TNC 640
Contouring Control for
Machining Centers andMilling-Turning Machines

07/2023

Contents

The TNC 640...
Where can it be used?

Versatile

4

Intuitive and user-friendly

6

Complete part machining

10

Fast and reliable machining at high contour fidelity

12Machining with five axes

17Intelligent machining

20

Automated machining

28

Minimize setup times

31

Programming, editing, and testing33

Programming on the shopfloor

35

Open to outside information

44

Workpiece measurement

50

Tool measurement

51

Inspecting and optimizing machine accuracy

52

Positioning with an electronic handwheel

53

Overview

54

The TNC contouring control for milling and milling-turning machines
What does it look like?

State-of-the-art multitouch operation
Highly practical user interface
What can it do?

Milling, turning, and grinding on one machine (option)
Dynamic Precision
Optimal tool guidance by the TNC 640
Machining and measuring 3D contours

TNC 640
with 24-inch
touchscreen

Guided tool tip
Swivel head and rotary table controlled by the TNC 640
Dynamic Collision Monitoring option (DCM)
Dynamic Efficiency
Active Chatter Control option (ACC)
Adaptive Feed Control option (AFC)
Machine any contour slot with trochoidal milling
Optimized roughing processes with OCM (option)
Global Program Settings (option)
The TNC 640 measures, manages and communicates
Pallet management and multiple machining
Tool management and workspace monitoring
The TNC 640 makes setup easy

How is it programmed?

A full range of possibilities with the TNC 640
Graphical support in any scenario
TNC 640
with 19-inch
touchscreen

Practical cycles for recurring operations
Practical turning cycles (option)
Practical functions for grinding and dressing (option)
Reusing programmed contour elements
Rapid availability of all information
Processing CAD files with the TNC 640
Uniformly digital job management with Connected Machining
StateMonitor: collect and evaluate machine data
The TNC 640 programming station

What accessories are
there?

Setup, preset setting, and measuring with touch trigger probes
Measuring length, radius, and wear inside the machine

TNC 640
with 19-inch
touchscreen (portrait)

Easy calibration of rotary axes with KinematicsOpt (option)
Fine motion control of axes

The functions and specifications described in thisbrochure apply to the TNC 640 with NC SW 34059x-17.

2... At a glance

User functions, accessories, options, specifications, comparison of controls

3Versatile
The TNC contouring control for milling and milling-turning machines

For more than 45 years, TNC controls from
HEIDENHAIN have proven themselves
every day on milling machines, machining
centers, and drilling machines. Over thisperiod, they have been continually further
developed, with focus placed on an
operating approach tailored to the needs of
the TNC 640 operator.
Multitouch operation
The TNC 640 comes with a keyboard andtouchscreen that puts zooming, rotating,and dragging all at your fingertips for fastand easy operation of the TNC 640.

4

Shop-oriented programming
The TNC 640 lets you program conventional
milling, drilling, turning, and grinding
operations right on the machine using theshop-oriented Klartext conversational
programming language from
HEIDENHAIN. With helpful dialog guidance
and informative visual aids, the TNC 640
provides optimal programming support,
including for turning operations.
For standard machining operations andeven complex applications, a wealth ofpractical machining and coordinatetransformation cycles are at your beck andcall.

Offline programming
The TNC 640 is easy to program remotely
as well. Its Ethernet interface ensures
extremely short upload times, even forlong programs.
Easy to operate
When it comes to simple machining tasks,
such as face milling or face turning, you
don’t need to write a program on the
TNC 640. That’s because the TNC 640
makes manual control equally easy—either
by means of the axis keys or, for maximum
sensitivity, with an electronic handwheel.

Universally deployable
The TNC 640 is particularly well suited tomilling, turning, grinding, HSC, and 5-axis
machining on machines with up to 24 axes.
The following applications play to thestrengths of the TNC 640:

High-speed cutting• Fast block processing• Short control-loop cycle time
• Motion control with jerk compensation• High spindle speed• Fast data transfer

Milling-turning machines• Easy, program-controlled switchingcapability between milling and turning• Extensive package of turning cycles• Constant cutting speed• Cutter radius compensation

Boring mills• Drilling and boring cycles• Drilling of oblique holes• Control of quills (parallel axes)

Universal milling machines• Shop-floor programming in Klartext, theconversational programming language
from HEIDENHAIN• Rapid preset setting with HEIDENHAIN
touch probes• Electronic handwheel capability

Five-axis machining with swivel headand rotary table• Tilting the working plane• Cylinder surface machining• Tool Center Point Management (TCPM)• 3D tool compensation• Fast program execution thanks to short
block-processing times

Machining centers and automatedmachining• Tool management• Pallet management• Controlled preset setting• Preset management• Automatic workpiece measurement with
HEIDENHAIN touch probes• Automatic tool measurement andbreakage inspection• Connection with host computer
Grinding operations• Convenient functions for jig grinding anddressing• Reciprocating stroke superimposed onto
the tool axis
• User-friendly cycles5Intuitive and user-friendly
State-of-the-art multitouch operation

The screen
In a clear format, the 24-inch widescreen
displays all of the information you need forprogramming, operating, and checking thecontrol and the machine, including program
blocks, tips, and error messages.
Extended Workspace Compact offers
even more information: alongside the main
window with its usual control interface
there is an additional window for displaying
any external application. You can also use asplit screen in the main window to display
your NC blocks on one side and thegraphical image and status display on theother. While the program is running, status
displays are available that inform you
about the tool position, current program,coordinate transformations, and more.
The TNC 640 even displays the current
machining time.
The operating panel
Like all of the TNCs from HEIDENHAIN, theoperating panel was designed with theprogramming process in mind. Program
entry is aided by the thoughtfularrangement of keys into function groups
for programming operating modes,
machine operating modes, management/
TNC functions, and navigation. Intuitive key
assignments, readily understood symbols,
and abbreviations unmistakably identify thevarious functions. The group of keys
containing NC Start/Stop and the feed rate/
rapid traverse potentiometers let you workthrough the essential operating sequencesin the Program Run, Single Block operating
mode with just one hand. This helps you
efficiently set up the NC program without
losing sight of the machine’s workspace.
Comments and ISO programs can also beeasily entered using the alphanumeric
keypad. The potentiometers for the axis
feed rate and spindle speed, which areclearly separated from each other, allow
you to perform fine adjustments. In
addition, the operating panel features acomplete set of PC keys and a trackball.

Extended Workspace Compact
as an additional window for any external
application
Main window for displaying two operating
modes, the program, the graphical image,and the machine status

PLC soft keys for machine functions

Self-explanatory soft keys for
NC programming

Ergonomic and sturdy design
The anodized finish on the keyboard unit ishighly resilient to chemical and mechanicalfactors. The engraved keyboard lettering,such as on the potentiometer scale,exhibits high scratch and abrasion
resistance.
Intuitive touchscreen operation
The operator-friendliness of the TNC 640
has proven itself over many years. Users
throughout the world use dialog keys,
navigation keys, and soft keys to operate
their TNC 640. For even more innovative
and user-friendly operation, the TNC 640
now also comes in a touchscreen version.
This version combines the proven benefits
of HEIDENHAIN controls with state-of-theart operation through tapping, swiping, anddragging gestures.

USB port for additional data storage orother pointing devices

Practical touchscreen
With an IP54 rating, the touchscreen isdesigned to handle harsh shop conditions
thanks to these characteristics:• Dust-protected• Splash-proof• Scratch-proof

Trackball and mouse buttons
for easy operation

To clean the screen, simply select thetouchscreen cleaning mode. This locks thescreen to prevent unintended operation.

Alphanumeric keyboard for comments or
ISO programming, and a set of PC keys
for controlling operating system functions

Axis-selection keys and numeric keypad

Gestures for multi-touch operation
The screen of the TNC 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 softkey row.
SymbolGestureTap
Double tap
Long press
Swipe

Drag

Two-finger dragSpreadPinch

Function keys for programming modes,
machine operating modes, TNC functions,management, and navigation

Override potentiometers
for feed rate and rapid traverse
Machine operating panel
with snap-on keys and LEDs

Override potentiometerfor spindle speed

6



7

Highly practical user interface

The key to safe and low-fatigue work is
having an intuitive screen layout and an
ergonomic, well-arranged keyboard.
Although HEIDENHAIN has been adheringto these principles for a long time, theTNC 640 offers a number of features thatmake working with the control evensimpler and easier than before.

Leading-edge design
The user interface of the TNC 640 boasts a
sleek outer appearance with gently
rounded edges, color gradients, and apleasingly uniform font. The different
screen areas are clearly delineated, and theoperating modes are indicated by special
operating mode symbols.
To help you evaluate the priority of error
messages, the TNC 640 displays them incolor-coded categories. A color-coded
warning triangle is also displayed.

8

The smartSelect functions overview
With dialog support, you can now readily
select functions that were previously
available only via soft key structures. As
soon as you open smartSelect, you areshown a tree structure with all of thesubordinate functions that can be definedin the control's current operating state. The
TNC also displays integrated help on theright-hand side of the smartSelect window.
When you make a selection with the cursor
or per mouse click, you immediately
receive detailed information about thefunction. The smartSelect feature is alsoavailable for the definition of machining
cycles, touch probe cycles, special
functions (SPEC FCT), and for parameter
programming.

Color-structured programs
The content of a program line can be quite
extensive:• Line number• Program function• Input value• Comment
To make sure you always keep an overview
even in complex programs, the TNC 640
displays the individual program elements indifferent colors. This allows you to see at a
glance which input values are editable.

Universal table editor
Regardless of whether you are editing atool, preset, or pallet table, the layout,
method of operation, and functions of thetable editor are always the same.

Info line
In the info line, the TNC 640 helps you
orient yourself by displaying the respective
status of the submode.
MOD function
The additional MOD operating mode offers
a wide variety of possible settings in astandardized layout, regardless of theoperating mode.
Simple operation
The TNC 640 can be conveniently operated
with a connected mouse, but many
machine shops lack an adequate surface
for a mouse. A touchscreen, however,
eliminates the need for additional
workspace for input devices and makes
everyday operation of the TNC 640 eveneasier thanks to swiping, direct selection ofoperating elements, and menu navigation.
The touchscreen is particularly helpfulwhen using the CAD Import function,
allowing you to rapidly zoom, drag, or
select with simple gestures.
User administration
The user administration feature of the
TNC 640 lets you define various roles andaccess rights for users, ensuring that eachuser can act only within his assigned rights.
This helps prevent the unintentional orunauthorized deletion of files and systemfile content. Many functions are alsoavailable only with the corresponding
permissions. Consequently, the user
administration feature of the TNC 640 not
only provides greater data security but also
increases machine operating safety.

9Complete part machining
Milling, turning, and grinding on one machine (option)

Does your workpiece need to be moved toa lathe or grinding machine for additional
machining steps after milling? Is all the
additional capacity planning, fixture
production, workpiece setup, and finishedpart inspection a burden? If so, then a
TNC 640 on a milling-turning machine cansave you a lot of time. With the TNC 640,
you can machine the complete part in one
setup using milling, turning, and grinding
operations in any sequence desired. And
when you're finished, you can measure thefinished part inside the machine using a
HEIDENHAIN touch probe.
The TNC 640 provides powerful functions
for NC-program-driven switching between
turning, dressing, and milling mode. This
gives you complete freedom to decide how
and when you want to combine the various
machining methods. And naturally, theability to switch between machining
modes is independent of the machine andits axis configuration. When switching
between modes, the TNC 640
automatically handles all of the internalchanges, such as switching to diameter
display, setting the preset in the center ofthe rotary table, and machine-dependentfunctions such as clamping the tool
spindle.*Programming as usual
Turning operations can be programmed asalways using the convenient HEIDENHAIN
Klartext programming language. In addition
to the standard path functions for defining
the turning contour, you can also employ
FK free contour programming, which is aneasy way to create contour elements notsuitably dimensioned for an NC program.
In addition, turning-specific recessing andundercutting contour elements areavailable and can be defined withinformative help illustrations. Even grinding
operations can be programmed as usualwith HEIDENHAIN Klartext dialog
guidance. If the contour is available as a
CAD file, then you can easily import it withthe aid of the CAD Import function (option).

