Feasibility study

Application of TAPTOR tool on FANUC CNC

Disclaimer
This brochure has been provided to you by FANUC Europe Corporation S.A. (“FANUC”) for convenience and
general information purposes only, with no intention of providing comprehensive, complete, accurate or up to
date information, and also contains information obtained from an independent FANUC customer not acting or
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or responsibility whatsoever for the accuracy, completeness, or usefulness of any information, application,
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products, use, processes or services, please contact FANUC at:
FANUC Europe Corporation
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Tel.: +352-727777-1

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Contents
1 Introduction......................................................................................................................................... 3
2 Requirements ..................................................................................................................................... 3
2.1 Options ............................................................................................................................................... 3
2.2 Parameter setting .............................................................................................................................. 3
2.2.1 Parameters related to tuning of the spindle motor ............................................................................. 4
2.2.2 General parameter to be set .............................................................................................................. 4
2.2.3 Parameters related the execution of NC programs............................................................................ 4
2.2.4 Parameter to be set before the cycle and reset after the cyle ........................................................... 4
3 Machining cycle for the TAPTOR tool ................................................................................................ 7
4 Using the TAPTOR cycle ................................................................................................................. 10
5 Tests on FANUC Robodrill machines .............................................................................................. 11
5.1 Taptor tool for M6 threads ................................................................................................................ 12
5.2 Taptor tool for M4 threads ................................................................................................................ 16
6 Appendix .......................................................................................................................................... 20

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1 Introduction
The company EMUGE-Werk Richard Glimpel GmbH & Co. KG (EMUGE) has developed a tool
called TAPTOR. This tool allows machining a thread in one process step by combining the drilling
and threading process into one process step. EMUGE has already developed a cycle for this tool on
a machine tool with SIEMENS CNC. The goal of this feasibility study is to investigate in which way
and under which conditions the TAPTOR tool can be used on machine tools with FANUC controls.
The feasibility study was carried out with the focus on RoboDrill machines with the FANUC control
series 3x-iB. Therefore, the optimization measures and parameter adaptions described in this report
are specific to these machines. The applicability to other machine has to be tested individually. A
detailed description of the machines used in this study can be found in chapter 5.

This report is based on the project description “Machbarkeitsuntersuchung zum Einsatz von Taptor-
Werkzeugen auf FANUC CNC” and summarizes the machining cycle that has been developed for
the TAPTOR tool (TAPTOR cycle), the required option configuration of the machine, the parameter
adaption and test results.

2 Requirements
2.1 Options

Apart from standard options on the Robodrill machines used in this study, the following options are
required to apply the described machining cycle for the TAPTOR tool:

- CS Contouring Control (-J852)

- AI Contour Control II (-S808)

2.2 Parameter setting

This chapter describes how the parameter setting has been permanently changed or changed during
the machining cycle (setting and resetting) on the Robodrill machines used in the feasibility study in
order to achieve the required quality of the machined thread with the TAPTOR cycle.
Therefore, the procedure described in this chapter is only valid for these machines. For other
machines, the described parameter setting can only be regarded as guideline.
The parameters relevant for the TAPTOR cycle can be categorized in parameters related to the
tuning of the spindle motor, general parameters, parameters related to machining process (accuracy,
cycle time,…) and execution of NC programs. The handling of theses parameters is discussed in the
following chapters.

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2.2.1 Parameters related to tuning of the spindle motor

Tuning of the parameters related to the spindle motor, as for example controller gains and feed
forward gains, might be required to achieve a sufficient accuracy of the tool path. The TAPTOR cycle
has been tested with two Robodrill machines, where an adjustment of theses parameters is required.
The overall parameters related to the spindles built into these two Robodrill machines are provided
with this report for comparison. The most important spindle parameters are listed in the appendix. It
is important to note that these parameters are only relevant for the exact same spindle motors. In
case that another spindle motor is used, an individual spindle tuning has to be done, if the required
accuracy cannot be achieved.

