QUEST 6/42 QUEST 8/51 QUEST 10/65

Transcription

1 OPERATOR S MANUAL TP6793 QUEST 6/42 QUEST 8/51 QUEST 10/65 MULTI-TASKING CNC Lathes Equipped with the GE Fanuc 16i-T, 18i-T, or 21i-T Control Revised: January 18, 2008 Manual No. M-392D Litho in U.S.A. Part No. M D June, 2007

2 - NOTICE - Damage resulting from misuse, negligence, or accident is not covered by the Hardinge Machine Warranty. Information in this manual is subject to change without notice. This manual covers the operation of Hardinge QUEST 6/42, 8/51, and 10/65 Multi-Tasking CNC lathes equipped with the of the following GE Fanuc controls: 16i-T 18i-T 21i-T In no event will Hardinge Inc. be responsible for indirect or consequential damage resulting from the use or application of the information in this manual. Reproduction of this manual in whole or in part, without written permission of Hardinge Inc., is prohibited. CONVENTIONS USED IN THIS MANUAL - WARNINGS - Warnings must be followed carefully to avoid the possibility of personal injury or damage to the machine, tooling, or workpiece. - CAUTIONS - Cautions must be followed carefully to avoid the possibility of damage to the machine, tooling, or workpiece. - NOTES - Notes contain supplemental information. - TRADEMARK NOTICE - Windows is a registered trademark of Microsoft Corporation. Hardinge Inc. One Hardinge Drive P.O. Box 1507 Elmira, New York U.S.A , Hardinge Inc. M-392D

3 READ COMPLETE INSTRUCTIONS CAREFULLY BEFORE OPERATING MACHINE, LOAD/UNLOAD AUTOMATION, OR BAR FEED SYSTEM When this instruction book was printed, the information given was current. However, since we are constantly improving the design of our machine tools, automation, and bar feed systems, it is possible that the illustrations and descriptions may vary from the machine, automation, or bar feed system you received. - WARNING - Occupational Safety and Health Administration (OSHA) Hazard Communication Standard , effective May 25, 1986, and various state employee right-to-know laws require that information regarding chemicals used with this equipment be supplied to you. Refer to the applicable section of the Material Safety Data Sheets supplied with your machine when handling, storing, or disposing of chemicals. Machine should only be used with a bar feed approved by Hardinge Inc. - SPINDLE TOOLING WARNING - Hardinge HQC (Quick-Change) collets MUST NOT be used in applications where the spindle is rotating without a bar or workpiece in the collet. Rotating the spindle without a bar or workpiece in the collet can result in the collet head being expelled from the spindle. Failure to comply with this warning can result in serious injury or death. HARDINGE SAFETY RECOMMENDATIONS Your Hardinge machine is designed and built for maximum ease and safety of operation. However, some previously accepted shop practices may not reflect current safety regulations and procedures, and should be re-examined to insure compliance with the current safety and health standards. Hardinge Inc. recommends that all shop supervisors, maintenance personnel, and operators be advised of the importance of safe maintenance, setup, and operation of machine tools. Our recommendations are described below. READ THESE SAFETY RECOMMENDATIONS BEFORE PRO- CEEDING ANY FURTHER. READ THE APPROPRIATE MANUAL OR INSTRUCTIONS before attempting operation or maintenance of the machine. Make certain that you understand all instructions. DON T ALLOW the operation or repair of equipment by untrained personnel. CONSULT YOUR SUPERVISOR when in doubt as to the correct way to do a job. WEAR SAFETY GLASSES AND PROPER FOOT PROTECTION at all times. When necessary, wear respirator, helmet, gloves, and ear muffs or plugs. DON T OPERATE EQUIPMENT unless proper maintenance has been regularly performed and the equipment is known to be in good working order. WARNING or INSTRUCTION TAGS are mounted on the machine for your safety and information. Do not remove them. DON T ALTER THE MACHINE to bypass any interlock, overload, disconnect, or other safety device. M-392D i

4 DON T OPERATE EQUIPMENT if unusual or excessive heat, noise, smoke, or vibration occurs. Report any excessive or unusual vibration, sounds, smoke, or heat as well as any damaged parts. REDUCE SPINDLE SPEED if vibration occurs. Bar stock straightness will have an effect on vibration and balance of the spindle system. NEVER OPERATE THE MACHINE SPINDLE without a work-holding device if the draw tube is in the spindle. TIGHTEN ALL DRAW TUBE SCREWS before beginning spindle operation. MAKE CERTAIN that the equipment is properly grounded. Consult National Electric Code and all local codes. DISCONNECT MAIN ELECTRICAL POWER before attempting repair or maintenance. ALLOW ONLY AUTHORIZED PERSONNEL to have access to enclosures containing electrical equipment. DON T REACH into any control or power case area unless electrical power is OFF. DON T TOUCH ELECTRICAL EQUIPMENT when hands are wet or when standing on a wet surface. REPLACE BLOWN FUSES with fuses of the same size and type as originally furnished. ASCERTAIN AND CORRECT the cause of a shutdown caused by overload heaters before restarting the machine. KEEP THE AREA AROUND THE MACHINE well lighted and dry. KEEP CHEMICAL AND FLAMMABLE MATERIAL away from electrical or operating equipment. HAVE THE CORRECT TYPE OF FIRE EXTINGUISHER handy when machining combustible material and keep chips clear of the work area. DON T USE a toxic or flammable substance as a solvent cleaner or coolant. MAKE CERTAIN THAT PROPER GUARDING is in place and that all doors are closed and secured. TO REMOVE OR REPLACE the collet closer it is necessary to remove the guard door at the left end of the machine. Make certain that the guard door is in place before starting the machine. DON T OPEN GUARD DOORS while any machine component is in motion. MAKE SURE chucks, closers, fixture plates, and all other spindle-mounted work-holding devices are properly mounted and secured before starting the machine. MAKE CERTAIN all tools are securely clamped in position before starting the machine. REMOVE ANY LOOSE PARTS OR TOOLS left on machine or in the work area before operating the machine. Always check the machine and work area for loose tools and parts especially after work has been completed by maintenance personnel. REMOVE CHUCK WRENCHES before starting the machine. ii M-392D

5 BEFORE PRESSING THE CYCLE START PUSH BUTTON, make certain that proper functions are programmed and that all controls are set in the desired modes. KNOW WHERE ALL stop push buttons are located in case of an emergency. CHECK THE LUBRICATION OIL LEVEL and the status of the indicator lights before operating the machine. MAKE CERTAIN that all guards are in good condition and are functioning properly before operating the machine. INSPECT ALL SAFETY DEVICES AND GUARDS to make certain that they are in good condition and are functioning properly before the cycle is started. CHECK THE POSITION of the tool top plate before pressing the Cycle Start push button. CHECK THE POSITION of any load/unload automation before pressing the Cycle Start push button. CHECK SETUP, TOOLING, AND SECURITY OF THE WORKPIECE if the machine has been OFF for any length of time. DRY CYCLE a new setup to check for programming errors. MAKE CERTAIN that you are clear of any pinch point created by moving slides before starting the machine. DON T OPERATE any equipment while any part of the body is in the proximity of a potentially hazardous area. DON T REMOVE CHIPS with hands. Use a hook or similar device and make certain that all machine movements have ceased. BE CAREFUL of sharp edges when handling a newly machined workpiece. DON T REMOVE OR LOAD a workpiece while any part of the machine is in motion. DON T OPERATE ANY MACHINE while wearing rings, watches, jewelry, loose clothing, neckties, or long hair not contained by a net or shop cap. DON T ADJUST tooling or coolant hoses while the machine is running. DON T LEAVE tools, workpieces or other loose items where they can come in contact with a moving component of the machine. DON T CHECK finishes or dimensions of workpiece near running spindle or moving slides. DON T JOG SPINDLE in either direction when checking threads with a thread gage. DON T ATTEMPT to brake or slow the machine with hands or any makeshift device. ANY ATTACHMENT, TOOL, OR MACHINE MODIFICATION not obtained from Hardinge Inc. must be reviewed by a qualified safety engineer before installation. USE CAUTION around exposed mechanisms and tooling especially when setting up. Be careful of sharp edges on tools. DON T USE worn or defective hand tools. Use the proper size and type for the job being performed. M-392D iii

6 USE ONLY a soft-faced hammer on tooling and fixtures. DON T USE worn or broken tooling on machine. MAKE CERTAIN that all tool mounting surfaces are clean before mounting tools. INSPECT ALL CHUCKING DEVICES daily to make certain that they are in good operating condition. Replace any defective chuck before operating the machine. Hardinge high speed spindles are balanced to an ISO G1.0 standard. High speed spindles require a work-holding device balanced to G2.5 or better. USE MAXIMUM ALLOWABLE gripping pressure on the chuck. Consider weight, shape, and balance of the workpiece. USE LIGHTER THAN NORMAL feedrates and depth of cut when machining a workpiece diameter that is larger than the gripping diameter. DON T EXCEED the rated capacity of the machine. DON T LEAVE the machine unattended while it is operating. DON T CLEAN the machine with an air hose. KEEP TOTE PANS a safe distance from the machine. Don t overfill the tote pans. DON T LET STOCK project past the back end of the collet closer or machine spindle without being adequately covered and properly supported. FOLLOW each bar feed manufacturer s guidelines. For performance and safe application, size and use feed tube bushings, pushers, and spindle liners according to bar feed information. MAKE CERTAIN that any bar feed mechanism is properly aligned with the spindle. If the bar feed is a floor-mounted type, it must be securely bolted to the floor. DURING HIGH SPEED APPLICATIONS, the bar stock must be contained within the collet closer and a bar feed not be used. Hardinge Inc. Recommends using a bar loader for feeding bar stock during high speed applications. Bar loaders feed the entire piece of bar stock into the spindle; then, the pusher is disengaged from the bar stock. UNLESS OTHERWISE NOTED, all operating and maintenance procedures are to be performed by one person. To avoid injury to yourself and others, be sure that all personnel are clear of the machine when opening or closing the coolant guard door and any access covers. FOR YOUR PROTECTION - WORK SAFELY iv M-392D

7 Table of Contents CHAPTER 1 - OPERATOR CONTROL PANELS Control Display Panel Manual Data Input Keyboard Special Key Functions for Windows Operation Operator Control Panel Control Interface Ports Standard Operator Interface PC-Based Operator Interface [Option] Stack Light [Option] On-Line Help System General Description P/S Alarms Methods of Operation Parameter Table Accessing the On-Line Help System Alarm Detail Operation Method Parameter Table Exiting the On-Line Help System CHAPTER 2 - POWER-UP AND CONTROL STATUS Power-Up Procedure Machine Warm-Up Program Machine Warm-Up Program Structure QUEST 8/51 Lathe QUEST 8/51 Lathe with Sub-Spindle QUEST 10/65 Lathe QUEST 10/65 Lathe with Sub-Spindle Power-Down Procedure Standard Operator Interface PC-Based Operator Interface [Option] Reviewing Control Status Position Key Program Key Offset Setting Key System Key Message Key M-392D v

8 CHAPTER 3 - OPERATIONAL MODES AND EDITING Automatic Mode Single Mode Edit Mode Word Scan Word Search Editing a Program Altering a Word Inserting a Word Deleting a Word Deleting Up to an End of Block Deleting Data Blocks Deleting a Program Edit Slow Mode Jog Mode Continuous Jog Incremental Jog Manual Data Input Mode Safe Start Subprograms Main Spindle Operation Sub-Spindle Operation Programs Entering a Program from the Keyboard Activating a Stored Program Running a Part Program for the First Time Stopping a Program Running in Automatic Mode Restarting a Stopped Program Dry Run and Machine Lock Modes Activating Dry Run and Machine Lock Exiting Dry Run and Machine Lock Background Edit Activating Background Edit Mode Editing an Existing Program Creating a New Program from the Keyboard Ending Background Editing Extended Part Program Editing [Option] Introduction Copy an Entire Program Copy Part of a Program Move Part of a Program Merge a Program Search and Replace Editing Machine Parameters Displaying the Program Directory vi M-392D

9 CHAPTER 4 - VDI TURRET TOP PLATE TOOLING Introduction Top Plate Configurations QUEST 6/42 & 6/42SP Lathe Turret Tooling Consideration Tool Holder or Tool Station Plug Removal Tool Station Plugs Plug Installation Left-Hand / Right-Hand Tool Selection Tool Holders Square Shank Tools Basic Configuration Reversible Tool Holders Installing Square Shank Tools Round Shank Tools Tool Holder Capacities Installing Round Shank Tools Removing Round Shank Tools CHAPTER 5 - ESA TURRET TOP PLATE TOOLING Introduction Top Plate Configuration Tool Holder or Tool Station Plug Removal Tool Station Plugs Introduction Tool Station Plug Installation Left-Hand / Right-Hand Tool Selection Square Shank Tools Basic Configuration Reversible Tool Holders Maximum Tool Extension Installing Square Shank Tools Round Shank Tools Tool Holder Capacities Maximum Z Axis Tool Extension for Sub-Spindle Operation Installing Round Shank Tools M-392D vii

10 CHAPTER 6 - HARDINGE TURRET TOP PLATE TOOLING Introduction Square Shank Tools Main Spindle Operation Qualified Tool Holders for Main Spindle Operation Left-Hand / Right-Hand Tool Selection Installing Square Shank Tooling Between-Center Turning on QUEST 6/42 Lathes Sub-Spindle Operation [Option] Maximum Tool Extension Cut-Off Tool Operating Limits Tooling Configuration Tooling Location Tool Mounting Position Tool Shank Modification Mounting Tools Round Shank Tools Round Shank Tool Holders Tool Setting Gauges Installing Round Shank Tools for Main Spindle Operation Installing Round Shank Tools for Sub-Spindle Operation Operating Limits Installation Procedure CHAPTER 7 - WORK SHIFT Introduction Manually Establishing Z Axis Work Shift VDI or ESA Turret Top Plate Hardinge Turret Top Plate CHAPTER 8 - TOOL OFFSETS Introduction Storing Tool Geometry Offsets in Memory Setting Tool Offsets for Non-Center Working Tools on the Turret Setting Tool Offsets for Center-Working Tools on the Turret Tool Probe [Option] Introduction Manual Tool Probe Operation Semi-Automatic and Automatic Tool Probe Operation Datuming the Tool Probe Tool Probe Datum Procedure Semi-Automatic Tool Probe Operation Automatic Tool Probe Operation Tool Probe Calibration Entering Tool Nose Radius Value and Orientation Code Adjusting Tool Wear Offsets Adjusting X and Z Axis Tool Wear Offsets Rules for Adjusting Wear Offsets viii M-392D

11 CHAPTER 9 - MAIN SPINDLE AND COLLET CLOSER Introduction Spindle Capacities Free Spindle Hydraulic Pressure Control Adjusting the Main Spindle Hydraulic Pressure Main Collet Closer Operation Automatic Operation Manual Operation Chucking Modes Switching the Chucking Mode Cleaning the Spindle Spindle Tooling Removing Spindle Tooling Installing Spindle Tooling Collet or Step Chuck Jaw Chuck Spindle Liners Introduction Spindle Liner Bushing Boring a Bushing to Size Installing or Removing the Spindle Liner CHAPTER 10 - TAILSTOCK Introduction Travel Specifications Tailstock Positions Fixed Home Position Adjustable Home Position (Retract) Rapid-to-Feed Position Overtravel Position Tailstock Safety Interlocks Cycle Start Interlock Overtravel Interlock Tailstock Movement Manual Movement Initiating Manual Movement Stopping Manual Movement Programmed Movement Initiating Programmed Movement Stopping Programmed Movement Checking and Adjusting Tailstock Feedrate Checking and Adjusting Tailstock Force Removing and Installing a Live Center Removing a Live Center Installing a Live Center M-392D ix

12 CHAPTER 11 - INPUT/OUTPUT DEVICES Introduction Input/Output Device Locations Standard Operator Interface PC-Based Operator Interface [Option] Input/Output Device Selection I/O Channel 0, 1, or I/O Channel Standard Operator Interface PC-Based Operator Interface Selecting the Input/Output Device RS-232 Serial Port (NC Data) Data Communications Protocol Tape Parity Check Baud Rate Stop Bits Checking and Modifying Communications Parameters RS-232 Port Parameter Settings Baud Rate Parameter Settings Stop Bit Parameter Settings Data Transfer RS-232 Serial Port (NC Data) Uploading Data through the RS-232 Port Uploading Control Parameters into Control Memory Uploading Part Programs into Control Memory Uploading Tool Offsets into Control Memory Downloading Data through the RS-232 Port Downloading Control Parameters from Control Memory Downloading Part Programs from Control Memory Downloading Tool Offsets from Control Memory Integrated Input/Output Devices Standard Operator Interface PC-Based Operator Interface CHAPTER 12 - OPERATOR MAINTENANCE Introduction Machine Air System Draining the Air Filter Bowls Adjusting the Machine Air Pressure Hydraulic System Standard Hydraulic Unit Filling the Oil Reservoir Hydrostatic Hydraulic Unit Filling the Oil Reservoir Coolant System Tramp Oil Pan Chip Removal x M-392D

13 CHAPTER 13 - OPTIONS AND MISCELLANEOUS FEATURES Machine Run Time Counter Accessing the Run Time Display Resetting the Run Time Counter to Zero Machine Cycle Time Counter Accessing the Cycle Time Display Clock Function Resetting the Clock Display Parts Counter Accessing the Parts Counter Display Resetting the Parts Counter to Zero Thread Cutting Cycle Retract High Pressure Coolant System Bar Feed Interface English / Metric Mode Establishing English / Metric Mode Axis Thrust Limitation Introduction Monitoring Axis Thrust Accessing the Axis Servo Tune Page Adjusting Axis Thrust Part Catchers Main Spindle Part Catcher [Option] Introduction Typical Part Unload Sequence Adjusting the Part Catcher for Part Length Adjusting the Part Catcher Extend / Retract Speeds Adjusting the Part Basket Extend / Retract Speeds Conveyor-Style Sub-Spindle Part Catcher [Option] Introduction Part Catcher M Codes Interlocks Capacity Part Catcher Gripper Pads Boring the Gripper Pads Changing the Gripper Pads Thru- Sub-Spindle Part Catcher [Option] Introduction Part Catcher Component Identification Selecting Part Catcher Components Changing Part Catcher Components Changing Sub-Spindle Draw Tubes Installing the Standard Draw Tube Installing the Part Catcher Draw Tube M-392D xi

14 Part Probe [Option] Introduction Set-Up Procedure Datuming the Part Probe Datuming the Part Probe on the X Axis Datuming the Part Probe on the Z Axis Maintenance Cleaning Probe and OMM Unit Windows Changing the Probe Batteries Sub-Spindle Part Present Detector [Option] Introduction Extending the Part Present Detector Range of Motion CHAPTER 14 - VDI LIVE TOOLING [Option] Introduction Types of Attachments Adjustable Dead Stop Live Tooling Collets and Capacities VDI 30 Live Tooling VDI 40 Live Tooling Live Tooling RPM Limit Live Tooling Attachment Installation Mounting the Attachment Installing / Removing Tools Maximum Tool Extension Procedure Live Tooling Attachment Removal Live Tooling Offsets Cross-Working Attachments End-Working Attachments VDI 30 Attachments VDI 40 Attachments Setting Tool Offsets for Live Tooling Setting Offsets for End-Working Tools Setting Offsets for Cross-Working Tools Tool Nose Radius Compensation Live Tooling Alignment Live Tooling Maintenance Lubricating the Live Tooling Attachment Lubricating the Live Tooling Pinion Gears Lubrication Frequency VDI 30 Turret VDI 40 Turret Lubrication Procedure Lubricating the Turret Index Shaft and Live Tooling Drive Shaft xii M-392D

15 CHAPTER 15 - ESA LIVE TOOLING [Option] Introduction Types of Attachments Live Tooling Collets and Capacities Live Tooling Attachment Installation Mounting the Attachment Installing Tools Maximum Tool Extension Tool Installation Procedure Live Tooling Offsets Cross-Working Attachments End-Working Attachments Setting Tool Offsets for Live Tooling Setting Offsets for End-Working Tools Setting Offsets for Cross-Working Tools Tool Nose Radius Compensation Live Tooling Maintenance Live Tooling Alignment CHAPTER 16 - TOOL LIFE MANAGEMENT Introduction Tool Life Measurement Units Number of Parts Amount of Machining Time Tool Life Management Program Bar Feed Operation Operation Determining Maximum Groups and Group Sizes Verifying Maximum Groups and Group Sizes Setting Maximum Groups and Group Sizes Determining the Measurement Unit Verifying the Measurement Unit Switching the Measurement Unit Resetting a Tool Group Counter M-392D xiii

16 CHAPTER 17 - SUB-SPINDLE AND COLLET CLOSER [Option] Introduction Cycle Start Safety Interlock Free Spindle Controlling Sub-Spindle Movement Automatic, Manual Data Input, or Single Mode E Data Word Feedrate Override Switch Jog Mode Axis Direction Keys Feedrate Override Switch Rapid Traverse Moving the Sub-Spindle Handwheel Control Moving the Sub-Spindle Sub-Spindle Tooling Removing Sub-Spindle Tooling Installing Sub-Spindle Tooling Collet or Step Chuck Jaw Chuck Sub-Spindle Collet Closer Hydraulic Pressure Control Adjusting the Hydraulic Pressure Sub-Spindle Collet Closer Operation Automatic Operation Manual Operation Chucking Modes Switching the Chucking Mode Main and Sub-Spindle Machining Set-Up and Operation Sample Machine Set-Up Set Up and Machine Main Spindle Operation Set Up and Machine Sub-Spindle Operation APPENDIX ONE Turret Travel Specifications X and Z Axes VDI 30 Turret Top Plate A1-1 VDI 40 Turret Top Plate A1-2 ESA Turret Top Plate A1-3 Hardinge Turret Top Plate A1-4 Y Axis [Option] A1-5 Tailstock Travel Specifications A1-6 Sub-Spindle Travel Specifications A1-6 Work Envelope Machine Equipped with Tailstock and VDI 30 Turret Top Plate A1-7 Machine Equipped with Tailstock and VDI 40 Turret Top Plate A1-8 Machine Equipped with Tailstock and ESA Turret Top Plate A1-9 Machine Equipped with Tailstock and Hardinge Turret Top Plate A1-10 Machine Equipped with Sub-Spindle and VDI 30 Turret Top Plate A1-11 Machine Equipped with Sub-Spindle and VDI 40 Turret Top Plate A1-12 Machine Equipped with Sub-Spindle and ESA Turret Top Plate A1-13 Machine Equipped with Sub-Spindle and Hardinge Turret Top Plate A1-14 xiv M-392D

17 Sample Tooling Layouts 10 Station VDI 30 Turret Top Plate A Station VDI 30 Turret Top Plate with Live Tooling A Station VDI 30 Turret Top Plate A Station VDI 30 Turret Top Plate with Live Tooling A Station VDI 30 Turret Top Plate A Station VDI 30 Turret Top Plate with Live Tooling A Station VDI 40 Turret Top Plate A Station VDI 40 Turret Top Plate with Live Tooling A Station ESA Turret Top Plate A Station ESA Turret Top Plate with Live Tooling A Station Hardinge Turret Top Plate A1-25 Spindle Torque and Horsepower Curves Main Spindle QUEST 6/42 Lathes Standard Spindle Drive A1-26 QUEST 8/51 Lathes Standard Spindle Drive A1-27 High Speed Spindle Drive, High Speed Range A1-28 High Speed Spindle Drive, Low Speed Range A1-29 QUEST 10/65 Lathes Standard Spindle Drive A1-30 High Speed Spindle Drive, High Speed Range A1-31 High Speed Spindle Drive, Low Speed Range A1-32 Sub-Spindle [Option] Standard Spindle Drive A1-33 High Speed Spindle Drive A1-34 Live Tooling VDI 30 and ESA Top Plates A1-35 VDI 40 Top Plate A1-36 Spindle Draw Tube Configurations QUEST 6/42 Lathes with Standard Spindle Drive A1-37 QUEST 8/51 Lathes with Standard Spindle Drive A1-38 QUEST 10/65 Lathes with Standard Spindle Drive A1-39 APPENDIX TWO G Codes A2-1 M Codes A2-3 Alarm Messages A2-7 Operator Messages A2-15 M-392D xv

18 - NOTES - xvi M-392D

19 CHAPTER 1 - OPERATOR CONTROL PANELS CONTROL DISPLAY PANEL The control display panel is shown in Figure 1.1. The panel consists of the display screen with associated soft keys. - NOTE - The optional PC-based operator interface is equipped with a touch screen display. The operator can select Windows functions by touching the display screen. The operator can select CNC soft key functions through the use the soft keys or directly by touching the soft key functions displayed on the screen. SOFT KEYS The ten unlabeled soft keys have various functions, depending on which function key is active. The function keys are located on the Manual Data Input panel. The soft key functions are displayed at the bottom of the control display screen. LEFT-HAND SOFT KEY This key is used to return to the initial state after a function has been accessed by pressing a soft key. RIGHT-HAND SOFT KEY This key is used to display further soft key functions which are not currently displayed. Figure Control Display Panel (18i-T Control Shown) TI4154 M-392D 1-1

20 MANUAL DATA INPUT KEYBOARD The available Manual Data Input panels are shown in Figures 1.2 through 1.5. This panel consists of keys relating to data input, data editing, and monitoring control functions. Refer to page 1-7 for information on special key functions relating to the Windows operating system on machines equipped with the optional PC-based operator interface. ALTER This key permits changes to an existing entry in an active program while in Edit mode. Refer to Edit mode in Chapter 3. This key is also used as the Tab key in the Windows environment on the optional PC-based operator interface. CAN (Cancel) This key is used to cancel or delete the last character or symbol which has been entered into the input buffer. It is also used, together with the appropriate function key, to clear the Data displayed on the screen. This key is also used as the Backspace key in the Windows environment on the optional PC-based operator interface. CURSOR CONTROL KEYS The and cursor control keys will shift the cursor forward or backward through the program one Data word at a time. The and cursor control keys will shift the cursor forward or backward through the program one Data block (program line) at a time. CUSTOM This key has no function on the standard operator interface. This key is used as the Control key in the Windows environment on the optional Windows based operator interface. DATA INPUT KEYS - NOTE - Most alphabetic keys on the Manual Data Input keyboard are used to input more than one character. The input from an alphabetic key is switched through the use of the Shift key. These keys are used to manually enter Data into the control. These keys input alphabetic, numeric, and other characters. In addition to these keys, the Alter, Insert, Delete, Input, EOB (End of Block), and Cancel keys are active. Data entered with the Data input keys is indicated on a line near the bottom of the display screen. 1-2 M-392D

21 DELETE This key causes the selected Data to be deleted. Refer to Edit mode in Chapter 3 for information on using the delete function. EOB GRAPH This key is used to input an End of Block (;) character. This key is used to graphically display the tool path while the program is being executed. Machine motion will occur unless Machine Lock mode is active. INPUT Refer to the GE Fanuc operator s manual for a description of the graphics feature. This key is used to set Data, which has been entered into the input buffer area, into the appropriate area in the control memory. Refer to Manual Data Input mode in Chapter 3. INSERT This key allows additional commands to be inserted in a program line while in Edit mode. Refer to Edit mode in Chapter 3. HELP This key allows the operator to access the machine on-line help system. Refer to page 1-22 for information relating to the on-line help system. This key is also used as the Escape key in the Windows environment on the optional PC-based operator interface. MESSAGE This key allows the operator to display alarm messages and operator messages issued by the machine control due to NC programming errors or machine hardware failures. OFFSET SETTING This key allows the setting and display of offset values. Refer to: Reviewing Control Status, in Chapter 2 Chapter 7 - Work Shift Chapter 8 - Tool Offsets M-392D 1-3

22 Figure Manual Data Input Panel (Non-CE Mark Machines with Standard Operator Interface) TI3818 Figure Manual Data Input Panel (CE Mark Machines with Standard Operator Interface) TI M-392D

23 Blank Key Figure Manual Data Input Panel (Non-CE Mark Machines with Optional PC-Based Operator Interface) TI4730 Figure Manual Data Input Panel (CE Mark Machines with Optional PC-Based Operator Interface) TI4731 M-392D 1-5

24 PAGE UP KEYS PAGE DOWN KEYS The Page keys are used to display information which requires more than one display page. Pressing Page or Page causes the control the display the previous or next page, respectively. POS (Position) Pressing the Position key will display the position Data in one of three ways: 1. In the absolute mode of the work coordinate system by pressing the Absolute soft key. 2. In the relative coordinate system by pressing the Relative soft key. 3. In the overall mode, indicating relative, absolute, machine coordinate, and distance to go, by pressing the All soft key. Use the Page keys to switch between the various position display screens. Refer to Chapter 2 for more information on the position display screens. PROG (Program) The Program function key allows the operator to perform the following: In Edit mode - Edit and display program memory. In Manual Data Input mode - Input and display Manual Data Input Data. In Automatic mode - Display the active part program. RESET This key can be activated any time while a part program is being executed. When the Reset key is pressed, axis and spindle motion are stopped. The M and G codes are reset to the power-up default status. The Reset key is also used to clear an alarm state after a fault has been corrected. SYSTEM - NOTE - To return to the start of a main part program, select Edit mode and press Reset. This key allows the setting and display of parameters and diagnostic Data. Refer to Chapter 2 for more information on the diagnostic and parameter screens. 1-6 M-392D

25 SPECIAL KEY FUNCTIONS FOR WINDOWS OPERATION - NOTE - The descriptions in this section relate only to machines equipped with the optional PC-based operator interface. The functions described in this section are discussed in terms of how they relate to the use of the CNC Manual Data Input keyboard in the Windows environment. Refer to your Microsoft Windows manual for additional information relating to the Windows operating system. Refer to Figures 1.4 and 1.5 for key locations. Alter Key Blank Key Cancel Key Custom Key Help Key This key is used as the Tab key This key is used as the Alternate key This key is used as the Backspace key This key is used as the Control key This key is used as the Escape key Shift + 1 Inputs the left brace symbol: { Shift + 2 Inputs the right brace symbol: } Shift + R Inputs the caret symbol: ^ Shift + S Inputs the backslash symbol: \ Shift + T Inputs the tilde symbol: ~ Shift + U Shift + Graph Inputs the underscore symbol: _ Access a Windows pop-up menu (equivalent to right click on a mouse) Custom + Help Toggles between the CNC display screen and the Windows Start Menu When using the Custom/Help key combination to toggle from the Windows Start Menu back to the Fanuc CNC screen, press the CNC Screen Display Function icon at the bottom of the display to clear the Windows tool bar. M-392D 1-7

26 OPERATOR CONTROL PANEL - NOTE - The functions described in this section are listed according to location on the operator control panel, from left to right. Refer to Figure 1.6. SPECIAL MODES BLOCK SKIP Press this push button to alternately activate and deactivate Block Skip mode. When this mode is active, the control will ignore any Data block preceded by a slash (/) code. The indicator light is illuminated when Block Skip is active. DRY RUN - NOTE - This mode must be OFF for normal machine operation. Press this push button to alternately activate and deactivate Dry Run mode. When this mode is active, programmed feedrates are ignored and cutting moves are performed at a Jog feedrate of 50 inches per minute. The indicator light is illuminated when Dry Run is active. Refer to Chapter 3 for information on using Dry Run mode. G00 This push button is a momentary switch. Pressing this push button releases the Edit Slow feature. Refer to Chapter 3 for information on Edit Slow mode. MACHINE LOCK - NOTE - This mode must be OFF for normal machine operation. Press this push button to alternately activate and deactivate Machine Lock mode. When this mode is active, all axis and spindle motion is inhibited. M, S, and T functions are also inhibited. The indicator light is illuminated when Machine Lock is active. Refer to Chapter 3 for information on using Machine Lock. 1-8 M-392D

27 AUTOMATION BOTH 2 MACH AUX 1 2 MAIN SUB CCW CW BLOCK SKIP OPTION STOP MACHINE LOCK COOLANT ON/OFF PART CATCHER INC DRY RUN REPEAT MODE G00 AUX TOOL PROBE 1 MAIN FREE DEC 2 SUB FREE TURRET STATION X Z C1 Y E C2 MDI SINGLE AUTO MACHINE MODES EDIT RAPID REF JOG RAPID REF 10X 1X 25 LOW 100X F % % RAPID OVERRIDE % 150 % FEED RATE OVERRIDE F % A INDEX MANUAL AXIS MOVEMENT X/Y OPEN/ CLOSE FEED HOLD CYCLE START 0 MACHINE PROGRAM POWER PROTECT Z/E RAPID TRAV Z/E GE/Fanuc OPEN/ CLOSE X/Y B C Figure Operator Control Panel TI4666A OPTION STOP - CAUTION - It is the responsibility of the part programmer to program the appropriate command to restart the spindle and coolant when program execution is resumed after an Option Stop. Press this push button to alternately activate and deactivate Option Stop mode. This function causes the control to stop execution of the part program AFTER executing an active block which contains an M01 code. The M01 code is ignored when Option Stop is not active. This function may be activated before or during execution of the block containing the M01 code. The indicator light is illuminated when Option Stop is active. When a block containing an M01 code is encountered and this function is active, the following occurs: The block is executed. All slide motion and spindle motion stops. The coolant pump turns OFF and Feed Hold turns ON. Option Stop can be activated in Dry Run mode. To resume program execution, press the Cycle Start push button. The Feed Hold push button light will turn OFF. REPEAT MODE Press this push button to alternately activate and deactivate Repeat mode. This function causes the active part program to cycle continuously. The indicator light is illuminated when Repeat is active. M-392D 1-9

28 MISCELLANEOUS FUNCTIONS AUX (Auxiliary) No Function. COOLANT ON/OFF This push button controls standard coolant operation. If coolant flow has been activated by a programmed M08 (Coolant ON), M13 (Spindle Forward/Coolant ON), or M14 (Spindle Reverse/Coolant ON), pressing this push button will stop the coolant flow. If coolant flow has not been activated by the program, pressing this push button will start coolant flow even though an M08, M13 or M14 has not been programmed. However, if the program is repeated the push button will not be active. The indicator light is illuminated when this function is active. PART CATCHER This push button allows the operator to alternately extend and retract the main spindle part catcher when the machine is in Jog mode. The indicator light is illuminated when the part catcher is extended toward the spindle. Refer to page 13-9 for additional information on the main spindle part catcher. TOOL PROBE This push button allows the operator to alternately deploy and stow the optional tool probe when the machine is in Jog mode. Refer to page 8-14 for additional information on the tool probe. AUTOMATION Option not available M-392D

29 SPINDLE CONTROL MAIN SPINDLE / SUB-SPINDLE 1 2 When Jog mode is active, this switch allows the operator to select the main spindle or sub-spindle as the spindle to be controlled by the push buttons in the Spindle area of the machine control panel. MAIN SPINDLE FREE 1 Press this push button to alternately activate and deactivate Main Spindle Free. When Main Spindle Free is activated, the spindle brake is released and the operator may rotate the main spindle by hand when Cycle Start is NOT active. The indicator light is illuminated when Main Spindle Free is active. SPINDLE CCW / SPINDLE CW This switch allows the operator to select the direction for non-programmed spindle motion (as viewed from the main spindle end of the machine) when the machine is in Jog mode. The spindle speed is controlled with the Spindle Increase Override and Spindle Decrease Override push buttons. The push button indicator light is illuminated when one of these functions is active. SPINDLE INCREASE OVERRIDE SPINDLE DECREASE OVERRIDE These push buttons have two applications: 1. Controlling spindle speed for non-programmed clockwise or counterclockwise spindle motion: a) Set the machine mode selector switch to Jog mode. b) Use the Main Spindle / Sub-Spindle switch to select the appropriate spindle. c) Use the Spindle CCW / Spindle CW switch to select the desired direction of rotation. d) Initiate spindle rotation by pressing the Spindle Increase Override push button and release to begin spindle motion. The first time this switch is pressed and released, the spindle speed will begin rotating at approximately 25 rpm. Use the Spindle Increase Override push button to increase spindle speed. The spindle speed will increase by approximately 25 rpm each time this key is pressed. Press the Spindle Decrease Override push button to slow the spindle. e) To stop spindle motion, press the Reset key or press and hold the Spindle Decrease Override push button until spindle motion ceases. M-392D 1-11

30 2. Override programmed spindle speed while spindle is active in Auto mode: Press the Spindle Decrease Override push button and release to decrease the spindle speed in ten percent increments to a minimum of 50%. This push button is illuminated when actual spindle speed is lower than the programmed spindle speed. Press the Spindle Increase Override push button and release to increase the spindle speed in ten percent increments to a maximum of 120%. This push button is illuminated when actual spindle speed is higher than the programmed spindle speed. Press the Spindle Increase Override and Spindle Decrease Override push buttons simultaneously to cancel the override function. The spindle speed will return to the programmed rate. SUB-SPINDLE FREE 2 Press this push button to alternately activate and deactivate Secondary Spindle Free. When Secondary Spindle Free is activated, the spindle brake is released and the operator may rotate the secondary spindle by hand when Cycle Start is NOT active. The indicator light is illuminated when Secondary Spindle Free is active M-392D

31 TURRET CONTROL TURRET STATION This rotary switch enables the operator to select the turret station to be indexed to the active position when the Turret Index push button is pressed. INDEX - CAUTION - The operator must be sure no interference exists within the machine work envelope before manually indexing the turret. - NOTE - The control must be in Jog mode to allow the Index push button to function. Press the Index push button to command the turret to index to the station selected with the Turret Station rotary switch. MACHINE POWER Switch A, Figure 1.6, turns the CNC control OFF when set to 0" and turns the CNC control ON when set to 1". PROGRAM PROTECT This switch is a two position, key operated switch. For normal operation, this switch should be turned to the ON position. When this switch is turned to ON, parameters cannot be edited and part programs cannot be edited or deleted. When this switch is turned to OFF, parameters can be edited and part programs can be edited or deleted. The key should be removed except when part program or parameter editing is required. The key cannot be removed from the switch when Program Protect is turned OFF. M-392D 1-13

