key
Enter the tool data (part 1)
Setup dimension X in X: 92 mm
Setup dimension Z in Z: 62 mm
Cutting radius R: 0.8 mm
Tool orientation WO: 1
(outside tool, machining direction
toward the chuck)
Tool angle A: 93
Tip angle B: 80
Wear compensation DX in X: 0 mm
Wear compensation DZ in Z: 0 mm
4.2
Creating tool T1
Enter the tool description
Press the Tool text soft key.

(The cursor is on the
position Q 1)
Enter text:
Press the Change text soft
key
Enter Roughing tool

Outside:
Select each letter with the
arrow keys and confirm
them with the Enter key
Save the entered text:

Press the Save soft key
Save the text number to the

parameter Tool text Q:
Press the Take over text
no. soft key
4.3
Creating tool T1
Press the Page forward key
Machining direction MD M3=3, M4=4: 3

(3=Machining direction to the right)
Cutting speed TS:
200 m/min
Feed rate TF: 0.4 mm/rev
Quantity PZ: No entry
Save the tool data:

Overview of tool data T1
Tool angle A: 93
Tip angle B: 80
Tool text Q: 1
Cutting speed TS: 200 m/min
Lifetime PT/Quantity PZ:
4.4
Create tool T2 by copying
Copying
You can copy tools of the same type. This reduces the amount of data entry.
The tool T2 differs from T1 in its setting dimensions and tip angle. The setting dimensions are
assumed at first, and will be determined exactly later.
Roughing tool T2

Tool angle: 93
Tip angle: 55
Assume tool data and specify the position in the tool manager
Load the tool data T1 into

the intermediate memory:
Press the Copy soft key
Place the cursor on position

T2:
Press the arrow key
Insert the tool data from the

intermediate memory to
position T2:
4.5
Adapt tool data
Press the Change soft key
Place the cursor on the input

field Tip angle B:
Press the arrow key
repeatedly
Tip angle B: 55
Save the tool data T2:

Tool angle A: 93
Tip angle B: 55
Tool text Q: 1
4.6
Finishing tool T6

Tool angle: 93
Tip angle: 55
Assume tool data and specify the position in the tool manager
The setting dimensions are assumed at first, and will be determined exactly later.
Load the tool data T2 into

the intermediate memory:

T6:
Press the arrow key
repeatedly
Insert the tool data from the

intermediate memory to
position T6:
4.7
Adapt the tool data (part 1)
Press the Change soft key
Place the cursor on the input

field Cutting radius R:
Press the arrow key
repeatedly

Q 2:
Press the arrow key

key
Enter the text Finishing tool

Outside with the onscreen keyboard

no. soft key
4.8
Adapt the tool data (part 2)
Cutting speed TS:

220 m/min
Save the tool data:

Tool angle A: 93
Tip angle B: 55
Tool text Q: 2
4.9
Creating tool T8
Threading tool T8
The setting dimensions are preliminarily entered

as 0.

T8: Press the arrow key
repeatedly
Add a new tool:

Press the Add soft key

Press the Threading tool
menu key
(outside tool, machining direction
toward the chuck)
4.10
Creating tool T8

Q 3:
Press the arrow key
Enter text:
key
Enter the text Thread cut

tool Outside with the onscreen keyboard

no. soft key

Shaft speed TS: 600 rev/min
4.11
Creating tool T8
Save the tool data:

Tool text Q: 3
Shaft speed TS: 600 rev/min
4.12
Creating tool T10
Recessing tool T10

Cutting width: 5 mm
The setting dimensions are preliminarily entered
as 0.

T10:
Press the arrow key
repeatedly
Add a new tool:

Press the Add soft key

Press the Recessing tool
menu key
Cutting width K: 5 mm
Special compensation DS: 0 mm
4.13
Creating tool T10

Q 4:
Press the arrow key
Enter text:
key
Enter the text Recessing

tool Outside with the onscreen keyboard

no. soft key

Cutting speed TS:
120 m/min
Quantity PZ: No entry
4.14
Creating tool T10
Save the tool data:

Cutting width K: 5 mm
Special compensation DS: 0 mm
Tool text Q: 4
4.15
4.16
Preparing for tool measurement
Tool measurement
The tool setting dimensions are determined relative to the measured tool T1.
First step: Determine the workpiece datum to set a measuring diameter

Further steps: Determine the setting dimensions of the tools by touching the workpiece.
Prepare the machine
Clamp a workpiece
Clamp tool T1
Entering the machine data
Call the main menu:

Press the Menu key
Select machine-data entry:

Press the Set S, F, and T
menu key
HEIDENHAIN MANUALplus 4110 Tool Measurement
5.1
Get a tool from the tool file:
Open the tool file:

Press the Tool list soft key
Assume tool T1:

