CNC Controls Drive Systems Laser Systems Service

MANUAL GUIDE i

Milling made easy

©2010 FANUC FA Europe S.A., Echternach, Luxemburg

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The training book was compiled by:

FANUC FA Europe S.A.

Zone Industrielle – L-6468 Echternach
www.fanuccnc.eu

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 MANUAL GUIDE i – Milling

Pages
1 Introduction 5

2 The CNC controller and operating panel 6

3 Main screen of MANUAL GUIDE i 7

4 Basic program functions 8

4.1 EDIT operating mode 8

4.1.1 Creating a new program 10
4.1.2 Program list 18
4.1.3 Changing the program 19
4.2 MEM operating mode 20
4.2.1 Graphically simulating the program 20
4.2.2 Converting the program 21
4.2.3 Executing the program 21
4.3 JOG operating mode 21

5 General information 22

5.1 Coordinate system of a milling machine 22

5.2 Zero point selection 23

6 ISO programming 24

7 Tools and offsets 28

8 Programming examples 30

8.1 Example 1 36

8.2 Example 2 58

8.3 Example 3 80

8.4 Example 4 104

3
4
1. Introduction

User-friendly shop floor programming

MANUAL GUIDE i, the user-friendly software for shop floor programming, makes it easier for
you to operate the machine. The innovative programming enables development from a drawing
to a production part in a very short time. Thanks to MANUAL GUIDE i, FANUC CNCs can be pro-
grammed, very easily and quickly, for turning, milling and compound machining. Self-explanatory
menus and graphic simulations guide the user through the programming, producing highly effi-
cient results even for complex machining processes.

The FANUC MANUAL GUIDE i software is based on the ISO code format and has an ergonomic
CNC user interface for programming cycles. It uses a Graphical User Interface with user-­friendly
icons which allow you to interactively create part programs in just a few steps. All of the relevant
information is displayed on one CNC screen. Having to constantly change between screens is
avoided as is the risk of getting lost in the numerous pop-up screens.

This training book will give you an overview of MANUAL GUIDE i software for the programming
of milling applications, including four practical programming examples. It was developed by
specialists and will facilitate your introduction to MANUAL GUIDE i software. You will be ready
to program even complicated parts with MANUAL GUIDE i once you have worked your way
through the four examples.

We wish you lots of fun and success when programming. We would be delighted to hear from
you if you have any suggestions relating to this training document.

5
 2. The CNC controller and operating panel

The programming software

MANUAL GUIDE i runs on all
“i” series CNC controllers from Model B CNC
Series 0i -TC/-MC Series 16i /18i /21i 30i /31i /32i CNC
FANUC. In this way we have com-
bined the highest reliability with
uncomplicated shop floor program-
ming. The targeted end result is
high machine availability as well as
quicker work progress.

FANUC Operating panel

The following CNC MDI keys are used when selecting and manipulating processes in MANUAL GUIDE i:

Entering data

Confirming entered data

Modifying existing data

Deleting entry to the left

Deleting data, e.g. a line

Scrolling page up/down

Moving the cursor in the direction of the arrow

MANUAL GUIDE i is normally started by pressing the key

Note: To start MANUAL GUIDE i please refer also to the machine builders operation manual.
6
 3. Main screen of MANUAL GUIDE i

The person using the CNC controller with MANUAL GUIDE i will find that all of the important
information is well laid out and easy to see on the main screen. The screen is subdivided into
four areas:

Machine information Program input

• Axis position • High quality editor
• Distance to go • Auxiliary function
• Spindle speed • Alarm function
• Load display
• Feedrate
• Modal G code

Milling simulation in 2D and 3D Soft keys

• Milling-specific
• Self-explanatory
• Intuitive

7
 4. Basic program functions

The following three main operating modes are available to the user:
• EDIT (create or change a new program)
• MEM (execute or graphically simulate a program)
• JOG (manual operation).

4.1 EDIT operating mode

The following operations can be executed in this mode: Create, alter, copy, delete new
programs or download or upload programs from/to external data carriers.

Using the soft keys, you can select all other menus from the main menu.

Simple selection thanks to the soft keys:

Examples

8
Menu selection for the machining cycles. Cycle selection for all operating modes:

Drilling
Pocketing

External and internal

contour milling

Slot milling

End face milling

Self-explanatory, easy-to-use data input menu for a milling cycle:

9
 4.1 EDIT operating mode

4.1.1 Creating a new program

To create a new program, press the soft key New Programme (“NEWPRG”).

Then enter a program number between 1 and 9999, e.g.: 4712 and press the soft key “CREATE”.

The program no. 4712 is opened.

If a program number has already been allocated, it is indicated by a corresponding message.

The new program is entered as follows:

• START
• CYCLE
• END

Each cycle consists of the following two parts:

• Cutting conditions
• Geometric data (workpiece contour).

10
Program start: • START

To aid comprehension, the following explana-

tions refer to this part drawing:

A personal template can be predefined for

the program start and be simply called up by
pressing the soft key “START” in the Selection
menu.

The required data for workpiece

machining is entered step by step.
The diagram of the program start
with the description of the blank
part for graphical simulation as well
as tool function or replacement are
repeated with minor modifications.

The controller allows you to store recurring program parts as a template in the Start menu and
to easily call them up as required. Typical application examples are: program start, tool function
or tool replacement and program end.

The blank part definition has its own

selection and input menu.

11
 4.1 EDIT operating mode

Machining: • CYCLE

There are a wide variety of machining cycles available for

milling. To select the required cycle press the soft key CYCLE.

Selection is simple as can be seen in the illustration below. In the following example, a cubic work-
piece is to be cut in several operations.
1. Face milling
2. Side milling
3. Pocketing
4. Drill four holes

End face milling

Using the cursor, select the menu for end face milling and confirm your entry by pressing the
“SELECT” softkey. Then, the Machining Conditions menu appears on the screen.