32 MANUAL AXIS MOVEMENT - NOTE - Refer to Figures 1.7 and 1.8 for illustrations showing axis definitions. MANUAL AXIS MOVEMENT SELECTOR SWITCH C 1 Z X Y E C 2 Selects the C 1 axis for manual axis control. The C 1 axis is radial motion of the main spindle. Selects the Z axis for manual axis control. The Z axis is linear motion of the turret parallel with the spindle centerline. Selects the X axis for manual axis control. The X axis is linear motion of the turret parallel with the spindle face and parallel with the machine bed. Selects the Y 1 axis for manual axis control. The Y 1 axis is linear motion of the turret parallel with the spindle face and perpendicular with the machine bed. Selects the E axis for manual axis control. The E axis is linear motion of the tailstock or sub-spindle parallel with the spindle centerline. Selects the C 2 axis for manual axis control. The C 2 axis is radial motion of the sub-spindle. -Z +Z +X Turret -X Main Spindle Sub-Spindle -E +E TI4642A Figure E, X, and Z Axis Definitions (Shown with Optional Sub-Spindle) 1-14 M-392D

33 Z/E The Z/E push buttons are momentary type switches that allow the operator to jog the selected axis in the indicated direction. The axis to be jogged is selected through the use of the Manual Axis Movement selector switch. Refer to Figure 1.7 for axis definitions. Active in Jog mode. X/Y The X/Y push buttons are momentary type switches that allow the operator to jog the selected axis in the indicated direction. The axis to be jogged is selected through the use of the Manual Axis Movement selector switch. Refer to Figures 1.7 and 1.8 for axis definitions. Active in Jog mode. RAPID TRAV (Rapid Traverse) This push button is a momentary type switch. Pressing this push button while simultaneously pressing one of the Jog directional push buttons causes the selected axis to move at approximately 150 in/min [3800 mm/min]. Refer to Jog Mode, in Chapter 3. MANUAL PULSE GENERATOR Manual pulse generator B, Figure 1.6, allows the operator to jog the selected axis by specific increments. The axis to be jogged is selected with the Manual Axis Movement switch and the increment is selected with the Rapid Override switch. +X +Y -X -Y Spindle Centerline Machine Bed TI4656 Figure X and Y Axis Definitions (Viewed from the Tailstock/Sub-Spindle End of the Machine) M-392D 1-15

34 MACHINE MODES AUTO Automatic mode allows execution of the active part program and modification of part programs using the Back Edit function. The indicator light is illuminated when automatic mode is active. Refer to Chapter 3 for an explanation of Automatic mode. SINGLE (Single Block) Single mode provides the operator with the ability to execute one block of Data each time the Cycle Start push button is pressed. Canned cycles are executed one pass at a time. The indicator light is illuminated when Single mode is active. Refer to the programmer s manual (M-391) for descriptions of the Canned Cycles. MDI (Manual Data Input) Manual Data Input mode allows manual input of a temporary program block. The indicator light is illuminated when Manual Data Input mode is active. Refer to Chapter 3 for an explanation of Manual Data Input mode. EDIT Edit mode allows the operator or programmer to edit a stored program when the Program Protect key switch is in the OFF position. To deactivate Edit mode, select another operating mode. The indicator light is illuminated when Edit mode is active. Refer to Chapter 3 for an explanation of Edit mode. RAPID REFERENCE Rapid Reference mode allows the operator to move the machine axes to their respective reference positions through the use of the Rapid Reference push button. The X axis must be moved to the reference position before the Y 1 or Z axis can be commanded to the reference position through the use of the Rapid Reference push button. The Rapid Reference push button allows the machine operator to move the selected axis to the reference position. The axis to be moved is selected through the use of the Manual Axis Movement selector switch. Active in Rapid Reference mode. The X axis must be moved to the reference position before the Y 1 or Z axis can be moved to the reference position. JOG Jog mode allows non-programmed movement of the axes. The indicator light is illuminated when Jog mode is active. Refer to Chapter 3 for an explanation of Jog mode M-392D

35 % RAPID OVERRIDE F % The Rapid Override switch has a dual function. Depending on which mode has been selected, the functions are as follows: In Jog mode, the operator can select the jog increment to be active when moving an axis with the manual pulse generator. The movement distance per division on the manual pulse generator is: LINEAR AXES (E, X, Y 1,Z) X1 =.0001 inches [.001 millimeters] X10 =.001 inches [.01 millimeters] X100 =.01 inches [.1 millimeters] ROTARY AXES (C 1,C 2 ) X1 =.001 degree X10 =.01 degree X100 =.1 degree In all other modes, the operator can modify the machine Rapid Traverse rate in steps from Low to 100%. It is active in Positioning Mode (G00). The Rapid Override switch controls the E, X, Y, and Z axes. % FEEDRATE OVERRIDE F % The Feedrate Override switch has a dual function. Depending on which mode has been selected, the functions are as follows: In Jog mode, the jog feedrate can be modified in predefined steps from 0-50 in/min [1270 mm/min]. In all other modes, the operator can modify programmed feedrates from 0% - 150%. A setting of 0" will stop G01, G02, & G03 motion. M-392D 1-17

36 SUB OPEN / CLOSE 2 Pressing this push button while Cycle Start is NOT active will cause the work-holding device in the secondary spindle to alternately open and close. The push button will be illuminated when the work-holding device is closed and will blink when the work-holding device is open. MAIN OPEN / CLOSE 1 Pressing this push button while Cycle Start is NOT active will cause the work-holding device in the main spindle to alternately open and close. The push button will be illuminated when the work-holding device is closed and will blink when the work-holding device is open. FEED HOLD This push button is a latching type switch that allows the operator to stop all programmed slide motion. However, the active spindle speed is not affected. Feed Hold can be activated while in Automatic, Single Block, or Dry Run modes. Cycle Start turns OFF when Feed Hold is activated. To resume normal operation after a feed hold, press Cycle Start. This push button is illuminated when Feed Hold is active. CYCLE START This push button is a latching type switch that initiates program execution when the control is in Automatic mode or Single mode. An additional function of this switch is to execute Manual Data Input commands. This push button is illuminated when Cycle Start is active. EMERGENCY STOP - CAUTION - DO NOT use the Emergency Stop push button to stop spindle rotation unless an emergency actually exists. - NOTE - The operator must wait approximately ten seconds from the time the Emergency Stop push button is pressed before attempting to clear the Emergency Stop. Emergency Stop push button C, Figure 1.6, is a latching type switch. When pressed, programmed slide motion and spindle rotation are stopped. The message Emergency Stop is displayed on the control screen. To return to normal operation: 1. Correct the problem that prompted the Emergency Stop condition. 2. Pull the Emergency Stop push button out to the first detent, wait two seconds; then, pull the push button out to the end of travel and release M-392D Revised: January 18, 2008

37 CONTROL INTERFACE PORTS STANDARD OPERATOR INTERFACE The standard operator interface, shown in Figure 1.9, is equipped with 2 Data input/output ports: ATA Flash Card Port RS-232 Serial Port (25 pin) Refer to Chapter 11 for information on using these input/output ports. ATA Flash Card Port RS-232 Serial Port Figure Data Input/Output Ports (Standard Operator Interface) TP4090 M-392D 1-19

38 PC-BASED OPERATOR INTERFACE [Option] - CAUTION - It is recommended that the control be powered down before connecting a keyboard or mouse to the CNC control. - NOTE - The universal serial bus (USB) ports are not active on machines using the Microsoft Windows NT operating system. The PC-based operator interface is equipped with the following: ATA Flash Card Port RS-232 Serial Port (15 pin) for PC Data RS-232 Serial Port (25 pin) for NC Data Universal Serial Bus (USB) Ports Keyboard Port Mouse Port Refer to Figure 1.10 for the location of the ATA flash card port and the RS-232 port used for NC Data input/output. Open the Data port cover, Figure 1.10, to gain access to the PC Data RS-232, universal serial, keyboard, and mouse ports. Refer to Figure 1.11 for port identification. Refer to Chapter 11 for information on using the ATA flash card and RS-232 serial ports. Data Port Cover ATA Flash Card Port RS-232 Port for NC Data Figure Data Input/Output Ports (Overall View) Keyboard TP4623A RS-232 Port for PC Data Mouse USB Port 1 USB Port 2 Figure PC and Data Input/Output Ports TP4624A 1-20 M-392D

39 STACK LIGHT [Option] The optional stack light, shown in Figure 1.12, is located at the left end of the lathe. The stack light is used to visually indicate the current status of the lathe. The colors and definitions are listed below: RED Emergency Stop or alarm condition. Automatic cycle is stopped. AMBER The lathe is in Automatic mode, but automatic cycle is not active. GREEN Automatic cycle active. Normal operation. Figure Optional Stack Light TP4955 M-392D 1-21

40 ON-LINE HELP SYSTEM GENERAL DESCRIPTION The on-line help system provides information and instructions relating to P/S alarms, methods of operation, and parameter tables. P/S Alarms - NOTE - Only the more difficult to understand P/S alarms are supported by the on-line help system. Information and remedies concerning specific P/S alarms is supplied. Methods of Operation Information concerning CNC machining operations. Parameter Table Displays ranges of parameter numbers based on parameter functions. ACCESSING THE ON-LINE HELP SYSTEM Press the HELP key to access the on-line help system. The following menu will be displayed: 1. Alarm Detail 2. Operation Method 3. Parameter Table - NOTE - When viewing Operation Method or Parameter Table screens, the help system will display two numbers in the upper right-hand corner of the screen; for example, ¼". The upper number indicates the current page number and the lower number indicates the total number of pages for that particular topic. Alarm Detail 1. Press the 1 Alm soft key. 2. Key in the alarm number and press the Select soft key. The alarm number and a detailed explanation will be displayed. 3. Repeat step 2 as needed. 4. Exit the on-line help system. Refer to Exiting the On-Line Help System M-392D

41 Operation Method 1. Press the 2 Opr soft key. 2. Key in the topic number and press the Select soft key. The selected topic and a detailed explanation will be displayed. 3. Repeat step 2 as needed. 4. Exit the on-line help system. Refer to Exiting the On-Line Help System. Parameter Table 1. Press the 3 Para soft key. Page 1 of 4 will be displayed. 2. Use the page keys to view the various pages, as needed. 3. Exit the on-line help system. Refer to Exiting the On-Line Help System. EXITING THE ON-LINE HELP SYSTEM Press the Help key again or press any of the following function keys to exit the on-line help system: - Message - Offset / Setting - Position - Program - System M-392D 1-23

42 - NOTES M-392D

43 CHAPTER 2 - POWER-UP AND CONTROL STATUS - CAUTION - The recommended operating temperature range is 50 to 95 F [7 to 35 C]. POWER-UP PROCEDURE - NOTE - It is important that the power-up procedure is followed as described to ensure safe, accurate, and repeatable machine operation. 1. Turn main disconnect switch A, Figure 2.1, ON. 2. Turn the main air valve on pressure regulator B, Figure 2.2, ON. - NOTE - Refer to Chapter 12 for information on draining the air filter bowls and refilling the coolant tank. 3. Drain air filter bowls C and D. 4. Check the coolant level. If necessary, add coolant. - CAUTION - When turning the Control ON/OFF switch to ON, DO NOT press any other push buttons or keys until the position or alarm screen is displayed. Some push buttons and keys are used for control maintenance or special operation commands. 5. Turn the Control ON/OFF switch to ON and wait until the CNC display screen is ON. 6. Pull the Emergency Stop push button out to the first detent, wait two seconds; then, pull the push button out to the end of travel and release. 7. Verify that the coolant guard door is closed. 8. Set the Machine Modes selector switch to Jog. 9. Set the Axis Selector switch to E. 10. Press the right-hand Z/E push button to move the tailstock or optional sub-spindle to the reference position. A Figure Power Case Door C B D TP4109A TP4101 Figure Air Control Assembly M-392D 2-1 Revised: January 18, 2008

44 11. Open and close the coolant guard door to perform the guard door switch verification and clear the verification alarm. 12. If the machine is equipped with a high-speed spindle and has been powered down for more than 4 hours, proceed to Machine Warm-Up Program. MACHINE WARM-UP PROGRAM - CAUTION - Factory-installed machine warm-up program O9000 will run the main spindle and sub-spindle (if equipped) for 3 minutes intervals at the following speeds: QUEST 8/51 Lathes: 2000, 4000, 6000, and 8000 rpm. QUEST 10/65 Lathes: 2000, 4000, and 6000 rpm. If the tooling installed in the main spindle is NOT capable of these spindle speeds, it will be necessary to copy and modify machine warm-up program O9000 to reduce the spindle speed to the maximum rating of the spindle tooling. If the machine is equipped with the optional Extended Part Program Editing, refer to page 3-15 for information on copying part programs. Refer to page 3-2 for information on editing a program. - NOTE - The factory-installed machine warm-up programs begin on page 2-3. The machine warm-up program is only used on a machine that is equipped with a high-speed spindle and has been powered down for more than 4 hours. 1. Set the Machine Modes selector switch to Automatic mode. - NOTE - The factory-installed machine warm-up program is O Select the machine warm-up program: A) Key in: O9000 (Factory-installed machine warm-up program) If the machine is NOT equipped with the optional Extended Part Program Editing, refer to page 3-10 for information on entering a program from the keyboard. -or- The number for the modified machine warm-up program (Refer to caution above) B) Press the Cursor ê key. 3. Press the Cycle Start push button to execute the machine warm-up program. 2-2 M-392D

45 MACHINE WARM-UP PROGRAM STRUCTURE - NOTE - Refer to the appropriate warm-up program, based on the machine model and if the machine is equipped with the optional sub-spindle. QUEST 8/51 LATHE O9000 (WARM UP Q51) ; G97 M3 S2000 P1 ; G4 X180. ; S4000 ; G4 X180. ; S6000 ; G4 X180. ; S8000 ; G4 X180. ; M30 ; QUEST 8/51 LATHE WITH SUB-SPINDLE O9000 (WARM UP Q51 WITH SUB) ; G97 M3 S2000 P1 ; M33 S2000 P2 ; G4 X180. ; S4000 P1 ; S4000 P2 ; G4 X180. ; S6000 P1 ; S6000 P2 ; G4 X180. ; S8000 P1 ; S8000 P2 ; G4 X180. ; M30 ; M-392D 2-3

46 QUEST 10/65 LATHE O9000 (WARM UP Q65) ; G97 M3 S2000 P1 ; G4 X180. ; S4000 ; G4 X180. ; S6000 ; G4 X180. ; M30 ; QUEST 10/65 LATHE WITH SUB-SPINDLE O9000 (WARM UP Q65 WITH SUB) ; G97 M3 S2000 P1 ; M33 S2000 P2 ; G4 X180. ; S4000 P1 ; S4000 P2 ; G4 X180. ; S6000 P1 ; S6000 P2 ; G4 X180. ; M30 ; 2-4 M-392D

47 POWER-DOWN PROCEDURE STANDARD OPERATOR INTERFACE 1. Be sure Cycle Start is not active. The Cycle Start push button light will be OFF. 2. Be sure the program has been completed and that the spindle and slides are stationary. 3. Press the Emergency Stop push button. 4. Turn the Control ON/OFF switch to OFF. 5. Turn the main air valve on pressure regulator B, Figure 2.2, OFF 6. Turn main disconnect A, Figure 2.1, OFF. PC-BASED OPERATOR INTERFACE [Option] 1. Be sure Cycle Start is not active. The Cycle Start push button light will be OFF. 2. Be sure the program has been completed and that the spindle and slides are stationary. 3. Press and hold the Custom key; then, press the Help key to display the Windows Start menu. 4. Release the Custom key. 5. On the touch screen, press Shut Down to display the shut-down menu. 6. Select Shut Down the Computer. 7. Press Yes and wait for the Windows shut-down to be completed. The following message will be displayed: It is now safe to turn off your computer 8. Press the Emergency Stop push button. 9. Turn the Control ON/OFF switch to OFF. 10. Turn the main air valve on pressure regulator B, Figure 2.2, OFF 11. Turn main disconnect A, Figure 2.1, OFF. M-392D 2-5

48 REVIEWING CONTROL STATUS The following descriptions refer to the control status displays. Refer to Chapter 1 for additional information on the manual Data input keyboard: POSITION KEY There are three (3) pages of position display Data. After the Position key is pressed, the position display page that was last active will appear on the control display screen. To access the other position display pages, press the appropriate soft key. The three position display pages are as follows: 1. ALL (Overall Position Display): This page shows the active program number and block number are displayed in the upper right-hand corner of the control display screen if the control is in Automatic mode. A) Relative: The axis position on the Relative Coordinate System. Position is displayed as U and W coordinates. B) Absolute: Axis position on the Work Coordinate System. After power-up, the origin of the Work Coordinate System is the intersection of the spindle face and the spindle centerline. Position is displayed as X and Z coordinates. This display can be modified by any one of the following: Active set of tool offsets Position Reset operation Work Shift offset C) Machine: Displays the turret reference position in relation to the origin of the Work Coordinate System, which is the intersection of the spindle face and the spindle centerline. D) Distance to Go: This is the distance remaining between current axis position and the programmed axis position. This register is displayed only while the control is in Automatic or Manual Data Input mode. 2. Absolute Position Display. Refer to part b under ALL (Overall Position Display). 3. Relative Position Display. Refer to part a under ALL (Overall Position Display). PROGRAM KEY Press the Program soft key to display the active program number, and active block sequence number and eleven blocks of the active program on the control display screen. To display other pages of the program, select Edit mode and use the page keys to read through the program. During execution of the active part program, the cursor will be positioned under the sequence number of the active block. If necessary, press the Reset key to return to the start of the program. 2-6 M-392D

49 OFFSET SETTING KEY When the Offset Setting key is pressed, the Offset and Setting soft keys are displayed. From the first Offset Setting screen, press the soft key expansion key once to display the Macro soft key. From the first Offset Setting screen, press the soft key expansion key twice to display the Work Shift soft key. OFFSET SOFT KEY Press the Offset soft key to access the geometry and wear soft keys. One of the two chapters will be displayed on the control display screen. The displayed page will be the page which was active when the Offset display was last viewed. To display the other chapter, press the corresponding soft key. Use the Page keys to view other pages within a chapter. The tool geometry and wear offset chapters display the following information: X and Z Tool Offsets (32 pair) Tool nose radius values Tool nose orientation numbers SETTING SOFT KEY Press the Setting soft key to access the system variables pages, which allows the operator or programmer to assign the system variables listed below. To modify these variables, use the page and cursor keys to move the cursor to the variable which is to be modified, enter the desired value, and press the Input key. Parameter Write = _(0:Disable 1: Enable) TV Check = _(0:OFF 1:ON) Punch Code = _(0:EIA 1:ISO) Input Unit = _(0:MM 1:Inch) I/O Channel = _(0-4:Channel No.) Sequence No. = _(0:OFF 1:ON) Tape Format = _(0:No CNV 1:ON) Sequence Stop = _(Program No.) Sequence Stop = _(Sequence No.) Parameter Write This parameter allows the control parameters to be edited. When set to 0", parameter editing is disabled. When set to 1", parameter editing is enabled. Refer to Chapter 3 for information on editing machine parameters. TV Check This parameter allows the activation or deactivation of parity checking. When set to 1", parity is checked from the beginning of each block to the beginning of the next block. When set to 0", vertical parity checking is disabled. M-392D 2-7

50 Punch Code This parameter allows the selection of EIA or ISO Data input format through the RS-232 serial port. When set to 0", the Data input format is set to EIA. When set to 1", the Data input format is set to ISO. Input Unit This parameter allows the selection of metric or inch operating mode. When set to 0", the operating mode is Metric. When set to 1", the operating mode is set to Inch. I/O Channel This parameter allows the selection of the logical I/O to be used by the control. The valid selections for the I/O port assignments are 0, 1, 2, or 4. I/O port assignments 0, 1, and 2 are used to select the RS-232 serial port and specify the port configuration. I/O port assignment 4 is used to select the ATA Flash Card port on the standard operator interface. I/O port assignment 4 is used to select the following group of input/output devices provided with the optional PC-based operator interface. ATA Flash Card Port RS-232 Serial Port 3½ Disk Drive Internal Hard Disk CD-ROM Drive Refer to Chapter 11 for additional information on Data input/output. Sequence No. This parameter allows the selection of automatic sequence number insertion. When active, sequence numbers will be automatically inserted into a program which is entered into memory from the manual Data input keyboard. When set to 0", automatic sequence number insertion is inactive. When set to 1", automatic sequence number insertion is active. Tape Format Not Active Sequence Stop (2 entries) These two entries are used together to provide the machine operator with the capability of stopping automatic part program execution after the program block specified has been completed. The first entry (Program No.) identifies the program to be monitored. The second entry (Sequence No.) identifies the sequence number (N word) of the last block to be executed by the CNC control during normal automatic operation. Once this block is executed, the CNC control will stop program execution. Press the Cycle Start push button to resume program execution. 2-8 M-392D

51 MACROS SOFT KEY Press the Macros soft key to display the macro variable registers. WORK SHIFT SOFT KEY Press the Work Shift soft key to display the work shift offset registers. SYSTEM KEY Press the System key to access the following information: Machine parameters and diagnostics PMC parameters, ladder, and diagnostics Control system configuration One of four chapters will be displayed on the control display screen. The displayed page will be the page which was active when the key was last deactivated. If necessary, press the soft key to display the desired chapter. Use the page keys to view other pages within a chapter. PARAMETER SOFT KEY Press the Parameter soft key to display machine parameters. These parameters establish many of the characteristics, specifications, and functions of the machine tool. The page that was active when the parameter chapter was last exited will be displayed. To view other pages within the chapter, press the Page key to move to the desired page. Refer to Chapter 3 for information on editing machine parameters. DIAGNOSTIC SOFT KEY Press the Diagnostic soft key to display the machine diagnostics chapter. The page that was active when the diagnostics chapter was last exited will be displayed. Use the Page keys to view other pages within the chapter. PMC SOFT KEY Press the PMC soft key to display the PMC information screen. The purpose of this screen is to view the PMC ladder, parameters, and diagnostics. SYSTEM SOFT KEY Press the System soft key to display the control system information screen. M-392D 2-9

52 MESSAGE KEY If ALM is displayed at the bottom right-hand corner of the control display screen during machine operation, press the Message key. After the Message key is pressed, one of the three chapters will be displayed. To display one of the other chapters, press the appropriate soft key. ALARM SOFT KEY Alarm Message chapter. This chapter displays alarms that create a feed hold condition. One alarm will be displayed on the control display screen at a time. The display is formatted to indicate which tool station has generated the alarm. Descriptions of each alarm are given in the alarm list in Appendix 2. MESSAGE SOFT KEY Operator Message chapter. Operator messages do not initiate a feed hold condition. They call the operator s attention to a specific machine condition. HISTORY SOFT KEY The control is capable of storing the last 25 alarms generated by the machine control. There are a maximum of five pages, with up to five alarms per page. Use the Page keys to display next or previous page. - NOTE - Alarm and Operator messages caused by an error generated in Background Edit mode will have no affect on a part program that is executing in the foreground M-392D

53 - NOTES - M-392D 2-11

54 - NOTES M-392D

55 CHAPTER 3 - OPERATIONAL MODES AND EDITING AUTOMATIC MODE - CAUTION - Before executing any part program in Automatic mode, it is recommended that the program be cycled through one time in Single mode. Refer to the instructions for Running a Part Program for the First Time, page Automatic mode allows selection and execution of the active part program. When Automatic mode is active and the Program key is pressed, the following soft keys are displayed on the control display screen: Program Check Current Next Operator Automatic mode is activated by the mode selector switch. SINGLE MODE Single mode allows the operator to execute one block of Data each time the Cycle Start push button is pressed. Canned cycles are executed one pass at a time. Single mode is activated by the mode selector switch. Refer to the programmer s manual (M-391) for descriptions of the Canned Cycles. EDIT MODE Edit mode allows creation of new part programs or modification of existing part programs held in memory. There are two ways to search through the program: Word Scan and Word Search. WORD SCAN The Word Scan function permits the operator to search through the program one word or one line at a time. - NOTE - The cursor is displayed below the address character of the selected word. 1. Use the cursor and keys to move the cursor word by word on the screen. 2. Use the cursor and keys to move the cursor line by line on the screen. 3. Continue pressing the cursor keys to make a continuous search. 4. Press the Page or Page key to display the preceding or following pages and search for the first word of that page. M-392D 3-1

56 WORD SEARCH Word Search permits a specified word to be searched for from the current cursor position using the following procedure: 1. Key in the Data word to be searched for. 2. Press the cursor key to search forward or cursor to search backward. If the Data word entered in step 1 is located, the cursor will be displayed below the first character in the Data word. EDITING A PROGRAM - NOTE - When Edit mode is active and the Program Protect key is turned OFF, Edit Slow mode is automatically activated. Refer to page 3-4 for information on Edit Slow mode. 1. Set the mode selector switch to Edit mode. - NOTE - The Program Protect key MUST be turned to OFF to allow creating, editing, or deleting of part programs. 2. Turn the Program Protect key to OFF. 3. Press the Reset key. 4. Activate the program as follows: a) Press the Program key. b) Key in the letter O followed by the number for the desired program. Example: O1111 c) Press the cursor key. 5. Search for the word to be modified using the Word Scan or Word Search function. 6. Alter, insert, or delete the word/block/program as described in the sections that follow. - CAUTION - If the Reset key is not pressed before selecting Automatic mode and the part program is executed, the program will begin executing at the point in the program where the cursor was located when Edit mode was exited. 7. Press the Reset key to rewind the part program back to the beginning. 8. Turn the Program Protect key to ON. 3-2 M-392D

57 Altering a Word - NOTE - The cursor MUST be positioned under the word to be altered. 1. Use the Word Scan or Word Search function to locate the Data word to be changed. 2. Key in the letter address and the new value. 3. Press the Alter key. Inserting a Word - NOTE - The cursor MUST be positioned under the word immediately preceding the location of the new Data word. 1. Use the Word Scan or Word Search function to find the Data word or End of Block immediately preceding the point in the program where the new Data word will be inserted. 2. Key in the Data word to be inserted. 3. Press the Insert key. Deleting a Word - CAUTION - The cursor MUST be positioned under the word which is to be deleted. 1. Use the Word Scan or Word Search function to find the Data word which is to be deleted. 2. Press the Delete key. Deleting Up to an End of Block 1. Position the cursor at the point where the deletion is to begin. 2. Press the EOB (End of Block) key; then, press the Delete key. - NOTE - The Data between the cursor and the next End of Block character will be deleted. The cursor will move to the address character of the next Data word in the program. M-392D 3-3

58 Deleting Data Blocks - NOTE - In the procedure which follows, all Data from the cursor to, and including, the block specified by the sequence number will be deleted. The cursor will move to the next sequence number in the program. 1. Position the cursor at the point where the deletion is to begin. 2. Key in the sequence number (N word) where the deletion is to end. 3. Press the Delete key. Deleting a Program 1. Press the Program key. 2. Key in the letter O and the number of the program to be deleted. Example: O Press the Delete key. The selected program will be deleted. EDIT SLOW MODE Edit Slow mode disables the Rapid Override switch and forces G00 positioning moves to be performed at 39 in/min [990 mm/min]. This will occur whenever Edit mode is selected and the Program Protect key is in the OFF position. This mode will remain active until the G00 push button is pressed or an M30 (End of Program) is read by the machine control JOG MODE - NOTE - Refer to Spindle Control, beginning on page 1-11, for information on non-programmed spindle motion. The Y1 axis controls the optional Y axis on the turret. The E axis controls the tailstock or optional sub-spindle. Jog mode permits non-programmed movement of the axes. Jog mode is activated by setting the mode selector switch to Jog. While in Jog mode, use the axis direction push buttons or the manual pulse generator to obtain the desired X, Y, Z, or E axis movement. CONTINUOUS JOG The Feedrate Override switch has a direct affect on the X, Y, Z, and E axis jog speeds. The jog feedrate for the X, Y, Z, and E axes is approximately 25 in/min [635 mm/min] when the feedrate override switch is set to 100% and approximately 37.5in/min [952 mm/min] when the corresponding switch is set to 150%. The Traverse push button will increase normal jog speeds. When the Traverse push button is pressed along with one of the axis push buttons, the feedrate override switch is ignored and the selected axis moves at approximately 236 in/min [6000mm/min]. Refer also to Incremental Jog. 3-4 M-392D

59 INCREMENTAL JOG The manual pulse generator permits the cross slide or carriage to be moved incrementally whenever Jog mode is active. The axis to be moved is selected by using the selector switch in the Manual Axis Movement section of the operator control panel. The movement increment is selected with the Rapid Override switch. The selected axis will move incrementally when the handwheel is rotated. The direction and distance is determined by the direction and amount of rotation of the handwheel. - NOTE - When moving the X axis with the machine in diameter mode, physical axis motion will be one half the selected increment. EXECUTING AN INCREMENTAL JOG 1. Set the mode selector switch to Jog mode. - NOTE - The X/Y and Z/E axis direction keys are also active and may be used to jog the axes. Refer to Continuous Jog. 2. In the Manual Axis Movement section of the operator control panel, use the selector to select the desired axis. 3. Set the Rapid Override switch to select the desired increment. Refer to Rapid Override, page 1-17, for information on increment selection. 4. To view axis position on the control display screen: a) Press the Position key. b) Press the Page key until the desired position display appears on the control display screen. 5. Turn the handwheel in the desired direction (+ or -). Observe the axis position registers to determine when the axis has been moved the required distance. If the X axis was selected in step 2, turn the handwheel in the plus direction to move the cross slide away from the spindle centerline and turn the handwheel in the minus direction to move the cross slide toward the spindle centerline. If the Y 1 axis was selected in step 2, turn the handwheel in the plus direction to move the turret away from the machine bed and turn the handwheel in the minus direction to move the turret toward the machine bed. If the Z axis was selected in step 2, turn the handwheel in the plus direction to move the carriage away from the face of the main spindle and turn the handwheel in the minus direction to move the carriage toward the face of the main spindle. If the E axis was selected in step 2, turn the handwheel in the plus direction to move the tailstock or sub-spindle away from the face of the main spindle and turn the handwheel in the minus direction to move the tailstock or sub-spindle toward the face of the main spindle. M-392D 3-5

60 MANUAL DATA INPUT MODE Manual Data Input mode allows the operator to input a single block of non-stored Data into the Manual Data Input memory. The Data can then be executed by pressing the Cycle Start push button. Once the Data in the Manual Data Input memory has been executed, it is erased from memory. USING MANUAL DATA INPUT - NOTE - Pressing the Reset key clears the Manual Data Input buffer. 1. Set the mode selector switch to Manual Data Input mode. 2. Press the Program key. 3. Press the Reset key. 4. Enter the Data into the Manual Data Input buffer using the Data input keys. Each Data block must end with a valid End of Block character. - NOTE - If an error is made while keying in the Data and the Insert key has not been pressed, press the Cancel key and key in the correct Data. 5. Press the Insert key to input and display the Data from step 4 into the Manual Data Input memory. - NOTE- To alter Data after it has been entered into the Manual Data Input memory, place the cursor on the word, key in the correct Data, and press the Alter key. If it is necessary to delete a word, place the cursor on the word and press the Delete key. The collet closer must be in the closed position before an Manual Data Input command can be executed. 6. Close the coolant guard door and press the Cycle Start push button to execute the Data. 3-6 M-392D

61 SAFE START SUBPROGRAMS Safe Start subprograms O1, O2, O3, O4, O998, and O999 have been developed by Hardinge Inc. to provide machine safety and to help simplify programming. These programs are loaded permanently into the control memory. The purpose of these programs is to reactivate start-up modes, for example: positioning mode, deactivate Tool Nose Radius Compensation, establish ipm feed, and move the turret to the safe index position. Refer to the programmer s manual (M-391) for more information on the Safe Start programming format. - CAUTION - If the machine is to be run in metric mode, the Z entry (pullback) in subprogram O2 must be converted to a metric value. The operator should be aware that program O999 is used for the main spindle ONLY. To avoid crash situations, program O998 must be used for the sub-spindle. (Continued on next page) M-392D 3-7

62 MAIN SPINDLE OPERATION - CAUTION - The Z axis coordinate defined in subprogram O999 MUST be programmed as a POSITIVE number. When machining on the main spindle, the safe index coordinates are defined by subprogram O999. The X axis safe index coordinate should be set to the X axis reference position and the Z axis safe index coordinate should be set to the length of the longest tool PLUS 1 inch [25.4 mm]. Refer to Figure 3.1 or 3.2. Subprogram O1 is used to exit the workpiece after performing an external machining operation on the workpiece. Subprogram O2 is used to exit the workpiece after performing an internal machining operation on the workpiece. Subprogram O999 is not called directly from the part program. Subprograms O1 and O2 call subprogram O999, which is used to deactivate the tool offset and command the turret to the safe index position. +X +Z +X +Z Z Z Safe Index = Z + 1 [25.4 mm] Figure Z Axis Safe Index Value for Main Spindle Operations (VDI Turret Top Plate) TI4691 Safe Index = Z + 1 [25.4 mm] Figure Z Axis Safe Index Value for Main Spindle Operations (Hardinge Turret Top Plate) TI M-392D

63 SUB-SPINDLE OPERATION - CAUTION - The Z axis coordinate defined in subprogram O998 MUST be programmed as a NEGATIVE number. When machining on the sub-spindle, the safe index coordinates are defined by subprogram O998. The X axis safe index coordinate should be set to the X axis reference position and the Z axis safe index coordinate should be set to the length of the longest tool PLUS 1 inch [25.4 mm]. Refer to Figure 3.3 or 3.4. Subprogram O3 is used to exit the workpiece after performing an external machining operation on the workpiece. Subprogram O4 is used to exit the workpiece after performing an internal machining operation on the workpiece. Subprogram O998 is not called directly from the part program. Subprograms O3 and O4 call subprogram O998, which is used to deactivate the tool offset and command the turret to the safe index position. +X +X +Z +Z Safe Index = Z + 1 [25.4 mm] Figure Z Axis Safe Index Value for Sub-Spindle Operations (VDI Turret Top Plate) Z TI4692 Z Safe Index = Z + 1 [25.4 mm] Figure Z Axis Safe Index Value for Sub-Spindle Operations (Hardinge Turret Top Plate) TI4744 M-392D 3-9

64 PROGRAMS ENTERING A PROGRAM FROM THE KEYBOARD - NOTE- Refer to Chapter 1 of the programmer s manual (M-391) for a description of the Data words used with this machine. Refer to Chapter 11 of this manual for information on loading part programs from tape, disk, or ATA flash card. 1. Set the mode selector switch to Edit mode. 2. Turn the Program Protect key to OFF. 3. Press the Program key. 4. Key in the letter and the program number at the Manual Data Input panel. Example: O Press the Insert key. 6. Press the EOB (End of Block) key. 7. Press the Insert key. 8. Enter each Data block as follows: A) Key in the letter addresses and values. B) Press the EOB (End of Block) key. C) Press the Insert key. 9. Turn the Program Protect key to ON. ACTIVATING A STORED PROGRAM 1. Set the mode selector switch to Automatic mode. 2. Press the Program key. 3. Key in the letter O followed by the number for the desired program. Example: O Press the cursor key M-392D

65 RUNNING A PART PROGRAM FOR THE FIRST TIME - CAUTION - Before executing any part program, be sure that all offsets are correct and that no interference exists in the working area of the machine tool. Operator should check and if necessary alter the coordinate values programmed in Safe Index Subprogram O998 or O999 to be certain that they are sufficient. Refer to Editing a Program, page 3-2, for instructions to edit an active program. When Cut-off and Feed Stock are the first operations on bar work, the operator must make certain that the stock face is placed flush with the collet face before starting the cycle. This will ensure that the turret tooling will not come in contact with workpiece and cause damage to either the turret tooling or the workpiece. When testing an operation that uses a self-releasing tap or die holder, activate Automatic mode immediately before the block containing the spindle reversal. After the Option Stop (M01) is read at the end of the tap or die operation, activate Single mode to test the remainder of the program. 1. Press the Reset key. 2. Press the Program key. 3. Activate the desired program. 4. Set the mode selector switch to Single mode. 5. Close the guard door. 6. Press the Check soft key. - NOTE - Program Check displays the Absolute Position and Distance to Go to complete the move. 7. Press the Option Stop push button. - NOTE - Single mode is used for first part set up (Block-by-Block execution). Automatic mode is used to run part programs in automatic mode. 8. Turn the Rapid Override switch to LOW. 9. Turn the Feedrate Override switch to 10%. - NOTE - Setting the Rapid Override switch to LOW causes non-cutting linear moves (G00) to be made at 39 in/min [990 mm/min]. Turning Feedrate Override switch to 0" stops X, Y, Z, and E axis motion. When the switch is turned to another setting axis motion will resume. 10. Press the Cycle Start push button to execute each block of Data. M-392D 3-11