Milling, turning, and grinding cycles
HEIDENHAIN controls have always been
known for their comprehensive andtechnologically advanced package ofcycles. The cycles of the TNC 640 include
multi-step, frequently recurring operations.
As you program, conversational guidance
and informative help graphics illustrating
the required parameter data provide
support. In addition to the well-known TNC
milling and drilling cycles, the TNC 640 also
provides a plethora of turning cycles forroughing, finishing, recessing, thread
cutting, recess turning, and more. Theseturning functions are based on softwarefrom the long-proven HEIDENHAIN turning
controls, allowing you to program evencomplex turning operations with ease on
the machine.

The TNC 640's more complex turning
cycles employ the same techniques as
those used for milling. As a result, TNC
programmers can build on their priorknowledge to rapidly enter the world ofturning operations on a milling machine
without retraining. The control also features
grinding cycles, including:• Define reciprocating stroke• Activate wheel edge
• Profile dressing

Interpolation turning (option 96)
Although you can create ring slots,
recesses, tapers, or any turning contour
using conventional turning operations, you
can also take advantage of interpolation
turning. In interpolation turning, the tool
executes a circular movement using thelinear axes. For outside turning, the cuttingedge is oriented towards the circle center,and for internal turning, away from thecenter. By varying the circle radius and theaxial position, any rotationally symmetricbody can be produced, even in a tilted
working plane.

Turning with a facing slide
A facing slide allows you to perform turning
operations on a stationary workpiece,
thereby enabling off-center or tilted-planeturning operations. With a facing slide,rotational movement is implemented by
the spindle, where an axis integrated into
the facing slide determines the extensionof the turning tool (facing stroke). With the
TNC 640, you don’t need to worry about
the complex motion involved. You simply
select the facing-slide mode with aprogramming command and program asalways with standard turning cycles. The
TNC 640 handles all of the calculations andexecutes the motion sequences.
Polar kinematics
With polar kinematics, the motions in theworking plane are performed by one linear
axis and one rotary axis. This greatly
increases the machining operations
possible on machines which have only two
linear axes. For example, front-face
operations become possible on rotary andcylindrical grinding machines. And on
milling machines, suitable rotary axes canreplace various linear axes, for example
when working on very large surfaces onlarge machine tools.

* The machine must be prepared for this function by
the machine manufacturer.

10

11

Fast and reliable machining at high contour fidelity
Dynamic Precision

The TNC 640 is designed for exceptional
accuracy and surface quality at highmachining speeds, regardless of whether
you are milling or turning. A variety oftechnologies, cycles, and functions
operating separately or in concern ensure
perfect surface finishes in extremely shortmachining times:• Optimized motion control• Effective jerk reduction• Dynamic contour look-ahead

The term Dynamic Precision covers anumber of HEIDENHAIN cutting solutions
that can dramatically improve the dynamic
accuracy of a machine tool. These solutions
shed new light on the competing demandsof accuracy, high surface quality, and shortmachining times. The dynamic accuracy ofmachine tools manifests itself in deviations
at the tool center point (TCP). These
deviations depend on kinetic quantities
such as speed and acceleration (includingjerk) arising from the vibration of machinecomponents and other factors.

All of these factors contribute todimensional inaccuracy and the formationof defects on the workpiece surface,
thereby impacting both quality andproductivity (in the case of quality-related
scrap). Dynamic Precision counteracts
these problems with intelligent control
technology to help improve the quality anddynamic performance of a machine tool.
As a result, production time and cost are
reduced.

Dynamic Precision contains the following
functions, which can be deployed
separately or in combination.
Function

Benefits

CTC
Cross Talk Compensation

Compensation of acceleration-dependent position Greater accuracy during acceleration phases
errors at the TCP

MVC
Machine Vibration Control

A superior surface finish
Damping of machine oscillations• AVD (Active Vibration Damping):
Compensates undesired effects of vibrations on
the feed axes
• FSC (Frequency Shaping Control):Suppresses the inducement of vibrations
through a correspondingly filtered feedforward
control

CTC + MVC–

Faster and more accurate machining

PAC
Position Adaptive Control

Position-dependent adaptation of control
parameters

Greater contour fidelity

LAC
Load Adaptive Control

Load-dependent adaption of control parameters
and the maximum axis acceleration

Higher accuracy whatever the load

MAC
Motion Adaptive Control

Motion-dependent adaptation of control
parameters

Less vibration and higher maximum acceleration
during rapid traverse

Vibration can significantly impair surface quality.

12

Visibly superior surface quality can be attained with MVC.



13

Optimal tool guidance by the TNC 640

High contour fidelity and surface quality
TNC controls from HEIDENHAIN are
known for their low-jerk and speed/
acceleration-optimized motion control,
enabling optimized surface quality andworkpiece accuracy. With the TNC 640, youare able to leverage the latest technologicaldevelopments. The TNC 640 anticipates
and thinks along with you, dynamicallycalculating the contour ahead of time. In
addition, special filters suppress machinespecific natural frequencies.

14

With its Look Ahead function, theTNC 640 recognizes directional changes
ahead of time and adapts the traversing
speed to the shape of the contour and thesurface to be machined. You simply
program the maximum machining speed
as the feed rate and, in Cycle 32
TOLERANCE, enter the maximum
permissible deviations from the ideal
contour. The TNC 640 automatically adapts
the machining to the tolerance that you
define. This method prevents contour
defects.

Advanced Dynamic Prediction (ADP)
expands upon the previous look-ahead
calculation of the permissible maximum
feed rate profile. ADP compensates fordifferences in the feed rate profiles
resulting from the point distribution onneighboring paths, especially in NC
programs originating from CAM systems.
Among other benefits, this results inparticularly symmetrical feed rate behavior
on the back-and-forth paths during
bidirectional finish milling, as well as verysmooth feed rate curves on neighboring
milling paths.

Fast machining and computing
processes
With a short block-processing time of at
most 0.5 ms, the TNC 640 can run fast
look-ahead calculations for optimal use of
the machine’s dynamic parameters.
Functions such as ADP and Look Ahead
therefore ensure not only high contour
fidelity and surface quality but also optimize
the machining time.

One basis for the TNC 640's high speed is
its uniformly digital control design. This
includes the integrated digital drive
technology from HEIDENHAIN as well as
digital interfaces connecting all of thecontrol components with each other:• Control components via HSCI(HEIDENHAIN Serial Controller Interface)• Encoders via EnDat 2.2
As a result, exceptionally high feed rates
can be implemented. In the process, theTNC 640 is capable of interpolating up to
five axes at the same time. To attain therequired cutting speeds, the TNC 640 candigitally control spindle speeds of up to
100 000 rpm.

The TNC 640's powerful 5-axis machining
capability even lets you economicallymanufacture complex 3D contours.
Programs for such contours are usuallycreated offline with CAM systems andtypically contain numerous short line
blocks that are transferred to the control.
With its short block-processing time, theTNC 640 quickly executes even complex
NC programs. The control’s computing
power can handle complex look-ahead
calculations in simpler NC programs as
well. Thus, regardless of the data volume of
the NC programs from your CAM system,
the TNC 640 will machine the workpiece tonear-perfect conformity with your program.



15

Machining with five axes
Guided tool tip

Machining and measuring 3D contours

Compensating for tool form error
Option 92, 3D-ToolComp, is a powerful
option for three-dimensional tool radiuscompensation. Angle-dependent delta
values describing the deviation of the toolfrom a perfect circle can be defined in acompensation table (see graphic).
The TNC 640 then corrects the radius value
defined for the tool’s current point ofcontact with the workpiece. In order todetermine the exact point of contact, theNC program must be created with surfacenormal blocks (LN blocks) by a CAM
system. The surface-normal blocks specify
the theoretical center point of the tool and,if applicable, the tool orientation relative tothe workpiece surface.

The ideal method is to create thecompensation table fully automatically.
This is done by measuring the shape ofthe tool with a laser system and a special
cycle such that the TNC 640 can make
immediate use of the table. If the form
errors of the tool being used are available
in a calibration chart from the tool
manufacturer, then you can also create
the compensation table manually.

Measuring 3D geometries
Cycle 444, 3D Probing, allows you tomeasure points on 3D geometries. To doso, you enter the coordinates of themeasuring point and the associated normal
vectors into the cycle. After probing, theTNC automatically calculates whether themeasuring points are within a prescribed
tolerance. You can then call the result via
system parameters in order, for example,
to have the program initiate rework. You
can also trigger a program stop and output
a message. After measurement, the cycle
automatically generates a straightforward
measurement report in HTML format. To
obtain even more accurate results, you canperform a 3D calibration of the touch probeprior to running Cycle 444. The cycle thencompensates for the switching behavior of
the individual touch probe in all directions.
Option 92 is required for 3D calibration andfor Cycle 444.

CAM systems generate 5-axis programs
using a postprocessor. In principle, suchprograms contain either all of thecoordinates of the machine’s existing
NC axes, or they contain NC blocks withsurface normal vectors. During five-axis
machining with three linear axes and two
additional tilting axes*, the tool is always
perpendicular to the workpiece surface oris tilted at a specific angle relative to it(inclined tool machining).
Regardless of the type of five-axis
programs you wish to run, the TNC 640
performs all of the necessarycompensating movements in the linear
axes arising from movements in the tilting
axes. The TNC 640’s TCPM function (ToolCenter Point Management), an
improvement upon the proven TNC
function M128, provides optimal tool
guidance and prevents contour gouging.
*

The machine and TNC must be adapted for thesefunctions by the machine manufacturer.

With TCPM, you can define the behavior of
the tilting and compensating movementsthat are automatically calculated by the
TNC 640:
TCPM defines the interpolation between
the start and end positions:• Face Milling: In face milling, primary
cutting is performed using the front faceof the tool (or the corner radius in thecase of toroid cutters). In the process,the tool center point movies along its
programmed path.
• Peripheral Milling: In peripheral milling,
primary cutting is performed with thelateral surface of the tool. The tool tip
also travels along its programmed path,but machining with the circumference ofthe tool results in a clearly defined plane.
As a result, peripheral milling is well
suited for the production of precise
surfaces using gear hobbing processes.
TCPM defines the effect of the
programmed feed rate with two
possibilities to choose from:• The actual speed of the tool tip relative
to the workpiece: in the case of large
compensating movements whilemachining close to the center of tilt, very
high axis feed rates may arise.



• Contouring feed rate of the axes
programmed in the respective NC block:the feed rate is generally lower, but you
attain better surface quality with large
compensating movements.
In order to achieve better surface quality,
an inclination angle is often configured
for contour machining, with corresponding
angle values in the NC program. The effectof the inclination angle can also be
configured via TCPM:• Angle of inclination defined as an axis
angle
• Angle of inclination defined as a spatial
angle
The TNC takes the inclination angle into
account in all 3D machining operations,
including with 45° swivel heads or tilting
tables. You can specify the angle ofinclination in the NC program via a
miscellaneous function or manually set itwith an electronic handwheel. The TNC 640
ensures that the tool remains on thecontour and does not damage theworkpiece.
You can use Cycle 444 to measure 3D
geometries even when TCPM is active.
The TNC 640 then automatically takes theinclination angle of the touch probe into
account.





Face milling

16

Peripheral milling

Inclined-tool machining

17

Swivel head and rotary table controlled by the TNC 640

Many five-axis operations that initiallyappear to be highly complex can be broken
down into common 2D movements thathave been tilted about one or more rotary
axes or wrapped around a cylindricalsurface. In order for you to create and edit
such programs quickly and easily without a
CAM system, the TNC supports you with
helpful functions.

Tilting the working plane*
Programs for contours and holes on
inclined surfaces are often extremelycomplex and require time-consuming
computing and programming work. But the
TNC 640 can save you a great deal ofprogramming time. You simply program themachining operation as usual in the mainplane (e.g., in X/Y); the machine thenperforms the operation in a tilted plane.
The PLANE function makes it easy for you
to define a tilted working plane: tilted
working planes can be specified in sevendifferent ways depending on theinformation available in the workpiecedrawing. Help images support you during
program entry.

