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Return to LibraryProgramming ManualforMazatrol Fusion 640M(Version C)Publication # H735PG0012E10/99CAUTIONThis Manual is published to assist experienced personnel on the operation, maintenanceand/or programming of Mazak machine tools.All Mazak machine tools are engineered with a number of safety devices to protectpersonnel and equipment from injury or damage. Operators should not, however, relysolely upon these safety devices, but should operate the machine only after fullyunderstanding what special precautions to take by reading the following documentationthoroughly.Do not attempt to operate or perform maintenance / repair on the machine without athorough understanding of the actions about to be taken. If any question exists, contactthe nearest Mazak service center for assistance.Certain covers, doors or safety guards may be open or removed to more clearly showmachine components. These items must be in place before operating the machine.Failure to comply with this instruction may result in serious personal injury or damage tothe machine tool.This manual was considered complete and accurate at the time of publication, however,due to our desire to constantly improve the quality and specification of all Mazakproducts, it is subject to change or modification.

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Return to LibrarySAFETY PRECAUTIONSSAFETY PRECAUTIONSPrefaceSafety precautions relating to the CNC unit (in the remainder of this manual, referred to simply asthe NC unit) that is provided in this machine are explained below. Not only the persons whocreate programs, but also those who operate the machine must thoroughly understand thecontents of this manual to ensure safe operation of the machine.Read all these safety precautions, even if your NC model does not have the correspondingfunctions or optional units and a part of the precautions do not apply.Rule1.This section contains the precautions to be observed as to the working methods and statesusually expected. Of course, however, unexpected operations and/or unexpected workingstates may take place at the user site.During daily operation of the machine, therefore, the user must pay extra careful attention toits own working safety as well as to observe the precautions described below.2.The meanings of our safety precautions to DANGER, WARNING, and CAUTION are asfollows:!: Failure to follow these instructions could result in loss of life.DANGER!: Failure to observe these instructions could result in serious harm to a humanlife or body.WARNING!: Failure to observe these instructions could result in minor injuries or seriousmachine damage.CAUTIONHGENPA0022ES-1

Return to LibrarySAFETY PRECAUTIONSBasics!WARNINGl After turning power on, keep hands away from the keys, buttons, or switches of theoperating panel until an initial display has been made.l Before proceeding to the next operations, fully check that correct data has been enteredand/or set. If the operator performs operations without being aware of data errors,unexpected operation of the machine will result.l Before machining workpieces, perform operational tests and make sure that the machineoperates correctly. No workpieces must be machined without confirmation of normaloperation. Closely check the accuracy of programs by executing override, single-block, andother functions or by operating the machine at no load. Also, fully utilize tool path check,solid check, and other functions, if provided.l Make sure that the appropriate feed rate and rotational speed are designated for theparticular machining requirements. Always understand that since the maximum usable feedrate and rotational speed are determined by the specifications of the tool to be used, thoseof the workpiece to be machined, and various other factors, actual capabilities differ fromthe machine specifications listed in this manual. If an inappropriate feed rate or rotationalspeed is designated, the workpiece or the tool may abruptly move out from the machine.l Before executing correction functions, fully check that the direction and amount ofcorrection are correct. Unexpected operation of the machine will result if a correctionfunction is executed without its thorough understanding.l Parameters are set to the optimum standard machining conditions prior to shipping of themachine from the factory. In principle, these settings should not be modified. If it becomesabsolutely necessary to modify the settings, perform modifications only after thoroughlyunderstanding the functions of the corresponding parameters. Modifications usually affectany program. Unexpected operation of the machine will result if the settings are modifiedwithout a thorough understanding.Remarks on the cutting conditions recommended by the NC!WARNINGl Before using the following cutting conditions:- Cutting conditions that are the result of the MAZATROL Automatic Cutting ConditionsDetermination Function- Cutting conditions suggested by the Machining Navigation Function- Cutting conditions for tools that are suggested to be used by the Machining NavigationFunctionConfirm that every necessary precaution in regards to safe machine setup has been taken –especially for workpiece fixturing/clamping and tool setup.l Confirm that the machine door is securely closed before starting machining.Failure to confirm safe machine setup may result in serious injury or death.S-2

