T O P C A M CNC

Complete

T O P T U R N
Machining
Tu r n i n g
Milling

T O P M I L L

M AT H E M AT I S C H T E C H N I S C H E
SOFTWARE-ENTWICKLUNG GMBH
 MTS CAD-CAM solution for turning and milling
For NC programming purposes, MTS is offering a programming system* and a shop-floor programming method* which
can be used in conjunction with each other thanks to an identical internal structure. In addition, our shop-floor pro-
gramming method includes several alternative input modes - from NC editor through to graphical geometry editor, inter-
active programming and teach-in operation right up to dialog programming. The operator can switch between these
functions as often as he wishes while making entries.
The postprocessor translates NC programs created with
the TOPCAM programming system into the programming
key* of the target CNC control. These can then be simula-
ted, tested for collisions and further processed, e. g. opti-
mized, in direct connection with the TOPTURN or TOP-
MILL shop-floor programming workstations which have
been set to this programming
key.
It is this unbroken line of pro-
cesses, connecting the pro-
gramming system with an
easy-to-use shop-floor/dia-
log programming method in
the programming key of any
desired CNC control, which
is the outstanding feature of
our CAD/CAM solution. This
combination of the program-
ming key and the postpro-
cessor can then be used as
a universal NC converter.

*Programming system and shop-floor programming

In everyday operations, we encounter both so-called computer-assi-
sted programming, using programming systems as employed in work
planning departments, as well as shop-floor programming, such as is
carried out directly on the CNC control of a machine tool. In the futu-
re, this differentiation will become less and less relevant as the use of
PC-based controls becomes more widespread.

Programming systems normally import the workpiece geometry from

CAD data and initially generate NC programs in a neutral, generic for-
mat, which is subsequently converted by postprocessors, into the pro-
gramming key* of the target control system.

Shop-floor programming involves creating NC programs directly in

the programming key* of the CNC control on the respective control
itself on the basis of a workshop drawing.

*Programming key
The programming key of a CNC control
system (also known as the command coding
or control syntax) is defined first to be the set
of programming functions according to
ISO/DIN that this control system is capable
of, including definition of the control-specific
deviations from this standard, and second as
the control-specific extensions by cycles,
contour-programming etc. The term pro-
gramming key is also used to describe the
definition of the contents of a legible text
language not based on the ISO/DIN stan-
dard.

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Management of tools, chucks, clamping devices and cutting data
The MTS products TOPCAM, TOPTURN and TOPMILL utilize a uniform management system for tools, chucks, clamping
devices, materials and cutting parameters/technology data. All standard tools for lathe and milling work as well as the
chucks and clamping devices are recorded in parameter form, so that users can themselves define the specific tools and
clamping devices to be used in their workshop. Profile turning tools can also be included using the appropriate CAD data.

The dimensions of all compo-

nents are taken into account for
collision tests.

The chucks and clamping devices available for lathes are jaw The cutting data management is
chucks, collet chucks and centering clamps. Vises, electromag- organized according to materi-
netic plates as well as a modular clamping kit are available for mil- als, tools and machining proces-
ling processes. ses.

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 TOPCAM
Integrated NC programming and 2D CAD
system for 2½D milling and for complete mill-
turn machining with driven tools on up to 7
axes.
One main feature of the TOPCAM programming
system, which is embedded in a fully-functional
2D CAD front-end, is the graphical user interface
linking it directly to the CAD data. In this system,
the programs are generated with the aid of a sim-
ple interactive dialog, the work plan being auto-
matically compiled as the program is created. The
MTS programming key is used as an intermedia-
te, control-independent NC data format.

TOPCAM offers the following basic functions:

• automatic generation of work plans and set-up sheets,

• work plan editor with graphical display of the individual
• machining steps and the functions 'move', 'delete',
• 'insert', 'activate' and 'move to background',
• editing of NC programs by subsequent re-entry in the
• machining dialog,
• CAD data exchange using DXF,
• bidirectional DNC program transmission between pro-
gramming system and CNC control
• optional direct link to TOPTURN and TOPMILL.
Complete mill-turn machining with driven tools on up to 5 configurable
axes (X, Z, C, Y, B) and with sub-spindle (Z2, C2), including all machi-
ning cycles, in particular radial and axial recess cycles with selectable
recessing or roughing machining, elimination of unnecessary cutting
paths, macros for workpart takeover to sub-spindle, automatic insertion
of diameter tolerances, fits, allowances, undercuts and relief grooves
form E/F according to DIN/ISO, radii and chamfers, 2½D milling with
driven tools on the planes: front face, chords and slanted chord surfa-
ces as well as circumferential surfaces with using the machining
cycles: pocket-milling, drilling, reaming, boring, thread-cutting and hole
patterns with user macros for sequences of operations with different
tools.