You can also use the PLANE function todefine the positioning behavior during
tilting to avoid unpleasant surprises when
the program is run. The settings fordefining the positioning behavior are
identical for all PLANE functions, making
operation much easier.
* The machine and TNC must be adapted for thesefunctions by the machine manufacturer.

Cylinder surface machining*
The programming of contours made up ofstraight lines and circles on cylindricalsurfaces for rotary tables is no problem
with the TNC 640. You simply program thecontour in the plane of an unrolled cylindersurface. The TNC 640 then performs themachining operation on the cylindricalsurface of the cylinder.
The TNC 640 features four cycles forcylindrical surface machining:• Slot milling (the slot width and tool
diameter are equivalent)• Guide-groove milling (the slot width isgreater than the tool diameter)• Ridge milling• Outside contour milling

Manual axis motion in the tool direction
on 5-axis machines
Correct tool retraction is very important in
five-axis machining. The virtual tool axis
function provides assistance by allowing
you to move the tool in the direction of thetool axis using external direction keys or ahandwheel. This function is especially
useful if you want to• retract the tool in the direction of the tool
axis during an interruption of a five-axis
machining program,• use the handwheel or external direction
keys to perform an operation in Manualmode with an inclined tool, or• move the tool with the handwheel in theactive tool axis direction duringmachining.

Feed rate for rotary tables in mm/min*
By default, the feed rate of rotary axes is
programmed in degrees/min. However, theTNC 640 can interpret this feed rate in
mm/min as well. The feed rate at thecontour is then independent of the
distance of the tool center point from thecenter of the rotary axis.

* The machine and TNC must be adapted for thesefunctions by the machine manufacturer.

18

19

Intelligent machining
Dynamic Collision Monitoring option (DCM)

The complex machine movements andnormally high traversing speeds of five-axis
machining make axis movements difficult
to predict. This makes collision monitoringa valuable function that relieves theoperator and protects the machine fromdamage.
NC programs from CAM systems may beable to avoid collisions of the tool or tool
holder with the workpiece but do notaccount for machine components in theworkspace—unless you invest in expensive
offline machine simulation software. But
even then, there is no guarantee that thearrangement of machine components stillmatches the simulation. In the worst casescenario, collisions won't manifest
themselves until the part is actuallymachined.

20

For cases such as these, the Dynamic
Collision Monitoring (DCM)* feature of
the TNC 640 provides the operator withpeace of mind. The control interrupts themachining process whenever a collision isimminent, thus increasing safety for boththe machine and its operator. This, in turn,helps prevent machine damage and any
resulting costly downtime. Unattended
shifts also become more reliable.

Dynamic Collision Monitoring (DCM) evenworks in both automatic mode andmanual operation. If the machine
operator is on a "collision course" during
workpiece setup, for example, then the
TNC 640 will detect the impending collisionand stop the axis with an error message.
The fixture import feature of DCM not only
enables graphical representation of the
fixtures, but also provides for collisionchecking during simulation and the actualmachining process. An additional level ofreliability is gained with the enhanced
checking for collisions between theworkpiece and the non-cutting part of thetool or the tool holder.
* The machine and TNC must be adapted for thesefunctions by the machine manufacturer.

Of course, the TNC 640 also shows theoperator which machine components areon a path toward collision, both in the error
message and in a graphical depiction. If acollision warning occurs, the TNC permits
tool retraction only in directions that will
increase the clearance between thecolliding objects.

A 3D file format for collision objects offers
further appealing benefits:• Convenient data transfer of standard 3D
file formats• Fully detailed illustration of machinecomponents• Greater exploitation of the machine’s
workspace

The machine manufacturer defines themachine components by using geometricbodies to describe the workspace and thecollision objects. For tilting devices, themachine manufacturer can also use thedescription of the machine kinematics todefine the collision objects.

The TNC 640 can also monitor tool carriers
such as holders for milling cutters or touchprobe housings. To this end, a tool-carrier
kinematic model is assigned to the tool in
the tool table. When the tool is inserted,
the respective tool carrier is activated in thecollision monitoring function.
Because the machine design itself
prevents collisions between certain
machine components, not all of themachine parts require monitoring. For
example, a HEIDENHAIN TT tool touchprobe clamped to the machine table forpurposes of tool measurement will nevercollide with the machine cabin. The
machine manufacturer can therefore limit
the machine elements that could collidewith each other.
When using Dynamic Collision Monitoring,please note the following:• DCM can help reduce the danger ofcollision, but DCM cannot completely
prevent all collisions.
• Only the machine manufacturer candefine machine components.
• Collisions between machinecomponents (such as a swivel head) andthe workpiece cannot be detected.
• DCM cannot be used in servo-lag
operation (no feedforward).
• DCM cannot be used for eccentricturning.

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Dynamic Efficiency

Under the rubric of Dynamic Efficiency,
HEIDENHAIN offers innovative TNC
functions that help the operator makeheavy machining more efficient andimprove process reliability. These software
functions not only support the operator but
also make the manufacturing process itself
faster, more stable, and more predictable—
in short, more efficient. Dynamic Efficiency
permits higher removal rates and therefore
increases productivity without making theoperator resort to special tools. At thesame time, it prevents tool overloading andpremature cutter wear. Dynamic Efficiency
makes your manufacturing overall more
economical while increasing processreliability.

Active Chatter Control option (ACC)

Dynamic Efficiency encompasses four
software functions:• Active Chatter Control (ACC) is an
option for reducing chatter tendencies
and permits higher infeeds• Adaptive Feed Control (AFC) is an
option for regulating the feed rate basedon the machining situation• Trochoidal milling is a function for tooland machine-friendly roughing of slots
and pockets• Optimized Contour Milling (OCM) is an
option for tool-friendly machining of any
pocket and island under consistentprocess conditions

Individually, each of these solutionsdelivers key improvements to themachining process. But in combination,these TNC functions bring out the fullpotential of the machine and tool while
reducing the mechanical load. They also
prove their worth under changing
machining conditions, such as interrupted
cuts, varying plunging processes, or simple
roughing operations. In practice, removal
rate increases of 20 to 25 percent are
possible.

Roughing operations (power milling) giverise to strong milling forces. Depending on
the rotational speed of the tool, theresonances in the machine tool, and thematerial removal rate during milling, thetool may begin to “chatter.” Chatter puts
the machine under heavy strain and causes
blemishes on the workpiece surface. Tool
wear is also accelerated and less evenly
distributed. In extreme cases, the tool may
even break.

To reduce chatter susceptibility,
HEIDENHAIN now offers a highly effective
optional control function called Active
Chatter Control (ACC). This option isparticularly beneficial during heavymachining:• Improved cutting performance• Higher removal rates (up to 25% andmore)• Lower forces on the tool, with increased
tool life• Less strain on the machine

Heavy machining without ACC (upper image)
and with ACC (lower image)

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23

Adaptive Feed Control option (AFC)HEIDENHAIN controls have always allowed
the operator to enter the feed rate for eachblock or cycle and also manually adjust thefeed rate to the actual machining situation
using an override potentiometer. But thisapproach relies on the experience of theoperator and requires him to be at themachine.
Adaptive Feed Control (AFC) automaticallyregulates the feed rate of the TNC, taking
into consideration the given spindle power
and other process data. The TNC firstrecords the maximum spindle power
during a teach-in cut. Prior to machining,
you define the limits (in a table) within
which the TNC is allowed to influence thefeed rate in "control" mode. You can flexibly
choose among various overload reactions
that have been defined by the machine
manufacturer.

Adaptive Feed Control (AFC) offers a seriesof benefits:
Process reliability
Roughing at high material removal rates
involves strong cutting forces, which inpractice can cause tool defects. If theoperator is unable to react quickly, perhaps
because he is responsible for multiple
machines or because the shift isunattended, then significant secondary
damage and cost may be incurred:• Costly rework on the workpiece• Irreparable workpiece damage• Damage to the tool holder• Machine downtime due to spindle
damageContinuous monitoring detects any
increase in spindle power due to tool wear
or defective inserts, and a replacement tool
can be automatically inserted.* In thisWorkpiece with secondary damage resulting from a broken indexable
insert24

Machine any contour slot with trochoidal millingmanner, AFC prevents potential secondary
damage due to tool wear while increasing
process reliability.
Reduced machining time
AFC regulates the feed rate of the TNC
based on the given spindle power. In
machining areas requiring less material
removal, the feed rate is appropriately
increased. This can significantly reduce themachining time.
Gentler on the machine
When the maximum teach-in power is
exceeded, the feed rate is reduced down
to the reference spindle power. As a result,the machine undergoes less strain, and themain spindle is protected from overloading.

The benefit of trochoidal milling is its ultraefficient machining of slots of all kinds. In
this cycle, roughing is performed withcircular movements, onto which a forward
linear movement is superimposed. This
procedure is referred to as trochoidal
milling. It is used particularly for millinghigh-strength or hardened materials, where
the high loads placed on the tool andmachine usually only permit small infeeds.

Thanks to the special cutting motion usedin trochoidal milling, however, there are no
added wear-inducing influences on the tool,and higher infeeds are possible. During
hobbing, the entire cutting edge can beused as well. You thereby attain a higher
material removal rate per tooth. Circularmotion plunging into the material exerts
less radial force on the tool. This reduces
the mechanical load on the machine andprevents vibration. Enormous time savings
can be realized by combining this milling
method with the integrated Adaptive Feed
Control (AFC) option.

The slot to be machined is described in acontour subprogram as a contour train. You
define the dimensions of the slot and thecutting data in a separate cycle. Any
residual material can then be easily
removed with a subsequent finishing cut.
The main benefits are as follows:• Contact over entire cutter length• Higher removal rates• Less strain on the machine• Less vibration• Integrated finishing of the side wall
• Superior chip removal* The machine must be adapted for this function
by the machine manufacturer.

Fully machined workpiece protected by AFC

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25

Optimized roughing processes with OCM (option)

Efficient machining strategies are a keybasis for economical NC manufacturing.
Roughing processes, in particular, offer
great potential for optimization because
they usually make up a sizeable portion of
the total machining time.
Process reliability and maximum removal
rates require optimal adaptation of the
cutting data to the characteristics of thetool and workpiece material. For thispurpose, Optimized Contour Milling(OCM) provides you with a cutting data
calculator that draws on an extensive
integrated material database. You can adapt
the automatically calculated cutting values
with regard to the mechanical and thermalload on the tool. Tool service life can be
managed with process reliability even at
the highest possible removal rates.
With OCM, you can rough out any pocket
and island with high process reliability andlower tool wear thanks to highly consistentprocess conditions. Simply program thecontour as usual in Klartext, or leverage theconvenient CAD import function. The
control then automatically calculates thecomplex movements required formaintaining consistent process conditions.
OCM takes void areas into account, whichsignificantly reduces machining times (withNC software version 16 or later).
Advantages of OCM over conventional
machining:• Reduced thermal load on the tool
• Superior chip removal• Consistent tool contact conditions(higher cutting parameters and higher
material removal rates)

The OCM option provides practical cycles
for roughing, side-wall finishing, and floor
finishing.

figures that are then used as a pocket,
island, or boundary for face milling in
conjunction with other OCM cycles.

OCM also permits chamfering anddeburring of contours. With this capability,
only those areas that can be machined
without collisions due to the tool geometry
are machined. In order to machine
standard shapes, OCM offers various

In the following machining example, boththe machining time and tool wear werereduced by a factor of three.

Global Program Settings (option)

The Global Program Settings option is usedespecially for the production of largemolds. It is available in the Program Run
operating modes and in MDI mode. This
option allows you to perform a variety of
coordinate transformations and settings,
and then apply them globally to a selected
NC program without actually modifying it.
You can even change the Global Program
Settings mid-program during a program
stop using a handy fillable form. When the
program is started, the TNC 640 moves toa new position as needed in accordancewith a positioning logic that you havedefined.

Conventional machining
S5000, F1200, ap: 5.5 mm
Overlap factor: 5 mm

The following functions are available:• Additional, additive datum shift• Superimposed mirroring• Handwheel superimpositioning, withaxis-specific memory of the paths
covered by the handwheel, including in a
virtual axis direction• Superimposed basic rotation• Superimposed rotation• Globally valid feed-rate factor• Mirroring of axes

Handwheel superimpositioning is possible
in various coordinate systems:• Machine coordinate system• Workpiece coordinate system (the active
basic rotation is taken into account)• Tilted coordinate system
You can select the desired coordinate
system in a clearly structured form.