2.2.2 General parameter to be set

If Parameter P1013.1 (ISCx) of the two axes involved in the TAPTOR cycle is 1 then P1013.7
(IESPx) has also to be set to 1. This parameter enables to specify a higher feed rate required for the
TAPTOR cycle when the increment system C is used. The setting of this parameter requires a power
off/on cycle. Therefore, this parameter cannot be set and reset during the cycle. However, this
parameter has no influence on other functions and does not have to be reset.

2.2.3 Parameters related the execution of NC programs

The following parameter have to be set that the expressions used in NC programs in this feasibility
study can be executed:

P3454.4 (G1B) = 1; Enables single bit setting with the programmable parameter input (G10)
P11648.2 (ESE)=1; ELSE statement can be used in conditional branches with IF statement

CAUTION:
Other parameters not listed might also influence the execution of the custom macro programs.
Therefore, the execution of an NC program using the TAPTOR cycle has to be carefully tested on
each machine.

2.2.4 Parameter to be set before the cycle and reset after the cyle

The parameters listed in this chapter must be changed before the cycle and have to be reset after
the cycle. This is done by a NC program using the programmable parameter input (G10). The
program for setting parameters (Pset) is defined by the parameters required for the TAPTOR cycle.
However, the program to reset the parameters after the cycle (Prst) has to reflect the individual
parameter setting of the machine. Sample programs are given in below.

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The following variables have to be replaced in the program without spaces before and after the
value:

NZaxis : Axis number of the Z-axis

NCSaxis : Axis number of the CS-axis
NSpindel: Spindle number of spindle
NPset : Program number for program Pset
NPrst : Program number for program Prst

Pset: NC program to set required parameters

Sample program Pset

ONPset (PSET TAPTOR)
#27=1013(PARAMETER)
#28=1(BIT)
#29= NCSaxis (AXIS)
#30=PRM[#27,#28]/[#29](INCREMENT SYSTEM)
IF[#30EQ1]THEN#31=10000
ELSE#31=1000
G10L52
N1432PNCSaxisR[999000*#31](CS MAX FEED RATE AICC)
N1660PNCSaxisR[100000*#31](Z ACCELERATION CUTTING)
N1737PNCSaxisR[10000*#31](CS MAX ACCELERATION)
N1769PNZaxisR16(Z ACCDEC TIME CONSTANT AFTER ITP)
N1769PNCSaxisR16(CS ACCDEC TIME CONSTANT AFTER ITP)
N1772R24(AICC PATH BELLSHAPE TIME CONSTANT)
N1783PNZaxisR[3000*#31](Z CORNER DECELERATION FEED)
N1783PNCSaxisR[250000*#31](CS CORNER DECELERATION FEED)
N4021PNSpindelR3000 (MAX SPINDLE SPEED CS)
N8465R0(MAX FEEDRATE AICC)
N8466R0(MAX FEEDRATE AICC ROTARY)
N11248PNZaxisR0(Z OVERLAP)
N11248PNCSaxisR0(CS OVERLAP)
N19503Q0R1(SMOOTH SPEED)
G11
G5.1Q1 (AICC ON)
M99

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Prst: NC program to reset parameters to original values

The NC program Prst resets the parameters to the original values before the application of the
TAPTOR cycle. Therefore, the values in program Prst have to represent the values of the individual
machine. This is done by replacing the symbol □ in the sample program with the parameter value of
the parameter number written in bold. The numbers after the comma have to be omitted.

Example:
N1432PNCSaxisR[□*#31](V RAPID TRAVERSE FEED)
If the value in Parameter 1432 for the axis with axis number NCSaxis is 3000.000, then the symbol □
has to be replaced by 3000. The numbers after the comma have been omitted.