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2½D programming system for milling using all common
machining methods such as drilling, reaming, boring, thre-
ading cycles, circular and rectangular pockets and pins, as
well as, in particular, contour parallel or meandering milling
of pockets with any type of edges and islands, holes and
finishing allowances and also with creation of radial and
linear hole patterns, approach and withdrawal macros for
contour milling and engraving of groups of entities with
optimization of the tool path.

Postprocessors
There are two different ver-
sions of the TOPCAM post-
processor:

• configurable ISO command

set postprocessor for 2-axes
turning and 3-axes milling, and
• cycle postprocessor that can
• be adapted to any type of
• CNC control generating the
cycles of the target CNC con-
trol.

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 Shop-floor programming and CNC simulation with TOPTURN and TOPMILL

The CNC simulators TOPTURN (for lathe and turnmill

operations) and TOPMILL (for milling) have a dual func-
tion within the MTS CAD/CAM solution:

1. Shop-floor programming in the programming key* of any

desired CNC control, with a uniform user interface and direct
linking to the machine tool.

2. CNC simulation, as an optional TOPCAM software enhan-

cement, for testing the programs generated by TOPCAM in
the machine-independent, neutral MTS programming key, or
for testing the neutral NC programs converted by the postpro-
cessor into the programming key of the specific target CNC
control (CNC simulation after postprocessing).

TOPTURN models a lathe which can be optionally equip-

ped with driven tools (supplementary axes C, Y and B) and
a sub-spindle for complete machining (supplementary axes
Z2, C2).

TOPMILL models a 3-axes vertical milling machining cen-

ter with configurable automatic tool changer, in the variants
rotational tool magazine and dual-arm gripper or pick-up-
magazine.

A mathematically exact 3D model of the workpart is com-

puted in parallel during machining, and precise collision
tests are carried out, taking into consideration all compo-
nents of the workspace within the framework of the 2D and
3D machine tool models.
Configuration

The wide range of practical utilization options which TOPTURN and TOPMILL offer
for shop-floor programming and CNC simulation is based on the comprehensive con-
figuration possibilities provided by their 2D and 3D machine tool models, which per-
mit the user to adapt these to the existing machine tools and CNC controls.

In addition to being able to define the dimensions of the workspace or the machine
table, the user can also define the strokes of the NC-axes and the position of machi-
ne zero coordinates and reference points.

The tooling systems are also configurable, as turret systems or tool magazines.