Press the Take over tool
soft key
Assume the cutting speed

and feed rate from the tool
file:
Press the S, F from tool
soft key
Entered and assumed machine data
Tool number T: 1
Cutting speed S: 200 m/min
Feed rate per revolution F:
0.4 mm/rev
Maximum shaft speed D: 2000 rev/min
Stopping angle A: No entry
Activate machine data:

The maximum speed depends on the machine and the clamped workpiece.
5.2
Confirm T1 with the tool-change key
Return to the main menu:

Specify the workpiece datum
Switch the spindle on

Position the tool to the workpiece
with the handwheels
Call the main menu:

Press the Menu key
Call the setup functions:

Press the Setup menu key
Call Set datum:

Press the Set axis values
menu key
5.3
Facing a surface
Workpiece face turning: Machine in X direction with the handwheel

Retract the tool in X direction
Define the faced surface as

workpiece datum:
Press the Z=0 soft key
Display: The actual value display now

shows 0 for the Z axis.
Return to the setup menu:


5.4
Determine the setting dimensions for T1
Setting dimensions for T1

The approximate setting dimensions for T1 are already entered. You determine the precise
setting dimensions as follows:
Setting dimension X: Turn and measure the measuring diameter

Setting dimension Z: Is already specified with the definition of the workpiece datum
Call the Measure tool function
Call the main menu:

Press the Menu key

menu key
(Tool T1 is already
activated.)
Select Measure tool:

Press the Measure tool
soft key
5.5
Producing the measuring diameter
Turn the measuring diameter

Retract the tool in Z direction
Measure the turned diameter (example: diameter = 58 mm)
Enter the setting dimensions
Enter the measuring

diameter in Measuring
point coordinate X
Press the Tale over X soft

key
The MANUALplus 4110 calculates the

setting dimension X and enters it in the
tool file.
Display: The actual value display now shows the value entered for the X axis.
Conclude measurement of
tool T1:
Notes on the setting dimension in Z: The position of the tool tip relative to the
workpiece datum is definitive for the programming and display. Small deviations from
the actual tool length neither impinge upon working with the machine nor upon the
quality of the workpiece machining.
5.6

You determine the precise setting dimensions as follows:
Setting dimension X: Touch measuring diameter

Setting dimension Z: Touch the end face (workpiece datum)
Activate tool T2
Situation after measurement of tool T1
Open the tool file:


T2:
Press the arrow key

soft key
5.7

soft key:
Entries and assumed machine data
Tool number T: 2
Feed rate per revolution F: 0.4 mm/
rev
Activate the tool:

Insert tool T2
Select the Measure tool

function:
soft key
5.8
Touch the measuring diameter with the tool

Enter the touched

measuring diameter in
Measuring point
coordinate X
Press the Take over X soft

key
Touch the end face with the tool

Enter the value 0 (position of

workpiece datum) for the
measuring point
coordinate Z
Press the Take over Z soft

key
tool T2:
5.9


Activate tool T6
Open the tool file:


T6:
Press the arrow key
repeatedly

soft key
5.10

soft key
Tool number T: 6
0.25 mm/rev
Activate the tool:

Insert tool T6

function:
soft key

Enter the touched

Measuring point
coordinate X

key
5.11


measuring point
coordinate Z

key
tool T6:
5.12


Activate tool T8
Open the tool file:


T8:
Press the arrow key
repeatedly

soft key
5.13

soft key
Tool number T: 8
Shaft speed S: 600 rev/min
Feed per revolution F:
Activate the tool:

The parameter Feed rate per revolution F is not evaluated for threading tools.
Insert tool T8

function:
soft key
5.14

Enter the touched

Measuring point
coordinate X

key


measuring point
coordinate Z

key
tool T8:
5.15


Activate tool T10
Open the tool file:


T10:
Press the arrow key
repeatedly

soft key
5.16

soft key
Tool number T: 10
0.2 mm/rev
Activate the tool:

Insert tool T10

Confirm T10 with the tool-change
key

function:
soft key

Enter the touched

Measuring point
coordinate X

key
5.17


measuring point
coordinate Z

key
tool T10:

5.18
Machine setup
The following functions are necessary for setting up the lathe:
Activating a tool
Entering technology data (shaft speed / cutting speed, feed rate, maximum speed)
Setting the workpiece zero point
Defining the protection zone
Defining the tool-change point
Prepare the machine
Clamp a workpiece
Clamp tool T1
Call the main menu:

Press the Menu key

menu key
HEIDENHAIN MANUALplus 4110 Machine Setup
6.1
Assume the tool, cutting speed and feed

rate from the tool file:
Open the tool file:


soft key

soft key
Entered and assumed machine data
Tool number T: 1
0.4 mm/rev
Activate machine data:

The maximum speed depends on the machine and the clamped workpiece.
Confirm tool

6.2
Set the workpiece datum
Call the main menu:

Press the Menu key
Call Set datum:

Press the Set axis values
menu key
6.3
Facing a surface
Position the tool to the workpiece

with the handwheels
Workpiece face turning:
Machine in X direction with the
handwheel
Retract in X direction
Define the faced surface as

workpiece datum:
Press the Z=0 soft key
Displays:
Actual value display for Z axis: 0

The field highlighted in blue in the
support graphics shows the datum
offset (distance between machine
datum and workpiece datum)


The tool may not be moved in Z direction after the face turning. Only after the faced
surface has been defined as the workpiece datum may the tool be moved in Z direction
again.
6.4
Setting the protection zone
Call the main menu:

Press the Menu key
Call Protection zone:

Press the Set protection
zone menu key
Protective zone monitoring is

deactivated.
6.5
Approach the protection zone
Move the tool tip to the protection

zone position via the handwheels
Accept the tool position as

protection zone
parameter:
Press the Take over
position soft key
Display: The field highlighted in blue

shows the distance from the machine
datum to the protection zone position.

(Protective zone monitoring
is activated.)

Symbols for protection zone monitoring:

Protective zone monitoring not activated
Protective zone monitoring activated
6.6
Defining the tool change point
Defining the tool change position
Call the main menu:

Press the Menu key
Call the setup functions:

Call Defining the tool

change point:
Press the Set tool change
point menu key
6.7
Defining the tool-change point
Approach the tool change position
Position the tool to the tool change point with the handwheels. (Always program the tool
change point far away enough from the workpiece to avoid damage during a tool change.)
Define the tool change

point:
Press the Take over
position soft key
Display: The fields highlighted in blue

show the distance from the machine
datum to the tool change point.


6.8
Create the Threaded stud cycle program
Threaded stud example program

This example illustrates a longitudinal machining procedure using the ICP programming feature.
The individual working steps for machining the ICP contour and integrating the contour into ICP
cycles are based on the workpiece drawing.
Prerequisites:
The workpiece blank is clamped

The roughing tool T1 is clamped
The tools to be used is defined and measured
The workpiece datum is defined
The tool change point is defined
The protection is defined and activated
The maximum shaft speed is defined
All values are based on aluminum workpieces.
HEIDENHAIN MANUALplus 4110 Linear Machining Example
7.1
Creating a cycle program
Activate the teach-in mode:

Press the Teach-in soft key
Call the program list:

Press the Program list soft
key
Enter program number 1

for Cycle program
Call cycle program 1

Press the Select soft key
7.2
Enter the program name:

key
Enter the text Threaded

stud with the on-screen
keyboard
Save the entered text:

Program the cycle Blankbar/tube.
Add a new cycle:

Press the Add cycle soft
key
Press the Define blank

menu key
7.3
Press the Blank Bar/Tube

menu key
Enter the cycle parameters:
Outside diameter X: 60 mm
Length Z: 100 mm
Inside diameter I: No entry
Right edge K: 1 mm
(face oversize)
Clamping range B: 20 mm
Clamp type J: 1
Conclude entry:
Press the Input finished
soft key
Test the cycle:

Press the Graphics soft key
Conclude entry:
7.4
Program the ICPlongitudinal cutting cycle

key
Press the Roughing cycles,

longitudinal/transverse
menu key
Press the ICP cutting

longitudinal menu key
Starting point X in X direction: 60

mm
Starting point Z in Z direction:
4 mm
Infeed depth P: 4 mm
I oversize X: 0.3 mm
K oversize Z: 0.1 mm
ICP contour number N:: 1
(specify the ICP contour number)
Tool number T: 1
0.4 mm/rev
Assume the tool number and technology data from the tool file (see following steps).
Create the ICP contour threaded stud. This is necessary to be able to test and
perform the cycle (see following steps).
7.5
Assume the tool and technology data from the tool file:
Open the tool file:

Assume the tool (cursor is

on the position T 1):
soft key

and feed rate:
soft key
7.6
Create the ICP contour Threaded stud
ICP contour Threaded stud:
The contour is described in the machining direction

The contour is described completely (including form elements)
Call the ICP editor.
Press the Edit ICP soft key
Press the Insert element

soft key
Contour element 1 (chamfer)
Press the Form elements

menu key
7.7
Press the Chamfer menu

key
Describe the contour element:
Starting point XS in X: 16 mm
Starting point ZS in Z: 0 mm
Chamfer width B: 1.5 mm
Element position J: 1
Special feed rate F: No entry
Conclude entry:
Unresolved elements are shown as

symbols below the graphics window
Contour element 2 (thread undercut)

menu key
7.8
Press the Thread undercut

DIN 76 menu key
Target point X in X: 20 mm
Target point Z in Z: 30 mm
Thread pitch FP: 1.5 mm
Undercut diameter I: No entry
K undercut length: No entry
W undercut angle: No entry
R undercut radius: No entry
Element position J: No entry
The MANUALplus 4110 determines the
undercut parameters from the thread
pitch.
Conclude entry:
The part of the contour you have entered

up to now is clearly defined, and is
displayed.
Contour element 3 (oblique cut)
Press the Line menu key
Angle A to the Z axis: No entry
Length of line L: No entry
7.9
Conclude entry:
Contour element 4 (horizontal line)

