CNC PILOT 640
The Control for Lathes andTurning-Milling Machines

09/2021

Contents

The CNC PILOT 640
Where can it be used?

Versatile and effective

4

Intuitive and user-friendly

6

Fast, accurate, and reliable machining

8

Effective, well-structured, and flexible

10

Describe and import contours

16

Realistic control prior to machining

18

Expandable for all cases

20

High-performance Teach-in mode (option)

26

Tool data and cutting data are readily available

30

Open for external information

32

Measuring workpieces

36

Tool measurement

37

Overview

38

CNC PILOT 640: the control for lathes and turning-milling machines
What does it look like?

Modern multi-touch operation and convenient screen layout
What can it do?

Fully digital control design
Smart machining
CNC PILOT 640
With a15.6-inch touchscreen

Make programming easy with smart.Turn (option)
High-performance NC programs with DIN PLUS
An NC program at the stroke of a key with TURN PLUS (option)

Interactive Contour Programming (ICP)The graphical simulation

Turning, drilling, and milling in a single setup (option)
Single-setup machining, including C and Y axis (option)
Machining with the B axis and simultaneous machining

CNC PILOT 640
With a24-inch touchscreen

Cycles, the pre-programmed working steps

The tool and technology database of the CNC PILOT 640

Windows 7, Windows 8, and Windows 10 are trademarks ofMicrosoft Corporation
Options are functions integrated into the control, allowing
the functionality of the CNC PILOT 640 to be adapted to thecustomer’s needs at a later time. Some options, however,must be adapted by the machine manufacturer.
The specifications described here apply to the following control
and NC software versions:
CNC PILOT 640 with NC software versions
688946-08 (export license required)
688947-08 (export license not required)This brochure supersedes all previous editions, which thereby
become invalid. Subject to change without notice.

2

Fully digital job management with Connected Machining
The DataPilot CP 640 programming station
Rapid availability of all information

What accessories are
there?

Machine setup, setting presets, and measuring with touch trigger probes

Determine the length, radius, and level of wear directly in the machine... At a glance

User functions
Options
Accessories
Specifications

Versatile and effective
CNC PILOT 640: the control for lathes and turning-milling machines

Thanks to its versatile design andprogramming capabilities, the
CNC PILOT 640 provides you with thesupport you need, regardless of whether
you make simple or complex parts insingle runs or batches. Operating andprogramming the CNC PILOT 640 is very
convenient and requires very little training.
The CNC PILOT 640 is designed for CNC
lathes and can be used on horizontal andvertical boring and turning mills.
The CNC PILOT 640 supports lathes with amain and counter spindle, a C axis, or
positionable spindle, B and Y axes, anddriven tools.
In multi-channel machining, different
machining steps can be performed
simultaneously using multiple slides.

Regardless of whether you are turning
simple parts or complex workpieces, the
CNC PILOT 640 gives you the benefits ofgraphical contour input and convenient
programming with smart.Turn.
If you need to program with variables,
control special machine components, oruse externally created programs, etc.,
you can simply switch to DIN PLUS, where
you’ll find the right solution for yourspecific task.
Compatibility
The CNC PILOT 640 can also run alreadyexisting NC programs from older
HEIDENHAIN lathes. A convenient importfilter makes it easy for you to transfer older
programs (e.g., from the CNC PILOT 4290)
to the new control for continued use.

From simple jobs on acompact machine ...

... to complex tasks,... to serial production

4

5

Intuitive and user-friendly
Modern multi-touch operation and convenient screen layout

The screen
The CNC PILOT 640 is equipped with apractical splash-proof, scratch-resistant,
IP54-rated touchscreen designed for harshshop conditions. The screen can be
operated by means of gestures alreadyfamiliar from mobile devices.
The CNC PILOT 640 is available in different
screen formats. The 19-inch version lends
itself to large or multi-channel machinesrequiring a larger field of view. The smaller
15.6-inch widescreen is ideal for compact
machines. In Programming mode, thewidescreen version ensures a comfortable
overview of your programs.

Display of operating modes and themachine status (configurable).
You can fill this area with up to
25 different display segments.
Different display segments are stored for
Manual mode and Automatic mode.

PLC soft keys for machine functions

The CNC PILOT 640 gives you an excellent
overview of the information you needduring programming, program verification,and machine operation.
While you’re programming, helpful images
explain the required parameters. And
during program simulation, tool movements are shown in realistic detail. While
the program is running on the machine, the
CNC PILOT 640 displays information about
the tool position, speed, motor loading,and the machine status.

Self-explanatory soft keys for therespective operating mode
Alphanumeric keyboard for comments
USB port
Keys for operating modes and functions

Keypad for numerical input and fast menu
selection

The keyboard
The CNC PILOT 640 doesn’t need an
excessive number of keys. All of thefunctions are clearly identifiable thanks
to easily understood symbols.
The keys on the numeric keypad are used
for entering data and selecting functions.
The menu window shows the available
functions via images. Soft keys let you
make changes to selected functions, apply
position values and technology data, andcontrol data input.

6

Ergonomic and sturdy design
The optimized stainless steel operating
panel of the CNC PILOT 640 features a
special protective cover, making it highly
resistant to contamination and wear. The
labeling on the ergonomically shaped keys
can withstand extreme shop conditions.
You can also adjust the feed rate, rapid
traverse, and spindle speed settings withhandy control knobs.
Intuitive touchscreen operation
The operator-friendliness of the
CNC PILOT 640 has proven itself overmany years. Users throughout the world
use dialog keys, navigation keys, and soft
keys to operate their CNC PILOT 640. For
even more innovative and user-friendly
operation, the CNC PILOT 640 now alsocomes in a touchscreen version. Thisversion combines the proven benefits of
HEIDENHAIN controls with state-of-the-art
operation through tapping, swiping, anddragging gestures.
Practical touchscreen
The touchscreen is ideal for a shopfloor
environment because it can still be
operated when exposed to coolant, oil, andother factors. To lock the screen forcleaning, simply select the “Touchscreen
Cleaning” mode. The touchscreen can also
be operated with different types of work
gloves.

Gestures for multi-touch operation
The screen of the CNC PILOT 640 can be
operated with gestures already familiar toyou from your smartphone or tablet. For
example, you can zoom in or out with
two fingers, or swipe to rapidly navigate
through programs, menus, and the soft-key
row.
SymbolGestureTap
Double tap
Long press
Swipe

Drag

Two-finger dragSpreadPinch

Navigation keys

Machine operating panel with override
potentiometers

7Fast, accurate, and reliable machining
Fully digital control design

Thanks to its digital design, the
CNC PILOT 640 can control the entire
motion system. This proven digitaltechnology from HEIDENHAIN enableshigh contour fidelity and fast machining athigh accuracy. What’s more, all control
components of the CNC PILOT 640 areconnected via a digital interface.

Smart machining

High contour fidelity
The CNC PILOT 640 dynamically calculates
the contour in advance, allowing the lathe
control to rapidly adapt the axis speed atcontour transitions. Special algorithms
control the axes, ensuring motion control
within the speed and acceleration limits.

Digital drive technology
A position controller, speed controller, andcurrent controller (if needed) are integrated
into the CNC PILOT 640. Its digital motor
control enables very high feed rates.

High availability
The fully digital design of the
CNC PILOT 640 connects all of thecomponents via purely digital interfaces.
Control components are connected via
the HEIDENHAIN Serial Controller

Interface (HSCI), a real-time protocol forfast Ethernet. Encoders are connected via
EnDat 2.2, the bidirectional interface from
HEIDENHAIN.
This results in high overall system
availability, from the main computer to theencoder. It is also diagnosable and immune
to interference.
The fully digital solution from HEIDENHAIN
ensures exceptionally high accuracy andsurface quality at high traversing speeds.

Load monitoring: detect tool wear andbreakage during machining*
Load Monitoring tracks the machine’s
spindle and motor loading, comparing itwith load values from a reference
operation. The CNC PILOT 640 cangraphically visualize the load values in a
separate window.
You can set two limit values that trigger
different error reactions. If the first limit
value is exceeded, the current tool is
flagged as worn, and the control
automatically exchanges it with apreviously defined replacement tool
during the next tool call. After the second
limit value has been exceeded, the
CNC PILOT 640 assumes that there is animpermissible load (e.g., tool breakage)and stops the machining operation. This
improves process reliability duringmachining, particularly during unattended
shifts.
* The machine and control must be adapted by themachine manufacturer for this function.