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Programming key* and NC compiler
Milling
A. Bradley CNC 8400LM
Anton CNC 3300
Bosch CC 100 M/200M
Bosch CC 300 M
DMG MILL PLUS
Deckel Contour 2
Deckel Contour 3/Dialog 4
Deckel Dialog 11/12
Emcotronic M1/M2
Engelhardt CNC 3300
Fanuc Series 0-MB/MC
Fanuc Series 6M/11M/16M
Fagor 8050M
FC 16 CNC
H & K CNC 781M/783M
Heidenhain TNC:
- 151/155/355/360 (ISO)
- 407/415/425 (ISO)
- 410/426/430/310 (ISO)
- 150/155/355/360 (cleart.)
- 407/415/425 (cleart.)
- 410/426/430/310 (cleart.)
Maho CNC 232 (cleart.)
Maho CNC 432/532
Maztrol M32/M+(EIA/ISO)
Mitsubishi M50
NUM 720F/750/760
Pronumerik CNC 640
Okuma OSP 5020M
Sanying
Sinumerik 3M/6M/7M
Sinumerik 810M/820M
Sinumerik 850M/880M
Sinumerik 802SD
Sinumerik 810D/840D
Traub MX8
Turning
Acramatic 900TC
A. Bradley CNC 8400LP
Anton CNC 3300
Bosch CC 200 T
Bosch CNC Alpha 2
Emcotronic T1/T1
Engelhardt CNC 3300
Fagor CNC 8020
Fanuc Series 0T/18T/21T
Fanuc Series 6T/10T/15T
Fanuc Series 150-TA
Gildemeister EPL1
The NC syntax of the CNC simulator is determined by the currently Gildemeister EPL2
activated programming key. This correlates all NC blocks to the
Lux-Turn
MTS programming key which is used as an internal universal pro-
gramming key. MTS programming key includes all commands defi- Maho 432T
ned in ISO/DIN 66025, parameter programming, comprehensive Mazatrol T32 (EIA/ISO)
extensions with canned cycles and geometric tool path commands Mazatrol TPLUS(ISO)
in the form of contour strings. Mitsubishi Meldas 310L
Mori Seiki MF-T4/T6
The target program code in an activated programming key is trans-
MANUAL PLUS
lated with the aid of a universal preprocessor which can convert the
CNC control specific program code into MTS programming key NCT 90T
code. This is normally possible owing to the wide range of MTS pro- NUM 720T/750T/760T
gramming key features. However, if the preprocessor is not able to Okuma OSP500L
model a particular control cycle, this cycle cannot be used in the Sinumerik 3T
simulation either.
Sinumerik 8T
Thus, NC programs originally written externally in a specific control Sinumerik 802SD
code can be simulated as long as all NC commands used in the pro- Sinumerik 805T
gram are available in the activated programming key, i. e. can be Sinumerik 810T/820T/
translated into the MTS programming key by the preprocessor. Sinumerik 850T/880T
Sinumerik 810D/840D
The combination of preprocessor and postprocessor enabled in this
Sinumerik 840C
way forms the NC compiler, which can translate NC programs from
one control-specific key into another programming key. SMT CC4200T
SUF 16 CNC
It is always possible to transfer an NC program from MTS shop-floor Traub TX8
programming systems to a specific CNC control and vice-versa as Traub TX8D/TX8F
long as the program does not contain any commands which are not
available in the target programming key set.
Here, we would like to refer to our
extensive range of programming key
examples provided in the control
cycles of the demonstration version
which you can download from our
web site.
http://www.mts-cnc.com
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 Set-Up - Programming - Automatic Mode

The shop-floor programming

stations TOPTURN and TOP-
MILL offer three distinct opera-
ting modes:
• set up
• programming
• automatic mode

completed by the quality

assurance functions:
• workpiece measurement at
cross-sections
• 3D workpiece display.

For graphical representation of the machine

tool operating modes, an optional software
enhancement: 3D machine-tool space with
3D material removal simulation and 3D
collision detection is available in addition
to the various standard schematic 2D repre-
sentations of longitudinal sections or top
views with longitudinal and transversal
cross-sections.

With the conventional navigation functions

(zoom, rotate, shift etc.), the 3D graphical
displays can be modified, parts of the machi-
ne tool can be blanked out and parts of the
workpiece can be cut away to enable vie-
wing of internal machining processes.

Set-up and tooling

As on a real machine tool, tools are selected using the tool

management and are installed in the tooling system, com-
pensation values are set, material blanks are defined and
clamped, and the workpiece coordinate origin is set in the
same way as on a real machine tool.

The CNC simulator motions can be controlled manually,

machining the virtual workpiece in the process, e. g. in order
to determine the workpart zero point or tool offsets by teach-
in.

Of course, the CNC simulators can also be set up automati-

cally using a set-up sheet included in the header of the NC
program. Conversely, it is possible to save the actual set-up
state in a set-up sheet.

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Programming
TOPTURN and TOPMILL offer
different shop-floor program-
ming modes. It is possible to
switch over from any of these
modes to another while pro-
gramming in order to suit the
task at hand. These modes
are:
• Interactive programming
• Use of an NC editor
• Use of a geometrie editor
• Teach-in operation
• Dialog mode programming
The first two programming
modes involve the input of NC
blocks by the programmer; in
the others, the NC blocks are
generated automatically.

In interactive programming,
NC editing and automatic
mode are used in combination.
Once an NC block or cycle has
been programmed, the corre-
sponding machining procedu-
re is simulated, thus allowing
immediate testing of an NC
block by simulation at the input
stage. After each block the
programmer can decide if he
wants to accept or modify the
block.