Machining time: 21 min 35 s
Tool: VHM end mill (Ø 10 mm)
Workpiece material: 1.4104
Machining with OCM

Tool after two parts

S8000, F4800, ap: 22 mm
Overlap factor: 1.4 mm
Machining time: 6 min 59 s
Tool: VHM end mill (Ø 10 mm)
Workpiece material: 1.4104

Tool after six parts

OCM is an effective, reliable, andconvenient way to improve yourthroughput• Create programs on the shop floor for
any pocket or island• Significantly higher machining speed• Considerable reduction in tool wear
• More chips in less time

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27

Automated machining
The TNC 640 measures, manages and communicates

The requirements gap between machining
centers and typical tool and moldmaking
machines is becoming ever narrower. Of
course, the TNC 640 is also very capable ofcontrolling automated manufacturing
processes. It features the necessaryfunctionality to initiate the propermachining operation in concatenatedmachining scenarios with individual
workpieces in any workholding
arrangement.

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Inspecting workpieces for propermachining and dimensional accuracy
The TNC 640 features numerous
measuring cycles for inspecting thegeometry of machined workpieces. Thisrequires inserting a touch probe from
HEIDENHAIN into the spindle in place ofthe tool. This allows you to do thefollowing:• Recognize a workpiece and call theappropriate part program• Check whether all machining operations
were conducted correctly• Determine infeeds for finishing• Detect and compensate for tool wear
• Inspect workpiece geometry and sortparts
• Log measured data
• Ascertain the machining trend• Check tolerances and configure various
reactions, such as an error message

Milling-tool measurement andautomatic compensation of tool data
In conjunction with the TT tool touch probe,
the TNC 640 lets you automaticallymeasure milling tools in the machine. The
TNC 640 then stores the determinedvalues, such as tool length and radius, in its
tool memory. By inspecting the tool duringmachining, you can quickly detect wear or
breakage for preventing scrap and rework.
If the measured deviations lie outside thespecified tolerances or if the monitored
tool life has been exceeded, the TNC 640
locks the tool and automatically inserts a
replacement tool.

Pallet management and multiple machining

Pallet Management
Pallet management functionality lets you
automatically machine workpieces in any
order. Upon insertion of the pallet, thecorrect machining program and preset areautomatically selected. You can also apply
coordinate transformations and measuring
cycles in the part programs. A palletcounter function lets you easily define thedesired quantity to be produced.
Batch Process Manager (option 154)
Batch Process Manager is a powerful
function for pallet machining and series
production. Its straightforward userinterface helps you plan your production
process and gather important information
on upcoming machining operations.

Batch Process Manager automaticallychecks for missing tools, insufficient tool
life, and required manual tool changes. The
results are displayed in the status overview.
Batch Process Manager shows thefollowing information in advance:• The machining sequence• The time of the next manual intervention• The program duration and run time
• Status information about preset, tool,and program
In Program Run mode, you also have theoption of using soft keys to perform acollision check for all pallet subprogramswith active collision checking (possible onlywith DCM (software option 40)).

Tool-oriented machining
In tool-oriented machining, a single
machining step is performed on all of apallet’s workpieces before moving to thenext machining step. This keeps thenumber of tool changes to a minimum andsignificantly shortens the machining time.
The TNC 640 supports you with convenient
fillable forms that allow you to assign atool-oriented operation to a pallet withmultiple workpieces. As always, you still
write the machining program in the normal
workpiece-oriented sequence.
You can also use this function even if yourmachine does not support pallet
management. In this case, you simply
define the position of the workpiece on themachine table in the pallet file.

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Minimize setup times
The TNC 640 makes setup easy

Tool management and workspace monitoring

Tool management*
For machining centers with an automatic
tool changer, the TNC 640 offers a central
tool memory area for numerous milling,
grinding, dressing, and turning tools. This
tool memory area is a freely configurable
file that can be optimally adapted to yourneeds. You can even have the TNC 640
manage your tool names. The control
prepares the next tool change while thecurrent tool is still cutting. This significantly
reduces the non-cutting time required fortool changes.
With the tool manager, the control now
shows only the required input fields basedon the selected tool type. Any data canalso be graphically depicted. Extended tool
management adds the "tooling list" and the"T usage order". These tables enable you to
detect the tool requirements in time andthus prevent interruptions during programrun.
* The machine must be adapted by the machine
manufacturer for this function.

Component Monitoring (option 155)
Overload often leads to damaged machinecomponents, and therefore to machine
downtime. For example, the spindle
bearing is often subject to a very high loadin machining strategies that have been
optimized for maximum efficiency, and cantherefore sustain undetected damage.
Component Monitoring warns you about
these dangers, and can even stop themachine tool if necessary. Thanks tocontinuous monitoring of the bearing loadand visualization of these values, themachining processes can be optimized
correspondingly.
However, the production quality of amachine tool is influenced not only byoverload. Components that are constantly
under load, such as guideways or therecirculating ball screw, are subject to wear
and thus have an influence on the finishedproduct. The TNC 640 uses the Component
Monitoring option to measure anddocument the momentary machine status.

The machine manufacturer can read andevaluate these data, and react using
predictive maintenance, thereby avoiding
unplanned machine downtimes. The
MONITORING HEATMAP function within
the NC program lets you color the
concurrent material removal simulation in
the workpiece view with the status of amonitoring task. That way you see in theworkpiece view where a component issubject to an excessive load.

Before machining can begin, the workpiecemust first be clamped, the machine must
be set up, the position of the workpiece inthe machine must be determined, and thepreset must be set. This is a timeconsuming but indispensable procedure
because any error directly reduces themachining accuracy. Particularly in small
and medium-sized production runs, as wellas in the case of very large workpieces,
setup times become a significant factor.

Fine manual axis control
During setup, you can use the axisdirection keys to move the machine axes
manually or with an incremental jog. A
simpler and more reliable way, however, is
to use the electronic handwheels from
HEIDENHAIN. With these handwheels, youare always close to the action, enjoy aclose-up view of the setup process, andcan control the infeed responsively andprecisely.

The TNC 640 features application-oriented,
real-world setup functions that support theoperator, help reduce non-productive time,and enable overnight, unattended
production. In conjunction with the touchprobes, the TNC 640 offers numerous
probing cycles for automatic workpiece
setup, setting the preset, and measuring
workpieces and tools.

Adapting the probing speed
In many cases, the workpiece must be
probed at unseen positions or in cramped
spaces, and the standard probing feed rateis usually too fast for this. In suchsituations, you can use the override knob tochange the feed rate during probing
without affecting the accuracy.

The TNC 640 supports L-shaped styli in the
probing cycles. They are used to quickly
and easily probe undercuts.

Workpiece alignment
The HEIDENHAIN touch probes andprobing functions of the TNC 640 reduce
the need for tedious manual alignment of
the workpiece:• You start by simply clamping theworkpiece in any position.
• The touch probe probes a surface todetermine the amount of workpiecemisalignment.
• The TNC 640 subsequently compensates
for the misalignment by performing a"basic rotation," in which either the NC
program is executed at the ascertained
angle of rotation or the rotary table isturned in order to correct themisalignment.
The TNC 640 offers you a comprehensive
package of cycles for setting up themachine tool:• Manual, automatic, and semiautomatic
cycles for presetting and forcompensating for misalignments in twoor three dimensions• Automatic probing cycle for repeating ameasurement along a line

Workpiece misalignment compensated forby rotating the coordinate system or rotating the
table

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31

Programming, editing, and testing
A full range of possibilities with the TNC 640

Setting presets
A preset allows you to assign a definedvalue displayed by the TNC to any positionon the workpiece. Finding this point quickly
and reliably reduces non-productive timeand increases machining accuracy.

Preset management with the preset
table
Preset management enables flexible
machining, shorter setup times, and higher
throughput. Setting up your machine isgreatly simplified.

The TNC 640 features probing cycles forautomatically setting presets. Ascertained
presets can be saved as follows:• Using the preset management• In a datum table• Through direct setting of the display

In preset management, you can save any
number of presets and assign anindividual basic rotation to each one. In
order to permanently save fixed presets inthe machine’s workspace, you can also
write-protect individual lines.
There are three possibilities for rapidly
saving the presets:• Via a soft key in Manual mode
• Via the probing functions• With the automatic probing cycles

Saving datums
Datum tables let you save positions ormeasured values from the workpiece.
Datums are always defined relative to theactive preset.

Besides being universally deployable, theTNC 640 is equally flexible when it comesto programming, setup, and machining.
Individual machining steps
You don’t need to create a complete
program in order to start machining with
the TNC 640. You can machine a workpiece
step by step using both manual machining
and automatic positioning in any sequence.

Programming at the machine
HEIDENHAIN controls are designed forshop-friendly programming right at themachine. Instead of requiring you to know
G-codes, the Klartext conversational
programming language provides its own
keys and soft keys for programmingstraight lines, arcs and cycles. At the pushof a button, HEIDENHAIN Klartext dialog
guidance opens and actively helps you
during programming on the TNC. Its clear
instructions prompt you to enter all of therequired data.

And even if you prefer ISO programming,
the TNC is still the right control: you canenter ISO command letters via soft keys ordirectly on the alphanumeric keyboard.

All interface texts, including Klartext tips,
dialog prompting, program steps and soft
keys, are available in numerous languages.

Setting a preseton a corner, for example, or in the center of acircular stud

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33

Programming in the shop
Straightforward function keys for complex contours

Graphical support in any scenario

Programming graphics
The two-dimensional programming
graphics give you additional assurance:
while you are programming, the TNC 640
renders every programmed movement on
the screen. You can opt for a plan view,side view, or front view. Tool paths or rapidtraverse movements can be hidden, andthe image’s scale can be changed.
Program verification graphics
For added certainty prior to machining, theTNC 640 can simulate and render themachining of the workpiece at highresolution. The TNC 640 provides various
view formats of the simulation:• Plan view at different levels of depth• Three projections• 3D view

The type and quality of the image can beselected, and details can be displayed at
magnification. The TNC 640 also displays
the calculated machining time in hours,
minutes, and seconds. You can use STL
files to integrate workpiece blanks andfinished parts in the program.
The 3D view lets you display the
programmed tool-center path in three
dimensions, and a powerful zoom function
lets you see even the tiniest details. The 3D
line graphics are especially helpful inverifying programs created offline, allowing
you to avoid undesired machining marks on
the workpiece, such as those that occur
when the postprocessor outputs points
incorrectly. The 3D view of the TNC also
provides a measuring function. When you
move the mouse pointer anywhere within
the image, the coordinates of that position
are displayed. The measurement window
also displays tool information.

During the machining simulation, theTNC 640 can also display all of the machinecomponents defined by the machinemanu­facturer, in addition to the workpieceand tool. This rendering capability is particularly useful in Test Run mode, informing you
ahead of time which positions are too
close to components and when the traversing path will be insufficient. This is ahuge benefit during machining with tilting
axes.
Program-run graphics
The program-run graphics display the
workpiece in real time in order to show you
the machining progress. Direct observationof the workpiece is usually impossible due
to coolant and the safety enclosure. Duringmachining, you can switch between
various operating modes at any time inorder to create programs, for example. And
at the press of a button, you can cast aglance at the machining progress while
programming.

Programming 2D contours
Two-dimensional contours are the breadand butter of a modern machine shop,
which is why the TNC 640 offers a variety
of ways to handle them. And regardless ofwhether you are programming a milling or
turning contour, you can always use thesame tools. This allows you to program asalways without a shift in thinking.
Programming with function keys
Are the contours properly dimensioned for
NC machining? In other words, are the end
points of the contour elements provided ineither Cartesian or polar coordinates? If
yes, then you can create the NC program
straightaway using function keys.

Straight lines and circular elements
To program a line segment, for example,
simply select the "linear traverse" pathfunction. The Klartext conversational
programming language of the TNC 640
then prompts you for all of the informationneeded by the programming block,including the target coordinates, feed rate,
tool compensation value, and machinefunctions. Functions for circular
movements, chamfers, and cornerrounding also simplify your programmingwork. In order to avoid surface blemishes
during approach or departure from thecontour, movement must be seamless—that is, tangential.