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CC controller
unit

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Angle encoder

Batch mode
The batch mode function lets you run
multiple main programs automatically. You
can also define the part programs and their
number of parts in a program list. The
CNC PILOT 640 can then automatically
execute this list without programs being
manually selected and started. Batch mode
is ideal for scenarios in which different
operations are performed on a consistent
raw material supplied by bar loaders or
robots.
Program-run graphics
The program-run graphics display themachining operation in real time, revealing
the current state of the workpiece. Direct
observation during machining is often
impossible. In addition, you can switch
between different operating modes at any
time, letting you simultaneously work on a
program, for example. Then, while
programming, you can simply press abutton to check the machining progress.

Graphical depiction of the load values with Load Monitoring89

Effective, well-structured, and flexible
Make programming easy with smart.Turn (option)

Has the safety clearance been correctly
entered, has the speed limitation beentaken into account, and what oversizes
have been defined? All of these questions
need to be considered by novice andexpert NC programmers alike during
conventional DIN programming.
The smart.Turn principle
The working block, called a unit, plays a
key role in smart.Turn programs. A unit
completely and unambiguously defines asingle working step. The unit includes thetool call, the technology data, the cycle call,and the approach and departure strategies,
along with global data such as the safety
clearance. All of these parameters are
displayed in an intuitive dialog box.

Intuitive and clearly formatted
Programs created with smart.Turn are
known for their intuitive structure and easy
understandability. The smart.Turn tool uses
section codes that clearly distinguishbetween the program head (containing
setup information), tools assigned in theturret, the workpiece description, and theactual machining operation.

The unit
All of the parameters of a smart.Turn unit
are contained in intuitive fillable forms. The
overview form gives you the big picture
about the selected unit, while subforms
provide information on the details of theworking block. Intuitive help images
illustrate all of the required inputs. If input
options are available, smart.Turn displays alist of the available options for selection.

You will be guided by the dialog to enter
data in this sequence:• Program head
• Tools assigned in the turret• Description of workpiece blank• Description of finished part
• Individual machining steps

And you do not need to stop the
manufacturing process to program withsmart.Turn, since you can create andtest the smart.Turn program while theprogram is running.

The smart.Turn approach ensures that the
program is easy to read and allows you tosave all information in the NC program formaking the part.

The smart.Turn principle gives you thereassurance that the working block is fully
and correctly defined. The unit’s DIN PLUS
commands are listed in the NC program bysmart.Turn. This gives you an overview ofall working-block details at any time.

Production data at a glance
The program head includes all important
information about the workpiece (e.g.,
drawing number, date, programmer,
material, fixture, etc.).
All of the information that is important for
setting up and machining the workpiece,
such as the tool assignment in the turret, is
included in the NC program.
Programming in more than one window
Up to six NC programs can be opened
simultaneously in the DIN PLUS editor. The
NC program to be displayed is selected via
the smart keys. This allows you to transfer
program blocks from one NC program toanother or quickly gain an overview ofcomplex NC programs, including
subprograms.

Intuitive dialogs, with help images
explaining the parameters

smart.Turn unit in the NC program

Input form in smart.Turn

10

smart.Turn program with section codes

Entry form for the program head11

Effective, well-structured, and flexible
Make programming easy with smart.Turn (option)

Programming made simple
Global parameters, such as oversizes,
safety clearances, coolant on/off, etc., aredefined once in the start unit and thentransferred by smart.Turn to the otherunits.
Within the NC program, smart.Turn lists
the DIN PLUS instructions of this unit. This
gives you an overview of all working block
details and provides you with an intuitive,
well-structured NC program.

Programming contours
The smart.Turn tool makes your workeasier and more flexible. Simple contours
can be defined with just a few entries in
the cycle. Complex contours can be
defined with graphical interactive
programming (ICP) or through an uploaded
DXF part description. Contours remainreadable and editable when stored in the
NC program, allowing you to makechanges in either smart.Turn or the ICP
editor.

The smart.Turn tool supports units forroughing, finishing, recessing, recess
turning, thread cutting, drilling, tapping, andmilling, as well as special units for program
start, program end, moving the C axis in/out, subprograms, and program-section
repeats.

Suggested technology data
The CNC PILOT 640 stores your cutting
data based on the workpiece material, tool
material, and type of machining operation.
Since the tool material is already specified
when you describe the tool, you only needto enter the workpiece material. This
provides smart.Turn with all of the data itneeds in order to suggest cutting values.

smart.Turn dialogs with help images

12

Contour follow-up
Another highlight of the CNC PILOT 640 is
its contour follow-up functionality. If you
define the workpiece blank at the
beginning of your smart.Turn or DIN PLUS
program, then the control will calculate thecurrent state of the blank after every cut.
The machining cycles always take thiscurrent state into account. Contour followup lets you avoid air cuts and optimize
approach paths through the space createdby material removal.

High-performance NC programs with DIN PLUS

Programming in DIN PLUS
Units are available in smart.Turn for all
machining tasks, including for special
functions. But if you need to program withvariables, control special machine modules,
or use complex functions not included insmart.Turn, then you can use DIN PLUS,
which puts high-performance machining
cycles, program branching, andprogramming with variables at yourdisposal. You can even switch between
smart.Turn and DIN PLUS programming
within a single program.

Because the units are based on DIN PLUS,
you can “dissolve” a unit anytime into a
DIN PLUS program section as a basis forfine-tuning and optimization.
The CNC PILOT 640 also lets you create
DIN programs or upload and use externallycreated programs.

High-performance cycles in DIN PLUS
The DIN PLUS cycles let you define thecontour section to be machined by simply
marking the appropriate area in theverification graphics. You can then
immediately test each working step inthe simulation.
The relevant commands can be selectedfrom a menu or entered directly in G-code.
A dialog box appears in which you enter
the parameters. All of these entries are
explained with visual aids and plain
language texts.
Thanks to these highly effective machining
cycles and their assignment to machining
sections, DIN PLUS delivers greater
effectiveness and flexibility thanconventional NC programming.

smart.Turn program in tree view with a dissolved smart.Turn unit

13

Effective, well structured, and flexible
An NC program at the press of a button with TURN PLUS (option)

TURN PLUS lets you create NC programsin very little time: after you’ve described
the workpiece blank and final contour, all
you need to do is select the workpiecematerial and workholding equipment.
TURN PLUS does everything else
automatically: it generates the working
plan, selects the machining strategy,
selects the tools and cutting data, andgenerates the NC blocks.
The result is a thoroughly commented
smart.Turn program with working blocks(units), giving you assurance and room for
optimization when first running the NC
program.
TURN PLUS can do all of this for millingand drilling operations with the C or Y axis
on front face and lateral surfaces, as wellas on rear-face surfaces on machines withcounter spindles.

An NC program at a keystroke
When short programming times areimportant, you can generate all of theworking steps with only a single keystroke.
Using the entered contour and theinformation from the technology database,
TURN PLUS automatically creates theworking plan and selects suitable work
strategies, tools, and cutting data. Thistakes only a few seconds, and you canmonitor each individual working step in theverification graphics. TURN PLUS has now
provided a logical sequence of machining
possibilities, such as “first transverseroughing, then longitudinal roughing,” or“finishing outside, then finishing inside”.
However, you can also adapt this sequence
on your own to suit various tasks. In thismanner, the CNC PILOT 640 also has themachining expertise of your company at its
disposal, even during automatic working
plan generation.

Automatic program generation for thecomplete contour
The CNC PILOT 640 control can automatically create NC programs for complex workpieces with machining operations on thefront face, rear side, and lateral surface as
well. After you have defined the geometry,
this can save you about 90 % of the timeotherwise needed to create a program.
Automatic program generation for thesecond setup
TURN PLUS knows the contours of theclamping devices and takes them into
account when automatically generating theworking plan. The cutting path is thereby
automatically kept at a safe distance fromthe workholding equipment. Once theprogram for the first setup is complete, you
can “rechuck” using interactive graphics.
The control then automatically generates
the program for the second setup without
you needing to re-enter the workpiecegeometry.

Inclined contours are no problem
When it comes to automatically generating
the NC program for inclined contours,
the control is confronted with uniquedemands. The angle at which the contour
falls is often steeper than the angle ofthe tool tip. In this case, the control
automatically selects a different tool andperforms the machining operation in the
opposite direction or as a recess. In any
case, the result is an executable NC
program.

Defining the machining sequence
A standard machining sequence can be
defined in the TURN PLUS dialog. Various
machining sequences, such as for chuckparts, shaft machining, etc., can be stored.
From the global main types of machining
operations, such as “roughing,” “finishing,”
or “drilling,” to details such as defining atool for a specific operation, the automatic
working plan generation (AWG) feature canbe adapted to suit the user’s requirements.