66 STOPPING A PROGRAM RUNNING IN AUTOMATIC MODE - CAUTION - Pressing either the Reset key or the Emergency Stop push button while a program is running in Automatic mode will leave the tool against the workpiece if performed at the wrong time. DO NOT stop the program with a tool against the workpiece unless absolutely necessary. Damage to the workpiece and/or tooling may result. There are several ways to stop a program running in Automatic mode: 1. Program a stop command in the part program where it is to be stopped. 2. Press the Feed Hold push button. - NOTE - Automatic operation can be restarted by pressing the Cycle Start push button when the Feed Hold push button has been used. 3. Press the Reset key. 4. Press the Emergency Stop push button RESTARTING A STOPPED PROGRAM 5. If the program was stopped by pressing the Emergency Stop push button, perform steps 1 through If the program was stopped by pressing the Reset key, perform steps 4 through Pull the Emergency Stop push button out to the first detent, wait two seconds; then, pull the push button out to the end of travel and release. 2. Press the Reset key. 3. Key in the letter O ; then, press the cursor key. The control will go to the beginning of the program. 4. If it is necessary to restart the program at a point other than the beginning: - CAUTION - Be sure the block selected in the next step is a safe starting point for the desired operation. A) Key in the letter N and the block number for the restart point. For example, N5". B) Press the cursor key. The control will search the program for the block specified in the previous step. 5. Press the Cycle Start push button. Program execution will resume at the block specified in step M-392D Revised: January 18, 2008

67 DRY RUN AND MACHINE LOCK MODES - CAUTION - If Machine Lock is not activated with Dry Run, slide motion will occur at a jog feedrate that is controlled using the Feedrate Override switch. The operator must make certain that no interference exists between the tooling, workpiece, or spindle before running the machine in Dry Run. - NOTE - Feedrate override has a direct affect on the Dry Run feedrate. When Dry Run mode is active, axis motion will occur at a feedrate of 100 in/min [2540 mm/min] when the feedrate override is set to 100%. When the feedrate override is set to zero, axis motion and program execution are inhibited. Cycle Start must be inactivate before Dry Run and Machine Lock modes can be activated. Activating Dry Run and Machine Lock modes together allows the operator to execute part programs without axis or spindle motion. ACTIVATING DRY RUN AND MACHINE LOCK 1. Set the mode selector switch to Automatic mode. 2. Activate the program. 3. Press the Machine Lock push button and Dry Run push button. 4. Close the coolant guard door. 5. If it is desired to run the program block-by-block, set the mode selector switch to Single mode. - NOTE - If Single mode is active, the Cycle Start push button must be pressed for each program block. 6. Press the Cycle Start push button. EXITING DRY RUN AND MACHINE LOCK 1. Press the Machine Lock push button and Dry Run push button to deactivate Dry Run and Machine Lock modes. 2. Turn the control OFF, wait a few seconds; then, turn the control ON. M-392D 3-13

68 BACKGROUND EDIT The Background Edit function enables the operator or programmer to edit or create a part program while a second program is being executed by the machine tool. An alarm or warning in Background Edit mode does not affect the program being executed in the foreground or vice-versa. ACTIVATING BACKGROUND EDIT MODE 1. Turn the Program Protect key to the OFF position. 2. Press the Program key. 3. Press the Operator soft key. 4. Press the Background Edit soft key. - NOTE - The editing functions which may be performed in Background Edit mode are the same as the foreground editing functions. Descriptions of the foreground editing functions begin on page 3-3. EDITING AN EXISTING PROGRAM 1. Activate Background Edit mode. 2. Key in the letter O and the desired program number. 3. Press the cursor key. CREATING A NEW PROGRAM FROM THE KEYBOARD 1. Activate Background Edit mode. 2. Key in the letter O and the desired program number. 3. Press the Insert key. 4. Press the EOB (End of Block) key. 5. Press the Insert key. 6. Refer to Entering a Part Program from the Keyboard, page ENDING BACKGROUND EDITING - CAUTION - If the Reset key is pressed while Background Edit is active, the part program that is being executed will stop and the offset will be canceled. The operator must escape Background Edit (Press the Background End soft key) to return to the main program. With the main program displayed, the operator must jog the turret to a safe area and restart the program at the beginning of the tool operation. 1. Press the Background End soft key. 2. Turn the Program Protect key to the ON position M-392D

69 EXTENDED PART PROGRAM EDITING [Option] INTRODUCTION Extended Part Program Editing provides the following capabilities: Copy or move all or part of a program to another program Merge a program at any location within another program Search for or replace a Data word in a program COPY AN ENTIRE PROGRAM This procedure creates a new program by duplicating an existing program. 1. Select Edit mode. 2. Turn the Program Protect key to the OFF position. 3. Press the Reset key. 4. If necessary, activate the source program as follows: a) Press the Program key. b) Key in the letter O followed by the number for the desired program. Example: O1111 c) Press the Cursor key. 5. Press the Operator soft key. 6. Press the right-hand soft key. 7. Press the Extended Edit soft key. 8. Press the Copy soft key. 9. Press the All soft key. 10. Key in only the number for the new program. DO NOT key in the letter O. 11. Press the Input key. 12. Press the Execute soft key. 13. If editing is complete, turn the Program Protect key to the ON position. M-392D 3-15

70 COPY PART OF A PROGRAM This procedure creates a new program by duplicating part of an existing program. 1. Select Edit mode. 2. Turn the Program Protect key to the OFF position. 3. Press the Reset key. 4. If necessary, activate the source program as follows: a) Press the Program key. b) Key in the letter O followed by the number for the desired program. Example: O1111 c) Press the Cursor key. 5. Press the Operator soft key. 6. Press the right-hand soft key. 7. Press the Extended Edit soft key. 8. Press the Copy soft key. 9. Select the beginning of the range to be copied by moving the cursor to the beginning of the range and pressing the CRSL~ soft key. 10. Select the end of the range to be copied by: Moving the cursor to the end of the range and pressing the ~CRSL soft key. -or- Pressing the ~BTTM soft key to indicate the end of the program as the end of the range to be copied. 11. Key in only the number for the new program. DO NOT key in the letter O. 12. Press the Input key. 13. Press the Execute soft key. 14. If editing is complete, turn the Program Protect key to the ON position M-392D

71 MOVE PART OF A PROGRAM This procedure creates a new program by extracting part of an existing program. The selected range will be removed from the original program. 1. Select Edit mode. 2. Turn the Program Protect key to the OFF position. 3. Press the Reset key. 4. If necessary, activate the source program as follows: a) Press the Program key. b) Key in the letter O followed by the number for the desired program. Example: O1111 c) Press the Cursor key. 5. Press the Operator soft key. 6. Press the right-hand soft key. 7. Press the Extended Edit soft key. 8. Press the Move soft key. 9. Select the beginning of the range to be moved by moving the cursor to the beginning of the range and pressing the CRSL~ soft key. 10. Select the end of the range to be moved by: Moving the cursor to the end of the range and pressing the ~CRSL soft key. -or- Pressing the ~BTTM soft key to indicate the end of the program as the end of the range to be moved. 11. Key in only the number for the new program. DO NOT key in the letter O. 12. Press the Input key. 13. Press the Execute soft key. 14. If editing is complete, turn the Program Protect key to the ON position. M-392D 3-17

72 MERGE A PROGRAM This procedure inserts a copy of the specified existing program within the currently active program. 1. Select Edit mode. 2. Turn the Program Protect key to the OFF position. 3. Press the Reset key. 4. If necessary, activate the source program as follows: a) Press the Program key. b) Key in the letter O followed by the number for the desired program. Example: O1111 c) Press the Cursor key. 5. Press the Operator soft key. 6. Press the right-hand soft key. 7. Press the Extended Edit soft key. 8. Press the Merge soft key. 9. Select the location where the specified program will be inserted by: Moving the cursor to the position where the program is to be inserted and pressing the ~CRSL soft key. -or- Pressing the ~BTTM soft key to indicate the end of the program as the position where the program is to be inserted. 10. Key in only the number for the program to be inserted. DO NOT key in the letter O. 11. Press the Input key. 12. Press the Execute soft key. 13. If editing is complete, turn the Program Protect key to the ON position M-392D

73 SEARCH AND REPLACE This procedure locates or replaces the specified Data. 1. Select Edit mode. 2. Turn the Program Protect key to the OFF position. 3. Press the Reset key. 4. If necessary, activate the program as follows: a) Press the Program key. b) Key in the letter O followed by the number for the desired program. Example: O1111 c) Press the Cursor key. 5. Press the Operator soft key. 6. Press the right-hand soft key. 7. Press the Extended Edit soft key. - NOTE - Be sure the cursor is located at the appropriate position in the program. The search or replace function will begin at the cursor position. 8. Move the cursor to the desired position in the program. 9. Press the Change soft key. - NOTE - A maximum of 15 characters can be input when specifying the Before or After Data. Data words specified as Before or After Data must be valid Data words. 10. Key in the Data word to be replaced. 11. Press the Before soft key. 12. Key in the new Data word. 13. Press the After soft key. 14. Press the Execute soft key to replace all occurrences of the specified Data word. -or- Press the Execute Single soft key to individually replace each occurrence the specified Data word. -or- Press the Skip soft key to search for the first occurrence of the specified Data word. 15. When editing is complete, turn the Program Protect key to the ON position. M-392D 3-19

74 EDITING MACHINE PARAMETERS - CAUTION - Use extreme caution when editing machine parameters. Making incorrect changes in the parameter table may disable the machine or cause undesirable machine behavior. 1. Press the Offset Setting key. 2. Press the Setting soft key. 3. If necessary, use the page up/down keys to display the Setting page that contains the Parameter Write field. 4. If necessary, use the cursor keys to move the cursor to the Parameter Write field. 5. Set the mode selector switch to Manual Data Input mode. 6. Turn the Program Protect key to the OFF position. 7. Key in the number 1" to enable parameter editing. 8. Press the Input key. - NOTE - The control is placed in P/S alarm No Press the System key. 10. Press the Parameter soft key. 11. Use the page and/or cursor keys to position the cursor on the parameter to be modified. 12. Key in the new parameter value. 13. Press the Input key. 14. Repeat steps 11 through 13 as needed. 15. Press the Offset Setting key. 16. Press the Setting soft key. 17. If necessary, use the page up/down keys to display the Setting page that contains the Parameter Write field. 18. If necessary, use the cursor keys to move the cursor to the Parameter Write field. 19. Key in the number 0" (zero) key to disable parameter editing. 20. Press the Input key. 21. Turn the Program Protect key to the ON position M-392D

75 22. Press the Reset key to cancel P/S alarm No NOTE - Depending on which parameters have been modified, the control may output P/S alarm No If this alarm message is displayed, it will be necessary to re-initialize the control using the following procedure: A) Press the Emergency Stop push button. B) Press the Control OFF push button. C) Wait approximately ten seconds. D) Press the Control ON push button. E) Pull the Emergency Stop push button out to the first detent, wait two seconds; then, pull the push button out to the end of travel and release. DISPLAYING THE PROGRAM DIRECTORY Use the following procedure to display program memory: 1. Set the mode selector switch to Edit mode. 2. Press the Program key. 3. Press the Library soft key. The program library (directory) will be displayed. M-392D 3-21 Revised: January 17, 2008

76 - NOTES M-392D

77 CHAPTER 4 - VDI TURRET TOP PLATE TOOLING INTRODUCTION QUEST series lathes are available with VDI ESA, or Hardinge turret top plates. Refer to Chapter 5 for information on tooling for ESA turret top plates. Refer to Chapter 6 for information on tooling for Hardinge turret top plates. TOP PLATE CONFIGURATIONS - CAUTION - Refer to page 4-2 for information concerning turret tooling for QUEST 6/42 & 6/42SP lathes equipped with the following combination of options: 12 or 16 station VDI 30 top plate Tool probe Sub-spindle part present detector QUEST series lathes are available with the following VDI top plate configurations: QUEST 6/42 & 6/42SP lathes 12 station VDI 30 top plate 10 station VDI 30 top plate 16 station VDI 30 top plate QUEST 8/51, 8/51SP, 10/65 & 10/65SP lathes 12 station VDI 30 top plate 10 station VDI 30 top plate 10 station VDI 40 top plate A live tooling option is available for the VDI top plate. Refer to Chapter 14 for information on live tooling for the VDI top plate. M-392D 4-1

78 QUEST 6/42 & 6/42SP LATHE TURRET TOOLING CONSIDERATION - CAUTION - A potential interference condition exists on QUEST 6/42 & 6/42SP lathes equipped with the following combination of options: 12 or 16 station VDI 30 top plate Tool probe Sub-spindle part present detector The retract position of the sub-spindle part present detector on machines equipped with this combination of options has been adjusted to avoid interference with the tool probe during part transfer between the main spindle and the optional sub-spindle. Refer to Figure 4.1. When machining on the sub-spindle, the new position of the part present detector could cause interference with the tool in the turret station immediately above the active turret station. It is possible to avoid this potential interference condition by doing either of the following: Install a short tool holder in the turret station immediately above the active turret station if all turret stations are required for tooling Install a tool plug in the turret station immediately above the active turret station if all turret stations are not required Refer to page for additional information relating to the optional part present detector. 4-2 M-392D

79 Turret Top Plate Potential Interference with this Tool Holder Part Present Detector Retracted (Adjusted Position) Part Present Detector Retracted (Standard Position) Tool Probe Mounted on Machine Headwall Active Turret Station Sub-Spindle TI5348 Figure Sub-Spindle Part Present Detector and Tool Probe Viewed from Left End of Machine M-392D 4-3

80 TOOL HOLDER OR TOOL STATION PLUG REMOVAL - WARNING - When removing a tool holder or tool station plug from a top plate, have a firm grip on the tool holder or tool station plug while loosening the clamp screw in the top plate. The turret is pressurized to prevent fluid contaminants from entering the turret assembly. The air pressure in the turret may cause the tool holder or tool station plug to begin moving out of the top plate when the clamp screw is loosened. TOOL STATION PLUGS - CAUTION - Failure to install tool station plugs at turret tool stations not equipped with tooling can result in damage to the machine tool. DO NOT use the plastic tool station plugs when operating a machine equipped with high pressure coolant. All QUEST series lathes are shipped with plastic tool station plugs installed in the turret top plate. Lathes equipped with the high pressure coolant option are also supplied with steel tool station plugs. The steel tool station plugs must be used in place of the plastic plugs on machines equipped with high pressure coolant. Install a tool station plug at each turret tool station not equipped with tooling. Refer to Figure 4.2 for an illustration of a tool station plug. Figure Tool Station Plug TI4263A PLUG INSTALLATION 1. Thoroughly clean the top plate and tool station plug. 2. Clean and check the O-ring on the tool station plug to be sure the O-ring is in good condition. 3. Aligning tool station plug B with coolant button C, insert the plug into the turret top plate as shown in Figure Tighten clamp screw A. A B C TI4681 Figure Installing a Tool Station Plug 4-4 M-392D

81 LEFT-HAND / RIGHT-HAND TOOL SELECTION Hardinge Inc. recommends that all cutting forces be directed into the machine base. Directing the cutting forces into the machine base will result in maximum tool life. Making the selection between left-hand or right-hand tooling should be based on: the position of the tool in relation to the spindle the direction of spindle rotation TOOL HOLDERS Hardinge Inc. offers tool holders in various lengths as measured from the edge of the turret top plate. The standard tool holders can be mounted in any of the top plate tool positions; however, if the machine has the Y axis option and it is programmed to be moved below the spindle centerline, a shorter Y-axis tool holder MUST be mounted in the top plate tool position nearest the way cover to maintain tooling clearance. BASIC CONFIGURATION SQUARE SHANK TOOLS Square shank tool holders obtained from Hardinge Inc. that are designed for QUEST series lathes are available for ¾", 1, 20 mm, or 25 mm tooling. Square shank tools are held in the tool holder by clamping block G, Figure 4.4. Clamp screws D and F apply force to the clamp block to secure the tool in the tool holder. Spring-loaded screw E is used to hold the clamp block in place when tension is removed from the clamping screws. When installing or removing square shank tooling, do not remove spring-loaded screw E. Clamping block G is held in the tool holder by the spring-loaded screw. REVERSIBLE TOOL HOLDERS Square shank tool holders obtained from Hardinge Inc. that are designed for QUEST series lathes are capable of using left-hand or right hand tooling. Refer to Left-Hand / Right-Hand Tool Selection, above. D E F G 1. Carefully remove screw E, the spring, and clamp block G. 2. Remove clamp screws D and F. 3. Thoroughly clean the tool holder body and all components that were removed. 4. Install clamp block G, the spring, and screw E on the upper or lower side of the tool holder, as needed. 5. Install clamp screws D and F. Figure Basic Square Shank Tool Holder TI4158 M-392D 4-5

82 INSTALLING SQUARE SHANK TOOLS - CAUTION - Refer to the Maximum Tool Extension table shown below. Refer also to Figures 4.5 and 4.6. Maximum Tool Extension Turret Top Plate Configuration VDI 30 VDI 40 Y Axis Option Maximum Tool Extension Inches [Millimeters] No [177.4] Yes [142.4] No [192.4] Yes [157.4] - NOTE - Hardinge recommends that tooling be selected that will direct all cutting forces into the machine base. Refer to Left-Hand / Right-Hand Tool Selection, page 4-5. The recommended tool mounting position is to have the tool seated against the edge of the tool holder, as shown in Figures 4.5 and Thoroughly clean the top plate, tool holders, and tooling. 2. Clean and check the O-ring on each tool holder to be sure the O-ring is in good condition. - CAUTION - Be sure the tool holder is mounted flush against the side of the turret top plate, as shown in Figure Aligning tool holder H with coolant button I, insert the tool holder shank into the turret top plate as shown in Figure NOTE - Maximum torque for the clamp screw is 17 lb-ft [23 N m] on VDI 30 top plates and 33 lb-ft [45 N m] on VDI 40 top plates. 4. Tighten clamp screw J. - CAUTION - Be sure the tool sits squarely in the slot of the tool holder. 5. Mount the tool in the tool holder and tighten two clamp screws K, Figure M-392D

83 Inches [Millimeters] Turret Top Plate Maximum Tool Extension Standard Turret: [177.4] Y-Axis Turret: [142.4] Main Spindle Recommended Tool Mounting Position TI4673A Figure Square Shank Tool Installation (Main Spindle Operation) Turret Top Plate Inches [Millimeters] Maximum Tool Extension Standard Turret: [177.4] Y-Axis Turret: [142.4] Recommended Tool Mounting Position Optional Sub-Spindle TI4684A Figure 4.6 Square Shank Tool Installation (Sub-Spindle Operation) M-392D 4-7

84 J H I TI4674 Figure Mounting a Square Shank Tool Holder Be sure the tool holder is flush against the side of the turret top plate. K TI4675 Figure Square Shank Tool Holder with Tool (Viewed from the Main Spindle) 4-8 M-392D

85 ROUND SHANK TOOLS TOOL HOLDER CAPACITIES - NOTE - Refer to the appropriate tooling catalog for information on tool holders and bushings. Round shank tool holders for QUEST series lathes are available from Hardinge Inc. in the following capacities: Turret Top Plate Configuration VDI 30 English Capacities ¾ inch Metric Capacities 20 millimeters 1 inch 25 millimeters 1¼ inch 32 millimeters VDI 40 1½ inch 40 millimeters When using round shank tooling with a diameter equal to the capacity hole of the tool holder, the tool can be mounted directly in the tool holder. When using round shank tooling with a diameter other than the sizes specified above, it will be necessary to use a tool holder bushing. INSTALLING ROUND SHANK TOOLS - CAUTION - When installing round shank tooling for sub-spindle operations, maximum tool extension is inches [ mm] from the centerline of the turret top plate tool mounting location. Refer to Figure Thoroughly clean the turret top plate, tool holders, and tooling. 2. Clean and check the O-ring on each tool holder to be sure the O-ring is in good condition. 3. If it is necessary to index the turret: A) Move the turret to a safe index position. B) Index the turret to the desired tool station. C) Move the turret to a convenient position for installing tools. - CAUTION - Be sure the tool holder is mounted flush against the side of the turret top plate. - NOTE - Hardinge recommends that tooling be selected that will direct all cutting forces into the machine base, resulting in maximum tool life. Refer to Left-Hand / Right-Hand Tool Selection, page Loosen two screws M, Figure M-392D 4-9

86 Turret Top Plate Inches [Millimeters] [177.73] Maximum Tool Extension [212.73] Optional Sub-Spindle Figure Maximum Round Shank Tool Extension for Sub-Spindle Operations TI4685A L O M N TI4677 Figure Mounting a Round Shank Tool Holder (Viewed from the Main Spindle) 4-10 M-392D

87 VIEW #1 VIEW #2 R Q P Q P S T U R S T U Figure Tool Setting Gauge Oriented for Main Spindle Tooling TI Aligning tool holder L with coolant button N, insert the tool holder shank into the turret top plate as shown in Figure Press the tool holder against the turret top plate and tighten two screws M. - NOTE - Maximum torque for the clamp screw is 17 lb-ft [23 N m] on VDI 30 top plates and 33 lb-ft [45 N m] on VDI 40 top plates. 7. Tighten clamp screw O. 8. Place setting bar S, Figure 4.11 or 4.12, in the tool holder and tighten set screws U so that there is a slight drag on the setting bar when it is rotated in the holder. 9. Loosen thumb screw R enough to allow locating bar Q to slide. 10. Place the machined side of tool setter support P flat against the side of the tool holder. 11. Rotate setting bar S until the machined flat is in line with the flat surface of locating bar Q, as shown in view # Tighten thumb screw R when the following conditions are met: a) The machined side of tool setter support P is flat against the side of the tool holder. b) The flat on setting bar S is perpendicular to locating bar Q. Refer to view # Loosen set screws U and remove gauge S. 14. If required, install the appropriate tool bushing in the round shank tool holder. M-392D 4-11

88 VIEW #1 VIEW #2 P Q R P Q S U T U T S R TI4686 Figure Tool Setting Gauge Oriented for Sub-Spindle Tooling 15. Install and adjust the tool for length. 16. Properly align the tool shank and tool bushing, if used, with the set screws in the tool holder. 17. Tighten set screws U just enough to apply a slight drag on the tool shank. 18. Place the machined side of tool setter support P against the side of tool holder. 19. Rotate the tool until the tool tip touches locating bar Q. 20. Tighten set screws U to secure the setting. 21. Repeat steps 1 through 20 for additional tools, as necessary. REMOVING ROUND SHANK TOOLS - WARNING - When removing a tool holder from a top plate, have a firm grip on the tool holder while loosening clamp screw O, Figure Loosen two screws M, Figure Loosen clamp screw O. 3. Remove the tool holder from the turret top plate. 4. Install a tool station plug if another tool holder is not to be installed. Refer to page 4-4 for information on tool station plugs. 5. Repeat steps 1 through 3 for additional tool holders, as necessary M-392D

89 - NOTES - M-392D 4-13

90 - NOTES M-392D

91 CHAPTER 5 - ESA TURRET TOP PLATE TOOLING INTRODUCTION QUEST series lathes are available with ESA, VDI, or Hardinge turret top plates. Refer to Chapter 4 for information on tooling for VDI turret top plates. Refer to Chapter 6 for information on tooling for Hardinge turret top plates. TOP PLATE CONFIGURATION The ESA turret top plate is a 12 station top plate. A live tooling option is available for the ESA top plate. Refer to Chapter 15 for information on live tooling for the ESA top plate. TOOL HOLDER OR TOOL STATION PLUG REMOVAL - WARNING - When removing a tool holder or tool station plug from a top plate, have a firm grip on the tool holder or tool station plug when releasing the tool holder from the top plate. The turret is pressurized to prevent fluid contaminants from entering the turret assembly. The air pressure in the turret may cause the tool holder or tool station plug to begin moving out of the top plate when the tool holder is released from the top plate. M-392D 5-1

92 TOOL STATION PLUGS INTRODUCTION - CAUTION - Failure to install tool station plugs at turret tool stations not equipped with tooling can result in damage to the machine tool. Install a tool station plug at each turret tool station not equipped with tooling. Refer to Figure 5.1 for an illustration of a ESA tool station plug. TOOL STATION PLUG INSTALLATION 1. Thoroughly clean the top plate and blanking plug. 2. Check the O-ring on the blanking plug to be sure the O-ring is in good condition. 3. Press and hold button "A", Figure Insert blanking plug "B" into the turret top plate as shown in Figure Release button "A" to clamp the blanking plug. 6. Tighten rear clamp screw "D", Figure Install and tighten four face screws C, Figure 5.2. TI5413 Figure Blanking Plug 5-2 M-392D

93 A B C C TI5435 Figure Blanking Plug Installed on Top Plate D Figure Rear Clamping Screw TP7130 M-392D 5-3

94 LEFT-HAND / RIGHT-HAND TOOL SELECTION Hardinge Inc. recommends that all cutting forces be directed into the machine base. Directing the cutting forces into the machine base will result in maximum tool life. Making the selection between left-hand or right-hand tooling should be based on: the position of the tool in relation to the spindle the direction of spindle rotation BASIC CONFIGURATION SQUARE SHANK TOOLS Square shank ESA tool holders obtained from Hardinge Inc. that are designed for QUEST series lathes are available for ¾", 1, 20 mm, or 25 mm tooling. Square shank tools are held in the tool holder by clamping block H, Figure 5.4. Clamp screws E and G apply force to the clamp block to secure the tool in the tool holder. Spring-loaded screw F is used to hold the clamp block in place when tension is removed from the clamping screws. When installing or removing square shank tooling, do not remove spring-loaded screw F. Clamping block H is held in the tool holder by the spring-loaded screw. REVERSIBLE TOOL HOLDERS Square shank ESA tool holders obtained from Hardinge Inc. that are designed for QUEST series lathes are capable of using left-hand or right hand tooling. Refer to Left-Hand / Right-Hand Tool Selection, above. 1. Carefully remove screw F, the spring, and clamp block H. 2. Remove clamp screws E and G. 3. Thoroughly clean the tool holder body and all components that were removed. 4. Install clamp block H, the spring, and screw F on the upper or lower side of the tool holder, as needed. 5. Install clamp screws E and G. E F G H TI5415 Figure Basic Square Shank Tool Holder 5-4 M-392D

95 MAXIMUM TOOL EXTENSION - CAUTION - When installing square shank tooling, the maximum X axis tool extension must not exceed the values listed in the table shown below. Refer also to Figure 5.5. Y Axis Option Maximum Tool Extension Inches [Millimeters] No [92.43] Yes [57.38] Tool Oriented for Main Spindle Operation Tool Oriented for Sub-Spindle Operation Maximum Tool Extension Maximum Tool Extension Recommended Tool Mounting Position Recommended Tool Mounting Position TI5459 Figure Maximum Square Shank Tool Extension M-392D 5-5

96 I TI5418 Figure Mounting a Square Shank Tool Holder J K TI5419 Figure Square Shank Tool Holder with Tool 5-6 M-392D

97 INSTALLING SQUARE SHANK TOOLS - NOTE - Hardinge recommends that tooling be selected that will direct all cutting forces into the machine base. Refer to Left-Hand / Right-Hand Tool Selection, page 5-4. The recommended tool mounting position is to have the tool seated against the edge of the tool holder, as shown in Figure Thoroughly clean the top plate, tool holders, and tooling. 2. Clean and check the O-ring on each tool holder to be sure the O-ring is in good condition. 3. If it is necessary to index the turret: A) Move the turret to a safe index position. B) Index the turret to the desired tool station. C) Move the turret to a convenient position for installing tools. 4. Press and hold button "I", Figure Insert the tool holder into the turret top plate as shown in Figure Release button "I" to clamp the tool holder. 7. Tighten rear clamp screw "D", Figure Install and tighten four face screws J, Figure CAUTION - Be sure the tool sits squarely in the slot of the tool holder. Refer to the maximum tool extension table on page 5-5. Refer also to Figure Mount the tool in the tool holder and tighten two clamp screws K, Figure Repeat as needed for additional tooling. M-392D 5-7

98 ROUND SHANK TOOLS TOOL HOLDER CAPACITIES - NOTE - Refer to the appropriate tooling catalog for information on tool holders and bushings. Round shank ESA tool holders obtained from Hardinge Inc. that are designed for QUEST series lathes are available with the following maximum tool shank capacities: English Tool Holder: 1¼ inches Metric Tool Holder: 32 or 40 millimeters When using round shank tooling with a diameter equal to the capacity hole of the tool holder, the tool can be mounted directly in the tool holder. When using round shank tooling with a diameter other than the sizes specified above, it will be necessary to use a tool holder bushing. 5-8 M-392D

99 MAXIMUM Z AXIS TOOL EXTENSION FOR SUB-SPINDLE OPERATION - CAUTION - DO NOT exceed the maximum Z axis tool extension defined in this section. When installing round shank tooling for sub-spindle operations, the maximum Z axis tool extension is inches [ mm] from the centerline of the turret top plate tool mounting location. Refer to Figure 4.9. Inches [Millimeters] [139.22] [212.73] Figure Maximum Round Shank Tool Extension for Sub-Spindle Operations TI5420A M-392D 5-9

100 INSTALLING ROUND SHANK TOOLS - CAUTION - When installing round shank tooling for sub-spindle operations, maximum tool extension is inches [ mm] from the centerline of the turret top plate tool mounting location. Refer to Figure Thoroughly clean the top plate, tool holders, and tooling. 2. Clean and check the O-ring on each tool holder to be sure the O-ring is in good condition. 3. If it is necessary to index the turret: A) Move the turret to a safe index position. B) Index the turret to the desired tool station. C) Move the turret to a convenient position for installing tools. - NOTE - Hardinge recommends that tooling be selected that will direct all cutting forces into the machine base, resulting in maximum tool life. Refer to Left-Hand / Right-Hand Tool Selection, page Press and hold button "L", Figure Insert the tool holder into the turret top plate as shown in Figure Release button "L" to clamp the tool holder. 7. Tighten rear clamp screw "D", Figure Install and tighten four face screws M, Figure Place setting bar Q, Figure 5.11 or 5.12, in the tool holder and tighten set screws S so that there is a slight drag on the setting bar when it is rotated in the holder. 10. Loosen thumb screw P enough to allow locating bar O to slide. 11. Place the machined side of tool setter support N flat against the side of tool holder "R". 12. Rotate setting bar Q until the machined flat is in line with the flat surface of locating bar O, as shown in view # Tighten thumb screw P when the following conditions are met: A) The machined side of tool setter support N is flat against the side of the tool holder. B) The flat on setting bar Q is perpendicular to locating bar O. Refer to view # M-392D

101 L TI5421 Figure Mounting a Round Shank Tool Holder M TI5436 Figure Round Shank Tool Holder Mounted on Top Plate M-392D 5-11

102 VIEW #1 VIEW #2 P O N O N Q R S P Q R S Figure Tool Setting Gauge Oriented for Main Spindle Tooling TI5437 VIEW #1 VIEW #2 N O P N O Q S R S R Q P TI5438 Figure Tool Setting Gauge Oriented for Sub-Spindle Tooling 5-12 M-392D

103 14. Loosen set screws S and remove gauge Q. 15. If required, install the appropriate tool bushing in the round shank tool holder. - CAUTION - When installing tooling for sub-spindle operation, DO NOT exceed the maximum tool extension specified on page Install and adjust the tool for length. 17. Properly align the tool shank and tool bushing, if used, with the set screws in the tool holder. 18. Tighten set screws S just enough to apply a slight drag on the tool shank. 19. Place the machined side of tool setter support N against the side of tool holder "R". 20. Rotate the tool until the tool tip touches locating bar O. 21. Tighten set screws S to secure the setting. 22. Repeat steps 3 through 21 for additional tools, as necessary. M-392D 5-13

104 - NOTES M-392D

105 CHAPTER 6 - HARDINGE TURRET TOP PLATE TOOLING INTRODUCTION QUEST series lathes are available with ESA, VDI, or Hardinge turret top plates. Refer to Chapter 4 for information on tooling for VDI turret top plates. Refer to Chapter 5 for information on tooling for ESA turret top plates. MAIN SPINDLE OPERATION SQUARE SHANK TOOLS Hardinge turret top plates are designed to use qualified square shank tool holders. Since these tools are length, width, and height qualified, both set-up time and downtime due to tool replacement are greatly reduced. Qualified Tool Holders for Main Spindle Operation Qualified tool holder dimensions are held to ±.003 inch [.076 mm]. A left-hand square shank qualified tool holder is illustrated in Figure 6.1. Refer to Table 6.1 for qualified tool holder dimensions. A F E C B H TI2701A Figure Qualified Tool Holder Dimension English (in.) Metric (mm) A B C E F H Table Qualified Tooling Dimensions M-392D 6-1

106 Left-Hand / Right-Hand Tool Selection - CAUTION - Read this section thoroughly before mounting square shank tooling for main spindle operations on the turret top plate. When using square shank tooling, Hardinge recommends the exclusive use of left-hand tools for the following reasons: 1. The use of left-hand tools insures that all cutting forces will be directed into the machine base and will result in maximum tool life. 2. In the event that a right-hand tool and a left-hand tool are mounted in adjacent tool stations, as shown on Figure 4., an interference situation is created. Both tools WILL NOT be able to locate against the tool stop on the turret. Refer to the close-up in Figure 6.3. This could create a potential safety hazard and MUST be avoided. Right-hand tooling can be used IF A CHAMFER IS MACHINED ON THE CORNER OF THE RIGHT-HAND TOOL HOLDER. Figure 6.4 shows the location and minimum size of the chamfer required to allow for safe use of right-hand tooling [38.10] English [Metric] [38.10] TI2499 Figure Tool Interference Illustration [1.60] [1.60] 45 CH x [2.8] Flat English [Metric] Figure Interference Close-Up TI2500 English [Metric] Figure Tool Shank Chamfer TI M-392D

107 Installing Square Shank Tools - CAUTION - The shank of the tool holder should be positioned firmly against the tool stop on the turret top plate, as shown in Figure 6.5. The notable exception is outlined in Between-Center Turning on QUEST 6/42 Lathes, on the next page. - NOTE - When using square shank tooling, Hardinge recommends the exclusive use of left-hand tools. This insures that all cutting forces will be directed into the machine base, resulting in maximum tool life. The wedge clamp can be located on either side of the tool slot centerline to accommodate both right-hand and left-hand tools. Referring to Figure 6.6, note that the larger side of the upper wedge should bear against the tool shank with the arrow pointing toward the tool shank. 1. Mount the wedge clamp on the top plate in the correct orientation for the tool to be installed. 2. Install the tool holder on the top plate and tighten the wedge clamp screws. This will automatically set the tool tip to the correct height as long as qualified tooling is used. Tool Shank Wedge Clamp Tool Shank Tool Shank Against Tool Stop TI4936 TI1908 Figure Tool Shank Positioned Against the Tool Stop Figure Tool Clamp Orientation M-392D 6-3

108 Between-Center Turning on QUEST 6/42 Lathes - CAUTION - Read this section thoroughly before mounting square shank tooling for between-center turning operations. - NOTE - The information in this section applies only to QUEST 6/42 lathes. When using a standard live center for between-center turning near the tailstock, a potential interference condition exists between the coolant ring on a Hardinge turret top plate and the tailstock enclosure. Refer to Figure 6.7. The minimum diameter that can be turned is inches [54 millimeters]. If it is necessary to turn a smaller diameter near the tailstock, two solutions are available: 1. Use an extended nose center, as shown in Figure or- 2. Extend the tool away from the tool stop a distance equal to: Finished Diameter Tool Extension 2 Refer to Figure 6.9. Example: Finished Diameter = 1.75 inches Tool Extension Coolant Ring Tailstock Enclosure TP4982 Figure Turning Near the Tailstock with a Standard Live Center Coolant Ring Tailstock Enclosure TP4983 Figure Turning Near the Tailstock with an Extended Nose Live Center Tool Extension Figure Extending the Tool Away from the Tool Stop TI M-392D

109 SUB-SPINDLE OPERATION [Option] Maximum Tool Extension - CAUTION - Turret tooling for sub-spindle operation MUST NOT extend more than 4¼ inches [108 mm] from the turret top plate on the X axis. An interference condition can exist if sub-spindle turret tooling extends more than 4¼ inches [108 mm] from the turret top plate on the X axis. Be sure all sub-spindle turret tooling does not extend beyond this limit Cut-Off Tool Operating Limits When using a cut-off tool during a cut-off and transfer operation from the main spindle to the sub-spindle, the following operating limits must be observed: the tip of the cut-off tool MUST extend 3.94 inches [100 millimeters] from the edge of the turret top plate. the face of the sub-spindle must be at least 1.80 inches [45.7 millimeters] from the face of the main spindle. Refer to Figure Refer to the chart on the next page to identify the correct square shank cut-off tool holder. Inches [millimeters] Square Shank Cut-Off Tool Holder Required Turret Top Plate 3.94 [100] Main Spindle Optional Sub-Spindle 1.80 [45.7] TI4925 Figure Cut-Off Tool Operating Limits M-392D 6-5

110 Model Numbers for Square Shank Cut-Off Tool Holders Machine Model English Top Plate Metric Top Plate QUEST 6/42 Lathe SG-CE SG-CEM QUEST 8/51 & 10/65 Lathes CL-CE CL-CM Tooling Configuration Sub-spindle operations require ¾ inch square shank tooling on English top plates and 20 millimeter square shank top plates on Metric machines. Tooling Location Square shank tooling for sub-spindle operations can only be mounted at odd numbers tool stations. 6-6 M-392D

111 Tool Mounting Position Square shank tooling for main spindle operations is mounted on the -Z face of the turret top plate and square shank tooling for sub-spindle operations is mounted on the +Z face of the turret top plate. Refer to Figure Toward Main Spindle Away from Main Spindle -Z Turret Top Plate Face +Z Turret Top Plate Face Square Shank Tool Slots for Main Spindle Operations Square Shank Tool Slots for Sub-Spindle Operations (Odd Numbered Tool Stations Only) Figure Hardinge Turret Top Plate (Sub-Spindle Machines Only) TI2737A M-392D 6-7