Contour element 4 (horizontal line):
Conclude entry:
7.10
Contour element 5 (rounding)

menu key
Press the Rounding menu

key
Rounding radius B: 4 mm
Conclude entry:
Contour element 6 (vertical line)
7.11
Conclude entry:
Contour element 7 (chamfer)

menu key
Press the Chamfer menu

key
Chamfer width B: 2 mm
Conclude entry:
7.12
Contour element 8 (horizontal line):
Conclude entry:
7.13
Conclude entry:
The threaded stud contour is

completely described.
Exit the input mode:

Enter the contour name
Press the Contour list soft

key

key

Threaded stud
7.14

soft key
Exit the contour list:

Exit the ICP editor, return to

cycle programming:
7.15
Conclude and test the ICP cutting longitudinal cycle
Conclude input of the

roughing cycle.
soft key
Test the cycle:

Warnings
The MANUALplus 4110 tests whether the cycle can be performed without error. Because of the
cutting geometry, residual material remains in this example. This leads to a warning (see the
soft key Warning no.: 1).
Check if any changes to the program are necessary. In this example the residual material is
carried off in the finishing cycle. No changes to the program are necessary.
Call the warning:

Press the Warning no.: 1
soft key
Confirm the warning:

Press the Enter key
7.16
Run the cycle
As a precaution, switch to
Single Block mode:
Press the Single Block soft
key
Set the feed rate override

feed rate override to 0%
Slowly increase the feed

rate override. The roughing
cycle is performed.
Run each block by pressing

Cycle Start (single block
mode)
Save the cycle:

7.17
Program the Approach tool change position cycle

key
Press the Single cuts menu

key
Press the Rapid traverse

positioning menu key
Press the T-Change

approach soft key
Sequence Q: 0
(approach the tool change position on a
diagonal path)
Tool number T: 1
(maintain T1)
Conclude entry:
soft key
7.18
Test the cycle:

(The bright dot is at the tool
change position.)
Run the cycle
Set the feed rate override feed rate override to 0%
Slowly increase the feed rate override. The tool moves to the tool change
position.
Insert finishing tool T6
Save the cycle:

7.19
Create the ICP finishing longitudinal cycle by copying
Place the cursor on the ICP

cutting longitudinal cycle
Press the arrow key
Press the Copy cycle soft

key
Place the cursor in front of

the insert position:
Press the arrow key

key
The new cycle and all parameters are

inserted below the cursor position.
7.20
Adapt the cycle
Press the Edit cycle soft key
Switch to Finishing cycle:

Press the Finishing run
soft key
Cycle parameters:
Starting point X: 60 mm
Starting point Z: 4 mm
ICP contour number N: 1
Tool number T: 6
0.25 mm/rev
Assume the tool number and technology
data from the tool file (see following
steps).
Call the tool list:

Position the cursor on T6:

Press the arrow key
repeatedly
Assume the tool:

soft key

and feed rate:
soft key
7.21
Conclude input:
soft key
Run a graphic simulation of the cycle

The tool-path simulation accounts for the exact geometry of the tool tip. Therefore, this
simulation is recommended for the finishing process.
Call the additional functions

of the simulation:
Press the Extra functions
soft key
Press the Track soft key
Press the Slide soft key
7.22
Conclude setting of the

additional functions:
Repeat the simulation with

new settings:
Run the cycle


(The finishing tool is not yet
confirmed.)
Confirm tool T6 with the

Tool change key
Activate Cycle Start again

rate override. The finishing
cycle is performed.
Measure the created diameter and correct the tool if necessary:
Retract with the handwheel

Measure the diameter
7.23
Select tool compensation

Situation after performing the finishing
cycle
Press the Tool offset soft

key
Press the X offset for tool

soft key
Perform the tool compensation
Set the handwheel resolution for

compensation
Set tool compensation with the X

handwheel
The compensation set via handwheel is

shown in the Delta X field (example:
0.04 mm)
Assume the compensation:

The saved compensation value is

shown in the T6 dx field (example:
0.04 mm)
Conclude compensation:
7.24
Repeat the ICP finishing longitudinal cycle
Save the cycle:

Press the Overwrite soft
key
The tool compensation and finishing cycle can be repeated as often as necessary until
the correct dimension is reached.

key

key
7.25

Press the T-Change

approach soft key
Sequence Q: 0
diagonal path)
Tool number T: 6
(maintain T6)

soft key
Test the cycle:

Run the cycle
position.
Use the threading tool T8
Save the cycle:

7.26
Program the Threading cycle

key
Select the Threading cycle:
Press the Thread cutting

menu key
Press the Threading cycle

menu key
End point of thread Z2: 29 mm
Thread pitch F1: 1.5 mm
Thread depth U: No entry
First cutting depth I: No entry
Tool number T: 8
Shaft speed S: 600 m/min
data from the tool file (see following
steps).
7.27
Call the tool list:

Position the cursor on T8:

Press the arrow key
repeatedly
Assume the tool:

soft key
Assume the shaft speed

from the tool file:
soft key

soft key
7.28

The wire frame graphics are recommended for graphical inspection of the threading cycle. For
better inspection, the thread cutting is tested relative to the entire contour.
Test the cycle:


soft key
Switch to Wire frame

graphics:
(deactivate)
Show all contours defined

until now:
Press the Contour view
soft key
Warnings
If Contour view is selected, the MANUALplus 4110 checks all previous machining procedures.
In this example the already known warning from the roughing cycle is output.
Check and confirm warnings:
Call the warning: Press the Warning no.: 1 soft key
Confirm the warning: Press the Enter key
7.29
Run the cycle.


(The threading tool is not yet
confirmed.)
Confirm tool T8 with the

Tool change key
Activate Cycle Start again

rate override. The
threading cycle is
performed.
Check the thread and correct the tool, if necessary.

The threading cycle is finished:
Retract with the handwheel

Measure the thread
Thread paths are always machined at the programmed feed rate (thread pitch),
regardless of the current feed-rate override.
7.30
Select tool compensation

Situation after performing the threading
cycle
Press the Tool offset soft

key
Press the X offset for tool

soft key
Compensating the threading tool
Set the handwheel resolution for

compensation
Set tool compensation with the X

handwheel
The compensation set via handwheel is

shown in the Delta X field (example:
0.04 mm)
Assume the compensation:

The saved compensation value is

shown in the T8 dx field (example:
0.04 mm)
Conclude compensation:
7.31
Repeat the last thread cut with the corrected tool
Press the Last cut soft key
Save the cycle:

The tool compensation and the last cut can be repeated as often as necessary until
the thread is correct.
7.32

key

key

Press the T-Change

approach soft key
Sequence Q: 0
diagonal path)
Tool number T: 8
(maintain T8)

soft key
Test the cycle:

7.33
Run the cycle.
Set the feed rate override to 0%
position.
Save the cycle:

Exit Teach-in:
7.34
Results:
The workpiece
The cycle program Threaded stud
The ICP contour Threaded stud
7.35
7.36
Create the Matrix cycle program
Matrix example program

This example illustrates transverse machining. (It is assumed that the reader is familiar with steps
explained in the previous example.)
Prerequisites:

The roughing tool T1 is clamped
The roughing tool T1 and finishing tool T6 is defined and measured
HEIDENHAIN MANUALplus 4110 Surface Machining Example
8.1
Activate Teach-in
Enter the program number and name
Program the cycle Blankbar/tube

key

menu key

menu key
Length Z: 50 mm
Right edge K: 1 mm
Type of clamping J: 1

soft key
Test the cycle:

8.2
Conclude entry:
Program the cycle ICP cutting transverse

key

menu key
Press the ICP cut

transverse menu key
Infeed depth P: 4 mm
(For programming of the ICP contour,
see Page 11)
Tool number T: 1
0.4 mm/rev
data from the tool file.

soft key
8.3
Test the cycle:

Run the cycle


rate override. The roughing
cycle is performed.
Save the cycle:

8.4

key

key

Switch to Approach tool

change position:
Press the T-Change
approach soft key
Sequence Q: 0
diagonal path)
Tool number T: 1
(maintain T1)

soft key
Test the cycle:

Run the cycle
position.
When the tool change position is reached: Insert finishing tool T6
8.5
Save the cycle:

Program the cycle ICP finishing longitudinal

The matrix is finished from the inside towards the outside. For this reason the ICP contour
Matrix finishing contour with the contour direction from inside to outside is used.

key

menu key
Press the ICP cutting

longitudinal menu key

soft key
see Page 20)
Tool number T: 6
0.25 mm/rev

soft key
8.6

simulation is recommended for the finishing process.
Test the cycle:

Switch from path display to display of

the cutter:

of the simulation:
soft key


new settings:
8.7
Run the cycle:


rate override. The finishing
cycle is performed.
Save the cycle:


key

key

8.8

change position:
Press the T-Change
approach soft key
Sequence Q: 0
diagonal path)
Tool number T: 6
(maintain T6)

soft key
Test the cycle:

Run the cycle
position.
Save the cycle:

8.9
Results:
The workpiece
The Matrix cycle program
The Matrix ICP contour for roughing

machining
The Matrix ICP contour for finishing

machining
8.10
Create the Matrix ICP contour
Notes on the Matrix ICP contour:
The contour is described in the machining direction

First step: Input of the contour without form elements (rough contour)
Second step: Superimposition of the form elements (roundings)
Create an ICP contour:
Call the ICP editor:


key
ICP Contour: 2
Enter the ICP contour
number
8.11
Call the element input:

soft key
Conclude entry:
8.12
Example: Surface machining

Conclude entry:
Target point X in X: No entry

Target point Z in Z: No entry
Angle A to Z axis: 81.5
Conclude entry:
(The oblique cut is an
unresolved element.)
8.13
Contour element 4 (arc)
Switch to arc entry:

Press the Arc soft key
Define the arc with center

and radius:
Press the Arc with Mp + R
menu key
Target point X in
Target point Z in
Center point I in
Center point K in
Radius R: 7.5 mm
Special feed rate
X: No entry
Z: No entry
X: 0 mm
Z: 11.6 mm
F: No entry
Conclude entry:
(There are two solutions.)
Display next solution:

Press the Next solution
soft key
(desired solution)
Press the Select solution

soft key
8.14
Switch to line entry:

Press the Line soft key
Angle A to Z axis: 5.5
Conclude entry:

soft key
(desired solution)

soft key
8.15
Conclude the rough

contour input:
Superimpose roundings
Press the Superimpose

form elements soft key
(Position for superimposing
is shown with a red square)

key
Describe the superimposed element:
Insert rounding:
(Next position for
superimposing is shown)
8.16

key
Rounding radius B: 2.5 mm

Insert rounding:
(Next position for

key

Insert rounding:
(Next position for
8.17

key
Insert rounding:
All contour transitions are imposed. The Matrix ICP contour is complete.
8.18

key

key

Matrix

soft key

Exit the ICP editor:

8.19
Create the Matrix ICP contour for finishing machining
Matrix finishing contour ICP contour

The matrix is finished from the inside towards the outside. For this reason the ICP contour
Matrix finishing contour with the contour direction from inside to outside is created.
Copy ICP contour


key
Position the cursor on the 2

Matrix ICP contour:
Press the arrow key
Prepare for copying:
Enter the new ICP contour

number 21 in the to field
Perform copying:
Press the Copy Yes soft key
Change the contour name:

key

Matrix finishing contour
8.20
Create the Matrix ICP contour for finishing machining

soft key
Load ICP contour:

Reverse the direction of the

ICP contour description:
Press the Turn contour
soft key
The small yellow rectangle indicates the

end of the contour.

8.21
8.22
Create the Form roll cycle program
Form roll example program

This example illustrates recessing machining. (It is assumed that the reader is familiar with steps
explained in the previous examples.)
Prerequisites:

The recessing tool T10 is defined, measured and inserted
HEIDENHAIN MANUALplus 4110 Recess Machining Example
9.1
Activate Teach-in
Enter the program number and name
Program the cycle Blankbar/tube

key

menu key

menu key
Length Z: 75 mm
Right edge K: 1 mm
Type of clamping J: 1

soft key
Test the cycle:

9.2
Conclude entry:
Program the ICP cut radial cycle:

key
Press the Recessing cycles

menu key
9.3
Press the ICP cut radial

menu key
Recessing width P: No entry
(The recessing width is derived from
the cutting width tool parameter.)
see Page 11)
Distance DX to the subsequent
recess: No entry
Distance DZ to the subsequent
recess: No entry
Q number of recess cycles: 1
Tool number T: 10
0.2 mm/rev

soft key

simulation is recommended for the recessing process.
9.4

of the simulation:
soft key
Conclude entry of the

Stop the simulation after

every traverse path:
Press the Single block soft
key
Test the cycle:

Display subsequent traverse

paths:
Press the Graphic
Continue soft key
repeatedly
9.5
Run the cycle

Switch single-block mode off:
Press the Single block soft

key (deactivate)


rate override. The
recessing cycle is
performed.
Save the cycle:

9.6
Create the ICP radial finishing cycle by copying
Press the Copy cycle soft

key
(The cursor is on the ICP
radial recessing cycle)

key
(The cycle is inserted below
the cursor position.)
Adapt the cycle:
Press the Edit cycle soft key

soft key
Check the cycle parameters:
(Same ICP contour as for roughing)
Distance DX to the subsequent
recess: No entry
Distance DZ to the subsequent
recess: No entry
Q number of recess cycles: 1
Tool number T: 10
0.2 mm/rev
(The cycle parameters assumed from
roughing are used for finishing.)