Technology data
Material
Speed
Feed rate
Tools

Reliably moving from programming to the first cut in the shortest possible time with TURN PLUS

14

15

Describe and import contours
Interactive Contour Programming (ICP)

Interactive Contour Programming (ICP)
helps in the case of complex parts orincomplete part dimensioning. With it, you
describe the contour elements directly as
they appear in the workpiece drawing.
Or—if the drawing is available in DXF
format—you simply import the contour.
Contour programming with ICP
You define an ICP contour by entering thecontour elements one after the other in thegraphic editor. When selecting the contour
elements, you merely specify the directionof the line or the direction of rotation of thecircular arc. The CNC PILOT 640 doesn’t
need much input to create the contour
element.
When entering the data, you decide
whether the coordinates are to be absoluteor incremental, whether lines are definedby their end point or length, and whether
circular arcs are to be specified by theircenter point or radius. You also specify
whether the path to the next contour
element should be tangential or nontangential.

Define the contour element in ICP.

16The CNC PILOT 640 calculates missing
coordinates, intersections, center points,
etc., if they are mathematically defined.
If the entered data permit multiple
mathematically possible solutions, then
you can view the alternative proposals andselect the one you prefer. You can also add
to or modify existing contours.
Superimposing form elements
The ICP editor recognizes the chamfer,rounding, and undercut form elements(DIN 76, DIN 509 E, DIN 509 F, etc.). You
can enter these form elements during
sequential contour definition. However, it isoften easier to first define the “rough”
contour and then superimpose the form
elements. This is done by selecting thecorner on which the form element is to beplaced and then inserting the element.

ICP contours for smart.Turn and
DIN PLUS
In smart.Turn, you have various possibilities
for describing the contour to be machined.
You can describe standard contours directly
within the unit, or you can use ICP todefine complex turning or milling contours
as well as linear or circular drilling andmilling patterns. The contour defined withICP is incorporated into the smart.Turn
program. Within the unit, you refer to thecontour section to be machined. ICP
contours are saved in the NC program in areadable and editable form. This gives you
the benefit of choosing either smart.Turn or
the ICP editor to edit the contours.
If you are working in DIN PLUS mode, you
can likewise use ICP to describe theturning and milling contours, as well as thelinear and circular patterns. In the contourrelated cycles, you enter a reference to thecontour section to be machined.
The ICP editor can be called from withinsmart.Turn.

ICP contour description in the NC program

DXF import of contours (option)
Why should you painstakingly enter
contour elements if the data already exists
in the CAD system? ICP gives you theoption of importing contours in DXF format
directly into the CNC PILOT 640. Not only
do you save time that would otherwise bespent on programming and testing but you
also ensure that the finished contour
exactly corresponds to the design
engineer’s specification. DXF contours
can describe workpiece blanks, finishedparts, contour trains, and milling contours.
They must be available as two-dimensional
elements within a separate layer (i.e.,
without dimension lines, wrap-aroundedges, etc.).
First, import the DXF file into the
CNC PILOT 640 via the network or theUSB flash drive. Since the DXF format isfundamentally different from the ICP
format, the contour is converted from DXF
to the ICP format during the import. This
contour is then treated as a normal ICP
contour, and is available for smart.Turn or
DIN PLUS programming.

Workpiece drawing

Contour description in the ICP editor

17Realistic control prior to machining
The graphical simulation

The timely detection of errors is very
important in NC programming. The
CNC PILOT 640 supports you during
program verification with its graphicalsimulation, with precision and the actual
dimensions of the contour and the cuttingedge, because the simulation works withthe geometry values from the tool
database.
Graphical simulation
Prior to machining, you can use thegraphical simulation to check the following:• Approach and departure behavior• The machining sequence• The proportioning of cuts
• The finished contour
Graphical simulation can display the tool
cutting edge, rendering the cutting-edge
radius, width, and position true to scale.
This lets you notice machining details andcollision risks early on.

Configuring views
If your lathe is equipped with driven tools
and a positionable spindle, a C axis, or a Yaxis, then CNC PILOT 640 also simulates
the machining operations of the front faceand lateral surface, or the XY and YZ plane.
You can select the combination of
windows best suited to the machining
operation. This gives you everything youneed to accurately inspect your drilling andmilling operations. The CNC PILOT 640
depicts C-axis machining operations on the“unrolled lateral surface”.

Wire-frame or cutting-path graphics,
and machining simulation
The CNC PILOT 640 supports different
renderings of the tool path and machining
process, thus allowing you to choose theoptimal type of verification based on thetool or the machining operation.
The wire-frame depiction is ideal for
examining the approach and departure
movements and the proportioning of cuts.
The wire-frame rendering shows the pathof the theoretical cutting point.
A more accurate contour check is possible
with the cutting-path depiction. The
cutting-path graphics take the exact
geometry of the tool tip into account,
immediately showing you if material will beleft behind, the contour will be damaged,or the overlaps will be too large. The
cutting-path depiction is particularly
helpful for recessing, drilling, and milling
operations dependent on the tool shapefor their outcome.

3D simulation
The realistic, high-resolution 3D simulation
allows you to evaluate the machining result
for turning, drilling, and milling processes
prior to machining. This even applies tocomplex multi-channel operations. All of
the workpieces are displayed, along withthe tool movements on all slides. Milling
and turning operations are shown in
different colors.

Showing multiple contour groups at the same time

The machining simulation (material
removal graphics) shows the machining
process realistically. The workpiece blankis rendered as a filled-in surface. The
CNC PILOT 640 simulates every tool
movement at the programmed cutting
speed and shows the removal of machinedmaterial.

Wire-frame depiction

18

Cutting path depiction

Machining the front face

The freely rotatable perspective permits
visual inspection of the workpiece blankand finished part from all angles. Intuitive
gesture control allows you to navigate to
and zoom in on any programmed detail,including on lateral-surface or front-faceC-axis contours, and on Y-axis contours in atilted plane. As a result, the 3D simulation
allows you to detect even the tiniest oferrors prior to machining.
Calculating the machining time
If your customer needs an offer quickly,
then you need precise information invery little time. With its machining time
calculator, the CNC PILOT 640 is aninvaluable aid. During simulation of thesmart.Turn or DIN PLUS program, the
CNC PILOT 640 calculates the time perunit for the programmed machining
operation.
Along with the total machining time, thetable displays the machining time and idle
time of each cycle or tool used. This helps
with calculations and immediately showswhether the machining operation can still
be optimized.

Calculating the machining time

19

Expandable for all cases
Turning, drilling, and milling in a single setup (option)

The CNC PILOT 640 features an extensive
package of powerful cycles for standard
machining operations and special
applications, thus optimally equipping
you for everyday shopfloor challenges.
Multiple plunging
The multiple plunging cycle lets you
machine deep and wide slots very
efficiently. The low lateral deflection of
the tool enables up to 50 % higher
feed rates than those of conventional
recessing cycles. In the process, the cycle
automatically executes all working steps(recessing, ridge removal, and finishing).
The CNC PILOT 640 can also perform
follow-up drilling and milling operations on
the front face or lateral surface in a single
setup. In addition, the control offers
numerous functions and practical cycles.
* Optional. The machine and the CNC PILOT 640
must be adapted for this function by the machine
manufacturer.

Hobbing
Hobbing allows you to conveniently andcost-effectively manufacture high-value
gear teeth. The CNC PILOT 640 enables
the complete machining of straight andangled gear teeth in a single clamping,calculating and executing all motion
sequences from a cycle.

Drilling, deep-hole drilling, tapping
The CNC PILOT 640 can perform individual
drilling, deep-hole drilling, and tapping
operations with the C or Y axis. Using
parameters, you can easily program infeed
reductions when drilling partly orcompletely through the workpiece.
Drilling and milling patterns
If holes, slots, or ICP milling cycles
are located at regular distances on astraight line or a circular arc, then the
CNC PILOT 640 greatly simplifies yourwork, letting you create these patterns on
the front face or lateral surface with just a
few keystrokes.

Contour and pocket milling
The milling cycles of the CNC PILOT 640
support both contour milling and pocket
milling. You define all of the importantdetails, such as the machining direction,
milling direction, approach behavior,
departure behavior, feed rates, etc. The
CNC PILOT 640 then automaticallyaccounts for the cutter radius. You can millthe pocket with a roughing stage and afinishing stage, resulting in high accuracy
and excellent surface quality.

Thread milling
The CNC PILOT 640 supports special
thread milling tools, allowing you toleverage the benefits of thread milling on
lathes with a C or Y axis.

The CNC PILOT 640 supports different
plunging strategies during smart.Turn and
DIN programming. You can choose
between direct, reciprocating, or helicalinfeeds, or an infeed at the pre-drilling
position.

Milling slots and simple figures
Milling slots couldn’t be easier with the
CNC PILOT 640. After you define the slot’s
position, depth, and cutting values, themilling cycles takes care of the rest
automatically.

Face milling
The face milling cycle machines individual
surfaces, equilateral polygons, or a circle,
even off-center ones.