Sample program Prst

ONPrst (PRST TAPTOR)
#27=1013(PARAMETER)
#28=1(BIT)
#29= NCSaxis (AXIS)
#30=PRM[#27,#28]/[#29](INCREMENT SYSTEM)
IF[#30EQ1]THEN#31=10000
ELSE#31=1000
G10L52
N1432PNCSaxisR[□*#31](CS MAX FEED RATE AICC)
N1660PNCSaxisR[□*#31](Z ACCELERATION CUTTING)
N1737PNCSaxisR[□*#31] (CS MAX ACCELERATION)
N1769PNZaxisR□ (Z ACCDEC TIME CONSTANT AFTER ITP)
N1769PNCSaxisR□ (CS ACCDEC TIME CONSTANT AFTER ITP)
N1772R□ (AICC PATH BELLSHAPE TIME CONSTANT)
N1783PNZaxisR[□*#31](Z CORNER DECELERATION FEED)
N1783PNCSaxisR[□*#31](CS CORNER DECELERATION FEED)
N4021PNSpindelR□ (MAX SPINDLE SPEED CS)
N8465R□ (MAX FEEDRATE AICC)
N8466R□ (MAX FEEDRATE AICC ROTARY)
N11248PNZaxisR□ (Z OVERLAP)
N11248PNCSaxisR□ (CS OVERLAP)
N19503Q0R□ (SMOOTH SPEED)  □=1 if bit P19503.0 (HPF)=1, else □=0
G11

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G5.1Q0 (AICC OFF)
M99

3 Machining cycle for the TAPTOR tool

CAUTION:
The TAPTOR cycle assumes that the thread is produced with a movement of the linear axis in
negative axis direction and the spindle axis in positive direction. Consequently, the retraction
movement is a movement in positive direction of the linear axis and negative direction of the spindle
axis.
If this is not the case, the TAPTOR cycle has to be adapted accordingly.

The TAPTOR cycle uses the spindle axis as feed axis in the CS contour control mode. The spindle
axis is interpolated with the axis generating the linear movement of the tool. The TAPTOR cycle is
a custom macro program that has to be called by a macro call with the parameters listed in Table 1:

G65 PNTaptor A□ B□ C□ I□ J□ K□ D□ E□
Macro Call Program number Parameters

Table 1: Parameter for TAPTOR cycle

A Axis number of the CS-axis (Spindle axis) --

B Axis number of the Z-axis (linear movement) --
C Safety Distance mm (with decimal point), absolute value
I Drilling depth (cylindrical) mm (with decimal point), absolute value
J Depth of undercut mm (with decimal point)
K Programmed pitch mm (with decimal point)
D Start angle deg (with decimal point)
Cutting speed of spindle rpm (with decimal point)
E
(Maximum value = 2750.)

Example of calling the TAPTOR cycle:

G65 P1234 A8 B3 C2. I17. J1. K1. D0. E2750.

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TAPTOR cycle PTaptor
ONTaptor(EMUGE TAPTOR V1)
#32=#4003(STORE G90 G91)
#33=#4001(STORE G0 G1 G2 G3)
IF[[#8EQ#0]OR[#8EQ0]]THEN#8=200(DEFAULT SPINDLE SPEED 200 1/min)
(---CALCULATION---)
#20=[[#4+#3-0.9*#5]/#6]*360(#20 DISTANCE CS DRILLDEPTH x1)
#9=SQRT[[POW[#6,2]/POW[360,2]]+1]*#8*360(#9 FEED RATE THREAD x1)
#10=SQRT[[POW[[0.9*#6],2]/POW[360,2]]+1]*#8*360(#10 FEED RATE THREAD x0_9)
#11=SQRT[[POW[[0.8*#6],2]/POW[360,2]]+1]*#8*360(#11 FEED RATE THREAD x0_8)
#12=SQRT[[POW[[0.7*#6],2]/POW[360,2]]+1]*#8*360(#12 FEED RATE THREAD x0_7)
#13=SQRT[[POW[[0.6*#6],2]/POW[360,2]]+1]*#8*360(#13 FEED RATE THREAD x0_6)
#14=SQRT[[POW[[0.5*#6],2]/POW[360,2]]+1]*#8*360(#14 FEED RATE THREAD x0_5)
#15=SQRT[[POW[[0.4*#6],2]/POW[360,2]]+1]*#8*360(#15 FEED RATE THREAD x0_4)
#16=SQRT[[POW[[0.3*#6],2]/POW[360,2]]+1]*#8*360(#16 FEED RATE THREAD x0_3)
#17=SQRT[[POW[[0.2*#6],2]/POW[360,2]]+1]*#8*360(#17 FEED RATE THREAD x0_2)
#18=SQRT[[POW[[0.05*#6],2]/POW[360,2]]+1]*#8*360(#18 FEED RATE THREAD x0_05)
#19=SQRT[[POW[[0.01*#6],2]/POW[360,2]]+1]*#8*360(#19 FEED RATE THREAD x0_01)