You simply specify the starting point or end
point of the contour and the approach or
departure radius of the tool. The control
handles the rest.
The TNC 640 can foresee a contour withradius compensation by up to 99 blocks,
thus taking back-cutting into account andavoiding contour gouging. This could be thecase, for example, when roughing acontour with a large tool.

Straight line
defined by its
end point

Circular pathwith smooth(tangential) connection with the preceding contour element,
defined by end point

Cornerrounding:
circular path with aseamless (tangential)
transition, defined by
its radius and corner
point

Circularpath
defined by its center,end point, androtational direction









Chamferdefined by thecorner point andchamfer lengthCircular pathdefined by its
radius, end point, androtational direction


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35

Programing free contours and Data Matrix codes

FK free contour programming
Not all workpieces are properly
dimensioned in accordance with the ISO
standard. Thanks to FK, the control’s
programming function for free contours,
you can simply enter the known data
without needing to convert or calculate
anything! In such cases, individual contour
elements can remain undefined as long as
the overall contour itself is defined. If thedata from the drawing yields more than
one possible mathematical solution, thenthe helpful TNC 640 programming graphics
show you the possible variants for yourselection.

36

Programming machining patterns withease and flexibility
Positions to be machined are often
arranged in patterns on the workpiece. The
TNC 640’s graphical support helps you
program a wide range of machining
patterns with ease and exceptional
flexibility. You can define as many point
patterns as desired with various numbersof points. During machining, you can thenhave all of the points executed as a unit, or
each point individually.

Fast and easy programming of ascannable Data Matrix code
Cycle 224 (Data Matrix code pattern) lets
you convert any text into a Data Matrix
code and machine it onto your workpiece
as a point pattern using, say, drilling
operations. The Data Matrix code can be
decoded with common scanning devices.
Serial numbers and production data canthus be permanently machined onto thepart. All you need to do after defining amachining cycle is enter the text (up to
255 characters) into the cycle and specify
the size and position of the drilling pattern.
The control automatically calculates theData Matrix code and performs themachining work on its own.

Practical cycles for recurring operations

Extensive machining cycles formilling and drilling
The TNC 640 offers you a package coveringa broad range of cycles, so you'll surely findthe right one for each task. The cycles are
divided into groups based on themachining technologies and strategies,
ensuring that you always maintain a clear
overview. You program them using
conversational guidance, assisted bygraphics that clearly illustrate all required
input parameters.
Standard cycles
In addition to drilling and tapping cycles(with or without a floating tap holder), a
variety of selectable cycles are available:• Thread milling• Reaming• Engraving• Boring• Hole patterns• Milling cycles for face milling a flat
surface• Roughing and finishing of pockets, slots,
and studs

Cycles for complex contours
Of great help in roughing pockets with any
contour are the control’s SL cycles(SL = Subcontour List) and OCM cycles(Optimized Contour Milling, option 167).
These functions refer to machining cycles
for pilot drilling, roughing, and finishing inwhich the contour or subcontours aredefined in subprograms. As a result, a
single contour description can be used forvarious operations with different tools.
Up to twelve subcontours can besuperimposed for the machining operation.
The control automatically calculates theresulting contour and the tool paths forroughing or clearing the surfaces.
Subcontours can be pockets or islands.
Multiple pockets are combined to form asingle pocket, with the tool bypassing any
islands. You can also program void areasthat are excluded from machining. Thissignificantly reduces machining times forcast parts or pre-machined workpieces.

During roughing, a finishing allowance on
the wall and floor surfaces is also taken
into account by the TNC 640. Whenroughing with different tools, the control
identifies residual material to be removedby smaller tools. A separate cycle is used
for finishing to the final dimensions.
OEM cycles
Machine manufacturers can incorporate
their specialized production expertise in theform of additional machining cycles andstore them in the TNC 640. However, theoperator can write his own cycles as well.
HEIDENHAIN makes this possible with its
PC software CycleDesign, which allows
you to create input parameters and arrange
the menu key structure of the cycles as
desired.

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37

Practical turning cycles (option)

3D machining with parametricprogramming
Simple, mathematically easy-to-describe
3D geometries can be programmed bymeans of parametric programming. At yourdisposal are basic arithmetical operations,
trigonometric functions, roots, powers,
logarithmic functions, parentheses, andlogical comparisons with conditional jump
instructions. Parametric programming also
gives you a simple way to implement 3D
operations.

38

Producing gears more effectively*
Highly complex motion sequences arenecessary during the machining of gears.
The TNC 640 gives you multiple cycles thatallow you to produce gears easily andeconomically. You can choose between
these two machining technologies:• Skiving• Hobbing
During skiving, cutting action is performedby means of an axial tool feed and a rolling
motion. Skiving is suitable for themachining of straight or oblique internaland external gear teeth. Significant
advantages can be gained by skiving
particularly during the production of internalgear teeth, compared with traditional gear
shaping. Additionally, the continuous
cutting process makes excellent surface
definition possible while at the same time
reducing process times.

Hobbing is a continuous cutting method
suitable for the production of straight or
oblique external gear teeth. This methodlets you manufacture gears productively,
accurately, and flexibly.
In both methods, axial motion issuperimposed onto a synchronized rotationof the tool and workpiece. The tool and theworkpiece axis must both be positioned atdefined angles relative to each other. The
TNC 640 handles these complex
calculations for you and automatically
executes all of the required motion andsynchronization.
* Option 157 (with turning mode, option 50 as well)

The TNC 640 also offers an extensive andtechnologically sophisticated package ofturning cycles. These cycles are equivalent
to the well-proven and long-standing corefunctions of the HEIDENHAIN lathe
controls. The appearance and functions of
the user interface, however, are alignedwith the familiar and well-proven Klartext
conversational programming language.
Cycle parameters used for both milling andturning are naturally designated by thesame number.

Machining simple contours
Various cycles are available for thelongitudinal and transverse machining of
simple contours. The area to be machined
can also be inclined, thus requiring aplunging movement. Of course, theTNC 640 automatically takes the angle ofthe turning tool into account.
Machining any contours
If the contours to be machined arecomplex and can no longer be defined withsimple cycle parameters, you can still
describe them using contour subprograms.
This process is identical to the procedureused for SL cycles in milling, for which you
use Cycle 14 to define the subprogram
describing the finished contour. You candefine the technology parameters in therespective turning cycle.

For the contour description, you use exactly
the same Klartext functions as you would
for defining a milling contour. FK freecontour programming is included as well.
Turning-specific recess and undercut
contour elements are also available, which
you can insert between contour elementsin the same manner as chamfers androunding arcs. Besides radial and axis
recesses, E, F, H, K, and U undercuts areavailable, as are thread undercuts.
Depending on the cycle, the TNC 640
machines parallel to the axis or the contour.
You define the machining operations(roughing, finishing) or the oversize with
dialog guidance in the corresponding
parameters.

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Practical functions for grinding and dressing (option)

Recessing
For these operations, as well, the TNC 640
features ample flexibility and functionality.
Simple longitudinal and transverse
recessing operations are possible, as arecontour recessing operations in which thecycle is machined along any desired
contour. You can work particularly
effectively when performing recess
turning: due to the direct alternation
between infeed and cutting, air cuts are
hardly necessary. Here, too, the TNC takes
the technological constraints into account(width of recessing tool, overlap, feed-rate
factor, etc.) and executes the operations
both quickly and reliably.

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.

In multiple plunging the solid material isrepeatedly plunged into along the contour,
and subsequently the remaining material iscut away. This makes it possible to safely
machine materials that are difficult to cut,since there are no radial loads and chips
are removed centrally.

Blank form update
Another highlight of the TNC 640 is its
blank form update feature. If you define theworkpiece blank at the beginning of yourprogram, the control computes the newblank form for each following step. The
machining cycles always adapt to thecurrent workpiece blank. The blank form
update feature helps you avoid air cuts andoptimize approach paths.

Simultaneous machining
The simultaneous roughing cycle and thesimultaneous finishing cycle both adapt the
inclination angle of the B axis to theworkpiece contour during turning. During
this process, the complex tool movements

40

Thread machining
Simple and extended cycles are available
for the longitudinal and transverse
machining of cylindrical or tapered threads.
You can use cycle parameters to define themanner in which the thread is produced.
This enables you to machine a wide variety
of materials.

Orientation of the turning tool
On milling-turning machines, it may benecessary to incline the tool during turningor change the side from which machining
should be performed. With the help of acycle, the TNC can change the inclination
angle of the tool for back cutting or canconvert an external turning tool into aninternal turning tool without the operator
needing to adjust the cutter position or theorientation angle in the tool table.
Eccentric turning (option)
With the eccentric turning function, you
can perform turning operations even if theworkpiece axis is not aligned with the axisof rotation due to the setup configuration.
During machining, the TNC 640
compensates for any eccentricity withcompensating movements in the linear
axis coupled with the rotating spindle.

The TNC 640 also lets you perform grinding
operations on your machine. Cycles for jig
grinding and dressing allow you to program
the respective function with great
convenience. In addition, the TNC 640 cansuperimpose a tool-axis reciprocating
stroke onto the programmed movements.
Optimized tool management supports theuser during every process, including
grinding and dressing. The TNC 640 is thus
the perfect basis for attaining the highest
degree of surface quality and accuracy inyour application.

Jig grinding*Jig grinding is the grinding of a 2D contour.
On a milling machine, jig grinding is
primarily used for finishing holes or premachined contours using a grinding tool.
You can program open and closed grinding
contours in the predefined grinding cycles
and then machine them. You also have theoption of superimposing a tool-axis
reciprocating stroke onto the tool’s motion.
Special cycles allow you to define, start,and stop the reciprocating stroke. The
reciprocating stroke enables uniform wearon the grinding tool and precise
geometries on ground surfaces.

Dressing*
Dressing cycles allow you “true up”
grinding tools inside the machine. During
dressing, the grinding tool is machinedwith a special dressing tool. Klartext cycles
are available for dressing the grinding tool’s
diameter or profile.
* The machine must be adapted for this function
by the machine manufacturer.

Machining with FreeTurn tools
The TNC 640 now supports efficient
outside turning operations with FreeTurntools. FreeTurn tools have different cuttingedges for different machining tasks, suchas for roughing and finishing. A rotation of
the tool axis switches the cutting edges.
This reduces the number of tool changes
and thus machining times.



41

Reusing programmed contour elements

Coordinate transformation
If you need a pre-programmed contour atdifferent locations and in different sizes on
the workpiece, then the TNC 640 offers you
a convenient solution in the form of
coordinate transformations.
Depending on the operation, you can shift
the datum (milling, grinding, and turning)
and rotate the coordinate system (millingand grinding) as well as mirror the contour(milling and grinding). With a scaling factor(milling and grinding), you can enlarge or
reduce contours to account for shrinkage
or oversizes.

Program-section repeats andsubprograms
Many machining operations repeat
themselves either on the same workpieceor on different workpieces. Once you haveprogrammed a detail, there is no need toprogram it again. With its subprogram
technology, the TNC can save you a great
deal of programming time.
In program-section repeats, you can labela section of the program, and the TNC will
repeat this section as many times as
required.

Rapid availability of all information

With the program call function, you caneven use a completely separate program at
any location in your current program. This
allows you to leverage already programmed
and frequently required working steps orcontours.
Of course, you can also combine these
programming techniques as often as
desired.

Do you have questions about aprogramming step but your User’s Manual
is not at hand? No problem: both the
TNC 640 control and the TNC 640
programming station feature TNCguide, aconvenient help system that displays theuser documentation in a separate window.
You can activate TNCguide simply bypressing the HELP key on the TNC
keyboard or directly on the touchscreen or
by clicking any soft key when the mousepointer has switched to a question mark.
This is easily done by clicking the help icon
permanently displayed on the TNC screen.