Machining conditions
Enter the machining conditions in the fol-
lowing screen:
When you have entered the machining
conditions, the next screen appears auto-
matically.

Geometric data
To enter the dimensions of the surface to
be milled.

12
Side milling

Using the cursor, select the cycle for “Outer wall contouring” and confirm your entry by pressing
the “SELECT” softkey.

Then the Machining Conditions menu appears on the screen.

Machining conditions
Enter the machining conditions in the following screen:

Geometric data
When you have entered the machining conditions, the screen appears automatically in which you
enter the dimensions for the exterior contour to be milled.

13
 4.1 EDIT operating mode

Pocketing

Using the cursor, select the menu for “Pocketing” and confirm your entry by pressing the
“SELECT” softkey.

Then the Machining Conditions menu appears on the screen.

Machining conditions
Enter the machining conditions in
the following screen:

Geometric data
When you have entered the machin-
ing conditions, the screen appears
automatically in which you enter
the dimensions for the pocket to be
milled.

14
 Example of workpiece

The workpiece contour to be machined is geo-

metrically described as per the drawing.

Normally this figure can only be programmed by

an experienced programmer. This problem can
be easily solved with the MANUAL GUIDE i.

Workpiece contour for the cycle

The workpiece contour is described with the help of the following soft keys:

In the example below, you can see the entries for the contour with the starting point in the
circular arc of radius 50 at the centre left, at position X-93 Y0. The contour description runs in an
anticlockwise direction. The transitions between the radii 50, 140, 30, 100 and from 50 back to
the initial point are tangential, but unknown. They are calculated automatically by the CNC.

Start position
Firstly, the start position for the contour description is specified.

15
 4.1 EDIT operating mode

Selection of the contour elements

Input of known dimensions Result

16
Drilling holes

Using the cursor, select the cycle for “DRILLING” and confirm your entry by pressing the
“SELECT” softkey.

Then, the Machining Conditions menu appears on the screen.

Machining conditions
Enter the machining conditions for
the drilling operation in the following
screen:

Geometric data
When you have entered the machining
conditions, the screen appears auto-
matically in which you enter the dimen-
sions for the hole pattern.

17
 4.1 EDIT operating mode

4.1.2 Program list

All the programs in the program list are displayed when the soft key “O LIST” is pressed.

The following information is

displayed: program number,
comment, date of creation or
alteration, time and size of the
program.

Program list options:

• NEW New program • M-CARD Memory card
• COPY Copy program • ALL DEL Delete all
• DELETE Delete program • SRTORD Sort programs
• EDTCOM Edit comment • OPEN Open program
• SEARCH Search program

Program input and display

The CNC controller conveniently allows you, by means of a standard memory card, to rapidly
read in/out programs and all other data such as tool offset, as well as machine and controller
data. The reading in/out of data is fully controlled by the menu using the soft keys.

The content of the memory card can also be displayed on the CNC controller screen. This guar-
antees an unrestricted, uncomplicated and above all a quick data exchange.

18
4.1.3 Changing the program

Press the soft key “OPEN” to display and subsequently make changes to the program.

You can edit cycles using the graphical aid by pressing the “ALTER” soft key on the original screen.

In the following example, the cycle G1020: FACHIN (ROUGH) is selected. The precise meaning of
the respective function is displayed in the marked field.

The changes are made in the input menu and are accepted by pressing the soft key “ALTER”.

19
 4.2 MEM operating mode

4.2 MEM operating mode

Programs can be graphically simulated, executed and converted to DIN/ISO in this operating
mode.

4.2.1 Graphically simulating the program

A program is graphically simulated in this operating mode. There are two different types of dis-
play:

a) Solid body graphical animation b) Tool path-line graphics

The machining is realistically displayed in solid body animation. You see the material removal by
the corresponding machining tool. The movement of the tool tip is displayed as a line in the tool
path-line graphics.

Zoom Function
By selecting the area using soft keys, detailed magni-
fications can be easily achieved.

It is as easy to operate as a DVD player.

20
4.3 JOG operating mode

4.2.2 Converting the program into ISO format

A “MANUAL GUIDE i ” program can be fully converted to a standard ISO program. Such a pro-
gram is hence not dependent on the make of the CNC controller. As a result you have the option
of universally using the “MANUAL GUIDE i ” program in the entire production area.

4.2.3 Executing the program

A program created using the “MANUAL GUIDE i ” can be executed directly in the original format.
You do not have to convert the program to execute it.

4.3 JOG operating mode

The machine can be manually operated in this operating mode. Using the JOG keys or a hand
wheel, the feed of the axes being processed can be either manually selected or set at rapid.
Amongst other things, the workpiece zero point and offset are determined if the machine does
not have an automatic measuring device or has no external tool pre-setting.

21
 5. General information

In the case of a machine for machining prismatic work-

pieces, the tool normally rotates whilst the workpiece
is firmly clamped to a table, a pallet or special equip-
ment. These machines are either mill­ing machines,
drilling machines, machining centres or special mecha-
nisms.

The movements for positioning or cutting or made by at

least three axes: the X axis (normally longitudinal move-
ments), the Y axis (normally transverse movements)
and the Z axis (movement along the tool axis).

5.1 Coordinate system of a milling machine

For machining prismatic workpieces, there are also machines with more than three axes. For
example with a rotary table for all-round machining in chucking as the fourth axis, a swivellable
head as the fifth axis, etc. In the example, you can see a vertical drilling and milling machine with
a multiple tool turret. The Z axis always executes a movement in parallel to the tool axis. If the
tool axis is in a horizontal position, e.g. in a horizontal drilling machine or machining centre, then
the Z axis is also horizontal and axes X and Y are arranged appropriately.

The normal machining plane of the machine

described above is the XY plane.
The tool axis is vertical to the XY plane. In
the program, the different machining planes
are specified by G codes.