(---CUTTING---)
N10G0G94G90AX[#1]=#7(INITIAL CS)

N11G01G91AX[#2]=-[#4+#3-0.9*#5]AX[#1]=#20F#9(Thread x1)
N12G91AX[#2]=-[#5/10]AX[#1]=[360*[#5/10]/[0.9*#6]]F#10(Thread x0_9)
N13G91AX[#2]=-[#5/10]AX[#1]=[360*[#5/10]/[0.8*#6]]F#11(Thread x0_8)
N14G91AX[#2]=-[#5/10]AX[#1]=[360*[#5/10]/[0.7*#6]]F#12(Thread x0_7)
N15G91AX[#2]=-[#5/10]AX[#1]=[360*[#5/10]/[0.6*#6]]F#13(Thread x0_6)
N16G91AX[#2]=-[#5/10]AX[#1]=[360*[#5/10]/[0.5*#6]]F#14(Thread x0_5)
N17G91AX[#2]=-[#5/10]AX[#1]=[360*[#5/10]/[0.4*#6]]F#15(Thread x0_4)
N18G91AX[#2]=-[#5/10]AX[#1]=[360*[#5/10]/[0.3*#6]]F#16(Thread x0_3)
N19G91AX[#2]=-[#5/10]AX[#1]=[360*[#5/10]/[0.2*#6]]F#17(Thread x0_2)
N20G91AX[#2]=-[#5/20]AX[#1]=[360*[#5/20]/[0.05*#6]]F#18(Thread x0_05)
N21G91AX[#2]=-[#5/20]AX[#1]=[360*[#5/20]/[0.01*#6]]F#19(Thread x0_01)

N22G91AX[#2]=[#5/20]AX[#1]=-[360*[#5/20]/[0.01*#6]]F#19(Thread x0_01)
N23G91AX[#2]=[#5/20]AX[#1]=-[360*[#5/20]/[0.05*#6]]F#18(Thread x0_05)
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N24G91AX[#2]=[#5/10]AX[#1]=-[360*[#5/10]/[0.2*#6]]F#17(Thread x0_2)
N25G91AX[#2]=[#5/10]AX[#1]=-[360*[#5/10]/[0.3*#6]]F#16(Thread x0_3)
N26G91AX[#2]=[#5/10]AX[#1]=-[360*[#5/10]/[0.4*#6]]F#15(Thread x0_4)
N27G91AX[#2]=[#5/10]AX[#1]=-[360*[#5/10]/[0.5*#6]]F#14(Thread x0_5)
N28G91AX[#2]=[#5/10]AX[#1]=-[360*[#5/10]/[0.6*#6]]F#13(Thread x0_6)
N29G91AX[#2]=[#5/10]AX[#1]=-[360*[#5/10]/[0.7*#6]]F#12(Thread x0_7)
N30G91AX[#2]=[#5/10]AX[#1]=-[360*[#5/10]/[0.8*#6]]F#11(Thread x0_8)
N31G91AX[#2]=[#5/10]AX[#1]=-[360*[#5/10]/[0.9*#6]]F#10(Thread x0_9)
N32G91AX[#2]=[#4+#3-0.9*#5]AX[#1]=-#20F#9(Thread x1)

