Responsible Reviewed/Approved Bill Mader 2/9/05 Dan Ornelas 2/11/05 Originator Date Mgr. Control Integration Engineering Date

ENGINEERING DOCUMENT 757-4002-373 Rev. B

SUBJECT: Tool Setter Calibration Procedure for TM Series Turning Centers

Tool Setter Calibration Procedure 757-4002-373 Rev. B Page 2 of 14 for TM Series Turning Centers

RECORD OF CHANGES Engineering Document 757-4002-373 Revision ECN # Revision Description Rev

By Date Appd

By Date

A 15833 Original Release WCM 2/9/05 DEO 2/11/05 B 16021 Added section XI on page 14 for fine tuning the

tool setter calibration values. WCM 3/29/06 DEO 3/30/06

Tool Setter Calibration Procedure 757-4002-373 Rev. B Page 3 of 14 for TM Series Turning Centers

I. INTENT

To provide a standardized procedure for calibrating the tool setter for TM series turning centers.

II. APPLICABILITY

Applies to TM series turning centers with the tool setter option.

III. INDEX

Page 3 Getting Started Pages 4-5 Tool Setter Stylus Alignment & Adjustmnets Pages 6-7 Tool Setter Calibration Screens Pages 7-10 X- Tool Setter Calibration Page 10 X+ Tool Setter Calibration Pages 11-13 Z- Tool Setter Calibration Pages 13-14 Z+ Tool Setter Calibration Page 14 Fine Tuning Adjustments

IV. GETTING STARTED

Before proceeding with the calibration process, various parts of known sizes will be required for attachment to the turret during the touch-off process. For the X-axis calibration process, a test bar (dowel pin or precision tool shank), along with a boring block of matching size, will be required. For the Z-axis calibration process, a test plate (usually secured with a magnet) will be required. When calibrating the tool setter, it is not required that one axis be calibrated before the other for a successful operation.

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V. TOOL SETTER STYLUS ALIGNMENT & ADJUSTMENTS

A. Begin with the basic alignment of the tool setter stylus. Check that the height of the stylus is adjusted so that the tip of the turning tools is centered up and down to the thickness of the stylus head. Move the stylus up or down as required by loosening the screw at the base of the stylus and tighten when positioned properly. Reference Figure 1.

Figure 1 – Tool Setter Height Adjustment

B. The head of the stylus needs to be parallel to the Z-axis travel. This is crucial for proper calibration of the tool setter. Using a tenth indicator, move the indicator tip back and forth across the head. Reference Figure 2. The head can be adjusted by alternately tightening or loosening the two set screws located on the right hand side of the tool setter. The adjustment can be precisely controlled by using this process. Reference Figure 3.

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Figure 2 – Indicating the Stylus Head

Figure 3 – Adjusting the Stylus Head

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VI. TOOL SETTER CALIBRATION SCREENS

A. From any screen, with the exception of the console test screens, select the “Menu” button on the console to display the menu options.

B. Select the “Utility Screens” soft key.

C. Select the “System Configuration” soft key (F1).

D. Select the “Hardware Configurations” soft key (F3). The “Hardware Configurations” screen will be displayed with various selections on the soft keys. Reference Figure 4.

Figure 4 – Hardware Configurations Screen

E. Caution!! Before proceeding, please be aware that the next step will display the tool setter calibration screen. Pressing buttons on this screen will cause machine movement to occur.

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F. Select the “Tool Setter Calibration” soft key (F2). The “Tool Setter Calibration” screen will be displayed. Reference Figure 5.

Figure 5 – Tool Setter Calibration Screen

VII. X- Tool Setter Calibration

A. Rotate the turret to the desired location for installing the test bar (dowel pin or precision tool shank) and a boring block.

B. Attach the boring block to the turret and insert the test bar into the holder, making sure that the bar is securely attached in the holder. Reference Figure 6.

C. After attaching the test bar, check the test bar for parallelism to the machine. Run an indicator back and forth across the test bar, verifying that the bar is as parallel to the Z-axis as possible. The bar should not be out of alignment any more than a couple of tenths. Make any necessary adjustments before proceeding to the next step. Reference Figure 7.

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Figure 6 – Dowel pin mounted in boring block with a sleeve

Figure 7 – Indicating a dowel pin for parallelism to the machine

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D. Move the axes back to the home position (upper, right-hand corner of the machine).