TNCguide generally displays theinformation instantaneously and in thecorrect context (context-sensitive help),
immediately giving you the information you
currently need. This function is particularly
helpful for soft keys and provides a detailed
explanation of their effects.
You can download the documentation in
the desired language free of charge fromthe HEIDENHAIN website and save it to
the appropriate language directory of the
TNC hard disk.

You can mark a program section as a
subprogram and then call it at any point in
the program and as often as you want.

TNCguide integrated in the control: e.g., on the TNC 640...

42

The following User’s Manuals are available
in the help system:• Klartext Programming• Setup, Testing, and Running NC
Programs• Programming of Machining Cycles• Programming of Measuring Cycles for
Workpieces and Tools• ISO Programming• TNC 640 Programming Station (installed
only with the programming station)... or at the programming station.

43Open to outside information
Processing CAD files with the TNC 640

CAD viewer
With the standardly available CAD viewer
software, you can open 3D CAD models
and drawings directly on the TNC 640.
Various view options as well as rotationand zoom capabilities allow for a detailed
visual inspection and analysis of your CAD
data. You can also use the viewer toascertain position values from a 3D model.
You simply select an arbitrary reference
point in your drawing and select thedesired contour elements. The CAD viewer
then displays the coordinates of theelements in a window. The CAD viewer
can depict the following file formats:• STEP files (.STP and .STEP)• IGES files (.IGS and .IGES)• DXF files (.DXF)• STL files (.STL)

CAD Import (option 42)
Why program complex contours if you
already have the drawing as a DXF, STEP,
STL or IGES file? After all, you have theability to extract contours or machining
positions from these types of CAD files.
This not only saves time otherwise spenton programming and testing, but you canalso be sure that the finished contour isexactly in accordance with the design
engineer’s specifications.
Extracting machining information directlyfrom CAD data offers additional
possibilities, particularly for the creation of
NC programs with a tilted machining plane.
You can also define the preset with a 3D
basic rotation of the 3D model and set a
datum with the appropriate 3D rotation in
the desired working plane.

You can easily save the working plane tothe clipboard and transfer it to the NC
program with the appropriate
transformation and the associated PLANE
command. In the defined working plane,
you can extract contours and machining
positions, and apply them to the NC
program.
Selecting contours is very convenient: Start
by selecting any element. Once you selecta second element, the TNC detects yourdesired machining direction and initiates
automatic contour detection. In doing so,
the TNC automatically selects all clearly
identifiable contour elements until thecontour closes or branches out. In thismanner, you can define extensive contours
with just a few steps. Then you can simply
copy the selected contour to an existing
Klartext program using the clipboard.

You can also select machining positions
and save them as point files, especially inorder to apply hole positions or starting
points for pocket machining. This can bedone very easily by selecting the desired
area. In a pop-up window with a filter
function, the TNC displays all of the holediameters within the area you haveselected. To select the desired holediameters and restrict the number of holepositions, simply select the corresponding
filter symbol to change the filter limits. A
zoom function and various configuration
possibilities round out the functionality of
CAD Import.
It is also possible to define the contour
program’s resolution for using it in older
TNC controls. You can also define atransition tolerance if the contour elements
are not completely connected.

Part program on the basis of the imported DXF file

44

The following positions can be defined aspresets:• The beginning, end, or mid-point of a line
• The beginning, end, or center point of acircular arc• Quadrant transitions or center point of acircle• Intersection of two lines, even only intheir extension• Intersection of a line and a circular arc• Intersection of a line and a circle
If multiple intersections between twoelements are possible (e.g., between astraight line and a circle), then you canselect the correct intersection.

Generating STL files (option)
The CAD Model Optimizer option makes it
possible to generate STL files from
3D models. The TNC 640 covers the
3D model displayed in the CAD viewer
with a mesh of triangles. This simplifies theoriginal model and removes errors, such as
small holes in a solid or self-intersectionsof a surface. The TNC 640 then generates
an STL file that you can use for various
functions of the control. For example, you
can then easily repair faulty files of fixturesor tool holders.

Display of a 3D model in the CAD viewer45

Uniformly 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 TNC 640, with its Connected
Machining package of functions,
integrates itself flexibly into your process
chain and helps you to optimize the transfer
of knowledge within your company. So let
your workshop, 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 TNC 640
Integrate the TNC 640 with the functions ofConnected Machining into your corporate
network and, via the control, connect theshop floor to PCs, programming stations,and other data storage media in theseareas of the company:• Design• Programming• Simulation• Production planning• Production
Even the basic version of the TNC 640 isequipped with two Gigabit Ethernet portsof the latest generation. The TNC 640 uses
the TCP/IP protocol to communicate with
NFS servers and Windows networks
without requiring additional software. The
fast data transfer at rates of up to
1000 Mbit/s ensures very shorttransmission times. The TNC 640 therefore
offers the optimal technological platform
for Connected Machining, the networkingof the control in the shop with all
production-related areas of your company.

Standard range of functions
For you to be able to use the data that you
transfer to the TNC 640 over a network, theTNC 640 offers attractive applications, evenas part of its standard range of functions.
The CAD viewer, PDF viewer or Mozilla
Firefox web browser enable the simplest
form of Connected Machining: access to
manufacturing process data right at thecontrol. In this case, operating web-based
documentation systems or ERP systems isjust as feasible as accessing your e-mailinbox. For example, the following fileformats can also be opened directly on the
TNC 640:• Text and PDF files• Graphic files with the extensions .gif,.bmp, .jpg or .png
• Spreadsheet files with the extensions .
xls, .xlsx, .odv or .csv
• html files: .htm, .html, .chm
• and several more

Data transfer
An enhanced solution for fully digital job
management within the context ofConnected Machining is the free-ofcharge TNCremo PC software. With it, you
can transfer remotely stored part programs
and pallet tables in both directions over the
Ethernet.
With the powerful TNCremoPlus PC
software, you can also transfer the screen
contents from the control to your PC using
the live-screen function.
Job-related data
With REMOTE DESKTOP MANAGER(option 133), you can operate a Windows
PC from the TNC 640. On the control, yougain direct access to EDP systems within
the process chain and make your machine
setup processes significantly more efficient
by reducing inconvenient legwork between
the machine and the office. Technicaldrawings, CAD data, NC programs, tool
data, work instructions, parts lists, andwarehouse information are digitally
available at the machine. E-mails can besent and received with ease. With a simple
keystroke on the machine operating panel,
you can switch between the control screen
and the screen of the Windows PC. This PC
can be a computer in the local network or
an industrial PC (IPC) in the machine’s
electrical cabinet.

Detailed data for the optimalorganization of production processes  
HEIDENHAIN DNC enables the connectionof existing machine tools to Windowsbased industrial applications, meaning thateven older TNC controls, like the
TNC 426/430 or the iTNC 530, can beconnected to modern inventory
management systems and productionactivity control systems. Use RemoTools
SDK to connect your applications to TNC
controls, or purchase an application that is
DNC-compatible.
Appropriate monitoring and controllingof applications
Efficient and secure digital communication
in a machine-tool context requires
standardized components, applicationrelevant information models and adherence
to current IT security guidelines.
HEIDENHAIN OPC UA NC Server offers
an interface based on OPC UA for
HEIDENHAIN controls. This internationallystandardized and widespreadcommunication technology makes it fastand easy to connect machines to yourproduction IT. You also save time when
integrating new functions because theapplication-oriented presentation of
information reduces programming andconfiguration effort.
• State-of-the-art IT security:
Authentication, authorization, andcryptography• Uncomplicated:
Guided connection configuration• Application-oriented:
Tailored to the demands of modern
industrial applications• Standardized:
OPC UA is the communication
technology recommended for
Industry 4.0• Freedom of choice:Open selection of operating system andtoolkit• Virtual testing environment:
Free HEIDENHAIN programming station• Expandable by the machine
manufacturer:
The machine manufacturer can also
extend the HEIDENHAIN OPC UA
NC Server, giving you access toadditional sensors, machine
subsystems, or values from PLC
programs.

CAD
CAM

46



47

StateMonitor: collect and evaluate machine data

StateMonitor collects and visualizes thestatuses of production machines. By
evaluating important data such as thecurrent machine status, machinemessages, override positions, andutilization history, StateMonitor provides indepth information about the machine's
degree of utilization. Based on the data itcollects, StateMonitor also reveals
machine-specific optimization potential. By
entering comments regarding machine
downtimes and setup times, the operator
can also uncover potential for improvement
at the organizational level. Via the
Messenger function, StateMonitor notifies
the right person by e-mail based on
individually combinable machine signals
and statuses.

Active support for production planning withan extensive range of functions for job datacollection:• Create and assign jobs
• Start and terminate jobs
• Plan setup times and interruptions• Store additional job data, such as
quantities produced

The TNC 640 programming station

StateMonitor even lets you connect
machines with different controls andsupports the following protocol types:
HEIDENHAIN DNC, OPC UA, MTConnect,and Modbus TCP.
For more information, please contact
HEIDENHAIN.

Creating programs
The programming, testing, and optimizingof HEIDENHAIN Klartext or ISO programswith the programming station substantiallyreduces machine idle times. And it’s easy
to get used to because every keystrokefeels the same: the programming station’s
keyboard is just like the one on themachine.

StateMonitor collects and visualizes thefollowing information from the networked
machines:• Operating modes• Override positions (spindle, rapid
traverse, feed rate)• Program status and program name, as
well as subprograms if applicable• Program run time
• SIK number and software number• Machine messages

PlantMonitor

What’s the purpose of a programming
station?
As easy as it is to write a part program on a
TNC 640 at the machine while a different
part is being machined, short reloading
times or high machine utilization may
hinder attentive programming work on the
shop floor. The TNC 640 programming
station lets you program the same way you
would at the machine but away from all thenoise and distractions.

Testing programs created offline
Naturally, you can also test programs thatwere written on a CAD/CAM system. The
various views of the program verificationgraphics help you easily spot contour
damage and hidden details.
Training with the programming station
Since the TNC 640 programming station isbased on the same software as the
TNC 640 control, it is ideal for apprentice
and advanced-level training. Programmingis performed on the original keyboard unit,
and even the test run feature runs exactly
as it would on the machine. This gives thetrainee the experience needed to safely
work on the real machine.
The TNC 640 programming station is also
optimally suited for teaching TNC
programming skills in schools, since the
TNC 640 can be programmed in Klartext
and with ISO codes.

Your workstation
The programming station software runs on
a PC. The PC screen shows you the same
TNC user interface as the control andoffers the familiar graphical support.
Depending on the version of the
programming station, there are multiple
ways of using it.
The free demo version contains all of the
TNC 640’s functions and allows shortprograms to be saved. Programming is
performed on the PC keyboard.
The version with a TNC operating panel
lets you create programs in theaccustomed manner on a keyboard
featuring the same function keys as thecontrol on the machine. It also has a PC
keyboard for ISO programming, file names,
and comments.
You can also work without the TNC
operating panel: a virtual keyboard for
operating the programming station isshown on the PC screen. This virtual
keyboard provides the TNC 640’s mostimportant dialog-opening keys.

Real-time notifications via
e-mailAccess over a web browser
from various terminals

Display and evaluate
multiple instances ofStateMonitor
Machine inventory
visualization

Job assignment, booking,and feedback

Organization and logging ofscheduled maintenance andidentified faults

Enhanced capturing andrecording of equipment-specificsignals

Comprehensive
evaluation of all
StateMonitor modules

StateMonitor

48

Machines connected overthe HEIDENHAIN DNC, OPC UA, MTConnect, and Modbus TCP interfaces

Further information:
Comprehensive descriptions of the
programming station and a free demo
version are available on the Internet atwww.heidenhain.com/programmingstations.

Forwarding to an external
SQL database for theprocessing of machine data
in an MES or ERP system49

Workpiece measurement
Setup, preset setting, and measuring with touch trigger probes

Workpiece touch probes* from
HEIDENHAIN help you keep costs down inthe shop and in serial production: whenused in conjunction with the TNC 640, they
enable the automated execution of setup,measurement, and inspection functions.
Upon contact with the workpiece surface,
the stylus of a TS touch trigger probe isdeflected. In that instant, the TS generates
a triggering signal that, depending on themodel, is transmitted either by cable or an
infrared beam to the control.
The touch probes are inserted directly into
the machine tool spindle and can beequipped with various taper shanks
depending on the machine. The ball tips,
which are made of ruby, are available indifferent diameters with various stylus
lengths.
* The machine and TNC must be specially adaptedby the machine manufacturer.