G17 = For machining in the XY plane

G18 = For machining in the XZ plane
G19 = For machining in the YZ plane

22
5.2 Zero point selection
Each moving axis of a CNC machine has a measuring system. Once the machine has been
switched on, these measuring systems must be synchronised with the CNC controller. There
are reference points for this purpose in the measuring systems, which are found at the positive
end of the axis’s traverse path and are usually started manually. There are also machines with
absolute measuring systems whereby the measuring system is permanently defined.

Symbol for the reference point

The workpiece zero point can be freely selected from the entire positioning range. The user logi-
cally sets the zero point to be programmed at the place it is easiest to program.

Symbol for the workpiece zero point

23
 6. ISO programming

Minimal knowledge of ISO programming is required for program generation with “MANUAL
GUIDE i .” Machining cycles are called up via 4-digit G functions. The G-code itself is irrelevant
to the user as the data is entered by graphic input displays. There are a few G-functions which
the user must know in order to be able to work with “MANUAL GUIDE i .” These are explained
below.

G0 = Rapid Traverse
With the command “G0”, one or several machine
axes can simultaneously be moved. The axes in
question move at high speed from the start to the
target point without interpolating,
e.g. G0 X110 Y50

G1 = Feed
With the command “G1” one or several machine
axes can simultaneously be moved at a pro-
grammed feed rate. In this case, the axes in ques-
tion move along a straight interpolating line from
the start to the target point.
For milling machines the feed is normally pro-
grammed in mm/minute,
e.g.: G1 X110 Y50 F100
(F = feed rate).

G90 = Absolute programming

In the case of absolute programming, all of the pro-
grammed positions refer to the selected workpiece
zero point.
Example: G90 G0 X50
X70
X110
X140
X170
X200

24
G91 = Incremental programming
In the case of incremental program-
ming, each dimension refers to the
previous position.
Example: G91 G0 X50
X20
X40
X30
X30
X30

The functions G90/G91 and G0/G1 are “self-maintaining (modal)”, which means that they
remain active until they are overwritten by the corresponding “complimentary function”.

G97 = Speed programming

The tool speed is programmed directly under the “S” address. Select the speed yourself if you are
experienced enough, or calculate it according to the following formula:
n = Speed in RPM
Vc = Cutting speed in m/min (255)
d = Diameter in mm (18.0)
Example: S4509 s [RPM]

G94 = Feedrate in mm/min

With drilling and milling tools, the feedrate is generally programmed in mm/min. G94 is
the basic controller setting and therefore does not need to be programmed specifically. The
feedrate is always programmed without a decimal point for drilling and milling applications. The
following formula is used to calculate the feedrate in mm/min:
Vf = Feedrate in mm/min
n = Speed in RPM (4509)
Z = Number of teeth (for drill 1)
Sz = Feedrate per tooth mm/tooth or mm/rev (0.25)
Example: F1127 F [mm/min]

25
 6. ISO programming

M codes (auxiliary functions)

M codes are characterised as auxiliary functions, with whose help the greatest range of machine
actions can be triggered. M functions are standardised to some extent and are hence the same in
all CNC machine tools. There are also free M functions, which are used differently by each machine
manufacturer. Please pay particular attention here to the operating instructions of the machine
manufacturer. The most important M functions are listed below:

M00 = Program stop unconditional

M01 = Program stop optional
M03 = Work spindle ON, clockwise
M04 = Work spindle ON, anticlockwise
M05 = Work spindle STOP
M06 = Tool exchange
M07 = Coolant 1 ON
M08 = Coolant 2 ON
M09 = Coolant OFF
M30 = Program end with resetting to program start
M98 = Subprogram call-up

“MANUAL GUIDE i” Program and G codes

The following diagrams show parts of a program generated using “MANUAL GUIDE i”:

Alongside there is a part of the program

for the previous example, in which the
machining conditions for pocketing are
highlighted in yellow. In the next program
line a contour is defined in subprogram
no. 801.

The actual contour form of the pocket

can either be saved directly to the same
program or as a separate subprogram.
Here, the contour is stored as a subpro-
gram with the number 801 (highlighted
in yellow). This has the advantage that
subprogram 801 can be used for roughing
and finishing.

26
Besides the special 4-figure G codes for cycles, programs created using “MANUAL GUIDE i”
also contain normal G codes, according to DIN 66025. Here are some examples:

G90 G54 G40 M9 M5 Typical dataset at the beginning of a program to move the CNC control-
ler to the basic position.
G0 G91 G28 Z0 Approach the reference point in the Z axis at a rapid traverse, e.g.: for
tool exchange
T1 Call tool no. 1, e.g.: for tool exchange
M6 Tool exchange
G43 H1 Apply tool length correction
D1 Apply tool radius
M30 Program end

You can save program sequences which are repeated often, e.g. tool exchange, yourself as a
template, open them at the touch of a button and insert them in the program. Then, you will only
need to change or adjust speeds, tool or offset numbers in the program.

27
 7. Tools and offsets

Tool commands have the address “T” and are programmed with a number.
This number refers either directly to the tool or the position in the tool magazine.
Individual details on the type of tool coding can be found in the appropriate machine operating manual.
In each case, the command “T17”, for example, will make tool number 17 ready for tool exchange, and
in the case of automatic machines, inserted in the working spindle by the change command “M6”.

The tool memory

The tool memory is opened by pressing the soft key “T-OFS”.

The CNC controller possesses a tool correction memory, in which the dimensions for the tool
length and radius are saved.

In addition, this memory also contains

tool data for the tool type, the installation
position and the shape or the tool nose
angle.

This data is required, for example, for the graphic representation during simulation.

28
Tool orientation

Tool tip angle

Tool length correction is usually measured from

the tip of the spindle to the tip of the tool. With mil-
ling tools, the radius of the milling unit is entered
as the radius correction.
This means that programming is very straightfor-
ward, and does not need to take a tool length or a
milling radius into account.