N50G#33G#32M99(RESTORE G0 G1 G2 G90 G91)

(#1 A AXIS NUMBER CS)

(#2 B AXIS NUMBER Z)
(#3 C SAFETY DISTANCE)
(#4 I DRILLING DEPTH)
(#5 J DEPTH OF UNDERCUT)
(#6 K PROGRAMMED PITCH)
(#7 D START ANGLE)
(#8 E CUTTING SPEED SPINDLE MOTOR)
(#9 FEED RATE THREAD x1)
(#10 FEED RATE THREAD x0_9)
(#11 FEED RATE THREAD x0_8)
(#12 FEED RATE THREAD x0_7)
(#13 FEED RATE THREAD x0_6)
(#14 FEED RATE THREAD x0_5)
(#15 FEED RATE THREAD x0_4)
(#16 FEED RATE THREAD x0_3)
(#17 FEED RATE THREAD x0_2)
(#18 FEED RATE THREAD x0_05)
(#19 FEED RATE THREAD x0_01)
(#20 DISTANCE CS DRILLDEPTH x1)
(#21 )
(#22 )
(#23 )
(#24 )
(#25 )

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(#26 )
(#27 )
(#28 )
(#29 )
(#30 )
(#31 )
(#32 STORE G90 G91)
(#33 STORE G0 G01)

4 Using the TAPTOR cycle

In general, custom macro programs are first searched for in the folder /USER/LIBRARY. Therefore,
it is recommended to store the programs PTaptor, Pset and Prst in this folder. However, different
search folder for custom macro programs can be defined by parameter setting.

Applying the TAPTOR cycle basically consists of the following steps:

1. Call macro program Pset to set the required parameters (chapter 2.2.4)
2. Switch on CS Contour Control
3. Call macro program of TAPTOR cycle PTaptor (chapter 3)
4. Switch off CS Contour Control
5. Call macro program Prst to reset the parameters (chapter 2.2.4)

If a number of threads is consecutively machined, meaning only positioning (G00) commands are
specified between calls of the macro program PTaptor, step 3 can be repeated without following the
order 1-5 each time. However, when all threads with the TAPTOR tool have been machined, steps
4 and 5 are mandatory.
CAUTION:
The custom macro program Prst (step 5) resets the parameters to the standard values, which are
required for all machining processes except the TAPTOR cycle. Therefore, if the custom macro
program Prst is not executed before any other machining process is started, for example because
of interruption of the program, Prst has to be executed separately.

The program below is in example, how the TAPTOR cycle could be inserted into a NC program.

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:
:
G65P8150  Call custom macro program Pset
M55  Switch on CS Contour Control (machine-specific M-Code)
G43H….  Tool length compensation
:
: (Positioning to safety distance above work piece)
:
G65P8149A8B3C2I11J0.7K0.7D0.E2750Z2  Call custom macro PTaptor
:
:
M56  Switch off CS Contour Control (machine-specific M-Code)
G65P8151  Call custom macro program Prst

5 Tests on FANUC Robodrill machines

The TAPTOR cycle has been tested on two Robodrill machines with a maximum spindle speed of
10000 rpm and 24000 rpm. The first machine was a Robodrill LiB5 with 10000 rpm spindle, the
second one a Robodrill LiB5-Adv. with 24000 rpm spindle.
The maximum spindle speed is limited by 2750 rpm when using the TAPTOR cycle developed in
this feasibility study. The execution of the cycle has been recorded with Servo Guide. The following
criteria have been evaluated and checked:
- Difference of spindle axis (CS axis) position in tapping and retract movement lower than
about 2°
- Avoid already decreasing pitch in last turn of thread with constant pitch
The test results are presented in chapter 5.1 and chapter 5.2 for the TAPTOR tool for M6 threads
and M4 threads.