soft key
9.7
Test the cycle:

Display subsequent traverse

paths:
Press the Graphic
Continue soft key
repeatedly
Run the cycle


rate override. The recess
finishing cycle is performed.
Save the cycle:

Press the Overwrite soft
key
9.8

key

key


change position:
Press the T-Change
approach soft key
Sequence Q: 0
diagonal path)
Tool number T: 10
(maintain T10)

soft key
Test the cycle:

Run the cycle
position.
Save the cycle:

9.9
Results:
The workpiece
The Form roll cycle program
The Form roll ICP contour
9.10
Create the ICP contour Form roll
Notes on the Form roll ICP contour:
The contour is described in the machining direction (toward the chuck)

First step: Input of the contour without form elements (rough contour)
Second step: Superimposition of the form elements (roundings)
Create an ICP contour


key
ICP Contour: 3
Specify the ICP contour
number
Call the element input:

soft key
The line connects

tangentially to the
subsequent element:
Press the Tangential
transition soft key
9.11
Conclude entry:
Contour element 2 (arc)
Only the radius is known for

the arc:
Press the Arc with R menu
key
Target point X in X: No entry

Target point Z in Z: No entry
Radius B: 5 mm
Conclude entry:
(The arc is an unresolved
element.)
9.12
Switch to line entry:

Press the Line soft key
Target point X in X: 49.5 mm

Angle A to Z axis: 6
Conclude entry:

soft key
(desired solution)
9.13
Conclude entry:
soft key
Angle A to Z axis: No entry
Conclude entry:
9.14
Conclude entry:
Angle A to Z axis: No entry
Conclude entry:
9.15
Conclude entry:
Conclude the rough

contour input:
9.16
Superimpose roundings
Press the Superimpose

form elements soft key
(Position for superimposing
is shown with a red square)

key

Insert rounding:
(Next position for
9.17

key

Insert rounding:
(Next position for

key

Insert rounding:
(Next position for
9.18

key

Insert rounding:
(Next position for

key
Rounding radius R: 1.5 mm

Insert rounding:
All contour transitions are imposed. The Form roll ICP contour is complete.
9.19

key

key

Form roll

soft key


9.20
Types of simulation
The graphic simulation feature enables you to check the machining sequence, the proportioning
of cuts and the finished contour before actual machining. In the Teach-in mode, this function
simulates the execution of a single cyclein Program run mode it simulates a complete cycle
or DIN program.
The simulation supports the following views:
Wire frame graphics

The MANUALplus 4110 draws the traverse paths as lines. The theoretical tool tip is the
reference point. This view is well suited for showing machining passes.
Cutting path graphics

In this view the cutter geometry of the tool is taken into consideration. Here you can check if
material remains, or if the contour is damaged.
Machining simulation
The blank is displayed as a white surface which is machined during the simulation (erasing
graphics).
Tool tip: For the wire frame and cutting path graphics you specify whether the tool tip is to be
shown, or whether the theoretical tip should be represent by a dot of light.
Wire frame graphics: Without display of

the tool tip. The dot of light (small
rectangle) represents the theoretical tool
point.
Cutting path graphics: With display of

the tool tip.
HEIDENHAIN MANUALplus 4110 Graphic Simulation
10.1
Types of Simulation
Setting the type of simulation

of the simulation:
soft key
Activate the cutting path

graphics:
Activate the cutter graphics:



new settings:
Set the machining

simulation:
Press the Machining
simulation soft key
Start the simulation:

Press the Graphic
Continue soft key
10.2
Enlarging, reducing, selecting a section for enlargement
Zoom functions
The zoom functions can be used to isolate a detail and magnify/reduce the displayed graphics.
Initial situation
Call the zoom functions:

Press the Zoom soft key
The red rectangle indicates the selected

section.
Change the image section
Reduce the section:

Press the Page forward
key
Increase the section:

Press the Page back key
Move the section:

Press the arrow keys
Assume the selected

section:
Press the Take over soft
key
Start the simulation:

Press the Graphic
Continue soft key
10.3
Enlarging, reducing, selecting a section for enlargement
Extend the view

Extending the view decreases the size of the workpiece. You then select the section desired.
Press the Extend view soft

key
10.4
Preparing program execution
Actions before executing a program:
Load the cycle program

Check the cycle program
Run a graphic simulation of the cycle program
Activate program run:
Call the main menu:

Press the Menu key
Press the Program run soft

key
(The program edited or used
most recently is loaded.)
HEIDENHAIN MANUALplus 4110 Executing Programs
11.1
Select the new program
Press the Program list soft

key
Place the cursor on the

program to be loaded:
Press the arrow keys
Warnings
The MANUALplus 4110 checks the program when it loads it. The error symbol appears if there
are errors or warnings.
Display warning:
Press the Info key
Clear the warning and close

the error window:
Press the Clear key
11.2
Checking the cycle

The cycle parameters are displayed if you place the cursor on the cycle. Check the program
before running it.
Place the cursor at the

beginning of the program:
Press the Program start
soft key
Place the cursor on the

cycle:
Press the arrow key
Run a graphic simulation of the program

soft key
11.3
Preparing the program
Prerequisites:
All tools to be used are defined and measured

The first tool is clamped
The cycle program has been checked
Run cycles individually
If Continuous run is disabled, the MANUALplus 4110 stops after each cycle.

soft key
To deactivate the
Continuous run mode:
Press the Continuous run
soft key
Run the cycle program (for each cycle)
Press Cycle Start. The cycle is started.

At a tool change:
Change the tool
Confirm the change with the tool-change key
Press Cycle Start again. The cycle is run.
The MANUALplus 4110 stops after executing the cycle.
11.4
Tool compensation
Note:
Tool compensation values can be applied during program execution.

Tool compensation values are saved together with the other tool data.
The new compensation value entered is added to the existing values, and is effective
immediately.
In the following example of a threaded stud, program run is stopped after the finishing cycle. The
workpiece is measured in the machine. The tool compensation is then entered and the finishing
cycle is repeated.
Interrupt the program run

Initial situation: Several workpieces
have already been produced. The
finishing tool is worn.
Deactivate the Continuous

run mode:
soft key
11.5
Tool compensation
Measure the workpiece
Run cycles N1 to N5
Stop the spindle
Measure the workpiece
Example: The diameter of the finishing

allowance is 0.2 mm too large.
Entering tool compensation values
Select tool compensation:

Press the Tool/Add
correct. soft key
(Tool correct. is already
active)
No compensation values have been

entered yet. DX und DZ have the value 0.
Enter the compensation value (0.2 mm)

in the DX + field
11.6
Tool compensation
Add the compensation

value:
(Compensation is activated.
It is shown in the T6 dx field
and in the DX field of the
dialog box.)
Exit the Tool correct

function:
Return to program run:

Repeat the finishing cycle with the corrected tool
Position the cursor on the

finishing cycle again:
Press the arrow key
Activate the Continuous

run mode:
soft key
(Cycles are run
continuously, without
interruption, up to the next
tool change.)
Repeat the finishing cycle, then run the other cycles
11.7
11.8

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User Training

2004 Dr. JOHANNES HEIDENHAIN GmbH

Longitudinal Machining Example

Surface Machining Example

Recess Machining Example

Axis directions and reference points

X axis: the cross slide is referred to as

Z axis: the saddle is referred to as the

Program a positive value to depart

Program a negative value to

The machine datum (M) is the origin

The workpiece datum (W) is the

HEIDENHAIN MANUALplus 4110 Basic Knowledge

Tool in front of or behind the workpiece

Tool in front of the workpiece

Tool behind the workpiece

This documentation assumes a lathe with tools in front of the workpiece.

HEIDENHAIN MANUALplus 4110 Basic Knowledge

The coordinate system

Two-dimensional coordinate system

The position of the tool tip is clearly

The MANUALplus 4110 recognizes

The coordinates entered for the axes X

Angles entered for the C axis are

HEIDENHAIN MANUALplus 4110 Basic Knowledge

Tool-tip radius compensation (TRC)

Programmed paths of traverse are

These inaccuracies are removed with

HEIDENHAIN MANUALplus 4110 Basic Knowledge

Feed rate and spindle speed

Feed rate per revolution in mm/rev

Feed per minute in mm/min.

Constant spindle speed

Constant cutting speed

Constant spindle speed:

Constant cutting speed:

Section 3: Low spindle speed

Maximum speed (speed limitation):

HEIDENHAIN MANUALplus 4110 Basic Knowledge

HEIDENHAIN MANUALplus 4110 Basic Knowledge

Data input keypad

Calls the main menu in the Machine and

Selects a mode of operation.

Deletes the character to the left of the cursor

Toggles the support graphics between internal and

Deletes all error messages

HEIDENHAIN MANUALplus 4110 User Components

Data input keypad

For value entry

Decimal point key

For entering the decimal point

For entering the algebraic sign

Confirms the entered value

Concludes data input and stores values

Moves the cursor in the indicated

Shows the information on the

Switches between two input windows

HEIDENHAIN MANUALplus 4110 User Components

Calls the error information or PLC status

Menu selection, soft keys

Menu selection (9-field box)

Example: The 4 key calls the Roughing cycles, longitudinal/transverse submenu.

Soft keys as toggle switches:

Mode activated (blue background)