Tool length correction is called by the “H” com-

mand, together with the function “G43” (G43 H17)
and tool radius correction by the “D” command,
together with the function “G41” (G41 D17) or
“G42”.
Radius correction is deleted by the “G40” com-
mand. Length correction is deleted by the “G49”
command.

Calling G41 or G42 offsets the milling tool by the

correction value along the normal to the program-
med workpiece contour, either to the left “G41” or
to the right “G42”, seen in the feed direction. When
milling an arbitrary contour, the milling unit always
remains on this offset path. In so doing, the CNC
controller always reads program lines in advance to
detect the pro­grammed contour, so that the inter-
sections can be calculated correctly for tangential
or non-­tangential contour transitions.

All “MANUAL GUIDE i“ cycles must be executed with the tool radius correction deleted, i.e. in G40. 29
The tool length can be corrected before the cycle by calling G43 H**.
 8. Programming examples

Creating a MANUAL GUIDE i Program

A MANUAL GUIDE i program is created in the following steps. You must pay particular attention to the
correct approaching of the cycle start point and returning to a defined withdrawal point.

1) Blank part definition (only if a program simulation is required)

2) Approaching the toolchange position
3) Tool selection
4) Inserting the required G and F functions (e.g. spindle ON, speed, coolant, feed)
5) Approaching the cycle start point
6) Cycle:Cutting conditions (e.g. pocketing, drilling, slot milling)
7) Cycle: Figure information (several figures e.g. drilling figures can be programmed after a cycle)
8) Moving to a defined withdrawal point
9) Repeating steps 2 to 8, to add additional machining processes
10) Program end, enter the required M and G functions

30
Example:

G1902 B100. D100. H30. I0. J0. K1.; Blank part definition

G0 Z300. ;
X100. Y100.; Approaching the toolchange position

T1; Tool selection

M6; Tool replacement

S1200 M3; Entry of speed and direction of rotation

G43 H1 D1; Activating tool length offset

X-25. Y-25.;
G0 Z2.; Approaching the cycle start point

G1020 T1. L38. F200. E150. W2.

P2. V0. C1. M1. A1. B4. Z2.
I100.; Cycle: Cutting conditions

G1220 T1. B0. H50. V50. U100.

W100.; Cycle: Workpiece geometry

G0 Z300.;
X-100. Y-100.; Moving to a defined withdrawal point

T0; Cancelling tool offset

M30; Program end

31
 8. Programming examples

Description of facing cycle

A facing cycle as illustrated below is always configured using the tab FACE.

Cutting area

Description of pocketing cycle

The terms CONCAVE and CONVEX refer to pockets or islands respectively when using MANUAL
GUIDE i.
A concave free figure (pocket) can also be combined with one or more convex free figures (islands)
to produce a pocket-island combination. The concave free figure (pocket) must always be the first
figure. The beginning and end of a pocket-island combination are denoted by G1990 and G1991,
which are inserted automatically by MANUAL GUIDE i into the part program. The contour elements
used to define the free figure can be of type “Part” and type “Blank”. In the case when the contour
element is of type “Part”, the tool is not allowed to cut over the contour element; in the case when
the contour element is of type “Blank”, the tool cuts over the contour element in order to deburr
the workpiece border. The diagram below shows the principle of a pocketing cycle.

Pocket Contour Island Contour Pocket Contour

Element Type Isla
32 Element Type Element Type
“Blank” Ele
“Part” “Part”
“Pa

Cutting area Cutting

Cutting area
 Pocket Contour Island Contour Pocket Contour
Element Type Island Contour
Element Type Element Type
“Blank” Element Type
“Part” “Part”
“Part”

Cutting area Cutting area

Cutting area

Normal Pocket Pocket-Island Combination Pocket-Island Combination

Refer to examples 1,2 Refer to example 4 Refer to example 3

“Side Thickness” and “Bottom Thickness” specify the amount of material to be removed from the
blank. These values can be entered to avoid any ‘air-cutting’ motion when using a pre-machined
workpiece, where the centre of the pocket has already been removed. When using a blank which
is not pre-machined, the data fields must be left empty.
DO NOT CONFUSE “SIDE THICKNESS” WITH “SIDE FINISH” AMOUNT, AND “BOTTOM
THICKNESS” WITH “BOTTOM FINISH” AMOUNT.
The diagrams below show how the cutting area of a pocket is defined.

Base Point

Side Thickness

Depth
Cutting area
Side Thickness

Bottom Thickness
Cutting area

33
 8. Programming examples

Warning:

When the SIDE THICKNESS and BOTTOM THICKNESS fields are empty, it is assumed that the
blank is as shown in the diagram below.

Rapid Motion

Cutting area

When the SIDE THICKNESS and BOTTOM THICKNESS fields are set to 0, the workpiece is
assumed to be pre-machined as shown in the diagram below.

Risk of Collision Rapid Motion

Description of outer contouring cycle

An outer contouring cycle always has to be combined with a figure of type CONVEX. The diagram
below shows the principle of an outer contouring cycle. During cutting, the tool is moving on a path
which is equidistant from the programmed part contour. After each cutting pass the tool path is
moved closer to the part shape.
Normally a pocket-island combination generates a more efficient tool path and shorter cycle time
(pocket with contour elements of type “Blank” and island with contour elements of type “Part”):
compare the animated simulations of example 1 and example 3 in this training handbook in order
to become familiar with the difference between a pocketing and a contouring cycle.

34
The diagrams below show the outer contouring cycle:

Cutting area

Side Thickness and Bottom Thickness specify the amount of material to be removed from the
blank. A value larger than zero has to be inserted.
DO NOT CONFUSE “SIDE THICKNESS” WITH “SIDE FINISH” AMOUNT, AND “BOTTOM
THICKNESS” WITH “BOTTOM FINISH” AMOUNT. The diagrams below show how the cutting
area during outer contouring is defined.
Base Point
Side Thickness

Bottom Depth
Depth
Thickness Cutting area Side Thickness
A A

Cutting area

A-A

Description of inner contouring cycle

An inner contouring cycle always has to be combined with a figure of

type CONCAVE. The tool path is analogous to an outer contouring cycle.
The diagram below shows the principle of an inner contouring cycle.