Cable-bound touch probes
For machines requiring manual toolchanges, as well as for grinding machines
and lathes:
TS 260• Axial or radial cable connection• High scanning accuracy
Wireless touch probes
For machines with an automatic toolchanger:
TS 460• Standard touch probe for radio andinfrared transmission• Compact dimensions• Energy-saving mode
• Optional collision protection• Thermal decoupling

Tool measurement
Measuring length, radius, and wear inside the machineTransceiver unit
Radio or infrared transmission isestablished between the TS or TT touchprobe and the SE transceiver:SE 660• For radio or infrared transmission (hybrid
technology)• Same SE for TS 460 and TT 460

A key factor in obtaining consistently highproduction quality is, of course, the tool.
This requires exact measurement of thetool dimensions and periodic inspection of
the tool for breakage, wear, and tooth
shape. For tool measurement,
HEIDENHAIN offers the TT triggering
tool touch probes.

SE 661• For radio or infrared transmission(hybrid technology)• Same SE for TS 460 and TT 460• EnDat functionality for transmission of
the switching state, diagnostics, andadditional information

These touch probes are installed directly
within the machine’s workspace, where
they enable tool measurement either
before machining or during interruptions.

The TT tool touch probes measure thetool length and radius. During probing of
the rotating or stationary tool, such as forindividual tooth measurement, the contact
plate is deflected and a trigger signal istransmitted directly to the TNC 640.
The TT 160 uses cable-bound signaltransmission, whereas the TT 460 sends
its signals via radio or infrared transmission.
It is thus particularly well suited for use on
rotary/tilting tables.

To prevent limiting the machining space
and to avoid collisions, the TT touch probemust occasionally be removed from themachine. The touch probe’s new magnetic
base features three contact points and a
setting screw. As a result, the touch probe
requires calibration only during initialinstallation and can then be re-installed andremoved with a quick hand movement.
Here are the benefits in a nutshell:• Fast re-installation without recalibration• Low-profile base
• Same accuracy as a permanent
installation

TS 642• Activation via switch in taper shank• Infrared transmission
TS 760• High scanning accuracy• High reproducibility• Low probing forces• Radio and infrared transmission

SE 660TS 460TT 460Further information:

Further 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.

50

TS 460 with collision protection

You can find detailed descriptions oftool touch probes on the Internet atwww.heidenhain.com or in the
Touch Probes for Machine Tools brochure.



51Inspecting and optimizing machine accuracy
Easy calibration of rotary axes with KinematicsOpt (option)

Accuracy demands are on the rise,
particularly in the realm of 5-axis
machining. Complex parts must be
manufactured with both precision andreproducible accuracy, including overextended periods of time.
The TNC function KinematicsOpt is an
important ingredient in helping you meetthese high requirements: with a
HEIDENHAIN touch probe inserted, a cycle
measures your machine’s rotary axes fully
automatically. The measuring process isthe same, regardless of whether the rotary
axis is a rotary table, tilting table, or aswivel head.

For calibrating the rotary axes, a calibration
sphere is mounted at any position on themachine table and probed with the
HEIDENHAIN touch probe. Prior to this,you define the resolution of themeasurement and the range that you wantto measure for each rotary axis.
Based on the measured values, the TNC
calculates the static tilting accuracy. The
software minimizes the spatial error arisingfrom the tilting movements and, at the endof the measuring process, automaticallysaves the machine geometry in therespective machine constants of thekinematics description.

Of course, a detailed log file is alsoavailable in which the measured andoptimized dispersion (measure of the static
tilting accuracy) is saved along with theactual measured values and the actual
compensation values.
Optimal use of KinematicsOpt requires ahighly rigid calibration sphere for reducing
the deformations caused by probing
forces. For this purpose, HEIDENHAIN
offers calibration spheres with highly rigid
holders of various lengths.

Positioning with an electronic handwheel
Fine motion control of axes

You can set up the workpiece by manuallyjogging the axes with the axis direction
keys, but this task is easier and more finely
controllable with the electronic
handwheels from HEIDENHAIN.
In this method, the axis slides are movedby the feed motor in accordance with the
handwheel’s rotation. For particularly highsensitivity, you can incrementally set theamount of traversing distance for eachhandwheel rotation.
Panel-mounted handwheel
The HR 130 panel-mounted handwheelfrom HEIDENHAIN can be integrated into
the machine operating panel or mounted toa different part of the machine.

Portable handwheels
The HR 510, HR 520, and HR 550 portable
handwheels are particularly helpful when
you work near the machine’s working
space. The axis keys and certain function
keys are built into the housing. In this way,
you can switch axes and set up themachine at any time—regardless of where
you happen to be standing. As a wirelesshandwheel, the HR 550 is ideal for use on
large machines. If you no longer need thehandwheel, simply attach it to the machineusing its built-in magnets.

Expanded range of functions of the
HR 520 and HR 550• Definable traversing distance per
revolution• Display for operating mode, actual
position value, programmed feed rate,
handwheel offset, spindle speed, anderror messages• Override potentiometers for feed rate,
handwheel offset, and spindle speed• Selection of axes by means of keys andsoft keys• Keys for continuous traverse of the axes
• Emergency stop button• Actual position capture• NC start/stop• Spindle on/off• Soft keys for machine functions definedby the machine manufacturer

HR 55052

53

Short description­✓­✓
Program entry

Position entry

Tool compensation

­
✓
­✓

0-7
77
78

42

Basic version: 3 axes plus closed-loop spindle

Turning operations

A total of 14 additional NC axes or 13 additional NC axes plus second spindle
Digital current and speed control
HEIDENHAIN Klartext
ISO
Importing of contours or machining positions from CAD files (STP, IGS, DXF) and saving
them as a Klartext contour program or Klartext point table

­
✓
­✓
­✓

Nominal positions for straight lines and arcs in Cartesian coordinates or polar coordinates
Incremental or absolute dimensions
Display and entry in mm or inches­✓­✓

Tool radius in the working plane, and tool length
Radius compensated contour look ahead for up to 99 blocks (M120)
Three-dimensional tool-radius compensation for changing tool data without having torecalculate an existing program

9

Contour elements

­
✓
­✓
­✓
­✓
­✓
­✓
­✓

OptionStandard

User function
OptionUser function

Standard

Overview
User functions

50/15850/15850/15850/15850/15850/15850/15850/15850/15850/158158

Program-controlled switchover between milling and turning
Constant cutting speed
Cutter radius compensation
Cycles for roughing, finishing, recessing, thread turning, and recess turning
Blank-form updating in contour cycles
Turning-specific contour elements for recesses and undercuts
Orientation of the turning tool for external turning / internal turning
Inclined turning
Speed limiting
Eccentric turning (additionally required: option 135)
Simultaneous turning operations

50/15850/158Straight line
Chamfer
Circular path
Circle center
Circle radius
Tangentially connected arc
Corner rounding
RecessUndercutTool tables­✓Multiple tool tables with any number of tools

Cutting data­✓

Automatic calculation of spindle speed, cutting speed, feed per tooth, and feed per
revolution
OCM: automatic calculation of overlap factor, milling feed rate, spindle speed, climb or upcut milling, lateral infeed, cutting speed, material removal rate, recommended cooling

Approaching anddeparting the contour
Adaptive feed control

45

AFC adapts the contouring feed rate to the current spindle power

Collision monitoring

40
40
40

Dynamic Collision Monitoring (DCM)
Graphic depiction of the active collision objects
Tool carrier monitoring

167
Constant contour speed­✓­✓

With respect to the path of the tool centerWith respect to the cutting edge

Parallel operation­✓

Program creation with graphical support while another program is running

3D machining

­✓

9
9
9
92

Motion control with highly smoothed jerk
3D tool compensation via surface-normal vectors
Changing the swivel-head angle with the electronic handwheel during program run without
affecting the tool tip position (TCPM = Tool Center Point Management)
Keeping the tool perpendicular to the contour
Tool radius compensation perpendicular to the tool direction
Manual traverse in the active tool-axis system
3D radius compensation based on the tool’s contact angle

Rotary table machining88Programming of cylindrical contours as if in two axes
Feed rate in mm/min

Fixture monitoring

40

Integration of fixtures, such as a vise, in your NC program (using CFG or STL files). The
control displays the fixtures in the simulation and monitors them for collisions

54

9
9

­
✓
­✓

Approach and departure on a straight line: tangential or perpendicular
Approach and departure on an arc

Free contour
programming­✓

FK free contour programming in HEIDENHAIN Klartext format with graphical support forworkpiece drawings not dimensioned for NC

Program jumps

­
✓
­✓
­✓

Subprograms
Program-section repeat
Any desired program as subprogram

55

Fixed cycles

­
✓
­✓

­✓

­
✓
­✓
­✓
­✓
­✓
­✓
­✓
­✓
­✓
Coordinate transformation ­✓­✓Q parameters
Programming with variables
­✓
­✓
­✓

50/15850/15850/15850/15850/158
96
156
157

167
8
44

Drilling, conventional and rigid tapping, rectangular and circular pockets
Peck drilling, reaming, boring, counterboring, centering
Area clearance cycles, longitudinal and transverse, paraxial and contour-parallel
Recessing cycles, radial/axial
Radial/axial recess turning cycles (combined recessing and roughing motion)
Milling internal and external threads
Turning of internal and external threads
Hobbing (also requires option 131)Interpolation turning
Function for grinding operation
Gear-system production
Clearing level and oblique surfaces
Complete machining of rectangular and circular pockets, rectangular and circular studs
Complete machining of straight and circular slots
Circular and linear point patterns
Point pattern: Data Matrix code
Contour train, contour pocket
Contour slot with trochoidal milling
Engraving cycle: engrave text or numbers in a straight line or on an arc
OEM cycles (special cycles developed by the machine manufacturer) can be integrated
Optimized Contour Milling (OCM) cycles: optimization of roughing processes
Shifting, rotating, mirroring, scaling (axis-specific)
Tilting the working plane, PLANE function
Manually definable: shifts, rotations, and handwheel superimpositioning can be manually
defined via global program settings
n

­
✓
­✓
­
✓
­✓
­✓
­✓
­✓
­✓

Calculator
Complete list of all current error messages
Context-sensitive help function for error messages
TNCguide: the integrated help system; user information available directly on the TNC 640
Graphic support for the programming of cycles
Comment and structure blocks in the NC program

Teach-in­✓Application of actual positions directly in the NC program

Program verificationgraphics
Display modes­✓

Graphical simulation of the machining operation, even while another program is being
executed
Plan view/projection in three planes/3D view, also in tilted working plane/3D line graphics
Detail zoom

Programming graphics­✓

In the Programming mode, the contours of entered NC blocks are rendered (2D pencil-tracegraphics), even while another program is running

Program-run graphics
Display modes­✓­✓

Real-time graphical simulation during execution of the milling program
Plan view / view in three planes / 3D view

Machining time­✓­✓

Calculation of machining time in the Test Run mode of operation
Display of the current machining time in the program run

56

­
✓
­✓

Option­✓­✓Mid-program startup at any block in the program and movement to the calculated nominal
position for continuation of the machining operation
Program interruption, contour departure and return

Preset management­✓

One table for saving any reference points (presets)

Datum tables­✓Multiple datum tables for storing workpiece-specific datums

Pallet tables­✓
154

Workpiece-oriented execution of pallet tables (with any number of entries for the selectionof pallets, NC programs, and datums)
Production process planning with Batch Process Manager

48
50/158

Touch probe calibration
Manual or automatic compensation of workpiece misalignment
Manual or automatic preset setting
Automatic tool and workpiece measurement
KinematicsOpt: automatic measurement and optimization of the machine’s kinematic model
Cycle for measurement of turning tools

Touch probe cycles

Parallel secondary axes

­
✓
­✓
­✓
­✓

­
✓
­✓
­✓

Conversational languages ­✓nMathematical functions =, +, –, *, /, sin , cos , tan , arc sin, arc cos, arc tan, a , e , In,log, a, a2 + b2
Logical operations (=, ≠, <, >)Calculating with parentheses
Absolute value of a number, constant π, negation, truncation of digits before or after thedecimal point
Functions for calculation of circles
Functions for text processing