112 Tool Shank Modification - CAUTION - Failure to modify the length of the tool holder shank may result in poor surface finish. The length of the tool slots used for sub-spindle operations is 1-13/16 inches [46 mm]. Due to the length of the tool slots, it will be necessary to shorten the shank of the tool holder to position the tool tip at a distance of 1-1/4 inches [31.8 mm] from the edge of the turret top plate. The final length of the tool, after modification, will be 3-1/16 inches [77.8 mm] from the tool tip to the end of the tool shank. Refer to Figure [38.1] English [Metric] 1.81 [46.0] TI2774 Figure Tool Length Modification Mounting Tools - NOTE - When using square shank tooling for sub-spindle operations, Hardinge recommends the exclusive use of right-hand tools. This insures that all cutting forces will be directed into the machine base, resulting in maximum tool life. The wedge clamp can be located on either side of the tool slot centerline to accommodate both right-hand and left-hand tools. Referring to Figure 6.6, note that the larger side of the upper wedge should bear against the tool shank with the arrow pointing toward the tool shank. 1. Mount the wedge clamp on the top plate in the correct orientation for the tool to be installed. 2. Install the tool holder on the top plate and tighten the wedge clamp screws. 6-8 M-392D

113 ROUND SHANK TOOLS Round shank tools 1½ inches or 40 millimeters in diameter can be mounted directly into the optional English or Metric round shank tool holders, respectively. Round shank tools in specific sizes ranging from 1/32 inch [1 millimeter] up to ¾ inch [20 millimeters] can be mounted in the round shank tool holders using the Hardinge Double-Angle Tool Holder Collet and Tool Holder System. Round shank tools in specific sizes ranging from ½ inch [12 millimeters] up to 1¼ inch [32 millimeters] can be mounted in the round shank tool holders using Hardinge HDC-12 bushings. ROUND SHANK TOOL HOLDERS QUEST 6/42 LATHE Hardinge drill holders are qualified at inches [31.75 mm] from the hole center to the turret face. Hardinge boring bar holders are qualified at inches [50.80 mm] from the hole center to the turret face. QUEST 8/51 and 10/65 LATHES Hardinge drill holders are qualified at inches [38.10 mm] from the hole center to the turret face. Hardinge boring bar holders are qualified at inches [71.44 mm] from the hole center to the turret face. Refer to the appropriate Hardinge tooling catalog for additional information. TOOL SETTING GAUGES - NOTE - Two separate tool setting gauges are supplied with QUEST series lathes. One gauge is used to set tools for main spindle operation. The other gauge is used to set tools for sub-spindle operation. Tool setting gauges are used to place the tool nose of round shank tools such as boring bars and internal threading tools on center with the spindle centerline. The tool slot centerline of the active station and the spindle centerline are the same distance from the top surface of the machine ways. Therefore, if the tool nose is positioned on the tool slot centerline, it will be on center with the spindle centerline. The tool setting gauge for main spindle operation mounts in the tool slot and provides a physical projection of the tool slot centerline. Once the tool setting gauge is mounted on the turret, the tool is rotated to bring the tool nose against the gauge. The tool setting gauge for sub-spindle operation is held against the side of the tool holder and provides a physical projection of the tool slot centerline. Once the tool setting gauge is properly set up, the tool is rotated to bring the tool nose against the gauge. M-392D 6-9

114 INSTALLING ROUND SHANK TOOLS FOR MAIN SPINDLE OPERATION 1. If not already installed, loosely mount wedge clamp A, Figure 6.13, on the top plate in the correct orientation for the tool to be installed. 2. Mount the round shank tool holder on the turret. 3. If required, install the appropriate tool cartridge in the round shank tool holder. 4. Insert the tool in the holder or tool cartridge and adjust the tool to length. Align the flat on the Hardinge Double-Angle Tool Holder Collet or the slot in Hardinge HDC-12 bushings and the flat on the tool shank with one of the groups of three set screws C, Figure NOTE - Orientation of the gauge for setting left-hand tools is shown in Figure Insert tool setting gauge B, Figures 6.13 and 6.14, in the turret tool slot with one of the chamfered edges toward the bottom of the slot. +X +Y B B A Spindle Centerline Figure Tool Setting Gauge (Front View) TI1908 C Figure Tool Setting Gauge (Side View) TI M-392D

115 6. Carefully position the tool setting gauge so the tool nose can be rotated to touch the inner face of the gauge; then, tighten wedge clamp A, Figure CAUTION - Be careful not to damage the tool nose. 7. Rotate the tool until the tool nose touches the inner face of the tool setting gauge. - CAUTION - When the set screws are fully tightened there is the possibility that the tool may rotate. This will damage the tool nose if it is against the tool setting gauge. - NOTE - To secure the tool, tighten the group of three set screws that align with the tool and tool holder as described in step Snug, but do not fully tighten any group of three set screws C, Figure 6.14, to hold the tool in place. 9. Loosen wedge clamp A, Figure 6.13, swing the tool setting gauge out of the way, and tighten the wedge clamp. 10. Fully tighten three set screws C, Figure 6.14, to secure the tool. 11. Loosen the wedge clamp and carefully position the tool setting gauge to check that the tool nose is still on center. If it has moved, repeat steps 6 through Remove the tool setting gauge from the turret and tighten the wedge clamp. M-392D 6-11

116 INSTALLING ROUND SHANK TOOLS FOR SUB-SPINDLE OPERATION - CAUTION - DO NOT use round shank tool holder adapter plates on machines equipped with the sub-spindle option. Use of the adapter plates may result in interference between the round shank tool holders and the sub-spindle. The operator must make certain that no interference exists between the turret tooling and the main spindle, workpiece, or sub-spindle before manually indexing the turret. Operating Limits - CAUTION - When installing round shank tooling for sub-spindle operations, maximum tool extension is 7.25 inches [184.1 mm] from the surface of the tool holder. When installing a drill or boring bar for sub-spindle operation, the following operating limits must be observed: maximum tool extension is 7.25 inches [184.1 millimeters] from the surface of the tool holder. Refer to Figure tool extension must provide a minimum of 1.25 inches [32 millimeters] clearance between the tool holder and the face of the sub-spindle at the end of the cut. Refer to Figure Turret Top Plate Inches [Millimeters] 7.25 [184.1] Maximum Tool Extension Optional Sub-Spindle TI4740A Figure Maximum Round Shank Tool Extension for Sub-Spindle Operations 6-12 M-392D

117 Inches [millimeters] Turret Top Plate Tool Holder Optional Sub-Spindle 1.25 [32.0] TI4926 Figure Minimum Tool Holder Clearance for Round Shank Tool Holders M-392D 6-13

118 Installation Procedure 1. Index the turret to the desired station. 2. Mount tool holder E on the turret, as shown in view #1 of Figure Refer to the illustration and complete steps 4 through Place setting bar I in the tool holder and tighten set screws D so that there is a slight drag on the setting bar when it is rotated in the holder. 5. Loosen thumb screw H enough to allow locating bar G to slide. 6. Place the machined side of tool setter support F flat against the side of the tool holder. 7. Rotate setting bar I until the machined flat is in line with the flat surface of locating bar G, as shown in view #2. 8. Tighten thumb screw H when the following conditions are met: A) The machined side of tool setter support F is flat against the side of the tool holder. B) The flat on setting bar I is perpendicular to locating bar G. Refer to view #2. 9. Loosen set screws D and remove gauge I. VIEW #1 VIEW #2 +X +Z F H G I H E I D E F G Figure Tool Setting Gauge for Sub-Spindle Tooling (Hardinge Turret Top Plate) TI M-392D

119 - CAUTION - Be sure that there is sufficient clearance between the sub-spindle tooling and the turret. 10. Place the tool in the tool holder at the desired length. 11. Tighten set screws D just enough to apply a slight drag on the tool shank. 12. Place the machined side of tool setter support F against the side of tool holder. 13. Rotate the tool until the tool tip touches locating bar G. 14. Tighten set screws D to secure the setting. 15. Repeat steps 1 through 14 for additional tools as necessary. M-392D 6-15

120 - NOTES M-392D

121 CHAPTER 7 - WORK SHIFT INTRODUCTION The work shift offset shifts the origin of the work coordinate system. Work Shift values (Z) are stored in the Work Shift file. The value stored in this file is active at all times. - CAUTION - The Work Shift file contains an X and a Z shift register. The X axis register in the Work Shift file should be set to zero at all times. The value entered into the Z axis Work Shift file must be a negative number. The values stored in the Work Shift file are added to the Absolute Position registers, thus shifting the origin of the work coordinate system by the amount stored in the Work Shift file. For example, if the Z axis is at 14 inches and the operator stores Z-2.5 in the Work Shift file, the Absolute Position registers would then display Z11.5 [14 +(- 2.5)]. Immediately after a Work Shift value is stored, the control adds it to the Absolute Position registers. The registers will remain modified until the Work Shift offset values are set to zero by the operator or from the part program. Typically, the part length is stored as the Z Work Shift offset and the X Work Shift offset IS NOT USED (set to zero). Since the Work Shift value is added to the Absolute Position registers, the part length is stored as a negative Z value. With the part length stored in the Work Shift file, the origin of the Absolute coordinate system is the intersection of the part face and the spindle centerline. - NOTE - Refer to the programmer s manual (M-391) for information on storing a work shift from the part program. M-392D 7-1

122 MANUALLY ESTABLISHING Z AXIS WORK SHIFT VDI OR ESA TURRET TOP PLATE - NOTE - This procedure is used to set the work shift on QUEST series lathes equipped with a VDI or ESA turret top plate. Refer to page 7-6 for the procedure that applies to QUEST series lathes equipped with a Hardinge turret top plate. 1. Load a workpiece into the collet or step chuck at the desired length. 2. Activate Jog mode. 3. Jog the turret to a safe position for indexing. - CAUTION - The machine operator must make certain that no interference exists between the spindle, spindle tooling, turret, turret tooling, tailstock, sub-spindle, or workpiece before manually indexing the turret. - NOTE - If an square shank tool holder is not available, install a tool holder at any convenient station. 4. Turn the Station switch to the number of a turret station equipped with a square shank tool holder. 5. Press the Turret Index push button to index the turret to the selected turret station. 6. Set the Feedrate Override switch to the desired setting. A setting of 150% will equal a jog feedrate of approximately 37.5 in/min [952 mm/min]. 7. Jog the tool holder to within 1 inch [25 mm] of the face of the workpiece. 8. Use the Manual Axis Movement switch to select the Z axis. - NOTE - Refer to page 1-17 for information on using the Rapid Override switch to select handwheel increments. 9. Use the Rapid Override switch to select the desired handwheel increment. 10. Place a shim or scale against the face of the workpiece; then, turn the handwheel in the appropriate direction to move the turret toward the face of the workpiece until a slight drag is felt when moving the shim between the tool holder and workpiece. Refer to Figure 7.1, 7.2, 7.3, or Press the Offset Setting key to display the offset pages. 12. Press the right hand soft key until the Work Shift soft key is displayed. 13. Press the Work Shift soft key to display the Work Shift registers. 7-2 M-392D

123 Turret Position Work Shift Main Spindle Shim Thickness Tool Holder Offset Value TI4682A Figure Establishing the Main Spindle Work Shift (VDI Turret Top Plate) Main Spindle Turret Position Tool Holder Offset Value Shim Thickness Optional Sub-Spindle Work Shift Figure Establishing the Sub-Spindle Work Shift (VDI Turret Top Plate) TI4683B M-392D 7-3

124 Turret Position Work Shift Main Spindle Shim Thickness Tool Holder Offset Value TI5443 Figure Establishing the Main Spindle Work Shift (ESA Turret Top Plate) Main Spindle Optional Sub-Spindle Turret Position Tool Holder Offset Value Shim Thickness Work Shift TI5444 Figure Establishing the Sub-Spindle Work Shift (ESA Turret Top Plate) 7-4 M-392D

125 14. If not already set to 0" (zero), set the X value under Shift Value to 0" as follows: A) Use the cursor keys to move the cursor to the X Data field under Shift Value. B) At the Manual Data Input keyboard, key in the number 0" (zero). C) Press the Input key. 15. Use the cursor keys to move the cursor to the Z Data field under Measurement. - NOTE - The tool holder offset value is the Z axis distance from the tool station centerline to the tool holder surface used to set the work shift. Refer to the appropriate tooling catalog for the tool holder offset value. 16. If setting work shift at the main spindle, key in: +(Tool Holder Offset Value + shim thickness) If setting work shift at the sub-spindle, key in: -(Tool Holder Offset Value + shim thickness) 17. Press the Input key. The Z axis Work Shift will be recorded in the Z Shift Value register. 18. Turn the handwheel in the appropriate direction to move the tool holder at least 1 inch [25 mm] from the face of the workpiece. 19. Jog the turret to a safe position for indexing. M-392D 7-5

126 HARDINGE TURRET TOP PLATE - NOTE - This procedure is used to set the work shift on QUEST series lathes equipped with a Hardinge turret top plate. Refer to page 7-2 for the procedure that applies to QUEST series lathes equipped with a VDI or ESA turret top plate. 1. Load a workpiece into the collet or step chuck at the desired length. 2. Activate Jog mode. 3. Jog the turret to a safe position for indexing. - CAUTION - The machine operator must make certain that no interference exists between the spindle, spindle tooling, turret, turret tooling, tailstock, sub-spindle, or workpiece before manually indexing the turret. 4. Turn the Station switch to the number of an empty turret station. 5. Press the Turret Index push button to index the turret to the selected turret station. 6. Set the Feedrate Override switch to the desired setting. A setting of 150% will equal a jog feedrate of approximately 37.5 in/min [952 mm/min]. 7. Jog the turret top plate to within 1 inch [25 mm] of the face of the workpiece. 8. Use the Manual Axis Movement switch to select the Z axis. - NOTE - Refer to page 1-17 for information on using the Rapid Override switch to select handwheel increments. 9. Use the Rapid Override switch to select the desired handwheel increment. 10. Place a shim or scale against the face of the workpiece; then, turn the handwheel in the appropriate direction to move the turret toward the face of the workpiece until a slight drag is felt when moving the shim between the turret top plate and workpiece. Refer to Figure 7.5 or Press the Offset Setting key to display the offset pages. 12. Press the right hand soft key until the Work Shift soft key is displayed. 13. Press the Work Shift soft key to display the Work Shift registers. 14. If not already set to 0" (zero), set the X value under Shift Value to 0" as follows: A) Use the cursor keys to move the cursor to the X Data field under Shift Value. B) At the Manual Data Input keyboard, key in the number 0" (zero). C) Press the Input key. 7-6 M-392D

127 Turret Position Work Shift Main Spindle Shim Thickness TI4733 Figure Establishing the Main Spindle Work Shift (Hardinge Turret Top Plate) Work Shift Main Spindle Turret Position Optional Sub-Spindle inches [ mm] Shim Thickness Figure Establishing the Sub-Spindle Work Shift (Hardinge Turret Top Plate) TI4734A M-392D 7-7

128 15. Use the cursor keys to move the cursor to the Z Data field under Measurement. 16. If setting work shift at the main spindle, key in the shim thickness as a positive (+) value. If setting work shift at the sub-spindle, key in: -( [ mm] + shim thickness) 17. Press the Input key. The Z axis Work Shift will be recorded in the Z Shift Value register. 18. Turn the handwheel in the appropriate direction to move the tool holder at least 1 inch [25 mm] from the face of the workpiece. 19. Jog the turret to a safe position for indexing. 7-8 M-392D

129 - NOTES - M-392D 7-9

130 - NOTES M-392D

131 CHAPTER 8 - TOOL OFFSETS INTRODUCTION The Tool Offset file is made up of two types of offsets: Tool Geometry Offsets and Tool Wear Offsets. The control has the capacity to store 32 sets of each offset type (Offsets 01 through 32) in separate files. - NOTE - Information stored in the Geometry and Wear Offset files is automatically converted into the correct units when a programmed G20 or G21 command is used to switch between inch and metric mode. Tool offsets are illustrated in Figures 8.1 through Machines equipped with an ESA turret top plate have the same X axis reference position and travel specifications as a machine equipped with a VDI 30 turret top plate. As indicated in Figures 8.5 through 8.8, the diameter of the ESA turret top plate is inches [35.00 millimeters] smaller per side than the VDI 30 turret top plate. Refer to the programmer s manual (M-391) for: a description of turret reference point and the tool nose reference point. information on activating and canceling tool offsets The following information is stored in the Tool Geometry Offset file: X Tool Dimension Diameter distance from the X axis tool touch-off point to the turret X axis reference point. Sign is determined by the direction from the tool nose reference point to the turret reference point. Z Tool Dimension Distance from the Z axis tool touch-off point to the turret Z axis reference point. Sign is determined by the direction from the tool nose reference point to the turret reference point. Tool Orientation: The orientation code describes the location of the center of the tool nose in relation to the tool nose reference point. Tool Nose Radius Value: The distance from the cutting edge to the center of the tool nose radius. M-392D 8-1

132 Turret Z Axis Reference Position Turret X Axis Reference Position This distance equals ½ the X Axis Tool Offset Z Axis Tool Offset Main Spindle +X Axis Tool Offset +Z Axis Tool Offset TI4679A Figure Square Shank Tool Offsets for Main Spindle Operation (VDI Top Plate) Turret Z Axis Reference Position Turret X Axis Reference Position This distance equals ½ the X Axis Tool Offset Z Axis Tool Offset Optional Sub-Spindle +X Axis Tool Offset -Z Axis Tool Offset TI4687A Figure Square Shank Tool Offsets for Sub-Spindle Operation (VDI Top Plate) 8-2 M-392D

133 Turret Z Axis Reference Position Z Axis Tool Offset This distance equals ½ the X Axis Tool Offset Turret X Axis Reference Position Main Spindle +X Axis Tool Offset +Z Axis Tool Offset TI4680A Figure Round Shank Tool Offsets for Main Spindle Operation (VDI Top Plate) Turret Z Axis Reference Position Z Axis Tool Offset This distance equals ½ the X Axis Tool Offset Turret X Axis Reference Position +X Axis Tool Offset -Z Axis Tool Offset Figure Round Shank Tool Offsets for Sub-Spindle Operation (VDI Top Plate) TI4688A M-392D 8-3

134 Inches [Millimeters] Turret Z Axis Reference Position [35.00] Turret X Axis Reference Position (Refer to the note on page 8-1) This distance equals ½ the X Axis Tool Offset Z Axis Tool Offset Main Spindle +X Axis Tool Offset +Z Axis Tool Offset TI5439A Figure Square Shank Tool Offsets for Main Spindle Operation (ESA Top Plate) Turret Z Axis Reference Position Inches [Millimeters] [35.00] This distance equals ½ the X Axis Tool Offset Turret X Axis Reference Position Refer to the note on page 8-1) Z Axis Tool Offset Optional Sub-Spindle +X Axis Tool Offset -Z Axis Tool Offset TI5440A Figure Square Shank Tool Offsets for Sub-Spindle Operation (ESA Top Plate) 8-4 M-392D

135 Inches [Millimeters] Turret Z Axis Reference Position Z Axis Tool Offset [35.00] Turret X Axis Reference Position (Refer to the note on page 8-1) Main Spindle This distance equals ½ the X Axis Tool Offset +X Axis Tool Offset +Z Axis Tool Offset TI5441A Figure Round Shank Tool Offsets for Main Spindle Operation (ESA Top Plate) Turret Z Axis Reference Position Inches [Millimeters] Z Axis Tool Offset [35.00] Turret X Axis Reference Position (Refer to the note on page 8-1) This distance equals ½ the X Axis Tool Offset Optional Sub-Spindle +X Axis Tool Offset -Z Axis Tool Offset TI5442A Figure Round Shank Tool Offsets for Sub-Spindle Operation (ESA Top Plate) M-392D 8-5

136 Turret Z Axis Reference Position Z Axis Tool Offset Turret X Axis Reference Position Main Spindle This distance equals ½ the X Axis Tool Offset +X Axis Tool Offset +Z Axis Tool Offset TI4736 Figure Square Shank Tool Offsets for Main Spindle Operation (Hardinge Top Plate) Turret Z Axis Reference Position This distance equals ½ the X Axis Tool Offset Turret X Axis Reference Position Z Axis Tool Offset Optional Sub-Spindle +X Axis Tool Offset -Z Axis Tool Offset TI4737 Figure Square Shank Tool Offsets for Sub-Spindle Operation (Hardinge Top Plate) 8-6 M-392D

137 Turret Z Axis Reference Position Z Axis Tool Offset This distance equals ½ the X Axis Tool Offset Turret X Axis Reference Position Main Spindle +X Axis Tool Offset +Z Axis Tool Offset Figure Round Shank Tool Offsets for Main Spindle Operation (Hardinge Top Plate) TI4738 Turret Z Axis Reference Position This distance equals ½ the X Axis Tool Offset Turret X Axis Reference Position Z Axis Tool Offset +X Axis Tool Offset -Z Axis Tool Offset Figure Round Shank Tool Offsets for Sub-Spindle Operation (Hardinge Top Plate) TI4739 M-392D 8-7

138 The Tool Wear Offset file allows the operator to enter minor dimensional changes for each tool to compensate for tool wear. The Tool Wear Offset files coincide with the Geometry Offset files. When a tool offset is activated, the control looks at the corresponding Tool Wear offset and performs the necessary corrections to compensate for tool wear. The Tool Offset files allow the operator to easily make corrections resulting from tool changes, eliminating the need for large-scale modifications to the part programs. The Data word format for the T word is T4. Tool Offsets are activated by the last two digits in the T word. The first two digits specify the turret station 8-8 M-392D

139 STORING TOOL GEOMETRY OFFSETS IN MEMORY - NOTE - Tool offset values can be entered using the following methods: Manually from the keyboard. Through the part program or a separate program. Refer to the programmer s manual (M-391) for information on storing tool offsets from a program. SETTING TOOL OFFSETS FOR NON-CENTER WORKING TOOLS ON THE TURRET 1. Load a workpiece of known diameter and length into the collet or chuck. 2. If it has not already been done, determine the Work Shift Offset following the appropriate procedure in Chapter 7. - NOTE - The work shift value must be in the Z axis work shift register to accurately set the tool offsets. 3. Enter the work shift value into the Z axis work shift register. 4. Activate Jog mode. 5. Set the Feedrate Override switch to the desired setting. - CAUTION - The machine operator must be sure that no interference exists between the spindle, spindle tooling, turret, turret tooling, or workpiece before indexing a turret. 6. Jog the turret to a safe position for indexing. 7. Index the turret to the selected station. 8. Mount the tool holder and tool onto the turret. 9. Jog the tool tip to within 1 inch [25 mm] of the face of the workpiece held in the spindle. 10. Place a shim or scale against the face of the workpiece and use the handwheel to move the turret on the Z axis to gently touch the tool tip to the shim so that a slight drag is felt when moving the shim, as shown in Figure 8.13 or Press the Offset Setting key. 12. Press the Offset soft key to access the Tool Offset pages. M-392D 8-9

140 O.D. Tool Shim Workpiece Workpiece Shim I.D. Tool TI4689A Figure Tool Touch-Off Points at Main Spindle (VDI Turret Top Plate Shown) TI4690A Figure Tool Touch-Off Points at Optional Sub-Spindle (VDI Turret Top Plate Shown) 13. If not already displayed, press the Geometry soft key to display the Tool Geometry Offset pages. 14. Use the page and cursor keys to position the cursor at the Z axis field for the desired offset. 15. If touching off on the main spindle, key in the letter Z and the thickness of the shim as a positive value. If touching off on the optional sub-spindle, key in the letter Z and the thickness of the shim as a negative value M-392D

141 16. Press the Measure soft key. The Z axis offset value for the tool will now be displayed under the appropriate offset number, as selected in step If touching off an O.D. working tool, jog the turret on the Z axis to clear the workpiece. If touching off an I.D. working tool, use the handwheel to position the tool tip approximately.125 inch [3.2 mm] from the face of the workpiece. 18. Use the cursor keys to position the cursor at the X axis field for the desired offset. 19. If touching off an O.D. working tool, jog the turret on the X axis to place the tool tip beyond the O.D. of the part as shown in Figure 8.13 or If touching off an O.D. working tool, use the handwheel to move the turret on the Z axis until the tool tip is past the face of the workpiece. 21. Place the shim against the O.D. of the workpiece and turn the handwheel in the appropriate direction until the tool tip gently makes contact with the shim, as shown in Figure 8.13 or Key in the diameter of the workpiece as a positive value. Example: Diameter = Input = X NOTE - Using the Measure soft key to set a tool geometry offset automatically resets the corresponding wear offset to zero. 23. Press the Measure soft key. The X axis offset value for the tool will now be displayed under the appropriate offset number. 24. Compensate for shim thickness: If touching off an O.D. working tool and the control is set for diameter programming, enter twice the shim thickness as a negative (-) value and press the Input+ soft key. If touching off an O.D. working tool and the control is set for radius programming, enter the shim thickness as a negative (-) value and press the Input+ soft key. If touching off an I.D. working tool, no shim compensation is needed. 25. Jog the turret in the +X direction to clear the diameter of the workpiece by at least 1 inch [25 mm] in the +X direction. 26. Jog the turret in the +Z direction to clear the face of the workpiece by at least 1 inch [25 mm] in the +Z direction. 27. Jog the turret to a safe position for indexing. 28. Index the turret to the next tool station that is to be set. 29. Repeat steps 8 through 28 as required for other tools. M-392D 8-11

142 SETTING TOOL OFFSETS FOR CENTER-WORKING TOOLS ON THE TURRET - CAUTION - This procedure is to be used for center-working tools such as drills, taps, and reamers ONLY. The X axis Wear Offset must always set to zero for center-working tools. 1. Load a workpiece of known diameter and length into the collet or chuck. 2. If it has not already been done, determine the Work Shift Offset following the appropriate procedure in Chapter 7. - NOTE - The work shift value must be in the Z axis work shift register to accurately set the tool offsets. 3. Enter the work shift value into the Z axis work shift register. 4. Activate Jog mode. 5. Set the Feedrate Override switch to the desired setting. - CAUTION - The machine operator must be sure that no interference exists between the spindle, spindle tooling, turret, turret tooling, or workpiece before indexing a turret. 6. Jog the turret to a safe position for indexing. 7. Index the turret to the selected station. 8. Mount the tool in the tool holder at the length desired. 9. Jog the tool tip to within 1 inch [25 mm] of the face of the workpiece held in the spindle. 10. Place a shim against the face of the workpiece and use the handwheel to move the turret in the appropriate direction to gently touch the tool tip to the shim until a slight drag is felt when moving the shim. 11. Press the Offset Setting key. 12. Press the Offset soft key to access the Tool Offset pages. 13. Press the Geometry soft key to access the Geometry Offset pages. 14. Use the page and cursor keys to position the cursor at the X axis field for the desired offset M-392D

143 - NOTE - Refer to the appropriate tooling catalog for information on tool holder dimensions. 15. If the control is set for diameter programming, enter twice the tool holder dimension as a positive (+) value and press the Input key. If the control is set for radius programming, enter the tool holder dimension as a positive (+) value and press the Input key. 16. Use the cursor keys to position the cursor at the Z axis field for the desired offset. 17. Key in the letter Z and the thickness of the shim as a positive value. - NOTE - Using the Measure soft key to set a tool geometry offset automatically resets the corresponding wear offset to zero. 18. Press the Measure soft key. The Z axis offset value for the tool will now be displayed under the appropriate offset number, as selected in step Move the turret in the appropriate Z direction to clear the workpiece. 20. Repeat steps 6 through 19 as required for other center-working tools. M-392D 8-13

144 INTRODUCTION TOOL PROBE [Option] The tool probe allows the operator to set tool geometry offsets quickly and accurately. The tool probe has been calibrated at the factory and is ready to use without further adjustment. Refer to Tool Probe Calibration, on page 8-21, for additional information. The tool probe has three available operating modes: Manual Mode Semi-Automatic Mode Automatic Mode MANUAL TOOL PROBE OPERATION - NOTE - The axis jog push buttons will not produce axis motion when the tool probe is activated and deployed. Axis motion is obtained through the use of the manual pulse generator. The optional sub-spindle must be at the E axis reference position before the tool probe can be activated and deployed. Once a tool has been probed, the X axis must be moved to the Reference Position before the turret can be indexed. This procedure assumes that all required turret tooling has been installed. Refer to: Chapter 4 for information on installing tooling on a VDI turret top plate. Chapter 5 for information on installing tooling on an ESA turret top plate. Chapter 6 for information on installing tooling on a Hardinge turret top plate. - CAUTION - The machine operator must be sure that no interference exists between the spindle, spindle tooling, tool probe, turret, turret tooling, or workpiece before indexing the turret. 1. Activate Rapid Reference mode. 2. Set the Manual Axis Movement switch to X. 3. Press the Rapid Reference push button to move the turret to the X axis reference position M-392D

145 4. If the machine is equipped with the sub-spindle option: A) Set the Manual Axis Movement switch to E. B) Press the Rapid Reference push button to move the sub-spindle to the reference position. 5. Activate Jog mode. - CAUTION - When the tool probe is turned ON, do not touch the probe with any object other than the tool that is being set. - NOTE - Activating the tool probe will cause the control to automatically display the tool geometry offset registers. 6. Press the Tool Probe push button to activate and deploy the tool probe. 7. Index the turret to the selected station. 8. Use the page and cursor keys to position the cursor at the desired offset number. - CAUTION - The machine operator must exercise care when approaching the tool probe stylus with the tool. DO NOT impact the tool probe stylus with the tool. 9. Set the Rapid Override switch to an appropriate value to safely approach the tool probe stylus with the tool. 10. Use the manual pulse generator to move the tool tip to a position near the appropriate side of the tool probe stylus. 11. Press the appropriate axis push button to choose which side of the tool probe stylus will be used. Refer to Figure Set the Rapid Override switch to the 1x position for manual pulse generator control. X/Z +X X/Z Tool Probe Stylus X/Z +Z X/Z C L TI4716 Figure Axis Push Buttons M-392D 8-15

146 13. Turn the manual pulse generator one increment at a time to move the tool tip carefully against the tool probe stylus until the probe is tripped. The offset will register on the display screen 14. Move the tool away from the tool probe stylus. 15. Repeat steps 8 through 14 if touching the tool off on another axis. 16. Activate Rapid Reference mode. 17. Set the Manual Axis Movement switch to X. 18. Press the Rapid Reference push button to move the turret to the X axis reference position. 19. Activate Jog mode. 20. Repeat steps 7 through 19 if touching off additional tools. 21. Press the Tool Probe push button to deactivate and retract the tool probe. SEMI-AUTOMATIC AND AUTOMATIC TOOL PROBE OPERATION Datuming the Tool Probe - CAUTION - The tool probe must be correctly calibrated in manual mode before semi-automatic or automatic operation is performed. All tools that are to be updated through semi-automatic or automatic tool probe operation MUST have an offset value that is approximately equal to the actual tool offset Data. This can be accomplished by either of the following methods: Manually touching off the tools Using the tool probe in manual mode - NOTE - It is recommended that a standard turning tool be used to datum the probe. The semi-automatic and automatic tool probe functions require that a master tool be used to datum the probe prior to use. A master tool is defined as a tool that has known offset values defined in the tool offset file. The process of datuming the tool probe for semi-automatic or automatic operation is not to be confused with calibrating the probe for manual operation. When the probe is calibrated for manual operation, parameters 5015 through 5018 are used to record the position of the probe stylus. Refer to Tool Probe Calibration, on page 8-21, for additional information. When the probe is datumed for semi-automatic or automatic operation, macro variables 522 through 531 are used to record the position of the probe stylus. Refer to Tool Probe Datum Procedure, on the next page M-392D

147 TOOL PROBE DATUM PROCEDURE - NOTE - Refer to Entering a Program from the Keyboard, page 3-10, for information on entering a program through the manual Data input keyboard. 1. Enter the following program into the control memory: O (Datum Auto Tool Probe) ; Program Number (Operator Message) #509=1 ; Specifies that Geometry and Wear Offsets are to be used #530=.785 ; #531=.3925 ; G98 ; Inch/Millimeter per Minute Feedrate M91 ; Enable Automatic Mode with Probe Extended G65 P9011 K2. T_. H_. ; Call Macro Program 9011, K2. = Sets all Probe Faces for Datum T_. = Tool Station and Offset for Master Tool, H_. - Tool Quadrant (Tool Orientation Code) M30 ; End of Program 2. Activate Rapid Reference mode. 3. Set the Manual Axis Movement switch to X. 4. Press the Rapid Reference push button to move the turret to the X axis reference position. 5. If the machine is equipped with the sub-spindle option: A) Set the Manual Axis Movement switch to E. B) Press the Rapid Reference push button to move the sub-spindle to the reference position. 6. Activate Jog mode. 7. Index the turret to the station with the master tool. 8. Press the Tool Probe push button to activate and deploy the tool probe. - CAUTION - The machine operator must exercise care when approaching the tool probe stylus with the tool. DO NOT impact the tool probe stylus with the tool. 9. Set the Rapid Override switch to an appropriate value to safely approach the tool probe stylus with the tool. 10. Use the manual pulse generator to move the tool tip within 1 inch [25 millimeters] of the corner of the two sides of the probe stylus to be used for datuming. 11. Activate Automatic mode. M-392D 8-17

148 - NOTE - Refer to Activating a Stored Program, page 3-10, for information on activating a program. 12. Verify the datum program entered in step 1 is active. 13. Press the Cycle Start push button to datum the probe. After datuming is complete, the tool will return to the position it was jogged to in step Activate Rapid Reference mode. 15. Set the Manual Axis Movement switch to X. 16. Press the Rapid Reference push button to move the turret to the X axis reference position. 17. Press the Tool Probe push button to retract the tool probe M-392D

149 Semi-Automatic Tool Probe Operation - CAUTION - The tool probe must be correctly calibrated before semi-automatic operation is performed. The probe must be datumed before semi-automatic operation is performed. Refer to Datuming the Tool Probe, page 8-16 for information on datuming the probe for semi-automatic operation. - NOTE - Refer to Entering a Program from the Keyboard, page 3-10, for information on entering a program through the manual Data input keyboard. 1. Enter the following program into the control memory: O (Semi-Automatic Tool Probe Cycle) ; Program Number (Operator Message) #509=1 ; Specifies that Geometry and Wear Offsets are to be used G98 ; Inch/Millimeter per Minute Feedrate M91 ; Enable Automatic Mode with Probe Extended G65 P9011 T_. H_. ; Call Macro Program 9011, T_. = Offset Location for Tool Data (1-32), H_. - Tool Quadrant (Tool Orientation Code) M30 ; End of Program 2. Activate Rapid Reference mode. 3. Set the Manual Axis Movement switch to X. 4. Press the Rapid Reference push button to move the turret to the X axis reference position. 5. If the machine is equipped with the sub-spindle option: A) Set the Manual Axis Movement switch to E. B) Press the Rapid Reference push button to move the sub-spindle to the reference position. 6. Activate Jog mode. 7. Index the turret to the selected station. 8. Press the Tool Probe push button to activate and deploy the tool probe. - CAUTION - The machine operator must exercise care when approaching the tool probe stylus with the tool. DO NOT impact the tool probe stylus with the tool. 9. Set the Rapid Override switch to an appropriate value to safely approach the tool probe stylus with the tool. 10. Use the manual pulse generator to move the tool tip within 1 inch [25 millimeters] of the corner of the two sides of the probe stylus to be used for datuming. 11. Activate Automatic mode. M-392D 8-19

150 - NOTE - Refer to Activating a Stored Program, page 3-10, for information on activating a program. 12. Verify the program entered in step 1 is active. 13. Press the Cycle Start push button to probe the tool. After probing is complete, the tool will return to the position it was jogged to in step Activate Rapid Reference mode. 15. Set the Manual Axis Movement switch to X. 16. Press the Rapid Reference push button to move the turret to the X axis reference position. 17. Press the Tool Probe push button to retract the tool probe. - NOTE - If probing additional tools, modify the values for the T and H words in program O3333 as needed for each tool to be probed. 18. Repeat steps 6 through 17, as needed, to probe additional tools. Automatic Tool Probe Operation - CAUTION - The tool probe must be correctly calibrated before automatic operation is performed. The probe must be datumed before automatic operation is performed. Refer to Datuming the Tool Probe, page 8-16 for information on datuming the probe for automatic operation. Automatic tool probe operation can be performed by using either of the following methods: Execute automatic tool probe operation from within the part program Call a subprogram to execute automatic tool probe operation Refer to the programmer s manual (M-391) for information on programming automatic operation of the tool probe M-392D

151 TOOL PROBE CALIBRATION The tool probe parameters are set at the factory when the probe is calibrated. Normally, it is not necessary to re-calibrate the probe unless one of the following occurs: The probe tip has been replaced. The turning center is operating at a temperature that is significantly different than that which the tool probe was calibrated at. - NOTE - The values for parameters 5015 and 5016 are set as diameter values. Parameters 5015 through 5018 define the locations of the stylus contact surfaces used to set tool offsets. Refer to Figure CALIBRATION PROCEDURE 1. Mount sufficient tooling on each turret to be able to probe all 4 surfaces on each tool probe stylus. 2. Set tool offsets for the tooling installed in step 1 using the procedure outlined under Setting Tool Offsets for Non-Center Working Tools on the Turret, starting on page Probe one of the tools installed in step 1 and observe any difference between the tool offset obtained in step 2 and the tool offset established by the tool probe. - NOTE - Refer to Chapter 3 for information on editing machine parameters. 4. Modify the associated parameters (5015 through 5018) as needed to produce the same offset using both steps 2 and Repeat steps 2 through 4 as needed until identical results are obtained when using both steps 2 and 3. +X +Z Parameter 5018 Parameter 5017 Probe Stylus Parameter 5015 Parameter 5016 C L Figure Tool Probe Parameter Definitions TI4717A M-392D 8-21