“Side Thickness”, “Bottom Thickness”, “Base Point” and “Depth” have

the same meaning as for a pocketing cycle.

35
 8. Programming examples

8.1 Example 1
In this first example, a workpiece, for which all the geometrical elements are known or have been
measured, is programmed using MANUAL GUIDE i. The geometrical shapes that are used are simple
contours that can be reduced to basic figures such as rectangles, circles or ellipses. Therefore in
this example, only predefined figures are used. In Examples 2, 3 and 4 that are found later in this
handbook, freely programmable shapes are explained in detail. These make it possible to enter complex
workpieces.

In Example 1, the following machining cycles will be applied:

End face milling (predefined rectangle)

Mill Ø40 mm

Contour milling (predefined circular figure)

Mill Ø40 mm

36
Pocketing (predefined rectangle)

Mill Ø10 mm

Centre drilling (square hole pattern)

Centre drill Ø12 mm

Drilling (square hole pattern)

Drill Ø10 mm

Image of finished part

37
 8.1 Example 1

New program

Select operating mode EDIT

New program

Enter the program number

using the keyboard

End the program input

by pressing the soft key
“Create”

Select the program list

38
8.1 Example 1

Editing the comments

Press the soft key to enter

a comment

Comment or workpiece
name

Finish by pressing
the key “Alter”

Open the program

Open the selected

program

39
 8.1 Example 1

Selection of further soft

keys. Press 1x

Blank part definition

Press the soft key “Start”

Select the blank part using

the arrow keys

2x

Confirm the selection by

pressing “Select”

40
8.1 Example 1

Note:
The blank part dimensions entered here are
only used for the graphic simulation and have
no influence on the tool path.

Enter the following values

on the keyboard:
B: 100
D: 100
H: 30
I: 0
J: 0
K: 1

Confirm data input by

pressing the soft key
“Insert”

Selection of a template

Press the soft key “Start”

Selection of a suitable
template
T1 = Tool selection
M6 = Tool change command
S1200 = 1200 rpm. Rotational speed
of spindle
H1 = Correction of tool length
D1 = Correction of tool radius
G43 = Activate tool length
correction

Press the soft key “Insert”

41
 8.1 Example 1

Note:
If there is no suitable template available, it
will be necessary to enter the data manually
or create a template (see User Manual).

Manually complete the

addresses marked with ?.
Manually alter the program
T1, H1, D1 and Z2

Note:
At the end of a manual data input, position
the cursor fully to the left in order to select
the whole line.

Press the soft key “Cycle”

Modify manually “Z2”

Selection of operating
mode Surface Milling

Select the operating mode

with the arrow keys

1x

Press the soft key “Select”

42
8.1 Example 1

Note: 1
The values marked with * are not obligatory.

Complete parameter

Note: 2
The feed rate is entered manually in mm/min.
Possible in G95 (mm/revolutions) if this was
programmed before the cycle.

1x

Complete parameter

End by pressing the soft

key “Insert”

Selection of the form of the

machining surface

Press the soft key “Select”

43
 8.1 Example 1

Complete parameter

End by pressing the soft

key “Insert”

Tool change

Press the soft key “Start”

Note:
The tool diameter is automatically compen-
sated by the machining cycle. Therefore
merely the tool length must be activated
with G43. Address D is obligatory, the cycles
however must be executed in G40.

End by pressing the soft

key “Insert”

44
8.1 Example 1

Correct manually

Press the soft key “Cycle”

Note:
At the end of a manual data input, position
the cursor fully to the left in order to select
the whole line.

Selection of operating
mode Side Milling

2x

End by pressing the soft

key “Select”

Complete parameter

Pay attention to values T and S

– The wall thicknesses still to be machined
must be specified with T and S
– These values are not to be confused with
K and H, which represent the finishing
dimension.

1x

45
 8.1 Example 1

Complete parameter

End by pressing the

soft key “Insert”

Selection of the form of the

machining surface

1x

End by pressing the

soft key “Select”

Complete parameter

End by pressing the

soft key “Insert”

46
8.1 Example 1

Tool change

Press the soft key “Start”

End by pressing the

soft key “Insert”

Correct manually

Note:
At the end of a manual data input, position
the cursor fully to the left in order to select
the whole line.

Press the soft key “Cycle”

47
 8.1 Example 1

Selection of operating
mode Pocket Milling

3x

Selection of pocket roughing

End by pressing the

soft key “Select”

Complete parameter

Pay attention to values T and S

– If the pocket is already machined, the
wall thickness still to be machined can be
determined with the aid of T and S.
– If the pocket is not yet machined, no
values may be entered for T and S.
– These values are not to be confused with
K and H, which represent the finishing
dimension.

1x

Safety distance
always > 0

End by pressing the

soft key “Insert”

48
8.1 Example 1

Selection of the form of the

pocket to be machined

Press the soft key “Select”

Complete parameter

End by pressing the

soft key “Insert”

Tool change

Press the soft key “Start”

49
 8.1 Example 1

End by pressing the

soft key “Insert”

Correct manually

Note:
At the end of a manual data input, position
the cursor fully to the left in order to select
the whole line.

Press the soft key

“Cycle”

Selection of operating
mode Drilling

Select “Drilling”

Press the soft key

“Select”

50
8.1 Example 1

Complete parameter

End by pressing the

soft key “Insert”

Select drill pattern

“Rectangular points”

4x

Press the soft key “Select”

Complete parameter

1x

51
 8.1 Example 1

Complete parameter

End by pressing the

soft key “Insert”

Tool change

Press the soft key “Start”

End by pressing the

soft key “Insert”

52
8.1 Example 1

Correct manually

Note:
At the end of a manual data input, position
the cursor fully to the left in order to select
the whole line.