E. Enter the X- offset into the associated data field. The offset is the distance from X zero (center of the bar) to the surface of the bar. In this test, this value will be half the diameter, or the radius, of the test bar. Note: The offset value is always a positive number in millimeters.

F. In order to achieve accurate results, the axis must touch the stylus at a slow feedrate. Set the feedrate percentage at a value between 10 and 20%; set rapid percentage at 100%.

G. Move the tool setter into position by pressing the “Advance Tool Setter” soft key (F6).

H. Slowly jog the axes towards the tool setter, positioning the center of the bar within 10mm of the topside of the tool setter head. This will be the start position required for performing the X- calibration process. Reference Figure 8.

Figure 8 – Positioning a dowel pin at the tool setter head

I. Press the “Calibrate X-“ soft key (F1) to initiate the calibration process. Press the flashing “Start Cycle” button on the console to confirm the operation.

J. The X-axis will begin moving slowly towards the tool setter head. When the test bar touches the tool setter head, the axis will rapidly move back approximately 10mm in the opposite direction. If the calibration process was successful, the screen will show a green LED indicator next to the X- Offset and X- Datem Location data fields. A red LED indicates that the tool setter is not calibrated for the associated direction.

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K. If the test bar was positioned more than 10mm from the tool setter head, the system will generate a fault. Re-position the test bar again to within 10mm of the tool setter head and repeat steps G and H.

VIII. X+ Tool Setter Calibration

A. Rotate the turret to the desired location for installing the test bar and a boring block.

B. Attach the boring block to the turret and insert the test bar into the holder, making sure that the bar is securely attached in the holder. Reference Figure 6.

C. After attaching the test bar, check the test bar for parallelism to the machine. Run an indicator back and forth across the test bar, verifying that the bar is as parallel to the Z-axis as possible. The bar should not be out of alignment any more than a couple of tenths. Make any necessary adjustments before proceeding to the next step. Reference Figure 7.

D. Move the axes back to the home position (upper, right-hand corner of the machine).

E. Enter the X+ offset into the associated data field. The offset is the distance from X zero (center of the bar) to the surface of the bar. In this test, this value will be half the diameter, or the radius, of the test bar. Note: The offset value is always a positive number in millimeters.

F. In order to achieve accurate results, the axis must touch the stylus at a slow feedrate. Set the feedrate percentage at a value between 10 and 20%; set rapid percentage at 100%.

G. Move the tool setter into position by pressing the “Advance Tool Setter” soft key (F6).

H. Slowly jog the axes towards the tool setter, positioning the center of the bar within 10mm of the bottom side of the tool setter head. This will be the start position required for performing the X+ calibration process.

I. Press the “Calibrate X+“ soft key (F2) to initiate the calibration process. Press the flashing “Start Cycle” button on the console to confirm the operation.

J. The X-axis will begin moving slowly towards the tool setter head. When the test bar touches the tool setter head, the axis will rapidly move back approximately 10mm in the opposite direction. If the calibration process was successful, the screen will show a green LED indicator next to the X+ Offset and X+ Datem Location data fields. A red LED indicates that the tool setter is not calibrated for the associated direction.

K. If the test bar was positioned more than 10mm from the tool setter head, the system will generate a fault. Re-position the test bar again to within 10mm of the tool setter head and repeat steps G and H.

Tool Setter Calibration Procedure 757-4002-373 Rev. B Page 11 of 14 for TM Series Turning Centers

IX. Z- Tool Setter Calibration

A. Rotate the turret to the desired location for installing the test plate.

B. Attach the test plate to the turret using a magnet, or by some other means, making sure that the plate is securely positioned on the face of the turret. Reference Figure 9. Note that the left side of the test plate is flush with the face of the turret.

Figure 9 – Test plate secured with a magnet for Z-axis calibration

C. After attaching the test plate, move the axes back to the home position (upper, right-hand corner of the machine).

D. Enter the Z- offset into the associated data field. The offset is the distance from the face of the turret to the surface of the plate. This value may be zero if the plate is secured flush to the turret face. Otherwise, this value would probably be the thickness of the plate. Note: The offset value is always a positive number in millimeters. Reference Figure 10.

E. In order to achieve accurate results, the axis must touch the stylus at a slow feedrate. Set the feedrate percentage at a value between 10 and 20%; set rapid percentage at 100%.