Even for simple contours such as circles,
rectangles and equilateral polygons, just a
few keystrokes are necessary to define theshape and position.
Drilling

Slot milling

Deep-hole drilling

Figure milling(circles, rectangles,
equilateral polygons)

Tapping

ICP contour milling

Thread milling

Face milling (single
surface, flat
surface, polygon)

Engraving cycles
Would you like to inscribe your workpieces?
That’s no problem with the CNC PILOT 640.
With just a few parameters, the smart.Turnengraving units can inscribe characters ofany size on a face or lateral surface, or in
the XY or YZ plane.
On the front face, the characters can bearranged in a line or an arc. You can define
the angle at which the characters arearranged on the lateral surface, and whenengraving with the Y axis. The time function
lets you engrave the current date and timeon your workpiece.
The engraving cycles are also available as
DIN PLUS cycles.
Deburring
The CNC PILOT 640 supports special units
and DIN PLUS cycles for deburring, letting
you program this operation with just a few
parameters.
Trochoidal milling
Trochoidal milling lets you efficiently
machine various pocket shapes (circles,
rectangles, and polygons) and any desired
slot. Roughing is performed with circular
movements superimposed onto forward
linear motion. Trochoidal milling enableshigh removal rates and reduces chatter.

Helical slot milling
The helical slot milling function is ideal forthe machining of lubrication grooves. You
simply enter all key parameters, such as
the pitch, milling multiple infeeds, etc.

Helical slot milling

Drilling or tapping

20

Face and lateral-surface milling

smart.Turn units and DIN PLUS cycles fordrilling

smart.Turn units and DIN PLUS cycles formilling21

Expandable for all cases
Single-setup machining, including C and Y axis (option)

The CNC PILOT 640 offers the rightsolution for any machining task andmachine design: it enables complex
machining operations with the C axis or
Y axis, as well as single-setup machining
on machines with a counter spindle.
You can also choose between the
programming modes DIN PLUS,
smart.Turn, and Teach-in for C-axis,
Y-axis, and single-setup machining.
C axis or positionable spindle*
For more demanding tasks, the
CNC PILOT 640 supports a C axis or
positionable spindle and a driven tool.
The driven tool makes it possible to drill
off‑center and to tap holes while the main
spindle is at rest. The C axis or positionablespindle permits milling and drilling
operations on the front face and lateralsurface of the workpiece. For programmingand inspecting these machining sections,
the workpiece is shown in the front faceview and in the unrolled lateral surfaceview.

Y axis*The CNC PILOT 640 lets you create slots
or pockets with even surfaces and verticalslot angles using the Y axis. You can define
the position of the milling contours on theworkpiece by defining the spindle angle.
For programming and verifying thesemachining sections, the workpiece isshown in the side and front face views. The
Y axis is supported in the smart.Turn and
DIN programming modes.
Counter-spindle expansion
For full-surface lathes, the CNC PILOT 640
provides the following control features:• Counter spindle with second C axis
• Movable tailstock (W axis)
Further assistance is provided by additional
functions, such as coordinatetransformation, spindle synchronization,and traversing to a fixed stop.
* The machine and control must be adapted by themachine manufacturer for this function.

Coordinate transformation
The contours of workpiece blanks andfinished parts can be mirrored about the
X axis or shifted relative to the workpiecedatum.
Spindle synchronization
The two spindles are electronically coupled
and rotate synchronously. This makes it
possible to transfer the workpiece fromone spindle to the other in mid-rotation,
thereby saving time otherwise spentbraking and starting the spindles. The
CNC PILOT 640 records any angular offset,taking it into account during later milling
operations on the counter spindle.

Eccentric turning and non-circularturning*
The CNC PILOT 640 provides convenient
cycles for eccentric turning operations andfor making non-circular turned parts. In thiscase, alongside actual contour machining,
additional traversing movements of the
X and Y axes are synchronously
superimposed onto the rotational
movement of the spindle. Eccentric
and non-circular parts can therefore bemachined without additional mechanicalelements.

External gear hobbing
Cycle G808 HOBBING allows you tomachine external cylindrical gears or helicalgears of any angle. During hobbing, therotations of the tool and the spindle aresynchronized while the cutter moves along
the workpiece axially.

* The machine and control must be adapted by themachine manufacturer for this function.

Traversing to a fixed stop
To ensure that the workpiece is firmly
pressed onto the opposing spindle surface,
the control monitors the nominal and actual
positions during traversing of the counterspindle, thereby detecting the fixed stop.
The CNC PILOT 640 monitors the motor
torque and uses it to reach theprogrammed contact force.

Single-setup machining: counter spindle (S3) with C axis (C2) on auxiliary
axis (W) and driven tool (S2).

Graphical contour programming for C-axis machining (milling and drilling)

22

First clamping

Cycle G808 automatically controls thesecomplex movements and allows you toconveniently enter all of the relevant
values. You can use gear parameters
directly from your drawing, and the cycle
will use them to calculate the sequence of
motion.

Spindle 1 (S1) with C axis (C1), as well as driven
tool (S2)Rear-face machining on the counter spindle after automatic workpiecetransfer

23

Expandable for all cases
Machining with the B axis and simultaneous machining

The B axis makes it possible to perform
drilling and milling operations in obliqueplanes. At first glance, the programming
work for these kinds of operations seems
very complex and compute-intensive. But
the CNC PILOT 640 lets you simply rotate
the coordinate system to the desired angle
and program the machining operation as
usual in the main plane. The machine thenexecutes the machining operation in thetilted working plane.
The B axis also features benefits for turning
operations. By tilting the B axis and rotating
the tool, you can bring the tool into
positions that allow you to perform
longitudinal and transverse machining on
the main spindle and counter spindle witha single tool. You can thereby reduce thenumber of tools needed as well as
eliminate certain tool changes.

Programming
The usual separation of the contour
description and the machining operation on
the CNC PILOT 640 also applies to drillingand milling operations in the tilted plane.
First, you rotate and shift the coordinate
system so that it lies in the tilted plane.
Then you define the hole pattern or the
milling contour as you would in the YZ
plane. The pattern and figure definitions of
the CNC PILOT 640 are available to you in
the process. This means that, for linear or
circular patterns and simple figures (circles,
rectangles, regular polygons, etc.), you only
need a few entries to describe the pattern
or figure in the tilted plane.

Simulation
In the Side View window, the simulationshows the hole pattern and milling contour
perpendicularly to the tilted plane, andtherefore without distortion. This ensuresthe easy verification of programmed holepatterns and milling contours. You can also
verify the tool movements in the Side View
window. If you want to check themachining operation in the tilted plane withrespect to the turning contour or the front
face, then add the Lathe Window or Front
Window. In the position display, the
CNC PILOT 640 shows the angle of thetilted plane and the tilt angle of the B axis
(beneath the simulation window). Do you
wish to view the currently active
coordinate system? At a keystroke, the
CNC PILOT 640 shows the current datum
and direction of the valid coordinate
system.

Machining in the tilted plane

24

Flexible use of tools*
If your machine is equipped with a B axis,
then you can use your tools much more
flexibly than before. On conventional
lathes, you need four different tools forlongitudinal and transverse turning on mainand counter spindles, but you can performthese tasks with just a single tool when
you employ a B axis.
You simply tilt the B axis and rotate the tool
to the normal position or to the position formachining from behind the workpiece,
whichever is required for longitudinal ortransverse turning on the main or counterspindle. All you need is a single call: the
CNC PILOT 640 calculates the tool lengths,
the tool angle, and the other tool data foryou.

Tool-use flexibility is increased significantly
when multiple tools are mounted in one
holder. If you have a combination of aroughing, finishing, and recessing tool, forexample, then you can complete essential
parts of the turning and recessing process
on the main spindle and counter spindle
without a tool change. And programming isvery easy. You simply indicate which toothof the tool to use and then define the tilting
angle and the tool position. This issufficient because the CNC PILOT 640
already has the rest position and the dataof each tool tooth in its database.

Simultaneous machining
The simultaneous roughing cycle andthe simultaneous finishing cycle both adapt
the inclination angle of the B axis to theworkpiece contour during turning. During
this process, the complex tool movements
are continuously monitored in order toavoid collisions between the tool / tool
holder and the workpiece. In simultaneousmachining, the tool is continuously
engaged at the optimal inclination angle,
allowing you to attain perfect surfaces
while increasing tool service life.

This type of flexibility reduces the numberof tools you need, and you save on
machining time by reducing the number oftool changes.
* The machine and the CNC PILOT 640 must be
adapted for this function.

Facing and ...

... longitudinal turning with the same tool ...

... and with multiple tools on one holder.