Return to LibrarySAFETY PRECAUTIONSProgramming!WARNINGl Fully check that the settings of the coordinate systems are correct. Even if the designatedprogram data is correct, errors in the system settings may cause the machine to operate inunexpected places and the workpiece to abruptly move out from the machine in the eventof contact with the tool.l During surface velocity hold control, as the current workpiece coordinates of the surfacevelocity hold control axes approach zeroes, the spindle speed increases significantly. Forthe lathe, the workpiece may even come off if the chucking force decreases. Safety speedlimits must therefore be observed when designating spindle speeds.l Even after inch/metric system selection, the units of the programs, tool information, orparameters that have been registered until that time are not converted. Fully check thesedata units before operating the machine. If the machine is operated without checks beingperformed, even existing correct programs may cause the machine to operate differentlyfrom the way it did before.l If a program is executed that includes the absolute data commands and relative datacommands taken in the reverse of their original meaning, totally unexpected operation ofthe machine will result. Recheck the command scheme before executing programs.l If an incorrect plane selection command is issued for a machine action such as arcinterpolation or fixed-cycle machining, the tool may collide with the workpiece or part of themachine since the motions of the control axes assumed and those of actual ones will beinterchanged. (This precaution applies only to NC units provided with EIA functions.)l The mirror image, if made valid, changes subsequent machine actions significantly. Usethe mirror image function only after thoroughly understanding the above. (This precautionapplies only to NC units provided with EIA functions.)l If machine coordinate system commands or reference position returning commands areissued with a correction function remaining made valid, correction may become invalidtemporarily. If this is not thoroughly understood, the machine may appear as if it wouldoperate against the expectations of the operator. Execute the above commands only aftermaking the corresponding correction function invalid. (This precaution applies only to NCunits provided with EIA functions.)l The barrier function performs interference checks based on designated tool data. Enter thetool information that matches the tools to be actually used. Otherwise, the barrier functionwill not work correctly. (This precaution applies only to the M640T and M640MT.)!CAUTIONl If axis-by-axis independent positioning is selected and simultaneously rapid feed selectedfor each axis, movements to the ending point will not usually become linear. Before usingthese functions, therefore, make sure that no obstructions are present on the path.S-3

Return to LibrarySAFETY PRECAUTIONSOperations!WARNINGl Single-block, feed hold, and override functions can be made invalid using system variables#3003 and #3004. Execution of this means the important modification that makes thecorresponding operations invalid. Before using these variables, therefore, give thoroughnotification to related persons. Also, the operator must check the settings of the systemvariables before starting the above operations.l If manual intervention during automatic operation, machine locking, the mirror imagefunction, or other functions are executed, the workpiece coordinate systems will usually beshifted. When making machine restart after manual intervention, machine locking, themirror image function, or other functions, consider the resulting amounts of shift and takethe appropriate measures. If operation is restarted without any appropriate measures beingtaken, collision with the tool or workpiece may occur.l Use the dry run function to check the machine for normal operation at no load. Since thefeed rate at this time becomes a dry run rate different from the program-designated feedrate, the axes may move at a feed rate higher than the programmed value.l After operation has been stopped temporarily and insertion, deletion, updating, or othercommands executed for the active program, unexpected operation of the machine mayresult if that program is restarted. No such commands should, in principle, be issued for theactive program.!CAUTIONl During manual operation, fully check the directions and speeds of axial movement.l For a machine that requires manual homing, perform manual homing operations afterturning power on. Since the software-controlled stroke limits will remain ineffective untilmanual homing is completed, the machine will not stop even if it oversteps the limit area.As a result, serious machine damage will result.l Do not designate an incorrect pulse multiplier when performing manual pulse handle feedoperations. If the multiplier is set to 100 times and the handle operated inadvertently, axialmovement will become faster than that expected.S-4

Return to LibraryOPERATIONAL WARRANTY FOR THE NC UNITOPERATIONAL WARRANTY FOR THE NC UNITThe warranty of the manufacturer does not cover any trouble arising if the NC unit is used for itsnon-intended purpose. Take notice of this when operating the unit.Examples of the trouble arising if the NC unit is used for its non-intended purpose are listedbelow.1.Trouble associated with and caused by the use of any commercially available softwareproducts (including user-created ones)2.Trouble associated with and caused by the use of any Windows operating systems3.Trouble associated with and caused by the use of any commercially available computerequipmentS-5

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Return to LibraryCONSTRUCTIONIntroductionPart 1Part 2MAZATROL PROGRAMMING PROCEDURESChapter 1MAZATROL PROGRAMChapter 2SYSTEM OF COORDINATESChapter 3FUNCTION OF KEYS AND SWITCHESChapter 4PROCEDURE BEFORE PERFORMING THE MACHININGMAZATROL PROGRAM FUNCTIONSChapter 1CALLING UP AND THE END OF THE PROGRAM DISPLAYChapter 2EDITION OF DATAChapter 3WINDOW FUNCTIONSChapter 4PROGRAM CREATIONChapter 5PRIORITY FUNCTION FOR THE SAME TOOLChapter 6COORDINATES MEASUREMENT FUNCTIONChapter 7TPC DATA CREATIONChapter 8BACKGROUND PROGRAMMINGChapter 9CASE OF APPEARANCE OF ALARMChapter 10 THREE-DIGIT G-FORMATAppendixAppendix 1 LIST OF M CODESAppendix 2 PROGRAM EXAMPLESAppendix 3 WHAT TO DO IN SUCH A CASE?GC-1