Press the soft key “Cycle”

Selection of operating
mode Drilling

1x

Select “Drill”

Press the soft key “Select”

Complete parameter

1x

53
 8.1 Example 1

Complete parameter

End by pressing the

soft key “Insert”

Select drill pattern

“Rectangular points”

4x

Press the soft key “Select”

Complete parameter

End by pressing the

soft key “Insert”

54
8.1 Example 1

Press the soft key “End”

End by pressing the

soft key “Insert”

End of the program

Program completed

55
 8.1 Example 1

Simulation

Select the operating mode:

AUTO (MEM)

Press the soft key

“Simulation”

Press the soft key “Rewind”

Press the soft key “Start”

56
8.1 Example 1

Simulation over

57
 8.2 Example 2

8.2 Example 2
In this example, a pocket is machined out of a workpiece with the aid of MANUAL GUIDE i.
The pocket geometry, which is known completely or has been measured, is entered as a freely program-
mable contour and registered as a subprogram. Storing a contour as a subprogram makes it possible to
re-use these for further cycles; for example for a simple cycle. Since it is a pocket, a concave contour
is selected.

The following machining cycles will be applied:

End face milling (predefined rectangle)

Mill Ø 40 mm

Pocketing (freely programmable concave contour,

registered as a subprogram)

Mill Ø 10 mm

58
8.2 Example 2

Image of finished part

59
 8.2 Example 2

New program

Select operating mode EDIT

New program

Enter the program number

using the alphanumeric
keyboard

End the program input

by pressing the soft key
“Create”

Select the program list

60
8.2 Example 2

Edit the comment

Select input of a comment

Comment or part designation

End the comment input

by pressing the soft key
“Alter”

Open the program

Open the selected program

61
 8.2 Example 2

Selection of further
soft keys
Press 1x

Blank part definition

Press the soft key “Start”

Select the blank part using

the arrow keys

2x

Confirm the selection by

pressing “Select”

62
8.2 Example 2

Note: The blank part dimensions entered

here are only used for the graphic simula-
tion and have no influence on the tool path.

Enter the following values

on the keyboard:
B: 160
D: 90
H: 30
I: 5
J: 5
K: 1

Confirm data input by press-

ing the soft key “Insert”.

Selection of a template

Press the soft key “Start”

Selection of a suitable
template
T1 = Tool selection
M6 = Tool change command
S1200 = 1200 rpm. Rotational
speed of spindle
H1 = Correction of tool
length
D1 = Correction of tool
radius
G43 = Activate tool length
correction

Press the soft key “Insert”

63
 8.2 Example 2

If there is no suitable template available, it

will be necessary to enter the data manually
or create a template (see User Manual).

Complete the addresses

marked with ?. Alter the
program manually: T1, H1
and D1 Z2.

Note: At the end of a manual data input,

position the cursor fully to the left in order to
select the whole line.

Press the soft key “Cycle”

Selection of operating
mode Surface Milling
Select the operating mode with the arrow
keys

1x

Press the soft key “Select”

Note 1: The values marked with * are not

obligatory.

Complete parameter

Note 2: The feed rate is entered manually in

mm/min. Possible in G95 (mm/revolutions) if
this was programmed before the cycle.

1x

64
8.2 Example 2

Complete parameter

End by pressing the soft key

“Insert”

Selection of the form of the

machining surface

Press the soft key “Select”

Complete parameter

End by pressing the

soft key “Insert”

65
 8.2 Example 2

Tool change

Press the soft key “Start”

Note: The tool diameter is automatically

compensated by the machining cycle.
Therefore merely the tool length must be
activated with G43. Address D is obligatory.
The cycle must be executed in G40.

End by pressing the

soft key “Insert”

Correct manually

Press the soft key “Cycle”

Note: At the end of a manual data input,

pos­ition the cursor fully to the left in order to
select the whole line.

66
8.2 Example 2

Selection of Pocket
Milling

3x

End by pressing the

soft key “Select”

Complete parameter

Pay attention to values T and S

– If the pocket is already machined, the
wall thickness still to be machined can be
determined with the aid of T and S.
– If the pocket is not yet machined, no values
may be entered for T and S.
– These values are not to be confused with
K and H, which represent the finishing
dimension.

1x

Complete parameter

End by pressing the

soft key “Insert”

67
 8.2 Example 2

Selection of the form of the

machining surface

3x

End by pressing the

soft key “Select”

Definition of pocket
geometry

Complete parameter

End by pressing the

soft key “OK”

Press the soft key “Line”

68
8.2 Example 2

End by pressing the

soft key “OK”

Note: For a radius, program the line up to the

theoretical intersection of both lines. Sequen-
ce line – radius – line.

Press the soft key “Radius”

End by pressing the

soft key “OK”

69
 8.2 Example 2

Press the soft key “Line”

End by pressing the

soft key ”OK“

Press the soft key “Radius”

70
8.2 Example 2

End by pressing the

soft key “OK”

Press the soft key “Line”

End by pressing the

soft key “OK”

71
 8.2 Example 2

Press the soft key “Radius”

Press the soft key “OK”

Press the soft key “Line”

72
8.2 Example 2

Press the soft key “OK”

Press the soft key “Radius”

End by pressing the

soft key “OK”

73
 8.2 Example 2

Press the soft key “Line”

End by pressing the

soft key “OK”

Press the soft key “Radius”

74
8.2 Example 2

Press the soft key “OK”

Press the soft key “Line”

End by pressing the

soft key “OK”

75
 8.2 Example 2

Press the soft key “Radius”

End by pressing the

soft key “OK”

Press the soft key “Line”

76
8.2 Example 2

End by pressing the

soft key “OK”

Note: The geometry of the pocket must

always be exactly closed. The start point
must correspond with the finish point.

Press the soft key “Create”

Note: The determined form can be saved as

a profile in a subprogram.