25

High-performance Teach-in mode (option)
Cycles, the pre-programmed working steps

Workpiece machining in Teach-in mode
For simple, non-recurring tasks, rework, or
thread repair, the cycles of the
CNC PILOT 640 simplify your work.
The help images illustrate the few entries
needed for the cycles. Before cutting, use
the simulation to assure yourself thatmachining will run as planned.
Thread-recut cycles
Even if the workpiece has been
unclampled, you can easily recut thethread with the CNC PILOT 640.
Simply clamp the workpiece, and position
the threading tool in the middle of a thread.
The CNC PILOT 640 remembers thisposition along with the spindle angle.
If you now position the tap in front of theworkpiece and enter the other thread
parameters, the CNC PILOT 640 has all theinformation it needs to recut this thread.

Fewer calculations
In Teach-in mode as well, the
CNC PILOT 640 automatically calculates
the proportioning of cuts during roughing,recessing, recess turning, or thread cutting
and calculates the number of strokes
required for deep-hole drilling. When
turning a taper, you can enter either thestarting point and the end point or thestarting point and the taper angle—
whichever is shown on your drawing.
Always available tool data
The CNC PILOT 640 uses a tool database.
Tool data such as the cutting radius, tool
angle, and point angle need to be enteredonly once for the setting dimensions to be
determined. The CNC PILOT 640 saves thedata. The next time you use the tool,
simply call the tool number. The
CNC PILOT 640 automatically considers
the correct tool dimensions, and you can
immediately machine to tolerance.

Suggested technology data
The CNC PILOT 640 stores your cutting
data based on the workpiece material, tool
material, and type of machining operation.
Because you have already entered thecutting material into the tool definition, you
only need to enter the material of yourworkpiece. This provides the cycle with allof the data required for suggesting the
cutting data.

Protective zone for the spindle
For each traversing movement in the (–Z)
direction, the CNC PILOT 640 checks
whether the programmed protective zone
is violated. If so, it stops the movement
and issues an error message.

Reference points
You can define the workpiece datum bytouching the workpiece with the tool or byentering the datum coordinates.

As a result, the current workpiece blank is
known to every Teach-in cycle so that air
cuts are avoided. This is possible with any
kind of turning operation.

Teach-in with contour follow-up
You can activate “contour follow-up”
by defining a workpiece blank.

Approach the tool-change point once andstore this position. Afterwards, a simple
cycle call suffices in order to return to thetool change point.

While a contour is being turned, the
CNC PILOT 640 automaticallycompensates for the deviations arisingfrom the cutter radius. This increases theprecision of your workpiece.

Threads, undercuts, parting

26

Single or multi-start longitudinal,
taper, or API threads

Longitudinal/transverse cutting forsimple contours

Radial/axial recessing for simple contours

Undercuts as per DIN 76,
DIN 509 E, or DIN 509 F

Longitudinal/transverse cutting withplunging

Longitudinal/transverse recess turning forsimple contours

Undercut form H, form K,or form U

Longitudinal/transverse ICP cutting forany contours

Radial/axial ICP recessing for any contours

Parting

Longitudinal/transverse ICP cutting forparallel contours

Longitudinal/transverse ICP recess
turning for any contours

Turning: cutting and finishing

Recessing and recess turning: cutting and finishing27

Multi-channel machining with multiple slides
Easily program complex machining

Regardless of whether multiple slides aremachining a single workpiece or multiple
workpieces are being machined
simultaneously in the workspace, thechallenge for the NC programmer is to
optimally divide the machining operation
between the available slides and spindles.
Programming
The command set of the CNC PILOT 640
takes into account machining for complex
machines. Special four-axis cycles andsynchronization commands facilitate thecreation of NC programs for machines withmultiple slides. The assignment of program
sections to slides or spindles gives the NC
program a clear structure.

Synchronous point analysis
Synchronous point analysis shows thechronological sequence of the machining
operation and the interdependency of theslides.
During the simulation, the CNC PILOT 640
calculates the machining time, nonproductive time, and waiting time, as well
as all tool changes and synchronous points.
Synchronous point analysis graphically
depicts the times, tool changes, andsynchronous points for each slide, making
the machining sequence transparent. Thisis a good basis upon which the NC
programmer can analyze and optimize
the machining operation.

By mirroring and/or moving the contour,
and by converting special NC commands, it
is also easy to program turning operations
that use the counter spindle, as well as
rear-side drilling and milling operations, fornearly any machine design.

Simulation
The graphical simulation shows all of theworkpieces and the tool movements of allslides. The CNC PILOT 640 takes the entire
work envelope into account. The tools andchucking equipment are shown to scale.
The graphical simulation also features ahigh degree of flexibility. You define what isdisplayed in the simulation window. You
can specify whether the window for lathe,
front-face or lateral machining is shown,or a combination of them. You can also
specify whether only the NC blocks of acertain slide are displayed, or the NC blocksof all slides.
With this support, you can effectively andthoroughly check complex, multi-slide
programs before making the first cut.

28

29

Tool data and cutting data are readily available
The tool and technology database of the CNC PILOT 640

Tool database
The standard tool database of the
CNC PILOT 640 stores 250 tools. This tool
memory can be expanded to 999 tools(option). The CNC PILOT 640 differentiates
between different types of turning, drilling,
and milling tools. The data to be enteredvary based on the tool type, ensuring that
all of the important parameters are
specified despite reduced data input.
The tool data are entered with the helpof dialog prompts in which you enterparameters such as the cutting-edge
radius, tool angle, point angle, cutting
material, and tool description. The data to
be input is explained through contextsensitive help images.
Tool list
In the tool list, the CNC PILOT 640
presents you with the complete tool data
in a clear format. Various sorting criteria canhelp you quickly find the desired tool.
This list not only gives you a good overview
of your tools, but it is also serves as thebasis for transferring tool data during
manual machining and for the creation of
NC programs.

Tool management in the tool list

30

Wear compensation
The CNC PILOT 640 can easily
compensate for tool wear both in the
X axis and in the Z axis. You can enter thecompensation values at any time, evenwhile the workpiece is being machined.

Turret assignment
You can view your machine’s programmed
turret assignment with all of the important
tool parameters at any time.
If you wish to change the tool assignmentor the tools in the turret, you can also
display the tool database entries in thelower window. Then you only need to
select the desired turret pocket and theproper tool from the database. You canapply the tool data to the turret assignment
entry at the stroke of a key.

Tool measurement
For measuring tools directly at themachine, the CNC PILOT 640 offers
multiple possibilities:• Via “touching off” the workpiece• Via an optical gauge* (option): the tool is
manually moved into the crosshairs of an
optical gauge, and the value is savedwith a keystroke.
• Via a tool touch probe* (option): the tool
moves in the direction of measurement.
Upon triggering of the tool touch probe(e.g., the TT 160 touch trigger probe)with a cuboid probe contact, the setting
dimension can be determined andstored.

Tool life monitoring (option)
For smart.Turn and DIN PLUS programs,
you can use the “Tool Life Monitoring with
Replacement Tool” option along withsimple tool life monitoring. The
CNC PILOT 640 then automatically inserts
a replacement tool as soon as the active
tool is worn out. When the last tool in thetool sequence is worn out, the
CNC PILOT 640 stops program execution.

Using an optical gauge or tool touch probe
for tool measurement makes determining
the tool data particularly easy, reliable, andaccurate.
* The machine and CNC PILOT 640 must be adaptedby the machine manufacturer for this function.

Tool editor

Tool selection for turret assignment

Technology Data (option)
With the CNC PILOT 640, cutting dataneed to be recorded only once. The control
saves these data based on the criteria of
workpiece material, cutting material, andtype of machining operation. Thanks to thisthree-dimensional table, the control always
knows the correct feed rate and the correct
cutting speed.
The CNC PILOT 640 determines the typeof machining operation based on the teachin cycle or the unit. The cutting material isentered with the tool description. Now
all you need to do is declare the material
at the start of your cycle program or
smart.Turn program, and the
CNC PILOT 640 suggests the correct
values for your machining operation.
You can use the cutting values or modify
them as needed.
By default, the technology database of the
CNC PILOT 640 stores the cutting data fornine combinations of workpiece materials
and tool materials. It can be expanded to
up to a total of 62 combinations (option).
Every combination of workpiece material
and tool material contains the cutting
speed, the main feed rate and secondary
feed rate, and the infeed for 16 types ofmachining operation.