152 ENTERING TOOL NOSE RADIUS VALUE AND ORIENTATION CODE - NOTE - If Tool Nose Radius Compensation is to be used, the tool nose radius value and the tool quadrant must be entered for each tool which uses Tool Nose Radius Compensation. 1. Press the Offset Setting key. 2. Press the Offset soft key to access the Tool Offset pages. 3. Press the Geometry soft key to display the tool geometry offsets. 4. Use the page and cursor keys to position the cursor at the R Data field for the desired offset. 5. Enter the tool nose radius value and press the Input key. - NOTE- The T value defines the orientation of the tool tip and has a range from 0 through 9. Refer to Figure Use the cursor keys to position the cursor at the T Data field for the desired offset. 7. Enter the tool orientation code number and press the Input key. 8. Repeat steps 4 through 7 for each tool, as required X 5 7 +Z 1 Main Spindle 6 Tailstock / Sub-Spindle 2 Figure Tool Orientation Codes TI M-392D

153 ADJUSTING TOOL WEAR OFFSETS Tool wear offset adjustments are made by adding to or subtracting from an existing offset value using positive or negative values and the Input+ soft key. Tool Wear Offsets that are intended to adjust the position of the tool nose in the -X or -Z direction are entered as NEGATIVE values. Tool Wear Offsets that are intended to adjust the position of the tool nose in the +X or +Z direction are entered as POSITIVE values. ADJUSTING X AND Z AXIS TOOL WEAR OFFSETS 1. Press the Offset Setting key to display the offset pages. 2. Press the Offset soft key to access the Tool Offset pages. 3. Press the Wear soft key to display the Wear Offset page. 4. Use the page and cursor keys to position the cursor at the X axis field for the desired offset. 5. Enter the X axis wear value as follows: If the control is set for Diameter Programming, enter the wear offset as a diameter value. If the control is set for Radius Programming, enter one half the measured (diameter) wear offset value. 6. Press the Input+ soft key. 7. Use the cursor keys to position the cursor at the Z axis field for the desired offset. 8. Enter the Z axis wear value. 9. Press the Input+ soft key. 10. Repeat steps 4 through 9 for each tool as required. RULES FOR ADJUSTING WEAR OFFSETS 1. Negative (-) offset values MUST be signed. 2. Wear Offset values may not exceed.5000 inch [ mm]. M-392D 8-23

154 - NOTES M-392D

155 CHAPTER 9 - MAIN SPINDLE AND COLLET CLOSER - WARNING - Tighten all draw tube screws before beginning spindle operation. - CAUTION - Never operate the main spindle without a work-holding device if the draw tube is in the spindle. INTRODUCTION The main spindle is equipped with a.875 inch [22.2 mm] stroke, hydraulically actuated collet closer. The hydraulic collet closer can be programmed for bar feed operation or it can be operated manually for machine setup and chucking operations. If repairs to the collet closer assembly are required, the ENTIRE ASSEMBLY must be removed and returned to the factory. Refer to the maintenance manual (M-393) for information on removing or installing the collet closer assembly. SPINDLE CAPACITIES - CAUTION - When machining bar stock that extends back into the spindle draw tube on a machine equipped with a high-speed spindle, spindle liners MUST be used when machining bar stock below the minimum size listed in the following table. Refer to Spindle Liners, page 9-13, for additional information. QUEST series lathes have the following maximum through-spindle capacities: Machine Model Maximum Through-Spindle Capacity Inch [Millimeter] Minimum Bar Stock Diameter for Operation without a Spindle Liner QUEST 6/42 Lathe [41.27] [38.10] QUEST 8/51 Lathe [50.80] [47.63] QUEST 10/65 Lathe [63.50] [60.33] M-392D 9-1

156 FREE SPINDLE A Free Spindle condition allows the main spindle to be turned by hand. To obtain a free spindle, proceed as follows: - NOTE - To obtain a free spindle, the control must be ON and the spindle must not be rotating. 1. Power up the machine as described in Chapter Press the control Reset key. 3. Press the Main Spindle Free push button. HYDRAULIC PRESSURE CONTROL The collet closer draw bar force is controlled by hydraulic oil pressure. The hydraulic pressure controls are located at the back of the machine. Knob A, Figure 9.1, 9.2, 9.3, or 9.4 is used to adjust the hydraulic pressure applied to the collet closer draw bar. Gauge B, Figure 9.1, 9.2, 9.3, or 9.4 registers the collet closer hydraulic pressure in psig and bars. Refer to Table 9.1, 9.2, or 9.3 to determine the approximate force that will be applied to the collet closer draw bar for a given pressure. A check valve system positively holds the closer open or closed, whichever is active, in the event of an hydraulic pressure failure. - CAUTION - DO NOT exceed the maximum pressure setting, as shown in Tables 9.1, 9.2, and 9.3. The collet closer hydraulic pressure should be maintained at 500 psi [34.5 bar] when operating at spindle speeds above 4,200 rpm. - NOTE - It is the responsibility of the machine operator or set-up person to properly adjust the collet closer hydraulic pressure, based on the type of material to be machined and the configuration of the workpiece. ADJUSTING THE MAIN SPINDLE HYDRAULIC PRESSURE 1. Loosen the knurled lock nut behind adjustment knob A, Figure 9.1, 9.2, 9.3, or Turn the adjustment knob clockwise or counterclockwise to decrease or increase the collet closer hydraulic pressure. 3. Tighten the knurled lock nut to secure the setting. 9-2 M-392D

157 B A TP4285 Figure Main Collet Closer Pressure Adjustment (Machine Equipped with Standard Spindle Drive and Tailstock) B A TP4196 Figure Main Collet Closer Pressure Adjustment (Machine Equipped with Standard Spindle Drive and Sub-Spindle) M-392D 9-3

158 B A TP4815 Figure Main Collet Closer Pressure Adjustment (Machine Equipped with High Speed Spindle Drive and Tailstock) B A TP4816 Figure Main Collet Closer Pressure Adjustment (Machine Equipped with High Speed Spindle Drive and Sub-Spindle) 9-4 M-392D

159 Gauge Pressure (psig) English Draw Bar Force (lbs) Gauge Pressure (bar) Metric Draw Bar Force (dan) 100 1, , , , , , , , ,678 Table Main Spindle Collet Closer Draw Bar Force (QUEST 6/42 Lathes) Gauge Pressure (psig) English Draw Bar Force (lbs) Gauge Pressure (bar) Metric Draw Bar Force (dan) 100 2, , , , , , , , ,450 Table Main Spindle Collet Closer Draw Bar Force (QUEST 8/51 Lathes) Gauge Pressure (psig) English Draw Bar Force (lbs) Gauge Pressure (bar) Metric Draw Bar Force (dan) 100 2, , , , , , , , , ,634 Table Main Spindle Collet Closer Draw Bar Force (QUEST 10/65 Lathes) M-392D 9-5

160 AUTOMATIC OPERATION MAIN COLLET CLOSER OPERATION For automatic operation, program M21 to open the collet and M22 to close the collet. The M21 (Open Collet) command may be executed while the spindle is running. M21 will remain active until it is canceled by an M22 (Close Collet) command. While M21 is active, the Main Open/Close push button will not be active. A programmed M22 (Collet Close) command will remain active until it is canceled by an M21 (Open Collet) command. MANUAL OPERATION - NOTE - Manual operation of the collet closer is not possible while Cycle Start is active. When the bar feed option is turned OFF, the collet closer can be manually operated in any mode. When the bar feed option is turned ON, the machine must be in Jog mode to manually operate the collet closer. Use the Main Open/Close push button to operate the collet closer manually. CHUCKING MODES There is no default chucking mode. The current chucking mode will remain active until canceled by the appropriate command (M27 or M28). External chucking mode permits the use of work-holding fixtures that grip the workpiece externally. Internal chucking mode permits the use of work-holding fixtures that grip the workpiece internally. SWITCHING THE CHUCKING MODE 1. Check to be sure the Main Open/Close indicator light is ON. Place a workpiece in the collet and press the Main Open/Close push button, if necessary. 2. Activate Manual Data Input mode. 3. Press the Program soft key. 4. At the manual Data input keyboard: Key in M28 for External Chucking Key in M27 for Internal Chucking 5. Press the Insert key. 6. Press the EOB (End of Block) key. 7. Press the Insert key. 8. Close the machine guard door and press the Cycle Start push button. 9. Press the control Reset key. The selected chucking mode will be active 9-6 M-392D

161 CLEANING THE SPINDLE As a general rule, the spindle and spindle draw tube should be cleaned between setups or monthly if a long-run job is on the machine. However, when the machine is run more than one shift per day or certain types of materials are being machined, it may be necessary to clean the spindle and spindle draw tube more often. Use the spindle tooling removal and installation procedures that follow for cleaning the spindle and draw tube. SPINDLE TOOLING - CAUTION - Read and follow all safety recommendations and operating limits for any work-holding device installed in the spindle. DO NOT EXCEED the rated capacity of the work-holding device. QUEST series machines are available with a standard or high speed main spindle. The high speed spindle is balanced to the ISO G1.0 standard and requires a work-holding device balanced to ISO G2.5 or better. All work-holding devices, other than Hardinge collets, should be carefully reviewed for speed limitations and balance specifications. Hardinge Inc. offers chucks balanced to G2.5 or better for high speed applications. REMOVING SPINDLE TOOLING - CAUTION - Do not operate the collet closer when a collet or step chuck is mounted in place without gripping a piece of stock or a plug of the correct size. 1. Power the machine up using the procedure outlined in Chapter 2. C 2. Press the control Reset key. 3. Activate Jog mode. 4. If necessary, press the Main Open/Close push button to open work-holding device in the collet closer. 5. At the left end of the machine, remove draw tube access cover C, Figure If present, remove the plug from the end of the spindle draw tube. Figure Main Spindle Draw Tube Access Cover TP4088 M-392D 9-7

162 7. Completely loosen six screws D, Figure NOTE - Six screws D, Figure 9.6, must be completely disengaged from the collet closer liner before draw tube nut E can be rotated. D F Removal of a jaw chuck or step chuck may require the assistance of a second person. 8. Rotate draw tube nut E, Figure 9.6, counterclockwise to disengage the draw tube from the work-holding device. E - WARNING - Be prepared to accept the weight of the work-holding device. 9. Remove the work-holding device from the spindle. Figure Main Spindle Draw Tube Nut 10. If the machine is equipped with the optional sub-spindle, cover the sub-spindle to protect it from chips while the main spindle is being cleaned. 11. Close the main coolant guard door. 12. From the collet closer end of the draw tube, use an air line to blow chips and coolant out of the spindle. - WARNING - The draw tube may be HOT when running aggressive duty cycles on machines equipped with a high speed spindle. 13. Completely remove the draw tube from the back of the spindle. 14. From the collet closer end of the draw tube, use an air line to blow chips and coolant out of the spindle a second time. 15. Clean the spindle and draw tube. 16. Lightly lubricate the bearing surfaces of the draw tube with Molylube Anti-Seize grease. 17. Lightly coat the remaining exterior surfaces of the draw tube with Mobiltemp SHC 32 grease. 18. Carefully replace the draw tube in the spindle. 19. If spindle tooling is to be installed at this time, proceed to Installing Spindle Tooling, beginning on page 9-9. If spindle tooling is not to be installed at this time: A) Replace the draw tube plug. B) Replace draw tube access cover C, Figure 9.5. TP M-392D

163 INSTALLING SPINDLE TOOLING - NOTE - For the best surface finish and part roundness, the main spindle and draw tube have been balanced together at the factory. Although the spindle and draw tube can be run in other positions, the best balance is when etched mark F, Figure 9.6, and spindle drive button G, Figure 9.7, are aligned. Two procedures are outlined in this section. The first procedure, which begins below, covers the installation of collets and step chucks. The second procedure, beginning on page 9-11, covers the installation of jaw chucks. Collet or Step Chuck This procedure assumes that any previously used spindle tooling has already been removed. If there is spindle tooling to be removed, perform the steps outlined under Removing Spindle Tooling, beginning on page 9-7. If previously used spindle tooling has just been removed, proceed to step 6. - CAUTION - Do not operate the collet closer when a collet or step chuck is mounted in place without gripping a piece of stock or a plug of the correct size. 1. Power the machine up using the procedure outlined in Chapter Press the control Reset key. 3. Activate Jog mode. 4. Remove draw tube access cover C, Figure If present, remove the plug from the end of the spindle draw tube. - NOTE - The collet and spindle bore MUST be clean. 6. Clean the spindle bore and the collet or step chuck and closer to be installed. G 7. Press the Main Spindle Free push button to release the spindle brake and allow the spindle to be rotated. 8. Manually position spindle drive button G, Figure 9.7, to the top dead center (12 o clock) position. 9. Press the Main Spindle Free push button again to have the brake secure the spindle drive button at 12 o clock. Figure Main Spindle Nose with Drive Button at Top Dead Center TP4820 M-392D 9-9

164 - WARNING - To insure operator safety: - DO NOT use cast iron step chucks. - DO NOT use a step chuck without a step chuck closer. - NOTE - Installation of a step chuck may require the assistance of a second person. 10. If installing a step chuck in the spindle, place the step chuck closer against the spindle and install the mounting screws securely. 11. Align the keyway in the collet with the key in the spindle and slide the collet into the spindle until it makes contact with the draw tube. 12. Carefully push the draw tube against the back of the collet while rotating the draw tube clockwise to start the threads of the collet into the threads of the draw tube. - NOTE - Adjustment of the collet or step chuck may require the assistance of a second person. 13. Select the largest diameter workpiece which is to be chucked and position this part in the collet or step chuck. 14. Rotate draw tube nut E, Figure 9.6, clockwise until the workpiece is gripped tightly; then, back the draw tube nut off ¼ to ½ turn. 15. Rotate the draw tube the shortest distance to locate etched mark F at top dead center (12 o clock) position. 16. Tighten six draw tube screws D. 17. Press the Main Open/Close push button to close the collet and test the gripping force on the workpiece. If the gripping force is satisfactory, then go to step 14. If the gripping force is more or less than desired, adjust knob A, Figure 9.1, 9.2, 9.3, or 9.4, to any setting between 100 and 500 psig (6.9 and 34.5 bars). Refer to Table 9.1, 9.2, or CAUTION - If the machine will not be operated with a bar feed system, the draw tube plug should be installed in the end of the spindle draw tube to prevent coolant and chips from entering the spindle drive motor compartment. 18. Install the plug in the end of the spindle draw tube if a bar feed system will not be used. 19. Replace draw tube access cover C, Figure M-392D

165 Jaw Chuck This procedure assumes that any previously used spindle tooling has already been removed. If there is spindle tooling to be removed, perform the steps outlined under Removing Spindle Tooling, beginning on page 9-7. If previously used spindle tooling has just been removed, proceed to step 6. - CAUTION - Do not operate the collet closer when a collet or step chuck is mounted in place without gripping a piece of stock or a plug of the correct size. 1. Power the machine up using the procedure outlined in Chapter Press the control Reset key. 3. Activate Jog mode. 4. Remove draw tube access cover C, Figure If present, remove the plug from the end of the spindle draw tube. - NOTE - The jaw chuck and spindle bore MUST be clean. 6. Clean the jaw chuck and spindle bore. 7. Press the Main Spindle Free push button to release the spindle brake and allow the spindle to be rotated. 8. Manually position spindle drive button G, Figure 9.7, to the top dead center (12 o clock) position. 9. Press Main Spindle Free push button again to have the brake secure the spindle drive button at 12 o clock. 10. Place the chuck in the spindle and install the mounting screws securely. 11. Carefully push the draw tube against the back of the chuck while rotating the draw tube clockwise to start the threads of the chuck into the threads of the draw tube. 12. Thread the draw tube onto the 3 jaw chuck as far as possible. 13. Rotate the draw tube counterclockwise to locate etched mark F, Figure 9.6, at top dead center (12 o clock) position. 14. Tighten six draw tube screws D. (Continued on next page) M-392D 9-11

166 15. Place a workpiece into the chuck and press the Main Open/Close push button to close the chuck and test the gripping force on the workpiece. If the gripping force is satisfactory, then go to step 12. If the gripping force is more or less than desired, adjust knob A, Figure 9.1, 9.2, 9.3, or 9.4, to any setting between 100 and 500 psig (6.9 and 34.5 bars). Refer to Table 9.1, 9.2, or CAUTION - If the machine will not be operated with a bar feed system, the draw tube plug should be installed in the end of the spindle draw tube to prevent coolant and chips from entering the spindle drive motor compartment. 16. Install the plug in the end of the spindle draw tube if a bar feed system will not be used. 17. Replace draw tube access cover C, Figure M-392D

167 SPINDLE LINERS INTRODUCTION - CAUTION - When machining bar stock that extends back into the spindle draw tube on a machine equipped with a high-speed spindle, spindle liners MUST be used when machining bar stock below the minimum size listed in the table shown on page 9-1. The spindle liner supports and aligns the bar stock in the spindle draw tube. Each spindle liner consists of four nylon spindle liner bushings, three spindle liner spacers, and one spindle liner nut. Bore the four spindle liner bushings to the appropriate size and install the spindle liner components in the spindle draw tube. SPINDLE LINER BUSHING - NOTE - A spindle liner requires four spindle liner bushings bored to the same size. A round capacity hole will always be used in the spindle liner bushing, regardless of the profile of the bar stock to be machined (round, square, hex,...). Referring to Figure 9.8, the dimensions of the spindle liner bushings are as follows: Machine Model Dimension A Inch [Millimeter] Dimension B Inch [Millimeter] Dimension C Inch [Millimeter] QUEST 6/42 Lathe QUEST 8/51 Lathe QUEST 10/65 Lathe A C B TP4838 Figure Spindle Liner Bushing (Cross Section View) M-392D 9-13

168 Boring a Bushing to Size 1. Install a 3 jaw chuck or step check in the machine spindle that will accommodate the O.D. of the spindle liner bushing. 2. Insert the spindle liner bushing into the selected work-holding device and press the Main Open/Close push button to close the work-holding device. - CAUTION - If drilling the capacity hole for clearance purposes, be sure to drill the capacity hole undersize. 3. If necessary, use a drill to open up the capacity hole to accommodate the boring bar. 4. Bore the capacity hole in the spindle liner bushing to a diameter that is.020 inch [.5 millimeter] larger than the bar stock to be machined. INSTALLING OR REMOVING THE SPINDLE LINER - NOTE - The spindle, draw tube, and spindle liner components must be cleaned before installation. 1. Press the control Reset key. 2. Activate Jog mode. 3. If the collet closer is in the closed position, press the Main Open/Close push button to set the collet closer to the open position. 4. On the machine, press the Emergency Stop push button. 5. On the bar feed unit or bar loader, press the Emergency Stop push button. 6. If necessary, move the bar feed unit or bar loader away from the machine. 7. Remove draw tube access cover C, Figure Install or remove the spindle liner bushings components. Refer to Figure 9.9. Installation: A) Install the spindle liner bushings and spacers. B) Install the spindle liner nut and tighten the three screws. Removal: A) Loosen the three screws and remove the spindle liner nut. B) Remove the spindle liner bushings and spacers M-392D

169 Spindle Liner Nut Spindle Liner Spacers Spindle Liner Bushings TP4806 Figure Spindle Liner Components Installed in Spindle Draw Tube 9. Replace draw tube access cover C, Figure Position the bar feed unit or bar loader in operating position. 11. Clear the Emergency Stop on the bar feed unit or bar loader. 12. Pull the Emergency Stop push button on the machine out to the first detent, wait two seconds; then, pull the push button out to the end of travel and release. 13. Press the control Reset key. M-392D 9-15 Revised: January 18, 2008

170 - NOTES M-392D

171 CHAPTER 10 - TAILSTOCK INTRODUCTION QUEST series lathes feature a hydraulically operated, programmable tailstock. The hydraulic system is located at the rear of the machine. The tailstock gives added support when machining long parts and reduces part deflection. This allows for closer tolerances, better surface finishes, and higher speeds and feeds than would otherwise be possible. - WARNING - Be sure all personnel are clear of the tailstock before initiating tailstock motion. - CAUTION - Always make certain the turret is in a safe index position before moving the tailstock toward the machine spindle. Check and, if necessary, adjust the tailstock feedrate before using the tailstock for machining operations. Refer to Checking and Adjusting Tailstock Feedrate, page Check and, if necessary, adjust the tailstock force before using the tailstock for machining operations. Refer to Checking and Adjusting Tailstock Force, page The tailstock assembly is advanced and retracted by means of a hydraulic cylinder. Tailstock motion can be controlled automatically from the part program or manually using push buttons on the operator control panel. There are two rates of motion: The rapid traverse rate (approximately 300 in/min [7620 mm/min]) The adjustable feedrate. The tailstock incorporates a safety shear feature to prevent damage to the tooling, turret, tailstock, and linear ways in the event that the turret contacts the tailstock. If contact is made between the tailstock and turret, the safety shear feature allows the tailstock to be pivoted away from the turret. Refer to the maintenance manual (M-393) for instructions on aligning the tailstock. Tailstock overtravel protection in the forward direction is provided by macro program If the tailstock reaches the overtravel coordinate programmed in macro program 9130, tailstock motion will stop and the machine is put into a feed hold condition. M-392D 10-1

172 TRAVEL SPECIFICATIONS The tailstock travel specifications are shown in Figure Tailstock Home (Retract) is a fixed position. The forward (extend) position can be adjusted to suit the workpiece length. +X Z [730.3] +Z 7.25 [184.2] Dependent on Tailstock Center used C L Main Spindle Tailstock at Forward Position Tailstock at Fixed Home Position NOTE: All dimensions are shown in inches [millimeters] TI4651A Figure Tailstock Travel Specifications 10-2 M-392D

173 TAILSTOCK POSITIONS Four tailstock positions are recognized by the control: Fixed Home Position Adjustable Home Position (Retract) Rapid-To-Feed Position Overtravel Position - NOTE - The programmer establishes the adjustable home, rapid-to-feed, and overtravel positions, as needed, through macro program When the tailstock is commanded to one of these positions, the tip of the tailstock center will be moved to the commanded position. Refer to the programmer s manual (M-391) for information on setting the adjustable home, rapid-to-feed, and overtravel positions through macro program FIXED HOME POSITION The fixed home position is at the maximum tailstock travel away from the machine spindle. Refer to Tailstock Movement, page 10-5, for information on moving the tailstock to this position. This position is NOT adjustable. Refer to Figure ADJUSTABLE HOME POSITION (RETRACT) The adjustable home position is located between the rapid-to-feed position and the fixed home position. This position is intended to minimize tailstock motion, resulting in lower cycle times. When the tailstock is commanded to the adjustable home position, the tip of the live center is positioned at the adjustable home position. RAPID-TO-FEED POSITION The rapid-to-feed position is the coordinate at which the rapid forward motion of the tailstock is reduced to provide acceptable contact with the workpiece. OVERTRAVEL POSITION The overtravel position is the coordinate at which the forward motion of the tailstock is stopped and the machine is put into a feed hold condition. M-392D 10-3

174 TAILSTOCK SAFETY INTERLOCKS There are two safety interlocks associated with the tailstock. These interlocks are designed to reduce the possibility of crashes that result from incorrect tailstock positioning. CYCLE START INTERLOCK To activate Cycle Start while in Automatic, Manual Data Input, or Single mode, the tailstock MUST be in one of the following positions: Fixed Home position Adjustable Home Position (Retract) Forward Position (Any coordinate between the rapid-to-feed and the overtravel positions) If the tailstock is not in one of these three positions, an alarm will be generated by the control when the Cycle Start push button is pressed. To clear the alarm, move the tailstock to the fixed home position. Refer to Tailstock Movement, page 10-5, for information on moving the tailstock. OVERTRAVEL INTERLOCK While in Automatic, Manual Data Input, or Single mode, M84 commands RAPID tailstock motion toward the machine spindle. Macro program 9130 MUST be executed to set the rapid-to-feed position so that the tailstock center will FEED onto the workpiece. If no workpiece is present, the tailstock will continue to move toward the machine spindle, resulting in an overtravel condition. Tailstock overtravel protection in the forward direction is provided by the overtravel coordinate programmed in macro program If the tailstock reaches the overtravel coordinate, an alarm will be generated and the machine will be put into a feed hold condition. To clear the alarm: 1. Press the control Reset key. 2. Press the right-hand Z/E push button to move the tailstock to the fixed home position at the rapid traverse rate M-392D

175 TAILSTOCK MOVEMENT - NOTE - Refer to the programmer s manual (M-391) for information on programming tailstock operation. Generally, the machine control must be in Jog mode to manually control tailstock motion. The notable exception is during between-center work. If M30 (End of Program) is active while in Automatic mode, it is possible to manually jog the tailstock without switching to Jog mode. Be aware that activating Jog mode will cancel this feature until another M30 is read by the control while in Automatic mode. The Z/E push buttons are used to jog the tailstock in the indicated direction. While in manual mode, the tailstock will always FEED toward the machine spindle and RAPID away from the machine spindle. MANUAL MOVEMENT Initiating Manual Movement 1. Activate Jog mode. 2. Set the Manual Axis Movement switch to E to select the tailstock. 3. Move the tailstock as follows: TOWARD THE MACHINE SPINDLE When the tailstock is to the right of the rapid-to-feed position: Press the left-hand Z/E push button to FEED the tailstock toward the machine spindle (-Z direction). Press the left-hand Z/E push button and the Rapid Traverse push button to RAPID the tailstock toward the machine spindle (-Z direction). TOWARD THE FIXED HOME POSITION Press the right-hand Z/E push button to RAPID the tailstock to the fixed home position. Stopping Manual Movement Manual tailstock motion can be stopped by pressing the Emergency Stop push button, Hold push button, or control Reset key. EMERGENCY STOP To initiate tailstock motion after an Emergency Stop: 1. Pull the Emergency Stop push button out to the first detent, wait two seconds; then, pull the push button out to the end of travel and release. 2. Press the control Reset key. 3. Activate Jog mode. 4. Press a Z/E push button to move the tailstock in the desired direction. HOLD or RESET To initiate tailstock motion after a Hold or control Reset, press a Z/E push button to move the tailstock in the desired direction. M-392D 10-5 Revised: January 18, 2008

176 PROGRAMMED MOVEMENT Initiating Programmed Movement - NOTE - The machine control MUST be in Automatic, Manual Data Input, or Single mode to command tailstock motion using M codes. M84 Tailstock Forward When an M84 is read by the control, the tailstock will RAPID forward (toward the machine spindle) until the rapid-to-feed position is reached. At that point, the tailstock will slow to the preset feedrate and feed onto the workpiece. M85 Tailstock Retract When an M85 is read by the control, the tailstock will move to the first home position encountered at RAPID TRAVERSE rate. M86 Tailstock Home When an M86 is read by the control, the tailstock will move to the fixed home position at the RAPID TRAVERSE rate. Stopping Programmed Movement Programmed tailstock motion can be stopped by pressing the Emergency Stop push button, Feed Hold push button, or control Reset key. EMERGENCY STOP To initiate programmed tailstock motion after an Emergency Stop: 1. Pull the Emergency Stop push button out to the first detent, wait two seconds; then, pull the push button out to the end of travel and release. 2. Press the control Reset key. 3. Activate Jog mode. 4. Press the right-hand Z/E push button to RAPID the tailstock to the fixed home position. 5. Reset the program to the beginning of the current operation. 6. Activate Automatic mode and press the Cycle Start push button M-392D Revised: January 18, 2008

177 FEED HOLD To initiate programmed tailstock motion after a Feed Hold, press the Cycle Start push button. RESET To initiate programmed tailstock motion after a control Reset: 1. Activate Jog mode. 2. Press the right-hand Z/E push button to RAPID the tailstock to the fixed home position. 3. Reset the program to the beginning of the current operation. 4. Activate Automatic mode and press the Cycle Start push button. M-392D 10-7

178 CHECKING AND ADJUSTING TAILSTOCK FEEDRATE 1. Activate Jog mode. 2. Press the right-hand Z/E push button to Home the tailstock. 3. Press the left-hand Z/E push button to move the tailstock toward the machine spindle and observe the current tailstock feedrate. The tailstock will move toward the machine spindle at the adjustable feedrate. 4. If the tailstock feedrate needs to be changed, turn knob C, Figure 10.2 or 10.3, in the required direction to increase or decrease the feedrate as desired. 5. Repeat steps 2 through 4 until the desired feedrate is achieved. A B A B C C Figure Hydraulic System (Machine with Standard Spindle) TP4285 TP4815 Figure Hydraulic System (Machine with High Speed Spindle) 10-8 M-392D

179 CHECKING AND ADJUSTING TAILSTOCK FORCE The force applied to the workpiece is controlled by hydraulic oil pressure which is regulated by valve A, Figure 10.2 or Gauge B indicates the force in pounds per square inch and bars. Table 10.1 lists the approximate force in pounds and dekanewtons which will be applied to the workpiece for a given gauge pressure. 1. Activate Jog mode. 2. Use the left-hand Z/E push button to engage the tailstock with the workpiece. 3. Check the tailstock hydraulic pressure on gauge B, Figure 10.2 or If the tailstock hydraulic pressure needs to be adjusted, go to step 4. If the tailstock hydraulic pressure does not need to be adjusted, go to step 6. English Metric Gauge Pressure (psig) Applied Force (lbs) Gauge Pressure (bar) Applied Force (dan) , , Table Applied Tailstock Force M-392D 10-9

180 - CAUTION - Recommended tailstock pressure is 350 psig (24 bars). For maximum operating safety and to ensure that the hydraulic tailstock functions correctly, never set the tailstock pressure below 200 psig [13.8 bars]. 4. Loosen the knurled lock nut on valve A and turn the adjusting nut in the required direction until the desired pressure registers on gauge B. Refer to Table Tighten the lock nut on valve A. 6. Press the right-hand Z/E push button to move the tailstock to the fixed home position. REMOVING A LIVE CENTER REMOVING AND INSTALLING A LIVE CENTER - NOTE - Release nut "E", Figure 10.4, requires a 2 inch wrench, which is supplied with the machine. The wrench part number is QC Remove the live center by rotating release nut "E", Figure 10.4, outward to push live center "D" from the tailstock bushing. INSTALLING A LIVE CENTER 1. Rotate the release nut inward before installing a live center. 2. Insert the live center into the tailstock bushing. The live center will be seated in the bushing the first time it contacts a workpiece. D E Figure Live Center and Release Nut TI M-392D

181 - NOTES - M-392D 10-11

182 - NOTES M-392D

183 CHAPTER 11 - INPUT/OUTPUT DEVICES INTRODUCTION QUEST series lathes are available with either the standard operator interface or the optional PC-based operator interface. When indicated, refer to the specific information relating to the appropriate operator interface. The purpose of this chapter is to explain the transfer of data between the various input/output devices and the CNC control. STANDARD OPERATOR INTERFACE INPUT/OUTPUT DEVICE LOCATIONS - NOTE - The RS-232 port supplied with the standard operator interface is a 25 pin connection. The standard operator interface is equipped with one ATA Flash Card port and one physical RS-232 port, shown in Figure ATA Flash Card Port RS-232 Serial Port Figure Data Input/Output Ports (Standard Operator Interface) TP4090 M-392D 11-1

184 PC-BASED OPERATOR INTERFACE [Option] - NOTE - The RS-232 port supplied with the PC-based operator interface is a 15 pin connection. The PC-based operator interface is equipped with the following devices for data input/output: ATA Flash Card Port RS-232 Serial Port (15 pin) for PC Data RS-232 Serial Port (25 pin) for NC Data 3½ Disk Drive Internal Hard Disk CD-ROM Drive Refer to Figures 11.2, 11.3, and Open the Data port cover, Figure 11.2, to gain access to the PC Data RS-232, universal serial, keyboard, and mouse ports. Cover for 3½ Disk Drive and CD-ROM Drive ATA Flash Card Port Data Port Cover RS-232 Port for NC Data Figure ATA Flash Card Port and Cover for RS-232 Port (PC-Based Operator Interface) TP4623A 11-2 M-392D

185 RS-232 Port for PC Data Figure RS-232 Port (PC-Based Operator Interface) TP4624A CD-ROM Drive 3½ Disk Drive Figure ½ Disk Drive and CD-ROM Drive (PC-Based Operator Interface) TP4622 M-392D 11-3

186 INPUT/OUTPUT DEVICE SELECTION The input/output device to be used is selected through the I/O Channel setting, which is discussed on page 2-8. The valid settings for the I/O Channel are 0, 1, 2, and 4. I/O CHANNEL 0, 1, OR 2 Three independent port assignments are available to allow the operator or programmer to establish three different I/O port configurations for the same physical RS-232 port. These three configurations are designated as channels 0, 1, and 2. Instead of changing the associated parameters to reassign the baud rate and stop bits, it is possible to select a different I/O port configuration and have the changes implemented by the control automatically. Setting the I/O Channel to 0, 1, or 2 selects the RS-232 port and selects which configuration will be active. Refer to page 11-6 for information on the RS-232 port. Refer to page 11-8 for information on the RS-232 port parameter settings M-392D

187 I/O CHANNEL 4 Standard Operator Interface Setting the I/O Channel to 4 selects the ATA Flash Card port. Refer to page for information on using the ATA Flash Card port. PC-Based Operator Interface Setting the I/O Channel to 4 allows the operator to select any of the following devices for data input/output: 3½ Disk Drive (Drive A:) Internal Hard Disk (Drive C: and D:) CD-ROM Drive (Drive E:) ATA Flash Card Port (Drive F:) SELECTING THE INPUT/OUTPUT DEVICE - NOTE - If the ATA flash card is to be used on the PC-based operator interface, it must be plugged into the flash card port BEFORE the control is turned ON. 1. Press Shift + Graph. 2. Select Data Input/Output Device from the menu. 3. If the desired device is already selected, press OK or Proceed to step Press Browse. 5. Select the desired device (A, C, D, E, or F). Refer to the following device definitions: A: 3½ disk drive C: hard disk, partition 1 D: hard disk, partition 2 E: CD-ROM drive F: ATA flash card port 6. Press OK to exit the device selection display. 7. Press OK to exit to the CNC display. M-392D 11-5

188 DATA COMMUNICATIONS PROTOCOL RS-232 SERIAL PORT (NC DATA) Data communications protocol consists of three basic types of information: parity, baud rate, and stop bits. The baud rate and stop bits are controlled by parameters, which may be modified as required. Tape Parity Check Tapes punched in EIA format (EIA Standard RS-244-B) contain an odd number of holes in each character and tapes punched in ASCII (ISO), (EIA Standard RS-358-B) contain an even number of holes in each character. This characteristic of having an odd or even number of holes punched in every character is called parity. The control accepts tape punched in either code, but each tape must be programmed in only one of the accepted codes. The control automatically determines the particular type of coding by decoding the first End of Block (;) character on the tape. Each character is checked for parity as it is read by the tape reader or computer. Refer to the appropriate manual to set the tape punch, tape reader, or computer to the desired parity. Baud Rate Baud rate is the speed at which data is transmitted from one device to another. To successfully transmit data between two devices, it is necessary to have both devices set to the same baud rate. The baud rate is set by three different parameters, depending on which I/O port is active. Refer to the I/O setting on Setting Page #1 to determine which I/O port is active. Refer to Input/Output Device Selection, page Refer to the appropriate manual to set the tape punch, tape reader, or computer to the desired baud rate. Stop Bits The control is capable of operating with 1 or 2 stop bits, depending on the requirement. The number of stop bits active in the machine control is controlled by three different parameters, depending on which I/O port is active. These parameters may be modified as required. Refer to Input/Output Device Selection, page Refer to the appropriate manual to set the tape punch, tape reader, or computer to the desired number of stop bits M-392D

189 CHECKING AND MODIFYING COMMUNICATIONS PARAMETERS Use the following procedure to check communications protocol parameters: 1. Press the System key. 2. Press the Parameter soft key. 3. Use the Page keys to display the parameter page to be viewed. Use the following procedure to check and modify communications protocol parameters as needed: 1. Press the Offset Setting key. 2. Press the Setting soft key. 3. If necessary, use the Page keys to display the Setting page that contains the Parameter Write field. 4. If necessary, use the cursor keys to position the cursor at the Parameter Write field. 5. Activate Manual Data Input mode. 6. Key in the number 1 (one). 7. Press the Input key. Parameter editing will be enabled. 8. Press the System key. 9. Press the Parameter soft key. 10. Use the Cursor and Page keys to position the cursor on the parameter to be modified. 11. Key in the new parameter value. 12. Press the Input key. 13. Repeat steps 10 through 12, as needed. 14. Press the Offset Setting key. 15. Press the Setting soft key. 16. If necessary, use the cursor keys to position the cursor at the Parameter Write field. 17. Key in the number 0 (zero). 18. Press the Input key. Parameter editing will be disabled. M-392D 11-7

190 RS-232 PORT PARAMETER SETTINGS Refer to Checking and Modifying Communications Parameters, starting on page 11-7, for information on modifying the parameter settings for the three I/O ports. These parameters may be modified as required. Baud Rate Parameter Settings I/O Port The valid parameter settings are as follows: Parameter Number Setting Baud Rate Stop Bit Parameter Settings I/O Port Parameter Number Bit Number The valid parameter settings are 0" for 1 Stop Bit and 1" for 2 Stop Bits. - NOTE - The Stop Bit parameter settings are displayed as one bit in an 8 bit binary number (0 or 1). The bits are read 0" to 7", from right to left M-392D