Programming aids

Returning to the contour

Standard

User function
OptionUser function

Standard

User functions and accessories

CAD viewer­✓

Compensation of movement in the secondary axes U, V, W through the principal axes X, Y, Z
Movements of parallel axes included in the position display of the associated principal axis
(sum display)
Defining the principal and secondary axes in the NC program enables execution on different
machine configurations
English, German, Czech, French, Italian, Spanish, Portuguese, Swedish, Danish, Finnish,
Dutch, Polish, Hungarian, Russian (Cyrillic), Chinese (traditional, simplified), Slovenian,
Slovak, Norwegian, Korean, Turkish, Romanian
Display of standardized CAD file formats on the TNC

Accessories
Electronic handwheels• HR 510/HR 520: portable handwheels• HR 550: portable wireless handwheel• HR 130: panel-mounted handwheel

Workpiece measurement• TS 260: workpiece touch probe with cable connection• TS 460/TS 760: workpiece touch probe with radio or infrared transmission• TS 642: workpiece touch probe with infrared transmission

Tool measurement• TT 160: triggering tool touch probe• TT 460: triggering tool touch probe with radio or infrared transmission

Programming station

Control software for PCs for programming, archiving, and training• Single-station license with original control keyboard/with operation via virtual keyboard• Network license with operation via virtual keyboard• Demo version (operated with PC keyboard—free of charge)

Software for PCs• RemoteAccess: software for remote diagnostics, monitoring, and operation• CycleDesign: software for creating your own cycle structure• TNCremo: software for data transfer—free of charge• TNCremoPlus software for data transfer with live-screen function• StateMonitor: software for recording, evaluating, and visualizing machine data

57

Options

OptionnumberOptionStartingfrom NC
software34059x-ID

Comment

0
1
2
3
4
5
6
7

Additional Axis 1
Additional Axis 2
Additional Axis 3
Additional Axis 4
Additional Axis 5
Additional Axis 6
Additional Axis 7
Additional Axis 801354540-01
353904-01
353905-01
367867-01
367858-01
370291-01
370292-01
370293-01

Additional control loops 1 to 8

8

Advanced Function
Set 1

01

617920-01

Rotary table machining• Programming of cylindrical contours as if in two axes
• Feed rate in mm/min
Interpolation: circular in 3 axes with tilted working plane
Coordinate transformation: tilting the working plane, PLANE function

9

Advanced Function
Set 2

01

617921-01

Interpolation: straight line in more than four axes (export license
required)
3D machining• 3D tool compensation via surface normal vectors• Using the electronic handwheel to change the angle of the swivel
head during program run without affecting the position of the tool
point (TCPM = Tool Center Point Management)• Keeping the tool perpendicular to the contour• Tool radius compensation perpendicular to the tool direction• Manual traverse in the active tool-axis system

18

HEIDENHAIN DNC

01526451-01

Communication with external PC applications over COM component

40

DCM Collision

02526452-01

Dynamic Collision Monitoring (DCM)
The control monitors the defined collision objects during all machine
movements

42

CAD Import

08526450-01

Import of contours from 2D and 3D models (e.g., STEP, IGES, DXF)

44

Global PGM Settings

08

576057-01

Global program settings

45

Adaptive Feed Control 02(AFC)579648-01

Adaptive feed control

46

Python OEM Process

01579650-01

Execution of Python application

48

KinematicsOpt

01630916-01

Touch-probe cycles for the automatic measurement of rotary axes

49

Double-Speed Axes

01

632223-01

Short control-loop cycle times for a direct drive motor

50

Turning

01634608-01

Turning functions:• Tool management for turning• Tool radius compensation• Switching between milling and turning mode
• Turning-specific contour elements• Package of turning cycles

52

KinematicsComp

05661879-01

Compensation of spatial errors for rotary and linear axes (export license
required)

56–61

HEIDENHAIN OPC UA 10
NC Server

1291434-01
to -06

Reliable and stable interface for the connection of state-of-the-art
industry applications; uncomplicated thanks to the use of standardized
designs. Each of the six SIK options enables an incoming OPC UA
connection via an application certificate

58

OptionnumberOptionStartingfrom NC
software34059x-ID

Comment

77

4 Additional Axes

01

634613-01

4 additional control loops78

8 Additional Axes

01

634614-01

8 additional control loops

92

3D-Tool Comp07

679678-01

3D radius compensation based on the contact angle (only with theAdvanced Function Set 2 software option)

93

Extended ToolManagement01676938-01

Extended tool management• Tooling list (list of all tools of the NC program)• T usage sequence (sequence of all tools inserted during the program)

96

Advanced Spindle
Interpolation

05

751653-01

Additional function for an interpolated spindle• Interpolation turning, coupling• Interpolation turning, contour finishing

101–130

OEM options

02579651-01
to -30

Options of the machine manufacturer

131

Spindle Synchronism

05806270-01

Synchronization of two or more spindles

133

Remote Desk.
Manager

01894423-01

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

135

Synchronizing
Functions

041085731-01

Advanced synchronization of axes and spindles

141

Cross Talk Comp.

02

800542-01

CTC: compensation of axis couplings

142

Pos. Adapt. Control

02800544-01

PAC: position-dependent adaptation of the control parameters

143

Load Adapt. Control

02800545-01

LAC: load-dependent adaptation of the control parameters

144

Motion Adapt. Control

02800546-01

MAC: motion-dependent adaptation of the control parameters

145

Active Chatter Control

02800547-01

ACC: active suppression of chatter during heavy machining

146

Machine Vibration
Control04800548-01

Damping of machine oscillations to improve workpiece surfaces.
The following functions are part of Machine Vibration Control (MVC):• Active Vibration Damping (AVD): active damping of vibrations in thecontrol loop
• Frequency Shaping Control (FSC): reduction of vibration inducement
by means of frequency-based feedforward control

152

CAD Model Optimizer 161353918-01

Conversion and optimization of CAD models• Fixtures• Workpiece blank• Finished part

154

Batch Process
Manager

08

1219521-01

Planning and executing multiple machining operations

155

Component
Monitoring

09

1226833-01

Monitoring for component overloading and wear

156

Grinding

101237232-01

Grinding functions:• Jig grinding• Ability to switch between normal operation and dressing mode
• Reciprocating stroke• Grinding cycles• Tool management for grinding and dressing

157

Gear Cutting

09

1237235-01

Functions for the machining of gear teeth

59

OptionnumberOptionStartingfrom NC
software34059x-ID

Comment

Specifications

158

Turning v2171359635-01

Turning functions (mill-turning version 2)• Includes all functions of software option 50 (Turning) plus cycles for
simultaneous roughing and finishing

Components

160

Integrated FS: Basic

101249928-01

Gen 3 exclusive:• Enables 4 safe control loops• Enables functional safety (FS)161

Integrated FS: Full

101249929-01

Gen 3 exclusive:• Enables the maximum number of safe control loops• Enabling of functional safety (FS)162

Add. FS Ctrl. Loop 1

101249930-01

Additional FS control loop 1

163

Add. FS Ctrl. Loop 2

101249931-01

Additional FS control loop 2

164Add. FS Ctrl. Loop 3

101249932-01

Additional FS control loop 3

165Add. FS Ctrl. Loop 4

101249933-01

Additional FS control loop 4

166Add. FS Ctrl. Loop 5

101249934-01

Additional FS control loop 5

167

Optimized Contour
Milling

101289547-01

OCM: optimize roughing processes and fully utilize milling tools with
the integrated cutting data calculator

169

Add. FS Full

111319091-01

Enabling of all FS axis options or control loops. Options 160 and 162 to
166 must already be set.

OptionSpecifications

Standard

Optionen

­
✓
­✓
­✓

­✓

MC main computer
CC or UxC controller unit
Multi-touch operation
19-inch screen (portrait, 1024x1280 pixels)
19-inch screen (1280x1024 pixels)
24-inch screen (1920x1080 pixels)
TE operating panel (suitable for 24-inch screen)

Operating system­✓

HEROS 5 real-time operating system for machine control

Memory­✓144 GB on HDR hard disk (total capacity: 320 GB)
21 GB on SSDR (total capacity: 32 GB)

Input resolution anddisplay step­✓­✓

Linear axes: down to 0.01 µm
Rotary axes: down to 0.000 01°

Interpolation

­✓
­✓
­✓

9
8

Block processing time­✓

≤ 0.5 ms (3D straight line without radius compensation)

Axis feedback control

­
✓
­✓
­✓
­✓

Position-loop resolution: signal period of the position encoder/4096
Position controller cycle time: 200 µs (100 µs with option 49)
Speed controller cycle time: 200 µs (100 µs with option 49)
Current controller cycle time: minimum 100 µs (minimum 50 µs with option 49)

Error compensation­✓

Linear and nonlinear axis error, backlash, reversal peaks during circular movements,
reversal error, thermal expansion
Static friction, sliding friction­✓
Data interfaces

­✓
­
✓
­✓
18
56-61

60

Linear in 4 axes
Linear in up to 6 axes (export license required)
Circular in 2 axes
Circular in 3 axes with tilted working plane
Helical: superimposition of circular and straight paths

Network interface for remote operation of the TNC using the TNCremo or
TNCremoPlus software from HEIDENHAIN
2 x Ethernet interface, 1 Gigabit
USB 3.0 (including 1 x USB 2.0 on the operating panel); the number of ports
depends on the hardware used
HEIDENHAIN-DNC for communication between a Windows application and the TNC(DCOM interface)
HEIDENHAIN OPC UA NC Server
Reliable and stable interface for the connection of state-of-the-art industrial
applications

Diagnostics­✓

Fast and simple troubleshooting through integrated diagnostic aids

Ambient temperature­✓­✓

Operation: +5 °C to +40 °C
Storage: –20 °C to +60 °C61Comparison of controls

Comparison of controls

TNC 620

TNC 640

NC software 81760x-17

NC software 34059x-17

Standard milling

High-end
milling / turning / grinding

Simple machining centers(up to 8 control loops, max. 2 of which are spindles)­✓­✓

Machine tools/machining centers(up to 24 control loops, max. 4 of which are spindles)–­✓

Milling / turning / grinding operations(up to 18 control loops + 2 spindles)–

OptionArea of application

Program entry
HEIDENHAIN Klartext format­✓­✓

ISO programming­✓­✓

CAD Import

OptionOptionCAD viewer­✓­✓

FK free contour programming

Option­✓Extended milling and drilling cycles

Option­✓OCM cycles

OptionOptionTurning cycles–

OptionFunctions for grinding–

OptionNC program memory

144 GB on HDR hard disk
(total capacity: 320 GB)

144 GB on HDR hard disk
(total capacity: 320 GB)
21 GB on SSDR (total capacity:
32 GB)

5-axis and high-speed machining

OptionOptionBlock processing time

1.5 ms< 0.5 ms

Input resolution and display step (standard)

0.01 μm

0.01 μm

Screen and keyboard

15-inch touchscreen/
19-inch touchscreen (portrait)

19-inch / 24-inch touchscreen

Touchscreen

­✓

­✓

62

Comparison of controls

TNC 620

TNC 640

NC software 81760x-17

NC software 34059x-17

Area of application

Standard milling

High-end
milling / turning / grinding

Adaptive Feed Control (AFC)–

OptionActive Chatter Control (ACC)

OptionOptionDynamic Collision Monitoring (DCM)–

Option–OptionKinematicsOpt

OptionOptionKinematicsComp–

OptionTouch probe cycles

Option­✓Pallet Management

Option­✓Parallel axis function­✓­✓

Fixture monitoring­✓–

Standard
Not available



63

Mastering
Nanometer nanometer
beherrschbaraccuracymachenDR. JOHANNES HEIDENHAIN GmbH
Dr.-Johannes-Heidenhain-Straße 583301 Traunreut, Germany +49 8669 31-0
 +49 8669 32-5061
info@heidenhain.dewww.heidenhain.com
892916-2C · 07/2023 · CD · Printed in Germany

HEIDENHAIN
worldwide