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5.1 Taptor tool for M6 threads
Robodrill LiB5 (10000 rpm)

Figure 1: Taptor M6, Robodrill LiB5 (10000 rpm), Spindle speed and position graph, Spindle speed in
rpm (green) / CS axis position in mm (red) / Z-axis position in mm (blue)

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Figure 2: Taptor M6, Robodrill LiB5 (10000 rpm), CS-Axis Difference Tapping and Retract, z-Position
0 mm corresponds to bottom of hole

Figure 3: Taptor M6, Robodrill LiB5 (10000 rpm), Pitch of thread over depth of hole, z-Position 0 mm
corresponds to bottom of hole

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Robodrill LiB5-Adv. (24000 rpm)

Figure 4: Taptor M6, Robodrill LiB5-Adv. (24000 rpm), Spindle speed and position graph, Spindle
speed in rpm (green) / CS axis position in mm (red) / Z-axis position in mm (blue)

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 Figure 5: Taptor M6, Robodrill LiB5-Adv. (24000 rpm), CS-Axis Difference Tapping and Retract, z-
Position 0 mm corresponds to bottom of hole

Figure 6: Taptor M6, Robodrill LiB5-Adv. (24000 rpm), Pitch of thread over depth of hole, z-Position 0
mm corresponds to bottom of hole

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5.2 Taptor tool for M4 threads
Robodrill LiB5 (10000 rpm)

Figure 7: Taptor M4, Robodrill LiB5 (10000 rpm), Spindle speed and position graph, Spindle speed in
rpm (green) / CS axis position in mm (red) / Z-axis position in mm (blue)

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Figure 8: Taptor M4, Robodrill LiB5 (10000 rpm), CS-Axis Difference Tapping and Retract, z-Position
0 mm corresponds to bottom of hole

Figure 9: Taptor M6, Robodrill LiB5 (10000 rpm), Pitch of thread over depth of hole, z-Position 0 mm
corresponds to bottom of hole

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Robodrill LiB5-Adv. (24000 rpm)

Figure 10: Taptor M4, Robodrill LiB5-Adv. (24000 rpm), Spindle speed and position graph, Spindle
speed in rpm (green) / CS axis position in mm (red) / Z-axis position in mm (blue)

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Figure 11: Taptor M6, Robodrill LiB5-Adv. (24000 rpm), CS-Axis Difference Tapping and Retract, z-
Position 0 mm corresponds to bottom of hole

Figure 12: Taptor M4, Robodrill LiB5-Adv. (24000 rpm), Pitch of thread over depth of hole, z-Position
0 mm corresponds to bottom of hole

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6 Appendix
Spindle Parameters adjusted for the tests in this feasibility study

CAUTION
The parameters in Table 2 were developed for the two Robodrill machines mentioned below.

The spindle parameter listed in Table 2 are related to the following Robodrill machines:
- Spindle 10000rpm: Robodrill LiB5 with spindle with maximum speed of 10000 rpm
- Spindle 24000rpm: Robodrill LiB5-Adv. with spindle with maximum speed of 24000 rpm

Table 2: Spindle parameters for Robodrill LiB5 (10000 rpm spindle) and Robodrill LiB5-Adv.
(24000 rpm spindle)

Parameter No. Description Spindle 10000rpm Spindel 24000 rpm

Feed-forward coefficient CS Contour
P4036 100 100
Control
Velocity loop feed forward coefficient CS
P4037 20 25
Contour Control
P4046 Velocity loop P (High) CS Contour Control 2 2
P4047 Velocity loop P (Low) CS Contour Control 2 2
P4054 Velocity Loop I (High) CS Contour Control 22 15
P4055 Velocity Loop I (Low) CS Contour Control 22 15
P4069 Position Gain CS contouring (High) 5000 5000
P4070 Position Gain CS contouring (Medium High) 5000 5000
P4071 Position Gain CS contouring (Medium Low) 5000 5000
P4072 Position Gain CS contouring (Low) 5000 5000

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