191 DATA TRANSFER RS-232 SERIAL PORT (NC DATA) Uploading Data through the RS-232 Port UPLOADING CONTROL PARAMETERS INTO CONTROL MEMORY - CAUTION - Always connect the RS-232 cable before applying power to the external device and always remove power from the external device before disconnecting the RS-232 cable. 1. Verify the machine control communications protocol as outlined under Checking and Modifying Communications Parameters, page Refer to the appropriate manual to set the tape reader or computer to the desired communications protocol. 3. Connect the interface cable from the tape reader or computer to the serial port. 4. Press the Offset Setting key. 5. Press the Setting soft key. 6. If necessary, use the Page keys to display the Setting page that contains the Parameter Write field. 7. If necessary, use the cursor keys to position the cursor at the Parameter Write field. 8. Activate Manual Data Input mode. 9. Key in the number 1 (one). 10. Press the Input key. Parameter editing will be enabled. 11. Press the System key. 12. Press the Parameter soft key. 13. Press the Operator soft key. 14. Activate Edit mode. 15. Press the soft key expansion key until the Read soft key is displayed. 16. Press the Read soft key. 17. Press the Execute soft key. 18. Set the tape reader or computer to transmit data to the machine control. 19. After the control parameters have been uploaded, activate Manual Data Input mode. 20. Press the Offset Setting soft key. 21. Key in the number 0 (zero). 22. Press the Input key. Parameter editing will be disabled. M-392D 11-9

192 23. Remove power from the external device; then, disconnect the RS-232 cable from the machine control. 24. Close the serial port cover. 25. Turn the control OFF and wait approximately 10 seconds. 26. Turn the control ON. UPLOADING PART PROGRAMS INTO CONTROL MEMORY - CAUTION - Always connect the RS-232 cable before applying power to the external device and always remove power from the external device before disconnecting the RS-232 cable. 1. Verify the machine control communications protocol as outlined under Checking and Modifying Communications Parameters, page Refer to the appropriate manual to set the tape reader or computer to the desired communications protocol. 3. Connect the interface cable from the tape reader or computer to the serial port. 4. Activate Edit mode. 5. Press the Program key. 6. Turn the Program Protect key to OFF. 7. Press the soft key expansion key until the Read soft key is displayed. - NOTE - If the program has no program number or if the program number is to be altered, key in the letter O and the desired program number. 8. Key in the letter O and the program number. Example: O Press the Read soft key. 10. Press the Execute soft key. 11. Set the tape reader or computer to transmit data to the machine control. - NOTE - When the program has been completely loaded into the control, it will appear as the active program on the control display screen. 12. After the part programs have been uploaded, turn the Program Protect key to ON. 13. Remove power from the external device; then, disconnect the RS-232 cable from the machine control. 14. Close the serial port cover M-392D

193 UPLOADING TOOL OFFSETS INTO CONTROL MEMORY - CAUTION - Always connect the RS-232 cable before applying power to the external device and always remove power from the external device before disconnecting the RS-232 cable. 1. Verify the machine control communications protocol as outlined under Checking and Modifying Communications Parameters, page Refer to the appropriate manual to set the tape reader, or computer to the desired communications protocol. 3. Connect the interface cable from the tape reader or computer to the serial port. 4. Activate Edit mode. 5. Press the Offset Setting key. 6. Press the Offset soft key. 7. Press the Operator soft key. 8. Press the soft key expansion key until the Read soft key is displayed. 9. Press the Read soft key. 10. Press the Execute soft key. - NOTE - The offset data will load directly into the offset registers. 11. Set the tape reader or computer to transmit data to the machine control. 12. Remove power from the external device; then, disconnect the RS-232 cable from the machine control. 13. Close the serial port cover. M-392D 11-11

194 Downloading Data through the RS-232 Port DOWNLOADING CONTROL PARAMETERS FROM CONTROL MEMORY - CAUTION - Always connect the RS-232 cable before applying power to the external device and always remove power from the external device before disconnecting the RS-232 cable. 1. Verify the machine control communications protocol as outlined under Checking and Modifying Communications Parameters, page Refer to the appropriate manual to set the tape punch or computer to the desired communications protocol. 3. Connect the interface cable from the tape reader or computer to the serial port. 4. Connect the interface cable to the output device and the serial port on the control. 5. Set the tape punch or computer to receive data. 6. Activate Edit mode. 7. Press the System key. 8. Press the Parameter soft key. 9. Press the Operator soft key. 10. Press the soft key expansion key until the Punch soft key is displayed. 11. Press the Punch soft key. 12. Press the ALL soft key to download all parameters -or- Press the NON ZERO soft key to download only parameters with non-zero values. 13. Press the Execute soft key. - NOTE - To stop the parameters from downloading, press the Reset key. Once the Reset key has been pressed, it is not possible to download the remaining parameters. It will be necessary to download all of the parameters. 14. After the control parameters have been downloaded, remove power from the external device and disconnect the RS-232 cable from the machine control. 15. Close the serial port cover M-392D

195 DOWNLOADING PART PROGRAMS FROM CONTROL MEMORY - CAUTION - Always connect the RS-232 cable before applying power to the external device and always remove power from the external device before disconnecting the RS-232 cable. 1. Verify the machine control communications protocol as outlined under Checking and Modifying Communications Parameters, page Refer to the appropriate manual to set the tape punch or computer to the desired communications protocol. 3. Connect the interface cable from the tape reader or computer to the serial port. 4. Connect the interface cable to the output device and the serial port on the control. 5. Set the tape punch or computer to receive data. 6. Activate Edit mode. 7. Press the Program key. 8. Key in the letter O and the program number. Example: O Press the soft key expansion key until the Punch soft key is displayed. 10. Press the Punch key. 11. Press the Execute soft key. - NOTE - When outputting to a tape punch, the control will automatically output 3 feet of leader and trailer tape. To shorten the leader or trailer length, press the Cancel push button while the leader or trailer is being punched, respectively. To stop the part program from downloading, press the Reset key. Once the Reset key has been pressed, it is not possible to download the rest of the part program. It will be necessary to download the entire part program. 12. After the part programs have been downloaded, remove power from the external device and disconnect the RS-232 cable from the machine control. 13. Close the serial port cover. M-392D 11-13

196 DOWNLOADING TOOL OFFSETS FROM CONTROL MEMORY - CAUTION - Always connect the RS-232 cable before applying power to the external device and always remove power from the external device before disconnecting the RS-232 cable. 1. Verify the machine control communications protocol as outlined under Checking and Modifying Communications Parameters, page Refer to the appropriate manual to set the tape punch or computer to the desired communications protocol. 3. Connect the interface cable from the tape reader or computer to the serial port. 4. Connect the interface cable to the output device and the serial port on the control. 5. Set the tape punch or computer to receive data. 6. Activate Edit mode. 7. Press the Offset Setting key. 8. Press the Offset soft key. 9. Press the Geometry soft key to display the Geometry offset page. 10. Press the Operator soft key. 11. Press the soft key expansion key until the Punch soft key is displayed. 12. Press the Punch key. 13. Press the Execute soft key. - NOTE - To stop the tool offsets from downloading, press the Reset key. Once the Reset key has been pressed, it is not possible to download the remaining tool offsets. It will be necessary to download all of the tool offsets. 14. After the tool offsets have been downloaded, remove power from the external device and disconnect the RS-232 cable from the machine control. 15. Close the serial port cover M-392D

197 INTEGRATED INPUT/OUTPUT DEVICES Standard Operator Interface Machines with the standard operator interface are equipped with an integrated ATA Flash Card Port. - NOTES - Any flash card used must be an ATA Flash Card. I/O Channel 4 must be selected. Refer to page 11-5 for information on selecting I/O Channel 4. FILE MANAGEMENT 1. Insert the ATA flash card into the flash card port. 2. Set the I/O Channel to If copying a program to the machine control, turn the Program Protect key to OFF. 4. If copying parameters to the machine control: A) Press the Offset Setting key. B) Press the Setting soft key. C) If necessary, use the Page keys to display the Setting page that contains the Parameter Write field. D) If necessary, use the cursor keys to position the cursor at the Parameter Write field. E) Activate Manual Data Input mode. F) Key in the number 1 (one). G) Press the Input key. Parameter editing will be enabled. 5. Activate Edit mode. 6. Press the System key. 7. Press the soft key expansion key until the ALL IO soft key is displayed. 8. Press the ALL IO soft key. 9. Press the appropriate soft key, based on the type of file to be copied to the control memory: Program: This function is used to transfer a program between the I/O device and control memory. Parameter: This function is used to transfer a parameter file between the I/O device and control memory. Offset: This function is used to transfer an offset file between the I/O device and control memory. M-392D 11-15

198 10. Press the Operator soft key. The following soft key functions will be displayed: FILE SEARCH This function is used to search the selected input/output device for a specific file name. A) Press the File Search soft key. B) Key in the number of the file, NOT a program name. C) Press the File Set soft key. D) Press the Execute soft key. If the specified file is found, it will be displayed at the top of the file listing. FILE READ This function is used to copy the selected file from the input/output device to the machine control. A) Press the File Read soft key. B) Key in the number of the file, NOT a program name. C) Press the File Set soft key. D) Press the Execute soft key. The selected file will be copied to the control memory. PUNCH This function is used to copy the machine parameters, offset register data, or the active program from the machine control to the input/output device A) If necessary, activate the program to be copied. Refer to Chapter 3 for information on activating programs. B) Press the Punch soft key. C) If a file name is to be assigned, key in the file name and press the File Name soft key. D) If a program name is to be changed, key in the new program name and press the O Set soft key. E) Press the Execute soft key. The selected file will be copied from the control memory to the input/output device. DELETE This function is used to delete a selected file from the input/output device. A) Press the Delete soft key. B) Key in the number of the file, NOT a program name. C) Press the File Set soft key. D) Press the Execute soft key. The specified file will be deleted from the input/output device M-392D

199 11. If a program was copied to the machine control, turn the Program Protect key to ON. 12. If control parameters were copied to the machine control: A) Activate Manual Data Input mode. B) Press the Offset Setting soft key. C) Key in the number 0 (zero). D) Press the Input key. Parameter editing will be disabled. 13. Press the Reset key. 14. Remove the ATA flash card and close the cover. M-392D 11-17

200 PC-Based Operator Interface Machines with the PC-based operator interface are equipped with the following integrated input/output devices: 3½ disk drive Internal Hard Disk CD-ROM Drive ATA Flash Card Port - NOTES - Any flash card used must be an ATA Flash Card. I/O Channel 4 must be selected. Refer to page 11-5 for information on selecting I/O Channel 4. If an ATA flash card is to be used, the flash card must be plugged into the flash card port BEFORE the control is turned ON. FILE MANAGEMENT 1. If the ATA flash card port is to be used, insert the ATA flash card into the flash card port before the control is turned ON. 2. Turn the machine control ON. 3. Set the I/O Channel to Select the input/output device to be used: A: 3½ disk drive C: internal hard disk, partition 1 D: internal hard disk, partition 2 E: CD-ROM drive F: ATA flash card port Refer to page 11-5 for information on the selecting the input/output device. 5. If copying a program to the machine control, turn the Program Protect key to OFF. 6. If copying parameters to the machine control: A) Press the Offset Setting key. B) Press the Setting soft key. C) If necessary, use the Page keys to display the Setting page that contains the Parameter Write field. D) If necessary, use the cursor keys to position the cursor at the Parameter Write field. E) Activate Manual Data Input mode. F) Key in the number 1 (one). G) Press the Input key. Parameter editing will be enabled M-392D

201 7. Activate Edit mode. 8. Press the System key. 9. Press the soft key expansion key until the ALL IO soft key is displayed. 10. Press the ALL IO soft key. 11. Press the appropriate soft key, based on the type of file to be copied to the control memory: Program: This function is used to transfer a program between the I/O device and control memory. Parameter: This function is used to transfer a parameter file between the I/O device and control memory. Offset: This function is used to transfer an offset file between the I/O device and control memory. 12. Press the Operator soft key. The following soft key functions will be displayed: FILE SEARCH This function is used to search the selected input/output device for a specific file name. A) Press the File Search soft key. B) Key in the number of the file, NOT a program name. C) Press the File Set soft key. D) Press the Execute soft key. If the specified file is found, it will be displayed at the top of the file listing. FILE READ This function is used to copy the selected file from the input/output device to the machine control. A) Press the File Read soft key. B) Key in the number of the file, NOT a program name. C) Press the File Set soft key. D) Press the Execute soft key. The selected file will be copied to the control memory. M-392D 11-19

202 PUNCH This function is used to copy the machine parameters, offset register data, or the active program from the machine control to the input/output device A) If necessary, activate the program to be copied. Refer to Chapter 3 for information on activating programs. B) Press the Punch soft key. C) If a file name is to be assigned, key in the file name and press the File Name soft key. D) If a program name is to be changed, key in the new program name and press the O Set soft key. E) Press the Execute soft key. The selected file will be copied from the control memory to the input/output device. DELETE This function is used to delete a selected file from the input/output device. A) Press the Delete soft key. B) Key in the number of the file, NOT a program name. C) Press the File Set soft key. D) Press the Execute soft key. The specified file will be deleted from the input/output device. 13. If a program was copied to the machine control, turn the Program Protect key to ON. 14. If control parameters were copied to the machine control: A) Activate Manual Data Input mode. B) Press the Offset Setting soft key. C) Key in the number 0 (zero). D) Press the Input key. Parameter editing will be disabled. 15. Press the Reset key. 16. Remove the ATA flash card and close the cover M-392D

203 - NOTES - M-392D 11-21

204 - NOTES M-392D

205 CHAPTER 12 - OPERATOR MAINTENANCE INTRODUCTION Operator maintenance is normally confined to cleaning the machine and maintaining the hydraulic fluid and coolant levels. It is a good practice to check all fluid levels at the beginning of each shift. The operator should also check the cooling fans periodically to see that they are free of obstructions and functioning properly. Refer to the maintenance manual (M-393) for more extensive maintenance procedures. MACHINE AIR SYSTEM The machine is equipped with a regulator and two-stage filter system to regulate and filter the incoming air supply. The filter/regulator assembly is located at the back of the machine. - CAUTION - The air filter bowl should be drained at least once a day. If more frequent draining is required, it may be necessary to install an air dryer in the air line. DRAINING THE AIR FILTER BOWLS 1. Turn the main air valve on regulator B, Figure 12.1, ON. 2. Unscrew drain valve C only enough to drain the bowl of the standard air filter. Close the valve when the air filter bowl has finished draining. 3. Unscrew drain valve D only enough to drain the bowl of the coalescing air filter. Close the valve when the air filter bowl has finished draining. A B C D Figure Air Filter/Regulator TP4101 M-392D 12-1

206 ADJUSTING THE MACHINE AIR PRESSURE Regulator B, Figure 12.1, is equipped with a pressure gauge that indicates the air pressure delivered to the machine. The recommended range for machine air pressure is 70 psig [4.8 bars] to 90 psig [6.2 bars]. If necessary, adjust the regulator to set the machine air pressure to within the recommended range. - NOTE - The machine is equipped with an air pressure sensor that will force the machine into Emergency Stop if the air pressure falls below 60 psig [4.1 bars]. 1. Turn main air valve on regulator B, Figure 12.1, ON. 2. Lift knob A, then turn the knob clockwise or counterclockwise to increase or decrease machine air pressure, respectively. 3. Press knob A down to lock the setting. STANDARD HYDRAULIC UNIT HYDRAULIC SYSTEM - NOTE - Use only Mobil DTE-13M hydraulic fluid in the standard hydraulic unit. The standard hydraulic unit provides hydraulic oil under pressure to operate the collet closer, spindle brake, and turret. The reservoir should be filled whenever the hydraulic fluid level drops below sight gauge E, Figure The reservoir should be drained, cleaned, and filled with fresh hydraulic fluid after every 1000 hours of operation. Refer to the maintenance manual (M-393) for instructions on draining and cleaning the standard hydraulic unit. Filling the Oil Reservoir - NOTE - It is recommended that the machine not be powered up for at least 10 minutes after oil has been added to the hydraulic tank. This will allow any air bubbles present in the oil to dissipate. It is recommended that the hydraulic oil be pre-filtered to 5 micron maximum particle size before being added to the hydraulic tank. 1. Power down the machine as outlined in Chapter Remove cap F, Figure 12.2, and SLOWLY fill the reservoir with Mobil DTE-13M hydraulic fluid until sight gauge E is filled. 3. Replace cap F. E TP4105 Figure Standard Hydraulic Unit (Shown with Cover Removed) F 12-2 M-392D

207 HYDROSTATIC HYDRAULIC UNIT - NOTE - The hydrostatic hydraulic unit is only used on machines equipped with the HydroGlide hydrostatic linear guideway option. Use only Mobil DTE-18M hydraulic fluid in the hydrostatic hydraulic unit. The hydrostatic hydraulic unit provides hydraulic oil under pressure to the linear guideway trucks. The reservoir should be filled whenever the hydraulic fluid level drops below sight gauge H, Figure The reservoir should be drained, cleaned, and filled with fresh hydraulic fluid after every 1000 hours of operation. Refer to the maintenance manual (M-393) for instructions on draining and cleaning the hydrostatic hydraulic unit. Filling the Oil Reservoir - NOTE - It is recommended that the machine not be powered up for at least 10 minutes after oil has been added to the hydraulic tank. This will allow any air bubbles present in the oil to dissipate. It is recommended that the hydraulic oil be pre-filtered to 5 micron maximum particle size before being added to the hydraulic tank. 1. Power down the machine as outlined in Chapter Remove cap G, Figure 12.3, and SLOWLY fill the reservoir with Mobil DTE-18M hydraulic fluid until sight gauge H is filled. 3. Replace cap G. G H TP5765 Figure Hydrostatic Hydraulic Unit (Shown with Cover Removed) M-392D 12-3

208 COOLANT SYSTEM Hardinge machine tools are designed using the latest technology and highest quality materials available. However, due to the ever-increasing number of coolant selections available, it is important to test material compatibility with each and every coolant. For additional information regarding coolant selection, coolant maintenance, and the coolant facilities on this machine, refer to the maintenance manual (M-393). - CAUTION - Whenever water-soluble coolants are used, it is important to use the manufacturer s recommended mix ratio (concentration). It is also important to maintain the coolant by keeping the proper concentration level when coolant is added to compensate for evaporation. Another important factor is coolant ph (acidity). Typically, the coolant ph should be in the range of 8.5 to 9. When the ph drops below 8.5 the rust inhibitors in the coolant start depleting, which can result in corrosion of machine components. Also, the quality of the water should be tested by the coolant manufacturer so that the proper coolant additives can be administered. Failure to follow these recommendations could result in damage to the machine, seals, and paint. If the coolant you have selected starts to react (cause material to rust, pit, swell, soften, crack, blister, etc.) with any portion of the machine tool, Hardinge suggests that you discontinue use and contact your coolant representative for alternative coolants. It should also be noted that certain chemicals react with different metals. Hardinge recommends that you consult with your coolant representative to assure that the material you are cutting does not react with the coolant you have selected. The coolant level should not be allowed to fall below the sight gauge on the coolant tank. The coolant tank should be drained and cleaned at least every six months or whenever the type or brand of coolant is changed. More frequent cleaning may be required if the material being machined contaminates the coolant. Refer to the maintenance manual (M-393) for instructions on draining and cleaning the coolant system. To fill the coolant tank, open the front coolant guard door and pour the required amount of coolant directly into the chip pan. Fill the coolant tank to the FULL line on the sight gauge tag. Either water-based or oil-based coolant may be used. The coolant tank fluid capacity is 40 gallons [152 liters] M-392D

209 TRAMP OIL PAN - WARNING - Dispose of waste oil in accordance with all applicable government guidelines. DO NOT introduce the waste oil into the hydraulic system. - NOTE - The tramp oil pan is only used on machines equipped with the HydroGlide hydrostatic linear guideway option. The machine has been designed to keep contamination of the coolant by the oil used for the hydrostatic linear guideways to a minimum. The oil drains from the machine and is collected in the tramp oil pan. The pan should be removed and emptied once a day. Empty the pan and place it back into position. 1. Slide tramp oil pan I, Figure 12.4, under the hydraulic units platform. 2. Insert the end of tramp oil return line J, Figure 12.5, into the pan. I J Figure Tramp Oil Pan Partially in Position TP5780 TP5782 Figure Tramp Oil Pan Completely in Position with Return line in Place (Viewed from Side of Machine) M-392D 12-5

210 CHIP REMOVAL (Machines Without an Optional Chip Conveyor) 1. Power down the machine as outlined in Chapter If coolant was ON, wait a few minutes to allow any coolant that was in use to drain back into the tank. 3. Move the coolant tank as needed to gain access to the chips. - WARNING - Do not remove chips with your bare hands. 4. Rake or shovel the chips into a suitable container. 5. Return the coolant tank to its opening under the front of the machine. 6. Check inside the work area to make certain that coolant will drain back into the coolant tank properly M-392D

211 - NOTES - M-392D 12-7

212 - NOTES M-392D

213 CHAPTER 13 - OPTIONS AND MISCELLANEOUS FEATURES MACHINE RUN TIME COUNTER The machine Run Time counter shows the total run time during automatic operation. The Run Time counter does not count during a feed hold or programmed stop condition. ACCESSING THE RUN TIME DISPLAY Press the Position function key. The Run Time is displayed at the bottom of the page. RESETTING THE RUN TIME COUNTER TO ZERO 1. Press the Offset Setting key. 2. If the Setting (Timer) page is not displayed: A) Press the Setting soft key. B) Use the page keys to display the Setting (Timer) page. 3. Activate Manual Data Input mode. 4. Turn the Program Protect key switch to the OFF position. 5. Press the Operator soft key. 6. Move the cursor to the number to be reset. 7. Key in 0" (zero) and press the Input key. 8. Repeat steps 6 and 7 as needed. 9. Turn the Program Protect key switch to the ON position. MACHINE CYCLE TIME COUNTER The machine Cycle Time counter shows the time of one automatic operation. The Cycle Time counter starts counting when Cycle Start is pressed and stops counting when an End of Program (M02/M30) is encountered. The Cycle Time counter does not count during a feed hold or programmed stop condition. The Cycle Time counter is automatically reset to zero when the Cycle Start push button is pressed, or when the control is turned OFF. ACCESSING THE CYCLE TIME DISPLAY Press the Position key. The Cycle Time is displayed at the bottom of the page. M-392D 13-1

214 CLOCK FUNCTION The clock function is displayed in the lower right corner of all screens. The clock function is displayed as a 24 hour clock. RESETTING THE CLOCK DISPLAY 1. Press the Offset Setting key. 2. If the Setting (Timer) page is not displayed: A) Press the Setting soft key. B) Use the page keys to display the Setting (Timer) page. 3. Activate Manual Data Input mode. 4. Turn the Program Protect key switch to the OFF position. 5. Press the Operator soft key. 6. Move the cursor to the number to be corrected. - NOTE - The display will not be updated if an invalid value is entered. Negative numbers are considered invalid values. 7. Enter the correct value and press the Input key. Refer to the following chart. ITEM MAXIMUM VALUE Year 2085 Month 12 Day 31 Hour 23 Minute 59 Second Repeat steps 6 and 7 as needed. 9. Turn the Program Protect key switch to the ON position M-392D

215 PARTS COUNTER The Parts Counter shows the total number of times a program has been run during automatic operation. The Parts Counter is increased by one (1) each time an M97 command is read by the control. - NOTE - The Part Required register is located on the same display screen as the Parts Counter register. When Part Required is set to any non-zero number and the machine is running in Repeat mode, program execution will stop when the number in the Part Counter register is equal to the number in the Part Required register. ACCESSING THE PARTS COUNTER DISPLAY Press the Position key. The Parts Counter is displayed at the bottom of the page. RESETTING THE PARTS COUNTER TO ZERO 1. Press the Offset Setting key. 2. If the Setting (Timer) page is not displayed: A) Press the Setting soft key. B) Use the page keys to display the Setting (Timer) page. 3. Activate Manual Data Input mode. 4. Turn the Program Protect key switch to the OFF position. 5. Press the Operator soft key. 6. Move the cursor to the number to be reset. 7. Key in 0" (zero) and press the Input key. 8. Repeat steps 6 and 7 as needed. 9. Turn the Program Protect key switch to the ON position. - NOTE - Part Required must be set to zero for continuous cycling of bar work. M-392D 13-3

216 THREAD CUTTING CYCLE RETRACT - NOTE - Thread Cutting Cycle Retract is NOT functional during G32 Threadcutting. This feature allows the operator to retract the tool from the workpiece during a threading pass. The tool retracts to an X coordinate equal to the X coordinate of the start point of the threading cycle and moves to the start point. The tool will follow the same basic retract movement that it would follow at the end of the thread. To retract the tool, press the Feed Hold push button. The tool will be retracted from the workpiece when the current lead is completed. The tool will NOT finish the threading pass. To restart the threading cycle, press the Cycle Start push button. The control will execute the threading cycle as programmed. The tool will re-execute the pass which was interrupted by Feed Hold. The CNC control will synchronize the re-entry of the tool with the thread on the workpiece. This will assure the thread will be properly formed when the threading cycle is completed. HIGH PRESSURE COOLANT SYSTEM The High Pressure coolant system option is used when special coolant-fed tools are mounted on the turret. When the High Pressure coolant system is operating, the standard machine coolant system is disabled. The pump unit is located externally from the machine and draws coolant from the machine s coolant reservoir. The coolant is then pumped to the special tools when they are in the cutting position. The spindle must be running before activating High Pressure coolant. When the option turned ON, the High Pressure coolant can be controlled manually by pressing the HP Coolant ON/OFF push button. The High Pressure coolant can also be activated and deactivated from the part program using the M10 and M11 commands, respectively. BAR FEED INTERFACE - NOTE - The bar feed interface must be activated for bar work and deactivated for slug work. 1. Press the Emergency Stop push button. - NOTE - The Block Skip push button indicator light will be ON when the bar feed interface is activated. 2. Press and hold the Spindle Increase and Spindle Decrease push buttons. 3. Press the Block Skip push button to activate or deactivate the bar feed interface. 4. Release the Spindle Increase and Spindle Decrease push buttons. 5. Pull the Emergency Stop push button out to the first detent, wait two seconds; then, pull the push button out to the end of travel and release M-392D Revised: January 18, 2008

217 ENGLISH / METRIC MODE One of the purposes of the Setting page is used to establish whether the control is to power-up and operate in English mode or Metric mode. This section outlines the procedure for selecting the desired operating mode. Through the use of the G20 (Inch Mode) and G21 (Metric Mode) commands, It is possible to operate in either mode regardless of which mode has been selected on the Setting page. However, the use of these two G codes will not automatically adjust the position registers to display the position values in the proper units (inches vs millimeters). - CAUTION - Part programs should usually be written in the same format as selected on the Setting page. Programs not written in the same format as established on the Setting page MUST contain the appropriate English / Metric G code, G20/G21 respectively. When required, this G code must be programmed by itself in the first Data block following the program number. The work shift values are NOT automatically changed to the appropriate units when the operating mode is changed. - NOTE - The tool offsets are automatically changed to the appropriate units when the operating mode is changed. ESTABLISHING ENGLISH / METRIC MODE 1. Press the Offset Setting function key. 2. Press the Setting soft key. 3. If necessary, use the Page keys to display the Setting page that contains the Input Unit field. 4. If necessary, use the cursor keys to position the cursor at the Input Unit field. 5. Activate Manual Data Input mode. 6. Key in the appropriate number (0:MM 1:INCH). 7. Press the Input key. 8. Turn the Control ON / OFF switch to OFF. 9. Wait a few seconds; then, turn the Control ON / OFF switch to ON and wait until the control display screen is ON. The machine will power up in the desired operating mode. M-392D 13-5

218 INTRODUCTION AXIS THRUST LIMITATION The E and Z axis servo drives are capable of delivering levels of thrust that exceed the limits of the machine tool. Therefore, axis thrust must be limited or machine life may be reduced. There is reference material available for the programmer that provides approximate thrust values based on drill diameter, spindle speed, feedrate, and the type of material being machined. Hardinge Inc. recommends the MACHINING DATA HANDBOOK from Metcut Research Associates, Inc. - NOTE - Thrust limits are not easily exceeded unless large diameter twist drills are being run with aggressive feedrates. Axis thrust is limited to the following: AXIS THRUST LIMIT English (Pounds-Force) Metric (Newtons) E 1,500 6,670 Z 2,250 10,000 MONITORING AXIS THRUST It is possible to monitor axis thrust as a percentage of how much current the E or Z axis servo motor is drawing compared to the maximum amount of current that the motor should draw. - CAUTION - The percentage of maximum current must not exceed the following limits: AXIS LIMIT VALUE E 107 Z 132 If the percentage of maximum current on the E or Z axis exceeds the limit value, an alarm message will be displayed. The percentage of maximum current is displayed under CURRENT (%) on the associated axis Servo Tune page. Refer to the position indicator shown in Figure M-392D

219 S ERVO MOT OR T UNING ZAXIS (PARAMETER) FUNC.BIT L OOP GAIN T UNING S T SET PERIOD INT GAIN PROP.GAIN FILTER VELOC.GAIN NUM. ~ ~ ~ ~ ~ ~ ~ ~ (MONIT OR ) ALARM 1 ALARM 2 ALARM 3 ALARM 4 ALARM 5 L OOP GAIN POS ERROR CURRENT % SPEED (RPM) AU T O O N ~ ~ ~ ~ ~ ~ ~ ~ (S V. S ET ) (SV.TUN) ( ) ( ) ( ) TI4179 Figure Servo Tune Screen (Z axis page shown) ACCESSING THE AXIS SERVO TUNE PAGE - CAUTION - DO NOT modify any of the parameters displayed on the Servo Setting and Servo Motor Tuning screens. If any of the parameters are modified, reload the machine parameters from the diskette supplied with the machine tool. Refer to Chapter 11 for information on loading machine parameters. 1. Press the System key. 2. Press the Parameter soft key. 3. If necessary, press the right hand soft key to display the Servo Parameter soft key. 4. Press the Servo Parameter soft key. 5. Press the Servo Tune soft key. 6. If necessary, use the Page keys to access the appropriate Servo Motor Tuning screen. 7. Observe the value shown to the right of CURRENT (%). Refer to the position indicator shown in Figure M-392D 13-7

220 ADJUSTING AXIS THRUST - NOTE - This procedure is to be performed during the operation that causes the axis overload. When performing machining operations where axis thrust is a concern, it is possible to minimize cycle time by adjusting the programmed feedrate to bring the value under CURRENT (%) as close to the limit without exceeding the limit. If the value displayed under CURRENT (%) on the appropriate axis Servo Tune page exceeds the limit, reduce axis thrust according to the following procedure: 1. Turn the Feedrate Override switch down by 10%. 2. Run the operation that caused the axis overload and observe the value displayed under CURRENT (%) on the axis Servo Tune page. If the value displayed under CURRENT (%) on the Servo Tune page still exceeds the limit, repeat steps 1 and 2. If the value displayed under CURRENT (%) on the Servo Tune page is under the limit, adjust the programmed feedrate in the part program according to the setting of the Feedrate Override switch. EXAMPLE Assuming that the Feedrate Override switch had to be set to 80% to allow the operation to be performed: 1. Multiply the programmed feedrate by.8". 2. Modify the programmed feedrate for the operation to match the number calculated in step M-392D

221 MAIN SPINDLE PART CATCHER [Option] Introduction PART CATCHERS The main spindle part catcher is controlled from the operator panel through the use of the Part Catcher push button when the machine is in Jog mode. The main spindle part catcher is controlled from the part program through the use of the following M codes: M25 - PART CATCHER RETRACT The M25 command rotates the part catcher arm to the spindle centerline for part pickup. M26 - PART CATCHER EXTEND The M26 command causes the following to occur: 1. The part catcher arm rotates toward the front of the machine and the part basket extends to receive the part. 2. The part basket retracts after a fixed period of time. Typical Part Unload Sequence 1. The part catcher arm rotates inward to a position under the spindle (M26). 2. The collet/chuck opens, ejecting the part onto the arm (M21). 3. The arm rotates outward and the basket extends to receive the part (M25). 4. The part falls from the arm into the basket. 5. The basket retracts. 6. The operator can open cover A, Figure 13.2, and remove the part from the basket by hand. A B Figure Main Spindle Part Catcher (External View) TP4612 M-392D 13-9

222 Adjusting the Part Catcher for Part Length 1. Loosen the screw in locking collar C, Figure Slide the part catcher toward or away from the machine headwall to adjust the position, as needed. 3. Tighten the screw in locking collar C. C Adjusting the Part Catcher Extend / Retract Speeds The part catcher extend and retract speeds are controlled by separate flow control valves and can be adjusted independently. Remove sheet metal cover D, Figure 13.4, from the front of the machine to gain access to the part catcher flow control valves. Flow control valve E, Figure 13.5, is used to adjust the speed at which the part catcher extends (moves toward the spindle centerline). Flow control valve F is used to adjust the speed at which the part catcher retracts (moves toward the front of the machine). Rotate the knob on a flow control valve clockwise to reduce speed. Rotate the knob on a flow control valve counterclockwise to increase speed. Figure Position Adjustment Locking Collar D Figure Front Cover TP4610 TP4158 E F Figure Part Catcher Extend/Retract Adjustments TP M-392D

223 Adjusting the Part Basket Extend / Retract Speeds The part basket extend and retract speeds are controlled by separate flow control valves and can be adjusted independently. Remove sheet metal cover B, Figure 13.2, to gain access to the part basket flow control valves. Flow control valve G, Figure 13.6, is used to adjust the speed at which the part catcher extends (moves toward the spindle centerline). Flow control valve H is used to adjust the speed at which the part catcher retracts (moves toward the front of the machine). Rotate the knob on a flow control valve clockwise to reduce speed. Rotate the knob on a flow control valve counterclockwise to increase speed. G H Figure Part Basket Extend/Retract Adjustments TP4605 M-392D 13-11

224 CONVEYOR-STYLE SUB-SPINDLE PART CATCHER [Option] Introduction The sub-spindle part catcher is a multiple axis part removal system designed to remove a workpiece from the sub-spindle and deposit the workpiece on a conveyor, which will carry the workpiece to an unload ramp located at the right end of the machine tool. - NOTE - It is the operator s responsibility to provide a suitable container or surface to receive the finished workpiece when it leaves the unload ramp. The lower edge of the unload ramp, shown in Figure 13.7, is approximately 23¾ inches from the floor. Figure Sub-Spindle Part Catcher Unload Ramp (Covers Removed for Clarity) TP M-392D

225 Part Catcher M Codes The sub-spindle part catcher is controlled through the use of the following six M codes: M221 PART CATCHER SLIDE EXTEND M221 commands the part catcher to slide OUT from the sub-spindle headwall to the fixed part pick-up position. Refer to Figure M222 PART CATCHER SLIDE RETRACT M222 commands the part catcher to slide IN to the part drop-off position over the part conveyor. M225 PART CATCHER ARM ROTATE DOWN M225 commands the part catcher arm to swing down to allow the part catcher to be retracted. M226 PART CATCHER ARM ROTATE UP M226 commands the part catcher arm to swing up to the part retrieve position at the spindle centerline. Refer to Figure M227 PART CATCHER GRIPPER CLOSE M227 commands the part catcher gripper to close and grip the workpiece. M228 PART CATCHER GRIPPER OPEN M228 commands the part catcher gripper to open and release the workpiece. TP4654 Figure Part Catcher Extended, Arm Rotated to Down Position TP4655 Figure Part Catcher Extended, Arm Rotated to Up Position M-392D 13-13

226 Interlocks 1. M221 must be active (Part Catcher Slide Extend) before M226 (Part Catcher Arm Rotate Up) can be commanded. 2. The sub-spindle must be at the reference position before M225 (Part Catcher Arm Rotate Down) can be commanded. 3. M225 (Part Catcher Arm Rotate Down) must be active before M222 (Part Catcher Slide Retract) can be commanded. Capacity The part catcher has the following workpiece capacity: Category English Units Metric Units Maximum Length 6 inches millimeters Maximum Diameter 2.5 inches 63.5 millimeters Maximum Weight 7 lb 3.18 Kg M-392D

227 Part Catcher Gripper Pads The part catcher grippers are designed to be equipped with nylon pads. The nylon pads are bored to the outer diameter of the workpiece to be machined. BORING THE GRIPPER PADS The gripper pad fixture, shown in Figure 13.10, is used to hold the gripper pads when they are bored to the required size. 1. Install a work-holding device capable of holding a 3½ inch workpiece in the machine spindle. 2. Insert blank gripper pads into the fixture and secure with four M3 x.5 x 10mm screws, supplied with the fixture. 3. Insert the gripper pad fixture into the spindle and close the work-holding device. 4. Bore the gripper pads to the required diameter. 5. Remove the gripper pad fixture from the spindle. 6. Remove the gripper pads from the gripper pad fixture. 7. Install the gripper pads on the part catcher gripper. Refer to Changing the Gripper Pads, page Gripper Pad Fixture Gripper Pads Figure Gripper Pad Fixture with Blank Gripper Pads TI4745 M-392D 13-15

228 CHANGING THE GRIPPER PADS 1. If necessary, bore the gripper pads as outlined in the preceding section. 2. Close the guard door. 3. Activate Rapid Reference mode. 4. Set the Manual Axis Movement switch to X. 5. Press the Rapid Reference push button to move the turret to the X axis reference position. 6. Set the Manual Axis Movement switch to E. 7. Press the Rapid Reference push button to move the sub-spindle to the reference position. - NOTE - Refer to Chapter 3 for information on using Manual Data Input mode. The guard door must be closed to execute commands in Manual Data Input mode. 8. Use Manual Data Input mode to: A) Extend the part catcher slide (M221). B) Rotate the part catcher arm to the up position (M226). 9. Open the guard door. 10. If necessary, loosen screws I, Figure 13.11, to remove the gripper pads currently installed on the grippers. 11. Clean the part catcher grippers. 12. Thoroughly clean the replacement gripper pads. 13. Install the replacement gripper pads. 14. Close the guard door. 15. Use Manual Data Input mode to: A) Rotate the part catcher arm to the down position (M225). B) Retract the part catcher slide (M222). I Figure Gripper Pad Mounting Screws TP M-392D