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Figure 10 – Determining the offset required for Z-axis calibration

F. Move the tool setter into position by pressing the “Advance Tool Setter” soft key (F6).

G. Slowly jog the axes towards the tool setter, positioning the plate within 10mm of the right side of the tool setter head. This will be the start position required for performing the Z- calibration process. Reference Figure 11.

H. Press the “Calibrate Z-“ soft key (F3) to initiate the calibration process. Press the flashing “Start Cycle” button on the console to confirm the operation.

I. The Z-axis will begin moving slowly towards the tool setter head. When the test plate touches the tool setter head, the axis will rapidly move back approximately 10mm in the opposite direction. If the calibration process was successful, the screen will show a green LED indicator next to the Z- Offset and Z- Datem Location data fields. A red LED indicates that the tool setter is not calibrated for the associated direction.

J. If the test plate was positioned more than 10mm from the tool setter head, the system will generate a fault. Re-position the test plate again to within 10mm of the tool setter head and repeat steps G and H.

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Figure 11 – Positioning the test plate at the tool setter head

X. Z+ Tool Setter Calibration

A. Rotate the turret to the desired location for installing the test plate.

B. Attach the test plate to the turret using a magnet, or by some other means, making sure that the plate is securely positioned on the face of the turret. Reference Figure 9. Note that the left side of the test plate is flush with the face of the turret.

C. After attaching the test plate, move the axes back to the home position (upper, right-hand corner of the machine).

D. Enter the Z+ offset into the associated data field. The offset is the distance from the face of the turret to the surface of the plate. This value may be zero if the plate is secured flush to the turret face. Otherwise, this value would probably be the thickness of the plate. Note: The offset value is always a positive number in millimeters. Reference Figure 10.

E. In order to achieve accurate results, the axis must touch the stylus at a slow feedrate. Set the feedrate percentage at a value between 10 and 20%; set rapid percentage at 100%.

F. Move the tool setter into position by pressing the “Advance Tool Setter” soft key (F6).

G. Slowly jog the axes towards the tool setter, positioning the plate within 10mm of the left side of the tool setter head. This will be the start position required for performing the Z+ calibration process.

Tool Setter Calibration Procedure 757-4002-373 Rev. B Page 14 of 14 for TM Series Turning Centers

H. Press the “Calibrate Z+“ soft key (F4) to initiate the calibration process. Press the flashing “Start Cycle” button on the console to confirm the operation.

I. The Z-axis will begin moving slowly towards the tool setter head. When the test plate touches the tool setter head, the axis will rapidly move back approximately 10mm in the opposite direction. If the calibration process was successful, the screen will show a green LED indicator next to the Z+ Offset and Z+ Datem Location data fields. A red LED indicates that the tool setter is not calibrated for the associated direction.

J. If the test plate was positioned more than 10mm from the tool setter head, the system will generate a fault. Re-position the test plate again to within 10mm of the tool setter head and repeat steps G and H.

XI. Fine Tuning Adjustments

Some adjustments may still need to be made even after calibrating the tool setter as described in the above procedures. The system allows for an operator to fine tune the calculated values for those process that may require tighter standards for part tolerances.

A. After calibrating the tool setter, calibrate a tool, via the Tool Setup screens, using the tool setter. This should be a standard turning tool that can be used to cut a test part for accuracy.

B. Create and run a program that will use this calibrated tool to turn a part to a specific diameter. In this example, this will be determining the accuracy of the X- calibration value.

C. After the test part has been cut, measure the diameter of the part for accuracy. Depending upon the desired tolerances, this measurement may meet acceptable standards. If not, the calculated value for the tool setter calibration will need to adjusted accordingly.

D. In the Tool Setter Calibration screen, the calculated calibration values are shown in the fields labeled “Datum Location”. There will be four different fields, one for X+, X-, Z+, and Z-. Reference Figure 5. Adjust the X- Datum Location vaule accordingly to achieve a tighter tolerance.

E. Re-cut the part and measure again for accuracy. The part should be within the desired tolerances. If not, repeat the adjustment and cutting processes as necessary until the desired tolerances are achieved.

F. As required, repeat steps B thru E with the appropriate tools in order to fine tune the remaining Datum Location values in the Tool Setter Calibration screen.