Input of cutting values in the technology editor

31Open for external information
Fully digital job management with Connected Machining

The smooth exchange of knowledge iscrucial for the success of a company. In
order for knowledge to be transferred
rapidly and without loss, e-mailcommunication capability is just as
important as the continuous availability ofelectronic production documents or thetransfer of data to ERP and productionactivity control systems. Tool and raw
material inventories, tool data, workholding
drawings, CAD data, NC programs, andinspection instructions must all be available
to machine operators on all shifts. Costeffective manufacturing therefore requires
an efficient process chain and a networked
control.
The CNC PILOT 640, with its
Connected Machining package offunctions, integrates itself flexibly into
your process chain and helps you to
optimize the transfer of knowledge
within your company. So let yourworkshop, as well, benefit from all of

the information available within yourcompany. Connected Machining makes
uniformly digital job management possible
within a networked manufacturing
environment. You thereby benefit from thefollowing:• Ease of data usage• Time-saving procedures• Transparent processes
The networked CNC PILOT 640
Integrate the CNC PILOT 640 with thefunctions of Connected Machining into
your corporate network and, via thecontrol, connect the shop floor to PCs,
programming stations, and other data
storage media in these areas of thecompany:• Design• Programming• Simulation• Production planning• Production

Even the basic version of the
CNC PILOT 640 is equipped with two
Gigabit Ethernet ports of the latest
generation. The CNC PILOT 640
communicates with NFS servers andWindows networks in the TCP/IP protocol
without additional software. The fast datatransfer of up to 1000 Mbit/s ensuresvery short transmission times. The
CNC PILOT 640 therefore offers the
optimal technological platform forConnected Machining, the networkingof the control in the shop with all
production-related areas of your company.

Standard range of functions
In order for you to be able to use thedata that you have transferred to the
CNC PILOT 640 via the standard network
connection, the CNC PILOT 640 offers
attractive applications, even in its standard
range of functions. The PDF viewer or
Mozilla Firefox web browser enable thesimplest form of Connected Machining:access to production process data directlyon the control. As a result, operating webbased documentation and ERP systems isjust as easy as accessing your e-mailaccount. The following other file formats
can also be opened directly on the
CNC PILOT 640:
• Text files ending in .txt or .ini
• Graphics files ending in .gif, .bmp, .jpg,
or .png• Table files ending in .xls or .csv
• HTML files
Data transfer with Connected Machining
Another solution for full digital job
management from Connected Machiningis the free-of-charge TNCremo PC
software. With it, you can• bidirectionally transfer remotely stored
part programs and tool or pallet tables,
including over the Ethernet, and• start the machine.

Detailed data for the optimalorganization of production processes
HEIDENHAIN DNC1) enables, among
other things, the connection of CNC PILOT
controls to inventory management andproduction-activity control systems.
Automatic feedback messages about
currently running production processes, forexample, can be set up over this interface.
1)

The machine must be adapted by the machine
manufacturer for this function.

One aspect of Connected Machining is theStateMonitor2) PC software, which gives
you access to the status of the current
machining operation. You can use thesoftware with any device that has a web
browser. This allows you to use
StateMonitor not only on your control or
PC but also on your smartphone or tablet.
On a well-designed display, you can quickly
gain an overview of the current machine
status or see whether any machinemessages are pending. This allows you

to react immediately and take appropriate
action. You can also easily configure
StateMonitor to send you an e-mail for
specific events, such as at the end of aprogram, for a machine stop, or for aservicing message.
2)

Option 18 is required

Component monitoring
During their lifecycle, load-sustaining
machine components such as guideways
and ball screws exhibit wear, thus causing
the quality of axis motion to diminish. This,in turn, affects production quality. With
Component Monitoring (option 155) and acycle, the control is able to measure thecurrent condition of the machine. As aresult, any deviations from the machine’s
shipping condition due to wear andaging can be measured. The machine
manufacturer can read and evaluate
the data, and react using predictive
maintenance, thereby avoiding
unplanned machine downtimes.

With the powerful TNCremoPlus PC
software, you can also transfer the screen
contents of the control to your PC using
the live-screen function.
CAD
CAM

32

Job-related data
With REMOTE DESKTOP MANAGER(option 133), you can operate a Windows
PC from the CNC PILOT 640. On thecontrol, you gain direct access to EDP
systems within the process chain andmake your machine setup processes
significantly more efficient by reducing
inconvenient legwork between themachine and the office. Technical drawings,
CAD data, NC programs, tool data, work
instructions, parts lists, and warehouse
information are digitally available at themachine. E-mails can be sent and received
with ease. With a simple keystroke on themachine operating panel, you can switch
between the control screen and the screenof the Windows PC. The PC can be acomputer in the local network or anindustrial PC (IPC) in the electrical cabinetof the machine.

33

Open for external information
The DataPilot CP 640 programming station

DataPilot CP 640 is the PC programming
station for the CNC PILOT 640 and is theorganizational system for the shop floor
and master tradesman’s office.
DataPilot CP 640 is the ideal complement
to the CNC PILOT 640 for program
creation, archiving, and training.
Creating programs
Programming, testing, and optimizing
smart.Turn or DIN PLUS programs with theprogramming station significantly reduces
machine idle times. This does not require amajor shift in thinking, because, with
DataPilot, programming and testing are
performed in the same manner as on thelathe. DataPilot is based on the same
software that is in the control. This also
gives you the assurance that a program
created with DataPilot can be immediately
run on the machine.

Archiving programs
Although the CNC PILOT 640 has a large
memory capacity, we recommend saving
the created program on an external system
as well. The CNC PILOT 640 has a USB
and an Ethernet interface. This gives you
everything you need in order to integrate
the CNC PILOT 640 into your existing
network or to connect the DataPilot PC
directly with the control.
Convenient program transfer functions
support programming as well as archivingon the DataPilot PC.

Rapid availability of all information

Training with DataPilot CP 640
Because DataPilot CP 640 is based on thesame software as the CNC PILOT 640, it isideally suited for training purposes.
Programming and program testing on the
DataPilot PC are performed in exactly thesame way as on the machine. Even setup
functions such as defining the workpiecedatum, measuring tools, running individual
cycles, or executing smart.Turn or
DIN PLUS programs are simulated with
DataPilot. This gives trainees theconfidence they will need for later
work on the machine.
System requirements
The DataPilot software can run on PCs
with the Windows 7, 8, 8.1, or Windows 10(64-bit) operating systems.

Do you have questions about aprogramming step, but your User’s Manual
is not at hand? That’s not a problem: The
CNC PILOT 640 and DataPilot CP 640
feature the convenient TURNguide help
system with which the user
documentation can be displayed in a
separate window.
You activate TURNguide by simply pressing
the Info key on the keyboard.
In most cases, TNCguide directly displays
the information in the proper context(context-sensitive help). This means thatyou immediately receive the informationthat you need. This function is particularly
helpful when you program cycles. The
cycle’s principle of operation is explained assoon as you press the Info key in an open
dialog box.

You can download the documentationin the desired language from theHEIDENHAIN homepage to thecorresponding language directory on
your control.
The help system contains the following
manuals:• CNC PILOT 640 User’s Manual• smart.Turn and DIN Programming
User’s Manual• DataPilot CP 640 user’s manual(installed only with a programming
station)Trainer

Machine tool

PrinterTrainees
TURNguide integrated into the control, e.g., on the CNC PILOT 640 ...

34… or on the programming station.

35

Measuring workpieces
Machine setup, setting presets, and measuring withtouch trigger probes

Inspecting workpieces for completed
machining and dimensional accuracy
The CNC PILOT 640 features measuring
cycles for checking the geometry of themachined workpieces. To do this, simply
insert a 3D touch probe from HEIDENHAIN
into the turret instead of a tool:

The workpiece touch probes from
HEIDENHAIN help reduce costs in the
shop and for serial production. Setup,measurement, and control functions canbe automatically executed in conjunction
with the touch probe cycles of the
CNC PILOT 640.

• Check whether all of the machining
operations have been properly
performed• Determine infeeds for finishing• Detect and compensate for tool wear
• Inspect workpiece geometry and sortparts
• Log measured data
• Ascertain the machining trend

The stylus of a TS touch trigger probe isdeflected upon contact with a workpiecesurface. In that instant, the TS generates a
triggering signal that, depending on themodel, is transmitted to the control either
by cable, radio transmission, or an infrared
beam.
HEIDENHAIN touch probes* for workpiecemeasurement are available in various
designs. The ball tips, which are made ofruby, are available in different diameters
and with various stylus lengths.
* The touch probes must be adapted to the
CNC PILOT 640 by the machine manufacturer.

Touch probes with signal transmission
via cable for machines with manual toolchanging, as well as for grinding machines
and lathes:
TS 260: new generation, axial or radialcable connection
TS 248: like the TS 260 but with reduced
deflection forces

Tool measurement
Determine the length, radius, and level of wear directlyin the machine

Exact measurement of the tool dimensions
is a decisive factor in ensuring aconsistently high level of production quality.
The TT tool touch trigger probes from
HEIDENHAIN serve this purpose.
TT 160 : new generation, signaltransmission to the NC via a cable

TS 150: compact dimensions and highprobing accuracy

TT 460: new generation, signaltransmission to transceiver via radio andinfrared beam

Touch probes with radio or infrared signaltransmission for machines with anautomatic tool changer:

The SE 660 is a transceiver for tool andworkpiece touch probes using radio or
infrared transmission.