229 THRU- SUB-SPINDLE PART CATCHER [Option] - CAUTION - Observe the sub-spindle operating limitations outlined in the programmer s manual (M-391) when running a sub-spindle equipped with the thru- sub-spindle part catcher. - NOTE - The thru- sub-spindle part catcher is capable of handling parts with diameters that fall within the following range: Introduction 3 16 " 1" The thru- sub-spindle part catcher provides the capability of feeding parts through the part catcher draw tube, which is installed in the sub-spindle, and out the right end of the machine. During part transfer from the main spindle to the sub-spindle, the part currently in the sub-spindle collet is pushed from the collet by the part being delivered from the main spindle. As subsequent parts are delivered from the main spindle to the sub-spindle, the parts in the part catcher draw tube are pushed toward the right end of the machine, out the exit tube, and down the ramp to a receptacle provided by the machine operator. Refer to Figure for an overall view of the thru- sub-spindle part catcher assembly. NOTE: Sub-spindle assembly not shown. Part Catcher Guard Refer to Figure for close-up view. Collet and Guide Bushing Draw Tube Assembly Exit Tube Safety Switch Clamp Part Catcher Ramp Safety Switch TI4788 Figure Isometric View of Thru- Sub-Spindle Part Catcher Assembly M-392D 13-17

230 Part Catcher Component Identification COLLET GUIDE BUSHINGS Three collet guide bushings, each machined for a different capacity, are supplied with the thru- sub-spindle part catcher. A collet guide bushing is always installed in the sub-spindle collet when the thru- sub-spindle part catcher is to be used. Refer to Selecting Part Catcher Components for information on selecting the correct collet guide bushing. One blank collet guide bushing is also included with the thru- sub-spindle part catcher. The blank collet guide bushing can be used for the following: Replace a worn or damaged collet guide bushing Produce a custom size collet guide bushing for the part to be machined PART CATCHER DRAW TUBE ASSEMBLY One draw tube assembly is supplied with the thru- sub-spindle part catcher. This draw tube assembly will replace the standard sub-spindle draw tube when the thru- sub-spindle part catcher is to be used. PART CATCHER DRAW TUBE LINERS Two draw tube liners are supplied with the thru- sub-spindle part catcher. A draw tube liner must be installed in the part catcher draw tube when the thru- sub-spindle part catcher is to be used for parts that are 9/16 inch or less in diameter. Refer to Selecting Part Catcher Components for information on selecting the correct draw tube liner. EXIT TUBES Three exit tubes are supplied with the thru- sub-spindle part catcher. An exit tube is always installed when the thru- sub-spindle part catcher is to be used. Refer to Selecting Part Catcher Components for information on selecting the correct exit tube. Selecting Part Catcher Components The following part catcher components will be selected based on the diameter of the part to be machined. Collet Guide Bushing Part Catcher Draw Tube Liner Exit Tube Part Size Ranges Collet Guide Bushing Capacity Hole Draw Tube Liner Size Exit Tube Size 3/16, 5/16 Small Small Small 5/16, 9/16 Medium Medium Medium 9/16, 1 Large None Large The three configurations are shown in Figures 13.13, 13.14, and M-392D

231 Collet Guide Bushing Collet Draw Tube Assembly Draw Tube Nut Draw Tube Retaining Screws 1/16 [1.6 mm] Exit Tube Anti-Rotation Bracket TI4789 Figure Section View Showing Components for 1 Inch Maximum Part Diameter M-392D 13-19

232 Collet Guide Bushing Draw Tube Liner Collet Draw Tube Assembly Draw Tube Nut Draw Tube Retaining Screws 1/16 [1.6 mm] Exit Tube Draw Tube Liner Anti-Rotation Bracket TI4790 Figure Section View Showing Components for 9/16 Inch Maximum Part Diameter M-392D

233 Collet Guide Bushing Draw Tube Liner Collet Draw Tube Assembly Draw Tube Nut Draw Tube Retaining Screws 1/16 [1.6 mm] Exit Tube Draw Tube Liner Anti-Rotation Bracket TI4791 Figure Section View Showing Components for 5/16 Inch Maximum Part Diameter M-392D 13-21

234 Changing Part Catcher Components Part catcher components will be changed for either of the following reasons: Accommodate a different part size Replace a worn component - CAUTION - Do not operate the collet closer when a collet is mounted in place without gripping a piece of stock or a plug of the correct size. 1. Power the machine up using the procedure outlined in Chapter Press the control Reset key. 3. Activate Jog mode. 4. If necessary, press the Sub Open/Close push button to open work-holding device in the collet closer. 5. At the right end of the machine, pull safety switch clamp K to disengage safety switch L, Figure Loosen the mounting nuts and remove part catcher guard J. 7. Remove four thumbscrews O and tube clamps P, Figure Remove exit tube Q. 9. Remove two insert blocks N. 10. If a draw tube liner is in the draw tube: A) Remove the two M4 screws and lock washers located at T. B) Slide the liner out of the draw tube. 11. Remove the collet from the sub-spindle: - NOTE - The six draw tube retaining screws must be completely disengaged from the collet closer liner before draw tube nut can be rotated. A) Using the T-handle hex wrench provided, completely loosen the six draw tube retaining screws, shown in Figures 13.13, 13.14, and B) Rotate the draw tube nut counterclockwise to disengage the draw tube from the collet. C) Remove the collet from the sub-spindle. J M TP4717 Figure Part Catcher Guard L K M-392D

235 Refer to Figure for an overall view of the part catcher. R P Q S T U O X W V Y N TI4796 Figure Exit Tube Clamps and Anti-Rotation Bracket 12. Remove the guide bushing from the collet. 13. Clean the collet and guide bushing; then, place in storage. 14. Cover the main spindle to protect it from contaminants while the sub-spindle is being cleaned. 15. Close the main coolant guard door. 16. From the collet closer end of the draw tube, use an air line to blow any contaminants present out of the sub-spindle. 17. Press the Sub Open/Close push button to set the collet closer to the closed position. M-392D 13-23

236 18. If necessary, install the appropriate draw tube liner, based on the diameter of the part to be produced, in the draw tube. Secure the draw tube liner with the two M4 screws and lock washers provided. Refer to Selecting Part Catcher Components, page 13-18, for additional information on component selection. 19. Install two insert blocks N. - NOTE - There should be approximately 1/16 clearance between the end of the draw tube or draw tube liner and the end of the exit tube. Refer to Figures 13.13, 13.14, and Install the appropriate exit tube Q, based on the diameter of the part to be produced. Refer to Selecting Part Catcher Components, page 13-18, for additional information on component selection. 21. Install two exit tube clamps P and secure with four thumbscrews O. 22. Press the Sub Open/Close push button to set the collet closer to the open position. 23. Install the appropriate collet guide bushing, based on the diameter of the part to be produced, in the collet to be used. Refer to Selecting Part Catcher Components, page 13-18, for additional information on component selection. 24. Install the collet in the sub-spindle using the basic information provided in Installing Sub-Spindle Tooling, beginning on page Replace part catcher guard J, Figure 13.16, and secure the mounting nuts. 26. Use clamp K to engage safety switch L. 27. Position a part receptacle under ramp M M-392D

237 Changing Sub-Spindle Draw Tubes INSTALLING THE STANDARD DRAW TUBE This procedure is used when it is necessary to change from the part catcher draw tube to the standard draw tube. - CAUTION - Do not operate the collet closer when a collet or step chuck is mounted in place without gripping a piece of stock or a plug of the correct size. 1. Power the machine up using the procedure outlined in Chapter Press the control Reset key. 3. Activate Jog mode. 4. If necessary, press the Sub Open/Close push button to open work-holding device in the collet closer. 5. At the right end of the machine, pull safety switch clamp K to disengage safety switch L, Figure Loosen the mounting nuts and remove part catcher guard J. 7. Remove four thumbscrews O and tube clamps P, Figure Remove exit tube Q. 9. Remove two insert blocks N. - CAUTION - DO NOT remove two alignment blocks R. 10. Remove four screws X and two tube support blocks Y. 11. If a draw tube liner is in the draw tube: A) Remove the two M4 screws and lock washers located at T. B) Slide the liner out of the draw tube. 12. Clean all items removed in steps 7 through 11; then, place in storage. 13. Remove the collet from the sub-spindle: - NOTE - The six draw tube retaining screws must be completely disengaged before the draw tube nut can be rotated. A) Completely loosen the six draw tube retaining screws, shown in Figures 13.13, 13.14, and B) Rotate the draw tube nut counterclockwise to disengage the draw tube from the collet. C) Remove the collet from the sub-spindle. M-392D 13-25

238 14. Remove the guide bushing from the collet. 15. Clean the collet and guide bushing; then, place in storage. 16. Cover the main spindle to protect it from contaminants while the sub-spindle is being cleaned. 17. Close the main coolant guard door. 18. From the collet closer end of the draw tube, use an air line to blow any contaminants present out of the sub-spindle. 19. Remove screw W and two bushings V from anti-rotation bracket U. 20. Completely remove the draw tube from the back of the sub-spindle. 21. Use an air line to blow any contaminants present out of the sub-spindle a second time. 22. Clean the sub-spindle, standard draw tube, and part catcher draw tube. 23. Lightly coat all exterior surfaces of the part catcher draw tube with Mobiltemp SHC 32 grease; then, place in storage. 24. Lightly lubricate the bearing surfaces of the standard draw tube with Molylube Anti-Seize grease. 25. Lightly coat the remaining exterior surfaces of the standard draw tube with Mobiltemp SHC 32 grease. 26. Carefully slide the standard draw tube into the sub-spindle. 27. If spindle tooling is to be installed at this time, install the tooling according to the procedure outlined in Installing Sub-Spindle Tooling, beginning on page If spindle tooling is not to be installed at this time, install the draw tube plug. 28. Replace part catcher guard J, Figure 13.16, and tighten the mounting nuts. 29. Use clamp K to engage safety switch L M-392D

239 INSTALLING THE PART CATCHER DRAW TUBE This procedure is used when it is necessary to change from the standard draw tube to the part catcher draw tube. 1. Power the machine up using the procedure outlined in Chapter Press the control Reset key. 3. Activate Jog mode. 4. If necessary, press the Sub Open/Close push button to open work-holding device in the collet closer. 5. At the right end of the machine, pull safety switch clamp K to disengage safety switch L, Figure Loosen the mounting nuts and remove part catcher guard J. - NOTE - Six screws A, Figure 13.18, must be completely disengaged before draw tube nut B can be rotated. Removal of a jaw chuck or step chuck may require the assistance of a second person. 7. Completely loosen six screws A, Figure Rotate draw tube nut B counterclockwise to disengage the draw tube from the work-holding device. - WARNING - Be prepared to accept the weight of the work-holding device. 9. Remove the work-holding device from the sub-spindle. 10. Clean the work-holding device; then, place in storage. 11. Cover the main spindle to protect it from contaminants while the sub-spindle is being cleaned. 12. Close the main coolant guard door. 13. From the collet closer end of the draw tube, use an air line to blow any contaminants present out of the sub-spindle. 14. Completely remove the draw tube from the back of the sub-spindle. 15. Use an air line to blow any contaminants present out of the sub-spindle a second time. 16. Clean the sub-spindle, standard draw tube, and part catcher draw tube. 17. Lightly coat all exterior surfaces of the standard draw tube with Mobiltemp SHC 32 grease; then, place in storage. 18. Lightly lubricate the bearing surfaces of the part catcher draw tube with Molylube Anti-Seize grease. A B TP4133 Figure Standard Draw Tube Nut M-392D 13-27

240 19. Lightly coat the remaining exterior surfaces of the part catcher draw tube with Mobiltemp SHC 32 grease. 20. Carefully slide the part catcher draw tube into the sub-spindle. - CAUTION - Be sure bushings V, and screw W extend through the hole in bracket S. 21. Install two bushings V, and screw W into anti-rotation bracket U, as shown in Figure Torque screw W to 60 lb-in [6.8 N m]. 22. Press the Sub Open/Close push button to set the collet closer to the closed position. 23. If necessary, install the appropriate draw tube liner, based on the diameter of the part to be produced, in the draw tube. Secure the draw tube liner with the two M4 screws and lock washers provided. Refer to Selecting Part Catcher Components, page 13-18, for additional information on component selection. 24. Thoroughly clean the two mounting surfaces for brackets Y. 25. Thoroughly clean two alignment blocks R. - NOTE - Locate brackets Y against alignment blocks R before securing with screws X. 26. Install two brackets Y using four screws X. Torque screws X to 25 lb-ft [33.9 N m]. 27. Install two insert blocks N. - NOTE - There should be approximately 1/16 clearance between the end of the draw tube or draw tube liner and the end of the exit tube. Refer to Figures 13.13, 13.14, and Install the appropriate exit tube Q, based on the diameter of the part to be produced. Refer to Selecting Part Catcher Components, page 13-18, for additional information on component selection. 29. Install two exit tube clamps P and secure with four thumbscrews O. 30. Press the Sub Open/Close push button to set the collet closer to the open position. 31. Install the appropriate collet guide bushing, based on the diameter of the part to be produced, in the collet to be used. Refer to Selecting Part Catcher Components, page 13-18, for additional information on component selection. 32. Install the collet in the sub-spindle using the basic information provided in Installing Sub-Spindle Tooling, beginning on page Replace part catcher guard J, Figure 13.16, and secure the mounting nuts. 34. Use clamp K to engage safety switch L. 35. Position a part receptacle under ramp M M-392D

241 INTRODUCTION PART PROBE [Option] - CAUTION - Although overtravel protection is built into the probe, the probing velocity must not exceed 18 inches/minute to insure that the machine stopping distance does not exceed the probe overtravel. The optional part probe extends the versatility of the machines by providing automatic size checking and updating of tool offsets. Outside diameters, inside diameters, and lengths can be checked when a cutting operation is not active. The system consists of a measuring probe which is datumed in reference to a known surface. The probe is a multi-directional switch that is programmed to contact the workpiece at the desired inspection point. Contact can be made from any direction. When the probe stylus makes contact, a signal is generated which is relayed to the interface where it is converted into a form the machine control will accept. The control compares the inspection point to the calibration point and offsets are automatically corrected when required. The slide then backs off and a second signal is relayed to the interface, indicating the stylus has reseated and the probe is ready for the next measurement. SET-UP PROCEDURE - NOTE - The probe holder installs in the same manner as a standard round shank tool holder. Refer to Chapter 4, 5, or 6 for information on installing tool holders. 1. Mount probe holder F, Figure or 13.20, on the turret at the desired station. 2. Place OMP unit E in the probe holder and tighten mounting screws G just enough to hold the probe in position. 3. Screw probe A into OMP unit E and tighten at D using the spanner wrench provided with the probe. 4. Position the turret midway between the reference position and the spindle face and spindle centerline. B A G C D E F G F Figure Part Probe Mounted on a Hardinge Top Plate TP4688 TP4693A Figure Part Probe Mounted on a VDI Top Plate M-392D 13-29

242 5. Adjust OMP unit E, Figure 13.19, and OMM unit I, Figure 13.21, so that the optical window on the OMP unit and the window on the OMM unit are aligned. 6. Tighten mounting screws G, Figure or Tighten screw H, Figure NOTE - The probe stylus has a 360 degree rotational capability. However, it is important that the center of the stylus ball coincides with the X axis centerline of the turret. 8. Mount probe stylus C, Figure 13.19, on the probe with screw B so that the center of the stylus ball is approximately on line with the X axis center line of the turret top plate. 9. Index the turret to the station with the probe mounted on it. 10. Place a center in the spindle work-holding device. 11. Jog the turret to position the center of the stylus ball on center with the spindle centerline. 12. Adjust the probe stylus until the center of the ball is on the spindle centerline. This will place the center of the ball on the X axis centerline of the turret. 13. Tighten screw B using the wrench provided. 14. Datum the part probe, as outlined on the next page. I H TP4689 Figure Part Probe OMM Unit on the Main Spindle Headwall M-392D

243 DATUMING THE PART PROBE - CAUTION - The part probe must be correctly datumed before automatic operation is performed. When the probe is datumed for automatic operation, macro variables 500 and 501 are used to record the position of the probe stylus. Datuming the Part Probe on the X Axis - NOTE - The program in step 1 is only an example to illustrate program structure. Turret station, tool offset, and coordinate Data may vary, depending on workpiece geometry and probe location on the turret top plate. If necessary, refer to Entering a Program from the Keyboard, page 3-10, for information on entering a program through the manual Data input keyboard. In this example, a piece of bar stock has been turned to a diameter of inches for the purpose of datuming the probe on the X axis. 1. Enter a program similar to the following into the control memory: O (Radial Datum X Axis Part Probe) ; Program Number (Operator Message) G10 P0 Z ; Set Work Shift, if Required G0 G40 G98 X16.5 Z6. T0 ; Positioning Mode, Cancel Tool Nose Radius Compensation, Inch/Millimeter per Minute Feedrate, Move Turret to Safe Index Position, Cancel Tool Offset T0800 ; Index to Probe Station, No Tool Offset Active X3. Z.5 T0808 ; Move to Position Probe as Required, Activate Probe Offset M90 ; Part Probe ON G4 X1. ; Dwell to Allow Probe ON X1.76 Z-.375 ; Position Probe for X Axis Datuming as Required G65 P9013 X1.75 ; Call Macro Program 9013, X1.75 = Known Diameter of the Bar stock G0 X3. Z.5 ; Move to Clear Bar stock in Spindle X16.5 Z6. T0 ; Move Turret to Safe Index Position, Cancel Tool Offset M30 ; End of Program 2. Activate Automatic Mode. - NOTE - Refer to Activating a Stored Program, page 3-10, for information on activating a program. 3. Verify the datum program entered in step 1 is active. 4. Press the Cycle Start push button to datum the probe on the X axis. 5. Proceed to Datuming on the Z Axis, on the next page. M-392D 13-31

244 Datuming the Part Probe on the Z Axis - NOTE - The program in step 1 is only an example to illustrate program structure. Turret station, tool offset, and coordinate Data may vary, depending on the Z axis surface to be used for datuming and probe location on the turret top plate. If necessary, refer to Entering a Program from the Keyboard, page 3-10, for information on entering a program through the manual Data input keyboard. In this example, the spindle face will be used for datuming the probe on the Z axis. 1. Enter a program similar to the following into the control memory: O (Datum Z Axis Part Probe) ; Program Number (Operator Message) G10 P0 Z ; Set Work Shift, if Required G0 G40 G98 X16.5 Z6. T0 ; Positioning Mode, Cancel Tool Nose Radius Compensation, Inch/Millimeter per Minute Feedrate, Move Turret to Safe Index Position, Cancel Tool Offset T0800 ; Index to Probe Station, No Tool Offset Active X5. Z.5 T0808 ; Move to Position Probe as Required, Activate Probe Offset M90 ; Part Probe ON G4 X1. ; Dwell to Allow Probe ON X3.625 Z.05 ; Position Probe for Z Axis Datuming as Required G65 P9017 Z0. T8. ; Call Macro Program 9017, Z0. = Known Z Position, T8. = Offset Location for Part Probe G0 X5. Z.5 ; Move to Clear Spindle X16.5 Z6. T0 ; Move Turret to Safe Index Position, Cancel Tool Offset M30 ; End of Program 2. Activate Automatic Mode. - NOTE - Refer to Activating a Stored Program, page 3-10, for information on activating a program. 3. Verify the datum program entered in step 1 is active. 4. Press the Cycle Start push button to datum the probe on the Z axis. The probe is now datumed and is ready for automatic operation. Refer to the programmer s manual (M-391) for information on programming automatic operation of the part probe M-392D

245 MAINTENANCE - CAUTION - Only a minimum amount of maintenance can be done by user. Dismantling of Renishaw equipment is a highly specialized operation and must be carried out by an authorized service center. Equipment requiring repair that is still under warranty should be returned to Hardinge Inc. Adjustment to the stylus spring pressure may affect probe repeatability. Refer to the Renishaw LP2 Probe document supplied with the probe. Do not use sharp cleaning tools. Do not use a degreasing agent when washing the probe cavity. The probe system requires minimum maintenance. Approximately once a month the cavity between front cap K, Figure 13.22, and inner seal Q, Figure 13.23, should be checked for contaminants. A build-up of dirt or fine chips could eventually cause the probe to malfunction. 1. Use the hex pin wrench supplied with probe to remove screw L and stylus J, Figure Remove cap K, using spanner wrench supplied with the probe. 3. Remove seal N, Figure 13.23, and compression spring O. 4. Wash out cavity P and all parts with a jet of coolant. J K M N O P L TP754 Figure Probe and Stylus Assembly Q Figure Probe Disassembled TP751 M-392D 13-33

246 5. Check rear O-ring R, Figure 13.24, for damage or wear and replace if necessary. 6. If inner seal Q, Figure 13.23, is pierced or damaged, return the probe to Hardinge Inc. 7. Reverse the procedure to reassemble. Front cap K, Figure 13.22, need only be finger tight. R Figure Rear O-Ring TP755 CLEANING PROBE AND OMM UNIT WINDOWS The optical windows on the probe and OMM units should be checked several times during each work shift for any accumulation of dirt or chips which might interfere with probe operation. Use glass cleaner and a rag to clean the windows at least once per shift. More frequent cleaning may be required depending on the material being machined M-392D

247 CHANGING THE PROBE BATTERIES - NOTE - The probe unit is supplied with four 3 volt lithium batteries. Two 3 volt lithium batteries are required for probe operation. 1. Loosen screws G, Figure or 13.20, and remove the probe assembly from probe holder F. 2. Remove cap S, Figure 13.25, using a coin or screwdriver. 3. Remove battery retractor T and the old batteries. 4. Install the battery retractor and two fresh batteries in the probe, positive end first. Refer to Figure for the correct position of the battery retractor. 5. Install cap S. 6. Re-install the probe assembly on the top plate. Refer to page Re-calibrate the probe. S T Figure Battery Orientation TP4694 Battery Retractor Figure Battery Retractor Position TP4695 M-392D 13-35

248 SUB-SPINDLE PART PRESENT DETECTOR [Option] - CAUTION - Refer to page 4-2 for information concerning turret tooling for QUEST 6/42 & 6/42SP lathes equipped with the following combination of options: 12 or 16 station VDI 30 top plate Tool probe Sub-spindle part present detector INTRODUCTION Sub-spindle part present detector "U", Figure 13.27, is commanded from the part program to check the sub-spindle for a part. Refer to the programmer s manual (M-391) for an explanation of the M codes used to command the sub-spindle part present detector. U Figure Part Present Detector TP M-392D

249 EXTENDING THE PART PRESENT DETECTOR An extension is provided in the event an application requires positioning the part present detector arm further from the face of the sub-spindle. - CAUTION - Care must be used to avoid an impact between the part present detector and the main machine headwall when the part present detector extension is installed. 1. Note the radial position of part present detector arm "V", Figure Loosen two screws "W". 3. Remove the part present detector arm from main shaft "Z". 4. Thread extension "X" into the main shaft. 5. Tighten set screw "Y". 6. Install the part present detector arm and position radially as noted in step Tighten two screws "W". RANGE OF MOTION The range of motion for the part present detector is 120. Refer to View "B", Figure M-392D 13-37

250 Extension Not Installed Extension Installed V W X Y Z VIEW "A" VIEW "B" 120 TP5349 Figure Part Present Detector Extension and Range of Motion M-392D

251 - NOTES - M-392D 13-39

252 - NOTES M-392D

253 CHAPTER 14 - VDI LIVE TOOLING [Option] INTRODUCTION A live tooling option is available on QUEST series lathes equipped with a VDI top plate. The live tooling attachments are not included with the machine tool and must be purchased separately. VDI 30 live tooling attachments have a maximum spindle speed of 8000 rpm, as measured at the tool tip, and can be operated at 30 percent of the total duty cycle at 8000 rpm. VDI 40 live tooling attachments have a maximum spindle speed of 6000 rpm, as measured at the tool tip, and can be operated at 30 percent of the total duty cycle at 6000 rpm. TYPES OF ATTACHMENTS - CAUTION - Live tooling attachments are available with or without through-tool coolant capability. Live tooling attachments without through-tool coolant capability can be run with or without coolant, as the machining process requires. Live tooling attachments with through-tool coolant capability MUST be run with coolant turned ON. Refer to page 14-3 for information on live tooling RPM limits for through-tool coolant attachments, based on coolant pressure. The live tooling attachments are identified by axis of operation and if they have internal (thru-tool) coolant. VDI 30 live tooling attachments are designed to use ER 25 collets to grip the tools. VDI 40 live tooling attachments are designed to use ER 32 collets to grip the tools. Cross-Working Attachment: This attachment locates the center of the drill or milling tool on the centerline of the tool station, with the spindle of the attachment aligned with the X axis. End-Working Attachment: This attachment locates the center of the drill or milling tool on the centerline of the tool station, with the spindle of the attachment aligned with the Z axis. M-392D 14-1

254 ADJUSTABLE DEAD STOP Each live tooling attachment is equipped with an adjustable dead stop. The dead stop can be adjusted against the end of the tool to prevent the tool from sliding in the tool holder during high-thrust machining operations. The adjustable dead stop is threaded and can be adjusted using a small common-blade screwdriver. The adjustable dead stop for all cross-working live tooling attachments is accessed through the front of the tool holder. Refer to Figure The adjustable dead stop for end-working live tooling attachments equipped with internal coolant is accessed through the front of the tool holder. The adjustable dead stop for end-working live tooling attachments NOT equipped with internal coolant is accessed through the back of the tool holder. Refer to Figure Access to Dead Stop Figure Cross-Working Live Tooling Attachment TI4811 Access to Dead Stop (Attachment without internal coolant) Access to Dead Stop (Attachment with internal coolant) TI4812 Figure End-Working Live Tooling Attachment 14-2 M-392D

255 VDI 30 LIVE TOOLING LIVE TOOLING COLLETS AND CAPACITIES - NOTE - ER 25 and ER 32 collets conform to DIN ER 25 collets are capable of employing English tools with a shank size from 0.02 inches up to and including 0.63 inches. ER 25 collets are capable of employing Metric tools with a shank size from 0.5 millimeters up to and including 16 millimeters. VDI 40 LIVE TOOLING ER 32 collets are capable of employing English tools with a shank size from 0.04 inches up to and including 0.79 inches. ER 32 collets are capable of employing Metric tools with a shank size from 1.0 millimeters up to and including 20 millimeters. LIVE TOOLING RPM LIMIT - CAUTION - DO NOT exceed the RPM limits for through-tool coolant live tooling attachments, as indicated in graphs 14.1 and NOTE - The RPM limits DO NOT apply to live tooling attachments without through-tool coolant capability Live tooling attachments with through-tool coolant capability are subject to an RPM limit, based on the pressure of the coolant supplied to the attachment. The coolant pump delivers approximately 187 psi [12.9 bar]. Refer to graphs 14.1 and 14.2 for RPM limits. M-392D 14-3

256 End-Working Toolholder Internal Coolant Maximum Coolant Pressure, (PSI) Spindle Speed, (RPM) Graph End-Working Attachments TI4750A Cross-Working Toolholder Internal Coolant Maximum Coolant Pressure, (PSI) Spindle Speed, (RPM) Graph Cross-Working Attachments TI4751A 14-4 M-392D

257 MOUNTING THE ATTACHMENT LIVE TOOLING ATTACHMENT INSTALLATION - NOTE - All turret tool stations can be used for live tooling applications. 1. Power-up the machine according to the procedure outlined in Chapter Press the control Reset key. 3. Activate Jog mode. - CAUTION - The machine operator must be sure that no interference exists between the spindle, spindle tooling, turret, turret tooling, or workpiece before manually indexing the turret. 4. Move the turret to a safe position for indexing. - WARNING - Stay clear of the turret and turret tooling when indexing the turret. Physical injury can result. 5. Manually index the turret to position the desired tool station: a) Set the Turret Station switch to the tool station to be indexed to the active position. b) Press the Index push button. 6. Thoroughly clean the turret top plate and the live tooling attachment. 7. Clean and check the O-ring on the live tooling attachment to be sure the O-ring is in good condition. 8. If mounting an end-working attachment, loosen two screws D, Figure 14.4 or CAUTION - NEVER force the live tooling attachment into the turret top plate. Be sure the live tooling attachment is mounted flush against the side of the turret top plate, as shown in Figure 14.3, 14.4, 14.5, or NOTE - When installing a VDI 40 live tooling attachment, the flats on the end of the drive shaft must be oriented 90 (perpendicular) to the gear rack on the shaft, as shown in Figures 14.5 and If necessary, rotate the spindle of the VDI 40 live tooling attachment to allow the attachment to seat properly. 9. Aligning live tooling attachment A with coolant button C, mount the live tooling attachment on the turret top plate, as shown in Figure 14.3, 14.4, 14.5, or M-392D 14-5

258 10. If mounting an end-working attachment, press the tool holder against the turret top plate and tighten two screws D, Figure 14.4 or NOTE - Maximum torque for the clamp screw is 17 lb-ft [23 N m] on VDI 30 top plates and 33 lb-ft [45 N m] on VDI 40 top plates. 11. Tighten clamp screw B. 12. If necessary, remove cap E, Figure 14.11, or cap F, Figure 14.12, and install the proper collet for the tool to be used. Replace the cap, but DO NOT TIGHTEN M-392D

259 1 A B C TI4714A Figure Mounting a VDI 30 Cross-Working Live Tooling Attachment A B D 9 3 C TI4872 Figure Mounting a VDI 30 End-Working Live Tooling Attachment M-392D 14-7

260 Be sure the tool holder is flush against the side of the turret top plate Gear Rack for Clamp Screw A B C Note the Orientation of the Flats on the Drive Shaft 5 6 TI47886 Figure Mounting a VDI 40 Cross-Working Live Tooling Attachment Be sure the tool holder is flush against the side of the turret top plate Gear Rack for Clamp Screw A B 10 9 D 3 C Note the Orientation of the Flats on the Drive Shaft 5 6 TI4885 Figure Mounting a VDI 40 End-Working Live Tooling Attachment 14-8 M-392D

261 INSTALLING / REMOVING TOOLS Maximum Tool Extension - WARNING - DO NOT exceed these maximum tool extension values. Personal injury and damage to the tooling and machine can result. - NOTE - All dimensions are shown in inches [millimeters]. Cross-working live tooling attachments have the following maximum tool extension from the edge of the turret top plates: VDI 30 Turret: [177.4] VDI 30 Turret with Y-Axis Option: [142.4] VDI 40 Turret: [192.4] VDI 40 Turret with Y-Axis Option: [157.4] Refer to Figures 14.7 and Inch [Millimeter] Inch [Millimeter] Maximum Tool Extension Standard Turret: [177.4] Y-Axis Turret: [142.4] Maximum Tool Extension Standard Turret: [192.4] Y-Axis Turret: [157.4] TI4715 Figure Maximum Tool Extension for VDI 30 Cross-Working Attachments TI4715 Figure Maximum Tool Extension for VDI 40 Cross-Working Attachments M-392D 14-9

262 End-working live tooling attachments oriented for sub-spindle operation have a maximum tool extension of inches [ mm] from the centerline of the turret top plate tool mounting location. Refer to Figures 14.9 and Inch [Millimeter] Inch [Millimeter] Maximum Tool Extension [177.73] Maximum Tool Extension [177.73] [70.00] [90.00] [212.73] Maximum Tool Extension [212.73] Maximum Tool Extension TI4704 Figure Maximum Tool Extension for VDI 30 End-Working Attachments (Oriented for Sub-Spindle Operation) TI4704 Figure Maximum Tool Extension for VDI 40 End-Working Attachments (Oriented for Sub-Spindle Operation) M-392D

263 Procedure - NOTE - Wrenches are supplied with the live tooling attachments. 1. Insert the tool into the attachment and set to length. 2. Secure the tool: On cross-working attachments, mount a wrench on spindle E, Figure 14.11, and use a second wrench to turn cap F in the clockwise direction to tighten. On end-working attachments, mount a wrench on spindle H, Figure 14.12, and use a spanner wrench to turn cap G in the clockwise direction to tighten. Reverse the procedure to remove the tooling. E F TI4209 Figure Cross-Working Attachment G H TI4210 Figure End-Working Attachment M-392D 14-11

264 LIVE TOOLING ATTACHMENT REMOVAL - WARNING - When removing a live tooling attachment from the top plate, have a firm grip on the attachment while loosening the clamp screw in the top plate. The turret is pressurized to prevent fluid contaminants from entering the turret assembly. The air pressure in the turret may cause the tooling attachment to begin moving out of the top plate when the clamp screw is loosened. 1. If removing an end-working attachment, loosen two screws D, Figure 14.4 or Loosen clamp screw B, Figure 14.3 or 14.4, 14.5, or Remove the tool holder from the turret top plate. 4. Install a tool station plug if another tool holder is not to be installed. Refer to page 4-4 for information on tool station plugs. 5. Repeat steps 1 through 4 for additional tool holders, as necessary M-392D

265 LIVE TOOLING OFFSETS Live tooling offsets are set in the same manner as standard tooling. However, there are some considerations to be aware of that will simplify setting the tool offsets for tools mounted in live tooling attachments. These considerations are outlined below. Refer to page for information on setting live tooling offsets. CROSS-WORKING ATTACHMENTS Cross-working attachments are qualified on the Z axis. The centerline of the spindle in the cross-working attachment will always be located at the Z axis reference position of the turret top plates. Therefore, the Z axis tool offset will always be 0". Figures 14.7 and 14.8 illustrate a cross-working drill/mill attachment mounted on the turret top plate. END-WORKING ATTACHMENTS End-working attachments are qualified on the X axis. Figures 14.9 and illustrate an end-working drill/mill attachment mounted on the turret top plate. VDI 30 Attachments The centerline of the spindle in the VDI 30 end-working attachment will be located inches [70.0 mm] from the side of the turret top plate. On machines set for diameter programming, this will result in an X tool geometry offset of inches [ mm]. On machines set for radius programming, this will result in an X tool geometry offset of inches [70.00 mm]. VDI 40 Attachments The centerline of the spindle in the VDI 40 end-working attachment will be located inches [90.0 mm] from the side of the turret top plate. On machines set for diameter programming, this will result in an X tool geometry offset of inches [ mm]. On machines set for radius programming, this will result in an X tool geometry offset of inches [90.00 mm]. M-392D 14-13

266 SETTING TOOL OFFSETS FOR LIVE TOOLING The live tooling feature allows milling, drilling, and tapping operations to be performed on either the diameter or face of the workpiece. The method used to establish the tool offset values for live tooling are similar to the method used for standard tooling. Live tooling attachments can be mounted at any tool station on the turret top plate. Setting Offsets for End-Working Tools - NOTE- VDI 30 end-working live tooling attachments place the tool centerline inches [70.0 mm] from the X axis turret face. When establishing tool offsets, this dimension must be doubled for machines that have been set for Diameter Programming. VDI 40 end-working live tooling attachments place the tool centerline inches [90.0 mm] from the X axis turret face. When establishing tool offsets, this dimension must be doubled for machines that have been set for Diameter Programming. This procedure assumes that the live tooling attachment has already been mounted on the turret top plate and the tooling has been installed in the attachment. Refer to page 14-5 for information on installing live tooling attachments. 1. Load a workpiece of known diameter and length into the collet closer or chuck. 2. If it has not already been done, determine the Work Shift Offset following the appropriate procedure in Chapter 7. - NOTE - The work shift value must be in the Z axis work shift register to accurately set the tool offsets. 3. Enter the work shift value into the Z axis work shift register. 4. Activate Jog mode. 5. Set the Feedrate Override switch to the desired setting. - CAUTION - The machine operator must be sure that no interference exists between the spindle, spindle tooling, turret, turret tooling, or workpiece before manually indexing the turret. 6. Jog the turret to a safe position for indexing. 7. Select the desired turret station using the Turret Station switch. 8. Press the Index push button to index the turret to the selected station. 9. Jog the tool to within 1 inch [25 mm] of the workpiece being held in the spindle M-392D

267 10. Place a shim against the part face and use the handwheel to move the turret on the Z axis to gently touch the tool tip to the shim so that a slight drag is felt when moving the shim. 11. Press the Offset Setting function key. 12. Press the Offset soft key to access the Tool Offset pages. 13. Press the Geometry soft key to display the Tool Geometry Offset pages. 14. Use the page and cursor keys to position the cursor at the X axis field for the desired offset. 15. Key in the appropriate value from the following table: Programming Mode Diameter Radius Programming Unit Value to Enter as Offset VDI 30 Top Plate VDI 40 Top Plate Inch Millimeter Inch Millimeter Press the Input key. 17. Use cursor keys to position the cursor at the Z axis field for the desired offset. 18. Press the Operator soft key. 19. Key in the letter Z and the thickness of the shim as a negative value. - NOTE - Using the Measure soft key to set a tool geometry offset automatically resets the corresponding wear offset to zero. 20. Press the Measure soft key. The Z axis offset value for the tool will now be displayed under the appropriate offset number, as selected in step Turn the handwheel in the appropriate direction to clear the workpiece. 22. Repeat steps 6 through 21 for each tool as required. M-392D 14-15