1x

Enter the following values

on the keyboard:
Sub-prog-no. 1101
Designation of the figure:
Pocket 01

End by pressing the

soft key “OK”

77
 8.2 Example 2

Selection of the
template end

Press the soft key “End”

Press the soft key “Insert”

Program completed
78
8.2 Example 2

Simulation

Select the operating mode: AUTO

(MEM)

Press the soft key

“Simulation”

Press the soft key “Rewind”

Press the soft key “Start”

Simulation over
79
 8.3 Example 3

8.3 Example 3
In this example, an island is machined out of a workpiece with the aid of MANUAL GUIDE i.
The island geometry includes several unknown geometrical elements. For the machining of the island,
a combination of two freely programmable contour figures is selected - a freely programmable pocket
and a freely programmable island. The rectangular blank part is entered as a freely programmable pocket
contour (concave), whereby the contour elements are of type “Blank”.The island in the centre is entered
as a freely programmable island contour (convex); the contour elements are of type “Part”.This pocket-
island combination results in the most efficient tool path for machining an island out of a workpiece.
Alternatively, a contour milling cycle could be entered (as indicated in Example 1); but in this case, the
cycle time would be increased.
Pocket-island combinations can only be entered when using freely programmable contours. Here, G1990
marks the beginning and G1991 marks the end of the combined figures in the part program. Both G codes
are inserted automatically by MANUAL GUIDE i into the part program and may not be deleted manually.
Predefined figures (e.g. rectangles or circles) can not be added to a pocket-island combination.
The difference between contour elements of the type “Blank” and type “Part” is that the milling tool
may cross a contour element of type “Blank”, and may even be required to do so, in order not to leave a
burr on the workpiece, whereas in the case of contour elements of type “Part”, the tool may not breach
the contour.

80
8.3 Example 3

In this example, the following machining cycle is applied:

Pocketing (combination of a freely programmable

pocket of type “Blank” type and a freely programma-
ble island of type “Part”; combination registered as a
subprogram)

Mill Ø 10 mm

Image of finished part

81
 8.3 Example 3

New program

Select operating mode EDIT

New program

Enter the program number

using the alphanumeric
keyboard

End the program input

by pressing the soft key
“Create”

Select the program list

82
8.3 Example 3

Edit a comment

Select input of a comment

Comment or part designation

End the comment input

by pressing the soft
key “Alter”

Open the program

Open the selected program

83
 8.3 Example 3

Selection of further
soft keys
Press 1x

Blank part definition

Press the soft key “Start”

Select the blank part using

the arrow keys

2x

Confirm the selection by

pressing “Select”

84
8.3 Example 3

Note: The blank part dimensions entered

here are only used for the graphic simula-
tion and have no influence on the tool path.

Enter the following values

on the keyboard:
B: 120
D: 110
H: 20
I: 15
J: 15
K: 0

Confirm data input by

pressing the soft key
“Insert”

Selection of a template

Press the soft key “Start”

Selection of a suitable
template
T1 = Tool selection
M6 = Tool change command
S1200 = 1200 rpm. Rotational
speed of spindle
H1 = Correction of tool
length
D1 = Correction of tool
radius
G43 = Activate tool length
correction

Press the soft key “Insert”

85
 8.3 Example 3

If there is no suitable template available,

it will be necessary to enter the data
manually or record a fixed format (see
User Manual).

Complete the addresses

manually with ?
Change over the program
manually: T3, H3 and D3.

Press the soft key “Cycle”

Note: At the end of a manual data input,

position the cursor fully to the left in order
to select the whole line.

Selection of pocket
machining
Select the operating mode
with the arrow keys

3x

Press the soft key “Select”

Note 1: The values marked with * are not

obligatory.

Complete parameter

Note 2: The feed rate is entered manually

in mm/min. Possible in G95 (mm/revolu-
tions) if this was programmed before the
cycle.

1x
86
8.3 Example 3

Complete parameter

Press the soft key “Insert”

Selection of the pocket

type and geometry
definition

3x

Selection of the form of the

pocket to be machined

End by pressing the

soft key “Select”

Blank part definition

Press the soft key “OK”

87
 8.3 Example 3

Press the soft key “Line”

1x

Press the soft key

“Blank Part”

End by pressing the

soft key “OK”

88
8.3 Example 3

Press the soft key “Line”

Note: The line type “Blank Part” remains

automatically selected.

End by pressing the

soft key “OK”

Press the soft key “Line”

89
 8.3 Example 3

End by pressing the

soft key “OK”

Press the soft key “Line”

End by pressing the

soft key “OK”

90
8.3 Example 3

Press the soft key “Create”

1x

Select the option “Create SP”

Enter values and text.

End by pressing the

soft key “OK”

Note:
This concludes the blank part definition.

Note:
The part to be machined is inserted as an
island.

Press the soft key “Alter”

91
 8.3 Example 3

Press the soft key “Create”

Note: The island must show the type “Part”.

In this example the MANUAL GUIDE i has
automatically selected “Part”.

Press the soft key “Island”

End by pressing the

soft key “OK”

92
8.3 Example 3

Press the soft key “Line”

End by pressing the

soft key “OK”

Press the soft key “Line”

93
 8.3 Example 3

Press the soft key “Tangent”

End by pressing the

soft key “OK”

Press the soft key “Arc”

Do not forget to select

“Tangent”

Press the soft key “Short”

Press the soft key “OK”

94
8.3 Example 3

Press the soft key “Line”

Press the soft key “OK”

Press the soft key “Line”

95
 8.3 Example 3

Press this soft key, which

records the current position,
and enter 15 mm depending
on requirements.

Press this soft key, which

records the current position

Enter 10 mm, depending on

the version

96
8.3 Example 3

End by pressing the

soft key “OK”

Press the soft key “Line”

End by pressing the

soft key “OK”

97
 8.3 Example 3

Press the soft key “Chamfer”

End by pressing the

soft key “OK”

Press the soft key “Line”

98
8.3 Example 3

End by pressing the

soft key “OK”

Press the soft key “Chamfer”

End by pressing the

soft key “OK”

99
 8.3 Example 3

Press the soft key “Line”

End by pressing the

soft key “OK”

Note: The geometry of the pocket or the

island must always be exactly closed. The
start point must correspond with the finish
point.