The TT 160 and TT 460 are 3D touch
trigger probes for the measurement andinspection of tools. The disk-shaped probe
contact of the TT is deflected during tactile
probing of a tool. In that instant, the TT
generates a trigger signal that istransmitted to the control, where it is thenfurther processed. The trigger signal isgenerated by means of a wear-free andhighly reliable optical sensor.

TS 460: new generation standard touchprobe for radio and infrared transmission,
with compact dimensions
TS 740: high probing accuracy andrepeatability, low probing force, featuring
infrared transmission

SE 660Further information:
You can find detailed descriptions ofworkpiece touch probes on the Internet
at www.heidenhain.com or in the
Touch Probes for Machine Tools brochure.

36

Thanks to its robust design and highprotection rating, these tool touch probes
can be installed in the machining envelopeof the machine tool, where they enable
tool measurement directly inside themachine. Fast, easy, and particularly
precise tool measurement is the result.
The tool touch probes from HEIDENHAIN
are an ideal addition for improving theefficiency and quality of your production
system.

TT 160Further information:
TS 460You can find detailed descriptions oftool touch probes on the Internet atwww.heidenhain.com or in the
Touch Probes for Machine Tools brochure.

37Configuration•

Operating modes
Manual operation•

Basic version: X and Z axis, main spindle
0-6
Driven tool and auxiliary axes (U, V, W)
55+0-6 C axis and driven tool
70+0-6 Y axis
54+0-6 B axis
94+0-6 Parallel axes U, V, W (display function and compensation)
132+0-6 Counter Spindle•
Digital current and speed control•
11
Teach-in mode

8

Program run

Setup functions

Programming
Cycle programming

Sequential arrangement of fixed cycles, with each cycle being run immediately after input orgraphically simulated and subsequently saved

9
8

17
17
17

Setting the workpiece datum
Defining the tool-change point
Defining the protection zone
Defining machine dimensions
Manual programs
Tool measurement by touching the workpiece
Tool measurement with a TT tool touch probe
Tool measurement with an optical gauge
Workpiece measurement with a TS workpiece touch probe

•
•
•
•
•
•

8
8
8
8
8
8
8
8
8+55
8+55
8+55
8+55
8+55
8+55
8
8
8
8+9

38

Manual slide movement through axis-direction keys, an intermediate switch, or electronic
handwheels
Graphical support for entering and running cycles without storage of the machining steps, indirect alternation with manual machine operation
Thread rework (thread repair) in a second workpiece setup

In Single Block mode or Full Sequence mode:
DIN PLUS programs
smart.Turn programs
Cycle programs•

Interactive Contour
Programming (ICP)

Turning cycles for simple or complex contours, and contours described with ICP
Contour-parallel turning cycles
Recessing cycles for simple or complex contours, and contours described with ICP
Repetitions with recessing cycles
Recess turning cycles for simple or complex contours, and contours described with ICP
Undercut and parting cycles
Engraving cycles
Threading cycles for single or multi-start longitudinal, taper, or API threads, and threads withvariable pitch
Cycles for axial and radial drilling, deep-hole drilling, and tapping operations with the C axis
Thread milling with the C axis
Axial and radial milling cycles for slots, figures, single surfaces, and centric polygon surfaces,
and for complex contours described with ICP for machining with the C axis
Helical slot milling (multi-start) with the C axis
Deburring of ICP contours
Linear and circular patterns for drilling and milling operations with the C axis
Context-sensitive help images
Transfer of cutting values from the technology database
Use of DIN macros in cycle programs
Conversion of cycle programs to smart.Turn programs

smart.Turn
programming

TURN PLUS

OptionStandard

User functions
OptionUser functions

Standard

Overview
User functions

8/9
8/9
8/9
8/9
8/9
8/9
8/9
8/9
8/9+55

Contour definition with linear and circular contour elements
Immediate display of entered contour elements
Calculation of missing coordinates, intersections, etc.
Graphical display of all solutions for selection by the user if more than one solution is possible
Chamfers, rounding arcs, and undercuts available as form elements
Input of form elements immediately during contour creation or through later superimposition
Changes to existing contours can be programmed
Machining attributes available for individual contour elements
C-axis machining on the front face and lateral surface:• Description of individual holes and hole patterns (only in smart.Turn)• Description of figures and figure patterns for milling (only in smart.Turn)• Creation of freely definable milling contours
9+70 Y-axis machining on the XY and ZY planes (only in smart.Turn):• Description of individual holes and hole patterns• Description of figures and figure patterns for milling operations• Creation of freely definable milling contours
8/9+55+ Programming of the rear face for complete machining with the C and Y axes
70+132
8/9+42 DXF Import: importing of contours for lathe and milling operations
9

The basis is the “unit,” which is the complete description of a machining block (geometry,technology, and cycle data)
9
Dialog boxes divided into overview and detail forms
9
Fast navigation between the forms and the input groups via the "smart" keys
9
Context-sensitive help images
9
Start unit with global settings
9
Transfer of global values from the start unit
9
Transfer of cutting values from the technology database
9
Units for all turning and recessing operations for simple contours and ICP contours
9+55/70 Units for drilling and milling operations with the C or Y axis for holes, milling contours, anddrilling and milling patterns that are simple or that have been programmed with ICP
9+55/70 Units for trochoidal milling operations for pockets and slots
9+55+ Unit for hobbing (machining of gear teeth)135
9+55 Special units for activating/deactivating the C axis, as well as for subroutines and section
repeats
9+55/70 Verification graphics for the workpiece blank and finished part, as well as for C- and Y-axis
contours
9
Turret assignment and other setup information in the smart.Turn program
9
Parallel programming
9
Parallel simulation
9
Trochoidal milling9
Hobbing
9
Multiple plunging•
Batch Mode (automatic execution of multiple different main programs)
63

Automatic smart.Turn program generation with:• Automatic tool selection• Automatic turret assignment• Automatic calculation of the cutting data
• Automatic generation of the machining sequence in all working planes, including for C-axis
machining (with option 55) and Y-axis machining (with option 70)• Automatic cutting limit through chucking equipment• Automatic generation of work blocks for rechucking during complete machining• Automatic generation of work blocks for rear-face machining (with option 132)

39

DIN PLUS
programming

•
•
•
•

•
•
•

•
•
•
•
•
•
Simulation

Programming in DIN 66025
Expanded command format (IF ... THEN ... ELSE ...)
Simplified geometry programming (calculation of missing data)
Powerful fixed cycles for area clearance, recessing, recess turning, and thread machining
55
Powerful fixed cycles for drilling and milling with the C axis
70Powerful fixed cycles for drilling and milling with the Y axis
Subprograms
Technology functions for complete machining:• Traversing to a fixed stop
• Controlled parting
131/132 • Spindle synchronism
132• Mirroring and converting• Mechatronic tailstock
Programming with variables
8/9
Contour description with ICP
Program verification graphics for workpiece blank and finished partTurret assignment and other setup information in the DIN PLUS program
9
Conversion of smart.Turn units into DIN PLUS command sequences
Parallel programming
Parallel simulation

•

•
•
•

Graphical simulation of the cycle process, the cycle program, the smart.Turn program, or the
DIN PLUS program
Depiction of the tool paths as pencil-trace or cutting-path graphics; special identification of
the rapid traverse paths
Machining simulation (2-D material-removal graphics)
Side view or front face view, or 2-D view of (unrolled) cylindrical surface for verification of
C-axis machining operations
Display of programmed contours
View of the tilted plane (B-axis machining)
View of front face and YZ plane for verification of Y-axis machining
Three-dimensional rendering of the workpiece blank and finished part
Simulation of mirrored contours for rear-face machining
Shifting and magnifying functions
Block scan in the simulation
Depiction of multi-channel machining operations•

Real-time depiction of currently running workpiece machining

•
•
55
•
54
•
•
132

Concurrent simulation

54

B-axis machining

54

Machining with the B axis
Tilting the working plane
Rotating the machining position of the tool

9+54

Simultaneous turning

135
135

Cycles for eccentric turning and for the manufacture of oval and polygonal contours
Superimpositioning of traversing movements of the X and Y axes synchronously to therotational motion of the spindle•

Eccentric machining

Machining time analysis

Monitoring function

40

•
•
•

Tool database

OptionStandard

User functions
OptionUser functions

Standard

Overview
User functions (continued)