268 Setting Offsets For Cross-Working Tools - NOTE - Cross-working live tool attachments place the tool centerline at the Z axis turret reference position. Therefore, the Z axis tool offset will be equal to 0 (zero). This procedure assumes that the live tooling attachment has already been mounted on the turret top plate and the tooling has been installed in the attachment. Refer to page 14-5 for information on installing live tooling attachments. 1. Load a workpiece of known diameter and length into the collet closer or chuck. 2. If it has not already been done, determine the Work Shift Offset following the appropriate procedure in Chapter 7. - NOTE - The work shift value must be in the Z axis work shift register to accurately set the tool offsets. 3. Enter the work shift value into the Z axis work shift register. 4. Activate Jog mode. 5. Set the Feedrate Override switch to the desired setting. - CAUTION - The machine operator must be sure that no interference exists between the spindle, spindle tooling, turret, turret tooling, or workpiece before manually indexing the turret. 6. Jog the turret to a safe position for indexing. 7. Select the desired turret station using the Turret Station switch. 8. Press the Index push button to index the turret to the selected station. 9. Jog the tool until it is positioned over the workpiece O.D. 10. Press the X push button. 11. Press the desired handwheel increment push button. 12. Place a shim against the part O.D. and use the handwheel to move the turret on the X axis to gently touch the tool tip to the shim so that a slight drag is felt when moving the shim. 13. Press the Offset Setting key. 14. Press the Offset soft key to access the Tool Offset pages. 15. Press the Geometry soft key to display the Tool Geometry Offset pages M-392D

269 16. Use the page and cursor keys to position the cursor at the X axis field for the desired offset. 17. Key in the diameter of the workpiece as a positive value. Example: Diameter = Input = X NOTE - Using the Measure soft key to set a tool geometry offset automatically resets the corresponding wear offset to zero. 18. Press the Measure soft key. 19. Compensate for shim thickness: If the control is set for diameter programming, enter twice the shim thickness as a negative (-) value. If the control is set for radius programming, enter the shim thickness as a negative (-) value. 20. Press the Input+ soft key. The X Offset will be decreased by the amount specified in step Use the cursor keys to position the cursor at the Z axis field for the desired offset. 22. Key in 0" (zero). 23. Press the Input key. 24. Turn the handwheel in the appropriate direction to clear the workpiece. 25. Repeat steps 6 through 24 for each tool as required. TOOL NOSE RADIUS COMPENSATION For typical live tooling applications, Tool Nose Radius Compensation is not required. Tool Nose Radius Compensation may be required for live tooling during C-Axis operations. Refer to the programmer s manual (M-391) for information on Tool Nose Radius Compensation or C-Axis. LIVE TOOLING ALIGNMENT The live tooling attachments are factory set to be on center and should require no further adjustment. M-392D 14-17

270 LIVE TOOLING MAINTENANCE LUBRICATING THE LIVE TOOLING ATTACHMENT - NOTES - Each live tooling attachment must be removed from the turret top plate at least once per month to be inspected and lubricated. 1. Move the turret to a safe index position. 2. Index the turret top plate to a convenient position for removing the live tooling attachment. 3. Open the main coolant guard door. 4. Press the Emergency Stop push button. 5. Wipe coolant, chips, and other contaminants J from the live tool attachment and turret top plate. 6. Unthread the clamp screw just enough to be able to remove the live tooling attachment. Pull the live tooling attachment straight out from the top plate. 7. Inspect the live tooling attachment for wear and the amount of grease on spline I, Figure 14.13, or flats K, Figure Lightly coat spline I or flats K with Molylube Anti-Seize grease. 9. Check O-ring J or L to be sure that it is in good condition. 10. Mount the live tooling attachment on the turret top plate. - NOTE - Maximum torque for the clamp screw is 17 lb-ft [23 N m] on VDI 30 top plates and 33 lb-ft [45 N m] on VDI 40 top plates. 11. Tighten the clamp screw. 12. Close the main coolant guard door. 13. Pull the Emergency Stop push button out to the first detent, wait two seconds; then, pull the push button out to the end of travel and release. 14. Repeat steps 2 through 13, as needed, for additional live tooling attachments. TP4221 Figure VDI 30 Cross-Working Live Tooling Attachment K I L Figure VDI 40 End-Working Live Tooling Attachment TP M-392D Revised: January 18, 2008

271 LUBRICATING THE LIVE TOOLING PINION GEARS Lubrication Frequency VDI 30 TURRET If the live tooling is generally run at less than 5000 rpm, the live tooling pinion gears must be inspected and lubricated every 500 hours of operation. If the live tooling is generally run at 5000 rpm or faster, the live tooling pinion gears must be inspected and lubricated every 250 hours of operation. VDI 40 TURRET If the live tooling is generally run at less than 4000 rpm, the live tooling pinion gears must be inspected and lubricated every 500 hours of operation. If the live tooling is generally run at 4000 rpm or faster, the live tooling pinion gears must be inspected and lubricated every 250 hours of operation. Lubrication Procedure 1. Move the turret to a convenient position for accessing top plate cover M, Figure Open the main coolant guard door. 3. Press the Emergency Stop push button. 4. Wipe coolant, chips, and other contaminants from the turret top plate. 5. Remove six screws N and the associated lock washers to remove turret cover M. 6. Apply KLÜBER ISOFLEX Topas NCA 152 grease to pinion gears O, Figure Replace turret cover M using lock washers and screws N, Figure Torque screws N to 120 lb-in [162 N m]. Q M O N P TP4227 Figure Turret Top Plate Cover (VDI 30 Turret Shown) TP4218 Figure Live Tooling Pinion Gears (VDI 30 Turret Shown) M-392D 14-19

272 LUBRICATING THE TURRET INDEX SHAFT AND LIVE TOOLING DRIVE SHAFT The turret index shaft and live tooling drive shaft must be inspected and lubricated every 2000 hours of operation. 1. Move the turret to a convenient position for accessing top plate cover M, Figure Open the main coolant guard door. 3. Press the Emergency Stop push button. 4. Wipe coolant, chips, and other contaminants from the turret top plate. 5. Remove six screws N and the associated lock washers to remove turret cover M. - CAUTION - Use only a manually operated grease gun. - NOTE - A manually operated grease gun will require approximately 4½ strokes to deliver the required amount of grease. 6. Using a manually operated grease gun, apply 4.0 cc of KLÜBER ISOFLEX Topas NCA 15 grease to grease fittings P and Q. 7. Replace turret cover M using lock washers and screws N, Figure Torque screws N to 120 lb-in [162 N m] M-392D

273 - NOTES - M-392D 14-21

274 - NOTES M-392D

275 CHAPTER 15 - ESA LIVE TOOLING [Option] INTRODUCTION A live tooling option is available on QUEST series lathes equipped with a ESA top plate. The live tooling attachments are not included with the machine tool and must be purchased separately. ESA live tooling attachments have a maximum spindle speed of 8000 rpm, as measured at the tool tip, and can be operated at 30 percent of the total duty cycle at 8000 rpm. TYPES OF ATTACHMENTS - CAUTION - Live tooling attachments are available with or without through-tool coolant capability. Live tooling attachments without through-tool coolant capability can be run with or without coolant, as the machining process requires. Live tooling attachments with through-tool coolant capability MUST be run with coolant turned ON. The live tooling attachments are identified by axis of operation and if they have internal (thru-tool) coolant. Cross-Working Attachment: This attachment aligns the centerline of the tool with the X axis. End-Working Attachment: This attachment aligns the centerline of the tool with the Z axis. LIVE TOOLING COLLETS AND CAPACITIES - NOTE - ER 25 collets conform to DIN ESA live tooling attachments are designed to use ER 25 collets to grip the tools. ER 25 collets are capable of employing English tools with a shank size from inches up to and including inches. ER 25 collets are capable of employing Metric tools with a shank size from 1.0 millimeters up to and including 16 millimeters. M-392D 15-1

276 LIVE TOOLING ATTACHMENT INSTALLATION - CAUTION - Failure to install tool station plugs at turret tool stations not equipped with tooling can result in damage to the machine tool. Refer to page 5-2 for information on ESA tool station plugs. MOUNTING THE ATTACHMENT - NOTE - All turret tool stations can be used for live tooling applications. 1. Thoroughly clean the top plate, live tooling attachments, and tooling. 2. Clean and check the O-ring on each tool holder to be sure the O-ring is in good condition. 3. If it is necessary to index the turret: A) Move the turret to a safe index position. B) Index the turret to the desired tool station. C) Move the turret to a convenient position for installing tools. 4. Press and hold button "A", Figure Insert the tool holder into the turret top plate as shown in View B. 6. Release button "A" to clamp the tool holder. A B VIEW A Live Tool Attachment Aligned for Installation VIEW B Live Tool Attachment Installed on Top Plate TI5451 Figure Live Tooling Attachment Installation (Cross-Working Attachment Shown) 15-2 M-392D

277 7. Tighten rear clamp screw "C", Figure Install and tighten four face screws B, Figure If necessary, remove cap D, Figure 15.3, and install the proper collet for the tool to be used. Replace the cap, but DO NOT TIGHTEN. C Figure Rear Clamping Screw TP7130 Cross-Working Live Tooling Attachment End-Working Live Tooling Attachment D D TI5452 Figure Collet Caps on Live Tool Attachments M-392D 15-3

278 INSTALLING TOOLS Maximum Tool Extension - WARNING - DO NOT exceed these maximum tool extension values. Personal injury and damage to the tooling and machine can result. - NOTE - All dimensions are shown in inches [millimeters]. Cross-working live tooling attachments have the following maximum tool extension from the edge of the turret top plates: Standard Turret: [212.42] Turret with Y-Axis Option: [177.37] End-working live tooling attachments oriented for sub-spindle operation have a maximum tool extension of inches [ millimeters] from the centerline of the turret top plate tool mounting location. Refer to Figure Cross-Working Live Tooling Attachment End-Working Live Tooling Attachment Oriented for Sub-Spindle Operation [139.22] Standard Turret: [212.42] Y-Axis Turret: [177.37] Inch [Millimeter] Figure Maximum Tool Extensions [212.73] TI M-392D

279 Tool Installation Procedure - NOTE - Wrenches are supplied with the live tooling attachments. 1. Insert the tool into the attachment and set to length. 2. Mount a spanner wrench on spindle E, Figure Use a wrench to tighten cap F. Cross-Working Live Tooling Attachment End-Working Live Tooling Attachment E F F E TI5454 Figure Tools Installed in Live Tool Attachments M-392D 15-5

280 LIVE TOOLING OFFSETS Live tooling offsets are set in the same manner as standard tooling. However, there are some considerations to be aware of that will simplify setting the tool offsets for tools mounted in live tooling attachments. These considerations are outlined below. Refer to page 15-7 for information on setting live tooling offsets. CROSS-WORKING ATTACHMENTS Cross-working attachments are qualified on the Z axis. The centerline of the spindle in the cross-working attachment will always be located at the Z axis reference position of the turret top plates. The Z axis tool offset will always be 0". END-WORKING ATTACHMENTS - NOTE - Machines equipped with an ESA turret top plate have the same X axis turret reference position and travel specifications as a machine equipped with a VDI 30 turret top plate. As indicated in Figure 15.6, the diameter of the ESA turret top plate is inches [35.00 millimeters] smaller per side than the VDI 30 turret top plate. End-working attachments are qualified on the X axis. The centerline of the spindle in the end-working attachment will be located inches [70.00 millimeters] from the X axis turret reference position. On machines set for radius programming, the X tool geometry offset will be inches [70.00 millimeters]. On machines set for diameter programming, the X tool geometry offset will be inches [ millimeters]. Inch [Millimeter] [35.00] Turret X Axis Reference Position (Refer to the note on this page) [70.0] Figure X Axis Tool Offset for End-Working Live Tooling Attachments TI5455A 15-6 M-392D

281 SETTING TOOL OFFSETS FOR LIVE TOOLING The live tooling feature allows milling, drilling, and tapping operations to be performed on either the diameter or face of the workpiece. The method used to establish the tool offset values for live tooling are similar to the method used for standard tooling. Live tooling attachments can be mounted at any tool station on the turret top plate. Setting Offsets for End-Working Tools - NOTE- ESA end-working live tooling attachments place the tool centerline inches [70.00 millimeters] from the X axis turret reference position. When establishing tool offsets, this dimension must be doubled for machines that have been set for Diameter Programming. This procedure assumes that the live tooling attachment has already been mounted on the turret top plate and the tooling has been installed in the attachment. Refer to page 15-2 for information on installing live tooling attachments. 1. Load a workpiece of known diameter and length into the collet closer or chuck. 2. If it has not already been done, determine the Work Shift Offset following the appropriate procedure in Chapter 7. - NOTE - The work shift value must be in the Z axis work shift register to accurately set the tool offsets. 3. Enter the work shift value into the Z axis work shift register. 4. Activate Jog mode. 5. Set the Feedrate Override switch to the desired setting. - CAUTION - The machine operator must be sure that no interference exists between the spindle, spindle tooling, turret, turret tooling, or workpiece before manually indexing the turret. 6. Jog the turret to a safe position for indexing. 7. Select the desired turret station using the Turret Station switch. 8. Press the Index push button to index the turret to the selected station. 9. Jog the tool to within 1 inch [25 millimeters] of the workpiece being held in the spindle. M-392D 15-7

282 10. Place a shim against the part face and use the handwheel to move the turret on the Z axis to gently touch the tool tip to the shim so that a slight drag is felt when moving the shim. 11. Press the Offset Setting function key. 12. Press the Offset soft key to access the Tool Offset pages. 13. Press the Geometry soft key to display the Tool Geometry Offset pages. 14. Use the page and cursor keys to position the cursor at the X axis field for the desired offset. 15. Key in the appropriate value from the following table: Programming Mode Diameter Radius Programming Unit Value to Enter as Offset Inch Millimeter Inch Millimeter Press the Input key. 17. Use cursor keys to position the cursor at the Z axis field for the desired offset. 18. Press the Operator soft key. 19. Key in the letter Z and the thickness of the shim as a negative value. - NOTE - Using the Measure soft key to set a tool geometry offset automatically resets the corresponding wear offset to zero. 20. Press the Measure soft key. The Z axis offset value for the tool will now be displayed under the appropriate offset number, as selected in step Turn the handwheel in the appropriate direction to clear the workpiece. 22. Repeat steps 6 through 21 for each tool as required M-392D

283 Setting Offsets for Cross-Working Tools - NOTE - Cross-working live tool attachments place the tool centerline at the Z axis turret reference position. Therefore, the Z axis tool offset will be equal to 0 (zero). This procedure assumes that the live tooling attachment has already been mounted on the turret top plate and the tooling has been installed in the attachment. Refer to page 15-2 for information on installing live tooling attachments. 1. Load a workpiece of known diameter and length into the collet closer or chuck. 2. If it has not already been done, determine the Work Shift Offset following the appropriate procedure in Chapter 7. - NOTE - The work shift value must be in the Z axis work shift register to accurately set the tool offsets. 3. Enter the work shift value into the Z axis work shift register. 4. Activate Jog mode. 5. Set the Feedrate Override switch to the desired setting. - CAUTION - The machine operator must be sure that no interference exists between the spindle, spindle tooling, turret, turret tooling, or workpiece before manually indexing the turret. 6. Jog the turret to a safe position for indexing. 7. Select the desired turret station using the Turret Station switch. 8. Press the Index push button to index the turret to the selected station. 9. Jog the tool until it is positioned over the workpiece O.D. 10. Press the X push button. 11. Press the desired handwheel increment push button. 12. Place a shim against the part O.D. and use the handwheel to move the turret on the X axis to gently touch the tool tip to the shim so that a slight drag is felt when moving the shim. 13. Press the Offset Setting key. 14. Press the Offset soft key to access the Tool Offset pages. 15. Press the Geometry soft key to display the Tool Geometry Offset pages. M-392D 15-9

284 16. Use the page and cursor keys to position the cursor at the X axis field for the desired offset. 17. Key in the diameter of the workpiece as a positive value. Example: Diameter = Input = X NOTE - Using the Measure soft key to set a tool geometry offset automatically resets the corresponding wear offset to zero. 18. Press the Measure soft key. 19. Compensate for shim thickness: If the control is set for diameter programming, enter twice the shim thickness as a negative (-) value. If the control is set for radius programming, enter the shim thickness as a negative (-) value. 20. Press the Input+ soft key. The X Offset will be decreased by the amount specified in step Use the cursor keys to position the cursor at the Z axis field for the desired offset. 22. Key in 0" (zero). 23. Press the Input key. 24. Turn the handwheel in the appropriate direction to clear the workpiece. 25. Repeat steps 6 through 24 for each tool as required. TOOL NOSE RADIUS COMPENSATION For typical live tooling applications, Tool Nose Radius Compensation is not required. Tool Nose Radius Compensation may be required for live tooling during C-Axis operations. Refer to the programmer s manual (M-391) for information on Tool Nose Radius Compensation or C-Axis. LIVE TOOLING MAINTENANCE Refer to the maintenance manual (M-393) for information on live tooling maintenance. LIVE TOOLING ALIGNMENT Live tooling alignment is set at the factory and should require no further adjustment M-392D

285 - NOTES - M-392D 15-11

286 - NOTES M-392D

287 CHAPTER 16 - TOOL LIFE MANAGEMENT INTRODUCTION The basic concept of Tool Life Management is that after a specific number of parts or a specific amount of machining time, the control will automatically begin using another tool in place of the current tool being used for a particular operation. Tools are assigned to specific groups, as designated by the programmer. The control will monitor the measurement value assigned to each tool group and automatically switch to the next tool in the group when the counter for that tool group reaches the measurement value specified by the programmer. TOOL LIFE MEASUREMENT UNITS Tool life can be measured using one of the two following methods: 1. Number of parts (machined by the tool) 2. Amount of machining time (on the tool) Only one of these methods may be used at a time. Number of parts will be the active measurement unit when the machine is shipped from the factory. Refer to Determining the Measurement Unit, page 16-5, for information on verifying or switching the active measurement unit. An alarm message will be displayed when any tool group has reached its programmed tool life and an M30" (End of Program) is read by the control. At that point, the machine operator will replace the tooling and reset the counter relating to the affected tool group. Refer to Resetting a Tool Group Counter, page NUMBER OF PARTS When this type of measurement is used, the control will increment the tool group counter for the active tool each time the tool group is called by the part program. AMOUNT OF MACHINING TIME When this type of measurement is used, the control will run the tool group counter for the current tool whenever G01, G02, or G03 is active. M-392D 16-1

288 TOOL LIFE MANAGEMENT PROGRAM When using Tool Life Management, tools and offsets are assigned to specific groups. These groups are established by the programmer through the use of a Tool Life Management program, which is independent of the part program. The Tool Life Management program will define the parameters required for Tool Life Management. The Tool Life Management program defines the following parameters: Group numbers. Tool life value for each group. Tool stations and offsets for each group. - CAUTION - When the Tool Life Management program is executed, all Tool Life Management counters will be reset to 0 (zero). When using Tool Life Management, the machine operator MUST load and execute the Tool Life Management program BEFORE executing the part program for the first time. Refer to the programmer s manual (M-391) for information on the Tool Life Management program and how to incorporate Tool Life Management information in the part program. BAR FEED OPERATION There are no special considerations for running bar jobs. When running a bar job and using Tool Life Management, the programmer will program an M30 at the end of the part program and the machine operator will activate Repeat mode to cause the part program to loop. Refer to page 1-9 for information on Repeat mode M-392D

289 OPERATION DETERMINING MAXIMUM GROUPS AND GROUP SIZES The maximum number of tool groups and maximum number of tools per group are established by parameter 6800, bits 0 and 1. Be sure that bits 0 and 1 are set to appropriate values to allow for the necessary number of tool groups and tools per group to be programmed in the Tool Life Management Program. The bits in parameter 6800 are numbered as follows: Set bits 0 and 1 according to the following chart: Bit 1 Bit 0 Max No. of Groups Max Tools per Group When the machine is shipped from the factory, the maximum number of groups and maximum tools per group will be set to 16. Verifying Maximum Groups and Group Sizes 1. Press the System key. 2. Press the Parameter soft key. 3. Use the Page keys to display the page that contains parameter Compare bits 0 and 1 to chart above to determine the maximum groups and group sizes. Setting Maximum Groups and Group Sizes 1. Press the Offset Setting key. 2. Press the Setting soft key. 3. If necessary, use the Page keys to display the Setting page that contains the Parameter Write field. 4. If necessary, use the cursor keys to position the cursor at the Parameter Write field. 5. Activate Manual Data Input mode. 6. Key in the number 1 (one). M-392D 16-3

290 7. Press the Input key. Parameter editing will be enabled. 8. Press the System key. 9. Press the Parameter soft key. 10. Use the Page and Cursor keys to position the cursor at parameter Record the current number in parameter Key in the entire parameter value with bits 0 and 1 set to the appropriate values. 13. Press the Input key. 14. Press the Offset Setting key. 15. Press the Setting soft key. 16. If necessary, use the cursor keys to position the cursor at the Parameter Write field. 17. Key in the number 0 (zero). 18. Press the Input key. Parameter editing will be disabled M-392D

291 DETERMINING THE MEASUREMENT UNIT The two types of measurement units available are Number of Parts and Amount of Machining Time. To verify which measurement unit is active, it is necessary to view parameter 6800, bit 2. To switch the type of measurement unit to be used with Tool Life Management, it is necessary to modify parameter 6800, bit 2. The bits in parameter 6800 are numbered as follows: Verifying the Measurement Unit 1. Press the System key. 2. Press the Parameter soft key. 3. Use the Page keys to display the page that contains parameter If parameter 6800, bit 2 is set to 0, Number of Parts is active. If parameter 6800, bit 2 is set to 1, Amount of Machining Time is active. Switching the Measurement Unit 1. Press the Offset Setting key. 2. Press the Setting soft key. 3. If necessary, use the Page keys to display the Setting page that contains the Parameter Write field. 4. If necessary, use the cursor keys to position the cursor at the Parameter Write field. 5. Activate Manual Data Input mode. 6. Key in the number 1 (one). 7. Press the Input key. Parameter editing will be enabled. 8. Press the System key. 9. Press the Parameter soft key. 10. Use the Page and Cursor keys to position the cursor at parameter Record the current number in parameter Key in the entire parameter value with bit 2 set to the appropriate value. 13. Press the Input key. 14. Press the Offset Setting key. 15. Press the Setting soft key. 16. If necessary, use the cursor keys to position the cursor at the Parameter Write field. 17. Key in the number 0 (zero). 18. Press the Input key. Parameter editing will be disabled. M-392D 16-5

292 RESETTING A TOOL GROUP COUNTER Resetting the control or turning the control OFF will have NO AFFECT on the tool group counters. When all of the tools in a tool group have reached the tool life specified in the Tool Life Management program and an M30 End of Program is read, the following alarm message will be displayed: 1006 TOOL GROUP LIFE END The expired tool groups will be listed near the bottom of the Tool Life Management screen on the control display. The control can display more than one tool group number at a time, when applicable. Resetting the counter for the expired tool group(s) will clear the alarm and allow machine operation. - NOTE - It is not necessary to change machine modes to reset tool group counters. Use the following procedure to reset the tool group counter(s): 1. Press the Offset Setting key. 2. Press the right-hand soft key. 3. Press the Tool Life soft key. - NOTE - Each time a cursor control key is pressed, the cursor will move to the next tool group in the corresponding direction. 4. Use the cursor control keys to move the cursor to the desired tool group. 5. Press the Operator soft key. 6. Press the Clear soft key. 7. Press the Execute soft key. The tool group counter at the cursor position will be reset to 0 (zero). 8. Repeat steps 4 through 7 to reset additional tool group counters, as needed M-392D

293 - NOTES - M-392D 16-7

294 - NOTES M-392D

295 CHAPTER 17 - SUB-SPINDLE AND COLLET CLOSER [Option] - WARNING - Tighten all draw tube screws before beginning spindle operation. - CAUTION - Never operate the sub-spindle without a work-holding device if the draw tube is in the spindle. INTRODUCTION The sub-spindle allows parts to be machined at both ends without stopping the machine to end-for-end the workpiece. This reduces cycle times by eliminating part handling by the operator. Drilling, boring, turning and facing operations can be performed on parts which are chucked in the sub-spindle. Depending on the machining sequence which is selected, the first side of the workpiece is machined in either the main spindle or the sub-spindle. The workpiece is then transferred to the other spindle to complete machining of the second side. The sub-spindle travel specifications are shown in Appendix One. CYCLE START SAFETY INTERLOCK Cycle Start is inhibited when the main spindle and sub-spindle work-holding devices are both open. At least one work-holding device must be closed before Cycle Start can be activated. FREE SPINDLE A Free Spindle condition allows the sub-spindle to be turned by hand. To obtain a free spindle, proceed as follows: - NOTE - To obtain a free spindle, the control must be ON and the sub-spindle must not be rotating. 1. Power up the machine as described in Chapter Press the control Reset key. 3. Press the Sub Spindle Free push button. M-392D 17-1

296 CONTROLLING SUB-SPINDLE MOVEMENT AUTOMATIC, MANUAL DATA INPUT, OR SINGLE MODE - NOTE - When E axis motion is programmed by itself, the sub-spindle moves at the programmed feedrate. When E axis motion is programmed with X and/or Z axis motion, the sub-spindle moves at a compensated feedrate to cause the sub-spindle to complete the move at the same time as the other axes. Linear motion of the sub-spindle assembly, designated the E axis, is performed by a servo drive system that is controlled by the CNC control. The E Data word is used to command direction and distance when moving the ball screw driven sub-spindle in Automatic, Manual Data Input, or Single mode. The face of the sub-spindle is the sub-spindle reference point. The maximum programmable feedrate (G01 active) is 394 in/min [10,000 mm/min]. The machine is forced into a Feed Hold condition when Automatic, Manual Data Input, or Single mode is active and any interlocked door is opened or cover removed. The Feed Hold condition is released when the door is closed or cover replaced. Press the Cycle Start push button to resume program execution. E Data Word The E Data word commands an absolute move referenced against the Z0 (zero) position of the machine coordinate position. Positive E coordinates are to the right of Z0 and negative E coordinates are to the left of Z0. The Z0 position will be equal to the face of the main spindle unless modified through the Work Shift offset. Refer to Chapter 7 for information on the Work Shift offset. Feedrate Override Switch The Feedrate Override switch allows the machine operator to adjust the programmed feedrate of the sub-spindle from 0% to 150%, up to a maximum feedrate of 394 in/min [10,000 mm/min] M-392D

297 JOG MODE Axis Direction Keys When a Z/E push button is pressed while Jog mode is active and the Manual Axis Motion switch is set to the E axis, the servo drive system causes the sub-spindle to move in the selected direction at a jog feedrate of 25 in/min [635 mm/min] when the Feedrate Override switch is set to 100%. Refer to Feedrate Override Switch, below. FEEDRATE OVERRIDE SWITCH The Feedrate Override switch allows the machine operator to adjust the jog feedrate of the sub-spindle from 0 to 37.5 in/min [952 mm/min]. RAPID TRAVERSE The Traverse push button allows the machine operator to jog the sub-spindle on the E axis at approximately 150 in/min [3810 mm/min], regardless of the setting of the Feedrate Override switch. MOVING THE SUB-SPINDLE 1. Activate Jog mode. 2. Use the Manual Axis Motion switch to select the E axis. 3. Set the Feedrate Override switch to the desired setting. 4. Press the appropriate Z/E push button to jog the sub-spindle in the desired direction. Handwheel Control The handwheel can be used to move the sub-spindle incrementally on the E axis whenever Cycle Start is not active. The E axis is selected with the Manual Axis Motion switch. The movement increment is selected by with the Rapid Override switch. The sub-spindle will move incrementally when the handwheel is rotated. The direction and distance is determined by the direction and amount of rotation of the handwheel. MOVING THE SUB-SPINDLE 1. Activate Jog mode. 2. Use the Manual Axis Motion switch to select the E axis. 3. Use the Rapid Override switch to select the desired increment. 4. To view axis position on the control display: A) Press the Position key. B) Press the Page key until the desired position display appears on the control display. 5. Turn the handwheel in the desired direction (+ or -). Observe the axis position display to determine when the axis has been moved the required distance. Turn the handwheel in the plus (+) direction to move the sub-spindle away from the face of the main spindle. Turn the handwheel in the minus (-) direction to move the sub-spindle toward the face of the main spindle. M-392D 17-3

298 SUB-SPINDLE TOOLING This section covers the removal and installation of spindle tooling, such as collets, step chucks, and jaw chucks. - CAUTION - Read and follow all safety recommendations and operating limits for any work-holding device installed in the spindle. DO NOT EXCEED the rated capacity of the work-holding device. QUEST series machines are available with a standard or high speed sub-spindle. The high speed spindle is balanced to the ISO G1.0 standard and requires a work-holding device balanced to ISO G2.5 or better. All work-holding devices, other than Hardinge collets, should be carefully reviewed for speed limitations and balance specifications. Hardinge Inc. offers chucks balanced to G2.5 or better for high speed applications. REMOVING SUB-SPINDLE TOOLING - CAUTION - Do not operate the collet closer when a collet or step chuck is mounted in place without gripping a piece of stock or a plug of the correct size. 1. Power the machine up using the procedure outlined in Chapter Press the control Reset key. 3. Activate Jog mode. 4. If necessary, press the Sub Open/Close push button to open work-holding device in the collet closer. 5. At the right end of the machine, remove draw tube access cover A, Figure If present, remove the plug from the end of the spindle draw tube. 7. Completely loosen six screws B, Figure A D B C Figure Draw Tube Access Cover at Right End of Machine TP4135A Figure Spindle Draw Tube TP4133A 17-4 M-392D

299 - NOTE - Six screws B, Figure 17.2, must be completely disengaged from the collet closer liner before draw tube nut C can be rotated. Removal of a jaw chuck or step chuck may require the assistance of a second person. 8. Rotate draw tube nut C counterclockwise to disengage the draw tube from the work-holding device. - WARNING - Be prepared to accept the weight of the work-holding device. 9. Remove the work-holding device from the spindle. 10. Cover the main spindle to protect it from chips while the sub-spindle is being cleaned. 11. Close the main coolant guard door. 12. From the collet closer end of the draw tube, use an air line to blow any contaminants present out of the spindle. - WARNING - The draw tube may be HOT when running aggressive duty cycles on machines equipped with a high speed sub-spindle. 13. Completely remove the draw tube from the back of the spindle. 14. From the collet closer end of the draw tube, use an air line to blow any contaminants present out of the spindle a second time. 15. Clean the spindle and draw tube. 16. Lightly lubricate the bearing surfaces of the draw tube with Molylube Anti-Seize grease. 17. Lightly coat the remaining exterior surfaces of the draw tube with Mobiltemp SHC 32 grease. 18. Carefully replace the draw tube in the spindle. 19. If spindle tooling is to be installed at this time, proceed to Installing Spindle Tooling, beginning on page If spindle tooling is not to be installed at this time: A) Replace the draw tube plug. B) Replace draw tube access cover A, Figure M-392D 17-5

300 INSTALLING SUB-SPINDLE TOOLING - NOTE - For the best surface finish and part roundness, the sub-spindle and draw tube have been balanced together at the factory. Although the spindle and draw tube can be run in other positions, the best balance is when etched mark D, Figure 17.2, and spindle drive button E, Figure 17.3, are aligned. Two procedures are outlined in this section. The first procedure, which begins below, covers the installation of collets and step chucks. The second procedure, beginning on page 17-8, covers the installation of jaw chucks. Collet or Step Chuck This procedure assumes that any previously used spindle tooling has already been removed. If there is spindle tooling to be removed, perform the steps outlined under Removing Sub-Spindle Tooling, beginning on page If previously used spindle tooling has just been removed, proceed to step 6. - CAUTION - Do not operate the collet closer when a collet or step chuck is mounted in place without gripping a piece of stock or a plug of the correct size. 1. Power the machine up using the procedure outlined in Chapter Press the control Reset key. 3. Activate Jog mode. 4. Remove draw tube access cover A, Figure If present, remove the plug from the end of the spindle draw tube. - NOTE - The collet and spindle bore MUST be clean. 6. Clean the spindle bore and the collet or step chuck and closer to be installed. 7. Press the Sub-Spindle Free push button to release the spindle brake and allow the spindle to be rotated. 8. Manually position spindle drive button E, Figure 17.3, to the top dead center (12 o clock) position. 9. Press the Sub-Spindle Free push button again to have the brake secure the spindle drive button at 12 o clock. E Figure Sub-Spindle Nose with Drive Button at Top Dead Center TP M-392D

301 - WARNING - To insure operator safety: - DO NOT use cast iron step chucks. - DO NOT use a step chuck without a step chuck closer. - NOTE - Installation of a step chuck may require the assistance of a second person. 10. If installing a step chuck in the spindle, place the step chuck closer against the spindle and install the mounting screws securely. 11. Align the keyway in the collet with the key in the spindle and slide the collet into the spindle until it makes contact with the draw tube. 12. Carefully push the draw tube against the back of the collet while rotating the draw tube clockwise to start the threads of the collet into the threads of the draw tube. - NOTE - Adjustment of the collet or step chuck may require the assistance of a second person. 13. Select the largest diameter workpiece which is to be chucked and position this part in the collet or step chuck. 14. Rotate the draw tube nut C, Figure 17.2, clockwise until the workpiece is gripped tightly; then, back the draw tube off ¼ to ½ turn. 15. Rotate the draw tube the shortest distance to locate etched mark D at top dead center (12 o clock) position. 16. Tighten six draw tube screws B. 17. Press the Sub Open/Close push button to close the collet and test the gripping force on the workpiece. If the gripping force is satisfactory, then go to step 14. If the gripping force is more or less than desired, adjust knob F, Figure 17.4 or 17.5, to any setting between 100 and 500 psig (6.9 and 34.5 bars). Refer to Table CAUTION - If the machine will not be operated with a bar feed system, the draw tube plug should be installed in the end of the spindle draw tube to prevent coolant and chips from entering the spindle drive motor compartment. 18. Install the plug in the end of the spindle draw tube if a bar feed system will not be used. 19. Replace draw tube access cover A, Figure M-392D 17-7

302 Jaw Chuck This procedure assumes that any previously used spindle tooling has already been removed. If there is spindle tooling to be removed, perform the steps outlined under Removing Sub-Spindle Tooling, beginning on page If previously used spindle tooling has just been removed, proceed to step 6. - CAUTION - Do not operate the collet closer when a collet or step chuck is mounted in place without gripping a piece of stock or a plug of the correct size. 1. Power the machine up using the procedure outlined in Chapter Press the control Reset key. 3. Activate Jog mode. 4. Remove draw tube access cover A, Figure If present, remove the plug from the end of the spindle draw tube. - NOTE - The jaw chuck and spindle bore MUST be clean. 6. Clean the jaw chuck and spindle bore. 7. Press the Sub-Spindle Free push button to release the spindle brake and allow the spindle to be rotated. 8. Manually position spindle drive button E, Figure 17.3, to the top dead center (12 o clock) position. 9. Press the Sub-Spindle Free push button again to have the brake secure the spindle drive button at 12 o clock. 10. Place the chuck in the spindle and install the mounting screws securely. 11. Carefully push the draw tube against the back of the chuck while rotating the draw tube clockwise to start the threads of the chuck into the threads of the draw tube. 12. Rotate draw tube nut C, Figure 17.2, to thread the draw tube onto the 3 jaw chuck as far as possible. 13. Rotate the draw tube counterclockwise to locate etched mark D at top dead center (12 o clock) position. 14. Tighten six draw tube screws B. (Continued on next page) 17-8 M-392D

303 15. Place a workpiece into the chuck and press the Sub Open/Close push button to close the chuck and test the gripping force on the workpiece. If the gripping force is satisfactory, then go to step 12. If the gripping force is more or less than desired, adjust knob F, Figure 17.4 or 17.5, to any setting between 100 and 500 psig (6.9 and 34.5 bars). Refer to Table CAUTION - If the machine will not be operated with a bar feed system, the draw tube plug should be installed in the end of the spindle draw tube to prevent coolant and chips from entering the spindle drive motor compartment. 16. Install the plug in the end of the spindle draw tube if a bar feed system will not be used. 17. Replace draw tube access cover A, Figure M-392D 17-9

304 SUB-SPINDLE COLLET CLOSER The sub-spindle on QUEST series lathes is equipped with a.5 inch [12.7 mm] stroke, hydraulically actuated collet closer. If repairs to the collet closer assembly are required, the ENTIRE ASSEMBLY must be removed and returned to the factory. Refer to the QUEST series lathe maintenance manual (M-393) for information on removing or installing the sub-spindle collet closer assembly. HYDRAULIC PRESSURE CONTROL - NOTE - The sub-spindle collet closer has an operational pressure range of 60 psig [4.14 bars] to 500 psig [34.5 bars]. The sub-spindle collet closer draw bar force is controlled by hydraulic oil pressure. The hydraulic pressure controls are located at the back of the machine. Sub-spindle collet closer pressure is controlled with adjustment knob F, Figure 17.4 or Gauge G registers the collet closer hydraulic pressure in psig and bars. Refer to Table 17.1, page 17-11, to determine the force that will be applied to the collet closer draw bar for a given pressure. A check valve system positively holds the closer open or closed, whichever is active, in the event of a hydraulic pressure failure. - CAUTION - DO NOT exceed the maximum pressure setting, as shown in Table NOTE - It is the responsibility of the machine operator or set-up person to properly adjust the collet closer hydraulic pressure, based on the type of material to be machined and the configuration of the workpiece. F G TP4196 Figure Sub-Spindle Collet Closer Pressure Adjustment (Machine with Standard Spindle Drive) M-392D

305 G F TP4816 Figure Sub-Spindle Collet Closer Pressure Adjustment (Machine with High Speed Spindle Drive) Adjusting the Hydraulic Pressure 1. Loosen the knurled lock nut behind pressure adjustment knob F, Figure 17.4 or Turn pressure adjustment knob D clockwise or counterclockwise to decrease or increase the collet closer hydraulic pressure. 3. Tighten the knurled lock nut to secure the setting. Gauge Pressure (psig) English Draw Bar Force (lbs) Gauge Pressure (bar) Metric Draw Bar Force (dan) 100 1, , , , , , , , ,678 Table Sub-Spindle Collet Closer Draw Bar Force M-392D 17-11