Press the soft key “Create”

100
8.3 Example 3

Press the soft key “OK”

Selection of the
template end

Press the soft key “End”

Press the soft key “Insert”

101
 8.3 Example 3

Program completed

Simulation

Select the operating mode:

AUTO (MEM)

Press the soft key

“Simulation”

Press the soft key “Rewind”

Press the soft key “Start”

102
8.3 Example 3

Simulation over

103
 8.4 Example 4

8.4 Example 4
In this example, a pocket is machined out of a workpiece with the aid of MANUAL GUIDE i leaving an
island in the centre.
The symmetrical pocket geometry includes several unknown geometrical elements and is generated by
“reflection/mirroring”. For machining the pocket with the island, a combination of two freely program-
mable figures is selected. One is a freely programmable pocket (concave) of type “Part” and the other
is a freely programmable island contour (convex), also of type “Part”, since in this case, in contrast to
Example 3, the tool may not infringe on either of the two figures.

In this example, the following machining cycle is applied:

Pocketing (combination of freely programmable pocket of

“Blank” type and freely programmable island of “Part” type;
combination stored/filed as a subprogram)

Mill Ø 10 mm

104
8.4 Example 4

Image of finished part

105
 8.4 Example 4

New program

Select operating mode EDIT

New program

Enter the program number

using the alphanumeric
keyboard

End creation of the program

by pressing the soft key
“Create”

Select the program list

106
8.4 Example 4

Edit a comment

Select input of a comment

Comment or part designation

End the comment input by

pressing the soft key “Alter”

Open the program

Open the selected program

107
 8.4 Example 4

Selection of further
soft keys
Press 1x

Blank part definition

Press the soft key “Start”

Select the blank part using

the arrow keys

2x

Confirm the selection by

pressing “Select”

108
8.4 Example 4

Note: The blank part dimensions entered

here are only used for the graphic simula-
tion and have no influence on the tool path.

Enter the following values

on the keyboard:
B: 100
D: 60
H: 20
I: 50
J: 0
K: 0

Confirm data input by

pressing the soft key “Alter”

Selection of a template

Press the soft key “Start”

Selection of a suitable
template
T1 = Tool selection
M6 = Tool change command
S1200 = 1200 rpm. Rotational
speed of spindle
H = Correction of tool length
D = Correction of tool radius
G43 = Activate tool length
correction

Press the soft key “Insert”

109
 8.4 Example 4

If there is no suitable template available, it

will be necessary to enter the data manually
or record a fixed format (see User Manual).

Complete the addresses

manually with ?
Change over the program
manually: T3, H3 and D3.

Press the soft key “Cycle”

Note: At the end of a manual data input,

position the cursor fully to the left in order to
select the whole line.

Selection of pocket
machining
Select the operating mode
with the arrow keys

3x

Press the soft key “Select”

Note 1: The values marked with * are not

obligatory. Leave the boxes blank in the
case of premachined parts.
Note 2: Pay attention to values T and S
– If the pocket is already machined, the
wall thickness still to be machined can
be determined with the aid of T and S.
– If the pocket is NOT pre-machined,
DON’T enter any value for data fields T
and S.
– Do not mistake the data fields T and S
with the finishing dimensions K and H.
Complete parameter
Note 3: The feed rate is entered manually in
mm/min. Possible in G95 (mm/revolutions) if
this was programmed before the cycle.

1x
110
8.4 Example 4

Complete parameter

Press the soft key “Insert”

Selection of the pocket

type and geometry
definition

3x

Selection of the form of the

pocket to be machined

End by pressing the

soft key “Select”

Press the soft key “OK”

111
 8.4 Example 4

Press the soft key “Line”

1x

Note: Option “Part” is automatically selected.

End by pressing the

soft key “OK”

112
8.4 Example 4

Press the soft key “Radius”

End by pressing the

soft key “OK”

Press the soft key “Arc”

113
 8.4 Example 4

End by pressing the

soft key “OK”

Select this point

Press the soft key “Select”

Press the soft key “Arc”

114
8.4 Example 4

Enter the different values

for machining

End by pressing the

soft key “OK”

Press the soft key “Next”

115
 8.4 Example 4

Select this point

Press the soft key “Select”

Selection of further soft keys

Press the soft key “Mirror”

116
8.4 Example 4

End by pressing the

soft key “OK”

Select elements for reflection/

mirroring

3x

Press the soft key “Select”

117
 8.4 Example 4

Press the soft key “Yes”

Selection of previous
soft keys

Note: The geometry of the pocket or the

island must always be exactly closed. The
start point must correspond with the finish
point.

Press the soft key “Create”

118
8.4 Example 4

Note: If the graphic blocks are entered

directly in the main program, it is possible
to proceed straight away with the soft key
“Island”.

1x

Press the soft key “OK”

Press the soft key “Alter”

Press the soft key “Create”

119
 8.4 Example 4

Press the soft key “Island”

Enter the different values for

machining

End by pressing the

soft key “OK”

120
8.4 Example 4

Press the soft key “Arc”

End by pressing the

soft key “OK”

Note: The geometry of the pocket or the island

must always be exactly closed. The start point
must correspond with the finish point.

Press the soft key “Create”

121
 8.4 Example 4

End by pressing the

soft key “OK”

Selection of the
template end

Press the soft key “End”

End by pressing the

soft key “Insert”

122
8.4 Example 4

Program completed

Simulation

Select the operating mode:

AUTO (MEM)

Press the soft key

“Simulation”

Press the soft key “Rewind”

Press the soft key “Start”

123
 8.4 Example 4

Simulation over

124
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