•
10
•
•
•
•
•
•
10
•
•
8/9

Technology database

8/9
8/9
8/9
10
User administration•

Conversational languages •For 250 tools
For 999 tools
Tool description can be entered for every tool
Automatic inspection of the tool-tip position relative to the machining contour
Compensation of the tool-tip position in the X/Y/Z plane
Fine compensation of tool via handwheel with application of compensation values in thetool table
Automatic tool-tip and cutter radius compensation
Tool monitoring for the service life of the indexable insert or of the number of produced
workpieces
Tool monitoring with an automatic tool change after expiration of tool life
Management of multipoint tools (multiple inserts or reference points)
Support of quick-change tool systems
Access to cutting data upon definition of workpiece material, cutting material, and the type ofmachining operation. The CNC PILOT 640 differentiates between 16 types of machining
operations. Every combination of workpiece material and tool material contains the cutting
speed, the main feed rate, the secondary feed rate, and the infeed for 16 types ofmachining operation.
Automatic determination of the type of machining operation from the cycle or themachining unit
The cutting data are entered in the cycle or in the unit as suggested values
Nine combinations of workpiece material and tool material (144 entries)
62 workpiece-material / tool-material combinations (992 entries)
Configurable linkage of permissions to user roles• Logging on to the control with a user account• User-specific HOME folder for simplified data management• Role-based access to the control and network data
English, German, Czech, French, Italian, Spanish, Portuguese, Dutch, Swedish, Danish,
Finnish, Norwegian, Slovenian, Slovak, Polish, Hungarian, Russian (Cyrillic), Romanian, Turkish,
Chinese (traditional and simplified), Korean

Calculation of machining times and idle times
Consideration of the switching commands triggered by the CNC
Representation of time per individual cycle or per tool change
151

Load monitoring: detection of tool wear and breakage during machining

155

Component Monitoring: monitoring of component wear and overloading

41

Overview
Options

OptionnumberOptionStarting ID
with NCSoftware
688946688947-

0
1
2
3
4
5
6
7

Additional Axis

01
01
01
01
01
01
01
03

8

Teach-In

01

9

10

smart.Turn

Tools and Technology

01

01

Comment

OptionnumberOptionStarting ID
with NCSoftware
688946688947-

Comment

354540-01
353904-01
353905-01
367867-01
367868-01
370291-01
307292-01
370293-01

Additional control loops 1 to 8

94

Parallel Axes

01

679676-01

Support for parallel axes (U, V, W)
Combined display of principle and secondary axes

131

Spindle Synchronism

01

806270-01

Synchronization (of two or more spindles)

132

Counter Spindle

01806275-01

Counter spindle (spindle synchronism, rear-face machining)

133

04

894423-01

632226-01

Cycle programming• Contour description with ICP• Cycle programming• Technology database with nine workpiece-material / tool-material
combinations

Remote Desktop
Manager

Display and remote operation of external computer units(e.g., a Windows PC)

135

Synchronizing
Functions

03

1085731-01 Advanced synchronization of axes and spindles

137

State Reporting

06

1232242-01 State Reporting Interface (SRI): provision of operating conditions

143

Load Adapt. Control

01

800545-01

LAC: load-dependent adaptation of control parameters

151

Load Monitoring

03

1111843-01

Monitoring of the tool load

153

Multi-channel

05

1217032-01 Multi-channel capability: up to three channels for asynchronous
multi-slide machining

155

Component Monitoring 07

632227-01

632228-01

smart.Turn• Contour description with ICP• Programming with smart.Turn• Technology database with nine workpiece-material / tool-material
combinations
Tools and technology• Tool database expanded to 999 entries• Technology database expanded to 62 workpiece-material /tool-material combinations• Tool life monitoring with exchange tools

11

Thread Recutting

01

632229-01

Threads• Thread recutting• Handwheel superimpositioning during thread cutting

17

Touch Probe Functions

01

632230-01

Tool measurement and workpiece measurement• Determining tool-setting dimensions with a tool touch probe• Determining tool-setting dimensions with an optical gauge• Automatic workpiece measurement with a workpiece touch probe

18

HEIDENHAIN DNC

01526451-01

Communication with external PC applications over COM component

24

Gantry Axes

01

634621-01

Gantry axes via master-slave torque control

42

DXF Import

01

632231-01

DXF import: importing of DXF contours

46

Python OEM Process

01579650-01

Python application on the CNC PILOT 640

49

Double-Speed Axes

01

632223-01

Short control-loop cycle times for direct drives

54

B-Axis Machining

01825742-01

B axis: tilting the working plane, rotating the machining position of the
tool

55

C-Axis Machining

01633944-01

C-axis machining

63

TURN PLUS

01825743-01

TURN PLUS: automatic generation of smart.Turn programs

70

Y-Axis Machining

01

661881-01

Y-axis machining

77

4 Additional Axes

03

634613-01

4 additional control loops78

8 Additional Axes

03

634614-01

8 additional control loops

42

160 to 167 Integrated FS
169

Add. FS Full

1226833-01 Monitoring for component overloading and wear

07

Enabling of functional safety (FS) and safe control loops

08

Enabling of remaining safe control loops

43

Accessories

Overview
Specifications

Accessories

Specifications

Electronic handwheels• HR 180 panel-mounted handwheels with connection to position inputs, and• An HR 130 serial panel-mounted handwheel or a portable serial HR 510 (FS),HR 520 (FS), HR 550 FS handwheel

Tool measurement

3D touch trigger probes:• TT 160 with a cuboid probe contact and cable connection• TT 460 with a cuboid probe contact and radio or infrared transmission

Workpiece measurement• TS 150, TS 248, TS 260: touch trigger probe with cable connection, or• TS 460 touch trigger probe with radio or infrared transmission, or• TS 740 touch trigger probe with infrared transmission

DataPilot CP 640, MP 620

Software for PCs

44

Programming station for PC for programming, archiving, and training for the CNC PILOT 640• Full version with license for single station or multiple stations• Demo version (free of charge)• TeleService software for remote diagnostics, monitoring, and operation• TNCremo software for data transfer—free of charge• TNCremoPlus software for data transfer with live-screen function

Components

MC main computer and 19-inch screen (1280 x 1024 pixels) for multi-touch operation, orMC main computer and 24-inch screen (1920 x 1080 pixels), orMC main computer with integrated 15.6-inch screen (1366 × 768 pixels) or
19-inch screen (1280 × 1024 pixels) or 24-inch screen (1920 x 1080 pixels) for multi-touch
operation
CC, UEC, or UMC controller unit
TE operating panel (19-inch or 15.6-inch) with the following:• Integrated machine operating panel• Feed-rate and spindle override potentiometers• Available with electronic handwheel (only for 19-inch version)Operating system

HEROS 5 real-time operating system for machine control

NC program memory

7.7 GB (on CFR Compact Flash memory card)

Input resolution and display step

X axis: 0.5 μm; diameter: 1 μm
U, V, W, Y, Z axis: 1 μm
B, C1/C2 axis: 0.001°

Interpolation

Straight: in 2 main axes (max.: ±100 m), optional in 3 main axes
Circle: in 2 axes (max. radius: 999 m), optional additional linear interpolation of the third axis
C1/C2 axis: interpolation of the linear axes X and Z with the C1/C2 axis (option)
B axis: 5-axis interpolation between X, Z, Y, B, and C axis (option)

Feed rate

mm/min or mm/revolution
Constant cutting speed
Max. feed rate (60 000/number of pole pairs × ball screw pitch) at fPWM = 5000 Hz

Main spindle

Maximum: 60 000 rpm (with option 49, max. 120 000 rpm) for motors with one pole pair

Axis feedback control

Integrated digital motor control for synchronous and asynchronous motors
Position control resolution: signal period of the position encoder/1024
Position controller cycle time: 0.2 ms
Speed controller cycle time: 0.2 ms
Current controller cycle time: minimum 0.05 ms

Error compensation

Linear and nonlinear axis error, backlash, reversal peaks during circular movements,
static friction

Data interfaces

1000BASE-T Gigabit Ethernet interface
4 x USB (1 x USB 2.0 on front; 3 x USB 3.0 on rear)

Diagnostics

Fast and simple troubleshooting through integrated diagnostic aids

Ambient temperature

Operation:
In electrical cabinet: 5 °C to 40 °C
In operating panel: 0 °C to 50 °C
Storage: –20 °C to 60 °C

45

46

Mastering nanometer accuracy

DR. JOHANNES HEIDENHAIN GmbH
Dr.-Johannes-Heidenhain-Straße 583301 Traunreut, Germany +49 8669 31-0
 +49 8669 32-5061
info@heidenhain.dewww.heidenhain.com
895949-29 · 5 · 09/2021 · CD · Printed in Germany

HEIDENHAIN
worldwide