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Return to LibraryIntroductionThis manual describes only programming based on the MAZATROL language of theMAZATROL FUSION 640M system. The description given in this manual assumes that thereaders have already read the relevant Operating Manual and thoroughly understood itscontents.Programming in the MAZATROL language uses an interactive method that allows the system tobe operated in accordance with the messages displayed on the CRT monitor. Thus, even a userwho is to operate the system for the first time can readily create and edit programs.Carefully read this manual and the Operating Manual to correctly operate the MAZATROLFUSION 640M system and use its capabilities to their maximum.NOTE:The MAZATROL FUSION 640M controls the machining center by digital calculation, but it ispossible that the machining cannot be performed because of the processing of a calculationerror. Before proceeding with automatic operation therefore, do not fail to inspect the path ofthe tool on the display in order to verify that the machining is being done correctly.H735P0A011E1

Return to LibraryOrganization of this manualThe following outlines the organization of this r row – Directions for using the chapterLower row – Contents of the chapterThose who are going to set up a MAZATROL program for the first time must first read thispart. Actually operate the MAZATROL FUSION 640M system from the beginning asdirected in Chapter 4, “PROCEDURE BEFORE PERFORMING THE MACHINING.” Youwill then be able to roughly understand the entire operating procedure from toolregistration to creation of a MAZATROL program. Those who already have anexperience in creating a program using the MAZATROL M-1, M-2, M-32 or MAZATROLFUSION 640M system will be able to understand the functions and usage of the M640Msystem just by directly reading Part 2, “MAZATROL PROGRAM FUNCTIONS.”The program architecture, coordinates systems, and operation keys are discussed hereas the basic information required for program creation in MAZATROL language. Inaddition to the program creation procedures, successive processing procedures up tomachining are described in order after the discussion of the basic information.2MAZATROLPROGRAMFUNCTIONSUse the functions of the MAZATROL FUSION 640M system only after understanding theMAZATROL program architecture and program creation procedures described in Part 1.Also, use this part as a reference whenever required, such as in cases where you haveonly a slight idea (or have forgotten) how to use a function, as you create a MAZATROLprogram.How to call up the PROGRAM display, how to edit data, how to use a function, anddetails of each function are described here. How to create programs in the backgroundmode, and how to act in the event of alarms are also discussed.APPENDIXAn M-code list, sample programs, and a Q&A (Questions and Answers) list arecontained. Read this appendix as appropriate.How to use this manualNext, how to use this manual is briefly described below.1.In Part 2, “MAZATROL PROGRAM FUNCTIONS,” where the operating procedures forcarrying out the MAZATROL language functions are described, the order of selecting menuitems is indicated at “Menu selection.” Use the section as quick reference during menuselection.2.In Part 2, “MAZATROL PROGRAM FUNCTIONS,” where the operating procedures aredescribed, the arrow “!” under the description of each step of the procedure is followed byadescription of the results of the particular operation.Example:(1) Press the SEARCH menu key.!The message SEARCH DATA? will be displayed and the menu will change to thefollowing address menu:The section underlined above denotes the results of the operation.2E

Return to LibraryPART 1MAZATROL PROGRAMMINGPROCEDURESPart 1 describes the architecture of MAZATROL programs, coordinate systems,the keys to be used for programming, and simplified programming procedures.H735P10011E

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Return to LibraryCONTENTSPage1MAZATROL PROGRAM. 1-12SYSTEM OF COORDINATES . 2-12-1Machine Coordinates System . 2-12-2Workpiece Coordinates System. 2-22-3Machine Coordinates System and Workpiece Coordinates System . 2-32-4Basic Coordinates. 2-32-5Auxiliary Coordinates. 2-43FUNCTION OF KEYS AND SWITCHES. 3-14PROCEDURE BEFORE PERFORMING THE MACHINING . 4-14-1Diagram of Preparation for the Machining . 4-14-2Part Drawings and Stock Materials. 4-34-3Registration of Tools. 4-54-3-1Calling up the TOOL FILE display .4-54-3-2Registration of tools.4-64-4Creation of Simple Programs. 4-94-4-1Program structure.4-94-4-2Calling up the PROGRAM display .4-104-4-3Assigning workpiece numbers .4-114-4-4Creating a program.4-134-4-5Creation of common unit .4-134-4-6Creation of basic coordinates system unit .4-15C-1

Return to Library4-4-7Face machining unit .4-174-4-8Line machining unit.4-274-4-9Point machining unit (1) .4-374-4-10 Point machining unit (2) .4-464-4-11 End unit .4-534-4-12 End of the program.4-544-5Registration of Tools in a Tool Data File. 4-564-5-1Pocket numbers and tool numbers .4-564-5-2TOOL DATA display .4-574-5-3TOOL LAYOUT display .4-594-5-4Registration of tools.4-624-6Check of the Machining Path . 4-65C-2 E

Return to LibraryMAZATROL PROGRAM11MAZATROL PROGRAMThe machining MAZATROL program of a workpiece consists in principle of the following fourunits:1.Common unitThis concerns a unit which is obligatorily entered in the program head. It specifies the commondata to a program assembly such as the material, the initial point, the machining of severalworkpieces, etc.2.Basic coordinates system unitUse to specify the value of the