A special NC editor is provi-

ded to assist manual NC pro-
gramming, giving the possibili-
ties to detect and display syn-
tax errors or out-of-range
motions at the input stage alre-
ady.

In teach-in mode, the work-

piece can be machined under
manual control. The resulting
tool paths are translated into
ISO/DIN commands (G00 and
G01) and then inserted into
the NC program.
The Geometry editor (WOP -
workshop-orientated pro-
gramming) makes program-
ming of even the most com-
plex contours easy and requi-
res no separate calculations.
The dimensions taken from
the drawings are entered in
the dialog and are then con-
verted to contour path com-
mands (extensions to the stan-
dard ISO/DIN command set).
The transition points, circle
centers, roundings and cham-
fers are calculated automati-
cally during this procedure.
Collisions will be immediately
detected during simulation.

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 Dialog programming mode
Dialog programming mode provides easy input of complex machining stages, one or several related input screens being filled in by
the user with graphical assistance. The input is checked for validity of combinations, value ranges and alternatives with logical com-
bination functions.

Dialog programming can be used to create and edit NC programs in the respective programming key without having to resort to expli-
cit editing of NC blocks. Dialog steps are selected individually, starting from the overview of the machining functions arranged in a
tree structure.

The most efficient method of creating a program is to combine dialog programming with the geometry editor and interactive pro-
gramming, whereby the NC editor can be used to display the resulting NC program at any time.

The user can customize the form,

contents and functions of a dialog
input. He can also add new input
screens, e. g. to complete user-
specific machining cycles.

At this point it must be stressed that

shop-floor programming can be
extended by an adapted, graphics-
supported dialog programming
mode for every TOPTURN or TOP-
MILL programming key.

Since it is possible to create a cor-

responding MTS-CNC simulation
programming key for any given
CNC control, one specific applica-
tion is to use the combination of
these capabilities as a modern,
easy-to-use dialog for program-
ming elderly CNC controls.

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Automatic mode
In automatic mode, NC programs can be simulated in continuous sequence or block by block in real time with override
function, or in an accelerated test run. Dynamic simulation is displayed graphically in two dimensional or optionally three
dimensional views. The manufacturing, feed and tool usage times as well as the volume of workpiece material removed
by machining are calculated concurrently.

The comprehensive collision detection calculations support the run-in of NC programs, especially in tight workspaces,
complicated clamping situations or critical tool location combinations (danger of collision with neighbour tools).

Quality and dimensional accuracy of the workpiece being machined can be monitored at any time in the course of the
simulation using the 'measure' and 3D workpiece display functions. A tool path display is provided to allow analysis of
the tool movements.

System requirements

The software can be run on WIN- 64 MB of main memory are ade- For optional 3D simulation, 128 MB
DOWS 95/98/ME/NT/2000/XP opera- quate for 2D CNC simulation. main memory, a powerful processor
ting systems, either as a stand-alone and a high-performance graphics card
or as a network version. are recommended.

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 About MTS http://www.mts-cnc.com
email: mts@mts-cnc.com
MTS was founded in Berlin in 1980 by Dr. Hans-Joachim Pfeiffer. Its
corporate mission is to develop software for technical applications, Tel.: +49-30-349 96 00 Fax: +49-30-349 96 025
using mathematical methods.

We have been specializing in the development of CAD/CAM and

CNC software for more than 20 years.

Our activities focus firstly on the software packages presented here:

TOPCAM, TOPTURN and TOPMILL, representing the results of 20
years continued further development, and secondly, on project-
oriented development work on contract for third parties. The latter
mainly involves extensive adaptations of our standard software for
major manufacturers of CNC controls and machine tools, e.g. in the
projects:

• CNC simulation of complete machining on lathes and mill-turn

centers (7 axes)
• CNC simulation of Swiss type CNC lathes (10 axes)
• Programming and simulation of multi-spindle CNC machine tools
(24 or more axes)

Another important sphere of our activities involves software-

related training of our clients' staff.

We hold regular training courses on our standard software

and also provide a telephone hotline service.

You can also order our software in the following

languages: Chinese (simplex & traditional),
Czech, English, French, German, Hungarian,
Italian, Polish, Portuguese, Russian, Slovakian,
Spanish, Swedish, Thai, Turkish and
Vietnamese.

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